Using the supplied infrared setter to enter the actuator's setting program, torque values, limits and all other control and indication functions can be set safely and quickly even in hazardous areas. IQ setting and adjustment can be performed with the actuator's main power on or off. The Rotork IQ series was the world's first valve actuator that could be commissioned and queried without opening the electrical compartment.
Standard diagnostic functions check the control system, valve and actuator status, displayed through icons and help screens on the actuator display. Pressing a setter button monitors the instantaneous torque at the corresponding valve position on the display.
The built-in data logger captures operation and valve torque data, prompting the user to maintain the valve as required. IQ Insight software running on a PC and/or the Rotork intrinsically safe communicator can access the data logger to configure and log all actuator functions. Whether an actuator is fitted with a setter is identified by the yellow label on the terminal compartment cover.
As shown in Figures 1, 2 and 3. Fig. 1 manual operation; Fig. 2 local control; Fig. 3 actuator display.
1.1.1 Manual operation
Press the manual/auto lever to the manual position. Turn the handwheel to engage the clutch, then release the lever — it springs back, and the handwheel remains engaged until the actuator is electrically operated, when the handwheel automatically disengages and returns to motor drive. If required, a padlock with a 6.5 mm hook can lock the clutch in either state.
1.1.2 Electric operation
Check that the supply voltage matches the actuator nameplate, then switch on. No phase check is needed. Do not operate electrically if the initial setting has not been performed — at minimum, complete the primary setting with the infrared setter.
Selecting local/stop/remote: the red selector chooses local or remote; each state can be padlocked with a 6.5 mm hook. With the selector locked in local or remote, the stop function remains effective. The selector can also be locked in STOP to prevent local or remote electric operation. Turn the red selector clockwise to LOCAL: the adjacent black knob then opens and closes; counter-clockwise stops the actuator. Turn the red selector counter-clockwise to REMOTE: remote control is then limited to open and close, with clockwise rotation of the black knob still stopping the actuator.
Display components: 1. red valve-position lamp; 2. yellow valve-position lamp; 3. green valve-position lamp; 4. LCD; 5. infrared sensor; 6. infrared signal confirmation lamp (red).
The LCD has two valve-position display modes: with mains power on, and with mains power off. With power on, the pale-yellow backlight and one position lamp light, and the display shows the valve opening percentage or an end-of-travel symbol. By standard, red = open, yellow = mid-travel, green = closed; the open/close lamp colors can be reversed if required.
Fully open / fully closed / mid-travel / valve alarm — after loss of mains the LCD is battery-powered and continues to show the valve position via the yellow lamp and percentage reading. In no case does the battery power the backlight or the position lamps.
The upper half of the IQ display has four icons — valve, control system, actuator and battery alarms — each representing an alarm condition. The standard help screens also check operation and alarm status. The valve alarm icon shows that a valve fault has caused torque beyond the actuator setting, tripping the actuator. Possible causes:
After a torque trip, electric operation in the same direction is inhibited and the icon remains; running the actuator in the opposite direction clears it. If the actuator stopped at a set travel end, no valve alarm icon shows — handwheel the valve to "feel" its stiffness.
The control alarm icon shows while a valid ESD or interlock signal exists in the remote control system. While present, local and remote operation are inhibited — understand the remote control conditions first.
Actuator alarm / battery alarm — the actuator alarm icon shows while an actuator alarm exists, inhibiting electric operation. Possible causes: motor thermal trip; low battery on power loss; power failure; control-system alarm; see battery alarm. The battery alarm icon shows when the actuator detects a low, flat or missing battery. With power on and a flat battery detected — and the power-loss inhibit function [OS] active — both battery and actuator alarm icons show and electric operation is inhibited. Replace the battery immediately when the battery icon shows; the actuator checks battery status about every 10 minutes. After replacement the icon remains for about 10 minutes until the next good check.
1.5.1 Setting procedure
Rotork IQ actuators pioneered adjustment without opening the electrical compartment once wiring is complete. The infrared setter sets torque, limits and other functions; it is intrinsically safe and can be adjusted live in hazardous areas.
All settings are stored in non-erasable memory inside the actuator. The setter lets the user view every function through the display window; each setpoint can be viewed and, if required, changed. The setting program has two levels: primary settings cover travel-end limits, torque values and limits; secondary settings cover control, indication and option functions.
All IQ functions are configured at the factory to the Rotork standard initial (default) settings unless otherwise specified at order. If problems arise during adjustment, recall the default settings to return the actuator to its factory configuration, then repeat field adjustments. Use defaults with care — after delivery this is essential for safe operation by the valve end user.
1.5.2 The setter
9 V battery (supplied and fitted); working distance 0.75 m from the actuator display window.
| 1. ↓ | display next function |
| 2. → | display next function across |
| 3. − | decrease / change displayed value or option |
| 4. + | increase / change displayed value or option |
| 5. ↵ | confirm new value or option |
Pressing the two arrow keys together returns the display to the valve-position indication.
Setter local controls: 5. stop actuator; 6. open actuator; 7. close actuator; 8. infrared transmit window. The red lamp should flash. To replace the battery, remove the six screws on the setter's rear cover; replacement must be done in a safe area — note the battery type marked inside the rear cover for hazardous-area use, and refit the cover with the red lamp aligned to the IR window. Pressing a key sends commands to the actuator by IR pulse, so keep the setter aimed at the display window within 0.75 m.
1.5.3 Entering the setting program
With the actuator securely coupled to the valve, switch on the mains and set the selector to LOCAL or STOP.
Press ↓ — the display changes to torque + position. Press ↓ again — the protection password prompt appears. The setting functions can be password-protected.
