ABB Contrac PME120AI User manual

Instructions
4268151 EN Electrical Part-Turn Actuator
PME120-AI/-AN (Contrac)
For continous control; rated torque 100 Nm;
with integrated or for separate electronic unit

2
Content
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Safety and precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Long-time storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Actuator check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the Actuator to the Valve . . . . . . . . . . . . . . . . . . . . 6
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . 8
Integrated electronic unit (standard) . . . . . . . . . . . . . . . . . . . 8
Integrated electronic unit (bus comunication) . . . . . . . . . . . . 8
Separate electronic unit EAN823 (standard) . . . . . . . . . . . . . 9
Separate electronic unit EAN823 (bus communication) . . . . 9
Signal input and output (conventional triggering) . . . . . . . . 10
Fuses at actuator with integrated electronic unit . . . . . . . . . 11
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Set-up via local control panel (LCP) . . . . . . . . . . . . . . . . . . 12
Adjustment using the configuration program . . . . . . . . . . . 13
Functions and signals at the LCP . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Motor and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjusting the brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing the position sensor . . . . . . . . . . . . . . . . . . . . . . . 14
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Electrical test values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Legend
1. Device Identification
1.1 Actuator ID label
1. Actuator type
2. Device number / No. of non-standard version (if applicable)
3. Rated torque / Year of manufacture
4. Permissible ambient temperature / protection class
5. Min./max. positioning travel / max. speed
6. Filled-in oil type
7. Associated electronics
8. Permissible voltage range / Mains frequency (only with PME120AI)
9. Power consumption / Fuse (only with PME120AI)
10.Available for customer-specific information
1.2 ID Label of electronic unit
The ID labels of the power electronic unit are located on
the cover of the local control panel.
1.2.1 ID Label for hardware description
1. Electronic unit type
2. Device no. / No. of non-standard version (if applicable)
3. / Year of manufacture
4. Not used
5. Permissible ambient temperature / Protection class
6. Not used
1.2.2 ID Label for software description
1 Associated actuator type
2 Rated values for torque / force / speed
3 Fabrication No.
4 No. of non-standard version
5 Actuator firmware release
Danger
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury
Warning
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury or serious property damage.
Caution
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury or property damage.
Important
Indicates useful hints or other special infor-
mation which, if not observed, could lead to
a decline in operating convenience or affect
the functionality.
1Antrieb / Actuator: CONTRAC ....
2 F-Nr./No NL
3 M = Jahr/Year CE
4t= IP66
5 min......max. ....... max. .........
6 Öl / Oil:
7 Elektronik/Electronics
8
9
10
ABB Automation
D-32425 Minden
Made in Germany
1Elektronik / Electronics Type: ....
2 B-Nr./No. ...... NL
3 Jahr/Year
4
5 t = ..................°C IP 66 CE
6
ABB Automation
Made in Germany
1 Für / For
Antrieb / Actuator Typ / Type. . . . . . . .
2 Nennwerte / Rated values
M=....... .......°/s
3 F-Nr. / No.: . . . . . . . . . . . . . . . . . . . . . .
4 NL. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 SW Version . . . . . . . . . . . . . . . . . . . . .

