I-Tork ELECTRIC ACTUATOR

RPC (Remote Position Controller)

USER’S MANUAL
Installation & Operation

MODEL : RPC-07-A
(2011. JULY)

i-Tork Controls Co., Ltd.

74-6, Chunui-Dong, Wonmi-Gu, Bucheon-Si, Kyunggi-Do,
Korea
TEL : +82-2-855-1365 FAX : +82-2-855-1367
Website : http://www.i-tork.com E-Mail : [email protected]

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Table of Contents
1. CHECKPOINTS PRIOR TO USE & NOTICE FOR WIRING
2. SYNOPSIS
3. STANDARD SPECIFICATIONS
4. MAIN FUNCTIONS & HOW TO USE
1) INPUT SIGNAL SELECTION
2) INPUT SIGNAL SET-UP & CHANGE (CH1)
3) SIGNAL FAIL SAFE POSITION
4) DELAY TIME (Motor Recess Time Set-Up when running in reverse direction)
5) DEAD BAND (Tolerance Set-Up)
6) HOW TO MANUALLY OPERATE WITH BUTTONS
7) A-FULL (Functions) SET-UP
8) AUTO SETTING (A-SCAN)
9) MANUAL SET-UP (CH2)
10) ADJUSTMENT OF OUTPUT
11) REV: How-To-Use when Actuator and Valve/Damper are in opposite direction
12) HOW TO CHECK LED STATUS
5. TOOLS REQUIRED
6. POTENTIOMETER SET-UP
7. LIMIT SWITCH SET-UP
8. HOW TO CHECK RPC OPERATION
9. RPC LAY-OUT
10. LCD LAY-OUT (Optional)
11. HOW TO REPLACE RPC
12. ELECTRICITY WIRING DIAGRAM
1) ITQ0080-70500-F (1PH)
2) ITQ0100-70500-F (1PH)
3) ITQ0160-70500-F (1PH)
4) ITQ0160-80500-F (3PH)
5) ITQ0160-84500-F (1PH / MCC : Built-In)
6) ITQ0160-90500-F (24V DC)
7) ITQ0160-96500-F (DC 24V/MCC built in)
8) ICMQ0160-81500-F (3PH / INTEGRAL / DISPLAY : LED / MCC built in)
9) ICMQ0160-82500-F (3PH / INTEGRAL / DISPLAY : LCD / MCC built in)

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Many thanks for purchasing our ITQ series electric actuator.

For safe and proper operation, please carefully read this manual prior to use and keep this
manual for further reference.
Important Notice: Due to the purpose of quality improvement, the contents in this manual
are subject to change without any prior notice.

1. CHECKPOINTS PRIOR TO USE & NOTICE FOR WIRING

1) Ensure the specifications (Model No. Main power, Control power, Options) of delivered
actuator meet your requirements.
2) Ensure the application such as butterfly, ball valves and Damper etc. meet your
equipment.
3) Ensure mounting of actuator on the application is correct and tight.
4) Ensure the settings of actuator such as limit switches, stopper bolts and indicator are
correct.
5) Ensure electric wiring (Power, input/output signal) is correct.
6) Never do disassembly, modification
7) Do not perform wiring job in wet conditions
8) Always disconnect the power before carrying out electrical wiring.
9) If 3Ph Power is used, ensure wiring is correct
10) In case of 3-phase motor, must check rotating direction first before normal operation.
A. Open actuator about 50% by manual, supply power to actuator for about 5
seconds. Push CLOSE button and check whether actuator moves toward close
direction or not.
B. If yes, it is OK.
C. In case of reverse direction, cut the power supply to Actuator and ensure phase
wiring is correct
11) Generally, output signal is set by factory before delivery and no need to set. If you
change CAM, reset the output signal.
12) Disassembly, modification without factory‟s consent may affect the performance of the
actuator, and i-Tork does not guarantee.
13) Actuator‟s shape, wiring diagram and the contents in this manual are subject to change
due to quality improvement without individual notice.

