6A Complete Electronics Assembly, Chassis, PCB’s, Transformer, Cables, 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 and Bracket only.6E Optional extra Relays and Remote Input PCB.(Positive or negative switching).6G Main PCB with Liquid Crystal Display (LCD), Fixing Ring and Screws.6H Folomatic PCB.6J Folomatic and Current Position Transmitter (CPT) combined PCB.6K CPT PCB.6L CPT and Current Torque Transmitter (CTT) combined PCB.6M Pakscan 2 Wire Control PCB.6P CTT PCB.6Q DC/DC Converter.6R Modbus PCB (normal isolation).6S Dual Modbus PCB.6W Power Module and Single Phase Starter.(IQ actuators only)6X Profibus PCB.6Y Foundation Fieldbus PCB.Module 6 Chassis and Looms CompleteFull details from the actuator nameplate must be given when enquiring about or ordering spare parts.Full details from the actuator name plate must be given when enquiring about or ordering spare partsWorkshop and Spare Parts ManualIQ, IQM and IQML Mk 2 Range Actuators Module 6 ElectronicsAll mechanical sizes. 3 phase and single phasePRINTED CIRCUIT BOARDS HAVE STATIC SENSITIVE DEVICES, AVOID TOUCHING THE BOARD, ALWAYS HANDLE BY THE EDGES.The main PCB on Module 6A and 6G is fitted with an Electrically Erasable and Programmable Read OnlyMemory (EEPROM). After fitting a new 6A or 6G Module to an actuator its EEPROM will require programming before commissioning the actuator. The following methods of achieving this are available:If details of the actuator, which can be found on theactuator nameplate are supplied when ordering the spare 6A or 6G Module the EEPROM will be programmed by Rotork to the same specification as originally supplied. Pre programmed spare PCB’s will be labelled with the actuator serial number.Alternatively if the EEPROM fitted to the original PCB is undamaged it may be fitted to the new PCB.After fitting a new Module 6 always reset the actuator travel limits and check all other Primary and Secondary settings using the instructions in Publication E170E2.Pic 71Module 6A Electronics Assembly CompleteThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Contactor Actuator Type SizeA.B.B V.B.C. 10,12,18, 20,25,35. CE15C 40,70 CE15E 90,91,95Disconnect all cables from the main PCB and any option cards fitted to it, note their positions for ease of reassembly.123 4 87652Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, fit two of these screws into the threaded holes in the cover to jack it out.Care must be taken inremoving this cover as there is an electrical cable between it and the main PCB. Disconnect the plug and socket. Retain this cover and ‘O’ ring seal for refitting.Remove Main PCBRemove the main PCB together with its mounting ring from the four chassis legs. Note itsposition relative to the gearcase to ensure corrwect alignment when refitting replacement module.Move the four chassis legs outboard towards the casting. There is no need to remove them at this stage. Take note of cable routing so that it can be refitted in exactly the same position on reassembly.Remove Optional Relay Board, if fittedTake note of plug and socket positions so that the PCB can be refitted in the same position.Disconnect Power ModuleDisconnect 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.Pic 71Pic 19Pic 81Pic 82Pic 83Pic 198Pic 226Pic 199Module 6A Electronics Assembly CompleteDisconnect plugs from sockets SK1-SK3 and SK10.This sketch gives the position ofall cable looms when powermodule is being secured to thegearcase, ensure that no cablesare trapped when tightening thefour screws. Tighten down to6.8nm (5lb/ft).9101112 161514133Remove Power Module Before removing power module take note of the cable routing so that it can be replicated when fitting replacement. Remove the four power module fixing screws.Click the four chassis legs into position. Reconnect motor cables marked U,V,W onto marked terminals on right hand contactor, connect 3 phase supply cables marked 2,3,1 to marked terminals on left hand contactor. Connect plug to socket 3 also plugs to SK1 and SK10 if used.Ensure that all heavy current power connections on the contactors are angled towards the centre of the chassis and Tyraped together.Refit Optional Relay PCB (if supplied)Position relay PCB in