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rotork SI Series Installation And Maintenance Instructions Manual
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rotork SI Series Installation And Maintenance Instructions Manual

rotork SI Series Installation And Maintenance Instructions Manual

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SI Range
Installation and
Maintenance
Instructions
PUB021-003-00
Date of issue 10/10

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Summary of Contents for rotork SI Series

  • Page 1 SI Range Installation and Maintenance Instructions PUB021-003-00 Date of issue 10/10...
  • Page 2 Instantaneous internal hydraulic pressure and valve position are displayed on the integral indication display. * Maintenance – Troubleshooting. Visit our web site at www.rotork.com for more information on the Rotork Fluid Systems SI and other Rotork actuator ranges.
  • Page 3 9.1 Settings Menu 3.2 Display – Local Indication 7.1 Procedure Overview 9.2 Controller Set-up Menu 3.3 Display – Alarm Indication 7.2 The Rotork Setting Tool Pro 9.3 Interrupter Timer 7.3 The Actuator Display – 9.4 Help Screens 4 Optional manual Operation...
  • Page 4 Under no circumstances Should further information and guidance Si-2-Q100 to Q130 Act 1974. relating to the safe use of the Rotork should any modification or alteration be (Si-2.1-Q100 to Q130) carried out on the actuator as this could Fluid Systems SI range of actuators be For the USA: NFPA70, National Electrical required, it will be provided on request.
  • Page 5 Note the Material Safety specification electrical compartment covers in covering the type of hydraulic oil order to commission the SI actuator. supplied by Rotork Fluid Systems for WARNiNG: Rotork Fluid Systems will not accept use within the supplied power units are...
  • Page 6 Operating your Si Actuator 3.1 Electrical Operation 3.2 display–local indication As standard, a red lamp signifies valve open, yellow intermediate, and Check that power supply voltage is the green closed. Open and closed colour same as that stamped on the actuator functions can be reversed.
  • Page 7 Operating your Si Actuator continued mid-Travel Open 3.3 Alarm indication When an active actuator alarm is present the alarm icon will be displayed. Yellow indicator, internal hydraulic Red indicator, internal hydraulic The SI display incorporates Also, the display will cycle between pressure and percentage valve open pressure and valve open symbol an actuator alarm indication...
  • Page 8 Optional manual Operation For fail-open actuators (spring acts Hand pump Operation Optional manual operation may have WARNiNG: been specified for your SI actuator. in anti-clockwise direction when Power to the actuator should be See specific manual override label looking from above the actuator), For all SI-1-Q and SI-2-Q70 &...
  • Page 9 mounting the Actuator 5.1 lifting At all times trained and experienced personnel should ensure safe lifting, Ensure the valve is secure before fitting particularly when mounting actuators. the actuator as the combination may be top heavy and therefore unstable. WARNiNG: SI-1-Q31 to SI-2-Q80 (SI-2.1-Q80), The actuator should be fully supported quarter- turn actuators should be...
  • Page 10 ISO 5211 mounting rotation of 93°. made if mounting in this orientation. with a square female drive and two Consult Rotork Fluid Systems. mounting PCD's as detailed in the Adjustment Procedure – Spring Cap NOT PERmiTTEd: The actuator must applicable actuator datasheet.
  • Page 11 mounting the Actuator continued 5.6 mechanical Travel WARNiNG: Adjustment Q110-130 Q41 actuators have two travel Adjustment Screw A adjustment screws. It is important that Travel is adjusted by stop bolts in the hydraulic cylinder and spring canister. both screws are adjusted equally to Stop Screw ensure that both are in contact with On fail-closed actuators the hydraulic...
  • Page 12 RECOmmENdEd: The actuator can be mounted in these orientations. The unit mounted and serviced in this position. will have to be removed for servicing PERmiTTEd: Consult Rotork Fluid NOT PERmiTTEd: The actuator must Systems. Modifications need to be NOT be mounted in these orientations.
  • Page 13 mounting the Actuator continued Spring-to-extend actuator Spring-to-retract actuator 5.8 mounting Si-l to Valve piston rod piston rod The standard actuator is supplied with (Valve stem down to close – fail closed) (Valve stem down to close – fail open) the cylinder mounted on a base plate that is machined to accept four pillars •...
