Manuales Válv y Actuador Válv Seccionamiento

INSTALLATION AND
MAINTENANCE MANUALS
ISTRUCTIOS,
STORAGE
ISTALLATIO &
MAITEACE MAUAL
TRUIO BALL VALVES
TSW FULLY WELDED TYPE
F1 & FA Models
(O-RING SEALS)
Doc. : OIMM-F1-FA-001_Rev.0
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Rev.
13/10/2011
Date
Doc:OIMM-F1-FA-001.Rev0
First issued
Description
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Issued by
For any clarification please contact info@rmtvalvomeccanica.com
I. Griffanti
Checked by
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Page 1 of 29
SUMMARY
1.
2.
SCOPE ......................................................................................................................................... 3
PRELIMINARY INFORMATION ............................................................................................. 3
2.1 - SAFETY WARNINGS ............................................................................................................ 3
2.2 - VALVE FUNCTION AND SERVICE ................................................................................... 4
3. HANDLING & STORAGE ......................................................................................................... 5
3.1 EQUIPMENT WEIGHT ......................................................................................................... 5
3.2 PACKING AND SHIPPING .................................................................................................. 5
3.3 STORAGE .............................................................................................................................. 5
3.4 - INSPECTION AND HANDLING OF THE EQUIPMENT ................................................... 5
4. VALVE INSTALLATION .......................................................................................................... 6
4.1 VALVE LIFTING................................................................................................................... 6
4.2 LINE INSULATION .............................................................................................................. 7
4.3 COUPLING TO PIPELINE .................................................................................................... 7
4.4 TYPICAL INSTALLATIONS. .............................................................................................. 8
4.4.1 ABOVE GROUND INSTALLATION. ........................................................................... 8
4.4.2 UNDERGROUND INSTALLATION. ............................................................................ 9
5. START-UP................................................................................................................................. 10
5.1 - PIPE CLEANING (LINE FLUSHING) ................................................................................ 10
5.2 - HYDROSTATIC TESTING OF THE LINE ........................................................................ 11
6. OPERATION ............................................................................................................................. 12
6.1 - VALVE OPERATION .......................................................................................................... 12
6.2 - LEVER (WRENCH ) OPERATED BALL VALVES INSTRUCTIONS ............................ 12
6.3 - GEARBOX OPERATED BALL VALVES INSTRUCTIONS ........................................... 12
6.4 - ACTUATOR INSTRUCTIONS ............................................................................................ 12
7. REQUIRED TESTING FREQUENCIES .................................................................................. 13
7.1 - FST / Full Stroke Test............................................................................................................ 13
7.2 - PST / Partial Stroke Test........................................................................................................ 14
8. PERIODIC INSPECTION & MAINTENANCE ...................................................................... 14
8.1 - SAFETY NOTES .................................................................................................................. 14
8.2 - ENVIRONMENTAL SAFETY............................................................................................. 14
8.3 - MAINTENANCE INTERVAL ............................................................................................. 15
8.4 GREASE INJECTION.......................................................................................................... 15
8.4.1 STEM LEAKAGE ......................................................................................................... 15
8.4.2 SEAT LEAKAGE .......................................................................................................... 15
8.4.3 GREASING PROCEDURE........................................................................................... 16
8.4.4 PRODUCTS FOR GREASING AND FLUXING......................................................... 16
8.5 VALVE REPAIR .................................................................................................................. 16
9. ASSEMBLY & DISASSEMBLY ............................................................................................. 17
10.
RECOMMENDED FOR ASSEMBLY .................................................................................. 18
11.
SPECIAL TOOLS................................................................................................................... 19
12.
RECOMMENDED SPARE PARTS ...................................................................................... 19
13.
BODY CAVITY - SAFETY INFORMATION ...................................................................... 19
14.
TYPICAL DRAWINGS ......................................................................................................... 20
ANNEX A - HANDLING AND STOCKING PROCEDURE ........................................................ 26
ANNEX B - TROUBLESHOOTING (FAULT FINDING CORRECTION) ............................... 27
ANNEX C BOLT TIGHTENING TORQUE ............................................................................... 28
ANNEX D REFERENCE DRAWINGS PART LIST ............................................................. 29
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1. SCOPE
The purpose of this manual is to provide users with the necessary instructions for properly
installing, commissioning and servicing the valves. In the various operations above mentioned it is
very important to strictly follow the instructions below to ensure a proper operation of the valve and
avoid any risky situation in order to ensure to have an expected lifetime of 20 years.
It has to be noted that the products to which the following instructions apply are designed and built
pursuant to the following regulations:
API6D ISO 14313.
PRESSURE EQUIPMENT DIRECTIVE 97/23/EC only if required by Customers P.O.
This manual provides instructions to define operation modes that avoid any possible risk and inform
about possible residual risks.
IT IS IMPORTANT TO NOTE WHAT FOLLOWS:
The products compliance with API 6D ISO 14313 regulation is certified by the API mark
on the valves nameplate.
The products compliance with PED 97/23/EC regulation (if applicable) is certified by the
CE mark on the valves nameplate.
The API and CE marks certify the product was designed and built in compliance with the
rules and the requirements of PED and API regulations and under the supervision of a
Chartered Surveillance Body.
WARIG - In case of maintenance that requires stem disassembling, it is mandatory to contact
RMT-VM not to invalidate valve warranty, API certification and CE certification (if applicable).
2. PRELIMIARY IFORMATIO
2.1 - SAFETY WARIGS
Pressure containing systems are intrinsically dangerous.
Valve must be used, inspected and maintained by skilled personnel only.
Strictly adhere to company & local authority procedure/laws.
Always wear the correct safety equipment and clothing.
Always use original spare parts only.
Valve body cavity is isolated from the line when the valve is in fully open or fully closed
position.
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WARIG: Body cavity could be pressurised without pressure in line.
Before starting any maintenance action , before disassembling the valve from the pipeline (not
applicable for valves welded to the line) the following steps shall be performed:
1- Check pressure and temperature : valve shall be @ ambient temperature , line pressure shall
be ambient pressure , valve body cavity shall be relieved (ref. to sect. 5 on how to operate
vent and drain).
2- Any liquid , gas or other dangerous component trapped into the valve shall be drained and
properly handled according to the plant safety procedures & local authority procedure/laws.
3- Drain , flush and dry the valve. For safety reasons no fluid shall remain into the valve.
2.2 - VALVE FUCTIO AD SERVICE
Valves supplied are designed for:
1- Bi-directional on-off service only;
2- This valve must be kept always either in fully open or fully closed position ;
3- Do not use as flow regulator (throttling service) to avoid detrimental phenomena like
cavitation .
Pressure / temperature limits of the valve and materials of the main components are stamped on
manufacturer plate (fixed to the valve body). Said limits shall not be exceeded.
The compatibility of used materials with the fluid processed is verified by valve manufacturer
whenever the service is fully documented in user specification and/or data sheets.
The user will be otherwise responsible for checking the fluid/material compatibility.
The valve is not provided with safety accessories against overpressure except when the valve seats
are DPE ( double piston effect ) design. In that case a pressure relief valve is installed on the valve
body only to prevent the increase of pressure in the vale body cavity. Setting of this valve depends
on the process condition.
The user shall therefore protect the line where the valve is installed with suitable safety devices to
avoid that the specified operational pressure / temperature limits are exceeded.
Pipeline pressure shock (water hammer) shall be avoided to prevent any valve serious damage.
Final user shall install any device useful to prevent pipeline pressure shock.
Pipeline thermal shock shall be avoided to prevent any valve serious damage.
Final user shall install any device useful to prevent pipeline thermal shock.
The user shall install the valve in such a way that any external load condition not considered in this
manual do not impair the valve operation.
WARIG Final user is responsible to protect the pipeline from excessive pressure or
temperature. Final user shall install any device to prevent pressure or temperature shock.
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WARIG - either axial nor bending loads from the piping are considered within the valve
calculation.
WARIG - o wind or seismic loads are considered within the valve calculation
WARIG - The plate on the valve shows several descriptive data and the necessary information
about residual risks and maximum pressure and working condition /limit accepted.
Removing or tampering this plate may be highly dangerous for those in charge of operation or
maintenance.
3. HADLIG & STORAGE

3.1 EQUIPMET WEIGHT
The weight of the valve is specified on the dimensional drawing supplied together with the valve to
the customer. If required, a certified statement of the weight may be supplied as well.
3.2 PACKIG AD SHIPPIG
Please refer to the excerpt from CP 12 procedure of RMT-VM, ANNEX A herein enclosed.
3.3 STORAGE
Please refer to the excerpt from CP 12 procedure of RMT-VM, ANNEX A herein enclosed.
Standard cases can be stored outdoor taking the precaution to fix a cellophane sheet on the top.
For optimum protection and in case of long storage period (more than one month), we recommend
undercover storage.
Do not remove any protection from the equipment during storage period.
3.4 - ISPECTIO AD HADLIG OF THE EQUIPMET
On shipping documents (packing list) identify the equipment contained, gross and net weight.
Check the cases have not been damaged during the transport. If a tag number, commodity code or
piping class are specified by the customer, identify the valves using reference number stamped on
the manufacturer plate.
Visually inspect all the valves to assure that they have not been damaged during the transport.
In case of paint damaging, touch-up the damaged painted surface.
Do not remove any protection from the valve (end flanges, stem connection, etc.).
Protections shall be removed just before the installation in order to assure maximum protection to
valve internal parts and coupling surfaces.
If the valve is supplied with an operator ( gearbox ) already installed always use valve lifting lugs to
lift the complete equipment; do not use operator lifting points to handle the valve.
The valves are shipped in the fully open position (with exception of a fail spring close actuator
installed).
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Always keep the valves in fully open or fully closed position (090).
During handling pay particular attention to the valve ends in order to avoid any mechanical damage
of sealing surfaces or butt weld faces (as applicable).
For valve handling always use straps sized to the weight that has to be lifted: do not use chains or
hooks in contact with the machined surfaces.
4. VALVE ISTALLATIO
To install the valve in the line, follow specific procedures provided by the constructor or by the
engineering company.
Before installing the valve in the pipeline:
please remove the protection from the valve ends just before the installation to avoid that
foreign matters can fall inside the valve bore ;
it is recommended to check all the operator functions (lever , gearbox , actuator as

applicable).
In case the operator is directly supplied by the valve manufacturer a functional test of the manual
operator or actuator (as applicable) is already performed as standard procedure.
Before the installation of the valve into the line make sure that the valve bore is perfectly aligned
with the pipe-line axis.
During the pipeline construction or valve installation:
the valve shall not support the line ;
avoid inducing any strain in the valve body.
4.1 VALVE LIFTIG

To lift the valve, belts or chains suitable for valve assembly weight must be used.
If the valve is provided with lifting lugs / lifting eyes (typically for DN 6 and larger, refer to
specific project valve drawings), the above devices must be used, on the contrary (for smaller
valves) the belts can be secured to valve body.
WARIG: Do not use operator lifting points to lift valve + actuator/operator assembly.
Lifting instructions are put outside valve package, please find below an example.
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VALID FOR SIZE AS FAR 6" FULL BORE & LARGER
VALVE HANDLING
INSTRUCTION
VALID FOR SIZE AS FAR 6" REDUCE BORE
T
O
N
T
O
N
AL
ED
W
O
L
ED
W
O
L
AL
4.2 LIE ISULATIO

Some valves may be used with fluids at high temperature and in this case the outside surface of the
valve may reach a dangerous temperature for users and in general for people and animals. In order
to avoid any damage, those in charge of operation and/or maintenance of the valve shall mount
protective devices that prevent any contact.
For safety purposes, in case of valves used for fluids having a temperature equal to or higher than
200C, the outside surface shall be properly insulated to avoid remarkable differences in
temperature between the inside and outside of the valve.
If insulation is not made, there could be differential deformations between the inside and outside
that could generate some serious malfunctioning of the valve.
It is recommended to those in charge of operation or maintenance to effectively insulate the outside
surface of the valves that men or animals may touch if the temperature of the surface reaches
unacceptable values. In general the accepted temperature range varies from 20C to +60C.
4.3 COUPLIG TO PIPELIE
Depending on the foreseen solution for coupling the valve to the pipe for the RF, RTJ, BW, SW
valves, do as follows:
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RF type: the coupling to the line is to be made with flanges that comply with ASME B16.5
regulation with regard to the GAUGE and based on which the flanges are to be
positioned (see ASME B16/5 regulation). Between each flange of the valve and each
flange of the line, flat gaskets shall be placed and they shall comply with ASME
B16/5 rules (and the coupling shall be made with bolts and nuts that comply with
ASME B16/5 rules).
RTJ type: the coupling may be made as above mentioned for the RF type but with RING
JOINTS that comply with ASME B 16.5 rules.
ENBLOC type: the coupling to the line is to be made via two end points with NPT threaded
holes (upon request GAS threaded) whose size and types can be inferred from the
valves plate.
ENBLOC type with end point to be welded: the coupling to the line is to be made via welding
of the pipe to the BW or SW end points of the valve. The valves plate features the
DN and the type of material of the end points to be welded
WARIG either axial nor bending loads from the piping are considered within the valve
calculation.
4.4 TYPICAL ISTALLATIOS.

TSW fully welded ball valves can be installed in two typical configurations:
Above ground piping
Underground piping.
4.4.1 ABOVE GROUD ISTALLATIO.
For above ground installation, the typical valve design is made by:
A standard glandplate (without stem extension);
The operator is assembled directly on valve operator flange;
Emergency grease injections (if available) are assembled directly on valve body.
For valves with BW ends, depending on piping material (yield strength and thickness), the
Customer can require a transition pup-piece welded to valve closures. (OPTIONAL).
If required by the Customer, for large sizes drain and vent connections can be provided with
Floating Ball Valves lever operated (OPTIONAL).
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The figures below show a typical above ground installation.

Operator on
the Gland
Standard
Glandplate
Optional FSE
vent & drain
Optional
Pup-Pieces
4.4.2 UDERGROUD ISTALLATIO.

For underground installation, the typical valve design is made by: (see also dwg F1-2 at section 14):
A stem extension, length as per Customers request;
The operator is assembled on the top of stem extension;
Emergency grease injections (if available) and vent/drain connections are provided with
extension pipes to put injection / venting points at the top lever of stem extension.
For valves with BW ends, depending on piping material (yield strength and thickness), the
Customer can require a transition pup-piece welded to valve closures. (OPTIONAL).
If required by the Customer, for large sizes drain and vent connections can be provided with
Floating Ball Valves lever operated (OPTIONAL).
The figures below show a typical underground installation (with an example from one site).
Operator on
the Extension
Extended
Connections
for
Vent, Drain
& Grease
Injectors
Stem
Extension
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OTE: when stem extension is particularly long (>2m) it is possible to pack the valve separated
from stem extension, in order to reduce the dimensions on the package.
In this case, RMT provides to the Customer a special Stem Extension Assembly Procedure, to
ease site operations and warrant the alignment of the various flanges and brackets.
For this special option, fitting extension pipes (for drain, vent and injectors) are provided with
flanges, so they also can be delivered separately from the valve.
See Figure 5 Stem Extension at section 14 of this manual.
5. START-UP
WARIG Before starting any of the start-up or commissioning operations each valve must be
proof tested (Full Stroke Test - FST) according to section 7.
5.1 - PIPE CLEAIG (LIE FLUSHIG)
Soft seated valves are designed to handle only clean fluid (without presence of abrasive or hard
particles).
Before using the valve keep it in fully open position in order to reduce the possibility of
accumulation of dirty inside the body cavity.
Please note that pipe cleaning is recommended in any case (even for metal seated ball valves).
Before operating the valve clean the line from all foreign matters that can be entered during the
construction.
To clean the line strictly adhere to specific procedure supplied by the constructor or the engineering
company.
Once the line is properly cleaned valve body cavity shall then be flushed :
valve shall be placed in the partial open position and the applicable procedure for the line
flushing shall then be applied.
As alternative the body cavity shall be flushed using the drain and/or vent connection :
valve shall be left or placed in the full open position , drain and/or vent connection shall be
used.
Whichever will be the procedure applied , body cavity shall be drained from the fluid and shall then
be dried using clean air : drain and/or vent connection shall be used.
Every time the drain / vent connection needs to be used please take care of the following
information:
drain and/or vent connections are supplied with the valve;
feature (standard is NPT threaded) , dimensions and quantity depend on valve size according
to the applicable standards and codes;
vent connection and related fitting shall be used to reduce the pressure inside the valve body
cavity;
drain connection and related fitting shall be used to empty the fluid trapped into the body
cavity after the venting.
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Standard fittings installed on our valves are plugs or bleeders.

