ABB RHDE250 Operating Instructions Manual Download | Manualshive

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Safety

42/68-167-EN

RHDE250 ... 4000 (Contrac)

5

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1 Safety

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1.1

General Safety Information

The “Safety” chapter provides an overview of the safety aspects to be observed for the
operation of the device.

The device is built based on state-of-the-art technology and is operationally safe. It was tested
and left the factory in a proper state. The requirements in the manual as well as the
documentation and certificates must be observed and followed in order to maintain this state for
the period of operation.

The general safety requirements must be complied with completely during operation of the
device. In addition to the general information, the individual chapters of the manual contain
descriptions about processes or procedural instructions with specific safety information.

Only the observance of all safety information enables the optimal protection of personnel as well
as the environment from hazards and the safe and trouble-free operation of the device.

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The actuators are used for operating final control elements (valves, vanes, etc.). They may only
be operated using the appropriate Contrac electronic unit for field or rack installation. Do not
use these actuators for any other purpose. Otherwise, a hazard of personal injury or of damage
to or impairment of the operational reliability of the device may arise. In addition to these
operating instructions, the relevant documentation for the electronic unit and software tools
must be observed.

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Repairs, alterations and enhancements or the installation of replacement parts is only
permissible as far as described in the manual. Further actions must be verified with ABB
Automation Products GmbH. Excluded from this are repairs performed by ABB-authorized
specialist shops.

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1.2

Technical limits

The device is designed for use exclusively within the stated values on the name plate and in the
technical specifications (see "Technical Specifications” chapter and/or data sheet). These must
be complied with accordingly, e.g.:

• The maximum operating temperature may not be exceeded.

• The permitted operating temperature may not be exceeded.

• The housing protection system must be observed.

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Summary of Contents for RHDE250

Page 1: ... Turn Actuator RHDE250 4000 Contrac Pos 1 Titelblätter Copyright BA IA Aktorik Antriebe Contrac RHDE250 4000 Contrac 9 mod_1181413072187_3101 doc 102665 Rated torque 250 4000 Nm 185 2950 lbf ft In explosion proof design P R O F I B U S PROCESS FIELD BUS ...

Page 2: ... Minden Germany Tel 49 551 905 534 Fax 49 551 905 555 CCC support deapr de abb com Copyright 2007 by ABB Automation Products GmbH Subject to change without notice This document is protected by copyright It assists the user with the safe and efficient operation of the device The contents may not be copied or reproduced in whole or in excerpts without prior approval of the copyright holder Pos 3 Inh...

Page 3: ...ety information 10 1 14 Maintenance safety information 10 2 Explosion protection safety precautions 11 2 1 Operation via frequency transformer 11 2 2 Preventing electrostatic charging 11 3 Design and function 12 4 Installation 13 4 1 Actuator check 13 4 2 Mounting position 13 4 3 Installation instructions 14 4 4 Assembly with the valve 14 4 4 1 Preparation 14 4 4 2 Adjusting the stops in dependenc...

Page 4: ...34 6 1 Automatic manual mode 34 6 2 Manual operation 34 7 Maintenance 35 7 1 Inspection and overhaul 35 7 2 Brake adjustment 36 7 3 Oil change 36 7 4 Filling capacity 37 8 Trouble shooting 38 8 1 Electrical test values 38 9 Technical data 39 9 1 General information 39 9 2 Technical Data RHDE250 39 9 3 Technical data RHDE500 RHDE800 40 9 4 Technical data RHDE1250 RHDE2500 40 9 5 Technical data RHDE...

Page 5: ...ators are used for operating final control elements valves vanes etc They may only be operated using the appropriate Contrac electronic unit for field or rack installation Do not use these actuators for any other purpose Otherwise a hazard of personal injury or of damage to or impairment of the operational reliability of the device may arise In addition to these operating instructions the relevant...

