Rotex QTF Series User manual
RTX-IOM-QTF-R01-0217
Page 2of 26
www.rotexautomation.com
Contents
1. Introduction ..................................................................................................................................................3
1.1 Definitions................................................................................................................................................4
1.2 General safety information.......................................................................................................................4
2. Operating principle .......................................................................................................................................4
3. Label description ..........................................................................................................................................5
4. Installation information.................................................................................................................................5
4.1Safety Notes .............................................................................................................................................7
4.2 Technical Specifications...........................................................................................................................7
4.3 Operating Conditions ...............................................................................................................................7
4.4 Service information..................................................................................................................................8
5. Installation ....................................................................................................................................................9
5.1 Mounting..................................................................................................................................................9
5.2 Setting ....................................................................................................................................................10
6. Operation ....................................................................................................................................................12
6.1 Operating Principle (Standard Mode) for double acting ........................................................................12
6.2 Operating Principle (Standard Mode) for spring return–Fail CW.........................................................13
7. Maintenance................................................................................................................................................14
8. Disassembly................................................................................................................................................15
9. Assembly for double acting & standard mode spring return (fail CW) ......................................................17
9.1 Speed limitation chart for Single as well as Double acting ....................................................................21
10. Part list........................................................................................................................................................22
10.1 Part list for QTF32 .................................................................................................................................22
10.2 Part list for QTF40 - QTF110.................................................................................................................23
10.3 Part list for QTF125 - QTF350...............................................................................................................24
11. Packaging & storage...................................................................................................................................26
12.Assistance...................................................................................................................................................26
RTX-IOM-QTF-R01-0217
Page 3of 26
www.rotexautomation.com
1.Introduction
Thank you for choosing ROTEX product. Each product is fully inspected after the
production to offer you the highest quality. In order to fully utilize the product, we
strongly recommend users to read this manual carefully and understand.
This manual provides information on installation; operation and maintenance
procedures and related instructions for the ROTEX make pneumatic rack & pinion
actuator.
The aim of this literature is to support the installation, operation & maintenance of
products in correct manner. Detail technical specification can be found in product
catalogue which are available on our website.
The manual should be given to the end user.
The manual can be changed or revised without any prior notice. Any changes in
product's specification, structure, and/or any components may not result into a
immediate revised version of the manual.
The manual should not be duplicated or reproduced for any purpose without any
consent of Rotex Manufacturers & Engineers Private Limited, INDIA.
Manufacturer Warranty
For the safety, it is vital to follow instructions in the manual. ROTEX will not be liable for
any damages which are caused by users' negligence.
ROTEX will not be liable for any damage/accidents caused due to any
alteration/modification of the product & parts which have not been done by ROTEX. If
alteration/ modification are necessary, please contact the ROTEX directly.
ROTEX warrants the product from the date of original retail purchase of the product for
one (1) year, except as otherwise stated.
ROTEX warranty will expire in case product have been subjected to abuse, accident,
alteration, modification, tampering, negligence, misuse, faulty installation, lack of
reasonable care, repair or service in any way that is not contemplated in the
documentation for the product, or if the model or serial number has been altered,
tampered with, defaced or removed; damages that occurs in shipment, failure due to
power surge, and cosmetic damage. Improper or incorrectly performed maintenance or
report voids this Limited Warranty.
For detailed warranty information, please contact :
ROTEX MANUFACTERURS & ENGINEERS PRIVATE LIMITED, Manapada road, Dombivli
(e), Maharashtra, India, Pin –421204.
RTX-IOM-QTF-R01-0217
Page 4of 26
www.rotexautomation.com
1.1 Definitions
WARNING:
If not observed, user incurs a high risk of severe damage to product and/or fatal
injury to personnel.
CAUTION:
If not observed, user may incur damage to product and/or injury to personnel.
NOTE:
Advisory and information comments provided to assist maintenance personnel to carry
out maintenance procedures.
WARNING FOR ATEX:
If not observed, user incurs a high risk of severe damage to actuator and/or fatal
injury to personnel.
