ABB RHDE250 User manual

—
ABB MEASUREMENT & ANALYTICS | OPERATING INSTRUCTION
RHDE250 to RHDE4000 (Contrac)
Electrical rotary actuator
—
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/RHDE250_4000-EN Rev. B 08.2018 Original instruction
—
RHDE250
RHDE500
RHDE800
RHDE1250
RHDE2500
RHDE4000
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 RHDE250 / 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.
Copyright© 2018 ABB
All rights reserved 3KXE111016R4201

2 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
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Use in potentially explosive atmospheres .............5
Ex marking.................................................................................5
Standards ..................................................................................5
Thermal motor monitoring ....................................................5
Overview ....................................................................................6
Technical data for the cable set (for Ex-relevant range)... 7
3Design and function .................................................. 9
Design ........................................................................................9
Principle of operation..............................................................9
Device designs........................................................................10
4Product identification ............................................ 13
Name plate .............................................................................. 13
5Transport and storage............................................ 13
Inspection................................................................................ 13
Transporting the device........................................................ 13
Safety instructions............................................................ 13
Returning devices................................................................... 13
Storing the device ..................................................................14
6Installation ............................................................... 14
Safety instructions.................................................................14
Mounting .................................................................................14
Actuator check................................................................... 14
Installation instructions................................................... 15
Fastening the actuator..................................................... 15
Mounting position............................................................. 15
Assembly with the final control element ......................16
Installation variants .......................................................... 17
Dimensions.............................................................................. 19
Control actuator RHD250 ................................................19
Control actuator RHD500 / RHD800 .............................20
Control actuator RHD1250 / RHD2500.......................... 21
Control actuator RHD4000..............................................22
Connection pipe and link rod ..........................................23
7Electrical connections.............................................26
Safety instructions.................................................................26
Conductor cross-section on control actuator ..................26
Conductor cross-section on electronic unit......................26
Cable glands............................................................................ 27
Selection of suited connection cables ...............................27
Connection of cable shielding .............................................28
Sensor-connection chamber ...........................................28
Motor connection chamber.............................................28

Electronic Unit EBN853 (Contrac)....................................... 29
Analog / Digital ................................................................. 29
PROFIBUS DP® ................................................................... 30
Analog / Digital ..................................................................31
PROFIBUS DP® ................................................................... 32
Analog / Digital ................................................................. 33
8Commissioning ....................................................... 34
9Operation................................................................. 34
Safety instructions ................................................................ 34
Automatic mode / Handwheel mode................................. 34
Manual operation................................................................... 34
Handwheel operation in combination with positioning
loop monitoring ................................................................ 35
10Diagnosis / error messages ...................................36
Electrical test values ............................................................. 36
11Maintenance .............................................................37
Safety instructions ................................................................ 37
General..................................................................................... 37
Inspection and overhaul ....................................................... 37
Maintenance plan.............................................................. 37
Removing the motor and adjusting the brakes ............... 38
Oil change ............................................................................... 38
Oil types.............................................................................. 38
12Repair ........................................................................39
Returning devices .................................................................. 39
13Recycling and disposal............................................39
Notice on RoHS II-Directive 2011/65/EU........................... 39
14Approvals and certifications ................................. 40
15Additional documents............................................ 40
16Appendix ...................................................................41
Return form............................................................................. 41
Installation declaration......................................................... 42

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 3
Change from one to two columns
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:
DANGE
R
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 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 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]
Change from tw o to one column

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 5
2Use in potentially explosive atmospheres
Change from one to two columns
Explosion proof Contrac actuators are classified as type II
devices for operation in potentially explosive atmospheres for
days and device category 2.
They are designed for use in Ex zones 1 and 21.
Can of course also be used in zones 2 and 22 (for gas and dust
atmosphere).
Ex marking
Actuator components
Full identification II 2 GD ck Ex de [ib] ib II B T4
or
IP6x T=130 °C ZELM 04 ATEX 0209 X
Motor with brake II GD Ex de IIB T4
Gearing II 2GD ck T4
Position sensor II 2G Ex [ib] ib IIC T4
Anti-condensation heater II 2G Ex d II C
Connection areas II 2G/D Ex e II B T4
Standards
Applicable standards
• EN 50 014
• EN 50 018
• EN 50 019
• EN 50 020
• EN 50 0281-1-1
• EN 13 463-1
• EN 13 463-5
• EN 13 463-8
Thermal motor monitoring
In Contrac control actuators for use in potentially explosive
atmospheres, additional independent monitoring of motor
temperature is required.
Monitoring can be performed using the ABB SD241-B monitoring
unit or a comparable certified tripping unit for thermistor
temperature sensors.
The motor temperature monitoring unit interrupts the power
supply as soon as the motor temperature up-scales the
permissible limit value.
Change from tw o to one column