3
2. General
2.1 Proper use
Control actuators are intended to be used exclusively for actuating final control elements (valves,
vanes, etc.). Do not use these actuators for any other purpose. Otherwise, a hazard of personal injury
or of damage to or impairment of the operational reliability of the device may arise.
2.2 Safety and precautions
When mounting the actuator in areas which may be accessed by unauthorized persons, take the re-
quired protective measures.
- Control actuators perform movements for positioning vanes and valves. Handle properly and with
care. Otherwise, a hazard of bruise injuries may arise.
- When changing the oil of the actuator, thoroughly remove any oil that may have run down on the
floor during the procedure to avoid accidents.
- Dispose of the waste oil in compliance with the respective local regulations. Make sure that no waste
oil reaches the water cycle.
- Only qualified specialists who have been trained for these tasks are authorized to mount and adjust
the control actuator, and to make the electrical connection.
- When working on the actuator itself or its electronics always observe the locally valid accident pre-
vention regulations and the regulations concerning the construction of technical installations.
3. Storage
Contrac actuators may be stored under moist and aggressive condition for a short time. The equipment
is protected against external corrosive influences. However, direct exposure to rain, snow, etc. must be
avoided.
Actuators, equipped with an anti condensation heater, are additionally protected by desiccant placed
in the connector (and in the terminal box of the separate electronics, if present). The desiccant guaran-
tees sufficient protection for approximately 150 days. It can be regenerated at a temperature of 90° C
within 4 h.
The desiccant must be removed prior to commissioning the actuator or the electronics.
3.1 Long-time storage
If you intend to store or transport the device for a longer time, we recommend to wrap it in plastic foil
and add desiccant. Regularly check if the desiccant is still active.
4. Delivery State
If not otherwise specified by the customer, Contrac actuators are delivered with the following standard
configuration:
Behavior in 0/100% position: Shut-off with rated torque / force
Setpoint function: Linear; setpoint = positioning value
Input (setpoint): 4 ... 20 mA 1)
Function: Positioner, parameter: setpoint
Output (actual value): 4 ... 20 mA 1)
Digital inputs : 1) DI 1 switch-over manual/automatic and v.v.
DI 2 / DI 3 manual control +/-
Digital outputs: 1) DO 1 ready to operate, DO 2/3 end position signalling
Range: Not adjusted
The configuration of your actuator may differ from the standard configuration specified above. It can be
called up for display using the configuration program.
1) Not available for bus communication

4
5. Assemblies
Table 1: PME 120
5.1 Operating mode
5.1.1 Normal mode
The motor triggered by the power electronics drives the output shaft (9) via oil-lubricated spur gears.
The drive lever mounted on the shaft transmits rotary motion to the valve.
The brake built in the motor (5) acts as a retainer when the power is off.
5.1.2 Handwheel mode
- Allows you to move the actuator manually when the electrical power is off.
- Turn the lock lever (4) clockwise
- Turn the handwheel (7) to move the lever to the wanted position.
- Release the lock lever.
The friction clutch is designed such that a handwheel force of around 11 N suffices to create the rated
torque on the actuator. If you should feel a considerable counter-force when moving the actuator by
hand, do not increase the force you apply to the handwheel. Otherwise, you might damage the actuator
or valve.
6. Technical Data
Table 2:
1) actuator is equipped with additional electrical heater
1: Lever
2: Mechanical stops
3: Gearbox
4: Lock lever
5. Motor
6. Cover
(incl. electronics
for PME 120 AI)
7. Handwheel
8. Connector
9. Ouput shaft
10.Ball-and-socket joint
(d0036rxa)
1
2
3
5
4
6
78
9
10
PME 120 AI PME 120 AN
Rated torque [Nm] 40 ... 100
Starting torque [Nm] appr. 1.2 x rated torque (break-away torque in end positions 2
x rated torque for short time)
Rated speed [°/s] 1.5 ... 4.5
Weight approx. 45 kg approx. 32 kg
Ambient temperature (-25) 1) -10 ... +55°C (-25) 1) -10 ... +65°C
Associated electronic unit integrated in actuator for field mounting: EAN 820
for rack mounting: EAS 822
Power supply
(on electronic unit)
115 V AC (94 V ... 130 V) or 230 V AC
(190 V ... 260 V); 47.5 ... 63 Hz
Max. power consumption with
115 / 230 V AC [A] 1.0 / 0.5
Current consumption in positioning
mode: approx. 40 ... 50% of Imax., each

5
7. Lubrication
Prior to delivery the actuator is filled with 2.5 l oil in factory.
Fig. 1:
7.1 Lubricants
Table 4:
8. Mounting
8.1 Actuator check
- Is the actuator filled with the appropriate oil type?
- Is enough oil in the actuator?
- Did you fasten the separately delivered vent screw in the highest bore (depending on the mounting
orientation)?
- Has the actuator integrated or separate electronic unit?
8.2 Mounting orientation
All mounting orientations seen in Figure 2 are permissible. To facilitate mounting and maintenance,
however, it is recommended to use orientation IMB 3.
8.3 Mounting instructions
- Make sure that the actuator is accessible from all sides to ensure convenient handwheel operation,
electrical connection, and replacement of assemblies.
- Avoid direct exposure to rain, snow and other environmental influences. Select the mounting site
accordingly.
- Exclusively mount the actuator on a rigid, non-vibrating support to avoid relative motion between
the actuator and the valve.
- When mounting the actuator close to heat sources use an insulating layer or shielding.
IMB 3 IMB 6 IMB 7 IMB 8 IMV 5 IMV 6
1) 2) 1) 2)
1) 2)
1) 2) 1) 2)
1) 2)
Min. oil quantity;
approx. [l] 2.2 2.5 2.2 2.2 2.5 2.5
Min. oil level [mm]
under inspection
screw
45 2 42 20 23 17
Table 3: The arrow indicates the position of the inspection screw 1) and the vent screw 2). After having mounted the
actuator, replace the highest inspection screw with the separately delivered vent screw.
Actuator type Ambient temperature Oil type Motorbearing
(grease)
PME 120AI
(with integrated electronic unit) (-25) 1) - 10°C ... + 55°C
Mobil SHC 629 ESSO Beacon 325
PME 120AN
(for separate electronic unit) (-25) 1) - 10°C ... + 65°C