Page 6: ...life One of these symbols in conjunction with the Danger warning indicates an imminent danger If it is not avoided death or serious injury will result Warning Bodily injury The symbol in conjunction with the Warning message indicates a possibly dangerous situation If it is not avoided death or serious injury could result Caution Slight injuries The symbol in conjunction with the Caution message in...

Page 7: ...angle and min max actuating speed 6 Filled oil types 7 Associated Contrac electronic unit 8 Explosion protection class 9 Certification authority 10 Free for customer specific entry Pos 4 13 Sicherheit Aktorik Allgemein Pflichten des Betreibers 10 mod_1181723170562_3101 doc 105157 1 5 Operator liability The operators must strictly observe the applicable national regulations in their countries with ...

Page 8: ...ces Through its publications ABB conducts an open dialog with the public This product solution is manufactured from materials that can be reused by specialized recycling companies 1 8 1 Information on WEEE directive 2002 96 EC Waste Electrical and Electronic Equipment This product solution is not subject to the WEEE directive 2002 96 EC and relevant national laws e g ElektroG in Germany Dispose of...

Page 9: ... movements for positioning vanes and valves etc Only qualified specialists who have been trained for these tasks are authorized to mount and adjust the control actuator and to make the electrical connection When working on the actuator itself or the electronics always observe the locally valid accident prevention regulations and the regulations concerning the construction of technical installation...

Page 10: ...s take the required protective measures Lock the handwheel with a cotter pin in order to a void unintentional manual actuator operation Switch off the power supply to the motor prior to any manual operation Pos 4 30 Überschriften 1 1 1 spaltig S Z Sicherheitshinweise zur Wartung 10 mod_1181811822343_3101 doc 106052 1 14 Maintenance safety information Pos 4 31 Sicherheit Aktorik Elektr Schwenkantri...

Page 11: ...101 doc 102922 2 1 Operation via frequency transformer Pos 6 4 Ex technische Sicherheitshinweise Aktorik Antriebe Allgemein Betrieb am Frequenzumformer 9 mod_1181416045984_3101 doc 102803 The frequency converter electronic unit may not installed or used within the hazardous area Check whether the electronic unit is loaded with the parameters of the actuator it is connected to Check the electronic ...

Page 12: ...ns 115 V AC 230 V AC Motor Temperature Monitoring Unit e g SD241B Contrac power electronic unit Contrac actuator in explosion proof design M00190 non Ex Ex Motor with temperature sensor brake Motor brake line shielded Sensor line shielded Signal line from to control system controller shielded Motor connection area Sensor connection area anti condensation heater optional Sensor electronic unit Actu...

Page 13: ...ing position Pos 11 5 Montage Aktorik Elektr Schwenkantriebe RHDE250 4000 Einbaulage Zeichnung 10 mod_1181815089156_3101 doc 106121 The spur gears of the actuator RHDE250 4000 Contrac are oil lubricated They contain the max oil quantity when leaving the manufacturer Once the actuator is installed replace the uppermost check plug by the separately supplied venting plug IMB 3 IMB 6 IMB 7 IMV 6 1 2 M...

Page 14: ...may not be exceeded Pos 11 10 Überschriften 1 1 1 spaltig S Z Zusammenbau mit dem Stellglied 10 mod_1181634985953_3101 doc 103507 4 4 Assembly with the valve Pos 11 11 Überschriften 1 1 1 1 spaltig Vorbereitung 10 mod_1181635035296_3101 doc 103530 4 4 1 Preparation Pos 11 12 Montage Aktorik Elektr Schwenkantriebe Allgemein Vorbereitung 10 mod_1181569909062_3101 doc 103083 Warning Electrical voltag...

Page 15: ...nt 5 Fasten the counter nuts 6 Fasten the stop in the other mounting position close to the end position depending on the toothing Pos 11 16 Überschriften 1 1 1 1 spaltig Kraftabhängige Anschlageinstellung 10 mod_1181635174750_3101 doc 103626 4 4 3 Adjusting the stops in dependence of the torque Pos 11 17 Montage Aktorik Elektr Schwenkantriebe Allgemein Kraftabhängige Anschlageinstellung 10 mod_118...