6 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 2 Use in potentially explosive atmospheres
Overview
Figure 1: Allocation of the Contrac components when using in potentially explosive atmospheres (example)

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 7
Technical data for the cable set (for Ex-relevant range)
Motor connection Motor temperature monitoring Signal terminal (option)
Wire conductor 8 × 1.5 2 × 1.5 8 × 0.5
Mat.-No. 9280271 9280272 9280183
Manufacturer Huber + Suhner Huber + Suhner Bröckskes (Helu-Kabel)
Type RX125 S2 B 8g1.5 mm2 BK RX125 S2 2×1.5 mm2 BK So-LTG-PUR-8 × 0.5
(HK-So-Li12YC11Y-OB-8 × 0.5)
Sheathing diameter 14.3 ±0.4 mm
(0.56 ±0.02 in)
8.0 ±0.4 mm
(0.31 ±0.02 in)
8.5 ±0.4 mm
(0.33 ±0.02 in)
Nominal voltage Uo / U
(Uo also applies to wire / shielding)
600 / 1000 V 600 / 1000 V 300 / 500 V
Wire / wire test voltage 3.5 kV 3.5 kV 1.2 kV
Temperature range Motor connection Motor temperature monitoring Signal terminal (option)
Moving −25 to 125 °C (−13 to 257 °F) −25 to 125 °C (−13 to 257 °F) −40 to 90 °C −40 to 194 °F)
Not moving −40 to 125 °C (−40 to 257 °F) −40 to 125 °C (−40 to 257 °F) −50 to 90 °C (−58 to 194 °F)
Protective earth GNYE
Environment UV-resistant and weather-proof UV-resistant and weather-proof UV-resistant and weather-proof
Motor connection Motor temperature monitoring Signal terminal (option)
Cable gland 13.5 to 18 / M25 × 1.5 Exe 4 to 8.5 / M20 × 1.5 Exe
Mat.-No. 9287589 9287588
Manufacturer Rabe-System-Technik Rabe-System-Technik
Type CMDEL-T ADE 1F
Article no. 00222574 00816674
Cable diameter 13.5 to 18 mm
(0.53 to 0.71 in)
4 to 8.5 mm
(0.16 to 0.33 in)
Material Brass, nickel-plated Brass, nickel-plated
Standard seal insert Neoprene Neoprene
O-ring Perbunan Neoprene
Temperature range −40 to 100 °C (−40 to 212 °F) −40 to 100 °C (−40 to 212 °F)
IP rating IP 68 - 10 bar (140.04 psi) IP 68 - 5 bar (72.52 psi)
Certificate LCIE 97 ATEX 6005 X / 01 LCIE 97 ATEX 6008 X / 03
Marking II 2 G D
Ex e II / Ex tD
Ex II 2 G D, Exe II

8 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 2 Use in potentially explosive atmospheres
… Technical data for the cable set (for Ex-relevant range)
Option
Motor connection Motor temperature monitoring Signal terminal (option)
Manufacturer Pflitsch Pflitsch
Type blue globe ATEX blue globe ATEX
Diameter M25 × 1.5 KAD20-16/16-11 M20 × 1.5 KAD14-9/9-5
Article no. bg225 msex bg220 msex
Temperature range −40 to 115 °C (−40 to 239 °F) −40 to 115 °C (−40 to 239 °F)
IP rating IP 68 IP 68
Certificate PTB 06 ATEX 1036 X PTB 06 ATEX 1036 X
Marking II 2 G Ex e II II 2 D Ex tD A21 IP68
Note
If the specified cable harness does not meet all safety-relevant requirements, the proper installation material must be used.
Change from one to two columns

