AWT Range

Installation and
Maintenance Instructions

This manual contains important safety

information. Please ensure it is thoroughly
read and understood before installing,
operating or maintaining the equipment.

PUB005-003-00
Date of issue 05/11
 CONTENTS
Page
This manual provides instruction on:
1 Health and Safety 2
1.1 Motor Temperature 2
* Manual and electrical (local and remote) operation.
2 Storage 2
* Preparation and installation of the actuator onto
the valve. 3 AWT Actuators 2
3.1 Syncroset Actuators 2
* Subsequent commissioning and adjustment of the 3.2 Syncropak Actuators 3
position limit and torque switches for correct valve operation. 4 Operating your AWT 3
4.1 Operating by Hand 3
* Commissioning and adjustment of the actuator settings to suit 4.2 Operating Electrically - Syncroset 3
site-specific control and indication requirements. 4.3 Operating Electrically - 3
Syncroset with Local Push Button Control
* Maintenance – Troubleshooting. 4.4 Operating Electrically - Syncropak 4
4.5 Selecting Local/Stop/Remote 4
* Sales and Service. Operation – Syncropak
4.6 Local Control – Syncropak 4
4.7 Remote Control – Syncropak 4
4.8 Valve Position Indication 4

5 Preparing the Drive Bush 5

5.1 10A to 35A – Thrust Base Types A and Z 5
5.2 10A to 35A – Non-Thrust Base Type B 5
5.3 40A to 95A – Thrust Base Types A and Z 6
5.4 40A to 95A – Non-Thrust Base Type B 7
 1

Page Page Page

6 Mounting the Actuator 8 10 Changing the AOP Gear Ratio 17 13 Troubleshooting 27

6.1 Rising Stem Valves – Top Mounting 8 13.1 Syncropak Actuators 27
11 Folomatic Setting Procedure 18
6.2 Valve with Gearbox – Side Mounting 9 13.2 Actuators Fail to Start on 27
11.1 Configuration of Folomatic 19
6.3 Non-Rising Stem Valves – Top Mounting 9 Remote Control
and CPT PCB
6.4 Handwheel Sealing 9 13.3 Actuators Fail to Start on 27
11.2 Commissioning the Folomatic 21
Local Control
7 Cable Connections 9 Controller and the CPT
13.4 Actuators Fail to Start - 27
7.1 Earth/Ground Connections 9 11.3 Folomatic PCB set up for Limit 23
Syncroset Actuators
7.2 Removing Terminal Cover 9 Switch controlled valves
13.5 Valve Jammed – All Actuators 27
7.3 Cable Entry 10 11.4 Folomatic PCB set up for Torque 23
13.6 Valve Not Seating Correctly 27
7.4 Connecting to Terminals 10 Seating valves
13.7 Actuator Runs Without Driving Valve 27
7.5 Replacing Terminal Cover 10 11.5 Folomatic / CPT PCB 23
– Likely Causes
11.6 Deadband Adjustment 24
8 Setting Instructions 11
11.7 Motion Inhibit Timer 24 14 Lubrication and Maintenance 28
8.1 Setting the Limit Switches 11
11.8 Split Range Control 24 14.1 Oil 28
8.2 Selecting Torque or Limit Priority 13
11.9 Folomatic Status - Folomatic PCB 25 14.2 Lubrication 28
8.3 Selecting Torque Values 13
LED Display 14.3 Maintenance 28
9 Add-On-Pak — Setting Instructions 14 12 Electrical Start-up 26
9.1 Setting the Indication 14
12.1 Wiring Up 26
9.2 Setting the Switches – Closing Direction 15
12.2 Start-up – Syncroset Actuators 26
9.3 Setting the Switches – Opening Direction 15
12.3 Phase Rotation Check - 26
9.4 Single Turn Pot 16
Syncroset Actuators
9.5 Current Position Transmitter 16
12.4 Syncropak Actuators 26
(CPT) Setting
 1 Health and Safety 2 Storage 3 AWT Actuators
2

This manual is produced to enable a user and those persons working on If your actuator cannot be installed 3.1 Syncroset Actuators
competent user to install, operate, this equipment should be familiar with immediately, store it in a dry place until
Each standard Syncroset consists of
adjust and inspect Rotork AWT range their responsibilities under any statutory you are ready to connect incoming
four basic sub-assemblies:
valve actuators. provisions relating to the health and cables. If the actuator has to be
safety of their workplace. installed but cannot be cabled it is
The electrical installation, maintenance 1. Motor.
recommended that the plastic transit
and use of these actuators should be
carried out in accordance with the
WARNING: With respect to cable entry plugs are replaced with 2. Oil-filled worm gearbox with
handwheel operation of Rotork metal plugs which are sealed with PTFE handwheel and de-clutch
National Legislation and Statutory
electric actuators, under no tape. mechanism.
Provisions relating to the safe use of
this equipment, applicable to the site of circumstances should any additional The Rotork double-sealed construction 3. Limit and torque switch mechanism.
installation. lever device such as a wheel- will preserve internal electrical
key or wrench be applied to the components perfectly if left 4. Terminal box.
For the UK: Electricity at Work Regulations handwheel in order to develop undisturbed.
1989 and the guidance given in the The user must provide motor
more force when closing or opening
applicable edition of the ‘IEE Wiring Rotork cannot accept responsibility for reversing contactors and associated
Regulations’ should be applied. Also the valve as this may cause damage deterioration caused on site once the control equipment.
the user should be fully aware of his to the valve and/or actuator or may covers are removed.
duties under the Health and Safety Act cause the valve to become stuck in
the seated/backseated position. Every Rotork actuator has been fully
1974. For the USA: NFPA70, National
tested before leaving the factory to
Electrical Code® is applicable.
1.1 Motor Temperature give years of trouble-free operation,
The mechanical installation should be providing it is correctly installed,
With excessive use the motor surface
carried out as outlined in the manual commissioned and sealed.
temperature could reach 132°C (270°F).
and also in accordance with relevant
standards such as British Standard Where appropriate the user must
Codes of Practice. ensure the actuator is suitably
protected against its operating
Only persons competent by virtue of
environment. Should further
their training or experience should be
information and guidance relating to
allowed to install, maintain and repair
the safe use of the Rotork AWT range Fig. 3.0 AWT Syncroset,
Rotork actuators. Work undertaken
of actuators be required, contact Standard Sealed
must be carried out in accordance
Rotork.
with instructions in the manual. The
 4 Operating your AWT
3

4.1 Operating by Hand 4.2 Operating Electrically –

Syncroset
See warning in Health and safety
Section 1.0 page 3 regarding For all Syncroset actuators, it is
handwheel operation vital that electrical connections to
the control equipment and phase
To engage handwheel drive, depress
rotation are correct before allowing
the Hand/Auto lever into Hand position
the actuator to operate the valve
and turn the handwheel to engage
(refer to Section 12).
the clutch. The lever can now be
released and it will return to its original The basic syncroset actuator does not
position. The handwheel will remain have actuator mounted local open/
Fig. 3.1 AWT Syncroset with Local Fig. 3.3 AWT Syncropak engaged until the actuator is operated close or local/remote selectors. Control
Controls, Doubled Sealed electrically when it will automatically will be via control equipment remote to
3.2 Syncropak Actuators disengage and return to motor drive. the actuator.
As an optional extra, syncroset
actuators can be supplied with local Each standard Syncropak consists of If required the Hand/Auto lever can
controls. four basic sub-assemblies: be locked in either position using a 4.3 Operating Electrically –
padlock with a 6.5 mm hasp. Syncroset with Local Push
Note: 40A to 95A Syncrosets are 1. Motor. Button Control
always double sealed.
2. Oil-filled worm gearbox with The black selector switch can be
handwheel and de-clutch turned to select either: Local, Remote,
mechanism. or Stop.When selecting Stop, note
3. Limit and torque switch mechanism that the selector switch rides over and
automatically depresses the red push
4. Integral starter with associated button into the Stop position.
control equipment and double-
sealed terminal box.

Fig. 3.2 AWT Doubled Sealed Syncroset

Fig. 4.0 Hand Operation
 4 Operating your AWT cont.
4

The red pushbutton on the starter 4.5 Selecting Local/Stop/Remote 4.6 Local Control – Syncropak
cover has two functions: push-to-stop Operation – Syncropak
With the red selector positioned at
and turn-to-start, in either direction.
The red selector enables either Local Local (anti-clockwise) the adjacent
or Remote control, lockable in each black knob can be turned to select
position using a padlock with a 6.5 mm Open or Close. For Stop turn red knob
hasp. When the selector is locked in clockwise.
the Local or Remote positions the Stop
facility is still available. The selector can 4.7 Remote Control – Syncropak
also be locked in the Stop position to
prevent electrical operation by Local or Rotate the red selector to the Remote
Remote control. position (clockwise), this gives remote
control only for Open and Close but
local Stop can still be used by turning Fig. 4.3 Valve Position Indicator
the red knob anti-clockwise.
Syncropak type actuators also provide
4.8 Valve Position Indication illuminated cover indication (mains
Valve position is indicated mechanically power on) as shown in Figure 4.4.
by a pointer as detailed in Figure 4.3
Fig. 4.1 Syncroset Push Button Controls and Figure 4.4. Note that the pointer
stays central during valve travel. When Valve Lamp
the Add-on-pak is fitted, pointer Position (Syncropak) Symbol
4.4 Operating Electrically
– Syncropak movement is continuous between Shut Open Red
and Open.
Check that power supply voltage Mid-Travel White
agrees with that stamped on the
Shut Green
actuator nameplate. Switch on power
supply. It is not necessary to check
phase rotation. Fig. 4.4. Valve Position Indication
Fig. 4.2 Syncropak Controls
 5 Preparing the Drive Bush
5

5.1 10A to 35A – Thrust Base 5. Refit the drive bush assembly into 5.2 10A to 35A – Non-Thrust Base
Types A and Z the base casting on the actuator, Type B
ensuring that the slots in the drive
Removal of Drive Bush for Undo the four capscrews securing the
bush are located into the drive dogs
Machining base plate to the gearcase and remove
of the hollow output shaft.
the base plate. The drive bush and its
Turn actuator onto its side, remove
6. Refit the base plate and secure with retaining clip can now be seen.
the two caphead screws holding base
caphead screws.
plate onto thrust base, pull out the Types B3 and B4 removal
drive bush complete with its bearing
Using external circlip pliers, expand the
assembly. Before machining the drive
circlip while pulling on the drive bush.
bush, remove the thrust bearing from
The drive bush will detach from the
it as follows:
actuator centre column with the circlip
1. Locate and loosen the two set retained in its groove. This can be seen
screws in the steel bearing stop ring. Fig. 5.0 Base Assembly in Figure 5.2.
2. Unscrew the bearing stop ring from
the drive bush, slide the bearing off Re-assembly
the drive bush. Keep the stop ring 1. Remove all swarf from the drive
and beaing in a safe, clean place bush, ensuring that the ‘O’ rings
ready for re-assembly. on the drive bush and bearing stop
3. Machine the drive bush to suit rings are in good condition, clean
the valve stem, allowing generous and greased.
Fig. 5.1 Type A Thrust Base Components
clearance on screw thread for rising 2. Slide bearing onto drive bush and
stem valves. Ensure that the male ensure that it is fitted down to the
thread on the bush is not damaged. shoulder.
3. Grease the bearing.
4. Screw bearing stop ring with the set
screws uppermost onto the drive
bush, tighten down hand tight. Lock
Fig. 5.2 B Type Bushes
with the two set screws.
 5 Preparing the Drive Bush cont.
6

Types B3 and B4 re-assembly

Grease drive bush and circlip. With the
circlip fitted in its groove offer the drive
bush up to the actuator centre column
ensuring the drive dogs are aligned.
Expand the circlip while pushing the
drive bush into the centre column.
The drive bush will move further in.
Release circlip pliers ensuring the
circlip is correctly seated in both the
drive bush and centre column grooves.
Replace the base plate and fix with four
capscrews.
5.3 40A to 95A – Thrust Base
Types A and Z Fig. 5.3 Type A Thrust Base Components Fig. 5.4 Type A Thrust Base Components Fig. 5.5 Type A Drive Bush
Removal of Drive Bush for
Machining Loosen setscrew and unscrew retainer If the actuator has a type A drive bush,
using hammer and punch. Remove it can be fitted in position 1 or 2 to
Engage Hand and turn handwheel until drive bush and machine to suit valve suit the position of the valve mounting
retainer set screw is visible through stem or gearbox input shaft. Allow flange.
hole in actuator base. generous clearance on screw thread for
rising stem valves.

Fig. 5.6 Type A Drive Bush Position 1

 5 Preparing the Drive Bush cont.
7

5.4 40A to 95A – Non -Thrust Base

Type B and B1.
For type B and B1 the output shaft
can be bored and keyed to ISO 5210
standard. There is no drive bush to
machine.
Types B3 and B4.
These are identical drive bushes secured
by cap-headed screws. B3 is supplied
pre-machined to ISO 5210 standard.
B4 is supplied blank and must be
machined to suit the input shaft of the
gearbox or valve that it will drive.
Fig. 5.7 Type A Drive Bush in Position 2 Fig. 5.9 Tightening Retainer Set Screw

Fig. 5.8 Type Z3 Drive Bush Fig. 5.10 B3/B4 Drive Bush
 6 Mounting the Actuator
8

(Refer to Section 13 for actuator b) Fitting Thrust Base to Valve

weights.) WARNING: Do not lift the – Actuator Sizes 10 to 35 only
actuator and valve combination via
Ensure the valve is secure before fitting the actuator. Always lift the valve/ Fit the machined drive bush into the
the actuator as the combination may actuator assembly via the valve. thrust base as previously described.
be top heavy and therefore unstable. Remove the thrust base from the
Each assembly must be assessed on an actuator, place it on the threaded
If it is necessary to lift the actuator individual basis for safe lifting. valve stem with the slotted end of the
using mechanical lifting equipment
6.1 Rising Stem Valves drive bush uppermost and turn it in
certified slings should be attached as
– Top Mounting the opening direction to engage the
indicated in Figure 6.0 for vertical valve
thread. Continue turning until the base
shafts and Figure 6.1 for horizontal a) Fitting the Actuator and Base is positioned onto the valve flange. Fit
shafts. as a Combined Unit – securing bolts but do not tighten at
Fig. 6.1 Horizontal Lifting All Actuator Sizes this stage. Lower the actuator onto the
Fit the machined drive bush into the thrust base and rotate the complete
At all times trained and experienced thrust base as previously described, actuator until the drive dogs on the
personnel should ensure safe lifting, lower the actuator onto the threaded actuator output shaft engage into the
particularly when mounting actuators. valve stem, engage Hand and wind the drive bush. Actuator flange should now
WARNING: The actuator should handwheel in the opening direction to be flush with base flange.
be fully supported until full valve engage the drive bush onto the stem. Continue to turn actuator until fixing
shaft engagement is achieved and Continue winding until the actuator is holes align. Using bolts supplied fix
the actuator is secured to the valve firmly down on the valve flange. Wind actuator to thrust base and tighten
flange. two further turns, fit securing bolts and down. Open valve by two turns and
tighten fully. firmly tighten down fixings onto valve
A suitable mounting flange conforming
to ISO 5210 or USA Standard MSS flange.
Fig. 6.0 Vertical Lifting
SP101 must be fitted to the valve.
Actuator to valve fixing must conform
to Material Specification ISO Class 8.8,
yield strength 628 N/sq mm.
 6 Mounting the 7 Cable Connections
9
Actuator cont.
6.2 Valve with Gearbox 7.2 Removing Terminal Cover
– Side Mounting WARNING: Ensure all power
supplies are isolated before Using a 6mm Allen key loosen the four
Check that the mounting flange is removing actuator covers. captive screws evenly. Do not attempt
at right angles to the input shaft, to lever off the cover with a screwdriver
and that the drive bush fits the shaft Check that the supply voltage agrees as this will damage the ‘O’ ring seal.
and keyway with adequate axial with that stamped on actuator
nameplate. A plastic bag in the terminal
engagement. Engage Hand, offer up
compartment contains spare cover
actuator to the input shaft and turn A switch or circuit breaker must be ‘O’ ring seal, wiring diagram and
handwheel to align key way and key. included in the wiring installation of instruction book and terminal screws
Slide on to shaft and tighten fixing the actuator. The switch or circuit where applicable.
bolts. breaker shall be mounted as close
to the actuator as possible and
6.3 Non-Rising Stem Valves shall be marked to indicate that it Fig. 7.0 Earthing Point
– Top Mounting is the disconnecting device for that
particular actuator. The actuator
Treat as for side mounting except that
must be protected with overcurrent
when thrust is taken in the actuator,
protection devices rated in accordance
a thrust nut must be fitted above the
with Rotork publication E330E electric
drive bush and securely tightened.
motor performance data for AWT type
actuators.
6.4 Handwheel Sealing
Ensure that sealing plug in centre of 7.1 Earth/Ground Connections
handwheel (or spindle cover tube
A lug with a 6mm diameter hole is
depending on which is fitted) is sealed
cast adjacent to the conduit entries
with PTFE tape and fully tightened,
for attachment of an external earthing Fig. 7.2 Commissioning Kit
ensuring that moisture does not
strap by a nut and bolt. An internal
pass down the centre column of the
earth terminal is also provided.
actuator.
Fig. 7.1 Removing the terminal
cover-Syncropak
 7 Cable Connections cont.
10

