rotork S2 Installation Manual

SM-6000

Installation Manual

Series

Redefining Flow Control

Rotary Actuators

with Local Remote Switch

Contents

Section Page

Product Overview 3

1 - General Information 4

2 - Specifications 7

2.1 - Optional Equipment 8

3 - Installation 9

3.1 - Typical Wiring Diagram 12

3.2 - Microprocessor Based Motor 13
Drive & Controller Setup

4 - Operating your SM6000 14

4.1 - Status Description 16

4.2 - Start Up 17

4.2.1 - Select Automatic Mode 20

4.3 - Range of Operation - Setup 23

4.3.1 - Range of Operation 23

4.3.2 - Set Zero and SPAN 27

4.3.3 - Setting Limit Switches 32

4.3.4 - Operating Speed 34

5 - Setup & Calibration 36

5.1 - Setup & Calibration - Level 1 37

5.1.1 - Max Cmd Cal 38

5.1.2 - Min Cmd Cal 38

5.1.3 - Speed 39

5.1.4 - CMD Type 39

5.1.5 - LOS Act 39

5.1.6 - LOS Pos 40

5.1.7 - CUR P Gain 40

5.1.8 - CUR I Gain 40

5.1.9 - Min Pos 41

Section Page

5.1.10 - Max Pos 41

5.1.11 - Max Torque % 42

5.1.12 - Save Config 42

5.2 - Communications 43

5.2.1 - HART Control Options 43

5.2.2 - PROFIBUS Control Options 45

5.2.3 - Foundation Fieldbus 47
Control Options

5.3 - Setup and Calibration - Level 2 49

5.3.1 - MOTOR PWM 50

5.3.2 - MAX TORQUE 50

5.3.3 - INPUT VOLT 50

5.3.4 - MOTOR RATE 50

5.3.5 - PASS ENBLD 50

5.3.5.1 - PASSWORD 50

5.3.6 - LOOP 50

5.3.7 - LOAD FACT DEFS 50

6 - Faults & Troubleshooting 52

6.1 - Fault Status Indication 52

6.2 - Troubleshooting 53

7 - Local Operation - Handcrank Direction 54

8 - Mounting Conversion 55

9 - Parts Identification 56

10 - Drive Arm Dimensions 59

11 - Overall Dimensions 60

12 - Linkage Options 61

13 - User Settings 62

Notes 63

This manual contains important safety
information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.

2

Due to wide variations in the terminal
numbering of actuator products, actual
wiring of this device should follow the
PRINT SUPPLIED with the unit.

Product Overview

Rotork Process Controls designs and
manufactures high quality, durable actuators
designed for trouble-free performance under the
most demanding conditions.

With its field-proven design, the SM-6000 S2 is a perfect fit
for all of your high performance requirements. The SM-6000
S2 Series are rotary actuators internally geared to produce
up to 26,000 ft. lbs. (35,251 Nm) of torque at unrestricted,
continuous modulating duty.

These actuators are ideally suited for dampers, vanes, valves
and other process control applications requiring high speed,
high torque and exact positioning control.

The SM-6000 S2 actuator features a menu-driven non­intrusive setup using control knobs and vacuum fluorescent
display.

These controls are also used to programme the internally
mounted digital amplifier.

Features

• From 25º to 120º rotation.

• Torque range up to 35,256 Nm

(26,000 lbf-ft).

• Double ‘O’ ring sealing.

• Continuous unrestricted

modulating duty.

• Temperature range from -40 to +85 ºC
(-40 to +185 ºF).

• Automatic torque limiting.

• Self-locking drive system to hold in last

position and prevent backdriving.

• Manual override standard.

• HART, Profibus and Foundation

Fieldbus available.

Figure 1.0. SM6000-S2 actuator

Redefining Flow Control

3

1 - General Information

INTRODUCTION

Rotork Process Controls designs, manufactures, and
tests its products to meet national and International
standards. For these products to operate within their normal
specifications, they must be properly installed and maintained.
The following instructions must be followed
and integrated with your safety program when installing,
using, and maintaining Rotork Process Controls products:

Read and save all instructions prior to installing, operating,
and servicing this product. If any of the instructions are
not understood, contact your Rotork Process Controls
representative for clarification.

Follow all warnings, cautions, and instructions marked
on, and supplied with, the product. Inform and educate
personnel in the proper installation, operation, and
maintenance of the product.

Install equipment as specified in Rotork Process Controls
installation instructions and per applicable local and national
codes. Connect all products to the proper electrical sources.
To ensure proper performance, use qualified personnel to
install, operate, update, tune, and maintain the product.

When replacement parts are required, ensure that the
qualified service technician uses replacement parts
specified by Rotork Process Controls. Substitutions may
result in fire, electrical shock, other hazards, or improper
equipment operation.

RECEIVING / INSPECTION

Carefully inspect for shipping damage. Damage to the
shipping carton is usually a good indication that it has
received rough handling. Report all damage immediately to
the freight carrier and Rotork Process Controls, Inc.

Unpack the product and information packet - taking care to
save the shipping carton and any packing material should
return be necessary. Verify that the items on the packing list
or bill of lading agree with your own.

STORAGE

If the actuator will not be installed immediately, it should
be stored indoors in a clean, dry area where the ambient
temperature is not less than -20° F. The actuator should
be stored in a non-corrosive environment. The actuator is
not sealed to NEMA 4 until the conduit entries are properly
connected.

WARNING

Before installing the actuator, make sure that it is suitable
for the intended application. If you are unsure, consult
Rotork Process Controls prior to proceeding.

WARNING - SHOCK HAZARD

Installation and servicing must be performed only by
qualified personnel.

WARNING ELECTROSTATIC DISCHARGE

This electronic control is static-sensitive. To protect the
internal components from damage, never touch the
printed circuit cards without using electrostatic discharge
(ESD) control procedures.

4

1 - General Information

EQUIPMENT RETURN

A Returned Goods authorization (RG) number is required to
return any equipment for repair. This must be obtained from
Rotork Process Controls. (Telephone: [phone]) The
equipment must be shipped, freight prepaid, to the following
address after the RG number is issued:

Rotork Process Controls, Inc.
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Attn: Service Department

To facilitate quick return and handling of your equipment,
include:

1. RG Number on outside of box

2. Your Company Name, Contact Name, Phone/Fax

3. Address

4. Repair Purchase Order Number

5. Brief description of the problem

IDENTIFICATION LABEL

An identification label is attached to each actuator. When
ordering parts, requesting information or service assistance,
please provide all of the label information. YOU MUST

SUPPLY THE SERIAL NUMBER WITH ALL ENQUIRIES.

ABBREVIATIONS USED IN THIS MANUAL

A Ampere
AC Alternating Current
°C Degrees Celsius
CW Clockwise
ACW Anti-clockwise
CCW Counter-clockwise
DC Direct Current
°F Degrees Fahrenheit
G Earth Ground
Hz Hertz
in. lbs Inch Pounds
kg Kilogram
L Line (power supply)
lbs Pounds Force
LVDT Linear Variable Differential Transformer
mA Milliamp
mfd Microfarad
mm Millimeters
N Newton (force)
NEMA National Electrical Manufacturing Association
Nm Newton Meter
NPT National Pipe Thread
PCB Printed Circuit Board
PH Phase
PL Position Limit switch
RPM Revolutions per Minute
SEC Second
SPDT Single Pole Double Throw
TL Torque Limit Switch
V Volts
VA Volt Amps
VAC Volts AC
VDC Volts DC
VFD Vacuum Fluorescent Display
VR Variable Resistance
W Watt

Figure 1.1. Actuator identification label.

Redefining Flow Control

5

1 - General Information

Figure 1.2. SM6000-S2 actuator.

GENERAL DESCRIPTION, ACTUATOR

The SM-6000 is an AC input, DC driven electric actuator
designed for high modulation service. This actuator uses a
Rotork Process Controls locally mounted, or remotely located
microprocessor- based motor drive and controller. A wide
array of standard options are available for this actuator.

The SM-6000 Series actuators provide the highest speed,
torque, modulation rate, and positioning accuracy of any
electric actuator in the Rotork Process Controls product line.

With the standard control electronics, they are self-contained
automatic positioning devices capable of moving the largest
loads at speeds typical of electrohydraulic devices, and with
an unrestricted modulation rating. These high-performance
actuators are electrically controlled, self-contained, high
speed, high torque devices. With essentially unlimited
rotational travel, they provide a superior solution for any
modern actuation application.

The SM-6000 is designed using an all steel gear train
submersed in an oil bath, and conservatively rated bearings.
This design assures the longest possible life while reducing
the risk of costly repairs and unscheduled maintenance.

An internally mounted electronic controller converts AC
power input to DC power.

The DC power is then controlled by a microprocessor based
digital servo amplifier that efficiently controls speed and
torque of the drive motor.

The motor drives through high efficiency helical bevel gearing
that provides smooth and quiet operation at rated load
indefinitely in the event of power loss or shutoff.

A holding brake at the rear of the motor will hold the full
rated load in the last position until power is restored. The
holding brake is always in the released state whenever power
is applied to the actuator. It is an electrically released, spring
set type holding brake. The brake is constantly in a stand-by
mode, and does not stop the motor. The motor does the
braking electrically, so there is no wear on the brake because
the brake is only holding, and not stopping the load. The load
is always supported by the motor, even when the command
input is not changing.

A local override handcrank at the rear of the motor can
be used to manually position the load when power is
interrupted.

The SM-6000 is well equipped with popular standard
features, and a wide variety of standard options are available
to suit most applications.

Special factory supplied options and designs are also available.

