rotork IQT, IQTM, IQTFS, IQTF Installation And Maintenance Information

IQT Range

Installation and Maintenance Instructions

This manual contains important safety information. Please ensure it is thoroughly read and understood before installing,

operating or maintaining the equipment.

PUB002-004-00 Date of issue 01/11

The Rotork Setting Tool allows actuator control, indication and protection functions to be configured to suit site requirements. In addition, the new Setting Tool Pro also allows downloading of datalogger and uploading/downloading of configuration files. Files are transferred to and from the Setting Tool Pro via Rotork Insight.

It is essential that all the actuator settings are checked for compatibility with the valve, process and control system requirements before the actuator is put into service. Please read this publication.

When Rotork personnel or nominated agents are contracted to carry out site commissioning and/or acceptance, documentation of commissioned actuator configuration can be made available for customer records.

Rotork Setting Tool Pro

Rotork Setting Tool

This manual covers IQT range actuators:

* IQT - Operation of isolating/regulating 1/4 turn valves. * IQTM - Operation of modulating 1/4 turn valves. * IQTF * IQTFS -

Operation of part-turn and slow speed multi-turn valves. Battery failsafe.

It provides instruction on:

* Manual and electrical (local and remote) operation.

* Preparation and installation of the actuator onto the valve.

* Commissioning and adjustment of the Primary Settings for correct valve operation.

* Commissioning and adjustment of the Secondary Settings to suit site-specific control and indication requirements.

* Maintenance – Troubleshooting.

* Sales and Service.

Refer to Publication E185E for repair, overhaul and spare part instructions.

THE ROTORK IQT RANGE – THE FIRST 1/4 TURN VALVE ACTUATOR THAT YOU CAN COMMISSION AND INTERROGATE WITHOUT REMOVING ELECTRICAL COVERS.

Using the supplied infra-red Setting Tool to access the actuator set up procedures, “point and shoot” 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 IQT allows commissioning and adjustment to be carried out with the main power supply to the actuator switched on or off.

Standard diagnostics access information about the control system, valve and actuator status in the form of display icons and help screens.

Instantaneous valve torque and position can be monitored on the actuator with a single key press of the Setting Tool.

The on board Datalogger captures operational and valve torque data enabling informed maintenance choices to be made. IQ Insight software for PC allows the Datalogger to be interrogated, as well as the complete actuator set up to be configured and recorded.

The actuator containing the Setting Tool will be identified with a yellow label on the terminal cover.

