SCHIEBEL AB Series User manual

Operating instructions for actuators type AB with
SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07

CONTENTS
Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07
Contents
Contents 2
Operating instructions for actuators type AB
with SMARTCON control unit 4
1 Introduction/Notes........................................................... 4
2 General................................................................... 4
2.1 Overview.............................................................. 4
2.2 Serialnumberandnameplate............................................... 5
2.3 Operatingmode......................................................... 5
2.4 Protectionclass......................................................... 6
2.5 Mountingposition ....................................................... 6
2.6 Directionofrotation...................................................... 6
2.7 Protectiondevices....................................................... 7
2.7.1 Electromechanical protection devicesn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.7.2 Electricalprotectiondevices........................................... 7
2.8 Ambienttemperature..................................................... 7
2.9 Deliveryconditionoftheactuators ........................................... 7
2.10 Informationnotice(tag) ................................................... 8
3 Packaging,transportandstorage............................................... 8
3.1 General............................................................... 8
3.2 Storage............................................................... 8
3.3 Long-termstorage....................................................... 9
4 InstallationInstructions ...................................................... 9
4.1 MechanicalConnection................................................... 9
4.2 Electricalconnection ..................................................... 10
5 Commisioning..............................................................12
5.1 General............................................................... 12
5.2 Switching the actuator to manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Mechanical default settings, preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4 Adjustment of the mechanical position indication (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5 Additionalcomponents(Option).............................................14
5.6 Parameterize of the SMARTCON control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.7 Endlimitsetting......................................................... 14
5.7.1 EndlimitOPEN.................................................... 14
5.7.2 EndlimitCLOSE ................................................... 17
5.8 Finalworks............................................................17
6 Controlunit................................................................18
6.1 Operatingunit..........................................................18
6.2 Displayelements........................................................19
6.2.1 Graphicdisplay .................................................... 19
6.2.2 LEDDisplay.......................................................19
6.3 Operation.............................................................20
6.3.1 Operationmode....................................................21
6.3.2 Configuration...................................................... 21
6.3.3 Configurationexample...............................................22
6.3.4 "TEACHIN“ ....................................................... 23
7 Parametermenu ............................................................ 24
7.1 Parametergroup:Endlimit................................................. 24
7.2 Parametergroup:Torque..................................................25
7.3 Parametergroup:Speed(option)............................................26
7.4 Parametergroup:Ramp(optional)........................................... 27
7.5 Parametergroup:Control..................................................27
7.6 Parametergroup:Password................................................27
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Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07 CONTENTS
7.7 Parametergroup:Position .................................................28
7.8 Parametergroup:Binaryinputs ............................................. 28
7.9 Parametergroup:Binaryoutputs ............................................ 30
7.10 Parameter group: Position output (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.11 Parametergroup:Stepmode...............................................34
7.12 Parametergroup:Positioner(option).......................................... 35
7.13 Parameter group: PID controller (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.14 Parameter group: PROFIBUS DP (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.15 Parametergroup:DeviceNet(option) .........................................39
7.16 Parameter group: Characteristic curves (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.17 Parameter group: Identification (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.18 Parameter group: System parameters (locked) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.19 Parametergroup:Miscellaneous............................................. 41
8 Statusarea ................................................................ 42
8.1 Status................................................................ 42
8.1.1 Status–Bin.Outputs................................................ 42
8.1.2 Status–Bin.Inputs................................................. 42
8.1.3 Status–Analoguevalues.............................................42
8.1.4 Status–Absolutevalues..............................................43
8.1.5 Status–Firmware.................................................. 43
8.1.6 Status–Serialnumber............................................... 43
8.2 History ...............................................................43
9 Infraredconnection.......................................................... 43
