rotork CK Atronik Series User guide

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CK Range
CKa& CKra – Atronik Start Up Guide
Modular Design Electric Valve Actuators

CKa& CKra Atronik Start Up Guide
2
1. CK – Valve Actuation 2
2. Actuator Identification 3
3. Commissioning 4
3.1 Mechanical Switch Mechanism 4
3.2 Additional Indication Drive 8
4. CK Atronik 14
4.1 Standard Settings 14
4.2 Option Settings 15
CK actuators have been developed with over 60 years
of experience in actuation solutions. Our valve actuation
products range from standard mechanical actuators to
advanced digital actuators with integral controls.
Rotork has an extensive product range catering for all
industries. Our actuation solutions deliver state-of-the-art
performance, value and reliability to the global valve industry.
We can help you through the process of product selection
and specification from the installation of a single actuator up
to complex system integration.
With an international network of offices and distributors we
can fully support customer and end user requirements. Over
1,000 service technicians are employed by our company,
partners and representatives, providing the necessary
worldwide infrastructure to fully support actuators in the field.
1. CK – Valve Actuation
Worldwide coverage
Our extensive international network enables us to think
globally and act locally when it comes to supporting our
customers. Rotork provides an efficient sales service, after
sales commissioning and maintenance support throughout
the life of the actuator.
Global manufacturing
Product reliability and integrity are priorities in CK product
development. Our quality control teams source components
from suppliers throughout the world to ensure our customers
always receive first class actuation solutions.
Customer support
Rotork provide service support solutions to maximise your
productivity and reduce your operational risk.
Information about this manual
The information and instructions included in this manual are
applicable for all CKaand CKra actuators. For information or
instructions on other CK Range actuators please visit
www.rotork.com
Contents
Section Page Section Page
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2. Actuator Identification
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CKaAtronik
Atronik Module Nameplate
The Atronik name plate will enable you to identify your unit.
Example below:
Mark Description
1Model
2Serial Number
3Power Supply
4Customer Supply
5Backup Supply
6 P max
7Wiring Diagram
8Internal Diagram
9Temperature Range
10 Manufacturing Year
11 Serial No. Code Bar
12 QR Code
13 IP Degree
14 Address
Atronik Name Plate
Conduit Entries
Switch Mechanism Cover
Protective Earth Connection
(M6x1p x 10 Deep)
Plug and socket housing
Atronik Interface
Hand Wheel
Motor
Hand / Auto lever
1
2
34
56
78
9
10
13
14
: 06.2018Year
: -30ºC/+70ºC
: D0000000
: K00000000
: 24VDC/5W
: 3~380V/50Hz
: ATRONIK
: S0000000102
Temp. range
: 3,5
Internal diag.
Wiring diag.
Bkp supply
Cust. supply
P max. kW
Power supply
Model
Serial nº
: --
Supplied and Tested by Rotork
IP 68
Pol.Ind.110, 20100 (Spain)
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CKa& CKra Atronik Start Up Guide
4
3.1 Mechanical Switch Mechanism
Test Feedback Switches
1) Confirm the torque or limit switches are functional by
monitoring feedback on the Atronik status indicators
during switch testing.
The main power supply must be maintained
during this test procedure to ensure feedback
viatheAtronik.
It is not possible to test a switch that is already actuated
by the mechanism (for instance, at the end of travel
limits). To ensure that all switches can be tested correctly,
move the actuator to a mid-travel position and confirm
that none of the switches are active before beginning the
test procedure.
2) Test position switches in both directions using a flat
screw-driver to turn LS TEST. Clockwise (CW) for open
and anti-clockwise (ACW) for close.
The applicable status indicator will illuminate when the
switch is active. Verify that mid-travel is illuminated prior
to testing the switch status.
3. Commissioning
Test Feedback Switches
3) Test torque switches in both directions using a flat
screwdriver to turn TS TEST (ACW for open, CW for
close).
Torque switch status is shown via the fault indicator. Fault
should illuminate when the torque switch is engaged in
either direction.
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A
B
A 5 mm Allen (Hex.) key and 0.8 x 4 mm flat screwdriver are
required to perform commissioning of the CK Mechanical
Switch Mechanism.
Set torque limits
A Indicator/Adjustment Point
B Torque Cam Clutch Screw
1) Move the valve to a mid-travel position and loosen the
Torque Cam Clutch 1.5 turns using a flat screwdriver.
2) Adjust each Torque Cam to the desired value (between
min. & max.) by moving the cam using a screwdriver on the
adjustment point.
CAUTION: Ensure the screwdriver remains
perpendicular to the switch mechanism faceplate
when adjusting the torque trip limits to avoid
introducing an offset to the set value.
3. Commissioning
COpen Torque Adjustment Point
DClose Torque Adjustment Point
3) Tighten the Torque Cam Clutch Screw once both torque
trip limits have been set.
CAUTION: Ensure the Torque Cam Clutch Screw is
tightened enough to fully deform the spring washer
underneath the screw head.
EFactory Calibration Fixings
WARNING: Do not adjust the fixings or position
of the yellow torque indicator plates. These are
factory configured for 40-100% adjustment of the
actuator torque and under no circumstances should
be moved.
C D
E
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CKa& CKra Atronik Start Up Guide
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F
Set Position Limits
F OLS Indicator Window
G OLS Adjustment Screw
H Drive Clutch Shaft
I CLS Indicator Window
J CLS Adjustment Screw
1) Move actuator to the valve CLOSED position using
handwheel operation.
2) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to “SET” position as shown on the switch
mechanism faceplate.