Page 16: ...4 Lbf ft 670 Nm 494 Lbf ft 670 Nm 494 Lbf ft lever clamping screw tightening torque 79 Nm 58 Lbf ft 195 Nm 144 Lbf ft 390 Nm 288 Lbf ft 390 Nm 288 Lbf ft Mounting screw property class 8 8 tensile strength 12 mm 0 47 inch 18 mm 0 71 inch 20 mm 0 78 inch 20 mm 0 78 inch tensile strength 800 N mm2 116032 pounds square inch 800 N mm2 116032 pounds square inch 800 N mm2 116032 pounds square inch 800 N ...

Page 17: ... drive element instead of the standard lever the following installation conditions must be observed Max perm temperature of shaft Type radial force at distance x N lbf Distance x from shaft edge mm inch axial force N lbf max output torque RHDE250 1767 397 24 40 1 57 310 69 69 A short term overload up to double the rated torque is possible RHDE500 7542 1695 51 35 1 38 1310 294 50 A short term overl...

Page 18: ...n use the current mechanical stops The following parameters must be observed Type bore diameter mm inch Key width mm inch Hub length mm inch Minimum yield strength of hub Rp 0 2 N mm2 pounds square inch RHDE250 30 0 033 1 18 0 0013 8 0 015 0 051 0 31 0 0006 0 0020 50 1 97 320 46412 80 RHDE500 50 0 039 1 97 0 0015 14 0 018 0 061 0 55 0 0007 0 0024 70 2 76 320 46412 80 RHDE800 50 0 039 1 97 0 0015 1...

Page 19: ... El Schwenkantrieb RHD 250 Contrac Maßbild Hebeltrieb 5 mod_1152865563125_3101 doc 34924 4 1 2 3 M00112 265 50 16 5 21 50 0 0 5 1 45 0 0 1 5 150 40 120 8 33 3 0 2 60 30 0 033 0 000 200 40 Ø18 30 74 18 23 100 120 L 220 L 18 100 120 23 99 19 Fig 6 Dimensions in mm 1 Cone 1 10 2 Welding bushings are part of shipment 3 Connection pipe 1 1 4 DIN 2440 resp 1 1 4 schedule 80 pipe size L acc to requiremen...

Page 20: ...L 8 66 L 0 71 3 94 4 72 0 91 3 90 0 75 Fig 7 Dimensions in Inch 1 Cone 1 10 2 welding bushings are part of shipment 3 Connection pipe 1 1 4 DIN 2440 resp 1 1 4 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angular deflection of ball and socket joint Pointing towards the actuator max 3 Pointing away from the actuator max 10 Pos 11 29 Seitenumbruch 0 mod_11265323...

Page 21: ...ltrieb 5 mod_1153291203031_3101 doc 35504 M00103 1 2 3 4 L 45 14 0 018 0 061 53 8 0 2 105 120 Ø22 23 21 92 28 105 120 L 230 99 70 28 5 25 343 26 17 80 50 0 039 0 60 150 200 250 63 Ø48 Ø41 ø37 5 Fig 8 Dimensions in mm 1 Cone 1 10 2 welding bushings are part of shipment 3 Connection pipe 1 1 2 DIN 2440 resp 1 1 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angu...

Page 22: ...6 5 91 7 87 9 84 2 48 1 89 1 61 1 48 US Fig 9 Dimensions in Inch 1 Cone 1 10 2 welding bushings are part of shipment 3 Connection pipe 1 1 2 DIN 2440 resp 1 1 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angular deflection of ball and socket joint Pointing towards the actuator max 3 Pointing away from the actuator max 10 Pos 11 32 Seitenumbruch 0 mod_1126532...

