K Range. High Torque Electric Valve Actuators. Redefining Flow Control

K Range High Torque Electric Valve Actuators Redefining Flow Control

Contents Section Page K Range Actuator 3 K Range High Torque Features 4 Enclosure Options Drive Options 6 K Range Performance Summary 7 Actuator Motors 8 Wiring Diagram 9 Dimensional Drawings 10 Rotork is the global market leader in valve automation and flow control. Our products and services are helping organisations around the world to improve efficiency, assure safety and protect the environment. We strive always for technical excellence, innovation and the highest quality standards in everything we do. As a result, our people and products remain at the forefront of flow control technology. Uncompromising reliability is a feature of our entire product range, from our flagship electric actuator range through to our pneumatic, hydraulic and electro-hydraulic actuators, as well as instruments, gearboxes and valve accessories. Rotork is committed to providing first class support to each client throughout the whole life of their plant, from initial site surveys to installation, maintenance, audits and repair. From our network of national and international offices, our engineers work around the clock to maintain our position of trust. Rotork. Redefining flow control. 2

K Range Actuator With the K Range high torque actuator, Rotork is now able to offer all the proven design advantages of its established ranges at higher torque values than have previously been possible. Available in three models, K4000, K00 and K7000, these actuators offer torque ratings of up to 7000 Nm and thrust ratings of up to 111 kn. Standard K Range high torque features include: Double-sealing against the environment, protecting electrical integrity at all times Standard wiring diagrams for any valve type Thrust or non-thrust mounting flange dimensions to International (ISO) valve standards Advanced counter switch mechanism featuring combined torque position limit switches at each end of travel Integral starter and control circuit option (Rotork Syncropak) Three base options for each size of actuator Watertight enclosures Redefining Flow Control 3

K Range High Torque Features Syncroset 4 6 1 3 Syncroset actuators incorporate the motor and limit and torque switches only. This minimizes the electrical equipment at the valve location and is therefore particularly suitable for locations where access is difficult or where excessive vibration may be experienced. However the reversing starter must be separately specified, purchased, installed and tested by the customer and the valve control system is therefore incomplete until wired in the field. Features 2 1. Low ratio worm / wormwheel gear combined with final spur reduction gear offering a combined drive efficiency above that of conventional worm reduction designs. The gearcase is oil filled for normal operation in a temperature range of -30 to +70 o C. 2. Separate thrust bases providing increased stem acceptance and thrust if required. Base and flange dimensions to ISO standards. 3. Very advanced all metal counter switch mechanism featuring combined torque and position switch with torque switch latch which prevents valve hammering throughout travel with non-self-locking gears. Switch mechanism is quickly and easily set using only a conventional screwdriver. As with other Rotork designs, the reaction force on the wormshaft, in direct proportion to the output torque is used to trip the 'Open' and 'Close' adjustable torque switches. 4. Built-in squirrel cage motor with winding thermostat, specially designed for valve operation and combining low inertia with high torque. Class F insulation as standard.. Hammerblow backlash feature permitting motor to gain full speed before unsticking tight stem nuts, etc. 6. Hand/auto selector lever insures positive engagement of handwheel drive. Power drive automatically restored by motor start unless lever padlocked to prevent it. Generously proportioned wormdrive handwheel provided as standard operating through hammerblow mechanism. The side handwheel ratio is 90:1 giving a mechanical advantage of 33:1. 7. High output speeds at high torque enable large valves to be operated quickly and permit favorable top mounted actuator configuration. Auxilary limit switches Motor and thermostat Syncropak Travel limit and torque switches Local Controls Remote control indication and interlocks Three phase power supply Reversing contactor starter Rotork Syncropak actuators incorporate the starter and local controls with considerable economy in site wiring as shown. This arrangement also enables the essential elements of the valve control system to be factory wired and tested and sealed by Rotork Quality Control. Because Syncropak incorporates everything required for operation from a three phase supply, it can be tested on local control by the valvemaker and site contractor with undivided contractual responsibility by Rotork for reliable operation. Syncropak options increase economy and add system reliability by providing a high degree of fault monitoring. Interposing relays enable light current cable to be used for distant remote control and indication. See publication RCIE - for details. Note: 'K' Range high torque actuators are manufactured with the same wiring diagram options as the Rotork 'K' Range product. In addition, the 'K' Range high torque counter switch mechanism can accept both extra end position and mid position switches. Remote control indication and interlocks Three phase power supply Syncropak or Syncroset? Any motorised valve requires a reversing contactor starter to switch the three phase motor in response to control signals. This may be separately installed or incorporated in the actuator. Rotork Syncroset actuators require separate starter facilities. Rotork Syncropak actuators contain their own starter and control equipment in a factory sealed and tested package. Reversing contactor starter Auxilary Motor limit and switches thermostat Local Controls Travel limit and torque switches 4

