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IQ Range

IQ Multi-turn
Electric Valve Actuators
Control and Monitoring Facilities

Redefining Flow Control


Contents


Section Page

IQ3 – In control 3
Actuator electrical specification 4
Control specification 6
Indication, monitoring and datalogging 9
Indication options 10
Fieldbus systems 11
Actuator circuit diagrams 12
ESD and interlock control circuits 15
Remote control circuits 16
Analogue control circuits 18
Partial stroke function 19

Rotork’s proven IQ range of actuators now


includes absolute position measurement,
large information rich display, enhanced data
logging, status and asset management plus
additional control and indication features and
options. IQ range actuators are self-contained,
non-intrusive units for local and remote
electrical operation of valves.
IQ multi-turn actuator range:
• IQ – three-phase power supplies.
• IQS – single-phase power supplies.
• IQD – DC power supplies.
The IQ range comprises an electric motor, reduction gearing,
reversing starter, position and torque limitation with local
control and indication, remote control inputs and indication
outputs. Actuator enclosures are all double-sealed watertight
IP66 and IP68 (7 metres - 72 hours), NEMA 4 and 6. Enclosure
are also available suitable for use in Hazardous areas.
The following specification covers standard and optional
control and monitoring features. Options selected must be
specified with order.
Refer to publication PUB002-038 for full IQ range
performance and specification

2
IQ3 - In control

IQ - the first valve actuator you can commission Insight2 –Actuator configuration and
and interrogate without removing electrical analysis tool for PC
covers. With the Rotork Bluetooth® Setting Insight2 PC software allows all IQ set-up configuration
Tool Pro or PC based Insight2, commissioning and datalogger information to be reviewed, analysed and
and analysis of IQ actuators is simple, fast and reconfigured. The visually interactive application is a stand-
alone program running under Microsoft Windows™ operating
convenient.
systems. Intuitive and clear menus make analysing data from
® an IQ simple and fast.
New Rotork Bluetooth Setting Tool Pro
All settings including torque, limit and indication contacts are Data Logging & Configuration
made using the non-intrusive, hand held, Rotork Bluetooth®
Every IQ includes an on board data logger. The data logger
Setting Tool Pro, included with each order. Connection to the
captures and stores valve, actuator and control signal
actuator is made using Bluetooth wireless communication
operation and status data and can be viewed on the actuator
after an initial infra-red log-on to ensure security is
display or using Insight2. Log data is time and date stamped
maintained. Settings are also password protected.
and can be analysed by playing back on an event by event
Using the tool, the on board datalogger and asset basis.
information can be viewed on the actuator display. In
In addition, actuator set-up configuration can be viewed
addition, configuration and datalogger files can be extracted
and stored using IQ Insight2 for complete actuator asset
from the actuator to the Rotork Bluetooth® Setting Tool Pro
management or future upload/replication of other units.
for transfer to office based PC running Insight2. The tool is
watertight and intrinsically safe so can be used in wet and/or
hazardous areas. Data upload/download is non-intrusive via Features:
Bluetooth. The tool can store up to 10 datalogger files which • Actuator configuration
includes unit configuration file.
• Valve torque profile - open/closed instantaneous and
If required, a PC running Insight2 can be directly connected average torque against valve position
to an actuator to allow set-up, adjustment and analysis.
• Nameplate data
For more information refer to PUB095-001 available at
www.rotork.com. • Number of operations
• Control option card configuration
Setting Tool Specification
• Valve and actuator position starts log
Waterproof IP67, Certified EEx ia IIC T4 (intrinsically safe).
• Operation signal log
Power Supply 4 x AAA 1.5 V Batteries (supplied & fitted).
• Actuator control status log
Operating range up to 10 m from actuator display window.
• Operational statistics
Setting Tool(s) are dispatched with each order. Setting Tools
are suitable for use with any IQ or IQT range actuator. • Service alarms.

For more information on Setting Tool and commissioning


refer to PUB002-039 available at www.rotork.com.

Redefining Flow Control 3


Actuator electrical specification

Power supply Uninterruptible power supplies

The electrical supply type and nominal operating voltage must Standard actuators can be operated on UPS systems
be specified at time of order. Actuator torque performance is providing the above specified tolerances are not exceeded
guaranteed with a voltage tolerance +/-10% and frequency and waveforms, harmonics, spikes etc. adhere to recognised
tolerance +/-5%. Actuators are capable of starting and supply standards such as EN50160.
running up to speed with a maximum 15% volt drop.
Conduit entries
Non-standard tolerances
IQ range actuators have a separately sealed terminal
Where voltage and/or frequency variations may be compartment incorporating a segregated terminal block and
experienced outside those quoted below, or where operation cable / conduit entries.
under large volt drop conditions may be required, please
It is the responsibility of the installer to ensure the appropriate
apply to Rotork.
cable / conduit adaptors, glands and blanking plugs are fitted
in order to maintain hazardous area certification and ingress
IQ range power supplies protection rating. Certified adaptors and blanking plugs are
IQ – 3-phase power supplies available as optional extras.

IQ actuators are available for operation with the following IQ range


standard 3-phase, three wire, nominal power supplies:
Three threaded conduit entries are provided, tapped: 1 x M40
50 Hz and 2 x M25. When specified, the actuator will be dispatched
220, 240, 380, 400, 415, 440, 460, with adaptors: 1 x 11/2” and 2 x 1” imperial to BS3643, “Ex”
500, 550, 660 and 690 Volts certified or as an alternative, 1 x PG29 and 2 x PG16.
60 Hz
208, 220, 230, 240, 380, 440, 460, Options
480, 575 and 600 Volts
If specified with order, a fourth conduit entry can be provided,
Refer to publication PUB002-038 for IQ performance summary tapped M25 or with adaptor to 1" ASA NPT or as an
and PUB002-046 for IQ – 3-phase power supply rating data. alternative, PG16. Adaptors are available to convert standard
conduit entries. Additional conduit entries can be provided.
IQS – single-phase power supplies Please apply to Rotork.

