rotork IQ Series Quick guide

IQ Range
Thrust Compensator Option
Instructions for Safe Use, Installation,
and Maintenance
This manual contains important safety
information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.
PUB002-132-00
Date of issue 04/18

2 IQ3 manual – Section: Introduction
Table of Contents
1. Introduction_____________________________3
2. Preparing the Drive Bush_________________4
2.1 Thrust Compensators All Sizes ...............4
2.2 Disassembly of bearing assembly:
IQ10 – IQ35 .............................5
2.3 Reassembly:
IQ10 – IQ35 .............................5
2.4 Disassembly of bearing assembly:
IQ40 – IQ95 ............................6
2.5 Reassembly:
IQ40 – IQ95 ............................6
3. Mounting the Actuator __________________7
4. Fitting the Thrust Compensator __________8
4.1 Fitting the Actuator and Thrust Compensator as a
combined Unit: IQ10 – IQ35.................8
4.2 Fitting Thrust Compensator to Valve Actuator:
IQ40 – IQ95 .............................8
5. Weights _________________________________9
WARNING: This document must be read in
conjunction with the IQ Instructions for Safe
Use, Installation, Basic Setup and Maintenance
Manual (PUB002-039).
1. Introduction
The thrust compensator assembly is designed to
absorb excess thrust being delivered to the valve
structure as the result of stem expansion due to
temperature variation or high speed operation. In
addition, it is designed to maintain sufficient thrust
to retain valve closed position sealing on cooling and
contraction.
CAUTION: Each compensator is individually
configured for the specific, individual valve details
provided. It is therefore mandatory that each
actuator-compensator assembly remains paired
and is fitted only to the intended valve as specified
with the enquiry/order.
Fig. 1.1 Rotork Thrust Compensator
2. Preparing the Drive Bush
2.1 Thrust Compensators All Sizes
Place the thrust compensator with the base plate (2)
facing upwards. Remove the 4 cap-headed screws (1)
holding the base plate (2) in place and remove the base
plate (2) to gain access to the drive bush assembly (3).
Remove the drive bush assembly (3) complete with
its bearing assembly from the thrust compensator
housing. Before machining the drive bush, the bearings
and O-rings must be removed.
WARNING: Do not remove or tamper with
recessed cap-headed screws(*). Adjustment or
removal may result in application failure and/or
injury.
CAUTION: Failure to remove the bearing and
O-rings from the drive bush prior to machining
may result in damage to the bearing or O-ring
components.
WARNING: Component assembly and mass may
present a finger trap hazard.

IQ3 manual – Section: Preparing the Drive Bush 3
Fig. 2.1.1
2.2 Disassembly of bearing
assembly: IQ10 – IQ35
Locate and loosen the locking socket
set screw in the bearing stop ring (7).
Unscrew the bearing stop ring from the
drive bush (5). Slide the bearing (6) off
the drive bush (5). Keep the drive bush
(5) and stop ring (7) in a safe clean
place.
Ensure the male thread and the O-ring
on the drive bush is not damaged
during machining. Machine the drive
bush (5) to suit the valve stem, allowing
for generous clearance on the screw
thread for rising stem valves.
Fig. 2.2.1
2.3 Reassembly:
IQ10 – IQ35
WARNING: Failure to fully clean
and grease the drive bush and
O-rings before reassembly could
result in damage.
Remove all swarf from the drive bush
(5) ensuring the O-rings on the drive
bush (5) and bearing stop ring (7) are
undamaged, clean and greased.
Slide the bearing assembly (6) onto the
drive bush (5) and ensure it is fitted
down to the drive bush shoulder.
Screw the bearing stop ring (7) with
the locking socket set screw uppermost
on to the drive bush (5) until it is hand
tight. Tighten the locking socket set
screw to lock rotation of the bearing
stop ring (7).
The locking socket set screw must
be sufficiently tight to prevent the
assembly working loose during
operation. Refer to the following table
for correct tightening information.
continued over...
Thrust
Compensator
Housing
Recessed cap
headed screws(*)
1. Cap screws
3. Drive Bush Assembly
2. Base plate
7. Bearing
Stop Ring
6. Sealed Thrust
Bearing
5. Drive Bush
4. Retaining
Plate

4 IQ3 manual – Section: Preparing the Drive Bush
Locking Socket
Screw Size
Torque
Nm lbf.ft
M4 2.2 1.62
M6 7.8 5.75
Grease and refit the drive bush
assembly (3) into the thrust
compensator housing ensuring that the
slots on the drive bush (3) are located
into the drive dogs of the hollow input
shaft inside the thrust compensator
housing.
Refit the base plate (2) and secure with
cap-headed screws (1). Tighten M6
cap-headed base retaining screws (1) to
11 Nm / 8 lbf.ft.
2.4 Disassembly of bearing
assembly: IQ40 – IQ95
Locate and remove the snap ring (12)
using a suitable tool. Remove the split
collar (11). Slide the thrust bearng (10)
and O-rings (9) off the drive bush (8).
Keep the bearing, O-rings and drive
bush locating components in a safe
clean place. The split collar (11) must be
kept as a matched pair.
Machine the drive bush (8) to suit
the valve stem, allowing a generous
clearance on the screw thread.
Fig. 2.4.1
2.5 Reassembly:
IQ40 – IQ95
WARNING: Failure to fully clean
and grease the drive bush and
O-rings before reassembly could
result in damage.
Remove all swarf from the drive bush
(8) and refit O-rings, ensuring all
O-rings are undamaged, clean and
greased (for typical greases refer to
PUB002-039 Section 11, weights and
measures).
Slide the thrust bearing (10) onto the
drive bush and ensure it is fitted down
to the drive bush shoulder. Grease and
refit matched pair split collar (11) and
snap ring (12).
Grease and refit the drive bush
assembly (3) into the thrust
compensator housing ensuring that the
slots on the drive bush (3) are located
into the drive dogs of the hollow input
shaft inside the thrust compensator
housing.
Refit the base plate (2) and secure with
cap-headed screws (1). Tighten M6
cap-headed base retaining screws (1) to
11 Nm / 8 lbf.ft.
12. Snap Ring
11. Split Collar
10.Thrust
Bearing
9. O-rings
8. Drive Bush

