rotork IQT3, IQTM3, IQTFM3, IQTF3 Original Instructions Manual

IQT Range

3rd Generation IQT

Original instructions for Safe Use,
Installation, Basic Setup and Maintenance

This manual must be consulted where ever this
symbol is marked. This manual contains important
safety information. Please ensure it is thoroughly
read and understood before installing, operating
or maintaining the equipment.

PUB002-065-00
Date of issue 09/16

Table of Contents

1. Introduction _____________________________3

1.1 Identif ying Actuator Parts ..................3

1.2 Rotork Set ting Tool .......................4

1.3 Introduction to this manual .................5

2. Health and Safety _______________________5

2.1 ATEX/IECFM Certified Actuators .............7

3. Storage _________________________________7

4. Operating your IQT Actuator _____________8

4.1 Operating by Hand ........................8

4.2 Operating Electrically ......................8

4.3 Display - Local Indication ...................9

4.4 Display – Home screen selection ............10

4.5 Display Status Indication – Travel ............11

4.6 Display Status Indication – Control ...........11

4.7 Display Alarm Indication ...................11

4.8 Batter y Alarm ...........................11

5. Preparing the Drive Bush _______________ 12

5.1 Bases F05 to F07 and FA05 to FA07 ..........12

5.2 Bases F10 to F16

and FA10 to FA16 ........................12

5.3 Machining the Drive Bush .................12

5.4 Fitting the Drive Bush .....................12

2

6. Mounting the Actuator ________________ 13

6.1 IQT Actuators ...........................13

6.2 IQTM Actuators .........................13

6.3 IQTF Actuators ..........................13

6.4 Lifting the Actuator ......................13

6.5 Securing Actuator to Valve .................13

7. Cable Connections _____________________ 14

7.1 Terminal Block Layout ....................14

7.2 Earth/Ground Connections. . . . . . . . . . . . . . . . . 14

7.3 Removing Terminal Cover ..................14

7.4 Cable Entry .............................15

7.5 Connecting to Terminals ..................15

7.6 Replacing Terminal Cover ..................15

8. Commissioning - Basic Settings _________ 16

8.1 Connecting to the Actuator ................17

8.2 Securit y - Password ......................18

8.3 Basic Settings Menu ......................19

8.4 Basic Set tings – Limits ....................20

8.5 Close Settings ...........................21

8.6 Open Set tings. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8.7 Torque Switch Bypass .....................22

9. Maintenance, Monitoring and
Troubleshooting _______________________ 24

10. Environmental _________________________ 26

11. Weights and Measures _________________ 27

12. IQT Approvals _________________________ 28

13. Approved Fuses _______________________ 30

14. Vibration, Shock and Noise _____________ 30

15. Conditions of Safe Use _________________ 31

15.1 Thread details for ATEX and

IECEx Approved actuators .................31

15.2 Maximum constructional flamepath gaps

for ATEX and IECEx Approved actuators. ......31

1. Introduction

1.1 Identifying Actuator Parts

Conduit Entries (Standard)

Motor Cover

Name Plate

Open / Close
Selector

Oil Plug (optional)

Display Window

Hand Wheel

Local / Remote / Stop Selector

Control Cover

Oil Plug (optional)

Hand-Auto Lever

Conduit Entries (Optional)

Battery Sealing Plug

Metal (8mm Allen key required)
Plastic (10mm Allen key required)
as appropriate.

Terminal Cover

Base

Travel Stops

Oil Plug
(optional)

Protective
Earth Point

IQT3 manual – S ection: I ntroduct ion 3

1.2 Rotork Setting Tool

The Rotork Bluetooth® Setting Tool Pro
(BTST) combines the legacy IR and IrDA
communication protocols with the latest

Bluetooth

IrDA suppor t for older Rotork products is
retained (for use as an IR communication
tool, please refer to publications
PUB002-003 and PUB002-004).

The new BTST is able to connect to Rotork

Bluetooth

related software to setup and complete
missions. Missions are configurable
programs of instructions that are to be
performed by the BTST on an actuator and
include (but are not limited to) downloading
configuration and Data logger files as
well as uploading specific configurations
to the actuator. Different missions can be
programmed into the BTST via Insight2.

®

wireless technology. IR /

®

wireless enabled actuators and

Rotork Bluetooth® Setting Tool Pro

Specification

Enclosure: IP54

The BTST has been built in accordance with
the following standards:

ATEX II 1 G, Ex ia IIC T4 Ga

IECEx – Ex ia I IC T4 Ga

USA – FM Int Safe Class I, Div 1, Groups A,
B, C & D, T4

Canada – CSA Exia Int Safe, Class I, Div 1,
Groups A, B, C & D, T4

Ambient Temperature Range:

Tamb = -30 °C to +50 °C

Operating Range:

Infra Red 0.75m

Bluetooth

Enclosure Materials:

Polycarbonate ABS blend, Polycarbonate
and Silicon Rubber

®

10m

Instructions for Safe Selection,
Installation, Use, Maintenance
& Repair

1. The BTST must only be used in hazardous

areas (potentially explosive atmosphere)
permitted by the equipment classification,
temperature class and ambient temperature
range stated above (this is also stated on
the back of the BTST).

2. The following checks must be conducted
on the BTST prior to taking it into a
hazardous area:

a. The BTST function must be checked by
ensuring that the red or green LED, either in
the clear window or under the ‘Enter’ key
of the BTST, illuminates when any button
is pressed. If an LED does not illuminate,
there is a potential functional problem with
the BTST and the inspection or battery
replacement stated below in paragraph 6
must be per formed.

b. If the BTST is likely to come in contact
with aggressive substances (e.g. solvents
that may affect polymeric materials), then
it is the responsibility of the user to take
suitable precautions (e.g. regular check s
as part of the routine inspections or
establishing that the enclosure materials
are resistant to the specific chemicals) that
prevent the BTST being adversely affected,
thus ensuring that the type of protection is
not compromised.

3. It is essential that the actuator settings
are checked for compatibilit y with the valve,
process and control system requirements
before the ac tuator is put into service.

No user adjustment of the BTST is required.

4.

5. The BTST must be inspected ever y three

months, in a safe (non-hazardous), dry area
by suitably trained personnel, to ensure it
has been maintained in accordance with the
applicable code of practice.

6. In accordance with the BTST
hazardous area approvals and with the
recommendations from the approved
battery suppliers, the following are
mandatory requirements for safe use:

a. The inspections or replacement of the
batteries must be conducted in a safe (non­hazardous), dry area.

b. The batteries must be removed from the
BTST when it is not expected to be used for
3 months or longer.

c. Discharged batteries must be removed
from the BTST to prevent possible damage.

d. The battery compartment of the BTST
must be inspected every 3 months for any
battery leakage. If any batter y leakage has
occurred then the BTST must not be used.

4 IQT3 manual – S ection: I ntroduct ion

e. Only the following approved Alkaline ­Manganese or Zinc-Manganese type ‘AAA’
size batteries must be fitted to the BTST:

- Duracell: Procell MN2400

- Energizer: E92

f. Always replace all four batteries
at the same time. Always use four
unused batteries of the same approved
manufacturer, type and expiry date code.

g. Ensure the batteries are fitted with the
correct polarity. The battery polarit y (+)
is indicated on the inside of the batter y
compartment of the BTST.

7. The BTST contains no other user
replaceable parts and it cannot be repaired
by the user. If the BTST is faulty or needs
repairing, it must not be used.

1.3 Introduction to this manual

This manual covers IQT 3rd Generation
actuators:

IQT Operation of isolating/

regulating

IQTM Operation of modulating

1

/4 turn valves.

1

/4 turn valves.

IQTF Operation of part-turn and slow

speed multi-turn valves.

IQTFM Operation of part-turn and

slow speed multi-turn valves for
modulating duty.

This manual provides instruction on:

• Manual and electrical (local and
remote) operation.

