Rotork S2 User manual

Rotary Actuators

with Local Remote Switch

SM-6000

Series

Installation Manual

A4 US

Redefining Flow Control

A4US

US A4

A4 US

Contents

This manual contains important safety

information. Please ensure it is thoroughly

read and understood before installing,

operating or maintaining the equipment.

Due to wide variations in the terminal

numbering of actuator products, actual

wiring of this device should follow the

PRINT SUPPLIED with the unit.

Section Page

Product Overview 3

1 - General Information 4

2 - Speciﬁcations 7

2.1 - Optional Equipment 8

3 - Installation 9

3.1 - Typical Wiring Diagram 12

3.2 - Microprocessor Based Motor 13

Drive & Controller Setup

4 - Operating your SM6000 14

4.1 - Status Description 16

4.2 - Start Up 17

4.2.1 - Select Automatic Mode 20

4.3 - Range of Operation - Setup 23

4.3.1 - Range of Operation 23

4.3.2 - Set Zero and SPAN 27

4.3.3 - Setting Limit Switches 32

4.3.4 - Operating Speed 34

5 - Setup & Calibration 36

5.1 - Setup & Calibration - Level 1 37

5.1.1 - Max Cmd Cal 38

5.1.2 - Min Cmd Cal 38

5.1.3 - Speed 39

5.1.4 - CMD Type 39

5.1.5 - LOS Act 39

5.1.6 - LOS Pos 40

5.1.7 - CUR P Gain 40

5.1.8 - CUR I Gain 40

5.1.9 - Min Pos 41

5.1.10 - Max Pos 41

5.1.11 - Max Torque % 42

5.1.12 - Save Conﬁg 42

5.2 - Communications 43

5.2.1 - HART Control Options 43

5.2.2 - PROFIBUS Control Options 45

5.2.3 - Foundation Fieldbus 47

Control Options

5.3 - Setup and Calibration - Level 2 49

5.3.1 - MOTOR PWM 50

5.3.2 - MAX TORQUE 50

5.3.3 - INPUT VOLT 50

5.3.4 - MOTOR RATE 50

5.3.5 - PASS ENBLD 50

5.3.5.1 - PASSWORD 50

5.3.6 - LOOP 50

5.3.7 - LOAD FACT DEFS 50

6 - Faults & Troubleshooting 52

6.1 - Fault Status Indication 52

6.2 - Troubleshooting 53

7 - Local Operation - Handcrank Direction 54

8 - Mounting Conversion 55

9 - Parts Identiﬁcation 56

10 - Drive Arm Dimensions 59

11 - Overall Dimensions 60

12 - Linkage Options 61

13 - User Settings 62

Notes 63

Section Page

A4US

US A4

A4 US

Redefining Flow Control

Figure 1.0. SM6000-S2 actuator

Rotork Process Controls designs and

manufactures high quality, durable actuators

designed for trouble-free performance under the

most demanding conditions.

With its field-proven design, the SM-6000 S2 is a perfect fit

for all of your high performance requirements. The SM-6000

S2 Series are rotary actuators internally geared to produce

up to 26,000 ft. lbs. (35,251 Nm) of torque at unrestricted,

continuous modulating duty.

These actuators are ideally suited for dampers, vanes, valves

and other process control applications requiring high speed,

high torque and exact positioning control.

The SM-6000 S2 actuator features a menu-driven non-

intrusive setup using control knobs and vacuum fluorescent

display.

These controls are also used to programme the internally

mounted digital amplifier.

Features

•From 25º to 120º rotation.

•Torque range up to 35,256 Nm

(26,000 lbf-ft).

•Double ‘O’ ring sealing.

•Continuous unrestricted

modulating duty.

•Temperature range from -40 to +85 ºC

(-40 to +185 ºF).

•Automatic torque limiting.

•Self-locking drive system to hold in last

position and prevent backdriving.

•Manual override standard.

•HART, Profibus and Foundation

Fieldbus available.

Product Overview

A4US

US A4

A4 US

INTRODUCTION

Rotork Process Controls designs, manufactures, and

tests its products to meet national and International

standards. For these products to operate within their normal

specifications, they must be properly installed and maintained.

The following instructions must be followed

and integrated with your safety program when installing,

using, and maintaining Rotork Process Controls products:

Read and save all instructions prior to installing, operating,

and servicing this product. If any of the instructions are

not understood, contact your Rotork Process Controls

representative for clarification.

Follow all warnings, cautions, and instructions marked

on, and supplied with, the product. Inform and educate

personnel in the proper installation, operation, and

maintenance of the product.

