Rotork Iqt3 User manual

IQT Range

Original instructions for Safe Use,

Installation, Basic Setup and Maintenance

This manual must be consulted where ever this

symbol is marked. This manual contains important

safety information. Please ensure it is thoroughly

read and understood before installing, operating

or maintaining the equipment.

PUB002-065-00

Date of issue 09/16

3rd Generation IQT

Table of Contents

1. Introduction_____________________________3

1.1 Identifying Actuator Parts ..................3

1.2 Rotork Setting Tool .......................4

1.3 Introduction to this manual .................5

2. Health and Safety _______________________5

2.1 ATEX/IECFM Certified Actuators .............7

3. Storage _________________________________7

4. Operating your IQT Actuator _____________8

4.1 Operating by Hand........................8

4.2 Operating Electrically ......................8

4.3 Display - Local Indication ...................9

4.4 Display – Home screen selection ............10

4.5 Display Status Indication – Travel ............11

4.6 Display Status Indication – Control...........11

4.7 Display Alarm Indication...................11

4.8 Battery Alarm ...........................11

5. Preparing the Drive Bush_______________ 12

5.1 Bases F05 to F07 and FA05 to FA07..........12

5.2 Bases F10 to F16

and FA10 to FA16 ........................12

5.3 Machining the Drive Bush .................12

5.4 Fitting the Drive Bush .....................12

6. Mounting the Actuator ________________ 13

6.1 IQT Actuators ...........................13

6.2 IQTM Actuators .........................13

6.3 IQTF Actuators ..........................13

6.4 Lifting the Actuator ......................13

6.5 Securing Actuator to Valve.................13

7. Cable Connections _____________________ 14

7.1 Terminal Block Layout ....................14

7.2 Earth/Ground Connections. . . . . . . . . . . . . . . . . 14

7.3 Removing Terminal Cover..................14

7.4 Cable Entry.............................15

7.5 Connecting to Terminals ..................15

7.6 Replacing Terminal Cover ..................15

8. Commissioning - Basic Settings_________ 16

8.1 Connecting to the Actuator ................17

8.2 Security - Password ......................18

8.3 Basic Settings Menu ......................19

8.4 Basic Settings – Limits ....................20

8.5 Close Settings...........................21

8.6 Open Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 21

8.7 Torque Switch Bypass .....................22

9. Maintenance, Monitoring and

Troubleshooting _______________________ 24

10. Environmental_________________________ 26

11. Weights and Measures_________________ 27

12. IQT Approvals _________________________ 28

13. Approved Fuses _______________________ 30

14. Vibration, Shock and Noise_____________ 30

15. Conditions of Safe Use _________________ 31

15.1 Thread details for ATEX and

IECEx Approved actuators .................31

15.2 Maximum constructional flamepath gaps

for ATEX and IECEx Approved actuators.......31

IQT3 manual – Section: Introduction 3

1. Introduction

1.1 Identifying Actuator Parts

Oil Plug (optional)

Hand-Auto Lever

Hand Wheel

Control Cover

Display Window

Motor Cover Terminal Cover

Conduit Entries (Standard)

Conduit Entries (Optional)

Local / Remote / Stop Selector Base Travel Stops

Protective

Earth Point

Name Plate

Battery Sealing Plug

Metal (8mm Allen key required)

Plastic (10mm Allen key required)

as appropriate.

Oil Plug (optional)

Open / Close

Selector

Oil Plug

(optional)

4 IQT3 manual – Section: Introduction

1.2 Rotork Setting Tool

The Rotork Bluetooth

Setting Tool Pro

(BTST) combines the legacy IR and IrDA

communication protocols with the latest

Bluetooth

wireless technology. IR /

IrDA support for older Rotork products is

retained (for use as an IR communication

tool, please refer to publications

PUB002-003 and PUB002-004).

The new BTST is able to connect to Rotork

Bluetooth

wireless enabled actuators and

related software to setup and complete

missions. Missions are configurable

programs of instructions that are to be

performed by the BTST on an actuator and

include (but are not limited to) downloading

configuration and Data logger files as

well as uploading specific configurations

to the actuator. Different missions can be

programmed into the BTST via Insight2.

Rotork Bluetooth

Setting Tool Pro

Specification

Enclosure: IP54

The BTST has been built in accordance with

the following standards:

ATEX II 1 G, Ex ia IIC T4 Ga

IECEx – Ex ia IIC T4 Ga

USA – FM Int Safe Class I, Div 1, Groups A,

B, C & D, T4

Canada – CSA Exia Int Safe, Class I, Div 1,

Groups A, B, C & D, T4

Ambient Temperature Range:

Tamb = -30 °C to +50 °C

Operating Range:

Infra Red 0.75m

Bluetooth

10m

Enclosure Materials:

Polycarbonate ABS blend, Polycarbonate

and Silicon Rubber

Instructions for Safe Selection,

Installation, Use, Maintenance

& Repair

1. The BTST must only be used in hazardous

areas (potentially explosive atmosphere)

permitted by the equipment classification,

temperature class and ambient temperature

range stated above (this is also stated on

the back of the BTST).