1.5.4 Setting mode — password
The correct password must be entered to set or adjust functions. The factory default is [ld]; if a site password has been set, that password must be displayed.
Use + or − to scroll the password from 00 to FF (hexadecimal); with the correct password displayed press confirm — two "setting" bars appear and remain on every function screen.
1.5.5 New password
To set a new password, enter setting mode at the password display. Press ↓ — the display changes to [PC]. Scroll with +/− to the desired password; press confirm — the password changes to [IE]. Note: the new password becomes effective the next time setting mode is entered.
1.5.6 Check mode
Settings can be reviewed without the correct password: all functions are view-only — no changes, no setting bars. After entering the desired mode, press ↓ to display the program branch symbol.
1.5.7 Program branch point [Cr]
Press the key to enter primary settings (see Section 8, page 20, primary function setting). Press the key to enter secondary settings.
1.5.8 Actuator display
In setting/check mode, every primary and secondary function listed in the expansion chart can be displayed individually with the arrow keys. ↓ always shows the first function of the next program row; → shows the next function within the same row, cycling within the row.
During setting the position lamps continue to indicate valve position; the function appears symbolically in the upper half of the LCD and its value in the lower half. Depending on the function, the value is an option or a number; in setting mode +/− changes it, in check mode it does not; in setting mode confirm enters a new value into memory — the value blanks then re-displays to confirm.
Upper half: the function, e.g. tC = closing torque; lower half: the value, e.g. 40%.
1.5.9 Returning to valve-position display
Four ways: 1) about three minutes after the last setting action the display returns automatically; 2) press the two arrow keys together; 3) press ↓ until the position shows; 4) whatever is displayed, move the red local/stop/remote selector to REMOTE.
Primary settings determine whether the actuator operates the valve correctly. If delivered assembled to the valve, primary setting may already be complete — electric operation is only permitted after primary setting is complete and checked.
Browsing primary settings: with the actuator coupled and powered, set the red selector to LOCAL or STOP and use the IR setter within 0.75 m of the window. Proper use of the keys shows each function and its value; the right half of the LCD explains each function.
Setting without mains: the IQ allows browsing and setting without power — drive the actuator one output revolution by handwheel; the setting is retained for 30 seconds, then the display returns to position indication; one more handwheel revolution re-enters the power-off setting function. Setting and operation must be verified by electric operation and function testing.
Browsing primary functions: P? PC Ir Ic protection password / change password / IrDA; Cr program branch; C1 C2 C3 closing direction, closing mode, opening mode; tC closing torque; LC close limit; position display.
1.6.1 C1 closing direction
The actuator can be set to close clockwise or counter-clockwise — operate manually to confirm; if the handwheel marking disagrees with reality, request a change from Rotork. Press +/− until the displayed character matches the correct closing direction. [C] = clockwise closing; [A] = counter-clockwise. Ensure the display responds to the direction setting. Press the key — the selection flashes, confirming it is set. Press the key.
1.6.2 C2 closing mode
Set torque-close (for seat valves) or limit-close (for non-seat valves) — follow the valve maker's advice. Without advice, use this table:
| Valve type | Closing | Opening |
| Wedge gate valve | Torque | Limit |
| Control valve | Torque | Limit |
| Butterfly valve | Limit | Limit |
| Through-conduit valve | Limit | Limit |
| Ball valve | Limit | Limit |
| Plug valve | Limit | Limit |
| Throttle valve | Limit | Limit |
| Sluice gate | Limit | Limit |
| Parallel slide | Limit | Limit |
Press +/− to display the desired choice: [ct] = torque-close, [cL] = limit-close. With the mode selected press the key — the selection flashes, confirming it is set. Press the key. Note: with torque-close set, the actuator outputs the [tC] torque at the valve seat position.
1.6.3 C3 opening mode
Torque-open (for seat valves) or limit-open (non-seat valves) — follow the valve maker's advice; without advice set limit-open. Use +/− to display the choice: [Ot] = torque-open, [OL] = limit-open. Press the key — the selection flashes, confirming. Note: with torque-open set, the actuator outputs the [tO] torque at the backseat position.
1.6.4 Tc closing torque value
The closing torque is settable — follow the valve maker's recommendation. It can be set from 40% of rating up to the rating, in 1% steps. Use +/− to show the recommendation; without one, increase gradually from small to large until the valve operates satisfactorily. Press the key — the value flashes, confirming it is set. Press the key. Note: the rating is on the actuator nameplate. Display shows 40% / 99% / 100% of rating.
tO opening torque value
The opening torque is settable — follow the valve maker's recommendation. It can be set anywhere from 40% of rating up to the rating in 1% steps. When opening-torque protection is not required, the "boost" function can be selected. With torque-open set, do not select boost unless the valve backseat can accept the rated torque. Use +/− to the recommended value; without one, increase gradually until satisfactory. Note: the rating is on the nameplate; boost torque is at least 140% of rating. Press the key — the selection flashes, confirming. When opening torque reaches the setting, the actuator trips and stops. Press the key. Display shows 40% / 99% / boost.
In check mode, after reviewing the opening torque, press the key to return to position display.
LC close limit — note: [LO] may be set first instead.
Note: in check mode the close-limit setting [LC] does not appear. The [LC] function display — closing limit. Handwheel the valve fully closed, up to one turn toward open. Press the key — two black bars flash and the fully-closed lamp lights, confirming the limit is set. Press the key. To verify, turn the handwheel one turn toward open (yellow lamp lights, closed lamp off), then one turn toward close (closed lamp lights, yellow off).