6

2 - Specifications

Output
Torque

ft. lb. (Nm) (RPM) (sec/90°) Running Stall lbs. kg inch mm

370 (502) 1.50 10 120-240/1-3/50-60/3@120 2 6 186 85 1.25 31.75

550 (746) 1.50 10 120-240/1-3/50-60/4@120 2 6 186 85 1.25 31.75

800 (1085) 1.56 10 120-240/1-3/50-60/5@120 3 9 204 93 1.375 34.925

1400 (1898) 1.52 10 120-240/1-3/50-60/8@120 4 12 254 115 1.75 44.45

2500 (3389) 1.57 10 120-240/1-3/50-60/12@120 6 12 403 183 2.375 60.325

4400 (5965) 1.65 10 240/1-3/50-60/7 7 12 613 279 2.875 73.025

6200 (8406) 1.56 10 240/1-3/50-60/8 8 12 956 435 3.625 92.075

8000 (10846) 1.19 12 240/1-3/50-60/12 12 12 1589 722 4.375 111.125

11000 (14914) 0.86 18 240/1-3/50-60/12 12 12 1589 722 4.375 111.125

16500 (22371) 0.58 26 240/1-3/50-60/12 12 12 2196 998 4.75 120.65

26000 (36540 0.36 42 240/1-3/50-60/12 12 12 3453 1570 5.5 139.7

• Rotation: 25º - 120 º.

• Duty Cycle: Unlimited and unrestricted continuous duty.

• Temperature: -40 to 185 °F (-40 to 85 °C). A high

temperature version to 225 °F (107 °C) is available.

• Environment Ratings: NEMA Type 4 (IP65).

• Lubrication Type: Synthetic oil bath.

• Oil Change Interval: 20 years for normal operation,

10 years for extreme operation.

• Gearing: All steel bevel and helical gearing.

• Hold on Loss of Power: Spring locking brake.

Output

Speed

Shift
Time

Input Power

Volts/Ph/Hz

Current Draw (A)
at 240 VAC Input

Actuator

Weight

Output Shaft

Diameter

• Command Signal Input: 4-20 mA, 0-5 VDC or
0-10 VDC.

• Position Transmitter: 4-20 mA transmitter used to
remotely track actuator position when power is available
to the actuator. Requires separate 24 VDC loop-power
supply for operation.

• Terminations: Screw type terminals accepting up to
#14 AWG wire.

• Mounting Orientation: Left hand, right hand
or vertical.

RH LH

• Mounting: Conventional foot mounted.

• Anti-Condensation Heater: 120 or 240 VAC, 30 Watt

with thermostat set for 110 °F (43.3 °C).

• Torque Limit: Adjustable from 1 to 200% of rated
torque. Warning: continued operation of unit in excess
of rated load will damage the actuator and connected
equipment.

• Positioning Accuracy: 0.1% of 90°.

• Position Limit Switches: Two single pole double throw

(SPDT) switches for end of travel use, rating: 20 amp,
120/240 VAC resistive load.

• Feedback: Absolute Encoder.

• Local Controls & Display: Front cover mounted control

Figure 2.1. Left and right hand mounting orientation.

knobs and Vacuum Fluorescent Display (VFD).

Redefining Flow Control

7

2.1 - Optional Equipment

• Performance: Faster speeds are available.
Consult factory.

• Drive Arm: Steel, for dimensions see section 10.

• Mechanical Stops: A plate that bolts to the front of the

actuator and limits drive arm movement is available

• Relays: Customer usable relay contacts are available to
detect: loss of feedback, loss of command signal, loss of
power or overtorque (stall).

• 1000 Ohm Potentiometer: Allows for ambient
temperature to 225 °F (107 °C). Requires remote
control enclosure.

Other options may be limited, consult factory.

• Auxiliary Position Limit Switches:

20 Amp, 120/240 VAC resistive load, (Quantity, 2-4)

5 Amp, 125 VDC resistive load, (Quantity, 2-4)
3 Amp, 250 VDC resistive load, (Quantity, 2-4)

• 2P + ST: Adds a second, tandem mounted feedback
potentiometer and one ST-4130 loop powered transmitter
assembly inside the electrical enclosure.

Requires separate 24 VDC power supply for operation,

or specify ST-4110 for sourced 4-20 mA operation.

• Pluggable Connections: Pluggable connectors on the
control enclosure for quick-disconnection using Cannon
style connectors. Typically used for remote mounted
control enclosure applications.

• Input Power: Internally mounted transformer to allow
operation on other input voltages. Standard optional
Input voltages are 480 VAC, 575 VAC. A 120 VA to 240
VAC step-up transformer is also available for applications
using 180 VDC motors when only 120 VAC input power
is available.

• Transitional Adapter Mounting Bases: Matches
SM-6000 to existing actuator footprint in the field for
replacement applications. Consult factory.

• High Temperature: Optional for ambient temperature to
225 °F (107 °C). Requires remote control enclosure. Other
options may be limited, consult factory.

• Linkage Adapter/Clevis Kit: Used to connect drive
arm to driven load for linkage applications. Includes two
clevises, two adjustment rods with lock nuts, two pipe
adapters, two pins for clevises.

8

3 - Installation

INSTALLATION NOTES

CAUTION

READ ALL INSTRUCTIONS CAREFULLY BEFORE STARTING
THE INSTALLATION IN ORDER TO ACCUSTOM YOURSELF
WITH THIS EQUIPMENT. FOLLOW ALL INSTRUCTIONS
DURING THE INSTALLATION. DO NOT APPLY POWER UNTIL
TOLD TO DO SO OR PERMANENT DAMAGE CAN RESULT.

1. Use care whenever carrying, setting, or working around

the actuator. This is a precision piece of equipment that
will be permanently damaged if dropped or mistreated
during handling. Damage due to abuse or mishandling is
not covered by the factory warranty.

2. The installation site must have environmental conditions

compatible with the actuator design. Do not use this
product in temperatures higher than the design allows,
or in explosive environments if it is not rated accordingly.
To maintain the environmental ratings, all covers must be
tightly closed at all times. All cover fittings must be used
and fastened securely. Using a
four capscrews securing the terminal compartment cover
(Fig. 3.1). The actuator is supplied with a wiring diagram,
certificate of conformance and terminal fixings stored in
the terminal compartment area (Fig 3.2 and Fig 3.3).

3. Read the actuator nameplate located on the outside of

the unit. It will reference a specific wiring diagram. Refer
to the wiring diagram to identify functions of terminals
(Fig. 3.2). Check that the supply voltage is the same as
that marked on the actuator nameplate. That diagram
MUST be used for wiring this product. Run wires as
indicated, but DO NOT apply power until later. To prevent
electrical noise pickup, power and signal wires must be
routed through separate metallic conduit and the signal
wires must also be shielded and the shield grounded (Fig.

3.1. A,B,C,D).

For actuators where the control enclosure must be

located away from the actuator, do not exceed a wire

run distance of fifty feet between the actuator and
the control enclosure.

When all connections are made, replace the wiring

diagram in the terminal compartment.

4. Replace Terminal Cover Ensure cover o-ring seal and

joint are in good condition and lightly greased before re­fitting cover. Seal any unused conduit entries with metal
plugs (Fig. 3.4. C,D).

3

/16’’ Hex key, remove the

C

A B

Figure 3.1. Terminal compartment cover

Figure 3.2. Terminal compartment.

Figure 3.3. Terminal fixings.

C

D

D

Figure 3.4.

Redefining Flow Control

9

3 - Installation cont.

5. The actuator must be securely anchored to a rigid

foundation before any load is applied to the output
shaft. All of the actuator mounting holes designed for
anchoring must have a bolt or stud, which should be of
the largest size that fits in the mounting hole (Fig. 3.5. A).

6. The drive arm (if used) should be attached to the actuator
output shaft using the hardware supplied. The drive arm
has a hole to attach the linkage to the load. This linkage
should be connected to the drive arm with a flexible
rod-end to accommodate misalignment, and the rod-end
must be sized for approximately twice the actuator full
load rating (Fig. 3.5. B).

7. The actuator is designed to withstand the rigors of
industrial environments. To maintain the environmental
ratings, all cover fixings must be used and fastened
securely (Fig. 3.6).

Mounting:

The outline and mounting dimensions for a standard unit
are shown in this manual. Sufficient room to remove the
cover should be provided for servicing and upgrade.

Orientation:

The unit is oil filled and must be mounted in the
configuration ordered. When mounting the unit, be sure
that no excessive axial or side loading is applied to the
output shaft.

B

A

Figure 3.5.

Output Drive Shaft:

The limit switches and position feedback are directly
connected to the output shaft. Positively secure the
output to the driven load shaft to prevent slippage, which
would cause misalignment or damage.

Local Overide:

When local override is required, push in handcrank
(Fig 3.7) and turn the crank in the appropriate direction
for the desired output shaft movement. Note: Do not
force handcrank if there is an obstruction as excessive
torque will be generated at the output shaft. The load or
actuator may be damaged as a result.

CAUTION - LOCAL OPERATION

WITH RESPECT TO HAND CRANK OPERATION OF
SM6000 SERIES ELECTRIC ACTUATORS, UNDER NO
CIRCUMSTANCES SHOULD ANY ADDITIONAL LEVER
DEVICE SUCH AS A WHEEL-KEY OR WRENCH BE APPLIED
TO THE HAND CRANK MECHANISM IN ORDER TO
DEVELOP MORE FORCE WHEN MOVING THE ACTUATOR
IN EITHER DIRECTION AS THIS MAY CAUSE DAMAGE
TO ACTUATED DEVICE, ASSOCIATED LINKAGES OR
ACTUATOR ITSELF.

Figure 3.6.

Figure 3.7.

10

3 - Installation cont.

If, during local operation, electric power is restored to the
actuator, the power cannot drive back through the manual
handcrank and harm the operator. Upon completion of
hand operation, the handcrank will spring return to its home
position allowing electric operation to resume.

The handcrank and holding brake compartment at the rear
of the motor relies upon the cover to maintain the watertight
NEMA Type 4 rating. This cover should be removed only
when work is being done internally, and should be reinstalled
tightly immediately upon completion.

This unit contains no internal mechanical stops as standard.
If it runs outside of the initial factory alignment of the limit
switches, a realignment of switches and feedback may be
required. However, no internal damage will occur.