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 9
3Design and function
Design
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

10 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 3 Design and function
Device designs
RHDE250 / 500 / 800 / 1250 / 2500 / 4000 (Contrac)
Operating mode S9; stallproof acc. to EN 60034-1
IP rating IP 66
Explosion protection ATEX
Humidity ≤95 % annual average; condensation not permitted
Ambient temperature −25 to 60 °C (−13 to 140 °F)
−30 to 40 °C (−22 to 104 °F)
(reduced operating speed at rated load and below −10 °C (14 °F))
Transport and storage temperature −30 to 60 °C (−22 to 140 °F)
Long-term storage temperature −30 to 40 °C (−22 to 104 °F)
Mounting position IMB 3, IMB 6, IMB 7, IMV 6; preferably IMB 3 in accordance with 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 Terminals in Ex e area; separately for motor and signals
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
RHDE250-10
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. 140°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight 61.5 kg (136 lb)
Associated electronic unit For field mounting: EBN853
For rack installation: EBS852
Thermal motor monitoring With motor temperature monitoring unitt SD241-B or similarly certified tripping unit for thermistor
temperature sensors
Motor BD 80 M1-4 B
Sensors Position transmitter and temperature sensor always available

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 11
RHDE500-10 RHDE800-10
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 x 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 106.5 kg (235 lb) 107 kg (236 lb)
Associated electronic unit For field mounting: EBN853
For rack installation: EBS852
Thermal motor monitoring With motor temperature monitoring equipment SD241B or similarly certified tripping unit for thermistor
temperature sensors
Motor BD 80 M1-4 B BD 80 M2-4 B
Sensors Position transmitter and temperature sensor always available
RHDE1250-12 RHDE2500-10 RHDE2500-25
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 282 kg (622 lb) 269.5 kg (594 lb) 282 kg (622 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
Thermal motor monitoring With motor temperature monitoring equipment SD241B or similarly certified tripping unit.
Motor BD 80 M2-4 B BD 90 L-4 B BD 80 M2-4 B
Sensors Position transmitter and temperature sensor always available

12 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 3 Design and function
… Device designs
RHDE4000-10 RHDE4000-40
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. 140°), with lever and limit stops the mechanical limits in accordance with
operating instruction should be complied with.
Weight Approx. 296 kg (653 lb) Approx. 284.5 kg (627 lb)
Associated electronic unit For field mounting: EBN861
For rack installation: EBS862
For field mounting: EBN853
For rack installation: EBS852
Thermal motor monitoring With motor temperature monitoring equipment SD241B or similarly certified tripping unit for thermistor
temperature sensors
Motor BD 100 L2-4 B BD 90 L-4 B
Sensors Position transmitter and temperature sensor always available
Change from one to two columns

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 13
4Product identification
Name plate
M10305
/ ActuatorCONTRAC .. ..
F
-Nr./No NL -/-
=Jahr/Year
CE
Ta = IP 66
Öl /Oil:
für/for
Elektronik/Electronics EBN.../EBS...
PTZ 16 ATEX 0017X
1
2
3
4
5
6
7
8
9
j
0044
s = min. ..... max. ......
F
v = .......... mm/s
II 2G
II 2D
ABBAutomationProducts GmbH
Schillerstraße 72
D-32425 Minden
Made in Germany
II2G ck Ex d e [ib] ib IIB T4 Gb, II 2D ck Ex tb IIIC T130°C
Antrieb
1Full type designation
2manufacturing number / NL-No.
(For no-list design)
3Output torque / Year of
manufacture
4Permissible ambient
temperature / IP rating / CE
mark with information about
the monitoring authority
5Min., max. operating angle /
max. operating speed / Heating
(optional)
6Filled oil types
7Associated Contrac electronic
unit
8Explosion protection degree
9Approval body and inspection
no.
0Free for customer-specific
information
Figure 3: Name plate (example)
5Transport 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
DANGE
R
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 39.