2. SYNOPSIS
As RPC (Remote Position Controller) is a controller dedicated for ratio-control system, it is
possible to provide Open/Close contact for forward/backward rotation comparing current
position value of the equipment and input signal since 12-bit A/D converter and 8-bit
microprocessor are used. Also, it shows/outputs current position value with the current values

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in range of 4 to 20mA as well.

3. STANDARD SPECIFICATIONS
1) Model : RPC-07-A
2) Power : 1Ph, 85~265VAC, 50/60Hz, Free Voltage (Option : AC/DC 24V)
3) Input Signal : 4-20mA DC / 1-5V DC / 2-10V DC / 0-5V DC / 0-10V DC
4) Input Resistance : 250Ω
5) Feed Back Potentiometer : 1KΩ
6) Output Signal : 4-20mA DC (SOURCE TYPE)
7) Load Resistance : Max. 750 Ω
8) Number of Output Contact : 2EA (Open Relay & Close Relay)
9) Motor Recess Time when running reverse direction (Delay Time)
1.0~8.5sec (0.5sec/1step, 0~15 Step)
10) Tolerance (Dead Band) : 0.1~4.5% (0.3%/1step, 0~15 Step)
11) Position Conversion Accuracy : ±0.5% ~ ±1.5% (might depend on circumstance)
12) Signal Fail Safe : Close / Open / Stop
13) Resolution : Min 1/1000
14) Ambient Temperature : -10℃~60℃ (Surface of RPC board)
15) Ambient Humidity : 90% RH Max (Non-Condensing)
16) Dielectric Strength Test : 1800VAC, 1Second (Input to Output, Power to GND)
17) Insulation Resistance : 500VDC more than 100MΩ
18) Vibration & Shock Test : (Axis: X, Y, Z) 10g (6g based on RMF), Frequencies: 0.2~34Hz,
less than 180min.

4. MAIN FUNCTIONS & HOW TO USE

1) INPUT SIGNAL SELECTION : According to the type of user‟s input signal, users can simply
set up input signal with Dip Switch set-up only.

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1 2 3

4~20mA DC ON OFF OFF

2~10V DC OFF ON OFF

0~5V DC OFF OFF ON

0~10V DC OFF ON ON

1~5V DC OFF OFF OFF

2) INPUT SIGNAL SET-UP & CHANGE (CH1)

ZERO SPAN

A. Input Signal Set-Up (Input : 4~20mA)

a. Input Signal Selection is ON-OFF-OFF (4~20mA DC)
b. After put the CH1 Dip Switch “ON”, please check if the POWER LED (White) light
goes in and out.
c. Input „Close‟ value (4mA), and please press “ZERO (Blank)” button until those LED
such as FAULT (Yellow), CLOSE (green), and OPEN (Red) blink twice, then please
put the hand off the “ZERO” button.
d. Input „Open‟ value (20mA), and press “SPAN (Gray)” button until those LED FAULT,
CLOSE, and OPEN blink twice, then please put the hand off the “SPAN” button.
e. Once input signal setup completed, please confirm if POWER (White) LED light is
„ON‟ after getting the „CH1 Dip Switch‟ off for sure.
f. Please enter input signal and check out if it is normally operated.
B. Input Signal Set-Up (other than 4 / 20mA)
a. When you want set up CLOSE 3~8mA, OPEN 16~21mA, please follow this.
b. Input Signal Selection is ON-OFF-OFF (4~20mA DC)
c. After put the CH1 Dip Switch “ON”, please check if the POWER LED (White) light
goes in and out.
d. Input „Close‟ value (3~8mA, user wants), and please press “ZERO (Blank)” button
until those LED such as FAULT (Yellow), CLOSE (green), and OPEN (Red) blink
twice, then please put the hand off the “ZERO” button.
e. Input „Open‟ value (16~21mA, user wants), and press “SPAN (Gray)” button until