The actuator is designed to give long, troublefree life when
installed and operated in accordance with factory guidelines.

Position Limit Switches

The actuator is supplied with two Position Limit Switches
PL1 (cam#1) & PL2 (cam#2) as standard (Fig. 3.8 and Fig.

3.9). These switches are mounted behind the control cover
assembly and are typically set to operate outside the normal
limits of travel to act as motor shutoff devices in the event of
over travel.

Two optional switches PL3 (cam#3) and PL4 (cam#4) can be
fitted to provide external travel limit switch indication.

Up to 4 additional switches can be supplied to provide
external travel limit switch indication.

Figure 3.8. Figure 3.9.

Redefining Flow Control

11

3.1 - Installation Wiring & Typical Wiring Diagram

A typical wiring diagram is shown below. Actual wiring
should follow the print supplied with the actuator. The
wiring diagram shows the fundamental connections for the
standard control scheme, and standard permanent magnet
DC motor. Items shown on print arrangement include limit
switches, feedback potentiometers, heater and encoders. To
meet special requirements, certain items shown may not be
supplied. In all instances the wiring diagram appropriate

to the equipment will be supplied with each unit.

TYPICAL WIRING DIAGRAM

Wiring should be routed to the actuator through customer
supplied conduit entries located on the control enclosure.
Generally, one conduit will contain input power and earth
ground wires. The other conduit would then contain low level
input and output signal wiring. It is required that all low level
signal wiring be a shielded type with the shield grounded at
source common.

After installation, it is required that all conduits be sealed to
prevent water damage and to maintain watertight NEMA 4
enclosure ratings.

Figure 3.10. Typical SM6000-S2 Wiring Diagram

12

3.2 - Microprocessor Based Motor Drive & Controller Setup

GENERAL DESCRIPTION

The microprocessor-based motor drive and controller is
designed for integral local or remote mount to control
appropriate Rotork Process Controls actuators.

A microprocessor-based control and an IGBT-based intelligent
power module (IPM) are used to drive the actuator to perform
highly accurate, bidirectional positioning.

The ‘Standard Setup’ is made via front cover-mounted local
control knobs and a local display (VFD) on the outside of the
actuator. See figure 4.2 for location of the local control knobs
and display.

The ‘Alternative Setup’ feature allows actuator setup using
push-buttons (no potentiometers or jumpers). See figures

4.13 and 4.14 for location of the push buttons. Self
diagnostics and prompts are available through an on-board
lighted display.

Specifications

• PowerInput:120/240VAC,+/-10%,singleorthree 

phase, 50/60 Hz.

• PowerOutput:Upto90VDC/180VDC,

15 Amperes Peak.

• CommandInputs:4-20mAinto200Ohmshunt

0-10 VDC into 100k minimum impedance or 0-5
VDC into 100k minimum Impedance.

• PositionFeedback:AbsoluteEncoder,1000Ohm 

potentiometer (optional), 4-20 mA (optional).

NOTE: THE FACTORY DEFAULT FEEDBACK SETTINGS
WERE FULLY TESTED AND INITIALLY SETUP AT THE
FACTORY AND NO OTHER ADJUSTMENT OF THE
ABSOLUTE ENCODER AND 1000 OHM POTENTIOMETER
SHOULD BE REQUIRED.

IF ADJUSTMENTS ARE NECESSARY PLEASE CONTACT
ROTORK PROCESS CONTROLS.

• PositionSignalOutput: Looppowered,isolated,
2-wire 4-20 mA signal.
Shows actuator position.

• EndofTravelPositionLimitSwitches:SwitchCams1

(CCW) & 2 (CW) to stop the actuator if end of travel
position is exceeded.

• PositionIndicationSwitches:(Optional)
Switch cams 3 & 4 for additional position indication
outputs. Up to 6 switches.

• AutomaticMode:Actuatorrespondstoremote
command input controls. Typically 4-20 mA or
bus communication.

• LocalMode:Actuatorrespondstolocal
pushbutton commands.

• OtherOutputs:
Form C fault relay output
Contact Rating
120 VAC, 2 Amperes

Active when any of the following conditions
are present:

 • Lossof4-20mAcommandsignal

 • Lossofpositionfeedbacksignal

 • MIN/MAXlimitswitchreached

 • Motorstalledcondition

 • Handcrankengaged

 • TorqueLimitExceeded.

Redefining Flow Control

13

4 - Operating your SM6000 Actuator

WARNING

Actuator may move when SPAN, ZERO or PRESET
functions are selected.

Display-Local Indication

A

L P= 100 C= 100
Act Strts = 19

B

Figure 4.1.

Local Control Knobs

L P= 100 C= 100
Act Strts = 19

L

R

A

Figure 4.2.

The actuator has two control knobs located below the VFD
Display window.

BC

The actuator Vacuum Fluorescent Display (VFD) provides 2 x
16 Character lines to allow setup and calibration of all user
parameters. The display can also be utilised to access the
diagnostic menus.

Line 1 (Fig. 4.1. A).

L = Local Mode

R = Remote Control

C = Remote Communications Mode

In Local, Remote and Automatic Modes line 1 shows actuator
Position and Command request in percentage of Zero - Span
range.

P = Actual Position

C = Command Position

Line 2 (Fig. 4.1. B).

Act strts = Actuator starts

Provides status or fault information depending on
Mode selected.

UP/DOWN SELECTOR KNOB (Fig. 4.2. A).

Located on left hand side as viewed from the front.
Depending on mode selected different functions apply
(see below).

ENTER/CANCEL KNOB (Fig. 4.2. B).

Located on right hand side as viewed from the front.
Allows parameters to be changed and accepted or
toggles between menus.

Local Mode

Rotate the selector knob anti-clockwise (UP)
and hold to move actuator output towards
the Span Position. Release when the
actuator has reached the desired position.

Rotate the selector knob clockwise (Down)
and hold to move actuator towards the
Zero position. Release when the actuator
has reached the desired position.

Setup Mode

Rotate the selector knob to the UP or
DOWN position to cycle through the
setup menu parameters.

14

4 - Operating your SM6000 Actuator

LOCAL/REMOTE SWITCH. (Fig. 4.2. C).

Located on the left hand side of the electrical housing as
viewed from the front.

NOTE:The switch can be fitted with a padlock to
prevent unauthorised operation.

LOCAL MODE

When the actuator is set to local mode It is possible to
position the actuator using the UP/DOWN selector knob.

Using the ENTER /CANCEL selector knob it is possible to
access and change parameters.

REMOTE MODE

Actuator will respond to remote control or communication
bus card commands.

Redefining Flow Control

15

4.1 - Status Description

STATUS DESCRIPTION

In REMOTE or Local mode Line 2 of the display shows status
parameters when no faults are active.

To cycle through the menu structure select LOCAL operation.

Using the ENTER/CANCEL selector knob it is possible to access
and change parameters.

Use the Enter/Cancel knob to cycle through the information
(Fig. 4.4).

1 Act Starts = xxxx

Total times the motor has been started since last power up.

2 Amp Starts = xxxxx

Total times the amplifier has been powered up or reset.

3 Temp. °C xx

Temperature in °C of the lower internal PCB’s.

4 Voltage xxx

Absolute value of DC motor voltage.

5 Current +/- xxxx

Motor current.

6 TORQUE

CurrenttorqueoutputXXX%.

7 FAULT HISTORY

Lists the last 10 faults or events. Select ENTER to
activate. F0 is the most recent event, F10 would be
the oldest.

Figure 4.4

L P= 100 C= 100
Act Strts = 19

Enter (E)

Cancel (C)

MAIN MENU

ACT STRTS

AMP STRTS

TEMP

VOLT

Figure 4.3.

CURRENT

TORQUE %

L Fault History

FLT HIST

F0 LOS CMD

LEVEL 2 ONLY

MOTOR

THEO PSN

CMD PSN

SPD

ERR

FEED FWD

RAW PSN

ZERO CURR

MOTOR

16

4.2 - Start Up

The actuator is fully tested and initially setup at the factory.
The factory default settings should be used to initially
commission the actuator on site.

WITH POWER OFF & LOAD DISCONNECTED

Verify that all wiring is correct and that the supply voltage
matches the voltage shown on the actuator identification
label. Refer to the wiring diagrams supplied with the actuator
for specific details (Fig. 4.5).

Ensure all electrical connections are tight and splash guard
refitted. Cable screens/shields must be suitably connected to a
reliable earth ground (Fig. 4.6).

To maintain the environmental ratings, all cover fixings must
be used and fastened securely (Fig. 4.7).

REMOVE CONTROL ASSEMBLY COVER (OPTIONAL)

CAUTION

DO NOT FULLY REMOVE COVER UNLESS THE WIRING
LOOMS ARE DISCONNECTED FROM THE MAIN PCB.

It is only necessary to remove the control cover assembly to
adjust and setup the position limit switch assemblies located
inside the control housing.

If the limit switches do not require adjustment leave the cover
assembly in place and go to Page 20 (Fig. 4.16).

Locate and remove four socket cap screws using a
key which secure the control assembly cover to the gearcase
(Fig. 4.7). Remove the cover far enough to clear the electrical
chassis taking care not to damage cables connecting the
VFD display and control knobs to the Logic control PCB. If
necessary disconnect the two cables from the Logic Control
PCB to the cover assembly (Fig. 4.8).

1

/4” Hex

Figure 4.5.

Figure 4.6.

Figure 4.7.

Figure 4.8.

Redefining Flow Control

17

4.2 - Start Up cont.

The cover assembly can now be relocated on to the left or
right hand side of the gear-case to facilitate setup. Use one of
the original fixings to secure the control cover assembly to the
gear-case (Fig. 4.9).

Reconnect looms to the main PCB if necessary (Fig. 4.10).

Figure 4.9.

REMOVE TOP & SIDE COVER ASSEMBLIES

The top and side cover assemblies may be removed for
clearer access to the Limit Switch assemblies. 3/16” Hex key.

Figure 4.12 shows top cover removed of an actuator fitted
with additional position limit switches for remote indication.

