User Manual QT4000
Contents
1. ELTORQUE User Manual QT4000 Electrical Part turn Valve Actuator Revision Date 29 09 2014 Author Bjorn Nybrodahl Q ELTORQUE User Manual QT4000 Revision history number date by EE SS S i Referenced documentation Technical Manual Eltorque Interfaces QT2500 4000 Eltorque Manager 3 Manual Rev 2 Page 2 of 27 Q ELTORQUE User Manual QT4000 TABLE OF CONTENTS Wes OT OTIS 4 2 Specifications and manual operation n rvnnnrnnnvennnnnnnnnennnnnnnnnennnnennnnennnnennnnennnnennnnennnnr 5 2 1 Technical data 5 22 PN CU CHO METTE EST T T TT TT 6 23 OPEN oe Tel 10 E 7 ZEE reilitedeliimi E 7 25 MANNA 9 3 MENS FAN AU OU Le 10 3 1 Mounting actuator on KU 10 SSC due INS E e MR T E EErEE ERr DEn 11 3 3 Configuration of actuator eene nennen nennen nnns 13 9 4 Selecting correct configuration sicco aoo E se geEebee see 15 4 Maintenance service and troubleshooting esses 17 ETE TET 17 4 2 MEAT NN 17 4 3 Internal WINING nennen nnns nnn nnn nennen nnns 18 2 internace replacement den 19 Se Keel Die Lee e EN TTE TET 20 9 AE 21 S1 TEN 21 o2 TET NON 23 e Sne E case ee es tse t 23 54 Control system E le 24 Contact information Eltorque AS N 7125 Vanvikan Norway Phone 47 74 85 55 20 Fax 47 74 85 55 12 Web www eltorque com2. EE m L N and PE GND S terminals Ze E TIT TENES VA 4 Install the control signal cables through the cable glands on the left and connect them according to specification below Fig 9 Connection terminals location Rev 2 Page 11 of 27 ELTORQUE CANopen interface terminals 1 Signal GND 2 CAN H 3 CAN L 4 Bridge with 2 for terminal resistor e TE S Configuration connector EE e x A f ine gt TE Fig 10 QT4000 control interface terminals User Manual QT4000 Control Interface functionality cable recommendations etc is described in the Technical Manual Eltorque Interfaces Hev 2 Page 12 of 27 e ELTO ROQUE User Manual QT4000 3 3 Configuration of actuator The QT4000 actuator is configured electronically using the Eltorque Manager 3 software and a USB configuration cable Manager 3 is distributed by e mail or can be downloaded from our website while the configuration cable can be purchased from local Eltorque distributor or the head office in Norway See page 1 for contact information The following parameters can be configured End positions Closed and Open Speed Torque and Near Closed region Fieldbus address Node ID for CANopen and Modbus Invertion of input and output for Digital and Analogue End positions and fieldbus address are mandatory while the other parameters can be
3. 4 11 12 13 2 seede I RCS Te EN E A ES 4 Dimensions SJ 5 EG AG CONG IOC a NR E E E E E A E EE EE OE E M 6 BV 4 10 Internal construction rervnrnnnnnnnrnavnnnennnnnnnvnnnennnnnnnnnnvnnnnnennnnnavnnnnnennnnnennnnnnennunnennnnnnenennnenne 15 FETE reg O a EA 4 15 Mese EE EE NN EN NN 11 12 Manual operation ccccceccceccseeceeeceeceeceeeseeeeeeceeeseeeseeseeeseeseuesaeeseessueeaueseeeseeeseeeges 5 8 18 DOWER CONSUMPIIO danzas aate E ent aa na 4 7 PONT SUDD ee 6 10 16 17 18 replaceable Componente nennen nennen nena nnne nnns nnne nnn nn 15 100 1 10 P 5 7 18 KOKO LOLS 4 5 9 18 I 4 5 6 7 8 9 11 12 18 20 21 Rev 2 Page 23 of 27 QELTORQUE User Manual QT4000 5 4 Control system examples Operator Station 17 touch monitor compact PC Mounted in PLC cabinet door Master panel ETHERNET Digital IO PUMP 1 CAN OPEN Pump control Start stop command PUMP 2 Started stopped feedback Failure feedback Power supply 230VAC 50 60Hz CAN OPEN Fig 22 Stand alone valve and pump control with operator stations Rev 2 Page 24 of 27 QELTORQUE User Manual QT4000 ETHERNET Ethernet to CANopen Converter for Valve Control Power supply Power supply 230VAC 50 60Hz CANopen 230VAC 50 60Hz serial power 7 z m z serial power Loo