IQ3 manual – Section: Mounting the Actuator 5
WARNING: The thrust
compensator assembly and
actuator should be fully supported
until full valve shaft engagement
is achieved and the assembly is
secured onto the valve flange.
A suitable mounting flange conforming
to ISO 5210 or USA Standard MSS
SP101 must be fitted to the valve.
Actuator to valve fixing must conform
to Material Specification ISO Class 8.8,
yield strength 628 N/mm2.
WARNING: Do not lift the
actuator and the valve combination
via the actuator. Always lift the
valve/actuator assembly via the
valve. Each assembly must be
assessed on an individual basis for
lifting.
Fig. 3.1
Fig. 3.2
3. Mounting the Actuator
WARNING: Refer to the Weights
and Measures section in this manual
to ensure correct lifting practices are
followed.
Ensure that the valve is secure before
fitting the actuator as the combination
may be top heavy and therefore
unstable.
If it is necessary to lift the actuator
using mechanical lifting equipment,
certified slings should be attached
as indicated in Fig 3.1. The thrust
compensator assembly may also require
lifting equipment, certified slings
should be attached to a minimum of 4
of the fixing holes with equal spacing
to ensure a stable, balanced lift.
At all times, trained and experienced
personnel should ensure safe lifting
particularly when mounting actuators.

6 IQ3 manual – Section: Fitting the Thrust Compensator
4. Fitting the Thrust
Compensator
4.1 Fitting the Actuator and Thrust
Compensator as a combined
Unit: IQ10 – IQ35
Fit the machined drive bush into the
thrust compensator as previously
described, lower the actuator onto
the threaded valve stem, engage hand
operation and wind the hand wheel to
engage the drive bush onto the stem.
Continue winding until the actuator
is fully lowered onto the valve flange.
Wind two further turns, fit securing
bolts and tighten fully to the required
torque indicated in PUB002-039 Fig.
6.1.3.
4.2 Fitting Thrust Compensator to
Valve Actuator: IQ40 – IQ95
Fit the loose base plate (2) and drive
bush assembly (3) on to the valve
stem. Lower the thrust compensator
housing onto the valve stem and drive
bush assembly (3). Rotate to align the
drive dogs of the hollow input shaft to
the slots on the machined drive bush
assembly (3). Lower until the thrust
compensator main body is positioned
onto the thrust compensator base
plate (2). Manually rotate the thrust
compensator assembly to align holes
in base plate (2) thrust compensator
housing and valve flange. Fit the
securing bolts and tighten to ensure
the thrust compensator is secure on
the valve flange.
WARNING: Remove lifting
equipment before commencing the
next step.
Fit the mounting studs to the actuator
until hand tight. Lower the actuator
onto the thrust compensator and
rotate until the mounting studs
are aligned with the holes on the
thrust compensator. Engage manual
operation, turn hand wheel until
the drive dogs on the actuator align
with the drive bush of the thrust
compensator. Lower the actuator until
the flange is flush with the thrust
compensator.
Using nuts provided, fix actuator to
thrust compensator and tighten to
required torque, 101 Nm / 74 lbf.ft.
Open the valve by 2 turns and firmly
tighten thrust compensator to the valve
flange. Fixings should be tightened as
per PUB002-039 Fig.6.1.3.
For all other Actuator mounting
instructions please refer to
PUB002-039.
Fig. 4.2.1
Thrust
Compensator
Housing
Recessed cap
headed screws(*)
1. Cap screws
3. Drive Bush Assembly
2. Base plate

IQ3 manual – Section: Weights 7
5. Weights
Standard Actuator only:
Actuator Size Weight
kg (lbs)
IQ10 31 (68)
IQ12 31 (68)
IQ18 31 (68)
IQ19 54 (119)
IQ20 54 (119)
IQ25 54 (119)
IQ35 75 (165)
IQ40 145 (320)
IQ70 145 (320)
IQ90 160 (353)
IQ91 150 (331)
IQ95 160 (353)
Thrust Compensator only:
Actuator Size Weight
kg (lbs)
IQ10-18 10 (22)
IQ19-25 16 (35)
IQ35 26 (57)
IQ40-95 200 (440)
Actuator and Thrust Compensator
combination:
Actuator Size Weight
kg (lbs)
IQ10 41 (90)
IQ12 41 (90)
IQ18 41 (90)
IQ19 70 (154)
IQ20 70 (154)
IQ25 70 (154)
IQ35 101 (223)
IQ40 345 (760)
IQ70 345 (760)
IQ90 360 (793)
IQ91 350 (771)
IQ95 360 (793)

PUB002-132-00
Date of issue 04/18
Original instructions: English language version only. 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 recognises all registered trademarks. The Bluetooth®word mark and logos are registered trademarks
owned by Bluetooth SIG, Inc. and any use of such marks by Rotork is under license. Published and produced in the UK by Rotork Controls Limited.
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