front of the contactors with sockets SK1 and SK4 to top left, reconnect plugs that are used. Position the four chassis legs so that the PCB is secured at its corners.Fit Replacement Power ModuleFirst check that the voltage tapping on the new item is set correctly, refer to tapping position on original item. Pic 201Pic 200Pic 201Pic 203Sketch 1Doc 584-1Pic 199Sketch 2Doc 537/01Pic 226Fitting Replacement Main PCBFirst check that replacement PCB is correctly labelled with the same serial number as that on the actuator name plate, if so then it was pre-programmed in the Rotork factory and can be fitted.If the replacement board was not ordered for a particular actuator or has been taken from another actuator then the EEPROM component on the main PCB must be transferred from the original board to its replacement.With the LCD (indication display) positioned as on original PCB, locate the four PCB clips onto the four chassis legs, these are a push and click fit.171819 232221204Using the correct tool asshown pull the EEPROM from its socket.When replacing the EEPROM ensure that the notches align on both EEPROM and socket, do not use exessive force when fitting as pins can get distorted.Reconnect PCBsReconnect all cables to main PCB and option card if fitted.Final Cable Routing CheckThe following four photographs will assist in the final check of cable routing and securing before fitting electronics cover.Top left view.Top right view.Lower left view.Pic 113Pic 114Pic 83Pic 196Pic 222Pic 223Pic 224View from above.Ensure that no cables will be damaged when the electronics cover is finally fitted.The battery is situated in its owncompartment located in thegearcase. Using an 8mm allenkey (hex wrench) remove theaccess plug.242526273029285Reconnect Electronics CoverEnsure that spigotted joint between cover and gearcase is clean, lightly greased and that the ‘O’ ring seal is serviceable. Reconnect the cable in cover onto the front of the main PCB. Refit cover locating the window over the display. Tighten down screws to 16.5nm (12lb/ft).Replace batteryWhilst the actuator is down for maintenance it is recommended that its battery be changed.The battery as fitted by Rotork is PP3 9 volt Ultralife Lithium cell, this exact type of battery MUST be fitted to all explosionproof units CENELEC/ FM/CSA.Disconnect the existing batteryand using the strap providedpull out of its plastic holder. Fitnew battery into strap and pushinto its holder, reconnect.Refit and tighten threaded plugafter lightly greasing thread andchecking sealing ‘O’ ring isserviceable.Recommission the actuatorusing Publication E170E2 andthe Rotork Infra Red SettingTool.Pic 225Pic 81Pic 19Pic 115Pic 25Pic 76Pic 28Module 6B Power PCB with transformer and chassis components (Re-using original contactor) 3 phase units onlyThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Contactor Actuator Type SizeA.B.B V.B.C. 10,12,18, 20,25,35. CE15C 40,70 CE15E 90,91,95Disconnect all cables from the main PCB and any option cards fitted to it, note their positions for ease of reassembly. Retain this item.303233 34 383736356Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, fit two of these screws into the threaded holes in the cover to jack it out.Care must be taken inremoving this cover as there is an electrical cable between it and the main PCB. Disconnect the plug and socket. Retain this cover and ‘O’ ring seal for refitting.Remove Main PCBRemove the main PCB together with its mounting ring from the four chassis legs. Note itsposition relative to the gearcase to ensure correct alignment when refitting.Move the four chassis legs outboard towards the casting,there is no need to removethem at this stage. Take note of cable routing so that it can be refitted in exactly the same position on reassembly. Retain this item.Remove Optional Relay Board if fittedTake note of plug and socket positions so that the PCB can be refitted in the same position. Retain this item.Disconnect Power ModuleDisconnect 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.Pic 203Pic 19Pic 81Pic82Pic 83Pic 198Pic 226Pic 199Module 6B Power PCB with transformer and chassis components (Re-using original contactor) 3 phase units onlyDisconnect