ABB LME620-AI User manual

Operating Instruction
42/68-273-EN
Electrical Linear Actuato
r
LME620-AI/-AN (Contrac)
r
Rated force 4 kN (900 lbf)

Blinder Text
2 LME620-AI/-AN (Contrac) 42/68-273-EN
Electrical Linear Actuator
LME620-AI/-AN (Contrac)
Operating Instruction
42/68-273-EN
09.2008
Rev. D
Manufacturer:
ABB Automation Products GmbH
Schillerstraße 72
32425 Minden
Germany
Tel.: [phone]
Fax: [phone]
[email protected]b.com
© Copyright 2008 by ABB Automation Products GmbH
Subject to change without notice
This document is protected by copyright. It assists the user with the safe and efficient operation of the
device. The contents may not be copied or reproduced in whole or in excerpts without prior approval of
the copyright holder.
Contents

Contents
42/68-273-EN LME620-AI/-AN (Contrac) 3
1Safety....................................................................................................................................................................5
1.1 General Safety Information ............................................................................................................................5
1.2 Intended use...................................................................................................................................................5
1.3 Technical limits...............................................................................................................................................5
1.4 Warranty provision .........................................................................................................................................6
1.5 Labels and symbols........................................................................................................................................6
1.5.1 Symbols and warnings ............................................................................................................................6
1.5.2 Name plate..............................................................................................................................................7
1.6 Operator liability .............................................................................................................................................7
1.7 Personnel qualification ...................................................................................................................................7
1.8 Returning devices...........................................................................................................................................8
1.9 Disposal..........................................................................................................................................................8
1.9.1 Information on WEEE directive 2002/96/EC (Waste Electrical and Electronic Equipment) ...................8
1.10 Transport safety information ..........................................................................................................................8
1.11 Storage conditions..........................................................................................................................................9
1.12 Installation safety information.........................................................................................................................9
1.13 Electrical installation safety information .......................................................................................................10
1.14 Operating safety information ........................................................................................................................10
1.15 Maintenance safety information ...................................................................................................................10
2Design and function ..........................................................................................................................................11
3Installation..........................................................................................................................................................12
3.1 Actuator check..............................................................................................................................................12
3.2 Installation position.......................................................................................................................................12
3.3 Installation instructions .................................................................................................................................12
3.3.1 Valve requirements ...............................................................................................................................13
3.4 Mounting examples ......................................................................................................................................13
3.5 Assembly with the valve ...............................................................................................................................13
4Electrical connection ........................................................................................................................................14
4.1 Cable shield..................................................................................................................................................14
4.1.1 Signal part .............................................................................................................................................14
4.2 Integrated Electronic Unit AI (standard) .......................................................................................................15
4.3 Integrated Electronic Unit AI (bus communication)......................................................................................15
4.4 Electronic unit in field mount EAN823 (standard) ........................................................................................16
4.5 Electronic unit in field mount EAN823 (bus communication) .......................................................................17
4.6 Configuration of digital input/output signals (standard control)....................................................................17
4.6.1 Standard................................................................................................................................................17
4.6.2 Downstream from step controller ..........................................................................................................18
5Operation............................................................................................................................................................19
5.1 Automatic / manual mode.............................................................................................................................19

Contents
4 LME620-AI/-AN (Contrac) 42/68-273-EN
6Maintenance.......................................................................................................................................................20
6.1 Inspection and overhaul ...............................................................................................................................20
6.2 Brake adjustment .........................................................................................................................................20
7Alarms / Errors...................................................................................................................................................21
7.1 Definition ......................................................................................................................................................21
7.1.1 Alarms ...................................................................................................................................................21
7.1.2 Error ......................................................................................................................................................21
7.2 Alarm diagram ..............................................................................................................................................22
7.3 Error diagram ...............................................................................................................................................23
8Trouble shooting ...............................................................................................................................................24
8.1 Electrical test values.....................................................................................................................................25
9Technical data....................................................................................................................................................26
9.1 General information......................................................................................................................................26
10 Appendix ............................................................................................................................................................27
10.1 Permits and certifications .............................................................................................................................27
11 Index ...................................................................................................................................................................29

