Electrical Linear Actuator RSDE (Contrac)

Transcription

1 Operating Instruction OI/RSDE10_50-EN Electrical Linear Actuator RSDE (Contrac) Rated force kn ( lbf) with explosion-proof design

2 Contents Blinder Text Electrical Linear Actuator RSDE (Contrac) Operating Instruction OI/RSDE10_50-EN Rev. C Translation of the original instruction Manufacturer: ABB Automation Products GmbH Process Automation Schillerstraße Minden Germany Tel.: Fax: Customer service center Phone: automation.service@de.abb.com Copyright 2016 by ABB Automation Products GmbH Subject to changes without notice This document is protected by copyright. It assists the user in safe and efficient operation of the device. The contents of this document, whether whole or in part, may not be copied or reproduced without prior approval by the copyright holder. 2 RSDE (Contrac) OI/RSDE10_50-EN

3 Contents 1 Safety General information and notes for the reader Intended use Target groups and qualifications Warranty provisions Plates and symbols Safety- / warning symbols, note symbols Name plate Transport safety information Storage conditions Installation safety information Safety information for electrical installation Operating safety information Maintenance safety information Safety instructions related to the raw materials and supplies Returning devices Integrated management system Disposal Information on WEEE Directive 2002/96/EC (Waste Electrical and Electronic Equipment) RoHS Directive 2002/95/EC Ex relevant safety instructions Operation via frequency transformer Preventing electrostatic charging Design and function Mounting Actuator check Installation instructions Valve requirements Installation position RSDE10 / RSDE RSDE Mounting examples Adaptation of actuator stroke to the valve stroke Assembly with the valve Electrical connections Cable shield Signal part Motor Terminal connection diagrams Power Electronic Unit EBN853 (Contrac) / EBN861 (Contrac) Power Electronic Unit EBS852 (Contrac) / EBS862 (Contrac) Operation Automatic mode / Handwheel mode Manual operation Handwheel operation in combination with positioning time-out function Maintenance Inspection and overhaul Removing the motor and adjusting the brakes OI/RSDE10_50-EN RSDE (Contrac) 3

4 Contents 7.3 Oil change Filling capacity Trouble shooting Electrical test values Specifications Technical data for the cable set (for Ex-relevant range) Appendix Approvals and certifications RSDE (Contrac) OI/RSDE10_50-EN

5 Safety 1 Safety 1.1 General information and notes for the reader You must read these instructions carefully prior to installing and commissioning the device. These instructions are an important part of the product and must be kept for future reference. These instructions are intended as an overview and do not contain detailed information on all designs for this product or every possible aspect of installation, operation and maintenance. 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 any previous or existing agreement, promise or legal relationship nor is it intended to change the same. This product is built based on state-of-the-art technology and is operationally safe. It has been tested and left the factory in perfect working order from a safety perspective. The information in the manual must be observed and followed in order to maintain this state throughout the period of operation. Modifications and repairs to the product may only be performed if expressly permitted by these instructions. Only by observing all of the safety instructions and all safety/warning symbols in these instructions can optimum protection of both personnel and the environment, as well as safe and fault-free operation of the device, be ensured. Information and symbols directly on the product must be observed. They may not be removed and must be fully legible at all times. 1.2 Intended use The actuators are used exclusively for operating final control elements (valves, vanes, etc.). They may only be operated using an appropriate Contrac electronic unit for field or rack installation. Using these actuators for any other purpose will introduce the risk of personal injury and can also damage or impair the device's operational reliability. In addition to this operating instruction, the relevant documentation for the power electronic unit and software tools must be observed. 1.3 Target groups and qualifications 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. The operating company must strictly observe the applicable national regulations relating to the installation, function testing, repair, and maintenance of electrical products. 1.4 Warranty provisions Using the device in a manner that does not fall within the scope of its intended use, disregarding this instruction, 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. OI/RSDE10_50-EN RSDE (Contrac) 5

6 Safety 1.5 Plates and symbols Safety- / warning symbols, note symbols DANGER <Serious damage to health / risk to life> This symbol in conjunction with the signal word "Danger" indicates an imminent danger. Failure to observe this safety information will result in death or severe injury. DANGER <Serious damage to health / risk to life> This symbol in conjunction with the signal word "Danger" indicates an imminent electrical hazard. Failure to observe this safety information will result in death or severe injury. WARNING <Bodily injury> This symbol in conjunction with the signal word Warning indicates a possibly dangerous situation. Failure to observe this safety information may result in death or severe injury. WARNING <Bodily injury> This symbol in conjunction with the signal word "Warning" indicates a potential electrical hazard. Failure to observe this safety information may result in death or severe injury. CAUTION <Minor injury> This symbol in conjunction with the signal word Caution indicates a possibly dangerous situation. Failure to observe this safety information may result in minor or moderate injury. This may also be used for property damage warnings. NOTICE <Property damage>! The symbol indicates a potentially damaging situation. Failure to observe this safety information may result in damage to or destruction of the product and/or other system components. IMPORTANT (NOTE) This symbol indicates operator tips, particularly useful information, or important information about the product or its further uses. It does not indicate a dangerous or damaging situation. 6 RSDE (Contrac) OI/RSDE10_50-EN

