Contents

Page
AQ Instruction Manual 1. Identifying actuator parts 3
2. Actuator mounting 4
2.1 Drive bush 4
2.2 Mounting 4
3. Site cabling 4
4. Operational settings 5
4.1 Travel limitation 5
4.2 Torque 5
4.3 Speed 6
4.4 Auxiliary switches 6
4.5 Position indication 7
4.6 Remote options 7
5. Final checks 7
6. Trouble shooting 7
7. Optional extras 8
7.1 Integral local control station 8
7.2 Positional limit switches 8
7.3 Extra auxiliary switches 9
7.4 2 speed control 9
7.5 Potentiometer 10
7.6 CPT 10
7.7 Folomatic 11
Publication number E570E 7.8 Battery pack 13
8. Lubrication 13
Date of issue 11/02
Appendix 1 14
(AQ100 AQ300 AQ800)
Rotork actuator is supplied Health and Safety The electrical installation, maintenance otherwise all power should 2
and use of these actuators should be be isolated and the actuator
This manual is produced to enable the carried out in accordance with removed to a non hazardous
Fully rig and performance tested. user to install, operate, adjust and BSEN60079-14:1997 area for repair or attention.
inspect Rotork AQ range valve No inspection or repair should be
Torque output set to maximum actuators.
unless otherwise specified. undertaken unless it confirms to the Only persons competent by virtue of
requirements given in these standards, their training and experience should
The electrical installation, maintenance and under no circumstances should be allowed to install, maintain and
Cable entries sealed for transit and use of these actuators should
protection. any modification or alteration be repair these actuators, and they should
conform to the requirements of the carried out on the actuator as this carry out this work in accordance with
Electricity (Factories Act) Special could very well invalidate the the instructions given in the manual.
Inclusive of commissioning kit. Regulations 1908 and 1944 and the conditions under which the certificate The user and those persons working
guidance given in the 15th Edition of was granted. on this equipment should be familiar
Inclusive of wiring diagram. the IEE wiring Regulations. The user with their responsibilities under the
should therefore make himself familiar These actuators are suitable for use in Health and Safety at Work etc. Act
with these regulations and other Zone 1 and Zone 2 explosive 1974 and relevant Statutory Provisions
Rotork actuator type is identified by a Statutory regulations and other
stainless steel label fitted to the main atmosphere only, and they should not relating to their work.
Statutory Provisions relating to the be installed in atmospheres where
body. safe use of this equipment. Also the Group IIC gases are present, or where Should further information and
user should be aware of his duties gases are present, with an ignition guidance relating to the safe
under the Health & Safety at Work etc. temperature less than 135 degree installation, maintenance and use of
Act 1974. Celsius, unless suitability for lower the Rotork ‘AQ’ Range actuator be
ignition temperatures has been required, this will be provided on
The mechanical installation should be indicated on the actuator nameplate. request.
carried out as outlined in the manual Any test instruments applied to the
and also in accordance with the actuator should be of equivalent
relevant British Standard Codes of certification.
Practice.
Access to live electrical conductors of
If the actuator has nameplates the actuator is forbidden in the
indicating that the actuator is suitable hazardous area unless this is done
for installation in Hazardous Gas Areas under a special permit to work
then the following regulations apply.
 1. Identifying actuator parts 3

1. Drive bush
Steel drive bush supplied blank. Valve
manufacturer to machine to suit valve spindle.
Retained in position by a single fixing screw.
2. Hand/auto lever
3. Handwheel
Handwheel is for manual operation and is
engaged by pulling hand auto lever towards
handwheel.
4. Mechanical stops
Two stop bolts are provided as mechanical
stops and should be adjusted to suit valve
open and closed positions 90º ± 5º.
5. Top cover
Screwed aluminium component locating with
main gear case body and sealed with ‘O’ ring.
Locking grubscrew is located in locking plate.
6. Cable entries
Two cable entries are provided for power and
control cables.
7. Terminal cover
8. Nameplate
(see Fig.1)