IQS12, IQS20, IQS25 and IQS35 are available for standard


nominal voltages:
Terminals
The IQ range actuators incorporate a terminal block
50 Hz
containing segregated metric screw terminal inserts. M5 pan
110, 220, 240
head terminal screws are provided for power terminals and
60 Hz M4 pan head terminal screws for control and indication.
110, 220, 230 The terminal box cover carries a terminal identification code
card. Each actuator is supplied with instruction book and
Refer to PUB002-001 for IQS performance summary and
wiring diagram.
PUB002-021 IQ single-phase power supply rating data.

IQD – DC power supplies Wiring


IQD10, IQD12, IQD20 and IQD25 are available for standard Jig built harnesses of individually numbered stranded
nominal voltages: conductors, tropical grade PVC insulated, connect internal
components to the sealed terminal block. All internal control
24 V*, 48 V*, 110 VDC connections to the printed circuit boards are via plugs and
Refer to publication PUB002-038 for IQD performance summary sockets. Wiring of contacts to outgoing terminals are sized for
and PUB002-021 for IQD DC power supply rating data. maximum applicable current.
* Limited by actuator size - refer to PUB002-021 IQD
performance summary.

Non-standard voltages
Actuators can be supplied to operate on power supply
voltages other than those quoted above.
Please apply to Rotork.

4
Actuator electrical specification

Motor “Torque off” during unseating or during starting/reversing


in mid travel against high inertia loads can be inhibited. A
IQ – 3-phase “jammed valve” protection circuit de-energises the motor if no
Integrally designed, Class F insulated, squirrel cage motor of movement occurs after receipt of a signal to open or close.
special high torque low inertia design. 15 minute rated with The IQ range incorporates a battery to maintain both local
cyclic duration factor of 25% at 33% of actuator output LCD and remote “S” contact indication of actuator/valve
rated torque with a design temperature rise not exceeding status when power to the actuator is isolated. Should manual
that permitted for Class B insulation at standard nominal operation of the valve take place during a power supply
voltage. Actuator rated up to 60 starts per hour at a rate not interruption, both local and remote indication is updated.
exceeding 600 starts per hour. Burnout protection by embedded Unlike other actuator makes, a secondary low voltage power
thermostats, with facility for bypassing under emergency supply is not required to update local and remote valve
shutdown control. Where applicable motors conform to position indication.
IEC60034, NEMA MG1 and EN15714-2.
Expected battery life is up to 5 years, but will depend on
IQS – single-phase usage and environment. The status of the battery is indicated
by the actuator display. Remote indication of battery status is
Integrally designed, single-phase capacitor start/run squirrel available with actuator “S” contact indication.
cage induction motor. Class F insulated, special high torque,
low inertia design. Rating, protection and compliance as per All actuator configured settings are stored in non-volatile
3-phase specification above. EEPROM (Electrically Erasable, Programmable Read Only
Memory). EEPROM does not require any power supply to
IQD – DC maintain the stored configured settings and is therefore
completely independent of the battery.
Class F insulated, permanent magnet DC motor. Rating,
protection and compliance as per 3-phase specification
Absolute Position Sensing
above.
Reliable valve position sensing is critical. Using the latest
Motor options technology and after several years of testing, the patented
Rotork IQ absolute encoder is contactless, has only four active
IQ Range parts, can measure up to 8,000 output turns with a resolution
Class H, nominal 30 minute rated motors are available for of 7.5° and has redundancy and self checking. Unlike existing
certain applications. Please apply to Rotork. absolute encoder designs, this technological breakthrough
increases position sensing reliability while providing zero-
Modulating power position measurement.

For applications requiring more than 60 starts/hour please


Protection features
refer to IQM PUB002-032.
The IQ range includes the following protection features:
Electrical Control Module – ECM Torque protection
Now incorporating a single integrated circuit, hard-wired If the torque produced in operating the valve when closing
logic control for the actuator together with HMI interface. or opening reaches that set for the active torque switch,
On board data logger records operational data, valve torque/ the motor will be de-energised. The torque switches are
position profiles and statistical information, all time and date independently configurable in the range 40 - 100% of rated
stamped. torque. Local and remote indication of torque trip is provided.

Torque Switch and Position Control Motor over temperature protection


Position and torque are adjustable as follows: For IQ range two thermostats are located within the motor
• IQ Range stator. The thermostats will trip and de-energise the motor
Position setting range: 2.5 to 8,000 turns, with a minimum if the temperature exceeds its rating. Local and remote
angular resolution of 7.5° at the output. indication of thermostat tripped is available. The thermostat
can be overridden during an ESD operation.
• Torque switch setting
40% to 100% Automatic phase rotation correction
For IQ range, output torque is obtained via measurement of The actuator will always run in the correct direction
wormshaft displacement under load and is independent of regardless of the sequence of power supply connection.
voltage, frequency and temperature fluctuations.