Install equipment as specified in Rotork Process Controls

installation instructions and per applicable local and national

codes. Connect all products to the proper electrical sources.

To ensure proper performance, use qualified personnel to

install, operate, update, tune, and maintain the product.

When replacement parts are required, ensure that the

qualified service technician uses replacement parts

specified by Rotork Process Controls. Substitutions may

result in fire, electrical shock, other hazards, or improper

equipment operation.

WARNING

Before installing the actuator, make sure that it is suitable

for the intended application. If you are unsure, consult

Rotork Process Controls prior to proceeding.

WARNING - SHOCK HAZARD

Installation and servicing must be performed only by

qualified personnel.

WARNING ELECTROSTATIC DISCHARGE

This electronic control is static-sensitive. To protect the

internal components from damage, never touch the

printed circuit cards without using electrostatic discharge

(ESD) control procedures.

RECEIVING / INSPECTION

Carefully inspect for shipping damage. Damage to the

shipping carton is usually a good indication that it has

received rough handling. Report all damage immediately to

the freight carrier and Rotork Process Controls, Inc.

Unpack the product and information packet - taking care to

save the shipping carton and any packing material should

return be necessary. Verify that the items on the packing list

or bill of lading agree with your own.

STORAGE

If the actuator will not be installed immediately, it should

be stored indoors in a clean, dry area where the ambient

temperature is not less than -20° F. The actuator should

be stored in a non-corrosive environment. The actuator is

not sealed to NEMA 4 until the conduit entries are properly

connected.

1 - General Information

A4US

US A4

A4 US

Redefining Flow Control

1 - General Information

EQUIPMENT RETURN

A Returned Goods authorization (RG) number is required to

return any equipment for repair. This must be obtained from

Rotork Process Controls. (Telephone: 414/461-9200) The

equipment must be shipped, freight prepaid, to the following

address after the RG number is issued:

Rotork Process Controls, Inc.

5607 West Douglas Avenue

Milwaukee, Wisconsin 53218

Attn: Service Department

To facilitate quick return and handling of your equipment,

include:

1. RG Number on outside of box

2. Your Company Name, Contact Name, Phone/Fax

3. Address

4. Repair Purchase Order Number

5. Brief description of the problem

IDENTIFICATION LABEL

An identiﬁcation label is attached to each actuator. When

ordering parts, requesting information or service assistance,

please provide all of the label information. YOU MUST

SUPPLY THE SERIAL NUMBER WITH ALL ENQUIRIES.

ABBREVIATIONS USED IN THIS MANUAL

A Ampere

AC Alternating Current

°C Degrees Celsius

CW Clockwise

ACW Anti-clockwise

CCW Counter-clockwise

DC Direct Current

°F Degrees Fahrenheit

G Earth Ground

Hz Hertz

in. lbs Inch Pounds

kg Kilogram

L Line (power supply)

lbs Pounds Force

LVDT Linear Variable Differential Transformer

mA Milliamp

mfd Microfarad

mm Millimeters

N Newton (force)

NEMA National Electrical Manufacturing Association

Nm Newton Meter

NPT National Pipe Thread

PCB Printed Circuit Board

PH Phase

PL Position Limit switch

RPM Revolutions per Minute

SEC Second

SPDT Single Pole Double Throw

TL Torque Limit Switch

V Volts

VA Volt Amps

VAC Volts AC

VDC Volts DC

VFD Vacuum Fluorescent Display

VR Variable Resistance

W Watt

Figure 1.1. Actuator identiﬁcation label.

A4US

US A4

A4 US

1 - General Information

GENERAL DESCRIPTION, ACTUATOR

The SM-6000 is an AC input, DC driven electric actuator

designed for high modulation service. This actuator uses a

Rotork Process Controls locally mounted, or remotely located

microprocessor- based motor drive and controller. A wide

array of standard options are available for this actuator.

The SM-6000 Series actuators provide the highest speed,

torque, modulation rate, and positioning accuracy of any

electric actuator in the Rotork Process Controls product line.

With the standard control electronics, they are self-contained

automatic positioning devices capable of moving the largest

loads at speeds typical of electrohydraulic devices, and with

an unrestricted modulation rating. These high-performance

actuators are electrically controlled, self-contained, high

speed, high torque devices. With essentially unlimited

rotational travel, they provide a superior solution for any

modern actuation application.

The SM-6000 is designed using an all steel gear train

submersed in an oil bath, and conservatively rated bearings.

