The Rotork IQ Range: A New Generation of Intelligent, Non-Intrusive 3-Phase Electric Valve Actuators
The Rotork IQ Range: A New Generation of Intelligent, Non-Intrusive 3-Phase Electric Valve Actuators
The Rotork IQ Range: A New Generation of Intelligent, Non-Intrusive 3-Phase Electric Valve Actuators
Features of the IQ 3
In the 40 years since the company was founded, Rotork
Actuation has become a byword for excellence in the field Reliability 4
of valve, sluice gate and damper actuation products for Intelligent actuation 5
the oil, gas, power, water and waste treatment industries Protection 6
- worldwide.
Applications 7
We owe our success to an uncompromising focus on Intelligent communication 8
quality at every stage - and at every level - of Rotork’s
Communication systems 10
operations.
Construction 12
From initial site survey, specification and design, through
Second stage gearboxes 14
to materials, manufacturing and testing processes,
Actuator specification 15
installation, commissioning and after-sales service we
accept nothing but the best. Performance summary 16
3
IQ - simply unmatched for reliability
Position measurement
Reliable process control depends on
accurate positioning of the valve at
end of travel and for fluid control, mid
travel. The patented IQ non-contacting
position measuring system is the most
simple yet devised for actuator
control. With only one moving part,
the resolver converts output centre
column rotation into an electronic
signal which is then compared to
position limits stored within a safe,
non volatile memory
Reduced components
Streamlining both mechanical and
electrical systems has increased
reliability. Improvements to the IQ
base, handwheel mechanism and
Protection - the key facilities, air exchanges are eliminated
control chassis have all increased
Vast experience in the application of - all internal components are
reliability of the actuator. The latest
electric actuators has enabled Rotork completely protected for life. Non-
“system on a chip” technology has
to lead the world in actuator ingress intrusive control selectors mean there
been applied to the IQ control
protection. Situated in environments are no moving shafts penetrating the
module. Component numbers have
ranging from desert to tundra, control enclosure.
been significantly reduced which in
offshore to underground, where turn reduces interconnection, wiring
flooding, humidity, extremes of heat Reliability through simplicity
and printed circuit board complexity.
and cold, ultra violet and corrosive The IQ combines simplicity of design Enhanced features have been
atmospheres are normal, actuators while extending specification and incorporated such as data logging,
have to perform unfailingly. Rotork performance. extra control and indication
understand that the most important functionality and better protection
factor in the reliability of an actuator is Torque measurement systems leading to increased reliability
protection from the environment - in An actuators ability to reliably and and specification.
simple terms, the enclosure. accurately determine the force applied
in operating a valve is fundamental Safety integrity
Double sealed for double in providing valve and actuator
From the outset the IQ was developed
protection protection. IQ utilises a patented
with a view to increasing the safety
The IQ enclosure is rated IP68 - 3 output torque measurement system
integrity status of valve actuation.
metres for 48hours, NEMA 4/4X/6. developed from familiar process
Once again through design and
It is completely watertight and dust- measurement techniques such as
innovation Rotork can provide the
tight and does not “breath”. The pressure transducers. Tried and tested
solutions, enabling process engineers
Rotork Double Seal system ensures in industry, this technology has been
to select actuators with defined safety
protection of internal components adapted for valve actuation. Under
integrity level evaluation. With
since they are separated from the load, the motor wormshaft thrust
international standards such as IEC
cable gland and terminal compartment reaction is converted into an electrical
61508, ISA-S84.01 and DIN 19 250
by a watertight terminal block. signal directly proportional to output
becoming a requirement for assessing
Protection is maintained during site torque using a piezo resistive sensor
safety integrity of process systems,
hook-up when terminal covers are embedded within torque transducer.
Rotork will be pleased to discuss your
removed and is independent of cable Accurate, repeatable torque
requirements.
gland sealing. measurement is gained independent
of variations in frequency, voltage and
Non-intrusive - sealed for life temperature.
IQ covers need not be removed for
site commissioning. All settings and
adjustments are made using the
supplied infra-red Setting Tool.