LO open limit — note: in check mode the open-limit setting [LO] does not appear. The [LO] function display — opening limit. Handwheel fully open, up to one turn toward close. Press the key — two black bars flash, the fully-open lamp lights, confirming the limit is set. Press the key. The fully-open symbol should appear (see Fig. 4.1). Return to position display. With setting done as above the position display indicates full open. Move the red selector to REMOTE to exit the setting program, then choose the desired control mode: local, stop or remote. Electric operation is safe only after correct setting. The display shows 50% position.
PC IrDA communication / local Ic — contact functions and values: contacts S1 r1, S2 r2, S3 r3, S4 r4; Cr program branch; control-mode settings ESD/ESD/ESD/ESD; local control holding; two-wire control; external interlock; condition control; torque-switch bypass — usable directions A1–A9, At. Option functions: additional indication CPT; remote proportional controller OF; remote control source OP; dwell timer OJ; power-loss inhibit OS. If OE, OF, OP or OJ cards are fitted and set to ON, the corresponding setting screens appear here. Help screens H1–H9. Initial options d1 d2. Return to position display.
After correct primary setting, perform secondary settings per control and indication needs, selecting any secondary function with the arrow keys as in Fig. 30. The actuator wiring diagram indicates any fitted optional functions. The optional IR control function [Or] and the power-loss inhibit [OS] are standard. In check mode the display is as in Fig. 31; in setting mode as in Fig. 32.
1.7.1 Control-mode configuration
Control-mode configuration affects actuator response under emergency protection, local control, remote interlock and two-wire remote control, and includes the non-seat torque-switch bypass. Unless specified at order, the default configuration applies. To change it, follow this section — ten configurable functions: A1 ESD emergency protection; A2 ESD contact form; A3 ESD thermal-protection bypass; A4 ESD over interlock; A5 ESD over local control; A6 local control holding; A7 two-wire control; A8 external interlock; A9 condition control; At non-seat torque-switch bypass. Local control holding (A6): the default is [On] (buttons latch); for non-latching (jog) button control press +/− to change to [OF]. Press the key — the selection flashes, confirming it is set. Local control holding.
1.7.2 Option — CPT (current position transmitter)
The settings include the CPT function providing 4–20 mA analog position feedback. CPT commissioning is an optional extra, internally or externally powered — check the wiring diagram for this function and connection details. Displayed as [HI], 20 mA output corresponds to full open; for 20 mA at full close, press +/− to change to [Lo]. Press the key — the selection flashes, confirming it is set. Note: with both Fologram (proportional controller) and CPT fitted, re-set the Fologram functions after re-setting CPT.
1.7.3 Option — Fologram remote control
The settings include the Fologram (proportional) controller for (analog) positioning of the valve — an optional control unit. Check the wiring diagram for this function. Before setting Fologram parameters, ensure the remote control source [bO] is set to [Od]; the Fologram setting display can be set to OFF for extra security.
With ON selected, the related additional function displays become available for adjustment. Note: on the Fologram setting screen (if the Fologram card is fitted), toggling ON/OFF does not affect operation; during setting the actuator should be in local or stop, with the signal applied to terminals 26 (+) and 27 (−).
1.7.3.1 OI — Fologram feedback
Before setting Fologram functions, set the Fologram feedback to suit the input signal. Press the keys until [OI] shows. With [OI] displayed, increase the signal to correspond to full open; for a high signal at full close, press +/− to change to [Lo]. Press the key. If [OI] is changed after Fologram setting, the Fologram parameters must be re-set; press the key until the Fologram setting display [OF] appears.
1.7.3.2 OF — Fologram setting screen
With the Fologram self-setting function enabled, further settings become available. Use +/− to select [On]; press the key — the selection flashes, confirming; press the key to enter the Fologram setting display. Fologram setting screens: close / open.
1.7.3.2 F1 — signal form
Use +/− to select [I] for current or [U] for voltage. With current selected, press the key — the selection flashes, confirming; press the key to [Fr].
1.7.3.3 Fr — signal range
Use +/− to select [05], [10] or [20] for 0–5 mA/V, 0–10 mA/V or 0–20 mA/V (i.e. 4–20 mA) signals. With 0–20 mA selected, press the key — the selection flashes, confirming; press the key to [FL].
1.7.3.4 FL — valve low signal
Signal at terminals 26 (+) and 27 (−): use +/− to select [blank] = valve closed, [01]–[99] = opening percentage, [=] = valve open, corresponding to the low signal — low signal closes the valve. Press the key — the selection flashes, confirming; press the key to [FH].
1.7.3.4 FH — valve high signal screen
Signal at terminals 26 (+) and 27 (−): use +/− to select [blank] = valve closed, [01]–[99] = opening percentage, [=] = valve open, corresponding to the high signal — high signal opens the valve. Press the key — the selection flashes, confirming; press the key to [Fd].
1.7.3.5 Fd — dead-band adjustment
If the actuator oscillates or responds to unnecessary signal fluctuations, increase the dead band; for finer control, decrease it. Use +/− to select the width, 00–99 corresponding to 0%–9.9% of the control signal. Note: maximum dead band is 9.9% of valve travel; the minimum should normally not be below 1%; the dead band is set to 1.2% of valve travel. Press the key — the selection flashes, confirming; press the key to [Ft].
1.7.3.6 Ft — inhibit run timer adjustment
The inhibit run timer delays actuator response to instantaneous signal changes to prevent unnecessary operation; once the system stabilizes, the actuator responds to steady changes as required. Use +/− to set the inhibit time in seconds, 0–99 s. An inhibit time of at least 5 s is normally recommended; 5 s is the default. Press the key — the selection flashes, confirming; press the key to [FA].
