rotork Insight 2 User manual

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1.0 INTRODUCTION..........................................................................................................................................7
1.1INSTALLING INSIGHT 2..................................................................................................................................7
1.2UNINSTALLING INSIGHT2..............................................................................................................................7
1.3UPDATING INSIGHT 2...................................................................................................................................7
2.0 LOGGING IN...............................................................................................................................................8
2.1LOGINSCREEN............................................................................................................................................8
2.2USER LEVELS..............................................................................................................................................8
2.2.1Viewer.............................................................................................................................................8
2.2.2 User................................................................................................................................................9
2.2.3 Service_Engineer.............................................................................................................................9
2.2.4 Administrator..................................................................................................................................9
3.0 HOME SCREEN .........................................................................................................................................10
3.1LAYOUT ..................................................................................................................................................11
3.2MENU BAR..............................................................................................................................................12
3.2.1 File................................................................................................................................................12
3.2.2 Connection....................................................................................................................................15
3.2.3 Security.........................................................................................................................................15
3.2.4 Tools.............................................................................................................................................16
3.2.5 Help ..............................................................................................................................................17
3.3ICON BAR................................................................................................................................................18
3.3.1 Open Configuration.......................................................................................................................18
3.3.2 SaveAs..........................................................................................................................................18
3.3.3 Save..............................................................................................................................................18
3.3.4 Print..............................................................................................................................................18
3.3.5. Send Configuration.......................................................................................................................18
3.3.6 Read Configuration........................................................................................................................18
3.3.7 Discard..........................................................................................................................................18
3.4SIDE PANEL..............................................................................................................................................19
3.4.1 Offline...........................................................................................................................................19
3.4.2 Bluetooth......................................................................................................................................19
3.5RANGE PANEL ..........................................................................................................................................20
3.6PRESENTATION WINDOW............................................................................................................................21
3.7STATUS BAR.............................................................................................................................................21
3.7.1 Connection Status..........................................................................................................................21
3.7.2 Actuator Login Level......................................................................................................................21
3.7.3 Insight 2LoginLevel ......................................................................................................................21
4.0 CONNECTING AND DISCONNECTING DEVICES..........................................................................................22
4.1SEARCHING FOR DEVICES.............................................................................................................................22
4.2CONNECTING TO AN ACTUATOR ....................................................................................................................23
4.3CONNECTING TO A BLUETOOTH SETTING TOOL .................................................................................................23
4.4DISCONNECTING FROM DEVICES....................................................................................................................23
5. CVA............................................................................................................................................................24
5.1CVQ/CVLDEVICE INFORMATION .................................................................................................................25
5.1.1 Valve Tag......................................................................................................................................25
5.1.2 CVA/CVQType...............................................................................................................................25
5.1.3 CVA Main PCB SoftwareVersion....................................................................................................25
5.1.4 Manufacturing Data......................................................................................................................25
5.1.5 ServiceNotes.................................................................................................................................25
5.1.6 DateofManufacture.....................................................................................................................25
5.1.7 CVA Hardware...............................................................................................................................25

