ABB PME120 User manual

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ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
PME120/RHD250 to 4000 (Contrac)
Electrical rotary actuator
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ABB Limited
Measurement & Analytics
Howard Road, St. Neots
Cambridgeshire, PE19 8EU
UK
Tel: [phone]
Fax: [phone]
Email: [email protected]m
ABB Automation Products GmbH
Measurement & Analytics
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
abb.com/actuators
ABB Inc.
Measurement & Analytics
125 E. County Line Road
Warminster, PA 18974
USA
Tel: [phone]
Fax: [phone]
Electrical rotary actuator for the
operation of final control elements
OI/PME/RHD250/4000-EN Rev. F 05.2019 Original instruction
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PME120
RHD250
RHD500
RHD800
RHD1250
RHD2500
RHD4000
Introduction
Compact actuator for the operation of final control
elements with preferably 90° rotary movement such
as valve flaps, ball valves, etc.
The nominal torque is transferred through a lever
actuator. A special electronic unit controls the
actuator. The special electronic unit serves as the
interface between actuator and control system.
Additional Information
Additional documentation on PME120 / RHD250 /
500 / 800 / 1250 / 2500 / 4000 (Contrac) is available
for download free of charge at
www.abb.com/actuators.
Alternatively simply scan this code:
—
We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations
contained therein. Any reproduction, disclosure to third parties or utilization of its
contents – in whole or in parts – is forbidden without prior written consent of ABB.
© ABB 2019 3KXE111014R4201

2 PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F
Table of contents
Change from one to two columns
1Safety.......................................................................... 3
General information and instructions.................................. 3
Warnings.................................................................................... 3
Intended use .............................................................................4
Improper use.............................................................................4
Notes on data safety ...............................................................4
Warranty provisions.................................................................4
Manufacturer’s address..........................................................4
2Design and function .................................................. 5
Design ........................................................................................5
Principle of operation..............................................................5
Device designs..........................................................................6
PME120..................................................................................6
RHD ........................................................................................ 7
3Product identification ..............................................9
Name plate ................................................................................9
4Transport and storage............................................10
Inspection................................................................................10
Transporting the device........................................................10
Safety instructions............................................................10
Returning devices...................................................................10
Storing the device ..................................................................10
5Installation ............................................................... 11
Safety instructions................................................................. 11
Mounting ................................................................................. 11
Actuator check................................................................... 11
Installation instructions................................................... 11
Fastening the actuator..................................................... 11
Mounting position............................................................. 11
Assembly with the final control element ...................... 12
Installation variants ..........................................................14
Dimensions.............................................................................. 16
Control actuator PME120.................................................16
Direct adapter PME120-AI/-AN ....................................... 17
Control actuator RHD250 ................................................18
Control actuator RHD500 / RHD800 ............................. 19
Control actuator RHD1250 / RHD2500..........................20
Control actuator RHD4000.............................................. 21
Connection pipe and link rod ..........................................22
6Electrical connections.............................................24
Safety instructions.................................................................24
Conductor cross-section on universal plug.......................24
Conductor cross-section on electronic unit......................25
Cable glands.......................................................................25
Selection of suited connection cables...........................25
Integrated PME120-AI Electronic unit.................................26
Analog / Digital..................................................................26
PROFIBUS DP®....................................................................27
Electronic unit EAN823 (Contrac) for PME120-AN............28
Analog / Digital..................................................................28
PROFIBUS DP®....................................................................29