1.7.3.7 FA — response to signal loss
Use +/− to select response [On] or no response [OF]. [On] — the fail direction is set by [FF]; [OF] — on fault the actuator runs to the position corresponding to the low signal. Press the key — the selection flashes, confirming; press the key to [FF]. Note: fail response "ON" is only effective with a non-zero signal range such as 4–20 mA.
1.7.3.8 FF — fail direction
With fail response [FA] enabled, use +/− to select, on signal loss: [L0] — run to the position for the minimum signal; [SP] — hold position at signal loss; [HI] — run to the position for the maximum signal. Press the key — the selection flashes, confirming. Fologram setting is now complete; remote proportional control can be selected.
The following remote control forms are available: standard hardwired; analog — optional Fologram; network control including optional Pakscan, optional Modbus and optional Profibus. The setting depends on the required remote form and whether the option card is fitted — check the actuator wiring diagram for the remote control method.
[Od] remote control box: the source depends on the fitted option card — [rE] standard hardwired remote control; optional Modbus bus; [bO] optional Fologram; [OP] optional Pakscan bus or Foundation fieldbus; [OF] all remote control disabled (local only). Press +/− to change the source until the desired setting shows. Press the key — the selection flashes, confirming it is set.
Standard hardwired remote control
If an inhibit timer is fitted and set as in the example above, the actuator operates: full open to 25% opening at rated speed; 25% opening to full close, and full close to 25% opening, at 1/6 rated speed; 25% opening to full open at rated speed. Note: with both Fologram and inhibit timer fitted and used, the Fologram inhibit time must equal the inhibit timer's "contact open" time; incorrect setting causes the slower delayed response and control problems. If "run" and "stop" times over 99 s are required, contact Rotork.
Default is [OF]. For setter local control press +/− to [On]. Press the key — the selection flashes, confirming; set the red selector to LOCAL and the setter keys control the actuator. Setter local control is for preventing damage to the actuator only (no red/black selector provided). [Or] options: [On] — setter local control only; [OF] — no local/remote control; [rE] — remote control only.
Default is enabled [OnOF]. This ensures that after a power loss with a flat battery and no display, if the actuator was handwheeled, the position-sensor circuit is altered so the actuator cannot be electrically operated even when mains returns.
Press the key — the display flashes, confirming it is set.
All IQ functions are configured at the factory to Rotork standard (default) settings — see the table at right — or as specified at order. Field setting with the setter overwrites the defaults; the "current" settings then govern operation while the defaults are retained. Reverting to factory defaults is rare, but when it happens the field settings must be repeated. Two defaults exist: d1 — Rotork standard settings or user-specified primary and secondary settings; d2 — limits only: factory-set turns and limits. Note: Fologram, Pakscan, Modbus, Profibus and Foundation fieldbus settings are not affected by d1 or d2 and are retained. With d1 entered, all primary and secondary functions except limits return to default (the Rotork standard table) — primary (except limits) and secondary settings must be checked and re-entered. With d2 entered, the limits are re-set to 25 turns as full travel with the current position at 50% (12.5 turns) — the limits must be re-set to the valve.
1.12.1 Maintenance — every Rotork actuator is fully tested before delivery; installed, sealed and commissioned per this manual it gives years of trouble-free service. The IQ series' unique double-sealed, non-intrusive housing protects the internals completely; routine checks should not open the compartment, as this may affect reliability. Routine maintenance by Rotork quality control includes: check the actuator-valve bolting is tight; keep the stem and drive sleeve clean and lubricated; for rarely operated valves establish an exercise plan; replace the actuator battery every five years.
1.12.2 The actuator battery — the battery supports the position-circuit changes and LCD position display during mains loss, ensuring position transmission and display while handwheeling with power off; with a data logger fitted it also supports event logging during mains loss. No actuator setting depends on the battery.
Warning: the battery holder is on the actuator housing and provides protection in hazardous areas — it must not be damaged. Removing it requires the actuator to be isolated. A unique circuit in the IQ battery function reduces consumption to extend life: typical tests show 7 years; conservatively Rotork recommends replacement every 5 years. A battery status icon shows on the display — if shown, replace the battery.
Replacement: in hazardous areas, "live work" permission and local regulations apply before removing/replacing the battery. Removing the battery with mains off loses data-logger records — replacement with mains on is recommended. If the mains cannot be restored and the battery is flat, check the limits after replacement. Removal: selector to STOP; the battery is in the sealed plug beside the handwheel root on top of the housing, under a labeled plug; remove the plug with an 8 mm hex wrench, keep the O-ring on the plug, disconnect the battery leads and pull the battery out by its black strap. Battery type: for CENELEC (ATEX) actuators only 9 V long-life manganese-alkaline; for FM/CSA certified units, 9 V long-life manganese-alkaline; UL-certified equivalent batteries may be used; for waterproof actuators, 9 V long-life manganese-alkaline or any equivalent 9 V battery.
Refitting: slip the strap over the new battery and insert it into the rubber sealing槽; reconnect the leads; refit the sealed plug with the O-ring intact and correctly seated; tighten with the 8 mm hex wrench.
1.12.3 Torque and position monitoring — as standard, IQ actuators include real-time torque + position monitoring to observe valve behavior during operation: changes in running conditions (differential pressure etc.) are detected, tight points in the stroke are precisely located, and torque growth can be measured against settings. With position displayed, select LOCAL or STOP and press the setter key.
The display splits: upper half instantaneous torque (% of rated), lower half position (% opening). Example: at 50% opening the display reads 19% of rated; torque range displays [00]–[99]% of rating in 1% steps, with [HI] above 99%. Position: [blank] = fully closed, [00]–[99] = opening percentage, [=] = fully open. For a stationary actuator the actual applied torque shows; hold the torque + position display by pressing + or − — the display holds for about 5 minutes after the last keypress.