10Maintenance............................................................... 44
11Troubleshooting ............................................................45
11.1 Errorlist .............................................................. 45
12Fuses ....................................................................45
13Spareparts................................................................47
14 Recommendations of Lubricants (for all manufactures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
14.1 MainCasing ........................................................... 47
14.1.1 Application temperature from -35◦C to +100◦C..............................47
14.1.2 Application temperature from -50 to +100 ◦C...............................47
14.1.3 Application temperature from -60 to +100 ◦C...............................47
14.2 SpurGears(actuatorsizeAB8-AB80)........................................ 48
14.3 Output Drive Type A and Spindle Drive (Linear Actuators) . . . . . . . . . . . . . . . . . . . . . . . . . . 48
14.4 PrecisionComponents....................................................48
14.5 BasicLubricantServiceInterval............................................. 48
14.6 LubricantRequirements...................................................49
15Training................................................................... 49
16 Original Declaration of Incorporation of Partly Completed Machinery . . . . . . . . . . . . . . . . . . . 50
17DeclarationofConformity.....................................................51
18DeclarationofConformity.....................................................52
19Technicaldata.............................................................. 54
19.1 Binaryinputs...........................................................54
19.2 Binaryoutputs..........................................................54
19.3 Analogueinputs.........................................................54
19.4 Analogueoutputs........................................................ 54
19.5 Auxiliaryvoltageinputandoutput............................................55
19.6 Mechanicreversingstarters................................................55
19.7 Elektronicreversingstarter.................................................56
19.8 Powersupply........................................................... 56
19.9 Connections ........................................................... 57
19.10 Miscellaneous..........................................................57
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Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07
SEC-OM-ENGLISH-CSC-V2.08-2019.11.07
Operating instructions for actuators type AB
with SMARTCON control unit
1 Introduction/Notes
These operating instructions apply to SCHIEBEL actuators of the type AB with integrated SMARTCON control
unit.
The scope of application covers the operation of industrial valves, e.g., globe valves, gate valves, butterfly
valves and ball valves. For other applications please consult with the factory.
The manufacturer shall not be liable for incorrect use and possible damage arising thereof. The risk shall be
borne solely by the user.
Using the unit as intended also entails the observance of these operating instructions!
When operating electrical equipment, certain parts inevitably carry hazardous voltage levels. Work
on the electrical system or equipment must be carried out only in accordance with electrical regulations by a
qualified electrician himself or by specially instructed personnel under the control and supervision of a qualified
electrician.
Maintenance instructions must be observed as otherwise the safe operation of the actuator cannot be guaran-
teed.
Failure to follow the warning information may result in serious bodily injury or property damage. Qualified
personnel must be thoroughly familiar with all warnings contained in this operating manual.
Proper transport, storage, installation, assembly and careful commissioning are essential to proper and safe
operation.
When working in potentially explosive areas, observe the European Standards EN 60079-14 ”Elec-
trical Installations in Hazardous Areas” and EN 60079-17 ”Inspection and Maintenance of Electrical
Installations in Hazardous Areas”.
Maintenance work on open actuators may only be conducted if these are de-energized. Reconnec-
tion during maintenance is strictly prohibited.
2 General
2.1 Overview
Figure 1: 1. . . Motor, 2. . . Connection compartment, 3. . . SMARTCON control unit, 4. . . Operating unit,
5. . . Handwheel, 6. . . Signalling lid, 7. . . Lever for manual operation
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Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07 2 General
2.2 Serial number and nameplate
Each actuator and each SMARTCON control unit carries a serial number. The serial number is a 8-digit
number that begins with the year and that can be read from the nameplate (see Figure 2 and 3)
The nameplate of the actuator is located under the hand lever and the nameplate of the SMARTCON control
unit is located on the control unti (see Figure 4).
Using this serial number, SCHIEBEL can uniquely identify the actuator (type, size, design, options, technical
data and test report).
Figure 2: nameplate of the actuator Figure 3: nameplate of the SMARTCON control unit
Figure 4: 1. . . nameplate of the SMARTCON control unit, 2. . . nameplate of the actuator
Actuators which are suitable for operation in explosive atmosphere (see EU-Richtlinie 94/9/EG and
EN60079-0 Standard) are separately designated by a special model plate (EEx, TÜV-Standard, see Fig-
ure 5 and 6).
Figure 5: nameplate of the actuator for operation in
explosive atmosphere
Figure 6: nameplate of the SMARTCON control unit
for operation in explosive atmosphere
2.3 Operating mode
There are two distinct modes of operation: open-loop control operation (operational mode S2 for ON-OFF)
and closed-loop control operation (operational mode S4) according to EN 60034-1. But since there is a great
number of varying and special models made to order, it is recommended to consult the motor model plate for
the mode of operation and the running time.