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those LED FAULT, CLOSE, and OPEN blink twice, then please put the hand off the
“SPAN” button.
f. Once input signal setup completed, please confirm if POWER (White) LED light is
„ON‟ after getting the „CH1 Dip Switch‟ off for sure.
g. Please enter input signal and check out if it is normally operated.
C. Change input signal into different kind (e.g. From 4~20mA DC to 0~10V DC)
a. Input Signal Selection is OFF-ON-ON (0~10V DC)
b. After put the CH1 Dip Switch “ON”, please check if the POWER LED (White) light
goes in and out.
c. Input „Close‟ value (0V DC), and please press “ZERO (Blank)” button until those
LED such as FAULT (Yellow), CLOSE (green), and OPEN (Red) blink twice, then
please put the hand off the “ZERO” button.
d. Input „Open‟ value (10V DC), and press “SPAN (Gray)” button until those LED
FAULT, CLOSE, and OPEN blink twice, then please put the hand off the “SPAN”
button.
e. Once input signal setup completed, please confirm if POWER (White) LED light is
„ON‟ after getting the „CH1 Dip Switch‟ off for sure.
f. Please enter input signal and check out if it is normally operated.
g. When you want to change Input signals (e.g. 2~10VDC, 1~5VDC, 0~5VDC),
please select “Input Signal Selection” switch for right signal, and do “b.”~”f.”
h. When Input signal select is 0~5V DC or 0 ~ 10V DC, RPC card doesn't supply A-
Full Function.
3) SIGNAL FAIL SAFE POSITION
A. Fail Close : Full Close to be operated when Signal
Fail / F-C On & F-O OFF
B. Fail Open : Full Open to be operated when Signal
Fail / F-C OFF & F-O On
C. Fail Stop : Stop when Signal Fail / both of F-C & F-
O should be all OFF or all ON
D. Factory set-up is „Fail Stop‟ (all OFF)
E. Exception : when input signal select is 0~5V or 0 ~10V, RPC card does not supply
Signal Fail Safe Position.
4) DELAY TIME (Motor Recess Time Set-Up when running in reverse
direction)
A. It is possible to set up the recess time of the motor when the
actuator is to move „forward to backward‟ (and vice versa) for
intended position since input signal is changed.
B. The range is „from 0 to F‟ which means 1.0sec to 8.5sec as 1

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level is 0.5sec: set-up levels are 15 levels in total as well.

C. Since lower level (closer to 0) means that the motor recess time is shorter when the
motor runs reverse direction, lower level may cause overheat of the motor
sometimes.
D. Factory set-up is “4 (3.0 sec)”.
5) DEAD-BAND (Tolerance Set-Up)

CLOSE

OPEN

A. It is possible to set up tolerance range for the actuator position according to input
signal.
B. The range is „from 0 to F‟ which means 0.1% to 4.5%: set-up levels are 15 levels in
total.
C. The lower level (closer to 0) means that there will be more possibilities for the
actuator not to be stopped for the intended position and „Hunting‟ may occur.
D. If „Hunting‟ continuously occurs, it may cause malfunction of Motor, RPC Card,
Potentiometer, Valve/Damper, and so on.
E. Factory set-up is “4 (1.3%)”.
6) HOW TO MANUALLY OPERATE WITH BUTTONS
A. Please simultaneously press the buttons „ZERO
ZERO SPAN
(Black)‟ and „SPAN (Gray)‟ at the same time.
B. If FAULT (Yellow) LED light is ON after those
LED lights such as FAULT (Yellow), CLOSE
(Green), and OPEN (Red) blink twice, please
put the hand off the buttons.
C. If ZERO (Black) button is pressed, those LED lights such as FAULT (Yellow), CLOSE
(Green), and OPEN (Red) blink twice and then it is operated for CLOSE direction with
CLOSE (Green) LED light ON. However, it is operated only for the time while the
button „ZERO (Black)‟ is pressed.
D. If SPAN (Gray) button is pressed, those LED lights such as FAULT (Yellow), CLOSE
(Green), and OPEN (Red) blink twice and then it is operated for OPEN direction with
OPEN (Red) LED light ON. However, it is operated only for the time while the button
„SPAN (Gray)‟ is pressed.