2. The following checks must be conducted

on the BTST prior to taking it into a

hazardous area:

a. The BTST function must be checked by

ensuring that the red or green LED, either in

the clear window or under the ‘Enter’ key

of the BTST, illuminates when any button

is pressed. If an LED does not illuminate,

there is a potential functional problem with

the BTST and the inspection or battery

replacement stated below in paragraph 6

must be performed.

b. If the BTST is likely to come in contact

with aggressive substances (e.g. solvents

that may affect polymeric materials), then

it is the responsibility of the user to take

suitable precautions (e.g. regular checks

as part of the routine inspections or

establishing that the enclosure materials

are resistant to the specific chemicals) that

prevent the BTST being adversely affected,

thus ensuring that the type of protection is

not compromised.

3. It is essential that the actuator settings

are checked for compatibility with the valve,

process and control system requirements

before the actuator is put into service.

No user adjustment of the BTST is required.

5. The BTST must be inspected every three

months, in a safe (non-hazardous), dry area

by suitably trained personnel, to ensure it

has been maintained in accordance with the

applicable code of practice.

6. In accordance with the BTST

hazardous area approvals and with the

recommendations from the approved

battery suppliers, the following are

mandatory requirements for safe use:

a. The inspections or replacement of the

batteries must be conducted in a safe (non-

hazardous), dry area.

b. The batteries must be removed from the

BTST when it is not expected to be used for

3 months or longer.

c. Discharged batteries must be removed

from the BTST to prevent possible damage.

d. The battery compartment of the BTST

must be inspected every 3 months for any

battery leakage. If any battery leakage has

occurred then the BTST must not be used.

IQT3 manual – Section: Health and Safety 5

e. Only the following approved Alkaline-

Manganese or Zinc-Manganese type ‘AAA’

size batteries must be fitted to the BTST:

- Duracell: Procell MN2400

- Energizer: E92

f. Always replace all four batteries

at the same time. Always use four

unused batteries of the same approved

manufacturer, type and expiry date code.

g. Ensure the batteries are fitted with the

correct polarity. The battery polarity (+)

is indicated on the inside of the battery

compartment of the BTST.

7. The BTST contains no other user

replaceable parts and it cannot be repaired

by the user. If the BTST is faulty or needs

repairing, it must not be used.

1.3 Introduction to this manual

This manual covers IQT 3rd Generation

actuators:

IQT Operation of isolating/

regulating 1/4turn valves.

IQTM Operation of modulating

1/4turn valves.

IQTF Operation of part-turn and slow

speed multi-turn valves.

IQTFM Operation of part-turn and

slow speed multi-turn valves for

modulating duty.

This manual provides instruction on:

• Manual and electrical (local and

remote) operation.

• Preparation and installation of the

actuator onto the valve.

• Basic Commissioning.

• Maintenance.

Refer to Publication PUB002-067

for repair, overhaul and spare part

instructions.

Refer to Publication PUB002-040

for secondary function

configuration instructions.

Using the supplied Rotork Bluetooth®

Setting Tool Pro to access the actuator

set up procedures, non-intrusive

setting of torque levels, position limits

and all other control and indication

functions can be made safely, quickly

and conveniently, even in hazardous

locations. The IQ allows commissioning

and adjustment to be carried out with

the main power supply to the actuator

switched on or off.

The setting tool is packed in the

shipping box identified with a

yellow label.

Visit our web site at www.rotork.com

for more information on the IQ, Insight2

and other Rotork actuator ranges.

2. Health and Safety

This manual is produced to enable a

competent user to install, operate, adjust

and inspect Rotork IQT range valve

actuators. Only persons competent by

virtue of their training or experience

should install, maintain and repair Rotork

actuators.

Under no circumstances should

replacement parts be used in Rotork

actuators, other than those supplied or

specified by Rotork.

Work undertaken must be carried out in

accordance with the instructions in this

and any other relevant manuals.

If the actuator is used in a manner not

specified in this manual and any other

Rotork manual, the protection provided

by the actuator may be impaired.

The user and those persons working

on this equipment should be familiar

with their responsibilities under any

statutory provisions relating to the

Health and Safety of their workplace.

Due consideration of additional hazards

should be taken when using the IQT

range of actuators with other equipment.

Should further information and guidance

relating to the safe use of the Rotork IQT

range of actuators be required, it will

be provided on request. The electrical

installation, maintenance and use of

6 IQT3 manual – Section: Health and Safety

these actuators should be carried out in

accordance with the National Legislation

and Statutory Provisions relating to the

safe use of this equipment, applicable to

the site of installation.