Safety
42/68-273-EN LME620-AI/-AN (Contrac) 5
1 Safety
1.1 General Safety Information
The “Safety” chapter provides an overview of the safety aspects to be observed for the
operation of the device.
The device is built based on state-of-the-art technology and is operationally safe. It was tested
and left the factory in a proper state. The requirements in the manual as well as the
documentation and certificates must be observed and followed in order to maintain this state for
the period of operation.
The general safety requirements must be complied with completely during operation of the
device. In addition to the general information, the individual chapters of the manual contain
descriptions about processes or procedural instructions with specific safety information.
Only the observance of all safety information enables the optimal protection of personnel as well
as the environment from hazards and the safe and trouble-free operation of the device.
1.2 Intended use
The actuators are used for operating final control elements (valves, vanes, etc.). They may only
be operated using the appropriate Contrac electronic unit. 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. In addition to these operating instructions, the
relevant documentation for the electronic unit and software tools must be observed.
Repairs, alterations and enhancements or the installation of replacement parts is only
permissible as far as described in the manual. Further actions must be verified with ABB
Automation Products GmbH. Excluded from this are repairs performed by ABB-authorized
specialist shops.
1.3 Technical limits
The device is designed for use exclusively within the stated values on the name plate and in the
technical specifications (see "Technical Specifications” chapter and data sheet). These must be
complied with accordingly, e.g.:
• The maximum operating temperature may not be exceeded.
• The permitted operating temperature may not be exceeded.
• The housing protection system must be observed.

Safety
6 LME620-AI/-AN (Contrac) 42/68-273-EN
1.4 Warranty provision
A use contrary to the device’s stipulated use, disregarding of this manual, the use of under-
qualified personnel as well as unauthorized alterations excludes the manufacturer of liability
from any resulting damages. The manufacturer’s warranty expires.
1.5 Labels and symbols
1.5.1 Symbols and warnings
Danger – <Serious damage to health / risk to life>
One of these symbols in conjunction with the “Danger“ warning indicates an imminent danger.
If it is not avoided, death or serious injury will result.
Warning – <Bodily injury>
The symbol in conjunction with the “Warning“ message indicates a possibly dangerous
situation. If it is not avoided, death or serious injury could result.
Caution – <Slight injuries>
The symbol in conjunction with the “Caution“ message indicates a possibly dangerous
situation. If it is not avoided, slight or minor injury can result. May also be used for property
damage warnings.
Notice – <Property damage>
The symbol indicates a possibly damaging situation. If it is not avoided, the product or
something in its area can be damaged.
Important
The symbol indicates operator tips or especially useful information. This is not a message for a
dangerous or damaging situation.

Safety
42/68-273-EN LME620-AI/-AN (Contrac) 7
1.5.2 Name plate
Fig. 1
1 Complete model name
2 Serial no./NL no. (no. of non-list version)
3 Rated force/year of manufacture
4 Permissible ambient
temperature/protection class/CE mark
5 Min./max. stroke/max. actuating
speed/heater
6 Filling lubricant
7 Associated Contrac electronic unit
8 Permissible voltage range/line frequency 1)
9 Power consumption/specifications for fuse
protection 1)
10 Blank for customer-specific entry
1) For LME620-AI only
1.6 Operator liability
The operators must strictly observe the applicable national regulations in their countries with
regards to installation, function tests, repairs, and maintenance of electrical devices.
1.7 Personnel qualification
The installation, commissioning and maintenance of the device may only be carried out through
trained specialist personell authorized by the plant operator. The specialist personnel must have
read and understood the manual and comply with its instructions.