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

IQelecCvr

Identifying Actuator Parts

III

Conduit entries

Terminal Cover

Base

Stop Bolts

Motor cover

Control Cover

Name plate

Display window

Hand / Auto

IQelecCvr

lever

Local / Remote / Stop selector

Open / Close selector

Battery sealing plug

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

Hand wheel

CONTENTS

Page

1 Health and Safety 2 2 Storage 3 Operating your IQT Actuator

3.1 Operating by Hand 3

3.2 Operating Electrically 3

3.3 Display – Local Indication 4

3.4 Display Status Indication – Travel 5

3.5 Display Status Indication – Control 5

3.6 Display Alarm Indication 5

4 Preparing Drive Bush 7

4.1 Bases F05 to F07 7 and FA05 to FA07

4.2 Bases F10 to F14 7 and FA10 to FA14

4.3 Machining the Drive Bush 7

4.4 Fitting the Drive Bush 7

5 Mounting the Actuator 8

5.1 IQT Actuators 8

5.2 IQTM Actuators 8

5.3 IQTF Actuators 8

5.4 Lifting the Actuator 8

5.5 Securing Actuator to Valve 8

5.6 Stop Bolts 9

Page

6 Cable Connections 10

6.1 Earth/Ground Connections 10

6.2 Removing Terminal Cover 10

6.3 Cable Entry 10

6.4 Connecting to Terminals 10

6.5 Replacing Terminal Cover 10

7 Commissioning 11

7.1 The Setting Procedure 11

7.2 The Rotork Setting Tools 12

7.3 Entering the Actuator 15 Setting Procedure

7.4 Setting Mode – Password 15

7.5 New Password 15

7.6 Checking Mode 15

7.7 Crossroad 16

7.8 The Actuator Display – 16 Setting/Checking Mode

7.9 Returning to Valve Position Display 16

8 Commissioning –

Basic Settings 17

Basic Settings Contents 18

9 Commissioning –

Configuration Settings

Configuration Settings Contents 29 Default Options 60

Page

10 IQT Battery Failsafe Instructions 62

10.1 Introduction 62

10.2 Specification 63

10.1 Commissioning instructions 64

11 Maintenance, Monitoring

and Troubleshooting

11 Torque-reference profile 69

11.1

11.2 Help Screens 73

11.3

11.4 Environmental 79

Setting Tool Pro Download & Upload

IQT Infrared Diagnostic & Configuration

12 Weights and Measures 80

Binary, Hexadecimal and Decimal Conversion Table 81

13 IQT Approvals 82

Approved Fuses 83 Maximum Flamepath Gaps 83

Appendix A 84

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

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. It should only be installed in hazardous area locations compatible with the gas 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 certification. 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 nonhazardous area for repair or attention.

WARNING: Thermostat Bypass

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

The

WARNING: Enclosure Materials

IQT actuators are manufactured from aluminium alloy with stainless steel.

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 Han

With respect to handwheel operation of Rotork electric actuators, see warning on p3.

This actuator must only be

located in areas where the risk of

impact to the viewing window is low.

Actuator may start and operate when remote control is selected, depending on remote control signal status and actuator configuration.

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 preserve 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.

Operating your IQT Actuator

3.1 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.

Fig. 3

To engage handwheel drive, turn the Hand/Auto lever clockwise whilst turning the handwheel, see Fig 3. The lever can now be released upon which 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 the Hand/Auto lever can be locked in either position using a padlock with a

6.5mm hasp.

3.2 Operating Electrically

Check that power supply voltage agrees with that stamped 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 Primary Settings have been made

8 page 17).

(refer to Section

Selecting Local/Stop/Remote Operation

The red selector enables either Local or Remote control, lockable in each position using a padlock with a 6.5mm 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. 3.1

Local Control

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

Remote Control

Rotate the red selector to the Remote position (clockwise), this gives remote control only for Open and Close but local Stop can still be used by turning the red knob anti-clockwise.

3.3 Display–Local Indication

Fig. 3.2 The Actuator Display

The display consists of:

1. Position Display - This is the main 7-segment position display with icons.

2. Text Display - This is a 2 line, 16 characters dot matrix display which allows text to be used to compliment the position display and icons.

3. Infra Red LED's.

4. 1 x Bi colour LED, 1 x Amber colour

LED for position indication.

5. Alarm Icon - This will be displayed for Valve, Control, and Actuator alarms. Alarm indication is supported by fault

description text in the lower display.

6. Battery Alarm Icon - This icon will be displayed when a battery is detected as low or flat. "Battery low" or "flat" will also be displayed in the lower display.

7. IR Icon - This icon flashes during infra red communication activity.

8. Percentage Open Icon - This icon will be displayed when a percentage Open value is in the upper display.

The liquid crystal display screen has 2 modes of position indication:

1. Valve position – power on

2. Valve position – power off

On power up the actuator’s liquid crystal display screen is back-lit with an amber light and one of the indicator lamps will be on, dependent on position. The display screen will show percentage open or an end of travel symbol. (See Figs 3.3, 3.4 and 3.5)

As standard, red lamp signifies valve open, amber intermediate, and green lamp signifies valve closed. Open and closed colour functions can be reversed on request.

Open

The two tri-colour LED's will be Red, the open symbol and "Open Limit" will be displayed

Open Limit

Fig. 3.3

Mid Travel

The two tri-colour LED's will be Amber, percentage open value will be shown and "Stopped" will be displayed when there is no actuator movement.

Stopped

Fig. 3.4

Closed

The two tri-colour LED's will be Green, closed symbol and "Closed Limit" will be displayed.

Closed Limit

Fig. 3.5

With the main power supply switched off, the display screen is powered by a battery and continues to display actuator position. However, the battery does not support screen back-lighting, position indicator lamps or dot matrix display.

LED Indicators

WARNING: Mid Travel LED colour may be affected by viewing angle and lighting level.

The Close LED colour can be changed to red if required. The Mid Travel amber LED can be switched off if required. Refer to Section 9.16, page 58.

3.4 Display Status Indication – Travel

The IQT display provides real time status indication. The top line of the text display is reserved for travel status indication. Fig 3.6 shows the travel status example

Closed Li mit

Fig. 3.6

Available travel status conditions displayed:

•

Closed Li mit

set closed limit position.

Open Limi t

• set open limit position.

Moving Op en

• the open direction.

Moving Cl osed

• the closed direction.

Stopped

• mid travel position, indicated in the top display (%open).