Following instructions shall be applied for a proper and safer use of the said fittings.
BLEEDERS
Valve body cavity is reduced loosen the screw inside the vent bleeder (screw is held and
secured by a safety ring to avoid the blow out risk ).
Once the pressure is reduced fitting shall be removed from its threaded connection to the
main valve body.
PLUGS
Drain plug shall be removed only after bleeding operation is completed.
Valves supplied with vent and drain connection (typically DN 6 and larger) shall feature:
bleeder installed in the vent connection ;
plug installed n the drain connection.
Valves supplied with drain connection only (typically DN 4 and smaller) shall feature:
bleeder installed in the drain connection ;
5.2 - HYDROSTATIC TESTIG OF THE LIE
If a line hydro-testing is performed during start-up, some precautions shall be kept to avoid any
damage of the valve internals.
Before the pressure is applied :
always check the fittings for the proper wrench-tightness.
Put the valve in half stroke (3060 deg.) position.
Valve shall remain in half stroke condition just for the time of the hydro-test to avoid permanent
damages on the seat insert or seat contact surface.
The fluids used for hydro-testing and start-up operations shall be compatible with the metallic and
non-metallic components of the valve.
calculation.
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6. OPERATIO
6.1 - VALVE OPERATIO
Trunnion ball valves shall be operated with:
Lever;
Gearbox;
Actuator (electric , pneumatic , hydraulic.)
Valve closes by rotating the stem clock-wise and opens by rotating the stem anti-clockwise.
Rotation is 90.
6.2 - LEVER (WRECH ) OPERATED BALL VALVES ISTRUCTIOS
Valves supplied with lever operator shall be operated as follows:
rotate lever anti-clockwise to open;
rotate lever clockwise to close.
The valve is in open position when the lever is aligned with the flow direction.
6.3 - GEARBOX OPERATED BALL VALVES ISTRUCTIOS
Valves supplied with gearboxes shall be operated as follows:
rotate gearbox hand-wheel anti-clockwise to open;
rotate gearbox hand-wheel clockwise to close.
Position & direction of operation are indicated on the gearbox with the means of a position
indicator.
6.4 - ACTUATOR ISTRUCTIOS
For valves provided with actuator refer to the relevant actuator manual.
calculation.
WARIG - Whichever will be the operator installed on the valve during the valve operation
Maximum Allowable Torque values shall not be exceeded.
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7. REQUIRED TESTIG FREQUECIES

The expected lifetime of the valves can be maintained and checked throughout a Proof Test (Full
stroke test-FST) in accordance with the procedure and frequency explained hereafter.
In order to increase the reliability of the valves RMT VM suggests also to use a Partial Stroke Test
(PST) with the procedure and frequency explained hereafter.
WARIG - For valves with standard 20 years lifetime requirement, FST is mandatory (see par.
7.1 below).
7.1 - FST / Full Stroke Test

The Full stroke test is the same test performed in RMT-VM before the valve left the company and
its necessary to verify that no leakage arises and the valve can be easily and safely moved under
pressure.
Since the trunnion side entry ball valves could be installed in two different positions (fully open or
fully closed) before starting check the required position and then follow the steps below from 1 to 7
respectively.
In case of any problems during both the tests refer to the troubleshooting table ANNEX B.
7.1.A - Valve installed in fully open position.
1.
Move the valve in the fully closed position. During this cycle measure its closing time and
compare it with the performance spec. of the device or the valve datasheet
2.
Pressurize one side of the valve with its max. shutoff pressure
3.
Open the vent hole (if possible) and check for any seat leakage, if not please check for
pressure drop by a manometer on the pipe line. Check also the leakage towards external
environment through the joints.
4.
Close the vent hole and move the valve to its initial open position. During this cycle measure
its opening time and compare it with the performance spec. of the device or the valve
datasheet
5.
With the valve still pressurized, check for stem leakage (i.e. by removing the stem grease
injector if possible) and for leakage through the body/closure joints and body/gland flange
joint
6.
During this cycle verify that the movement is smooth.
7.
Repeat the point 1 to 5 at least 3 times
7.1.B - Valve installed in fully closed position.
1.
2.
3.
Pressurize one side of the valve with its max shutoff pressure
Open the vent hole (if possible) and check for any seat leakage, if not please check for
pressure drop by a manometer on the pipe line. Check also the leakage towards external
environment through the joints.
Close the vent hole and move the valve in fully opened position. During this cycle measure its
opening time and compare it with the performance spec. of the device or the valve datasheet
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4.
5.
6.
7.
With the valve still pressurized, check for stem leakage (i.e. by removing the stem grease
injector if possible) and for leakage through the body/closure joints and body/gland flange
joint.
Move the valve in the fully closed position. During this cycle measure its closing time and
compare it with the performance spec. of the device or the valve datasheet
During the cycle verify that the movement is smooth.
Repeat the point 1 to 5 at least 3 times.
7.2 - PST / Partial Stroke Test

The PST enables the customer to verify the status of the valve: with the valve in its starting position
(open or closed) turn the ball by 15 and then put it back in its initial position.
Check for external leak through the stem housing and through the body/closure joints and
body/gland flange joint .
Verify that the movement is correct and repeat the cycle at least 3 times
8. PERIODIC ISPECTIO & MAITEACE

In standard condition the valve manufacturer do not require special maintenance.
RMT suggests only a periodic inspection of the valve, every 6 months about (External Visual
Check), with particular attention to the stem and stem gaskets.
8.1 - SAFETY OTES
The staff in charge of maintenance operations shall be trained to operate on components used to
contain fluids under pressure. It is important that this staff is aware that before acting on the valve,
the piping shall be depressurised and the valve separated from the line under pressure and it must be
in the OPEN position to eliminate the residual pressure inside (the valve is open on the
depressurised and separated pipe).
WARIG - Working on components while the pressure is on may cause serious damages or
injuries or the death of the user.
In case process fluid is an obnoxious liquid, before disassembling the valve it is necessary to
position the ball at 45 (50% open) and to accurately wash the valve inside and repeat the operation
at 135(-50% open).
8.2 - EVIROMETAL SAFETY
The pipe onto which the valve is installed may transport hazardous or lethal fluids for men and
animals or fluids that pollute the soil. In this case, before any intervention on the valve, agree on
the intervention modes with the person responsible for the safety of the system where the valve is
mounted.
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8.3 - MAITEACE ITERVAL

Maintenance interval shall be scheduled taking into account the following activities:
Monitoring activity
1
Body leakage
Every 6 month
N.A.
Seat leakage
Stem leakage
5 Years
N.A.
Maintenance activity
1
Actuator maintenance
Trim verification
Replacement of stem gaskets
Replacement of body-cover & stem gaskets
Replacement of other soft seals
x
N.A.
N.A.
N.A.
N.A.
To ease maintenance, refer to the instructions for finding anomalies in ANNEX B herein enclosed.
8.4 GREASE IJECTIO
RMT-VM valves do not require any lubrication but are equipped with a grease injector for
emergency interventions to eliminate or reduce leakage from the stem.
Upon request for big sizes (DN 6 and larger) some grease injectors may be positioned also in the
area of the seat seals units for emergency interventions to provisionally limit any leakage.
8.4.1 STEM LEAKAGE
In case of stem leakage, this can be provisionally eliminated by injecting
sealing grease using stem injector (pos.59) mounted on the gland. It is
recommended to use sealing grease suitable to working fluid temperature. If
stem leakage cannot be eliminated entirely or in any case for greater safety,
stem graphite (pos.73) can be replaced without removing the valve from the
line (see disassembling section 9, below).
8.4.2 SEAT LEAKAGE
In case of seat leakage, this can be provisionally eliminated by injecting
sealing grease using seat injectors (pos.60) if present on the valve. It is
recommended to use sealing grease suitable to working fluid temperature.
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8.4.3 GREASING PROCEDURE

Before injecting the grease it is always important to flux with a suitable fluid.
The injection pressure of the fluxing fluid and grease shall never exceed by more than 7kg/sq. cm
the pressure of the line where the valve is installed.
Do as follows:
- Inject washing fluid by opening and closing the valve 2 or 3 times.
- If the leakage does not stop, close the valve and inject sealing grease; see section 8.4.4
below for the types and quantities of grease.
- If the leakage continues, operate 2 or 3 times the valve, always in the OFF position, and
repeat the operation.
8.4.4 PRODUCTS FOR GREASING AND FLUXING
The recommended products for fluxing and greasing are the following:
Sealing grease:
RS Clare&CoL.td BTR555 or Total Lube 911
The grease shall have the following characteristics:
CAS classification:
the product is a blend of different types of grease and therefore it cannot be

classified under CAS
Base product:
Vegetable oil (CAS no. 68178-84-8)
Solubility in water:
None or neglectable
Quantities to inject: around 13 grams/inch size/SEATseat&insert unit

around 10 grams/inch size/stem
For the first greasing operation on valves that have not undergone this treatment before, the above
quantities shall be tripled.
The recommended fluxing fluid is Apex Industrial Chemicals Ltd ECO-SOLV. Other types of
products may be used, only if they are suitable with the working fluid..
WARIG Grease injection activities may create dangerous situations for the staff. It is
therefore recommended to remove the protective cap of the grease by initially unscrewing it by
half a tour to make sure it does not show any remarkable leakage. In this case, interrupt the
operation and repair.
8.5 VALVE REPAIR

These instructions refer to the glandplate flange / stem group only, because no other
components can be removed on TSW fully welded ball valves.
First of all isolate the part of pipe where it is mounted and depressurise the pipe upstream and
downstream.
Before any maintenance, it is recommended to check the spare parts available that are usually
necessary and are specified under section 12.
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As underlined in section 1, in order not to invalidate valve warranty, the valve stem / gland may be
disassembled only by the producer (RMT-VM).
If the user intends to proceed autonomously to its repair, he may disassemble the various
components and reassemble them as per section 9 below.
For safety reasons, it is necessary the user performs the pressure tests foreseen by API 6D
regulation before reinstalling the valve.
After a positive test, the same user is required to certify the results clearly mentioning the type of
valve, the maker and the serial number on the valves plate.
To reassemble the valve glandplate, the coupling capscrews shall be secured with a dynamometric
spanner pursuant to the torque wrench settings specified in ANNEX C.
WARIG - Reinstalling a valve in line without carrying out API6D tests may cause serious
accidents and/or cause events that may pollute the soil and the environment in general.
9. ASSEMBLY & DISASSEMBLY

SAFETY WARIG
Pressure containing systems are intrinsically dangerous.
Valve must be used, inspected and maintained by skilled personnel only.
Strictly adhere to company & local authority procedure/laws.
Always wear the correct safety equipment and clothing.
Always use original spare parts only.
Valve body cavity is isolated from the line when the valve is in fully open or fully closed
position.
Before starting any maintenance action , before disassembling glandplate and stem please perform
the following steps:
1. Check pressure and temperature : valve shall be @ ambient temperature , line pressure shall
be ambient pressure , valve body cavity shall be relieved ( ref. to sect. 5 on how to operate
vent and drain ).
2. Any liquid , gas or other dangerous component trapped into the valve shall be drained and
properly handled according to the plant safety procedures & local authority procedure/laws.
3. Drain , flush and dry the valve. For safety reasons no fluid shall remain into the valve.
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Page 17 of 29
LEVER OPERATED FULLY WELDED BALL VALVES DISASSEMBLY

(REF. TO ATTACHED DWG F1)
1. CLOSE THE VALVE.
2. REMOVE THE STEM NUT (51A).
3. REMOVE THE MANUAL LEVER OPERATOR (96) AND THE SECOND STEM NUT (51A).
OPERATE UP TO THIS POIT FOR LEVER MAITEACE OLY.
4. UNSCREW THE CAPSCREWS (52).
5. REMOVE ADAPTER FLANGE (12) , REMOVE STEM GASKET (73) & GLAND FLANGE (09),
REMOVE GLANDPLATE SEAL (35) & GASKET (74). STEM BEARING (16) & STEM SEALS
(34).
6. REMOVE THE STEM (05) FROM THE BALL (04).
OPERATE UP TO THIS POIT FOR GLAD FLAGE / STEM MAITEACE OLY.
CHECK THE COMPOETS ITEGRITY (SEALS, O-RIGS, STEM) AD WHE ECESSARY
REPLACE THOSE DAMAGED.
GEAR OR ACTUATED FULLY WELDED BALL VALVES DISASSEMBLY

(REF. TO ATTACHED DWG FA)
1. CLOSE THE VALVE. ONLY FOR ACTUATED VALVES AFTER THE VALVE CLOSING
DISCONNECT THE ACTUATOR AND ACCESSORIES FEEDING SOURCE / CABLES /
TUBES ( refer to the actuator/accessories applicable maintenance manual ).
2. REMOVE SCREW OR NUTS CONNECTING THE ACTUATOR TO THE ADAPER PLATE (12)
3. REMOVE THE GEAR / ACTUATOR.
OPERATE UP TO THIS POIT FOR GEAR / ACTUATOR MAITEACE OLY.
4. UNSCREW THE CAPSCREWS (52).
5. REMOVE ADAPTER FLANGE (12) , REMOVE STEM GASKET (73) & GLAND FLANGE (09),
REMOVE GLANDPLATE SEAL (35) & GASKET (74). STEM BEARING (16) & STEM SEALS
(34).
6. REMOVE THE STEM (05) FROM THE BALL (04).
OPERATE UP TO THIS POIT FOR GLAD FLAGE / STEM MAITEACE OLY.
CHECK THE COMPOETS ITEGRITY (SEALS, O-RIGS, STEM) AD WHE ECESSARY
REPLACE THOSE DAMAGED.
10. RECOMMEDED FOR ASSEMBLY

For the assembly, repeat the sequence of section 9 in the opposite way and take care to clean and
lubricate all the parts with mineral oil or grease compatible with the pipeline fluid / gas .
Reccomended Lubricant: Grease MOLYGUARD MOLY TEF or Grease AUDCO 733X.
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Page 18 of 29
11.SPECIAL TOOLS
To install and remove RMT-VM valves no special tools are required.
For the installation, or during glandplate / stem assembly after disassembling, a dynamometric
spanner is necessary to secure the screw and/or nuts to the driving torques foreseen in ANNEX C.
12. RECOMMEDED SPARE PARTS

12.1) Starting-up and commissioning of the system
Before starting, make sure there is a complete set of spare parts each 5 valves (or fraction) per type
where the system is installed.
12.2) Spare parts for the operation
To meet the repair requests over a working period of two years, it is advisable to dispose of a set of
spare parts every 3 valves.
Component part list, spare part list and recommended sets are specified in ANNEX D.
13. BODY CAVITY - SAFETY IFORMATIO

If the temperature of the fluid contained in body cavity registers
strong increases or status changes, this would generate
uncontrollable pressure increases in the locked cavity that could
exceed the designed pressure of the valve. To prevent the above
condition, TSE standard valves are equipped, the with Selfrelieving seats (SPE) that discharge automatically the fluid when
the pressure in the cavity exceeds by 2 to 7 bars the pipe pressure.
The same safe condition is applicable to valves in dual
configuration (one SPE seat and one DPE seat).
For special valves provided with double piston effect seats

(DPE), in order to prevent body cavity overpressure, a safety relief
valve is installed in body cavity, set to discharge body pressure
depending on process conditions.
WARIG: The site manager is responsible for the effectiveness of the safety systems to
guarantee the suitable level of pressure in the cavity of the valves body. Any fracture or
explosion in the valves body may cause damage to personnel, pollute the environment and cause
production losses
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Page 19 of 29
14. TYPICAL DRAWIGS

TSE trunnion Side Entry Ball Valves with O-ring seals can be provided with the following design /
configuration:
TSE Model
Temp. Range
Definition
Seating
Seals / Service
F1
FA
STD. TEMP.
STD. TEMP.
Soft Seated
Metal to Metal Seated
O-Ring seals / Standard

O-Ring seals / Abrasive
Notes
The above models can be characterized by different optional features (not reported in the drawings
here attached):
Optional Seat grease injectors (only for F1 model);
Optional additional seals (O-rings) for valve threaded fittings;
Optional stem extension;
Optional DPE seats or Dual configuration (SPE upstream +DPE downstream);
Optional double back-up, on each side of valve O-rings;
Optional secondary mechanical stop for stem anti-blowout (in this case valve stem must be
removed from body internal and not from valve glandplate).
Optional mechanical stops for stem rotation (in addition to actuator mechanical stops).
Optional Floating Ball Valves installed on vent and drain connections (instead of standard
plugs / fittings).
In the following pages typical drawings for the configurations listed in the above table are reported.
However, please refer also to specific drawings prepared by RMT for the project, delivered with
valves documentation.
NOTE: for specific projects TSW valves made in 2-pieces can be provided (one only closure). The
same instructions for 3-pieces valve body, reported in this manual, can be assumed.
For some projects the following additional design configurations can be provided:
TSE Model
Temp. Range
Definition
Seating
Seals / Service
F1-1
STD. TEMP.
Soft Seated
F1-2
STD. TEMP.
Soft Seated
All
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Notes
Lower trunnion instead of
bearing retainer plates.
Underground application
(see section 4.4 above)
Figure 5: stem extension
to be assembled on site.
I. Griffanti
Checked by
S. Caldara
Approved by
Page 20 of 29
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Page 21 of 29
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Page 22 of 29
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Page 23 of 29
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Page 24 of 29
5.1 Valve assembly c/w with stem extension.
5.2 - Extension pipe with flanged joint.
5.3 Upper detail: remote fitting connections.

Fig. 5: Example of valve with stem extension to be assembled on site.
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Page 25 of 29
ANNEX A - HANDLING AND STOCKING PROCEDURE

(EXCERPT from RMT-VM Internal procedure n CP12 )
PURPOSE
This procedure shall apply to the assembled valves and defines handling and stocking modes.
1. PACKAGING AND SHIPPING
1.1 Preparations for shipment
Flanges and threaded ends shall be protected by wooden or plastic disks or plastic sleeves to avoid
any damage.
Before mounting the protective devices, ensure (see API 6D 12.1-12-2-12-3) that the valve is fully
open, the inner part is dry and the surfaces exposed to the atmospheric agents and not painted are
protected by anti-corrosion products.
4. HANDLING
4.1 This activity shall be performed by using tools and means in compliance with the safety rules.
The staff in charge shall be properly trained.
4.2 It is preferable if the valves and their components are handled with bands rather than chains. If
chains are used, they shall not get in contact with wrought surfaces. Always use handles or
hooks.
4.3 Avoid to rewind the chains on handwheels or to have them pass through the breakthrough of
the valve when lifting.
4.4 Valves and their components shall never be positioned on concrete floors but on wooden,
plywood or cardboard surfaces (pay attention to the surfaces of the flanges).
4.5 Flanges shall always be protected by wooden or plastic disks.
4.6 Metal parts shall never touch any other metal part.
4.7 Ensure the valves and their components are never dragged or pushed on concrete floors.
4.8 After the hydraulic test, make sure the valves are emptied from the testing liquid, dried and the
wrought surfaces are oiled.
4.9 In handling parts, components or finished valves, the staff in charge shall make sure documents
and cards that define and trace the product are not lost or removed.
5. STOCKING
5.5 O-rings and rubber gaskets shall be stored in an ad hoc area protected from light and contained
in dark envelopes featuring the check dates - depending on the life cycle of the product - the
products code and the progressive identification number for each envelope.
The quality control staff shall keep a book ordered by expiry dates and envelope numbers in
order to maintain the quality of this type of material.
5.7 Areas for stocking finished components or complete valves are protected against atmospheric
agents and kept at room temperature, clean and properly lit.
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Page 26 of 29
ANNEX B - TROUBLESHOOTING (FAULT FINDING CORRECTION)

WARIG: For any problem, before dismantling or touching anything, please contact RMT-VM
sending e-mail to info@rmtvalvomeccanica.com with all the necessary details.
FAULT
Seat leakage
Body/glandplate
ext. leakage
Opening or
closing time not
in accordance
with site
requirements.
Operating torque
too high (manual
valves).
Ball movement
not correct (not
continuous but in
steps)
The valve can not

be operated
FINDING
CAUSES
When in suspect of seat

leakage:
Stroke the valve to the
fully closed position.
Discharge the residual
pressure left inside body
cavity through the drain
valve and the vent plug.
Allow the system to
stabilize for half an hour
minimum.
If the valve is tight no
water should drip out the
drain valve.
When any of the body
flanged connections drips
verify that the bolt tightening
torque of the joint
concerned is in accordance
with ANNEX C.
Make a full stroke test,
operate the valve and
measure opening/closing
time.
Seat insert damaged by fluid

particles (sand, dirt etc.).
Small leaks can be stopped by

injecting sealant into grease
nipples (refer to section 8.4.2).
External seal damaged or

aged.
External leaks can be stopped

replacing glandplate or stem
gaskets.
(Refer to section 9).
Sand, debris or dirt

contained into piping fluid
could be trapped around the
stem or around ball bushings
areas
Inject lubricant grease through the

Stem and seat grease fittings.
If this operation does not bring any
benefit dismantle the stem/gland
flange group and verify no galling,
scores or damages have occurred.
(Refer to section 8.4.1 and 9).
The valve has been left in

the same position without
any partial stroke test and
ball and seat are stick
together or the actuator has
a problem.
The valve has been left in
the same position without
any partial stroke test and
ball and seat are stick
together.
Flush valve body to clean ball

bushings areas.
Make a full stroke test,

operate the valve and check
for ball rotation.
Make a full stroke test, or a

partial stroke test (if
available) and check for ball
rotation.
CORRECTION
The actuator has a problem.

