ABB RHD Series Service Instruction Download | Manualshive

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RHD250 to 4000 (Contrac)

ELECTRICAL ROTARY ACTUATOR | SEI/RHD250/4000-EN REV. A

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Input configuration

Figure 59: Input configuration

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Summary of Contents for RHD Series

Page 1: ...he operation of final control elements with preferably 90 rotary movement such as valve flaps ball valves etc The nominal torque is transferred through a lever actuator A special electronic unit controls the actuator The special electronic unit serves as the interface between actuator and control system Additional Information Additional documentation on RHD250 to 4000 Contrac is available for down...

Page 2: ... of motor shaft sealing ring 18 Brake adjustment 19 Brake of motor series 1 19 Brake of motor series 2 19 5 Electrical connections 20 General 20 Covers 20 Electronic Unit EBN853 Contrac EBN861 Contrac EBS862 Contrac 21 Analog Digital 21 PROFIBUS DP 22 Electronic Unit EBN852 Contrac 23 Analog Digital 23 Fuses 24 Electronic unit for field installation 24 Electronic units for rack installation 24 Fus...

Page 3: ...irs to the product may only be performed if expressly permitted by these instructions Information and symbols on the product must be observed These may not be removed and must be fully legible at all times The operating company must strictly observe the applicable national regulations relating to the installation function testing repair and maintenance of electrical products Warnings The warnings ...

Page 4: ... connection between the product and your network or any other network as the case may be Operator shall establish and maintain any appropriate measures such as but not limited to the installation of firewalls application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security ...

Page 5: ... reaches the water cycle 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 Use the eye bolt at t...

Page 6: ... 40 mm 1 57 in RHD500 RHD800 30 mm 1 18 in RHD1250 RHD2500 40 mm 1 57 in RHD4000 40 mm 1 57 in Oil change Note Oils for different temperature ranges may not mixed During an oil change thoroughly remove any oil that may have escaped to avoid accidents Dispose of old oil according to local regulations Make sure that the oil does not enter the water cycle Make sure that any oil leaking from the devic...

Page 7: ...ug RHD500 RHD800 Mounting position IMB 3 IMB 6 IMB 7 IMV 5 IMV 6 IMB 8 Minimum oil level l gal Approx 10 2 65 Approx 11 5 3 04 Approx 10 2 65 Approx 10 2 65 Approx 10 2 65 Minimum oil level under inspection plug mm in 57 2 24 Lower edge of upper oil plug 15 0 59 37 1 46 Lower edge of upper oil plug RHD1250 RHD2500 Mounting position IMB 3 IMB 6 IMB 7 IMB 8 IMV 5 IMV 6 Minimum oil level l gal Approx...

Page 8: ...orques forces temperatures etc and derives the remaining operating time until the next routine maintenance is required Use the configuration program to view this information Apart from the load dependent maintenance intervals determined by the microprocessor we recommend routine maintenance at least every 10 years The following description of the maintenance work provide that the actuator is disco...

Page 9: ...unterpart soft metal into the lever gap in order to protect the expanding screw thread 4 Push the lever onto the shaft until it is nearly in the same position as it was before 5 Put the lever clamping bolt into the lever and tighten the nut s refer to Tightening torques and dimensions of lever screws on page 10 for torque values Ball and socket joint Figure 5 Ball and socket joint Figure 6 Use of ...

Page 10: ...llation 1 Push the bolt of the ball and socket joint into the lever hole 2 Put the crown nut onto the bolt and tighten it with the required torque refer to Tightening torques and dimensions of lever screws on page 10 for torque values 3 Secure the crown nut with a new cotter pin 1 Tightening torques and dimensions of lever screws Actuator Clamping Screw Limit stop screw Crown nut Expanding screw t...

Page 11: ... the flange screws allow to use forcing screws turn these screws clockwise to remove the flange 3 the thread length of the forcing screws should be at least 25 mm 7 Pull the flange3 from the shaft 8 Turn the forcing screws out 9 Take the O ring 1 and the sealing ring 2 out 10 Clean the shaft and the flange slightly grease the sealing ring 11 Replace the O ring and the sealing ring 12 Cover the key...

Page 12: ...rive shaft on page 11 9 Fasten the hand wheel 6 and re install the entire assembly tightening torque for the screws 3 20 Nm 15 ft lbs Sealing of the position sensor drive RHD250 RHD800 1 Flange fastening screw 2 O ring 3 Flange 4 Sealing ring 5 Shaft 6 Hexagon screw 7 Pinion Figure 10 Position sensor drive In order to change the O ring 2 and the sealing ring 4 firstly remove the position sensor Di...