Safety
8 LME620-AI/-AN (Contrac) 42/68-273-EN
1.8 Returning devices
Use the original packaging or a suitably secure packaging for returning the device for repair or
for recalibration. Include the properly filled out return form (see attachment) with the device.
According to EC guidelines for hazardous materials, the owner of hazardous waste is
responsible for its disposal or must observe the following regulations for its shipping:
All delivered devices to ABB Automation Products GmbH must be free from any hazardous
materials (acids, alkali, solvents, etc.).
1.9 Disposal
ABB Automation Products GmbH actively promotes environmental consciousness and has an
operational management system in accordance with DIN EN ISO 9001:2000, EN ISO
14001:2004 and OHSAS 18001. Our products and solutions should have minimum impact on
the environment and persons during manufacture, storage, transport, use and disposal.
This includes the environmentally friendly use of natural resources. Through its publications
ABB conducts an open dialog with the public.
This product/solution is manufactured from materials that can be reused by specialized
recycling companies.
1.9.1 Information on WEEE directive 2002/96/EC (Waste Electrical and Electronic Equipment)
This product/solution is not subject to the WEEE directive 2002/96/EC and relevant national
laws (e.g., ElektroG in Germany).
Dispose of the product/solution directly in a specialized recycling facility and do not use the
municipal garbage. Only privately used products may be disposed of in the municipal garbage
according to the WEEE directive 2002/96/EC. Proper disposal prevents negative effects on
people and the environment, and supports the reuse of valuable raw materials.
If it is not possible to dispose of old equipment properly, ABB Service can accept and dispose of
returns for a fee.
1.10 Transport safety information
Check the devices for possible damage that may have occurred during transport. Damages in
transit must be recorded on the transport documents. All claims for damages must be claimed
without delay against the shipper and before the installation.

Safety
42/68-273-EN LME620-AI/-AN (Contrac) 9
1.11 Storage conditions
The actuators may be stored under aggressive, moist conditions for a short time. The
equipment is protected externally against corrosive influences. However, direct exposure to
rain, snow, etc., must be avoided.
The permissible storage and transport temperatures must be observed.
Actuators equipped with an anti-condensation heater are additionally protected by desiccant,
which is placed in the following locations where condensation may be a problem:
Position sensor: in connection chamber
Electronic unit (separately supplied): electrical connection area
The desiccant guarantees sufficient protection for approximately 150 days. It can be
regenerated at a temperature of 90°C (114°F) within 4 h.
Important
Remove the desiccant prior to commissioning the actuator or the electronic unit.
If you intend to store or transport the device for a longer time, we recommend that you wrap it in
plastic foil and add desiccant. Check that the desiccant is still effective on a regular basis.
During longer periods of downtime (> 6 months) with thrust rod extended, the chrome-plated
stem surface must be protected with a suitable anti-corrosive agent. Before recommissioning,
clean the thrust rod to avoid damage by the stripper and thrust rod gasket.
1.12 Installation safety information
• Depending on how they are set up, the actuators perform movements for positioning vanes
and valves, etc.
• 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 the electronics always observe the locally valid
accident prevention regulations and the regulations concerning the construction of technical
installations.
• Make sure that no process forces are exerted on the control element.
• Do not use the motor or handwheel to lift the actuator.
• The load pick-up device on the actuator (eyebolt) must only be loaded in a vertical direction.
Only use the load pick-up device for lifting/lowering the actuator (without final control element
mounted).

Safety
10 LME620-AI/-AN (Contrac) 42/68-273-EN
1.13 Electrical installation safety information
The electrical connection may only be performed by authorized specialist personnel according
to the electrical plans.
Comply with electrical connection information in the manual. Otherwise, the electrical protection
class can be affected.
The secure separation of contact-dangerous electrical circuits is only guaranteed when the
connected devices fulfil the requirements of the DIN EN 61140 (VDE 0140 Part 1) (basic
requirements for secure separation).
For secure separation, run the supply lines separated from contact-dangerous electrical circuits
or additionally insulate them.
1.14 Operating safety information
Warning - risk of injury!
Note that the actuator position may be changed accidentally by the repelling power of the
valve when the brake is released!
Make sure that process forces are not exerted on the thrust rod.
Before switching on, ensure that the specified environmental conditions in the “Technical Data”
chapter or data sheet are complied with and that the power supply voltage corresponds with the
power electronic unit.
When there is a chance that safe operation is no longer possible, put the device out of operation
and secure against unintended operation.
When mounting the actuator in areas which may be accessed by unauthorized persons, take
the required protective measures.
Switch off the power supply to the motor prior for manual operation.
1.15 Maintenance safety information
Switch off the supply voltage for the power electronic unit and, if necessary, disconnect the
separately supplied anti-condensation heater (option) when working on the actuator or related
subassemblies and take precautions to prevent unintentional switch-on.