Redefining Flow Control 5


Actuator electrical specification Control specification

Lost phase protection Local Control


If any one or more power supply phases are lost, the motor Non-intrusive selectors are provided on the actuator’s
cannot be energised. Local and remote indication of lost electrical control cover, one for Local/Stop/Remote selection,
phase is available. pad-lockable in each position, and the other for Open/Close
control. Local control may be configured for maintained or
Jammed valve protection inching operation.
Should the actuator stall when attempting to unseat a valve Controls may be rotated to suit actuator orientation.
stuck in its seat, the motor will be de-energised within 7
Local control may be selected to operate using the supplied
seconds, preventing damage. Local and remote indication of
Rotork Bluetooth® Setting Tool Pro. The Setting Tool
jammed valve is available.
incorporates dedicated Open, Stop and Close buttons and
will operate over a nominal distance of 10 metres from the
Instantaneous reversal protection
display window.
The motor control logic introduces a delay in switching the
motor as a response to instant reversal of control signals, Vandal Resistant Local Control Option
preventing contact damage to the contactors. Overtorque
Control selectors removed, indication window with or
transients due to switching high inertia loads are prevented
without removable cover, control of Local, Stop and Remote
from causing a torque trip by the motor control logic.
selection and local Open and Close control is via the Rotork
Bluetooth® Setting Tool Pro.
ASTD Automatic Self Test and Diagnosis
On power up the actuator automatically tests its vital Remote Control
operational circuits and memory devices to ensure correct
operation. In the unlikely event of a device problem the There are six control inputs for remote control:
IQ diagnoses the cause and will automatically present this • Open, Close, Stop/Maintain/Drive enable
information in the form of an error message. Electrical
operation can be inhibited to prevent possible damage to • Emergency shut down (ESD)
the actuator and valve. The problem can then be accurately • Open interlock and Close interlock
investigated and corrected by maintenance personnel. Local
and remote indication of ASTD Fault is available. Control can be connected for maintained or push to run,
“inching” control. Refer to page 19 for remote control circuit
Power module schematics.
The power module incorporates a mechanically and Remote control inputs are opto-isolated interfaces with a
electronically interlocked reversing contactor starter.* For surge immunity of 2 kV. Standard control is positive switching
IQ range on AC supplies the control supply transformer, fed (negative switching is available if specified).
from two phases of the incoming power supply, provides
internal control circuit supplies and an isolated, nominal 24 The standard IQ actuator can be controlled using remote
VDC supply rated at 5 W for actuator fed remote control control signals defined as follows:
circuits. The transformer is of a “split bobbin” double Customer fed control circuit supply:
insulated design and incorporates short circuit and overload
Within the ranges 20-60 VDC, 60-120 VAC.
protection. The Rotork Syncrophase™ circuit provides
automatic phase rotation correction and lost phase protection Actuator fed control circuit supply:
where applicable. 24 VDC. (120 VAC available if specified).

Option The current drawn for each control input:


Actuator fed remote control supply: Nominal 120 VAC supply, 5 mA at 24 VDC, 12 mA at 120 VAC
rated at 5 VA.
Minimum “ON” voltage: 16 V,
* IQS Single-phase, IQT and IQM modulating units utilise a
solid state motor starter. Maximum “OFF”: 8 V.
Minimum signal duration: 300 ms.
Maximum remote control cable capacitance:
2 μF core to core.

6
Control specification

IQD - DC actuator remote control The following ESD options can be configured:
Remote control is available within the ranges 20-60 VDC, • ESD Signal
60-120 VAC only. Note: for IQD at 110 VDC power supply, the Active high (contact making - NO)
maximum remote control input voltage is 60 VDC. Active low (contact breaking - NC)
For applications where the actuator is powered from a power • ESD Action
supply of limited capacity such as solar power charged, direct Close, Open, Stayput
current UPS system, power conservation is of prime importance.
• ESD Override
The IQD includes a “solar” feature* to minimise power
Motor thermostat*, local stop,
consumption when not operating, reducing the current drawn
active interlocks, interrupter timer option
by the actuator control to 10 mA (maximum). Applying a remote
“Open”, “Close” or “ESD” control signal or a discreet “wake Unless specified with order, the actuator will be dispatched
up” signal causes the actuator to power up its control circuits set for the following:
and after a delay of up to 10 seconds, respond to the remote
Active high signal (contact making - NO), Stayput. ESD will
control signal. Between 3 and 6 seconds after the control signal
not override motor thermostat, local stop, active interlock or
is removed, the actuator returns to the low current “solar” state.
interrupter timer.
As part of this routine, in order to save power, the actuator fed
* Factory configured. Bypassing the motor thermostat will invalidate
24 VDC remote control supply is disabled when in solar mode. hazardous area certification.
i.e. actuator 24 VDC fed remote control supply is unavailable
for applying a signal to power up the actuator control when
Interlocks
operation is required and therefore a discreet externally fed
“wake up” signal or externally powered control signals must External hardwired interlocks for opening and/or closing can
be used. be configured to inhibit local and remote operation until the
external contacts are made. Interlock circuits may be added
with any of the remote control circuits. The interlock inputs
Three modes of control are available:
operate from a separate common allowing for isolation
• Standard - sleep function disabled, 24 VDC remote control between the safety system and operation control system.
supply available at all times. Refer to page 15 for standard interlock circuit options.
• “Solar” sleep function enabled, 24 VDC remote control
supply disabled when asleep. Conditional control
• “Solar” sleep function enabled, 24 VDC remote control For applications where a high level of control integrity is
supply enabled when asleep. required the IQ can be configured for “conditional control”.
In this mode, operation is conditional on two discrete signals
Unless otherwise specified, the actuator will be dispatched being applied. Looking at an example of a “close valve”
configured in the “solar” mode of control. Remote control command, by applying a signal to the “remote close input”
signals must therefore be a minimum of 10 second duration. and “close interlock input” simultaneously the actuator will
The 2-wire remote control form is not available (refer to page operate and close the valve. If only one signal is applied or
17). For Fieldbus system control please apply to Rotork. a signal is lost, the actuator will failsafe by staying put or
stopping. When conditional remote control is configured the
In local control and when “awake”, the actuator will draw interlock inputs are not active in local operation.
approximately 100 mA (with 24 VDC Power Supply) from the
supply in the quiescent state. Drive Enable
Remote control option The remote stop/maintain input can be configured as a drive
enable input; remote electrical operation is prevented unless
For customer fed remote control in the range 60-125 VDC an a dedicated “drive enable” signal is applied. The probability
alternative control circuit is available (note: IQD is limited to of operation caused by spurious control signals and/or
20-60 VDC and 40-120 VAC only). actuator fault can be minimised and therefore integrity
increased.
Emergency Shut Down – ESD
Two levels of increased integrity are available. Level 1 is user
An active ESD signal will override any local or remote control configurable from the standard configuration menus. Level
signal. The ESD input operates from a separate common to 2 is factory enabled and acts directly in hardware to prevent
that used for Open, Close, and Stop remote control signals. operation and therefore must be specified with order. Drive
Refer to page 15 for ESD circuit options. enable acts in a similar way to interlocks and conditional
control, however just a single input is used to control
operation in both opening and closing directions.

