Workshop and Spare Parts Manual

IQ, IQM and IQML Mk 2 Range Actuators

Module 1C Resolver Drive Mechanism
All mechanical sizes

Module 1C consists of the following

components:-

Bevel Gear.
Bevel Pinion.
Gear Shaft.
Pic 122 Oil Seal.
Spring Clips.
Resolver Printed Circuit Board and Fixing
Screws.
Resolver Magnet.
Magnet Spring.

Module 1C Components

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Module 1C Resolver Drive Mechanism
All mechanical sizes

Removing Actuator Drain Oil

from Valve To drain oil remove the two
plugs situated in the gearcase,
Before dismantling the retain these plugs.
actuator, isolate and Pic 13
disconnect incoming Pic 26
electrical supply to actuator.
Remove and retain any
adaptors or reducers from the
threaded cable entries.
Actuator sizes 12 through 35
can be removed from their
base leaving this to maintain
the valve position. In this case
the base must be protected
from the environment by 1 4
placing a plastic bag over it. Remove Top
Handwheel
Alternatively, the actuator and
base can be removed as one To remove top handwheel,
piece. locate and remove the large cap
Pic 27 Pic 14
head screw located in gearcase
Sizes 40,70,90,91,95 can only below handwheel.
be removed together with their
base and drive coupling.

Remove Actuator from

Valve or Gearbox
Only persons competent by
virtue of their training and
experience should be allowed 2 5
to remove the actuator from The nylon retainer can be pulled
the valve or gearbox. As the out using tapered pliers and
actuator may be installed at rotating the handwheel
any angle, correct slinging of clockwise. The handwheel can
this unit must be judged in now be lifted off.
each individual case. Pic 170
Actuator weights. Keep handwheel and nylon
10,12,18=32Kgs/70lb retainer in a safe place for
20,25, =52Kgs/115lb refitting to new gearcase.
35 =75Kgs/165lb
40 =200Kgs/440lb
90,95 =230Kgs/507lb
91 =220Kgs/485lb

Actuator Direct 6
Mounted onto Rising Remove Side Geared
Stem Valves Handwheel
Ensure pressure is removed To remove side handwheel and
from pipeline, move valve its associated worm gearbox,
‘open’ a short distance to Pic 75 remove the securing bolts and Pic 171
eliminate any locked in on size 10 through 40 also
pressure, close the valve fully. remove nylon retainer as per
Take the weight of the actuator last paragraph. Gearbox must
on the sling before removing now be lifted off straight. Retain
the actuator to valve fixings, this module for refitting to new
wind the handwheel in a close gearcase.
direction when actuator will
move up the valve stem, ensure
sling is holding the weight at all
times. 3 7

2
Module 1C Resolver Drive Mechanism
All mechanical sizes

To Remove the Clutch Remove Motor

Spring Sizes 10,12,18,20,25,35
only.
Locate the ‘O’ ring on top of the
Do not remove on sizes
centre column, press down on pic 43
the steel washer beneath the 40,70,90,91,95.
‘O’ ring and roll the ‘O’ ring up Move on to photo No.
off the centre column. 20.
TAKE GREAT CARE WHEN
RELEASING THE SPRING.

8
To make the job safer the Motor Stator
appropriate clutch spring
compression tool can be Before removing motor stator
purchased direct from Rotork cover mark its position relative
or via your local agent. to the top of the gearcase.
Pic 44
Remove and retain the four cap Pic 16
head screws, slide the stator off
the gearcase.

9 12
Remove Clutch Ring Motor Rotor
Using a pair of pliers pull clutch Using an allen key (hex wrench)
ring up and off the centre and a spanner remove and
column. Depression of the retain the bolt and nut securing
Pic 45
hand/auto lever will raise the the rotor shaft, slide the rotor Pic 49
clutch ring and assist in its shaft off and retain in a safe
removal. place for refitting.

10 13
Remove Clutch Yoke DO NOT MISLAY THE COIL
SPRING AT THE OUTBOARD
Noting its position lift yoke out END OF THE ROTOR SHAFT.
from its pivot point, retain this RETAIN FOR REFITTING.
item for refitting. Pic 46
Pic 109

11 14

3
Module 1C Resolver Drive Mechanism
All mechanical sizes

The centre column, wormwheel

Disconnect Torque and bevel gear can now be
Transducer PCB pulled from the top of the
gearcase, rotate actuator back
This PCB is situated in the onto its base.
motor compartment and fitted Pic 50 Pic 53
to the wormshaft thrust plate, it
must be disconnected before
the wormshaft is removed.