This design assures the longest possible life while reducing

the risk of costly repairs and unscheduled maintenance.

An internally mounted electronic controller converts AC

power input to DC power.

The DC power is then controlled by a microprocessor based

digital servo amplifier that efficiently controls speed and

torque of the drive motor.

The motor drives through high efficiency helical bevel gearing

that provides smooth and quiet operation at rated load

indefinitely in the event of power loss or shutoff.

A holding brake at the rear of the motor will hold the full

rated load in the last position until power is restored. The

holding brake is always in the released state whenever power

is applied to the actuator. It is an electrically released, spring

set type holding brake. The brake is constantly in a stand-by

mode, and does not stop the motor. The motor does the

braking electrically, so there is no wear on the brake because

the brake is only holding, and not stopping the load. The load

is always supported by the motor, even when the command

input is not changing.

A local override handcrank at the rear of the motor can

be used to manually position the load when power is

interrupted.

The SM-6000 is well equipped with popular standard

features, and a wide variety of standard options are available

to suit most applications.

Special factory supplied options and designs are also available.

Figure 1.2. SM6000-S2 actuator.

A4US

US A4

A4 US

Redefining Flow Control

2 - Speciﬁcations

• Rotation: 25º

120º.

• Duty Cycle: Unlimited and unrestricted continuous duty.

• Temperature: -40 to 185 °F (-40 to 85 °C). A high

temperature version to 225 °F (107 °C) is available.

• Environment Ratings: NEMA Type 4 (IP65).

• Lubrication Type: Synthetic oil bath.

• Oil Change Interval: 20 years for normal operation,

10 years for extreme operation.

• Gearing: All steel bevel and helical gearing.

• Hold on Loss of Power: Spring locking brake.

• Mounting: Conventional foot mounted.

• Anti-Condensation Heater: 120 or 240 VAC, 30 Watt

with thermostat set for 110 °F (43.3 °C).

• Torque Limit: Adjustable from 1 to 200% of rated

torque. Warning: continued operation of unit in excess

of rated load will damage the actuator and connected

equipment.

• Positioning Accuracy: 0.1% of 90°.

• Position Limit Switches: Two single pole double throw

(SPDT) switches for end of travel use, rating: 20 amp,

120/240 VAC resistive load.

• Feedback: Absolute Encoder.

• Local Controls & Display: Front cover mounted control

knobs and Vacuum Fluorescent Display (VFD).

• Command Signal Input: 4-20 mA, 0-5 VDC or

0-10 VDC.

• Position Transmitter: 4-20 mA transmitter used to

remotely track actuator position when power is available

to the actuator. Requires separate 24 VDC loop-power

supply for operation.

• Terminations: Screw type terminals accepting up to

#14 AWG wire.

• Mounting Orientation: Left hand, right hand

or vertical.

RH LH

Figure 2.1. Left and right hand mounting orientation.

Output

Torque

Output

Speed

Shift

Time Input Power

Volts/Ph/Hz

Current Draw (A)

at 240 VAC Input

Actuator

Weight

Output Shaft

Diameter

ft. lb. (Nm) (RPM) (sec/90°) Running Stall lbs. kg inch mm

370 (502) 1.50 10 120-240/1-3/50-60/3@120 2 6 186 85 1.25 31.75

550 (746) 1.50 10 120-240/1-3/50-60/4@120 2 6 186 85 1.25 31.75

800 (1085) 1.56 10 120-240/1-3/50-60/5@120 3 9 204 93 1.375 34.925

1400 (1898) 1.52 10 120-240/1-3/50-60/8@120 4 12 254 115 1.75 44.45

2500 (3389) 1.57 10 120-240/1-3/50-60/12@120 6 12 403 183 2.375 60.325

4400 (5965) 1.65 10 240/1-3/50-60/7 7 12 613 279 2.875 73.025

6200 (8406) 1.56 10 240/1-3/50-60/8 8 12 956 435 3.625 92.075

8000 (10846) 1.19 12 240/1-3/50-60/12 12 12 1589 722 4.375 111.125

11000 (14914) 0.86 18 240/1-3/50-60/12 12 12 1589 722 4.375 111.125

16500 (22371) 0.58 26 240/1-3/50-60/12 12 12 2196 998 4.75 120.65

26000 (36540 0.36 42 240/1-3/50-60/12 12 12 3453 1570 5.5 139.7

A4US

US A4

A4 US

2.1 - Optional Equipment

• Performance: Faster speeds are available.

Consult factory.

• Drive Arm: Steel, for dimensions see section 10.