Fig.1 Fig.2
2. Mounting actuator 3. Site Cabling 4
instructions

2.1 Drive Bush Cable Entries

To remove drive bush from actuator To remove terminal cover first remove
base first remove retaining screw. 4 fixing bolts.
If actuator is fitted with alternative
mounting base, this must be removed Remove transit blanking plugs and
first, before drive bush can be make cable entries to the appropriate
removed. Determine keyway position standard. Blank off unused entry with
in drive bush to suit. Reassemble drive steel blanking plug.
bush to actuator base and secure with
retaining screw. Connections
Connect power supply and terminate
2.2 Mounting Actuator to Valve control cables to appropriate
Secure actuator to valve with four standard.
fixing bolts. Refer to actuator wiring diagram
Check cast groove in actuator base is enclosed with instruction manual.
not obstructed. It’s purpose is to Re-fit terminal cover after checking
protect the AQ actuator in the event condition of ‘O’ ring seal and greasing
of a product leak from the valve spigot. Secure cover with 4 fixing
spindle/gland packing. bolts.
Check base fixing bolts are tight.
4. Operational settings 5

WARNING! Open Stop

Electrical operation with top cover Hand wind valve to fully open position.
removed must not be carried out in Adjust lock nut/stop bolt to suit valve Folomatic/C.P.T.
explosion hazardous areas without open position.
official permit.
Closed Stop
4.1 Travel Limitation Hand wind valve to closed position. Close torque
The AQ range is designed to stop at end Adjust lock nut/stop bolt to suit valve and speed
of travel by torque limitation against closed position. Open and closed control Main P.C.B.
stop bolts. Stop bolts should therefore stopbolts are now set.
be set to the precise stopping point Lamp
4.2 Torque setting Auxiliary
required. switches
(Fig. 3)
To set Remove top cover by undoing grub Limit switches
screw in locking plate and unscrew (if fitted)
Open and closed bolts are set for
approximately 90° valve travel and cover.
should be adjusted as necessary to suit
the valve. Open direction.
Not adjustable - factory set to actuator
Engage hand/auto clutch level by pulling rated torque.
lever towards actuator handwheel. Close direction.
Manual mode of operation is now Adjustable from 30% rated torque to
selected. rated torque.
Closed torque is adjusted by turning Fuses Motor
'close torque' pot on main PCB.
Anticlockwise to reduce torque.
Clockwise to increase torque. Fig.3
 6

Note: Red LED on main PCB will Clockwise to close actuators

illuminate when actuator torques off Closed Auxiliary Switch (CAS)
in either direction. Move valve to fully closed position.
Locate bottom cam on the shaft, lift and
4.3 Setting speed control turn cam clockwise until switch just
(Fig.3) operates, release cam. Switch is now set.
Actuator operating speed range is
recorded on the nameplate. The Open Auxiliary Switch (OAS)
operating speed is varied within this Move valve to fully open position.
range by adjusting speed control Locate second cam up from bottom of
potentiometer located on main PCB. shaft. Push cam down and rotate
anticlockwise until switch just operates,
Turn pot clockwise to increase speed. release cam. Switch is now set.

Turn pot anticlockwise to decrease Anti-clockwise to Close actuators

speed. Closed Auxiliary Switch (CAS)
Move valve to the fully closed
4.4 Setting Auxiliary Switches position. Locate bottom cam on the
(Fig.4) shaft, lift and turn cam anti-clockwise
The actuator incorporates two until switch just operates, release cam.
independently operated open and Switch is now set.
closed auxiliary switches to provide
end of travel indication. Fig.4 Open Auxiliary Switch (OAS)
Move valve to fully open position.
Auxiliary Switch Cam adjustment is by Locate second cam up from bottom of
finger tip rotation in each direction, shaft. Push cam down and rotate
cams are compression spring loaded clockwise until switch just operates,
and held in position by taper centres. release cam. Switch is now set.
 5. Final check 6. Trouble Shooting 7