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5.1.8 Main Controller Serial No...............................................................................................................25
5.1.9 UPS Controller Serial No.................................................................................................................25
5.1.10 Position Sensor Serial No..............................................................................................................25
5.1.11 Motor SensorSerial No................................................................................................................25
5.1.12 Force Sensor Serial No. ................................................................................................................26
5.1.13 User Interface Serial No...............................................................................................................26
5.2ACTUATOR CONFIGURATION -CVAVALVE SETUP .............................................................................................26
5.2.1 Valve Action Settings.....................................................................................................................26
5.2.2 MOVTag........................................................................................................................................26
5.2.3 Valve Action Settings.....................................................................................................................26
5.2.4 Input /OutputSetup......................................................................................................................27
5.3ADVANCED SETTINGS 1...............................................................................................................................27
5.3.1 Tight Shut Off................................................................................................................................27
5.3.2 Obstruction Action Active..............................................................................................................27
5.3.3 Obstruction Values Setup...............................................................................................................28
5.3.4 Manual Test Knob Setup................................................................................................................28
5.4ADVANCED SETTINGS 2...............................................................................................................................28
5.4.1 Travel Alarm Thresholds................................................................................................................28
5.4.2 Bumpless TransferSetup................................................................................................................28
5.5UPSCONFIGURATION AND STATUS ...............................................................................................................29
5.5.1 UPSConfiguration .........................................................................................................................29
5.5.2 UPSStatus Information..................................................................................................................30
5.6CVASTATUS............................................................................................................................................30
5.6.1 Actuator Position (%).....................................................................................................................30
5.6.2 Actuator Torque (%) ......................................................................................................................30
5.6.3 AnalogueDemandInput(mA)........................................................................................................30
5.6.4 Analogue Position Feedback (mA)..................................................................................................30
5.6.5 ESDInput Status............................................................................................................................30
5.7CVAMAIN DATALOGGER............................................................................................................................31
5.7.1 EventLogger .................................................................................................................................31
5.7.2 CVA Dwell Log...............................................................................................................................34
5.7.3 CVA TorqueLogs............................................................................................................................34
5.7.4 CVAMovement Log.......................................................................................................................35
6.0 IQ3 SETTINGS...........................................................................................................................................36
6.1ACTUATOR INFORMATION ...........................................................................................................................38
6.1.1 Actuator User Information.............................................................................................................38
6.1.2 Actuator Serial Numbers................................................................................................................38
6.1.3 Actuator Manufacturing Information.............................................................................................39
6.2ACTUATOR NAME PLATE.............................................................................................................................40
6.2.1 Actuator NamePlate Info..............................................................................................................40
6.2.2 Valve Manufacturing Information..................................................................................................41
6.2.3 Gearbox Manufacturing Information .............................................................................................42
6.3ACTUATOR SETTINGS..................................................................................................................................43
6.3.1 Basic Settings................................................................................................................................43
6.3.2 ESDConfiguration..........................................................................................................................44
6.3.3REMOTE CONFIGURATION ........................................................................................................................45
6.3.4 Local Configuration........................................................................................................................45
6.3.5 Special Mode Configuration...........................................................................................................46
6.4TORQUE SETTINGS.....................................................................................................................................47
6.4.1 CurrentTorqueReadings...............................................................................................................47
6.4.2 Actuator Torque Settings...............................................................................................................47
6.4.3 Torque Advanced Settings..............................................................................................................47
6.4.4 TorqueProfileSettings...................................................................................................................48
6.5POWER SETTINGS......................................................................................................................................48
6.5.1 Power Type....................................................................................................................................48
6.6DIGITAL INPUTSETTINGS.............................................................................................................................49

