Contents

page
1 Identifying Actuator Parts 2
1.1 Weights 2
‘Q’ Range electric 2 Mounting Actuator and
Setting Instructions 3
direct-drive 2.1 Drive Bush 3
2.2 Mounting Actuator onto Valve 3
quarter turn valve 2.3 Setting Mechanical Stops 3
actuators 2.4
2.5
Electrical Wiring-Up
Switch Settings
3
4
2.6 Selection of Remote Control
Functions 5
Instruction manual 3 Replacement of Top Cover
and Indication 5
3.1 Checking Electrical Operation 6
4 Final Checks 6
5 Optional Extras 6
5.1 Potentiometer Transmitter 6
5.2 Current Position Transmitter
(C.P.T.) 4-20mA output 6
5.3 Folomatic Proportional Control 8
6 Final Checks 9

Publication number E670E 7 Lubrication and Maintenance 10

Date of issue 01/07 Appendix 1
Folomatic Range Switches 10
Rotork actuator is supplied Health and Safety

■ Fully rig and performance tested This manual is produced to enable a equipment should be familiar with their
competent user to install, operate, responsibilities under the Health and
■ Torque output set to maximum adjust and inspect Rotork ‘Q’ Range Safety at Work Act 1974 and relevant
valve actuators. Statutory Provisions relating to their
■ Cable entries sealed for transit work.
protection The electrical installation, maintenance
and use of these actuators should Should further information and
■ Inclusive of commissioning kit conform to the requirements of the guidance relating to the safe
“Electricity at Work Regulations 1989” installation, maintenance and use of
■ Inclusive of wiring diagram and the guidance given in the IEEE the Rotork ‘Q’ Range actuator be
Wiring Regulations”. For the USA: required, this will be provided on
Rotork actuator type is identified by a NFPA70, Electrical code ® is applicable. request.
stainless steel label fitted to the main Also any other national legislation
body. applicable. Warning: With respect to handwheel
operation of Rotork electric actuators,
The mechanical installation should be under no circumstances should any
carried out as outlined in this manual additional lever device such as a
and also in accordance with the wheel-key or wrench be applied to
relevant British Standard Codes of the handwheel or in order to develop
Practice. more force when closing or opening
the valve as this may cause damage
Only persons competent by virtue of to the valve and/or actuator or may
their training and experience should be cause the valve to become stuck in
allowed to install, maintain and repair the seated/backseated position.
these actuators, and they should carry
out this work in accordance with the
instructions given in this manual. The
user and those persons working on this Nameplate
 2
1 Identifying actuator
parts

1 Drive Bush 6 Conduit Entries 1.1 Weights

Steel Drive Bush supplied blank. Two cable entries are provided for
Valve manufacturer to machine to suit power and control cables. Q100 Standard 11kg
valve spindle. Q100 Pak 12kg
7 Terminal Cover Q300 Standard 21kg
2 Hand Auto Lever Terminal Cover secured with 4 fixing Q300 Pak 22kg
Returns to auto position when motor bolts sealed with ‘O’ Ring.
is engaged unless it is locked in the
hand position. Note: more effort will be 8 Name Plate
required to operate this lever when it Name plate states serial number and
has ‘torqued off’ at end of travel. technical specification.

3 Hand Wheel 9 Motor

Handwheel is for manual operation Warning: With excessive use motor Fig. 2. Top cover in secured position.
and is engaged by pulling hand auto surface temperature could reach
lever up towards the handwheel. See 132°C.
health and safety warning on page 1.

4 Mechanical Stops
Two stop bolts are provided with a
setting range of 80° to 100° of output
movement.

5 Top Cover
Top cover secured with 6 fixing bolts
and sealed with a special seal.
 3
2 Mounting actuator and
setting instructions

