rotork CK Series User guide

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CK Range
CK Standard & CKR- Start Up Guide
Modular Design Electric Valve Actuators

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CK Standard and CKRStart Up Guide
2
CK – Valve Actuation 2
CK Mechanical Switch Mechanism – Switch Testing 3
Test feedback switches 3
CK Mechanical Switch Mechanism – Basic Settings 5
Set Torque Limits 5
Set Position Limits 6
CK Additional Indication Drive – Switch Testing 8
Test feedback switches 8
CK Additional Indication Drive – Basic Settings 10
Set Torque Limits 10
Set Position Limits 10
Setting Local Position Disc 12
Setting Intermediate Switches 14
Setting the POT 15
Setting the CPT 16
CK actuators have been developed with over 20 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.
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 CK Standard and CKRactuators. For
information or instructions on other CK Range actuators
please visit www.rotork.com
Contents
Section Page Section Page

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Keeping the World Flowing
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Before following any of the setting instructions included in
this document it is important to pay attention to the warnings
and safety instructions included in PUB111-007 provided with
the actuator.
A 5mm Allen (Hex.) key and 1.0 x 5.5mm flat screwdriver are
required to perform testing of the CK Mechanical
Switch Mechanism.
Test feedback switches
WARNING: Isolate the main power supply and all
control and indication wiring before removing the
Plug & Socket cover
.
1) Undo the four retaining cap screws on the switch
mechanism cover and remove the cover to show the
switch mechanism.
2) Confirm the torque or limit switches are functional by
measuring the relevant feedback terminals on the plug
assembly (see below).
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.
3)
Test position switches in both directions using a flat
screwdriver to turn LS TEST (CW for open, ACW for close).
4) Link a continuity meter across the following pairs of
terminals to test each individual function.
N/C CLS – Normally Closed (break when active) Close Limit
contact for motor control
N/O CLS – Normally Open (make when active) Close Limit
contact for feedback indication
N/C OLS – Normally Closed (break when active) Open Limit
contact for motor control
N/O OLS – Normally Open (make when active) Open Limit
contact for feedback indication
INFO: It is important to recognise the rotation of the
exposed plug when performing actuator function
diagnostics. The central “U” locating point provides
an orientation reference for this testing procedure.
N/O OLS
N/C OLS
N/O CLS N/C CLS
19
18
17 16
15
14
12
13
CK Mechanical Switch Mechanism – Switch Testing

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CK Standard and CKRStart Up Guide
4
CK Mechanical Switch Mechanism – Switch Testing
Test feedback switches (cont.)
5) Test torque switches in both directions using a flat
screwdriver to turn TS TEST (ACW for open, CW for
close).
6) Link a continuity meter across the following pairs of
terminals to test each individual function.
N/C CTS – Normally Closed (break when active) Close
Torque contact for motor control
N/O CTS – Normally Open (make when active) Close Torque
contact for feedback indication
N/C OTS – Normally Closed (break when active) Open
Torque contact for motor control
N/O OTS – Normally Open (make when active) Open Torque
contact for feedback indication
INFO: It is important to recognise the rotation of the
exposed plug when performing actuator function
diagnostics. The central “U” locating point provides
an orientation reference for this testing procedure.
N/C CTS
5
N/C OTS
9 8
N/O CTS
6
7
N/O OTS
10
11
4

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A
B
CK Mechanical Switch Mechanism – Basic Settings
A 5mm Allen (Hex.) key and 0.8 x 4mm flat screwdriver are
required to perform commissioning of the CK Mechanical
Switch Mechanism.
INFO: For CK Standard and CKRactuators, the
required end of travel action (torque or position)
is determined by the set of switches cabled to the
controlling switch gear - refer to actuator terminal
plan and site field wiring.
Set Torque Limits
A Indicator/Adjustment Point
B Torque Cam Clutch Screw
COpen Torque Adjustment Point
DClose Torque Adjustment Point
EFactory Calibration Fixings
WARNING: Do not adjust the fixings or position of
the yellow torque indicator plates. These are factory
configured and should not be removed under any
circumstance.
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. (40%) & max. (100%) - by moving the cam using a
screwdriver on the adjustment point.
CAUTION: To avoid introducing an offset to the set
value when adjusting the torque trip limits. Ensure
the screwdriver remains perpendicular to the switch
mechanism faceplate.
3) Tighten the Torque Cam Clutch Screw once both torque
trip limits have been set.
CAUTION: Tighten the Torque Cam Clutch Screw
until the spring washer is fully deformed under the
screw head.
C D
E