Remove and retain the

‘Horseshoe’ shaped flange.
Turn the drive end of the
wormshaft anti-clockwise as it
is pulled out, this will also force
out the wormshaft thrust plate.
15 19
Remove Wormshaft Remove Centre Column
and Integral Base. Sizes
Retain the wormshaft and 40,70,90,91,95 only
bronze bushing, also the thrust
plates, do not separate the two Pic 176
thrust plates. Pic 52 Remove Base Fitting
Screws
Refit the motor stator back in Re-position actuator onto its
position temporarily to avoid terminal end, support with sling
damaging the cables when the or wood blocks. Remove the
actuator is turned over. base to gearcase cap head
screws.

16 20
Remove Lower Centre Remove Centre Column
Column Circlip and Base
Turn actuator onto its terminal It is advisable to use two
compartment. Using the persons and a sling for safe
correct size circlip pliers Pic 48 Pic 177
removal of this module as it
remove the smaller circlip could weigh up to 60kg (size
securing the shaft to the 95). With one person holding the
bearing. base, drive out the centre
column with a hammer and
block of wood, place a sling
around the base casting after it
has moved out a short distance
and take the weight, unit can
now be lowered onto the bench.
17 21
Remove Centre Column A resolver drive shaft, bevel
gear, resolver PCB and magnet
Looking into the top of the are included in this module 1C.
gearcase, ensure that the hand/ To gain access to them the
auto cam is not resting on the Pic 116 electronics cover must be
top face of the wormwheel, if it removed, also on sizes
is then push it into the position 10,12,18,40,70,90,91,95 the
shown. complete electronics module
must come out.

18

4
Module 1C Resolver Drive Mechanism
All mechanical sizes

Move the four chassis legs

Remove Electronics outboard towards the casting,
Cover they cannot be removed at this
stage. Take note of cable
Using a 6mm allen key (hex routing so that it can be refitted
wrench) remove the four cap Pic 19 in exactly the same position on Pic 198
head screws securing the reassembly.
cover, fit two of these screws
into the threaded holes in the
cover to jack it out.

22 26
Care must be taken in Removal of Optional
removing this cover as there is
an electrical cable between it Relay Board (if fitted)
and the main PCB, disconnect
the plug and socket, retain this Take note of plug and socket
Pic 81 positions so that the PCB can Pic 226
cover and ‘O’ ring seal for
refitting. be refitted in the same position.
Retain this PCB in a clean, dry
and secure place for refitting.
On sizes 20,25,35 only.
The resolver drive can be
replaced without removing
electronics module.

23 27
Remove Electronics Removal of Power
Chassis Module with Contactors
Printed circuit boards have Disconnect the following cables:-
static sensitive devices, 3 phase power, marked 1-2-3.
avoid touching the board, Pic 196 3 phase motor, marked U-V-W. Pic 199
always handle by the edges. Also socket SK3

Main PCB
Unclip the main (front) PCB
and its mounting ring from the
four chassis legs.

24 28
Disconnect all cables from the Remove and retain the four
main PCB. Retain this PCB in a power module fixing screws.
clean, dry and secure place Retain this module in a clean,
ready for refitting dry and secure place ready for
refitting.
Pic 197 Pic 200

25 29

5
Module 1C Resolver Drive Mechanism
All mechanical sizes

Fit new pinion gear onto drive

Remove Resolver shaft and secure with spring clip
Magnet provided. Lightly grease shaft
before fitting into gearcase.
Using a small screwdriver
remove the spring clip holding Pic 233
the magnet onto the shaft.
Pic 118
Care must be taken to avoid
damage to any of the PCB
components..

30 34
Remove and Replace Refit Magnet
Resolver PCB Before fitting new magnet
ensure it is clean and free
Remove the two screws
securing the PCB to the Pic 78 from ferrous particles.
Locate the ‘D’ shape hole in the Pic 80
gearcase, replace existing PCB
magnet onto the drive shaft, fit
for new item, secure with two
the coil spring next and secure
screws and spring washers.
with the spring clip. Care must
be taken to avoid damage to the
resolver PCB.

31 35
On sizes 40,70,90,91,95 Refit Electronics Module
ensure that the nylon spacers
are positioned on the fixings The electronics module
screws between the PCB and previously removed from the
the gearcase casting. original gearcase can now be
Pic 215 refitted, first confirm that all
cables from the terminal bung Pic 203
and motor loom have been
pulled through into the
electronics compartment.