Stem packing too tightened
(if present).
Inject lubricant grease through the

seat/stem grease fitting in order to
reduce friction coefficient.
Flush valve body to clean ball
bushings areas.
Reduce line pressure and, at the
same time, inject lubricant through
the seat/stem grease fittings and
try to operate the valve. If no
change happens disassemble the
stem, check for valve components
(stem / ball bushings) and replace
damaged ones.
Stem failure.
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Page 27 of 29
ANNEX C BOLT TIGHTENING TORQUE

(GLANDPLATE CAPSCREWS)
Bolt size
[mm]
M8
M10
M12
M14
M16
M20
M24
M27
M30
M36
0
Rev.
A193 B7
A320 L7
[Nm]
11
22
37
58
88
170
292
424
578
1001
A193 B7M
A320 L7M
[Nm]
10
20
33
52
42
82
141
204
279
483
13/10/2011
Date
A453 Gr.660
[Nm]
11
23
38
60
52
100
172
249
340
590
First issued
Description
A193 B8M Cl.2

[Nm]
9
17
29
52
42
88
152
8.8 UNI 3740

[Nm]
10
20
34
53
82
161
278
401
548
955
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A4 Gr.70
[Nm]
2
4
7
11
17
33
58
S. Caldara
Approved by
Page 28 of 29
ANNEX D REFERENCE DRAWINGS PART LIST

Here attached an example of standard documentation provided by RMT with the valves.
REFERENCE DRAWINGS
P.O. No. : xxxxx
RMT-VM JOB No. : yyyyy
Job-ITEM
GENERAL
ARRANGEMENTS
DRAWINGS
CROSS SECTIONAL
DRAWINGS
xxxx-1
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Page 29 of 29
STEM EXTENSION ASSEMBLING INSTRUCTIONS

STROKE SETTING - PAINTED MARKS FOR OPEN AND CLOSE POSITION
STROKE SETTING - REMARKS AND NOTES FOR SPECIAL FEATURES
VALVE TYPE : TRUNNION MOUNTED BALL VALVE SIDE ENTRY FULLY WELDED
NPS : 42 CLASS : 900 ENDS : BW + BW PUPS
Document nr.
101354 INST 001
0
Rev.
25/05/2011
Date
First issue
Description
Griffanti
Issued by
Caldara
Approved by
RMT Valvomeccanica S.r.l. Via dei Patrioti - 21058 Solbiate Olona (VA) Italy - Ph.. +39 (0) 331 375 441 - Fax +39 (0) 331 376 847
info@rmtvalvomeccanica.com
- www.rmtvalvomeccanica.com
page 1 of 16
STEM EXTENSION ASSEMBLING INSTRUCTIONS

Following instructions shall be applied for installation of stem extension and extended pipes on
RMT Trunnion Mounted Fully Welded Ball Valves 42 #900 BW with Pups.
To reduce and to facilitate the on-site operations extension and stem extension are shipped as a premounted set.
Some of the following photos are picked up during the installation in RMT factory thats why
valves and components may be shown unpainted.
Preliminary operations
Remove the protections installed on the components and carefully clean the surfaces.
Lubricate the valve stem , the keys and the stem extension housing to facilitate the assembling.
Lubrication shall be carried out just before starting the assembling.
Lifting of the extension and stem extension

Install the supplied lifting lug on the head of the stem extension.
Connect a proper lifting device and lift the assembly.
For safety and to increase the stability fix a rope or similar in two opposite holes located on the
upper ribs of the extension.
WARNING :
Ribs are installed to reinforce the extension , it increase the safety in particular during handling and
installation of the valve.
Ribs are provided with holes to facilitate lifting , handling and assembling.
Holes on the ribs shall only be used for lifting the extension and stem extension as supplied ( premounted set ).
Valve shall be lifted using the four lifting points provided on the body.
page 2 of 16
page 3 of 16
Valve lifting points before painting ( pink lugs )
Valve lifting points after painting
page 4 of 16
Extension and stem extension installation on the valve

Check the correct position of the plate that will fix the extended pipes for emergency seat sealant
injectors ( seat greaser ) , vent , drain , emergency stem sealant injector ( stem greaser ).
Place the extension and stem extension on the top of the valve stem.
Install the four pins supplied for the assembling ( holes for pins are blind holes on the valve mating
flange ).
page 5 of 16
Check the position of the two stem keys and the two slots on the stem extension housing , also
check the correct alignment of the holes for studs and pins located on the valve mating flange and
the respective holes located on the extension flange.
Rotate the extension and stem extension until the keys , slots and holes will be coincident.
page 6 of 16
Move down slowly the extension and the stem extension carefully checking the mating of the
extension stem housing , and the valve stem.
Carry on until the pins mate with the holes on the extension lower flange.
page 7 of 16
Once the pin are engaged with extension flange move down slowly until the extension flange match
with the valve mating flange
Install and tighten the supplied studs and nuts to finally fix the extension on the valve.
page 8 of 16
Extended pipes installation

Identify the extended pipes for emergency seat sealant injectors ( seat greaser ) , vent , drain ,
emergency stem sealant injector ( stem greaser ).
To facilitate the identification on each pipe is fixed a tag plate.
The plate is printed as follows:
1. pipe service on the front side
2. PO nr. , tag nr. , valve serial nr. on the back side
For your convenience please check the following tag plate photos.
Tag plate front side
Tag plate back side
Vent and drain extended pipes are supplied in two different legs :
1. the first is connected to the valve body with a RTJ flange
2. the second is connected to the first with a RF flange.
Vent and drain extended pipe first leg is double flanged RTJ x RF.
Stem and seat sealant injectors extended pipe are supplied in a single leg pipe ( 2 seat extension
pipes , 1 stem extension pipe each valve ).
Previously described tag plates are attached to every pipe leg.
page 9 of 16
For your convenience please check the following pipe sketches.
page 10 of 16
page 11 of 16
page 12 of 16
page 13 of 16
Installation of Vent & Drain extended pipes

123456-
Screw the studs on the body blind threaded holes

Install the RTJ gasket on its groove on the body ( vent ) or on the pipe extension (drain )
Place the first leg on its final position mating the flange on the body connection
Screw and tighten nuts on the studs
Place the spiral wound gasket on the RF side of the first leg just installed
Place the second leg on the spiral wound gasket approaching the spacer plate welded on the
upperside of the extension
7- Install the studs and nuts
8- Tighten at the right torque value
Installation of Seat & Stem Sealant extended pipes

1- Place the spiral wound gasket on the RF connection
2- Place the flange of the extension pipe on the spiral wound gasket and on the spacer plate
welded on the upperside of the extension
3- Install the studs and nuts
4- Tighten at the right torque value
Installation of the rack plate

To finally fix the extended pipes place the rack plate on the spacer plate on the upperside of the
extension and fix it with the supplied screws.
page 14 of 16
STROKE SETTING
PAINTED MARKS FOR OPEN AND CLOSE POSITION
Marks showing the fully open and fully close position of the valve are located on the valve stem and
on the valve mating flange (extension to valve side) , and also on the stem extension and on the
extension mating flange (actuator to extension side).
To verify the correct alignment of the ball marks are painted in RMT workshop according to the onsite assembler requirement.
Painted marks on the valve stem and on the valve mating flange
Painted marks on the extension upper flange and on the stem extension
page 15 of 16
STROKE SETTING
REMARKS AND NOTES FOR SPECIAL FEATURES
On the top of the extension a flange with machined mechanical stop is installed.
This flange limits the stroke to 92 ( 90 standard stroke ; +1 for open position ; +1 for closed
position ; total of 92).
This flange shall be used as a safety feature and gives a reference for not to exceed the open and
closed position.
Setting of the actuator stroke shall be carried out according to the actuator manufacturer instructions
, taking care of not to engage the flange stops with the stem extension keys.
Mechanical stop shall not bear the full force of the actuator , thats why:
actuator shall be operated preferably in manual mode;
as alternative , in case of manual mode is not available , actuator shall be operated at the lowest
pressure allowing the valve to move ( just enough to move SLOWLY ).
Setting the stroke of the actuator shall be done only without pressure in the pipeline.
Valve and extension pipes shall not be pressurized.
Stroke the actuator before the installation on the extension
check the position of the key slots on the actuator housing
compare the position of the said slots with the keys on stem extension
if the position is very different perform a preliminary stroke setting ( this reduce the risk of crashing
the keys on the flange mechanical stops )
Repeat for the opposite stroke.
Once the actuator is placed on the extension manually stroke it checking the painted marks.
Stroke and set the actuator until the marks will be coincident.
If the actuator stops to move do not force the stroke for any reason , lift the actuator and check the
valve safety mechanical stop and stem extension keys are not engaged.
In case of engaging
Move/stroke the actuator on the opposite side
check the status of the components
set the actuator reducing the stroke along the first stroke direction
For safety always check the keys versus mechanical stops position also in case of a non-engaging
condition.
Operate the acuator opening the valve , lift the actuator and check keys and mechanical stops.
Repeat for the closing stroke.
page 16 of 16
modbus
Modbus RTU Actuator Control

MFU Option Card
Installation Manual
Publication S175E V2.2
Issue 11/03
Modbus MFU Option Card Installation Manual
Note 1:
Throughout this manual the Modbus Module Mk2 may simply be referred to as the module.
Note 2:
The information in this manual relates to the following firmware release
EPROM version M201
Note 3:
The Modbus Module MK2 described in this manual is suitable for inclusion in Rotork IQ, IQT,
and Q range actuators.
As we are continually developing our products their design is subject to change without notice.
The contents of this document are copyright and must not be reproduced without the written
permission of Rotork Controls Ltd.
The name Rotork is a registered trademark
Windows is a registered trademark by Microsoft Corporation
2 of 68
Publication S175E V2.2 Issue 11/03
Contents
Contents
Glossary of Terms:.................................................................................................................. 5
Abbreviations: ......................................................................................................................... 5
INTRODUCTION............................................................................................................ 7
1.1
General .......................................................................................................................... 8
MODBUS OPTION CARD PROPERTIES................................................................. 9

2.1
2.2
2.3
Mechanical properties ................................................................................................... 9

Electrical Properties .................................................................................................... 10
Operation and Storage................................................................................................. 10
FITTING THE MODBUS MODULE OPTION CARD .............................................11

3.1
Inside an IQ or IQT actuator......................................................................................... 11
3.2
3.3
Inside a Q actuator....................................................................................................... 12
Replacing or Fitting a Modbus Module Option Card .................................................... 13
RS485 DATA HIGHWAY, CONNECTIONS AND MFU SETUP..........................15

4.1
4.2
4.2
Data Highway............................................................................................................... 15
Highway Topography................................................................................................... 16
Cable Types................................................................................................................. 17
4.4
4.5
Termination Network ................................................................................................... 17

Inter-connecting the Highway and Setting up the MFU................................................ 18
4.5.1 Single Highway with Analogue Input ........................................................................... 19
4.5.2 Dual Highway ........................................................................................................... 20
4.5.3 Single Highway with Internal Repeater ....................................................................... 21
THE ACTUATOR INPUT AND OUTPUT SIGNALS .............................................23

5.1
Control Outputs........................................................................................................... 23
5.1.1 Controls Priority ........................................................................................................ 26
5.1.2 Modbus Control using Individual Coil commands......................................................... 26
5.1.3 Modbus Control using the Actcon Register ................................................................. 27
5.1.4 Modbus Control using the Actuator Position DV register .............................................. 27
5.1.5 The IQ S contacts (Modbus DOs). ........................................................................... 27
5.1.6 IQ Modbus Network Control Disable feature ............................................................... 28
5.2 Actuator Digital Input Status Feedback ....................................................................... 28
5.2.1 Digital Inputs from All Actuator Types ......................................................................... 29
5.2.2 Digital Inputs from IQ and IQT Actuator ...................................................................... 31
5.2.3 Digital Inputs from IQT Actuator ................................................................................. 32
5.3 Actuator Analogue Input Feedback ............................................................................. 33
5.4
IQ Data Logger Information ......................................................................................... 33
MODBUS COMMUNICATION...................................................................................35
6.1
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Electrical Specification ................................................................................................ 35
6.2
6.3
Outer Protocol ............................................................................................................. 35

Repeaters .................................................................................................................... 35
6.4
Dual Channel Mode...................................................................................................... 36
MODBUS DATA BASE ..............................................................................................37

7.1
7.2
7.3
Modbus RTU Message Frame...................................................................................... 37

Modbus Address.......................................................................................................... 37
Function Code Support................................................................................................ 38
7.4
7.5
7.5
Broadcast Commands................................................................................................. 39
Data Location Offsets .................................................................................................. 40
Data Locations............................................................................................................. 40
7.5.1 Data Accessed with Function Code 01 - Read Coils .................................................... 40
7.5.2 Data Accessed with Function Code 02 - Read Discrete Inputs ..................................... 41
7.5.3 Data Accessed with Function Code 03 - Read Holding Registers ................................. 41
7.5.4 Data Accessed with Function Code 04 - Read Input Registers ..................................... 43
7.5.5 Data Accessed with Function Code 05 and 15 Force Single and Multiple Coils........... 44
7.5.6 Data Accessed with Function Code 06 and 16 Preset Single and Multiple Registers ... 45
7.5.7 Data Accessed with Function Code 07 Read Exception Status .................................. 45
7.5.8 Data Accessed with Function Code 08 Loopback Diagnostic Test ............................. 45
7.5.9 Data Accessed with Function Code 17 Report Slave ID ............................................ 46
7.6
Data Base Summary: ................................................................................................... 46
CONFIGURATION REGISTERS ..............................................................................49

8.1
Actuator Related Configurable Parameter Registers................................................... 51

8.1.1 Action on Loss of Comms (Register 7)........................................................................ 51
8.1.2 Limited Range Position Minimum and Maximum (Registers 8 and 9)............................ 51
8.1.3 Deadband and Hysteresis (Registers 10 and 14)......................................................... 52
8.1.4 Motion Inhibit Timer (Register11) ............................................................................... 53
8.1.5 Auxiliary Input Mask (Register 12) .............................................................................. 53
8.1.6 Comms Lost Position (Register 13) ............................................................................ 54
8.1.7 Slow Mode Range (Register 15) ................................................................................ 54
8.1.8 Valve Jammed Time (Register 16) ............................................................................. 54
8.1.9 Manual Movement Travel (Register 17) ...................................................................... 54
8.1.10 Watchdog Timeout (Register 18)................................................................................ 55
8.1.11
ESD DI4/Net Disable (Register 19) ........................................................................ 55
8.1.12 Analogue Input Max (Register 20) .............................................................................. 55
8.1.13 Comms Fault Timer (Register 21) .............................................................................. 55
8.2 Modbus Network Related Configurable Parameter Registers...................................... 55
8.2.1 Modbus Address (Register 22)................................................................................... 55
8.2.2 Baud Rate (Register 23)............................................................................................ 56
8.2.3 Parity and Stop Bits (Register 24) .............................................................................. 56
8.2.4 Data Base Format (Register 25)................................................................................. 56
8.2.5 Actuator Tag Name (Register 26 to 31) ...................................................................... 56
SETTING UP AND MAINTAINING THE MODBUS MODULE ............................57

9.1
Using a Network Configuration Tool............................................................................ 57
9.2
Setting up an IQ or IQT with the Setting Tool............................................................... 57
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Contents
9.3
9.4
Maintenance and Repair .............................................................................................. 59

Records ....................................................................................................................... 59
APPENDIX A MODBUS MODULE MK1 DATA BASE...............................................61

A.1 Introduction..................................................................................................................... 61
A.2 Input and Output Signals............................................................................................. 61
A.2.1 Control Outputs......................................................................................................... 61
A.2.2 Digital Input Status Feedback .................................................................................... 62
A.2.3 Analogue Input Status Feedback ............................................................................... 62
A.2 Modbus Communication.............................................................................................. 63
A.3 Modbus Data Base ....................................................................................................... 63
A.3.1 Function Code Support .............................................................................................. 63
A.3.2 Broadcast Messages ................................................................................................. 63
A.3.3 Data Locations .......................................................................................................... 64
A.4
A.5
Configuration............................................................................................................... 67
Records ....................................................................................................................... 67
Glossary of Terms:
Address
Fieldbus
Field Unit
Interoperability
Master/Slave
Modbus
Modbus RTU
Node
RS485
Segment
The unique address for a node on the fieldbus, range 0-247