The IQ series was the world's first actuator commissionable and queryable without opening the electrical compartment. The help-diagnostic screens give fast, complete fault searching.
1.13.1 Backlight and position lamps dark after power-on. After power-on the display should be backlit. Check the three-phase supply against the nameplate voltage; measure the phase voltages between terminals 1, 2 and 3 on the terminal strip.
1.13.2 No position display after power loss. After mains loss the internal battery supports only the LCD position display; if blank, the internal battery must be replaced and the travel limits re-set.
With power on, select LOCAL or STOP; the setter can display 8 help screens — also accessible in remote by double-pressing the setter key. Each screen shows indicator bars for special control or indication functions; each bar change represents a function reversal. Reference screens and descriptions: H1 — factors affecting electric operation; H2 — battery level and ESD control input; H3 — limits and actuator supply status; H4 — remote control inputs; H5 — remote interlock, local control input and motor thermal protection; H6 — torque-switch status and IR setter communication; H7 — travel limits, center sleeve and remote indication outputs; H8 — actuator position sensing; H9 — Rotork special.
Micro-switches on the Fologram board select current/voltage signal and range:
| Range | SW1 | SW2 | SW3 | SW4 | SW5 | SW6 | SW7 | SW8 |
| 0–5 mA | O | O | O | ● | O | O | O | O |
| 0–10 mA | O | O | O | ● | O | O | ● | O |
| 0–20 mA | O | O | O | ● | O | ● | ● | O |
| 4–20 mA | O | O | ● | O | ● | ● | O | |
| 0–50 mA | O | O | O | ● | ● | ● | ● | O |
| 0–5 V | O | O | O | O | O | O | O | O |
| 0–10 V | O | O | ● | O | O | O | O | O |
| 0–20 V | O | ● | O | O | O | O | O | O |
Note: O = off, ● = on. Open/close 1: closed — on signal loss the actuator runs to the travel end corresponding to the low signal. Open/close 1: open — on signal loss the AQ responds per switches 3 and 4 on the main board (6 and 7 for Q series).
2.1.1 Drive sleeve — remove the sleeve fixing bolts on the actuator base, then the sleeve. Two mounting bases are supplied; choose one before removing the sleeve, removing the first base if required. Mark the keyway position at full open, machine the sleeve to fit the stem, then refit the sleeve and bolts.
2.1.2 Mounting to the valve — bolt the valve to the actuator with the four fixing bolts; check the groove in the actuator base is clear — it protects the actuator should medium leak past the valve seal.
2.1.3 Field wiring — remove the four bolts of the terminal box and the plug; fit cable glands per the relevant standard; seal unused entries with solid plugs; connect power and control cables per the circuit diagram in the installation manual; check the O-rings, refit the cover and tighten.
Without permission, never operate electrically with the top cover open in hazardous areas.
2.2.1 Travel limits — AQ actuators limit travel by stop bolts using torque at the travel ends. The open and close stop bolts set the approximate 90° travel and should be adjusted to the valve: press the manual/auto clutch lever toward the handwheel to select manual; fully open the valve, adjust the open stop bolt to suit and lock it; fully close and adjust the close stop bolt, then lock. Both stop bolts are now set.
2.2.2 Torque setting — loosen the top cover screws and open it. The opening direction is not adjustable — factory-set to rated torque; the closing direction is adjustable from 30% to 100% of rated via the "close torque" potentiometer on the main board: counter-clockwise decreases, clockwise increases. Note: when torque stops the actuator in either direction, the red LED on the main board lights.
2.2.3 Speed setting — the speed range is printed on the nameplate. Adjust the speed-control potentiometer on the main board: clockwise increases speed, counter-clockwise decreases it (Fig. 3, Fig. 4).
2.2.4 Auxiliary switch setting — two independent auxiliary switches indicate the open and closed travel ends; adjust their cams by fingertip in each direction; the cams are spring-located. For a clockwise-closing actuator, the close-indicating auxiliary switch (CAS): close the valve fully, pull the lowest cam on the center shaft upward and rotate clockwise until the switch just actuates — release, and it is set; the open-indicating switch (OAS): full open, press the second cam down and rotate counter-clockwise until it just actuates, then release — set.
2.2.5 Continuous valve indicator — full open; reposition the continuous indicator with the red (open) lens over the bulb and tighten. Before fitting the top cover check the O-ring, grease the threads, refit and tighten the cover, ensuring the locking bolt aligns with the mark.
2.2.6 Remote control selection — the 8 selector switches on the main board choose control functions, local-control holding or key operation.
Check that the stop bolts are tight, the terminal box bolts tight, the top cover and its locking bolts tight, and the position indicator reading.
2.4.1 Valve leakage — 2.4.1.1 possible cause: stop bolts wrongly set. Remedy: reposition (follow valve maker's advice). 2.4.1.2 possible cause: valve torque too small. Remedy: increase torque. 2.4.1.3 possible cause: valve jammed. Remedy: free the valve.
2.4.1.4 The actuator runs but does not drive the valve: the manual/auto lever is locked in manual.
2.4.1.5 The actuator will not start: check and replace the fuses.
2.5.1 Complete local controller (Fig. 5) — two knobs: a two-position open/close selector and a lockable three-position local/stop/remote selector. Release the lock, set the three-position selector to LOCAL as labeled: rotate the control knob clockwise to CLOSE and the actuator runs closed; STOP stops it; on release the selector springs back to LOCAL; counter-clockwise to OPEN runs the actuator open; release the lock, set to REMOTE for remote control.