plugs from sockets SK1-SK3-SK10.Click the four chassis legs intoposition.39404142 464544437Remove Power Module Before removing power module take note of the cable routing so that it can be replicated when fitting replacement. Remove the four power module fixing screws.Remove Contactors from original Power Module and fit replacement unitUsing a 5mm allen key (hex wrench) remove the two screws securing the contactor mounting rail onto the plastic chassis. Remove the contactors complete with rail. Refit to new item. Tighten down rail fixing screws to3.4Nm (2.5lb/ft).Fit replacement Power ModuleFirst check that the voltage tapping on the new item is set correctly, refer to tapping position on original item.This sketch gives the position ofall cable looms when powermodule is being secured to thegearcase, ensure that no cablesare trapped when tightening thefour screws. Tighten down to6.8Nm (5lb/ft).Reconnect motor cables markedU,V,W onto marked terminals onright hand contactor. Connect 3phase supply cables marked2,3,1 to marked terminals on lefthand contactor. Connect plug tosocket 3 also plugs to SK1 andSK10 if used.Ensure that all heavy currentpower connections on thecontactors are angled towardsthe centre of the chassis andTyraped together.Pic 201Sketch 2Doc 537/01 Pic 200Pic 243Sketch 1Doc 548-1Pic 199 Pic 201Pic 203Module 6B Power PCB with transformer and chassis components (Re-using original contactor) 3 phase units onlyRefit optional Relay PCB (if supplied)Position relay PCB in front of the contactors with sockets SK1 and SK4 to top left,reconnect plugs that are used. Position the four chassis legs so that the PCB is secured at its corners.Top right view.47484950 545352518Reconnect Main PCBEnsure that all looms are connected to the main PCB and any option cards fitted to it.With the LCD (indication display) positioned as on original PCB, locate the four PCB clips onto the fourchassis legs, these are a push and click fit.Final Cable routing checkThe following four photographs will assist in the final check of cable routing and securing before fitting electronics cover.Top left view.Lower left view.View from above.Ensure that no cables will be damaged when the electronics cover is finally fitted.Reconnect Electronics CoverEnsure that spigotted jointbetween cover and gearcase is clean, lightly greased and that ‘O’ ring seal is serviceable. Reconnect the cable in cover onto the front of the main PCB.Pic 226Pic 197 Pic 196Pic 222Pic 223Pic 224Pic 225Pic 81Module 6B Power PCB with transformer and chassis components (Re-using original contactor) 3 phase units onlyRefit cover locating the window over the display. Tighten down screws to 16.5Nm (12lb/ft).Recommission the actuatorusing Rotork PublicationE170E2 and Rotork Infra RedSetting Tool.55565758599Replace BatteryWhilst the actuator is down for maintenance it is recommended that its battery be changed. The battery as fitted by Rotork isPP3 9volt Ultralife Lithium Cell. This exact type of battery MUST be fitted to all explosionproof units CENELEC/FM/CSA.The battery is situated in its own compartment located in the gearcase. Using an 8mm allen key (hex wrench) remove the access plug.Disconnect the existing battery and using the strap provided pull out of its plastic holder. Fit new battery into strap and push into its holder, reconnect. Refit and tighten threaded plug after lightly greasing and checking sealing ‘O’ ring is serviceable. Pic 19Pic 115Pic 25Pic 76Pic 28Module 6C Power PCB with contactors, transformer and chassis components 3 phase units onlyThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Contactor Actuator Type SizeA.B.B V.B.C. 10,12,18, 20,25,35. CE15C 40,70 CE15E 90,91,95Disconnect all cables from the main PCB and any option cards fitted to it, note their positions for ease of reassembly. Retain this item.60616263 6766656410Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, fit two of these screws into the threaded holes in the cover to jack it out.Care must be taken inremoving this cover as there is an electrical cable between it and the main PCB. Disconnect the plug and socket. Retain this cover and ‘O’ ring seal for refitting.Remove Main PCBRemove the main PCB together with its