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6.6.1 DI Function....................................................................................................................................49
6.6.2 DI Input Type.................................................................................................................................49
6.7PARTIAL STROKE SETTINGS...........................................................................................................................50
6.7.1 Partial Stroke Enable.....................................................................................................................50
6.7.2 Partial Stroke Initial Position..........................................................................................................50
6.7.3 Partial Stroke Position (%)..............................................................................................................50
6.7.4 Partial Stroke Time to Position (sec)...............................................................................................50
6.7.5 PartialStroke Time to Limit (sec)....................................................................................................50
6.8RELAYSETTINGS........................................................................................................................................51
6.8.1 MonitorRelay Function..................................................................................................................51
6.8.2 Relay Settings................................................................................................................................52
6.9OPTION CONTROL .....................................................................................................................................53
6.9.1 Option Source Selection.................................................................................................................53
6.9.2 Auxiliary MaskConfiguration.........................................................................................................54
6.9.3 Option 1-4Configuration...............................................................................................................54
6.10CONTROL SETTINGS .................................................................................................................................55
6.10.1 Position Settings..........................................................................................................................55
6.10.2 Interrupter Timer.........................................................................................................................56
6.11UISETTINGS ..........................................................................................................................................57
6.11.1 Indication Configuration..............................................................................................................57
6.11.2 Communication Configuration.....................................................................................................58
6.12LANGUAGE SETTINGS................................................................................................................................58
6.12.1 Display Language........................................................................................................................58
6.12.2 Language Option Details..............................................................................................................59
6.13NAMUR SETTINGS ...................................................................................................................................59
6.13.1 NamurStatus..............................................................................................................................59
6.13.2 Namur Mask Settings (All groups)................................................................................................60
6.14ANALOGUE CONTROL/CPT/CTT/AIOOPTION...............................................................................................60
6.15EXTRA RELAYS S5-S8...............................................................................................................................60
7.0 IQ3 DATA LOGGER....................................................................................................................................61
7.1EVENTLOGGER .........................................................................................................................................62
7.1.1 TimeLine.......................................................................................................................................62
7.1.2 Trace View.....................................................................................................................................63
7.1.3 List View........................................................................................................................................64
7.2TORQUE PROFILE ......................................................................................................................................65
7.3TORQUE LIMIT PROFILES .............................................................................................................................65
7.4TORQUE REFERENCE PROFILE .......................................................................................................................66
7.5TORQUE REFERENCE LIMIT PROFILES..............................................................................................................67
7.6STARTS LOG.............................................................................................................................................68
7.7MOVEMENT LOG ......................................................................................................................................69
7.8CURRENT PARTIAL STROKE PROFILE ...............................................................................................................70
7.9VIBRATION TREND LOG...............................................................................................................................71
7.10BATTERY VOLTAGE AND TEMPERATURE TREND LOG .........................................................................................72
7.10.1 Battery Voltage Trend..................................................................................................................72
7.10.2 Temperature Trend......................................................................................................................72
7.11MOTOR STARTS AND OUTPUT TURNS TREND LOG ...........................................................................................73
7.12MISCELLANEOUS DATALOG DATA................................................................................................................74
7.12.1 Motor Related Data.....................................................................................................................74
1.12.2 Power Related Data.....................................................................................................................74
1.12.3 Limit Related Data.......................................................................................................................75
1.12.4 Environmental Related Data........................................................................................................75
8.0 EH PRO AND SI PRO SCREENS...................................................................................................................76
8.1BASIC SETTINGS ........................................................................................................................................78
8.1.1 Valve Tag......................................................................................................................................78
8.1.2 Close Action...................................................................................................................................78