7 Safety Name plate Antrieb / Actuator : CONTRAC... F-Nr./No NL -/- F= Jahr/Year Ta = IP 66 s = min.... max.... v =... mm/s Öl / Oil: für/for Elektronik/Electronics EBN.../EBS... II 2G II 2D II 2G ck Ex de [ib] ib IIB T4 Gb, II 2D ck Ex tb IIIC T130 C ZELM 04 ATEX 0209 X 0044 ABB Automation Products GmbH Schillerstrasse 72 D Minden Made in Germany M00305 Fig. 1 1 Full name of model 2 Serial no. / NL no. (no. of non-list version) 3 Rated force / Year of manufacture 4 Permissible ambient temperature / Degree of protection / CE mark with information about the monitoring authority 5 Min./max. travel / max. operating speed / heater (option) 6 Filled oil types 7 Associated Contrac electronic unit 8 Explosion protection class 9 Approval body and inspection no. 10 Blank for customer-specific information OI/RSDE10_50-EN RSDE (Contrac) 7

8 Safety 1.6 Transport safety information WARNING - Falling or toppling loads! Risk of death or serious injury due to the device falling down or toppling over! Do not stand under suspended loads! Do not detach the hoisting equipment until installation is complete! Only use the dedicated load pick-up devices (eyebolts) for suspending the components! Check the devices for possible damage that may have occurred during 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. Ensure that the specified environmental conditions in the Technical Data chapter are complied with. 1.7 Storage conditions IMPORTANT (NOTE) The storage data provided below assumes that the devices are fully closed and thus comply with the degree of protection stated in the technical specifications. When devices are supplied, their degree of protection is guaranteed. If they have been subsequently tested or commissioned, the degree of protection must be ensured again 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 electronic unit. If you intend to store or transport the device for a long period of time (> 6 months), we recommend that you wrap it in plastic foil and add desiccant. Protect uncovered metallic surfaces with an appropriate long-term corrosion inhibitor. The relevant long-term storage temperatures must be observed. 8 RSDE (Contrac) OI/RSDE10_50-EN

9 o Safety 1.8 Installation safety information WARNING - Falling or toppling loads! Risk of death or serious injury due to the device falling down or toppling over! Do not stand under suspended loads! Do not detach the hoisting equipment until installation is complete! Only use the dedicated load pick-up devices (eyebolts) for suspending the components! 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. Make sure that no process forces are exerted on the control element. Do not use the motor or handwheel to lift the actuator. The load pick-up device on the actuator (eyebolt) must only be loaded in a vertical direction. Only use the load pick-up device for lifting/lowering the actuator (without final control element mounted). 1.9 Safety information for electrical installation The electrical connection may only be made by authorized specialist personnel and in accordance with the electrical circuit diagrams. The electrical connection information in the manual must be observed; otherwise, the type of electrical protection may be adversely affected. Safe isolation of electrical circuits which are dangerous if touched is only guaranteed if the connected devices satisfy the requirements of DIN EN (VDE 0140 Part 1) (basic requirements for safe isolation). To ensure safe isolation, install supply lines so that they are separate from electrical circuits which are dangerous if touched, or implement additional isolation measures for them. OI/RSDE10_50-EN RSDE (Contrac) 9

10 Safety 1.10 Operating safety information WARNING - risk of crushing! Danger of injuries due to crushing between external stop and valve yoke / actuator housing! Do not reach into the danger zone! Before switching on, make sure that the environmental conditions specified in the "Technical specifications" chapter or data sheet are complied with and that the power supply voltage corresponds to the voltage of the actuator. If there is a chance that safe operation is no longer possible, take the device out of operation and secure it against unintended startup. When the actuator is installed in areas that may be accessed by unauthorized persons, the operator must put appropriate protective measures in place. The handwheel must always be secured with a cotter pin to prevent it being activated unintentionally. While the handwheel is being operated, the power supply to the motor must be switched off Maintenance safety information 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 or the motor is removed! Make sure that process forces are not exerted on the thrust rod. 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 old oil according to local regulations. Make sure that no oil reaches the water cycle. Make sure that any oil leaking from the device cannot come into contact with hot parts. Switch off the supply voltage for the power electronic unit and, if necessary, disconnect the separately supplied anti-condensation heater (option) when working on the actuator or related subassemblies and take precautions to prevent unintentional switch-on. 10 RSDE (Contrac) OI/RSDE10_50-EN

11 Please Safety 1.12 Safety instructions related to the raw materials and supplies Observe the manufacturer's regulations and safety data sheets! Mineral oil and grease can contain additives that, under special conditions, may lead to adverse effects. Skin contact with oil or grease may cause skin damage (skin irritations, inflammations, allergies). Avoid long-term, excessive or repeated skin contact. If lubricants contact your skin, immediately wash with water and soap! Do not allow lubricants to get in contact with open wounds! If lubricant splashes into the eye, rinse with plenty of water for at least 15 minutes and then consult a doctor! When handling lubricants use appropriate skin protection and care products or wear oilresistant gloves. Lubricants that have run down to the floor are a potential source of danger, due to the slip hazard. Spread sawdust or use oil adsorbent to bind and remove the lubricants Returning devices Use the original packaging or suitably secure shipping containers if you need to return the device for repair or recalibration purposes. Fill out the return form (see the Appendix) and include this 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 shipping purposes: All devices delivered to ABB Automation Products GmbH must be free from any hazardous materials (acids, alkalis, solvents, etc.). Please contact Customer Center Service acc. to page 2 for nearest service location. OI/RSDE10_50-EN RSDE (Contrac) 11