Figure 4.10.

Figure 4.11.

18

Figure 4.12.

4.2 - Start Up cont.

Figure 4.13 shows the front view of the electrical chassis.

LOGIC CONTROL PCB

Figure 4.14 shows the logic Control PCB.

The PCB has one push button switch (SW1) (Fig. 4.13. A)
located at right top corner of the PCB and four push button
switches (SW2 to 5) located on the forward edge of the PCB.

If desired the switches SW2 to 5 can be used to duplicate the
function of the control knobs.

SW1 RESET

Clears microprocessor registers and restarts the control
program. Do not press during normal operation.

SW2 INCREASE

Local Mode: Press and hold to move the actuator
towards the Span position.

Setup Mode: Press to cycle through the setup menu
parameters.

Actuator will move when SPAN, ZERO or PRESET functions
are selected.

Figure 4.13.

A

SW3 MODE

Switches between LOCAL and
SETUP mode. Aborts a parameter change
when in SETUP mode.

SW4 ENTER

Allows changed parameters to be stored
and cycling of diagnostic display.

SW5 DECREASE

Local Mode: Press and hold to move the actuator
towards the Zero position.

Setup Mode: Press to cycle through the setup menu
parameters. Actuator will move when
SPAN, PRESET and ZERO functions
are selected.

Figure 4.14.

SW2

SW3

SW4

Figure 4.15.

Redefining Flow Control

SW5

19

4.2 - Start Up cont.

ENSURE THAT LOAD IS DISCONNECTED FROM

ACTUATOR OUTPUT DRIVE SHAFT.

APPLY POWER TO ACTUATOR

The actuator display should now illuminate showing actuator
model and software version for 5 seconds before displaying
the top menu (Fig. 4.16).

The actuator is set to Local Mode when it leaves the factory
(Fig. 4.17).

LOCAL MODE - OPERATION

With no load connected to the actuator output drive shaft.

Rotate the UP/DOWN Control knob clockwise and
anti-clockwise to test electrical operation. Confirm that
the direction of travel corresponds with the rotation of
the knob. Refer to Section 4.

Figure 4.16.

L P= 100 C= 100
Act Strts= 19

Figure 4.17.

L

SM-6060

Ver. 4.00

L P= 100 C= 100
Act Strts= 32

4.2.1 AUTOMATIC MODE - OPERATION

The actuator control mode must now be changed to
‘REMOTE’ to function test the actuators response to Analogue
control signal commands.

Ensure that actuator has been correctly configured for current
or Volts before applying any analogue command inputs.

If actuator is supplied with a Bus or HART input card
please refer to section 5.

R

Figure 4.18.

L

R

Figure 4.19.

L P=-0.0 C= 0.0
Act Strts= 65

20

4.2 - Start Up cont.

ENTER KNOB - SELECT ‘CANCEL’

SETUP MODE

Display now shows Setup Menu (Fig. 4.20).

C

S / pick param
Press

Figure 4.20.

Redefining Flow Control

21

4.2 - Start Up cont.

SAVE CONFIG

ENTER KNOB - SELECT ‘ENTER’

SAVING TO EEPROM

All changes saved to EEPROM (Fig. 4.22). All changes to
Parameters will be saved when cycling of power occurs.

S / pick param
Save Config

Figure 4.21.

E

S / pick param
Saving to EEPROM

Figure 4.22.

ENTER KNOB - SELECT ‘CANCEL’

Display returns to top menu and LOCAL Mode is now active.
The lower section of the display will show the last selected
menu option.

Actuator will now respond to applied Analogue Remote input
signal. Apply a 50% command signal (mA or Voltage) to the
actuator. Verify that the actuator moves the output to desired
position (Fig. 4.23).

Apply a 00% command signal (mA or Voltage) to the
actuator. Verify that the actuator moves the output to
desired position (Fig. 4.24).

Apply a 100% command signal (mA or Voltage) to the
actuator. Verify that the actuator moves the output to
desired position (Fig. 4.25).

INITIAL COMMISSIONING COMPLETE.

C

L P=49.8 C=50.1
Temp. .C 33 27

Figure 4.23.

L P=-0.2 C= 0.0
Temp. .C 33 27

Figure 4.24.

L P= 100 C= 99.7

22

Temp. .C 33 27

Figure 4.25.

4.3 - Range of Operation - Setup

4.3.1 RANGE OF OPERATION

The following procedure will calibrate the ZERO and SPAN
limits of travel and adjustment of the Position Limit Switches
if necessary.

With Linkage disconnected apply power to the unit.

The actuator should be in local mode to start this operation as
noted in Figure 4.18. Refer to section 4 for instructions. The
unit may have been moved out of its normal limits of electrical
travel for shipping purposes. In this case Figure 4.27 shows
the actuator at 149% of travel. The actuator will respond to
decreasing requests only, until it reaches the 100% position of
travel, after which it may be driven in either direction between
limits (Fig. 4.28).

During operation it is possible that one end of travel switch
is tripped and adjustment is required to facilitate movement
to the desired SPAN or ZERO position. In this case it will be
necessary to adjust one or both of the travel limit switches.

Fig 4.28 shows that the increasing limit switch cam#1 has
been activated.

WARNING

Isolate power supply before inserting tools in to the
electrical housing.

Figure 4.26.

L P= 149 C= 149
Temp. .C 32 27

Figure 4.27.

L P= 100 C= 100

Move actuator output shaft in the increasing direction and
observe rotation of cam switch assembly to verify CW or
ACW operation. Using a 1/8” hex wrench loosen the
appropriate locking screw (screws are numbered on the
cam end plate) (Fig 4.29).

Move the switch cam in the decreasing direction to allow the
actuator to run its full required position of travel.
Once adjusted tighten the locking screw.

Repeat the procedure for the Decreasing travel limit
if necessary.

Flt: Inc Limit

Figure 4.28.

Figure 4.29.

Figure 4.30.Figure 4.31.

Redefining Flow Control

23

4.3 - Range of Operation - Setup cont.

L

R

OPERATING SPEED

The actuator output speed is factory preset to 100%. During
the initial calibration of this unit it is recommended that the
speed is reduced to 10% to achieve greater accuracy when
setting the ZERO and SPAN position limits.

To change the actuator speed.

Select ‘LOCAL’ operation

Figure 4.32.

L P= 149 C= 149
Temp. .C 32 27

C

UP/DOWN KNOB - SELECT ‘SPEED SETUP MENU’

Use the UP/DOWN knob to scroll through menus.

Until‘Speed=XXX’isdisplayed(Fig.4.33).

ENTER KNOB - SELECT ‘ENTER’

The motor speed can now be adjusted by using the
UP/DOWN knob.

D

S / pick param
Speed = 100

Figure 4.33.

E

/ to Speed
ENT = acpt 100

Figure 4.34.

24

4.3 - Range of Operation - Setup cont.

UP/DOWN KNOB - HOLD TO REDUCE SPEED

Hold the UP/DOWN KNOB until the actuator speed indicates
10% (Fig. 4.35).

D

/ to Speed

ENTER KNOB - ENTER TO SAVE VALUE

Select ‘ENTER’ to set the actuator speed to 10% (Fig. 4.36).

UP/DOWN KNOB - SELECT ‘SAVE CONFIG’

Actuator configuration should be saved to EEPROM before
exiting the menu (Fig. 4.37).

ENT = acpt 10

Figure 4.35.

E

S / pick param
Speed = 10

Figure 4.36.

S / pick param
Save Config

Figure 4.37.

Redefining Flow Control

D

25

4.3 - Range of Operation - Setup cont.

ENTER KNOB - ENTER TO SAVE TO EEPROM

ENTER KNOB - SELECT ‘CANCEL’ TO RETURN TO TOP
MENU (Fig. 4.39).

E

S / pick param
Saving to EEPROM

Figure 4.38.

C

L P= 26.4 C= 26
Volt = 0 816

Figure 4.39.

26

4.3 - Range of Operation - Setup cont.

4.3.2 SET ZERO AND SPAN

ENSURE THAT LOAD IS DISCONNECTED
FROM ACTUATOR OUTPUT DRIVE SHAFT.

The operating speed of the actuator is now set to 10% of
rated. The ZERO and SPAN can now be set.

Note: Careful attention must be used during the setting
of the ZERO and SPAN of the actuator. Typically the ZERO and
SPAN positions are set just inside or at the full open and full
closed positions. If necessary, use two people during the setup
procedure. One person to run the actuator and the second
person to verify the position of the device coupled to the
actuator.

Figure 4.40.

End of Travel Position Limit Switches:

The actuator is fitted with two Position Limit switches to
prevent electrical operation beyond the set Zero and Span
positions.

During operation it is possible that the Position Limit Switches
are tripped and ‘Flt. Inc or Dec Limit, is displayed (Fig. 4.41).
(To adjust Limit switch positions (see start of section 4.3).

L P= 100 C= 100
Flt: Inc Limit

Figure 4.41.

L P= 26.4 C= 26.4
Volt = 08168

Figure 4.42.

Redefining Flow Control

27

4.3 - Range of Operation - Setup cont.

SET ZERO POSITION

The ZERO position is the position that the actuator will travel
to when given its minimum command. Typically this is the
closed position of the device. To set the ZERO position, follow
the procedure below:

ENTER KNOB - SELECT ‘CANCEL’ TO ENTER
SETUP MODE

Figure 4.43.

UP/DOWN KNOB - SELECT ‘ZERO’ MENU

The actuator position in this menu is shown as a 5 digit
encoder count (Fig. 4.44).

C

S / pick param
Press

S / pick param
ZERO = 06616

Figure 4.44.

D

28

4.3 - Range of Operation - Setup cont.

Use UP/DOWN knob to move actuator output to desired
ZERO position.

ENTER KNOB – SELECT ‘ENTER’ TO ADJUST
ZERO POSITION

Whilst at the desired ZERO position - Select ‘ENTER’ to Set the
new ZERO position. (Fig. 4.45).

