43 68 14 en 12 2005

Service Instruction Electrical Linear Actuators for
43/68-14 EN
Continuous Modulating Control
RSD10 ... RSD200 (Contrac)
Rated Force 10 ... 200 kN
(2250...45000 lbf)
®
P R O F I
PROCESS FIELD BUS
B U S
Electrical Linear Actuators for Continuous Modulating Control
RSD10 ... RSD200 (Contrac)
Service Instruction
Document No. 43/68-14 EN
Issued: December 2005
Manufacturer:
ABB Automation Products GmbH
Schillerstr. 72
32425 Minden
Germany
Tel: +49 551 905-534

Fax: +49 551 905-555
© Copyright 2005 by ABB Automation Products GmbH

We reserve the right to technical amendments
This document is protected by copyright. Information in this document is intended only to assist the
user in safe and efficient operation of the equipment. Its contents are not to be reproduced in full or
part without prior approval of legal owner.
2 Electrical Linear Actuators for Continuous Modulating Control RSD10 ... RSD200 (Contrac) 43/68-14 EN
Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
Important information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety and precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mounting position and filling capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Oil specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Thrust rod sealing ring and scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sealing ring of hand wheel drive / hand wheel shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Exchange of position sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Dismounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Position sensor conversion gearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical Test Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test values (position sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Test values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Winding resistance (motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Failure detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LED signals at the local control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Failures at brake, fuse or wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operation mode (MAN / AUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Input configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operation behind step controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Failure Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Failure due to response of positioning loop monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
User Interface Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
43/68-14 EN Electrical Linear Actuators for Continuous Modulating Control RSD10 ... RSD200 (Contrac) 3
Important information
1 Important information
1.1 General
Read and save all instructions prior to installing, operating, and servicing this product. If any of the
instructions are not understood, contact your ABB representative for clarification.
1.2 Symbols
In order that you can make the best use of this document and to ensure safety during commissioning,
operation and maintenance of the equipment, please note the following explanation of the symbols
used.
Explanation of the symbols used:
Symbol Signal Word Definitions

DANGER DANGER indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
STOP (High level of risk.)
WARNING WARNING indicates a potentially hazardous situation which, if not

avoided, could result in death or serious injury.
(Medium level of risk.)
CAUTION CAUTION indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
(Low level of risk.)
NOTICE NOTICE indicates a potentially harmful situation which, if not avoided,
may result in damage of the product itself or of adjacent objects.
(Damage to property)
IMPORTANT IMPORTANT indicates useful hints or other special information which,
if not observed, could lead to a decline in operating convenience or af-
fect the functionality.
(Does not indicate a dangerous or harmful situation.)
As well as the instructions in this document, you must also follow the generally applicable accident
prevention and safety regulations.
If the information in this document is insufficient in any situation, please contact our service depart-
ment, who will be happy to help you.
Please read this document carefully before installation and commissioning
To ensure proper performance, use qualified personnel who have

been trained, qualified and certified by ABB to install, operate, up-
date, tune, and maintain the actuator, the electronic units and the wir-
ing.
ABB will not take any responsibilty for personal injuries or material
damages which were caused by non-trained, non-qualified or non-
certified personnel.
1.3 Transport and storage

Carefully inspect for shipping damage. Damage to the shipping carton is usually a good indication that
it has received rough handling. Report all damage immediately to the freight carrier and your ABB rep-
resentative. Verify that the items on the packing list or bill of lading agree with your own.
Introduction
2 Introduction
This service instruction refers to the ABB linear actuators RSD10... RSD200. It amends and deepens
the routine maintenance description in the standard instruction, which we strongly recommend also
be available for all maintenance work.
position
internal sensor
limit stop
position sensor
conversion gearing
motor
hand wheel drive sleeve
differential
spring package
gearing
thrust rod external limit stop
Fig. 1: RSD...; main components
2.1 Safety and precautions