• Preparation and installation of the
actuator onto the valve.

• Basic Commissioning.

• Maintenance.

Refer to Publication PUB002- 067
for repair, overhaul and spare part
instructions.

Refer to Publication PUB002- 040
for secondary function
configuration instructions.

®

Using the supplied Rotork Bluetooth
Setting Tool Pro to access the actuator
set up procedures, non-intrusive
setting of torque levels, position limits
and all other control and indication
functions can be made safely, quickly
and conveniently, even in hazardous
locations. The IQ allows commissioning
and adjustment to be carried out with
the main power supply to the actuator
switched on or off.

The setting tool is packed in the
shipping box identified with a
yellow label.

Visit our web site at www.rotork.com
for more information on the IQ, Insight2
and other Rotork actuator ranges.

2. Health and Safety

This manual is produced to enable a
competent user to install, operate, adjust
and inspect Rotork IQT range valve
actuators. Only persons competent by
virtue of their training or experience
should install, maintain and repair Rotork
actuators.

Under no circumstances should
replacement parts be used in Rotork
actuators, other than those supplied or
specified by Rotork.

Work undertaken must be carried out in
accordance with the instructions in this
and any other relevant manuals.

If the actuator is used in a manner not
specified in this manual and any other
Rotork manual, the protection provided
by the actuator may be impaired.

The user and those persons working
on this equipment should be familiar
with their responsibilities under any
statutory provisions relating to the
Health and Safety of their workplace.
Due consideration of additional hazards
should be taken when using the IQT
range of actuators with other equipment.
Should further information and guidance
relating to the safe use of the Rotork IQT
range of actuators be required, it will
be provided on request. The electrical
installation, maintenance and use of

IQT3 manual – S ection: H ealth and Saf ety 5

these actuators should be carried out in
accordance with the National Legislation
and Statutory Provisions relating to the
safe use of this equipment, applicable to
the site of installation.

For the UK: Electricity at Work
Regulations 1989 and the guidance
given in the applicable edition of the
“IEE Wiring Regulations” should be
applied. Also the

user should be fully
aware of his duties under the Health and
Safety Act 1974.

For the USA: NFPA70, National Electrical

®

is applicable.

Code
For Canada: CEC, Canadian Electrical

Code is applicable
The mechanical installation should be

carried out as outlined in this manual
and also in accordance with relevant
standards such as British Standard Codes
of Practice. If the actuator has nameplates
indicating that it is suitable for installation
in hazardous areas then the actuator may
be installed in Zone 1, Zone 21, Zone
2 and Zone 22 (or Div 1 or Div 2, class
I or Class II) classified hazardous area
locations only. It should not be installed in
hazardous area locations with an ignition
temperature less than 135 °C, unless
suitability for lower ignition temperatures
has been indicated on the actuator
nameplate.

6 IQT3 manual – S ection: H ealth and Saf ety

It should only be installed in hazardous
area locations compatible with the gas
and dust groups stated on the nameplate.

The electrical installation, maintenance
and the use of the actuator should be
carried out in accordance with the code
of practice relevant for that particular
Hazardous Area certification.

No inspection or repair should be
undertaken unless it conforms to the
specific hazardous area certification
requirements. Under no circumstances
should any modification or alteration
be carried out on the actuator as this
could invalidate the actuators hazardous
area approval cer tification. Access to live
electrical conductors is forbidden in the
hazardous area unless this is done under
a special permit to work, otherwise
all power should be isolated and the
actuator moved to a non-hazardous area
for repair or attention.

WARNING: Service Altitude

The actuator installation altitude must
be restricted to less than 2000 m
as defined by IEC61010-1 (Safety
requirements for electrical equipment
for measurement, control and
laboratory use).

WARNING: Motor Temperature

Under normal operation the
temperature of actuator’s motor cover

surfaces can exceed 60 °C above
ambient.

WARNING: Surface Temperature

The installer/user must ensure that the
actuator surface temperature rating
is not influenced by external heating/
cooling effect (e.g. valve/pipeline
process temperatures).

WARNING: Thermostat Bypass

If the actuator is configured to bypass
the motor thermostat then the
hazardous area, low voltage directive
and CE certification will be invalidated.
Additional electrical hazards may occur
when using this configuration. The
user should ensure that any necessary
additional safety measures are
considered.

WARNING: Enclosure Materials

IQT range of actuators are
manufactured from aluminium alloy
with stainless steel fasteners and the
non-thrust bases are manufactured in
aluminium.

The cover window is toughened glass
which is retained with a 2-part silicone
cement and the battery plug will be
either stainless steel or PPS (Poly­Phenolyne Sulfide).

The wireless aerial is made from
Polytetrafluoroethylene (PTFE).

The user must ensure that the
operating environment and any
materials surrounding the actuator
cannot lead to a reduction in the safe
use of, or the protection afforded
by, the actuator. Where appropriate
the user must ensure the actuator is
suitably protected against its operating
environment.

WARNING: Operating by Hand

With respect to handwheel operation
of Rotork electric actuators, refer to
sec ti o n 4.1.

WARNING: Actuator may start
and operate when remote is
selected. This will be dependent on
remote control signal status and
actuator configuration.

2.1 ATEX/IECFM Certified Actuators

Special Conditions

This actuator must only be located in
areas where the risk of impact to the
viewing window is low.

This equipment includes some
exterior non-metallic parts including
the protective coating. To avoid the
possibility of static build up, cleaning
must only be carried out with a damp
cloth.

WARNING:

External Enclosure

Fasteners

Enclosure fasteners are stainless steel
grade A4 80 except for the following.

In these cases the fasteners are carbon
steel grade 12.9. If in doubt check the
grade marked on the relevant fastener
or contact Rotork.

All sizes of Actuator ATEX & IECEx:

Ex db IIB T4 (T6) Gb (-20 to +70

o

C)
Electronics, Motor & Terminal
enclosures

o

Ex db IIB T4 (T6) Gb (-30 to +70

C)
Electronics, Motor & Terminal
enclosures

o

Ex db IIB T4 (T6) Gb (-40 to +70

C)
Electronics, Motor & Terminal
enclosures

o

Ex db IIB T4 (T6) Gb (-50 to +40

C)
Electronics, Motor & Terminal
enclosures

Certificate number: Sira 15ATEX1011X
or IECEx SIR 15.0010X

o

Ex db IIC T4 (T6) Gb (-50 to +40

C)

Terminal enclosure
Certificate number: Sira 15ATEX1012X

or IECEx SIR 15.0011X

FM Approved:

Explosionproof, Class I, Div 1,
Groups C, D (-50 to +40

o

C)
Electronics, Motor & Terminal
enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-20 to +70

o

C)

Electronics & Motor enclosures
Explosionproof, Class I, Div 1,

Groups B, C, D (-30 to +70

o

C)

Electronics & Motor enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-40 to +70

o

C)

Electronics & Motor enclosures
Explosionproof, Class I, Div 1,

Groups B, C, D (-50 to +40

o

C)

Electronics & Motor enclosures

CSA Approved:

Explosionproof, Class I, Div 1,
Groups C, D (-50 to +40

o

C)
Electronics, Motor & Terminal
enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-20 to +70

o

C)
Electronics, Motor & Terminal
enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-30 to +70

o

C)
Electronics, Motor & Terminal
enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-40 to +70

o

C)
Electronics, Motor & Terminal
enclosures

Explosionproof, Class I, Div 1,
Groups B, C, D (-50 to +40

o

C)
Electronics, Motor & Terminal
enclosures

For detailed approvals information
and Fahrenheit temperature ranges,
see page 28.

3. Storage

If your actuator cannot be installed
immediately, store it in a dry place until
you are ready to connect incoming
cables.

If the actuator has to be installed but
cannot be cabled it is recommended
that the plastic transit cable entry plugs
are replaced with metal plugs which
are sealed with PTFE tape.