Page 23: ...ieb 5 mod_1153894291312_3101 doc 36177 4 5 L 74 9 Ø26 24 5 104 5 25 32 30 110 140 I L 250 120 70 200 75 250 300 350 460 120 100 20 Ø 60 Ø52 5 Ø48 5 US 35 0 076 0 030 0 0 2 2 0 0 7 4 0 2 110 140 4 3 2 1 M00114 Fig 10 Dimensions in mm 1 Cone 1 10 2 Welding bushings are part of shipment 3 Connection pipe 2 DIN 2440 resp 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipmen...

Page 24: ... 0 0 0 2 9 0 0 0 8 4 33 5 51 4 3 2 1 M00114 Fig 11 Dimensions in Inch 1 Cone 1 10 2 welding bushings are part of shipment 3 Connection pipe 2 DIN 2440 resp 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angular deflection of ball and socket joint Pointing towards the actuator max 3 Pointing away from the actuator max 10 Pos 11 35 Seitenumbruch 0 mod_1126532365...

Page 25: ...8828_3101 doc 36460 4 5 9 0 4 Ø38 30 5 141 37 42 5 40 135 165 I L 300 L 140 140 Ø85 0 090 0 036 400 87 537 125 5 163 5 38 42 5 25 0 0 1 8 0 0 6 1 Ø76 Ø68 Ø58 US 12 31 135 165 4 1 2 3 0 2 M001 Fig 12 Dimensions in mm 1 Cone 1 10 2 Welding bushings are part of shipment 3 Connection pipe 2 1 2 DIN 2440 resp 2 1 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angul...

Page 26: ...US 0 47 1 22 5 31 6 50 4 1 2 3 0 0 0 8 M001 Fig 13 Dimensions in Inch 1 Cone 1 10 2 welding bushings are part of shipment 3 Connection pipe 2 1 2 DIN 2440 resp 2 1 2 schedule 80 pipe size L acc to requirements The pipe is not included in shipment 4 Angular deflection of ball and socket joint Pointing towards the actuator max 3 Pointing away from the actuator max 10 Pos 12 Seitenumbruch 0 mod_11265...

Page 27: ...tor Consider the following issues Consider the local regulation concerning the setup of electrical devices within hazardous areas This applies particularly to EN 60079 14 for the setup of the screen and the potential compensation between the actuator the electronic unit and the motor protection unit see 1 in chapter Cable shield page 28 and chapter Terminal connection diagrams page29 ff For the co...

Page 28: ...the shield 1 Remove approx 2 cm of cable sheathing 3 from the end of the cable 2 Separate the shield and peel it back to its inner sheathing 4 3 Push the cable through the cable gland and fasten with clamp 1 4 Make sure that the shielding is touching the clamp and the electronic unit housing 2 Pos 13 7 Überschriften 1 1 1 1 spaltig Motor 10 mod_1182501159359_3101 doc 108596 5 1 2 Motor Pos 13 8 El...

Page 29: ...107576 Important The electrical connection is provided by terminals on the actuator and on the electronic unit 24V 30 RB 31 I U 26 27 1 7 2 8 3 9 4 10 13 5 11 14 6 12 15 L N 17 19 20 21 22 23 24 SD241B U1 V1 70 1 71 2 W1 1 2 J 17 19 20 21 22 23 24 U V W Br Br PE PE H1 H2 11 Uv 24V RB 28 29 10 18 mains M00208 M3 motor brake Contrac ex actuator sensors Ex non Ex heater approx 6 W option screen conne...

Page 30: ... 30 31 U V W Br Br PE H1 H2 L N Bus out Bus in S1 SD241B 18 non Ex Ex heater approx 6 W option motor conn chamber sensor conn chamber motor brake Contrac Ex actuator mains ext fuse sensor BA1 endp 0 BA2 endp 100 10 13 11 12 115 V AC 230 V AC Screen at both ends up to the sub distribution board One sided screening in further wiring possible 1 1 1 1 1 Fig 16 Electrical connection PROFIBUS DP option ...