• Mechanical Stops: A plate that bolts to the front of the

actuator and limits drive arm movement is available

• Relays: Customer usable relay contacts are available to

detect: loss of feedback, loss of command signal, loss of

power or overtorque (stall).

• 1000 Ohm Potentiometer: Allows for ambient

temperature to 225 °F (107 °C). Requires remote

control enclosure.

Other options may be limited, consult factory.

• Auxiliary Position Limit Switches:

20 Amp, 120/240 VAC resistive load, (Quantity, 2-4)

5 Amp, 125 VDC resistive load, (Quantity, 2-4)

3 Amp, 250 VDC resistive load, (Quantity, 2-4)

• 2P + ST: Adds a second, tandem mounted feedback

potentiometer and one ST-4130 loop powered transmitter

assembly inside the electrical enclosure.

Requires separate 24 VDC power supply for operation,

or specify ST-4110 for sourced 4-20 mA operation.

• Pluggable Connections: Pluggable connectors on the

control enclosure for quick-disconnection using Cannon

style connectors. Typically used for remote mounted

control enclosure applications.

• Input Power: Internally mounted transformer to allow

operation on other input voltages. Standard optional

Input voltages are 480 VAC, 575 VAC. A 120 VA to 240

VAC step-up transformer is also available for applications

using 180 VDC motors when only 120 VAC input power

is available.

• Transitional Adapter Mounting Bases: Matches

SM-6000 to existing actuator footprint in the field for

replacement applications. Consult factory.

• High Temperature: Optional for ambient temperature to

225 °F (107 °C). Requires remote control enclosure. Other

options may be limited, consult factory.

• Linkage Adapter/Clevis Kit: Used to connect drive

arm to driven load for linkage applications. Includes two

clevises, two adjustment rods with lock nuts, two pipe

adapters, two pins for clevises.

A4US

US A4

A4 US

Redefining Flow Control

3 - Installation

INSTALLATION NOTES

CAUTION

READ ALL INSTRUCTIONS CAREFULLY BEFORE STARTING

THE INSTALLATION IN ORDER TO ACCUSTOM YOURSELF

WITH THIS EQUIPMENT. FOLLOW ALL INSTRUCTIONS

DURING THE INSTALLATION. DO NOT APPLY POWER UNTIL

TOLD TO DO SO OR PERMANENT DAMAGE CAN RESULT.

1. Use care whenever carrying, setting, or working around

the actuator. This is a precision piece of equipment that

will be permanently damaged if dropped or mistreated

during handling. Damage due to abuse or mishandling is

not covered by the factory warranty.

2. The installation site must have environmental conditions

compatible with the actuator design. Do not use this

product in temperatures higher than the design allows,

or in explosive environments if it is not rated accordingly.

To maintain the environmental ratings, all covers must be

tightly closed at all times. All cover fittings must be used

and fastened securely. Using a 3/16’’ Hex key, remove the

four capscrews securing the terminal compartment cover

(Fig. 3.1). The actuator is supplied with a wiring diagram,

certificate of conformance and terminal fixings stored in

the terminal compartment area (Fig 3.2 and Fig 3.3).

3. Read the actuator nameplate located on the outside of

the unit. It will reference a specific wiring diagram. Refer

to the wiring diagram to identify functions of terminals

(Fig. 3.2). Check that the supply voltage is the same as

that marked on the actuator nameplate. That diagram

MUST be used for wiring this product. Run wires as

indicated, but DO NOT apply power until later. To prevent

electrical noise pickup, power and signal wires must be

routed through separate metallic conduit and the signal

wires must also be shielded and the shield grounded (Fig.

3.1. A,B,C,D).

For actuators where the control enclosure must be

located away from the actuator, do not exceed a wire

run distance of fifty feet between the actuator and

the control enclosure.

When all connections are made, replace the wiring

diagram in the terminal compartment.

4. Replace Terminal Cover Ensure cover o-ring seal and

joint are in good condition and lightly greased before re-

fitting cover. Seal any unused conduit entries with metal

plugs (Fig. 3.4. C,D).

Figure 3.1. Terminal compartment cover

Figure 3.2. Terminal compartment.

Figure 3.3. Terminal ﬁxings.

Figure 3.4.

A B

A4US

US A4

A4 US

3 - Installation cont.

5. The actuator must be securely anchored to a rigid

foundation before any load is applied to the output

shaft. All of the actuator mounting holes designed for

anchoring must have a bolt or stud, which should be of

the largest size that fits in the mounting hole (Fig. 3.5. A).