Redefining Flow Control 7


Control specification

Analogue Control Option Action on loss of signal

The IQ proportional controller enables the valve to be Stayput, Move to high or low signal positions.
positioned in proportion to an analogue signal. Positioning
With live zero current control loops i.e. 4-20 mA, at 50% of
can take place over the whole valve stroke or a set portion.
the set low signal (2 mA) the controller invokes the set action.
If manual intervention is required, analogue control can be
overridden using the manual/auto input. Refer to page 18 for NOTE: As the signal decays, movement toward the set low
analogue control connections. signal position may occur until it is determined as “lost”.
Valve position, derived from the actuators non-contacting position
Tuning
sensor, is compared with the position demand signal input. The
difference (error) triggers the actuator to drive the valve in the • Deadband
direction that cancels the error and therefore the flow, pressure,
Deadband range 0% – 25.5%
level or temperature etc determined by the valve’s position is
automatically adjusted in proportion to the analogue demand Used to allow for overrun or demand signal oscillation and
signal. The control loop may be tuned using the controller’s so prevent “hunting” or unnecessary movement (movement
deadband, hysteresis and the Motion Inhibit Timer controls. without effecting a required control change).
For example a 5% deadband will cause the motor to be de-
Application
energised once the actual position is within 5% of the demand
Motor-driven actuators are suitable for proportional control in position. Subsequent inertia will then bring the final position
automatic control loops in which the system rate of change is nearer the demand position.
relatively slow, and high accuracy continuous modulation is not
essential; level controls in water treatment plants are typical • Hysteresis
applications. Motor operated regulating valves and sluice gates
Hysteresis range 0% – 25.5% but must always be ≤ to the
are driven through nut and screw or wormgear mechanisms
Deadband setting.
which must be self-locking and are therefore mechanically
inefficient. Frequent operation will cause rapid wear of these Hysteresis further refines the accuracy of the position
components. The control scheme must recognise mechanical controller.
system limitations and be tuned to accordingly.
The controller will run the actuator towards the demand
position until the deadband position is reached and then
Regulating valve applications
continue by the value of the hysteresis setting. The actuator
IQ actuators with reversing motor contactors and hammerblow will not restart unless it overshoots and runs outside the
are suitable for up to 60 starts/hour with an average torque deadband or a change places the demand position outside the
not exceeding 33% of rated torque. deadband.

Modulating valve applications • MIT


IQM and IQML actuators with solid state motor control, MIT range 0 – 255 seconds.
configurable DC injection motor breaking and direct drive are
The motion Inhibit Timer (MIT) may be set to prevent the
suitable up to a 1200 starts/hour. For more information please
actuator moving excessively or unnecessarily. Oscillating signals
refer to PUB002-038.
and/or response to small signal changes can effectively be
filtered out. A delay is set (in seconds) as a period of inactivity
Accuracy
after a response to a signal change. The actuator will not move
Based on speed not exceeding 29 rpm and output turns ≥10, until the MIT has elapsed and the demand signal changes
an accuracy of ≤ 1% may be achieved. The maximum signal sufficiently to move outside the deadband.
change required to cause response in the same direction (ie.
not through deadband) is 1%. Overall accuracy is a function of Interrupter Timer Option - Reduced speed, hydraulic
valve, coupling and actuator inertia and backlash and therefore shock or surge prevention
output speeds should be kept as low as practicable. Rotork do
not recommend analogue control with output speeds greater Where the operating time of the valve must be reduced to
than 29 rpm. prevent hydraulic shock or “water hammer”, or to prevent surges,
the Interrupter Timer option can be included. Pulsed operation
Configuration with independently adjustable “on” and “off” time periods in the
range 2-100 seconds can be selected to operate over any portion
Analogue signal types and ranges: of the closing and/or opening valve stroke. The interrupter timer
mA: 0-5, 0-10 and 0-20 (4-20); input impedance 220 Ω is active for both local and remote control and can be configured
Volts: 0-5, 0-10 and 0-20; input impedance 5.7 kΩ to be bypassed under ESD operation if required.
Controller can be configured to close, open or move to the
position set for low or high signal input.

8
Indication and monitoring and datalogging

Local Position and Local Monitoring Indication Unless otherwise specified S contacts will be configured
as follows:
A back-lit dual stacked liquid crystal display gives digital
indication from fully Open to fully Closed in 0.1% increments. • S1 – contact makes at fully Closed
Four LED’s coloured red, green and yellow for indication of
• S2 – contact makes at fully Open
Open, Close and intermediate positions respectively are also
provided. The display includes a dot matrix display for status • S3 – contact breaks at fully Closed
and error message reporting.
• S4 – contact breaks at fully Open
With the Rotork Bluetooth® Setting Tool Pro, actuator torque
can also be displayed allowing the valve torque against *NOTE: Maximum total combined current through all
position to be monitored in real time. Diagnosis is available for four relays must not exceed 8 A.
monitoring valve, actuator and control system status. The local
display can be rotated to suit actuator orientation. LED colours Monitor Relay
can be reversed. Please specify at time of order.
An independent relay with a volt-free changeover contact for
monitoring actuator electrical availability is provided. Contacts
Remote position and monitoring indication
are nominally rated at 5 mA to 8 A, 120 VAC, 30 VDC.
Four latching, volt free, single pole contacts, S1, S2, S3 However as long as the switching power remains within the
and S4 are provided, each one independently configurable specified limit of 170 W (inductive) or 240 W (resistive), then
using the Rotork Bluetooth® Setting Tool Pro to signal one of the following maximum ratings can be achieved: -
the following:
Maximum switching Voltage – 120 VAC or VDC
• Valve Position
Maximum switching Current – 8 A
Fully Open, fully Closed (exact) or any intermediate
positions (0-99% open) The relay will de-energise under any one, or combination, of
the following conditions:
• Status
Valve opening, closing, moving (continuous or pulsing • Loss of one or more of the power supply phases
signal), local stop selected, local selected, remote selected,
• Loss of control circuit supply
open or close interlock active, ESD active.
• Local control selected
• Valve Alarms
Motor tripped on torque in mid travel, motor tripped on • Local stop selected
torque going open, going closed, valve jammed, actuator
being operated by handwheel. • Motor thermostat tripped