mounting ring from the four chassis legs. Note itsposition relative to the gearcase to ensure corrwect alignment when refitting replacement module.Move the four chassis legs outboard towards the casting,there is no need to removethem at this stage. Take note of cable routing so that it can be refitted in exactly the same position on reassembly. Retain this item.Remove optional Relay Board (if fitted)Take note of plug and socket positions so that the PCB can be refitted in the same position. Retain this item.Disconnect Power ModuleDisconnect 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.Pic 203Pic 19Pic 81Pic 82Pic 83Pic 198Pic 226Pic 199Module 6C Power PCB with contactors, transformer and chassis components 3 phase units onlyDisconnect plugs from sockets SK1-SK3-SK10.This sketch gives the position ofall cable looms when powermodule is being secured to thegearcase, ensure that no cablesare trapped when tightening thefour screws. Tighten down to6.8Nm (5lb/ft).68697071 7574737211Remove Power Module Before removing power module take note of the cable routing so that it can be replicated when fitting replacement. Remove the four power module fixing screws.Fit replacement Power ModuleFirst check that the voltage tapping on the new item is set correctly, refer to tapping position on original item.Click the four chassis legs into position.Reconnect motor cablesmarked U,V,W onto markedterminals on right handcontactor. Connect 3 phasesupply cables marked 2,3,1 tomarked terminals on left handcontactor. Connect plug tosocket 3 also plugs to SK1 andSK10 if used.Ensure that all heavy currentpower connections on thecontactors are angled towardsthe centre of the chassis andTyraped together.Refit optional RelayPCB (if supplied)Position relay PCB in front ofthe contactors with sockets SK1and SK4 to top left, reconnectplugs that are used. Position thefour chassis legs so that thePCB is secured at its corners.Pic 201Pic 200Pic 201Pic 203Sketch 1Doc 548-1Pic 199Sketch 2Doc 537/01Pic 226Module 6C Power PCB with contactors, transformer and chassis components 3 phase units onlyReconnect Main PCBEnsure that all looms are connected to the main PCB and any option cards fitted to it.Lower left view.76777879 8382818012With the LCD (indication display) positioned as on original PCB, locate the four PCB clips onto the four chassis legs, these are a push and click fit.Final Cable routing checkThe following four photographs will assist in the final check of cable routing and securing before fitting electronics cover.Top left view.Top right view.View from above.Ensure that no cables will be damaged when the electronics cover is finally fitted.Reconnect Electronics CoverEnsure that spigotted jointbetween cover and gearcase is clean, lightly greased and that ‘O’ ring seal is serviceable. Reconnect the cable in cover onto the front of the main PCB.Refit cover locating the window over the display. Tighten down screws to 16.5Nm (12lb/ft).Pic 197 Pic 196Pic 222Pic 223Pic 224Pic 225Pic 81Pic 19Module 6C Power PCB with contactors, transformer and chassis components 3 phase units onlyReplace BatteryWhilst the actuator is down for maintenance it isrecommended that its battery be changed. The battery as fitted by Rotork isPP3 9volt Ultralife Lithium Cell. Thisexact type of battery MUST be fitted to all explosionproof units CENELEC/FM/CSA.8485868713The battery is situated in its own compartment located in the gearcase. Using an 8mm allen key (hex wrench) remove the access plug.Disconnect the existing battery and using the strap provided pull out of its plastic holder. Fit new battery into strap andpush into its holder, reconnect. Refit and tighten threaded plug after lightly greasing and checking sealing ‘O’ ring is serviceable.Recommission the actuator using Rotork PublicationE170E2 and Rotork Infra Red Setting Tool.Pic 115Pic 25Pic 76Pic 28Module 6D Contactor Assembly, Contactors and Brackets only, 3 phase units onlyThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Contactor Actuator Type SizeA.B.B V.B.C. 10,12,18, 20,25,35. CE15C 40,70 CE15E 90,91,95Disconnect all cables from the main PCB and any option cards fitted to it, note their positions for ease of reassembly. Retain