2.5.2 Travel limit switches — setting procedure: after the stop bolts are set, the travel limit switches stop the actuator very near those positions. For a clockwise-closing actuator the close travel switch (CLS) and for counter-clockwise closing the open switch (OLS): switch to manual, turn the handwheel clockwise to the travel end, pull up the second cam from the top and rotate clockwise until the switch just actuates — release, and it is set. For counter-clockwise closing the open switch (OLS), for clockwise closing the close switch (CLS): manual, handwheel counter-clockwise to the end, press the upper cam down and rotate counter-clockwise until it just actuates — release, set. Note: the open/close indication auxiliary switches must be set to actuate before the travel limit switches so the indications are correct.
Verify: electrically close the actuator — the red LED on the main board should NOT light; if it lights, the close limit is wrongly set (effectively a torque close). Electrically open — the red LED should not light; if it does, the open limit is wrongly set (a torque open). If only one direction needs limit operation, set only that direction's switch and ensure the other direction's cam does not actuate its switch at the end (the red lamp on the board should light — that direction is torque open/close).
2.5.3 Auxiliary switches — four more auxiliary switches can be fitted in the switch mechanism, each independently adjustable to any point of travel, per the circuit diagram and valve-maker or user requirements (Fig. 6).
Setting: place the valve where switching is needed, pull the lowest cam (IAS4) upward and rotate until the switch just actuates — set. The other three likewise: third cam IAS3 — press down and rotate; second cam IAS2 — pull up and rotate; first (top) cam IAS1 — press down and rotate (Fig. 6).
2.5.4 Two-speed control — available: slow running at the closing end of travel to prevent water hammer. Setting: place the actuator where slow speed should begin; rotate the lowest auxiliary-switch cam clockwise (counter-clockwise for counter-clockwise-closing actuators) until the switch just actuates — set. Test: full open, run toward close at the set speed; at the auxiliary-switch point the actuator automatically slows to minimum until fully closed. Note: opening from closed runs at the preset speed (see 4.4).
2.5.5 Potentiometer — for position feedback, measurable with a multimeter. Setting: full close; rotate the potentiometer lock knob clockwise to release it; rotate the base, measuring between terminals 23 and 32 in the terminal box to about 50 Ω (terminals 28 and 14 for counter-clockwise closing); tighten the lock knob — the potentiometer is set.
2.5.6 Current position transmitter (CPT) — 4–20 mA output (Fig. 7). Adjusting zero and span gives continuous position indication. Electrical: the CPT is internally or externally powered — check with the circuit diagram supplied. Check whether the valve closes clockwise or counter-clockwise. Setting: 1. signal direction — locate jumper J7 per Fig. 7: (a) clockwise closing with low signal at close, and counter-clockwise closing with low signal at open: J7 parallel to the board edge; (b) clockwise closing with low signal at open, and counter-clockwise closing with low signal at close: J7 at right angles to the board edge. 2. Move the valve to the low-signal travel end: unplug the connector (1–6) at SKT 2 on the CPT board; measure the relevant pins with a multimeter; rotate the potentiometer base to ~50 Ω, lock the potentiometer and refit the plug. 3. Adjust the CPT zero trim for the required minimum signal. 4. Move the valve to the high-signal end. 5. Adjust the CPT span trim for the required maximum signal. 6. Return to the low-signal end and re-check; re-adjust if needed.
2.5.7 Proportional controller (Fig. 7) — zero/span/timer/dead band. Adjust zero and span so input and feedback correspond; refer to the circuit diagram and user manual for precise setting. With the selector at LOCAL the actuator behaves like any local open/close unit, so initial setting is done in local mode per this manual. Note: combining proportional control with two-speed control lets the actuator approach the setpoint at minimum speed, minimizing overshoot with a narrow dead band. With local operation and the demand signal present, the actuator slows near the setpoint, then returns to set speed past it — normal, showing the operator only the approximate demand position. Setting:
2.5.7.1 Determine the closing direction (clockwise/counter-clockwise) and whether the low command signal is open or close. Per Fig. 7 find switches 1 and 2 on the proportional/CPT board: (a) clockwise closing, low = close: SW1 to the board edge, SW2 inboard; low = open: SW1 inboard, SW2 to the edge. (b) Counter-clockwise closing, low = close: SW1 and SW2 both inboard; low = open: both to the edge.
2.5.7.2 Confirm the command signal type and range: find the DIP switch on the proportional board per Fig. 7 and set the current/voltage range per the table. Note: unless specified at order, factory setting is 4–20 mA.
2.5.7.3 With 4–20 mA command, choose hold-in-place or a travel end on signal loss: set proportional board switch 1 to "On" and main-board switches 3 (P1) and 4 (P2) to "On" to close on signal loss; both to "Off" to open; one On/one Off to hold.
2.5.7.4 Check the command cabling: (a) current/voltage signal to terminals 9 (−) and 12 (+); (b) user-supplied potentiometer: terminals 9, 12 (center tap) and 18.
2.5.7.5 Selector to LOCAL; valve to the low-signal end; unplug SKT 2 on the proportional/CPT board (marked 1–6) and measure the relevant pins; rotate the potentiometer base to ~50 Ω, lock it and refit. Note: if the potentiometer was pre-adjusted for the CPT, no further adjustment is needed when setting the proportional controller.
2.5.7.6 Set the command signal to the required minimum.
2.5.7.7 Find the zero trim and adjust until the green lamp (valve closed) or red lamp (valve open) on the board just lights, steadily. Clockwise rotation lights the corresponding lamp.
2.5.7.8 Run the valve to the other travel end (the high-signal end).
2.5.7.9 Set the command signal to the required maximum.
2.5.7.10 Find and adjust the span trim until the red lamp (valve open) or green lamp (closed) just lights, steadily; clockwise rotation lights the corresponding lamp.