• Actuator Alarms Data Logger


Lost phase, customer 24 VDC (120 VAC) supply lost,
battery low, internal failure detected, thermostat tripped. The on-board data logger allows download of historical
actuator/valve performance via Bluetooth to PC or PDA. For
• Service Alarms hazardous areas the intrinsically safe Rotork Bluetooth® Setting
High Torque, High High Torque, Max. No. of starts per Tool Pro is available. Rotork Insight2 PC software allows data
hour, total starts, total turns, service intervals. logger information of operational events and statistics all time
Each contact can be configured either ‘normally open’ or and date stamped plus valve torque/position profiles, to be
‘normally closed’. analysed. Refer to page 3.

Contact rating
Contacts are nominally rated at 5 mA to 5 A, 120 VAC,
30 VDC. However as long as the switched circuit power
remains within the specified limit of 60 W (inductive) or 150
W (resistive), then the following maximum ratings can be
achieved: -
Maximum switching Voltage – 120 VAC or VDC
Maximum switching Current – 5 A*
For example, to operate a 48 VDC external relay (inductive),
the maximum permissible current that can be switched
through S1 – S8 contacts is calculated by the equation P/V=I
i.e. 60 (W) / 48V = 1.25 A

Redefining Flow Control 9


Indication options

Indication Options Remote Valve Torque Analogue Indication - CTT

Remote Valve Position Analogue Indication - CPT The Current Torque Transmitter (CTT) provides a non-
contacting internally fed 4-20 mA analogue signal
The Current Position Transmitter (CPT) provides a non- proportional to actuator output torque (0-120% of rated
contacting internally fed 4-20 mA analogue signal torque). When stationary the CTT output will continue to
proportional to valve position. Selectable for minimum indicate the current torque.
signal corresponding to fully Closed or fully Open position
with automatic zero and span setting. The maximum external
Extra indication contacts
impedance that may be connected to the signal is 500 Ohms
at nominal supply voltage. Repeatability is within ± 1% and The extra indication contacts option provides up to eight
linearity ± 1% of total valve travel. additional changeover contacts, S5-S8 and S9-S12. Each
contact is latching, volt free and rated at 5 mA to 5 A, 120
Auxiliary Powered CPT (not available with IQD) VAC, 30 VDC. The extra indication contact functions are
independently configurable in the same way as the standard
The auxiliary powered CPT maintains analogue position contacts using the Rotork Bluetooth® Setting Tool Pro. The
indication when the mains power is switched off. An auxiliary extra indication contact functions can be configured to the
24 VDC supply is permanently connected to the actuator, same functions as S1-S4. Refer to page 9.
which is automatically switched in to provide power to the
CPT on mains failure. On re-instating the mains, the auxiliary
supply is automatically switched out.
Note: on mains failure, a surge of up to 1 Amp is required to
switch in the auxiliary supply. The “power off” quiescent load
is nominally 180 mA, but will depend on the options fitted. It
is recommended that the 24 V auxiliary supply is permanently
applied to the actuator to limit switch surge current.

10
Fieldbus systems

Pakscan HART®
Rotork’s own 2-wire system for control and data transmission HART (Highway Addressable Remote Transducer) is a process
to and from the actuators. control communication protocol. The signal consists of two
parts, the analogue 4-20 mA current loop and a superimposed
An internally mounted Pakscan field unit connects the actuator
digital signal. Traditionally the 4-20 mA loop is used for control
to the field network. By arranging the field cable in a loop the
and the superimposed digital signal for feedback, diagnostics
system automatically provides a fault tolerant redundant path
and configuration. Configuration and feedback using the
for the data signals. The communication distance may be up
HART digital signal can be achieved using the host connected
to 20 km in length without the need for repeaters, up to 240
to the actuator to select the parameters required. The majority
actuators may be connected to the loop and a master station
of the user configurable settings can be made over the HART
supervises the system. Communication from the master station
communication protocol.
to the host uses Modbus protocol over RS232 and RS485.
System settings for the actuator are programmable over the Please refer to PUB092-001.
Bluetooth data link.
Additional Inputs and Outputs
Please refer to PUB059-030.
When used in conjunction with a fieldbus network the
Modbus actuator can also collect additional feedback information
from other devices in the field such as level switches or
Single or dual Modbus Modules may be included in the IQ proximity detectors. It is also possible with some systems to
actuator to provide remote serial communication to the control provide additional output control functions to operate remote
functions and for status feedback data. The field network equipment, pump starters etc. In order to provide these
uses an RS485 data highway, either 2 or 4 wire, and can be features the actuator requires the Fieldbus Remote I/0 option
duplicated where redundancy is required. The communication which includes 4 digital inputs for feedback data and 4 dry
is half duplex and the protocol used is Modbus RTU with data contact relay outputs for control.
rates up to 38 K baud. The actuator variables necessary to set
up the system are programmable over the Bluetooth data link. Refer to Publication PUB058-001 Rotork Network
Compatibility for more information and links to other
Please refer to PUB091-003. network documentation.