this item.888990 91 9594939214Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, fit two of these screws into the threaded holes in the cover to jack it out.Care must be taken inremoving this cover as there is an electrical cable between it and the main PCB. Disconnect the plug and socket. Retain this cover and ‘O’ ring seal for refitting.Remove Main PCBRemove the main PCB together with its mounting ring from the four chassis legs. Note itsposition relative to the gearcase to ensure corrwect alignment when refitting replacement module.Move the four chassis legs outboard towards the casting,there is no need to removethem at this stage. Take note of cable routing so that it can be refitted in exactly the same position on reassembly.Remove Optional Relay Board (if fitted)Take note of plug and socket positions so that the PCB can be refitted in the same position.Remove and replace ContactorsDisconnect 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.Pic 210Pic 19 Pic 81Pic 82Pic 83Pic 198Pic 226Pic 199Module 6D Contactor Assembly, Contactors and Brackets only, 3 phase units onlyUsing a 5mm allen key (hex wrench) remove the two screws securing the contactor mounting rail onto the plastic chassis. Remove the contactors complete with rail. Replace with new item, tighten down rail fixing screws to3.4Nm (2.5lb/ft).lRefit optional RelayPCB (if supplied)Position relay PCB in front ofthe contactors with sockets SK1and SK4 to top left, reconnectplugs that are used. Positionthe four chassis legs so that thePCB is secured at its corners.96979899 10310210110015Reconnect all cables to replacement contactors ensuring that connections are on the correct terminals and screws are tight.If the four chassis legs were removed earlier then click them back into position. Ensure that all heavy current power connections on the contactors are angled towards the centre of the chassis and Tyraped together.Reconnect Main PCBEnsure that all looms areconnected to the main PCB andany option cards fitted to it.With the LCD (indication display)positioned as on original PCB,locate the four PCB clips ontothe four chassis legs, these area push and click fit.Final Cable routingcheckThe following four photographswill assist in the final check ofcable routing and securingbefore fitting electronics coverTop left view.Pic 200Pic 199Pic 202Sketch 2Doc 537/01Pic 226Pic 197Pic 196Pic 222Module 6D Contactor Assembly, Contactors and Brackets only, 3 phase units onlyTop right view.Refit cover locating the window over the display. Tighten down screws to 16.5Nm (12lb/ft).104105106107 11111010910816Lower left view.View from above.Ensure that no cables will be damaged when the electronics cover is finally fitted.Reconnect Electronics CoverEnsure that spigotted jointbetween cover and gearcase is clean, lightly greased and that ‘O’ ring seal is serviceable. Reconnect the cable in cover onto the front of the main PCB.Replace BatteryWhilst the actuator is down for maintenance it is recommended that its battery be changed. The battery as fitted by Rotork isPP3 9volt Ultralife Lithium Cell. This exact type of battery MUST be fitted to allexplosionproof units CENELEC/FM/CSA.The battery is situated in its own compartment located in the gearcase. Using an 8mm allen key (hex wrench) remove the access plug.Disconnect the existing battery and using the strap provided pull out of its plastic holder. Fit new battery into strap and push into its holder, reconnect. Refit and tighten threaded plug after lightly greasing and checking sealing ‘O’ ring is serviceable.Pic 223Pic 224Pic 225 Pic 81Pic 19Pic 115Pic 25Pic 76Module 6D Contactor Assembly, Contactorsand Brackets only, 3 phase units onlyRecommission the actuatorusing Rotork PublicationE170E2 and Rotork Infra RedSetting Tool.Pic 2811217Module 6E Optional extra Relays and Remote Input PCB Positive or negative switchingThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Disconnect all cables from the main PCB and any option cards fitted to it, note their positions for ease of reassembly.113 114115 116 12011911811718Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, fit two of these screws into the threaded holes in the cover to jack it out.Care must