Workshop and Spare Parts Manual for IQ, IQM and IQML Mk 2 Range Actuators

Module 2 Bases & Drive Nuts Sizes 10-35

Module 1 Gearcase Module 7 Terminal Bung

Module 2 Drive Nuts Sizes 40-95

Module 11 Comprehensive Spares Kit

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Pic 3 Pic 2 Pic 8

Pic 12 Pic 11

Module 4 Handwheel

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Module 5 Motor

Pic 5 Pic 71

Module 6 Electronics Module 55 Terminal Cover

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Module 20 Electronics Cover

Health and Safety This manual is produced to enable a competent user to install, operate, adjust and inspect Rotork IQ range valve actuators. The electrical installation, maintenance and use of these actuators should be carried out in accordance with the National Legislation and Statutory Provisions relating to the safe use of this equipment, applicable to the site of installation. For the UK: Electricity at Work Regulations 1989 and the guidance given in the applicable edition of IEE Wiring Regulations should be applied. Also the user should be fully aware of his duties under the Health and Safety Act 1974. For the USA: NFPA70, National Electrical Code is applicable..

The mechanical installation should be carried out as outlined in the manual and also in accordance with relevant standards such as British Standard Codes of Practice. If the actuator has nameplates indicating that it is suitable for installation in Hazardous Gas Areas then the actuator is suitable for use in Zone 1 and Zone 2 (or Div.1 and Div.2) explosive atmospheres where gasses are present with an ignition temperature less than 135oC, unless suitability for lower ignition temperatures has been indicated on the actuator nameplate. Any test instruments applied to the actuator should be of equivalent certification. The electrical installation , maintenance and the use of these actuators should be carried out in accordance with the

code of practice relevant for that particular Hazardous Gas Area certification. No inspection or repair should be undertaken unless it comforms to the specific Hazardous Gas Area certification requirements. Under no circumstances should any modification or alteration be carried out on the actuator as this could invalidate the conditions under which its certification was granted. Access to live electrical conductors is forbidden in the hazardous area unless this is done under a special permit to work, otherwise all power should be isolated and the actuator moved to a non hazardous area for repair or attention. Only persons competent by virtue of thier training or experience

should be allowed to install, maintain and repair Rotork actuators. Work undertaken must be carried out in accordance with instructions in the manual. The user and those persons working on this equipment should be familiar with their responsibilities under ant statutory provisions relating to the Health and Safety of their workplace. WARNING Motor Temperature With excessive use the motor surface temperature could reach 132oC (270oF).

Before starting work on actuator The Rotork spare parts module sheets, contained in this manual, give detailed instructions on the removal and replacement of modules. Before commencing work, isolate all electrical supplies to the actuator and observe site safety regulations. On completion of repair, refer to publication E170E2 for commissioning and start up procedures.

Remember that your actuator is only as watertight or explosionproof as you make it, after completeing work. Conduit entries should be sealed in accordance with surrounding environment and with any requirements of the regulatory authority. Seal unused entries with threaded metal plugs. Do not use plastic plugs if supplied with the actuator, as these are purely to protect the actuator during transit. For ease of dismantling-The Rotork IQ tool kit is available.

Ordering of spare parts It is essential when ordering a spares module to give the actuator type and serial number. Additional information obtained from the actuator name plate would be helpful to enable Rotork to double check the actuator specification. Spares modules may be ordered from your local representative, valve supplier, or direct from Rotork.

Recommended spares holding It is difficult for Rotork to make recommendations for stocking spare parts, as customer requirements obviously differ according to their individual company policy. Howerver we make the following recommendations for use as a guide only.

Spares module assemblies for each size of actuator Module Number Description Quantity of Actuators 1-10 11-49 50+

Module 1 GEARCASE 1A Gearcase, Resolver PCB, Centre Column, Wormshaft & Wormwheel, Torque Transducer 1B Centre Column, Clutch Assembly, Resolver Drive Mechanism 1C Resolver Drive Mechanism, PCB, Oil Seals, Drive Shaft Gears 1D Wormshaft & Wormwheel, Oil Seals, Circlip & Fixing Screws etc. 1E Wormshaft & Wormwheel Maintenance Kit, O Rings, Seals, Bearings, Screws etc. 1F Gearcase Maintenance Kit, O Rings, Seals, Bearings, Circlips, Screws etc. 1G Hand/Auto Mechanism, Lever, Cam, Spring, Seal 1H Resolver PCB & Fixing Screws 1H/1 Resolver Magnet, Clip & Spring 1J Torque Transducer 1K Battery Removal Strap, Cover Plug 1K/1 Battery only 1L Battery Cover Plug only