The digital, two-way, multi-drop communication links.
The Modbus option card fitted to the actuator
The capability for a device from one manufacturer to interact with that
of another manufacturer, on a fieldbus network, without loss of
functionality
The method of communication used by the Modbus Module. The
fieldbus requires a Modbus master to control the data exchange on
the highway.
The communication protocol used for data exchange.
The version of the protocol available from the Rotork module.
A single device on the fieldbus
The electrical properties of the data highway as defined by the IEC
standard, copper conductors, 2 wire twisted pair.
A section of an RS485 fieldbus that is terminated in its characteristic
impedance. Each Segment can include up to 32 devices.
Abbreviations:
Comms
MFU
RAM
ROM
RTU
SW
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Communications
Modbus Field Unit
Random Access Memory
Read Only Memory
Remote Terminal Unit
Software
(This page is intentionally blank)
6 of 68
Introduction
INTRODUCTION
The Rotork Modbus Module Actuator Control option card (MFU) uses 2 wire RS485 and the Modbus
RTU protocol to allow for information exchange and control over the data highway between the
actuator and a suitable host system with a Modbus capability.
The current version of the MFU assembly may be fitted into the IQ, IQT or Q range of electric
actuators, including modulating versions. The module is an integral part of the actuator in which it is
housed and is fitted within the main double sealed electrical housing. This electrical housing need
never be opened once the actuator leaves the assembly plant. All adjustments to the settings for the
module may be made via the Modbus data highway using a Modbus master. The IQ and IQT
actuators also allow the primary settings to be adjusted via the infra-red programming link. (If the data
highway speed was not specified at time of order, or it is changed, it may be necessary to change the
links on a Single Highway plus Repeater option.)
The Modbus module circuits do not impinge on the actuator control electronics; the actuator itself
remains fully self-protecting. The module performs the tasks of network interface, actuator data
collection and the issuing of actuator commands.
The Modbus module may command the actuator into which it is fitted to open, stop, close, perform an
ESD operation or move to a set position. Commands to the module come from the network and will
have been generated in a master controller. The module operates in Master/Slave communication
mode only using Modbus RTU protocol.
Motor
Electrical
Compartment
Handwheel
IQ range
Local Controls
Terminal Cover
Local Controls
IQT range
Terminal Cover
Electrical
Compartment
Local Controls
Electrical
Compartment
Q range
Handwheel
Terminal Cover
Fig 1: The Modbus Module
Mk2 Option Card Actuator
Compatibility
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Handwheel
1.1
General
The Modbus module has three variants:
q
q
q
Single RS485 highway plus one analogue input channel

Dual Independent isolated RS485 highways
Single RS485 highway with inbuilt isolating repeater
RS485
Highway
Analogue
Input
Single Highway + Analogue Input

RS485
Highway 1
RS485
Highway 2
Dual Highway
RS485
Highway 1
RS485
Highway 1
Single Highway + Repeater

Fig 2: The Types of Modbus Module Mk2 Option Card
Communication Media
Protocol
Mode
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RS485 2 wire highway (single or dual), half duplex

Modbus RTU
Master/Slave, module is a slave
MFU Properties
MODBUS OPTION CARD PROPERTIES
2.1
Mechanical properties
The MFU comprises two printed circuit boards connected together and the assembly is fitted inside
the actuator electrical housing.
Mezzanine
Jumper links
Main card
Fig 3: The MFU dual highway module showing the mezzanine and main board (IQ actuator)
Mezzanine Card - The small printed circuit board carries the RS485 highway
connections and protection circuits.
There are two versions of the mezzanine, one for single highway and
a second for two highway (or one highway with repeater) use.
Main Card
The larger motherboard is profiled to suit the actuator into which it fits.
The IQ actuator assembly is shown. It carries the processor, memory
components and power supplies for the module.
The primary connection to the actuator circuits is by a multipin connector on the Main Card that, due to
its physical shape, may only be fitted in the correct polarisation. Internal wiring harnesses connect to
the Main Card for other signals and options within the actuator. The Mezzanine Card carries the
RS485 connector and termination and biasing resistors, this couples to the wiring harness routed to
the terminal compartment of the actuator. Power for the Mezzanine Card is taken from the Main Card
and the whole assembly is powered from the actuator.
All the connectors are polarised to prevent incorrect insertion.
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2.2
Electrical Properties
The MFU connects directly to the main board of the actuator. The MFU does not sit in the main
control path for the actuator and does not affect the actuator control integrity.
An EPROM stored program controls the processor on the module, the software can be updated by
replacing this chip.
The Modbus RS485 fieldbus data highway connections are fully isolated from the actuator electronics.
2.3
Operation and Storage
The MFU is designed to be stored in the actuator and operated within the same environment as the
actuator. The constraints are:
q
q
q
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Operating temperature:
Storage temperature:
Relative Humidity:
-40 C to +70 C
o
o
-50 C to +85 C
o
5% to 95% (<50 C) non-condensing
Fitting the MFU
FITTING THE MODBUS MODULE OPTION CARD
3.1
Inside an IQ or IQT actuator
The MFU is suitable for fitting into IQ Mk2 actuators with 3000 or 5000 series wiring diagrams and IQT
with 6000 or 7000 series wiring diagrams. The connections and fitting in an IQT is similar to that for an
IQ and the following information effectively relates to both actuator types. The MFU is normally located
in the first option board slot inside the IQ/IQT electrical housing using connection SK1. In addition the
MFU can be fitted inside IQ Mk1 actuators in certain cases.
EPROM
SK2
SK7
K
SK5
SK8
SK10
Fig 4: The MFU profiled for the IQ or IQT actuator

The Interface card must be correctly profiled and loaded with the appropriate connectors to match the
IQ/IQT actuator. The illustration (Fig 4) shows the IQ/IQT version of the MFU.
With the IQ/IQT actuator the remote inputs are always present (they are conditioned by the MFU) and
there is an option to include Digital Outputs from relay contacts. If the MFU is required to operate the 4
digital outputs that can be controlled from the card then the Extra Relay Indication card associated
with these outputs must be fitted into the actuator. The following table describes the wiring harnesses
and their function in the IQ and IQT actuator.
MFU Socket
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24V power supply input from actuator

Modbus RS485 Fieldbus connection
Remote Digital Input connections
Digital Output connections j
Data Logger Information
Analogue Input connection k
Note: j Requires Extra Relay Indication board to be fitted
k Only available on Single Channel module, 3000-400 or 6000-400
1
SK2
SK3
SK5
SK7
SK8
SK10
Wiring Harness
3.2
Inside a Q actuator
The MFU is fitted in the option board position in this actuator. Only one option board may be fitted at
any one time. The necessary internal components must also be present; in this case a potentiometer
and auxiliary limit switches at end of travel must be fitted to the actuator.
The illustration (Fig 4) shows the Q version of the circuit board.
EPROM
SK2
SK11
SK10
SK9
Fig 5: The MFU module profiled for the Q actuator

Digital Outputs from relay contacts are not supported from the Q actuator, nor is the ability to report
the status of the remote control inputs as Digital Inputs. The following table shows the wiring
harnesses that must be fitted and the function of each loom for the Q range actuator.
SK2
SK3
SK9
SK10
SK11
Note:
Wiring Harness
24V power supply input from actuator
Modbus RS485 Fieldbus connection
Limit switches
Analogue Input connection j
Potentiometer
j - Only available on Single Channel module
1
MFU Socket
In a Q actuator there is a direct connection from PL2 on the Modbus Module to SK5 of the actuator
main board.
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Fitting the MFU
3.3
Replacing or Fitting a Modbus Module Option Card
The MFU should be replaced or fitted only in a suitable environment. The actuator must be made
electrically safe before opening any covers and in the case of an IQ or IQT it is advisable to
disconnect the internal battery. The electrical housing cover should be removed and the existing MFU
carefully unplugged from its main connector. Once removed from the main connector the wiring loom
connectors should be removed. The replacement board is fitted in the reverse order to removal. The
wiring harnesses are polarised so that only the correct one will fit its mating part on the circuit board.
If the operation is to fit an MFU for the first time then the necessary wiring looms must be added to the
internal wiring harness of the actuator. The actuator wiring diagram shows the connectors and
harnesses used. The wiring harnesses are fitted inside the actuator before attempting to fit the MFU.
Once the looms are in place connect them to the MFU, then fit the MFU to the actuator main board
connector.
Once the module is fitted the actuator should be re-assembled and, in the case of the IQ or IQT, the
battery replaced.
The MFU must not be split between its Mezzanine card and the Interface card. Only complete
assemblies should be fitted or exchanged.
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RS485 Data Highway, Connections and MFU Setup
RS485 DATA HIGHWAY, CONNECTIONS AND MFU SETUP
4.1
Data Highway
The MFU uses RS485, 2 wire, half duplex, Modbus RTU communications at various data rates. The
rules governing the installation and connection of an RS485 highway should be observed at all times
to produce a successful installation. The RS485 highway does not allow power to be transferred and
the MFU is powered from the actuator itself. The MFU can only report data when the actuator is
powered up.
PLC
T Terminator
2 wire highway
Screened cable
Fig 6: Typical RS485t Data Highway

The data highway must be terminated with a proper termination resistor at the end. The highway itself
can use tapped spur or stub connections to the actuators but it is recommended to keep any stub
lengths to a minimum for successful operation. Alternatively the connection can be made in and out of
each actuator in a daisy chain arrangement. The length of the highway and number of devices
connected will vary from project to project. The standard permits up to 32 devices to be connected on
a section, though one of these will be the PLC. If more devices are needed (up to the maximum
addressable of 247) then RS485 repeaters may be added after each group of 32. The standard default
address used by the Modbus Module is 247.
The length of the highway will determine the maximum speed for the data transmission. The greater
lengths are obtained at the lower transmission speeds.
Although RS485 requires only 2 wires for data transmission the standard also requires that all the
nodes on the network have a maximum common mode differential of +7 volts. This requires the
ground potential at all points to be within the 7volt limit. If the equipment is distributed over a wide
area, or an area with poor ground conductivity, it may be necessary to connect a third wire between all
the nodes. Most successful installations use 3 wires and Rotork provides a common terminal on the
actuator.
Since the data passes over a single 2 wire cable there are periods between messages when no
devices are actively driving the lines. In order to ensure that data continues to flow correctly after
these periods it is advisable to ensure the lines are biased to suitable voltage levels during the time
the line is idle. The MFU contains internal biasing circuits that ensure suitable levels are maintained on
the line even with no device transmitting.
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4.2
Highway Topography
Two different connection topologies can be used for RS485. The first system is to use a trunk line with
various spurs or drop lines from it. This system will require the location of the taps in junction boxes
near to the actuators. With the second the actuators can be directly connected to the trunk line in a
daisy chain. All the configurations require the cumulative total of the drop lines and stub lines to be
kept within the permitted maximum for the network speed to be used.
It is good practice to avoid spurs wherever possible.
PLC
Spur
T
Tap
Tap
Tap
Trunk Cable
Tap
Tap
PLC
T
Trunk Cable
Fig 7: RS485 Data Highway Topology
The maximum Trunk length and that for each spur and the cumulative total are dependent on the
system speed in use. The table below suggests the maximum figures for cable type A, also defined
below. The segment length is the total of the trunk and all the spurs added together.
Data Rate (Baud)
300
600
1k2
2k4
4k8
9k6
19k2
38k4
57k6
115k2
Maximum
Segment Length
24.0 km
12.0 km
12.0 km
6.0 km
3.0 km
1.5 km
1.2 km
1.0 km
750 metres
500 metres
Total Spur
Length
2.0 km
1.0 km
1.0 km
500 metres
500 metres
500 metres
500 metres
300 metres
200 metres
100 metres
(Note that each actuator includes up to 0.6 metres of Drop length)

Actuator Type
Internal Drop length (metres)
IQ
IQT
0.6
0.6
0.3
Within each actuator there is a short drop line or stub connection wire from the terminals to the MFU
itself. This length must be included in any calculation for total and individual drop lengths.
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4.2
Cable Types
The network must be connected using a suitable cable. Two conductors plus a shield and drain wire
are required as a minimum, though Rotork recommends the use of a 3 wire cable to ensure the
common mode voltage between all the actuators and the PLC is kept within the RS485 specified
limits.
Amongst the cable manufacturers Belden have the PVC jacketed 3105A single pair 2 core cable,
which meets the minimum requirement. Belden 3106A has and extra core and therefore has sufficient
conductors to include a common wire between all the nodes on the network and meets the Rotork
recommendation. Information on Belden cable may be found on the Belden web site
(www.belden.com) or at http://bwcecom.belden.com/, where a search on RS-485 will reveal technical
papers and cable information.
Data Pair
Data Pair
Common
Screen
Screen
Belden 3105A
Belden 3106A
Belden Part No.
Total Number of
Conductors
3105A
Paired - EIA Industrial
RS-485 PLTC/CM
AWG
(stranding)
dia. Inches
Nom. DCR
Insulation material
Nom
Nominal
Nominal
Impedance Capacitan
O.D.
(ohms)
ce
22 AWG
(7 x 30)
Overall PVC jacket

48.2 ohm/km Datalene insulated 7.26 mm
twis ted pair
120
11.0 pF/ft
22 AWG
(7 x 30)
Overall PVC jacket

48.2 ohm/km Datalene insulated 7.67 mm
twisted pair
120
11.0 pF/ft
3106A
Composite - EIA
Industrial RS-485
PLTC/CM
Fig 8: Typical RS485 cable

The terminals to which the wires connect in the each actuator type will be different and the actuator
wiring diagram must be consulted to establish the connections.
4.4
Termination Network
In order to operate correctly all RS485 highways must be terminated at each end of the main trunk line
using a 120 ohm resistor. These will usually be near the scanner PLC and near the furthest actuator.
The resistors are connected across the data line A and data line B. If the termination resistors are not
fitted there is a possibility that the network communications will be unsatisfactory. In some cases
network data line biasing may also be necessary, however to minimise this requirement the actuator
transceiver chips include secure turn round components.
There is a termination resistor inside each actuator, one side of the resistor is brought to a terminal
whilst the other is already connected to data line A. Linking the Terminator terminal to data line B
completes the connection to place the resistor across the data lines.
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120 ohm
RS485
Highway
Terminator
Data 1A
Data 1B
Analogue
Input
Single Highway + Analogue Input

120 ohm
RS485
Highway 1
Terminator
Data 1A
Data 1B
RS485
Highway 2
Terminator
Data 2A
Data 2B
120 ohm
Dual Highway
120 ohm
RS485
Highway 1
Terminator
Data 1A
Data 1B
RS485
Highway 1
Terminator
Data 1A
Data 1B
120 ohm
Single Highway + Repeater

Fig 9: Termination for RS485 highway
Note:
4.5
When using the single highway with internal repeater the termination should always be
fitted on both sides of the repeater since there are no other devices on the highway
section.
Inter-connecting the Highway and Setting up the MFU
The three MFU variations allow for various different highway connections. The single channel version
can be used for simple highways, and where there is an analogue transmitter connected it will also
return the value from the transmitter signal. The dual channel version is used for redundant highway
applications where the highway integrity is important and the single highway with repeater can be
used for either ring topology connections or applications where distances are extended.
In some cases the single channel with repeater is applied in a ring connection so that the
communications can travel either way around the ring. In this mode the number of devices that can be
interconnected will depend on the speed of operation of the highway as each unit introduces a small
propagation delay.
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4.5.1
Single Highway with Analogue Input

PLC/ Host
c
Terminator
Actuator
1A
1B
Common
c
RS485
Highway
Terminator
Actuator
1A
1B
Common
Analogue
Input
Tx
4-20 mA
+ Tx Power Supply
I/P A
I/P B
Common
Fig 10: Single Highway + Analogue Connections

With the single channel option the actuator is connected to only one highway and an additional input is
provided for measuring and reporting an analogue variable. The connection of the actuator to the
highway uses terminals 1A and 1B, the terminal numbers depend on the actuator type and are
indicated on the actuator wiring diagram. The last actuator on the highway has the termination resistor
connected by linking the highway 1B terminal to the Terminator terminal. Take care to ensure that the
correct polarity is observed on the data highway connection, all the 1A terminals must be connected
together on one data line and all the 1B terminals on the other.
Data line 1A is positive with respect to data line 1B when the MFU is transmitting a 1.
If an analogue input is being used it is connected to the analogue input terminals. The MFU caters for
both current and voltage analogue signals. There is no power supply on the card for the analogue
transmitter and an external power supply must be used to power it.
q
q
For voltage inputs connect I/P A to the positive signal and analogue Common to the
negative signal from the transmitter
For current inputs connect I/P A to I/P B (to insert the conditioning resistor). The current
input positive is to I/P A and I/P B whilst the current input negative is connected to the
analogue Common.
There are no links or settings required on the MFU card when this version is being used.
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4.5.2
Dual Highway
PLC/ Host
Channel
1
RS485
Highway
Channel 1
Actuator
Terminator 1
Channel
2
1A
1B
Common 1
Terminator 2
2A
2B
Common 2
RS485
Highway
Channel 2
Actuator
Terminator 1
1A
1B
Common 1
Terminator 2
2A
2B
Common 2
Fig 11: Dual Highway Connections
LK5
EPROM
4
3
2
1
LK6
SK1
LK10
9
8
7
SK3
SK2
SK5
SK7
SK8
SK10
Fig 12: Jumper Settings for Dual Highway Option