After assembly in the controlled Global Warranty &
4 environment of our manufacturing Customer Lifetime Care
IQ - big on intelligence
Thermostatic protection
Two thermostats embedded in the
motor windings directly sense motor
temperature, tripping the actuator
control circuit in the event of motor
windings overheating.
6
Customised features
7
Intelligent communication - lifetime support
9
Communication systems
that work with you
10
Pakscan IIE Master Station
Available in single or hot standby
configurations the Pakscan IIE master
station can control 240 field devices
over a loop distance of up to 20km -
without the need for signal repeaters.
The Pakscan IIE is mounted in a
133mm high 19” rack and each
master station comes complete with
dual host communication ports (RS232
and RS485), a user interface LCD
screen and operator keypad. The rack
can house a single unit, two single
units operating independently or a Hot
Standby system. The Hot Standby
version of the IIE features two identical
modules and transfer between the
main and standby is transparent
and automatic in the event of a
component failure.
For further details see publication
S110E.
6 1
5 4
12
1 Hand operation 6 Motor and drive
Direct drive handwheel (or Motor shaft and worm shaft separate
independently geared handwheel on to facilitate actuator speed change.
larger sizes) to provide reliable Low inertia high torque motor. The
emergency manual operation in the motor produces peak torque rapidly
event of a power supply failure. after starting but with very little
With low speed padlockable* overrun when de-energized. The
hand/auto clutch for safe operation winding thermostat provides accurate
even when the motor is running. temperature sensing independent of
ambient temperature conditions to
Note: power operation always has optimize the motor’s thermal capacity.
2 preference unless hand/auto lever is The motor drive includes a lost
purposely locked into ‘hand drive’. motion ‘hammerblow’ to assist in
Lost motion ‘hammerblow’ effect is unseating tightly shut valves.
provided with both direct and
independently geared handwheels. Single worm and wheel drive running
in an oil bath for maximum life with
2 Infra red settings ambient temperature tolerance.
All actuator settings and diagnostics
are made through the sealed 7 Thrust base
indication window. It is not necessary Thrust base for type ‘A’ couplings
to remove electrical covers exposing lubricated for life and detachable, up
the integral controls on site. to size IQ35, to allow actuator
removal without disturbing the valve
3 Local controls position. On sizes IQ40 and above the
Local controls and padlockable* thrust base is an integral part of the
Local/Stop/Remote selector switch gearcase assembly.
operate internal reed switches,
avoiding penetrating shafts which Easily removable drive bushing for
3 would have to be sealed to prevent machining to suit valve stem for
moisture ingress. convenient valve adaptation.
4 Position control
Hall effect magnetic pulse system
accurately measures and controls the
stroke of the actuator without using
gears and switches.
5 Terminal compartment
Separately sealed terminal
compartment ensures the integrity of
the electrical equipment even when
the terminal cover is removed during
site wiring. *Suitable for 6mm / 1/4 inch padlock
13
Gearboxes
3 Introduction p20
4 Mechanical p20
4.1 Enclosure p20
4.2 Valve/actuator interface p21
4.3 Handwheel p21
4.4 Lubricant p21
4.5 Finish p21
5 Electrical p22
5.1 Power supplies p22
5.2 Control p22
5.3 Indication, monitoring and
data logging p23
5.4 Fieldbus system control p24
5.5 Protection p24
5.6 Actuator set-up p25
15
Performance summary
1 Performance data
Actuator output speeds
rpm at 50 Hz 18 24 36 48 72 96 144 192
rpm at 60 Hz 21 29 43 57 86 115 173 230
IQ10 34 34 34 34 34 34
25 25 25 25 25 25
IQ12 81 81 81 68 48 41
60 60 60 50 35 30
IQ95 3000
2200
* Due to the effects of inertia and drive nut wear, speeds not recommended for direct mounted gate valve applications.
