K Range - Rotork

K Range
High Torque
Electric Valve Actuators
Redefining Flow Control
Contents
SectionPage
K Range Actuator
3
K Range High Torque Features
4
Enclosure Options
5
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,
K5500 and K7000, these actuators offer torque
ratings of up to 7000 Nm and thrust ratings of
up to 1115 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
6
1
3
4
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.
2
Remote
control
indication
and
interlocks
Three
phase
power
supply
Features
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 oC.
Reversing
contactor
starter
Auxilary
limit
switches
Motor
and
thermostat
Travel limit
and torque
switches
Local
Controls
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.
5. 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.
Syncropak
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 - 34 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.
7. High output speeds at high torque enable large valves
to be operated quickly and permit favorable top mounted
actuator configuration.
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.
4
Remote
control
indication
and
interlocks
Reversing
contactor
starter
Auxilary
Motor
limit
and
switches thermostat
Local
Controls
Travel limit
and torque
switches
Three
phase
power
supply
`O' ring
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
5
173
205
79
Drive Options
5
114
Drive Options
F40A
Three basic output drive column assemblies are available as
standard on all sizes of ‘K’ Range high torque actuators.
34 equi.spaced
356 PCDseparate base
The F40A
is a larger version of the F35AL
which provides enlarged stem acceptance and maximum
415
thrust rating.
260
8 holes drilled thro'
Dimensions shown below are to International (ISO)
dimensions.
50 Pilot bore
F35E
The F35E 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.
5
82
40 55
224
260
M36
M30
8 holes drilled thro'
40 equi.spaced
127
300
406 PCD
45
476
*Note: Optional Flange Type 3 & Type 4 with the following
dimensions can be offered
5
260
356 PCD
82
8 Holes drilled and tapped
M30 equi. spaced
Type 3 : 8 x M24 x 216 spigot dia x 356 PCD x 415 OD
415
Type 4 : 8 x M30 x 230 spigot dia x 406 PCD x 476 OD
M30
F35AL
79
173
205
5
45
The F35AL 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
356 PCD
8through
Holes drilled the
and tapped
actuator center column which
in this form is
415
M30 equi. spaced
simply fitted with a pair of male dogs which engage with the
drive bush.
5
114
260
8 holes drilled thro'
34 equi.spaced
356 PCD
79
205
50 Pilot bore
173
415
5
114
260
8 holes drilled thro'
34 equi.spaced
356 PCD
260
M36
40 55
224
415
50 Pilot bore
5
127
300
8 holes drilled thro'
40 equi.spaced
406 PCD
476
40 55
224
260
M36
5
6
8 holes drilled thro'
equi.spaced
127
300
406 PCD
K Range Performance Summary
Performance Data
Spindle acceptance
Actuator Size
K4000 F35E
Rising
(mm)
Non-rising
(mm)
Max.
Thrust
(kN)
Rated
Torque
(Nm)
-
82
-
4,000
K4000 F35AL
110
95
446
4,000
K4000 F40A
125
105
1,115
4,000
K5500 F35E
-
82
-
5,500
K5500 F35AL
110
95
446
5,500
K5500 F40A
125
105
1,115
5,500
K7000 F35E
-
82
-
7,000
K7000 F35AL
110
95
446
7,000
K7000 F40A
125
105
1,115
7,000
Stall torque is 1.2-1.6 of rated torque. Limit switch turns range for all sizes is 5-1250 output turns.
Actuator Size
Motor
K4000
K5500
K7000
415 V
50 Hz
3-ph
Output
Speed
(rpm)
Approx. Current A (Amps)
Av. Load
Power
Factor
Efficiency
(%)
4.8
0.65
65
7.5
0.71
71
21
7.5
0.71
71
40
21
7.5
0.71
71
51
21
7.5
0.71
71
160
59
25
9.2
0.70
73
20
140
55
21
7.5
0.71
71
30
160
65
25
9.2
0.70
73
40
220
65
29
11.3
0.70
77
Locked
Rotor
Rated
Torque
Av. Load
Nominal
(kW)
20
120
35
15
30
140
40
21
40
140
48
20
140
30
140
40
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 15 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.
