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
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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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Setting Intermediate Switches
The AID Module can include four additional switches to
indicate configurable intermediate positions.
CAUTION: The actuator position limits must be
configured prior to setting the Intermediate
Switches.
1) Move the actuator to the desired intermediate position
using electrical operation or the handwheel.
2) Move the switch cam along the shaft against the spring to
allow free rotation of the cam.
3) Rotate the cam to ensure the desired switch behaviour is
achieved. The intermediate position switches can be supplied
with normally open or normally closed contact form.
4) Confirm the switch has been engaged/disengaged by
measuring continuity across the relevant terminals during
cam adjustment – refer to actuator wiring diagram
and pictorial annotations (right) for the relevant switch
information.
5) Repeat steps 1 to 4 for each intermediate position switch.
IP4 IP3 IP2 IP1
3. Commissioning
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CKa& CKra Atronik Start Up Guide
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Setting the POT
The AID Module can include a potentiometer (POT) to
report intermediate position to the Atronik control module.
Alternatively, the POT can provide a direct potentiometric
output or drive the AID CPT option (refer to next page).
The POT drive includes four different sized gears that allow
the single turn POT to be scaled according to the total valve
travel. For information on which ratio is suitable for your
application please contact Rotork.
If the POT is connected to the Atronik, fine adjustment of the
POT travel is not required.
CAUTION: The actuator position limits must be
configured prior to setting the AID POT drive.
1) Loosen off the retaining grub screw using a 1.5 mm Allen
(Hex.) Key.
2) Rotate the POT drive assembly away from the driving gear.
3) Move the actuator to the Closed Limit position using
electrical operation or the handwheel.
4) If the POT signal is not wired to the Atronik, connect a
test meter to the POT terminals* – refer to actuator wiring
diagram and POT Setting Information table below.
5) Rotate the POT input gears anti-clockwise until the POT
cannot rotate any further. Confirm the POT is triggering the
Close Limit indicator on the Atronik or reading the required
resistance value.
6) Refit the POT assembly to the AID chassis and ensure the
teeth mate correctly with the position drive gear.
CAUTION: Extra care must be taken to ensure the
correct POT input gear is mated with the position
drive gear.
7) Tighten the retaining grub screw to prevent movement of
the POT drive assembly.
8) Move the actuator to the Open Limit position using
electrical operation or the handwheel.
9) Monitor POT rotation throughout valve travel and ensure
the maximum POT travel is not exceeded. A different gear
selection may be necessary if POT travel is exceeded.
10) Confirm the POT is triggering the Open Limit indicator on
the Atronik or reading the required resistance value.
POT Setting Information
Travel Direction Value at Closed Limit Value at Open Limit Measurement Terminals
Clockwise Low High 30 & 31
Clockwise High Low 31 & 32
Anti-Clockwise Low High 31 & 32
Anti-Clockwise High Low 30 & 31
*Potentiometer terminals may not be accessible if the AID
CPT option is also fitted. In this instance it is important to
ensure the POT does not slip throughout full valve travel.
Calibration of the 4 − 20mA CPT output is detailed on the
next page.
3. Commissioning
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Setting the CPT
Once the POT drive is commissioned for full valve travel, the
CPT can be calibrated to output a 4-20 mA loop powered
signal. This can be used as direct actuator position feedback
to the site control system.
The CPT option includes two different trimming potentiometers
to enable zero and span values to be calibrated.
CAUTION: The actuator position limits and POT drive
must be configured prior to setting the AID CPT.
1) Run the actuator to the Closed position limit using
electrical operation or the handwheel.
2) Connect a powered test meter across the CPT terminals
and measure the transmitted current – refer to actuator
wiring diagram.
3) Rotate the ZERO trimming potentiometer so that 4 mA is
output from the CPT.
4) Run the actuator to the Open position limit using
electrical operation or the handwheel.
5) Rotate the SPAN trimming potentiometer so that 20 mA is
output from the CPT.
6) Adjustment of the SPAN will cause the ZERO to change
a small amount. It is important to repeat steps 1 to 5 a
second time in order to remove this calibration error.
3. Commissioning
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CKa& CKra Atronik Start Up Guide
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4. CK Atronik
4.1 Standard Settings
Configuration of the Atronik control module is performed via DIP switches located on the user interface PCB within the
Atronikenclosure.
