Key Takeaways
Subject at a glance
This article is about the Rotork IQ family of intelligent electric valve actuators and their setting tools. It explains what they do, how they are installed, and how technicians read and set them up.
Safety first
The documentation highlights safe lifting, correct mounting, certified cable entries, grounding, and careful setup before any powered movement.
Non-intrusive setup
Configuration and diagnostics happen through a sealed window using infrared or Bluetooth tools. Covers stay closed; risk stays low. [1]
Strong mechanics, smart limits
Oil-bath gearing, thrust bases, and machinable drive bushes pair with electronic position and torque limits for precise motion. [2]
Manuals as tools
Exploded assemblies, display legends, status messages, terminal layouts, and mounting drawings turn the paperwork into part of the toolkit. [2]
Story & Details
What the IQ range is for
Rotork IQ actuators automate multi-turn and part-turn valves in water, energy, and process plants. They are built for harsh sites where reliability matters every day. Sizes cover a wide torque span, with tables linking frame sizes to torque, speed, and valve couplings for correct selection. [1][2]
Each unit is a sealed package: motor, gear train, electronic limits, local controls, and a separate terminal compartment. The double-sealed layout means wiring work does not expose control electronics to weather or dust. [2]
From crate to flange
Safe handling comes first. Use proper lifting gear and respect the listed weights. Never lift by the handwheel. After positioning, align the output and stem before tightening bolts to the torque values shown for each flange size, given in newton-metres and pound-feet. For rising-stem valves, the drive bush is machined to the stem with the correct clearance so the stem can travel freely. For non-rising stems, set clean axial alignment and secure coupling engagement. Gearbox side-mounts follow the same logic. [2]
Inside the thrust base
Here torque becomes thrust. The assembly stacks a retaining plate, drive bush, O-rings, thrust bearing, spacer ring, and snap rings. Remove the bearing set and seals before machining the bush, clean out swarf, then re-grease and reassemble. Larger frames may use split collars or different spacers, but the goal is the same: carry thrust through the bearing into the base without side-loads or misalignment. [2]
Hand control and selectors
Manual operation is a core feature. A hand/auto mechanism lets the handwheel engage for safe manual movement, then disengage for motor drive. Do not add bars or keys to the wheel; that bypasses protection and can damage parts. A red Local/Stop/Remote selector and a black open/close knob define who commands movement. In Local, the knob runs the valve; in Remote, the control system does—yet the knob can still stop motion; in Stop, both are blocked. Color coding keeps roles clear. [1][2]
Displays, LEDs, and messages
The front window combines a numeric field and an analogue arc. It can show position, torque, or both. Text lines show “Opening,” “Closing,” “Stopped,” or alarm text. LEDs add quick cues: green/red for end states, yellow for in-transit or warnings, blue for communication. Alarm and battery icons appear when checks detect issues; the battery warning stays until the condition clears. Users can fix the “home” screen to position only, torque only, torque plus position, or a positioner view with demand vs. actual. [2]
Non-intrusive configuration
Setup runs through infrared or Bluetooth with a handheld tool or app. Menus guide limits, indication, torque switch bypass for commissioning, and defaults. Because covers stay closed, there is less chance of moisture ingress or contact with live parts. Advanced options live in a companion configuration manual, which assumes basic IQ familiarity and points to a separate safety manual for integrity-rated functions. [1][3][4]
Wiring, terminals, and grounding
Supply must match the nameplate. In hazardous areas, use approved cable glands, adapters, and metal blanking plugs for any spare entries. A circular terminal map shows numbered points. Power, control, feedback, positioner signals, and networks have defined terminals. Use crimp or ring lugs and tighten to the stated torque. An external earth point bonds the housing; internal earths tie metallic parts together. Never switch or fuse the protective earth. [2][4]
Ratings, approvals, and care
Product pages and manuals note ingress protection, double-sealed housings, and approvals that cover gas, vapour, and dust atmospheres, depending on variant. The gear train is factory-lubricated for long service. Routine care focuses on inspection and watching data. Rising torque at the same position or repeated alarms are early warnings. The built-in logger stores torque, position, and events for trend checks. [1][2][4]
Conclusions
Hardware and guidance in balance
Motors, gears, and thrust bases do the hard work. Displays, menus, and clear manuals make that work safe and repeatable. When both parts align, commissioning is faster and risk is lower.
Indication that reduces doubt
Large digits, an analogue arc, LEDs, and plain text alarms remove guesswork. Choosing a steady home screen—position, torque, or both—helps crews see the right signal the moment they look.
Data that pays back
The actuator is also a sensor. Logs show how a valve behaves over time. Read them well, and the plant gets early notice before a seat wears or a stem begins to bind. Quiet prevention beats noisy failure.
Sources
[1] Rotork — Electric Intelligent Actuators (IQ3 overview)
https://www.rotork.com/products/electric-intelligent-actuators/iq3
[2] Rotork — IQ Range: Safe Use, Installation, Basic Setup and Maintenance (PUB002-039-00, official PDF)
https://rcl-p-001.sitecorecontenthub.cloud/api/public/content/pub002-039-000712-pdf-rtkimportassetb743cd.pdf
[3] Rotork — IQ Full Configuration Manual (PUB002-040, official PDF)
https://rcl-p-001.sitecorecontenthub.cloud/api/public/content/pub002-040-000413-pdf-rtkimportasset5267c3.pdf
[4] Rotork — IQ Actuator Safety Manual (PUB002-057, official PDF)
https://media.rotork.com/api/public/content/pub002-057-000216-pdf-rtkimportasset5b457d.pdf
[5] Rotork (YouTube) — IQ3 Absolute Encoder and Battery (institutional overview)
https://www.youtube.com/watch?v=rMKEdL-bX8A
Appendix
Actuator
A device that turns electrical energy into controlled movement to open, close, or position a valve with defined torque and travel limits.
Battery alarm
A visual warning that the internal backup battery is low, discharged, or missing. It stays active until checks pass after replacement or power cycling.
Bluetooth setting tool
A handheld or app-based interface that connects wirelessly through the window so technicians can configure and read data without opening the enclosure.
Cable gland
A threaded fitting that seals and supports a cable where it enters an enclosure. Certified types preserve protection in wet, dusty, or hazardous areas.
Drive bush
A removable coupling in the thrust base. It is machined to match the valve stem so one actuator frame can adapt to many stems.
Handwheel
A manual wheel used for positioning when power is off or during setup. A hand/auto mechanism engages or isolates the wheel as needed.
Hazardous-area certification
Approval that a model meets rules for use where flammable gas, vapour, or dust may be present, under schemes such as ATEX and IECEx.
IQ range
Rotork’s family of intelligent electric actuators that combine gearing, local indication, non-intrusive setup, and data logging for industrial valves.
Linear drive unit
A setup that converts rotary motion into straight travel with a lead screw and yoke so the actuator can drive linear-stroke valves.
Torque switch bypass
A commissioning mode that temporarily overrides the normal torque trip so a valve can be seated fully during setup. Use with care and under control.
My Diary - Leonardo Cardillo 