Mechanical data
Actuator size s IQ10 IQ20 IQ35 IQ40 IQ70 IQ90 IQ91 IQ95
IQ12 IQ25
IQ18
Flange size ISO 5210 F10 F14 F16 F25 F25 F30* F25 F30
MSS SP - 102 FA10 FA14 FA16 FA25 FA25 FA30* FA25 FA30
Non-rising mm 38 51 57 73 73 N/A 73
ins 1 /21
2 2 /41
2 /8
7
2 /8
7
N/A 27/8
Handwheel ratio Standard Direct Direct Direct Direct 15:1 15:1 15:1 15:1
Optional 12:1 13.5:1 22.5:1 15:1 or 30:1 45:1 30:1 45:1
30:1
N o n - T h r u s t
Position 2
Type A Type Z3
for sizes IQ40, 70 for sizes IQ40, 70, 90
and 90 and 95 increased
stem acceptance
and reach
3 Introduction 4 Mechanical
4.1 Enclosure and ambient
IQ actuators are self contained units for local and remote temperatures
electrical operation of valves. Comprising an electric motor, All IQ actuator hazardous and non-
reduction gearing, reversing starter with local controls, turns hazardous area enclosures are built to
a watertight standard. Through the
and torque limitation with electronic logic controls and use of non-intrusive commissioning
monitoring facilities, all housed in a double-sealed and site adjustment using the
supplied infra-red IQ Setting Tool, the
watertight enclosure to IP68 3 metres-48 hours, NEMA 4, hermetic, factory-sealed enclosure
4X and 6. protects internal components for life
as covers never need removing. The
All torque and turns settings and configuration of the terminal compartment is sealed from
other areas by the Rotork double
indication contacts are effected using the non-intrusive, seal, maintaining watertight integrity
even during site connection.
hand held infra-red, IQ Setting Tool, which is included with
each order. Actuators are available with the
following enclosure types for which
The following specification covers standard features and the ambient working temperature
ranges are stated. Where option
available optional features. Options selected must be temperatures are indicated, changes
specified with enquiry. to some actuator components are
required and therefore the
temperature requirement must be
specified. Hazardous area approvals
for other country standards are
available, please apply to Rotork.
20
CENELEC EExde IIB: 4.3 Handwheel Lube WIG Medium-NLGI-123.
CENELEC Norm EN50014 and
Handwheels are provided to allow Extreme temperature service:
EN50019 for EExde IIBT4.
manual operation of the valve during Where actuator service requires
Temperature -20˚C to +70˚C
electrical power interruption. operation outside of the standard
(-4˚F to +158˚F).
IQ10 - IQ40 Direct acting top -30˚C to +70˚C alternative lubricants
*Option -30˚C to +70˚C
mounted handwheel. Option: side are available, please apply to Rotork.
(-22˚F to +158˚F).
*Option -40˚C to +70˚C mounted geared handwheels.
4.5 Finish
(-40˚F to +158˚F). IQ70 - IQ95 Side mounted geared
handwheel. Option: alternative gear Actuators up to size IQ30 are finished
CENELEC EExde IIC:
ratios. in polyester powder coating, colour
CENELEC Norm EN50014 and
During electric operation of the silver grey. Actuators size IQ40 and
EN50019 for EExde IICT4.
actuator the handwheel is above are finished in air-dried
Temperature -20˚C to +70˚C
mechanically disengaged from the urethane reinforced synthetic alkyd
(-4˚F to +158˚F).
drive. To engage handwheel resin colour, silver grey. For full
FM: Factory Mutual - Explosionproof operation, the hand/auto selection specification of paint finish see
Class 1, Div 1, Groups C, D, E, F, G lever is depressed and released after publication E151E.
hazardous areas to NEC Article 500. which handwheel operation remains Finish options
Temperature -30˚C to +60˚C selected. When electrical operation
(-22˚F to +140˚F). Colour: Other colours may be
takes place, the actuator will
*Option -40˚C to +60˚C specified, please apply to Rotork
automatically return to motor drive
(-40˚F to +140˚F). without lever or handwheel kick- Offshore: 2 pack epoxy coatings are
* Alternative for Group B hazardous back. The hand /auto selection lever available for extreme environmental
area. Temperatures as for Groups C & incorporates a facility for locking in conditions, please apply to Rotork.