14 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 5 Transport and storage
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.
6Installation
Safety instructions
DANGE
R
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.
Please observe the following safety instructions
• Only qualified specialists may mount and adjust the control
actuator, and make the electrical connection.
• When working on the actuator or the electronics always
observe the locally valid accident prevention regulations and
the regulations concerning the construction of technical
installations.
• Switch off the supply voltage and take precautions to
prevent unintentional switch-on.
Mounting
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.
• Check the oil level when installing the device in positions
other than IMB 3.
• Once the actuator is installed, fasten the vent valve in the
uppermost oil hole.
• Prior to commissioning the device, make sure that the motor
and the connection chambers are free of dirt, humidity and
corrosion.

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 15
Installation instructions
• Make sure that no process forces are exerted on the final
control element.
• Do not lift the actuator by the motor or handwheel.
• The load pick-up device (eyebolt) attached to the actuator
may only be loaded in the vertical direction. Only use the load
pick-up device to lift / lower the actuator (without final
control element mounted).
• Make sure that the actuator is accessible from all sides so
that convenient handwheel operation, electrical connection,
or exchange of assemblies is possible.
• Select the installation location such to avoid direct exposure
to rain, snow and other environmental influences.
• The control actuators can withstand vibration loadings in
accordance with EN 60068-2-6, Table C.2 to 150 Hz and max.
2 g.
• The substructure should be designed to be level and torsion-
resistant.
• The drive elements (lever/coupling rod) must not cause
additional vibration loadings (e.g., use spring couplings or
vibration absorbers in the coupling rod.)
• When mounting the actuator close to heat sources use an
insulating layer or shielding.
• Make sure that the max. ambient temperature of 60 °C
(140 °F) or 40 °C (104 °F) for the lower temperature design is
not up-scaled. If required, provide a sunshield to protect
against direct sunlight.
• The maximum tilt angle of 140° must not be exceeded.
Fastening the actuator
1..Place the actuator on the fastening device in the correct
position. Pay attention to the rotating direction in
combination with the final control element.
2.Fasten the actuator using four screws. Use the biggest
possible screw diameter and observe the tightening torque
(see table Locking and fastening elements on page 17).
Mounting position
The spur gears of the actuator are oil lubricated.
They contain the max. oil quantity when leaving the
manufacturer. Once the actuator is installed replace the
uppermost check plug by the separately supplied venting plug.
M10304
IMB 3 IMB 6 IMB 7 IMV 6
12
1Control screw 2 Vent valve
Figure 4: Permissible mounting positions
The mounting positions presented are permissible.
To facilitate mounting and maintenance, however, it is
recommended that you use position IMB 3
For each mounting position, you should check the specified oil
level before commissioning, Oil types on page 38.
Note
It is important that sufficient cooling air is supplied and
sufficient space is available should components need to be
exchanged.
To achieve this, allow for the following minimum distances:
Actuator Space
RHDE250 40 mm (1.57 in)
RHDE500 / 800 30 mm (1.18 in)
RHDE1250 / 2500 40 mm (1.57 in)
RHDE4000 40 mm (1.57 in)