3) The CLS Adjustment Screw must now be rotated to
make the closed limit switch inside the switch mechanism.
The CLS Indicator Window will show one of four
possible symbols. Please refer to Figure 1 on page 7
fordirectioninput.
4) Depending on where the mechanism is in the cycle, it
is possible that the switch will be approached from the
wrong direction, in which case it is necessary to move
through the limit and approach it from the correct
direction. This is done to avoid the need to wind through
the whole mechanism to reach the limit position. The
correct direction to approach the limit is shown by the
arrow next to the Adjustment Screw input.
5) Perform two checks to confirm the CLOSED limit position
switch has been made correctly.
a. The feel of the Adjustment Screw will noticeably
change providing more mechanical resistance at the
switching point of the contact.
b. Confirm the switch has been made by checking the
CLOSED limit indicator is illuminated on the Atronik.
6) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to “RUN” position as shown on the switch
mechanism faceplate.
7) Rotate the CLS and OLS Adjustment Screws a small
amount in both directions to re-engage the mechanism
drive. A click will be heard as the drive drops back into
engagement and the adjustment screws will no longer
move in either direction.
Step 7 must be done or the limit will be lost when the
actuator is moved.
G
H
I
J
CLS
OLS
3. Commissioning
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8) Move actuator to the valve OPEN position using handwheel
operation.
9) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to “SET” position as shown on the switch
mechanism faceplate.
10) The OLS Adjustment Screw must now be rotated to make
the open limit switch inside the switch mechanism. The OLS
Indicator Window will show one of four possible symbols.
Please refer to Figure 1 below for direction input.
11) Depending on where the mechanism is in the cycle, it is
possible that the switch will be approached from the wrong
direction, in which case it is necessary to move through
the limit and approach it from the correct direction. This
is done to avoid the need to wind through the whole
mechanism to reach the limit position. The correct direction
to approach the limit is shown by the arrow next to the
Adjustment Screw input.
12) Perform two checks to confirm the OPEN limit position
switch has been made correctly.
a. The feel of the Adjustment Screw will noticeably
change providing more mechanical resistance at the
switching point of the contact.
b. Confirm the switch has been made by checking the
OPEN limit indicator is illuminated on the Atronik.
13) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to “RUN” position as shown on the switch
mechanism faceplate.
14) Rotate the OLS and CLS Adjustment Screws a small amount
in both directions to re-engage the mechanism drive. A click
will be heard as the drive drops back into engagement and
the adjustment screws will no longer move in either direction.
Step 14 must be done or the limit will be lost when
the actuator is moved.
CLSOLS
Rotate the OLS/CLS Adjustment Shaft Clockwise. Rotate the OLS/CLS Adjustment Shaft Anti-Clockwise.
CLSOLS CLSOLS
3. Commissioning
CLSOLS CLSOLS
Rotate the OLS/CLS Adjustment Shaft In the direction
shown next to the Shaft input.
The limit switching point is near or made.
Figure 1.
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CKa& CKra Atronik Start Up Guide
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Test Feedback Switches
3) Test torque switches in both directions using the TS TEST
lever shown on the left side of the unit between the AID
module and Mechanical Switch Mechanism (move DOWN
for open, UP for close).
Torque switch status is shown via the fault indicator. Fault
should illuminate when the torque switch is engaged in
either direction.
3.2 Additional Indication Drive
The Additional Indication Drive (AID) supplements the
mechanical switch mechanism to increase functionality.
Test Feedback Switches
1) Confirm the torque or limit switches are functional by
monitoring feedback on the Atronik status indicators
during switch testing.
The main power supply must be maintained
during this test procedure to ensure feedback
viatheAtronik.
It is not possible to test a switch that is already actuated by
the mechanism (for instance, at the end of travel limits). To
ensure that all switches can be tested correctly, move the
actuator to a mid-travel position and confirm that none of
the switches are active before beginning the test procedure.
2) Test position switches in both directions using the LS TEST
lever shown on the right side of the unit between the AID
module and Mechanical Switch Mechanism (move DOWN
for open, UP for close).
The applicable status indicator will illuminate when the
switch is active. Verify that mid-travel is illuminated prior to
testing the switch status.
3. Commissioning
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Setting Local Position Disc
The AID module includes a Local Position Disc that should be
configured to show Open and Close limit positions. A series
of reduction gears ensure a suitable range of travel can be
accommodated. If more turns are required please contact
Rotork.
CAUTION: The actuator position limits must be
configured prior to setting the Local Position Disc.
CAUTION: The AID cover orientation can be
adjusted through 360º in 90º increments. If this is a
requirement then the following instructions must
be adjusted by the same increment in the same
direction.
1) Move the actuator to the CLOSED limit using electrical
operation or the handwheel.
2) Loosen off the Position Disc Retaining Screw by 1 turn.
3) Rotate the Position Disc so that CLOSE reads horizontally
and hold the disc in place.
4) Tighten the Position Disc Retaining Screw until the Position
Disc is firmly locked in place.
5) Confirm the CLOSE label is aligned correctly with the cover
indication arrow.
3. Commissioning
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CKa& CKra Atronik Start Up Guide
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6) Move the actuator to the OPEN limit using electrical or
operation or the handwheel.
7) Loosen off the Position Disc Retaining Screw by 1 turn
whilst holding the CLOSE portion of the Position Disc.
8) Rotate only the red OPEN portion of the disc so that OPEN
reads horizontally and then hold both portions in place.
9) Tighten the retaining screw until the Position Disc is firmly
locked in place.
10) Confirm the OPEN label is aligned correctly with the cover
indication arrow.
3. Commissioning
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