Profibus®
Profibus connectivity is possible by fitting the Profibus DP
interface module within the IQ actuator. This allows the
IQ to be integrated into a standard Profibus network. Full
compatibility with the fieldbus standard EN 50170 is provided
and the module carries Profibus certification for inter-
operability. The network allows full control of the actuator
and feedback of status data to the host. The Rotork Profibus
module has two communication ports to facilitate redundant
fieldbus wiring where reliability is paramount, data rates up
to 1.5 M baud are supported.
Please refer to PUB088-001.

Foundation Fieldbus®
IQ actuators may be connected to a Foundation Fieldbus
network (H1) by the inclusion of a Rotork FF-01 module.
The device complies with fieldbus standard IEC 61158-2,
using a 2-wire electrical connection to the highway and has
been certified for inter-operability. The Foundation highway
exchanges data and control between devices and full actuator
functionality is available. Each actuator has full link scheduler
capability complete with function blocks for analogue and
digital inputs/outputs in addition to the standard transducer
block. Foundation fieldbus networks are capable of operating
without a host system as a supervisor, allowing the field
devices to communicate directly between themselves.
Please refer to PUB060-007.

Redefining Flow Control 11


Actuator circuit diagram - basic

IQ Actuator Basic Circuit Diagram 100 B 0000, drawn in mid-travel, power off

Motor 3
Motor
Switching 1 Actuator Power Supply
Module 2 Refer to page 4
E (power supply connections will vary with
Thermostat
actuator type. Connections shown are
FS1 for IQ 3-phase only).

Position &
Torque/Limit PS1
Control Isolated, nominal 24 VDC, 5W
– 4 Power Supply (120 VAC 15 VA option)
Available for actuator fed remote control.
5
+ Refer to page 6.

Local Indication Remote Indication


Refer to page 9
42 Monitor Relay Monitors actuator
MONITOR
RELAY

Close Limit
TAG 01234
43 availability (shown de-energised –
44 unavailable). Refer to page 9.
6
Make at Fully Shut S1 7 Indication Contacts
8 Shown in default configuration.
Make at Fully Open S2 9 Configuration can be changed using
Local and Remote Break at Fully Shut
10 the Bluetooth® Setting Tool to indicate
S3 11
Position Indication any valve position, status and alarm
9V Back-up Supply 12
(Main Power Off) Break at Fully Open S4 settings. Refer to page 9.
13

Local Controls Remote Controls


Refer to page 7
Close 33
Stop/Maintain 34
Open 35
Common –ve 20–120 VAC/VDC 36
Remote Control Inputs
Refer to pages 15 and 16 for
ESD 25
Open Interlock 37
control circuit types.
Close – Open Stop
Local – Remote Close Interlock 38
Common –ve 20–120 VAC/VDC 31

Data Logger/Bluetooth® (page 3) Bluetooth® Interface

Valve Condition Actuator IrDA™ Interface


Data Monitoring Configuration

For applicable Circuit Diagram


Optional Control refer to the Matrix on page 14.
and Indication Equipment

The Bluetooth® Setting Tool enables


options to be configured

NOTE: Terminal numbers subject to change - Refer to supplied circuit diagrams.

12
Actuator circuit diagram - options

Optional control and indication equipment

Close Limit S5 14 Extra Indication Contacts


15
16
Shown in default configuration.
Open Limit S6 17
18 Configuration can be changed using the
19 Rotork Bluetooth® Setting Tool Pro to
Torque Trip Mid-Travel S7 20
21 indicate status various valve and actuator
24 position, and alarm settings. Contacts are
Remote Selected S8 30
46 shown in not true state.
47 Refer to page 10

Analogue Position Control Valve Position – CPT


Folomatic 24 V nominal
4–20 mA
23 A
26 Analogue Input Signal
27 } for Folomatic
22

28
29
Valve Torque – CTT
Manual/Auto 39 For manual/auto
Common
24 VDC (-ve)
110 VAC (0 V) 45
41 } connections refer to
page 18
24 V nominal
4–20 mA
29 A
28

Pakscan Profibus
2-Wire Loop RS485 Highway
Care should be taken to ensure that circuits connected 29 Screen
to terminals 4 or 5 are not connected directly or 24 Profibus 1–B
indirectly to ground. 26 Profibus 1–A

26 2 Wire 'A' (In)


27 2 Wire 'B' (Out) 27 Profibus 2–B
28 2 Wire 'C' Common 28 Profibus 2–A
29 Screen 45 Screen

Modbus Foundation Fieldbus


2 Wire/4 Wire RS485 Highway IEC61158–2 Highway

24 Field Connection '1A'


26 Field Connection '1B' 27 Field Connection '+'
27 Field Connection '2A' 28 Field Connection '–'
28 Field Connection '2B' 29 Screen
23 Common
29 Screen

NOTE: Terminal numbers subject to change - Refer to supplied circuit diagrams.

Redefining Flow Control 13


Actuator circuit diagrams – number code

Standard Control and Indication Options


Basic IQ range actuator circuit diagram 100 B 0000 include local control and indication station,
remote open/stop/close ESD and interlock control and 4 configurable indication contacts.