4. Rev 2 Page 3 of 27 Q ELTORQUE User Manual QT4000 1 INTRODUCTION Eltorque offers a model range of electric valve actuators suitable for use in a wide variety of industrial environments The Eltorque actuators are characterized by Compact size and good torque to size weight ratio Flexible control interfaces for easy integration with a wide range of control systems Low power consumption Electronic configuration of speed torque and other parameters Easy and cost effective installation Maintenance free The QT4000 is suitable for use on part turn valves with an operating torque between 2500 and 4000 Nm Most part turn valves utilize quarter turn 90 movement but the QT4000 can easily be configured to an operation area within the range 0 359 During the purchasing process it is important to consider the following parameters Valve interface It must be checked that the spindle and valve mounting holes either fit directly onto the actuator or alternatively consider spindle adapters and valve brackets The QT4000 has replaceable guidance ring and valve adapter which can be customized to fit directly onto most valves Max operation torque The actuator must have sufficient torque to operate the valve in all applicable conditions The QT4000 s maximum torque will decrease below 4000 Nm at motor speeds above 120 rom but speed can be set lower and torque higher in the valve s near closed region Closing time This is usually dete
5. is blocked by e g foreign objects inside pipe On butterfly valves the maximum torque is required to move disc in and out of gasket Hence should only the torque in the near closed region be set according to the valve s specified operation torque Torque in the travel area will be considerably lower Ball valves tend to have a constant torque through the whole operation area but the maximum torque is reached when the valve movement starts so called breakaway torque The actual operation torque of the valve can be checked by attaching a torque wrench with measuring gauge to the manual operation shaft of the actuator The shaft has a 12x12 mm square on the end hence can a standard 72 pipe socket fit onto it Torque wrench must have a torque range of at least 0 10 Nm and accuracy of 0 25 Nm Output torque is calculated by multiplying measured torque with a factor of 452 i e 9 0 Nm corresponds to 4000 Nm Rev 2 Page 15 of 27 QELTORQUE User Manual QT4000 9 7 100955 area nat configurable Fixed accel decelaration ramp Torque is the same as in the travel area Status Open h p S00 1600 2400 3200 4000 Speed 50 100 150 200 rpm Max torque at 200 rpm is 3200 Nm e ME Running and holding torque options Near closed area Configurable 0 20 Closed tolerance Configurable 0 10 1 A Status Closed 5 d Running and holding torque options 1600 2400 3200 40
6. manual operation above and around it 1 2 Apply grease on valve spindle to ease mounting and avoid corrosion Lift actuator onto valve utilizing the 3 lifting devices on the actuator s center flange Align valve spindle with valve adapter and lower actuator onto valve flange Note Keep hands away from the valve flanges to avoid crushing damages Use crank handle on manual operation shaft to turn actuator and align fastening holes of the valve flanges Note In order to achieve optimal functionality of valve position indicator actuator should be positioned as shown on Fig 5 Insert valve fastening screws and if applicable lock washers Tighten fastening screws to the specified torque Rev 2 Page 10 of 27 User Manual QT4000 Fig 6 QT4000 on valve Fig 7 Position adjustment e ELTQ ROQUE User Manual QT4000 3 2 Electrical installation Electrical installation can only be designed and made by personnel with the appropriate skills and competence Ensure all such work is done according to applicable laws and regulations 1 Loosen the top cover fastening screws 2 Remove actuator s top cover to gain access to connection terminals Fig 8 Removing top cover Make sure fuses are disconnected before connection of power supply cables is started rm dh 3 Install the power supply t d i5 EC S cables through the cable S glands on the right side MIE EEE y e and connect them to the dem
7. screw 3 4 turns Fig 20 Interface fastening screw 4 Pull the interface slightly towards the outer housing and then lift it straight up 5 Toreplace interface follow step 1 4 in opposite order The interface is equipped with 2 guiding pins in the bottom These needs to align with the holes in the position sensor holder during replacement Em wen ll N ES NE S Fig 20 Interface removal Fig 19 Interface guiding holes 6 Re configure actuator as described in section O Rev 2 Page 19 of 27 ELTORQUE 4 5 Troubleshooting Problem description No light in indicator LED No response from actuator on the control system Indicator LED is Red The actuator does not respond to control signals On a fieldbus system the actuator gives torque alarm Indicator LED is Red The actuator responds normally to control signals On a fieldbus system the actuator gives temperature alarm Indicator LED is Red The actuator does not respond to control signals On a fieldbus system the actuator gives temperature alarm Indicator LED is Red The actuator attempts to move valve when a control signal is given On a fieldbus system the actuator gives torque alarm Indicator LED is normal The actuator does not respond to control signals On a fieldbus system the actuator is not available Rev 2 User Manual QT4000 Cause amp solution No power supply check fuses and wirin