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2 General
Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07
2.4 Protection class
Actuators with three-phase motors are standardly equipped with the IP 66 protection system (according to DIN-
Standard 40050). Explosion-proof actuators and actuators with plugs are furnished with the IP 65 protection
system. Exceptions are the AC, DC and brake-motor actuators as well as those for other protection systems
made to special order.
CAUTION: The protection class specified on the nameplate is only effective when cable
glands also provide the required protection class, the cover of the connection compartment
is carefully screwed and the mounting position (see section 2.5, page 6) is observed.
We recommend metallic screwed cable glands with a metrical thread. Furthermore, cable inlets
not be needed must be closed with screw plugs. On explosion-proof actuators cable glands with
protection class
EEx e according EN60079-7 must be used. After removing covers for assembly purposes or adjustment
work, take special care upon reassembly so that seals are not damaged and remain properly fastened. Im-
proper assembly may lead to water entrances and to failures of the actuator.
Allow a certain sag in the connector cables before reaching the screwed cable glands so that water can drip
off from the connector cables without running to the screwed cable glands. As a result, forces acting on the
screwed cable glands are also reduced. (see section 2.5)
2.5 Mounting position
In principle, the installation position is irrelevant. However, based on practical experience, it is advisable to
consider the following for outdoors use or in splash zones:
•Mount actuators with cable inlet facing downwards
•Do not arrange the motor so that it hangs downwards
•Ensure that sufficient cable slack is available
2.6 Direction of rotation
Unless specifically ordered otherwise, the standard direction is (see Figure 7 and Figure 8):
Clockwise rotation = Close Counter-clockwise rotation = Open
Clockwise rotation of the actuator is given when the output shaft turns counter clockwise when looking on the
output shaft.
Figure 7: AB3 - AB80
Figure 8: AB100 - AB500
All data in these operating instructions refer to the standard rotating direction.
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Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07 2 General
2.7 Protection devices
2.7.1 Electromechanical protection devicesn
The torque protection of the actuators with integral SMARTCON control unit is controlled mechanically by plate
springs which pass the current torque through a conductive plastic potentiometer to the control unit.
The switch off torque can be changed in the menu of the control unit for the left and right direction. The factory
default switch off torque is set to the ordered torque. If no torque was specified in the order, the actuator is
supplied from the factory with the maximum adjustable torque.
See also section 7.2, page 25
2.7.2 Electrical protection devices
All motors have temperature switches as standard equipment (temperature sensors upon special order), which
are wired into the control and protect the motor from overheating.
In the housing of the connection plug super fast safety fuses are located the protect the integrated thyristors
(electronic reversing contactors).
Further we recommend the installation of a motor protection circuit breaker on site as additional protection for
rapid engine warming up (block). The tripping current must be adjusted to 1.2 . . . 1,5-times of the motor current,
or at explosion-proof models proceed according to the corresponding guidelines of the National Explosion
Protection Authority.
2.8 Ambient temperature
Unless otherwise defined according to special order, the following operational temperature generally applies:
•open-loop control actuators from -25◦C to +70◦C
•closed-loop control actuators from -25◦C to +60◦C
•Explosion-proof actuators from -20◦C to +40◦C (according to EN60079-0 Standard).
Warning: The maximum operational temperature also depends on the built-in components. Please observe
the technical data sheets.
2.9 Delivery condition of the actuators
For each actuator, an inspection report is generated upon final inspection. In particular, this comprises a full
visual inspection, calibration of the torque measurement in connection with an extensive run examination and
a functional test of the micro controllers.
These inspections are conducted and documented according to the quality system and can be found in the
document gag (mounted on the handwheel).
The basic setting of the end position must be performed after assembly on the actuator.
CAUTION: Commissioning instructions (see section 5, page 12) must be strictly observed!
During assembly of the supplied valves at the factory, end postions are set and documented by
attaching a label (see Figure 9).During commissioning at the plant, these settings must be verified.
Figure 9: Label
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3 Packaging, transport and storage
Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07
2.10 Information notice (tag)
Each actuator is provided with a bilingual tag containing key information, which is attached to the handwheel
after final inspection. This tag also shows the internal commission registration number (see Figure 10)
Figure 10: tag
3 Packaging, transport and storage
You can order the actuators to be delivered with or without packing. Special packing requirements must be
specified along with your order. Use extreme caution when unpacking or repacking the actuator.