16 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 6 Installation
… Mounting
Assembly with the final control element
WARNING
Risk of injuries due to crushing between the lever and the
stops or between the lever and the coupling rod,
respectively!
• Prior to starting any mechanical work on the device,
switch off the voltage supply to the motor and take
precautions to prevent unintentional switch-on.
WARNING
Risk of injury due to live parts!
• When working on the actuator or the related subassembly,
switch off the power supply for the electronic unit and
separate anti-condensation heater (option), and take
precautions to prevent unintentional switch-on!
NOTICE
Vibrational loading may cause the lever cover to come off!
• Secure the lever cover with the appropriate screw locking
devices!
Note
Before finally coupling the actuator to the valve, let it once
overshoot the actual ‘OPEN’ and ‘CLOSED’ end positions by at
least 10 %.
Preparation for mounting with lever
1..Make sure that the shaft and lever hole surface are clean and
free of grease.
2.Determine the length of the coupling tube (not included in
the scope of delivery) on-site.
3.Move the final control element to the ‘CLOSED’ end position.
4.Use the handwheel to move the actuator into the proper end
position. Observe the permissible angle.
5.Refer to relevant data sheet for the required length of the
connection pipe.
6.In order to fasten the second ball-and-socket joint, provide a
cone in the lever of the final control element, in accordance
with the dimensions.
7.Insert the ball-and-socket joint, and secure with crown nut
and split-pin.
8.Remove the welding bushings and weld them to the coupling
tube.
9.Insert the link rod between the two ball-and-socket joints
and screw it in.
10.The ‘L’ dimension can be adjusted by turning the link rod.
11.When adjustment is finished, fasten the counter nuts.
Travel-dependent stop adjustment
1.Remove the lever cover.
2.Move the actuator lever / final control element to the end
position requiring finer mechanical adjustment.
3.Put the limit stop onto the toothing as close to the actuator
lever as possible and fasten it with screws.
4.Do not fix the mechanical limit stops within the adjusted
operating range.
5.Move the driver lever towards the limit stop using the
handwheel; turn the link rod for fine adjustment.
6.Tighten the counter nuts.
7.Fasten the limit stop in the other mounting position close to
the end position, depending on the toothing.
8.Re-attach the lever cover. Observe the tightening torque!
Force-dependent stop adjustment
1.First make adjustment as described in Travel-dependent
stop adjustment (action steps 1 to 4).
2.Prior to re-fastening the counter nut, turn the link rod with
the hand wheel locked in place to provide pretension in the
closed position of the valve.
3.Lock the hand wheel.
4.Turn the link rod or slightly shift the mechanical limit stop to
get a small gap between the lever and the limit stop. The
procedure depends on the stiffness of the linkage
arrangement.
5.Tighten the counter-nuts and limit stop screws.
6.Re-attach the lever cover. Observe the tightening torque!

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 17
Installation variants
Locking and fastening elements
Locking screws of mechanical limit stops
Actuator Tightening torque Nm (lbf-ft)
RHDE250 79 (58)
RHDE500 / 800 195 (144)
RHDE1250 / 2500 670 (494)
RHDE4000 670 (494)
lever clamping screw
Actuator Tightening torque Nm (lbf-ft)
RHDE250 79 (58)
RHDE500 / RHD800 195 (144)
RHDE1250 / RHD2500 390 (288)
RHDE4000 390 (288)
Mounting screw (property class 8.8)
Actuator Hole diameter
Nm (in)
tensile strength
N/mm2 (lbf/in2)
Yield strength
N/mm2 (lbf/in2)
RHDE250 12 (0.47) 800 (116032) 640 (93550)
RHDE500 / RHD800 18 (0.71)
RHDE1250 / RHD2500 20 (0.78)
RHDE4000 20 (0.78)
Lever cover
Actuator Tightening torque Nm (lbf-ft)
RHDE250 2.5 +0.5 (1.8 +0.4)
RHDE500 / RHD800 6.5 +0.5 (4.8 +0.4)
RHDE1250 / RHD2500 25 +5 (18.4 +3.9)
RHDE4000 25 +5 (18.4 +3.9)
Specifications for linkage of ball-and-socket valve in driver lever cone
Actuator Ball-and-socket
j
oint
Thread Tightening
torque
Nm (lbf ft)
RHDE250 Ball-and-socket
j
oint A24
M14 x 1.5 45 (33)
RHDE500 / RHD800 Ball-and-socket
j
oint B30
M18 x 1.5 93 (69)
RHDE1250 / RHD2500 Ball-and-socket
j
oint B35
M20 x 1.5 126 (93)
RHDE4000 Ball-and-socket
j
oint B50
M30 x 1.5 258 (190)
Mounting with lever
M10303
b
a
3°
10°
1 2
3
4
5
6
7
1Actuator lever
2Mechanical limit stop with
locking screw
3Lever clamping screw
4Fixing screws
5Flap lever
6Mounting surface
(rigid, level support)
7Link rod α≥15° (≥20°)*, βin
accordance with final control
element manufacturer
Figure 5: Component lever actuator
* For actuator types RHD(E)800, RHD(E)1250, RHD(E)2500 and RHD(E)4000

