Abb Rsd series User manual

Operating Instructions

42/68-285-EN

Electrical Linear Actuato

RSD10 ... 200 (Contrac)

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Rated force 10 kN ... 200 kN

(2200 ... 45000 lbf)

P R OF I

BU S

PROCESS FIELD BUS

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Blinder Text

2 RSD10 ... 200 (Contrac) 42/68-285-EN

Electrical Linear Actuator

RSD10 ... 200 (Contrac)

Operating Instructions

42/68-285-EN

05.2008

Rev. D

Manufacturer:

ABB Automation Products GmbH

Schillerstraße 72

32425 Minden

Germany

Tel.: +49 551 905-534

Fax: +49 551 905-555

[email protected]b.com

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.

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Contents

42/68-285-EN RSD10 ... 200 (Contrac) 3

1Safety....................................................................................................................................................................5

1.1 General Safety Information ............................................................................................................................5

1.2 Proper 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 Mounting position .........................................................................................................................................12

3.2.1 RSD10 / RSD20 ....................................................................................................................................12

3.2.2 RSD50 / RSD100 / RSD200 .................................................................................................................13

3.3 Installation instructions .................................................................................................................................13

3.3.1 Valve requirements ...............................................................................................................................14

3.4 Mounting examples ......................................................................................................................................14

3.5 Adaptation of actuator stroke to the valve stroke.........................................................................................15

3.6 Assembly with the valve ...............................................................................................................................15

4Electrical connection ........................................................................................................................................16

4.1 Cable shield..................................................................................................................................................16

4.1.1 Signal part .............................................................................................................................................16

4.2 Terminal connection diagrams .....................................................................................................................17

4.2.1 Power Electronic Unit EBS853 (Contrac) / EBS861 (Contrac) .............................................................17

4.2.2 Analog / digital.......................................................................................................................................17

4.2.3 PROFIBUS DP......................................................................................................................................18

4.2.4 Power Electronic Unit EBS852 (Contrac) / EBS862 (Contrac) .............................................................19

4.2.5 Analog / digital.......................................................................................................................................19

Contents

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5Operation............................................................................................................................................................20

5.1 Automatic / manual mode.............................................................................................................................20

6Maintenance.......................................................................................................................................................21

6.1 Inspection and overhaul ...............................................................................................................................21

6.2 Brake adjustment .........................................................................................................................................22

6.3 Oil change ....................................................................................................................................................22

6.4 Filling capacity..............................................................................................................................................23

7Trouble shooting ...............................................................................................................................................24

7.1 Electrical test values.....................................................................................................................................24

8Technical data....................................................................................................................................................25

8.1 General information......................................................................................................................................25

8.2 Technical Data RSD10 ... RSD20 ................................................................................................................25

8.3 Technical Data RSD50.................................................................................................................................25

8.4 Technical Data RSD100...............................................................................................................................26

8.5 Technical Data RSD200...............................................................................................................................26

9Appendix ............................................................................................................................................................27

9.1 Permits and certifications .............................................................................................................................27

10 Index ...................................................................................................................................................................29

Safety

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1 Safety

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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.

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1.2 Proper use

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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.

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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.

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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.

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Safety

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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.

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1.5 Labels and symbols

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1.5.1 Symbols and warnings

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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.

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Safety

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1.5.2 Name plate

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Fig. 1

1 Complete Name plate

2 Fabrication no./ NL no. (no. of non-

standard version)

3 Rated force / Year of manufacture

4 Permissible ambient temperature and

protection class / CE mark

5 min./max. stroke and max. actuating

speed / heater

6 Filled oil types

7 Associated Contrac electronic unit

8 blank

9 blank

10 Blank for customer-specific entry

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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.

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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.

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Safety

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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.).

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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.

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1.10 Transport safety information

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Check the devices for possible damage that may have occurred from improper 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.

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Safety

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1.11 Storage conditions

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The actuators may be stored under moist and aggressive condition for a short time. The

equipment is protected externally against corrosive influences. However, direct exposure to

rain, snow, etc., must be avoided.

Observe the permissible storage and transport temperatures.

Actuators, equipped with an anti-condensation heater, are additionally protected by desiccant,

which is placed in the following locations:

Servo motor: under the brake cover

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. Regularly check whether the desiccant is still active.

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.

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1.12 Installation safety information

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• 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.

• The eyebolt at the top of the actuator may only be used to lift or lower the actuator vertically.

• Do not use the handwheel to lift or to lower the actuator..

• Do not use it if the actuator is mounted at the valve! Make sure that the final control element

is not exposed to process forces.

