rotorit Instruction manual for ‘K’ Range Syncropak and Syncroset electric valve actuators K30, K60, K150, K300, K500, K600, K800 and K1000 actuators Publication BRVE/4 Issue 11/04your actuator cannot be installed immediately stor it in a «ry place until required and do not break conduit entry seals until you are ready to wire up, ‘The Rotork double sealed construction will preserve internal electrical componeris perfectly, if leftundisturbed, Rotork cannot accept responsibilty for deterioration caused ‘onsite once the actuator covers are removed. Every Rotork actuator has been fully tested before leaving the factory to give you years of trouble tree operation provided itis corectl installed and sealed. Contents 1. Operating the actuator 2. Position indication 3. Actuator bases 2 4. Preparing the drive bush_ . 2 5. Mounting the actuator onthe valve 3 6. Setting the switch mechanism 4 7. Wiring up and electrical start up 6 8. Trouble shooting, lubrication and maintenance 7 THIS IS NOW YOUR PROPERTY, DO NOT DAMAGE IT. DO’S & DONT’S ON ACTUATORS 1, DONOT use crow bart it the top cover of wooden casing by Using the actuatorhandwhee!asafulerum pln. 2 On opening the case, chock actuators for visible damages and {ako immociate action tonotity insurance il damages ae noticed, '¥ damaged parts are not attended especially on Switch Mech ‘side, the 1 68 sealing fect willbe lost and components may get rusted. 3, Though actuators are made to 1, ensure that the actutors ‘are not used immediate, they are stored in. covered-dry| placo and do not break te coals Le, sealing pivgs & screwed colar. Otherwise te ofetof 68 wil belos 4. When the dive sleeve is taken out for machining and while Folxing, please ensure thatthe dive sit in the sieve is in ‘lgnment wth the centre column dive dogs. Also ensure thatthe “O' Rings are intact and not damaged. DO NOT modly any’ actuator components withoutour permission, 5. While mounting an actuator on toa vale, please make sure that the correct valve and actuator are coupled. i an oversized ‘actuators coupledtoa vale, then the valve slem wi gt bent or the base wil get damaged. tthe actuator is too small forthe ‘pplication, the actuator wil not be abe to close the valve ght shut 6. DONOT start an actuator atthe end ofits travel, Always check thatthe actuator and the valve are inthe midway oftheir travelto| iow forthe checking ofthe rection of rotation, 7. DONOT ty torun a syncrosat actuator rom direct three phase ‘supply. Aways take tho power supply trough a control box with contactors and ensure thatthe correct direction of rotation i siventothe actuator. 8. Atways connect the actustor motor thermostat in series withthe Contactor coils (both open & close contactors) for motor protection. 8. DO NOT engage the hand auto lover when the actuator is running 10, DO NOT use internal appliances tke pipes and crow bars to increase the leverage of hand auto lever or handwheel. This wll only damagetheintrnalparsofactuator. " 11, When engaging the hand auto lever please make sure that the «dogs in cl ring and handwheel are not against each othe, this an be seen the hand auto lever does not go fly tots stop Psion. both the dogs aro against eachother, release the hand _autoleverand tur the handwheel further by about 45 degrees for ‘easeot engagement. - 12, Please make sure that the sealing"O Rings are kept saely ast \when any ofthe actuator covers are removed. The'0' Rings must bbe undamaged and kept clean. Also ensure to replace them inthe Correct position when rising the cover and make sure thet the coverscrews.are full tightened ater assembly. 18, 00 NOT use one operator to engage the hand auto lever and a ‘20nd operatorto rotate the hand wheelatthe game time, ass practice may cause damage tothe handwheel dogs and cluch gs. One operator can engage and operate the hand auto mechanism, 14. Whenthe acuatoisitedtothe valve, DONOT ly the valve and ‘he actuator assembly onthe florin sucha fashion thal he total weight ofthe complete valve is resting onthe actuator or onthe hand auto lever ofthe actuator. Aways rest the uniton a wooden block at an angle such thatthe actuator is clear of al weight or contact wth he loo r ether obstructions and thus damages ae avoided, 18, DONOTit moe than one actuator atime (even when using a rane) since damage can be caused by crashing one actuator ‘against another 16. Install the actuator as por the instruction manual which is despatched along witheach actuator 17, Ensure isolation of power before opening electrical compartment 18. Ensure thatthe valve spindle kept lean andlighty brcated. 18. Ensure that covers are fited corecy at all times and thatthe overhoiding screws are ful ghtoned, 20, Ensure that the actuator base holding bots (when fited tothe valve) are othe corectsize & length and are ful tightened1 Operating the actuator Allactuators Rotork'K’ Range actuators, Each "K’ Range Syncfoset & Syncropak actuator consists of four basic sud ‘ascombles, 1. Motor 2, Ol ited gear box with hand whee! and ‘eclutch mechanism. 8, Limitand torque svitch mechanism, 4.Terminalbox ‘Syneropak actuators also contain integral sarterand asenclated contolequipment Operating your actuator Manually To engage handuhee! move hand aut lever In the tection of erow and tun handiwheet toongage the hand auté mechanism. ‘Thelevercannowbe released. ‘The handwhes!crive wil remain engaged Luntl the actuator is operated electrically. Whon tis, operated electrically will ‘automaticaly disengage the handwheel and retum to ‘Auto. If required, the hand auto levereanbe securedin ether position with 5/16" clameter hasp padlock. Electrically Powersupply another connections shall be ‘made as perwing diagram suppieg wth the actuator. Syneroset ‘Syrerosel actuators require separate starter facies, ‘Syneropak ‘Syreropak actuators contain thelr own integral stator and contotcreuts. Selecting ‘Local’ or ‘Remiote’ control ‘To black selector switch located on the starter cover can be tumedio select any one othe three contotpostions. ‘Local’, 'Remote' or ‘Off Winen selecting ‘Of, nto thatthe soloctor sw ler rides over the red pushbutton and automaticaly depresses ‘Any poston can be maintained by using a ‘14 clameternasp padlock. ‘To open or close the valve or stop the actuator electrically. “The red pushbution located on the starter ‘cover has two functions, push o stop, turn {stan imnethercrection. 2Position indication Allactuators Position indication Is not supplied as standard on’K’ Range actuators. Local indleation is avaiable at an optional extraintwotame. 1. Three position, showing ‘Open’, termediatoand Closed 2. Continuous indication trom ‘Open to Close. (On syncropak actuators ony local positon incication is iluminated RedYelow!Green for‘Opon'ntermediate’/'Cosed. For setting instructions for local positon Indicators soe section 6 Seting the switen mechanism Remote position indication 'K Range Syncroset and Syncropak ‘actuators canbe ited witha potentiometer for remote: poston indication. For seting Instructions see section. ‘Three position indication (shown in intermediate poston) OR ‘see indenter Moving ‘Ope symbol dec pons sybol Vas potion “Cloewd tomes Open =~ @ oO Continuous Position indication For Flame Proof Actuator (Show in intermediate postion) ‘cose uminated—_Potenioneter symect sear” Bena a ing ‘eh symbat Pomter (esuntatieor coon Vave postion ‘sed ernie! Ope! om @—— Oo “tumnstign Geen Yow ea { Opional en Syperopak actuators For Water Tight Actuators (Shown in infermodate poston) Pointer od ‘symbol a symbol arated ciao window Tie pon Grotto ‘Cone r Synba " © c “ease fed Wen Geen + Optional on Sypeopak actuators