6
8.4 Mounting the Actuator to the Valve
8.4.1 Preparing the Equipment
- Make sure that the shaft and lever bore surface are clean and free of grease.
- Determine the length of the stay tube (not included in the scope of delivery).
- Move the valve to the “CLOSED“ position.
- Move the actuator to the corresponding end position using the handwheel. Observe the permissible
angle.
- Spacing “L“ minus 140 mm yields the required length of the link tube.
- Drill a cone bore into the valve lever for mounting the second ball-and-socket joint, as shown in
Figure 4.
- Insert the ball-and-socket joint, secure with crown nut and split-pin.
- Remove the welding bushings and weld them to the stay tube (C 15 to DIN 17210)
- Insert the link rod between the two ball-and-socket joints and screw it in.
- If required adjust “L” by turning the link rod.
- When all adjustment steps are finished, fasten the counter nuts.
8.4.2 Adjusting the Stops in Dependence of the Travel
- Move the output lever / valve to the position requiring fine adjustment.
- Put the stop onto the toothing as close to the output lever as possible and fasten with screws.
- Move the output lever towards the stop using the handwheel; turn the coupling rod for fine adjust-
ment.
- Fasten the counter nuts.
- Fasten the stop in the other mounting position close to the end position, depending on the toothing.
8.4.3 Adjusting the Stops in Dependence of the Torque
- First proceed as described above for travel-dependent adjustment.
- Prior to re-fastening the counter-nut lock the handwheel and then turn the coupling rod in such a
way that an initial tension occurs in the valve’s closing position.
- Fasten the counter-nuts.
Fig. 2: Mounting PME 120, example
α≥ 15 °
βaccording to dimensions specified by the valve manufacturer
β
10
3
°
°
α
tightening torque
for limit stop screws: 46 Nm
echanical
limit stop
coupling
rigid, vibration-free
support
flap
lever
lever
boring diameter for
fastening screws: 12 mm
tensile strength:
≥400 Nm
tightening torque for
lever clamping screw:
23 Nm
r00304e1

7
Fig. 3: Dimensional drawing
1. Output lever
2. Link tube
3. Ball-and-socket joint
4. Welding bushings (C15 to DIN 17210)
5. Counter nuts
6. Crown nuts
62 - 78 62 - 78
60
46
32
21
14
15
18
61
L - 140
14
L
16
6
3
34
42
5
5
r00305x1
M14 x 1.5
left / right
cone 1 : 10

8
9. Electrical Connection
Each actuator requires a Contrac electronic unit. Proper actuator operation requires an actuator spe-
cific software loaded in this associated electronic unit. See electronic unit instructions for details. Com-
pare the data labels on both, electronic unit and actuator, in order to ensure a correct hardware and
software assignment.
9.1 Integrated electronic unit (standard)
Power and signal cables are connected to the integrated electronic unit via a plug.
Fig. 4: Electrical connection, standard
The following steps must be performed to switch the actuator to automatic mode (AUT):
- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.
- Make sure that the supply voltage is present on digital input 1 (DI 1).
- Activate AUT mode via the configuration program.
9.2 Integrated electronic unit (bus comunication)
Fig. 5: Electrical connection, PROFIBUS DP
r00295e2
24V
11
+- -
+
RB
+ -
12
I
U
910
3
1
+ - + - + - +
-
15
4
13 16
517 618 21 7192282023
LN
Uv
24V
+
RB
+ -
12
Sub Distribution Board
Contrac Actuator
ext.
fuse
mains
(single
phase)
DI1 DI2 DI3 DO1 DO3DO2 Uv setpoint
+ HART
0/4..20 mA act. value
0/4..20 mA
transmitter
4..20 mA
Han10E
insert
(Option)
Han24E
insert
MAN/AUT MAN (+) MAN (-) ok/fault end 0% end 100%
113
LN
BBA
Bus in Bus out
A
S1
r00011x1
ext.
fuse
mains
(single phase)
Han24E
insert
red green red green
bus termination
Contrac
Actuator
bus terminals A...B