be taken inremoving this cover as there is an electrical cable between it and the main PCB. Disconnect the plug and socket. Retain this cover and ‘O’ ring seal for refitting.Remove Main PCBRemove the main PCB together with its mounting ring from the four chassis legs. Note itsposition relative to the gearcase to ensure corrwect alignment when refitting replacement module.Move the four chassis legs outboard towards the casting,there is no need to removethem at this stage. Take note of cable routing so that it can be refitted in exactly the same position on reassembly.Removal of Optional Relay Board Module 6ETake note of plug and socket positions so that the PCB can be refitted in the same position.Replace Optional Relay PCB with new itemPosition relay PCB in front of the contactors with sockets SK1 and SK4 to top left, reconnect plugs that are used. Position the four chassis legs so that the PCB is secured at its corners.Pic 70Pic 19Pic 81Pic 82Pic 83Pic 198Pic 226Pic 226Positive or negative switchingReconnect Main PCBEnsure that all looms are connected to the main PCB and any option cards fitted to it.Lower left view.121122123124 12812712612519With the LCD (indication display) positioned as on original PCB, locate the four PCB clips onto the four chassis legs, these are a push and click fit.Final Cable routing checkThe following four photographs will assist in the final check of cable routing and securing before fitting electronics cover.Top left view.Top right viewView from above.Reconnect Electronics CoverEnsure that spigotted jointbetween cover and gearcase is clean, lightly greased and that the ‘O’ ring seal is serviceable. Reconnect the cable in cover onto the front of the main PCB.Refit cover locating the window over the display. Tighten down screws to 16.5Nm (12lb/ft).Pic 197Pic 196Pic 222Pic 223Pic 224Pic 225Pic 81Pic 19Positive or negative switchingReplace BatteryWhilst the actuator is down for maintenance it isrecommended that its battery be changed. The battery as fitted by Rotork isPP3 9volt Ultralife Lithium Cell. Thisexact type of battery MUST be fitted to all explosionproof units CENELEC/FM/CSA.12913013113220The battery is situated in its own compartment located in the gearcase. Using an 8mm allen key (hex wrench) remove the access plug.Disconnect the existing battery and using the strap provided pull out of its plastic holder. Fit new battery into strap andpush into its holder, reconnect. Refit and tighten threaded plug after lightly greasing and checking sealing ‘O’ ring is serviceable.Recommission the actuator using Rotork PublicationE170E2 and Rotork Infra Red Setting Tool.Pic 115Pic 25Pic 76Pic 28Module 6G Main PCB with Liquid Crystal Display (LCD) and fixing ringThe actuator may remain in situ on the valve if required when changing out this module.First isolate the actuator from all electrical supplies.Disconnect all cables from themain PCB and any option cardsfitted to it, note their positionsfor ease of reassembly.133134135136 13913813721Remove Electronics CoverUsing a 6mm allen key (hex wrench) remove the four cap head screws securing the electronics cover, 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 main PCB. Disconnect the plug and socket. Retainthis cover and ‘O’ ring seal for refitting.Remove Main PCB Remove the main PCB together with its mounting ring from the four chassis legs. Note its position relative to the gearcase to ensure corrwect alignment when refitting replacement module.Remove Option Card iffittedDisconnect all cables from theoption card noting theirpositions, remove the fixingscrews securing option card tomain PCB and unplug card.Transfer this option card ontothe replacement PCB.Fitting replacementMain PCBFirst check that replacementPCB is correctly labelled withthe same serial number as thaton the actuator name plate, if sothen it was pre-programmed inthe Rotork factory and can befitted.If the replacement board wasnot ordered for a particularactuator or has been taken fromanother actuator then theEEPROM component on themain PCB must be transferredfrom the original board to itsreplacement.Using the correct tool as shownpull the EEPROM from itssocket.Pic 65Pic 19Pic 81Pic 82Pic 83Pic 112Pic 113。