8. 00 Rm speed 50 100 150 rpm Fig 14 Torque speed and region settings Under Fieldbus settings you can set the Node ID of actuators with CANopen or Modbus Control Interface It is important that all actuators in the network have a unique Node ID and that it is set correctly according to the layout of the control system Incase the actuator has Analogue or Digital interface the Fieldbus settings will be replaced by settings related to calibration and invention of input and output signals Rev 2 Page 16 of 27 e ELTQ RQUE User Manual QT4000 4 MAINTENANCE SERVICE AND TROUBLESHOOTING 4 1 Maintenance The QT4000 is in principle maintenance free all bearings and gears are lifetime lubricated and components are designed to last throughout the actuator s lifetime It is however recommended that the actuator is inspected regularly to reveal any damages caused by mechanical impact corrosion etc Top cover gasket and manual operation shaft seal should be lubricated with suitable lubricants if they appear to be dry 4 2 Internal construction All replaceable components are located inside the actuator s motor and electronics housing Remove the top cover to provide easy access to replaceable components Fig 16 Removing top cover Rev 2 Page 17 of 27 e ELTQ ROQUE User Manual QT4000 Component overview 1 Control interface and connection terminals Position sensor below interface AC DC Power supply Interface pow
9. are met Operating temperature is kept within specified limits Actuator is placed indoors and not exposed to direct sunlight Protected from extensive corrosive atmospheres like on open deck of ships or other areas exposed to salt water spray Cleaning with strong alkaline or acidic chemicals can also cause corrosion problems Actuator must not be placed in hazardous areas where the presence of explosive atmospheres might cause explosion hazard 2 4 Actuator duty type When electric valve actuators operate they generate internal heat due to thermal loss in motor and control electronics The QT4000 combines low power consumption with high efficiency to ensure that internal thermal loss is kept low otill duty cycle needs to be considered when designing the valve control system to ensure that the actuators can operate the valves without over heating In case the actuator s internal temperature becomes too high it will send out an alarm signal via the control interface Should the temperature continue to rise the actuator will shut down the motor until temperature decreases to a safe level To avoid problems with over temperature alarms and actuator shutting down duty cycle requirements should be considered before selecting actuator P lclose trest loos trest Loos Valve position I Time Fig 3 Open Close and positioning duty Actuators used for Open Close duty either open or close the valves intermediat
10. changed to achieve better valve control performance 1 Install Eltorque Manager 3 and if Manager 3 required driver for configuration cable Driver Installation file on your computer 2 S A CDM setup Manager3 setup version 3 1 4 msi 2 Connect configuration cable to a USB port on your computer 3 Start Manager 3 4 Connect cable to Actuator s configuration connector Make sure actuator has power and that the indicator LED is lit before attempting to connect actuator with Eltorque Manager 3 Fig 12 Connection of configuration cable Rev 2 Page 13 of 27 e ELTQ RQUE User Manual QT4000 5 Press Connect to establish communication with the actuator 6 Select appropriate configuration values depending on valve and control system see section 3 4 for more information 7 Use Crank Handle to move actuator and valve to closed position Press Set C amp O and Closed is set to the actual position while Open is set 90 away in counter clockwise direction If further adjustment of end positions are required move actuator to desired position and press Set Closed or Set Open 8 Press Hall Disable and Open to move valve to open position 9 Press Close to close valve again 10 Disconnect configuration cable and refit top cover 11 Check that indicator LED changes from Red to Yellow when top cover is in place CEJEItorque Manager 3 4 6 Oy EN ELTORQUE Configuration Advanced History Internal A