7.3 Cable Entry 7.4 Connecting to Terminals

Remove red plastic transit plugs. Make Refer to the wiring diagram inside the
cable entries appropriate to the cable terminal cover to identify functions of
type and size. Ensure that threaded terminals. Check that supply voltage
adapters, cable glands or conduit are is the same as that marked on the
tight and fully waterproof. Seal unused actuator nameplate. Remove power
cable entries with a steel or brass terminal screen.
threaded plug.
Begin by connecting these cables and
replace screen. When all connections
are made ensure wiring diagram is
replaced in the terminal compartment.
Note: with AWT Syncroset correct Fig. 7.4 Standard Sealed
phase rotation is essential for Terminal Compartment
electrical operation and must be
checked at start-up stage.
All Rotork AWT Syncroset 3-phase
actuators are tested for correct phase 7.5 Replacing Terminal Cover
rotation in terminal order 1(W), 2(V), Ensure cover ‘O’ ring seal and spigot
3(U) (refer to Section 11 and actuator joint is in good condition and lightly
wiring diagram). greased before re-fitting cover.
Fig. 7.3 Conduit Entries
 8 Setting Instructions
11

There are four basic steps that must be If the actuator was received pre- 4. If the indicator is reading correctly 5. Note the direction of handwheel
carried out to ensure correct operation mounted on the valve, then the valve at both ends of the valve stroke, operation to close the valve
of the valve. supplier should have already carried out then it can be assumed that the (standard is ‘clockwise’). If anti-
all three steps. To check if the actuator valvemaker has already set the clockwise direction is required to
• Setting the direction of travel.
is correctly set carry out the following: switches to operate at the end of close the valve, the Valve Position
• Setting the limit switches to operate travel. If required, Torque/Limit Indicator will be reversed to that
1. With the actuator securely bolted to
at the end of travel. Function and Valve may be checked shown in Fig 8* and DIP switch 2.1
the valve, engage handwheel drive.
(refer to Sections 8.2 and 8.3). will be selected to ‘ON’.
• Selecting the correct Torque or Limit
function for the type of valve. * A Conversion Kit is available.
• Adjusting the torque switch value
for each direction of travel.

2. Fully open the valve by hand and

Fig. 8 Valve Position Indicator
check that the position indicator
(Clockwise to Close)
pointer moves over to the Open
position just before the valve
If the actuator was supplied separately
reaches its open stop.
from the valve or if the check proved
3. Fully close the valve and check that that it is not correctly set up, then the
the position indicator pointer now following procedure must be carried
moves over to the Shut position, out.
just before the valve reaches its
closed stop.
 8 Setting Instructions cont.
12

Firstly, check and set all the DIP switches as required using the table below as a guide to each function.
Standard actuator default: All switches off.

Function Switch OFF Switch ON

SW2.1 Direction to Close Clockwise to close Anti-Clockwise to close
SW2.2 Local Control Local operation maintained Local push to run
SW2.3 Interlock Operation Interlocks disabled Interlocks Enabled
SW2.4 Thermostat By-Passed during ESD Thermostat Active Thermostat Bypassed
SW2.5 Control Option No Control Option Control Option Fitted
SW2.6 ESD Direction ESD to Close ESD to Open
SW2.7 Status Indication Relay (SIR) When both switches are “off” the function of SIR is disabled
SW2.8
SW2.7 SIR Relay When switch 2.7 is “on” and 2.8 is “off” the function of SIR is Thermostat
SW2.8
SW2.7 SIR Relay When switch 2.7 is “off” and 2.8 is “on” the function of SIR is Local control selected
SW2.8
SW2.7 SIR Relay When switch 2.7 is “on” and 2.8 is “on” the function of SIR is Remote control selected
SW2.8
SW2.9 Unused - -
SW2.10 Unused - -
SW2.11 Unused - -
SW2.12 Unused - -

Table 1.
 8 Setting Instructions cont.
13

8.1 Setting the Limit Switches 1. Refer to Fig. 8.2.

Using a 4mm Allen key as a lever,
Caution: Damage to the valve can 6 break open locknut (1) and anti-
occur due to incorrect setting of the 3 clock stopnut (2) and run them
switch mechanism. 4 together with their locking washer
Using a 5mm Allen key remove the 1 5 along the screwed shaft (5), toward
three switch mechanism cover screws, 2 7 the indicator end of the assembly
pull cover off squarely and retain in
2. Leave all three components loose
a safe place. Engage handwheel by 8 on the shaft.
pushing down on the hand auto lever
whilst turning the handwheel. Once INDICATION DRIVE 3. Refer to Fig. 8.3. Using a 4mm Allen
engaged the lever can be released and key, loosen clutch nut (4) by turning
the actuator will remain in hand drive. Fig 8.1 switch mechanism it anticlockwise until it is finger
Locate the Switch Mechanism screwed – Screwed shaft assembly tight. Note that the screwed shaft
shaft assembly. can now be turned with the fingers.
1. Lock nut 5. Screwed shaft
2. Anti-clockwise switch/stop nut 6. Travelling nut 4. As the screwed shaft is turned, the
3. Locking washer 7. Clockwise switch/stop nut travelling nut (6) will move up and
4. Clutch 8. Over travel guide down the shaft.