12 Safety 1.14 Integrated management system ABB Automation Products GmbH operates an integrated management system, consisting of: Quality management system to ISO 9001:2008 Environmental management system to ISO 14001:2004 Occupational health and safety management system to BS OHSAS 18001:2007 and Data and information protection management system Environmental awareness is an important part of our company policy. Our products and solutions are intended to have a minimal impact on the environment and on people during manufacturing, storage, transport, use, and disposal. This includes the environmentally-friendly use of natural resources. We conducts an open dialog with the public through our publications Disposal This product is manufactured from materials that can be reused by specialist recycling companies Information on WEEE Directive 2002/96/EC (Waste Electrical and Electronic Equipment) This product is not subject to WEEE Directive 2002/96/EC or relevant national laws (e.g., ElektroG in Germany). The product must be disposed of at a specialist recycling facility. Do not use municipal garbage collection points. According to the WEEE Directive 2002/96/EC, only products used in private applications may be disposed of at municipal garbage facilities. 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 RoHS Directive 2002/95/EC With the Electrical and Electronic Equipment Act (ElektroG) in Germany, the European Directives 2002/96/EC (WEEE) and 2002/95/EC (RoHS) are translated into national law. ElektroG defines the products that are subject to regulated collection and disposal or reuse in the event of disposal or at the end of their service life. ElektroG also prohibits the marketing of electrical and electronic equipment that contains certain amounts of lead, cadmium, mercury, hexavalent chromium, polybrominated biphenyls (PBB), and polybrominated diphenyl ethers (PBDE) (also known as hazardous substances with restricted uses). The products provided by ABB Automation Products GmbH do not fall within the current scope of the directive on waste from electrical and electronic equipment according to ElektroG. If the necessary components are available on the market at the right time, in the future these substances will no longer be used in new product development. 12 RSDE (Contrac) OI/RSDE10_50-EN

13 Ex relevant safety instructions 2 Ex relevant safety instructions IMPORTANT (NOTE) Technical modifications to the actuator or motor cancel the explosion protection. Before installing the actuator, review the information on the ID label regarding device class, Ex category, Ex zone and temperature class to make sure the actuator is approved for operation in the relevant hazardous area. In the event of deviations, the actuator may not be put into operation. Check the oil level and mounting position prior to commissioning the device in explosive atmospheres. 2.1 Operation via frequency transformer The frequency converter may not installed or used within the Ex area. Check whether the actuator is connected to the right electronic unit, see section "Specifications". Check whether the associated electronic unit has been configured using the correct actuator parameters. To do this, check the relevant information on the name plate of the actuator and the electronic unit with respect to actuator type, ambient temperature range of actuator, and NL number, if applicable. On delivery, the positioning time-out function of the electronic unit associated with the actuator is activated. Deactivating this setting is not permitted. Rapid traverse mode is not allowed to be used on Ex actuators. Therefore, it is not possible to select it via the user interface. Activating the breakaway function is not permitted. Activating the "Position dependent switch-off" function with 2x torque/force is not permitted. The Contrac power electronic unit must be upstream of the motor temperature monitoring unit SD241-B or a similar, certified tripping unit. 2.2 Preventing electrostatic charging Due to the possibility of impermissible electrostatic charging of the housing occurring, the effects of high-voltage sources on the equipment must be prevented. Electrostatic charging can also occur if the device is wiped with a dry cloth or if large amounts of dust flow around the device in dusty environments. To prevent charging of this type from occurring, the device may only be cleaned using a damp cloth. Dust flowing round the device should be prevented by installing a flow restrictor or partition. OI/RSDE10_50-EN RSDE (Contrac) 13

14 Design and function 3 Design and function Fig. 2: RSDE10 50 (illustrations may differ from actual installation) 1 Servo motor 2 Handwheel 3 Thrust rod 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 stroke time ensure excellent control quality and a long actuator life. 14 RSDE (Contrac) OI/RSDE10_50-EN

15 Design and function 115 V AC / 230 V AC motor temperature monitoring unit (z.b. SD241B) DCS / controller signal cable from / to DCS / controller (screened) temperature sensor cable Contrac electronic unit non-explosive area motor- / brake cable (screened) sensor cable (screened) brake motor wiring chamber explosive area Fig. 3: Ex design motor with temperature sensor sensor electronics position sensor Contrac actuator in explosion-proof design sensor wiring chamber (anti-condensation heater optional) M00266 OI/RSDE10_50-EN RSDE (Contrac) 15