11. ctuator information Actuator type OT4000MT Interface LAN pen DW version 1 0 3 Compiled 14 11 12 8 54 33 Serial nn 1 SFI na 277 rd A E Fos D aa Quick settings lenc 1023 Emergency Speed normal range rpm 100 Templ 29 C e s 29 C Torque normal Nm 4000 Ke Speed near closed rpm ZU Torque near closed Mm 4000 AN In Near closed region 4 15 Set Configure J___ _ 6 ap sew Torque ot Closing time 97 41 s C AMNOpen settings NN TUN UL mes Node id B gee Baudrate 5 ETE m Select all Load file 14 41 54 COM 29 opened 14 42 05 Tongue normal 50 14 42 08 Tongue normal 37 14 42 15 Torque lim closed 70 14 42 27 MID CFG SERIAL 1 Fig 13 Eltorque Manager 3 screenshot For more information about the functionality of the software please refer to the Eltorque Manager 3 Manual Rev 2 Page 14 of 27 Q ELTORQUE User Manual QT4000 3 4 Selecting correct configuration The Q14000 offers an easy but advanced configuration set up which allows accurate adjustments depending on valve and control system characteristics Please consider the following items when selecting configuration values The actuator s output torque is limited to 4000 Nm for motor speeds above 150 rpm Set torque values according to valve s torque specifications with a suitable safety margin If torque is set too high the valve might be damaged in case it
12. e positions are not approached The valves are rarely operated and the interval between operations may be a few minutes or even several months Open Close duty will be relevant for QT4000 actuators with Digital control interface Actuators used for positioning duty will approach defined intermediate positions to set a static flow through a pipeline applicable positions also include Open and Closed Positioning duty will be relevant for QT4000 actuators with Analogue or Fieldbus Interface For both these duty types the same maximum continuous running time tclose Or tpos is 5 minutes followed by a rest period trest of minimum 5 minutes Rev 2 Page 7 of 27 Q ELTORQUE User Manual QT4000 trest tmod pr Valve position 4 Time Fig 4 Modulating duty Modulating duty applies for actuators used on control valves where accurate and quick control of flow level temperature etc is desired The actuators will be controlled automatically by a regulator or PLC depending on process data from sensors like flow meters level and temperature sensors and some applications might require valve position adjustments within intervals of a few seconds This kind of operation puts higher demand on the actuator in terms of accuracy wear resistance low internal heat generation and good heat dissipation Modulating duty is relevant for QT4000 with Analogue or Fieldbus Interfaces Running time for modulating duty is limited by th
13. e relative on time tmoa trest lt 0 5 The duty type limitations stated above applies for maximum operation temperature and torque see section 2 1 If operating temperatures and or torque are lower the actuator can be operated more than the duty type limitations stated above Rev 2 Page 8 of 27 Q ELTORQUE User Manual QT4000 2 5 Manual operation In case of power failure control system error or another fault preventing normal operation of the actuator it can be operated manually without the need of additional tools 1 Unscrew and remove Manual Operation shaft cover 2 Loosen the spring spline holding the crank handle 3 Attach crank handle on MO shaft 4 Turn Clockwise to close or Counter clockwise to open valve Valve position can be seen on the visual indicator in the center of the actuator s top cover 5 When MO is completed remove crank handle and refit it onto its holder 6 Refit spring spline and MO shaft cover NB Max 9 Nm Note The actuator has a sensor Fig 5 Manual operation which is sensing that the MO shaft cover is removed Actuator cannot be operated remotely until the cover is replaced and tightened against the top cover The actuator s indicator LED will be Red when cover is removed and motor current will be switched off Rev 2 Page 9 of 27 ELTORQUE 3 INSTALLATION 3 1 Mounting actuator on valve Before mounting actuator please make sure there is sufficient space for