4.5 Continuous Position Indicator PCB Check stop bolts and lock nuts are Valve leaking
Ensure valve is in the fully open switch ON OFF tight. i) Likely cause: Travel limitation stop
position. Re-position continuous bolts incorrectly set.
indicator with red (open) lens over
1 ESD ESD No ESD Check terminal cover fixing bolts are
tight. Action: Reset stop bolts (refer
bulb and tighten securing screw. 2 TBY Stat No stat
to valve manufacturer).
by-pass by-pass
Replacement of Top Cover Check top cover is screwed on hand
3 P1 Both “On” Both “Off” ii) Likely cause: Insufficient torque
Check condition of 'O' ring and P2 Close Priority Open Priority tight and locking grubscrew is tight.
4 selected.
replace if necessary. Grease thread and One Switch On and
spigot. Screw on top cover and hand One Switch OFF = Stayput Check indication reads: Action: Increase torque control
tighten. Secure in position with 5 ESD ESD Close ESD Open Red Open setting.
locking grubscrew in locking plate.
6 C/A Clockwise Anti-clock Green Close iii)Likely cause: Obstruction of valve
Close Close
4.6 Remote Options Action: Inspect and remove
7 PTR Maintain Push to
The 8 switch selector on main PCB in local run in local
enables different remote control Actuator runs without driving valve
8 Fail Failsafe No Failsafe
functions to be chosen, also on 'local' Hand/auto lever padlocked in manual.
if fitted
control the option of maintained
control or 'push to run'. Actuator fails to start
Check fuses.
Replace fuse.
7. Optional extras 8
(Refer to actuator wiring diagram)

7.1 Integral Local Control Station For Local Control Clockwise to close actuators: Closed Checking travel limit switch operation
(Refer to Fig. 5) Disengage locking lever. Turn selector travel Limit Switch (CLS) Electrically run actuator to closed
This module consists of a rotary knob to 'local' position indicated on and position. Red LED should not be
direction (open/close) selector knob label. Anti-clockwise to close actuators: illuminated. If LED is illuminated
for local operation and a three To energise the actuator closed, turn Open travel Limit Switch (OLS) closed limit switch is incorrectly set,
position lockable rotary direction control knob clockwise Engage manual operation (see 4.1). (actuator torquing off against stop
local/remote/stop selector knob. towards 'closed' position. Turn handwheel clockwise until stop is bolts).
reached. Locate second cam down. Lift
To stop actuator turn local/remote and turn cam clockwise until switch Electrically run actuator to open
selector to 'stop' position. Knob will just operates. Release cam, switch is position. Red LED should not be
spring back to 'local' position. now set. illuminated. If LED is illuminated open
To energise the actuator open, turn travel limit switch is incorrectly set
direction control knob anti-clockwise Clockwise to close actuators: Open (actuator torquing off against stop
towards 'open' position. travel Limit Switch (OLS) bolts).
and
For Remote Control Anti-clockwise to close actuators: If limit operation is required at one
Disengage locking lever turn selector Close travel Limit Switch (CLS) end of travel only, set limit switch for
knob to 'remote' position indicated on Engage manual operation (see 4.1). that direction. At the opposite end of
label. Turn handwheel anti-clockwise until travel ensure limit switch cam does not
stop is reached. Locate top cam. operate switch (LED will then be
7.2 Travel Limit Switches Depress cam and turn anti-clockwise illuminated indicating actuator has
Fig.5 (Fig.6) until switch just operates. Release cam, torqued off in that direction).
Setting Procedure switch is now set.
Set stop bolts to required open and
closed position noting travel limit Note: Open and close auxiliary
switch operation will stop the actuator switches must now be set to trip
short of these positions. before set travel limit positions to
enable positive indication refer to 4.4.
 9