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8.1.3 Open Action...................................................................................................................................78
8.1.4 Close Pressure (Limit) (%)...............................................................................................................78
8.1.5 Close Pressure (Mid) (%)................................................................................................................78
8.1.6 Open Pressure (Limit) (%)...............................................................................................................78
8.1.7 Open Pressure (Mid) (%)................................................................................................................78
8.1.8 Closed Limit...................................................................................................................................78
8.1.0 Open Limit.....................................................................................................................................78
8.2CONTACT RELAYS ......................................................................................................................................79
8.2.1 Contact– Function.........................................................................................................................79
8.2.2 Contact– Value.............................................................................................................................79
8.2.3 Contact– Form..............................................................................................................................79
8.3GENERAL SETTINGS....................................................................................................................................80
8.3.1 Remote Select................................................................................................................................80
8.3.2 Configure Local Controls................................................................................................................80
8.3.3 Low Power Mode...........................................................................................................................80
8.3.4 Closed LED Colour..........................................................................................................................80
8.4DIGITAL CONTROL .....................................................................................................................................81
8.4.1 Remote Priority .............................................................................................................................81
8.4.2 Hold Position.................................................................................................................................81
8.4.3 Position Hysteresis.........................................................................................................................81
8.4.4 OverPressure Hysteresis................................................................................................................81
8.4.5 Under Pressure Hysteresis..............................................................................................................81
8.5ESD/PARTIAL STROKE................................................................................................................................82
8.5.1 ESD...............................................................................................................................................82
8.5.2 Partial Stroke.................................................................................................................................83
8.5.3 Reference Partial StrokeTest Recorded Values...............................................................................83
8.6ANALOGUE CONTROL.................................................................................................................................84
8.6.1 Analogue Control...........................................................................................................................84
8.6.2 Flow Characterisation....................................................................................................................85
8.7INTERRUPTER TIMER ..................................................................................................................................86
8.7.1 Interrupter Timer...........................................................................................................................86
8.7.2 Interrupter Timer Direction............................................................................................................86
8.7.3 Interrupter Timer Start (%).............................................................................................................86
8.7.4 Interrupter Timer Stop(%).............................................................................................................86
8.7.5 Interrupter TimerInterval..............................................................................................................86
8.7.6 Interrupter Timer On Time.............................................................................................................86
8.7.7 Interrupter Timer Off Time.............................................................................................................86
8.7.8 Interrupter Timer withESD Enabled...............................................................................................86
8.8ACTUATOR STATISTICS................................................................................................................................87
8.8.1 Number of Times Open Limit Reached............................................................................................87
8.8.2 Number of Times Close LimitReached............................................................................................87
8.8.3 Time Spent Moving Open (sec).......................................................................................................87
8.8.4 Time Spent Moving Closed (sec).....................................................................................................87
8.8.5 Numberof ESD Events...................................................................................................................87
8.8.6 Numberof Motor Starts.................................................................................................................87
8.8.7 Number of Accumulator Recharges................................................................................................87
9.0 BLUETOOTH SETTING TOOL SCREENS.......................................................................................................88
9.1BTSTINFORMATION..................................................................................................................................88
9.1.1 Firmware Version..........................................................................................................................88
9.1.2 BatteryStatus(mV).......................................................................................................................88
9.1.3 Numberof Files.............................................................................................................................88
9.1.4 Free Space on the BTST (Bytes) ......................................................................................................88
9.1.5 Flash Memory sizeon BTST (Bytes).................................................................................................88
9.2CVA......................................................................................................................................................88
9.3IQ2.......................................................................................................................................................89
9.4EHP......................................................................................................................................................89

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9.5IQ3.......................................................................................................................................................89
9.6SIP........................................................................................................................................................89
9.7MISSIONS................................................................................................................................................89
9.7.1 Create Missions.............................................................................................................................89
9.7.2 Custom Mission.............................................................................................................................92
9.7.3 Review/Edit Mission......................................................................................................................93
9.7.4 DeleteMission...............................................................................................................................93
9.7.5 Delete All Missions.........................................................................................................................93
9.7.6 Format BST....................................................................................................................................94

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1.0 Introduction
1.1 Installing Insight 2
1.2 Uninstalling Insight 2
1.3 Updating Insight 2
1.1 Installing Insight 2
The Insight 2 program canbe downloaded from the Insight 2 download page on:
www.rotork.com/en/support/index/downloads
You will be required to Log in with your Rotork Internet Portal Account to access this page.
(To register for a free Rotork Internet Portal Account click register and fill out the application form)
On the IQ Insight 2 download page you can view information aboutthe software and the minimum
PC operating requirements. It is worth noting down the program access passwords for future use.
When you are satisfied that your machine is compatible with Insight 2, click Download IQ-Insight 2
Software for PC. This will begin the software package download for the latest version of Insight 2.
Once the download is complete, extract the install package to a user specified save location. Open
the Setup.exe file to load the installation wizard and begin the program install process. Follow the
on-screen prompts to install Insight 2.
1.2 Uninstalling Insight 2
To uninstall Insight 2 use the Uninstall Insight 2 start menu shortcut or proceed through the standard
Windows software management feature. This can be found within the control panel.
For XP users use the “Add/Remove Programs” feature.
For Vista and 7 usersuse the “Uninstall a program”
feature.
Select Insight 2 from the program list and select uninstall. Follow the onscreen wizard to complete
the removal of Insight 2.
1.3 Updating Insight 2
Insight 2 will be updated periodically to add new features and increased compatibility with new
Rotork actuators. To update your copy of Insight 2 please follow instructions detailed on the
download page of the Rotork website www.rotork.com/en/support/index/downloads.

