IQ Range Installation and Maintenance Instructions

1 IQ RangeInstallation andMaintenance InstructionsPublication number E170E2 Date of issue 01/05 Please ensure that this publication is thoroughly read and understoodThe rotork Setting Tool allows actuator control, indication and protection functionsto be configured to suit site requirements. It is essential that all the actuatorsettings are checked for compatibility with the process and control systemrequirements before the actuator is put into service. Please read this rotork personnel or nominated agents are contracted to carry out sitecommissioning and/or acceptance, documentation of commissioned actuatorconfiguration can be made available for customer manual provides instruction on:*Manual and electrical (local and remote) operation.

2 *Preparation and Installation of the actuator ontothe valve.*Subsequent commissioning and adjustment of thePrimary Settings for correct valve operation.*Commissioning and adjustment of the SecondarySettings to suit site-specific control and indicationrequirements.* Maintenance Troubleshooting.*Sales and to Publication E180E2 for repair, overhaul andspare part rotork IQ Range THE FIRST VALVE ACTUATOR THAT YOUCAN COMMISSION AND INTERROGATE WITHOUT REMOVINGELECTRICAL the supplied infra-red Setting Tool to access the actuator set upprocedures, point and shoot setting of torque levels, position limits andall other control and indication functions can be made safely, quickly andconveniently, even in hazardous locations.

3 The IQ allows commissioningand adjustment to be carried out with the main power supply to theactuator switched on or diagnostics access information about the control system, valveand actuator status in the form of display icons and help valve torque and position can be monitored on the actuatorwith a single key press of the Setting on board Datalogger captures operational and valve torque dataenabling informed Maintenance choices to be made. IQ Insight softwarefor PC and PDA allows the Datalogger to be interrogated, as well as thecomplete actuator set up to be configured and actuator containing the Setting Tool will be identified with a yellowlabel on the terminal our web site at more information on the IQ andother rotork actuator Health and Safety232 Storage33 Operating your IQ Operating by Hand Operating Electrically Display 4 Local Display Alarm Indication 54 Preparing Drive IQ10 to IQ35 7 Thrust Base Types A and IQ10 to IQ35 8 Non-Thrust Base Type IQ40 to IQ95 8 Thrust Base Types A and IQ40 to IQ95 9 Non-Thrust Base Type B5 Mounting the Rising Stem

4 Valves 11 Top Valve with Gearbox 11 Side Non-Rising Stem Valves 11 Top Handwheel IQM Modulating Actuators IQML Linear Drive IQML Adjusting Linear Stroke126 Cable Earth/Ground Connections Removing Terminal Cover Cable Entry Connecting to Terminals Replacing Terminal Cover 157 The Setting Procedure The Setting Tool Entering the Actuator 18 Setting Setting Mode Password New Password Checking Mode Procedure Branch The Actuator Display 19 Setting/Checking Returning to Valve 19 Position Display8 Commissioning Primary Functions 20 Primary Functions Contents 219 Commissioning Secondary Functions29 Secondary Functions Contents 31 Default Options6310 Maintenance , Monitoringand Troubleshooting Help Screens IrDA Diagnostics & Configuration 7211 Weights and Measures74 Binary, Hexadecimal and Decimal 75 Conversion Table12 IQ Approvals76 CONTENTSPagePageThis manual is produced to enable acompetent user to install, operate,adjust and inspect rotork IQ rangevalve electrical Installation .

5 Maintenanceand use of these actuators should becarried out in accordance with theNational Legislation and StatutoryProvisions relating to the safe use ofthis equipment, applicable to the site the UK: Electricity at WorkRegulations 1989 and the guidancegiven in the applicable edition of the IEE Wiring Regulations should beapplied. Also the user should be fullyaware of his duties under the Healthand Safety Act the USA: NFPA70, National ElectricalCode is mechanical Installation should becarried out as outlined in the manualand also in accordance with relevantstandards such as British StandardCodes of Practice.

6 If the actuator hasnameplates indicating that it is suitablefor Installation in Hazardous Gas Areasthen the actuator is suitable for use inZone 1 and Zone 2 (or Div 1 and Div 2)explosive atmospheres only. It shouldnot be installed in atmospheres wheregases are present with an ignitiontemperature less than 135 C, unlesssuitability for lower ignitiontemperatures has been indicated on theactuator test instruments applied to theactuator should be of equivalentcertification. The electrical Installation , Maintenance and the use of theactuator should be carried out inaccordance with the code of practicerelevant for that particular HazardousGas Area inspection or repair should beundertaken unless it conforms to thespecific Hazardous Gas Areacertification requirements.

7 Under nocircumstances should any modificationor alteration be carried out on theactuator as this could invalidate theconditions under which its certificationwas to live electrical conductors isforbidden in the hazardous area unlessthis is done under a special permit towork, otherwise all power should beisolated and the actuator moved to anon-hazardous area for repair persons competent by virtue oftheir training or experience should beallowed to install, maintain and repairRotork actuators. Work undertakenmust be carried out in accordance withinstructions in the manual. The userand those persons working on thisequipment should be familiar with theirresponsibilities under any statutoryprovisions relating to the Health andSafety of their :Motor TemperatureWith excessive use the motor surfacetemperature could reach 132 C (270 F).

8 Thermostat BypassIf the actuator is configured to bypassthe motor thermostat, when using theESD function, the hazardous areacertification will be and IndicationWhere the actuator build allows remotecontrol and indication supplies higherthan 150V but below 300V (refer to actuator wiring diagram) theremote control and indication suppliesmust be derived from a supply which isdesignated as Installation category(overvoltage category) ll as defined inBSEN 61010 (Safety Requirements ForElectrical Equipment for measurement,control and laboratory use).Enclosure MaterialsIQ10 to IQ35 are manufactured fromaluminium alloy with stainless steelfasteners and the thrust bases aremanufactured in cast iron.

9 IQ40 to IQ95enclosures are manufactured inaluminium alloy and cast iron withstainless steel fasteners and the thrustbases are manufactured in cast user must ensure that theoperating environment and anymaterials surrounding the actuatorcannot lead to a reduction in the safeuse of, or the protection afforded by,the actuator. Where appropriate theuser must ensure the actuator issuitably protected against it s further information andguidance relating to the safe use of theRotork IQ Range of actuators berequired, it will be provided on : Operating by HandWith respect to handwheel operationof rotork electric actuators.

10 Seewarning on and Safety1If your actuator cannot be installedimmediately store it in a dry place untilyou are ready to connect the actuator has to be installed butcannot be cabled it is recommendedthat the plastic transit cable entry plugsare replaced with metal plugs which aresealed with PTFE rotork double-sealed constructionwill preserve internal electricalcomponents perfectly if is not necessary to remove anyelectrical compartment covers in orderto commission the IQ cannot accept responsibility fordeterioration caused on-site once thecovers are rotork actuator has been fullytested before leaving the factory to giveyears of trouble free operation,providing it is correctly commissioned,installed and Operating by HandWARNINGWith respect to handwheeloperation of rotork electricactuators.