Actuator has reached the

Actuator is traveling in

Actuator has stopped in a

Tim er Acti ve

• enabled only. Interrupter Timer has stopped the actuator mid travel for a period equal to the set Timer Off time. Refer to 9.13 page 55.

3.5 Display Status Indication – Control

The bottom line of the text display is reserved for control status indication and is displayed for approximately 2 seconds after the control mode or signal is applied. Fig 3.7 shows the control status example

Interrupter Timer option

Remote Co ntrol

Closed Li mit

Remote Co ntrol

Fig. 3.7

Available control status conditions displayed:

•

Local Con trol

red selector.

•

Local Sto p

selector.

Local control selected -

Local stop selected – red

•

Remote Co ntrol

selected – red selector.

•

Local Clo se

– black selector.

•

Local Ope n

– black selector.

•

Remote Cl ose

or analogue) signal applied.

•

Remote Op en

or analogue) signal applied.

•

Remote ES D

emergency shut down signal applied.

•

Remote Bu s Op en

signal applied.

•

Remote Bu s Cl ose

applied.

•

Remote Bu s ES D

emergency shut down signal applied.

* Bus Control option fitted may be

Pakscan, Profibus, Modbus, DeviceNet or Foundation Fieldbus. Refer to actuator wiring diagram.

Remote control

Local close signal applied

Local open signal applied

Remote close

Remote open

Remote hardwired

Remote Bus * open

Remote Bus* signal

Remote Bus*

(hardwired

3.6 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:

General Alarm

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 3.8 shows the status example

TORQUE TRIP CL

Stopped

TORQU E TRIP CL

Fig. 3.8

Available alarm conditions displayed:

Valve Alarms

TORQUE TRIP CL

• while moving in the close direction.

TORQUE TRIP OP

• while moving in the open direction.

MOTOR STAL LED

• detected after a signal to move.

Control Alarms

ESD A CTIVE

• present the ESD signal overrides all local and remote control signals. Once the ESD action is carried out operation is inhibited while the ESD signal is maintained. Refer to 9.3 ESD Action page 32.

INTERLOCK AC TIVE

• interlocks are configured on and are

active. Refer to 9.3 Interlock page 34. Operation in the direction of an active interlock(s) is inhibited. Note that when conditional control is configured, an active interlock will not inhibit local control operation.

tripped off on torque

no movement

ESD signal applied. When

Open and/or close

Actuator Alarms

•

THERMOSTAT T RIP

thermostat has tripped due to extended motor operation. Operation is inhibited until the thermostat resets automatically when the motor control cools. Check actuator duty cycle against process requirements (running time, torque, ambient temperature).

•

PHASE LOS T

The phase supply the actuator connected to terminal 3 is lost. Operation is inhibited.

•

24V LOST

supply (terminals 4 & 5) has tripped. Check remote control wiring. Supply is protected with a resettable fuse.

•

LOCAL CON TROL FAIL

of control selectors (black and red).

•

CONFIG ER ROR

in the configuration (set up) of the actuator. Check and reset basic setting and check configuration settings.

•

POS SENSO R FAIL

the position sensing system – contact Rotork.

Motor control

(3-phase models only).

The 24 volt customer

Check operation

There may be an error

Detected failure in

•

TORQ SENS OR FAIL

in the torque sensing system – contact Rotork.

EEPROM MI SSING

•

Battery Alarm

Detected failure

Contact Rotork

Open Limit

BATTERY LOW

Fig. 3.7

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

LOW

If the battery is flat or missing the display will indicate

BATTERY FLAT

BATTERY

When a low or flat battery alarm is displayed the battery should be replaced immediately. It is essential that the correct battery type is fitted to maintain actuator certification. Refer to page 67.

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 battery check and clear the alarm.

PWR LOSS INHI BIT

If, on power up, the actuator detects a discharged battery and actuator power loss inhibit feature [OS] is enabled (refer to page 57), both battery and general alarm icons will be displayed and the bottom line will indicate alternately

BATTERY FLAT

inhibited. The battery must be replaced and the limits must be reset. Refer to Section 11, page 67 and Section 8, page 17.

PWR LOSS INHI BIT

. Electrical operation will be

and

Preparing Drive Bush

4.1 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 4.

Fig. 4

Clear access to the drive bush is now available as shown in figure 4. Using the a 3mm allen key, unscrew the two capscrews retaining the drive bush and remove the drive bush from the actuator.

Fig. 4.1

4.2 Bases F10 to F14 and FA10 to FA14

Removal of the drive bush does not require the removal of the actuator base. Using a 3mm 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 4.2.

