Rotork IQT250 Actuator Troubleshooting

we have a Retork, can't recall the model.

Do you have a electrical or maintenance department, to make sure its the valve and not any utility issue.

The start checking the valve such as the sensors/limit switchs and go from there.

We already did that. Please go through my replies for rest of the comments. I have mentioned all the steps I have taken.

Please include information for the environment around the Rotork actuator. If salt spray, then look to the wiring conduit glands, and re-terminate wires after cleaning contacts.

First, you should make the call to Rotork, listen carefully, and heed their advice, especially if the actuator is still under warranty.

http://documents.tips/documents/rotorke110e.html

"Power supply and cable connections were verified to be okay". Is a common statement from a newbie....

It is very possible the above observations may cause confusions?

You did not specify where and how much power you have verified?

1. Have you measured it at the power source end but not on the driven end?

2. The power "verified" may not be real? you can at least a lamp /connect another load, to see if enough power is available to actuate the load?

3. Have you done any continuity tests?

You need to develop a systematic way of effective troubleshooting and validation!

Yes, I am pretty much a newbie. The actuator had stopped responding to the operator commands from control room. Below mentioned are the steps I followed:

1. Checked the LCD display for any alarm notifications and found none.
2. Checked the local mode operation from the actuator control panel and found that the unit is not responding.
3. Operated the valve using the actuator's hand wheel and confirmed that the valve is not jammed. This also confirmed that the limit switches are operational as open/close statuses as well as state of motion were being correctly displayed.
4. Checked the 24 VDC power supply from DDC panel and was found to be perfect.
5. Opened the cable termination chamber and confirmed availability of 24 VDC power supply in the unit. Cleaned and rewired the power and signal cables.

In order to investigate further, the setting tool is required without which it is impossible to go through data logs of the unit. We have ordered a new unit along with setting tool as an urgent replacement and the existing unit can be removed from service only after the the new one is delivered. The logs can be checked for any fault history once the setting tool is available.

Now the only part left will be the double sealed front control panel where the converters, motor control PCB and main PCB are kept. The maintenance manual clearly states that there is no field serviceable parts there and shall not be opened. Still, we would like to give it a try before sending it to the third party for repair since the warranty got expired long ago.

Getting digital meter to read voltages is nice but power integrity May not be reliable..

The next steps I would suggest if I may, is to manually simulate the expected operation of the device in question. Manually applying power instead of turning its shaft which you claimed is free and non-binding.

1. Disconnect, mark and label all wires going to the proportional valve in question.

2. Bring a fully charged portable 24 volt (battery) power supply next to the device in question.

3. Observe polarity and take note as you do the following, momentary, manually connect the portable power leads to the motor... Try as much as possible to bypass or jump any control switches, (limit, reversing, etc.) and/or sensors that are in series, going to the motor..

4. Observe for any mechanical response, like slight motor shaft movement, motor humming sound as you conduct these additional steps .....

If you can post some pictures, it will be helpful for everyone to visualize the condition..

good luck!

Will definitely try this one out. However, the actuator is powered by a switching power supply unit which is also serving 4 other similar units. We verified reliability of the faulty unit's power source by connecting with working actuators.

I work at an Airport and hence cannot share with you images of equipment because of the company's security policies. However, I am sharing some pictures of the model which I found online. Below is the link to its installation manual.

http://www.rotork.com/doc-dl/463

Rather than looking at it like some complicated electronically monitored assembly, troubleshoot it like any other motor controller you have in the plant.

It has a main power supply, reversing contactor, motor overload heaters & forward & reverse control contacts, over-torque switches that interrupt the power to the reversing contactor, a clutch switch that prevents electrical operation when the manual actuator is engaged, and end of travel limit switches that also interrupt the power to the reversing contactor. Possible internal thermal switches in the motor, look for extra small gauge wires. Open circuit = bad.

The LCD display ( a good name=Rotork) should show you what the designer thought would go bad, so you are looking for something unusual, like a wire fell off, so the control doesn't even know you are trying to do anything.

You got my point right. The LCD was supposed to display alarm notification if the fault was something the manufacturers had foreseen. It is supposed to display "MOTOR STALLED" alarm if the unit does not respond to a command, local as well as remote. But there are no alarms on display.We are waiting for the replacement unit to arrive so that we can experiment on the control module. The intention of my thread is to know whether any one else have experience a similar problem from this product.

Any time that you find an HMI (Human Machine Interface) panel/readout that is blank or unresponsive, then you know that you must first determine why. It could be power, fluid ingress, a failed pc board, etc., etc. Get the LCD to display correctly before you do anything else.

The LCD display is working perfectly. It is just that there are no alarm notifications regarding the failure displayed on it.

Dear Raj,

We have received "Motor Stalled" alarm in one of our MOV.Just tried to solve the problem.What may be the reason?

The mechanism is jammed, the motor is burned out, the limit switches are improperly set, the process conditions exceed the ratings of the MOV, etc., etc..

That list usually happens on a Friday at about 3:45

Some insight might come from knowing the method to determine Stall Condition by the motor/valve controller:

1. Motor is commanded to move, and after some time, no mechanical movement is detected, a speed switch, limit switch, tachometer.

2. Motor current stays at locked rotor value (about 5-6 times the full load current) for more than a few seconds.

A clamp on ammeter can help you troubleshoot further.

Good day! What should I do to resolve problem #2? Should I replace the power module?

I'd guess that the mechanism was locked up, you should see if you can move it by the manual override.

Also, check to make sure you have current on all 3 phases while the locked rotor condition. If one phase is open, then you will draw a lot of current in the other two, but no rotational torque to move anything.

What model are you referring to Asir? it could be the handwheel mechanism does not disengaged from manual operation when operating motor operation.

1. Best that you have the setting tool

2. Do you know the wiring diagram no.