K
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The actuator can be connected to two highways when redundant communication links are required.
The connection of the actuator to the highways uses terminals 1A and 1B for highway 1 and 2A and
2B for highway 2, the terminal numbers depend on the actuator type and are indicated on the actuator
wiring diagram. The last actuator on the highway has the termination resistors connected by linking
Terminator terminal to the B terminal on the appropriate highway connection. Take care to ensure that
the correct polarity is observed on the connection on each data highway, all the 1A terminals must be
connected together on one data line and all the 1B terminals on the other for highway 1, all the 2A
terminals are connected together on one data line and all the 2B terminals on the other for highway 2.
Data line A is positive with respect to data line B when the MFU is transmitting a 1.
The dual channel MFU uses a single Modbus address common to both channels, so it is not possible
to run the same highway to both channels on the card.
One Modbus address for the card common for both channels
There are a number of jumper links on the mezzanine board, which must be in the correct position.
These links determine the function of the card and when in the dual channel mode they must be
positioned as shown in the diagram.
4.5.3
Single Highway with Internal Repeater
With this option a single highway passes through the Modbus Module and an internal repeater
regenerates the data signals. The input to output connection is also isolated and this then allows the
next section of cable to reach the maximum specified distance and the number of connected devices
on the section to be 32. Termination resistors may be required at all connection points.
In addition to allowing for signal regeneration with the internal repeater it is also possible to connect
the last device on the network back to the PLC in a ring configuration. As each highway section is
isolated from its neighbours the ring topology affords a degree of redundancy. The PLC channels must
not be used simultaneously unless there is a section of the network that is broken.
Data line 1A is positive with respect to data line 1B when the MFU is transmitting a 1.
There are a number of jumper links on the mezzanine board that must be in the correct position for the
card to function as a single channel module. The repeater section is able to wait for the correct period
after transmitting data before changing to receive mode, this is important to ensure good
communications on the highway. The time for the delay is set by jumpers on the mezzanine and varies
according to the data transmission speed chosen.
The internal repeater supports data speeds from 2400 to 115200 baud
Jumper Settings:
Speed (Baud)
LK1
LK2
LK3
LK4
LK5
LK6
LK7
LK8
LK9
LK10
2400/4800
9600/19200
38400 - 115200
Left
Left
Left
Left
Left
Left
Left
Left
Left
Left
Left
Left
Top
Top
Top
Top
Top
Top
Left
Right
Right
Left
Left
Right
Left
Right
Right
Left
Left
Right
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PLC/ Host
Channel
1
RS485
Highway
Actuator
Terminator 1
Channel
2
1A
1B
Common 1
Terminator 2
2A
2B
Common 2
Optional
Return
RS485
Highway
Actuator
Terminator 1
1A
1B
Common 1
Terminator 2
2A
2B
Common 2
Fig 13 Single Highway with Internal Repeater Connections
Speed 2400
(Baud) 4800
9600
19200
38400
57600
115200
LK6
LK10
9
8
7
SK1
EPROM
SK3
4
3
2
1
LK5
SK3
SK2
SK5
SK7
SK8
Fig 14: Jumper Settings for Single Highway with Internal Repeater Option
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SK10
Input and Output Signals
THE ACTUATOR INPUT AND OUTPUT SIGNALS
The Modbus Module allows the actuator to be controlled by, and to report data to, a suitable host
device using Modbus RTU protocol. This section explains the data signals that are available for
exchange and their meaning in relation to the actuator functionality. The data locations used for the
Modbus registers and coils is given later in this manual.
This section also gives information on the other control inputs available for moving the actuator.
PLC
Actuator
Outputs - Commands
Inputs - Feedback
RS485 data highway
Fig 15: Input and Output Data Direction
5.1
Inputs are defined as signals originating at the actuator and fed back to the PLC over the
RS485 network.
Outputs are defined as signals originating at the PLC and operating the actuator
controls.
Control Outputs
The Modbus module can be used to control the actuator and position the valve. The valve may be
moved fully closed, fully open or to an intermediate position. Additionally the actuator can make the
valve adopt an Emergency Shut Down position. The actuator may also be operated from its local
controls or by hard wired direct contact inputs (in the case of the IQ and IQT the Auxiliary Input Mask
must be correctly set).
As well as controlling the actuator the MFU can also be used to operate 4 discrete output relays when
fitted to an IQ/IQT actuator with the relay card fitted.
The control commands have three potential sources:
q Modbus RS485 network generated commands
q Actuator Local Controls
q Direct contact input controls
The full list of commands is shown in the table. The actuator types show whether the command is
applicable to that actuator type.
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Command
IQ actuator
IQT actuator
Q actuator
j
j
j
j
j
j
j
j
Local Controls
Open
Close
Stop
Direct Hard Wired Inputs

Open
Close
Stop/Maintain
Emergency Shut Down
Open Interlock (active prevents opening)
Close Interlock (active prevents closing)
k
k
k
k
Modbus over the network

Open
Close
Stop
Emergency Shut Down
Relay output DO-1*
Relay output DO-2*
Relay output DO-3*
Relay output DO-4*
Analogue Position demand
Note: j Requires Extra Relay Indication board to be fitted

k Push to Run action only. Maintained action not available if analogue positioning is
used
The Modbus RS485 network commands will operate the actuator provided
Local/Local Stop/Remote selector is in Remote,
Modbus commands are not inhibited by the Inhibit/DI4 input parameter setting and DI4
condition
No interlock is active on IQ or IQT actuators.
There is no standing hard wired control input active
No alarm condition prevents it from moving
Open
A digital command to cause the actuator to open to the fully open

position as indicated by the Open limit switch. Under correct operation
the actuator stops either when the open limit switch is reached, when
the torque exceeds the value set and the open limit switch has been
reached, or a new command is sent over the network.
Close
A digital command to cause the actuator to close to the fully closed

position as indicated by the Close limit switch. Under correct operation
the actuator stops either when the close limit switch is reached, when
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the torque exceeds the value set and the close limit switch has been
reached, or a new command is sent over the network.
Note:
Many IQ multi-turn actuators are set to open until the open limit switch is reached and,
close until the closing on torque switch trips, but it is dependant on the type of valve.
The IQT and Q normally operate 90-degree valves, use stop bolts on the actuator or
gearbox, and stop when these are reached. The control room indication is always taken
from the end of travel limit switch settings
Stop
Emergency Shut Down A digital command that causes the actuator to drive to its
Emergency position. There are settings within the actuator to
determine if this is a closed, open or stay put action.
Relay Output DO1 to DO4

These 4 commands are used to energise and deenergise the internal relays on the additional relay board in an IQ or
IQT actuator. (These outputs are referred to as S5-S8 in the standard
actuator documentation when there is no MFU in the actuator.) The
resulting outputs can be used for operating other equipment such as a
pump or indication light. The IQ/IQT actuator is not able to control
these relays directly from the main board when the MFU is fitted. They
will maintain their last state if power is removed from the actuator. On
restoration of power the relays will be reset to their de-energised
condition and the coils will report 0.
Analogue Position
This function is only available over the Modbus RS485 network.
To initiate Analogue Position Control a value must be written the
Position DV register (range 0-100.0%, resolution 0.1%), the valve will
open to the appropriate amount and stop in that position (within the
deadband setting). If a subsequent digital command to open or close
the valve is issued, from any source, this will take priority over the
analogue position command. Once the setpoint is reached the
positioning controller is switched off. A new write to the Position DV
register will initiate positioning mode once more. The register location
is listed later in this manual.
Provided limited range positioning is not invoked the values 0% and
100% written to this register produce a special case output where the
command is revised so as to fully close the valve to its tight shut off
position (0%) and fully open the valve (100%).
Hard Wired Stop The hard wired stop input acts as a change of state input. If the
actuator is moving, opening the Stop input will stop the actuator. If the
Stop input is already open and a Modbus command is sent to the
actuator, the command will be initiated. To stop the actuator the hard
wired input must be closed and opened again.
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With no other command present this digital command causes an

actuator motor that is running to stop.
5.1.1
Controls Priority
Since there are three potential sources for control inputs the Modbus module assigns a priority for
those occasions when two or more commands are applied simultaneously.
In addition, for the IQ and IQT actuator, the remote control hard wired inputs can be used as discrete
input signals, to report the status of other devices. The associated Auxiliary Input Mask parameter
must be set for the IQ or IQT to select the required function. In the case of the hard wired input for
ESD this can be configured either as an ESD/DI-4 signal or as a Modbus Command Inhibit to prevent
network control signals from moving the actuator.
High Priority
Low Priority
Local Stop
Local Close
Hard Wired Close
Modbus Close
Local Open
Hard Wired Open
Modbus Open
Hard Wired ESD
Hard Wired Stopm
Modbus Stop
Modbus ESD
Modbus Position
Mechanically interlocked to prevent both at the same time
The IQ/IQT can be set so that Local Stop has a higher priority than ESD
Only one Modbus command is possible at a time

m
If a Modbus command is applied whilst Hard Wired Stop is present, stop is cancelled
Fig 16: Controls Priorities
5.1.2
Modbus Control using Individual Coil commands
The open, close, stop, ESD and DO-1 to DO-4 controls can be written using function code 05 or 15 to
write to single or multiple coils. Writing the value FF00 turns a coil on and 0000 turns it off. The MFU
provides a degree of intelligence in operating the coils for the open, close, stop and ESD functions.
When one coil is turned on, all the others are turned off, so only one can be on at a time. The actuator
will obey the last command it receives, so if two writes using function code 05 follow each other closely
the last one will win.
A multiple coil write by function code 15 to turn on more than one of the open, close, stop and ESD
coils in the same command is not permitted. If an attempt to energise more than one of these coils in
one command is made an exception response is generated and the multiple write ignored.
With the open and close coils these will turn off once the actuator completes the command, a new
command is sent, the actuator is placed in local or some other interruption occurs. For example the
close coil will de-energise once the actuator reaches the close position and stops. The stop and ESD
coils remains latched once turned on and are cleared by another command or writing 0 to the coil.
The ESD action works slightly differently in that even if the coil is reset to 0, the action remains latched
in the actuator. This is because a network ESD command overrides the actuator local controls. In
order to remove the ESD action it is necessary to write a new command and if the actuator has local
selected then the only command that will clear the latch is a write to the stop coil.
In the case of the DO-1 to DO-4 relays they will follow the command, energising when turned on and
de-energising when turned off. These relays also maintain their status if the actuator power is
removed and reset to the de-energised state only when the power is restored.
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5.1.3
Modbus Control using the Actcon Register
A single register is provided to allow the digital control of the actuator. Writing a value to the register
with function code 06 or 16 causes the actuator to open, close, stop or ESD and at the same time
cancels any other command set. This method of control removes the need to reset commands written
with a code 05 coil write with a second write to the same location. The number written changes any
coil states already set to the new value.
Actcon Register (Register 5)
Value
Stop
0
4 255
No action
5.1.4
Close
Open
ESD
No action
No action
No action
Modbus Control using the Actuator Position DV register
The analogue position control function will take priority over an earlier coil or Actcon register command
to open, stop, close or ESD the actuator when a value is written to the Actuator Position DV register.
The controller will then position the actuator to the desired value.
The analogue position control function is cancelled either by the actuator achieving the desired
position or a coil or Actcon register write to one of the open, stop, close, ESD coils.
Note that when limited range positioning is used and the actuator is in the fully closed or fully open
positions, DV values of 0% and 100% (plus the deadband setting) are not acted upon since under or
over range position values (those outside 0-100%) are not catered for.
5.1.5
The IQ S contacts (Modbus DOs).
The IQ/IQT actuator has four S contact outputs that may be configured to report the status of the
actuator with signals such as Open Limit, Closed Limit etc. These are identified as S1 to S4.
In addition an optional additional relay board can be fitted with four more relays. The status of these
relays is then adjusted by Modbus commands on outputs DO-1 to DO-4. Note that these relays are
latching and, if energised, will not change state when the actuator power is removed.
IQ or IQT with Additional Relay Output board fitted
Actuator
Main
Board
MFU
S1 - S4
DO-1to DO-4
Output Board
Fig 17: IQ and IQT relay outputs DO-1 to DO-4

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5.1.6
IQ Modbus Network Control Disable feature
It is possible to set the IQ or IQT ESD/DI-4 input so that the IQ/IQT actuator ignores open, stop, close,
ESD and position control signals sent over the Modbus network. If the ESD DI-4 / Net Disable
parameter is set to Active then when the ESD input is connection is made (i.e. 24 volts applied to
ESD), Modbus control is not allowed. This feature is independent of the Auxiliary mask setting. When
the ESD DI-4 / Net Disable parameter is set to active, no ESD will be available.
5.2
Actuator Digital Input Status Feedback
The Modbus module can report over the network a comprehensive data set relating to the status of
the valve and actuator as indicated in the table below. The conventional contact indications are also
available from the actuator limit switches and indication contacts.
Status Feedback
IQ actuator
IQTactuator
Q actuator
Actuator Moving
Close Limit
Open Limit
Running Closed
Running Open
Remote selected
Local Stop selected
Local selected
Thermostat Tripped
Monitor Relay
Valve Obstructed
Valve Jammed
Valve Moving by Hand
Moving Inhibited
Position Control Enabled
Watchdog Recovery
Battery Low
Open Interlock input
Close Interlock input
DI 1
DI 2
DI 3
DI 4
Slow Mode
Note: j This bit is reported when within the slow mode band, but does not affect the actuator.
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5.2.1
Digital Inputs from All Actuator Types
Actuator Moving Whenever the actuator position is changing due to the motor running
or in the case of the IQ or IQT if the output drive is moving, this bit will
be set true (1).
Close Limit
Open Limit
Running Closed Whenever the actuator motor contactor used to drive the actuator in
the closing direction is energised this bit will be true (1).
Running Open
Remote Selected This bit is true (1) when the actuator three position remote/local
stop/local selector is in the Remote position. The selector must be in
this position for Modbus control to be permitted.
Local Stop
The actuator three position selector passes from Local to Remote or

Remote to Local through the Local Stop position. The switch can also
be placed in Local Stop. When the switch is in the Local Stop position
this bit will be true (1). Remote control of the actuator is not possible
when the selector is in this position.
Local Selected
This bit is true (1) when the actuator three position remote/local
stop/local selector is in the Local position. Remote control of the
actuator is not possible when the selector is in this position.
Thermostat
If the temperature of the motor windings rises above the thermostat

trip value, the thermostat contact will open and this signal will be
present (1). There are no adjustments for the temperature at which
the thermostat trip operates. The motor will be stopped if the
thermostat trips. Only once the motor has cooled down and the
thermostat has reset itself can a new Remote, Host or Local
command to move the actuator be carried out. A setting on the
actuator main board allows the ESD command to override the
thermostat. The bit will remain set at logic 1 until the motor cools down
and the thermostat resets itself.
Monitor Relay
This signal is true (1) when actuator remote control is not available.
The actuator Monitor Relay status is a composite signal for a number
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This data bit indicates that the actuator has reached the closed
position. The limit switch should be set slightly within the actual valve
stroke to allow for torque seating or overshoot on closing without
damaging the valve. The data bit will remain true (1) even if the
position is passed through or exceeded.
This data bit indicates that the actuator has reached the open position.
The limit switch should be set slightly within the actual valve stroke to
allow for torque seating or overshoot on opening without damaging
the valve. The data bit will remain true (1) even if the position is
passed through or exceeded.
Whenever the actuator motor contactor used to drive the actuator in

the opening direction is energised this bit will be true (1).
of alarms. This signal will be set true if the actuator selector is in Local
or Local Stop (not in Remote) or if the thermostat trips. The mains
supply is also monitored and if one of the three phases is lost the
monitor relay bit is set. If the actuator is operated from a single phase
supply and this is lost then communications with the actuator will also
be lost. Where a 3 phase supply is used, if the phase associated with
the control circuits is lost then communications with the actuator will
be lost.
Note:
Note:
Valve Obstructed This bit will be true (1) if the actuator stops in mid travel, following a
command, when not expected to do so. If the actuator torque exceeds
the trip value set during commissioning then the motor will stop and
motion will cease. The reason for the actuator stopping will be the
high torque due to an obstruction and not a Stop signal or reaching
the desired setpoint position.
The bit will remain true (1) until the actuator position changes by 2%
or more.
Attempting to restart the actuator to move towards the obstruction (even if the
obstruction no longer exists) is not possible, the actuator will not restart. The actuator
must be electrically reversed away from the obstruction before attempting to continue in
the original direction.
Valve Jammed
This bit will be true (1) if the actuator is stationary at the end of travel
and fails to move away from the seat of the valve when a network
command requests it to do so. The actuator will trip on excessive
torque due to the valve being jammed in the seat. The MFU fails to
see movement and reports this status after the time set in the
associated parameter during the MFU set up.
The bit will remain true (1) until the actuator position changes by 2%
or more.
Attempting to restart the actuator to move out of the seated position is not possible. The
actuator must be reversed before it will run in the same direction again. The jammed
seat must first be released manually before electrical control is attempted. The problem
may be overcome by adjusting the actuator torque setting which is designed to provide
extra power on leaving the seated position.
Valve Moving by Hand

The manual movement of the valve is reported as true (1)
if the actuator is moved by the handwheel away from the last position.
The percentage of travel required to trip the indication is set in the
associated parameter during MFU set up.
The bit will remain true (1) until the actuator is moved electrically by
either the local controls or a network command.
Moving Inhibited This bit will be true (1) when the Motion Inhibit Timer is active or, in
the case of the IQ/IQT, the Interrupter Timer is active, or both are
active.
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The Motion Inhibit Timer is used in position control to prevent the

actuator from exceeding its prescribed number of starts per hour, or to
reduce the effects of hunting during closed loop control.
The Interrupter Timer in the IQ/IQT can be used over part or the entire
actuator stroke to slow down the effective speed of valve travel.
When under network control, the control signal does not need to be
re-applied when this bit is true, as the action will continue once the
time has elapsed.