Fig. 4.2

The range of IQT drive bushes is shown in figure 4.3. Please refer to PUB002001 for maximum stem acceptance details.

Fig. 4.3

4.3 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.

4.4 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.

Mounting the Actuator

5.1 IQT Actuators

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

5.2 IQTM Actuators

The IQTM range of actuators are suitable for modulating control duty of up to 1200 starts per hour in accordance with IEC 34-1 to S4 50%. Commissioning of IQTM range actuators is identical to the standard IQT (refer to Sections 7, 8 and 9).

5.3 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).

5.4 Lifting the Actuator

(Refer to Weights and Measures page 80 for actuator weight.)

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

If it is necessary to lift 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. 5

WARNING:

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

Fig. 5.1

5.5 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 page 9.

Secure actuator to valve with four fixing bolts. Check that the cast groove in actuator base is not obstructed see Fig 5.1. Its purpose is to protect the actuator in the event of a product leak from the valve stem/gland packing. Check base fixing bolts are tight.

5.6 Stop Bolts

It is recommended that stop bolt adjustment be carried out by the valvemaker/supplier before the valve is fitted into pipework. Once installed, the valve maker/supplier should be consulted before stop bolt readjustment is carried out. Stop bolts can be wired to prevent tampering. After setting or adjustment of stop bolts the actuator limits must be reset, refer to Limits LC, LO page 24.

The IQT stop bolts are located below the terminal compartment. Stop bolt adjustment allows +/– 5º variation of travel at each end position. Screwing bolts in reduces movement, out increases movement. For clockwise closing valves the right hand bolt is the closed stop as shown with spanner in fig 5.2. The left is the open stop. Stop bolts are factory set to give a nominal 90º travel.

Fig. 5.2

Stop Bolt sizes.

IQT 125 to 500: M12 bolt requiring 19mm AF spanner.

IQT1000 & 2000: M20 bolt requiring 30mm AF spanner.

Adjustment for non seating valves types

For closed and open stop position adjustment:

Undo stop bolt lock-nut. Move actuator and valve to the required stopping position (it may be necessary to unscrew stop bolt to allow more travel). Screw stop bolt in until a stop is felt. Tighten stop bolt lock nut.

Adjustment for seating valves types

For closed and open stop position adjustment:

Undo stop bolt lock-nut. Move actuator and valve to the required seating position of the valve (it may be necessary to unscrew stop bolt to allow more travel). Screw stop bolt in until a stop is felt and then back off by 3 turns. Tighten stop bolt lock-nut.

Reset actuator limits

Refer to Limits LC, LO page 24.

Cable Connections

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 of the actuator. The switch or circuit breaker shall be mounted as close to the actuator as possible and shall be marked to indicate that it is the disconnecting device for that particular actuator. The actuator must be protected with overcurrent protection devices rated in accordance with Rotork publication No. E135E Electric motor performance data for IQT range actuators.

WARNING: Actuators for use on phase to phase voltages greater than 600V A.C.must not be used on supply systems such as floating, or earthphase systems, where phase to earth voltages in excess of 600V A.C. could exist.

6.1 Earth/Ground Connections

A lug with a 6mm 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.

6.2 Removing Terminal Cover

Using a 6mm 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 inside of the terminal compartment cover 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. 6

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

6.3 Cable Entry

Only appropriate certified ExplosionProof entry reducers, glands or conduit may be used in hazardous locations.

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.

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

6.4 Connecting to Terminals

On EExde enclosure units connections to the power and control terminals must be made using AMP type 160292 ring tabs for power and earth terminals and AMP type 34148 ring tabs for the control 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.

6.5 Replacing Terminal Cover

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

Commissioning

7.1 The Setting Procedure

The Rotork IQT range of actuators is the first that enables commissioning to be carried out without removing covers.

Setting torque, limit and other functions is achieved by using the Infra-Red Setting Tool. The Setting Tool is certified Intrinsically Safe to allow commissioning in hazardous areas.

All the commissioning functions are stored in non-volatile memory in the actuator. The Setting Tool enables the user to view all the functions in turn via the actuator display window. As each function is viewed its setting can be checked and, if required, changed within the bounds of that function.

Commissioning may be carried out with main power switched on or off. Refer to page 17 for Power Off Setting.

The setting procedure is divided into two stages:

1. Basic Settings

Settings for end of travel limit actions, torque values, limit positions etc.

2. Configuration Settings

Settings covering the control, indication and optional equipment functions.