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2.0 Logging In
2.1 Login Screen
2.2 User Levels
2.2.1 Viewer
2.2.2 User
2.2.3 Service Engineer
2.2.4 Administrator
2.1 Login Screen
Below is the login screen forInsight 2.
This screen provides the user with four access levels on a drop down menu that require the
corresponding passwords to beentered. The check box in the bottom left allows Insight 2 to
remember your login details for easy access to the program in the future.
2.2 User Levels
The Privilege Level drop down menu presents 4 selections.
This selection will determine the available access levels visible when connecting to a Rotork
Bluetooth device.
2.2.1 Viewer
As a Viewer you can connect to any Bluetooth equipped Rotork device. These include: IQ3, CVA, EH
Pro, SI Pro and Rotork Bluetooth Setting Tool Pro. Viewer level prevents operators from modifying
the settings of an actuator.
Default Insight 2 Viewer Password: ROTORK

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2.2.2 User
As a User you can perform all the tasks of a Viewer with the ability to modify setting values. An
actuator User login allows you to change some settings within the actuators configuration.
Default Insight 2 User Password: ROTORK
2.2.3 Service Engineer
This login is reserved for the use of Rotork Service Engineers.
2.2.4 Administrator
This Login is reserved for the use of Rotork Engineers.

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3.0 Home Screen
3.1 Layout
3.2 Menu Bar
3.2.1 File
3.2.2 Connection
3.2.3 Security
3.2.4 Tools
3.2.5 Help
3.3 Icon Bar
3.3.1 Open Configuration
3.3.2 Save As
3.3.3 Save
3.3.4 Print
3.3.5 Send
3.3.6 Receive Configuration
3.3.7 Discard
3.4 Side Panel
3.4.1 Offline
3.4.2 Bluetooth
3.5 Range Panel
3.6 Presentation Window
3.7 Status Bar
3.7.1 Connection Status
3.7.2 Actuator Login level
3.7.3 Insight 2 Login Level

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3.1 Layout
For the purpose of this manual the main Insight 2 screen has been split into six areas as shown
below.
Description
Colour
Menu Bar
Blue
Icon bar
Orange
Side Panel
Purple
Range Panel
Yellow
Presentation Window
Green
Status Bar
Red

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3.2 Menu Bar
3.2.1 File
New Configuration
Use this function to create a new
default configuration for a compatible
Rotork product. There are 5 types of
actuator that can be configured with
Insight 2. The name and save location
of the configuration can be modified
appropriately if required.
Once “Ok” is selected the loading screen will appear as Insight 2
prepares the new configuration. This will appear in the Offline
section of the side menu (for side menu information see section
3.4.1) under the correctactuator type.
NOTE: using thisfunction on a live actuator will clear any
previous configuration. Ensure a copy of the existing
configuration is saved before using thisfeature.

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Open
Configuration
The configuration option allows the user to open saved configuration files. Opened files will be shown in
the Offline section of the Side menu under the relevantactuator type.
Firmware
This function is only available for Rotork Service Engineers and Service centres.
Save
When a configuration in the Offline section is changed the user can save those changes.

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Save As
This function enables the user to save configuration files from the Offline or Online sections of the side
menu to a directory on the PC. These will be available for future offline use. This feature is to be used
for saving the configuration and datalogger files in the format to be read by Insight 2. For other formats
use the exportfeature.
Export
Configuration
This exports the current actuator configuration as either a Comma Separated Value (.csv) or a Text file
(.txt)
Configuration and DataLogs
This exports the current actuator configuration and data log file as either a Comma Separated Value
(.csv) or a Textfile (.txt). The data log must be viewed within Insight 2 prior to exporting the data.
Exit
The Exit function will close Insight 2 and disconnect from any active Bluetooth device.