14. er supply connector Interface motor connector Bracket PSU amp Motor Motor with manual operation shaft LED Hall sensor PCB Valve position indicator 110 240 V AC DC connection een Fig 17 Internal components 4 3 Internal wiring LED and hall sensor ecc A PSU 1 PSU 2 40V 40V 150W 150W HR dd 3 Position sensor 80 V 40V CONTROL INTERFACE GND Fig 18 QT4000 connection schematics Rev 2 Page 18 of 27 e ELTO ROQUE User Manual QT4000 Connection schematics explanation 1 LED and Hall sensor is connected to Control Interface via a 5 pole cable with contacts in both ends 2 Position sensor is connected to Control Interface via a 5 pole cable but with a 6 pole contact 3 The actuator has 2 power supplies of 40V 150 W each These are connected in series to supply 80V to the motor The Control Interface itself is powered by 40V taken from one of the power supplies 4 Both power supplies get supply voltage from the same connection terminals 4 4 Interface replacement The QT4000 has a modular design and it is possible to convert from one type of control to another simply by replacing the control interface 1 Remove top cover as described in section 5 2 Disconnect the interface from the power Supply motor position sensor and LED Hall sensor PCB 3 Loosen the interface fastening
15. er turn valves with a 90 degrees movement between Closed and Open position An electric device for operation of valves in various process control Valve actuator systems The surface of the valve which the actuator is fastened to Most Valve flange commonly it is holes for 4 screws where hole size and distance between them is defined in EN ISO 5211 standard Valve adapter Electronic device controlling the valve actuator according to signals Sie from an overall control system e g PLC or other type of electronic Interface controller The set up of parameters which affects the actuator s performance Configuration and behavior TA Area in which the permanent or periodical presence of explosive substances causes a risk of explosion A Programmable Logic Controller is a digital computer used for automation of industrial processes such as control of machinery on factory assembly lines measurement and control of process plants etc oimple control utilizing relays on off switches and indicators Allows only Open or Closed functionality for a valve actuator otep less control utilizing analogue current or voltage signals e g 4 20 mA 0 10 V etc Allows positioning of the valve actuator between Open and Closed A fieldbus is an industrial computer network for real time distributed control of various devices including valve actuators When Eltorque valve actuators are controlled by Fieldbus the functionality is extended in ter
16. g Supply voltage can be checked using a voltage meter L N voltage should be 110 240 V AC or DC Voltage on Interface power supply connector should be 40V on black blue wires and 80V on black red wires Press measurement probes into the connector grooves to obtain easy access to current conducting metal Fig 21 Interface power supply connector Manual operation shaft cover not in position Actuator s internal temperature is 10 C or less from the motor current shut down limit If possible allow actuator to cool down by leaving it in standby mode for 15 minutes or more Actuator has over heated and the motor current is shut down to prevent damage Make sure surrounding temperature is within limits and that the duty type requirements are followed See section 2 for more details Valve operation torque is too high please check torque by manual operation OR Actuator torque has been set too low increase it by using Eltorque Manager 3 as described in section 0 Faulty control system please ask system vendor for support OR Problem with control signal wiring please contact local Eltorque agent for support Page 20 of 27 Q ELTORQUE User Manual QT4000 5 APPENDIX 5 1 Terminology Term A valve is a device that regulates the flow of materials gases fluidized solids slurries or liquids by opening closing or partially Valve obstructing various passageways This manual mostly refers to quart