18 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 6 Installation
… Mounting
Installation with additional output elements
When mounting an additional drive element instead of the
standard lever, the following installation conditions must be
observed:
Maximum permissible shaft loads
Type radial force at
distance x
N (lbf)
Distance x
from shaft
edge
mm (in)
axial force
N (lbf)
Max. output
torque
RHDE250 1767 (397.24) 40 (1.57) 310 (69.69) Occasionally,
2 times
nominal torque
for a short time
RHDE500 /
RHDE800
7542 (1695.51) 35 (1.38) 1310 (294.50)
RHDE1250 /
RHDE2500
10100 (2270.57) 50 (1.97) 1750 (393.42)
RHDE4000 14142 (3179.25) 55 (2.17) 2455 (551.91)
M10347
X
FR
Figure 6: Shaft end
Configuring the drive element hub
The new output element is mechanically connected to the
actuator shaft via a hole with feather key groove. This
connection must be constructed so that the nominal torque and
any possible output torque is transmitted accurately.
The drive element must be mounted securely on the output drive
shaft with suitable measures to prevent axial shift. For the new
drive element, you can use the current mechanical stops.
The following parameters must be observed:
Type bore diameter
mm (in)
Feather key width
mm (in)
Hub length
mm (in)
RHDE250 30 +0.033
(1.18 +0.0013)
8 −0.015 / −0.051
(0.31 −0.0006 /
−0.0020)
50 (1.97)
RHDE500 /
RHDE800
50 +0.039
(1.97 +0.0015)
14 −0.018 / −0.061
(0.55 −0.0007 /
−0.0024)
70 (2.76)
RHDE1250 /
RHDE2500
70 +0.075 / +0.030
(2.76 +0.0030 / +0.0012)
20 −0.022 / −0.074
(0.79 −0.0311 /
−0.0029)
100 (3.94)
RHDE4000 85 +0.090 / +0.036
(3.35 +0.0035 / +0.0014)
25 −0.018 / −0.061
(0.98 −0.0007 /
−0.0024)
140 (5.51)
Minimum yield strength of the hub Rp 0.2 for all actuators:
• 320 N/mm2(46412.80 lbf/in2)
Change from tw o to one column

RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B 19
Dimensions
Control actuator RHD250
S
S
M10248
310 (12.20)
125 (4.92)
344 (13.54) 34 (1.34)
32 (1.26)
145 (5.71)
Ø132 (5.20)
57,5 (2.26)
135 (5.31)
125 (4.92)
219 (8.62)
275 (10.83)
355 (10.04)
179 (7.05) 107 (4.21)
60 (2.36)
50 (1.97)
12 (0.47)
115 (4.53)
30 (1.18)
33 (1.30)
30 (1.18)
8 (0.31)
0
-0.013 (-0.00051)
-0.015 (-0.00059)
-0.051 (-0.00200)
96 (3.78)
66 (2.60)
39 (1.54)
170 (6.69)
330 (12.99)
533 (20.98)
230 (9.06) 324 (12.76) 60 (2.36)
17 (0.67)
1
213
1 S = Center of gravity
2 Removal dimension
3 Space for removing the plug
Figure 7: Dimensions in mm (in)

20 RHDE250 to RHDE4000 (Contrac) ELECTRICAL ROTARY ACTUATOR | OI/RHDE250_4000-EN REV. B
… 6 Installation
… Dimensions
Control actuator RHD500 / RHD800
M10252
S
S
40 (1.57)
70 (2.76)
30 (1.18)
260 (10.24)
300 (11.81)
14 (0.55)
50 (1.97)
53,5 (2.11)
318 (12.52) 115 (4.53)
58 (2.28)
93 (3.66) 115
(4.53)
45 (1.77)
185 (7.28)
324 (12.76)
577 (22.72)
18 (0.71)
195 (7.68)
60 (2.36)
Ø132 (5.20)
440 (17.32)
57,5 (2.26)
416 (16.38)
150 (5.91)
150 (5.91)
280 (11.02)
170 (6.69)
136
(5.35)
145 (5.71)211 (8.31)
70 (2.76) 470 (18.50)
335 (13.19)
520 (50.47)
-0.018 (-0.00071)
-0.061 (-0.00240)
0
-0.016 (-0.00063)
1
3
1
2
1S = Center of gravity
2Removal dimension
3Space for removing the plug
Figure 8: Dimensions in mm (in)