Page 13: ...does not damage the sealing ring 11 Fasten the hood 3 and thighten the screws 1 crosswise with 23 Nm 17 ft lbs 12 Fasten the pinion 7 and tighten the hexagon screw 6 with 42 Nm 31 ft lbs Motor By the time of printing this document Contrac actuators use two basic motor series Motor type MC 71 MC 100 of the series 1 feature a C at the end of the name code motor type MC 71 MC 100 of the series 2 feat...

Page 14: ...ng ring in any case 7 Install the motor in reverse order Motor flange O ring 1 Motor screw 2 O ring 3 Flange 4 O ring 5 Screw 6 Motor Figure 13 Exemplary depiction of motor connection additional flange 3 not used for all motors In order to change the flange O ring proceed as follows 1 Disconnect the electrical power supply prior to any maintenance 2 Make sure that the oil level is below the O ring...

Page 15: ... brake fastening screws 3 and put brake body with disk aside 1 Retaining ring plier 2 Retaining ring 3 Brake pinion Figure 15 Brake removal II example shows motor of series 1 4 Use an appropriate retaining ring pliers 1 to get the retaining ring 2 for the brake pinion 3 out 5 Pull the brake pinion 3 from the shaft 1 Key 2 Flange screw 3 Extraction tool Figure 16 Removal of the motor flange example...

Page 16: ... Split ring removal 2 Use appropriate split ring pliers 1 and removal tool to remove the split ring 2 and the fan 3 1 Removal tool Figure 19 Removal tool 3 Remove the fan 1 Rear end of motor shaft 2 Brake cover screws Figure 20 Undo brake cover 4 Undo brake cover screws 2 1 Sealing ring 2 Brake cover Figure 21 Remove brake cover 5 Remove brake cover 2 1 Shrinkable tube 2 Brake screws Figure 22 Bra...

Page 17: ...emoval tool Figure 25 Pinion removal 12 Undo pinion screw 1 use appropriate retainer to secure the screw when re assembling DELO ML 5228 or LOCTITE 243 both medium firm detachable 13 Use appropriate removal tool 3 to pull the pinion 2 from the shaft 14 Do not damage the threaded center hole 1 Key hole 2 Key 3 Front flange 4 Motor housing Figure 26 Remove the key 15 Remove the key 2 note the key po...

Page 18: ...t the extraction tool claws 2 pull at the inner ball bearing ring 3 Exchange of motor shaft sealing ring A Sealing ring seat with shoulder B sealing ring seat without shoulder C Oil 1 Sealing ring 2 shoulder 3 Sleeve 4 Motor flange Figure 30 Inside of the motor flange 1 Take the old sealing ring out 2 Grease the new sealing ring and press it in the flange as shown in Figure 30 make sure that the o...

Page 19: ...y 3 and thrust plate 4 6 Tighten the socket head screws 2 evenly Brake of motor series 2 WARNING Risk of injury Note that the actuator position may be changed accidentally by the external load on the drive when the brake is released or the motor is removed 1 Socket head screws 2 Coil body 3 Thrust plate 4 Brake disk 5 Base plate Figure 33 Brake of motor series 2 In automatic mode the brake is perm...

Page 20: ...Cables with cable end sleeve 3 Crimp carrier 4 Cables with crimp pins 5 Plug housing 6 Carrier 7 Male carrier Figure 34 Exemplary illustration of cable connection to the actuator plug housing may contain alternatively a terminal carrier or a crimp carrier Covers A Screws B Cover or similar component Figure 35 Exemplary cover Terminal covers and other components at the Contrac actuators and electro...

Page 21: ...TARY ACTUATOR SEI RHD250 4000 EN REV A 21 Electronic Unit EBN853 Contrac EBN861 Contrac EBS862 Contrac Analog Digital BE digital input BA digital output Figure 36 Control via analog input 0 4 to 20 mA HART communication or digital inputs ...

Page 22: ... Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 5 Electrical connections Electronic Unit EBN853 Contrac EBN861 Contrac EBS862 Contrac PROFIBUS DP BA digital output Figure 37 Control via fieldbus PROFIBUS DP ...

Page 23: ...c ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 23 Electronic Unit EBN852 Contrac Analog Digital BE digital input BA digital output Figure 38 Control via analog input 0 4 to 20 mA HART communication or digital inputs ...

Page 24: ...e safe operation for the special switching conditions of electronic unit EBN861 Note that the cable cross sectional area between the fuse and the electronics must be at least 2 5 mm2 13 AWG Electronic units for rack installation Type Fuse Installation location Rated current of fuse Design at 115 V AC at 230 V AC EBS852 External fuse External 16 A slow Mains fuse In connection chamber 12 5 A slow 1...