When mounting the actuator in areas which may be accessed by unauthorized persons, take the re-
quired protective measures.
STOP - The actuators perform movements for positioning vanes and valves. Handle properly and with care.
Otherwise, a hazard of bruise injuries may arise.
STOP - 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 the waste oil in compliance with the respective local regulations. Make sure that no waste
oil reaches the water cycle.
- Only qualified specialists who have been trained, qualified and certified by ABB for these tasks are
authorized to mount and adjust the actuator and to make the electrical connection. ABB will not take
any responsibility for personal injuries or material damages which were caused by non-trained, non-
qualified or non-certified personnel.
- When working on the actuator itself or the electronics always observe the locally valid accident pre-
vention regulations and the regulations concerning the construction of technical installations.
- Use the eye bolt at the actuator to lift or lower it. Only load it vertically. Do not lift or lower the actu-
ator when it is mounted on a valve or similar final control element.
- Switch-off the voltage supply; make sure that unintentional switching on is not possible.
- Make sure that switching off the power supply does not affect the plant process.
- Make sure that the final control element is not exposed to process forces.
- Refill the oil and check all mechanical and electrical interfaces for proper connection once the in-
stallation, commissioning, service or maintenance work is done.
- Consider the weight of the components.
- Exclusively use genuine spare parts supplied by the ABB service organization.
2.2 Tools
IMPORTANT Maintenance at CONTRAC actuators requires tools which are usually available in a workshop. Please
consider that all dimensions are based on the metric system. This applies also for the wrench sizes,
threads etc. Using improper tools may damage the actuator or its components. Use appropriate
sleeves for the installation of the sealing rings (see chpt. 4 for details).
Lubrication
3 Lubrication
The spur wheel gearings of RSD10... RSD200 are oil lubricated. They contain the max. oil quantity
when they leave the manufacturer. In order to avoid any overpressure in the gearbox (e. g. due to ther-
mal influence) replace the uppermost check screw by the separately supplied venting screw once the
actuator is installed.
Standard actuators are delivered with a venting screw with a metal cap. Actuators which are equipped
with an anti-condensation heater are delivered with a venting screw with a plastic cap.
3.1 Mounting position and filling capacity
CAUTION If the actuator has been used, stored or transported in an other position than the installation position,
the oil level needs some time to settle. This may take up to 2 days for big actuators at cold tempera-
tures. Leave enough time before you measure the oil level.
If the actuator operating position is going to be changed from IMV1 position (motor at the top) to an-
other position, change the motor shaft sealing ring before.
3.1.1 RSD10... RSD20
1) 2) 1) 2)
1) 2)
1) 2)
IMV 1 IMV 3 IMB 5 1) IMB 5

(r00017xa)
Fig. 2: oil level; 1) = inspection screw, 2) = venting screw
Type RSD10 / RSD20 RSD10 / RSD20 RSD10 / RSD20 RSD10 / RSD20
oil quantity, approx. [ltr]

max. stroke 100 mm 3.8 5.4 3.8 3.8
max. stroke 300 mm 6.4 8.8 6.4 6.7
oil level [mm] below

inspection screw with
40 0 28 75
fully retracted thrust
rod
Table 1: Filling capacity RSD10 / RSD20
Lubrication
3.1.2 RSD50
2
1 2
2
1
1
IMV 1 IMV 3 IMB 5 1) IMB 5 (r00262xa)
Type RSD 50 RSD 50 RSD 50 RSD 50
oil quantity, appr. [ltr]

max. stroke 120 mm 7 10 upon request 7
max. stroke 300 mm 10 12 12

0
inspection screw
49 (150 at 300 mm upon request 35
with fully retracted
stroke)
thrust rod
Table 2: Filling capacity RSD50
3.1.3 RSD100
2)
1) 2)
2)
1)
1)
IMV 1 IMV 3 IMB 5 IMB 5 (r00263x2)

upon request

inspection screw with 15 (150 mm stroke)
47 upon request 43
fully retracted thrust 130 (300 mm stroke)
rod
Lubrication
3.1.4 RSD200
2)
1) 2)
2)
1)
1)
(r00262xa)
1)
IMV 1 IMV 3 IMB 5 IMB 5

max. Hub 180 mm 15.5 23 18
upon request
max. Hub 300 mm 19.5 28.5 24

0 (180 mm stroke)
inspection screw with 48 upon request 100
30 (300 mm stroke)
fully retracted thrust rod
3.2 Oil specifications
Oil specification
Ambient temperature Oil type used by manufacturer for first fill- Possible other oil types
ing
+ 1°C... + 85°C 1) Mobil SHC 632 --
- 10°C... + 65°C ESSO Spartan EP 220 Aral Degol BMB 220
(L-CKC to ISO TR 3498) BP Energol
GR-XP 220
Shell Omala 220
Mobilgear 630
- 30°C... + 50°C Mobil SHC 629 --
Table 5:
1)
only available as non-standard solution
Maintenance
3.2.1 Oil change