17. ion otator coils utilized as heating elements in case of low temperatures Manual override without tools max 9 Nm torque 100 turns on crank handle 90 movement on valve Configurable using Eltorque Manager Software Guidance ring and valve adapter can be customized on request Control interfaces Manual operation Fig 1 External measurements Rev 2 Page 5 of 27 a ELTQ RQUE User Manual QT4000 2 2 External construction a Joe Rev 2 Guidance ring fastening screws Guidance ring with valve flange Valve spindle adapter Lifting devices max 80 kg load each Motor and electronics housing Front view Gear housing Cable glands for control signal cables Cable glands for power supply cables otatus indicator light Hed Alarm Yellow 2 Standby Closed Blinking 2 Closing Green Standby Open Blinking Opening Green short flash Standby Positioned Red Yellow Green sequence Actuator is re booting Cover for manual operation shaft Valve position indicator Top cover Crank handle for manual operation Bottom view Fig 2 External construction Page 6 of 27 Q ELTORQUE User Manual QT4000 2 3 Operating conditions The Q14000 is especially suitable for use below deck on ships and other offshore vessels due to its compact design low power consumption and robust construction It can also be used in other applications as long as the following criteria
18. ms of positioning commands feedback and configuration The Eltorque Modbus interface is using RS 485 serial communication utilizing the Modbus protocol Modbus is a fieldbus which allows communication with max 31 actuators connected to the same master slave network Master slave means that the Modbus controller is a master which actively sends commands and requests to the slave actuators PLC Digital Control Analogue Control Fieldbus Control Modbus Rev 2 Page 21 of 27 Q ELTORQUE User Manual QT4000 CANopen Rev 2 The Eltorque CANopen interface is using the CAN Controller Area Network communications standard CANopen is a fieldbus which allows communication between max 127 actuators connected to the same network It is not a master slave network ref Modbus hence all nodes in the network can actively send messages at their own initiative The communication is prioritized meaning that urgent messages are transmitted and received before information with lower priority Compared to Modbus CANopen has the following advantages e More reliable communication i e it is more likely that the information transmitted is received correctly by the recipient e More nodes pr network max 127 e More control and configuration features available Page 22 of 27 Q ELTORQUE User Manual QT4000 5 2 Ordering information 5 3 Index Closing lu E 4 5 veto
19. p 1A Loop 1B ME le Loop 2A Loop 2B Loop 3A Loop 3B Loop 4A Loop 4B Fig 23 Valve control system as an integrated part of a larger control system Rev 2 Page 25 of 27 Q ELTORQUE User Manual QT4000 Notes Rev 2 Page 26 of 27
20. rmined as a part of the process development In some cases the closing time should be as short as possible if the valve for example is shutting down a system in case of failure In other cases it is desired with a longer closing time to avoid shock waves in pipe systems with high pressure or flow Remote Control The QT4000 can be controlled remotely by four different types of control Digital Open Close Analogue 4 20 mA Modbus Fieldbus max 31 actuators per network CANopen Fieldbus max 127 actuators per network For more details about the functionality of these Control Interfaces refer to the Technical Manual Control interfaces for Eltorque QT4000 Valve actuators Additionally the actuator can be configured and controlled from a standard computer using a dedicated cable and software tool Eltorque Manager 3 Rev 2 Page 4 of 27 QELTORQUE User Manual QT4000 2 SPECIFICATIONS AND MANUAL OPERATION 2 1 Technical data Pa QT74000 Weight 0 69kgincl Valve Adapter and Guidance ring Encapsulation IP68 5m 1 hr i Corrosion protected aluminium and steel enclosure Operation temperature 25 55 C Black Digital Open Close Analogue 4 20 mA CANopen and Modbus Fieldbus oa Range 360 0 4 resolution EEN Position feedback not corrupted by power failure 110 240 V AC DC 50 60 Hz Max 480VA Over under temperature Motor current Is switched off in case of over temperature protect
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