NOTE: For IQT Battery Failsafe

instructions, see Section 10 page 62.

WARNING: All IQT actuator functions are configured before dispatch to Rotork standard default settings unless alternatives have been specified with the order. Should difficulty be encountered during commissioning the default settings can be reinstated, returning the actuator configuration to its original manufactured state. Site commissioning can then begin again

(refer to Section 9.18 page 59).

The default function should be used with caution as settings selected after manufacture may be essential for the safe operation of the valve and/or plant.

Actuator Display

Position Display

or a percentage open value.

Torque and Position

Password P?

Crossroad cr

Basic Settings Configuration Settings

Direction Indication Contacts Limit Actions Control Mode Torque Values Options Limit Positions Help Screens Defaults

Note: The Basic Settings must be commissioned first.

This may be an open or closed symbol

Refer to Section 11.

Torque

PC k Ir k tP

Commissioning continued

7.2 The Setting Tool (old version)

Specification

Enclosure IP67

Certification EEx ia IIC T4 (intrinsically safe) FM, INT SAFE, Class I & II Div 1 Groups A B C D E F G, T4A CSA, Exia, Class I, II Div 1 Groups A B C D

Power supply 9V Battery (supplied and fitted)

Operating range 0.75m (from actuator display window)

Name Instruction

1. m Key* Display next function down

Key* Display next function across

Key Decrease/change displayed function’s value or option setting

Key Increase/change displayed function’s value or option setting

Key Enter displayed value or option setting

* Pressing the two arrow keys together returns the actuator display to the position indication mode

Infra-red local operation (when enabled)

Key Stop actuator

Key Open actuator

Key Close actuator

8. Infra-red Transmitter Window

Fig. 7.1 The Setting Tool

Setting Tool Battery Replacement

Battery status can be checked by looking at the Infra-red transmitter window while depressing any Setting Tool button. A flashing red indicator should be seen.

Battery replacement must be carried out in a safe area. To replace the battery remove the six caphead screws in the back of the Setting Tool. Remove the back cover to expose the battery.

In order to maintain hazardous area certification fit only Duracell MN1604 or Rayovac Alkaline Maximum NoAL-9V battery types. Refit cover ensuring red indicator LED faces the transmitter window in the back cover.

When a button is depressed the Setting Tool transmits the relevant instruction to the actuator by infra-red pulses and must therefore be directly in front of the actuator indicator window and at a distance no greater than 0.75m.

7.2 The Setting Tool Pro (new version)

Specification

Enclosure IP54 This Setting Tool Pro has been built in accordance with the following standards: USA - Hazardous Area.

Factory Mutual - Explosion Proof to NEC Article 500. Intrinsically Safe, Class 1, Div 1, Groups A, B, C & D, T4. Canada - Hazardous Area.

Temperature Tamb = -30ºC to 50ºC Power supply 2x 1.5V Batteries (supplied and fitted) Operating range 0.75m (from actuator display window)

Name Instruction

1. m Key* Display next function down

i Key Display previous function up

Key* Display next function across

k o

Key Display previous function across

Key Decrease/change displayed function’s value or option setting

Key Increase/change displayed function’s value or option setting

Key Initiate download/upload mode

Key Enter displayed value or option setting

* Pressing these two arrow keys together returns the actuator display to the position indication mode

CSA - Exia Intrinsically Safe, Class 1, Div 1, Groups A, B, C & D, T4.

Fig. 7.2 The Setting Tool Pro

Infra-red local operation (when enabled)

Key Stop actuator

Key Open actuator

10.

Key Close actuator

11.

12. Infra-red Transmitter Window

Commissioning continued

Download / Upload Function

This new feature has been introduced with the new Rotork Setting Tool Pro. It allows the user to download datalogger files and download/upload configuration files. The new tool is weatherproof and intrinsically safe and so it can be used safely in all environments. For more information refer to Section 11.1, page 70.

Setting Tool Pro Battery Replacement

Battery status can be checked by looking at the Infra-red transmitter window while depressing any Setting Tool Pro button except the download button. A flashing red indicator should be seen.

Battery replacement must be carried out in a safe area. To replace the battery remove the six cap head screws in the back of the Setting Tool Pro. Remove the back cover to expose the battery.

In order to maintain hazardous area certification the actuator Setting Tool Pro shall only be fitted with the following AA size, alkaline-manganese, approved battery types:

Duracell, Coppertop, type MN1500 Duracell, Procell, type MN1500 GP, Super Alkaline, type GP15A

Other types of AA size batteries, including Duracell, Ultra, type MN1500, must not be fitted. For battery replacement see Section 7.