Electronic unit EAS822 (Contrac) for PME120-AN............ 30
Analog / Digital ................................................................. 30
Electronic unit EBS853 (Contrac) / EBS861 (Contrac).....31
Analog / Digital ..................................................................31
PROFIBUS DP® ................................................................... 32
Electronic Unit EBN852 (Contrac)....................................... 33
Analog / Digital ................................................................. 33
Analog / Digital ................................................................. 34
7Commissioning ........................................................35
8Operation..................................................................35
Safety instructions ................................................................ 35
Automatic mode / Handwheel mode................................. 35
Manual operation................................................................... 35
Handwheel operation in combination with positioning
loop monitoring ................................................................ 36
9Diagnosis / error messages ...................................37
Electrical test values ............................................................. 37
10Maintenance .............................................................38
Safety instructions ................................................................ 38
General..................................................................................... 38
Inspection and overhaul ....................................................... 38
Maintenance plan.............................................................. 38
Removing the motor and adjusting the brakes ............... 39
Oil change ............................................................................... 39
PME oil types .....................................................................40
RHD oil types .....................................................................40
11Repair ....................................................................... 42
Returning devices .................................................................. 42
12Recycling and disposal ........................................... 42
Notice on RoHS II-Directive 2011/65/EU........................... 42
13Approvals and certifications ................................. 43
14Additional documents............................................ 43
15Appendix .................................................................. 44
Return form.............................................................................44
Installation declaration......................................................... 45

PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F 3
Change from one to two column
1Safety
General information and instructions
These instructions are an important part of the product and
must be retained for future reference.
Installation, commissioning, and maintenance of the product
may only be performed by trained specialist personnel who have
been authorized by the plant operator accordingly. The specialist
personnel must have read and understood the manual and must
comply with its instructions.
For additional information or if specific problems occur that are
not discussed in these instructions, contact the manufacturer.
The content of these instructions is neither part of nor an
amendment to any previous or existing agreement, promise or
legal relationship.
Modifications and repairs to the product may only be performed
if expressly permitted by these instructions.
Information and symbols on the product must be observed.
These may not be removed and must be fully legible at all times.
The operating company must strictly observe the applicable
national regulations relating to the installation, function testing,
repair and maintenance of electrical products.
Warnings
The warnings in these instructions are structured as follows:
DANGER
The signal word ‘DANGER’ indicates an imminent danger.
Failure to observe this information will result in death or
severe injury.
WARNING
The signal word ‘WARNING’ indicates an imminent danger.
Failure to observe this information may result in death or
severe injury.
CAUTION
The signal word ‘CAUTION’ indicates an imminent danger.
Failure to observe this information may result in minor or
moderate injury.
NOTICE
The signal word
‘
NOTIC
E
’
indicates possible material damage.
Note
‘Note’ indicates useful or important information about the
product.

4 PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F
… 1 Safety
Intended use
Control actuators are used exclusively for operating final control
elements (valves, valve flaps, etc.).
They may only be operated using a suited Contrac electronic unit
for field installation or mounting rack installation.
In addition to this operating instruction, the relevant
documentation for the electronic unit and software tool must be
observed.
Improper use
The following are considered to be instances of improper use of
the device:
• For use as a climbing aid, for example for mounting
purposes.
• For use as a bracket for external loads, for example as a
support for piping, etc.
• Material application, for example by painting over the
housing, name plate or welding/soldering on parts.
• Material removal, for example by spot drilling the
housing.
Notes on data safety
This product is designed to be connected to and to
communicate information and data via a network interface.
It is operator’s sole responsibility to provide and continuously
ensure a secure connection between the product and your
network or any other network (as the case may be).
Operator shall establish and maintain any appropriate measures
(such as but not limited to the installation of firewalls,
application of authentication measures, encryption of data,
installation of anti-virus programs, etc.) to protect the product,
the network, its system and the interface against any kind of
security breaches, unauthorized access, interference, intrusion,
leakage and / or theft of data or information.
ABB Automation Products GmbH and its affiliates are not liable
for damages and / or losses related to such security breaches,
any unauthorized access, interference, intrusion, leakage and /
or theft of data or information.
Warranty provisions
Using the device in a manner that does not fall within the scope
of its intended use, disregarding this manual, using
underqualified personnel, or making unauthorized alterations
releases the manufacturer from liability for any resulting
damage. This renders the manufacturer's warranty null and void.
Manufacturer’s address
ABB Automation Products GmbH
Measurement & Analytics
Schillerstr. 72
32425 Minden
Germany
Tel: [phone]
Fax: [phone]
Customer service center
Tel: [phone]
Email: [email protected]

PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F 5
2Design and function
Design
1Hand wheel crank
2Plug
3Lever
4Ball-and-socket joint
5Lever cover
6Adjustable stops (under the
lever cover)
7Gear housing
8Control motor
9Cover (for PME120-AI incl.
electronic unit)
jHand wheel release
Figure 1: PME120 (illustrations may differ from actual installation)
M10575
1c
d
f
i
h
g
e
b
1Hand wheel crank
2Handwheel
3Ball-and-socket joint
4Output lever
5Lever cover
6Output shaft
7Adjustable stops
(under the lever cover)
8Control motor
9Handwheel unlock
Figure 2: RHD (illustrations may differ from actual installation)
Principle of operation
Compact actuator for the operation of final control elements
with preferably 90° rotary movement such as valve flaps, ball
valves, etc.
The nominal torque is transferred through a lever actuator.
A special electronic unit controls the actuator. The special
electronic unit serves as the interface between actuator and
control system.
During continuous positioning, the electronic unit varies the
motor torque steplessly until the actuator force and the control
valve force are balanced. High response sensitivity and high
positioning accuracy with short positioning time ensure an
excellent control quality and a long actuator life.
Change from tw o to one column

6 PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F
… 2 Design and function
Device designs
PME120
PME120-AI (integrated electronic unit) PME120-AI (separate electronic unit)
Operating mode S9 – 100%; stall-proof acc. to IEC 60034-1/EN 60034-1
IP rating IP 66 acc. to IEC 60529/EN 60529
NEMA 4X acc. to CAN/CSA22.2 No. 94
Humidity ≤95 % annual average; condensation not permitted
Ambient temperature −10 to 55 °C (15 to 130 °F)
−25 to 55 °C (−15 to 130 °F)
−10 to 65 °C (15 to 150 °F)
−25 to 55 °C (−15 to 130 °F)
−1 to 85 °C (30 to 185 °F)
Transport and storage temperature −25 to 70°C (−15 to 160 °F) −40 to 70 °C (−40 to 160 °F)
Long-term storage temperature −25 to 40 °C (−15 to 105 °F) −30 to 40 °C (−25 to 105 °F)
Mounting position any position; preferably IMB 3 acc. to IEC 60034-7 / EN 60034-7
Coating 2-layer component epoxy (RAL 9005, black)
Anti-condensation heater – Optional (separate power supply or power feed from
Contrac electronic unit)
Electrical connection – Electronic unit – Actuator connection cable:
Optional 5 m (16 ft), 10 m (32 ft) or 20 m (65 ft)
Max. 30 m (98 ft) for electronic unit EAN823
Max. 480 m (1575 ft) for electronic unit EAS822
(Follow the ‘electronic unit’ data sheet!)
Power supply for motor and sensors Via Contrac electronic unit only
PME120-AI PME120-AN
Nominal torque 100 Nm (80 lbf-ft), adjustable to 0.5, 0.75 or 1 × nominal torque
Starting torque 1.2 × nominal torque (break-away torque in end positions for short time 2 × nominal torque)
Rated time for 90°; adjustable 20 to 900 s
Rated operating speed, adjustable 4.5 to 0.1 °/s
Rated time for 90°; adjustable
(Temperature design −1 to 85 °C)
45 to 900 s
Rated operating speed, adjustable
(Temperature design −1 to 85 °C)
2.0 to 0.1 °/s
Operating angle Typically 90° (min. 35°; max. 270°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight Approx. 36 kg (79 lb) Approx. 32 kg (70 lb)
Associated electronic unit Integrated electronic unit For field installation: EAN823
For rack installation: EAS822
Motor EM24
24 V 3~ asynchronous motor, insulation material class F DIN EN 60085
Sensors Position transmitter and temperature sensor always available

PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F 7
RHD
RHD250 / RHD500 / RHD800 / RHD1250 / RHD2500 / 4000
Operating mode S9 – 100%; stall-proof acc. to IEC 60034-1/EN 60034-1
IP rating IP 66 acc. to IEC 60529/EN 60529
NEMA 4X acc. to CAN/CSA22.2 No. 94
Humidity ≤95 % annual average; condensation not permitted
Ambient temperature −10 to 65 °C (15 to 150 °F)
−30 to 50 °C (−20 to 125 °F)
−1 to 85 °C (30 to 185 °F)*
Transport and storage temperature −40 to 70 °C (−40 to 160 °F)
Long-term storage temperature −30 to 40 °C (−22 to 104 °F)
Mounting position any position; preferably IMB 3 acc. to IEC 60034-7 / EN 60034-7
Coating 2-layer component epoxy (RAL 9005, black)
Anti-condensation heater Motor winding: directly from electronic unit.
Signal space: separate heating resistor; separate power supply or power feed from Contrac electronic unit
Electrical connection Plug connection with crimp snap-in contacts or screw terminals
Connection cable for electronic unit – actuator available as an option (see ordering information for
electronic unit)
Power supply for motor and sensors Via Contrac electronic unit only
* 85 °C / 185 °F- design not available for all RHD variants.
RHD250-10
Nominal torque 250 Nm (185 lbf-ft), adjustable to 0.5, 0.75 or 1 × nominal torque
Starting torque 1.2 × nominal torque (break-away torque in end positions for short time 2 × nominal torque)
Rated time for 90°; adjustable 10 to 900 s
Rated operating speed, adjustable 9.0 to 0.1°/s
Operating angle Typically 90° (min. 35°; max. 270°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight Approx. 45 kg (99 lb)
Associated electronic unit For field mounting: EBN853
For rack installation: EBS852
Motor MCS 71 BA
Sensors Position transmitter and temperature sensor always available

8 PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F
… 2 Design and function
… Device designs
RHD500-10 RHD800-10
Nominal torque 500 Nm (370 lbf-ft), adjustable to 0.5, 0.75 or 1 ×
nominal torque
800 Nm (590 lbf-ft), adjustable to 0.5, 0.75 or 1 ×
nominal torque
Starting torque 1.2 ×nominal torque (break-away torque in end positions for short time 2 ×nominal torque)
Rated time for 90°; adjustable 10 to 900 s
Rated operating speed, adjustable 9.0 to 0.1°/s
Operating angle Typically 90° (min. 35°; max. 140°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight Approx. 94 kg (207 lb) Approx. 97 kg (214 lb)
Associated electronic unit For field mounting: EBN853
For rack installation: EBS852
Motor MCS 71 BA MCS 80 BA
Sensors Position transmitter and temperature sensor always available
RHD1250-12 RHD2500-10 RHD2500-25
Nominal torque 1250 Nm (920 lbf-ft), adjustable to
0.5, 0.75 or 1 × nominal torque
2500 Nm (1850 lbf-ft), adjustable to 0.5, 0.75 or 1 × nominal torque
Starting torque 1.2 × nominal torque (break-away torque in end positions for short time 2 × nominal torque)
Rated time for 90°; adjustable 12 to 900 s 10 to 900 s 25 to 900 s
Rated operating speed, adjustable 7.5 to 0.1°/s 9.0 to 0.1 °/s 3.6 to 0.1 °/s
Operating angle Typically 90° (min. 35°; max. 140°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight (including lever-type actuator) Approx. 227 kg (500 lb) Approx. 232 kg (511 lb) Approx. 227 kg (500 lb)
Associated electronic unit For field mounting: EBN853
For rack installation: EBS852
For field mounting: EBN861
For rack installation: EBS862
For field mounting: EBN853
For rack installation: EBS852
Motor MCS 80 BA MC 90 BA MCS 80 BA
Sensors Position transmitter and temperature sensor always available
RHD4000-10 RHD4000-40
Nominal torque 4000 Nm (2950 lbf-ft), adjustable to 0.5, 0.75 or 1 × nominal torque
Starting torque 1.2 × nominal torque (break-away torque in end positions for short time 2 × nominal torque)
Rated time for 90°; adjustable 10 to 900 s 40 to 900 s
Rated operating speed, adjustable 9.0 to 0.1°/s 2.25 to 0.1°/s
Operating angle Typically 90° (min. 35°; max. 270°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight Approx. 290 kg (639 lb) Approx. 283 kg (624 lb)
Associated electronic unit For field mounting: EBN861
For rack installation: EBS862
For field mounting: EBN853
For rack installation: EBS852
Motor MC 100 BA MC 90 BA
Sensors Position transmitter and temperature sensor always available
Change from one to two columns

PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F 9
3Product identification
Name plate
1Full type designation
2Manufacturing number / NL-no.
(In the case of a non-listed
design)
3Output torque / Year of
manufacture
4Permissible ambient
temperature / IP-IP rating / CE
marking
5Min., max. operating angle /
max. operating speed / Heating
(optional)
6Filled oil types
7Associated Contrac electronic
unit
8Permissible voltage range /
mains frequency (for
PME120-AI only)
9Power consumption /
specifications for fuse
protection (for PME120-AI only)
jFree for customer-specific
information
Figure 3: PME name plate
1Full type designation
2Manufacturing number / NL-no.
(In the case of a non-listed
design)
3Output torque / Year of
manufacture
4Permissible ambient
temperature / IP-IP rating / CE
marking
5Min., max. operating angle /
max. operating speed / Heating
(optional)
6Filled oil types
7Associated Contrac electronic
unit
8Free
9Free
jFree for customer-specific
information
Figure 4: RHD name plate

10 PME120/RHD250 to 4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/PME/RHD250/4000-EN REV. F
4Transport and storage
Inspection
Check the devices immediately after unpacking for possible
damage that may have occurred from improper transport.
Details of any damage that has occurred in transit must be
recorded on the transport documents.
All claims for damages must be submitted to the shipper
without delay and before installation.
Transporting the device
Safety instructions
DANGER
Danger to life due to falling or toppling loads.
Risk of death or serious injury due to the device falling down
or toppling over!
• Standing under suspended loads is prohibited.
• Do not detach the hoisting equipment until installation is
complete.
• Only use the dedicated load pick-up devices (eyebolts) for
suspending the components.
Consider the following items during transport:
• Pay attention to the device weight details.
• Do not expose the device to humidity during transport.
Pack the device accordingly.
• Pay attention to the permissible transportation
temperatures for the device.
Returning devices
For the return of devices, follow the instructions in Repair on
page 42.
Storing the device
Note
The storage data provided below assumes that the devices are
fully closed and thus comply with the IP rating stated in the
specification.
When devices are supplied, their IP rating is guaranteed. If the
devices have been tested or commissioned, the IP rating needs
to be guaranteed before they are put into storage.
The devices may be stored under moist and corrosive conditions
for a short time. The equipment is protected against external
corrosive influences. However, direct exposure to rain, snow,
etc., must be avoided.
The permissible storage and transport temperatures must be
observed.
Devices equipped with a heater are also protected by desiccant,
which is placed in the following locations where condensation
may be a problem:
Position sensor: In connection chamber
Electronic unit In electrical connection chamber
The desiccant guarantees sufficient protection for
approximately 150 days. It can be regenerated at a temperature
of 90 °C (114 °F) within 4 h.
Remove the desiccant prior to commissioning the actuator or
the electronics.
If you intend to store or transport the device for a prolonged
period (> 6 months), we recommend that you wrap it in plastic
film and add desiccant.
Protect uncovered metallic surfaces with an appropriate long-
term corrosion inhibitor.
The relevant long-term storage temperatures must be observed.