  • Page 14 Cable Connections 6.1 Earth/Ground Connections Actuators containing a Setting Tool, WARNiNG: fitted to the inside of the terminal Ensure all power supplies are isolated An M6 earth stud is located adjacent to compartment cover, are identified with before removing actuator covers. the conduit entries for attachment of an a self-adhesive yellow label on the external protective earthing strap.
  • Page 15 Confirm that supply voltage Rotork Fluid Systems factory, it may be is the same as that marked on the necessary to bleed the actuator. Follow actuator nameplate.
  • Page 16 All SI actuator functions are configured The power supply must be connected menu Structure and energised for commissioning to Rotork Fluid Systems standard purposes. The setting procedure is default settings before despatch unless divided into two stages: alternatives have been specified with the order.
  • Page 17 Commissioning continued 7.2 The Setting Tool Pro Name instruction Key* Display next function down. Display previous function up. Key* Display next function across right. Display previous function across left. Decrease/change displayed function’s value or option setting. Increase/change displayed function’s value or option setting. Non-functional on SI actuators.
  • Page 18 Commissioning continued 7.3 The Actuator display – 7.4 Entering the Actuator Setting/Checking mode Setting Procedure TOP PORTiON Function e.g. Actuator settings are password Actuator functions are displayed in (cl) = Configure code form in the top portion of the protected. The password must be Local Controls entered to change settings.
  • Page 19 Commissioning continued 7.5 Exit Setting mode 7.6 Setting mode and Password 7.7 Change Password (PE) 7.9 Crossroad Branch [Cr] Use the keys to scroll through To change to a new password refer to There are four ways to exit setting This branch provides access to all the available passwords [00]–[FF] section 9.3.
  • Page 20 (See Section 7.4.) Rotork supplied an actuator wiring diagram for this actuator; it will be required to carry out commissioning. If a duplicate is required, contact Rotork Fluid Systems. The actuator nameplate information will be required to provide the proper diagram.
  • Page 21 Commissioning – Primary Functions continued Positional Display Primary Functions Contents Password Section Page Crossroads Crossroads Configuration Menu Configuration Remote Control Settings Controller Set-up Int. Timer Help Screens lC Closed Limit lO Open Limit Closed Limit Remote Select Deadband Demand Low I.
  • Page 22 Configuration Closed limit menu The (Cr) menu gives access to the Set the closed position limit. Using Configuration settings [C the local controls, move the actuator electrically to the valve's fully closed Positional Display mechanical limit and back off 2% by running the actuator in the open direction.
  • Page 23 Remote Control Open limit menu Set the open position limit. Using the local controls, move the actuator electrically to the valve's fully open Positional Display Positional Display mechanical limit and back off 2% by running the actuator in the closed direction.
  • Page 24 Remote Select Press the keys to move to the Set the remote control type. There five next or previous option. options available: After selection of the required remote [OF] No remote control system Positional Display control option press the key. available.
  • Page 25 Configure local Remote Priority There are two options available to Remote Priority sets the overriding configure operation of the local priority in the event both Open and controls: Push-to-Run [Pr] and Maintain Close inputs are asserted simultaneously. Positional Display Positional Display [nn].
  • Page 26 ESd Action ESd local Stop Override Set the action to be taken when an This setting determines if an ESD signal ESD signal is received. Their are four will override a local stop command. The options: De-energise all solenoid valves two options are On [On] and Off [OF].
  • Page 27 ESd Contact Type Analogue Signal Failure Action Set the action to be taken upon loss of Set the ESD contact type. There are two analogue signal. There are three options: options: Positional Display No alarm [OF]. Positional Display O] - Apply signal to initiate ESD. Alarm [ A].
  • Page 28 Rotork supplied an actuator wiring diagram for this actuator; it will be required to carry out commissioning. If a duplicate is required, contact Rotork Fluid Systems. The actuator nameplate information will be required to provide the proper diagram.
  • Page 29 Commissioning – Secondary Functions continued Positional Display Secondary Functions Contents Password Section Page Crossroads Crossroads Settings Menu Configuration Remote Control Settings Controller Set-up Int. Timer Help Screens Controller Set-up Menu Interrupter Timer Closed Limit Remote Select Deadband Demand Low I. Timer Enabled Limit Flags Help Screens Open Limit...
  • Page 30 Settings menu The Settings Menu functions include If the actuator was started at 40%, settings that affect actuator travel the controller will command it to dEmANd characteristics (deadband and move in the open direction until it Position initial direction of Travel hysteresis) , partial stroke parameters reaches 49.7% (Demand –...
  • Page 31 Posn. deadband Posn. Hysteresis Hold limit limit Hysteresis Set Position Deadband adjustment. Set the Position Hysteresis adjustment. Configure Limit Maintenance. There are In the display Limit Hysteresis is In the display, Position Deadband In the display, Position Hysteresis two options available: expressed as a % of operating range is expressed as a % of operating is expressed as a % of operating...
  • Page 32 Partial Stroke Pressure Hysteresis Closed lEd Colour Partial Stroke PP & PS Position The default value is green [9r] for the Partial Stroke Position (PP) and In the display Pressure Hysteresis is This is the position to which the expressed as a % of operating range closed position (inert) with the red LED Partial Stroke limit (PS).
  • Page 33 Partial Stroke limit This is the position from which the actuator should be commanded to partial stroke and will be either the Open Limit of travel or the Closed Limit of travel. The default value is [OP], the Open Limit. If the Closed Limit is the position from which the actuator should be commanded to partial stroke use the...
  • Page 34 Controller demand input Calib. demand input Calib. Set-up menu From the Positional Display press the This function calibrates the actuator This function calibrates the actuator key to display the password entry for a voltage or current Close demand for a voltage or current Open demand screen.
  • Page 35 CPT Current Calibration low Power mode Setting instructions for actuators where It is possible to use an external supply the Current Position Transmitter (CPT) is such as a solar power supply for the in use. This provides an analogue actuator’s 24 VDC system. If this is 4–20 mA output position feedback the case it is beneficial to limit current signal.
  • Page 36 Password Edit The default value is [id]. Next time that the setting mode is required it will be necessary to enter the new password and press the key. PRESS THE KEy to display the next item in the Controller Set-up Menu. To configure a new password, the actuator must be in setting mode.
  • Page 37 Reset to defaults Standard factory default settings for Si actuators: All SI actuator functions are configured to factory default (standard) settings before despatch (see the table opposite). Alternative factory settings can be requested at Function default Setting time of order. Any settings entered during site commissioning will overwrite factory defaults.
  • Page 38 Reset to defaults continued Having selected (rd) in the [CS] Standard factory default settings for Si actuators: Controller Set-up menu, the display will show the current password, for example Function default Setting [id]. Secondary Functions – [CS] Controller Set-up (lP) Low Power Mode Selection [OF] Not Low Power...
  • Page 39 Relay Fault Relay is delineated. In some cases it will be the top of the display the displayed information will alternate between necessary to contact Rotork to clear the [EE] EEPROM Fault fault satisfactorily. actuator pressure/position and fault code screens.
  • Page 40 Once a failure has occurred, through the (CF) Menu option. If the fault Alternatively, in setting mode and from the actuator will not operate until the persists contact Rotork Fluid Systems. the Crossroads (Cr) display position configuration is corrected and the fault press the key until Controller is cleared.
  • Page 41 Display If the hydraulic power unit fault appears If the hand operation fault appears If a solenoid driver fault appears consult consult Rotork Fluid Systems. consult Rotork Fluid Systems. Rotork Fluid Systems. The fault cannot be viewed or accepted The fault cannot be viewed or accepted...
  • Page 42 (CF) Menu option. Reverse the actuator, which will clear detected. the fault and then re-try the original If the fault persists contact Rotork Fluid If the fault persists contact Rotork Fluid command. To clear the fault remove the command Systems.
  • Page 43 Confirm Faults continued under Pressure at End of Travel [uP] Actuator Stalled in mid-Travel [St] unsuccessful Partial Stroke [PS] loss of demand Signal during Analogue (Positioning) Control [dn] Position Position Position Position Display Display Display Display This fault indicates that the valve is The actuator has either failed to start A fault occurred while the actuator was obstructed or has become tight at the...
  • Page 44 interrupter interrupter interrupter interrupter Timer menu Timer Enable Timer direction Timer Start The default setting for (OJ) is [OF], The interrupter timer is used to slow The default for timer direction is [Cl], Using the key select the position the actuator as it approaches or leaves Timer Disabled.
  • Page 45 interrupter interrupter interrupter interrupter Timer Stop Timer interval Timer On Time Timer Off Time Using the key select the position The default for Timer ON and OFF Using the key select the actuator Using the key select the actuator for the TimER TO STOP WHEN THE times will be in units of 100ms which is run pulse in the range 100ms to 99 stop pulse in the range 100ms to 99...