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CK Standard and CKRStart Up Guide
6
CK Mechanical Switch Mechanism – Basic Settings
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 the actuator to the valve CLOSED position using the
handwheel.
2) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to the “Set” position as shown on the switch
mechanism faceplate.
3) The CLS Adjustment Screw must now be rotated
to engage 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 this case it is necessary to move
through the limit and approach it from the correct
direction. This avoids 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 engaged correctly.
a. The feel of the Adjustment Screw will noticeably
change providing more mechanical resistance at the
switching point of the contact.
b. Use a continuity meter on the appropriate terminals –
12 & 13 for motor control and 14 & 15 for indication
feedback to check the switch is engaged.
6) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to the “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.
CAUTION: This must be done or the limit will be lost
when the actuator is moved.
G
H
I
J
N/O OLS
N/C OLS
N/O CLS N/C CLS
19
18
17 16
15
14
12
13
N/C CLS – Normally Closed (break when active) Close Limit
contact for motor control
N/O CLS – Normally Open (make when active) Close Limit
contact for feedback indication
N/C OLS – Normally Closed (break when active) Open Limit
contact for motor control
N/O OLS – Normally Open (make when active) Open Limit
contact for feedback indication
CLSOLS

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CK Mechanical Switch Mechanism – Basic Settings
8) Move the actuator to the valve OPEN position using the
handwheel.
9) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to the “Set” position as shown on the switch
mechanism faceplate.
10) The OLS Adjustment Screw must now be rotated to
engage 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 this case it is necessary to move through the
limit and approach it from the correct direction. This avoids
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 engaged correctly.
a. The feel of the Adjustment Screw will noticeably
change providing more mechanical resistance at the
switching point of the contact.
b. Use a continuity meter on the appropriate terminals –
16 & 17 for motor control and 18 & 19 for indication
feedback to check the switch is engaged.
13) Using a flat screwdriver, depress the Drive Clutch Shaft
and rotate to the “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.
CAUTION: This must be done or the limit will be lost
when the actuator is moved.
Rotate the OLS/CLS Adjustment Shaft Clockwise. Rotate the OLS/CLS Adjustment Shaft Anti-Clockwise.
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.
CLSOLS
CLSOLS CLSOLS
CLSOLS CLSOLS

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CK Standard and CKRStart Up Guide
8
CK Additional Indication Drive – Switch Testing
Test feedback switches
WARNING: Isolate the main power supply to the
actuator and remove the Plug & Socket cover.
1) Undo the four retaining cap screws on the switch
mechanism cover and remove the cover to show the
switch mechanism.
2) Confirm the torque or limit switches are functional by
measuring the relevant feedback terminals on the plug
assembly (see below).
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.
3) Test the position switches in both directions using the
LS TEST lever shown on the right hand side of the unit
between the AID module and the Mechanical Switch
Mechanism (move DOWN for open, UP for close).
4) Use a continuity meter across the following pairs of
terminals to test each individual function.
N/O OLS
N/C OLS
N/O CLS N/C CLS
19
18
17 16
15
14
12
13
N/C CLS – Normally Closed (break when active) Close Limit
contact for motor control
N/O CLS – Normally Open (make when active) Close Limit
contact for feedback indication
N/C OLS – Normally Closed (break when active) Open Limit
contact for motor control
N/O OLS – Normally Open (make when active) Open Limit
contact for feedback indication
INFO: It is important to recognise the rotation of the
exposed plug when performing actuator function
diagnostics. The central “U” locating point provides
an orientation reference for this testing procedure.

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CK Additional Indication Drive – Switch Testing
Test feedback switches (cont.)
5) Test the torque switches in both directions using the
TS TEST lever shown on the left hand side of the unit
between the AID module and Mechanical Switch
Mechanism (move DOWN for open, UP for close).
6) Use a continuity meter across the following pairs of
terminals to test each individual function.
N/C CTS
5
N/C OTS
9 8
N/O CTS
6
7
N/O OTS
10
11
4
N/C CTS – Normally Closed (break when active) Close
Torque contact for motor control
N/O CTS – Normally Open (make when active) Close Torque
contact for feedback indication
N/C OTS – Normally Closed (break when active) Open
Torque contact for motor control
N/O OTS – Normally Open (make when active) Open Torque
contact for feedback indication
INFO: It is important to recognise the rotation of the
exposed plug when performing actuator function
diagnostics. The central “U” locating point provides
an orientation reference for this testing procedure.