2.1 Drive bush mounting onto a vertical valve shaft. Either direction may be set first, the
To remove Drive Bush from the Q100 Trained and experienced personnel left hand stop is for the open position
actuator base first remove circlip. should be used to ensure safe lifting and the right for closed.
particularly when mounting actuators
To remove Drive Bush from the Q300 at other angles. Procedure
actuator base first remove retaining Back out both mechanical stops by
screw. A suitable mounting flange conforming two turns. Engage hand/auto clutch
to ISO 5211 must be fitted to the valve. lever by pulling lever up towards
Determine keyway position in Drive actuator handwheel, manual mode of
Bush with valve fully open. Ensure that the position of both valve operation is now selected and will
and actuator are the same, i.e. both remain in hand until the actuator is
Machine drive bush to suit valve open or both closed. operated electrically.
spindle. Re-assemble drive bush to
Lower the actuator onto the valve Hand wind the valve to the exact
actuator base and secure with circlip
aligning the drive nut keyway or position that you wish the valve to
or retaining screw.
machined square onto the valve shaft. Fig.1 stop. Screw in the appropriate
Bolt down the actuator onto the flange
2.2 Mounting actuator onto using 4 studs or bolts of the
mechanical stop as far as it will go and
valve 2.3 Setting mechanical tighten lock nut, repeat this procedure
appropriate size and material in the other direction.
Refer to page 2 for actuator weights. conforming to ISO Class 8.8 yield stops
Ensure that the valve is secured firmly stress 628 N/SQmm. (Assuming valve is clock to close).
before fitting actuator to it as the 2.4 Wiring up
combination once bolted together may Warning: Do not lift the actuator and The ‘Q’ Range of actuators are First remove the terminal cover.
be top heavy and therefore unstable. valve combination from the actuator. designed to stop on torque at each Inside will be a commissioning bag
Always lift the actuator and valve end of travel onto these mechanical containing terminal screws and
If it is necessary to lift the actuator assembly via the valve. Each stops. There are 10° or adjustment at washers, spare cover seals, also the
with a sling then please refer to the assembly must be assessed on an each end giving 80° to 100° of valve appropriate wiring diagram and
photograph fig. 1 showing the individual basis for safe lifting. movement. instruction book.
 4

Cable Entries 2.5 Switch settings it is suggested that the lower pair of For clockwise to close actuators.
Remove the two red plastic transit switches, Close Aux Switch (CAS) and
Please note, the ‘Q’ range of
plugs, make cable entries appropriate Open Aux Switch (OAS) should be Closed auxiliary switches (CAS)
Actuators are designed to stop on
to the cable type and size. Ensure that used for remote end of travel Move valve to the fully closed position.
torque at each end of travel onto the indication. If there is a bank of four
any threaded adaptors and cable pre-set stop bolts (Refer to Para 2.3) Locate bottom cam on the shaft, lift
glands are tight and fully watertight. switches the top two are Intermediate and turn cam clockwise until switch
therefore there are no end of travel Aux Switches (IAS 1 & 2) which can
Seal off unused entry with a steel or limit switches to set. just operates, release cam. Switch is
brass blank. be set independently to operate at any now set.
point of travel.
Auxiliary switches
Warning: Ensure that all cables to Open auxiliary switches (OAS)
Setting Warning: Actuator should
be terminated are electrically Move valve to fully open position.
be electrically isolated from main
isolated. Locate second cam up from bottom of
power and control supplies.
shaft. Push cam down and rotate anti-
Connections If required a continuity meter may be clockwise until switch just operates,
Referring to both site and actuator connected across the appropriate release cam. Switch is now set.
wiring diagrams connect power supply switch terminals to assist in switch
and control cables using the screws, settings. For Anti-clock to close actuators.
spring and plain washers supplied.
Replace wiring diagram and To gain access to switches first Closed auxiliary switches (CAS)
instruction book back into the terminal remove top cover from main Move valve to the fully closed position.
compartment for future reference. Gearcase. To secure cover during Locate bottom cam on the shaft, lift
settings there are two threaded holes and turn cam anti-clockwise until
Refit the terminal cover after checking Fig. 3 in the side of the Gearcase (Fig 2). switch just operates, release cam.
that ‘0’ ring seal is fully serviceable. Switch is now set.
Dependant on the actuator electrical Auxiliary Switch Cam adjustment is by
Secure the cover with its four fixing
specification there will be two or four finger tip rotation in each direction,
screws.
auxiliary switches available for the cams are compression spring loaded
customer to use (Fig. 3). and held in position by taper centres.
 5
3 Replacement of top
cover and local indication
For clockwise to close actuators 2.6 Selection of remote
control functions
Close - Green cam
Release locking screw, rotate cam The 8 Switch Selector on the main
anti-clockwise to reduce torque. (larger) PCB enables different remote
Re-tighten locking screw. control functions to be chosen, also
on ‘Local’ control the option of
Open - Red cam “maintained” control or “push to run”.
Release locking screw, rotate cam
clockwise to reduce torque. PCB On Off
Re-tighten locking screw. switch
Fig. 5. Q’ Standard Indicator Disc
For anti-clock to close actuators 1 ESD ESD No ESD
Fig. 4
2 TBP Stat by-pass No stat by-pass ‘Q’ Standard
Close-Red cam Before replacing the top cover run
Open auxiliary switches (OAS)
Release locking screw, rotate cam. actuator to one end of travel, adjust
Move valve to fully open position. 3 PTR Maintain in Local No maintain in
Locate second cam up from bottom of local the indicator disc to this position and
Anti-clockwise to reduce torque. re-tighten securing screw, ensure that
shaft. Push cam down and rotate 4 C/A Clockwise close Anti-clock close
Re-tighten locking screw. the cover seal is serviceable and in it’s
clockwise until switch just operates,
release cam. Switch is now set. 5 ESD ESD close ESD open correct position, flange faces should
Open-Green cam be clean and lightly greased.