32 36
Remove and Replace Power Module with
Looms from Bung,
Resolver Shaft and Contactors 3ph Input to contactor,
Gear 24V to PCB,
Battery Loom,
Ribbon cable
and
Before securing the power Terminals 4 and 5, Resolver loom.
module into position locate the Folomatic and
The resolver shaft and pinion CPT Looms.
gear can now be removed by Pic 204 cables into their correct area as
pulling them through into the shown in adjacent sketch.
gearcase.

3ph to Motor,
Torque Transducer and
Motor Thermostat Cables.

33 37

6
Module 1C Resolver Drive Mechanism
All mechanical sizes

Click the four chassis legs into Ensure that all heavy current
position.. power connections on the
contactors are angled towards
the centre of the chassis and tie
wrapped together.
Pic 203

38 42
Locate power module into Refit Optional Relay
gearcase, yellow voltage PCB (if supplied)
tapping panel should be at
bottom left position. Position relay PCB in front of
Pic 201 the contactors with sockets SK1 Pic 226
and SK4 to top left, reconnect
plugs that are used. Position
the four chassis legs so that the
PCB is secured at its corners.

39 43
Ensuring that no cables are Reconnect Main PCB
trapped tighten down fixing
screws to 11nm. Ensure that all looms are
connected to the main PCB.

Pic 200 Pic 197

40 44
Reconnect motor cables With the LCD (indication
marked u,v,w onto marked display) positioned at the top,
terminals on right hand locate the four PCB clips onto
contactor. Connect 3 phase the four chassis legs, these are
supply cables marked 2,3,1 a push and click fit.
onto marked terminals on left Pic 199 Pic 196
hand contactor. Connect plug to
socket 3 also plugs to SK1 and
SK10 if used.

41 45

7
Module 1C Resolver Drive Mechanism
All mechanical sizes

Final Cable Routing Reconnect Electronics

Check Cover

The following four photographs Ensure that spigotted joint

will assist in the final check of between cover and gearcase is
cable routing and securing Pic 222 clean, lightly greased and that Pic 81
before fitting electronics cover. the ‘O’ ring seal is serviceable.
Reconnect the cable in cover
Top left view. onto the front of the main PCB.

46 50
Top right view. Refit cover locating the window
over the display. Tighten down
screws to 16.5nm (12lb/ft)

Pic 223 Pic 19

47 51
Lower left view Sizes 20,25,35 only

Refit Original
Wormwheel to Centre
Column Pic 119
Pic 224
Before fitting, check wormwheel
for wear on the gear teeth and
drive pins.

48 52
View from above. Fit New Resolver Bevel
Gear
Slide new bevel gear onto
Pic 225 centre column beneath the Pic 120
wormgear with its teeth facing
towards the base.
Ensure that no cables will be
damaged when the electronics
cover is finally fitted.

49 53

8
Module 1C Resolver Drive Mechanism
All mechanical sizes

Sizes 10,12,18 only Refit Original Clutch

Yoke
Remove the spring clip from Sizes 20,25,35 only
around the new centre column
using a small screwdiver. Refit original yoke by placing it
Pic 130 onto its pivot pin. Pic 47

54 58
Sizes 10,12,18 only Refit Clutch Ring and
Spring
Refit original wormwheel by Sizes 10,12,18,20,25,35
sliding it onto the centre
column from the top, drive pins
only
Pic 45
uppermost, refit spring clip. Pic 131
Check that centre column Slide clutch ring down the
components are fitted in the centre column with drive pins
correct order as per down towards the wormwheel.
photograph and from the top,
namely:- spring clip,
wormwheel, steel spacer, steel
thrust washer, bevel gear with
teeth facing towards drive end.

55 59
Sizes 10,12,18,20,25,35 Place the coil spring, steel
spacer with its chamfer
only
uppermost onto the centre
column in that order.
Refit Centre Column
Pic 53 Pic 43
Turn the actuator onto its
terminal compartment. Lightly
grease the lower end of the
centre column before fitting
into the gearcase. Locate it
through the base seal and
bearing and push onto the
mechanical stop, only hand
force should be necessary.
56 60
Using the correct size of circlip Press down on the steel spacer
pliers fit the new circlip onto the to compress the spring. Slide
lower end of the centre column. the ‘O’ ring over the centre
column and down into its
groove.TAKE GREAT CARE
WHEN FITTING THIS SPRING. Pic 44
Pic 48
To make this job safer the
appropriate clutch spring
compression tool can be
purchased direct from Rotork or
via your local agent.