The Rotork double-sealed construction
will preser ve internal electrical
components perfectly if left
undisturbed.

It is not necessary to remove any
electrical compartment covers in order
to commission the IQT actuator.

Rotork cannot accept responsibility for
deterioration caused on-site once the
covers are removed.

Every Rotork actuator has been fully
tested before leaving the factory to
give years of trouble free operation,
providing it is correctly commissioned,
installed and sealed.

IQT3 manual – S ection: Sto rage 7

4. Operating your IQT Actuator

4.1 Operating by Hand

WARNING

With respect to handwheel
operation of Rotork electric
actuators, under no circumstances
should any additional lever device
such as a wheel-key or wrench
be applied to the handwheel in
order to develop more force when
closing or opening the valve as
this may cause damage to the
valve and/or actuator or may cause
the valve to become stuck in the
seated/ backseated position.

Keep clear of the handwheel
when engaging hand operation.
Actuators driving valves via
extension shafts may be subject
to retained shaft torsion which
can cause the handwheel to rotate
when hand operation is engaged.

To engage handwheel drive pull the
Hand/Auto lever into “Hand” position
and turn the handwheel to engage the
clutch. The lever can now be released
where it will return to its original
position. The handwheel will remain
engaged until the actuator is operated
electrically when it will automatically
disengage and return to motor drive.

If required for local lockout purposes
the Hand/Auto lever can be locked in
either position using a padlock with a

6.5 mm hasp.

Locking the lever in the "hand"
position prevents electrical operation of
the actuator moving the valve.

4.2 Operating Electrically

Check that power supply voltage
agrees with that on the actuator
nameplate. Switch on power supply.
It is not necessary to check phase
rotation.

Do not operate the actuator
electrically without first checking,
using the infra-red Setting Tool,
that at least the Basic Settings have
been made (refer to Section 8).

Selecting Local/Stop/Remote
Operation

The red selector enables either Local
or Remote control, lockable in each
position using a padlock with a

6.5 mm hasp.
When the selector is locked in the

Local or Remote positions the Stop
facility is still available. The selector can
also be locked in the Stop position to
prevent electrical operation by Local or
Remote control.

Fig. 4.2.1 IQT3 Local Controls

Local Control

With the red selector positioned at
Local (anti- clockwise) the adjacent
black knob can be turned to select
Open or Close. For Stop, turn red knob
clockwise.

Remote Control

Rotate the red selector to the Remote
position (clockwise), this allows remote
control signals to operate the actuator.
Local Stop can still be used by turning
the red knob anti-clockwise.

8 IQT3 manual – S ection: O perating yo ur IQT Actuat or

4.3 Display - Local Indication

2

8

9

5

Fig. 4.3.1 Segment Display

1. Position display

This is the main segment display for
position and torque; position indication
to 1 decimal place.

10

6

7

1

2. Analogue Scale

Scale 0% to 100% is used when
Analogue torque (% of rated) or
Positioning (% position / demand)
homescreens are selected. Refer to
section 4.4.

3. Infra-red LEDs

Used for older models of setting tool
and to initiate a data connection using
Bluetooth wireless technology.

4. Dual position LEDs

Consisting of 2 x Yellow for mid
position and 2 x bi-colour (Red / Green)
for end of travel indication.

5. Bluetooth indication LED

A dual intensity LED for indicating an

44

active connection using Bluetooth
wireless technology.

6. Alarm Icon

This will be displayed for valve, control

3

and actuator alarms. Alarm indication
is supported by fault description in the
text in the line above the main display.

7. Battery Alarm Icon

This icon will be displayed when
a battery is detected as low or
discharged. "Battery low" or
"Discharged" will also be displayed in
the text display above.

8. Infra-Red Icon

This icon flashes during setting tool
communication activity. LEDs will also
flash when keys are pressed.

9. Percentage Open Icon

This icon will be displayed when an
integer open value is displayed e.g.

57. 3 .

10. Dot Matrix Display

A high resolution 168x132 pixel display
for displaying setup menus and Data
logger graphs.

When a positional display is active,
the status and active alarms will be
displayed.

The LCD screen is made up of two
layers; the main segment display and
the dot matrix display. The displays
are dual stacked so that either display
can be enabled to show different
information. This also allows a
combination of both displays for added
flexibility.

On power the LCD is backlit with a
white light to enable the best viewing
contrast in all lighting conditions. For
additional positional indication, the
LEDs at either side of the LCD are used
for Closed (green), mid-travel (yellow)
and Open (red) as standard. These LEDs
are fully configurable in the settings
menu or on request at time of order.

IQT3 manual – S ection: O perating yo ur IQT Actuat or 9

4.4 Display – Home screen selection

YY

1

2

3

44

5

6

7

8

9

10

1

2

3

44

5

6

7

8

9

10

The actuator display can be set to show
any one of the following home screens:

• Position indication

• Position & Digital Torque indication

Position & Analogue Torque indication

•

•

Position & Control Demand indication

The default home screen is Position.

Permanent Home Screen display.

Using the setting tool (refer to 8.1)
connect to the actuator.

From the Settings menu, select
Indication, Local Display. From
the available settings, select Home
Screen. Enter the password if
requested (refer to section 8.2), select
Home screen and from the dropdown
list, select the required Home screen
for permanent display:

Home screens indicate the live
conditions measured by the actuator
when mains power is applied. When
mains power is switched off the
actuator battery powers the display
and it will show the position indication
display only.

The required home screens can be
set by the user either as a permanent
display or as a temporary display for
valve or actuator operational analysis.

Temporary Home Screen display.

Using the setting tool (refer to 8.1)

or

the available home screens until
the required one is displayed. The
selected screen will remain displayed
for approximately 5 minutes after the
last setting tool command or until the
actuator power is cycled.

arrow keys, scroll through

Fig. 4.4.1 Home Screen Selection

Position

- Default valve position display

Torque (A) + Pos - Position with
analogue torque indication

Torque (D) + Pos

-

digital torque indication
Positioner - Position with digital and

analogue position demand indication

Position with

Once selected, the set display will be
the active, permanent home screen.
Refer to Figs 4.4.2 to 4.4.5.

Fig. 4.4.2 Position

Fig. 4.4.3 Torque (D) + Position

Fig. 4.4.4 Torque (A) + Position

Fig. 4.4.5 Positioner

10 IQT3 manu al – Secti on: Operatin g your IQT Actuator

4.5 Display Status Indication –
Travel

The IQT display provides real-time
status indication. The top line of the
text area is reserved for travel status
indication.

Fig 4.5.1 shows the travel status
example of CLOSED LIMIT

4.6 Display Status Indication –
Control

The bottom line of the text area is
reserved for control status indication
and is displayed for approximately 2
seconds after the control mode or
signal is applied.

Fig 4.6.1 shows the control status
example Remote Control.

4.7 Display Alarm Indication

The IQT display provides alarm indication
in the form of text and alarm icons.

There are 2 alarm icons:

General Alarm:

Battery Alarm:

4.8 Battery Alarm

Fig. 4.5.1

Fig. 4.6.1

The general alarm icon will be
supported with text in the bottom line
indicating the particular alarm, or if
more than one is present, each alarm
will be displayed in sequence.

Fig 4.7.1 shows the status example:

TORQUE TRIP CLOSED

Fig. 4.7.1

Fig. 4.8.1

The actuator checks the battery level
at approximately 1 hour intervals. The
battery alarm icon is displayed when
the actuator detects its battery as
being low and the display will indicate
BAT TERY LOW. If the battery is flat
or missing the display will indicate
BATTERY DISCHARGED.

When a low or discharged battery
alarm is displayed the batter y should
be replaced immediately. It is essential
that the correct batter y type is fitted to
maintain actuator certification. Refer to
section 9 for details.

After replacing a battery the alarm
icon will continue to be displayed
until the next check and may take
up to 1 hour. Cycling the power
will force a batter y check and clear
the alarm.