Note: the parameter changes must be saved to
configuration to prevent loss of data.

UP/DOWN KNOB - SELECT ‘SAVE CONFIG’ MENU

Rotate the UP/DOWN knob until the display reads Save Config
(Fig. 4.46).

E

/ to ZERO
ENT = acpt 13028

Figure 4.45.

D

ENTER KNOB - ENTER TO SAVE TO EEPROM

Actuator configuration must be saved to EEPROM before
exiting the menu (Fig. 4.47).

S / pick param
Save Config

Figure 4.46.

E

S / pick param
Saving to EEPROM

Figure 4.47.

Redefining Flow Control

29

4.3 - Range of Operation - Setup cont.

SET SPAN POSITION

The SPAN position is the position that the actuator will travel
to when given its maximum command. Typically this is the
open position of the device. To set the SPAN position, follow
the procedure below:

ENTER KNOB - SELECT ‘CANCEL’ TO ENTER
SETUP MODE

Figure 4.48.

L P= 26.4 C= 26.4
Volt = 08168

C

S / pick param
Press

UP/DOWN KNOB - SELECT ‘SPAN’ MENU

SET SPAN POSITION

ENTER KNOB - SELECT ‘ENTER’ TO
ADJUST POSITION

Use UP/DOWN knob to move actuator output to desired
SPAN position.

ENTER KNOB - SELECT ‘ENTER’ TO SAVE
SPAN POSITION

Whilst at the desired SPAN position - Select ‘ENTER’ to Set
the new SPAN position. The actuator position in this menu is
shown as a 5 digit encoder count (Fig. 4.51).

Note: the parameter changes must be saved to configuration
to prevent loss of data.

Figure 4.49.

D

L / pick param
SPAN = 20243

Figure 4.50.

E

/ to SPAN

30

ENT = acpt 20031

Figure 4.51.

4.3 - Range of Operation - Setup cont.

UP/DOWN KNOB - SELECT ‘SAVE CONFIG’ MENU

Rotate the UP/DOWN knob until the display reads Save
Config. (Fig. 4.52).

D

S / pick param
Save Config

ENTER KNOB - ENTER TO SAVE TO EEPROM

Actuator configuration must be saved to EEPROM before
exiting the menu (Fig. 4.53).

ENTER KNOB - SELECT ‘CANCEL’

Select ‘CANCEL’ to exit setup mode.

The SPAN position has now been set (Fig. 4.54).

If limits have not been set adjustment of the position limit
switches is required. See start of section 4.3.

Figure 4.52.

E

S / pick param
Saving to EEPROM

Figure 4.53.

C

L P= 0.0 C= 0.0
Volt = 1 8168

Figure 4.54.

Redefining Flow Control

31

4.3 - Range of Operation - Setup cont.

4.3.3 SETTING LIMIT SWITCHES

SET INCREASING POSITION LIMIT
SWITCH CAM#1

It is now possible to set the CW & AC W position limit
switches.

With actuator set to LOCAL mode (see section 4.2) move
output shaft to the AC W end of travel position. As viewed
from the lever output shaft end.

This could be the ZERO or SPAN position depending on
configuration.

The switch acts as an emergency backup to de-energize
the motor drive and is generally set to trip if the actuator is
operated outside the SPA N or ZERO travel positions.

Locate locking set screw #1 on the switch cam end plate
assembly.

1

With a
screw (Fig. 4.55).

Rotate the cam CW until the switch operates (Fig. 4.57) then
back off so that the cam just releases the switch.

Tighten the set screw (Fig. 4.58).

The switch is now set to operate just after the anti-clockwise
(ZERO or SPAN ) position is reached.

/8” Hex key loosen (DO NOT REMOVE) locking grub

Figure 4.55.

SET DECREASING POSITION LIMIT
SWITCH CAM#2

With actuator set to LOCAL mode (see section 4.2) move
output shaft to the CW end of travel position. As viewed
from the lever output shaft end.

This could be the ZERO or SPAN position depending on
configuration.

Locate locking set screw #2 on the switch cam end plate
assembly (Fig. 4.56).

1

With a
screw.

Rotate the cam ACW until the switch operates then back off
so that the cam just releases the switch (Fig. 4.57).

Tighten the set screw (Fig. 4.58).

The switch is now set to operate just after the ACW (ZERO
or SPAN) position is reached.

/8” Hex key loosen (DO NOT REMOVE) locking grub

Figure 4.56.

Figure 4.57.

Note:
CW = Clockwise
ACW = Anti-Clockwise (Counter- Clockwise)

32

Figure 4.58.

4.3 - Range of Operation - Setup cont.

SET ADDITIONAL LIMIT SWITCHES (If fitted)

Repeat the procedure for switches CAM #3 to #6
as required.

REFIT TOP AND SIDE COVERS

Check condition of o-ring seals (replace if necessary) and refit
cover assemblies.

REFIT LOCAL CONTROL COVER ASSEMBLY

Remove the control cover assembly from its temporary
position and refit to front of control housing. Take care not
to damage looms between the cover assembly and the main
PCB. Disconnect wiring looms if necessary. Be sure to check
condition of the o-ring seals (replace if necessary) and refit
with cover.

Figure 4.59.

Redefining Flow Control

33

4.3 - Range of Operation - Setup cont.

4.3.4 OPERATING SPEED

The actuator output speed can now be changed to suit the
process requirement.

To change the actuator speed.

Figure 4.60.

ENTER KNOB - SELECT ‘CANCEL’

L P= 149 C= 149
Temp. .C 32 27

C

S / pick param
Ctrl Type = Man

UP/DOWN KNOB - SELECT ‘MENU’

Use the UP/DOWN knob to scroll through menus until ‘Speed

=XXX’isdisplayed(Fig.4.62).

UP/DOWN KNOB - SELECT SPEED

The motor speed can now be adjusted by using the
UP/DOWN knob until the display shows the desired
speed (10 - 100%) (Fig. 4.62).

Figure 4.61.

D

S / pick param
Speed = 100

Figure 4.62.

U

34

D

4.3 - Range of Operation - Setup cont.

ENTER KNOB - ENTER TO SAVE VALUE

Set new speed setting.

NOTE:
CYCLING THE POWER TO THE ACTUATOR
AT THIS STAGE WILL REMOVE RECENT CHANGES.

TO AVOID LOSS OF SETTINGS USE UP/DOWN
KNOB TO SCROLL TO THE ‘SAVE CONFIG‘
MENU (Fig. 4.64).

E

/ to Speed
ENT = acpt 100

Figure 4.63.

D

S / pick param

ENTER KNOB - ENTER TO SAVE VALUE

Save new speed setting to EEPROM (Fig. 4.65).

ENTER KNOB - CANCEL TO EXIT MENU

Save Config

Figure 4.64.

E

S / pick param
Saving to EEPROM

Figure 4.65.

Redefining Flow Control

C

35

5 - Setup and Calibration

SM-6000 S2 MENU STRUCTURE

SECT 5.1 SETUP & CALIBRATION

SECT 5.2 COMMUNICATIONS

SETUP MODE

There are two levels of Setup and Calibration.

Level 1: Customer Settings for initial setup and fine
tuning of the actuator operation.

Level 2: Diagnostic and Advanced Settings (Section 5.3).
User may wish to consult Rotork Process Controls
before making changes to level 2 parameters.

LEVEL 1 MENU STRUCTURE

SPAN

ZERO

MAX CAL

MIN CAL

SPEED

COMMS OPT

CMD TYPE

LOS ACT

MAX TORQUE

HART

LOS POS

CUR P GAIN

CUR I GAIN

MIN POS

MAX POS

SAVE CONFIG

CTRL MECH

HART ADDR

COM LOS ACT

COM LOS P

PROFIBUS

CTRL MECH

PROFI ADDR

FB POS LIM

COM LOS ACT

FFBUS

CTRL MECH

FB POS LIM

COM LOS ACT

COM LOS P

Figure 5.1. Level 1 Menu Structure

36

COM LOS TO

COM LOS P

COM LOS TO

COM LOS TO

5.1 - Setup and Calibration - Level 1

WARNING: SETTING THE OUTPUT TORQUE HIGHER
THAN 100% RATED MAY RESULT IN DAMAGE TO THE
ACTUATOR AND OR LINKAGE.

CAUTION: OPERATION AND CALIBRATION OF THE UNIT
MAY BE AFFECTED.

WARNING! ACTUATOR OUTPUT SHAFT
MAY MOVE DURING LEVEL 1 SETUP.

LEVEL 1

SPAN

Used to set the maximum travel limit of the actuator.

ZERO

Used to set the minimum travel limit of the actuator.

CTRL TYPE

Used to set the control mode of the actuator.

L = Local Mode (Fig 5.2)

When Local /Remote selector switch is set to Local operation
actuator can be operated by using the UP/DOWN selector
knob.

NOTE:
CYCLING THE POWER TO THE ACTUATOR AT THIS
STAGE WILL REMOVE RECENT CHANGES.

TO AVOID LOSS OF SETTINGS USE UP/DOWN KNOB TO
SCROLL TO THE ‘SAVE CONFIG‘ MENU.

L P= 100 C= 100
Amp Strts = 159

Figure 5.2. Local Mode

R= REMOTE Mode (Fig 5.3)

When Local/Remote selector set to Remote actuator responds
to hardwired remote control inputs only.

C = Remote Communications mode (Fig 5.4)

When Local/Remote selector set to Remote actuator responds
to serial commands when bus option cards are fitted.

S = Setup Mode (Fig. 5.5)

Allows access to menus and parameter changes.

R P= 100 C= 100
Flt: LOS-command

Figure 5.3. Automatic Mode

C P= 100 C= 100
Curr = -0.2 4052

Figure 5.4. Remote Communications Mode

S / pick param
Ctrl Type = REMOTE

Figure 5.5. Setup Mode

Redefining Flow Control

37

5.1 - Setup and Calibration - Level 1 cont.