1.2 General safety information
Products supplied by Rotex, in its "as shipped" condition, are safe if the instructions
contained within this manual are strictly adhered to and executed by well-trained,
equipped, prepared and competent personnel.
WARNING:
For the protection of personnel working on Rotex actuators, this manual should
be reviewed and implemented for safe installation, disassembly and reassembly.
Close attention should be noted to the WARNINGS, CAUTIONS and NOTES
contained in this manual.
2.Operating principle
A rack and pinion actuator is a type of linear actuator that comprises a pair of gears
which converts rotational motion into linear motion.
Pinion engages teeth on a rack; rotational motion applied to the pinion causes the rack
to move relative to the pinion, thereby translating the rotational motion of the pinion
into linear motion.
RTX-IOM-QTF-R01-0217
Page 5of 26
www.rotexautomation.com
3.Label description
Label of the actuator defines the precise feature of that particular actuator. This
description is written below the ROTEX logo and is as follow.
Model: QTF –Actuator series
50 –Size of the actuator
E –Indicates spring return actuator
8 –Spring set code
Max. pr.: - 8 Bar –Actuator should not be operated above 8 bars.
Seal: NBR –Seal material is NBR.
Temp.: -20 °C to +80 °C –Operating temperature range for the actuator.
4.Installation information
Ensure that the actuator will not be exposed to pressure in excess to the maximum rating as
indicated on the actuator nameplate or technical documents.
Ensure that throughout the installation there are no leaks of the supply medium.
NOTE: Depending upon control unit, actuators may exhaust the supply media to
atmosphere in normal operation; this may not be permitted in some applications. In
case of any doubt, please consult the Rotex technical team for clarifications.
The maximum operating temperature for the actuator depends on seals used in the actuator.
Refer nameplate for operating temperature range.
Ensure that the maximum operating temperature as indicated on the nameplate is not
exceeded during operation, transportation or storage of the actuator.
The environment and surrounding should not affect or limit the operational safety of the
product.
Ensure the product is protected against impact, vibration or any kind of violent movement
during operation, transportation and storage.
RTX-IOM-QTF-R01-0217
Page 6of 26
www.rotexautomation.com
Product should not be installed in hazardous area that is not compatible with the gas group
and temperate class indicated on the nameplate.
The actuator should be lifted only with the lifting lugs provided on the actuator. (QTF 200 &
above)
CAUTION: Lifting lugs on the actuator are meant only for lifting actuator and
not complete valve assembly.
WARNING FOR ATEX:
While lifting actuator housing should not impact on the other light or
rusty metal.
Valve on which actuator is installed should be earthed properly to
discharge static charge.
Rotex actuator can be mounted on valve in any desired position. However it is recommended
to align the centreline of the pneumatic actuator module along the pipeline.
Ensure proper tightening of fasteners and mounting accessories to avoid loosening during
operation.
All the tubing, fitting and actuation media should be free from contamination and filtered to the
desired level. Quality of media should be as per ISO 8573-1. For additional information consult
Rotex.
Ensure proper adjustments of the stopper bolt to desired opening and closing of the valve.
Once proper installation is done, check for smooth continuous operation. If undesired
operation occurs, check for correct pressure and volume flow.
NOTE: Flow may be restricted by undersize tubing or fitting. These may throttle the flow
resulting in reduce pressure or volume causing intermittent or undesired movement.
Paralle mounting - recommonded
Perpendicular mounting
RTX-IOM-QTF-R01-0217
Page 7of 26
www.rotexautomation.com
4.1 Safety Notes
Keep hands and clothing away from valve ports and actuator pinion at all times.
Ensure air supply has been disconnected from actuator before any disassembly takes
place.
Never remove end caps when actuator is pressurized.
Actuators must be sized accurately for proper operation
Operating actuators over temperature or pressure limits will result in damage to
actuators.
4.2 Technical Specifications
Mounting is in accordance with ISO 5211/DIN 3337/VDI/VDE 3845 (NAMUR).
Dimensions are as per Rotex Manufacturers & Engineers Private Limited Technical
Brochure.
