SCHIEBEL AB3 User manual

Operating Instructions for Actuators Type AB with
Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27

CONTENTS
Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
Contents
Contents 2
Hazard Warnings 4
Operating instructions for actuators type AB
with SMARTCON control unit Version 1.2 5
1 Introduction/Notes........................................................... 5
2 General................................................................... 5
2.1 Overview.............................................................. 6
2.2 Serialnumberandnameplate............................................... 6
2.3 Operatingmode......................................................... 7
2.4 Protectionclass......................................................... 7
2.5 Mountingposition ....................................................... 7
2.6 Directionofrotation...................................................... 8
2.7 Protectiondevices....................................................... 8
2.7.1 Electromechanical protection devices (design potentiometer torque) . . . . . . . . . . . . . . 8
2.7.2 Mechanical protection devices (design switch for torque) . . . . . . . . . . . . . . . . . . . . . . 8
2.7.3 Electricalprotectiondevices........................................... 8
2.8 Ambienttemperature..................................................... 9
2.9 Deliveryconditionoftheactuators ........................................... 9
2.10 Informationnotice(tag) ................................................... 10
3 Packaging,transportandstorage...............................................10
3.1 General...............................................................10
3.2 Storage...............................................................10
3.3 Long-termstorage.......................................................11
4 InstallationInstructions ......................................................11
4.1 MechanicalConnection................................................... 11
4.2 Mountingpositionofthecontrolunit..........................................12
4.3 Electricalconnection .....................................................13
5 Commisioning..............................................................15
5.1 General...............................................................15
5.2 Switching the actuator to manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.3 Mechanical default settings, preparation (only for design potentiometer for travel) . . . . . . . . . 16
5.4 Adjustment of the mechanical position indication (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.5 Additionalcomponents(Option).............................................18
5.6 Parameterize of the SMARTCON control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5.7 UserLevelandPermissions................................................18
5.8 Setting of the end positions (design potentiometer for travel). . . . . . . . . . . . . . . . . . . . . . . . . 18
5.8.1 EndlimitOPEN.................................................... 18
5.8.2 EndlimitCLOSE ................................................... 21
5.9 Setting of the end positions (design for switch for travel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.9.1 Roller-type Counter (operational range starting at 1 rev. at the output) . . . . . . . . . . . . . 21
5.10 Finalworks............................................................22
6 Maintenance............................................................... 22
7 BatteryReplacement......................................................... 23
8 Fuses .................................................................... 23
9 Spareparts................................................................ 25
10 Recommendations of Lubricants (for all manufactures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1 MainCasing ........................................................... 25
10.1.1 Application temperature from -35°C to +100°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.1.2 Application temperature from -50 to +100 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10.1.3 Application temperature from -60 to +100 °C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27 CONTENTS
10.2 SpurGears(actuatorsizeAB8-AB80)........................................ 26
10.3 Output Drive Type A and Spindle Drive (Linear Actuators) plus Failsafe units. . . . . . . . . . . . . 26
10.4 PrecisionComponents....................................................26
10.5 BasicLubricantServiceInterval.............................................27
10.6 LubricantRequirements................................................... 27
11Training................................................................... 28
12 Original Declaration of Incorporation of Partly Completed Machinery . . . . . . . . . . . . . . . . . . . 29
13DeclarationofConformity..................................................... 30
14DeclarationofConformity..................................................... 31
15Technicaldata.............................................................. 33
15.1 Binaryoutputs.......................................................... 33
15.2 Binaryinputs...........................................................33
15.3 Analoginputs .......................................................... 35
15.4 Analogoutput ..........................................................36
15.5 Auxiliaryvoltageinputandoutput............................................ 36
15.6 Mechanicalreversingstarter................................................ 37
15.7 Electronicalreversingstarter ...............................................38
15.8 Microswitch ...........................................................38
15.9 Powersupply........................................................... 39
15.10 Connections ........................................................... 39
15.11 Miscellaneous..........................................................39
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Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
SEC-ENGLISH-Gefahrenhinweise-V1.00-20210701
Hazard Warnings
Hazard warnings in this manual indicate potential harm to the user or the product. For the person interacting
with the product, the level of risk includes consequences ranging from slight, up to lethal injuries. As for the
product, disobeying the warnings may cause damage to the equipment and/or void the warranty. Therefore,
said warnings are made apparent to instruct and warn the user, which precautions have to be made prior to
performing any actions described in this manual. The user must read and be familiar with the manual, before
performing any tasks as described in this manual.