This bit will be true (1) when a Position command is
being actioned. This data can be used to indicate that positioning
mode has control of the actuator.
Watchdog Recovery
The MFU watchdog automatically resets the processor if
it is tripped. This bit will be true (1) following a watchdog trip for the
time period set in the associated watchdog timeout parameter.
5.2.2
Digital Inputs from IQ and IQT Actuator
Battery Low
Applicable to IQ and IQT actuators only. The status of the internal

battery is monitored and should it fall below a critical level this signal
will become true (1). The battery is used to power the circuits used to
keep track of the valve position when the actuator mains power is
switched off. This battery is used only when the actuator has no power
feed and the valve is actually moved.
Open Interlock
Applicable to IQ and IQT actuators only. The input contact to the

Open Interlock is monitored by the MFU. Whenever the input contact
is closed this bit will be true (1). If the actuator is not using the
interlock function then this input can be used as a digital status
feedback for a plant signal not associated with the actuator. If the
interlock circuit is being used then this bit will indicate the existence of
an interlocking input that can prevent the actuator from opening.
Close Interlock
Applicable to IQ and IQT actuators only. The input contact to the

Close Interlock is monitored by the MFU. Whenever the input contact
is closed this bit will be true (1). If the actuator is not using the
interlock function then this input can be used as a digital status
feedback for a plant signal not associated with the actuator. If the
interlock circuit is being used then this bit will indicate the existence of
an interlocking input that can prevent the actuator from closing.
Digital Input DI-1 Applicable to IQ and IQT actuators only. This bit reports the status of
the contact connected to the actuator hard wired Open terminals. The
input can be used to control the actuator or simply to report the status
of a plant feedback signal. The function is set in the Auxiliary Input
Mask parameter which determines whether the bit is reported as true
(1) for a closed contact or an open contact and whether the input
controls the actuator or not. Note that the input is always reported
even when it is also controlling the actuator.
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the contact connected to the actuator hard wired Close terminals. The
the contact connected to the actuator hard wired Stop/Maintain
terminals. The input can be used to control the actuator or simply to
report the status of a plant feedback signal. The function is set in the
Auxiliary Input Mask parameter which determines whether the bit is
reported as true (1) for a closed contact or an open contact and
whether the input controls the actuator or not. Note that the input is
always reported even when it is also controlling the actuator.
the contact connected to the actuator hard wired ESD terminals. The
A configuration feature also allows DI-4 to be set to act as a Disable
Fieldbus Control input. In this mode when the input is made
(irrespective of the Auxiliary Mask setting) the actuator cannot be
controlled over the network. This can be useful during plant
commissioning to prevent unwanted valve movement.
5.2.3
Digital Inputs from IQT Actuator
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Slow Mode
Applicable to IQT actuators only. In positioning mode, when the IQT

actuator approaches its setpoint the motor automatically switches to
slow mode and the actuator runs at a lower speed. This allows any
developed inertia to be dissipated and a better positional accuracy to
be achieved without overshoot. The deviation from the setpoint at
which slow mode is adopted is set in the associated parameter.
When slow mode is in use this bit will be true (1).
The IQ and Q actuators also report this bit, but these actuators do not
have a slow mode capability.
5.3
Actuator Analogue Input Feedback
The Modbus module makes available over the network a number of analogue variables. These
contain information about the valve and actuator. If the single highway with analogue input variant of
the Modbus module is used one associated plant measurement is also available.
Analogue Feedback
Actuator Instantaneous Torque
Valve Position
IQ actuator
IQT actuator
Q actuator
Analogue Input j
Note: j Requires the Single Highway + Analogue Input Modbus Module
5.4
Torque
The currently developed torque value is reported as an Integer Value

in the range 0 to 120 (0-78 hex) representing the percentage of
actuator rated torque generated.
Valve Position
The current valve position is reported as an Integer Value in the range

0 to 1000 (0 3E8 hex) representing the percentage position to 0.1%
resolution.
The IQ and IQT actuator automatically scales the valve position value
reported from the setting of the limit switches.
The Q actuator requires the valve to be stroked fully between the
open and close limit switches for the value to be automatically scaled.
This scaling is retained in EEPROM when the actuator power is
removed.
If Limited Range Positioning is invoked by setting the appropriate
parameters, then the reported valve position 0 to 100% follows the
limited range of valve travel.
Analogue Input
The current value of the analogue input is reported as an Integer

Value in the range 0 to 1000 (0 3E8 hex) representing the
percentage value to 0.1% resolution.
The input may be 0 to 5V or 0 to 20mA d.c. from an externally
powered field transmitter (the actuator does not provide the power for
the transmitter).
The input must be calibrated during the set up of the MFU using the
Analogue Input Max parameter. Apply a 100% signal and write a
value to the parameter, the current value will then be reported as
100%. The scaling is retained in EEPROM when the actuator power is
removed.
IQ Data Logger Information
The Modbus module also makes available some of the IQ and IQT data logged information from
registers in the data base. The data available is updated between 90 and 120 seconds after the
actuator stops moving provided the actuator selector is in Remote.
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Close Torque Set
The actuator setting for the maximum generated torque value

permitted when the actuator is moving towards the closed position is
recorded in this register.
Open Torque Set
The actuator setting for the maximum generated torque value

permitted when the actuator is moving towards the open position is
recorded in this register.
Torque at x% when opening There is a set of registers that each record the last value
for the torque generated when the actuator is moving from closed to
open and reaches a particular position (x%). The registers contain 11
values of torque generated in 10% position increments between 0%
and 100% of valve travel.
Torque at x% when closing There is a set of registers that each record the last value
for the torque generated when the actuator is moving from open to
closed and reaches a particular position (x%). The registers contain
11 values of torque generated in 10% position increments between
100% and 0% of valve travel.
Motor Starts Closing Direction

Two registers (one double register) contain the
total number of times the motor contactor to close the valve has been
operated. The first register contains the low order 16 bits. The counter
cannot be reset to zero.
Motor Starts Opening Direction Two registers (one double register) contain the
total number of times the motor contactor to open the valve has been
operated. The first register contains the low order 16 bits. The counter
cannot be reset to zero.
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Modbus Communication
MODBUS COMMUNICATION
6.1
Electrical Specification
Line Electrical Specification:
6.2
RS485, two wire, half duplex
Outer Protocol
Modbus Transmission Mode
Supported Baud Rates
RTU (8 bit Binary data)

300, 600, 1k2, 2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2
(2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2 when using the
internal repeater option)
Number of bits per character

Start bits
Data bits (LSB first)
Parity (configurable)
Stop bits (configurable)
1
8
Odd, Even, None
1 or 2
Error checking
CRC
Message turn round time/delay time

Minimum period between request and response:
Data Speed
(Baud)
Turn Round
Time (mS)
300
600
1k2
2k4
4k8
9k6
19k2
38k4
57k6
115k2
188
100
60
40
28
24
20
20
20
20
Repeater
NAk
NAk
NAk
3.5
3.5
3.5
3.5
3.5
3.5
3.5
Delayj ( S )
Note: j In the Single Highway with Internal Repeater Modbus Module option there is a
propagation delay in the repeater.
k NA = not applicable, the repeater function cannot be used below 2400 baud.
Maximum period between request and response: 190 mS
6.3 Repeaters
A single segment supports up to 32 nodes, one of which is usually the PLC. The addition of repeaters
allows the segment to be extended in length or increase the number of nodes connected or both. The
maximum lengths at different speeds are discussed in section 4.2. The number of repeaters in a single
highway should be kept to a minimum and the usual recommendation is no more that 9. If more
repeaters are added this can seriously extend the delay between a message being sent and the
response arriving at the PLC.
The Single highway with Inbuilt Isolating Repeater version of the Modbus Module introduces
propagation delays as mentioned above. Care must be taken in any system design to allow for these
delays.
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6.4
Dual Channel Mode
The dual channel version of the Modbus module has two ports and allows two data highways to be
used for communication from the host system to the module. These highways operate independently
with a limit of 32 devices per segment and the ports on the module communicate with their associated
highway. There is some interaction between the ports since a single processor serves them and the
following points must be noted.
The module only has one setting for the units address, communication speed and format.
Both the comms ports share one set of common values for these parameters.
When communication is active, every device on the highway reads all the data request or
command messages. Each unit then responds only those messages aimed at its
address.
Port 1 has priority over Port 2. Since every message is read the host system must allow
an idle time on Port 1 to allow Port 2 time to read its messages completely.
A minimum time gap equivalent to 11 bytes of data should be left between data requests
on both highways. This will ensure that the processor has sufficient time to respond to
messages directed at Port 2. Without this idle period messages directed at Port 2 may
not be acknowledged and a response may not be generated.
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Modbus Data Base
MODBUS DATA BASE
The data in the Modbus Module may be collected using a number of different Modbus function codes.
Similarly the commands to the MFU can be either register or discrete based. This inbuilt flexibility is
designed to allow for any host device to be able to access the actuator over a Modbus network in the
simplest way.
This section provides information on the function codes supported and the data that may be collected
or commands issued using those codes.
In all cases registers and discrete locations are numbered from 0 and do not include any offsets.
7.1
Modbus RTU Message Frame
Message synchronisation is maintained by simulation, the receiving MFU monitors the elapsed time
between receipt of characters. If 3 and one-half character times elapse without a new character or
frame completion, then the next byte received will be the start of a new message and begin with the
address.
Modbus
Address
Function
Code
Register or
Discrete
Address
Number of
Registers or
Bits
Data
Field
CRC
Check
8 bits
8 bits
16 bits
16 bits
N bits
16 bits
Fig 18: Modbus transaction format
7.2
Modbus Address
The Modbus Module allows slave addresses in the range 0 to 247 to be used for devices; the
addresses above 247 are reserved for special functions. Address 0 is recognised by all the
slaves and is used for global Broadcast messages only. This leaves 247 addresses for use by
the connected Modbus Modules on the data highway.
Note that the dual highway unit uses a single address for both highway connections.
Single RS485 highway plus one analogue input channel

Address range supported = 0 to 247 (0 for broadcast)
Dual Independent Isolated RS485 highways

Both channels must share the same address
Single RS485 highway with inbuilt isolating repeater

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7.3 Function Code Support

Details of the Request and Reply formats for messages can be found in the Modbus Reference Guide.
PI-Mbus-300. The following table lists the function codes supported by the Modbus Module.
Function
Code
01
02
03
04
05
06
07
08
15
16
17
Modbus Name
Addressing
Read Output Coil Status

Read Input Status
Read Holding Registers
Read Input Registers
Force Single Coil
Preset Single Register
Read Exception Status
Loopback Diagnostic Test
Force Multiple Coils
Preset Multiple Registers
Report Slave ID
Exception Response
Code
01
02
03
06
Discrete
Discrete
Register
Register
Discrete
Register
Discrete
Register
Meaning
Illegal function code or incorrect message length
Illegal data address (Register or discrete address invalid)
Illegal data value
Busy
To read data the function code to use will depend on whether the data is to be read as single bits or as
16 bit registers. For example, code 01 reads data as discrete bits, whereas code 03 reads the data as
registers. In many cases Discrete and Register access reads the SAME data.
Code 01 - Read Coils

This is used to read discrete (bit) data from the data base to obtain
information about the status of the output coils (commands).
Code 02 - Read Input Status Requests

This is used to read discrete (bit) data from the data base to obtain
information about the actuator current status such as open or closed
positions achieved.
Code 03 - Read Holding Register Requests

All the data in the MFU can be read using function code 03. Discrete
data is mapped into registers that are available for this command.
Code 04 - Read Input Register Requests

Actuator position and torque registers, plus the status bits are
accessible with function code 04.
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Modbus Data Base
Code 05 and 15 - Force Single Coil or Multiple Coils

The output coils are the discrete outputs from the actuator or its digital
control commands. Code 05 writes one coil per message whilst code
15 can write values to several at once.
Code 06 and 16 - Preset Single Register or Multiple Registers

Registers are used for position control and also for digital control and
can be accessed singly, or in multiples with these codes. Function
code 06 writes a single 16 bit register whilst function code 16 can
write several in one transaction.
Code 07 Read Exception Status

This is a specific short message function code which returns
predetermined discrete data from the MFU. The message is used to
allow fast transfer of a small data packet.
Code 08 - Loopback Diagnostic Test

The purpose of the Loopback Test is to test the communication
system between the Modbus module and the host. The MFU
supports this test when used with diagnostic code 00, Return Query
Data, and 02, Return Diagnostic Register. No other diagnostic test
codes are supported.
Function Code 17 Report Slave ID

This function code generates a response that contains specific
information about the MFU and actuator (providing the data has been
entered on setup).
Exception Response Codes

Error code 01 will be presented back to the host if the function code in
the data message is not one of those supported by the Modbus
Module or the message length is not as expected.
Error code 02 will be presented back to the host if the Data Address is
not valid for the Modbus Module.
Error code 03 will be presented back to the host if the value to be
written in a coil or register write is not valid for the register or coil
location chosen in the MFU.
Error code 6 will be generated back to the host if the MFU is unable to
respond with a correct message because it is busy.
7.4
Broadcast Commands
Broadcast commands are only supported for specific registers, coils and commands.
39 of 68
Stop and ESD
Code 05 writes to coils 0 (Stop) and 3 (ESD) are supported for

address 0 broadcast.
Code 06 writes to register 5 (Actuator Digital Control) with values 0

(Stop) and 3 (ESD) are supported for address 0 broadcast.
7.5
Data Location Offsets
The locations given in the data base are those, which should appear in the messages as they are
transmitted on the Modbus link. Some host systems offset the addresses so far as the user is
concerned. In such cases the address programmed into the host would be different to those listed. All
data locations listed start from 0. Please check the host system documentation carefully to determine
if any offsets are required.
Typical Offsets are:
7.5
Function
Code
Offset to be added to
formulae result
1
2
3
4
5
6
1
10001
40001
30001
1
40001
Data Locations
The data locations in the following tables are all numbered from 0. For a definition of the actuator
functions listed refer to section 5. Not all the listed signals are available from every actuator type. For
the DO-1 to DO-4 options on IQ and IQT the relay output board must be fitted.
Note:
7.5.1
All data locations listed start from 0, it may be necessary to add an offset to match the
number required for the PLC.
Data Accessed with Function Code 01 - Read Coils
Location
(Bit)
0
1
2
3
4
5
6
7
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
Data
Stop command output coil status
Close command output coil status
Open command output coil status
ESD command output coil status
DO-1 output coil status
Note: Coil on when the state is true, reports as a 1.
40 of 68
Range
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
Modbus Data Base
7.5.2
Data Accessed with Function Code 02 - Read Discrete Inputs
Location
(Bit)
0
1
2
3
4
5
6
7
RO
RO
RO
RO
RO
RO
RO
RO
Actuator moving
Closed limit
Open limit
Running closed
Running open
Remote selected
Local Stop selected
Local selected
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
8
9
10
11
12
13
14
15
RO
RO
RO
RO
RO
RO
RO
RO
Thermostat tripped
Monitor relay
Valve obstructed
Valve jammed
Valve moving by hand
Moving inhibited
Position control enabled
Watchdog recovery
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
16
17
18
19
20
21
22
23
RO
RO
RO
RO
RO
RO
RO
RO
Battery low
Open interlock active
Close interlock active
DI-1
DI-2
DI-3
DI-4
Slow mode
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
R/W
Data
Range
Note: When the input is true the status reports as a 1.
7.5.3
Data Accessed with Function Code 03 - Read Holding Registers
The accessible registers that can be read with this function code also include the Input registers.
Location
(Reg/Bit)
R/W
0
0
0
0
0
0
0
0
0
1
2
3
4
5
6
7
RO
RO
RO
RO
RO
RO
RO
RO
Actuator moving
Closed limit
Open limit
Running closed
Running open
Remote selected
Local Stop selected
Local selected
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0
0
8
9
RO
RO
Thermostat tripped
Monitor relay
0-1
0-1
41 of 68
Data
Range
Location
(Reg/Bit)
R/W
0
0
0
0
0
0
10
11
12
13
14
15
RO
RO
RO
RO
RO
RO
Valve obstructed
Valve jammed
Moving inhibited
Watchdog recovery
0-1
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
RO
RO
RO
RO
RO
RO
RO
RO
Battery low
DI-1
DI-2
DI-3
DI-4
Slow mode
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
1
1
1
8
9
10
11
12
13
14
15
RO
RO
RO
RO
RO
RO
RO
RO
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
RO
RO
Valve Position
0-3E8 hex
(0.0 100.0%)
RO
Analogue Input
0-3E8 hex
(0.0 100.0%)
R/W
Actuator Digital Control
R/W
Actuator Position DV (desired value)
2631
R/W
Actuator Tag name
Data
Range
0
0
0
0
0
0
0
0
0-78 hex
(0 120%)
0-3
0 = stop,
1 = close
2 = open
3 = ESD
0-3E8 hex
(0.0 100.0%)
12 bytes
ASCII char
The following Data Logger information is also accessed by function code 03. Torque values are in the
range 0 120%. The registers are updated with new data a short period after the actuator stops
42 of 68
Modbus Data Base
movi ng provided the actuator selector is in remote. The values may not contain the updated
information for up to 2 minutes.
Location
(Reg/Bit)
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
7.5.4
R/W
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
RO
Data
Close Torque set
Open Torque set
Torque at 0% - open direction
Torque at 0% - close direction
Close Contactor counts low order
Close Contactor counts high order
Open Contactor counts low order
Open Contactor counts high order
Range
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-78 hex
0-FFFF hex
0-FFFF hex
0-FFFF hex
0-FFFF hex
Data Accessed with Function Code 04 - Read Input Registers
Location
(Reg/Bit)
0
0
0
1
0
2
0
3
0
4
0
5
0
6
0
7
RO
RO
RO
RO
RO
RO
RO
RO
Actuator moving
Closed limit
Open limit
Running closed
Running open
Remote selected
Local Stop selected
Local selected
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0
0
0
RO
RO
RO
Thermostat tripped
Monitor relay
Valve obstructed
0-1
0-1
0-1
43 of 68
8
9
10
R/W
Data
Range
Location
(Reg/Bit)
R/W
0
0
0
0
0
11
12
13
14
15
RO
RO
RO
RO
RO
Valve jammed
Moving inhibited
Watchdog recovery
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
1
1
1
0
1
2
3
4
5
6
7
RO
RO
RO
RO
RO
RO
RO
RO
Battery low
DI-1
DI-2
DI-3
DI-4
Slow mode
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
1
1
1
1
1
1
1
1
8
9
10
11
12
13
14
15
RO
RO
RO
RO
RO
RO
RO
RO
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
RO
RO
Valve Position
0-3E8 hex
(0.0 100.0%)
RO
Analogue Input
0-3E8 hex
(0.0 100.0%)
7.5.5
Data
Range
0
0
0
0
0
0
0
0
0-78 hex
(0 120%)
Data Accessed with Function Code 05 and 15 Force Single and Multiple Coils
Location
(Bit)
0
1
2
3
4
5
6
7
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
R/W
Data
Range
0-FF00
0-FF00
0-FF00
0-FF00
0-FF00
0-FF00
0-FF00
0-FF00
hex
hex
hex
hex
hex
hex
hex
hex
Using code 05 write FF00 (hex) to turn on the command, DO-1 to DO-4 are turned off by writing 0.
The other coil commands are cleared by various means as explained in section 5.1.2.
44 of 68
Modbus Data Base
Using code 15 write 1 to turn on the command and 0 to turn off the command.
The commands to open, close, stop or ESD the actuator are not cancelled by writing a 0. The
actuator latches the instruction and will complete the action unless a subsequent counter command is
received before the action is completed.
7.5.6
Data Accessed with Function Code 06 and 16 Preset Single and Multiple Registers
Location
(Reg/Bit)
5
-
R/W
R/W
Actuator Position DV (desired value)
R/W
Data
Range
0-3
0 = stop,
1 = close
2 = open
3 = ESD
0-3E8 hex
(0.0 100.0%)
The Actuator Digital Control register allows one of the four commands to be selected by writing the
appropriate value.
Provided limited range positioning is not invoked, the Actuator Position DV register assigns a special
importance to the values 0% and 100% written to this register. The command is revised so as to fully
close the valve to its tight shut off position (0%) and fully open the valve (100%).
7.5.7
Data Accessed with Function Code 07 Read Exception Status
Code 07 reads a predefined data set with minimal overheads and is used for fast data transfer. A
single byte is returned.
Location
(Bit)
0
1
2
3
4
5
6
7
7.5.8
R/W
RO
RO
RO
RO
RO
RO
RO
RO
Data
ESD coil status
Open coil status
Close coil status
Stop coil status
Closed position limit
Open position limit
Monitor relay
Reserved
Range
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
Data Accessed with Function Code 08 Loopback Diagnostic Test
The Loopback Test is used to test communications only. In a correctly working unit the return
message is the same as the query sent. Two codes are supported.
45 of 68
Code
00
02
Data
Return query data
Return diagnostic register
The Diagnostic Register contains the following data.