IQT3 manual – S ection: O perating yo ur IQT Actuat or 11

5. Preparing the Drive Bush

5.1 Bases F05 to F07 and FA05 to
FA07

The base adaptor must be removed to
give access to the drive bush. Remove
the four capscrews and base adaptor as
shown in figure 5.1.1.

Fi g. 5 .1.1

Clear access to the drive bush is now
available as shown in figure 5.1.1.
Using the a 3 mm allen key, unscrew
the two capscrews retaining the drive
bush and remove the drive bush from
the actuator.

Fig. 5.1.2

5.2

Bases F10 to F16
and FA10 to FA16

Removal of the drive bush does not
require the removal of the actuator
base. Using a 3 mm allen key, unscrew
the two capscrews retaining the drive
bush.

Capscrews can be used to remove the
drive bush by screwing into the drive
bush as shown in figure 5.2.1.

Fig. 5.2.1

The range of IQT drive bushes is shown
in figure 5.2.2. Please refer to PUB002­038 for maximum stem acceptance
details.

5.3

Machining the Drive Bush

Once removed, the drive bush can
be machined to suit the valve stem.
Ensure machined position allows correct
orientation of actuator-to valve flange
and correct direction to close the valve.

5.4

Fitting the Drive Bush

Note: The drive bush can be fitted in
four possible positions, 90º apart. Fit
the drive bush into the centre column
ensuring that the stem orientation,
actuator position and direction
of operation are correct for valve
operation. Secure the drive bush with
the capscrews. For F05, FA05, F07 and
FA07 bases, refit the base adaptor and
secure with the four capscrews.

12 IQT3 m anual – Sec tion: Prepa ring the Dri ve Bush

Fig. 5.2.2

6. Mounting the Actuator

Refer to Section 11 Weights and

Measures for actuator weight.

6.1 IQT Actuators

The IQT range of actuators are suitable
for part turn applications requiring up to
60 starts per hour.

6.2 IQTM Actuators

The IQTM range of actuators are suitable
for modulating control duty of up to
1200 starts per hour in accordance with
IEC 60034-1 to S4 50%. Commissioning
of IQTM range actuators is identical to
the standard IQT (refer to Sections 7, 8
and 9).

6.3 IQTF Actuators

The IQTF range of actuators are suitable
for part-turn and multi-turn, non-thrust
applications requiring low speed and low
operating turns. Commissioning of IQTF
range actuators is similar to the standard
IQT (refer to Sections 7, 8 and 9).

6.4 Lifting the Actuator

Ensure the valve is secure before fitting
the actuator, as the combination may be
top heavy and therefore unstable.

When lifting the actuator using
mechanical lifting equipment certified
slings should be attached as indicated
in Figure 5. At all times trained and
experienced personnel should ensure
safe lifting, particularly when mounting
actuators.

WARNING: Do not lift the

actuator by the handwheel.

A suitable mounting flange conforming
to ISO 5210 or USA Standard MSS
SP101 must be fitted to the valve.
Actuator to valve fixing must conform
to; Material Specification ISO Class 8.8,
yield strength 628 N/sq mm.

WARNING: Do not lift the
actuator and valve combination via
the actuator. Always lift the valve/
actuator assembly via the valve.

Fig. 6.4.1

WARNING: The actuator should
be fully supported until full valve
stem engagement is achieved and
the actuator is secured to the valve
flange.

Fig. 6.4.2

6.5 Securing Actuator to Valve

Before engagement ensure that the
actuator and valve are in the same
position (i.e. closed) and the drive bush­machining matches the stem position.
Actuator position can be determined
using the display (refer to section 3.3
page 4) and if necessary can be moved
using the handwheel (refer to section

3.1 page 3). It may be necessary to
adjust the stop bolts to enable sufficient
travel. Refer to section 5.6.

Tighten down onto valve flange to the
required torque, see table B.

Imperial Size

1

/4 - Hex

5

/16 - Hex

3

/8 - Hex

7

/16 - Hex

1

/2 - Hex

9

/16 - Hex

5

/8 - Hex

3

/4 - Hex

7

/8 - Hex

1 - Hex

Metric Size

M5 - Hex

M6 - Hex

M8 - Hex

M10 - Hex

M12 - Hex

M16 - Hex

M20 - Hex

M24 - Hex

Torque

Nm lbf.ft

6.7 4.9

12.6 9.3

21.4 15.8

33.6 24.8

50.8 37.4

71.5 52.7

99.2 73.2

170.8 126.0

271.3 200.1

406.0 299.5

Torque

Nm lbf.ft

3.0 2.2

5.4 4.0

12.8 9.4

25.0 18.4

42.9 31.6

100.5 74.2

198.2 146.2

340.3 251.0

Table B

IQT3 manual – S ection: M ounting the Ac tuator 13

7. Cable Connections

7.1 Terminal Block Layout

Fi g. 7.1.1 Terminal number s refer to connections as shown on the actuator circuit diagram

14 IQT3 ma nual – Sect ion: Cable Conn ections

WARNING:
Ensure all power supplies are
isolated before removing actuator
covers.

Check that the supply voltage agrees
with that stamped on actuator
nameplate.

A switch or circuit breaker must be
included in the wiring installation or
the actuator. The switch or circuit
breaker must meet the relevant
requirements of IEC60947-1 and
IEC60947-3 and be suitable for the
application. The switch or circuit
breaker must not disconnect the
protective earth conductor. The switch
or circuit breaker must be mounted
as close to the actuator as possible
and shall be marked to indicate that
it is the disconnect device for that
particular actuator. The actuator
must be protected with overcurrent
protection devices rated in accordance
with publications PUB002-018 (3-phase
actuators) or PUB002-019 (single-phase
actuators). The switch or circuit breaker
shall disconnect both poles of a three
phase supply.

WARNING:
The maximum supply for actuators
connected to phase-earthed systems
is 500 VAC.

7.2

Earth/Ground Connections

A lug with a 6 mm diameter hole is
cast adjacent to the conduit entries for
attachment of an external protective
earthing strap by a nut and bolt. An
internal earth terminal is also provided,
however it must not be used alone as
the Protective Earth connection.

7.3

Removing Terminal Cover

Using a 6 mm Allen key loosen the four
captive screws evenly. Do not attempt
to lever off the cover with a screwdriver
as this will damage the O-ring seal
and may damage the flamepath on a
certified unit.

Actuators containing a Setting Tool
fitted to the actuator are identified
with a self-adhesive yellow label on the
outside of the terminal compartment
cover.

The wiring code card fixed in the cover
is particular to each actuator and must
not be interchanged with any other
actuator. If in doubt check the serial
number on the code card with that of
the actuator.

Fig. 7.3.1

A plastic bag in the terminal
compartment contains: Terminal screws
and washers, spare cover O-ring seal,
wiring diagram and instruction book.

7.4

Cable Entry

Only appropriate certified Explosion-Proof
entry reducers, glands or conduit may be
used in hazardous locations. In hazardous
locations, only one appropriate certified
Explosion-Proof thread adaptor per entry
may be used.

Remove red plastic transit plugs. Make
cable entries appropriate to the cable
type and size. Ensure that threaded
adaptors, cable glands or conduit are
tight and fully waterproof. Seal unused
cable entries with a steel or brass
threaded plug. In hazardous areas an
appropriately certified threaded blanking
plug must be used without the use of an
interposing thread adaptor.

The cable entries on the actuator
terminal housing are tapped M25 x 1.5p.

For installation in USA and Canada:
Conduit seals must be installed at the
enclosure. M25 x 1.5p to either

3

/4", 1", 1.25" or 1.5" NPT thread

1

/2",

adaptors are factory fitted.

7.5

Connecting to Terminals

Refer to the wiring diagram inside the
terminal cover to identify functions of
terminals. Check that supply voltage
is the same as that marked on the
actuator nameplate.

Remove power terminal screen.

Begin by connecting these cables and
replace screen.