Design and function
42/68-273-EN LME620-AI/-AN (Contrac) 11
2 Design and function
Fig. 2: LME620-AI/AN (illustrations may differ from actual installation)
1 Cover (for LME620-AI incl. electronic unit)
2 Handwheel
3 Thrust rod
4 Commissioning and service field (ISF)
Functionality
Actuator for the operation of final control elements with preferably linear movement. The
actuator thrust rod transfers the force directly to the final control element.
A continuous power electronic unit controls the actuator. The electronic unit serves as the
interface between actuator and control system.
During continuous positioning the power electronic unit varies the motor torque steplessly until
the actuator force and the restoring process forces are balanced. High response sensitivity and
high positioning accuracy with short positioning time ensure an excellent control quality and a
long actuator life.

Installation
12 LME620-AI/-AN (Contrac) 42/68-273-EN
3 Installation
3.1 Actuator check
Before you start to install the actuator make sure that the delivery status corresponds to the
ordered status and to the intended use.
• Make sure that the motor and the connection chambers are free of dirt, moisture and
corrosion.
• Make sure adequate travel is provided for the valve stroke.
3.2 Installation position
Fig. 3
The actuator's gearing LME620-AI/-AN (Contrac) is lubricated with grease. This means that any
mounting position can be selected.
3.3 Installation instructions
• Make sure that the actuator is accessible from all sides to ensure convenient hand wheel
operation, electrical connection, and replacement of assemblies.
• Avoid direct exposure to rain, snow and other environmental influences.
• Make sure that the drive elements (thrust rod and valve stem) are not exposed to any
additional vibrational loading equivalent to more than double the rated force (e.g., by a spring
coupling or a vibration absorber between thrust rod and valve stem).
• The maximum rated force of the actuator must not be permanently exceeded. Occasionally
and for short periods only, loads of up to twice the rated force are permissible.
• When mounting the actuator close to heat sources use an insulating layer or shielding.
• In IMV 1 mounting position, the actuators are resistant against vibrational loading acc. to EN
60068-2-6, table C.2 up to 150 Hz and additionally 1 g/30 min. If the operating conditions do
not allow you to estimate whether the actuator's vibrational loading is permanently exceeding
the proven contingent by a significant amount, you will need to reduce the maintenance
intervals accordingly.

Installation
42/68-273-EN LME620-AI/-AN (Contrac) 13
3.3.1 Valve requirements
• The force in the end position can be up to 2.5 times higher than the rated force.
3.4 Mounting examples
Fig. 4: Mounting example LME620-AI/-AN (Contrac)
1 Servo motor
2 Handwheel
3 Mounting screws (8.8)
4 External stop
5 Coupling
6 Valve stem
7 Valve yoke
8 Valve
9 Mechanical position indicator
10 Thrust rod
3.5 Assembly with the valve
1. Drive the thrust rod completely in and put the actuator onto the valve yoke.
2. Make sure the valve stem is aligned with the center of the bore and at right angles to the
actuator seat (permissible parallel deviation < 0.1 mm (0.009 inch) with regard to total
stroke).
3. Fasten the actuator to the yoke with screws of property class 8.8 (tensile strength 800
N/mm2(116032 pounds/square inch); yield strength 640 N/mm2(93550 pounds/square
inch)).
4. Use the hand wheel to drive the thrust rod out; link the rod with the valve stem via the
coupling.
5. Manually retract the thrust rod to check whether or not the external stop of the actuator is on
the housing flange before the valve cone touches the cover.
6. If required, adjust with the coupling (only possible within certain limits!).

Electrical connection
14 LME620-AI/-AN (Contrac) 42/68-273-EN
4 Electrical connection
Each actuator requires a Contrac electronic unit which is loaded with the type specific-software.
Carefully consider the instructions for the electronic unit and compare the data labels of the
actuator and the electronic unit in order to ensure a proper hard- and software assignment.
4.1 Cable shield
4.1.1 Signal part
Fig. 5: Fitting the shield
1. Remove approx. 2 cm of cable sheathing (3) from the end of the cable.
2. Separate the shield and peel it back to its inner sheathing (4).
3. Push the cable through the cable gland and fasten with clamp (1).
4. Make sure that the shielding is touching the clamp and the electronic unit housing (2).