For the UK: Electricity at Work

Regulations 1989 and the guidance

given in the applicable edition of the

“IEE Wiring Regulations” should be

applied. Also the

user should be fully

aware of his duties under the Health and

Safety Act 1974.

For the USA: NFPA70, National Electrical

Code®is applicable.

For Canada: CEC, Canadian Electrical

Code is applicable

The mechanical installation should be

carried out as outlined in this manual

and also in accordance with relevant

standards such as British Standard Codes

of Practice. If the actuator has nameplates

indicating that it is suitable for installation

in hazardous areas then the actuator may

be installed in Zone 1, Zone 21, Zone

2 and Zone 22 (or Div 1 or Div 2, class

I or Class II) classified hazardous area

locations only. It should not be installed in

hazardous area locations with an ignition

temperature less than 135 °C, unless

suitability for lower ignition temperatures

has been indicated on the actuator

nameplate.

It should only be installed in hazardous

area locations compatible with the gas

and dust groups stated on the nameplate.

The electrical installation, maintenance

and the use of the actuator should be

carried out in accordance with the code

of practice relevant for that particular

Hazardous Area certification.

No inspection or repair should be

undertaken unless it conforms to the

specific hazardous area certification

requirements. Under no circumstances

should any modification or alteration

be carried out on the actuator as this

could invalidate the actuators hazardous

area approval certification. Access to live

electrical conductors is forbidden in the

hazardous area unless this is done under

a special permit to work, otherwise

all power should be isolated and the

actuator moved to a non-hazardous area

for repair or attention.

WARNING: Service Altitude

The actuator installation altitude must

be restricted to less than 2000 m

as defined by IEC61010-1 (Safety

requirements for electrical equipment

for measurement, control and

laboratory use).

WARNING: Motor Temperature

Under normal operation the

temperature of actuator’s motor cover

surfaces can exceed 60 °C above

ambient.

WARNING: Surface Temperature

The installer/user must ensure that the

actuator surface temperature rating

is not influenced by external heating/

cooling effect (e.g. valve/pipeline

process temperatures).

WARNING: Thermostat Bypass

If the actuator is configured to bypass

the motor thermostat then the

hazardous area, low voltage directive

and CE certification will be invalidated.

Additional electrical hazards may occur

when using this configuration. The

user should ensure that any necessary

additional safety measures are

considered.

WARNING: Enclosure Materials

IQT range of actuators are

manufactured from aluminium alloy

with stainless steel fasteners and the

non-thrust bases are manufactured in

aluminium.

The cover window is toughened glass

which is retained with a 2-part silicone

cement and the battery plug will be

either stainless steel or PPS (Poly-

Phenolyne Sulfide).

The wireless aerial is made from

Polytetrafluoroethylene (PTFE).

The user must ensure that the

operating environment and any

materials surrounding the actuator

cannot lead to a reduction in the safe

use of, or the protection afforded

by, the actuator. Where appropriate

the user must ensure the actuator is

suitably protected against its operating

environment.

WARNING: Operating by Hand

With respect to handwheel operation

of Rotork electric actuators, refer to

section 4.1.

WARNING: Actuator may start

and operate when remote is

selected. This will be dependent on

remote control signal status and

actuator configuration.

IQT3 manual – Section: Storage 7

2.1 ATEX/IECFM Certified Actuators

Special Conditions

This actuator must only be located in

areas where the risk of impact to the

viewing window is low.

This equipment includes some

exterior non-metallic parts including

the protective coating. To avoid the

possibility of static build up, cleaning

must only be carried out with a damp

cloth.

WARNING:

External Enclosure

Fasteners

Enclosure fasteners are stainless steel

grade A4 80 except for the following.

In these cases the fasteners are carbon

steel grade 12.9. If in doubt check the

grade marked on the relevant fastener

or contact Rotork.

All sizes of Actuator ATEX & IECEx:

Ex db IIB T4 (T6) Gb (-20 to +70 oC)

Electronics, Motor & Terminal

enclosures

Ex db IIB T4 (T6) Gb (-30 to +70 oC)

Electronics, Motor & Terminal

enclosures

Ex db IIB T4 (T6) Gb (-40 to +70 oC)

Electronics, Motor & Terminal

enclosures

Ex db IIB T4 (T6) Gb (-50 to +40 oC)

Electronics, Motor & Terminal

enclosures

Certificate number: Sira 15ATEX1011X

or IECEx SIR 15.0010X

Ex db IIC T4 (T6) Gb (-50 to +40 oC)

Terminal enclosure

Certificate number: Sira 15ATEX1012X

or IECEx SIR 15.0011X

FM Approved: