rotork EH Pro Series, Installation And Maintenance Instructions Manual

Page 1: ...on and Maintenance Instructions This manual contains important safety information Please ensure it is thoroughly read and understood before installing operating or maintaining the equipment PUB021 034...

Page 2: ...th Setting Tool Pro via Insight II It is essential that all the actuator settings are checked for compatibility with the valve process and control system requirements before the actuator is put into s...

Page 3: ...ing of internal hydraulic pressure levels position limits and all other control and indication functions can be made safely quickly and conveniently even in hazardous locations Standard diagnostics in...

Page 4: ...nit HPU Torque requirements up to 600 000 Nm 5 3 million lbf in and thrusts up to 5 500 000 N 1 2 million lbs can be accommodated All electronics are protected in a watertight or explosion proof enclo...

Page 5: ...erride Pump Hydraulic Reservoir Oil Drain Plug Pump Motor Actuator Center Body Hydraulic Cylinder Manual Override Lever Manifold 1 2 NPT Cable Entries Accumulator If applicable Terminal Compartment Sp...

Page 6: ...ics Configuration 18 7 10 Partial Stroke Test 18 7 11 Full Stroke Test 19 7 12 Crossroad Cr 19 7 13 Actuator Display Setting Checking Mode 19 7 14 Returning to Valve Position Display 20 8 Commissionin...

Page 7: ...ation in hazardous areas then the actuator may be installed in Zone 1 and Zone 2 classified hazardous area locations only It should not be installed in hazardous area locations with an ignition temper...

Page 8: ...ic fluid must be disposed of safely see environmental section Note the PRODUCT SAFETY DATA SHEETS covering the type of hydraulic oil supplied by Rotork Fluid Systems for use within the supplied power...

Page 9: ...ady to connect incoming cables If the actuator is to be installed but not immediately cabled it is recommended that any plastic cable entry transit plugs be replaced with a suitable metal plug The dou...

Page 10: ...upper knob clockwise 3 2 Display Local Indication Fig 3 2 The Actuator Display The display consists of 1 Position Display This is the main 7 segment position display with icons 2 Text Display This is...

Page 11: ...has reached the set closed limit position Open Limit Actuator has reached the set open limit position Moving Open Actuator is traveling in the open direction Moving Closed Actuator is traveling in the...

Page 12: ...e minimum set demand signal In a 4 20 mA system the demand signal has dropped below 2 mA or it goes above 22mA PS UNABLE TO RUN The actuator may not be at the correct limit to start the test or a new...

Page 13: ...be set via controller configuration Refer to Section 8 3 8 1 Open Switch Adjustment Move the valve actuator to the fully open position Locate the proper switch cam Push the cam down and rotate anti c...

Page 14: ...is is due to the nature of fixed displacement pumps Optional manual operation may have been specified for your EH actuator For all EH actuators optional manual operation is provided with a hydraulic h...

Page 15: ...the actuator has been bolted to the valve flange or adaptor and keys inserted the position of the stop bolts should be checked to ensure full opening and closing of the valve If the preset end positio...

Page 16: ...must not be used alone as the protective Earth Connection 6 2 Removing Terminal Cover Using a 6mm hexagon key loosen the four captive screws evenly Do not attempt to lever off the cover with a screwd...

Page 17: ...ion and lightly greased before re fitting cover WARNING Ensure the oil fill plug is always tight before stroking the actuator in either direction 6 Cable Connections continued Heading ATTENTION RED PL...

Page 18: ...sure values and limit positions 2 Configuration Settings Settings covering the control indication and optional equipment functions All EH actuator functions are configured before despatch to Rotork Fl...

Page 19: ...Name Instruction 1 m Key Display next function down 2 k Key Display next function across 3 Key Decrease change displayed function s value or option setting 4 Key Increase change displayed function s...

Page 20: ...on setting 9 Infrared transmitter window 10 Key Non functional on EH actuators 11 Key Non functional on EH actuators Pressing these two arrow keys together exits setting mode and returns the actuator...

Page 21: ...ransmitter window 10 Key Non functional on EH actuators 11 Key Non functional on EH actuators Pressing these two arrow keys together exits setting mode and returns the actuator display to the pressure...

Page 22: ...tured from the following materials Polycarbonate ABS blend Polycarbonate Silicon Rubber If the Rotork Setting Tool Pro and Rotork Bluetooth Setting Tool Pro are likely to come into contact with aggres...

Page 23: ...rd displayed press the enter key PRESS THE KEY Two setting bars will appear and will remain visible on every function display screen In addition Password Correct will be displayed for 3 seconds Defaul...

Page 24: ...ooth Setting Tool Pro To enable communication with Insight II the actuators Bluetooth interface must be enabled The default setting for the Bluetooth interface is OF disabling Bluetooth OF Off Default...

Page 25: ...of the screen Depending on the actuator function displayed its setting may be an option or a value Text relating to the function and setting values will be displayed in the lower display 7 11 Full Str...

Page 26: ...ION Function e g OP Open Pressure TOP RIGHT PORTION Function Setting e g Value 90 LOWER DISPLAY Function Open Pressure Setting Value 90 7 14 Returning to Valve Position Display There are five ways of...

Page 27: ...Settings With the actuator mounted on the valve the power supply on and Local or Stop control selected point the setting tool at the actuator indicator window from a distance of no more than 0 75m By...

Page 28: ...Close Action k Open Action m m CP k cP k OP k oP Close Pressure Limit k Close Pressure Mid k Open Pressure Limit k Open Pressure Mid m m LC k LO Set Close Limit k Set Open Limit m m 50 Position Displ...

Page 29: ...needs to be changed as it cannot be done through software alone The actuator can be configured to either close on Pressure hydraulic or spring for seating valves or Limit for non seating valves 50 m...

Page 30: ...ndicating that it has been set Open Action C3 Open Action Stop on Limit Torque This setting allows the maximum cut off pressure in a normally open actuator while travelling from the closed electrical...

Page 31: ...SS THE KEY The displayed option will flash stored indicating that it has been set Open Pressure at Limit OP Open Pressure at Limit 90 Torque This setting allows the maximum cut off pressure in a norma...

Page 32: ...e the valve and process conditions are within the specified operational limits before increasing the pressure value Open Pressure at Mid oP Open Pressure at Mid 0 Torque To set the closed and open ele...

Page 33: ...displayed option will flash stored indicating that it has been set Set Close Limit Move to Close Torque Set Open Limit LO Move the actuator to the open position by using the local controls 50 m 50 m...

Page 34: ...SP Partial Stroke Set up ESD Partial Stroke m FI Analogue Input Type FL Set Demand Closed FH Set Demand Open Co CPT Output Type Sc Set CPT Closed SO OP Set CPT Open FF Analogue Fail Action Analogue C...

Page 35: ...g 9 1 If you have chosen to enter Configuration Settings in the setting mode the display will be as Fig 9 2 Refer to Section 7 Fig 9 1 Fig 9 2 PRESS THE k KEY 9 1 Accessing the Configuration Settings...

Page 36: ...The r contact form can be set normally open nO or normally closed nC Unless specified with order the default setting for indication contact is the following r1 CL Closed Limit nO 9 2 This screen will...

Page 37: ...specified and fitted if any There are five options available to configure the remote control source rE Digital Default Select this option for hard wired pushbutton relay contact control AI Analogue Se...

Page 38: ...ating that it has been set Low Power Mode LP Low Power Mode Off There are two options available gr Green Default Select this option for the LED to be green at the closed limit and red at the open limi...

Page 39: ...uator has been commissioned on site Using Insight II it can then be compared against subsequent tests carried out at a later date The actuator needs to be positioned at a limit to perform this test SF...

Page 40: ...ue When the desired value is on the display PRESS THE m KEY The displayed value will flash indicating that it has been set PH Position Hysteresis Position Hysteresis 0 5 This feature will vent the int...

Page 41: ...gnal applied to the actuator will override any existing or applied local or remote control signal Press the or key to select the required ESD action E De Energise Default This option will de energise...

Page 42: ...D OF No Reset Default Select this option if the actuator does not need to be reset after a ESD event or loss of mains power Ed After ESD Select this option if the actuator must be manually reset after...

Page 43: ...is inactive These settings will work in conjunction with the ESD Manual Reset rE option To change the action to be carried out press the or key until the required setting is displayed PRESS THE KEY Th...

Page 44: ...o Ys PRESS THE KEY P Stroke Setup Yes This function performs a partial stroke of the actuator and records the position and internal hydraulic pressure against time in both the open and closed directio...

Page 45: ...CPT current position transmitter Analogue IP Type Current Analogue Input Type Analogue Control 1 FI 9 6 Apply the analogue Close demand current or voltage signal corresponding to the Close position to...

Page 46: ...ype Position Set CPT Output Co To calibrate the CPT output for the closed limit position connect a current measuring device to the CPT terminals Press the or keys until the required output is shown on...

Page 47: ...p starts Some understanding of the operational design parameters is required to optimally set Deadband and Hysteresis If the actuator was at the closed limit and a demand position input of 50 was rece...

Page 48: ...SS THE KEY The displayed option will flash stored indicating that it has been set Analogue IP Close Hyst 0 5 Hysteresis Closing HC The opening hysteresis value is displayed as a of full stroke The def...

Page 49: ...fault for timer direction is CL timer operation will start in closing and stop in opening pulsing operation around the close position If pulsing operation is required to stop in closing and start in o...

Page 50: ...icating that it has been set Using the or key select the actuator stop period in the range 100 mS to 99 seconds JF set to 25 gives an Interrupter Timer off pulse length of 2500 mS or 25 seconds depend...

Page 51: ...ke this into account Example The interrupter timer may be overridden when the actuator is under software ESD signal command This will mean the actuator will run to limit without stop start action unde...

Page 52: ...nd should be investigated A full functional test should be carried out to ensure any underlying fault does not affect the actuator performance If the fault persists then contact Rotork Displayed text...

Page 53: ...re version number that is installed on the actuator Firmware Version vxxx xxxx Firmware Version Un This option displays the current firmware version number that is installed on Channel 1 of the networ...

Page 54: ...ayed option will flash stored indicating that it has been set Press the k key to display Pb Baud Rate The actuator Pakscan Field Control Unit baud rate must be set to the loop baud rate For a Pakscan...

Page 55: ...igital signal inputs they are simply designated as AUX 4 to AUX 1 Rules 1 Function bit set to 0 Any function bit set to 0 indicates that the particular aux input is to be treated as a digital signal f...

Page 56: ...ds will be maintained Aux I P 4 3 2 1 Function 0 0 1 1 3 Invert 0 0 1 1 3 i e set PF to 33 3 Only an ESD input is needed The requirement is for push to run control with a NO contact input Aux I P 4 3...

Page 57: ...ue outside this range is entered the address set will revert to 01 for 00 or F7 for value above F7 PRESS THE KEY The displayed option will flash stored indicating that it has been set Press the k key...

Page 58: ...tal signal inputs they are simply designated as AUX 4 to AUX 1 Rules 1 Function bit set to 0 Any function bit set to 0 indicates that the particular aux input is to be treated as a digital signal for...

Page 59: ...w Set Point Position Refer to section 9 14 PF Modbus Remote Auxiliary Input continued Modbus Parity PP 5 Remote I P Setting Ensure that the correct Od Control Type setting is selected refer to section...

Page 60: ...s To set the address the Profibus module must be isolated from the host by disconnecting the RS485 highway or turning off the host device Using the or keys display the required address Address to be s...

Page 61: ...ital signal inputs they are simply designated as AUX 4 to AUX 1 Rules 1 Function bit set to 0 Any function bit set to 0 indicates that the particular aux input is to be treated as a digital signal for...

Page 62: ...ng the open and close commands will be maintained Aux I P 4 3 2 1 Function 0 0 1 1 3 Invert 0 0 1 1 3 i e set PF to 33 3 Only an ESD input is needed The requirement is for push to run control with a N...

Page 63: ...79 for conversion If an address value outside this range is entered the address set will revert to 01 for 00 or 3F for value above 3F PRESS THE KEY The displayed option will flash stored indicating t...

Page 64: ...mply designated as AUX 4 to AUX 1 Rules 1 Function bit set to 0 Any function bit set to 0 indicates that the particular aux input is to be treated as a digital signal for field status reporting e g a...

Page 65: ...is OP Network The factory default for PF Aux I P Mask is OF 0000 1111 Examples 1 The full range of remote controls is needed Open and Close are NO and ESD and Stop maintain is NC Aux I P 4 3 2 1 Funct...

Page 66: ...setting is for 0 to be the Close limit Use the or key to select the desired valve position for a 0 command 0 DV Valve Closed PRESS THE KEY The displayed option will flash stored indicating that it ha...

Page 67: ...communications whereas Profibus DeviceNet check for a loss of communications addressed specifically to themselves The default setting is off OF and the default timeout is 255 sec Use the or key to dis...

Page 68: ...settings for EH actuators Function d1 Default Setting P Password Unaffected will remain as set Bt Bluetooth Communication OF Switched Off Basic Configurations C2 Close Action CP Stop on Pressure C3 Op...

Page 69: ...mer Off Jd Interrupter Timer Start Direction CL Start Closing JC Interrupter Timer Close Position 25 25 Open JO Interrupter Timer Open Position 25 25 Open JS Interrupter Timer Interval OF Time in Seco...

Page 70: ...moving the oil fill plug when the electrical power is removed from the actuator The oil level should be within 50mm 2 of the filler breather If it is necessary to top up hydraulic fluid ensure that th...

Page 71: ...l Mixed Metals HPU motor and motor windings No No No No Yes Yes Yes Yes 14 04 02 17 04 01 17 05 05 17 04 07 Use licensed recyclers Plastics Glass filled nylon Covers electronics chassis No No 17 02 04...

Page 72: ...elay indicators H6 Solenoid and pump driver outputs H7 Fault indicators 1 H8 Fault indicators 2 H9 Driver logic indicators Open Holding Limit Close Limit Close Holding Limit Open Limit Reached Moving...

Page 73: ...intain Remote 1 Remote 2 Maintain Close Remote 1 Remote 2 ESD Open Help Screen 3 All remote signals designated with 1 are standard hard wired remote inputs When a network system such as Pakscan Profib...

Page 74: ...r fault present Note Bar indication is real time and reactive Int Timer Started Int Timer Fault Relay Inhibiting Output Monitor Relay Output Int Timer Waiting for First Movement Help Screen 5 Interrup...

Page 75: ...Transducer Checksum Fault Hardware Solenoid Fault Driver Fault Local Controls Hydraulic Fault Power Fault Help Screen 7 EEPROM Checksum Bar On EEPROM checksum error EE Hardware Fault Bar On Hardware f...

Page 76: ...vement PS Loss of Analogue Demand Signal Bar On Analogue demand signal not present dn Note Bar indication is real time and reactive Open No Expected Command Movement Close De energise Command All ESD...

Page 77: ...0111 1111 7F 127 1000 0000 80 128 1000 0001 81 129 1000 0010 82 130 1000 0011 83 131 1000 0100 84 132 1000 0101 85 133 1000 0110 86 134 1000 0111 87 135 1000 1000 88 136 1000 1001 89 137 1000 1010 8A...

Page 78: ...EH 1 1 Pro Hydraulic Schematic Actuator specific hydraulic layout and component list Wiring Diagram Actuator specific information terminal identification and connection options Supply Voltage Compare...

Page 79: ...E F G DIP II 1 EFG Enclosure NEMA Type 6 Temperature Code T4 Temperature 40 C to 60 C Option 50 C to 60 C e increased safety terminal facility is only available on single phase and DC versions when sp...

Page 80: ...imum L mm Manifold Block Main Enclosure Flange Joint 0 10 12 50 Control Knob Shaft Main Enclosure Cylindrical 0 20 25 00 Terminal Bung Terminal Housing Cylindrical 0 20 26 00 Indicator Shaft Bushing M...

Page 81: ...Tightly close bleed valve 3 2 8 When finished pre charging turn the T handle 2 fully anti clockwise then open bleed valve 3 to release residual gas 2 9 Use a wrench to prevent the gas valve assembly f...

Page 82: ...hrough 3 5 4 2 Open bleed valve 3 until all gas pre charge is released from the accumulator 4 3 Remove the charging assembly The accumulator can now be safely removed from the system Accumulator Remov...

Page 83: ...representative or the factory direct at the address on the nameplate quoting the actuator type and serial number A full list of our worldwide sales and service network is available on our website at...

Page 84: ...Y 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 META...