4.3 Operating Conditions
Supply pressure, max
(Standard)
Model
psi
bar
kg/cm2
Direct Acting
116
8.0
8.1
Spring return
116
8.0
8.1
Operating temperature, max
(Standard)
Model
Deg F
Deg C
Direct Acting
176
80
Spring return
176
80
RTX-IOM-QTF-R01-0217
Page 8of 26
www.rotexautomation.com
4.4 Service information
Normal recommended service interval for this actuator series is 5 years.
NOTE: Storage time is counted as part of the service interval.
This procedure is applicable with the understanding that all pneumatic pressure has
been removed from the actuator.
Remove all piping and mounted accessories that will interfere with the module.
When removing seals from seal grooves; use a commercial seal removing tool or a
small screwdriver with sharp corners rounded off.
Use a non-hardening thread sealant on all pipe threads.
CAUTION: Apply the thread sealant as per the manufacturer’s
instructions.
All parts should be thoroughly inspected for excessive wear, stress cracking and
pitting. Attention should be directed to threads, sealing surfaces and areas that will
subjected to sliding and rotating motion.
Actuator parts that reflect any of the above listed characteristics should be replaced
with new parts.
Rotex recommends that disassembly of the actuator modules should be done in a
clean area on a workbench.
After reassembly, the actuator needs to be stroked for several times to ensure the
desired function and safety.
RTX-IOM-QTF-R01-0217
Page 9of 26
www.rotexautomation.com
5.Installation
WARNING: Do not remove spring module while spring is compressed
NOTE:
Ensure the installation meets the legal and regulatory requirements of
the country and state of use.
Until the actuator is installed, keep it in its original packaging and stored
between 4°C and 49°C (40 °F and 120 °F).
Ensure the operating medium meets the requirements, described in
service information (heading 4).
Use proper rigging to handle the actuators weighing more than 30 kg (66
lb) to avoid personal injury.
5.1 Mounting
Keep the valve on which the actuator is to be mounted in home position, until the
installation is complete. Ensure that valve is secure.
Fix the brackets on the valve.
Ensure the coupling slides on the stem smoothly without any play.
Check the other end of the coupling with the actuator for the length of engagement.
Mount the actuator on the bracket with fasteners.
Tighten all the fasteners to the torque as shown below.
Sr. no.
Actuator model
Bolt size (#9)
Tightening torque (Nm)
1
QTF 32
M6
8
2
QTF 40
3
QTF 50
4
QTF 63
5
QTF 80
6
QTF 90
M8
20
7
QTF 100
8
QTF 110
9
QTF 125
10
QTF 150
M10
40
11
QTF 175
12
QTF 200
M12
70
13
QTF 250
14
QTF 300
15
QTF 350
RTX-IOM-QTF-R01-0217
Page 10 of 26
www.rotexautomation.com
5.2 Setting
All actuators are factory set to 0 and 90 degrees. Even minor adjustments of the stroke
adjustment screws (5A and 5B) will result in over travel or incomplete travel of the
pinion.
Loose nut #13 & rotate screw 5A in counter clock wise
direction (CCW) to set over travel (close)
Loose nut #13 & rotate screw 5A in clock wise direction
(CW) to set under travel (close).
Loose nut #13 & rotate screw 5B in counter clock wise
direction (CCW) to set over travel (open).
Loose nut #13 & rotate screw 5B in clock wise
direction (CW) to set under travel (open).
RTX-IOM-QTF-R01-0217
Page 11 of 26
www.rotexautomation.com
Pie chart below shows the exact degree of pinion travel.
Table below shows required revolution of the bolts for 1° travel of pinion for each actuator.
Sr.
No.
Actuator
Double acting
Actuator
Spring return
Revolution of bolts
for 1° travel of pinion
1
QTF 32
QTF32-E
Half quarter turn
2
QTF 40
QTF 40-E
Half quarter turn
3
QTF 50
QTF 50-E
Half quarter turn
4
QTF 63
QTF 63-E
Half quarter turn
5
QTF 80
QTF 80-E
Quarter turn
6
QTF 90
QTF 90-E
Quarter turn
7
QTF 100
QTF 100-E
Quarter turn
8
QTF 110
QTF 110-E
Quarter turn
9
QTF 125
QTF 125-E
Quarter turn
10
QTF 150
QTF 150-E
Quarter turn
11
QTF 175
QTF 175-E
Quarter turn
12
QTF 200
QTF 200-E
Quarter turn
13
QTF 250
QTF 250-E
Quarter turn
14
QTF 300
QTF 300-E
Quarter turn
15
QTF 350
QTF 350-E
Quarter turn
RTX-IOM-QTF-R01-0217
Page 12 of 26
www.rotexautomation.com
6.Operation
Actuator is fitted with NPT connection.