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E. If those buttons “ZERO (Black)” and “SPAN (Gray)” are pressed again at the same
time, , those LED lights such as FAULT (Yellow), CLOSE (Green), and OPEN (Red) blink
twice and then it is set back to „stand-by‟ for further operation.
F. Or it just passes about 15 seconds without pressing those buttons “ZERO (Black)”
and “SPAN (Gray)”, then it is set back to „stand-by‟ for further operation.
7) A-FULL (Functions) SET-UP
A. If the signal of 4.3mA(2%) or lower is given, it is
“Full Close”. If the signal of 19.7mA(98%) or higher
is given, it is “Full Open”.
B. When Input signal select is 0~5V DC or 0 ~ 10V DC,
RPC card doesn't supply A-Full Function.
C. Factory set-up is “On”.
8) AUTO SETTING (A-SCAN)
A. Please press the button “A-SCAN (Red)”. A-SCAN
B. If FAULT (Yellow) LED light is ON after those LED lights such as
FAULT (Yellow), CLOSE (Green), and OPEN (Red) blink twice,
please put the hand off the button “A-SCAN”.
C. The actuator is automatically operated for Full Close and Full
Open and measures the range.
D. Please check out if “OPEN (Red)” LED blinks when OPEN is operated and/or “CLOSE
(Green)” LED blinks when CLOSE is operated.
E. Once Auto-Setting completed, it returns to „stand-by‟ after those LED lights such as
FAULT (Yellow), CLOSE (Green), and OPEN (Red) blink twice.
F. Please give input signal and check out if it is normally operated.
G. If running Auto Setting, it will delete those values currently saved and it will save
new values, so please be noticed.
H. Please run only once for initial installation, Limit Switch CAM adjustment,
Potentiometer replacement, and/or RPC replacement.

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9) MANUAL SET-UP (CH2)

A. It is possible to set up the Actuator‟s
range without changing the Limit Switch.
B. Please check out if the POWER (White)
LED light blinks after getting „CH2 Dip
Switch‟ ON.
C. Using the handle, please move the
actuator to intended Close position.
D. Please press the button ZERO (Black).
E. If those LED lights such as FAULT (Yellow), CLOSE (Green), and OPEN (Red) blink
twice, please put the hand off the button “ZERO”.
F. Once again, using the handle, please move the actuator to intended Open position.
G. Please press the button „SPAN (Gray)‟.
H. If those LED lights such as FAULT (Yellow), CLOSE (Green), and OPEN (Red) blink
twice, please put the hand off the button “SPAN” as well.
I. After getting „CH2 Dip Switch‟ OFF for sure, please check out if POWER (White) LED
light is ON.
J. Please give input signal and check out if it is normally operated.
K. If you do “CH2” set up, RPC card doesn't supply A-Full Function.
10) ADJUSTMENT OF OUTPUT
A. Once every set-up finished, please check out if
output value is normally output.
B. Please get the actuator to Full Close and then
check if 4mA is output.
C. In order to adjust output value for Close, please
refer to the picture “9. RPC Layout” and change
ZERO (H103I) for adjustment of output value. If
turning CW (Clockwise), output value gets increased. If turning CCW
(Counterclockwise), output value gets decreased.
D. Please move the actuator to Full Open and then check out if 20mA is output.
E. In order to adjust output value for Open, please refer to the picture “9. RPC Layout”
and change SPAN (H500I) for adjustment of output value. If turning CW (Clockwise),
output value gets increased. If turning CCW (Counterclockwise), output value gets
decreased.
F. Please repeat Open and Close 2 or 3 times and check out if output value is normal.

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11) REV : How-To-Use when Actuator and

Valve/Damper are in opposite direction
A. For the actuator, CW (clockwise) is “Close”
and CCW (Counterclockwise) is “Open”.
B. It is used when moving directions of
actuator and valve are different.
C. For the valve, when CW (Clockwise) is
“Open” and CCW (Counterclockwise) is
“Close”, it is used with „REV Dip Switch‟ ON.
D. CW=Clockwise CCW=Counterclockwise
12) HOW TO CHECK LED STATUS

LED SIGNAL

White On Power On

POWER Input Signal Setup(CH1)

White Flickering
or, manual setup (CH2) status

Green On Closing or Full Close

CLOSE
Green Flickering Closing (applicable only at A-SCAN)