Hazard warnings in this manual are presented in these three forms:
WARNING: These warning notices refer to personal safety.
Failure to obey these notices could result in personal injury
or death.
CAUTION: General precautions must be made. Failure to obey
these notices could result in personal injury and/or equipment
damage.
NOTE: Directs the user’s attention to essential information.
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Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
SEC-OM-ENGLISH-ABCSC-V1.2-16xx-V2.02-2023.04.27
Operating Instructions for Actuators Type AB with Control Unit
1 Introduction/Notes
NOTE: These operating instructions apply to SCHIEBEL actuators of the type AB with integrated ACTUSMART
control unit version V1.2 with a firmware version of 1600 or newer.
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.
NOTE: Using the unit as intended also entails the observance of these operating instructions!
WARNING: 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.
CAUTION: Maintenance instructions must be observed as other-
wise the safe operation of the actuator cannot be guaranteed.
WARNING: 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.
CAUTION: Proper transport, storage, installation, assembly and
careful commissioning are essential to proper and safe operation.
WARNING: When working in potentially explosive areas,
observe the European Standards EN 60079-14 ”Electrical
Installations in Hazardous Areas” and EN 60079-17 ”Inspec-
tion and Maintenance of Electrical Installations in Hazardous
Areas”.
WARNING: Maintenance work on open actuators may only be
conducted if these are de-energized. Reconnection during
maintenance is strictly prohibited.
2 General
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2 General
Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
2.1 Overview
1
2
3
4
5
6
7
Figure 1: 1. . . Motor, 2. . . Connection compartment, 3. . . SMARTCON control unit, 4. . . Operating unit,
5. . . Handwheel, 6. . . Signalling lid, 7. . . Lever for manual operation
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).
190733/1
No.:
1980 1266
Type:
AB5 E 20
20,0rpm
40,0revs.
120sec
IP67
Open:
40,0-60Nm (45,0Nm)
Close:
40,0-60Nm (45,0Nm)
2019
L11-A020
Josef Benc Gasse 4, 1230 Vienna, Austria
Figure 2: nameplate of the actuator Figure 3: nameplate of the SMARTCON control unit
1
2
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 2014/34/EU and
EN60079-0 Standard) are separately designated by a special model plate (Ex, TÜV-Standard, see Figure
5 and 6).
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Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27 2 General
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.
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 protec-
tion class, the cover of the connection compartment is carefully
screwed and the mounting position (see section 2.5, page 7) 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 Ex e ac-
cording 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. Improper assem-
bly may lead to water entrances and to failures of the actuator.
CAUTION: The cover of the control unit (see figure 1, page 6)
must not be opened!
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
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2 General
Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
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.
2.7 Protection devices
2.7.1 Electromechanical protection devices (design potentiometer torque)
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 Operating Instructions for SMARTCON Control Units
2.7.2 Mechanical protection devices (design switch for torque)
All actuators have at least one torque switch for clockwise and counter-clockwise rotation. These can be sep-
arately adjusted and are preset ex works to the torque required
NOTE: The adjusting screws are varnish-protected and must not be reset without prior consultation with the
Schiebel company.
However, the torque for the relevant rotating direction can be reduced by means of plastic cams on the torque
switch. Counter-clockwise rotation torque is reduced as follows: Using a screwdriver, turn the plastic cam
marked “L“in the direction of the decreasing scale markings (clockwise).
To reduce the clockwise rotation torque, turn the plastic cam marked “R“in the direction of the decreasing scale
markings (clockwise). See Figure 9.
Figure 9
2.7.3 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
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Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27 2 General
(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 (according to EN60079-0 Standard):
Type min. Temp. max. Temp
Standard -20°C +40°C
TT40 -40°C +40°C
TT50 -50°C +40°C
HT60 -20°C +60°C
HT70 -20°C +70°C
CAUTION: 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 15)
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 10).During commissioning at the plant, these
settings must be verified.
Figure 10: Label
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3 Packaging, transport and storage
Operating Instructions for Actuators Type AB with Control Unit
OM-ENGLISH-ABCSC.V1.2-16xx-V2.02-2023.04.27
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 11).
Figure 11: 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.
CAUTION: 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.
CAUTION: Prior to start-up of the actuator (refer to section 5,
page 15) all of the silica gel must be removed!
3.2 Storage
NOTE: Observing the following precautions will help to avoid damage when storing actuators:
• Store actuators in well-ventilated, dry premises
10