1 0 0 B 0 0 0 0
Type / Duty
1 IQ Standard
2 IQM Modulating
3 IQT Standard
4 IQTM Modulating
5 IQ Standard Japan
6 IQM Modulating Japan
Power Supply
0 IQ 3-Phase/IQT with 24 VDC Customer supply
1 IQ 3-Phase/IQT with 120 VAC Customer supply
2 IQ 1-Phase with 24 VDC customer supply
3 IQ 1-Phase with 120 VAC customer supply
4 IQ DC with 24 VDC customer supply
5 IQ/IQT DC Solar with 24 VDC customer supply
8 IQT backup (EXTERNAL SUPPLY)
9 IQT backup (INTERNAL BATTERY)
Analogue 4-20mA
1 Position Indication (CPT)
2 Torque Indication (CTT)
3 Position Control/Indication (Folomatic/CPT)
4 Analogue Monitoring (Network only)
5 Position Indication (CPT) Loop Powered
6 Torque indication (CTT) Loop Powered
7 Position Control/Indication (Folomatic/CPT) with Loop Powered CPT
Network
B Basic no network control (hardwired only)
K Pakscan 2-wire digital control
P Profibus 2-wire digital control
M Modbus 2-wire digital control
F Foundation Fieldbus 2-wire digital control
H HART 2-wire analogue control/digital feedback
W Pakscan Wireless
R Pakscan Wired & Wireless
Network Options
1 Auxiliary power (no network fitted)
2 Single Channel
3 Dual Channel
4 Repeater (Modbus only)
5 Single Channel (Auxiliary powered)
6 Dual Channel (Auxiliary powered)
7 Repeater (Modbus only/Auxiliary powered)
Remote Options
1 Negative switching remotes (positive common)
2 BBC Remotes (isolated commons)
Indication Options
1 Extra relay contacts S5-S8 (4 additional contacts)
2 Extra relay contacts S5-S12 (8 additional contacts)
Plugs & Sockets
1 Interrputer Timer (2 speed timer)
2 Disconnect module (Profibus only)
3 Reserved
4 Interrputer Timer & Disconnect Module (Profibus only)

NOTE: Subject to change - Refer to Rotork with your requirement.

14
Actuator circuit diagrams – number code
ESD Control Circuits Interlock Control
ESD and Interlock control circuits may be added Circuits
ESD Control Circuits Interlock Control
to any of the Remote or Analogue circuits Form 1F Circuits
shown on pages 16-18.
Form 1F
Emergency Shut Down ESD signal will override any existing 4
Customer
local or remote signal. The actuator can be configured to fitted link
4
open, close or stayput as a response to an ESD signal. ESD 31 Customer
signals must be derived from a latching contact. The actuator fitted link
31
can be configured to respond to an ESD from a “making” 4
or “breaking” contact. Customer
Open
4 fitted link
permissive
If required, ESD operation can be configured to override the 31 Customer
37
Open
fitted link
motor thermostat, local stop, active interlocks or Interrupter 31 37 permissive

Timer option. Overriding the motor thermostat during ESD 38 Close


permissive
will invalidate hazardous area certification. 38 Close
37 25 permissive
Unless specified with order the actuator will be dispatched
set for the following: Active high signal (contact making), 37 25
38 5
Stayput on ESD. ESD will not override motor thermostat, local
stop, active interlock or interrupter timer. 38 5
Open/Close Interlock
25 active – Internally fed
ESD
Changes in ESD configuration are made using the supplied (Stayput) Open/Close Interlock
25 active – Internally fed
Rotork Bluetooth® Setting Tool Pro. 5 ESD
(Stayput) 4
Interlock circuit control 5 Customer
fitted link
4
The default setting is for the interlock function turned OFF. If 31 Customer
interlock facilities are required the Rotork Bluetooth® Setting fitted link
31
Tool Pro can be used to configure the interlocks ON.
Interlocks are active in both local and remote control. If only
ESD - Internally fed 37
one interlock is required, the other must be linked out as
shown. ESD - Internally fed 37
38 Close
permissive
Traditional hardwired interlock systems between actuators Form 2F
such as “Main and Bypass” in steam plant can be easily 38 Close
25 permissive
arranged using the IQ “S” contacts to derive the permissive Form 2F
control signal. 25
5
4
5Close Interlock
4 active – Internally fed
31
Close Interlock
active – Internally fed
31
4

4
37 31

37
38 31
ESD
(Stayput)
38
25 ESD 37
(Stayput) Open
permissive
Key 25
5 37
38 Open
Close
permissive
Key
4 24 VDC -ve / 120 VAC N
5
Line/+ve
permissive
38
25 Close
31 ESD/IL Common 20-60 VDC and 60-120 VAC Line/+veCommon
permissive
4 24 VDC -ve / 120 VAC N
20-60 VDC
Open 25
37
31 ESD/ILInterlock
Common 20-60 VDC and 60-120 VAC 60-120 VAC
Common
5
38 Close Interlock 20-60 VDC Line/+ve
37 Open Interlock 60-120 VAC 5 Common
5 24 VDC +ve / 120 VAC 20-60 VDC
38 Close Interlock Line/+ve 60-120 VAC
Common
ESD - Externally fed Open/Close20-60Interlock
VDC
5 24 VDC +ve / 120 VAC active – Externally fed
60-120 VAC
ESD - Externally fed Open/Close Interlock
NOTE: Terminal numbers subject to change - Refer to active – Externally fed
supplied circuit diagrams.