Use soft belts for hoisting equipment. Do not attach hoisting belts to the handwheel.
3.1 General
The indicator lids of all actuators contain a minimum of 5 g of silica gel ex factory.
WARNING! Prior to start-up of the actuator (refer to section 5, page 12) all of the silica gel
must be removed!
3.2 Storage
CAUTION
Observing the following precautions will help to avoid damage when storing actuators:
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Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07 4 Installation Instructions
•Store actuators in well-ventilated, dry premises
•Protect against floor dampness by storing actuators on wooden grating, pallets, mesh boxes or shelves
•Protect the actuators against dust and dirt with plastic foil
•Actuators must be protected against mechanical damage. It is not necessary to open the controller of
the actuator for servicing batteries or similar operations.
•The storage temperature must be between -20◦C to +40◦C
It is not necessary to open the controller of the actuator for servicing batteries or similar operations.
3.3 Long-term storage
CAUTION: If you intend to store the actuator for over 6 months, follow additionally the instruc-
tions below:
•CAUTION: The silica gel in the connection compartment must be replaced after 6 months of storage
(from date of delivery from SCHIEBEL’s factory in Vienna)
•After replacing the silica gel, brush with glycerine the connection cover seal. Then, carefully close again
the connection compartment
•Coat screw heads and bare spots with neutral grease or long-term corrosion protection
•Renovate damaged paintwork arising from transport, improper storage, or mechanical influences.
•Wrap the motor (especially the brake motor) with oiled paper.
•Every 6 months. all measures and precautions for long term storage must be checked for effectiveness
and corrosion protection and silica gel renewed.
•Failure to follow the above instructions may lead to condensation which can damage to the
actuator.
4 Installation Instructions
Installation work of any kind of actuator may only be performed by qualified personnel.
4.1 Mechanical Connection
Make sure that the fitting flanges and the actuator flanges match each other, and that the borehole matches
the shaft or, in the case of actuator model “A“(threaded bushing), that the actuator and fitting threads match
each other.
•Grease the spindle.
•Clean all exposed parts which have been coated with anti-corrosive.
•Thoroughly clean the bolting surfaces of the fittings.
•Lightly grease the connecting joints between the actuator and the fittings.
•Place the actuator on the fittings or the gear.
•Tighten the fastening screws crosswise (torque acc. below table).
size torque [Nm] for screws 8.8
M6 10
M8 25
M10 48
M12 84
M16 206
M20 415
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4 Installation Instructions
Operating instructions for actuators type AB with SMARTCON control unit
OM-ENGLISH-CSC-V2.08-2019.11.07
For output type A (unbored threaded bushing), you must sufficiently lubricate both needle
bearings in the output form after processing and cleaning the spindle nut.
For this purpose, use the optional SCHIEBEL grease lubricant or a grease lubricant according to
our recommendation (section 14, page 47).
4.2 Electrical connection
Electrical connections may only be carried out by qualified personnel.
Please observe all relevant national security requirements, guidelines, and regulations.
The equipment should be de-energized before working on electrical connections.
Furthermore, confirm the absence of electrostatic discharges during the connection.
First of all, connect the ground screw.
The line and short circuit protection must be done on the system side.
The ability to unlock the actuator is to be provided for maintenance purposes.
For the dimensioning the rated current is to be used (see Technical Data).
Check whether the power supply (voltage, frequency) is consistent with the connection data (see
name plate of the motor)
The connection of electrical wiring must follow the circuit diagram.
This can be found in the appendix of the documentation. The circuit diagram can be ordered from SCHIEBEL
by specifying the serial number.
The standard model can be ordered with the following connection options:
•size 1: connection of the control signals and power supply via plugs (see Figure 11) with screw connec-
tion.
•size 2: connection of the control signals is the same as size 1, the connection of the power supply is
made by an additional plug (see Figure 13), both plugs aer with screw connection.
•Explosion-proof actuators or on special request the connection will be mady via terminals (see Figure
12).
18
2
3
76
5
4
Figure 11: 1. . . metallic cable glands (closed with blind screw connections at delivery) M32x1,5,
2. . . M40x1,5, 3. . . M25x1,5, 4. . . plug Han6E (for power supply), 5. . . plug Han24E (for control sig-
nals)„6. . . plug for options, 7. . . connection plug plate, 8. . . connection plug housing
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