Enclosure Options Enclosure options All 'K' Range high torque actuators are o-ring sealed from the environment and the exclusive Rotork 'double-sealed' feature means that the terminal compartment is separately sealed from the rest of the enclosure to insure that the actuator is permanently protected even during long periods of on-site wiring when the terminal cover is removed. `O' ring Redefining Flow Control

Drive Options 20 79 173 Drive Options Three basic output drive column assemblies are available as standard on all sizes of K Range high torque actuators. Dimensions shown below are to International (ISO) dimensions. F40A 8 holes drilled thro' 114 260 The F40A equi.spaced is a larger version of the F3AL 36 PCDseparate base which provides enlarged stem acceptance and maximum 41 thrust rating. 0 Pilot bore F3E The F3E is the basic torque only form. The center column is terminated with a Type 'E' bore diameter and keyway suitable for attachment to valve makers' gearbox, etc. 82 260 40 127 M36 224 M30 260 36 PCD 8 Holes drilled and tapped M30 equi. spaced 41 4 F3AL The F3AL is a separate thrust base which is added to the standard gearcase and which contains its own sealed thrust bearing and aluminum bronze drive bush. This feature 260 maintains the maximum rising stem acceptance available 36 PCD 8 through Holes drilled the and tapped actuator center column which in this form is M30 equi. spaced 41 simply fitted with a pair of male dogs which engage with the drive bush. 79 20 173 8 holes drilled thro' 40 equi.spaced 300 406 PCD 476 82 * Note: Optional Flange Type 3 & Type 4 with the following dimensions can be offered Type 3 : 8 x M24 x 216 spigot dia x 36 PCD x 41 OD Type 4 : 8 x M30 x 230 spigot dia x 406 PCD x 476 OD 8 holes drilled thro' equi.spaced 114 260 36 PCD 41 0 6 8 holes drilled thro' equi.spaced 127 300 406 PCD

K Range Performance Summary Performance Data Actuator Size Rising (mm) Spindle acceptance Non-rising (mm) Max. Thrust (kn) Rated Torque (Nm) K4000 F3E - 82-4,000 K4000 F3AL 110 9 446 4,000 K4000 F40A 12 10 1,11 4,000 K00 F3E - 82 -,00 K00 F3AL 110 9 446,00 K00 F40A 12 10 1,11,00 K7000 F3E - 82-7,000 K7000 F3AL 110 9 446 7,000 K7000 F40A 12 10 1,11 7,000 Stall torque is 1.2-1.6 of rated torque. Limit switch turns range for all sizes is -120 output turns. Actuator Size Motor Output Speed (rpm) Locked Rotor Approx. Current A (Amps) Rated Torque Av. Load Av. Load Nominal (kw) Power Factor Efficiency (%) K4000 K00 K7000 41 V 0 Hz 3-ph 20 120 3 1 4.8 0.6 6 30 140 40 21 7. 0.71 71 40 140 48 21 7. 0.71 71 20 140 40 21 7. 0.71 71 30 140 1 21 7. 0.71 71 40 160 9 2 9.2 0.70 73 20 140 21 7. 0.71 71 30 160 6 2 9.2 0.70 73 40 220 6 29 11.3 0.70 77 Note: For other power supply options refer to Rotork. Redefining Flow Control 7