Redefining Flow Control 15


Remote control circuits

Remote control system wiring Open/Close push-to-run


schematics for standard IQ are control.
shown opposite.
Standard actuators are dispatched without Form 1A
terminal links.
A commissioning bag located in the terminal Internal supply -ve (zero) 4
compartment includes terminal screws, spare
cover o-rings, actuator circuit diagram, and the Common for remote controls
Installation and Maintenance instruction PUB002- on 20 to 60 VDC or 36
039. The actuator that includes the Rotork 60 to 120 VAC
Bluetooth® Setting Tool Pro will be indicated with
a yellow label on the terminal compartment cover.
Remote control inputs are opto-isolated interfaces
with a surge immunity of 2 kV. Standard control is
positive switching (negative switching is available Close 33
if specified). Close

The standard IQ actuator can be controlled using


remote control signals defined as follows: Stop/maintain 34

Customer fed control circuit supply: Within the


ranges, 20-60 VDC or 60-120 VAC.
Open 35
Actuator fed control circuit supply: Open

24 VDC, 5 W rated. (120 VAC, 15 VA available if


Internal 24 VDC supply +ve
specified).
(or internal 120 VAC) 5
The current drawn for each control input:
8 mA at 24 VDC, 12 mA at 120 VAC.
Minimum “ON” voltage: 16 V. Form 2A
Maximum “OFF”: 8 V.
Minimum signal duration: 300 ms. Internal supply -ve (zero) 4

Maximum remote control cable capacitance:


2 μF core to core.
Common for remote controls
on 20 to 60 VDC or 36
60 to 120 VAC

Close 33
Close

Stop/maintain 34

Open 35
Open

Internal 24 VDC supply +ve


(or internal 120 VAC) 5
Line/+ve

Zero/-ve

NOTE: Terminal numbers subject to change - Refer to supplied circuit diagrams.

16
Remote control circuits

Open/Close maintained Open/Stop/Close Two-wire control; energize to Two-wire control; energize to


control with mid-travel maintained control. Open, de-energize to Close. Close, de-energize to Open.
reverse. (Configure for Open priority). (Configure for Close priority).
Customer to link 5 - 33. Customer to link 5 - 35.
Form 1B Form 1C Form 1D Form 1E

4 4 4 4

36 36 36 36

Internally fed circuits


Open

33 33 33 33
Close Close
Close

34 34 34 34

Close

35 35 35 35
Open Open
Open

5 5 5 5
Stop

Form 2B Form 2C Form 2D Form 2E

4 4 4 4

Zero/-ve Zero/-ve
36 36 36 36

Externally fed circuits


Open

33 33 33 33
Close Close Close

34 34 34 34

Close

35 35 35 35
Open Open Open

5 5 Stop 5 5
Line/+ve

Line/+ve
Zero/-ve Zero/-ve
Line/+ve Line/+ve
Zero/-ve Zero/-ve

Max 60 V AC or DC (for higher Max 60 V AC or DC (for higher


voltages, apply to Rotork) voltages, apply to Rotork)

Redefining Flow Control 17


Analogue control circuits

Analogue Folomatic control only Analogue Folomatic control with


internally fed remote manual override
+ve
26 26
Customer
Customer analogue
analogue Customer
Customer analogue
analogue
output
output signal
signal output
output signal
signal
27 27
-ve *Manual
Manual

5
*
Auto
Auto
4

Customer
Customer
36
Key fitted
fitted links
links

41
26 Folomatic +ve
39
27 Folomatic -ve
33 Close
Close contact
contact

5 24 VDC +ve
35 Open
Open contact
contact
4 24 VDC -ve

36 Control Common 20-60 VDC or 34 Stop/maintain


Stop/maintain
(optional)
(optional)
60-120 VAC

41 Folomatic Common 20-60 VDC

45 Folomatic Common 60-120 VAC Analogue Folomatic control with


externally fed remote manual override
39 Folomatic manual/auto

33 Remote manual Close 26


Customer
Customer analogue
analogue
output
output signal
signal
35 Remote manual Open 27

34 Remote manual Stop/Maintain 36

For
For control
control in
in range
range 20-60
20-60 VDC
VDC
connect
connect common
common toto 36
36 and
and 41
41

41
For
For control
control in
in range
range 60-120
60-120 VAC
VAC
connect
connect common
common toto 36
36 and
and 45
45
45
*
Auto
Auto
39
* Line/+ve
Line/+ve
Manual
Manual
33 Close
Close contact
contact

35 Open
Open contact
contact

34 Stop/maintain
Stop/maintain
(optional)
(optional)

* If Manual/Auto override is required this must be enabled in


the configuration menus

NOTE: Terminal numbers subject to change - Refer to supplied circuit diagrams.

18
Partial stroke function

The actuator can be set to perform a partial Interlock Control


Interlock Control
Circuits
stroke test upon a valid signal being applied to Circuits
the Open Interlock. This allows for systems to
be tested periodically without interruption, to
verify valve movement. 4
4
The partial stroke function is enabled by selecting partial
31
stroke in the interlock menu. Further partial stroke functions 31
such as Partial Stroke – Limit, Position and Timeout can then
be adjusted to suit the application. As the function uses the
Partial Stroke
Open Interlock, the interlock function cannot be used with
37 Partial Stroke
partial stroking. 37
For extra diagnostic coverage, there are two new relay 38
configurations that can be used – Partial Stroke Active and 38
Partial Stroke Error, which can be found in the relay setting
menu, refer to PUB002-040 for further details.
5
5
Open/Close Interlock
active – Internally
Open/Close fed
Interlock
active – Internally fed

Key
Key
4 24 VDC -ve / 120 VAC N
4 24 VDC -ve
31 ESD/IL Common 20-60 VDC or 60-120 VAC
31 ESD/IL Common 20-60 VAC/VDC
37 Open Interlock
37 Open Interlock
38 Close Interlock
38 Close Interlock
5 24 VDC +ve / 120 VAC L
5 24 VDC +ve

NOTE: Terminal numbers subject to change - Refer to supplied circuit diagrams.

Redefining Flow Control 19


Redefining Flow Control

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service network is available on our website.

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Brassmill Lane, Bath, UK for more information on
tel +44 (0)1225 733200 this product range
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email mail@rotork.com

As part of a process of on-going product development, Rotork reserves the right to amend and change
specifications without prior notice. Published data may be subject to change. For the very latest version
release, visit our website at www.rotork.com
PUB002-041-00 The name Rotork is a registered trademark. Rotork recognises all registered trademarks. The Bluetooth®
word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks
Issue 10/12 by Rotork is under license. Published and produced in the UK by Rotork Controls Limited. POWSH1012