Location
R/W
Data
(Reg/Bit)
-
0
1
2
3
7.5.9
RO
RO
RO
RO
Range
Memory Status Fault

Auxiliary control input active
Position controller enabled
Highway ESD active
0-1
0-1
0-1
0-1
Data Accessed with Function Code 17 Report Slave ID
The Slave ID data response includes 20 registers, (40 bytes) of ASCII data to give the device name,
software version and service tag number.
Byte
0 23
24 28
29 40
7.6
Data
Rotork Modbus Module. (first two characters are nulls)
Software version: Mxxx (where xxx is the revision number)
Tag Number (12 bytes)
Data Base Summary:
Data
Stop
Close
Open
ESD
0
1
2
3
Type
(register =
16bits)
Digital Output
Digital Output
Digital Output
Digital Output
Output DO-11(relays 5)
Output DO-2 (relays 6)
4
5
6
7
Digital Output
Digital Output
Digital Output
Digital Output
Actuator moving
Close position limit
Open position limit
Valve running close
Valve running open
Selector in remote
Selector in local stop
Selector in local
Thermostat tripped
Monitor relay
Valve obstructed
Valve jammed
Manual movement
MIT/Interrupter timer
Watchdog
Battery low
0/0
0/1
0/2
0/3
0/4
0/5
0/6
0/7
0/8
0/9
0 / 10
0 / 11
0 / 12
0 / 13
0 / 14
0 / 15
1 / 16
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
46 of 68
Location
(Reg / Bit)
01
02
Accessed by MODBUS function code

03
04
05
06
15
16
Other
01
01
01
01
03
03
03
03
05
05
05
05
07
07
07
07
01
01
01
01
03
03
03
03
05
05
05
05
15
15
15
15
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
02
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
04
04
04
04
04
04
04
04
04
04
04
04
04
04
04
04
04
15
15
15
15
07
07
07
Modbus Data Base
Data
Open Ilock input active

Close Ilock input active
Hard wired input DI-1
Slow mode
1 / 17
1 / 18
1 / 19
1 / 20
1 / 21
1 / 22
1 / 23
Type
(register =
16bits)
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital Input
Digital input
Instantaneous torque
Valve position
Analogue input
2/3/4/-
Actuator digital control

Position demand output
Action on loss of signal
Min position
Max position
Deadband
MIT
Aux mask
Comms lost position
Hysteresis
Slow mode range
Jammed time
Manual movement travel
Watchdog timeout
ESD DI4/Net disable
Analogue input max
Comms fault timer
Address
Baud rate
Parity, Stop bits
Database format
Actuator Tag number
Data logger data
Memory status OK/Fault
Aux control input active
Positioner enabled
Highway ESD active
47 of 68
Location
(Reg / Bit)
01
02
03
03
03
03
03
03
03
04
04
04
04
04
04
04
Input reg
Input reg
Input reg
03
03
03
04
04
04
5/6/7/8/9/10 / 11 / 12 / 13 / 14 / 15 / 16 / 17 / 18 / 19 / 20 / 21 / 22 / 23 / 24 / 25 / 26 31 / 32 59 / -
Output reg
Output reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
Parameter reg
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
03
Diagnostics
Diagnostics
Diagnostics
Diagnostics
/0
/1
/2
/3
02
02
02
02
02
02
02
Accessed by MODBUS function code

03
04
05
06
15
16
Other
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
06
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
16
08 (02)
08 (02)
08 (02)
08 (02)
48 of 68
Configuration Registers
CONFIGURATION REGISTERS
In order to make the best use of the MFU, the module has a number of configurable parameter
registers that may be adjusted to optimise the performance of the actuator. All the parameter registers
have factory default setting designed to meet the most common requirements for the actuator. If these
are not suitable for a particular application then by using a Modbus communication tool the values can
be changed.
The Modbus Module contains 20 configurable parameter registers; with the IQ and IQT actuator some
of these can be altered by using the infra-red communications link and the setting tool. By using a
Modbus communication tool connected to the RS485 highway all the registers may be reviewed and
altered to suit the particular application for the actuator.
Care must be exercised with access to these parameter registers as they can alter the complete
performance of the actuator, including selecting a different operating data base.
This section of the manual describes each variable parameter register and should be used for
reference when using the configuration tools. All the registers can be read using function code 03
(Read Holding Registers). The contained values may be altered using function code 06 (Preset Single
Register) or function code 16 (Preset Multiple Registers).
Actuator Related Network Configurable Parameter Registers

Description
Value/Range
Action on Loss of Comms
0 = Nothing (No Action)

1 = Open
3 = Close
5 = Stop
7 = Position
Any other value = Off
Limited Range Position

Minimum
Limited Range Position
Maximum
Deadband j
0 100%
0000 0064 hex
0 100%
0000 0064 hex
0.0 25.5% k
0000 00FF hex
0 255 sec
0000 00FF hex
0 255
0000 00FF hex
0 100%
0000 0064 hex
0.0 25.5%
0000 00FF hex
0 100%
0000 0064 hex
Motion Inhibit Time

Aux Input Mask
Comms Lost Position
Hysteresis j
Slow Mode Range
49 of 68
Default
Value
0 = Nothing
(0000 hex)
Location
(Register)
7
03
06
16
0%
0000
100%
0064 hex
5.0%
0032 hex
3 sec
0003 hex
15
000F hex
0%
0000 hex
2.0%
0014 hex
5%
0005 hex
03
06
16
03
06
16
10
03
06
16
11
03
06
16
12
03
06
16
13
03
06
16
14
03
06
16
15
03
06
16
R/W Access
Description
Valve Jammed Time
Manual Movement Travel
Watchdog Timeout
ESD DI-4/Net Disable
Analogue Input Max
Comms Fault Timer
Note:
Value/Range
0 255 sec
0000 00FF hex
0 100%
0000 0064 hex
0 255 sec
0000 00FF hex
DI-4 is ESD = 0
DI-4 is Net Disable = 1
0 1023
0000 3FF hex
0 255 sec
0000 00FF hex
Location
(Register)
16
03
06
16
17
03
06
16
18
03
06
16
19
03
06
16
20
03
06
16
21
03
06
16
R/W Access
j - Setting the deadband lower than the hysteresis, or the hysteresis greater than the
deadband causes the hysteresis to be set to 0.1%
k - IQ Setting tool only allows 0.0 to 9.9% deadband to be set
Modbus Network Related Network Configurable Parameter Registers
Description
Modbus Address
Baud Rate (baud)
Value/Range
1 247
0001 00F7 hex
0 = not used
1 = 300
6 = 9k6
2 = 600
7 = 19k2
3 = 1k2
8 = 38k4
4 = 2k4
9 = 57k6
5 = 4k8
A = 115k2
(values in hex)
Parity/Stop bits
0
1
2
3
4
5
Data Base Format
Modbus Mk1/Mk2
0 = Mk1
1 = Mk2
Any ASCII char
(12 characters max)
Actuator Tag Name
50 of 68
Default
Value
5 sec
0005 hex
10%
000A hex
10 sec
000A hex
ESD
0000 hex
0
0000 hex
10 sec
000A hex
= No parity, 1 stop bit

= No parity, 2 stop bits
= Even, 1 stop bit
= Even, 2 stop bits
= Odd, 1 stop bit
= Odd, 2 stop bits
Default
Value
247
00F7 hex
9k6
(0006 hex)
Location
(Register)
22
03
06
16
23
03
06
16
None/1
(0000 hex)
24
03
06
16
Mk2
(0001)
25
03
06
16
(blank)
all = 0000
26 to 31
03
06
16
R/W Access
8.1
Actuator Related Configurable Parameter Registers
These parameter registers set up the response of the actuator will take to various control and network
actions.
8.1.1
Action on Loss of Comms (Register 7)
This register is used in conjunction with register 13 (Comms Lost Position) and 21 (Comms Fault
Timer).
The Action on Loss of Comms register defines the actuator action that will result after the time set for
the Comms Fault Timer (register 21) if there is no network communication activity detected by the
MFU.
The action may be
q Nothing
q
q
q
q
8.1.2
Open
Close
Stop
Position
(0)
(1)
(3)
(5)
(7)
No action, actuator will complete any command in process (the default

setting)
The actuator will open the valve
The actuator will close the valve
The actuator stops
The actuator will adjust the valve position to the setting given in the
Comms Lost Position (register 13).
Limited Range Position Minimum and Maximum (Registers 8 and 9)
These parameter registers are used to define the positions in the range of valve travel that will be
reported as 0 to 100% if it the whole travel from the closed position to the open position is not used. In
addition the position demand setpoint output value will also be modified to follow this limited range.
It is possible to make the position data reported and the position controller relate to a reduced span of
actual valve travel. In this mode the position data relates to the reduced portion of the valve stroke.
This is sometimes used where the valve is required to have a 0% position (or 100% position) that is
not the same as the fully closed position (or fully open position). These parameters define the actual
limited range of valve travel that will be used for the position reporting and control by the positioner.
0% ----------------- Reported Position --------------------- 100%
Valve Stroke
CLOSED
OPEN
Position Minimum Setting
Position Maximum Setting
Fig 19: Limited Range Position Control and Reporting

Note that the digital open and close commands will still make the valve travel over its full stroke. The
special case analogue commands of 0% and 100% that would otherwise cause the actuator to travel
to the limit switch or torque off positions are inhibited if values other than 0 and 100 are set in these
parameters.
The values inserted relate to the maximum total valve travel between closed and open and represent
the point in the full stroke which will now be used for the limited stroke 0 and 100 values.
51 of 68
8.1.3
Deadband and Hysteresis (Registers 10 and 14)
When using position control by sending a value to the Actuator Position DV setpoint there are a
number of parameter registers used to tune the position controller and reduce the possibility of
damage to the actuator. These two registers are set to prevent hunting around the setpoint due to high
inertia of the valve. They will require adjustment for each specific application. In addition the Motion
Inhibit Timer is used to ensure the actuator does not carry out an excessive number of starts in a
given period.
Deadband
The control used for the positioner is proportional only. The MFU will
run the actuator to the desired position and then it stops. As the
actuator and valve combination have some inertia there is a possibility
that the desired position may be overrun and the positioner will then
reverse the direction of travel to make the valve adopt the desired
position. This overshoot and return may continue for a number of
cycles and is known as hunting, the valve and actuator combination
will hunt around the setpoint if the inertia is high. To prevent this from
happening there is a Deadband setting whereby once the actuator
enters the deadband the motor will be stopped. For example a 5%
deadband will cause the motor to be stopped once the actual position
is within 5% of the desired position. The inertia will then bring the
actual position nearer the desired position.
The deadband is the allowable error around the setpoint.
Hysteresis
In addition to the deadband a second setting, hysteresis, further

refines the performance of the position controller. The positioner will
run the actuator towards the setpoint DV until the actual position is
within the deadband minus the hysteresis setting. This has the effect
of instructing the actuator to stop when it is nearer the DV. The
actuator will not restart unless it overshoots and runs outside the
deadband or a new command places the new desired position outside
the deadband.
0%
Setpoint DV = 50%
Position MV = 50%
Valve Stroke
100%
CLOSED
OPEN
Position Minimum Setting
Position Maximum Setting
47% 48% 49% 50% 51% 52% 53%
nnnnoooooooooooooonnnn
Hysteresis
Deadband
Fig 20: Deadband and Hysteresis settings
Hysteresis
Deadband
Hysteresis = 1%
Deadband = 3%
The Hysteresis is the amount of movement inside the deadband

permitted before the motor stops.
52 of 68
8.1.4
Motion Inhibit Timer (Register11)
The Motion Inhibit Timer setting is the period that must elapse between consecutive starts of the
actuator motor when in positioning mode. The idle period will prevent the actuator motor from
exceeding its rated number of starts per hour.
In addition, when tuning the valve positioner the setting can be used to allow the plant dynamics to
stabilise between valve movements.
8.1.5
Auxiliary Input Mask (Register 12)
This parameter register relates to the IQ and IQT actuators only and allows the auxiliary inputs (open,
stop, close, ESD) to be set to control the actuator or simply report their status. In addition it allows the
sense of the input (open or closed contact) that is reported as true (1) to be set. Actuator control
always requires a true (1) input signal. The status of the inputs is always reported over the network
and they can be used to report associated plant inputs instead of controlling the actuator.
The register should be considered in its binary format using the low order byte. The number has the
7 6 5 4
3 2 1 0
7 6 5 4
binary form x x x x , y y y y , requiring 8 bits. Each bit in the high order nibble, x x x x , either enables
3 2 1 0
or disables the associated input for control of the actuator. The bits in the low order nibble, y y y y ,
determines if the input reports a closed contact as a '1' or an open contact as a '1'. Only when the
input is a '1' as set by the mask and the contact state will the actuator respond to the input if it is also
set to control the actuator.
To allow an input to act as a control signal its associated bit in the high order nibble must be set to a '1'
in the mask. To allow a closed contact to be reported as a '1' then its associated bit in the low order
nibble must be set to '1' in the mask.
Bit
Position
Value
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Function
Disable ESD input as command
Enable ESD input as command
Disable Stop/Maintain input as command
Enable Stop/Maintain input as command
Disable Close input as command
Enable Close input as command
Disable Open input as command
Enable Open input as command
Report closed contact on ESD input as 0
Report closed contact on ESD input as 1
Report closed contact on Stop/Maintain input as 0
Report closed contact on Stop/Maintain input as 1
Report closed contact on Close input as0
Report closed contact on Close input as 1
Report closed contact on Open input as 0
Report closed contact on Open input as 1
The following examples show how the Auxiliary Input Mask settings can be applied.
53 of 68
Most Significant Bit
Example 1
Example 2
Example 3
Bit 7
7
X
Enable
DI-4
ESD
0
1
0
Example 1
Example 2
Example 3
8.1.6
Bit 6
6
X
Enable
DI-3
Stop
0
1
0
Least Significant Bit

Bit 5
5
X
Enable
DI-2
Close
0
1
0
Bit 4
4
X
Enable
DI-1
Open
0
1
0
Bit 3
3
Y
Bit 2
2
Y
Bit 1
1
Y
Bit 0
0
Y
Invert
DI-4
Invert
DI-3
Invert
DI-2
Invert
DI-1
1
1
0
1
1
0
1
1
0
1
1
0
The default value of '15' (0000,1111 binary or 0F hex) makes all 4

inputs report closed contacts as true (1) and none of the inputs will
operate the actuator.
The value 255 (1111,1111 binary or FF hex) makes all 4 inputs report
closed contacts as true (1) and all the inputs control the actuator in
their predefined way.
The value 0 (0000,0000 binary or 00 hex) makes all 4 inputs report
open contacts as true (1) and none of the inputs will operate the
actuator.
Comms Lost Position (Register 13)
The setting in this parameter register determines the position in the range 0 to 100% that the actuator
will move to if the Modbus network communications stops being received, provided the Fault Mode
(Register 1) is set to 'Position'. No action will be taken unless the communications stops for a period
equal or greater than the setting in the Comms Fault Timer (Register 21).
8.1.7
Slow Mode Range (Register 15)
This parameter register is only applicable to IQT actuators. The Slow Mode Range sets the deviation
between the setpoint and current position in positioning mode inside which the actuator motor will slow
to minimum speed.
If the setpoint (DV) is 50% and the setting for this parameter is 10%, then when the actuator moves
within the range 40% to 60% the motor will adopt low speed. The actuator does not use slow mode for
digital (Open/Close) commands.
8.1.8
Valve Jammed Time (Register 16)
Parameter register 16 sets the time delay that must elapse without any actuator movement before
deciding the Valve Jammed status bit must be set. Valve Jammed is only announced if the actuator is
asked to move and fails to respond when it should. The time must be long enough to ensure that the
valve is not moving at all.
8.1.9
Manual Movement Travel (Register 17)
Manual Movement Travel sets the amount of valve travel not under motor action that is permitted
before being considered 'Manual Movement'. The setting must be sufficiently large to cover over run of
position control due to valve inertia. Too small a setting will result in Manual Movement alarms each
time the valve is positioned, particularly if the deadband is small.
54 of 68
8.1.10
Watchdog Timeout (Register 18)
If the watchdog trips to reset the processor the Watchdog Recovery data bit is set. The data bit will
automatically reset to '0' after the time period set in this parameter register.
8.1.11
ESD DI4/Net Disable (Register 19)
In the IQ/IQT actuator this input determines the mode of operation for the ESD/DI-4 remote input. The
input can be used either to disable control of the actuator from the network, or to act as an ESD/digital
input. When this setting is made 'Active' the input will disable network control of the IQ/IQT when the
contact input is closed irrespective of the Aux Mask setting.
8.1.12
Analogue Input Max (Register 20)
The MFU includes an analogue input channel for a process input. This input will require calibration to
ensure it is accurately reported.
This parameter can only be set when the MFU is on line and the analogue input should be connected
to a calibration source. When the register is set this causes the analogue input to be sampled and the
value read to be used for the input to be reported as 100.0%. If the parameter register is simply read
then the value displayed is the raw analogue input value.
Apply a 100% input and write any number between 1 and 1023, but different from the currently
register value, write the new value and read back from the MFU. The number in the register will
change to the raw A/D value equivalent to the currently applied analogue signal and the reported
value for the Analogue Input in register 4 will read 1000 decimal, 03C8 hex(100.0%).
8.1.13
Comms Fault Timer (Register 21)
Parameter register 21, the Comms Fault Timer setting, determines the number of seconds that
network communication must be absent before the setting for the Fault Mode will be carried out.
8.2
Modbus Network Related Configurable Parameter Registers
These parameter registers set up the MFU for network communications.

