Workshop and Spare Parts Manual for

IQ, IQM and IQML Mk 2 Range Actuators

Pic 3

Module 2 Bases & Drive Nuts

Sizes 10-35

Pic 2

Module 1 Gearcase

Pic 12

Pic 8

Module 7 Terminal Bung

Pic 11

Module 2 Drive Nuts

Sizes 40-95

Module 11 Comprehensive
Spares Kit
Pic 1

Pic 4

Pic 7

Module 4 Handwheel

Pic 5

Module 5 Motor

Module 20 Electronics Cover

Pic 71

Module 6 Electronics

Pic 9

Module 55 Terminal Cover

Health and Safety

This manual is produced to enable
a competent user to install,
operate, adjust and inspect Rotork
IQ range valve actuators.
The electrical installation,
maintenance and use of these
actuators should be carried out in
accordance with the National
Legislation and Statutory
Provisions relating to the safe use
of this equipment, applicable to the
site of installation.
For the UK: Electricity at Work
Regulations 1989 and the
guidance given in the applicable
edition of IEE Wiring Regulations
should be applied. Also the user
should be fully aware of his duties
under the Health and Safety Act
1974.
For the USA: NFPA70, National
Electrical Code is applicable..

Before starting work on

actuator
The Rotork spare parts module
sheets, contained in this manual,
give detailed instructions on the
removal and replacement of
modules.
Before commencing work, isolate
all electrical supplies to the
actuator and observe site safety
regulations.
On completion of repair, refer to
publication E170E2 for
commissioning and start up
procedures.

The mechanical installation should

be carried out as outlined in the
manual and also in accordance
with relevant standards such as
British Standard Codes of
Practice.
If the actuator has nameplates
indicating that it is suitable for
installation in Hazardous Gas
Areas then the actuator is suitable
for use in Zone 1 and Zone 2 (or
Div.1 and Div.2) explosive
atmospheres where gasses are
present with an ignition
temperature less than 135oC,
unless suitability for lower ignition
temperatures has been indicated
on the actuator nameplate.
Any test instruments applied to the
actuator should be of equivalent
certification. The electrical
installation , maintenance and the
use of these actuators should be
carried out in accordance with the
Remember that your actuator is
only as watertight or
explosionproof as you make it,
after completeing work. Conduit
entries should be sealed in
accordance with surrounding
environment and with any
requirements of the regulatory
authority.
Seal unused entries with threaded
metal plugs. Do not use plastic
plugs if supplied with the actuator,
as these are purely to protect the
actuator during transit.
For ease of dismantling-The
Rotork IQ tool kit is available.

code of practice relevant for that

particular Hazardous Gas Area
certification.
No inspection or repair should be
undertaken unless it comforms to
the specific Hazardous Gas Area
certification requirements. Under
no circumstances should any
modification or alteration be
carried out on the actuator as this
could invalidate the conditions
under which its certification was
granted.
Access to live electrical
conductors is forbidden in the
hazardous area unless this is
done under a special permit to
work, otherwise all power should
be isolated and the actuator
moved to a non hazardous area
for repair or attention.

should be allowed to install,

maintain and repair Rotork
actuators. Work undertaken must
be carried out in accordance with
instructions in the manual. The
user and those persons working
on this equipment should be
familiar with their responsibilities
under ant statutory provisions
relating to the Health and Safety
of their workplace.

WARNING
Motor Temperature
With excessive use the motor
surface temperature could reach
132oC (270oF).

Only persons competent by virtue

of thier training or experience

Recommended spares
holding

Ordering of spare parts

It is essential when ordering a
spares module to give the
actuator type and serial
number.
Additional information obtained
from the actuator name plate
would be helpful to enable Rotork
to double check the actuator
specification.

It is difficult for Rotork to make

recommendations for stocking
spare parts, as customer
requirements obviously differ
according to their individual
company policy. Howerver we
make the following
recommendations for use as a
guide only.

Spares modules may be ordered

from your local representative,
valve supplier, or direct from
Rotork.