Red On Opening or Full Open

OPEN
Red Flickering Opening (applicable only at A-SCAN)

Auto Setting status

Yellow On
or, manual operation status

Yellow Flickering No input signal

Yellow + Green Flickering Potentiometer Fault

FAULT Motor does not run when Auto Setting

Yellow + Red Flickering
No change of P.K value
(Auto Setting)
Valve moves to reverse direction

Input Signal Memory Fault

Yellow + Green + Red
Input Signal 4-20mA or A-SCAN range
Flickering
DATA lost

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5. TOOLS REQUIRED
1) Wrench (mm) : 1set
2) Screw Driver (-) : 1ea
3) Monkey Spanner 200mm : 1set
4) Signal Generator (0~20mA DC or 0~10V DC) : 1set
5) Multi-Tester : 1set
6) Measuring Instrument for output signal confirmation (0~25mA) : 1set

6. POTENTIOMETER SET-UP

1) ITQ0080~ITQ3000
A. Please get the actuator „Full Close‟.
B. Using measuring instrument such as DMM (Digital Multi Meter), please confirm if the
resistance value between P1 (Orange) and P2 (Purple) is 80 to 120Ω.
C. If the value measured is not in the range, please adjust with tools so that the
Potentiometer value measured can be in the range.
D. Please get the actuator „Full Open‟.
E. Please confirm if the resistance of both ends P1 (Orange) and P2 (Purple) at the
Potentiometer is 980Ω or lower.
F. When Full Open, if the resistance of both ends P1 (Orange) and P2 (Purple) is higher
than 980Ω as measured, the equipment may occur malfunction so Open CAM should
be adjusted.
2) IQL04~IQL25 & ITQ6000~ITQ9000 (Gearbox Type)

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A. Please get the Actuator „Full Close‟.

B. Using measuring instrument such as DMM (Digital Multi Meter), please confirm if the
resistance value between P2 (Purple) and P3 (Gray) is 80 to 120Ω.
C. If the value measured is not in the range, please adjust with tools so that the
Potentiometer value measured can be in the range.
D. Please get the Actuator „Full Open‟.
E. Please confirm if the resistance of both ends P2 (Purple) and P3 (Gray) at the
Potentiometer is 980Ω or lower.
F. When Full Open, if the resistance of both ends P2 (Purple) and P3 (Gray) is higher
than 980Ω as measured, the equipment may occur malfunction so Open CAM should
be adjusted

7. LIMIT SWITCH SET-UP

1) Please pull the HAND/AUTO Lever of the actuator to HNAD and then turn the handle CW
(Clockwise) so that the Valve/Damper will be Full Close.
2) Using wrench, please release the bolts for Close Limit CAM and then turn the „CLS CAM‟
clockwise or counterclockwise so that it is matched with the Limit Switch contact. And
then, exactly fix the bolts.
3) Please pull the HAND/AUTO Lever of the actuator to HNAD and then turn the handle
CCW (Counterclockwise) so that the Valve/Damper will be Full Open.
4) Using wrench, please release the bolts for Open Limit CAM and then turn the „OLS CAM‟
clockwise or counterclockwise so that it is matched with the Limit Switch contact. And
then, exactly fix the bolts.

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8. HOW TO CHECK RPC OPERATION

Actuator Position Full Close Full Open

4mA ~ 20mA 4mA 20mA

2V ~ 10V 2V 10V

Input Signal 0V ~ 10V 0V 10V

0V ~ 5V 0V 5V

1V ~ 5V 1V 5V

Output Signal 4mA ~ 20mA 4mA 20mA

LED Status Close (Green) On Open (Red) On

Auto Setting Close (Green) Flickering Open (Red) Flickering

No Input Signal Fault (Yellow) Flickering

9. RPC LAYOUT

1) Model Selection
A. “Q” : Model “ITQ” (Quarter turn actuator)
B. “L” : Model “IQL” (Linear actuator)
2) Potentiometer Position Selection
A. QS or DA : Model “ITQ” (Quarter turn actuator)
However, except for ITQ6000~ITQ9000 Gear box
B. GL or RA : Model IQL (Linear actuator) & Gear box (ITQ6000~ITQ9000)