Use the lowermost plug to drain the oil. If the actuator basement does not allow to put an appropriate
catchment device under the lowermost drain plug keep this one closed and open the uppermost drain
plug. Push the pipe of a hand pump through this opening until the end reaches the bottom. Use the
hand pump to get the oil manually out into the catchment device.
NOTICE Do not mix oil for different temperature ranges. Dispose of the waste oil in compliance with the respec-
tive local regulations. Make sure that no waste oil reaches the water cycle.
Proceed as follows to drain or change the oil (consider previous hints):
- Provide a container which is capable to take the expected oil quantity acc. to table 1 to 4.
- Open or undo the venting screw (fig. 2 ... fig. 5).
- Unscrew the lowermost inspection screw and use it to drain the oil.
- Make sure that all of the oil is out of the actuator.
- Take a new sealing ring before you screw in and tighten the drain screw.
- Complete other maintenance work (if required).
- Refill the appropriate amount of oil and tighten the venting screw.
- Check the oil level. See CAUTION hint in chpt. 3.1 for details.
4 Maintenance
Contrac actuators feature a robust construction. As a result, they are highly reliable and require only
little maintenance. The maintenance intervals depend upon the effective load.
The built-in microprocessor evaluates the actual load factors (e.g. torques, movements, temperatures,
etc.) and derives the remaining operating time until the next routine maintenance is required. Use the
configuration program for viewing this information.
CAUTION All maintenance work must be carried out by qualified specialists who have been trained for this task.
Apart from the load dependent maintenance intervals determined by the microprocessor we recom-
mend routine maintenance; at least every 10 years.
4.1 Thrust rod sealing ring and scraper ring
Firmly bonded deposits on the thrust rod may damage the scraper and sealing rings in the actuator
flange. In order to change these components proceed as follows (procedure implies the actuator dis-
connected from any electrical supply, removed from the valve and safely placed):
STOP The spring package may save some energy, if it had been compressed. In order to avoid that the sud-
denly releasing springs throw the flange throw the workshop when you take the flange screws out, first-
STOP ly loosen the screws slightly. Then make sure that the springs are completely released (e. g. knock with
a rubber hammer on the actuator housing). In the next step loosen the flange screws completely, take
them out and pull the flange from the housing.
Maintenance
4.1.1 RSD10 / RSD20

actuator oil drain
housing screw
spring
package
actuator
housing oil drain
screw
flange
O - ring flange flange (d0215rxa)
flange guide bushing sealing
screw sealing ring rings
grub screw
scraper ring
external
limit stop
thrust rod (sc68_008)
(d0216rxa)
Fig. 6:
- Drain the oil.

- Undo the grub screw in the external limit stop and take the limit stop apart.
- Undo the flange srews and pull the flange apart.
- Pull the flange from the shaft.
- Replace scraper rings, sealing rings and O-rings; see fig. 6 for mounting position.
- Check guide bushing and flange O-ring; replace if necessary.
- Cover the lower, threaded part of the thrust rod properly in order to avoid any damage of the sealing
rings when pushing the flange over the thrust rod when reassembling.
- Reassemble the actuator in reverse order.
- Tighten the flange screws crosswise; see table for torque values.
RSD10/ RSD20
flange screw M8 x 90 20 Nm (14.75 lbf-ft) 20 Nm (14.75 lbf-ft)
flange screw M8 x 40 23 Nm (17 lbf-ft) 23 Nm (17 lbf-ft)
Table 6:
Maintenance
4.1.2 RSD50...RSD200
The scraper ring, O-rings and the guide bushing for the actuator types RSD 50 ... RSD200 are placed
in a additional sealing flange, which is mounted in the housing flange. This facilitates the exchange /
replacements of these components, since there is no need to remove the housing flange.
spring
package
O-ring
drain
housing screw
flange housing
O-ring
screw flange
sealing guide
flange bushing
sealing
ring sealing flange
scraper screw
ring
grub external
screw limit stop
thrust rod (sc68_009)
Fig. 7:
STOP If the housing flange must be removed for any reason, make sure that the internal spring package is
properly released.
STOP - Drain the oil.
- Undo the grub screw in the external limit stop and take the limit stop apart.
- Undo the sealing flange srews and pull the sealing flange out.
- Pull the flange from the shaft.
- Replace scraper rings, sealing rings and O-rings; see fig. 7 for mounting position.
- Check guide bushing and flange O-ring; replace if necessary.
- Cover the lower, threaded part of the thrust rod properly in order to avoid any damage of the sealing
rings when pushing the flange over the thrust rod when reassembling.
- Reassemble the actuator in reverse order.
- Tighten the flange screws crosswise; see table for torque values.
RSD50 RSD100 RSD200