2.5.7.11 Set the local/remote selector to REMOTE — the valve is now controlled by the remote proportional controller.
Dead band and inhibit-timer adjustment: both are multi-turn trims, factory-set to minimum (fully counter-clockwise) to ease zero/span setting. Dead band: if the actuator should not respond to small signal changes, rotate the dead-band control clockwise; normally no oscillation should occur — e.g. running toward increasing signal, the actuator should stop when input matches feedback. If it oscillates, increase the dead band as needed. Inhibit timer: prevents response to unnecessary rapid signal changes; set to the maximum inhibit time to avoid unnecessary operations and maximize working life. The red and green lamps on the board indicate signal change direction: red = running open, green = running closed; if both light, the signal change does not match the inhibit time. Inhibit time is adjustable 2–40 s; clockwise increases. Refit the top cover with the O-ring seated and tighten the locking bolts.
2.5.8 Setting AQ actuators with backup battery
Installation and commissioning are as for the standard actuator; after completion: 1. switch off the AC power; 2. open the top cover; 3. set micro-switches 1, 2, 5 and 8 on the main board as desired. Note: factory setting is run-closed on power loss. 4. Open the backup-battery cover, plug the floating connector into the board, refit the cover with the vent downward and remove the vent plug. 5. Restore AC power — the actuator now has standard functions plus running in the selected direction on AC power loss. Warning: the backup battery then supplies DC via terminals 22 and 24 — never short these terminals.
AQ actuators ship with DEXRON II lubricant with 20% paraffin, suitable for -40 °F (-40 °C) to 160 °F (70 °C). When replacing, use DEXRON II without added paraffin unless the ambient temperature is below -40 °F (-40 °C).
3.1.1 Syeroset valve electric device (Syncropak actuator) specifications:
| Type | "A" series rated load | "A" rated travel | "M" rated load | "M" rated travel |
| Multi-turn | 34–3000 Nm | 18–144 r/min | 17–271 Nm | 18–144 r/min |
| Linear | — | 7000–31000 N | — | 5–115 mm |
| Part-turn | 340–85000 Nm | 0–90° | 130–31000 Nm | 0–90° |
3.1.2 Actuator input signal selectable from: 0–10 mA (DC), 4–20 mA (DC), 1–5 V (DC). Other values to user requirements. 3.1.3 Standard or flameproof product per application: (a) rated voltage: single-phase 220 V 50 Hz; three-phase 380 V 50 Hz; (b) flameproof actuators: per GB3836.1-83 "General requirements for explosion-proof electrical equipment for explosive atmospheres" and GB3836.2-83 "Flameproof electrical equipment"; marking d IIBT4; enclosure IP68.
3.1.4 Sycroset valve electric device — each consists of four basic parts: (a) motor; (b) oil-bath gearbox with handwheel and clutch; (c) travel and torque limit switch mechanism; (d) terminal box.
3.1.5 Syeropak control actuator — the standard control actuator consists of four basic parts: (a) motor; (b) oil-bath gearbox with handwheel and clutch; (c) travel and torque limit switch mechanism; (d) complete drive and interlock control unit.
3.2.1 Manual operation — first press the clutch lever to manual, then turn the handwheel gently until the clutch is set before releasing the lever. Manual engagement is retained until electric operation, when the lever automatically disengages back to automatic. To lock the lever long-term in automatic or manual, use a 5/16" pin in the desired position as shown.
3.2.2 Electric operation — for Syncropak actuators there is a local/remote selection: a switch group at one end of the Pak box. A black selector with three positions — local, remote, off. In local, operate the red knob: clockwise runs the actuator open; counter-clockwise closes. In remote, the actuator runs reversibly from the control room. In OFF, the selector handle rides on the red knob and pushes in to stop all electric operation; to hold the selector in a position long-term, lock it to the cover with a 1/4" padlock; on the 1600 series the cover shows separate symbols for local and remote.
3.2.3 Valve position indication — valve position is shown by a pointer and dial; once powered, the Syncropak opening state is shown by lamp color: fully open — red; mid-travel — white; fully closed — green. Note: while running, the pointer rests mid-scale; only with an AOP1 fitted does the pointer move continuously between close and open.
3.2.4 Switch mechanism commissioning — two basic rules for mechanical position adjustment: (a) adjust the limit switches at full open and full close; (b) correctly select torque-switch or limit-switch function to suit the valve characteristics — torque values may be set in special cases. The electric valve was adjusted before delivery.
3.2.4.1 Verifying the adjustment — with the actuator mounted on the valve, handwheel to full open: the position pointer should sit exactly at full open; then to full close, the pointer exactly at full close — that is normal. If they disagree, adjust.
3.2.4.2 Limit-switch adjustment — operate to full open or full close. Note: clockwise is normally the valve closing direction; if counter-clockwise, the reverse. Remove the three screws of the switch-mechanism cover with a 5/32" hex wrench and carefully lift the cover off with both hands — never pry with a screwdriver (Fig. 6).
With the cover off, the switch mechanism is visible as in Fig. 7. Loosen lock nuts 17 and 18 so they move outward along screw shaft 15, then back off the clutch nut 22 three turns counter-clockwise. Screw shaft 15 should now turn by hand (Fig. 8), with moving nut 16 traveling along the shaft.
Turn shaft 15 counter-clockwise by hand until moving nut 16 meets the pawl 19. Holding the shaft, keep rotating; via the over-travel guide 20, continue until the guide strikes the over-travel stop 21 — you will hear the micro-switch click at the end of travel. Hold the guide against the switch, then tighten the clutch nut. With the clutch nut fully tight, release the pressure on the guide: it should stay at the stop with no reset click; a click means the procedure above was not followed.