  • Page 46 interrupter ESd Override The interrupter timer may be overridden when the actuator is under ESD signal command. C or O must be selected for the interrupter timer to override the ESD action. If E is selcted then the interrupter timer does not operate. Refer to (EA), (EO), (Ec) (see Section 8.2).
  • Page 47 limit Flags Help Screens Access the following Help Screens to moving Closed With the actuator powered up and Open Holding Limit Close Limit Local or Stop selected, eleven Help aid in troubleshooting the topics listed: Bar On = Actuator is moving in the Screens can be accessed using the Closed direction.
  • Page 48 local Controls Remote Signals local Fitted Remote 1: ESd Local Mode Hand Remote 1: Remote 2: Selected Operation Open Bar On = Local controls fitted. Bar On = ESD signal present. Hand Operation Remote 2: Open Local Local Remote 1: Remote 2: Bar On = Manual override in use.
  • Page 49 digital Feedback Control Flags P.Stroke / Remote- Int Timer Local Command Started Over Int. Timer Fault Relay Pressure Inhibiting Output Hydraulic Monitor Status Relay Output Solenoid Driver Int. Timer Fault Waiting for First Movement Help Screen 4 Help Screen 5 Partial Stroke / Remote-local interrupter Timer Started Command...
  • Page 50 driver Outputs Error Flags 1 Solenoid Pressure No. 1 Transducer Fault Position Solenoid Closing EEPROM Transducer No. 2 Checksum Fault Solenoid Opening Hardware Solenoid No. 3 Fault Driver Fault Pump Local Controls Hydraulic Fault Power Fault Help Screen 6 Help Screen 7 Solenoid No.1 EEPROm Checksum Bar On = Solenoid No.1 energised.
  • Page 51 Error Flags 2 Error Flags 3 Actuator Stalled Loss of Analogue Bar On = Actuator movement is stalled Demand Signal [St]. Over Partial Position Partial Stroke Fault Pressure in Stroke Checking Bar On = Actuator has failed to Mid Travel Fault Fault complete desired movement [PS].
  • Page 52 Note: Bar indication is real time and Help Screen A Help Screen B reactive. Open Command For Rotork Fluid Systems use only. Bar On = Actuator is acting on an Open command. Close Command Bar On = Actuator is acting on a Close command.
  • Page 53 Standard Applications the actuator for 30 minutes and • Ensure valve stems and drive nuts are 10 cSt Mineral Oil Every Rotork Fluid Systems actuator has check that the actuator has not clean and properly lubricated. Unless specially ordered for extreme been fully tested before despatch to give drifted off the open limit.
  • Page 54 10.2 Environmental End-user advice on disposal at end of product life Subject Definition Remarks / examples Hazardous Recyclable EU Waste Code Disposal Electrical & Printed circuit boards All Products 20 01 35 Use specialist recyclers Electronic Wire All Products 17 04 10 Equipment Glass Lens/Window...
  • Page 55 46.0 / 12.2 SI-2-L350/105 320 / 706 48.5 / 12.8 SI-2-Q120 560 / 1235 41.0 / 10.8 SI-2-L400/105 Consult Rotork Consult Rotork SI-2-Q130 800 / 1764 41.0 / 10.8 SI-2-L450/105 Consult Rotork Consult Rotork Note - For SI-L actuators, weights and volumes of oil are for standard stroke lengths as stated in the applicable data sheet.
  • Page 56 Power unit Number.: Model code for power unit only. Serial Number: Always have this to hand if contacting Rotork Fluid Systems for assistance. Wiring diagram Number: Wiring diagram will give information on the actuator specification and terminals for incoming cables.
  • Page 57 Hazardous Area Approvals Russia – Hazardous Area Brazil – Hazardous Area international – Hazardous Area Rotork SI actuators are approved to many standards. The accompanying list Si-1: Si-1: Si-1: was accurate as of 12 October 2010. GOST R. Ex dme* IIB T4 INMETRO.
  • Page 58 Special Conditions of Safe use (Explosion-proof Actuators) Si-2.1 maximum Gap minimum l The maximum constructional gap (Ic), is less than that required by Table 2 of EN 60079-1:2004 (or IEC 60079-1:2003 ), as detailed below: Electrical Cover / Centre Housing (Spigot Joint) 0.150 26.20 Terminal Cover (Long &...
  • Page 60 As we are continually developing our products, their design is subject to change without notice. The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and produced in the UK by Rotork Fluid Systems. POWSH1010 www.rotork.com...

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