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CK Standard and CKRStart Up Guide
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CK Additional Indication Drive – Basic Settings
A 5mm Allen (Hex.) key and 0.8 x 4mm flat screwdriver with at
least 120mm shaft length are required to perform commissioning
of the CK Mechanical Switch Mechanism. A small torch may be
required in environments with low level lighting.
Set Torque Limits
The torque limits can be set using the same method
previously described in this manual at the beginning of the
Basic Settings section. Access to the torque setting inputs is
maintained whilst the AID module is fitted.
Set Position Limits
The position limits can still be set with the CK AID module in
place. The OLS/CLS Indicator windows and adjustment screws
can be accessed through the labelled holes in the AID chassis.
CAUTION: It is important to remove the POT drive
assembly (if fitted) from the drive gearing prior to
setting the position limits. Refer to Setting the POT
section, steps 1 and 2 for instructions on adjusting
this component.
1) Move the actuator to the valve CLOSED position using the
handwheel.
2)
Using a flat screwdriver, depress the Drive Clutch Shaft and
rotate to the “Set” position as shown on the AID faceplate.
3) The CLS Adjustment Screw must now be rotated
to engage the closed limit switch inside the switch
mechanism. The CLS Indicator Window will show one of
four possible symbols. Please refer to Figure 2 on page 11
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 this case it is necessary to move through the
limit and approach it from the correct direction. This avoids
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. Use a continuity meter on the appropriate terminals –
12 & 13 for motor control and 14 & 15 for indication
feedback to check the switch is engaged.
6)
Using a flat screwdriver, depress the Drive Clutch Shaft and
rotate to the “Run” position as shown on the AID 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.
CAUTION: This must be done or the limit will be lost
when the actuator is moved.

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8) Move the actuator to the valve OPEN position using the
handwheel.
9)
Using a flat screwdriver, depress the Drive Clutch Shaft and
rotate to the “Set” position as shown on the AID faceplate.
10) The OLS Adjustment Screw must now be rotated to
engage the open limit switch inside the switch mechanism.
The OLS Indicator Window will show one of four possible
symbols. Please refer to Figure 2 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 this case it is necessary to move through the
limit and approach it from the correct direction. This avoids
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. Use a continuity meter on the appropriate terminals –
16 & 17 for motor control and 18 & 19 for indication
feedback to check the switch is engaged.
13)
Using a flat screwdriver, depress the Drive Clutch Shaft and
rotate to the “Run” position as shown on the AID 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.
CAUTION: This must be done or the limit will be lost
when the actuator is moved.
Rotate the OLS/CLS Adjustment Shaft Clockwise. Rotate the OLS/CLS Adjustment Shaft Anti-Clockwise.
Rotate the OLS/CLS Adjustment Shaft in the direction shown
next to the Shaft input.
The limit switching point is near or made.
Figure 2.
CK Additional Indication Drive – Basic Settings

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CK Standard and CKRStart Up Guide
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CK Additional Indication Drive – Basic Settings
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 360⁰ in 90⁰ 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.

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CK Additional Indication Drive – Basic Settings
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.

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CK Standard and CKRStart Up Guide
14
CK Additional Indication Drive – Basic Settings
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

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CK Additional Indication Drive – Basic Settings
Setting the POT
The AID Module can include a potentiometer for remote
position feedback. This can provide a potentiometric output
or a 4-20 mA scaled position output via the Current Position
Transmitter 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.
CAUTION: The actuator position limits must be
configured prior to setting the AID POT drive.
1) Loosen off the retaining grub screw using a 1.5mm 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) Connect a test meter across the POT terminals* – refer
to actuator wiring diagram and POT Setting Information
table below.
5) Rotate the POT input gears until the required resistance
value has been reached.
6) Refit the POT assembly to the AID chassis and ensu
re the
teeth mate correctly with the position drive gear.
C AUTION: 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) Confirm the POT is 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. Current should change through 4-20 mA however
tuning may be required. Refer to the next page for tuning
instructions.

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CK Standard and CKRStart Up Guide
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CK Additional Indication Drive – Basic Settings
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) Monitor position feedback using a powered test meter
across the CPT terminals – 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) Monitor position feedback using a powered test meter
across the CPT terminals – refer to actuator wiring diagram.
6) Rotate the SPAN trimming potentiometer so that 20 mA is
output from the CPT.
7) Adjustment of the SPAN will cause the ZERO to change
a small amount. It is important to repeat steps 1 to 6 a
second time in order to remove this calibration error.

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Notes

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PU B111- 0 03 - 0 0
Issue 11/17
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. POWJB0519
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.