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Safety

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1.13 Electrical installation safety information

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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 fulfill 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.

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1.14 Operating safety information

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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.

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1.15 Maintenance safety information

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• When changing the oil of the actuator, thoroughly remove any oil that may have run down on

the floor during the procedure to avoid accidents.

• Dispose of the waste oil in compliance with the respective local regulations. Make sure that

no oil reaches the water cycle.

• Switch off the supply voltage for the power electronic unit and separate anti-condensation

heater (option) when working on the actuator or related subassemblies and take precautions

to prevent unintentional switch-on.

• Make sure that any oil leaking from the device cannot come into contact with hot parts

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Design and function

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2 Design and function

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Fig. 2: RSD10 ... 200 (illustrations may differ from actual installation)

1 Servo motor

2 Hand wheel

3 Thrust rod

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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.

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Installation

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3 Installation

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3.1 Actuator check

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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 IMV 1.

• Did you fasten the separately delivered venting plug (spare part no. 9287338) in the

uppermost bore (depending on the mounting orientation)?

• 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.

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3.2 Mounting position

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The gears of the actuator RSD10 ... 200 (Contrac) 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.

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3.2.1 RSD10 / RSD20

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Fig.3

1 Inspection plug

2 Venting plug

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Installation

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3.2.2 RSD50 / RSD100 / RSD200

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Fig. 4

1 Inspection plug

2 Venting plug

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All mounting orientations shown in and fig. Fig. 4 are permissible. To facilitate mounting and

maintenance, however, it is recommended to use orientation IMV 1. For each mounting

position, check the oil level prior to commissioning.

In order to ensure sufficient ventilation and space for motor de-/installation allow for min.

80 mm (3.15 inch).

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3.3 Installation instructions

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• 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.

• 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 clearly allow you to estimate whether the vibrational loading remains significantly

below the proven contingent, reduce the maintenance intervals accordingly.

• Make sure that the thrust rod and the valve stem are not exposed to additional vibrational

loading that exceeds by 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 may not be permanently exceeded. For a short

period, the force can be increased by up to twice the rated force is permitted.

• When mounting the actuator close to heat sources use an insulating layer or shielding.

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Installation

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3.3.1 Valve requirements

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• The force in the end position can be up to 2.5 times higher than the rated force.

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3.4 Mounting examples

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M00310

Fig. 5: Installation example RSD10 ... 200 (Contrac)

1 Cover for thrust rod

2 Servo motor

3 Hand wheel

4 Mounting screws (8.8)

5 external stop

6 Coupling

7 Valve stem

8 Valve yoke

9 Valve

10 Mechanical position indicator

11 Thrust rod

12 Screw plug for stop position

13 Thrust rod cover

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Installation

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3.5 Adaptation of actuator stroke to the valve stroke

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The factory-set actuator stroke corresponds to the stroke named on the ID-label + 1 mm

(0.04 inch). If an application requires stroke adjustment, proceed as follows (comply with

min./max. stroke; see "Technical Data"):

Important

With a mounting position other than IMV 1, drain the oil until the oil level is below the thrust rod

cover (Fig. 5/13).

1. Manually drive the thrust rod completely out. The internal limit stop should now be touching

the driving sleeve.

2. Loosen the screws of the thrust rod cover and remove the cover.

3. Open the screw plug in the thrust rod cover.

4. Both Allen clamping screws are accessible through the opening. Loosen the screws.

5. Use the hand wheel to drive in the thrust rod until the actuator stroke matches the required

valve stroke.

6. Turn the internal limit stop (slotted ring nut) clockwise until it is touching the drive sleeve.

Finally, turn it back approx. 1 turn.

7. Tighten both Allen screws to the required torque.

RSD10 / RSD20: 26 Nm

RSD50: 26 Nm

RSD100: 40 Nm

RSD200: 69 Nm

8. Reattach the cover for the thrust rod.

9. Screw in the lateral screw plug.

10. Fill the oil according to mounting position.

Pos: 8.22 /Übersc hriften/1.1/1-spal tig/V - Z/Zusammenbau mit dem Stellglied @ 10\mod_118163 4985953_3101.doc @ 103507

3.6 Assembly with the valve

Pos: 8.23 /Mont age/Aktorik/Linear antriebe/Allgemein/ Zusammenbau mit dem Stel lglied @ 10\mod_1181891414750 _3101.doc @ 106349

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!).