Page 25: ...les for cable glands 2 Cable gland 3 Analog input fuse 4 Terminals signals 5 Anti dewing heater fuse 6 Terminals motor cable 7 Power supply fuse 8 Terminals power supply Figure 39 Fuses in connection housing part 1 Intermed circuit fuse 2 Brake fuse Figure 40 Fuses in control housing part Fuse location EBN861 EBS862 Figure 41 1 Intermed circuit fuse 2 Brake fuse Figure 42 Fuses in EBN861 EBS 862 ...

Page 26: ... respect to the switch on characteristic of these electronic units The wire cross section must be at least 2 5 mm2 13 AWG A Electronic unit Figure 43 External fuses Figure 44 External fuse 35 A Figure 45 Thermal circuit breaker 16 A Fuse location in EBS852 NOTICE Remove the cover of the connection chamber carefully in order to avoid any damage of the fuses or the fuse holder 1 Dig output fuses 2 M...

Page 27: ...d gear pair of the position sensor is held in place by a tension spring 1 to ensure backlashfree motion when the direction of rotation is reversed 1 Set the stop pin to the center position as shown in Figure 50 1 Fastening screws 2 Position sensor 3 Shaft gear 3 Sensor cable Figure 49 Mounting position Example shows RHD500 2 Align the sensor and its gears with the actuator set the first toothed ge...

Page 28: ... 3 Shaft gear 3 Sensor cable Figure 51 Mounting position Example shows RHD500 2 Align the sensor and its gears with the actuator set the first toothed gear in 09 00 o clock position Figure 51 onto the drive shaft gear 3 3 Slightly move the sensor back and forth to pre tension the toothed gears with the difference z until the second toothed gear snaps in 4 Fasten the screws 1 tightly 5 Fasten senso...

Page 29: ...al switch on HINWEIS If you loosen the motor terminal box for whatever reason use an appropriate liquid sealing compound for the sealing surface e g Elastosil E41 in addition to the rubber gasket before you fasten the box Note Check wiring and proper terminal connections before you start the test procedure Test values position sensor 1 Signal terminals Figure 52 Signal terminal location The in out...

Page 30: ... 4 6 ground 7 Terminal 5 for cable 5 Figure 53 Motor terminal box for MCS71BA MCS 71 BA Measuring points Resistance Winding resistance 5 at 20 C motor terminal 4 1 4 2 4 3 21 Ω Winding resistance 5 at 20 C brake terminal 5 6 2180 Ω 1 Terminal 1 for cable 1 2 Terminal 2 for cable 2 3 Terminal 3 for cable 3 4 Terminal 6 for cable 6 5 Terminal 5 for cable 5 6 ground 7 Terminal 4 Figure 54 Motor termi...

Page 31: ...oth LED flash alternatively Actuator failure e g out of adjusted range actuator cannot be moved via command buttons or commands from the process control system reset is only possible once the failure reason is eliminated Figure 55 Commissioning and service field 9 Troubleshooting NOTICE Check wiring polarity and all plug and terminal connections before you start detailed trouble shooting The follo...

Page 32: ...32 RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 9 Troubleshooting General Figure 56 General ...

Page 33: ...RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 33 Failures at brake fuse or wiring Figure 57 Failures at brake fuse or wiring ...

Page 34: ...34 RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 9 Troubleshooting Operation mode MAN AUT Figure 58 Operation mode MAN AUT ...

Page 35: ...RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 35 Input configuration Figure 59 Input configuration ...

Page 36: ...36 RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 9 Troubleshooting Operation behind step controller Figure 60 Operation behind step controller ...

Page 37: ...RHD250 to 4000 Contrac ELECTRICAL ROTARY ACTUATOR SEI RHD250 4000 EN REV A 37 Failure Diagram Figure 61 Failure Diagram ...

Page 38: ...elect step controller Actuator over runs end position s Change the software settings for the end position behavior to Position dependent switch off and enter the associated switch off position Adjust the mechanical limit stops in order to avoid an end position over run Actuator moves into an end position once it reaches a setpoint De activate close tight in the software settings for modulating con...

Page 39: ...erned Some of the subjects in Troubleshooting on page 31 refer to the user interface Use the numbering in table 5 to facilitate the navigation The user interface software does not use any numbering in the menus A Operate B Diagnosis C Configure D Service A 1 Positioner B 1 Status C 1 General D 1 Initial setting A 2 Controller B 2 Alarms Failures C 2 Operation D 2 Test B 3 Maintenance C 3 End posit...

Page 40: ...or notice With regard to purchase orders the agreed particulars shall prevail ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document We reserve all rights in this document and in the subject matter and illustrations contained therein Any reproduction disclosure to third parties or utilization of its contents in whole or in parts is f...

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