Spares module assemblies for each size of actuator

Module Number

Description
1-10

Module 1
GEARCASE
1A
Gearcase, Resolver PCB, Centre Column, Wormshaft & Wormwheel, Torque Transducer
1B
Centre Column, Clutch Assembly, Resolver Drive Mechanism
1C
Resolver Drive Mechanism, PCB, Oil Seals, Drive Shaft Gears
1D
Wormshaft & Wormwheel, Oil Seals, Circlip & Fixing Screws etc.
1E
Wormshaft & Wormwheel Maintenance Kit, O Rings, Seals, Bearings, Screws etc.
1F
Gearcase Maintenance Kit, O Rings, Seals, Bearings, Circlips, Screws etc.
1G
Hand/Auto Mechanism, Lever, Cam, Spring, Seal
1H
Resolver PCB & Fixing Screws
1H/1 Resolver Magnet, Clip & Spring
1J
Torque Transducer
1K
Battery Removal Strap, Cover Plug
1K/1 Battery only
1L
Battery Cover Plug only

1
1
2
1
1
1
2
2
2

Quantity of Actuators
11-49

2
2
5
2
2
2
1
5
5
5

50+

1
1
1
5
5
10
5
5
5
2
5
5
5

Spares module assemblies for each size of actuator

Module Number

Description
1-10

Quantity of Actuators
11-49

50+

Module 2
Bases
2A
Base Assembly Complete, Castings, Bearing, Drive Bush, Seals, Screws. Sizes 10 to 35
2A
Drive Bush & Retainer. Sizes 40 to 95
2B
Base Casting(s), Screws. Sizes 10 to 35
2B
Drive Bush only. Sizes 40 to 95
2C
Drive Bush only. Sizes 10 to 35
2D
Thrust Bearing Assembly only. Sizes 10 to 35
2E
Drive Bush & Thrust Bearing Assembly. Sizes 10 to 35
2F
Base Maintenance Kit.

1
1
1
1
1
1
2

2
3
1
3
3
2
3
3

Module 4
Handwheel
4A
Top Handwheel - Complete.
4B/1 Side Handwheel - Complete.
4B/2 Side Handwheel & Spur Box Complete.
4C/1 Top Handwheel Maintenance Kit.
4C/2 Side Handwheel Maintenance Kit.

1
1

1
1
1
2
2

Module 5
Motor
5A
Stator/Rotor Assembly, Motor Cover, Bearing, Screws & O Ring.
5B
Stator/Rotor Maintenance Kit, Bearing, Screws & O Ring.

1
-

2
1

5
2

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2

5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5

Module 6/2
Electronics for IQM & IQML Actuators
6T
Power Module for Solid State Starter (SSS).
6U
Solid State Starter.
6V
Optional Remote Input PCB, Negative Switching.

1
1
1

2
2
2

5
5
5

Electronics for IQ Single Phase

Power Module & Single Phase Starter.

Module 7
Terminal Bung
7A
Terminal Bung, Cable Looms, Watertight/WT & Explosionproof.
7B
Commissioning Bag, Terminal Screws & Washers, O Ring Seal.

1
2

1
5

1
8

Module 11
Comprehensive Spares Kit
Comprised of all components in kits 1E, 1F, 2F, 4C/1, 4C/2, 5B & 55C.

1
1
1
1
1
1

2
1
1
1
1
1

5
2
2
2
2
2

2
1

1
5
2

1
8
5

Module 6/1
Electronics
6A
Complete Electronics Assembly, Chassis, PCBs, Transformer, Cable Looms,
Contactors, Fixings.
6B
Electronic Chassis Assembly Power 1, Power PCB with Transformer.
6C
Electronic Chassis Assembly Power 2, as Module 6B plus Contactors.
6D
Contactor Assembly, Contactors & Bracket only.
6E
Optional extra Relays & Remote Input PCB, Positive or Negative Switching.
6G
Main PCB with Liquid Crystal Display (LCD), PCB, Fixing Ring & Screws.
6H
Folomatic PCB.
6J
Folomatic & Current Position Transformer (CPT) Combined PCB.
6K
CPT PCB.
6L
CPT & Current Torque Transmitter (CTT) Conbined PCB.
6M
Pakscan 2 Wire Control PCB.
6P
CTT only PCB.
6Q
DC/DC Convertor PCB.
6R
Modbus PCB.
6S
Dual Modbus PCB.
6X
Profibus PCB.
6Y
Foundation Fieldbus PCB.

6W

Module 20
Electronics Cover
20A
Electronics Cover Complete, Control Knobs, Local Control PCB, Plastic Window,
Enclosures, Watertight, Explosionproof, CENELEC, FM & CSA.
20B
Local Control PCB, Looms & Screws.
20C
Open/Close Knob (Black), Return Spring & Clip.
20D
Local/Stop/Remote Knob (Red), Fixing Clip.
20G
Locking Latch Assembly.
20H
Both Local Control Knobs.
20J
Plastic Window (Watertight Enclosure only).
Module 55
Electrical Covers
55A
Terminal Cover, Fixing Screws, O Ring , Label.
55C
Terminal Cover Screws & O Ring Seal.
Electronics Cover Screws & O Ring Seal.