5.1.1 MAX CMD CAL

Used to calibrate the analogue command signal to the
desiredMAXposition.
This maximises resolution and optimises accuracy.

The analogue control signal should be applied to
terminals as follows.

Voltage TB2-1 (+ve) TB2-2 (-ve)

Current TB2-4 (+ve) TB2-3 (-ve)

Refer to the identification label located on the outside
of the actuator for wiring diagram details.

1 - Enter setup mode (see section 4.2).

2 - Use the ENTER knob to scroll through menus until

’MAX=XXXX’isdisplayedonline2.

3 - Select ‘ENTER’.

SETCMNDTOMAXwillappearonline1ofthedisplay.

4 - Apply the maximum input command e.g. 20 mA.

5 - Select ‘ENTER’ to accept the new Max Cal value,

Select ‘CANCEL’ to exit the Max Cal setup mode.

5.1.2 MIN CMD CAL

Used to calibrate the analogue command signal to the desired
MIN position.
This maximises resolution and optimises accuracy.

1 - Enter setup mode (see section 4.2).

2 - Use the ‘Enter‘ knob to scroll through menus until

’MIN=XXXX’isdisplayedonline2.

3 - Select ‘ENTER’.

SET CMND TO MIN will appear on line 1 of the display.

4 - Apply the minimum input command e.g. 4 mA.

5 - Select ‘ENTER’ to accept the new Min Cal value,

Select ‘CANCEL’ to exit the Min Cal setup mode.

E

C

S / pick param
Max Cal = 7684

Figure 5.6. MAX CMD CAL

E

C

S / pick param
Min Cal = 1541

38

Figure 5.7. MIN CMD CAL

5.1 - Setup and Calibration - Level 1 cont.

5.1.3 SPEED

The actuator output speed is adjustable from 1 - 100% of its
rated value.

1 - Enter setup mode (see section 4.2).

2 - Use the UP/DOWN knob to scroll through menus until

‘Speed=XXX‘appearsonline2ofthedisplay.

3 - Select ‘ENTER’.

4 - Hold the UP/DOWN knob until desired value is displayed.

5 - Select ‘ENTER’ to accept new Speed value, or select

‘CANCEL’ to abort without changing the speed value.

5.1.4 CMD TYPE

Used to select between Current (4-20 mA) or Voltage
(0-5 VDC or 0-10 VDC).

1 - Enter setup mode (see section 4.2).

2-UseUP/DOWNknobuntil‘COMMAND=XXXX’is

displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select Current or Voltage.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

U

D

S / pick param
Speed = 100

Figure 5.8. SPEED

U

D

S / pick param
Cmd Type = Volt

5.1.5 LOS ACT

Used to determine the actuator action on loss of analogue
control signal when the actuator is set to Automatic Mode of
operation.

LOCK - Stayput or Lock in place.
POS - Go to Preset Position.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until LOS ACT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select desired value.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

Figure 5.9. CMD TYPE

U

D

S / pick param
LOS Act = Lock

Figure 5.10. LOS ACT

Redefining Flow Control

39

5.1 - Setup and Calibration - Level 1 cont.

5.1.6 LOS POS

Used to determine the position that the actuator will move to
on loss of analogue control signal.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until LOS POS is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select desired value.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

5.1.7 CUR P GAIN

Used to adjust the proportional gain of the actuator.
Modifies the response of the actual position against desired
position. Range 1-99.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until CUR P GAIN is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select desired value.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

U

D

S / pick param
LOS Pos = 18844

Figure 5.11. LOS POS

U

D

S / pick param
Cur P Gain = 40

5.1.8 CUR I GAIN

Used to adjust the integral gain of the actuator where system
response varies over time. Range 0-99.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until CUR I GAIN is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select desired value.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

Figure 5.12. CUR P GAIN

U

D

S / pick param
Cur I Gain

Figure 5.13. CUR I GAIN

= 20

40

5.1 - Setup and Calibration - Level 1 cont.

5.1.9 MIN POS

Used to set the position regarded as ZERO when limited range
positioning is required. Only applicable when the FB Pos Limit
is active. For example if MIN POS is set to 10% this is reported
as the ZERO (0%) position.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until MIN POS is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to move the actuator to the

desired position.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

5.1.10 MAX POS

Used to set the position regarded as SPAN when limited
range positioning is required. Only applicable when the FB Pos
Limit is active. For example if MAXPOSissetto90%thisis
reported as the SPAN (100%) position.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until MIN POS is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to move the actuator to the

desired position.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

U

D

S / pick param
Min Pos = 0

Figure 5.14. MIN POS

U

D

S / pick param
Min Pos = 100

Figure 5.15. MAX POS

Redefining Flow Control

41

5.1 - Setup and Calibration - Level 1 cont.

5.1.11 MAX TORQUE %

Used to limit the output torque produced by the actuator.
Exceeding the value will result in an over torque alarm being
displayed.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until Max TORQUE is displayed.

Max value = 200% of rated,

3 - Select ‘ENTER’

4 - Use UP/DOWN knob to select desired value.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

5.1.12 SAVE CONFIG

Used to save setup parameters to EEPROM. Any parameter
changes MUST be saved prior to power off. On power up
the on board processor will use the last values stored in the
EEPROM.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until SAVE CONFIG is displayed.

3 - Select ‘ENTER’ to save changes to EEPROM.

CANCEL to exit the menu.

U

D

S / pick param
Max Torq % = 100

Figure 5.16. MAX TORQUE %

U

D

SETUP COMPLETE

Set the REMOTE/Local parameter to REMOTE.

S / pick param
Save Config

Figure 5.17. SAVE CONFIG

42

5.2 - Communications

COMMS OPT

Used to select specific menus when a BUS communications
option card is fitted.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COMS OPT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the actuator

control protocol.

Choices are:

NONE No Bus Protocol option fitted.
HART
PROFIBUS
FFBUS (Foundation Fieldbus)

5 - Select ‘ENTER’ to accept the change.

The selected communication protocol options will now be
available.

Note that the unit must be fitted with the appropriate Bus
system card to support the menus.

5.2.1 HART CONTROL OPTIONS

CTRL MECH

The actuator can be controlled via commands received over
the Hart protocol communications channel or as a direct
analogue (4-20 mA) input signal request.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until CTRL MECH is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the actuator control type.

Menu choices are:
COMMS = HART protocol control
ANALOG = 4-20 mA Analogue Control only.

5 - Select ENTER to accept the change.

CANCEL to exit the menu.

HART

CTRL

MECH

Figure 5.18

HART

ADDR

U

D

S / pick param
COMMS Opt = HART

Figure 5.19. COMMS OPT

U

D

S / pick param
Ctrl Mech = COMMS

Figure 5.20. CTRL MECH

U

COM

LOS ACT

COM

LOS P

COM

LOS TO

HART ADDR

Used to set the address assigned to the device on the
HART network. Range 1 to 64.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until HART ADDR is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob until desired address is displayed

5 - Select ‘ENTER’.

CANCEL to exit the menu.

Redefining Flow Control

D

S / pick param
HART Addr = 0

Figure 5.21. HART ADDR

43

5.2 - Communications cont.

COM LOS ACT

Action on loss of HART communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS ACT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired action.

Menu choices are:

LOCK - Stayput or Lock in place.
POS - Go to Preset Position.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

COMM LOS P

Position actuator will move to on loss of HART
communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS P is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired position.

Range 0-100%.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

U

D

S / pick param
COM LOS Act = Stop

Figure 5.22. COM LOS ACT

U

D

S / pick param
COMS LOS P = 781

COMM LOS TO

Time delay before action is taken on loss of HART
communication. Maximum of 10 seconds.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS TO is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired delay time.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

NOTE: To avoid loss of settings use the ‘SAVE CONFIG’
menu to save changes to the EEPROM. See p42
for details.

Figure 5.23. COMM LOS P

U

D

S / pick param
COMS LOS TO = 63

Figure 5.24. COMM LOS TO

44

5.2 - Communications cont.

5.2.2 PROFIBUS CONTROL OPTIONS

CTRL MECH

The actuator can be controlled via commands received over
the Profibus protocol communications channel or as a direct
analogue (4-20 mA) input signal request.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until CTRL MECH is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the actuator control type.

Menu choices are:

COMMS = Profibus protocol control
ANALOG = 4-20 mA Analogue Control only.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

PROFI ADDR

Used to set the address assigned to the device on the Profibus
network. Range 1 to 127.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until PROFI ADDR is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob until desired address is displayed.

5 - Select ‘ENTER’.

CANCEL to exit the menu.

PROFIBUS

CTRL

MECH

Figure 5.25

PROFI
ADDR

U

D

S / pick param
Ctrl Mech = COMMS

Figure 5.26. CTRL MECH

U

D

FB POS

LIM

COM

LOS ACT

COM

LOS P

COM

LOS TO

FB POS LIMIT

Feedback position limiting. When enabled the actuator
will return a zero value when the actuator is below the MIN POS

limitand100%abovetheMAXPOSLimit.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until FB POS LIMIT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN to select Enable or Disable function.

5 - Select ‘ENTER’.

CANCEL to exit the menu.

Redefining Flow Control

S / pick param
PROFI addr = 126

Figure 5.27. PROFI ADDR

U

D

S / pick param
FB Pos Limit = No

Figure 5.28. FB POS LIMIT

45

5.2 - Communications cont.

COM LOS ACT

Action on loss of Profibus communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS ACT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired action.

Menu choices are:

LOCK - Stayput or Lock in place.
POS - Go to Preset Position.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

COMM LOS P

Position actuator will move to on loss of Profibus
communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS P is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired position.

Range 0-100%.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

U

D

S / pick param
COM LOS Act = Stop

Figure 5.29. COM LOS ACT

U

D

S / pick param
COMS LOS P = 781

COMM LOS TO

Time delay before action is taken on loss of Profibus
communication. Maximum of 10 seconds.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS TO is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired delay time.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

NOTE: To avoid loss of settings use the ‘SAVE CONFIG’
menu to save changes to the EEPROM. See p42
for details.