Electrical connection
42/68-273-EN LME620-AI/-AN (Contrac) 15
4.2 Integrated Electronic Unit AI (standard)
Important
The power and signal cables are connected by universal plug to the integrated actuator
electronic unit.
Fig. 6
To switch the actuator to automatic mode (AUT), the following conditions must be met:
• Digital inputs DI1, DI2 and DI3 must be activated via the operator interface.
• Power must be on for the digital input (DI1).
• AUT is activated via operator interface.
4.3 Integrated Electronic Unit AI (bus communication)
Fig. 7: PROFIBUS DP

Electrical connection
16 LME620-AI/-AN (Contrac) 42/68-273-EN
4.4 Electronic unit in field mount EAN823 (standard)
Important
The electrical connection is provided by a plug on the actuator and the terminals on the electronic unit.
Fig. 8
To switch the actuator to automatic mode (AUT), the following conditions must be met:
• Digital inputs DI1, DI2 and DI3 must be activated via the operator interface.
• Power must be on for the digital input (DI1).
• AUT is activated via operator interface.

Electrical connection
42/68-273-EN LME620-AI/-AN (Contrac) 17
4.5 Electronic unit in field mount EAN823 (bus communication)
Fig. 9: PROFIBUS DP
4.6 Configuration of digital input/output signals (standard control)
4.6.1 Standard
Fig. 10: Potential wiring for default assignments

Electrical connection
18 LME620-AI/-AN (Contrac) 42/68-273-EN
4.6.2 Downstream from step controller
Fig. 11: Potential wiring for "Downstream from step controller" operation
Important
When operating the unit downstream from a step controller, the selector switch must be in the
position.
Important
When DI1 is assigned with DC +24 V, the electronic unit is write-protected.

Operation
42/68-273-EN LME620-AI/-AN (Contrac) 19
5 Operation
5.1 Automatic / manual mode
The servo motor triggered by the power electronics controls the axially fixed drive sleeve/nut
assembly via grease-lubricated spur gears. A ball bearing screw (see Figure Fig. 12) radially
fixed by an anti-twist arrester converts the rotary motion to a linear one.
A position sensor detects the current thrust rod position via mechanical reduction gearing
without backlash.
The motor brake locks the actuator in the current position if the power supply is cut off.
M00308
Fig. 12: Ball bearing screw with nut, cross-section
Manual mode allows you to move the actuator manually when the electrical power is off.
Caution - Risk of injury!
When pressing the hand wheel lock, restoring force from the valve may be present in the hand
wheel.
To prevent the hand wheel from turning unintentionally, hold the hand wheel with one hand.
1. Press the hand wheel lock.
Important
Turning the hand wheel to the right causes the thrust rod to extend.
2. Turn the hand wheel to move the part-turn actuator to the desired position.
3. Release the lock.

Maintenance
20 LME620-AI/-AN (Contrac) 42/68-273-EN
6 Maintenance
Important
All maintenance activities may only be performed by properly qualified persons.
Contrac actuators feature a robust construction. As a result, they are highly reliable and require
minimal 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, forces,
temperatures, etc.) and derives the remaining operating time until the next routine maintenance
is required.
Use the configuration program to view this information.
6.1 Inspection and overhaul
• Only use original spare parts for components such as ball bearings and gaskets when
overhauling the actuators.
• Maintenance activities should be performed once the remaining calculated time has expired.
• Inspection or maintenance is due after the time specified in the table.
Overhaul intervals:
Interval Measures
1 x per year Visual check of the gaskets for leaks, change
if necessary
Change, roller bearings and gaskets on motor
and gearing.
Max. every 10 years, preferably once the
calculated time before the next maintenance
operation has expired Check gear wheels for wear; replace if
necessary.
Make sure that no chippings or other material get into the gearbox during the maintenance
work.
6.2 Brake adjustment
Warning - risk of injury!
Note that the actuator position may be changed accidentally by the repelling power of the
valve when the brake is released!
Make sure that process forces are not exerted on the thrust rod.
Since the brake is permanently released in AUT mode it is not exposed to mechanical wear.
Any readjustment is not necessary. Enables users to test the configuration software of the
brake.