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.
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.
Number of starts
Motor is integral with actuator and hence as standard
protected IP68 – IS/IEC-60529 enclosure.
Protection
60 starts / hour.
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 15 min rating.
8
Wiring Diagram
Syncroset wiring
Diagram/coding
CIRCUIT DRAWN FOR VALVE IN THE SHUT POSITION
MOTOR
U
V
3ph
44
OPEN
WD
THERMOSTAT
Connect 43 and
44 in series with
both contactors.
W
43
CLOSE
1
2
3
4
5
6 7
8
ABCEFGHIJKLMN-
0
1
2
3
1
2
3
4
39
9
Blinker
40
1
3
42
Ref.Note 1
7
9
0
8
11
FR
12
10
33
34
35
13
14
FR
15
72
Potentiometer
36
Fixed Resistor
37
38
17
18
POT
20
33
19
CPT
34
-
35
21
AS4
22
A
+
24 VDC
+
33
24
POT1
34
35
1
Potentiometer
36
5
7
8
3
4
10
38
9
A
24 VDC
+
+
ZERO
11
1
32
17
18
2
CPT with
isolated O/P
21
23
14
33
+
-
32
+
4--20mA O/P
35
22
23
24 VDC
EXTERNAL
SUPPLY
-
IKPOT
16
15
-
35
A
+
34
34
24
19
INDEPENDENT LIMIT SWITCH
20
0
Ref.Note 8
25
13
16
Ref.Note 3
10
14
Separate T/L
11
Combined T/L
2
4
9
12
4
5
49
50
Ref.Note 7
48
59
ILS3
60
ILS4
51
52
61
ILS5
53
Ref.Note 7
3
1
47
Back Wiring
28
58
ILS2
Back Wiring
27
1NO/1NC CHANGE OVER CONTACTS
31
15
3
46
30
32
T/LS
OR
TS
2
45
29
AS3
1
57
ILS1
26
54
62
ILS6
55
56
5
7
8
6
ILS1
ILS2
47
17
19
18
20
27
25
AS1
26
28
29
31
32
30
21
23
24
2NO+2NC
POTENTIAL FREE CONTACTS
2NO+2NC POTENTIAL FREE CONTACTS
-
35
SPAN
1NO+1NC POTENTIAL FREE CONTACTS
34
14
12
AS2
CPT EXT.SUPPLY
33
Contactless
CPT
13
AS1
KMNPRSTU-
POT2
37
Ref.Note 2
6
THREE THERMOSTATIN MOTOR
ANTICLOCKWISE TO CLOSE
EXTERNAL POSITIONER + 230V AC CPT
EXTERNAL POSITIONER + LAMP FOR CLI
ADDITIONAL SWITCH.
3 THERMOSTAT + L/R INDN. SWITCH
EXTERNAL POSITIONER + 3 THERMOSTAT.
THERMOSTAT ON HEATER
3 THERMOSTAT + L/R INDN S/W + THERMOSTAT
ON HEATER.
PLUG & SOCKET + ADDITIONAL SWITCH.
1K DUAL GANG POT + POSITIONER
BLINKER INDICATION.
POSITIONER + P/B COVER ASSY.
POSITIONER.
SPECIAL POT 15K
3 THERMISTOR WITH TRIPPING UNIT.
SYNCROSET + P/B ASSY.