}
6 P2 Both switches Both switches
Release locking screw, rotate cam
Torque output adjustment ‘On’ ‘Off’
clockwise to reduce torque. ‘Q’ Pak
Torque cams are factory set to give 7 P1 gives ‘Close’ gives ‘Open’
maximum rated torque in both priority priority
The Pak cover contains the local
Re-tighten locking screw. indication. Re-fit the pak cover
directions. Torque can be reduced
down progressively if required, as One switch ‘On’ and one ‘Off gives ensuring the seal is serviceable and
‘Stayput’ mode in it’s correct position, flange faces
follows:
 6
4 Final checks 5 Optional extras

should be clean and lightly greased. Check stop bolt lock nuts are tight. 5.1 Potentiometer Setting
Run actuator to one end of travel, this transmitter Move the valve to the fully closed
will re-align the indicator pointer. Check terminal cover fixing bolts are position, loosen the two screws
tight. Actuator should be electrically securing the potentiometer bracket to
3.1 Warning isolated from main power and the gearcase and rotate the assembly
Check conduit entries are correctly control supplies before the top so that a nominal 50 ohms resistance
If possible electrical operation made off. is measured between terminals 23
should only be carried out with the cover is removed.
and 32 (or 14 and 23 for anti-
top cover fitted. Check indication is correct. clockwise closing valves). Re-tighten
Checking electrical operation fixing screws.
Check cast groove in actuator base is
Q-Standard Specification not obstructed. Its purpose is to
protect the actuator in the event of a
5.2 Current Position
Switch on power supply. product leak from the valve spindle/ Indication (C.P.T.)
Operate actuator open and closed
gland packing. 4-20mA output
using remote control if available. The CPT gives continuous indication
Check base to valve fixing bolts/nuts with adjustment for span and zero
Q-Pak Specification are tight. settings.

Switch on power supply. Electrical connections

Fig. 6 1 The CPT can be either internally
Rotate remote/stop/local selector knob
clockwise to ‘Local’ control. or externally powered. Use the Wiring
The Potentiometer is used for position Diagram supplied with the actuator to
feedback and may be directly check this.
Use open/close control knob on
connected to a voltmeter type
actuator to check operation. Also
indicating instrument.
check that stop position on selector 2 Check whether valve is clock or
stops the actuator. anti-clock to close.
 7
CPT Folomatic

