Workshop and Spare Parts Manual

IQ Mk 3 Range Actuators
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.
Publication 002-047-00 issue 06/13

Module 1C
Encoder Drive shaft, fixings and seals.

Module 1C Encoder Drive Shaft Assembly

Full details from the actuator name plate must be given when enquiring about or ordering spare parts
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.
The actuator may remain in situ
on the valve if required when
changing out this module.
WARNING
First isolate the
actuator from all
electrical supplies.
Remove Electronics
Cover
Using a 6mm allen key (hex
wrench) remove the four cap
head screws securing the
electronics cover.
If necessary fit two of these
screws into the threaded holes
in the cover to jack it out.
Care must be taken in
removing this cover as there is
an electrical cable between it
and the Logic Control PCB.
Disconnect the plug and
socket. Retain this cover and
‘O’ ring seal for fitting to the
new Gearcase Assembly.
Remove Main PCB
Disconnect the ribbon cable
located on the right hand side
of chassis from the Logic
Control PCB to the power
supply module.
Disconnect any cables and
looms connected to the top of
the Logic Control PCB and any
Option cards if fitted.
Publication 002-047-00 issue 06/13
Locate the two retaining clips
on either side of the chassis
mounts.
Depress the clips and carefully
remove the Logic Control PCB
together with its mounting ring
from the two chassis retaining
legs.
Position the two legs to the
sides to aid removal.
Note its position relative to the
gearcase to ensure correct
alignment when refitting
replacement module.
Move the two chassis legs
outboard towards the casting.
There is no need to remove
them at this stage.
Take note of cable routeing so
that it can be refitted in exactly
the same position on
reassembly.
Disconnect all remaining cables
from the Logic Control PCB and
any option cards fitted to it, note
their positions for ease of
reassembly.
Retain for fitting to the new
Gearcase Assembly.
Push back the two chassis
legs .
The legs may be removed from
the chassis at this stage.
Disconnect Power
Module (3 Phase)
Disconnect all cables going onto
the contactors taking note of
their positions:-
3 Phase Power marked 1-2-3.
3 Phase Motor marked U-V-W.
Coils marked C1-C2-CC.
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Disconnect Power Lift the module carefully away

from the gearcase.
Module (Single
Phase) Note: that there are cables
connected to the rear of the
Disconnect all cables going assembly.
from the terminal
compartment to the
capacitors and solid state Disconnect any looms connected
start relay taking note of to SKT 2 & SKT 4
their positions.

Remove Power
Remove the loom connected to
Module the Encoder.
Before removing power
module take note of the
cable routeing so that it can
be replicated when fitting
replacement.

Using a 5mm Allen wrench Using a 5 mm Allen wrench

locate and remove the five locate and remove two encoder
power module fixing screws. fixing screws.
The encoder can now be
withdrawn from the gearcase.

Note WARNING

IQ Sizes 40 to 95 Before removing the

Encoder drive shaft the
The contactor size is larger
however the removal gearbox oil must first be
procedure is the same. drained.
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Drain Oil Check that the condition of the

‘O’ Ring and the sealing face is
To drain the oil, remove the two satisfactory.
plugs situated in the gearcase. Renew if necessary.

The top or side hand wheel

assembly can also be removed
to facilitate draining and refilling
of the oil.

Remove Cover Tube or Remove Top Handwheel

Hub Sealing Cap Assembly (if fitted)
(if fitted)
Remove the fixing screws
The top or side handwheel locating the side handwheel hub
assembly should be fitted with assembly to the gearcase.
a Cover Tube or Sealing Cap to
help prevent ingress of moisture
To the centre column area.

Top Handwheel
Assembly Using suitable pliers remove the
circlip securing the encoder drive
shaft.
Locate and remove the 3 fixing
screws locating the cover tube
or blanking cap to the gearcase.

Remove Top Handwheel

Holding the end of the shaft
Assembly (if fitted) withdraw the shaft , oil seal and
bronze bush from the gearcase.
Remove the fixing screws
locating the handwheel hub
assembly to the gearcase.
Module 1C Encoder Drive Shaft Assembly All mechanical
Publication sizes.
002-047-00 issue 11/12

Publication 002-047-00 issue 06/13

Lightly grease the replacement Carefully refit Top or Side

encoder shaft , bronze bush handwheel assembly ensuring
and oil seal before assembly. ‘O’ ring is in position .

Slide the components in to Tighten down fixings with 6mm

place taking care not to damage Allen (hex wrench).
the oil seal.