Fig. 8.0 Fig. 8.2 Fig. 8.3

 8 Setting Instructions cont.
14

Setting Clockwise Limit 3. With over travel guide still held The Anticlockwise Limit switches are
(Valve usually closed) against the stop, run stop nut (2) now set.
clockwise down screwed shaft until
It is essential that the Clockwise By following the above procedure
it comes hard up against traveling
direction is set first. exactly, you have ensured:
nut (6).
1. With the valve in a Mid Travel 1. That the switches are set to cut off
4. Push washer (3) down the screwed
position (at least 3 turns away the motor before the valve reaches
shaft until it is against stop nut then
from the clockwise end of travel), its end of travel and that the motor
run lock nut (1) down until it clamps
turn screwed shaft (5) anticlockwise has time to come to rest.
both nuts and washer together.
until the traveling nut (6) comes to
2. That manual operation of the valve
the mechanical back stop (7).
can never alter the switch operating
2. Using a 4mm Allen key as a lever point which you have set.
tighten the clutch nut (4).
3. Using the handwheel wind the valve Fig. 8.4
fully clockwise. During this operation
the over travel guide will rotate to Setting Anticlockwise Limit
the right and operate the right-hand (Valve usually open)
bank of switches. 1. Wind the handwheel anticlockwise
4. Continue winding the handwheel until the valve comes to a
clockwise until the valve comes to a mechanical stop. DO NOT back
mechanical stop. wind the handwheel. The
actuator will automatically stop Fig. 8.5
The fully clockwise end of travel Limit before the valve open position is
Switches are now set. reached. 5. Lightly tighten locknut (1).
2. Refer to Fig. 8.5. 6. Release pressure on over travel
Pull over travel guide (8) in a guide. The guide should stay put
clockwise direction until it comes and switches should not be seen or
Fig. 8.6
hard up against its stop. The left heard to reset. If the switches
hand bank of switches will operate. reset, the setting anticlockwise
limit procedure must be repeated.
 8 Setting Instructions cont.
15

(approximately 55% of maximum rated

Valve Type Shut Open torque). Be prepared to increase this
Wedge Gate Torque Limit torque value if the valve fails to reach
Globe the closed position or tight shut off is
A B not achieved.
Thru-Conduit Limit Limit
Penstock Open Torque – The Open torque
C D knob should be selected to Max unless
Sluice Limit Limit the valve makers’ specific instructions
Parallel Slide recommend otherwise.
Ball, Plug,
Butterfly Open Torque Boost Position –
Fig. 8.7 The Open torque selector knob has a
position labeled Boost. When selected
8.2 Selecting Torque or Limit Fig 8.8
there will be no torque protection in
Priority the opening direction, allowing the
8.3 Selecting Torque Values
The actuator can be set to close on actuator to produce torque in excess
Torque for seating valve types or limit Controls A and B, in Figure.8.7, adjust of rated. Boost is only to be used
for non-seating valve types. the amount of torque the actuator will where a stuck valve will not open using
produce before the torque switch trips maximum torque.
Where the valve requires backseating and stops the motor.
on torque in the open position ‘Open CAUTION – Double check that the
or Torque’ should be set. Ideally, only the minimum torque Open Torque/Limit selector (D) is in the
necessary to achieve tight shut off Limit position when using Boost.
Selection of Torque or Limit end of should be applied. In practice this
travel priority is made by turning value will vary from valve to valve and NEVER SELECT BOOST WITH OPEN
controls marked C & D in Fig 8.7. In fluctuate with pressure, temperature, TORQUE/LIMIT SELECTOR IN THE
the absence of specific valve makers’ usage and service, etc. TORQUE POSITION.
instructions refer to Figure.8.8 as a
guide. Close Torque – In the absence of
specific valve makers’ instructions
If in any doubt about the correct it is recommended that the Close
settings for the valve, select Limit torque knob be selected to the first
in both directions. marked graduation above minimum
 9 Add-on-Pak
16

9.0 Add-on-Pak 9.1 Setting the Indication

AS SWITCHES – Setting Instructions
1. Unscrew the three fixing screws and
The Add-on-Pak (AOP) is an optional remove the AOP cover.
ADD-ON-PAK
extra providing continuous local cover
2. Close the valve fully and then open
indication. The Add-on- Pak may also
it three turns.
include the following:
3. To set the closed indication of clock
CAMS • 2 ‘AS’ auxiliary indication switches
to close valves, push the top of the
DRIVE FROM • 6 ‘AS’ auxiliary indication switches indication mechanism in a clockwise
ACTUATOR
direction until it butts against the
• 1k or 5k Ohm Potentiometer
plastic stop moulded in the AOP
position feedback
front plate. A slipping clutch allows
• 4-20mA Current Position Transmitter the indication mechanism to be
(CPT) position feedback moved.
Check the actuator wiring diagram for 4. Wind the valve closed to remove
STANDARD Add-on-Pak configuration. any backlash in the gear train. The
SWITCH MECHANISM POT AND GEAR closed indication position is now set.
INDICATION MECHANISM The Add-on-Pak is driven from the
switch mechanism via an adjustable 5. To set the open indication, loosen
Fig. 9.0 Add-on-Pak gear train which must be set for the the capscrew on the indication
valve turns range. If the valve turns mechanism. The open stop plate is
were quoted with actuator order, now free to rotate.
Rotork will have set the Add-on Pak
gear train and therefore only site
setting of cover indicator, auxiliary
switches (if fitted) and analogue
feedback device (if fitted) is required.
Instruction for setting the AOP assume
clockwise operation to close the valve.
For anti-clockwise to close valves, read
‘‘open’’ for ‘‘close’’ etc. Refer to Section
10 for AOP turns adjustment.
 9 Add-on-Pak cont.
17

gear selection scale 9.2 Setting the Switches 9.3 Setting the Switches
– Closing Direction – Opening Direction
capscrew
The switches can be independently This process takes place with the valve
spirol pin
adjusted to make or break at any being moved from the closed to the
indication position through the valve stroke open position. Identify the required
mechanism including open and shut. This process switch (refer to the wiring diagram).
open takes place with the valve being moved
indication stop from the open to the shut position.
Identify the required switch (refer to
closed
indication stop the wiring diagram).
1. Run the valve to the required switch
Fig. 9.1 AOP Indication Fig. 9.2 Open Indication stop tripping position.
2. Locate the cam adjacent to the
6. Wind the valve to the fully open selected switch. The cam must be
position. rotated to a position where the
7. Rotate the open stop plate switch operates
anticlockwise until it butts against 3. The cam is adjusted by pushing it Fig. 9.4 Switch Cam Adjustment
the open indication stop moulding. against its spring, and rotating it to
make or break the switch (for make 1. Run the valve from the closed
8. Re-tighten the capscrew on the
or break at selected valve position). position to the required switch
indication mechanism
tripping position.
9. The open position indication is now 4. Continue to close the valve, setting
the remaining switches required to 2. Locate the cam adjacent to the
set.
operate in the closing direction. selected switch. The cam must be
rotated to a position where the
switch operates
Fig. 9.3 Capscrew 3. The cam is adjusted by pushing t
against its spring, and rotating t to
make or break the switch (for make
or break at selected valve position).
 9 Add-on-Pak cont.
18

4. Continue to open the valve, setting

the remaining switches required to
operate in the opening direction.

9.4 Single Turn Pot

(refer to Figure.9.5) Ensure the AOP
Indication has been set. (Refer to 9.1)
1. Fully open the valve.
2. Locate the spirol pin in the
indication mechanism. This pin will
be lined up with a scale moulded in
the front plate of the AOP. Fig. 9.5 Single Turn Pot Fig. 9.6 Multi-turn Pot Fig. 9.7 CPT

3. The scale 1 to 4 relates to the four 9.5 Current Position Transmitter Check that the remote connections The AOP cover can now be refitted
gears on the potentiometer. (CPT) Setting to the CPT are suitable for internally using the three fixing screws.
1 = small gear, 4 = large gear. or externally powered systems as
The CPT gives continuous indication
4. Loosen the pot-mounting bracket applicable (see actuator wiring
with adjustment for Span and Zero
screw and disengage gear mesh. diagram).
settings and can be either internally
5. Rotate the pot to a Mid position and or externally powered. A multi-turn With the valve closed, set the minimum
re-engage the gear, corresponding potentiometer drives the CPT and required signal (4mA) by adjusting the
to the scale (1 to 4), with the large will be set by Rotork according to the Zero potentiometer on the CPT PCB.
gear on the AOP. valve turns supplied at time of order.
Operate the valve to the fully open
The actuator torque and limit switches
6. Tighten the screw on the pot - position and adjust the Span control
should be set (Refer to Section 8).
mounting bracket to secure the to give the required maximum signal
gears in mesh. (20mA).