Refit cover ensuring red indicator LED faces the transmitter window in the back cover.

The enclosure of the actuator Setting Tool Pro is manufactured from the materials:

Polycarbonate, ABS blend Polycarbonate Silicon Rubber

If the actuator Setting Tool Pro is likely to come into contact with aggressive substances (e.g. solvents that may affect polymetric materials), then it is the responsibility of the user to take suitable precautions (e.g. regular checks as part of the routine inspections or establishing that the materials are resistant to the specific chemical) that prevent it from being adversely affected, thus ensuring that the type of protection is not too compromised.

No form of repair must be attempted on the actuator Setting Tool Pro.

When a button is depressed the Setting Tool Pro transmits the relevant instruction to the actuator by infra-red pulses and must therefore be directly in front of the actuator indicator window and at a distance no greater than

0.75m.

Display Set-Up Mode

The Setting Tool and Setting Tool Pro arrow keys are used to access and navigate through the actuator set-up procedure using the actuator display. Each actuator function with it's current setting is represented on screen by a combination of code and text. The Setting Tool change keys (+ and –) allow the user to view the available setting options.

The examples of displayed functions

Close Action

are shown to the right. Note that a setting option or value is highlighted.

This instruction manual uses both code and text for description.

, [C2] and

Open Torq ue

, [tO]

Function Code

Function

Function Code

Function

Close Action

Close on Torque

Open Torque

40%

Setting

Code

Setting

Option

Setting

Value

Setting

Value

7.3 Entering the Actuator Setting Procedure

With the actuator securely mounted on the valve, the mains supply on and Local control or Stop selected.

PRESS THE m

The actuator upper display will remain the same and the lower display will change to Torque value. This will be represented by Torque = XX% and a bar graph. (For instantaneous torque

& position monitoring, refer to Section 11, page 68.)

PRESS THE m

The actuator display will change and the password protection display will be seen.

The Actuator Function Settings

can be protected by the Use

KEY.

Enter Pa ssw ord

ID Hex

of a Password

7.4 Setting Mode – Password

To enable setting and adjustment of the actuator functions the correct password must be entered. The factory set (default) password is [ld]. If the actuator has previously been set with a site password this must be entered.

Use the available passwords 00–FF (hexadecimal). With the correct password displayed press the enter key.

PRESS THE KEY

Two “setting” bars will appear and will remain visible on every function display screen. In addition, "Password Correct" will be displayed for 3 seconds.

keys to scroll through the

Enter Pa ssw ord

Password Co rrect

Default Password,

Setting Mode Enabled

7.5 New Password [PC]

To configure a new password, the actuator must be in setting mode with the password display – setting mode enabled – showing,

PRESS THE

The display will change to [PC]. Using the

or - key scroll through the available passwords until the desired password is displayed.

KEY.

PRESS THE KEY.

Change P ass word

IE Hex

Password Changed to [IE]

NOTE: The new password becomes

effective the next time setting mode is entered.

7.6 Checking Mode

The actuator function settings can be checked without entering the correct password. The settings can only be viewed and not altered. The setting bars will not be seen.

Enter Pa ssw ord

ID Hex

Password Display, Checking Mode

Once the procedure has been completed in the required mode

PRESS THE m

The procedure branch [Cr] (crossroad) display

can now be seen (refer to Section

7.7 page 16).

KEY.

Commissioning continued

7.7 Crossroad [Cr]

Basic Se tup Config S etu p

To access the Basic Settings press the arrow

Commissioning Basic Settings page 17).

To access the Configuration Settings press the arrow

Section 9 Commissioning Configuration Settings page 27).

key (refer to Section 8

key (refer to

7.8 The Actuator Display – Setting/Checking Mode

Actuator functions as laid out in the Basic and Configuration commissioning stages, can be individually displayed by using the Setting Tool arrow keys.

arrow key will always display

The the FIRST function on the next level DOWN within the procedure.

arrow key will always display

The

the NEXT function on the SAME level and will wrap around the functions on the same level.

The actuator display indicator lamps will continue to indicate valve position but will also flash during IR communication.

Actuator functions are displayed in code form in the top left portion of the liquid crystal display screen.

The setting for the displayed function is shown in the top right hand portion of the screen. Depending on the actuator function displayed, its setting may be an option or a value.

Text relating to the function and setting values will be displayed in the lower display.