8.2.1
Modbus Address (Register 22)
The Modbus Address is the address on the network that the Modbus module will respond to. The
address can be in the range 1 to 247, though 247 is generally not used as this is the default address
and may be used by any newly introduced device on the network.
With a dual channel unit both channels user the same address.
Changes to the register altering the address will become effective only after the actuator power is
cycled.
55 of 68
8.2.2
Baud Rate (Register 23)
Register 23 sets the communication baud rate. Note that the new setting for this register will not
become active until the actuator power is cycled. On a dual channel unit both channels operate at the
same baud rate.
8.2.3
Parity and Stop Bits (Register 24)
The parity and number of stop bits used in the communications is selected by altering the content of
this register. Note that the new settings for this register will not become active until the actuator power
is cycled. On a dual channel unit both channels operate using the same parity and stop bit setting.
8.2.4
Data Base Format (Register 25)
The Modbus module can utilise different data base formats, the one to use is selected by the content
of this register. Note that the new settings for this register will not become active until the actuator
power is cycled. On a dual channel unit both channels operate using the same data base.
The Mk2 data base is as detailed in section 7. Where the MFU is being used as a spare part to
replace the earlier design it is possible to select Mk1 data base where data and performance are as
the older unit. Appendix A gives the data base locations used by the Mk1 protocol.
8.2.5
Actuator Tag Name (Register 26 to 31)
The MFU may be programmed to contain a 12 character tag name string in these registers. Each byte
contains one character.
56 of 68
Setting Up the MFU
SETTING UP AND MAINTAINING THE MODBUS MODULE
In most applications the majority of the default settings in the Modbus Module will be suitable for the
operation of the valve and need not be altered. However, in every case it will be necessary to alter the
address since the default should never be used within a live system (the default value is 247).
9.1 Using a Network Configuration Tool

Any device capable of writing register values can be used to configure the Modbus Module. Changes
to the actuator related parameter registers become active immediately they are altered. Changes to
the network related parameters usually require a power cycle of the actuator.
The individual register values required may be different for each actuator and will depend on the
application and process being controlled as well as the actuator size, speed and other design features.
9.2 Setting up an IQ or IQT with the Setting Tool

The IQ and IQT actuator includes an infra red communication port for setting the actuator
performance, limit switches and so on. This communication link can be used to set some, but not all,
of the MFU parameter registers. The registers should still be checked with a Modbus host device to
ensure optimum actuator and network compatibility.
The diagram illustrates the access route through the actuator menu screens to reach the settings that
affect the MFU. Note that the [Od] function must be set to [OP], if it is not then the card will not be
able to control the actuator.
The parameters that may be set by using the Setting Tool and the infra red link are listed below. The
available range for the deadband setting when using the setting tool is less than the range found using
the configuration tools.
Register
No.
7
Description
8
9
10
11
12
13
22
23
Limited Range Position Minimum

Limited Range Position Maximum
Deadband
Motion Inhibit Time
Aux Input Mask
Comms Lost Position
Address
Baud Rate (baud)
24
Parity (1 stop bit)
57 of 68
Range
Nothing (No Action),
Stop, Close, Open,
Position
0 100%
0 100%
0.0 9.9%
0 255 sec
0 255 (00 FF hex)
0.0 100.0%
0 247
300, 600, 1k2, 2k4,
4k8, 9k6, 19k2, 38k4
Odd, Even, None
Default
Value
Nothing
0%
100%
5.0%
3 sec
15 (0F)
0.0%
247
9k6
None
Position Display
Position Display + Torque
Password
CR
R1
R2
R3
R4
A1
A2
A3
A4
A5
A6
A7
A8
A9
ESD
ESD
ESD
ESD
ESD
Maintained
2-wire
External
Conditional
action
contact
t/stat
override
override
local
control
interlocks
control
type
bypass
interlocks
local stop
control
OE
OI
OF
Od
OP
OJ
Or
OS
Extra
CPT
Folomatic
Remote
Bus
Interrupter
Setting
Power
indication
remote
control
system
timer
tool local
loss
contacts
control
source
option
control
inhibit
(must be
(must be
(must be
ON)
set to OP)
ON)
PA
PB
PF
PP
Address
Baud rate
Aux I/P
Parity
Range
See note
mask
setting
01-FF
See note
FI
Fr
FL
FH
Fd
Ft
FA
FF
Set point
Set point
Low set
High set
Position
MIT
Action
Action
signal
signal
point 0%
point
control
on loss
on loss
type
range
position
100%
deadband
of signal
of signal
limit
pos limit
position
R5
Etc.
Note: Baud rate settings:

01 = 110 (Mk1 protocol only)
03 = 300
06 = 600
12 = 1200
24 = 2400
48 = 4800
96 = 9600
19 = 19200
38 = 38400
Parity settings:
No = No parity
En = Even parity
Od = Odd parity
Stop bits always = 1
Fig 21: Setting tool menu structure and MFU settable parameters
58 of 68
Setting Up the MFU
9.3
Maintenance and Repair
There is no periodic service requirement for the MFU.

Repairs should not be attempted on the module. The mezzanine and main board are a pair and
should never be separated. Replacing the complete MFU assembly with a new replacement device
should rectify any failure. Static sensitive devices are used in the MFU, it is therefore mandatory to
observe anti-static precautions when handling or working on the unit.
9.4
Records
In order that a replacement can be easily introduced in the event of a device failure it is very important
to record and keep safe all the settings made for the variable registers. The table lists all the registers
that must be checked and set up for each Modbus module on a network. The data should be recorded
for each module.
Note:
q
Param
No.
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
q
Param
No.
22
23
59 of 68
Make a note of all changes to register settings to ensure that, in the case of a failure,
the replacement device can be swiftly set to the correct values.
Actuator Configurable Registers
Description
Setting
Notes
Setting
Notes

Limited Range Position Minimum
Limited Range Position Maximum
Deadband
Motion Inhibit Time
Aux Input Mask
Comms Lost Position
Hysteresis
Slow Mode Range
Valve Jammed Time
Manual Movement Travel
Watchdog Timeout
ESD DI-4/Net Disable
Analogue Input Max
Comms Fault Timer
Network Configurable Registers
Description
Address
Baud Rate (baud)
Param
No.
24
25
26-31
60 of 68
Description
Setting
Parity and Stop bits

Data Base Format
Actuator Tag Name
Notes
Appendix A - Mk1 Data Base
APPENDIX A MODBUS MODULE MK1 DATA BASE

A.1 Introduction
The Modbus Module Mk2 has the ability to replicate the data base used in the Mk1 design. This
permits the use of the Mk2 card as a spare part to replace Mk1 cards in most applications. For exact
compatibility please check the original system configuration.
When the module is used to replicate the Mk1 the main difference fro the Mk2 is in the data base for
collecting data and issuing commands. The electrical and physical properties remain as the same.
This section describes the Mk1 data base.
A.2 Input and Output Signals

A.2.1
Control Outputs
Command
Modbus over the network
Open
Close
Stop
Emergency Shut Down
Position Enable
Relay output DO-1j
Relay output DO-2j
Relay output DO-3j
Relay output DO-4j
Analogue Position demand (DV)
Local Controls
Open
Close
Stop
IQ actuator
IQT actuator
j
j
j
j
j
j
j
j
Direct Wired Inputs

Open
Close
Stop/Maintain
Emergency Shut Down
Open Interlock (active prevents opening)
Close Interlock (active prevents closing)
Note: j Requires relay output board to be fitted
61 of 68
A.2.2
Digital Input Status Feedback
Status Feedback
IQ
IQT
Actuator Moving
Close Limit
Open Limit
Thermostat Tripped
Monitor Relay
Local selected
Remote selected
Battery Low
Running Closed
Running Open
Interrupter Timer
MIT Active
Error
S1
S2
S3
S4
DI 3
DI 2
DI 1
DI 4
A.2.3
Centre column moving for any reason

End of travel position, closed position achieved
End of travel position, open position achieved
Motor temperature thermostat operated
Local or Local stop selected or Phase loss or
thermostat tripped
Selector in local control position
Selector in remote control position
Battery power low
Actuator close contactor energised
Actuator open contactor energised
Interrupter Timer operating
Motion Inhibit Timer active
Open Interlock present
Close Interlock present
Actuator in positioning mode
Device Fault, use Loopback Test to determine the
error.
Setting for S1 on the actuator
Remote input for Stop condition
Remote input for Close condition
Remote input for Open condition
Remote input for ESD condition
Analogue Input Status Feedback
Analogue Feedback
Actuator Instantaneous
Torque
Valve Position
62 of 68
Definition
IQ
IQT
Definition
Current torque value,
Scale: 0-120% = 0-65536
Current position,
Scale: 0-100% = 0-65536
A.2 Modbus Communication

The electrical properties of the MFU in Mk1 mode are the same as in Mk2 mode:
Line Electrical Specification:
RS485, two wire, half duplex (4 wire not supported)
Modbus Transmission Mode

Supported Baud Rates
RTU (8 bit Binary data)

300, 600, 1k2, 2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2
(2k4, 4k8, 9k6, 19k2, 38k4, 57k6, 115k2 when using the
internal repeater option)
Number of bits per character

Parity (configurable)
1 start bit, 8 data bits, Parity bit, 1 or 2 stop bits

Odd, Even, None
Variants
Single highway plus analogue input

Dual highway (one common address and baud rate)
Single highway with repeater
A.3 Modbus Data Base

Message format:
Modbus Address:
A.3.1
Function Code Support
Function
Code
01
02
03
04
05
06
07
08
15
16
17
A.3.2
RTU
1 to 247 (Dual channel version both channels must have
the same address.)
Modbus Name
Read Output Coil Status
Read Input Status
Read Holding Registers
Read Input Registers
Force Single Coil
Preset Single Register
Read Exception Status
Loopback Diagnostic Test
Force Multiple Coils
Preset Multiple Registers
Report Slave ID
Addressing
Discrete
Discrete
Register
Register
Discrete
Register
Discrete
Register
Broadcast Messages
Broadcast messages using code 05 and 06 are allowed to the following functions
Open command
ESD command
63 of 68
A.3.3
Data Locations
Note:
All data locations listed start from 0, it may be necessary to add an offset to match the
number required for the PLC.
Read Output Status Function code 01

Write Output Coil Function code 05 and 15
Location
R/W
Data
(Bit)
0
R/W
1
R/W
2
R/W
3
R/W
4
R/W
5
R/W
6
R/W
7
R/W
Read Input Status Function code 02

Location
R/W
Data
(Bit)
0
RO
Actuator moving
1
RO
Closed limit
2
RO
Open limit
3
RO
Thermostat Tripped
4
RO
Monitor Relay
5
RO
Local selected
6
RO
Remote selected
7
RO
Battery Low
Range
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
Range
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
8
9
10
11
12
13
14
15
RO
RO
RO
RO
RO
RO
RO
RO
Running Closed
Running Open
Interrupter Timer
MIT Active
Error
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
16
17
18
19
20
21
22
23
RO
RO
RO
RO
RO
RO
RO
RO
S1
S2
S3
S4
DI 3
DI 2
DI 1
DI 4
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
64 of 68
Read Output Registers Function code 03

Write Output Registers Function code 06 and 16
Location
R/W
Data
(Register)
0
R/W
Range
0-3
0 = stop,
1 = close
2 = open
3 = ESD
R/W
Analogue Position Demand (DV)
R/W
Deadband
R/W
Motion Inhibit Time
R/W
Minimum position
0-FFFF
(0 100%)
R/W
Maximum position
0-FFFF
(0 100%)
R/W
Data Base Format

(power must be cycled for change to take
effect)
0-4147 hex
(0 25.5%)
Read Input Registers Function code 04

Location
R/W
Data
(Register)
0
RO
RO
Valve Position
Read Exception Status Function code 07 (one byte response)

Location
R/W
Data
(Bit)
7 (msb)
RO
S1
6
RO
S2
5
RO
S3
4
RO
S4
3
RO
DI-3 (Stop)
2
RO
DI-2 (Close)
1
RO
DI-1 (Open)
0 (lsb)
RO
DI-4 (Esd)
65 of 68
0-FFFFhex
(0.0 100.0%)
0-00FF hex
(0 255 sec)
0-1
(0 = Mk1 data
1 = Mk2 data)
Range
0-FFFF hex
(0 120%)
0-FFFF hex
(0.0 100.0%)
Range
0-1
0-1
0-1
0-1
0-1
0-1
0-1
0-1
Loopback Test Function code 08

Supported Diagnostic Codes
Diagnostic
Code
00
Return query data
01
Restart communications
02
Return diagnostic register
04
Force slave listen only
10
Clear diagnostic counts
11
Return bus message count
17
Return slave busy count
Diagnostic Register contents

Location
(Bit)
0
EEPROM timeout error
1
Checksum error
2
Checksum error
3
Checksum error
4
Watchdog recovery
5
Reserved
6
Reserved
7
Reserved
8
Reserved
9
Reserved
10
Reserved
11
Reserved
12
RS485 highway ESD active
13
Auxiliary control input active
14
Positioner MIT active
15
Positioner enable flag
Function
Description
Bits 0 to 7 generate the error bit in the digital status register.

Bit 0
indicates an EEPROM timeout has occurred.
Bit 1 to 3
indicates that a checksum error has occurred
Bit 4
indicates whether the module has been reset by the watchdog.
Bit 12
indicates that an ESD has been received via the RS485 highway.
Bit 13
shows that an auxiliary input, (enabled for control), is active.
Bit 14
when set the MIT is active.
Bit 15
when set the actuator is operating in positioning mode
Report Slave ID Function code 17

Byte
Data
0 25
00Rotork IQ Modbus Module.
26 47
Software version: Mxxx (where xxx is the revision number)
66 of 68
Exception Reporting Supported codes

Exception
Response
Meaning
Code
01
Illegal function code or incorrect message length
02
Illegal data address (Register or discrete address invalid)
03
Illegal data value
06
Busy
A.4 Configuration
The module should be placed into Mk2 mode to set up all the configurable registers. Once these are
set the mode can be returned to Mk1 for use on the Mk1 network. The complete list of configurable
registers is given in section 8.
Some registers may be altered using the IQ Setting Tool Figure 19 shows the functions that are
accessible in this way.
A.5 Records
A complete set of records as indicated in section 9 should be retained for each installed actuator.
67 of 68
htpp://www.rotork.com
68 of 68
UK Head Office
USA Head Office
Rotork Controls Ltd

Bath
England
BA1 3JQ
Rotork Controls Inc

675 Mile Crossing Blvd
Rochester
New York 14624
USA
Tel: +44 (0) 1225 733 200

Fax: +44 (0) 1225 333 467
e-mail: mail@rotork.co.uk
Tel: +1 716 328 1550

Fax: +1 716 328 5848
e-mail: info@rotork.com

Manuales Válv y Actuador Válv Seccionamiento

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INSTALLATION AND

For any clarification please contact info@rmtvalvomeccanica.com

For any clarification please contact info@rmtvalvomeccanica.com

API6D ISO 14313.

PRESSURE EQUIPMENT DIRECTIVE 97/23/EC only if required by Customers P.O.

Pressure containing systems are intrinsically dangerous.

Valve must be used, inspected and maintained by skilled personnel only.

Strictly adhere to company & local authority procedure/laws.

Always wear the correct safety equipment and clothing.

Always use original spare parts only.

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WARIG: Body cavity could be pressurised without pressure in line.

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3. HADLIG & STORAGE

For any clarification please contact info@rmtvalvomeccanica.com

it is recommended to check all the operator functions (lever , gearbox , actuator as

the valve shall not support the line ;

avoid inducing any strain in the valve body.

4.1 VALVE LIFTIG

For any clarification please contact info@rmtvalvomeccanica.com

VALID FOR SIZE AS FAR 6" FULL BORE & LARGER

VALID FOR SIZE AS FAR 6" REDUCE BORE

4.2 LIE ISULATIO

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4.4 TYPICAL ISTALLATIOS.

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The figures below show a typical above ground installation.

4.4.2 UDERGROUD ISTALLATIO.

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For any clarification please contact info@rmtvalvomeccanica.com

Standard fittings installed on our valves are plugs or bleeders.

always check the fittings for the proper wrench-tightness.

Put the valve in half stroke (3060 deg.) position.

For any clarification please contact info@rmtvalvomeccanica.com

For any clarification please contact info@rmtvalvomeccanica.com

7. REQUIRED TESTIG FREQUECIES

7.1 - FST / Full Stroke Test

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7.2 - PST / Partial Stroke Test

8. PERIODIC ISPECTIO & MAITEACE

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8.3 - MAITEACE ITERVAL

Replacement of stem gaskets

Replacement of body-cover & stem gaskets

Replacement of other soft seals

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8.4.3 GREASING PROCEDURE

the product is a blend of different types of grease and therefore it cannot be

Vegetable oil (CAS no. 68178-84-8)

Quantities to inject: around 13 grams/inch size/SEATseat&insert unit

8.5 VALVE REPAIR

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9. ASSEMBLY & DISASSEMBLY

Pressure containing systems are intrinsically dangerous.

Valve must be used, inspected and maintained by skilled personnel only.

Strictly adhere to company & local authority procedure/laws.

Always wear the correct safety equipment and clothing.

Always use original spare parts only.

WARIG: Body cavity could be pressurised without pressure in line.

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LEVER OPERATED FULLY WELDED BALL VALVES DISASSEMBLY

GEAR OR ACTUATED FULLY WELDED BALL VALVES DISASSEMBLY

10. RECOMMEDED FOR ASSEMBLY

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3. HADLIG & STORAGE

4.1 VALVE LIFTIG

4.2 LIE ISULATIO

4.4 TYPICAL ISTALLATIOS.

4.4.2 UDERGROUD ISTALLATIO.

7. REQUIRED TESTIG FREQUECIES

8. PERIODIC ISPECTIO & MAITEACE

8.3 - MAITEACE ITERVAL

10. RECOMMEDED FOR ASSEMBLY

12. RECOMMEDED SPARE PARTS

13. BODY CAVITY - SAFETY IFORMATIO

14. TYPICAL DRAWIGS