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3) Input Voltage Selection

A. 85~265V AC, 1PH : Set up “1PH” for all
B. 220~460V AC, 3PH : Set up “3PH” for all
C. 24V DC : Set up “3PH” for all

10. LCD LAYOUT (Optional)

1) Current Status
A. CLOSING / FULL CLOSE
B. OPENING / FULL OPEN
C. STOP
2) Signal Fail Safe Position Set-up Status
A. F-CL : Fail Close
B. F-OP : Fail Open
C. None : Fail Stop
3) Tolerance (Dead Band) Set-up Status
4) When motor turns reverse (any opposite direction), recess time (=Delay Time) set-up
status.
5) Input signal value given to the Actuator
6) Actuator Current Position Value
7) Reverser Operating Status Confirmation
A. None : CW = Close, CCW = Open
B. R (Rev) : CW = Open, CCW = Close

11. HOW TO REPLACE RPC

1) Power must be turned OFF before starting replacement of RPC CARD.
2) Status of every switch should be setup same as the existing.
3) Please correctly and normally connect those cables of POWER, POTENTIOMETER (P.K),
INPUT SIGNAL, and OUTPUT SIGNAL.
4) Please get the actuator „Full Close‟ and then measure and confirm potentiometer (P.K)
value using measuring instrument such as DMM (Digital Multi Meter).
5) Please power ON and then check out if the POWER (White) LED light is ON.
6) Please press A-SCAN (RED) button for about 2 seconds for operating AUTO SCAN at
least once for sure.
7) Once AUTO SCAN correctly completed, please confirm if POWER (White) LED light is ON.
8) Please give input signal and confirm if it is normally operated.

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12. ELECTRIC WIRING DIAGRAMS

1) ITQ0080-70500-F (1PH)
A. Model : ITQ-0080 (80NM)
B. Incoming & Control Power :1PH, AC 110V / AC 220V, 50/60Hz

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2) ITQ0100-70500-F (1PH)
A. Model : ITQ-0100 (100NM)
B. Incoming & Control Power :1PH, AC 110V / AC 220V, 50/60Hz

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3) ITQ0160-70500-F (1PH)
A. Model : ITQ-0160 ~ ITQ-9000 (160NM ~ 9000NM)
B. Incoming & Control Power : 1PH, AC 110V / AC 220V, 50/60Hz

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4) ITQ0160-80500-F (3PH)
A. Model : ITQ-0160 ~ ITQ-9000 (160NM ~ 9000NM)
B. Incoming Power : 3PH, AC 380~460V
C. Control Power : 1PH, AC 110V / AC 220V, 50/60Hz (Option : DC 24V)

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5) ITQ0160-84500-F (3PH / MCC built-in)

A. Model : ITQ-0160 ~ ITQ-9000 (160NM ~ 9000NM)
B. Incoming Power : 3PH, AC 380~460V, 50/60Hz (MCC built-in)
C. Control Power : Internal 1PH, AC 220V

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6) ITQ0160-90500-F (24V DC)

A. Model : ITQ-0160 ~ ITQ-0500 (160NM ~ 500NM)
B. Incoming & Control Power : DC 24V

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7) ITQ0160-96500-F (DC 24V/MCC built in)

A. Model : ITQ-0160 ~ ITQ-0500 (160NM ~ 500NM)
B. Incoming & Control Power : DC 24V

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8) ICMQ0160-81500-F (3PH / INTEGRAL / DISPLAY : LED / MCC built in)

A. Model : ITQ-0160 ~ ITQ-9000 (160NM ~ 9000NM)
B. Incoming Power : 3PH, AC 380~460V, 50/60Hz
C. Control Power : Internal DC 24V

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9) ICMQ0160-82500-F (3PH / INTEGRAL / DISPLAY : LCD / MCC built in)

A. Model : ITQ-0160 ~ ITQ-9000 (160NM ~ 9000NM)
B. Incoming Power : 3PH, AC 380~460V, 50/60Hz
C. Control Power : Internal DC 24V

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