Page 31: ...I U 26 27 1 7 2 8 3 9 4 10 13 5 11 14 6 12 15 L N 17 19 20 21 22 23 24 SD241B U1 V1 W1 1 2 3 M J 17 19 20 21 22 23 24 U V W Br Br PE PE 11 Uv 24V RB 28 29 10 1 2 M00210 motor brake Contrac ex actuator sensors Ex non Ex heater approx 6 W option screen connected to both ends one sided screening in further wiring possible transmitter 4 20mA Setpoint HART 0 4 20mA act pos 0 4 20mA DO 1 o k fault DO 2 ...

Page 32: ...r approx 6 W option see notice on this side motor conn chamber sensor conn chamber motor brake Contrac Ex actuator sensor mains 115 V AC 230 V AC ext fuse mains 110 V AC 230 V AC ext fuse Screen at both ends up to the sub distribution board One sided screening in further wiring possible DO1 endp 0 DO2 endp 100 1 1 1 1 1 Fig 18 Electrical connection PROFIBUS DP option Important For separate heat su...

Page 33: ... 1 7 2 8 3 9 4 10 13 5 11 14 6 12 15 L N 17 19 20 21 22 23 24 SD241B U1 V1 W1 1 2 3 M J 17 19 20 21 22 23 24 U V W Br Br PE PE 11 Uv 24V RB 28 29 10 1 2 M00210 motor brake Contrac ex actuator sensors Ex non Ex heater approx 6 W option screen connected to both ends one sided screening in further wiring possible transmitter 4 20mA Setpoint HART 0 4 20mA act pos 0 4 20mA DO 1 o k fault DO 2 endp 0 DO...

Page 34: ...ever with ball and socket joints and a coupling rod A position sensor detects backlash free the current position of the drive shaft Adjustable limit stops prevent overloading of the valve in the event of an operating error The motor brake locks the actuator in the current position if the power suplly is cut off Pos 15 5 Überschriften 1 1 1 spaltig G L Handradbetrieb 10 mod_1181715640046_3101 doc 1...

Page 35: ...nspektion und Überholung 10 mod_1181640404046_3101 doc 103748 Only use genuine spare parts such as ball bearings gaskets and oil may be used to overhaul the actuators Proceed acc to table when performing maintenance activities Inspection or maintenance is due after the time specified in the table Overhaul intervals Interval Measures 1 x per year Visual check of the gaskets for leaks change if nece...

Page 36: ...enkantriebe Allgemein Ölwechsel 10 mod_1181632020265_3101 doc 103369 Important Oils for different temperature ranges may not mixed 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 Filling capacity 2 Open and remove th...

Page 37: ...V 6 Minimum oil quantity approx 10 l 2 65 gal 1 11 5 l 3 04 gal 1 10 l 2 65 gal 1 10 l 2 65 gal 1 Min oil level mm under inspection plug 57 mm 1 24 inch Lower edge of upper oil plug 15 mm 2 17 inch Lower edge of upper oil plug Filling capacities RHDE1250 2500 Installation position IMB 3 IMB 6 IMB 7 IMV 6 Minimum oil quantity approx 29 l 7 67 gal 1 32 l 8 47 gal 1 24 l 6 35 gal 1 26 5 l 7 01 gal 1 ...

Page 38: ...nic unit are not wired Make connection actuator does not react Brake does not release no mechanical click Check the brake air gap approx 0 25 mm and electrical connection to the brake check winding resistance of the brake coil actuator does not run in AUT mode although AUT is selected in the user interface Binary input 1 BE 1 not wired Make connection Check the software settings for the binary inp...

Page 39: ...cting cable electronics actuator optional see ordering information of electronics Power supply for motor and sensors Only via Contrac electronic unit refer to the data sheet for the electronic unit Pos 21 4 Überschriften 1 1 1 spaltig S Z Technische Daten RHDE250 10 mod_1181713737546_3101 doc 104812 9 2 Technical Data RHDE250 Pos 21 5 Technische Daten Datenblatt Aktorik Antriebe Schwenkantriebe Ex...