9
9.3 Separate electronic unit EAN823 (standard)
The electrical connection is done with a combined plug on the actuator and with screw terminals on the
electronics.
Fig. 6: Electrical connection EAN 823, standard
- The following steps must be performed to switch the actuator to automatic mode (AUT):
- Activate digital inputs DI 1, DI 2 and DI 3 via the configuration program.
- Make sure that the supply voltage is available on digital input 1 (DI 1).
- Activate AUT mode via the configuration program.
9.4 Separate electronic unit EAN823 (bus communication)
Fig. 7: Electrical connection: EAN 823, PROFIBUS DP
r00009x1
24V
30
+- -
+
RB
+-
31
I
U
26 27
1
+-+-+- +
-
7
28 39410 13 5111461215
LN
17 18 19 20 21 22 23 24
1212 31314
M
3~
17 18 19 20 21 22 23 24
UVWBrBr PE
H1 H2
Uv
24V
+
RB
+-
28 29
Sub Distribution Board
ext.
fuse
mains
(single
phase)
DI1 DI2 DI3 DO1 DO3DO2 Uv setpoint
+ HART
0/4..20 mA act. value
0/4..20 mA
transmitter
4..20 mA
MAN/AUT MAN (+) MAN (-) ok/fault end 0% end 100%
Contrac
Actuator
Han10 E plug Han24 E plug
Sensors
Motor Brake
Heater
approx. 6W
(Option)
Contrac
Electronic Unit
LN
Bus out
Bus in
28 29 30
BBAA
31 S1
17 18 19 20 21 22 23 24
UVWBr
H1 Br H2
17 18 19 20 21 22 23 24
1231314
M
3~
PE
12
r00010x1
Contrac
Actuator
Contrac
Electronic Unit
ext.
fuse
mains
(single
phase)
red green red green
bus terminals A...B
Sensors
Motor Brake
Heater
approx. 6W
(Option)
Han10 E plug Han24 E plug
screw
terminals
bus termination

10
9.5 Signal input and output (conventional triggering)
9.5.1 Standard
Fig. 8:
** Write-protected when applying +24 V DC to DI 1.
9.5.2 Behind a step controller
Fig. 9:
** Write-protected when applying +24 V DC to DI 1.
9.6 Wiring for ectronic units in a mounting rack
Refer to operating instructions 42/68-821 for installation details.
Uv
24V
24V
+-
--
+
+
RB RB
+-
+- I
U
Uv
+- +- +- +
AUT
-Y+Y
MAN
14 28 30
26
131211
910
8
7
6
4
32
1515 29 31
27
Ok
(r00358x1)
end pos. 0% end pos. 100%
setpoint + HART 0/4...20 mA
act. value 0/4...20 mA
Transmitter
(Option)
NC
NC
NO NO
Electronic
Unit
(r00359x1)
Uv
24V
24V
+-
--
+
+
RB RB
+-
+- I
U
Uv
+- +- +- +
-Y+Y
14 28 30
26
131211
910
8
7
6
4
32
1515 29 31
27
Ok
end pos. 0%
act. value 0/4...20 mA
end pos. 100%
controller
enable controller **
NC
NC
NO NO
Transmitter
(Option)
Electronic
Unit

11
9.7 Fuses at actuator with integrated electronic unit
Table 5:
9.7.1 Fuse arrangement
Fig. 10:Fuse arrangement
Fuse type U = 115 V U = 230 V
External fuse(extern) 16 A, slow
Mains fuse 6.3 A slow 3.15 A slow
Low temperature heater (only for low tempera-
ture version) 2 A 2 A
Fuse for protection against active 20 mA current
feed at set-point input 0.04 A (fast) 0.04 A (fast)
Relay fuse for DO 1, DO 2, DO3 (not changeable) 3 x 0.5 A; medium
mains fuse
fuse against active feed
at 20 mA set point input
low temperature heater
(d0155rxa)