When all connections are made ensure
wiring diagram is replaced in the
terminal compartment.

To ensure secure electrical
connections, it is important
that the requisite washers are
used as shown in Figure 7.5.1.
Failure to do so may result in
connections working loose or
screws not clamping down on
wire termination tags. Spring
washers must be compressed.
Screw tightening torques must not
exceed 1.5 Nm (1.1 lbf.ft)

4 or 5 mm
Pan Head

Spring
washer

Plain
washers

Fig. 7.5.1

Wire tag

To comply with Ex e
certification, terminals numbered
1 - 3 and earth must be fitted with
1 off AMP ring tag 160292 per
terminal and terminals numbered
4 - 47 must be fitted with 1 off
AMP ring tag 34148 per terminal
when required.

7.6

Replacing Terminal Cover

Ensure cover O-ring seal and spigot
joint are in good condition and lightly
greased before re-fitting cover.

WARNING:

Wiring may exceed 83 ºC in a 70 ºC
ambient.

ATTENTION: RED PLASTIC PLUGS IN CONDUIT

ENTRIES ARE FOR TRANSIT ONLY.

FOR LONG TERM PROTECTION FIT SUITABLE

ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER

L'ENTRATA CAVI SONO SOLO TEMPORANEI.
PER UNA PROTEZIONE PERMANENTE PREGO

SOSTITUIRLI CON APPOSITI TAPPI METALLICI.

PLASTICO EN LAS ENTRADAS DE CABLE
SON UNICAMENTE PARA TRANSPORTE.

PARA PROTECCION PERMANENTE COLOCAR

ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND

NUR FÜR DEN TRANSPORT GEEIGNET. FÜR

DAVERHAFTEN SCHUTZ SIND DIESE GEGEN

GEEIGNETE BLINDSTOPFEN AUSZÜTAUSCHEN.

ATTENTION: LES BOUCHONS PLASTIQUES

ASSURENT UNE PROTECTION TEMPORAIRE.

POUR UNE PROTECTION DEFINITIVE UTILISER

METAL PLUGS.

ATENCION: LOS TAPONES ROJOS DE

TAPONES METALICOS APROPIADOS.

DES BOUCHONS METALLIQUES.

IQT3 manual – S ection: C able Connec tions 15

8. Commissioning - Basic

Settings

All actuator settings, Data logger and
asset management data is accessed
using the supplied Rotork Bluetooth®
Setting Tool Pro. Status and alarm data
in addition to that shown on the home
screen can also be accessed.

THE CONTROL COVER MUST
NOT BE REMOVED; NO USER
CONFIGURABLE SETTINGS ARE
AVAILABLE WITHIN THE CONTROL
ENCLOSURE. THE CONTROL
COVER IS SEALED BY A QUALIT Y
LABEL WHICH IF BROKEN MAY
INVALIDATE WARRANTY.

This instruction details the basic
settings that must be completed before
the actuator is put into service.

ELECTRICAL OPERATION MUST
NOT TAKE PLACE UNTIL THE BASIC
SETTINGS HAVE BEEN MADE AND
CHECKED.

The basic settings affect the correct
operation of the valve by the actuator.
If the actuator has been supplied with
the valve, the valvemaker or supplier
may have already made these settings.

Settings and operation must be
verified by electric operation and
function test of the actuated valve.

THIS PUBLIC ATION PROVIDES
INSTRUCTION ON MAKING THE
BASIC SETTINGS ONLY.

For instruction on control and
indication settings and for information
on diagnostics refer to PUB002-040.

16 IQT3 man ual – Secti on: Commissio ning - Basic Se ttings

8.1 Connecting to the Actuator

The Rotork Setting Tool incorporating

Bluetooth wireless technology (Rotork
Bluetooth® Setting Tool Pro – BTST) is

shown below. It is identified by the key
symbols being clear and a clear seal
between the top and bottom casings.

The Infra-red only tool has filled
yellow keys and a yellow seal between
casings.

The Rotork Bluetooth® Setting Tool
Pro with the relevant navigation and
configuration keys is shown below.

Up

Left/Decrease

Back

Select/Save

Down

Right/Increase

Forward

Connecting to the actuator
using Bluetooth

The default security set in the actuator
for Bluetooth connection is by initiation
using an infra red command. This
means that the user must be in close
proximity and in direct line of sight of
the actuator.

Point the setting tool at the actuator
display window within a range 0.25 m
(10 in) and Press

key.

The screen will change to the Main
Menu screen.

Fi g. 8 .1.1

The Setting Tool will automatically
connect using Bluetooth which
takes up to 5 seconds and when
connected will be indicated by blue
lights illuminating on the tool and
in the actuator display window.
Once connected, the tool can be
used without pointing it at the
actuator display window.

Bluetooth connection will be
maintained while setting tool key
commands are made. After a period
of 6 minutes with no key commands,
Bluetooth connection will be turned off
and the Setting tool and display blue
lights will go out. To manually turn
off Bluetooth connection at any time,
press the setting tool

and keys

together.

IQT3 manual – S ection: Co mmissionin g - Basic Set tings 17

8.2 Security - Password

The default security level for connecting
to the actuator is by infra-red Bluetooth
initiation. This requires that the user
is at the actuator within 0.25 metre
distance and in direct line of sight
of the display. For instruction on
connecting to the actuator refer to 8.1.

All actuator settings can be viewed
with the actuator selected to Local,
Stop or remote.

To change an actuator setting, the
actuator must be selected to Local or
Stop and a correct password entered.

If the actuator is selected to Remote
and a setting is selected, the following
warning will be displayed:

Fig. 8.2.1

Select OK to return to settings screen.

With the actuator selected to Local
or Stop and when any function is
selected, the Password screen will be
displayed:

Fig. 8.2.2

The factory set default password
ROTORK is displayed and the OK
key is highlighted.

Press the

key.

The setting screen will again be
displayed. The example below shows
Settings – Limits – Close Settings
with the function Action highlighted:

Close Settings
Direction Clock Anti

Action Limit Torque

Y Y

Torque 100%
Set Limit
Open Settings
Action Limit Torque
Torque 60%

Stopped

2/15

Fig. 8.2.3

Press the key to select.

The function and its setting option or
range will then be highlighted:

Close Settings
Direction Clock Anti

Action Limit

Y Y

Torque 100%
Set Limit
Open Settings
Action Limit Torque
Torque 60%

Stopped

Torque

2/15

Fig. 8.2.4

If the user does not wish to change
the function value, press the
back button to escape without
changing.

18 IQT3 manu al – Secti on: Commissioning - Basic Set tings

Use the or arrow keys to change
the setting to the required value, the
example below show a close action of
Torque having been selected.

Close Settings
Direction Clock Anti

Action Limit

Y Y

Torque 100%
Set Limit
Open Settings
Action Limit Torque
Torque 60%

Stopped

Torque

2/15

Fig. 8.2.5

Press the key to select.

The highlight will return to the function
name only and its stored setting will be
displayed:

Close Settings
Direction Clock Anti

Action Limit Torque

Y Y

Torque 100%
Set Limit
Open Settings
Action Limit Torque
Torque 60%

Stopped

2/15

Fig. 8.2.6

The password will be requested
the first time a function is selected.
Once correctly entered, the
password will not be required to
be entered again for the duration
of setting tool communication with
the actuator. Other functions can
be set as required.

8.3 Basic Settings Menu

Settings Menu

Limits

Indication

Control

ESD

Security

Defaults

CLOSE SETTINGS

Direction (CW/ACW)
Action (Torque/Limit)
Torque (40 - 100%)
Set Limit

OPEN SETTINGS

Action (Torque/Limit)
Torque (40 - 100%)
Set Limit
Turns
Position
Speed

TORQUE SWITCH
BYPA SS

Open
Open Position (0 - 95%
Close
Closing Position (100 - 5%)

AUTO LIMIT SETTING

IQT3 manual – S ection: Co mmissionin g - Basic Set tings 19

8.4 Basic Settings – Limits

Settings and operation must be
verified by electric operation and
function test of the actuated valve.