Warning: The C.P.T. can only be 2 Move valve to the low signal end
set-up with the actuator top cover of travel.
removed and the C.P.T. power
supply switched on. Where the 3 Locate socket 2 (SKT 2) on
C.P.T. is externally powered then folomatic CPT printed circuit board
only this supply (15-40 VDC) need and remove socket. Socket pins are
be switched on, valve movement to marked 1-6 using a multi-meter
set ‘zero’ and ‘span’ can be reading ohms, test between
achieved using the actuator appropriate pins (see table below).
handwheel. Adjust potentiometer described in
section 5.1 until approximately
If the C.P.T. is internally powered 50 ohms is measured. Lock
then the mains supply must be potentiometer. Reconnect socket
switched on to do the settings. into CPT circuit board.
The C.P.T. printed circuit board is
situated inside the actuator top SW2 DIL switches 1-8 Indication Socket Pin
cover. All electrical connections in Folomatic switch settings for input system number ohms
Fig. 7 Links J7 SW1 signal levels. (See appendix 1.)
this area are well insulated. Clockwise to close
Low output at close
However, only a fully insulated or 4 to 5 = 50
Setting of CPT b For a clock to close valve and low
trimming tool should be used for Anti-clockwise to
1 Signal direction signal at open close
adjustment and great care taken
a Using Fig 7 locate the duel links and Low output at open
not to touch mains voltage
J7. For a clock to close valve and For anti-clock to close valve and
connection in the electrical Clockwise to close
low signal at closed and low signal at closed. Low output at open
compartment.
For an anti-clock to close valve Links J7 must be positioned at or 4 to 6 = 50
and low signal at open. right angles to the edge of the Anti-clockwise to
close
Links J7 must be positioned board. Low output to close
parallel to the edge of the board.
 8

4 Adjust the CPT zero trimmer functions like any other with Open/ Setting the folomatic Note: If the range required was
potentiometer to required minimum Stop/Close local control. The actuator 1 Determine whether the valve is indicated at the time of ordering -
signal. should therefore be set to work initially clock or anticlock to close and also correct range will be set. If not then
under local control in accordance with whether it is to open or close on a low folomatic will be set for 4-20mA.
5 Move valve to the high signal end this Instruction Book. demand signal.
of travel. 3 When using a 4-20mA control loop
WARNING: The Folomatic module Using Fig 7 locate switches 1 and 2, signal it is possible to select whether
6 Adjust the CPT span trimmer to select as follows: the actuator will “stay put” or fail to the
can only be set-up with the top
give required maximum signal. 4mA end of travel on loss of signal.
cover removed, main power a For Clockwise closing valves Switch No 1 on folomatic DIL switches
7 Move valve back to the low signal supply on and the customers Input signal low to close, SW1 to be selected ‘on’.
end of travel and re-check the instrumentation signal (normally selected towards edge of board, Switches P1 and P2 on Main Board
minimum reading and adjust if 4-20mA) applied. SW2 selected away from board. DIL Switches (Fig. 7).
necessary. Both selected ‘on’ gives fail to the
The Folomatic printed circuit board Input signal low to open, SW1 close end of travel.
5.3 Folomatic proportional is situated inside the actuator top selected away from edge of board, Both selected ‘off’ gives fail to the
cover. All electrical connections in SW2 towards edge of board.
control open end of travel.
this area are well insulated. One switch ‘off’ and one ‘on’ will give
Zero/Span/Timer/Dead band b For anti-clockwise closing
However, only a fully insulated ‘stay put’.
The Folomatic Proportional Control valves
trimming tool should be used for Input signal low to close, SW1 and
Module sets the valve position relating adjustment and great care taken 4 Check that incoming control
to an input signal with adjustments for SW2 away from edge of board.
not to touch mains voltage cables are connected to the following
Zero and Span setting. Refer to the connections in the electrical Input signal low to open, SW1 and terminals:
Wiring Diagram supplied in the compartment. SW2 towards edge of board.
actuator and also the customers a Current or voltage signal to 9
instructions for exact setting. 2 Determine what control input (-VE) and 12 (+VE), or alternatively.
signal is going to be used, refer to Fig.
When the actuator Local/Off/Remote 7 and locate the block of DIL switches b Customers Potentiometer derived
selector is set to ‘Local’ the actuator and select range required. signal to 9,12 (Wiper) and 18.
 9
6 Final Checks

