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