Connect to the actuator as described in
Section 8.1. From the Position display
home screen press the

key. The

main menu will be displayed.

Navigate to Settings using the

keys and press to select.

Fig. 8.4.1

20 IQT3 manua l – Sectio n: Commissioni ng - Basic Set tings

The settings menu will be displayed:

Settings

Limits

Indication
Control
ESD
Security
Defaults

Navigate to Limits using the
and press to select.

keys

The setting first selected to be
changed will require a password to
be entered – refer to section 8.2.

The limit settings are shown below
with their factory default values:

Limits

Close Settings

1 / 15

Direction

2 / 15

Action

3 / 15

Torque

4 / 15

Set Limit

5 / 15

Action

6 / 15

Torque

7 / 15

Set Limit

8 / 15

Turns 25

9 / 15

Position

10 / 15

Speed

Torque Switch Bypass

11 / 15

Opening

12 / 15

OP. Bypass Pos 10%

13 / 15

Closing

14 / 15

CL. Bypass Pos

15 / 15

Auto Set Limit

Clock Anti
Limit Torque

Open Settings

Limit Torque

95.0

On X

On X

Auto Limit Setting

Function Close Direction (1 / 15) is shown highlighted. Use
functions. Functions will be highlighted in turn.

Off

Off

to scroll through

40%

40%

40%

90%

1 / 15

8.5 Close Settings

1 / 15. Close Direction

Function sets the direction required to
close the valve. Manually operate the
actuator and valve to establish closing
direction.

to select Close Direction

Press
function. Use or to check
required setting. Press to set.

2 / 15. Close Action

The actuator can be configured close
on torque for seating valve types or
limit for non-seating valve types.

Refer to Valve manufacturer
for recommended setting. In the
absence of valvemaker instruction
refer to the following table.

Valve Type

Wedge gate Torque Limit

Globe Torque Limit

Butterfly Limit Limit

Through Conduit Limit Limit

Ball Limit Limit

Plug Limit Limit

Sluice gate Limit Limit

Penstock Limit Limit

Parallel Slide Limit Limit

Close
Action

Open
Action

Press to select Close Action
function. Use
required setting. Press

or to check

to set.

3 / 15. Close Torque

The value of torque available to close
the valve can be set between 40%
and 100% of rated. The actuator
rated torque value is shown on its
nameplate.

to select Close Torque

Press
function. Use key to decrease value
and key to increase value.

key to set.

Press

4 / 15 Set Close Limit

Press to select Close Limit Function.
The actuator will display the following
Instruction:

Fig. 8.5.1

Move the actuator and valve to the
close position. Allow for overrun by
winding in the opening direction by
½ to 1 turn of the handwheel.

to set the close limit position.

Press

8.6 Open Settings

5 / 15. Open Action

The actuator can be configured open
on torque for seating valve types or
limit for non-seating valve types.

Refer to Valve manufacturer
for recommended setting. In the
absence of valvemaker instruction
set open action to “Limit ”.

to select Open Action

Press
function. Use or to check
required setting. Press to set.

6 / 15. Open Torque

The value of torque available to open
the valve can be set between 40%
and 100% of rated. The actuator
rated torque value is shown on its
nameplate.

to select Open Torque

Press
function. Use key to decrease value
and key to increase value.

to set.

Press

IQT3 manual – S ection: Co mmissionin g - Basic Set tings 21

7 / 15. Set Open Limit

Press to select Open Limit Function.
The actuator will display the following
instruction:

Fig. 8.6.1

Move the actuator and valve to the
open position. Allow for overrun by
winding in the closing direction by
½ to 1 turn of the handwheel.

to set the open limit position.

Press

8 / 15. Turns (not editable)

Shows the actuator output turns
between the set Closed and Open limit
positions.

Note: IQTF is limited to a

maximum of 22 turns.

9 / 15. Position (not editable)

Shows the actuator current position in
terms of % open.

Note: Turns and Position values do
not update while being displayed
on screen. To see updated values,

key to return to Settings

use
Menu, then select Limits.

10 / 15. Speed (IQT only)

The IQT speed is adjusted between
25 - 100% of rated.

to select speed. Use key to

Press
decrease value and key to increase
value. Press to set.

8.7 Torque Switch Bypass

The default setting for opening and
closing torque switch bypass is Off
(torque protection active at all times).
Bypassing the torque protection allows
torque up to approximately 150% of
rated to be available. The valvemaker
/ integrator should be consulted
to confirm the valve structure and
interface components can withstand
the additional torque/thrust.

11 / 15. Opening

Opening torque protection can be
bypassed over a configurable portion
of the opening stroke. When enabled,
torque up to approximately 150% of
rated torque is available for opening
“sticky” valves.

to select Opening Torque

Press
Switch Bypass function. Use or
to check required setting.

to set.

Press

12 / 15. Opening Bypass Position

When enabled (refer to 9 / 12), the
position over the opening stroke where
the torque protection is bypassed can
be configured in the position range 0%
(closed limit) to 95% open. Outside the
bypass position, torque switch value
will revert to that set, refer to 6 / 12.

to select Opening Bypass

Press
Position function. Use key to
decrease value and key to increase
value. Press to set.

13 / 15. Closing

Closing torque protection can be
bypasses over a configurable portion
of the closing stroke. When enabled,
torque up to approximately 150% of
rated torque is available for closing
the valve. Outside the bypass position,
torque switch value will revert to that
set, refer to 3 / 12.

to select Closing Torque

Press
Switch Bypass function. Use or
to check required setting.

to set.

Press

22 IQT3 manu al – Sectio n: Commission ing - Basic Set tings

14 / 15. Closing Bypass Position

When enabled (refer to 11 / 12), the
position over the Closing stroke where
the torque protection is bypassed can
be configured in the position range
100% (open limit) to 5% open.

to select Closing Bypass

Press
Position function. Use key to
decrease value and key to increase
value. Press to set.

15 / 15. Auto Set Limit

The IQT comes with the feature to
automatically set the limits. In order
to perform this, the valve must
require less than 40% of rated torque
throughout travel. Actuators that
require more than 40% should be
setup manually.

Once activated the actuator will
attempt to find the Close limit first and
then the Open limit. During this time
the actuator will run without warning
through its full travel. No limits will
be set until the full cycle has been
completed. If the actuator detects
an obstruction (or torque increases
past 40%) then a limit may be set
incorrectly. If in doubt perform the limit
setting manually.

to select Auto Limit Set

Press
function. The actuator will display the
following instruction:

Info

Confirm OK to set limits
NOTE: Must be in Local

!

OK Cancel

Fig. 8.7.1

Press to initiate the auto setup.

The actuator will attempt to run to
the Close limit first, then run to the
Open limit. Once both limits have
been detected by a high mechanical
resistance, the limits will be saved to
memory.

If the sequence is interrupted or a
fault detected during the setup, the
following error will be displayed:

Error

Auto Limit Set Failed

OK Cancel

Fig. 8.7.2

IQT3 manual – S ection: Co mmissionin g - Basic Set tings 23

9. Maintenance, Monitoring
and Troubleshooting

Maintenance

Every Rotork actuator has been fully
tested before dispatch to give years of
trouble-free operation providing it is
installed, sealed and commissioned in
accordance with the instructions given in
this publication.

The IQT actuator’s unique double
sealed, non-intrusive enclosure provides
complete protection for the actuator
components.

The IQT actuator gearing is located in an
oil bath and is lubricated for life and does
not need replenishing. Should the oil be
removed or lost it must not be electrically
operated as premature failure may result.

Covers should not be removed for routine
inspection as this may be detrimental to
the future reliability of the actuator.

The electrical control module cover is
bonded by the Rotork quality control
seal. It should not be removed as the
module contains no site-serviceable
components.