12
10.Setup
The actuator only requires the basic settings (adaptation to the operating range) in order to be operated
with the standard or custumer specific configuration. Use the Local Control Panel (LCP) for these set-
tings. Use the appropriate configuration software for more detailed parameter changes or diagnosis
functions.
10.1Set-up via local control panel (LCP)
10.1.1Operating elements
1. Write-protect switch (Default setting: OFF)
2. LED for 100% position Indication if adjustment procedure, saved position, or fault by different
flash frequencies.
3. Drive buttons Press to cause drive motion
4. Reset button Press to restart processor
5. Power LED Indicates available mains supply
6. RS 232 socket Connection socket to PC
7. Potential toggle switch Connection of reference potential to the system or protective earth (by
default set to system) of electronic unit
8. LED for 0% position Indication if adjustment procedure, saved position, or fault by different
flash frequencies..
9. Accept button (0%) Press to define current position as 0%; simultaneously press push but-
ton 9 + 10 to complete the adjustment procedure.
10. Accept button (100%) Press to define current position as 100%; simultaneously press push
button 9 + 10 to complete the adjustment procedure
Figure 11: Local Control Panel (LCP)
The actuator range is not preset in factory!
10.1.2Setup procedure
- Undo the screws of the LCP cover
- Swing the cover to the side
10.1.3Initial situation
- Electronics connected to power supply and actuator
- Write-protect switch (1) set to “OFF” position
- Electronics in operating mode “MAN” (no signal on DI 1)
- No fault (if a fault occurs, both LEDs flash alternately at 4 Hz)
1
2
3
4
5
6
7
8
9
10
(r0110rxa)

13
10.1.4Setting
10.1.4.1 “Setting” mode
- Set electronics to “setting” mode by pressing both push buttons (3) simultaneously for approx. 5
seconds, until both LEDs (2 + 8) are flashing synchronously at approx. 4Hz. („setting mode“ is the
standard electronic unit status after passing the final factory test)
10.1.4.2 Defining first position (0% or 100%)
(Higher precision in 2nd position)
- Move to desired position by pressing one of the push buttons (3).
- To accept the position for 0% or 100%, press push button (10) or (9); the associated LED flashes at
approx. 2 Hz when value is correctly accepted, the other one continues to flash at approx. 4Hz
10.1.4.3 Defining second position (0% or 100%)
- Move to second position by pressing tho other of the push buttons (3).
- To accept the position, press push button (10) or (9); both LEDs (2) and (8) are flashing at approx. 2
Hz when values are accepted correctly.
10.1.4.4 Saving the settings
- Save the settings by simultaneously and shortly pressing the push buttons (10 + 9); the LEDs (2 + 8)
are „ON“ (without flashing) for approx. 5 sec before they extinguish and the setting procedure is
completed.
- If the selected range is too small for the actuator, both LEDs will flash again at 4Hz. Repeat the ad-
justment procedure with a wider range (min. positioning travel).
(See positioning travel specification on actuator ID label)
10.1.4.5 Correction after setup
- If the setting is to be corrected after accepting the first value, first press the Reset button (4) and
then repeat the setting.
- If the correction is to be re-done after saving the settings, the entire adjustment procedure must be
repeated.
10.2Adjustment using the configuration program
Context-sensitive help information is available in the configuration program at all times. For basic han-
dling and installation instructions refer to the associated manual, number 41/68-001.
A conductive ground connection is established between the PC and the CONTRAC electronics with the
RS 232 communication cable. If the PC is grounded, this may cause a ground loop in the installation.
10.3Functions and signals at the LCP
Table 6:
Function Indication
Adjustment
Change-over to adjustment mode:
Press and hold both drive buttons for approx. 5
seconds
Both LEDs flash synchronously at approx 4Hz
after time has expired.
Moving to an end position
Use associated drive button on LCP
Both LEDs continue to flash at 4Hz while driv-
ing.
Saving the first end position
Press button 0% or 100%
The associated LED flashes at approx. 2Hz,
the other continues at 4Hz.
Saving the second end position
Press button 0% or 100%
The associated LED flashes at approx. 2Hz
synchronously to the first one.
Confirm settings
Press 0% and 100% buttons simultaneously
Both LEDs are briefly „ON“ together and then
extinguish.
Operation
Normal operation: MAN / AUT LED off
Driving with button on CSF
Priority over control system
LED off
Bootstrap mode
Electronic is in bootstrap mode during the data trans-
fer of e. g. firmware, objects or motor charcteristics;
use ECOM688 software for this procedure.
Both LED are „ON“; actuator is not available
Fault (both LEDs flash alternately at 4Hz)
Reset:
Resets fault indications
If no „Failure“ conditions exist, both LEDs
extinguish (if the actuator had been moved out
of its operating range, drive it back prior to the
reset).