7. Run the valve closed. A slipping

clutch will automatically set the
potentiometer. Fig. 9.8 AOP Cover
 10 Changing the AOP Gear Ratio
19

If the valve turns range was pecified 8. Remove the circlip and washer
with actuator order the AOP will be from the end of the lower shaft on
factory set with the correct gear ratio. the detached AOP frontplate.
To adjust the AOP gear train to suit the 9. Add/remove the required number of
valve turns range: gear clusters and spacers, according
to the table in Figure 10.0.
1. Close the valve
10. Replace the circlip and washer
2. Remove the three fixing screws
on the lower shaft on the detached
securing the AOP cover and remove
section of the AOP frontplate.
the cover ensuring the ‘O’ ring is
not damaged. Fig. 10.1 Limit Switch Shaft in 11. Align the detached section with Fig. 10.2 AOP Front Plate Fixing Screws
Switch Mech the rest of the AOP.
3. Whilst observing the limit switch
shaft, operate the actuator from one 12. The cam shaft and shaft retaining
end of travel to the other and count 5. Check if the correct number of the gear clusters, will engage first
the number of turns of the shaft. gear clusters and spacers are fitted as shown in Figure 10.4.
to your AOP. If the correct number is
4. Use the table in Figure 10.0 to used, refer to Section 9 for AOP 13. Align the remaining shafts and
determine the number of gear setting instructions. push the AOP frontplate on to the
clusters and spacers you require. pillars.
6. Refer to Fig. 10.2.
Turns of Limit Number of Number of If the number of gear clusters and 14. When fully located, secure the AOP
Switch Shaft Gear Clusters Drive Spacers spacers is not correct remove the with the three capscrews. Fig. 10.3 AOP Gear Clusters and Spacers
0.52–1.04 1 8 three capscrews located on the AOP Refer to Section 9 for AOP
1.05–2.12 3 7 frontplate, which secure to the setting instructions.
2.13–4.28 5 6
pillars. 15. Replace the cover and secure with
4.29–8.68 7 5 7. Refer to Fig. 10.3. the three fixing screws.
8.69–17.53 9 4 Pull the frontplate away from the
actuator. The frontplate with gear
17.54–32.00 11 3 clusters and spacers will detach from
Fig. 10.0 Gear and Spacer Combinations the AOP backplate and pillars.
Fig. 10.4 AOP re-alignment and
for Required Valve Torque engagement
 11 Folomatic Setting Procedure
20

Syncropak Actuators Fitted with detailed in earlier sections of this hole in the electrical housing. If this
Folomatic Proportional Control and booklet and that it is operating method is adopted make sure that the
Current Position Transmitter (CPT) correctly with the Local / Remote ‘o’ ring has been removed from the
Selector switched to Local and using cover spigot and that the wiring loom
When an Awt Syncropak actuator
the Local pushbuttons. The Folomatic is not trapped.
is specified with the Folomatic
controller output is disabled when
Proportional Control option, the CPT When refitting, again make sure that
the Local / Remote selector is in the
will also be present on the same pcb. the ‘o’ ring is fitted correctly and that
Local position and the actuator will
These instructions cover the set up of the wiring loom is not trapped.
only respond to signals from the Local
both devices since their operation is
pushbuttons.
inter related.
In order to set up the Folomatic
The Folomatic proportional control
controller it is necessary to gain access
and CPT pcb enables the valve to
to the Folomatic / CPT pcb. This
be controlled to a position that is
is fitted inside the actuator control
proportional to an externally applied,
housing immediately behind the
anologue Demand signal. The
pushbutton cover. It is accessible
Folomatic controller is suitable for
once the pushbutton cover has been
externally sourced anologue Demand
removed by unscrewing the four allen
signals in the ranges, 0 to 20mA, 0
screws securing the pushbutton cover
to 10mA, 0 to 5 volts or 0 to 10 volts
to the electrical housing. Make sure
with or without offset (live) zero such
that the pushbutton cover is adequately
as 4 to 20mA.
supported and that the electrical
Before commencing with the set connections between the pushbuttons
up of the Folomatic controller refer / selector switch assembly and the
to the actuator wiring diagram, control system remain connected.
which can be found in the actuator
It is suggested that the pushbutton
terminal compartment, and any
cover, once removed, can be
Customer instructions for exact setting Switch Bank 3 (SW3) Switch Bank 1 (SW1) Switch Bank 2 (SW2)
conveniently supported by one allen
requirements. Make sure that the Switches 1 & 2 Switches 1 to 8 Switches 1 & 2
screw passed through the bottom right
actuator has been commissioned
screw hole in the pushbutton cover
in accordance with the instructions Fig 11.1 Folomatic / CPT PCB
and screwed into the top left tapped
 11 Folomatic Setting Procedure cont.
21

11.1 Configuration of Folomatic and CPT PCB Switch Bank SW1, Switch 8 is used when a remotely mounted Auto / Manual
selector is employed. This type of control is only available when the Folomatic
Step 1 – Configuration of DIP Switches
controller is externally powered by providing an externally sourced 24 Volt DC
Main PCB – Please refer to table 1 on page 12 to enable the Folomatic Option. supply to the Auto / Manual input terminal on the actuator terminal bung.
Switch Bank 1 (SW1) - Demand Signal Folomatic always selected SW1 Switch 8 - ON
SW1 is a bank of 8 switches mounted in the centre of the Folomatic pcb, Folomatic only when remote Manual / Auto selector is in Auto SW1 Switch 8 - OFF
numbered 1 to 8 from the left as shown on Fig 11.1.
Switch Bank 2 (SW2) – CPT Power Source
Switch Bank SW1, Switches 1, 2 and 3 are used for setting the Folomatic pcb
to suit the incoming Demand signal. Switches 1, 2 and 3 should be configured SW2 is a bank of 2 switches mounted at the bottom of the right hand side of the
according to the table below. Folomatic pcb, numbered 1 & 2 from the left as shown on Fig 11.1.
Switch Bank 2 switches are used to configure the power supply source for the
0 to 10mA SW1 Switch 1 - ON SW1 Switch 2 - OFF SW1 Switch 3 - OFF
Current Position Transducer (CPT) when it is being used on an actuator that is
0 to 20mA SW1 Switch 1 - ON SW1 Switch 2 - ON SW1 Switch 3 - OFF fitted with a Folomatic controller, check details of your wiring diagram and system.
0 to 5 Volts SW1 Switch 1 - OFF SW1 Switch 2 - OFF SW1 Switch 3 - OFF If the CPT is not in use configure SW2 Switches 1 and 2 to the internally powered
0 to 10 Volts SW1 Switch 1 - OFF SW1 Switch 2 - OFF SW1 Switch 3 - ON position (ON).