Refit Encoder
Assembly

Secure the Encoder shaft It is important to align

assembly with a new circlip. the encoder drive shaft
with the input socket.

Refit Drain Plugs.

Fill Gearbox With Oil Refit the Encoder loom to the

socket on top of the assembly.
Before fitting hand drive fill
gearcase with fresh oil through
the hand drive aperture, ensure Locate the Encoder in position
all oil drain plugs are sealed, and using a 5 mm Allen wrench
that the sliding clutch coupling tighten the two fixings to 0.5Nm.
is down in the drive position and
bring the oil level up to the top
of the clutch but no higher.

Oil Capacities
IQ sizes Litres US Pints
10,12,18 0.5 1
20,25 1 2.1
35 1.5 3.2
40,70,90,91,95 3 6.3 Refit Power Module

Refit Top Handwheel Before securing the power

Check the condition of the ‘O’
ring is serviceable. And sealing
face is satisfactory.
module into position locate the
cables into their correct area.
Lift the module carefully into
position in the gearcase.

Note: that there are cables

connected to the rear of the
assembly.
Module 1C Encoder Drive Shaft Assembly All mechanical
Publication sizes.
002-047-00 issue 11/12

Publication 002-047-00 issue 06/13

Using a 5mm Allen wrench

Reonnect all remaining cables
locate and tighten screws
to the Logic Control PCB and
ensuring no cables are
any option cards fitted to it, note
trapped , tighten down fixing
their original positions.
screws to 11Nm (8lb/ft).

Refit 3 Phase Power

Module

Note

IQ Sizes 40 to 95
Take care to route the cables in
The contactor size is larger
their original positions.
however the replacement
procedure is the same.
Locate the two retaining clips
on either side of the chassis
Reconnect motor cables
mounting legs.
marked U, V, W onto marked
terminals on right hand
Carefully relocate the logic
contactor. Connect 3 phase
control PCB into position and
supply cables marked 2, 3, 1 to
snap the retaining clips into
marked terminal on left hand
position.
contactor.

Reconnect the ribbon cable

Reconnect Power located on the right hand side of
Module (Single Phase) the chassis from the logic
control PCB to the power
Reconnect all cables going from module.
the terminal compartment to the
capacitors and solid state start
relay taking note of their
original positions.

Refit Electronics cover

First check the spigotted joint is

Reconnect Main PCB
If legs have been removed
relocate onto chassis plate.
Close mounting legs back to
centre position.
clean ,lightly greased and the
‘O’ ring seal is serviceable.
Connect the cable loom from
HMI PCB to logic control PCB.
Refit cover taking care not to
trap any cables.

Using a 6mm Allen key (hex

wrench) tighten 4 screws to
16.5Nm (12lb/ft).
Module 1C Encoder Drive Shaft Assembly All mechanical sizes.

Publication 002-047-00 issue 06/13

Replace battery
Disconnect the existing battery and using the strap
provided pull out of its plastic holder.
Whilst the actuator is down for
maintenance it is recommended
Fit new battery into strap and push into its holder,
that its battery be changed.
reconnect.
The battery as fitted by Rotork
is generally a PP3 9 volt
Refit and tighten threaded plug after lightly greasing
Ultralife Lithium cell.
thread and checking sealing ‘O’ ring is serviceable.
For Hazardous area certified
units ONLY approved battery
types must be used.

See Below for Approved Battery

Types

BATTERY TYPES

For European hazardous area certified actuators (ATEX / IEC Ex) use a
lithium manganese dioxide battery as stated in Table 1 BELOW.

For FM and CSA certified enclosures use an Ultralife U9VL lithium

manganese dioxide battery. Equivalent, UL recognised, batteries may
be used.

For watertight (WT) actuator enclosures Rotork recommend a lithium

manganese dioxide battery, however any equivalent 9V battery may be
used.

If in doubt regarding the correct battery type, contact Rotork.

Table 1

Enclosure Type Battery Type Detail

ATEX/IEC Ex Ultralife PP3 U9VL or
Standard Temp Types U9VL-J-P Recommission the actuator using Publication Pub 002-039-00 and
the Rotork Bluetooth Setting Tool.
ATEX/IEC Ex Rotork Part Numbers 95-462 or
Low/High Temp 95-614

The battery is situated in its

own compartment located in the
gearcase.

Using an 8mm allen key (hex

wrench) remove the access
plug.