14
11. Maintenance
Contrac actuators have a robust construction. As a result, they are highly reliable and require only little
maintenance. The maintenance intervals depend upon the effective load and are therefore not specified
here.
The built-in microprocessor evaluates the actual load factors (e.g. torques, temperatures, etc.) and
derives the remaining operating time until the next routine maintenance is required. Use the configura-
tion program for viewing this information.
11.1 Motor and gears
All maintenance work must be carried out by qualified specialists who have been trained for this task.
As a rule, perform the following routine maintenance works:
- Check the shafts and gears.
- Check the motor pinion gear and the respective mating gear.
- Replace the motor’s rotary shaft seal and ball bearings.
- Check the position sensor.
- Change the oil; then make a visual check and check for proper operation.
11.2 Adjusting the brake
The actuator setting may be changed accidentally by the repelling power of the valve when the brake is
released!
In automatic mode the brake is permanently released. Therefore, it is not exposed to wear and does
not require any re-adjustment.
11.3 Replacing the position sensor
11.3.1 Dismounting
- drive actuator into 50% position
- delete the current position setting by pressing the drive buttons on the LCP for at least 5 sec.
- switch-off the voltage supply
- disconnect the connector plug from pcb
- undo the two fastening screws (1) of the position sensor and pull the sensor out of the gears.
11.3.2 Mounting
The toothed gear pair of the position sensor is held in place by a tension spring (3), to ensure sufficient
free motion when the direction of rotation is reversed
- set the stop pin to the center position, as seen in Figure 12
- connect the plug (5) to the PCB
- align the sensor and its gears with the actuator; set the first toothed gear in 11:00 o’clock position
(see Figure 13) onto the drive shaft gear (4)
- slightly move the sensor back and forth to pre-tension the toothed gears with the difference “z“ until
the second toothed gear snaps in
- fasten the screws (1) tightly.
Figure 12: Position sensor Figure 13: Mounting position
Z
1
2
1
3
(r00329x1)
1
4
1
(r00335x1)

15
Figure 14: Connecting the ribbon cable plug to the PCB
After mounting is completed readjust the actuator range as described in section 10 of this manual.
5
(r00336x1)

16
12. Troubleshooting
This section only describes how to handle hardware errors. Refer to the configuration program’s online
help for errors related to the software.
12.1 Electrical test values
Figure 15: Motor block diagram
Error Possible reason Measures to be taken
Valve cannot be moved by actu-
ator
Malfunction of actuator or valve
(e.g. cable gland fastened too
tightly)
Disconnect the actuator from the
valve.
If the actuator is working prop-
erly then, the valve is likely to be
defective. Otherwise, the actua-
tor seems to be the error source.
Actuator does not react No communication Set up communication using the
configuration program
Motor / brake is defective Check the winding resistances
of the motor and brake.
Digital inputs of electronics are
not connected
Connect
Brake does not release (no audi-
ble “click“ noise)
Check the air gap (should be
around 0.25 mm) and the electri-
cal connection of the brake.
Check the winding resistance of
the brake coil.
Actuator does not work in auto-
matic mode, although “AUT“ has
been selected in the configura-
tion program
Digital input 1 (DI 1) has not been
connected.
Connect DI 1.
LEDs on the commissioning and
service field are flashing simulta-
neously
Actuator has not been adjusted
properly
Adjust the actuator.
Table 7:
Winding resistance ± 5% at 20° C (motor) L1 (blue) - L2 (black):3,4 Ω
L1 (blue) - L3 (violet):3,4 Ω
Winding resistance ± 5% at 20° C (brake) 50 Ω
Table 8:
L1 L2
L3 (r00334x1)

17

42/68-151EN Rev. C
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