7.3 Extra Auxiliary Switches (Fig. 6) 7.4 Two Speed Control

Four auxiliary switches are The actuator incorporates a two speed
incorporated into the switch function to enable slow running at the
mechanism. Each switch can be closed end of travel. This feature is
independently adjusted to trip at any designed to prevent hydraulic shock in
point throughout actuator cycle/valve pipeline control.
stroke. Refer to wiring diagram and
valve makers/clients instruction for Setting Procedure
required auxiliary switch tripping Move actuator to position where slow
position. running is required to start. Locate
bottom cam of the extra auxiliary switch
Setting Procedure cams. Turn cam clockwise for clock to
Move valve to required switch tripping close actuators - anti-clockwise for anti-
position. Locate bottom cam (IAS 4). clock to close actuators until switch just
Lift and turn cam until switch just operates. Switch is now set.
operates release cam. Switch is now
set. To Test:
Move actuator to fully open position.
Repeat operation until all required
switches are set: Run actuator closed - actuator will run at
speed set on speed control (See 4.3).
3rd cam - IAS3 - depress and turn cam.
At the point where bottom switch trips,
2nd cam - IAS2 - lift and turn cam. actuator will automatically run at
minimum speed until closed position is
1st (top) cam - IAS1 - depress and turn reached.
cam.
Fig.6
 10

Note: From closed position, actuator 7.6 Current Position Transmitter

will run open at selected speed set (CPT) 4-20mA Output (fig. 7)
previously (See 4.3).
The CPT gives continuous indication
with adjustment for span and zero
7.5 Potentiometer settings.
The pot is used for position feedback
and may be connected to a voltmeter Electrical connections
type indicating instrument. 1. The CPT can be either internally or
externally powered. Use the wiring
Setting diagram supplied with the actuator to
Move actuator to fully closed position. check this.
Unlock pot by turning knurled nut
clockwise. Rotate pot casing so that a 2. Check whether valve is clock or
approximately 50 ohms resistance is Fig.7
anti-clock to close.
measured between terminal 23 and 32
of terminal bung (23-14 Anticlock to Setting of CPT
close actuator) For a clock to close valve and low Locate socket 2 ( SKT 2) on folomatic
1. Signal Direction. Using Fig 7 locate
signal at open CPT printed circuit board and remove
the duel links J7.
Lock pot by turning knurled nut anti- and socket. Socket pins are marked 1-6
clockwise. Pot is now set. For anti-clock to close valve and low using a multimeter reading ohms, test
a For clock to close valve and low
signal at closed. between appropriate pins (see table
signal at closed
opposite). Turn potentiometer body as
and
Links J7 must be positioned at right described in section 7.5 until
For an anti-clock to close valve and
angles to the edge of the board. approximately 50 ohms is measured.
low signal at at open.
Lock potentiometer. Reconnect socket
2. Move valve to the low signal end into CPT circuit board.
Links J7 must be positioned parallel to
of travel.
the edge of the board.
 11