Turn the actuator back onto its

base.

57 61

9
Module 1C Resolver Drive Mechanism
All mechanical sizes

Refit Wormshaft Explosionproof Units

Sizes 10,12,18,20,25,35. only

Remove motor cover (stator) The black plastic cable retainer

that was temporarily refitted to can now be clicked into position
Pic 52 on the flange, ensure that the Pic 108
gearcase.
‘cut out’ aligns with the motor
Before fitting wormshaft check cables.
that the ‘O’ ring seal and lip
seal on the bronze bush are
serviceable and lightly greased.
Slide wormshaft into the
gearcase and rotate it
clockwise so as to engage into
the wormwheel.
62 66
Reconnect the Torque Fit Rotor to Wormshaft
Transducer Slide the rotor shaft onto the
end of the wormshaft, align the
Reconnect the grey colour Pic 51 bolt hole and fit shouldered bolt
multi core cable onto the PCB. Pic 49
and Nyloc nut, tighten to 6.8Nm
(5lb/ft).

63 67
Refit the Torque Fit coil spring onto outboard end
of rotor shaft.
Transducer
Locate the torque transducer
assembly over the drive end of
the wormshaft, position the Pic 107
locating hole in the flange over Pic 109
the dowel pin in the gearcase.

64 68
Locate the ‘Horseshoe’ shaped Fit Motor Stator to
flange over the torque
transducer with its open ends Gearcase (WT only)
around the PCB. This will also
align a ‘cut out’ around the Slide stator over rotor shaft, do
motor cables. Fit the three not damage the windings, feed
Pic 50 the motor cables through into Pic 111
countersunk headed screws
and tighten down to 6.8Nm (5lb/ the electrical compartment.
ft).
ENSURE THAT NO CABLES
ARE TRAPPED BETWEEN
FLANGE AND GEARCASE.

65 69

10
Module 1C Resolver Drive Mechanism
All mechanical sizes

With the actuator positioned on

Fit Motor Stator to its terminal cover end and
Gearcase supported with wood blocks or
(Explosionproof Units sling, slide the centre column
only) into position in the gearcase.
Pic 110 The wormwheel may have to be Pic 177
moved slightly to achieve this.
On these units the motor loom
remains in the motor
compartment. To prevent it
being damaged it must be
positioned correctly in its
plastic retainer as follows:-
Position the stator onto the
rotor shaft, do not damage the
windings, whilst rotating the
stator anti-clockwise feed the 70 73
cables into the plastic retainer. Rotate base to align dowel pins
Ensure that the cables are in flange with corresponding
correctly positioned before holes in gearcase. Refit base
finally bolting stator casting fixing screws, tighten down to
onto the gearcase. Screws to 16.5Nm (12lb/ft). Reposition the
be tightened to 16.5Nm (12lb/ actuator back onto its base.
ft). Pic 176

74
Sizes 40,70,90,91,95 Sizes
only 20,25,35,40,70,90,91,95
Refit Centre Column
Refit yoke by placing it onto its
and Base Assembly
pivot pin.
Pic 173
Replace original bevel gear on
centre column for new item.
On sizes 70,90,91,95 first
remove the retaining spring
clip using a screwdriver as a
lever, refit using new clip
provided.

71 75
Check that a serviceable ‘O’ All mechanical sizes
ring is fitted onto the base to
gearcase joint and cast face is Refit Cltch Ring
lightly greased.
Slide the clutch ring down the
centre column with its smallest Pic 43
Pic 209 diameter towards the
wormwheel, the yoke may have
to be moved slightly so that
clutch ring engages onto the
wormwheel drive pins.

72 76

11
Module 1C Resolver Drive Mechanism
All mechanical sizes

Refit Clutch Spring Refit Top Handwheel

Sizes
Place the coil spring, steel 10,12,18,20,25,35,40
spacer with its chamfer
uppermost onto the centre Before fitting the handwheel
column in that order. Pic 43 Pic 41
ensure that top of gearcase and
handwheel hub are clean and
lightly greased and that the
seals and ‘O’ ring are
serviceable.

77 80
Press down on the steel Insert the handwheel nylon
spacer to compress the spring, retaining rod into its position in
slide the ‘O’ ring over the the gearcase. Refit the retaining
centre column and down into plug.
its groove. TAKE GREAT
CARE WHEN FITTING THIS Pic 44 Pic 15
SPRING. To make this job
safer the appropriate clutch
spring compession tool can be
purchased direct fro Rotork or
via your local agent.