16 Mounting 4 Mounting WARNING - Falling or toppling loads! Risk of death or serious injury due to the device falling down or toppling over! Do not stand under suspended loads! Do not detach the hoisting equipment until installation is complete! Only use the dedicated load pick-up devices (eyebolts) for suspending the components! 4.1 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 any position other than IMV 1 (refer to Fig. 4 and Fig. 5). Fasten the vent valve in the uppermost bore, depending on the actuator's mounting orientation (refer to Fig. 4 and Fig. 5). 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. 4.2 Installation instructions Make sure that the actuator is accessible from all sides to enable handwheel operation, electrical connection, and replacement of assemblies. Select an installation site that prevents direct exposure to rain, snow, and other environmental influences. During operation, an increase in the surface temperature caused by heat transfer via the interface to the valve on the actuator flange and on the thrust rod must not exceed 100 C (212 F). The surface temperature must be checked. In the IMV 1 and IMV 3 mounting positions, the actuators are more resistant to vibration loading of 1 g / 30 min. and frequencies of up to 150 Hz (in acc. with EN , Table C.2). In the IMB5 mounting position, vibration loading is not permitted. If the operating conditions do not allow you to make a clear assessment as to whether the vibration loading remains significantly below the proven contingent throughout the equipment's service life, the maintenance intervals must be reduced accordingly so that any oil leaks which may occur can be identified in good time. Make sure that the actuator elements (thrust rod and valve stem) do not introduce any additional vibration loading. This can be done by decoupling the linear actuator from the vibrations by using suitable measures (e.g., spring couplings or vibration absorbers between valve stem and thrust rod). When installing the actuator close to heat sources, use an insulating layer or shielding. Make sure the ambient temperature does not exceed 60 C (140 F). If necessary, use a cover to provide protection against direct sunlight. The internal mechanical end limit stop prevents the actuator thrust rod from leaving the housing. It must be attached so that there is at least a 3 % gap in front of the end position Valve requirements The force in the end position can be up to 2.5 times higher than the rated force. 16 RSDE (Contrac) OI/RSDE10_50-EN

17 Mounting 4.3 Installation position The gears of the RSDE10 50 actuators are lubricated with oil. The actuator is delivered factory-filled with the quantity of oil appropriate for IMV 1. Once the actuator has been installed, replace the uppermost inspection plug with the vent valve (supplied separately). Mounting position IMB 5 (handwheel down) is not permitted in the case of applications in Zones 21 and 22. IMPORTANT (NOTE) For more detailed information about the permissible mounting positions and the corresponding filling capacities, please refer to the section 7.4 "Filling capacity" RSDE10 / RSDE IMV 1 IMV 3 IMB 5 IMB 5 (handwheel down) Fig. 4: Mounting orientations 1 Inspection plug 2 Venting plug M RSDE50 Fig. 5: Mounting orientations 1 Inspection plug 2 Venting plug OI/RSDE10_50-EN RSDE (Contrac) 17

18 Mounting All mounting orientations shown in fig. Fig. 4 and Fig. 5 are permissible. To facilitate mounting and maintenance, however, it is recommended to use orientation IMV 1. For each mounting position, check the prescribed oil level prior to commissioning, see section 7.4 Filling capacity. In order to ensure sufficient ventilation and space for motor de-/installation allow for min. 80 mm (3.15 inch). 4.4 Mounting examples M00310 Fig. 6 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 adjustment 13 Thrust rod cover 18 RSDE (Contrac) OI/RSDE10_50-EN

19 Mounting 4.5 Adaptation of actuator stroke to the valve stroke 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 (NOTE) With a mounting position other than IMV 1, drain the oil until the oil level is below the thrust rod cover (Fig. 6/13). 1. Drive the thrust rod manually 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 (26 Nm (19.18 Lbf-ft)). 8. Reattach the cover for the thrust rod. 9. Screw in the lateral screw plug. 10. Fill the oil according to mounting position. 4.6 Assembly with the valve 1. Retract the thrust rod fully and place 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) in relation to the total stroke). 3. Fasten the actuator on the valve yoke using slightly oiled screws of property class 8.8 (tensile strength 800 N/mm 2 (116,032 pounds/square inch); yield strength 640 N/mm 2 (93,550 pounds/square inch)). IMPORTANT (NOTE) Observe the fastening torques and thread dimensions in the actuator flange! Actuator Tightening torque Flange thread RSDE10 / RSDE Nm ( lbf-ft) M16-20 deep RSDE Nm ( lbf-ft) M20-25 deep 4. Use the handwheel to extend the thrust rod; 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!). OI/RSDE10_50-EN RSDE (Contrac) 19