Provide air connections using proper fittings.
Air supply to meet above specifications & not to exceed 8 Bar.
Ensure air supply pressure is regulated to ensure maximum air supply is not exceeded.
Now the actuator is ready to perform…..
6.1 Operating Principle (Standard Mode) for double acting
Both ports A and B are used as inlet ports.
When air is supplied to Port A, the pistons are moved away from each other, and the
pinion is rotated CCW.
When air is supplied through Port B, the pistons come closer and return to their home
position, rotating the pinion CW.
RTX-IOM-QTF-R01-0217
Page 13 of 26
www.rotexautomation.com
6.2 Operating Principle (Standard Mode) for spring return–Fail
CW
Port A is used as inlet.
When air is supplied to Port A, the pistons are moved away from each other, the springs
are compressed, and the pinion is rotated CCW.
When the air is exhausted through Port A, the springs return the pistons to the home
position, rotating the pinion CW.
RTX-IOM-QTF-R01-0217
Page 14 of 26
www.rotexautomation.com
7.Maintenance
7.1 Recommended servicing
7.2 Lubrication
All the mountings, accessories and spare parts used or replaced must be original from
ROTEX.
ROTEX recommends “5140120004” grease for greasing rack & “5140120005” for
greasing seals.
Apply the grease with soft brush.
In case of any difficulty consult ROTEX distributor.
NOTE:
Carry out maintenance involving disassembling of actuator in a safe indoor place free
from dust, water.
Ensure that air supply has been disconnected.
Ensure proper lifting procedures are followed when moving or lifting actuators.
DO NOT use accessory, mounting holes on top of actuator for lifting.
If actuator is spring return, ensure actuator is in the failed position and springs are de-
energized before disassembling.
Life in cycles
Recommendations
(Refer part list page 22 to 25)
500,000
First clean & then apply grease on seals after cleaning #1/6/11/12/14/16
First clean & then apply grease on rack #3 and pinion #2.
1,000,000
Replace all plastic #7/12/15/18 and rubber parts #6/11/14/16/23.
Inspect springs for any rust or deformity. Replace if necessary.
RTX-IOM-QTF-R01-0217
Page 15 of 26
www.rotexautomation.com
8.Disassembly
Refer the view on page 22/23/24.
a. Loosen the lock nuts #13, and remove stroke
adjustment screws #5A and #5B, washers #10,
and o-rings #23.
b. Loosen the cover bolts #9 on each end cap gradually in 1
–3 - 2 –4 sequence.
The bolts are long enough to retain the cover connected to the
body until the spring tension is fully released.
CAUTION: Spring return actuator end caps are under spring tension. Caution
must be used while removing end cap bolts and end caps. It is recommended to
put actuator into a press during removal of end caps to ensure safe release of
spring tension
c. Rotate the pinion #2 in the counter clockwise direction
(For double acting & Spring return fail safe close
actuators) until the pinion becomes free.
Rotate the pinion #2 in the clockwise direction (For
Spring return fail safe open actuators) until the pinion
becomes free.
d. Pull the piston out from each side by holding with pliers.
CAUTION:NEVER attempt to remove pistons from actuator body
using air pressure when the end caps have been removed!!
RTX-IOM-QTF-R01-0217
Page 16 of 26
www.rotexautomation.com
e. Remove external circlip # 17 and then washers
#10 and #19.
f. Tap the pinion gently from the top using a
rubber mallet until the pinion is approximately half
way into the body. Remove the top pinion seal
#14 and the top pinion bearing #18. Remove the
cam #08.
g. Pull the pinion the rest of the way out of the body. Check
the pinion bearing #5 for its condition. If removal and
replacement of the pinion bearings are required, carefully
push the pinion bearing off with the help of a screw driver
and remove from the body. Remove the rack bearing #12.