6. The drive arm (if used) should be attached to the actuator

output shaft using the hardware supplied. The drive arm

has a hole to attach the linkage to the load. This linkage

should be connected to the drive arm with a flexible

rod-end to accommodate misalignment, and the rod-end

must be sized for approximately twice the actuator full

load rating (Fig. 3.5. B).

7. The actuator is designed to withstand the rigors of

industrial environments. To maintain the environmental

ratings, all cover fixings must be used and fastened

securely (Fig. 3.6).

Mounting:

The outline and mounting dimensions for a standard unit

are shown in this manual. Sufficient room to remove the

cover should be provided for servicing and upgrade.

Orientation:

The unit is oil filled and must be mounted in the

configuration ordered. When mounting the unit, be sure

that no excessive axial or side loading is applied to the

output shaft.

Output Drive Shaft:

The limit switches and position feedback are directly

connected to the output shaft. Positively secure the

output to the driven load shaft to prevent slippage, which

would cause misalignment or damage.

Local Overide:

When local override is required, push in handcrank

(Fig 3.7) and turn the crank in the appropriate direction

for the desired output shaft movement. Note: Do not

force handcrank if there is an obstruction as excessive

torque will be generated at the output shaft. The load or

actuator may be damaged as a result.

CAUTION - LOCAL OPERATION

WITH RESPECT TO HAND CRANK OPERATION OF

SM6000 SERIES ELECTRIC ACTUATORS, UNDER NO

CIRCUMSTANCES SHOULD ANY ADDITIONAL LEVER

DEVICE SUCH AS A WHEEL-KEY OR WRENCH BE APPLIED

TO THE HAND CRANK MECHANISM IN ORDER TO

DEVELOP MORE FORCE WHEN MOVING THE ACTUATOR

IN EITHER DIRECTION AS THIS MAY CAUSE DAMAGE

TO ACTUATED DEVICE, ASSOCIATED LINKAGES OR

ACTUATOR ITSELF.

Figure 3.5.

Figure 3.6.

Figure 3.7.

Table of contents

Other rotork Controllers manuals

rotork

rotork K-TORK Series Installation and operating instructions

rotork

rotork CML-250 Installation and operating instructions

rotork

rotork Remote Control Series User manual

rotork

rotork IQ Series User manual

rotork

rotork IQT Series User manual

rotork

rotork IQ70 F25 B4 Quick guide

rotork

rotork FAIRCHILD PAX1 User manual

rotork

rotork gp series Instruction Manual

rotork

rotork YT-200 Series User manual

rotork

rotork GPSA Series User manual

rotork

rotork Skilmatic SI 3 Quick guide

rotork

rotork LP/S Series Operating instructions

rotork

rotork CK Series User manual

rotork

rotork Profibus Modbus Module Mk2 User manual

rotork

rotork CK Series Technical specifications

rotork

rotork CK Atronik Series User guide

rotork

rotork IQ3 Range Quick guide

rotork

rotork Bifold EHPC210 Use and care manual

rotork

rotork CML Series Installation and operating instructions

rotork

rotork FAIRCHILD PAX1 User manual

rotork

rotork CK Series User guide

rotork

rotork IQ Range User manual

rotork

rotork YT-200 Series User manual

rotork

rotork Skilmatic SI Series User manual

Popular Controllers manuals by other brands

Digiplex

Digiplex DGP-848 Programming guide

YASKAWA

YASKAWA SGM series user manual

Sinope

Sinope Calypso RM3500ZB installation guide

Isimet

Isimet DLA Series Style 2 Installation, Operations, Start-up and Maintenance Instructions

LSIS

LSIS sv-ip5a user manual

Rockwell Automation

Rockwell Automation 1769-L31 installation instructions

Airflow

Airflow Uno hab Installation and operating instructions

ABB

ABB ACS580-01 drives Hardware manual

Panasonic

Panasonic GM1 Series Reference manual

Emerson

Emerson SW93 owner's manual

AutoAqua

AutoAqua Smart ATO micro SATO-120P manual

Panasonic

Panasonic FP? Positioning Unit RTEX Technical manual

Samson

Samson Type 5824 Mounting and operating instructions

Alpha IP

Alpha IP MIOB 21001 manual

Siemens

Siemens OpenAir GMA 1 Series Mounting instructions

Surecom

Surecom SR-629 user manual

Fishman

Fishman TriplePlay installation guide

Regulus

Regulus SRS1 T Installation and operation manual

rotork S2 User manual

Popular Controllers manuals by other brands