Figure 5.30. COMM LOS P

U

D

S / pick param
COMS LOS TO = 255

Figure 5.31. COMM LOS TO

46

5.2 - Communications cont.

5.2.3 FOUNDATION FIELDBUS
CONTROL OPTIONS

CTRL MECH

The actuator can be controlled via commands received over
the FFBUS protocol communications channel or as a direct
analogue (4-20 mA) input signal request.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until CTRL MECH is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the actuator control type.

Menu choices are:

COMMS = FFBUS protocol control.
ANALOG = 4-20 mA Analogue Control only.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

FB POS LIMIT

Feedback position limiting. When enabled the actuator
will return a zero value when the actuator is below the

MINPOSlimitand100%abovetheMAXPOSLimit.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until FB POS LIMIT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN to select Enable or Disable function.

5 - Select ‘ENTER’.

CANCEL to exit the menu.

FFBUS

CTRL

MECH

Figure 5.32

FB POS

LIM

U

D

S / pick param
Ctrl Mech = COMMS

Figure 5.33. CTRL MECH

U

D

S / pick param
FB Pos Limit = No

COM

LOS ACT

COM

LOS P

COM

LOS TO

COM LOS ACT

Action on loss of Foundation Fieldbus communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS ACT is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired action.

Menu choices are:

LOCK - Stayput or Lock in place.
POS - Go to Preset Position.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

Redefining Flow Control

Figure 5.34. FB POS LIMIT

U

D

S / pick param
COM LOS Act = Stop

Figure 5.35. COM LOS ACT

47

5.2 - Communications cont.

COMM LOS P

Position actuator will move to on loss of FFBUS
communication.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS P is displayed.

3 - Select ’ENTER’

4 - Use UP/DOWN knob to select the desired position.

Range 0-100%.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

COMM LOS TO

Time delay before action is taken on loss of FFBUS
communication. Maximum of 10 seconds.

1 - Enter setup mode (see section 4.2).

2 - Use UP/DOWN knob until COM LOS TO is displayed.

3 - Select ‘ENTER’.

4 - Use UP/DOWN knob to select the desired delay time.

5 - Select ‘ENTER’ to accept the change.

CANCEL to exit the menu.

NOTE: To avoid loss of settings use the ‘SAVE CONFIG’
menu to save changes to the EEPROM. See p42
for details.

U

D

S / pick param
COMS LOS P = 781

Figure 5.36. COMM LOS P

U

D

S / pick param
COMS LOS TO = 255

Figure 5.37. COMM LOS TO

RECORD YOUR USER SETTINGS IN SECTION 13.

48

5.3 - Setup and Calibration - Level 2

SM-6000 S2 MENU STRUCTURE

Level 2: Diagnostic and Advanced Settings.
User may wish to consult Rotork Process Controls
before making changes to level 2 parameters.

SETUP MODE

LEVEL 2

MOTOR

MAX TORQUE

INPUT VOLT

MOTOR RATE

PASS ENBLD

LOOP

LOAD FACT DEFS

SAVE CONFIG

Figure 5.38. Level 2 Menu Structure

Redefining Flow Control

49

5.3 - Setup and Calibration - Level 2 cont.

LEVEL 2 ADVANCED SETUP MENUS

CAUTION: SOME VARIABLES IN LEVEL 2 ARE FACTORY SET – DO NOT ADJUST!!

5.3.1 MOTOR PWM

Command used to represent motor speed in function of
maximum pulse width modulation.

To access the advanced setup and calibration menus rotate
the UP/DOWN knob clockwise and the ENTER/CANCEL knob
anti-clockwise.

Hold for 10 seconds.

5.3.2 MAX TORQUE

Used to match the motor output and control to the gearbox.

This value is factory set and must not be changed.

5.3.3 INPUT VOLT

Used to select the AC input voltage used by the Amplifier.
Check the actuator wiring diagram for additional notes on
selection of input power supplies.

This must match the hardware configuration. This value is
factory set and must not be changed.

5.3.4 MOTOR RATE

This is a factory set parameter and it is configured to match
the motor voltage as fitted.

This should not be changed.

U

D

S / pick param
Max Torq % = 100

Figure 5.39. MAX TORQUE

U

D

5.3.5 PASS ENBLD

Enable a 4 Digit system password. Select ‘YES’ to enable
password.

PASSWORD VALUE

Check function

5.3.5.1 PASSWORD

NOTE: IF PASSWORD IS SELECTED ‘ON’ THEN NO
CHANGES ARE ALLOWED UNLESS THE CORRECT
PASSWORD IS ENTERED.

Use UP/DOWN Selector to select ‘YES’.

Use CANCEL/ ENTER to enable Password.

Use UP/DOWN selector to select required password then
CANCEL/ENTER selector to store the new password.

Holding the UP/DOWN selector whilst changing the password
will increase the scroll rate accordingly.

MAKE A NOTE OF THE PASSWORD:

S / pick param
Input Volt = 120

Figure 5.40. INPUT VOLT

U

D

S / pick param
Pass Enbld = No

Figure 5.41. PASS ENBLD

50

5.3 - Setup and Calibration - Level 2 cont.

5.3.6 LOOP

Closed loop or Open loop control. The default setting of the
actuator is Closed loop control. Open loop is used for factory
setup only.

This value is factory set and must not be changed.

5.3.7 LOAD FACT DEFS

Used to revert the actuator back to the Factory default
Settings.

U

D

S / pick param
Loop = Run

Figure 5.42. LOOP

U

CAUTION: SAVE CONFIG

Used to save setup parameters to EEPROM. Any
parameter changes MUST be saved prior to power off.
On power up the onboard processor will use the last
values stored in the EEPROM.

Use UP/DOWN knob until SAVE CONFIG is displayed.

Select ‘ENTER’ to save changes to EEPROM.

CANCEL to exit the menu.

SETUP COMPLETE

RECORD YOUR USER SETTINGS IN SECTION 13.

D

S / pick param
Load Fact Defs

Figure 5.43. LOAD FACT DEFS

Redefining Flow Control

51

6 - Faults & Troubleshooting

6.1 FAULT STATUS INDICATION

Fault Diagnostics appear on line two of the display. When
more than one diagnostic is active, only the highest priority
will show.

Flt: Incr Limit

End of Travel Limit Switch for the increasing direction is
tripped.

Decrease actuator position to move off limit switch.

Flt: Decr Limit

End of Travel Limit Switch for the decreasing direction is
tripped.

Increase actuator position to move off limit switch.

Flt: Stalled

Actuator output speed is incorrect due to excessive load.

Momentary stall Flts are self-resetting.

Continuous or repetetive stall Flts indicate an improperly
loaded actuator. Reduce load.

Flt: LOS-Command

Loss of command signal.

Command signal is below 3.6 mA, or above 21.6 mA.

Return command signal to 4-20 mA range.

Flt: Crnk Engagd

The hand crank has been engaged.

Pull out hand crank to remove Flt.

Flt: LOS-Feedbk

If using an encoder, either the encoder is disconnected, the
encoder has reached the end of travel, or there is an internal
encoder fault.

If using a potentiomer, the feedback pot has been
disconnected or the feedback signal has risen above 4.9 V.

Flt: System Fail

Microprocessor has detected a system failure.

Simultaneously turn the UP/DOWN knob ACW and ENTER/
CANCEL knob CW to Clear the alarm.

Flt: Torq Limit

The current rating of the torque has been exceeded.

Simultaneously turn the UP/DOWN knob ACW and ENTER/
CANCEL knob CW to Clear the alarm.

Flt: Mtr Pol Re

Motor direction of operation or response is incorrect.

Motor leads possibly reversed.

Switch off and check motor wiring immediately!

Motor operation is checked automatically on power up.

52

U

C

Figure 6.1. Turn both knobs as shown to clear alarms.

6 - Faults & Troubleshooting cont.

6.2 TROUBLESHOOTING

Trouble Possible Cause Remedy

Actuator will increase position but
not decrease

Actuator will decrease position,
but not increase

LS2 is tripped

Actuator is at zero position

LS1 is tripped

Increase actuator to normal operating
range. Check LS2 and Zero Setup

Decrease actuator to normal operating
range. Check LS2 and SPAN Setup

No actuator power

Actuator will not move

Actuator oscillates during
movement

Actuator overshoots position Too high of integral gain Reduce Cur I gain

Poor response to command signal
change

Actuator moves, but motor
gets hot

Actuator does not respond to a
change in command

Actuator will not move and has lost
feedback

Motor is not connected

LS1 and LS2 are both tripped Verify LS1 and LS2 are setup correctly

Hand Crank engaged Remove hand crank engagement

Too high of proportional gain Reduce Cur P gain/CL gain

Too low of proportional gain Increase Cur P/CL gain

Amplifier defective Replace amplifier

Excessive noise on command
signal

Motor brake not disengaging Verify motor brake wiring

Motor brake module not setup Set per wiring diagram

Motor brake module defective replace phase control module

Wrong command type selected Verify current/voltage setup for command

Wiring disconnected Verify electrical connection

Actuator in Manual Place actuator in automatic

Feedback element is
disconnected

Actuator position is out of
operating range

Is LED D1 on? If no, turn off electrical
power and re-check electrical connections

Connect motor as shown in the wiring
diagram

Reduce noise. Also ensure that command
signal wiring is shielded with shield
grounded at source common only

Check feedback device connection

Hand crank actuator to operating range

Nothing on Display

No Transmitter Output’

Motor Runs but output shaft does
not rotate

Actuator Back drives when power
is removed

Hand crank does not move
output shaft

No Power to control/logic board

Amplifier defective Replace amplifier

No power to Transmitter

Incorrect wiring Verify electrical connections

Transmitter ID defective Replace transmitter

Motor Coupling defective

Holding brake improperly
adjusted

Holding brake worn Replace holding brake

Too heavy of a load Verify rating and load

Hand crank not engaged fully

Hand crank retaining Pin worn or
broken

Motor coupling defective

Is LED D1 on? If no, turn off electrical
power and re-check electrical connections

Transmitter is loop powered. See wiring
diagram to supply isolated power to
transmitter

Verify connection between motor and
gear box

Adjust spring force on holding brake

Verify hand crank couples with motor
shaft

Verify retaining pin

Verify connection between motor and
gearbox

Redefining Flow Control

53

7 - Local Operation - Handcrank Direction

10/370

10/550

10/800

10/1400

10/2500

10/4400

10/6200

12/8000

18/11000

26/16500

42/26000

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CW

CCW

CCW

CCW

CCW

CCW

Speed/Torque

Rotation

of Handcrank

Rotation of Output Shaft

(looking at the end of the output shaft)

54

8 - Mounting Conversion

10/370

10/550

10/800

10/1400

10/2500

10/4400

10/6200

12/8000

18/11000

26/16500

42/26000

0.85 qts. (27.2 fl.oz)

0.85 qts. (27.2 fl.oz)

1.6 qts. (51.2 fl.oz)

0.8 qts. (25.6 fl.oz)

2.2 qts. (70.4 fl.oz)

4.4 qts. (140.8 fl.oz)

4.2 qts. (134.4 fl.oz)

9.5 qts. (304 fl.oz)

9.5 qts. (304 fl.oz)

18.0 qts. (576 fl.oz)

2.1 qts. (67.2 fl.oz)

0.8 ltr.