DIP switch functions
Label Function OFF ON
ESD FUNCTION A
ESD Action A OFF and B OFF = Disabled
A ON and B OFF = Open
A ON and B ON = Stay put
A OFF and B ON = Close
ESD FUNCTION B
ESD NC/NO ESD Contact Form ESD active when signal applied
(normally open)
ESD active when signal removed
(normally closed)
PTR LOCAL Local Control Local control is push-to-run Local control is maintained
CLOSE DIRECTION Direction Clockwise to close Anti-clockwise to close
PRIORITY A
2-Wire Priority A OFF and B OFF = Close Priority
A ON and B OFF = No Priority
A ON and B ON = Open Priority
A OFF and B ON = No Priority
PRIORITY B
OPEN ACTION Open Action Stop on position limit Stop on torque limit
CLOSE ACTION Close Action Stop on position limit Stop on torque limit
LED LED Green = Close
Red = Open
Red = Close
Green = Open
STD/OPT CONTROL Control Source Hardwired control only Option control only
POWER Power 3-phase power supply 1-phase power supply
REL AY A
Relay Conditions Relay settings are determined by a combination of A, B and C.
Refer to below table for details.
REL AY B
REL AY C
SETUP Actuator speed* Actuator speed > 12 RPM Actuator speed ≤ 12 RPM
*SETUP switch does not alter actuator output speed.
Standard Relay Conditions
RELAY A RELAY B RELAY C Relay 1 Function Relay 2 Function
OFF OFF OFF Close Limit Open Limit
OFF OFF ON Torque Trip Motor Stall
OFF ON OFF Motor Stall Thermostat Trip
OFF ON ON Torque Trip Close Torque Trip Open
ON OFF OFF Mid Travel Torque Trip
ON OFF ON Remote Selected ESD Active
ON ON OFF Local Selected Stop Selected
ON ON ON Blinker Hand Operation
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4. CK Atronik
4.2 Option Settings
Extra Relays
Atronik can accommodate four additional relay contacts with configurable functions. These are determined by DIP switches
located on the extra relay PCB.
Switch 1 Switch 2 Switch 3 Relay 3 Function Relay 4 Function
OFF OFF OFF Open Limit Closed Limit
OFF OFF ON Torque Trip Open Torque Trip Closed
OFF ON OFF Blinker Local Selected
OFF ON ON Motor Stall ESD Active
ON OFF OFF Torque Trip ESD Active
ON OFF ON Hand Operation ESD Active
ON ON OFF Local Selected Mid Travel
ON ON ON Valve Alarm 24 VDC Power Fail
Switch 4 Switch 5 Switch 6 Relay 5 Function Relay 6 Function
OFF OFF OFF Closed Limit Open Limit
OFF OFF ON Torque Trip Closed Torque Trip Open
OFF ON OFF Mid Travel Local Selected
OFF ON ON Actuator Alarm Hand Operation
ON OFF OFF Stop Selected Hand Operation
ON OFF ON Remote Selected Motor Running
ON ON OFF Local Selected Motor Running
ON ON ON Mid Travel Motor Running
Positioner
The positioner option for Atronik enables control of actuator position with a proportional analogue signal.
Feedback is transmitted via 4-20 mA to provide remote intermediate position indication.
Switch No Function OFF ON
SW5
6Positioner Inverse Control signal is:
Close = low, Open = high
Control signal is:
Close = high, Open = low
5CPT Inverse Feedback signal is:
Close = 4 mA, Open = 20 mA
Feedback signal is:
Close = 20 mA, Open = 4 mA
4Signal Loss Action SW5-3 OFF and SW5-4 OFF = Close
SW5-3 ON and SW5-4 OFF = OFF
SW5-3 ON and SW5-4 ON = Open
SW5-3 OFF and SW5-4 ON = Stayput
3
2Input Type SW5-1 OFF and SW5-2 OFF = 0-20 mA
SW5-1 ON and SW5-2 OFF = 0-5 V
SW5-1 ON and SW5-2 ON = 0-20 V
SW5-1 OFF and SW5-2 ON = 0-10 V
1
SW4 0 – 9 Deadband 10* position switch with incrementing values: 0.5%, 1%, 2%, 3%, 5%, 10%
SW3 0 – 9 Motion Inhibit Timer 10* position switch with incrementing values: 1s, 2s, 5s, 10s, 30s, 60s
SW1 Set Open Inject signal for the Open position and hold SW1 for 3 seconds to set the value
SW2 Set Close Inject signal for the Close position and hold SW2 for 3 seconds to set the value
Deadband and MIT should be adjusted to provide suitable control accuracy while still filtering out unwanted signal fluctuations and noise.
* Position 0 is the lowest setting, incrementing by one for each subsequent setting value. Surplus positions will match the highest setting
value and are reserved for future use.
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PU B111-110 - 0 0
Issue 03/20
As part of a process of on-going product development, Rotork reserves the right to amend and change
specifications without prior notice. Published data may be subject to change. For the very latest version
release, visit our website at www.rotork.com
The name Rotork is a registered trademark. Rotork recognizes all registered trademarks. Published and
produced in the UK by Rotork. POWJB0320
Rotork plc
Brassmill Lane, Bath, UK
tel [phone]
fax [phone]
email [email protected]
Rotork is a corporate
member of the Institute
of Asset Management
www.rotork.com
A full listing of our worldwide sales and
service network is available on our website.