D. the hand or auto positions using a
CSA WT: Canadian Standard 6mm diameter hasp padlock (not
Association - Watertight supplied by Rotork), preventing
Wiring and components complying engagement of motor drive (locked in
with CSA Enclosure 4 and 4X. hand) or engagement of handwheel
Temperature -30˚C to +70˚C drive (locked in auto). Emergency
(-22˚F to +158˚F). disengagement of motor drive can be
*Option -40˚C to +70˚C selected by depressing and holding
(-40˚F to +158˚F). the lever during electric operation.
22
Remote control can be configured
so that the open signal and open
interlock (or closed signal and closed
interlock) can be combined to form a
remote open (or closed) signal that
can detect single faults. When
configured, interlocks will not be
active during local control.
Monitor relay Extra indication contacts Modbus RTU. System variables such
An independent relay with a volt-free The extra indication contacts module as unit address and data baud rate
changeover contact for monitoring provides an additional four change- are programmable over the infra-red
actuator electrical availability. over contacts, S5, S6, S7 and S8. data link. For more information
Contact rating 5mA to 5A, 120V AC, Each contact is latching, volt free and please refer to publication E121E.
30V DC. The relay can be configured rated at 5mA to 5A, 120V AC, 30V
to de-energise under any one, or DC. The extra indication contact Profibus
combination, of the following functions are independently A Profibus DP interface module is
conditions: configurable in the same way as the available to allow the actuator to be
Loss of one or more of the power standard contacts using the supplied integrated into a Profibus network.
supply phases. IQ Setting Tool. The extra indication Full compatibility with EN 50170 is
contact functions available are shown provided and the Profibus network
Loss of control circuit supply. allows full actuator control and
below:
Local control selected. feedback of data to the host. For
● Valve position more information please refer to
Local stop selected.
Fully open, fully closed or publication S113E.
Motor thermostat tripped. intermediate positions (0-99% open)
● Status Foundation Fieldbus
Data logger Valve opening, closing, moving An IEC 1158-2 compliant Foundation
(continuous or pulsing signal), local interface module allows the actuator
The on board data logger allows
stop selected, local selected, to be connected to a Foundation
infra-red, IrDA( (Infra-Red Data
remote selected, open or close network. The device has link
Association) standard, download of
interlock active, ESD active scheduler capability as well as digital
historical actuator/valve performance
data to PC or via an IrDA compatible ● Valve alarms and analogue function block
mobile telephone to a local base or Motor tripped on torque in mid capability. Foundation Fieldbus
the Rotork Lifetime Care Facility. For travel, motor tripped on torque actuators can communicate directly
hazardous areas the intrinsically safe going open, going closed, pre-set between themselves without the
Rotork Communicator tool is torque exceeded, valve jammed, need of a host supervisory system.
available. Rotork IQ-Insight PC actuator being operated by
software allows data logger handwheel 5.5 Protection
information of operational events and ● Actuator alarms The IQ control system incorporates
statistics all time and date stamped Lost phase, customer 24V DC the following valve, actuator and
plus valve torque/position profiles, (120V AC) supply lost, battery low, control protection:
both last operation and historical internal failure detected,
trends, all to be analyzed. thermostat tripped Obstructed valve (torque trip)
protection.
For more information please refer to
Lost phase protection plus automatic
publication E111E. 5.4 Fieldbus system control
Phase rotation correction by
Pakscan Syncrophase.
Indication options An internally mounted Pakscan field Jammed valve protection.
Remote analogue position indication: unit for remote control and status Motor thermostat protection.
The Current Position Transmitter (CPT) indication over a fault tolerant two-
Internal fault protection - ASTD
provides a contact-less internally fed wire serial link. Loop distances of up
(automatic self test & diagnosis).