Indication Socket pin 7.7 Folomatic Proportional This function will minimise Input signal low to open, SW1 selected
system number Ohms Control (Fig. 7) overshooting thus enabling a away from edge of board, SW2
Clockwise to close.
narrower deadband to be set. selected towards edge of board.
Zero/span/timer/dead band
Low output at close.
or 4 to 5 = 50 The Folomatic Proportional Control It should be noted that when the b For Anti-clockwise Closing Valves
Anti-clockwise to close. Module sets the valve position relating actuator is operated by local control Input signal low to close, SW1 and,
Low output at open. to an input signal with adjustments with a desired value signal present, it SW2 away from edge of board.
for Zero and Span setting. Refer to the will slow to minimum speed around
Clockwise to close.
Wiring Diagram supplied in the the desired value position and then Input signal low to open, SW1 and,
Low output at open.
or 4 to 6 = 50 actuator and also the customers speed up to set speed once desired SW2 towards edge of board.
Anti-clockwise to close. instructions for exact setting. value position is passed. This is quite
Low output at close. normal, indicating to the operator the 2 Determine what control input signal
When the actuator Local/Off/Remote approximate desired valve position. is going to be used. Refer to Fig 7 and
selector is set to 'Local' the actuator locate the folomatic P.C.B. dil switches.
3. Adjust the CPT zero trimmer to functions like any other with Open/ Setting the Folomatic Using appendix table 1 set the
give required minimum signal. Stop/Close local control. The actuator 1. Determine whether the valve is required current or voltage range.
should therefore be set to work clock or anticlock to close and also
4. Move valve to the high signal end initially under local control in whether it is to open or close on a low Note: Unless range required was
of travel. accordance with this Instruction demand signal. specified at time of ordering,
Manual. folomatic will be set assuming a
5. Adjust the CPT span trimmer to Using Fig. 7 locate switches 1 and 2, 4 - 20 MA range.
give required maximum signal. Note: The AQ folomatic incorporates a on folomatic/CPT PCB. select as
two speed function to enable the follows: 3 When using a 4-20mA control loop
6. Move valve back to the low signal actuator to run at minimum speed as signal it is possible to select whether
end of travel and re-check the it approaches the desired value. a For Clockwise Closing Valves the actuator will "stay put" or fail to
minimum reading and adjust if Input signal low to close, SW1 selected the selected end of travel on loss of
necessary. towards edge of board, SW2 selected signal.
away from board.
 12

Switch No 1 on folomatic DIL switches Using a multimeter reading ohms, test 7. Locate the 'zero' trimmer and Deadband and motion inhibit timer
to be selected 'on'. (See table between appropriate pins (see table adjust until the green indicator (if adjustment
Appendix 1). below). Turn potentiometer body as valve is at closed position) or red The deadband and motion inhibit
described in section 7.5 until indicator (if valve is at open position) timer controls are ten turn
Switches 3 (P1) and 4(P2) on Main approximately 50 ohms is measured. on the PCB just lights either flashing potentiometers incorporating a
Board DIL Switches. Both selected 'on' Lock potentiometer. Reconnect socket or steady, clockwise movement of zero slipping clutch to prevent
gives fail to the close end of travel. into CPT circuit board. trimmer will illuminate appropriate overwinding.
Both selected 'off' gives fail to open indicator.
end of travel. One switch 'off' and one Indication Socket pin Both controls will be factory set to
8. Operate the valve to the opposite
'on' will give 'stay put'. system number Ohms minimum (fully anti-clockwise)
end of travel (High Signal) using local
Clockwise to close.
enabling zero and span controls to be
control.
4. Check that incoming control cables Low output at close. set.
are connected to the following or 3 to 1 = 50 9. Set input signal to it's required
terminals. Anti-clockwise to close. maximum level. Deadband adjustment
Low output at open.
10. Locate the 'Span' trimmer and If the actuator overshoots or responds
a Current or voltage signal to 9 (-VE) Clockwise to close. adjust until the red indicator (if valve unnecessarily to small changes in
and 12 (+VE), or alternatively. Low output at open. is at the open position) or green signal, increase the deadband by
or 3 to 2 = 50 indicator (if valve is at the close turning the deadband control
b Customer's potentiometer derived Anti-clockwise to close. position) on the PCB just lights either clockwise. If greater sensitivity is
signal to 9,12 (Wiper) and 18. Low output at close.
flashing or steady, anti-clockwise required reduce deadband by turning
movement of span trimmer will anticlockwise. Check that hunting does
5. With actuator set to local control illuminate the appropriate indicator. not occur eg. when the actuator is
run the valve to the nominated low Note: If potentiometer was set for the moving in the increasing signal
signal end of travel. CPT it is not necessary to adjust 11. Set local/remote selector to direction, it should stop when the
potentiometer again for the folomatic. 'Remote'. The actuator is available for balance between the input signal and
Locate socket 2 (SKT 2) on folomatic/ Folomatic remote control to give full the actuator feedback potentiometer
CPT printed circuit board and remove 6. Set input signal to required valve stroke with maximum input is achieved. If hunting does occur,
socket. Socket pins are marked 1-6. minimum value. signal. increase the deadband as necessary.
 8 Lubrication 13

