ABB LME620-AI Original operating manual

P R OF I
BU S
PROCESS FIELD BUS
®
Service Instruction
43/68-13 EN
Electrical Linear Actuators for
Continuous Modulating Control
LME620AI / LME620AN (Contrac)
Rated Force 4 kN
(900 lbf)

2 Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 43/68-13 EN
Electrical Linear Actuators for Continuous Modulating Control
LME620AI / LME620AN (Contrac)
Service Instruction
Document No. 43/68-13 EN
Issued: October 2005
Manufacturer:
ABB Automation Products GmbH
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
© Copyright 2005 by ABB Automation Products GmbH
We reserve the right to technical amendments
This document is protected by copyright. Information in this document is intended only to assist the
user in safe and efficient operation of the equipment. Its contents are not to be reproduced in full or part
without prior approval of legal owner.

43/68-13 EN Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 3
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety and precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Actuator versions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LME620 AI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
LME620AN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grease specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring diagrams (Integrated electronic unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exchange of position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Electrical Test Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test values (position sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Winding resistance (motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LED signals at local control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Failures at brake, fuse or wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operation mode (MAN / AUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Input configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Operation behind step controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Failure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Failure due to response of positioning loop monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
User Interface Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Important information
4 Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 43/68-13 EN
1 Important information
1.1 General
Read and save all instructions prior to installing, operating, and servicing this product. If any of the in-
structions are not understood, contact your ABB representative for clarification.
1.2 Symbols
In order that you can make the best use of this document and to ensure safety during commissioning,
operation and maintenance of the equipment, please note the following explanation of the symbols
used.
Explanation of the symbols used:
As well as the instructions in this document, you must also follow the generally applicable accident pre-
vention and safety regulations.
If the information in this document is insufficient in any situation, please contact our service department,
who will be happy to help you.
Please read this document carefully before installation and commissioning
1.3 Transport and storage
Carefully inspect for shipping damage. Damage to the shipping carton is usually a good indication that
it has received rough handling. Report all damage immediately to the freight carrier and your ABB rep-
resentative. Verify that the items on the packing list or bill of lading agree with your own.
Symbol Signal Word Definitions
STOP
DANGER DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
(High level of risk.)
WARNING WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
(Medium level of risk.)
CAUTION CAUTION indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
(Low level of risk.)
NOTICE NOTICE indicates a potentially harmful situation which, if not avoid-
ed,
may result in damage of the product itself or of adjacent objects.
(Damage to property)
IMPORTANT IMPORTANT indicates useful hints or other special information
which, if not observed, could lead to a decline in operating conve-
nience or affect the functionality.
(Does not indicate a dangerous or harmful situation.)
To ensure proper performance, use qualified personnel who have been trained,
qualified and certified by ABB to install, operate, update, tune, and maintain the ac-
tuator, the electronic units and the wiring.
ABB will not take any responsibilty for personal injuries or material damages which
were caused by non-trained, non-qualified or non-certified personnel.

Introduction
43/68-13 EN Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 5
2 Introduction
This service instruction refers to
the ABB linear actuators
LME620AI (with integrated elec-
tronic unit) and LME620AN (for
separate electronic units). It
amends and deepens the routine
maintenance description in the
standard instruction, which we
strongly recommend to be also
available for all maintenance work.
2.1 Safety and precautions
When mounting the actuator in ar-
eas which may be accessed by un-
authorized persons, take the
required protective measures.
STOP
STOP - The actuators perform movements for positioning vanes and valves. Handle properly and with care.
Otherwise, a hazard of bruise injuries may arise.
- Only qualified specialists who have been trained, qualified and certified by ABB for these tasks are
authorized to mount and adjust the actuator and to make the electrical connection. ABB will not take
any responsibility for personal injuries or material damages which were caused by non-trained, non-
qualified or non-certified personnel.
- When working on the actuator itself or the electronics always observe the locally valid accident pre-
vention regulations and the regulations concerning the construction of technical installations.
- Do not lift or lower the actuator when it is mounted on a valve or similar final control element.
- Switch-off the voltage supply; make sure that unintentional switching on is not possible
- Make sure that switching off the power supply does not affect the plant process
- Make sure that the final control element is not exposed to process forces.
- Check all mechanical and electrical interfaces for proper connection once the installation, commis-
sioning, service or maintenance work is done.
2.2 Tools
IMPORTANT Maintenance at CONTRAC actuators requires tools which are usually available in a workshop. Please
consider that all dimensions are based on the metrical system. This applies also for the wrench sizes,
threads etc. Using improper tools may damage the actuator or its components.
Use appropriate sleeves for the installation of the sealing rings (see chpt. 5.2.2.2 for details).
hand
wheel
cover for
thrust
motor (AN)
includes also
plug
Fig. 1: LME...; main components
rod
integrated
motor
cover for
local control panel
(only LME620AI)
LME620AI
electronic unit with