20 Electrical connections 5 Electrical connections Each actuator requires a Contrac electronic unit which is loaded with the type-specific software. IMPORTANT (NOTE) Observe the instructions for the actuator and compare the specifications on the name plates of the actuator and the electronic unit in order to ensure the hardware and software assignment is correct. Instructions concerning use in Ex applications The electrical connection between the Contrac electronic unit and the Contrac actuator can be established using the cable set (order code 695). The cable set is not part of the Ex type examination certificate and must, therefore, be tested by the installer or operator to ensure it functions safely within the the complete installation. In this respect, the following issues must be taken into consideration: The specific regulations governing the installation of electrical systems in potentially explosive atmospheres must be observed during electrical installation work. The regulations as set out in EN must be observed, particularly in respect of installing the shield bonding and potential compensation between the actuator, electronic unit, and motor protection equipment. See Chapter Cable shield, page 21 and page 22 ff. The motor and position sensor may only be connected using IP 66 Ex cable glands in accordance with EN ff with EU type examination certificate in accordance with Directive 2014/34/EU. The motor may be connected using cable lugs or a solid conductor bent into a "U" shape. Make sure that sufficient strain relief measures are in place for all cable connections. Provide all cable cores in the connection areas with sufficient protection against contact with metal surfaces. A gap of at least 6 mm (0.24 inch) must be maintained between conductive components. Remove the desiccant in the connection area of the motor and position sensor. Do not change the factory-set installation position of the motor junction box. Seal any cable entries that are not required using ATEX-certified IP 66 sealing plugs. For thermal motor monitoring purposes, the motor must be connected to a tested tripping unit. A permissible tripping unit is: - ABB motor temperature monitoring unit SD241-B; with integrated tripping unit 3 RN CK 00, designation Ex II (2) GD, PTB 01 ATEX 3218, Siemens 20 RSDE (Contrac) OI/RSDE10_50-EN

21 Electrical connections 5.1 Cable shield Signal part 1 Fig Screw in screw (1). 2. Unscrew the cover for the connection area or disconnect the connectors (3). 3 2 M M00754 Fig. 8: Installing the cable shield 3. Cut the cable sheath (6) to the required length. 4. Separate the cable shield and pull it back over the outer sheath (7). 5. Push the cable through the cable gland and fasten it with the clamp (4). 6. Make sure that the cable shield is in contact with the clamp (1) and the housing (5). 7. Connect the cable as described in section 5.2 Terminal connection diagrams. 8. Check the cable connections to ensure they are seated firmly and fasten the cable gland. 9. Screw the cover of the connection area (3) back on tight. IMPORTANT (NOTE) When installing the connection area cover, ensure that the sealing ring is not damaged. If the sealing ring is damaged, contact the manufacturer. 10. Unscrew screw (1). IMPORTANT (NOTE) Unscrew screw (1) until it is pressing against the cover (2). Make sure the screw is in a recess on the cover (3) Motor The cable shield must be connected to the motor in a proper manner. OI/RSDE10_50-EN RSDE (Contrac) 21

22 Electrical connections 5.2 Terminal connection diagrams Power Electronic Unit EBN853 (Contrac) / EBN861 (Contrac) Analog / digital IMPORTANT (NOTE) The electrical connection is established via screw terminals on the actuator and on the electronic unit. mains ext. fuse 115 VAC / 230 VAC SD241-B 1) sub distribution board screen connected to both ends one-sided screening in further wiring possible PE L N DI 1 MAN/AUT 1 DI 2 MAN(+) DI 3 MAN (-) DO 1 o.k./fault DO 2 endp. 0% DO 3 endp. 100% Uv out Setpoint + HART 0/4...20mA transmitter mA RB + act. pos. 0/4...20mA RB 24V + - Uv 24V U I Contrac electronic unit non-ex U V W Br Br PE H1 H ) 1) 1) 1) motor sensor U1 V1 W1 1 2 conn. chamber conn. chamber ~ M ϑ heater approx 6 W (option) sensors Ex motor brake Contrac Ex-actuator Fig. 9 1) See also Page 20 M RSDE (Contrac) OI/RSDE10_50-EN

23 Electrical connections PROFIBUS DP Fig. 10 : 1) See also Page 20 OI/RSDE10_50-EN RSDE (Contrac) 23

24 Electrical connections Power Electronic Unit EBS852 (Contrac) / EBS862 (Contrac) Analog / digital IMPORTANT (NOTE) The electrical connection is established via screw terminals on the actuator and on the electronic unit. Fig. 11 1) See also Page 20 IMPORTANT (NOTE) *If you are using a separate heat supply, install 2 max. 6 A medium time-lag fuses (e.g., Neozed D01CE14) to protect the heater. 24 RSDE (Contrac) OI/RSDE10_50-EN

25 Operation 6 Operation WARNING - risk of crushing! Danger of injuries due to crushing between external stop and valve yoke / actuator housing! Do not reach into the danger zone! IMPORTANT (NOTE) The actuator is supplied with activated positioning loop monitoring in the power electronic unit as default settings. Do not de-activate this setting. 6.1 Automatic mode / Handwheel mode WARNING - Live components! Risk of death or serious injuries due to electricity and unexpected machine movements! In automatic mode the motor is always under power, even at standstill! The servo motor triggered by the power electronic unit moves the axially-fixed actuator sleeve/nut assembly via oil-lubricated gears. A ball bearing screw that is radially fixed by an anti-twist arrester (see Fig. 12) converts the rotary motion into a linear one. The screw is the upper part of the thrust rod and has an adjustable mechanical stop. A position sensor detects the current thrust rod position via mechanical reduction gearing without backlash. The brake integrated in the motor carries out the stop function if the supply voltage is switched off. Fig. 12: Ball bearing screw with nut, cross-section M00308 OI/RSDE10_50-EN RSDE (Contrac) 25