0.8 ltr.

1.5 ltr.

0.8 ltr.

2.1 l t r.

4. 2 ltr.

4 ltr.

9 ltr.

9 ltr.

17 l tr.

2 ltr.

NA

NA

NA

NA

NA

NA

0.11 qts. (3.5 fl.oz)

0.53 qts. (17 fl.oz)

0.53 qts. (17 fl.oz)

0.64 qts. (20.5 fl.oz)

0.64 qts. (20.5 fl.oz)

NA

NA

NA

NA

NA

NA

0.1 ltr.

0.5 ltr.

0.5 ltr.

0.6 ltr.

0.6 ltr.

To convert a Horizontally mounted SM-6000 to a vertically
mounted SM-6000:

• Unthreadtheexistingbreatherlocatednearthetop
surface of the gearbox.

• Addadditionallubricantperthechartbelow(seelistof

approved lubricants).

• Whileholdingafingeroverthebreatheropeningtipthe

gearbox to the vertical position.

• Removetheexistingtappedplugthatisatthehighest
point on the gearbox when in the vertical position.

• Quicklyinstallthetappedplugintothelowerlocation.
Fully tighten.

• Threadbreatherintotheupperopening.Fullytighten.

On the 5 largest units with two reservoirs relocate the
breathers from both reservoirs as noted above.

To convert a Vertical SM-6000 to a Horizontal SM-6000
follow same steps but do not remove lubricant.

Approved Lubricants

 •CastrolIsolubeEP220

  •MobilOmala220HD

  •KluberKlubersynthEG4-220

  •Tribol1510/220

Speed/Torque

Large Reservoir

Small Reservoir

English EnglishMetric Metric

Redefining Flow Control

55

48

9 - Parts Identification

370, 800 & 1400 ft. lb. units

56

9 - Parts Identification cont.

49

2500 ft. lb. unit

Redefining Flow Control

57

50

9 - Parts Identification cont.

4400, 6200, 8000, 11000, 16500, & 26000 ft. lb. units

58

10 - Drive Arm Dimensions

10/370

10.00 1.00 – – 1.08 .75 1.25 .75 – 1.39 .25 1.00 –

10/800

10.00 1.50 – – 1.50 1.00 1.38 1.00 – 1.54 .31 1.50 –

10/1400

10.00 1.50 – – 1.50 1.00 1.75 1.00 – 1.95 .38 1.50 –

10/2500

12.00 2.50 1.50 .50 2.63 1.00 2.38 1.00 4.50 2.68 .63 1.50 –

10/4400

12.00 2.50 1.50 .50 2.63 1.00 2.88 1.00 4.50 3.23 .75 1.50 –

10/6200

15.00 4.00 2.00 1.00 4.25 1.00 3.63 1.00 6.75 4.04 .88 1.50 2.00

12/8000 & 18/11,000

15.00 4.00 2.00 1.00 4.25 1.00 4.38 1.00 6.75 4.85 1.00 1.50 2.00

26/16,500

15.00 4.00 2.00 1.00 4.25 1.00 4.75 1.00 6.75 5.33 1.25 1.50 2.00

42/26,000

18.00 5.00 2.00 1.50 4.63 1.50 5.50 1.25 7.75 6.08 1.25 2.00 –

Speed/Torque

ABCDEFGHIJKLM

These dimensions are subject to change without notice and should not be used for preparation of drawings or fabrication
of installation mounting. For current installation manuals and other product information, see www.rotork.com.

Redefining Flow Control

59

11 - Overall Dimensions

These dimensions are subject to change without notice and should not be used for preparation of drawings or fabrication of installation
mounting. For current installation manuals and other product information, see www.rotork.com.

P

COVER REMOVAL

B

A

O N SHAFT DIA.

D

E

O

C

F

L

G

H

I

J

K

O M

4 PLACES

Model A B C D E F G H I J K L M N O P

10/370 37.60 26.63 12.49 6.58 5.32 5.91 2.36 4.72 2.95 3.50 10.88 1.50 0.56Ø 1.250/1.249Ø 0.25 x 0.25 KEY 8.00

10/800 38.47 28.24 12.59 6.58 6.34 6.01 2.25 4.50 4.09 4.50 13.00 0.50 0.56Ø 1.375/1.374Ø 0.31 x 0.31 KEY 8.00

10/1400 39.24 30.17 14.41 6.58 7.72 7.84 3.25 6.50 4.47 5.38 14.50 0.75 0.81Ø 1.750/1.749Ø 0.38 x 0.38 KEY 8.00

10/2500 43.77 32.49 15.35 6.58 9.45 8.35 3.54 7.09 5.90 2.17 7.09 1.26 0.88Ø 2.375/2.374Ø 0.63 x 0.63 KEY 8.00

10/4400 53.83 35.64 18.78 6.58 11.42 10.43 4.72 9.45 6.69 2.95 9.45 1.50 1.02Ø 2.875/2.874Ø 0.75 x 0.75 KEY 8.00

10/6200 63.67 38.87 22.28 7.87 13.66 12.40 5.31 10.63 8.35 3.74 11.02 1.65 1.30Ø 3.625/3.624Ø 0.88 x 0.88 KEY 8.00

12/8000 71.23 42.84 29.09 8.86 16.45 14.76 6.50 12.99 9.96 4.53 13.78 1.77 1.54Ø 4.375/4.374Ø 1.00 x 1.00 KEY 8.00

12/11000 71.23 42.84 29.09 8.86 16.45 14.76 6.50 12.99 9.96 4.53 13.78 1.77 1.54Ø 4.375/4.374Ø 1.00 x 1.00 KEY 8.00

26/16500 73.79 45.87 32.40 9.84 17.99 17.72 8.27 16.54 9.72 5.51 14.96 1.97 1.54Ø 4.750/4.749Ø 1.25 x 1.25 KEY 8.00

42/26000 80.48 51.98 36.54 12.40 21.85 19.69 9.45 18.90 12.41 7.87 21.26 1.97 1.30Ø 5.500/5.499Ø 1.25 x 1.25 KEY 8.00

60

12 - Linkage Options

370 ft. lb.

2500 &

4400 ft. lb.

6200 &

16500 ft. lb.

800 &

1400 ft. lb.

Notes:

1. Maximum total linkage length is specified to prevent
buckling under compressive load.

2. Special drive arm lengths are available to meet application
requirements.

Model

“A” LENGTH

in. (mm)

(See Note 3)

“B” MA XIMUM

LENGTH

ft. (m)

“C” LENGTH

in. (mm)

10 (254) 18 (5.5) 10 (254) 12 . 2 5 ( 311) 17 (432)

10 (254) 3 0 (9.1) 10 (254) 12 . 2 5 ( 311) 17 (432)

12 (305 ) 18 (5.5) 12 (305) 14.70 (373) 21.50 (54 6)

15 (381) 18 (5.5) 15 (381) 18.38 (4 67 ) 25.50 (648)

“D” LENGTH

in. (mm)

“E” LENGTH

in. (mm)

“F” DIA. HOLE

min.-max.

in. (mm)

0.75 - 1.5

(19 - 38.1)

1 - 2

(25.4 - 50.8)

1.5 - 3.5

(38.1 - 88.9)

2.5-5

(63.5 - 127)

“G” PIPE SIZE

1 - 1/4 (NPT)

1

/2 (NPT)

2 -

1

/2 (NPT)

2 -

1

/2 (NPT)

3 -

Redefining Flow Control

61

13 - User Settings

Span

Zero

Max.Cal.:

Min. Cal.:

Speed:

Cmd Type:

Cntrl Mech:

Comms Settings:

LOS Action:

P Gain:

I Gain:

Min Pos

Max Pos

Max. Torque (%):

Max. Torque (ft. lbs.):

Input Volts (tp amp from transformer):

Motor Rating:

Password:

Loop: Open

Closed

CZero 0%:

CZero 25%:

CZero 50%:

CZero 75%:

CZero 100%:

Additional Information:

62

Notes

Redefining Flow Control

63

Electric Actuators and Control Systems

Fluid Power Actuators and Control Systems

Gearboxes and Gear Operators

Projects, Services and Retrofit

Precision Control Instruments

UK

Rotork plc

tel + 44 (0)1225 733200
fax [phone]
email [e-mail]

USA

Rotork Process Controls

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

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

www.rotork.com

PUB052-003-00
Issue 06/12

As par t of a process o f on-go ing produc t develo pment, Rot ork reser ves the right to amend and
change spe cificat ions with out prior n otice. Publi shed data m ay be subjec t to change. F or the
very late st versi on releas e, visit our we bsite at w ww.rotork.c om

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