Actuator Motors Motors: Rotork actuator motors are 3-phase, minimum class 'F' insulated, and high torque low inertia motors of 1 minutes rating. The motors are spigot mounted and o-ring sealed to provide complete environmental protection during long periods of inactivity when condensation build up can otherwise cause deterioration. Valves have a limited travel and impose a varying load throughout the stroke and consequently the valve actuator motor cannot run continuously and conventional "FULL LOAD" ratings are not relevant. Hence our motors are short time rated, as the high inertia of continuously rated motors will inevitably damage the valves which are basically for "STOP DEAD" applications. Motor is integral with actuator and hence as standard protected IP68 IS/IEC-6029 enclosure. The following performance characteristics are standard for our motors: 1) A high stalling torque in comparison with that required to operate and seat valve will be available at high speed for unseating in with a lost motion hammer blow effect which is achieved by allowing the motor to reach full speed before the drive is taken up. 2) A relatively high starting torque to enable the valve to be inched. Number of starts 60 starts / hour. Protection Thermostat embedded in stator winding. Bearing Deep groove sealed ball bearing lubricated for life available. Fan Cooling The design of Rotork motors are such that it renders fan cooling unnecessary to achieve the 1 min rating. 8

Wiring Diagram CIRCUIT DRAWN FOR VALVE IN THE SHUT POSITION Syncroset wiring Diagram/coding 3ph V 43 44 U W MOTOR THERMOSTAT Connect 43 and 44 in series with both contactors. WD 2NO+2NC POTENTIAL FREE CONTACTS 1NO+1NC POTENTIAL FREE CONTACTS 1NO/1NC CHANGE OVER CONTACTS OPEN T/LS AS1 AS2 AS3 AS4 T/LS AS1 AS2 AS3 T/LS OR TS AS1 CLOSE 1 3 2 6 4 7 9 8 11 12 10 13 14 16 1 17 18 20 19 21 22 24 23 1 2 6 7 8 3 4 9 10 13 14 1 16 11 12 17 18 21 22 23 24 19 20 2 26 29 30 31 32 27 28 3 1 2 4 11 9 10 12 13 1 16 14 7 8 6 17 19 18 20 27 2 26 28 29 31 32 30 21 23 24 22 Ref.Note 3 Ref.Note 2 Ref.Note 1 1 2 3 4 6 7 8 9 Combined T/L Separate T/L Blinker Heater K6 41 Potentiometer 71 FR Fixed Resistor Potentiometer 72 FR Fixed Resistor 37 ZERO SPAN POT Potentiometer Potentiometer ILS3 ILS4 ILS ILS6 33 3 INDEPENDENT LIMIT SWITCH Ref.Note 8 ILS1 7 4 46 8 ILS2 47 1NO/1NC CHANGE OVER CONTACTS 2NO+2NC POTENTIAL FREE CONTACTS Contactless CPT CPT with isolated O/P ILS1 2 1 32 23 14 3 - + - + 37 IKPOT 49 1 3 33 3 36 38 33 ILS2 3 36 38 33 3 33 3 39 40 42 48 9 0 60 2 61 4 62 6 32 4 48 3 6 9 8 1 0 47 46 4 7 60 49 2 0 CPT 24 VDC - + + A POT1 POT2 0 1 2 3 1 2 3 4 CPT EXT.SUPPLY 24 VDC - A + + 24 VDC EXTERNAL SUPPLY 4--20mA O/P - A + 0 1 2 3 4 Back Wiring Back Wiring 6 7 Ref.Note 7 Ref.Note 7 Ref.Note Ref.Note 6 Ref.Note Ref.Note 4 A - ANTI CLOCKWISE TO CLOSE B - BACK WIRING ON ILS C - 110VAC CPT E - ADDITIONAL SWITCHES IN S/ MECH F - 230VAC CPT G - THREE THERMOSTAT IN MOTOR H - THERMOSTAT ON HEATER I - 3 T.STAT ON MOTOR + ADDL. SWITCHES J - ADDITIONAL SWITCHES + T.STAT ON HEATER K - 3 T.STAT IN MOTOR + EXTERNAL POSITIONER L - P/B ASSY + POSITIONER M - SEP. 1NO+INC CHANGEOVER TQ/LT SWITCH N - ADDL. SW + 3 T.STAT ON MOTOR + 110VAC CPT 0 - ADDL. SW. + 3 T.STAT ON MOTOR P - INTEGRAL PLUG & SOCKET Q - P/B ASSY. +3 T.STAT ON MOTOR R - ADL. CPT 1K POT S - 2NO2NC USED AS 1NO1NC IN ILS T - IK DUAL GANG POT U - P/B ASSY V - P/B ASSY. + LAMP FOR CLI W - P/B ASSY. + L/R INDN. SWITCH. X - 230VAC CPT + 3 T.STAT ON MOTOR Y - 3 T.STAT ON MOTOR + LAMP FOR CLI Z - 110VAC HEATER 3 - THREE THERMOSTATIN MOTOR A - ANTICLOCKWISE TO CLOSE C - EXTERNAL POSITIONER + 230V AC CPT D - EXTERNAL POSITIONER + LAMP FOR CLI E - ADDITIONAL SWITCH. F - 3 THERMOSTAT + L/R INDN. SWITCH G - EXTERNAL POSITIONER + 3 THERMOSTAT. H - THERMOSTAT ON HEATER J - 3 THERMOSTAT + L/R INDN S/W + THERMOSTAT ON HEATER. K - PLUG & SOCKET + ADDITIONAL SWITCH. M - 1K DUAL GANG POT + POSITIONER N - BLINKER INDICATION. P - POSITIONER + P/B COVER ASSY. R - POSITIONER. S - SPECIAL POT 1K T - 3 THERMISTOR WITH TRIPPING UNIT. U - SYNCROSET + P/B ASSY. NOTES : 1. Connect 1&2 in series with close contactor Connect 4& in series with open contactor. C.P.T. connections shown for 2 wire systems, For 3 wire systems connect to +ve of supply. 61 62 63 64 6 7 8 3 4 9 60 2. Connect 1&2 in series with open contactor Connect &6 in series with close contactor 6. 1watt single or dual gang pot either 2.k suitable for 0V AC/DC or 1k suitable for 110C AC/DC operation. Please specify pot. value while ordering. 21 43 44 4 46 47 48 49 0 1 2 33 3 36 37 38 39 40 41 42 22 23 24 2 26 27 28 29 30 31 32 3. Connect 1&2 in series with open contactor Connect 9&10 in series with close contactor 4. 100 ohms 1 watt suitable for 0V AC/DC operation. 7. Code Nos. 2&4 for back wiring. Terminals shown thus on Ref. Note. 7 are when Backwired. 8. ILS are independent limit switches which can be set for any point of travel 11 12 13 14 1 16 17 18 19 20 1 2 3 4 6 7 8 9 10 U V W E TERMINAL BLOCK LAYOUT Redefining Flow Control 9