26 Operation 6.2 Manual operation Handwheel mode allows you to move the actuator when the supply voltage is switched off. CAUTION - Risk of injury! When the handwheel lock is pressed, restoring force from the valve may be present in the handwheel. To prevent the handwheel from turning unintentionally, hold the handwheel with one hand. 1. Remove the cotter pin. 2. Press the handwheel lock. IMPORTANT (NOTE) Turning the handwheel clockwise causes the thrust rod to extend. 3. Turn the handwheel to move the valve stem to the desired position. 4. Release the lock. 5. Insert the cotter pin Handwheel operation in combination with positioning time-out function The positioning time-out function of the Contrac power electronic unit monitors the actuator's behavior. It monitors whether the travel commands trigger the corresponding processes. When the supply voltage is switched off, the positioning time-out function is disabled and handwheel operation is no longer monitored. If the actuator is moved via the handwheel while the supply voltage is switched on, the positioning time-out function recognizes this state as "Travel without travel command". A corresponding signal is output. There are several options for resetting this positioning loop error: Resetting via the commissioning and service field Resetting via the graphical user interface Changing the setpoint signal by at least 3 % for more than 1 s Wiring of binary inputs DI2 or DI3 (not with step controller) In the case of actuators with an Ex design, the positioning time-out function may not be deactivated. 26 RSDE (Contrac) OI/RSDE10_50-EN

27 Maintenance 7 Maintenance WARNING - Live components! Risk of death or serious injuries due to electricity and unexpected machine movements! In automatic mode the motor is always under power, even at standstill! WARNING - General risks! All maintenance activities may only be performed by properly qualified persons. Contrac actuators feature a robust construction. As a result, they are highly reliable and require minimal maintenance. The maintenance intervals depend upon the effective load and are therefore not specified here. The built-in microprocessor evaluates the actual load factors (e.g. torques, forces, temperatures, etc.) and derives the remaining operating time until the next routine maintenance is required. Use the configuration program to view this information. 7.1 Inspection and overhaul Only use genuine spare parts to overhaul the actuators (e.g., ball bearings, gaskets, and oil). Once the relevant periods have elapsed, maintenance activities must be carried out in accordance with the table below. Inspection or maintenance is due once the intervals specified in the table have passed, at the very latest. The replacement intervals for the thrust rod sealing ring (see Fig. 13/1), associated O-ring (see Fig. 13/2), stripper (see Fig. 13/3), and (flange) O-ring (see Fig. 13/4) should be fitted in at appropriate points between the intervals specified in the table. Fig. 13: Illustration of the thrust rod gasket (item 4 not applicable in the case of RSDE10 / RSDE20) OI/RSDE10_50-EN RSDE (Contrac) 27

28 Maintenance Overhaul intervals: Interval Measures 1 x per year Visual check of the gaskets for leaks. Remove and replace if leaks are present. Every 2 years Every 4 years Max. every 10 years, preferably once the remaining time to the next maintenance activity has elapsed Thrust rod sealing ring, associated O-ring, stripper, and (flange) O-ring Functional check: Drive the actuator 2 x through the entire stroke range and check for correct speed reduction. Check oil level. Replace oil, roller bearings, and gaskets on motor and gears. Check gear wheels for wear; replace if necessary. Replace after At surface temperature 5 years 100 C (212 F) 10 years 20 C (68 F) Make sure that no chippings or other materials get into the gears during maintenance work. Do not move the actuator during the oil level check. If the actuators are used within a category II2D area, the surfaces must be cleaned regularly to prevent dust deposits of more than 5 mm (0.20 inch). In order to avoid electrostatic charging, the device must be cleaned with a damp cloth. 7.2 Removing the motor and adjusting the brakes 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 or the motor is removed! Make sure that process forces are not exerted on the thrust rod. Since the brake is permanently released in AUT mode it is not exposed to mechanical wear. Any readjustment is not necessary. Use the test function of the configuration software to check the brake. 28 RSDE (Contrac) OI/RSDE10_50-EN

29 Maintenance 7.3 Oil change NOTICE! Do not mix oils for different temperature ranges. Dispose of old oil according to local regulations. Make sure that the oil does not enter the water cycle. Proceed as follows to drain or change the oil: 1. Provide a container capable of holding the expected oil quantity acc. to chapter 7.4 Filling capacity. 2. Open and remove the vent valve, see Fig Unscrew the lowermost drain plug and drain the oil. 4. Make sure all the oil is out of the actuator. 5. Screw in and tighten the oil drain plug. 6. Fill the container with the proper oil quantity and tighten the vent valve. Ambient temperature C ( F) Mobil SHC 629 Oil types (used at factory and present on delivery) OI/RSDE10_50-EN RSDE (Contrac) 29