Motion inhibit timer adjustment Refit top cover ensuring that the 'O' Actuators are set for fail closed as Rotork AQ Range actuators are
The motion inhibit timer is designed ring seal is in good condition, correctly standard. dispatched with gearboxes filed with
to prevent the actuator responding fitted and retaining grubscrew is tight. oil to DEXRON II specification plus the
unnecessarily to a rapidly fluctuating On loss
addition of 20% paraffin, suitable for
input signal when the average remains Final checks of power SW1 SW2 SW5 SW8 ambient temperatures ranging from -
constant. The timer should be set for See Section 4. Failsafe Close ON ON ON ON
22°F (-30°C) to 160°F (70°C).
the maximum inhibit time permissible
Failsafe Open ON ON OFF ON
for the control application. This will 7.8 Commissioning Instructions for If oil is replaced, DEXRON II should be
ensure maximum service life from the Stay Put with ON ON ON OFF used, however the addition of 20%
AQ Range Battery Pack Failsafe Local or
actuator by eliminating unnecessary Actuators Remote Control paraffin is not required unless ambient
operation. temperatures below -4°F (-20°C) are
Install and commission actuator as
likely to be encountered.
normal and per Instruction Book. 4 Remove cover of battery pack. Plug
The red and green indicators on the
floating connector into PCB socket.
PCB indicate a change of signal state: Oil Capacities
After site installation and Replace cover ensuring vent is
AQ100/300
commissioning has been completed: pointing down. Remove plastic plug
Red = in the open direction 1.5 pints/855cc.
from vent pipe.
Green = in the close direction
1 Switch off AC supply.
AQ800
2 Remove cover. 5 Switch on AC supply. Actuator will
If either indicator is flashing it 2.5 pints/1425cc
3 Set switches 1, 2, 5 and 8 on main now function as normal on AC and fail
indicates a change of signal state that
PCB to desired mode. as selected on loss of AC supply.
is being held off from operating the
actuator for a predetermined length
Note: Battery supply is automatically WARNING: A powerful battery is now
of time. This motion inhibit time is
disconnected 30mins after AC power providing DC potential to terminals 24
adjustable between 2 second and 40
failure. and 22. Care should be taken not to
seconds. To increase time turn motion
short out these terminals.
inhibit control clockwise.
Appendix 1 14
Folomatic PCB DIL switch settings voltage or current ranges

Gama SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 Off

0-5mA On

0-10mA Off/On
SW1 Off - actuator runs to low signal
end of travel on loss of signal.
0-20mA
SW1 On - actuator responds on loss of
4-20mA signal according to priority setting on
MAIN P.C.B.
0-50mA
Switches
3 and 4 “ON” = Fail to the close position
0-5V
3 and 4 “OFF” = Fail to the open position
One switch “ON” and one switch “OFF”
0-10V will give “Stay Put”

0-20V
15
 Published and produced in the UK by Rotork Controls Limited
UK head office USA head office As part of a process of on-going product
Rotork Controls Limited Rotork Controls Inc development, Rotork reserves the right to
telephone Bath 01225 733200 telephone Rochester (585) 328 1550 amend and change specification without
prior notice.
www.rotork.com telefax 01225 333467 telefax (585) 328 5848
email [email protected] email [email protected] Published data may be subject to change.
For the latest version release, visit our
website at www.rotork.com

The name Rotork is a registered trademark.

Rotork recognises all registered trademarks.
Rotork Controls Inc, Rochester, USA
Rotork Controls Ltd, Bath, UK