Page 40: ...heet SD241B 10 68 8 30 Pos 21 9 Überschriften 1 1 1 spaltig S Z Technische Daten RHDE1250 RHDE2500 10 mod_1181713869640_3101 doc 104858 9 4 Technical data RHDE1250 RHDE2500 Pos 21 10 Technische Daten Datenblatt Aktorik Antriebe Schwenkantriebe Ex El Schwenkantriebe RHDE1250 RHDE2500 Contrac Regelantrieb Ex 6 mod_1169128878968_3101 doc 61415 Model RHDE1250 12 RHDE2500 10 RHDE2500 25 Rated torque 12...

Page 41: ...peed adjustable 9 0 0 1 s 2 25 0 1 s Operating angle Typically 90 min 35 max 140 See instructions for limited operating angle if actuator is equipped with lever and limit stop Weight approx 296 kg 653 lb approx 284 5 kg 627 lb Related electronics For field installation For rack installation Model EBN861 1 Model EBS862 2 Model EBN853 3 Model EBS852 4 Thermal motor Monitoring With motor temperature ...

Page 42: ... Environment UV resistant and weather proof UV resistant and weather proof UV resistant and weather proof Cable gland 13 5 18 M25 x 1 5 Exe 4 8 5 M25 x 1 5 Exe Mat no 9287589 9287588 Manufacturer Rabe System Technik Rabe System Technik Type CMDEL T ADE 1F Item no 00222574 00816674 Cable diameter 13 5 18 mm 0 53 0 71 inch 4 8 5 mm 0 16 0 33 inch Material Brass nickel plated Brass nickel plated Stan...

Page 43: ...2006 42 EC By placing the CE mark on its devices ABB Automation Products GmbH declares its conformance with these directives Ex approvals The symbol indicates devices with an ignition proof design For devices in Ex design according to identification on an additional nameplate the following also applies Conforms with ATEX directive 94 9 EC By placing the CE mark on its devices ABB Automation Produc...

Page 44: ...ntact person Telephone Fax E Mail Device details Type Serial no Reason for the return description of the defect Was this device used for working with substances which pose a threat or health risk F Yes F No If yes which type of contamination please place an X next to the applicable items biological F corrosive irritating F combustible highly extremely combustible F toxic F explosive F other toxic ...

Page 45: ...cities 37 Filling capacity 36 37 Functional check 35 G General information 39 General Safety Information 5 I Ignition protection approvals 43 Ignition proof design 43 Inspection and overhaul 35 Installation 13 Installation instructions 14 Installation position 37 Installation safety information 9 L Labels and symbols 6 Lever for RHDE1250 RHDE2500 23 Lever for RHDE250 19 Lever for RHDE4000 25 Lever...

Page 46: ...nal connection diagrams 27 29 tightening torque 16 Time until next maintenance is required 35 Transport safety information 8 Trouble shooting 38 W Warranty provision 6 Wear 35 WEEE directive 8 Pos 25 4 Wechsel zwei auf einspaltig 0 mod_1130421955859_3101 doc 3829 Wechsel ein auf zweispaltig Pos 26 Rückseiten Minden_Aktorik 2 mod_1151575081640_3101 doc 32243 Ende der Stückliste ...

Page 47: ......

Page 48: ...thout notice Printed in the Fed Rep of Germany 10 2007 ABB 2007 3KXE111001R4201 42 68 167 EN Rev B ABB Limited Salterbeck Trading Estate Workington Cumbria CA14 5DS UK Tel 44 0 1946 830 611 Fax 44 0 1946 832 661 ABB Inc 125 E County Line Road Warminster PA 18974 USA Tel 1 215 674 6000 Fax 1 215 674 7183 ABB Automation Products GmbH Schillerstr 72 32425 Minden Germany Tel 49 551 905 534 Fax 49 551 ...

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