30 Maintenance 7.4 Filling capacity IMPORTANT (NOTE) The specified oil quantities are estimates. The minimum oil level below the inspection plug must be observed at all times! RSDE10 / RSDE20 Mounting position IMV 1 IMV 3 IMB 5 1) (handwheel down) Oil quantity, approx. Max. stroke 100 mm (4 inch) Max. stroke 300 mm (11,8 inch) Oil level below inspection plug when thrust rod retracted 3,8 l (1,01 gal.2)) 6,4 l (1,69 gal.2)) 40 mm (1,57 inch) 5,4 l (1,43 gal.2)) 8,8 l (2,33 gal.2)) 0 mm (0 inch) 3,8 l (1,01 gal.2)) 6,4 l (1,69 gal.2)) 28 mm (1,10 inch) IMB 5 3,8 l (1,01 gal.2)) 6,7 l (1,77 gal.2)) 75 mm (2,95 inch) RSDE50 Mounting position IMV 1 IMV 3 3) IMB 5 Oil quantity, approx. Max. stroke 120 mm (4.72 inch) Max. stroke 300 mm (11.8 inch) Oil level below inspection plug when thrust rod retracted 7 l (1,85 gal.2)) 10 l (2,64 gal.2)) 49 mm (1,93 inch) - 7 l (1,85 gal.2)) 13 l (3,43 gal.2)) 12 l (3,17 gal.2)) - 35 mm Max. stroke mm (1,26 inch) mm (3,54 inch) (11,8 inch) 1) Mounting position IMB 5 is not permitted in the case of applications in Zones 21 and 22. 2) US liquid gallon 3) IMV 3 not permitted for 120 mm stroke 30 RSDE (Contrac) OI/RSDE10_50-EN

31 Trouble shooting 8 Trouble shooting This chapter only covers hardware-related errors. For additional troubleshooting information, refer to the online help for the operator interface. Error Possible cause Troubleshooting Valve cannot be moved by actuator. Failure either on the actuator or the valve (e.g., stuffing box tightened too much). Disconnect actuator from valve. If the actuator moves, the valve is the possible cause. If the actuator does not move, the The actuator does not respond. Actuator does not run in AUT mode, although AUT is selected in the user interface. Actuator does not respond to control (LED 5 flashing at 1 Hz) (software version 2.00 and higher). LEDs in the commissioning and service field are flashing Incorrect electronic unit or incorrect data record. Incorrectly configured electronic unit. No communication with the control system. Incorrect wiring between actuator and electronic unit. Defective motor/brake. Binary inputs on the electronic unit are not wired. Brake does not release (no mechanical "click"). Digital input 1 (DI 1) not wired. Actuator to manual mode (MAN) via commissioning and service field. Actuator is not adjusted properly. actuator is the possible cause. Compare information on name plates for actuator and electronic unit. Check / change. Change the settings via the parameterization software. Check wiring. Check wiring. Check the winding resistance of the motor and brake. Check the brake lock. Make connection. Check the brake air gap (approx mm (0.010 inch)) and electrical connection to the brake. Check winding resistance of the brake coil. Make connection. Check the software settings for the digital inputs. Switch actuator to automatic mode (AUT). Adjust actuator. synchronously. LEDs flash alternately. Electronic unit / drive malfunction. Drive the actuator beyond the adjusted end position, either manually or using the buttons on Malfunction when approaching the end position. 8.1 Electrical test values Actuator in limit range of positioning sensor. the commissioning and service field; (if necessary disconnect from valve before). Drive the actuator back into the operating range and connect it to the valve. Readjust the actuator for the operating range. BD 80 K-4B BD 80 L-4B BD 90 L2-4B BD 100 L2-4B Winding resistance ± 5 % at 20 C (68 F) motor 18,2 Ω 8,04 Ω 3,88 Ω 2,57 Ω brake 910 Ω 910 Ω 648 Ω 575 Ω OI/RSDE10_50-EN RSDE (Contrac) 31

32 Specifications 9 Specifications RSDE (Contrac) Operating mode S9; stall-proof acc. to IEC / EN Degree of protection IP 66 acc. to IEC / EN 60529, Ex protection IP6x acc. to EN Humidity 95 % annual average; condensation not permitted Ambient temperature C ( F) (reduced operating speed at rated load and below -10 C (14 F)) Transport and short-term C ( F) storage temperature Long-term storage C ( F) temperature Mounting position IMV1; IMV3; IMB5; preferably IMV1 acc. to IEC / EN , see also section "Filling capacity" RSDE10 / RSDE20: The mounting position IMB 5 (handwheel down) is not permitted in the case of applications in Zones 21 and 22. RSDE50: Mounting position IMV 3 is not permissible for RSDE mm stroke. Coating 2-layer component epoxy (RAL 9005, black) Anti-condensation heater (optional) Electrical connection Power supply for motor and sensors Rated force Starting force Rated positioning speed, adjustable Stroke Motor winding: Signal space: Directly from the electronic unit. Separate heating resistor; separate power supply or power feed from Contrac electronic unit Terminals in Ex e area; separately for motor and signals Connecting cable for electronic unit actuator available as an option (see ordering information for electronic unit) Only via Contrac electronic unit (refer to the data sheet for the electronic unit) RSDE RSDE RSDE RSDE kn (2,200 lbf) 20 kn (4,400 lbf) (adjustable to 0.5 / 0.75 or 1x rated force) (adjustable to 0.5 / 0.75 or 1x rated force) 1.2 x rated force mm/s mm/s mm/s mm/s (254 5 s/inch) ( s/inch) (254 5 s/inch) ( s/inch) min.: 0 15 mm ( inch) / max mm (0 4 inch) or min.: 0 50 mm ( inch) / max mm ( inch) Approx. 57 kg (126 lb) Approx. 60 kg (132 lb) Approx. 82 kg (181 lb) Approx. 85 kg (187 lb) Weight (100 mm stroke) Weight (300 mm stroke) Associated electronic unit For field installation: Model EBN853 1) For rack installation: Model EBS852 2) Thermal motor monitoring With motor temperature monitoring unit SD241B 3) or similarly certified tripping unit for PTC thermistor detectors Motor type BD 80 K-4B BD 80L-4B Sensors Position and temperature sensor always present 1) Data sheet for EBN853: 10/ ) Data sheet for EBS852: 10/ ) Data sheet for SD241B: 10/ RSDE (Contrac) OI/RSDE10_50-EN