Switch Bank SW1, Switch 4 is used to select whether increasing or decreasing When the CPT is powered by the actuator (internally powered) it shares its power
Demand signal will close the valve. Configure switch 4 as shown below. supply with the Folomatic input circuit. Actuator terminals 4, 27 and 23 are
electrically common.
Decreasing signal to close valve SW1 Switch 4 – ON
When SW2 Switches are configured for an externally powered CPT actuator
Increasing signal to close valve SW1 Switch 4 – OFF terminal 23 is isolated from actuator terminals 4 and 27. It is essential that the
potential between the CPT and the Folomatic input (terminals 26 and 27) should
Switch Bank SW1, Switches 5, 6 and 7 are used to select the action required from not exceed 500 volts.
the Folomatic controller in the event of loss of Demand signal. Note: this action is
only applicable to systems having a Demand signal with a live zero, for example 4 CPT internally powered SW2 Switch 1 - ON SW2 Switch 2 - ON
to 20mA. CPT externally powered SW2 Switch 1 - OFF SW2 Switch 2 - OFF
No Action SW1 Switch 5 - OFF SW1 Switch 6 - OFF SW1 Switch 7 - ON
If the CPT is externally powered by a non-SELV (non-Safety Extra Low
Stayput SW1 Switch 5 - OFF SW1 Switch 6 - OFF SW1 Switch 7 - OFF Voltage) power supply additional precautions are required to ensure
Close valve SW1 Switch 5 - OFF SW1 Switch 6 - ON SW1 Switch 7 - OFF that the user is protected from electrical shock risk during the calibration
Open valve SW1 Switch 5 - ON SW1 Switch 6 - OFF SW1 Switch 7 - OFF
procedure and use of the equipment. These precautions are the
responsibility of the installation engineer.
 11 Folomatic Setting Procedure cont.
22

Switch Bank 3 (SW3) – ESD Function Step 2 – Configuration of Link A (LKA) and Link B (LKB)
SW3 is a bank of 2 switches mounted to the left of the centre of the Folomatic The positions on the Folomatic and CPT pcb of Links A and B are identified in
pcb, numbered 1 & 2 from the top as shown on Fig 11.1. Figure 11.2 below.
Switch Bank 3 switches are used to configure the action to be taken by the
actuator if an Emergency Shut Down (ESD) signal has been received by the
actuator.
The motor thermostat, if active, could interfere with the valve operation if it
trips during or prior to an ESD action. Switch Bank 3 Switch 1 allows the Motor
Thermostat to be bypassed during an ESD action if desired.
Switch Bank 3 switch 2 configures the direction of valve movement during an ESD.

Thermostat bypassed during ESD SW3 Switch 1 - ON

Thermostat active during ESD SW3 Switch 1 - OFF
Valve to close during ESD SW3 Switch 2 - ON
Valve to open during ESD SW3 Switch 2 - OFF

Link B (LKB) Link A (LKA)

Fig 11.2 Folomatic / CPT PCB

In Fig 11.2, Link A (LKA) is shown in the position for the Folomatic controller to
suit a clockwise to close valve.
 11 Folomatic Setting Procedure cont.
23

For anti-clockwise to close valves the 11.2 Commissioning the Folomatic travel while the valve is moved over Step 2 – Folomatic / CPT PCB
link LKA should be removed, rotated Controller and the CPT its complete stroke. It is important Adjustments
through 900 and refitted. In addition to ensure that the Add-on-Pak 1
In order to provide details of the During this part of the commissioning
switch SWl.1 on the main Syncropak potentiometer does not hit either of
commissioning procedure the procedure it will be necessary to adjust
pcb should be moved to the anti- its travel end stops at the ends of the
following instructions assume that: 7 trimming potentiometers that are
clockwise to close (ACW) position. valve stroke.
mounted on the Folomatic / CPT pcb
The valve is clockwise to close
In Fig 11.2 Link B (LKB) is shown in the Fully close the valve using the Local while appropriate Demand signals are
with a decreasing Demand signal
position for the CPT to give an output controls. applied to the actuator terminals and
to close the valve.
signal of 20mA at the valve fully open the valve is moved, as required.
With the actuator fully closed remove
position. To reverse the CPT’s operation AC power has been applied to
the Add-on-Pak 1 cover and loosen the Note: Potentiometers VR1, VR2, VR3,
the link LKA should be removed, the actuator.
potentiometer mounting bracket grub VR4 and VR6 all require 24 turns of
rotated through 900 and refitted.
Limit / torque switches and screw. their adjusting screw to move from
Add-on-Pak 1 have been set in end to end of potentiometer travel.
Disengage the potentiometer by
accordance with the instructions VR5 and VR8 require 25 turns of their
swinging the potentiometer and its
earlier in this booklet. adjusting screw to move from end to
mounting bracket away from its driving
end of potentiometer travel. All PCB
The Local / Remote selector gear.
mounted potentiometers are protected
switch has been set to Local. by a slipping clutches at the ends of
Rotate the potentiometer gear until it
is 5% to 10% of its total travel away travel. They can be moved to the
from its anticlockwise end stop. end of travel by rotating the adjusting
Step 1 – Add-on-Pak 1 screw for 25 turns in the appropriate
potentiometer. Re-engage the potentiometer drive direction. Some potentiometers make
without changing its feedback position an audible ‘click’ for each turn of the
This potentiometer provides the and tighten its fixing grub screw to lock
“feedback” signal that is compared adjusting screw, should you hear this it
it in position. is not cause for concern.
with the Demand signal by the
Folomatic controller. If the valve is not already in the
Maximum accuracy will be achieved fully closed position use the
with the Folomatic controller when actuator’s Local controls to move
the Add-on-Pak 1 potentiometer is the valve to the fully closed
driven over at least 80% of its total position.
 11 Folomatic Setting Procedure cont.
24

Adjust the CPT Zero potentiometer

VR2 Folomatic VR1 Folomatic VR8 to give an output of 4mA. Note:
Zero Span Rotating the potentiometer adjusting
screw clockwise increases the output
current.
Set Folomatic Span potentiometer
VR1 to its maximum position, fully
clockwise.
Set Folomatic Zero potentiometer VR2
to its minimum position, fully anti-
clockwise.
VR8 Set Folomatic Starting Deadband
CPT Zero potentiometer VR3 to its minimum
position, fully anti-clockwise.

VR6
Set Folomatic Stopping Deadband
CPT Scan
VR4 Folomatic potentiometer VR4 to its minimum
Stopping Deadband position, fully anti-clockwise.

Set Folomatic Motion Inhibit Time
potentiometer VR5 to its minimum
position, fully anti-clockwise.
Close Open Inhibit Loss of VR5 Folomatic VR3 Folomatic
LED LED LED Signal LED Motion Inhibit time Starting Deadband

Fig 11.3. Folomatic / CPT PCB

 11 Folomatic Setting Procedure cont.
25

11.3 Folomatic PCB Set up for Limit showing that a the Demand signal is Close LED should not be illuminated with the valve closed position to
Switch Controlled Valves still present thus ensuring that it is the but it may be difficult to achieve this the appropriate actuator terminals.
torque switch that is controlling the balanced condition as the Deadband
During set up of valves whose end(s) of Finely adjust the Folomatic Zero
valve. potentiometers have been set to
travel is controlled by limit switch use potentiometer VR2 until both the
minimum. If this is the case it is
the full range of the Demand signal. If torque seating is required at the high Open and Close LED’s are extinguished
sufficient to be at the threshold of the
Demand signal end of valve travel it is or at the threshold of changing over.
Open and Close LEDs changing over.
suggested that on a 4 to 20mA system Turn VR2 clockwise if the Open LED is
11.4 Folomatic PCB Set up for a Demand signal of say 19.8mA be Fully open the valve using the illuminated and anti-clockwise if the
Torque Seating Valves applied during set up. For proportional actuator’s Local controls. Close LED is illuminated.
control systems using other Demand
In order to ensure that the actuator Adjust the CPT Scan potentiometer Check that the CPT output is 4mA
signals similar adjustments to the signal
‘drives’ the valve into its seat in the VR6 so that 20mA can be measured at the appropriate actuator terminals
during set up should be made.
case of torque seating valves it is at the appropriate actuator terminals. and finely adjust the CPT Zero
recommended that during the set up Generally the amount of Demand Rotating VR6 clockwise will increase potentiometer VR8 if necessary.
procedure a slightly modified Demand signal offset should be approximately the current.
Fully open the valve using the
signal for the torque seating direction(s) half of the anticipated dead band
Increase the Demand signal applied actuator’s Local controls and apply
of operation is used. For example for a setting. For example on a 4 to 20mA
to the actuator terminals to the value the Demand signal corresponding
system using a Demand signal of 4 to system with a deadband of 2% the
that corresponds with the valve fully with the valve open position to the
20mA for full stroke and torque seating offset should be 0.16mA
open position. The Close LED should appropriate actuator terminals.
at the 4mA end of travel it is suggested
be illuminated. Rotate the Folomatic
that 4.2 mA is used as the set up Finely adjust the Folomatic Span
Span potentiometer VR1 anti-clockwise
Demand signal. 11.5 Folomatic / CPT PCB potentiometer VR1 until both the
until the Close LED is just extinguished.
Open and Close LED’s are extinguished
During normal operation a Demand Apply the Demand signal Again it may prove difficult to achieve
or at the threshold of changing over.
signal of 4mA will be present when the corresponding to the valve closed this balanced condition as the
Turn VR1 clockwise if the Open LED is
valve is required to travel fully to that position to the appropriate actuator Deadband potentiometers have been
illuminated and anti-clockwise if the
end of the valve stroke and therefore terminals. The Open LED on the set to minimum. If this is the case it is
Close LED is illuminated.
the valve will be driven by the actuator Folomatic PCB should be illuminated. sufficient to be at the threshold of the
until the actuator torque switch trips. Open and Close LEDs changing over. Check that the CPT output is 20mA
Rotate the Folomatic Zero
When the torque switch is tripped, at the appropriate actuator terminals
potentiometer VR2 clockwise until the Fully close the valve using the
stopping the actuator, the Folomatic and finely adjust the CPT Span
Open LED is just extinguished and the actuator’s Local controls and apply
Close LED will still be illuminated potentiometer VR6 if necessary.
Close LED has not illuminated. The the Demand signal corresponding
 11 Folomatic Setting Procedure cont.
26