78 81
Fill Gearcase with Oil Refit Geared Side
Handwheel
Before refitting hand drive fill
gearcase with fresh oil through All sizes
Pic 102
the hand drive aperture,
ensure that sliding clutch Lower the hand gear box onto Pic 171
coupling is down in the drive the actuator output shaft taking
position and bring oil level up care not to damage the oil seal.
to top of clutch but no higher. Secure with cap head screws or
Use gear oil type SAE hex heads as supplied. On sizes
80/90EP, alternatively a food 10 through to 40 also replace
grade lubricant can be used, the nylon retaining rod as
namely HydraLube GB Heavy. described in the previous
paragraph.

79 82
Oil Capacities Light Run
Sizes Litres US Pints Before returning the actuator to
10,12,18 = 0.3 0.63 the valve connect it to an
20,25 = 0.8 1.7 electrical supply of the correct
35 = 1.1 2.3 voltage and check that it is both
40 = 7.5 15.8 electrically and mechanically
70,90,91,95= 7.0 14.7 serviceable.

12
Module 1C Resolver Drive Mechanism
All mechanical sizes

Replace Battery Tighten down torque for Mounting Studs/Bolts

using ISO Class 8.8
Whilst the actuator is down for
maintenance it is IQ Flange Bolt Dia: Torque
recommended that its battery Pic 115 Act. Size ISO/USA Metric/Inches Nm/Lb/ft
be changed. The battery as
fitted by Rotork isPP3 9volt
Ultralife Lithium Cell. This 10,12,18 F10/FA10 M10 - 3/8 47/35
exact type of battery MUST be 20,25 F14/FA14 M16 - 5/8 230/170
fitted to all explosionproof units 35 F16/FA16 M20 - 3/4 230/170
CENELEC/FM/CSA.
40 F25/FA25 M16 - 5/8 230/170
70,91 F25/FA25 M16 - 5/8 230/170
90 ‘A’
Coupling F30/FA30 M20 - 3/4 407/300
83
90 ‘B’
The battery is situated in its
own compartment located in
Coupling F25/FA25 M16 - 5/8 230/170
the gearcase. Using an 8mm 95 F30/FA30 M20 - 3/4 407/300
allen key (hex wrench) remove
the access plug.
Pic 25
Electrically Reconnect
Actuator
Earth/Ground Connections
A lug with a 6mm diameter hole
is cast adjacent to the conduit
entries for attachment of an
external earthing strap by a nut
and bolt. An internal earth
84 terminal is also provided.
Disconnect the existing battery
and using the strap provided
pull out of its plastic holder. Fit Removing Terminal
new battery into strap and
push into its holder, reconnect.
Cover
Refit and tighten threaded plug Pic 76 Using a 6mm allen key (hex Pic 20
after lightly greasing and
checking sealing ‘O’ ring is wrench) loosen the four captive
serviceable. screws evenly. Do not attempt
to lever off the cover with a
screwdriver as this will damage
the ‘O’ ring seal and may
damage the flamepath of a
certified unit.

85 87
Refit actuator to valve or Cable Entry
gearbox and fully bolt down.
Only appropriate certified
explosionproof entry reducers,
glands or conduit may be used
in hazardous locations. Pic 23
Pic 27 Remove red plastic transit
plugs. Make cable entries
appropriate the cable size.
Ensure that threaded adaptors,
cable glands or conduit are tight
and fully waterproof. Seal
unused cable entries with a
steel or brass threaded plug. In
hazardous ares an appropriately
certified threaded blanking plug
86 must be used. 88

13
Module 1C Resolver Drive Mechanism
All mechanical sizes

Connecting to
Terminals
On EExde enclosure units
connections to the power and Pic 21
control terminals must be
made using AMP type 160292
ring tabs for power and earth
terminals and AMP type 34148
ring tabs for the control
terminals.
Refer to the wiring diagram
inside the terminal cover to
identify functions of terminals.
Check that supply voltage is
the same as that marked on 89
the actuator nameplate. When
all connections are made
ensure wiring diagram is
replaced in the terminal
compartment.

Replacing Terminal
Cover
Ensure cover ‘O’ ring seal and
spigot joint are in good
condition and lightly greased
before refitting cover. Tighten
down screws to 16.5Nm (12lb/
ft).

Recommision Actuator
Use Rotork Publication
E170E2 and Rotork Infra Red
Setting Tool.
Pic 28

90

14