All electrical power supplies to the
actuator must be isolated before any
maintenance or inspection is carried out,
except replacement of the battery.

Electrical supplies must be isolated before
actuator covers are removed – refer to
battery replacement instructions.

Routine maintenance should include the
following:

• Check actuator to valve fixing bolts
for tightness.

• Ensure valve stems and drive nuts are
clean and properly lubricated.

• If the motorised valve is rarely
operated, a routine operating
schedule should be set up.

• Replace actuator battery every
3 years.

• Check the actuator enclosure for
damage, loose or missing fasteners.

• Ensure there is not an excessive
build up of dust or contaminant
on the actuator.

• Check for any loss of lubricant.
(refer to section 11 for lubricants).

The Actuator Battery

The battery supports the actuator valve
position indication relays, Data logger
and the position display (LCD) only when
the main power supply is turned off. It
ensures the current position is indicated
and displayed when manual operation
takes place.

The battery is not required to retain
any actuator settings or track position
changes.

With mains power switched off and
without a battery fitted or when
discharged, all configured settings are
retained safely in EEPROM and position
changes are tracked by the absolute
encoder.

On power up, the correct, current
position will be displayed and the
actuator will operate normally.

WARNING: The battery holder in
the actuator gearcase also protects
the user from the hazardous live
connections inside the actuator and
therefore it must not be damaged.
The actuator must be isolated or
disconnected if the battery holder
has to be removed from the actuator
gearcase.

WARNING:
Battery Replacement
If the actuator is located within a

hazardous area permission must be
obtained in the form of a "hot work
permit" or other local regulation
before removal and/or replacement
of the battery.

Battery replacement must be carried out
with mains power isolated.

Battery Removal

The actuator must be selected to Stop
using the red selector – refer to section

4.2. Access to the battery is via a labelled
sealing plug situated on the main
gearcase near the handwheel hub.

Remove the sealing plug using the
appropriate Allen key, ensuring the
O-ring seal remains on the plug.
Disconnect the battery wiring loom from
the batter y terminals. Using the black pull
strap, lift the battery out of the rubber
sealing pocket.

24 IQT3 manual – S ection: M aintenance , Monitorin g and Troublesho oting

Fig. 9.7.1

Ba tte ry Types

For European hazardous area certified
actuators (ATEX / IEC Ex) use a lithium
manganese dioxide battery as stated in
Fig. 9.7.2 Battery Type Table.

For FM and CSA certified enclosures
use an Ultralife U9VL lithium
manganese dioxide battery. Equivalent,
UL recognised, batteries may be used.

For watertight (W T) actuator
enclosures Rotork recommend a lithium
manganese dioxide battery, however
any equivalent 9V battery may be used.

If in doubt regarding the correct
battery type, contact Rotork.

Enclosure Type Battery Type Detail

ATEX/IEC Ex -

Standard Temp

ATEX/IEC Ex -

Low/High Temp

Fig. 9.7.2 Battery Type Table

Ultralife PP3

Types

Rotork Part

Numbers:

U9VL or

U9VL-J-P

95-462 or

95-614

Fitting Replacement Battery

Fit the pull strap around the
replacement battery and insert into
the rubber sealing pocket. Reconnect
the batter y wiring loom to the battery
terminals. Refit the battery sealing plug
ensuring O-ring is in good condition
and correctly fitted. Hand tighten the
sealing plug to 8 Nm (6 lbf.ft) using the
appropriate Allen key.

Oil

Unless specially ordered for extreme
climatic conditions, Rotork actuators
are dispatched with gearcases filled
with Dextron II oil which is suitable for
ambient temperatures ranging from

-30 to +70 ºC (-22 to +160 °F).
IQT actuators do not require regular oil

changes (refer to Section 11, Weights
and Measures).

Torque and Position Monitoring

The IQT range of actuators incorporate
real time, instantaneous Torque &
Position monitoring as standard.
Torque & Position can be used to
monitor valve performance during
operation. The effect of process
changes (differential pressure etc.) can
be evaluated, tight spots in valve travel
can be pinpointed as well as gauging
the torque developed through stroke

in order to set appropriate open and
closed torque switch settings.

There a two home screen displays
that indicate torque and position
simultaneously. Refer to section 4.4

Analogue Torque and Position
indication

Fig. 9.7.3

Example shows that actuator at 35.0%
open, producing 27% of rated torque.
The warning triangle indicates the
actuator has torque tripped.

Note: The torque and position values
displayed are dynamic and will show
the actual torque and position values
currently measured. After a torque trip,
the torque value tends to drop away
as the internal mechanical components
relax as no drive is present.

IQT3 manual – S ection: M aintenance , Monitorin g and Troublesho oting 25

Digital Torque and Position indication

Fig. 9.7.4

Example shows that actuator at 35.0%
open, producing 27% of rated torque.
The status bar and warning triangle
indicate that the actuator has torque
tripped when closing.

Note: The actuator will torque trip and
stop when the value of torque reaches
that set for the open (when opening)
and closing (when closing) torque
switches (refer to 8.5 and 8.6). Due
to the effects of inertia (variable with
speed/load) and valve resilience, the
torque delivered and displayed may be
higher.

10. Environmental

End user advice on disposal at end of life of the product.
In all cases check local authority regulation before disposal.

Subject Definition Remarks / examples Hazardous Recyclable

Batteries

Electrical & Electronic
Equipment

Glass Lens/ Window IQ No Yes 16 01 20 Use specialist recyclers

Metals

Plastics

/Grease

Oil

Rubber Seals & O -rings Cover and shaft sealing Yes No 16 01 99

Lithium IQ battery Yes Yes 16 06 06

Alkaline Setting tool Yes Yes 16 06 04

Printed circuit boards All Products Yes Yes 20 01 35

Wire All Products Yes Yes 17 04 10

Aluminium Gearcases and covers No Yes 17 04 02

Copper/Brass Wire, IQ gears, motor windings No Yes 17 04 01

Zinc IQ clutch Ring and associated components No Yes 17 04 04

Iron/Steel Gears and bases No Yes 17 04 05

Mixed Metals IQ motor rotors No Yes 17 04 07

Glass filled nylon Covers, electronics chassis No No 17 02 04

Unfilled Gears No Yes 17 02 03 Use specialist recyclers

Mineral

Food Grade

Grease Side Handwheel / linear drive Yes No 13 02 08

Gearbox lubrication Yes Yes

Gearbox lubrication Yes Yes

EU Waste

Code

13 02 04

13 02 08

Disposal

Will require special treatment before
disposal, use specialist recyclers or
waste disposal companies

Use specialist recyclers

Use licensed recyclers

Disposal as general commercial waste

Will require special treatment before
disposal, use specialist recyclers or
waste disposal companies

May require special treatment before
disposal, use specialist waste disposal
companies

26 IQT3 manual – Section: Env ironmenta l

11. Weights and Measures

Oil

Unless specially ordered for extreme
climatic conditions, Rotork actuators
are dispatched with gearcases filled
with the following oils suitable for
ambient temperatures ranging from

-50 to +70 ºC (-58 to +158 ºF):

Size 1 – (IQT 125, 250, 500)
Castrol Aero HF585B
600ml / 1.3 pint (US)

Size 2 – (IQT 1000, 2000, 3000)
Castrol Aero HF585B
1600ml / 3.4 pint (US)

Base assembly

O-rings, use either Multis EP2 /
Lithoshield EP2 or equivalent for
all temperature ranges between

-50 and +70 ºC (-58 and +158 ºF).
Food grade lubricating oil is available

as an alternative: contact Rotork.

Actuator Size

IQT 125,
250, 500

IQT 1000,

2000

IQT 3000

Weight

kg (lbs)

22 (48.5) 0.6 (1.3)

37 (81.5) 1.6 (3.4)

39 (86.0) 1.6 (3.4)

Oil Capacities
litres (pt.-US)

Refer to actuator nameplate for oil
type. For oil plug location, refer to 1.1.