4-20mA analogue signal proportional to 20 km without repeaters and host
communications using Modbus Actuator control circuit supply
to valve position, selectable for
protocol. System variables protection.
minimum signal corresponding to
fully closed or fully open position programmable over the infra-red data Instantaneous reversal protection.
with automatic zero and span setting. link. For more information please Control signal fault protection
An externally powered version of the refer to publication SOOOE. (configurable).
CPT is also available.
Modbus
Single or dual Modbus modules may
Remote analogue torque indication be included in the IQ actuator to
The Current Torque Transmitter (CTT) provide fieldbus communications of
provides an internally fed 4-20mA all the actuator control functions and
analogue signal proportional to feedback data. The fieldbus uses an
actuator output torque 0 -100% RS485 data highway and the
24 rated. communications protocol used is
Standard specification
5.6 Actuator set-up 6.2 Power module 6.4 Torque and position control
All actuator settings may be The power module incorporates a Position and torque are adjustable as
configured using the supplied IQ mechanically and electronically follows:
Setting Tool over the infra-red interlocked reversing contactor Position setting range:
interface without the removal of any starter*. The control supply 2.5 to 100,000 turns, with a
covers. Setup can take place with transformer, fed from two phases of maximum angular resolution to 7.5˚
main power on or power off, during the incoming power supply, provides of actuator output center column.
which power is provided by the internal control circuit supplies and an Torque setting:
actuator battery. Each IQ actuator isolated, nominal 24V DC customer 40% to 100% rated torque.
includes a comprehensive installation supply rated at 5W for actuator fed
and maintenance manual providing remote control circuits. The Rotork Output torque is obtained via the
information on site commissioning Syncrophase circuit incorporates direct measurement of wormshaft
and adjustment. An actuator wiring phase rotation correction and lost thrust reaction under load and is
diagram is also included. As an phase protection. independent of voltage, frequency
option Rotork IQ-Insight software for and temperature fluctuations. Torque
PC allows configuration of actuator Option off during unseating or during
settings. For Bus control system Control circuit supply: starting/reversing in mid travel against
options, tools are available allowing Nominal 110V AC supply, rated at high inertia loads can be inhibited.
configuration testing over the serial 20VA. The jammed valve protection circuit
interface as well as by Setting Tool or de-energizes the motor if no
IQ-Insight software for PC. *Single Phase and IQM modulating units utilise a
solid state motor starter. movement occurs after a few seconds
from receipt of a signal to open or
6 Actuator components close.
6.3 Control module
6.1 Motor Incorporating a single integrated When power to the actuator is
circuit, hard-wired logic control for isolated, all settings are retained in an
Three phase, Class F, insulated
the actuator together with infra-red EEPROM. In the event of manual
squirrel cage motor of special high
(IrDA) interface for external non- operation of the valve during isolation
torque low inertia design. 15 minute
intrusive settings and interrogation by or loss of the power supply a battery
rated with cyclic duration factor of
IQ-Insight configuration and data provides power to the internal
25% at 33% of actuator output
logger viewer PC tool. On board data position-monitoring transmitter to
rated torque giving a temperature rise
logger records operational data, valve update the valve position data in the
not exceeding that permitted for
torque/position profiles and statistical EEPROM. The battery also drives the
Class B insulation at standard nominal
information, all time and date LCD display, without backlighting,
voltage. Actuator rated up to 60
stamped. and the four latching contacts S1-S4
starts per hour at a rate not
exceeding 600 starts per hour.
Burnout protection by embedded
thermostat, with facility for bypassing
under emergency shutdown control.
For details of motor performance
and use of uninterruptable power
supplies please refer to publication
E130E.
Motor options
Modulating:
For applications requiring more
than 60 starts/hour please refer to
IQM publication E410E.
IQ Single Phase:
Capacitor start/run squirrel cage
induction motor.
IQDC:
Permanent magnet, low inertia
design. 25
Standard specification
while the power to the actuator is average of 1/3 rated seating torque driving via extension shafting
not available. Based on a typical during stroke. For modulating duty incorporating vibration absorbing
application the minimum battery life during stroke please refer to IQM couplings may provide a satisfactory
is 5 years. Infra-red setting is also Range, publication E410E. solution.
available with main power off.