The Span should now be sufficiently now run on slightly farther into the 11.8 Split Range Control
accurate but if further accuracy is widened deadband which will negate
The Folomatic Span and Zero settings
required repeat the last six instructions. the effects of noise on the Demand
are not sufficient to allow split range
signal.
Set the Demand signal to a level control, for example 4 to 12mA and
corresponding to mid travel of the When VR3 and VR4 are set to 12 to 20mA. If split range control is
valve. minimum the starting and stopping required it will be necessary to offset
deadbands are less than 1% of valve the feedback potentiometer mounted
Select Remote on the actuator Local /
stroke. With VR3 and VR4 set to in Add-on-Pak 1. For example where
Remote selector switch. The actuator
maximum the starting deadband is 12 to 20mA is required it will be
will move the valve to its mid travel
approximately 10% of valve stroke necessary to set the Add-on-Pak 1
position but it will oscillate around
and the stopping deadband is potentiometer to approximately its half
that position. Increase the stopping
approximately 7.5% of valve stroke. way position during Step1 of these
deadband by rotating the Folomatic
instructions.
Stopping Deadband potentiometer
VR4 clockwise until the actuator stops
11.7 Motion Inhibit Timer
oscillating with both the Open and
Close LED’s extinguished. On some installations the Demand
signal is more sensitive than necessary
resulting in unnecessary valve
11.6 Deadband adjustment movements. This can be resolved
by using the Motion Inhibit Timer
Although the Folomatic system
potentiometer VR5. By increasing the
is now correctly set up with the
setting of VR5, (turning it clockwise)
actuator stopping in the middle of
a timer is started every time that the
the deadband any electronic noise
actuator motor stops. This timer
on the Demand signal could cause
prevents the actuator from starting
unnecessary movement of the actuator.
until the set time has elapsed. When
Should this occur it is recommended
VR5 is set to minimum the Motion
that the starting deadband be widened
Inhibit time is less than 100ms. When
by rotating the Folomatic Starting
set to maximum the Motion Inhibit
Deadband potentiometer VR3 in a
time is 60s +or- 15s.
clockwise direction. The actuator will
 11 Folomatic Setting Procedure cont.
27

11.9 Folomatic Status – Folomatic PCB LED Display The loss of signal protection is enabled and the signal is below the minimum level.
SW1,6 is in the ON position and is requesting that the valve close. If remote is
Loss of
Inhibit
Signal
Open
Close

selected the actuator should be closing or be at the close limit position. The flashing
Operating Condition open LED indicates that the normal output of the positioner would be attempting to
If power is present this indicates that the input signal is within range, the positioner is open the valve with the current input signal level, however this request is currently
enabled and that the actuator is at the requested position. being inhibited by the loss of signal detection.

The input signal is in range, the positioner is enabled but requires to close the valve The loss of signal protection is enabled and the signal is below the minimum level.
to get to the requested position. If remote is selected the actuator should be closing SW1,5 is in the ON position and is requesting that the valve open. If remote is
the valve or be at the close limit position. selected the actuator should be opening or be at the open limit position. The
flashing close LED indicates that the normal output of the positioner would be
The input signal is in range, the positioner is enabled but requires to open the valve attempting to close the valve with the current input signal level, however this request
to get to the requested position. If remote is selected the actuator should be opening is currently being inhibited by the loss of signal detection.
the valve or be at the open limit position.
This indication should not arise in normal operation. If it does it is most likely to be
The input signal is in range, the positioner is enabled and requires to close the valve attributable to loss of signal and both open and close directions being selected via
to get to the requested position. However the close operation is inhibited pending SW1. This mode of operation is not suppported within AWT.
the expiry of the motion inhibit timer.
The positioner is currently disabled as SW1,8 is in the OFF position and no Auto
The input signal is in range, the positioner is enabled and requires to open the valve signal is present on the terminal bung. However the actuator is at the position
to get to the requested position. However the close operation is inhibited pending corresponding to the input demand signal
the expiry of the motion inhibit timer.
The positioner is currently disabled as SW1,8 is in the OFF position and no Auto signal
The loss of signal protection is enabled and the signal is below the minimum level. is present on the terminal bung. The flashing close LED indicates that the positioner
SW1,5 and SW1,6 are in the OFF requesting that the actuator stays put. would, if enabled, attempt to close the valve.
The loss of signal protection is enabled and the signal is below the minimum level. The positioner is currently disabled as SW1,8 is in the OFF position and no Auto signal
SW1,6 is in the ON position and is requesting that the valve close. If remote is is present on the terminal bung. The flashing open LED indicates that the positioner
selected the actuator should be closing or be at the close limit position. would, if enabled, attempt to open the valve.
The loss of signal protection is enabled and the signal is below the minimum level.
SW1,5 is in the ON position and is requesting that the valve open. If remote is
All other indication combinations represent fault conditions and the Folomatic
selected the actuator should be opening or be at the open limit position.
assembly requires replacement
Key: LED off LED Flashing LED on
 12 Electrical Start-up
28