IQT3 manual – S ection: We ights and Me asures 27

12. IQT Approvals

Refer to actuator nameplate for unit
specific approval details.

European – Hazardous Area

ATEX (2014/34/EU) II 2 GD c

†

Ex db IIB T4 (T6
Ex tb IIIC T120°C (T80ºC

) Gb

†

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F)

Ex db IIC T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db, IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F)

Ex dbe IIB T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db IP66

& IP68

Temperature -20 to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F)

Ex dbe IIC T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F)

†T6 and T80°C temperature classes
rely on specific duty cycles see
section 15. Conditions of safe use.

International – Hazardous Area

IECEx. IEC60079-0 & IEC600679-1

†

Ex db IIB T4 (T6
Ex tb IIIC T120°C (T80ºC

) Gb

†

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (- 58 °F to +104°F)

Ex db IIC T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +70°C (-58°F to +158°F)

Ex dbe IIB T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +70°C (-58°F to +158°F)

28 IQT3 manua l – Sectio n: IQT Approva ls

Ex dbe IIB T4 (T6†) Gb

†

Ex tb IIIC T120°C (T80ºC

) Db IP66

& IP68

Temperature -20°C to +70°C (-4°F to +158°F)
*Option -30 °C to +70°C (-22°F to +158°F )
*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +70°C (-58°F to +158°F)

†T6 and T80°C temperature classes
rely on specific duty cycles see
section 15. Conditions of safe use.

USA – Hazardous Area

Explosionproof to NEC

FM
Article 500.

FM 3600, FM 3615 & FM3616
Class I, Division 1, Groups C & D
Class II, Division 1, Groups E, F & G

Temperature -30 °C to +70°C
(-22°F to +158°F)

*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F).

Class I, Division 1, Groups B, C & D
Class II, Division 1, Groups E, F & G

Temperature -30 °C to +70°C
(-22°F to +158°F)

*Option - 40°C to +70°C (-40 °F to +158°F)
*Option -50 °C to +4 0°C (-58°F to +104°F).

Canada – Hazardous Area

CSA Explosionproof to C22.2 No 30
CSA Dust Ignition Proof to C22.2

No 25
Class I, Division 1, Groups C & D
Class II, Division 1, Groups E, F & G

Temperature -30°C to +70°C (-22° F to +158°F)
*Option - 40° C to +70°C (-40°F to +158°F )
*Option -50°C to +40°C (-5 8°F to +104°F).

Class I, Division 1, Groups B, C & D
Class II, Division 1, Groups E, F & G

Temperature -30°C to +70°C (-22° F to +158°F)
*Option - 40° C to +70°C (-40°F to +158°F )
*Option -50°C to +40°C (-5 8°F to +104°F).

International Non Hazardous

Watertight, BS EN60529
IP66 & IP68, (7 metres for 72 hours).

Temperature -30°C to +70°C (-22° F to +158°F)
*Option - 40° C to +70°C (-40°F to +158°F )
*Option -50°C to +40°C (-5 8°F to +104°F)

US – Non Hazardous

NEMA Enclosure Type 4X & 6

Temperature -30°C to +70°C (-22° F to +158°F).
*Option - 40° C to +70°C (-40°F to +158°F )
*Option -50°C to +40°C (-5 8°F to +104°F).

Canada – Non Hazardous

Enclosure Type 4X & 6

Temperature -30°C to +70°C (-22° F to +158°F)
*Option - 40° C to +70°C (-40°F to +158°F ).
*Option -50°C to +40°C (-5 8°F to +104°F).

Rotork can supply actuators to national
standards not listed above. For details
please contact Rotork.

IQT3 manual – S ection: I QT Approvals 29

13. Approved Fuses

14. Vibration, Shock and Noise

Transformer

Type 1

Type 2

Type 3

Type 4

Transformer

Types 1-4

Transformer

Types 5

Transformer

Types 5

Transformer

All

Value Manufacturer Part number

5.0A Anti-Surge

2.5A Anti-Surge

2.0A Anti-Surge

2.0A Anti-Surge

Value Manufacturer Part number

20A ATO Littlefuse 166.7000.5206

Value Manufacturer Part number

20A ATO Littlefuse 166.7000.5206

Value Manufacturer Part number

500 mA Bussmann S505-500-R

FS3 – (Battery loom on ATEX builds only)

Value Manufacturer Part number

100 mA Quick blow

30 IQT3 man ual – Secti on: Approve d Fuses

AC – FS1

Schurter 8020.5018

SIBA 70-065-65

Schurter 8020.5015

SIBA 70-065-65

Schurter 8020.5014

SIBA 70-065-65

Schurter 8020.5014

SIBA 70-065-65

AC – FS2

DC – FS1

DC – FS2

Bussmann S500

Littlefuse 217

Standard IQT range actuators are suitable for applications where vibration and
shock severity does not exceed the following:

Type Level

Plant induced vibration

Shock

Seismic

Emitted noise

1g rms total for all vibration within the frequency range of 10 to 1000 Hz

5g peak acceleration

2g acceleration over a frequency range of 1 to 50 Hz if it is to operate
during and after the event

Tests have shown that at 1m generated noise does not exceed 65 db(A)

15. Conditions of Safe Use

15 .1 Thread details for ATEX and IECEx Approved actuators

Threaded Flamepath Thread Size Thread Length Actuator Type and Size

Battery Cover

Cable Entry

15.2 Maximum constructional flamepath gaps for ATEX and IECEx
Approved actuators.

Flamepath Max. Gap (mm) Min. Length (mm) Actuator

Motor Cover / Gearcase

Motor-shaft shroud / Gearcase

Motor-shaft / Shroud

Terminal Bung / Gearcase (IIB)

Terminal Bung / Gearcase (IIC, FM &

CSA Group B)

Terminal Cover / Gearcase

Electrical Cover / Gearcase

Encoder shaft / Encoder shaft bush

Encoder shaft bush / Gearcase

Note: Negative sign denotes an interference fit.

M40x1.5 10.00 All Types and Sizes

M25x1.5 20.00 All Types and Sizes

M40x1.5 20.00 All Types and Sizes

0.15 26.00

-0.05 / 0.00 26.00

0.24 25.00

0.20 27.00

0.115 27.00

0.15 27.00

0.15 26.00

0.08 27.00

0.07 25.00

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

IQT all sizes

When the equipment is marked with
a T6 temperature classification/ T80ºC
maximum surface temperature, the
following duty cycle is applicable:

IQT50, IQT100, IQT125, IQT250,
IQT500, IQT1000 and IQT2000

Nominal 60 starts at a rate of not
exceeding 600 starts per hour,
15 minutes rated based upon a
nominal 75% of rated torque.

IQT3000

Nominal 60 starts at a rate of not
exceeding 600 starts per hour,
15 minutes rated based upon a
nominal 50% of rated torque.

IQT3 manual – S ection: A pproved Fu ses 31

Keeping the World Flowing

UK

Rotork plc

tel [phone]
fax [phone]
email [e-mail]

As par t of a process o f on-go ing produc t develo pment, Roto rk reser ves the righ t to amend and ch ange spec ificatio ns withou t prior
notice. Pub lished dat a may be subje ct to change. F or the ver y latest ve rsion rel ease, visit o ur website at w ww.rotork.com

The name Rot ork is a regis tered trad emark. Roto rk recognis es all regis tered trad emarks . The Bluetooth
register ed tradema rks owne d by Bluetoot h SIG, Inc . and any use of suc h marks by Rot ork is under l icense. Pub lished and pr oduced
in the UK by Roto rk Controls Limited. PO WJB0916

USA

Rotork Controls Inc.

tel [phone]
fax [phone]
email [e-mail]

®

word mark an d logos are

A full listing of our worldwide sales and service
network is available on our website.

www.rotork.com

PUB002-065-00

Date of issue 09/16