33 Specifications RSDE RSDE Rated force 50 kn (11,000 lbf) (adjustable to 0.5 / 0.75 or 1x rated force) Starting force 1.2 x rated force Rated positioning speed, adjustable mm/s ( s/inch) mm/s ( s/inch) Stroke min.: 0 30 mm ( inch) / min.: 0 40 mm ( inch) / max.: mm (0 4.7 inch) max.: mm (0 4.7 inch) or or min.: 0 60 mm ( inch) / min.: 0 60 mm ( inch) / max.: mm ( inch) max.: mm ( inch) Weight (120 mm stroke) Weight (300 mm stroke) Approx. 130 kg (287 lb) Approx. 155 kg (342 lb) Approx. 146 kg (322 lb) Approx. 171 kg (377 lb) Associated electronic unit For field installation: Model EBN853 1) For rack installation: Model EBS852 2) For field installation: Model EBN861 3) For rack installation: Model EBS862 4) Thermal motor monitoring With motor temperature monitoring unit SD241B 5) or similarly certified tripping unit for PTC thermistor detectors Motor type BD 90 L2-4B BD 100 L2-4B (with brake and PTC) Sensors Position and temperature sensor always present 1) Data sheet for EBN853: 10/ ) Data sheet for EBS852: 10/ ) Data sheet for EBS861: 10/ ) Data sheet for EBS862: 10/ ) Data sheet for SD241B: 10/ OI/RSDE10_50-EN RSDE (Contrac) 33

34 Specifications 9.1 Technical data for the cable set (for Ex-relevant range) Motor connection Motor temperature monitoring Signal terminal (option) Wire conductor: 8 x 1,5 2 x 1,5 8 x 0,5 Mat. no.: Manufacturer: Huber+Suhner Huber+Suhner Bröckskes (HeluKabel) Type: RX125 S2 B 8g1.5 mm2 BK RX125 S2 2x1.5 mm2 BK So-LTG-PUR-8 x 0.5 (HK-So-Li12YC11Y-OB-8 x 0.5) Sheathing diameter: 14.3 ± 0.4 mm (0.56 ± 0.02 inch) 8.0 ± 0.4 mm (0.31 ± 0.02 inch) 8.5 ± 0.4 mm (0.33 ± 0.02 inch) Rated voltage Uo / U 600 / 1,000 V 600 / 1,000 V 300 / 500 V (Uo also applies to wire / shielding): Wire-wire test voltage: 3.5 kv 3.5 kv 1.2 kv Temperature range: moving: C ( F) C ( F) C ( F) fixed: C ( F) C ( F) C ( F) Protective conductor: GNYE Environment: UV-resistant and weather-proof UV-resistant and weather-proof UV-resistant and weather-proof Cable gland / M25 x 1.5 Exe / M25 x 1.5 Exe Mat. no.: Manufacturer: Rabe-System-Technik Rabe-System-Technik Type: CMDEL-T ADE 1F Item no.: Cable diameter: mm ( inch) mm ( inch) Material: Brass, nickel-plated Brass, nickel-plated Standard seal insert: Neoprene Neoprene O-ring: Perbunan Neoprene Temperature range: C ( F) C ( F) Degree of protection: IP bar (140,04 psi) IP 68-5 bar (72,52 psi) Certificate: LCIE 97 ATEX 6005 X / 01 LCIE 97 ATEX 6008 X / 03 Designation: II 2 G D Ex e II / Ex td Ex II 2 G D, Exe II Option Manufacturer: Pflitsch Pflitsch Type: blue globe ATEX blue globe ATEX Diameter: M25 x 1.5 KAD20-16/16-11 M20 x 1.5 KAD14-9/9-5 Item no.: bg225 msex bg220 msex Temperature range: C ( F) C ( F) Degree of protection: IP 68 IP 68 Certificate: PTB 06 ATEX 1036 X PTB 06 ATEX 1036 X Designation: II 2 G Ex e II II 2 D Ex td A21 IP68 IMPORTANT (NOTE) If the specified cable set does not meet all safety-relevant requirements, a more suitable installation material must be used. 34 RSDE (Contrac) OI/RSDE10_50-EN