Pos: 9 /======= Seitenumbruc h ========@ 0\mod_112653236576 8_3101.doc @ 3830

Electrical connection

16 RSD10 ... 200 (Contrac) 42/68-285-EN

Pos: 10.1 /Übersc hriften/1/D - F/Elektr ischer Anschluss @ 0\mod_1140 620471687_3101.doc @ 3143

4 Electrical connection

Pos: 10.2 /Elektr ischer Anschluss/ Aktorik/Antriebe/ Allgemein/Elektri scher Anschluss @ 16\mod_1197274 093609_3101.doc @ 14505 3

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.

Pos: 10.3 /Übersc hriften/1.1/1-spal tig/J - L/Kabelschi rm @ 10\mod_1181823716656_3101. doc @ 106187

4.1 Cable shield

Pos: 10.4 /Übersc hriften/1.1.1/1-s paltig/Signaltei l @ 10\mod_1182501083765_31 01.doc @ 108573

4.1.1 Signal part

Pos: 10.5 /Elektr ischer Anschluss/ Aktorik/Antriebe/ Allgemein/Kabelsc hirm Anschluss @ 10\mod_11818230 21906_3101.doc @ 106144

M00307

Fig. 6: 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).

Pos: 10.6/======= Seitenumbruch ======== @ 0\mod_1126532365768_3 101.doc @ 3830

Electrical connection

42/68-285-EN RSD10 ... 200 (Contrac) 17

Pos: 10.7 /Übersc hriften/1.1/1-spal tig/A - C/Anschluss pläne @ 0\mod_1139844727625_ 3101.doc @ 3179

4.2 Terminal connection diagrams

4.2.1 Power Electronic Unit EBS853 (Contrac) / EBS861 (Contrac)

Pos: 10.9 /Technisc he Daten / Datenblatt/ Aktorik/Antriebe/ Linearantriebe/Al lgemein/El. Ansc hluss mit separater Elekt ronik EBN853 (EBN861) @ 7\ mod_1172049298312_3101. doc @ 69413

4.2.2 Analog / digital

Important

The electrical connection is provided by a plug on the actuator and the terminals on the electronic unit.

Fig. 7

Electrical connection

18 RSD10 ... 200 (Contrac) 42/68-285-EN

4.2.3 PROFIBUS DP

Fig. 8

Pos: 10.10/======= Seitenumbruch ======== @ 0\mod_1126532365768_3101. doc @ 3830

Electrical connection

42/68-285-EN RSD10 ... 200 (Contrac) 19

Pos: 10.11 /Übersc hriften/1.1.1/1-s paltig/Leistungs elektronik EBS852 (Contr ac) / EBS862 (Contrac) @ 10\m od_1182165403125_3101.doc @ 107553

4.2.4 Power Electronic Unit EBS852 (Contrac) / EBS862 (Contrac)

Pos: 10.12 /Tec hnische Daten / Datenblatt/Aktorik/Antriebe/Linearantriebe/Allgemei n/El. Anschluss mi t separater Elektronik EBS852 (EBS862) @ 7\mod_117489558 2718_3101.doc @ 74303

4.2.5 Analog / digital

Important

The electrical connection is provided by a plug on the actuator and the terminals on the electronic unit.

Fig. 9

Pos: 11 /======= Seitenumbruch ======== @ 0\mod_11265323657 68_3101.doc @ 3830

Operation

20 RSD10 ... 200 (Contrac) 42/68-285-EN

Pos: 12.1 /Übersc hriften/1/A - C/Betri eb @ 10\mod_1175678278921_3101. doc @ 76015

5 Operation

Pos: 12.2 /Übersc hriften/1.1/1-spal tig/A - C/Automatik /Handbet rieb @ 10\mod_118171557 0281_3101.doc @ 104973

5.1 Automatic / manual mode

Pos: 12.3 /Bedienung/ Aktorik/Antr iebe/Linearantri ebe/Allgemein/Aut omatik / Handbetrieb @ 10\mod_118180 5435734_3101.doc @ 105927

The motor triggered by the power electronics controls the axially fixed drive sleeve /nut

assembly via oil-lubricated spur gears. A ball bearing screw (see Figure Fig. 10) radially fixed by

an anti-twist arrester converts the rotary motion to a linear one. The screw is the upper part of

the thrust rod and has an adjustable mechanical stop.

A position sensor detects backlash-free the thrust rod position via mechanical reduction

gearing.

The motor brake locks the actuator in the current position if the power supply is cut off.

Pos: 12.4 /Bedienung/ Aktorik/Antr iebe/Linearantri ebe/Allgemein/Sc hnittbild durch Kugelmut ter mit Spindel @ 10\mod_118190 0287234_3101.doc @ 106607

M00308

Fig. 10: Ball bearing screw with nut, cross-section