5 With actuator set to local control movement of span trimmer will Motion inhibit timer adjustment Check stop bolt lock nuts are tight.
run the valve to the nominated low illuminate the appropriate indicator. The Red and Green indicators on the
signal end of travel. PCB indicate a change of signal state: Check terminal cover fixing bolts are
11 Set Local/Remote Selector to tight.
6 Set input signal to required “Remote”. The actuator is available Red = opening direction signal
minimum value. for Folomatic remote control to give Green = closing direction signal Check conduit entries are correctly
full valve stroke with maximum made off.
7 Locate the ‘Zero’ trimmer and
input signal. If either indicator is flashing it
adjust until the green indicator (if valve
is at closed position) or red indicator indicates a change of signal state that Check indication is correct.
(if valve is at open position) on the 12 Deadband adjustment is being held off from operating the
PCB just lights either flashing or If the actuator overshoots or responds actuator for a predetermined length Check cast groove in actuator base is
steady, clockwise movement of zero unnecessarily to small changes in of time. This motion inhibit time is not obstructed. Its purpose is to
trimmer will illuminate the appropriate signal, increase the deadband by adjustable between 2 seconds and protect the actuator in the event of a
indicator. turning the deadband control 40 seconds to suit site conditions. product leak from the valve spindle/
clockwise. If greater sensitivity is However it is advisable to reduce the gland packing.
8 Operate the valve to the opposite required reduce deadband by turning delay time (anticlockwise adjustment
end of travel (High Signal) using local anticlockwise. Check that hunting of the trimmer) to minimum during the Check base to valve fixing bolts/nuts
control. does not occur e.g. when the actuator setting up procedure. are tight.
is moving in the increasing signal
9 Set input signal to it’s required direction, it should stop when the Refit top cover ensuring that the
maximum level balance between the input signal and indicator rod is aligned, that the cover
the actuator feedback potentiometer is seal is in good condition and lightly
10 Locate the’Span’trimmer and achieved without the green light greased, tighten down the 6 fixing
adjust until the red indicator (if valve flashing on after the red lamp had screws.
is at the open position) or green extinguished. If hunting does occur,
indicator (if valve is at the close increase the deadband as necessary.
position) on the PCB just lights either
flashing or steady, anticlockwise
 10
7 Lubrication and Appendix 1
maintenance

Rotork ‘Q’ range actuators are If your Rotork actuator has been Folomatic PCB DIL switch settings volatage or current
dispatched with gearboxes filled with properly installed and sealed normal ranges
oil to DEXRON 2 specification plus the valve operation produces little wear
addition of 20% paraffin, suitable for and tear so no routine maintenance is Range SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
ambient temperatures ranging from recommended. 0-5mA
-22°F / -30°C to 160°F / 70°C.
If the motorised valve is rarely 0-10mA
For applications where “foodgrade” operated a routine operating schedule
0-20mA
lubrication is specified Q range should be set up.
actuators despatched with 13-426 oil 4-20mA
medium and 13-427 grease medium. If your actuator cannot be installed
immediately store it in a dry place until 0-50mA
If oil is replaced, DEXRON 2 should required - do not remove transit plugs 0-5mA
be used, however the addition of 20% until you are ready to wire up.
paraffin is not required unless ambient 0-10mA
temperatures below -4°F / -20°C are A comprehensive “Maintenance and
0-20mA
likely to be encountered. Spare Parts Manual” (publication
number E680E) is available. Please Off
Oil Capacities apply to your nearest Rotork office or
Q100 1/2 pint/0.25l. agent. On
Q300 11/4 pint/ 0.85l. Off/On
SW1 Off - actuator runs to low signal
Mechanical maintenance end of travel on loss of signal.
After six months operation tighten
mounting bolts. SW1 On - actuator responds on loss
of signal according to priority setting
on main board switches P1 and P2.
Refer to page 8 para. 3.
 ®

As part of a process of on-going The name Rotork is a registered

product development, Rotork trademark. Rotork recognizes all
A full listing of our worldwide reserves the right to amend and registered trademarks.
change specifications without prior
sales and service network is notice. Published and printed by Rotork
available on our website at Published data may be subject to Controls Limited.
change. For the very latest version
www.rotork.com release, visit our website at
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