The switch is now set at full close, actuating just before the mechanical stop. During closing, for a limit-function valve, verify the closed position electrically: if the valve cannot fully close, hand-turn the mechanical stop, loosen clutch nut 22 and guide 20, allowing the guide to return to neutral; with the guide aid, rotate shaft 15 counter-clockwise until all switches have just actuated but the guide has not yet reached stop 21; tighten the clutch nut so the switch does not reset when the guide is released.
Electrically run the valve to full open — for safety do not back off at all. Press the over-travel guide clockwise by finger until it meets stop 21, holding it depressed; you will hear the switches click during this operation.
Still holding the guide down, rotate lock nut 17 clockwise along the shaft until it meets the moving nut; push washer 24 along the shaft until it meets lock nut 17; then turn lock nut 18 down until it clamps both lock nuts and the washer; lightly tighten nut 18. Release the guide pressure — it should rest at the stop with no reset click; a click on release means the adjustment is not right.
The switch is now set at full open. The procedure then ensures: (a) the switches cut motor power before the valve reaches the travel end; (b) handwheel operation does not disturb the set switch positions.
3.2.4.3 Torque or limit control switch selection (Fig. 9) — check the torque/limit selector in the OPEN or CLOSE position against Table 6, or the valve maker's specific instructions; move selectors C and D if necessary to suit the valve. Correct torque/limit functions by valve type: if the electric valve was purchased complete, the valve maker may have set the correct function; absent specific instructions, use Table 1 to select torque and limit correctly.
3.2.4.4 How to select the torque value? — selectors A and B must be adjusted before the torque switch cuts the motor; select the torque value to suit the valve. Theoretically closing requires minimum torque, but in practice it varies with valve size and external factors (temperature, application, etc.). For these reasons start with selector A at the first calibrated position (minimum, A = closing torque). If the valve still does not close tight, continue increasing the closing torque. Selector B should be at maximum (B = opening torque) unless the valve maker advises otherwise. The torque setters have locking tabs to prevent unauthorized tampering. After setting both torques, lock by bending the appropriate tab. If opening torque is irrelevant, the torque adjuster may be set to "boost" — no locking needed there.
3.2.4.5 Refitting the switch-mechanism cover — if the indicator lamp is central, support it while refitting; ensure the O-ring is sound (spares in the terminal box). Insert the square-pin indicator in the cover top and push in; refit and tighten the three screws.
3.2.5 Add-On-pak 1 intermediate auxiliary switch adjustment — completely independent of the switch mechanism above. The supplied Aopt1 must meet the actuator turn-count requirements in timing and gear ratio, or be corrected. Aopt1 uses a proportional mechanism adjusting the pointer travel to suit the valve; verify over the full stroke by hand — the pointer should run continuously from close to open; otherwise the proportional gearing or ratio is wrong. Correctly set, the switches will trip at the required valve positions. Note: clockwise = close, counter-clockwise = open.
In the closing direction, operate the valve from a suitable mid position to the required trip point; loosen nut 10 on the back of the camshaft so switches IAS4, 5 and 6 just trip; partly tighten the nut. In the opening direction, operate to the required trip point; release nut 10 again and adjust the outer cam 13 to trip switches IAS1, 2 and 3; fully tighten the nut. Adjustment diagram: Fig. 10, Fig. 12.
3.2.6 Potentiometer adjustment — the potentiometer drive mounts only on the switch mechanism. Loosen the drive screws coupling the gear drive coupling; close the valve; rotate the gear coupling counter-clockwise (viewed from the switch-mechanism front) until it reaches its stop; tighten the drive screws. The potentiometer drive should suit the AOP1 with the valve fully open (Fig. 12).
Normally the correct potentiometer gear meshes with the main potentiometer drive gear to match the actuator output turns to full valve travel. With the gear chosen, use a 3/12" hex wrench to free the potentiometer assembly from its mounting post; release the potentiometer gear and rotate the potentiometer shaft about 20° off the travel end.
3.2.7 Current position transmitter (CPT) adjustment — adjustable from zero to full scale, internally or externally powered. The adjustments below refer to the CPT mounted behind the knob cover (Fig. 13).
3.2.7.1 Signal direction: (1) confirm whether the valve closes clockwise or counter-clockwise. (2) On Fig. 13 locate the double-throw connector J7: clockwise closing (low signal at close) and counter-clockwise closing (low signal at open) — J7 must be moved parallel to the board edge; clockwise closing (low signal at open) and counter-clockwise closing (low signal at close) — J7 must be moved at right angles to the board edge.
3.2.7.2 Commissioning: (1) move the valve to the small-signal travel end. (2) Adjust the CPT zero trim to the required minimum signal. (3) Move the valve to the large-signal travel end. (4) Adjust the span trim to the required maximum signal. (5) Return to the small-signal end and re-check; re-adjust if needed. For the CPT on the printed board in the switch-mechanism compartment (Fig. 14): (a) first adjust the torque and limit switches as above and rotate the actuator to full close; (b) set the transmitter mechanical zero, checking the selected gear suits the full stroke; (c) check that the remote connection to the CPT matches internal or external supply (see wiring diagram); (d) valve closed, adjust the zero potentiometer on the CPT board to the required minimum signal; (e) full open, adjust the span potentiometer to the required maximum signal — for maximum signal at closed position, swap the potentiometer drive gears, re-engage with the valve open clockwise, reconnect the supply and repeat zero and span as above.
3.2.8 Flashing indicator adjustment — factory-set to the actuator output turn range; normally no further adjustment.
3.2.9 Proportional controller adjustment — same as AQ type.