Ă203 Dimensional Drawings Ø 610 B 143 182 492 12 317 Ø 416 A 64 266 238 40 460 114 448 Ø 47 FACE A Ø 203 Ø 242 Ø 260 Actuator Size Output Speed (rpm) Motor Dimensions (mm) A B K4000 40 648 178 K00 20, 30 648 178 40 76 23 K7000 20 648 178 30, 40 76 23 Bases: Note that F3E bases are integral within the above dimensions. F3AL and F40A are external bases which bolt to Face A. 10

Dimensional Drawings Ø 610 143 182 492 12 317 448 Ø 416 A 460 114 64 B 238 40 FACE A Ø 47 Ø 203 Ø 242 Ø 203 3 260 Actuator Size Output Speed (rpm) Motor Dimensions (mm) A B K4000 40 648 178 K00 20, 30 648 178 40 76 23 K7000 20 648 178 30, 40 76 23 Bases: Note that F3E bases are integral within the above dimensions. F3AL and F40A are external bases which bolt to Face A. Redefining Flow Control 11

Redefining Flow Control www.rotork.com A full listing of our worldwide sales and service network is available on our website. Rotork plc Brassmill Lane, Bath, UK tel +44 (0)122 733200 fax +44 (0)122 3367 email mail@rotork.com Rotork Controls (India) PVT. LTD., 28B Ambattur Industrial Estate (North), Chennai 600098 tel +91 44 39 600 fax +91 44 262 7108 email chennai.sales@rotork.com Scan with your smart phone for more information on this product range PUB009-001-00 Issue 03/1 As part of a process of on-going product development, Rotork reserves the right to amend and change specifications without prior notice. Published data may be subject to change. For the very latest version release, visit our website at www.rotork.com The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and produced in the UK by Rotork Controls Limited. POWTG031