In setting mode the Setting Tool

keys will cause the setting to be changed. In checking mode the settings cannot be altered.

In setting mode, once displayed, a new setting can be entered into the actuator memory by pressing the The setting will flash off and back on, confirming its selection, and " will be displayed for 2 seconds in the text display.

TOP LEFT PORTION

Function e.g.

Close Torque

40%

tC = Torque Close

TOP RIGHT PORTION

Function Setting e.g. Value = 40%

key.

Stored

LOWER DISPLAY

Setting Value: 40%

Typical Actuator Function Display

Setting Mode Enabled

Function: Close Torque

7.9 Returning to Valve Position Display

There are five ways of returning to valve position display:

1. Approximately 5 minutes after the last Setting Tool operation the display will automatically return to position display.

2. Press the together.

3. Press the display returns to position.

4. Select Remote control using the red Local/Stop/Remote selector.

5. If you have the new Setting Tool Pro then you can use the key to return to position display.

and

arrow keys

arrow key until the

iarrow

Commissioning – Basic Settings

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

The actuator’s Basic Settings affect the correct operation of the valve by the actuator. If the actuator has been supplied with the valve, the valve maker or supplier may have already made these settings.

This instruction assumes setting mode has been entered (refer to section 7.4 page 15).

Viewing the Basic Settings

With the actuator mounted on the valve, the power supply on and Local or Stop control selected, point the Setting Tool at the actuator indicator window from a distance of no more than 0.75m. By pressing the m key and, when appropriate, the it is possible to move through the procedure, displaying the various functions and their settings as shown in Fig. 8.1 (refer to page 18).The right-hand side of Fig.8.1 explains the function of each LCD display.

key,

Power Off Setting

IQT allows settings to be viewed and set without main power. To enable this function, engage handwheel drive and rotate until the output drive moves (refer to page 3). The Setting Tool can now be used. As long as a Setting Tool key press takes place within the 30 seconds timeout period, Power Off Setting will remain enabled. If no infra-red Setting Tool communication takes place the display will return to indicating position. The actuator must then be operated by handwheel to re-enable Power Off Setting.

Settings and operation must be verified by electric operation and function test of the actuator to ensure correct operation.

Viewing the Basic Settings

Function Description

Torque and Position Display

Torque

P? k PC k Ir k tP Password k Password Change k IrDA k Torque Reference Profile

Cr k Configuration Crossroad k Configuration Settings, refer to page 32.

C2 k C3 Direction to Close k Close Action k Open Action

tC k tO Torque Value Closing k Torque Value Opening

LC k LO Limit Closed k Limit Open

Position Display

Fig. 8.1 Basic Setting Displays

Position Display

(This may be an open or closed symbol or a % open value.)

REFER TO SECTION 7, COMMISSIONING

BASIC SETTINGS CONTENTS

page

C1 Direction to Close 19 C2 Close Action 20 C3 Open Action 21 tC Torque Value Closing 22 tO Torque Value Opening 23 LC Set Limit Closed 24 LO Set Limit Open 24 AA Speed Setting 25

Direction to Close

The actuator can be configured to be clockwise or anti-clockwise to close. Manually operate actuator and valve to establish correct closing direction. Conversion Handwheel direction labels are available.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

Using the + or - key, display the character conforming to correct closing direction.

Close Di rec tion

Clockwis e

[C] in the Setting Field Indicating

Clockwise to Close

Close Di rec tion

Anticloc kwi se

[A] in the Setting Field Indicating

Anti-clockwise to Close

Having ensured that the display corresponds to the established closing direction

PRESS THE KEY.

The displayed option will flash (stored), indicating that it has been set.

PRESS THE k KEY.

Close Action

IQT actuators are designed to stop at the end of travel by torque limitation against the actuator stop bolts. Stop bolts should therefore be set to the precise stopping position required, refer to section 5.6.

IQTF actuators can be configured to close on torque or limit. Refer to valve manufacturers instructions.

Refer to valve manufacturer

for recommended setting.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

Using the + or - key, display the required option.

Close Act ion

Close on Torque

[Ct] in the Setting Field Indicating

Close on Torque - default setting.

Close Act ion

Close on Li mit

[CL] in the Setting Field Indicating

Having selected the required option

Close on Limit.

PRESS THE KEY.

The displayed option will flash (stored), indicating that it has been set.

PRESS THE k KEY.

NOTE:

When set to close on torque, the actuator will apply the level of torque as set for [tC] in seating the valve (refer to [tC] page 22).