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3.2.2 Connection
Discover Devices
This initialises a search for all Bluetooth enabled actuators* and setting tools within the Bluetooth
adaptor range (setting tools can only be found whilst in slave mode, refer to the Bluetooth Setting Tool
manual for more information).
Recent Discovered Devices
This provides a list of previously connected devices that the operator can connect to without requiring a
Bluetooth search*.
*Actuators must be in a Bluetooth visible mode and within range of the Bluetooth adapter to be
discovered with Insight 2.
3.2.3 Security
Change Privilege
This enables the user to change their privilege level within Insight 2 by re-opening the Login screen (see
section 2 Logging In).
Change Application Password
This function enables the current user to change the Insight 2 login passwords for the current privilege
level and any lower privilege level.

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Change Actuator Password
This function is reserved for Rotork Service Engineer use only.
3.2.4 Tools
Sensor Calibration
This function is reserved for Rotork Service Engineer use only.
Zero Thrust
This function is reserved for Rotork Service Engineer use only.
CP Chat
This function is reserved for Rotork Service Engineer use only.
Unit Setting
The units displayed within Insight 2 can be set to Metric or Imperial to suit various global markets
(Insight 2 default = Metric).
Install Actuator Devices
This function enables Insight 2 to be updated using a compressed ADF file package provided by Rotork.
All future updates will be supported via this feature to ensure reliable compatibility with the continually
expanding Rotork product offering.
To download the latest ADF file please visit the Insight 2 download page:
http://www.rotork.com/customers/index/iqinsight2.
Save the ADF file to an accessible PC directory and then browse to the file through the Install Actuator
Devices function.

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On successful installation of the update you will be requested to restart Insight 2.
3.2.5 Help
View Help
Insight 2 Help
This help file is currently under construction. Future releases will include information about various
Insight 2 functions.
Actuator Help
This help file is currently under construction. Future releases will include information aboutvarious
Rotork actuator functions relevant to the connected actuator type.
About Us
Shows the current version number of the Insight 2 program and contains a brief description about the
purpose of Insight 2.

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3.3 Icon Bar
3.3.1 Open Configuration
This allows the user to open a saved Configuration file (.icf) from a PC directory in the Offline
section of the Side panel.
3.3.2 Save As
This function enables configuration files from the Offline or Online sections of the side menu to
be saved in a PC directory.
3.3.3 Save
When a configuration is open in the Offline Section, this function enables the user to save any
modifications to the settings.
3.3.4 Print
This will print the current information in the presentation window as it is shown on the screen
(only available when actuator information is displayed within the window).
3.3.5. Send Configuration
This function will send all visible configuration changes to the connected actuator. Send
Configuration will only be possible when connected to a Bluetooth device.
3.3.6 Read Configuration
This function will read a device’s current configuration. Read Configuration will only be possible
when connected toa Bluetooth device.
3.3.7 Discard
Removes any unsaved configuration changes (highlighted yellow) displayed within the
presentation window.

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3.4 Side Panel
3.4.1 Offline
Actuators
All offline actuator configurations opened in Insight 2 are stored for the session under their respective
actuator type (see Fig 1). Configurations can be edited and viewed (with the correct privilege level) from
the expanded menu (See fig 2).
Fig 1
Fig 2
Firmware
This function is reserved for Rotork Service Engineer use only.
3.4.2 Bluetooth
Actuators
All actuators that have been found by after a Bluetooth search(see 1.0 and 4.0) will be visible here. The
expanded menu can only be accessed once a connection to the device has been established.

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Bluetooth Setting Tool
All visible Bluetooth Setting Tools currently in slave mode and available for connection (See Bluetooth
Setting Tool Manual for details) will be visible in this section. The expanded menu can only be accessed
once a connection to the Bluetooth Setting Tool has been established.
3.5 Range Panel
The Range Panel will indicate which actuator range the current configuration or data log belongs to. If
the device is currently connected through Insight 2 the serial number and valve tag will also be
displayed.