Actuator versions
6 Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 43/68-13 EN
3 Actuator versions
Linear actuators LME620 are available in two versions:
- LME620 AI (with integrated electronics)
- LME620 AN (for separate electronics)
3.1 LME620 AI
Fig. 2: LME620AI with dismounted electronic unit
3.2 LME620AN
Fig. 3: LME620AN with available, separate electronic units
LME120AI hood with integrated
electronic unit
(68de0039)
(68de0038)
LME620AN
electronic unit EAN823
for field installation electronic unit EAS822
for rack installation
plug
EAN823
without plug
EAN823
with plug
(68d0233)
(d0138rxa))
(68d_0228)

Lubrication
43/68-13 EN Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 7
4 Lubrication
The spur wheel gearings of LME620AI / LME620AN are grease lubricated.
4.1 Mounting position
Any mounting orientation is permissible. To facilitate mounting and maintenance, however, it is recom-
mended to use orientation IMV 1 (thrust rod downwards).
In all mounting orientations the actuator may not be exposed directly to rain, snow or other environ-
mental influences.
4.2 Grease specifications
Table 1:
5 Maintenance
Contrac actuators feature a robust construction. As a result, they are highly reliable and require only
little maintenance. The maintenance intervals depend upon the effective load.
The built-in microprocessor evaluates the actual load factors (e.g. torques, movements, temperatures,
etc.) and derives the remaining operating time until the next routine maintenance is required. Use the
configuration program for viewing this information.
CAUTION All maintenance work must be carried out by qualified specialists who have been trained for this task.
Switch-off the power supply and protect the actuator against unintentional switch-on prior to any main-
tenace. Make sure that disconnecting the power or any mechanical linkage does not endanger the any
process or person. Make sure that the actuator is not exposed to process forces during the maintenance
work.
Apart from the load dependent maintenance intervals determined by the microprocessor we recom-
mend routine maintenance at least every 10 years.
The following description of the maintenance work provide that the actuator is disconnected from the
valve and that all electrical supply is disconnected.
Actuator type Grease specification
spindle Optimol Optipit
gear wheels ESSO Beacon 325

Maintenance
8 Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 43/68-13 EN
5.1 Sectional view
Fig. 4: Sectional view of LME620...
motor
brake
handwheel
mechanism
thrust rod
sensor
drive pinion

Maintenance
43/68-13 EN Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 9
5.2 Motor
LME620 uses an integrated motor. The stator is integrated into the actuator housing which makes the
motor housing a part of the actuator housing.
5.2.1 Motor removal
STOP
STOP Note that the actuator position may be changed accidentally by the external load on the drive when the
brake is released or the motor is removed
- remove the rear cover (cover with electronics at LME620 AI)
- unscrew the 4 motor fastening screws (1)
- loosen the 4 grub screws (2)
- take the brake body with rotor out (3)
- take the stator (4) out
NOTICE The lower end of the stator shaft is supported by 2 separated disk springs. Make sure you get them out
with the motor.
Fig. 5: Rear view of LME620
(without cover / electronic unit) Fig. 6:
1
(68de_0039)
3
4
(68de0014)

Maintenance
10 Electrical Linear Actuators for Continuous Modulating Control LME620AI / LME620AN (Contrac) 43/68-13 EN
5.2.2 Motor shaft sealing ring
The motor shaft sealing ring prevents that debris or dirt get into the motor housing.
Once the stator is out, use two appropriate hooks (1) to pull the motor sealing ring (2) out; see fig. 7.
5.2.2.1 Removal
Fig. 7:
5.2.2.2 Installation
Fig. 8:
- grease the new sealing ring and press it in the flange as shown in fig. 8.
- make sure that the „open“ part of the sealing ring points towards the interior of the gearbox; see fig. 8.
- use appropriate squeezer or similar device to press the sealing ring uniformly into the flange (see right
part of fig. 8)
5.2.3 Motor installation
- put the stator into the actuator housing
- make sure, the hose protected cables are within the groove (see fig. 9)
- put the rotor with the brake body into the stator housing
- tighten the 4 motor screws
- tighten the 4 grub screws to tense rotor / stator housing
- use appropriate retainer (DELO-ML 5228 or LOCTITE 243; both medium-firm; detachable) to secure
the grub screws
(refer to fig. 5 + 6 for reference no.)
1
(68de0015)
sleeve flange
sealing ring
interior of
squeezer
gearbox
mounting
sleeve
gearbox
(68de0007)