- - 1 - - 1 - - 1 1 2 5 1 2 5 2 5 10 1 2 5 1 2 5 1 2 5 - 1 2 2 5 5 2 5 5 2 5 5

- 1 2 - 1 3 - - 1 - 1 3 - 1 3 - 1 2 - 1 3 1 2 3 - - 1 - - 1 - - 1 - 1 2 - 1 2 1 2 5 - 1 2 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 2 5 1 1 1 2 5 8 2 5 8 1 2 5 1 2 5 1 1 2 1 1 2 1 1 2 1 1 2 1 1 2 - 1 1 2 5 8 1 2 5

Module 2 Bases 2A Base Assembly Complete, Castings, Bearing, Drive Bush, Seals, Screws. Sizes 10 to 35 2A Drive Bush & Retainer. Sizes 40 to 95 2B Base Casting(s), Screws. Sizes 10 to 35 2B Drive Bush only. Sizes 40 to 95 2C Drive Bush only. Sizes 10 to 35 2D Thrust Bearing Assembly only. Sizes 10 to 35 2E Drive Bush & Thrust Bearing Assembly. Sizes 10 to 35 2F Base Maintenance Kit. Module 4 Handwheel 4A Top Handwheel - Complete. 4B/1 Side Handwheel - Complete. 4B/2 Side Handwheel & Spur Box Complete. 4C/1 Top Handwheel Maintenance Kit. 4C/2 Side Handwheel Maintenance Kit. Module 5 Motor 5A Stator/Rotor Assembly, Motor Cover, Bearing, Screws & O Ring. 5B Stator/Rotor Maintenance Kit, Bearing, Screws & O Ring. Module 6/1 Electronics 6A Complete Electronics Assembly, Chassis, PCBs, Transformer, Cable Looms, Contactors, Fixings. 6B Electronic Chassis Assembly Power 1, Power PCB with Transformer. 6C Electronic Chassis Assembly Power 2, as Module 6B plus Contactors. 6D Contactor Assembly, Contactors & Bracket only. 6E Optional extra Relays & Remote Input PCB, Positive or Negative Switching. 6G Main PCB with Liquid Crystal Display (LCD), PCB, Fixing Ring & Screws. 6H Folomatic PCB. 6J Folomatic & Current Position Transformer (CPT) Combined PCB. 6K CPT PCB. 6L CPT & Current Torque Transmitter (CTT) Conbined PCB. 6M Pakscan 2 Wire Control PCB. 6P CTT only PCB. 6Q DC/DC Convertor PCB. 6R Modbus PCB. 6S Dual Modbus PCB. 6X Profibus PCB. 6Y Foundation Fieldbus PCB. Module 6/2 Electronics for IQM & IQML Actuators 6T Power Module for Solid State Starter (SSS). 6U Solid State Starter. 6V Optional Remote Input PCB, Negative Switching. Electronics for IQ Single Phase 6W Power Module & Single Phase Starter. Module 7 Terminal Bung 7A Terminal Bung, Cable Looms, Watertight/WT & Explosionproof. 7B Commissioning Bag, Terminal Screws & Washers, O Ring Seal. Module 11 Comprehensive Spares Kit Comprised of all components in kits 1E, 1F, 2F, 4C/1, 4C/2, 5B & 55C. Module 20 Electronics Cover 20A Electronics Cover Complete, Control Knobs, Local Control PCB, Plastic Window, Enclosures, Watertight, Explosionproof, CENELEC, FM & CSA. 20B Local Control PCB, Looms & Screws. 20C Open/Close Knob (Black), Return Spring & Clip. 20D Local/Stop/Remote Knob (Red), Fixing Clip. 20G Locking Latch Assembly. 20H Both Local Control Knobs. 20J Plastic Window (Watertight Enclosure only). Module 55 Electrical Covers 55A Terminal Cover, Fixing Screws, O Ring , Label. 55C Terminal Cover Screws & O Ring Seal. Electronics Cover Screws & O Ring Seal.

Spares module assemblies for each size of actuator Module Number Description Quantity of Actuators 1-10 11-49 50+