Remove the bottom pinion bearing #15, the bottom pinion
seal #11, and the end cap seals #16.
RTX-IOM-QTF-R01-0217
Page 17 of 26
www.rotexautomation.com
9.Assembly for double acting & standard mode spring
return (fail CW)
NOTE:
Follow the sequences as given below to ensure proper assembly.
Use only the recommended accessories and lubricants.
a. Clean all the parts.
b. Fit bottom pinion bearing #15 and bottom pinion seal #11
on to the pinion #2. Apply recommended grease over the
pinion bearing surface #15 and on the bottom pinion seal
#11. Apply a thin coat all over the surface; avoid excess
grease. Insert pinion carefully into the body #1 from the
bottom, approximately half way.
c. While installation of cam #8 match cam slot with pinion #2
slot properly as shown.
d. Install top pinion seal #14 on pinion and apply
a light layer of grease. Install top pinion
bearing #18 on pinion. Push the pinion the
rest of the way into the body.
Apply gentle force while rotating the pinion to
facilitate the insertion.
RTX-IOM-QTF-R01-0217
Page 18 of 26
www.rotexautomation.com
e. Install polyacetal washer #10, SS washer #19, and
external circlip #17 on top of pinion. Check for free
rotation of pinion.
f. Apply recommended grease over the bore of the body; avoid excess grease.
g. Rotate the pinion so that the dot on the pinion is positioned close to the two dots on
the top pad of the actuator body for accurate pinion alignment.
For CCW assembly dot on the pinion is positioned close to the two dots on the top
pad of the actuator body, then assemble piston.
For CW assembly dot on the pinion is positioned close to the single dot on the top
pad of the actuator body, then assemble piston
RTX-IOM-QTF-R01-0217
Page 19 of 26
www.rotexautomation.com
h. Fit rack bearing in piston with rack.
i. Apply grease on outer surface of rack
bearing and put some grease in pocket
j. Ensure both the pistons are engaged in the same position.
Same amount of gap between the face of each piston and the end of the body will
confirm this.
k. For spring return actuators, insert the springs.
NOTE:
While assembling springs and end caps on spring return actuators, it is necessary to
have the actuator body in the vertical position. This is required to ensure that springs
remain properly aligned and centered during assembly.
q. Fix the seals #16 on the left and right end caps and install on to body.
Ensure the air ports on the end caps are aligned properly.
Ensure uniform tightening sequence of the bolts 1 –3 –2 –4.
r. Install stroke adjustment screws #5A and 5B with o-rings #23, washers #24, and
lock nuts #13.
s. Apply air to Port A to move pistons to the extended 90 degree position.
t. Adjust stroke adjustment screw #5A for the 90 degree position, turning clockwise
until the screw is barely touching the piston. Tighten the lock nut.
RTX-IOM-QTF-R01-0217
Page 20 of 26
www.rotexautomation.com
WARNINGS
Use only genuine spares parts supplied by Rotex.
Use only the recommended accessories and lubricants.
Install, operate and maintain as per the instructions and recommendations of this
manual.
No metal should fall on actuator body to ensure no spark generation in actuator
body.
All accessories should have explosion protection or intrinsically safe.
Any deviation from the above warnings will cease the responsibilities of Rotex.
u. For spring return actuators, release the air pressure, for double acting actuators,
apply air to Port B. This will bring the pistons back to the 0 degree position.
v. Adjust the stroke adjustment screw #5A for the 0 degree position, turning clockwise
until the bolt is barely touching the piston. Tighten the lock nut.
w. Apply air as required to stroke the actuator several times to confirm that the stroke
adjustment screws are set correctly and ensure that there is no air leakage from any
of the seals.
x. Re-install or repack for storage (see section 11 for Packaging and Storage).
y. For flower spring structure follow the instructions same as that of concentric structure.
z. For positioning of flower spring structure please refer fig.
This manual suits for next models
15
Table of contents
Other Rotex Controllers manuals