Life tests
Standard IQ life test is based on 7.5 Safety integrity
6.5 Conduit entries, terminals
and wiring 10,000 open/close/open cycles Electromagnetic compatibility
(500,000 output turns) with directive (EMC)
Three threaded conduit entries are maximum seating torque at stroke Actuators conform to the
provided tapped: 1 x 11/2 and 2 x 1” end and an average of 1/3 max. requirements of the European
ASA NPT. seating torque during stroke. Economic Community EMC Directive
Unless otherwise specified, actuator Actuators are stalled against a solid 89/336/EEC as amended by
will be dispatched with adapters: 1 x object 25 times to prove durability. 92/31/EEC. Contact Rotork for a copy
M40 and 2 x M25 metric to BS3643, of our Declaration of Conformity.
“Ex” certified or as an alternative, 7.2 Frequency of operation Low voltage directive (LV)
1 x PG29 and 2 x PG16.
IQ actuators are suitable for valve Actuators conform to the
It is the responsibility of the installer requirements of the European
duty up to 60 starts per hour.
to ensure the appropriate cable/ Economic Community Low Voltage
conduit adapters and blanking plugs IQM Modulating service: up to 1200 Directive 73/23/EEC amended by
are fitted, in order to maintain starts per hour. 93/68/EEC by the application of EN
hazardous area certification and 60204-1 1993. Contact Rotork for a
IQ Single Phase: up to 60 starts per
ingress protection levels. Certified copy of our Declaration of
hour.
adapters and blanking plugs are Conformity.
available as optional extras. IQDC: up to 60 starts per hour.
Machinery directive
Conduit entry options Actuators follow the provision of the
7.3 Operating temperature Machinery Directive (89/392/EEC) as
If specified with order, a fourth amended by 91/368/EEC and
conduit entry can be provided tapped Actuators are suitable for operation
93/44/EEC.
1” ASA NPT with adapter to M25 or for ambient temperatures in the
as an alternative PG16. range -30˚C to +70˚C. Please note - The IQ must not be put into service
Hazardous area certification defines until the equipment into which it is
Separately sealed compartment
the temperature operating range to being incorporated has been declared
containing segregated metric thread
maintain certification. Refer to 4.1. to be in conformity with the
M5 power and M4 control terminals.
provisions of the European
Terminal screws and washers are For temperatures outside this range
Community Machinery Directive
supplied with the actuator. The please apply to Rotork.
(89/392/EEC) 91/368/EEC and
terminal box cover carries a terminal
93/44/EEC. Contact Rotork for a copy
identification code card. An
7.4 Vibration of our Declaration of Incorporation.
Installation and Maintenance manual
(E170E2) and wiring diagram are Standard IQ Range actuators are
suitable for applications where 7.6 Noise
enclosed with each actuator.
vibration severity does not exceed the Independent tests have shown that at
Jig built harnesses of individually
following: 1m generated noise did not exceed
numbered stranded conductors,
61db(A).
tropical grade PVC insulated, connect Plant induced: Where the cumulative
internal components to the sealed level of all vibration within the
terminal block. All internal control frequency range of 10 to 1000Hz is
connections to the printed circuit less than 1g rms.
boards are via plugs and sockets.
Shock: 5g peak acceleration.
Seismic: Frequency range 1 to 50Hz,
7 Design specification 2g acceleration if it is to operate
7.1 Design life during and after the event. 5g if it is
only required to maintain structural
For isolating duty, torque ratings of
integrity.
actuators are based on a minimum
maintenance free life of 10,000 Where excessive plant induced
open/close/open cycles with rated vibration is anticipated, mounting the
26
seating torque at stroke end and an actuator remote from the valve and
27
UK head office USA head office
Rotork Controls Limited Rotork Controls Inc
telephone Bath 01225 733200 telephone Rochester (716) 328 1550
telefax 01225 333467 telefax (716) 328 5848
Rotork Controls Inc, Rochester, USA
email mail@rotork.co.uk email info@rotork.com Rotork Controls Ltd, Bath, UK