Ref.Note 5
2
3ACDEFGHJ-
Potentiometer
23
T/LS
0PQRSTUVWXYZ-
7
Potentiometer
Fixed Resistor
16
AS3
6
Ref.Note 5
AS2
71
5
Ref.Note 6
1NO/1NC CHANGE OVER CONTACTS
6
4
AS1
41
2
5
Ref.Note 4
T/LS
5K6
Heater
ANTI CLOCKWISE TO CLOSE
BACK WIRING ON ILS
110VAC CPT
ADDITIONAL SWITCHES IN S/ MECH
230VAC CPT
THREE THERMOSTAT IN MOTOR
THERMOSTAT ON HEATER
3 T.STAT ON MOTOR + ADDL. SWITCHES
ADDITIONAL SWITCHES + T.STAT ON HEATER
3 T.STAT IN MOTOR + EXTERNAL POSITIONER
P/B ASSY + POSITIONER
SEP. 1NO+INC CHANGEOVER TQ/LT SWITCH
ADDL. SW + 3 T.STAT ON MOTOR + 110VAC
CPT
ADDL. SW. + 3 T.STAT ON MOTOR
INTEGRAL PLUG & SOCKET
P/B ASSY. +3 T.STAT ON MOTOR
ADL. CPT 1K POT
2NO2NC USED AS 1NO1NC IN ILS
IK DUAL GANG POT
P/B ASSY
P/B ASSY. + LAMP FOR CLI
P/B ASSY. + L/R INDN. SWITCH.
230VAC CPT + 3 T.STAT ON MOTOR
3 T.STAT ON MOTOR + LAMP FOR CLI
110VAC HEATER
45
46
48
55
53
54
56
57
59
60
58
49
51
52
50
22
NOTES :
1. Connect 1&2 in series with close contactor
Connect 4&5 in series with open contactor
2. Connect 1&2 in series with open contactor
Connect 5&6 in series with close contactor
3. Connect 1&2 in series with open contactor
Connect 9&10 in series with close contactor
4. 100 ohms 1 watt suitable for 50V AC/DC
operation.
61
62
63
53
54
55
56
57
58
59
60
43
44
45
46
47
48
49
50
51
52
33
34
35
36
37
38
39
40
41
42
22
23
24
25
26
27
28
29
30
31
11
12
13
14
18
19
20
1
2
3
4
8
9
5. C.P.T. connections shown for 2 wire systems,
For 3 wire systems connect 34 to +ve of supply.
6. 1watt single or dual gang pot either 2.5k suitable
for 50V AC/DC or 15k suitable for 110C AC/DC
operation. Please specify pot. value while ordering.
21
7. Code Nos. 2&4 for back wiring. Terminals shown
thus on Ref. Note. 7 are when Backwired.
U
8. ILS are independent limit switches which can be
set for any point of travel
15
16
5
6
V
64
17
7
W
32
10
E
TERMINAL BLOCK LAYOUT
Redefining Flow Control
9
Dimensional Drawings
143
448
182
317
152
492
540
Ø 610
Ø 416
Ø 457
FACE A
460
114
654
B
266
238
34
A
Ă203
Ø 203
Ø 242
Ø 260
Actuator Size
Output Speed
(rpm)
Motor Dimensions
(mm)
A
B
K4000
40
648
178
K5500
20, 30
648
178
40
756
235
20
648
178
30, 40
756
235
K7000
Bases: Note that F35E bases are integral within the above dimensions.
F35AL and F40A are external bases which bolt to Face A.
10
Dimensional Drawings
143
448
182
317
492
152
540
Ø 610
Ø 416
FACE A
A
460
114
Ø 203
654
B
238
34
Ø 457
Ø 242
Ø 203
343
Actuator Size
Output Speed
(rpm)
260
Motor Dimensions
(mm)
A
B
K4000
40
648
178
K5500
20, 30
648
178
40
756
235
20
648
178
30, 40
756
235
K7000
Bases: Note that F35E bases are integral within the above dimensions.
F35AL 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
Rotork Controls (India) PVT. LTD.,
28B Ambattur Industrial Estate (North), Chennai 600098
tel
+44 (0)1225 733200
fax
+44 (0)1225 333467
emailmail@rotork.com
tel
+91 44 3955 5600
fax
+91 44 2625 7108
emailchennai.sales@rotork.com
PUB009-001-00
Issue 03/15
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The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and
produced in the UK by Rotork Controls Limited. POWTG0315