Open Action

IQTF actuators can be configured to close on torque or limit. Refer to valve manufacturers instructions.

Refer to valve manufacturer for recommended setting. In the absence of valvemaker instructions set “Open Limit”.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

Using the + or - key display the required option.

Open Acti on

Open on Torque

[Ot] in the Setting Field Indicates

Open on Torque - defualt setting.

Open Acti on

Open on Lim it

[OL] in the Setting Field Indicates

Open on Limit.

PRESS THE KEY.

The displayed option will flash (stored), indicating that it has been set.

PRESS THE k KEY.

NOTE:

When set to open on torque, the actuator will apply the level of torque as set for [tO] in back seating the valve (refer to [tO] page 23).

Close Torque

The value of torque available in the close direction can be configured.

Refer to valve manufacturer

for recommended value.

The closing torque value can be varied between 40% and Rated (100%), in 1% increments.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

Using the + and - keys, the display recommended value. In the absence of a recommended torque value, try a low setting and increase until satisfactory valve operation is achieved.

If the actuator fails to

complete a closed valve operation due to the set torque being reached ( this may indicate a valve and/or process problem or change. It is the responsibility of the user to ensure the valve and process conditions are within specified operational limits before increasing the Set Close torque value.

Torq ue Trip CL

Alarm, page 5)

PRESS THE KEY.

The displayed value will flash (stored), indicating that it has been set.

Should the set level of torque be developed in closing, the actuator will torque trip and stop.

PRESS THE k KEY.

NOTE: Rated torque is quoted on the

actuator nameplate.

Close Torque

40%

40% of Rated Torque

Close Torque

99%

99% of Rated Torque

Close Torque

100%

Rated Torque

Open Torque

The value of torque available in the open direction can be configured.

Refer to valve manufacturer

for recommended value.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

The opening torque value can be varied between 40% and Rated, in 1% increments. In addition “Boost” can be configured when no open torque protection is required.

BOOST SHOULD NOT BE SELECTED WHEN THE ACTUATOR HAS BEEN CONFIGURED TO OPEN ON TORQUE

UNLESS BACK SEATING AT RATED TORQUE IS ACCEPTABLE.

Using the recommended torque value.

In the absence of a recommended torque value, try a low setting and increase until satisfactory valve operation is achieved.

(refer to [C3] page 21)

and - keys, display the

If the actuator fails to

complete a open valve operation due to the set torque being reached ( this may indicate a valve and/or process problem or change. It is the responsibility of the user to ensure the valve and process conditions are within specified operational limits before increasing the Set Open torque value.

Torq ue Trip OP

Alarm, page 5)

NOTE: Rated torque is quoted on the

actuator nameplate. Boost torque is at least 140% of Rated torque.

PRESS THE KEY.

The displayed value will flash (stored), indicating that it has been set.

Should the set level of torque be developed in opening, the actuator will torque trip and stop.

PRESS THE m KEY.

Open Tor que

40%

Open Tor que

99%

Open Tor que

100%

Rated

Open Tor que

Boost

In checking mode, on pressing the key after reviewing open torque setting, the display will revert to valve position.

Set Limit Closed

Set Limit Open

NOTE: It is possible to set the Open

Limit Position [LO] first.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

When in checking mode Set

NOTE:

Limit Closed [LC] does not appear.

With [LC] displayed

Set Clos e L imit

Move to Clo se

Limit Closed

Move valve manually to the closed position. Allow for overrun by winding actuator output open by

/2 to 1 turn.

PRESS THE KEY.

The two bars will flash (stored) and the closed indicator lamp will illuminate, indicating closed limit position has been set.

PRESS THE k KEY.

To check closed limit position hand wind valve open until the amber lamp illuminates. Wind valve back closed until the closed lamp illuminates.

Torque

P? k PC k Ir k tP

c1 k c2 k c3

tC k tO

LC k LO

When in checking mode Set

NOTE:

Limit Open [LO] does not appear.

With [LO] displayed

Set Open Li mit

Move to Ope n

Limit Open

Move valve manually to the open position. Allow for overrun by winding actuator output closed by

/2 to 1 turn

PRESS THE KEY.

The two bars will flash (stored) and the open indicator lamp will illuminate, indicating open limit position has been set.

PRESS THE m

The open symbol (refer to Fig. 3.3. page 4) should now appear.

KEY.

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rotork IQT, IQTM, IQTFS, IQTF Installation And Maintenance Information

Specifications and Main Features

Frequently Asked Questions

User Manual