12.1 Wiring Up 5. Operate the Close limit switch by If there are no local controls, push
rotating the front plate to stop the down and engage then hold down
The actuator must be securely bolted
motor. Rotate clockwise for clockwise- the hand/auto lever until the remote
to the valve (refer to Sections 5 and 6)
to-close valves and anticlockwise for stop button is pperated. To correct
and cabled/connected in accordance
anticlockwise-to close valve. the phase rotation, electrically isolate
with Section 7 before start-up.
the 3-phase power supply and
6. If the motor does not stop, rotate
Check that the limit switches have transpose any two of the three supply
the front plate in the opposite
been set (see Section 8). cables at actuator power terminals 1-2-3.
direction. If the motor stops, then the
12.2 Start-up – Syncroset Actuators Closed limit switch is wired into the 3. When correct rotation is achieved
Open contractor circuit. Correct the run actuator to full limits of travel in
Syncroset actuators require a pair Fig. 12.0 wiring and re-test. If operating both the open and closed directions.
of reversing contactors to switch the open and closed switches do
the 3-phase power supply to the 3. If there are no Local control Open/ 4. Apply full working pressure to the
not stop the motor, then neither
actuator for motor directional Stop/Close buttons adjacent to in the closing direction an increase
switch is connected into the contractor
control. the actuator then a communications of closing torque may be needed
circuits. Correct the wiring and re-test.
link must be set up between site (refer to Section 8.3).
The Torque/Limit switches supplied in 7. Prove the Open limit switch in the
the actuator must be wired correctly and remote control centre.
same manner then remove the lock 12.4 Syncropak Actuators
into the control circuits of the reversing 4. Select close and the motor should from the hand auto lever and check
contactors. be heard to run but will not drive the phase rotation, (refer to Fig 12.1). The units do not require externally
the valve. fitted motor reversing contactors as
To check the integrity of the Torque/
they are an integral part of this type of
Limit switches in the contactor control 12.3 Phase Rotation Check
actuator. A permanent 3-phase power
circuit: – Syncroset Actuators
supply is required on terminals 1-2-3.
1. Determine the valve closing direction 1. With the valve still in a mid travel
The Syncropak units are not phase
– clockwise or anticlockwise (refer to position select Closed and check
sensitive therefore a phase rotation
handwheel label). that output shaft is rotating in the
check is not required. The unit will
closed direction as indicated by the
2. Engage Hand drive and wind always rotate in the correct direction.
arrow on the handwheel.
handwheel until valve is in a Mid
For remote control and indication
Travel position. Lock the hand/auto 2. If the valve starts moving in the
connections check the supplied wiring
lever down in hand position opening direction, stop the
Fig. 12.1 diagram.
(refer to Fig 12.0). actuator immediately.
 13 Troubleshooting
29

13.1 Syncropak Actuators 13.4 Actuator Fails to Start 13.6 Valve Not Seating Correctly
– Syncroset Actuators
Check that the clutch lever is 1. The Close Torque/Limit selector
not padlocked in hand before Check remote contact circuits and incorrectly set for valve type - (Refer
troubleshooting unless you wish to run operation. Contactors switch the supply to Section 8).
the motor without driving the valve. to the actuator motor.
2. The Close Torque setting is too low.
Increase as necessary - (Refer to
13.2 Actuator Fails to Start on 13.5 Valve Jammed – All Actuators
Section 8).
Remote Control
Likely Causes:
The packaged controls of Rotork 13.7 Actuator Runs Without
1. Reversed phase rotation/incorrect
Syncropak make fault location simple. Driving Valve – Likely Causes
rotation (not applicable to
Set the selector switch to Local and
Syncropak - (Refer to Section 12). 1. Clutch lever is padlocked in Hand
switch on the power supply, at which
(Refer to Section 4).
point the indication lamp should light. 2. Limit switches not set. (Refer to
If the actuator starts correctly in each Section 8). 2. Drive bush not correctly secured in
direction when the pushbutton is place (Refer to Section 5).
turned, the fault can only be in the To free valve jammed open:
remote control circuit. Manual operation of the handwheel
utilising the hammer-blow mechanism
13.3 Actuator Fails to Start on should be sufficient to unjam the valve.
Local Control
To free valve jammed shut:
Set the selector switch to Local and
switch the power on. If the actuator Loosen the mounting bolts evenly to
fails to start, remove the terminal cover release thrust. Free the valve manually
and check that all three phase terminals using the handwheel and retighten the
are live with the correct voltage as mounting bolts.
indicated on the nameplate.
If the motor is very hot, the thermostat
will have tripped. Allow the motor to
cool and the thermostat to auto-reset.
 14 Lubrication and Maintenance
30

14.1 Oil 14.2 Lubrication 14.3 Maintenance

Unless specially ordered for extreme The AWT actuator is factory filled Every Rotork actuator has been
climatic conditions, Rotork actuators for life with lubricating oil SAE 80EP. fully tested before dispatch and will
are dispatched with gearcases filled Under normal circumstances there is no give years of trouble-free operation
with SAE 80EP oil suitable for ambient requirement to replace or top up the providing it is installed, sealed and
temperatures ranging from –22°F/– actuator gearcase oil. It is essential that commissioned in accordance with the
30°C to 160°F/70°C. valve components such as threaded instructions given in this publication.
stems, drive nuts, guides etc are kept
Food grade lubricating oil is available as Covers should not be removed for
clean and lubricated.
an alternative: contact Rotork. routine inspection as this may be
detrimental to the future reliability of
Actuator Nett Weight kg / lb Oil Capacity the actuator.
Size Syncroset Syncropak litres / pt.-US The AWT Syncropak pushbutton
cover should not be removed as the
10A 18 / 40 23 / 51 0.3 / 0.63
module contains no site-serviceable
12A 18 / 40 23 / 51 0.3 / 0.63 components. All electrical power
18A 18 / 40 23 / 51 0.3 / 0.63 supplies to the actuator must be
isolated before any maintenance or
19A 35 / 77 43 / 51 0.8 / 1.7 inspection is carried out.
20A 35 / 77 43 / 95 0.8 / 1.7
Routine maintenance should include
25A 35 / 77 43 / 95 0.8 / 1.7 the following:
35A 68 / 150 73 / 161 1.1 / 2.3 • Check actuator to valve fixing bolts
40A 134 / 296 138 / 304 7.5 / 15.8 for tightness.
70A 176 / 388 217 / 479 7.0 / 14.7 • Ensure valve stems and drive nuts
90A 176 / 388 217 / 479 7.0 / 14.7 are clean and properly lubricated.
91A 213 / 470 217 / 479 7.0 / 14.7 • If the valve is rarely operated, a
95A 176 / 388 217 / 479 7.0 / 14.7 routine operating schedule should
be set up.
Fig. 14 Actuators Weights and Oil Volumes
 31
Rotork Sales and Service

If your Rotork actuator has been

correctly installed and sealed, it will
give years of trouble-free service.
Should you require technical assistance
or spares, Rotork guarantees the best
service in the world. Contact your local
Rotork representative or the factory
direct at the address on the nameplate,
quoting the actuator type and serial
number.
A full listing of our worldwide sales
and service network is available on our
website at www.rotork.com

UK head office USA head office

Rotork Controls Limited Rotork Controls Inc
Brassmill Lane 675 Mile Crossing Blvd
Bath Rochester
BA1 3JQ NY 14624
tel +44 (0)1225 733200 tel +1 (585) 247 2304
fax +44 (0)1225 333467 fax +1 (585) 247 2308
email [email protected] email [email protected]
 32
Notes
 33
Notes
 Heading

Published and produced in the U.K. by Rotork Controls Ltd.

ATTENTION: RED PLASTIC PLUGS IN CONDUIT ENTRIES ARE FOR TRANSIT ONLY.
FOR LONG TERM PROTECTION FIT SUITABLE METAL PLUGS.

ATTENZIONE: I TAPPI IN PLASTICA ROSSA PER L'ENTRATA CAVI SONO SOLO

TEMPORANEI. PER UNA PROTEZIONE PERMANENTE PREGO SOSTITUIRLI CON
APPOSITI TAPPI METALLICI.

ATENCION: LOS TAPONES ROJOS DE PLASTICO EN LAS ENTRADAS DE CABLE

SON UNICAMENTE PARA TRANSPORTE. PARA PROTECCION PERMANENTE
COLOCAR TAPONES METALICOS APROPIADOS.

ACHTUNG: DIE ROTEN PLASTIKSTOPFEN SIND NUR FÜR DEN TRANSPORT

GEEIGNET. FÜR DAVERHAFTEN SCHUTZ SIND DIESE GEGEN GEEIGNETE
BLINDSTOPFEN AUSZÜTAUSCHEN.

ATTENTION: LES BOUCHONS PLASTIQUES ASSURENT UNE PROTECTION

TEMPORAIRE. POUR UNE PROTECTION DEFINITIVE UTILISER DES BOUCHONS
METALLIQUES.
As we are continually developing our products,
the design of Rotork actuators is subject to
change without notice. The latest product and
technical information is available at our website:
www.rotork.com.

The name Rotork is a registered trade mark.

Rotork recognises all registered trade marks.

POWSH0511