sealing flange screw 23 Nm (17 lbf-ft) 23 Nm (17 lbf-ft) 23 Nm (17 lbf-ft)
housing flange screw 40 Nm (29.5 lbf-ft) 70 Nm (52 lbf-ft)
Table 7:
Maintenance
4.2 Sealing ring of hand wheel drive / hand wheel shaft

1
7
3
2
4
6 5 (sc68_001)
Fig. 8: Handwheel
STOP Restoring process forces may move the actuator when you release the handwheel!
In order to change the handwheel O-ring (1) of the drive proceed as follows:
STOP
- Make sure that the oil level is below the O-ring (1).
- Drain the oil if necessary (see chpt. 3.2.1 for details).
- Turn flange screws (3) out.
- Pull entire hand wheel drive assembly out of the gearing engagement.
- Replace the O-ring (1).
- If additionally the shaft sealing ring (4) needs to be replaced, turn the wheel fastening screws (5) out
and put the hand wheel (6) aside.
- Take the shaft sealing ring (4) out.
- Grease the new the shaft sealing ring (4) slightly with oil and put it into the groove; consider the ex-
emplary hints and illustration of chpt. 4.1.
- Fasten the hand wheel (6) and re-install the entire assembly; tightening torque for the
screws (3) = 20 Nm (15 ft-lbs).
Maintenance
4.3 Motor
By the time of printing this document, Contrac actuators use 2 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 feature a „D“.
Motor type MC..112 of the series 1 features a „B“ at the end of the name code, motor type MC..112....
of the series 2 features a „C“. See 4.3.1 for details.
Both series differ in minor details which are named where applicable.
4.3.1 Motor assignment and tightening torque
Actuator Motor Tightening torque
RSD10-5,0 MCS 71 BA / MCSS 71 BA 40 Nm (29.5 lbf-ft)
RSD50-3,0 MC 90 BA 40 Nm (29.5 lbf-ft)
RSD50-10,0 MCS 100 BA 69 Nm (51 lbf-ft)
RSD100-1,5 MC 90 BA 40 Nm (29.5 lbf-ft)
RSD100-10,0 MC 112 BA 69 Nm (51 lbf-ft)
RSD200-0,7 MC 90 BA 40 Nm (29.5 lbf-ft)
RSD200-5,0 MC 112 BA 69 Nm (51 lbf-ft)
Table 8: Tightening torque for motor screws
4.3.2 Motor removal

STOP 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.
STOP
motor motor
connection
cable
motor terminal
box
motor
fastening
screws
Fig. 9: Rear motor view (exemplified; motor series 1)
- Disconnect the motor / actuator from any electrical supply.

- Disconnect motor connection cable in the motor terminal box.
- Drive the actuator via the handwheel slightly out of the end position inorder to release the internal
tension of the spring package.
- Drain the oil.
- Undo the 4 motor fastening screws.
- Pull the motor carefully out.
- Once the motor overhaul is finished, replace the motor sealing ring in any case.
- Install the motor in reverse order. See table 8 for motor screw tightening torque.
Maintenance
4.3.3 Motor flange O-ring
motor
2
5
3
4
(r00051rxa)
Fig. 10: Exemplary depiction of motor connection; additional flange (3) not used for all motors
In order to change the flange O-ring proceed as follows:

- Make sure, that the oil level is below the O-ring (4).
- Drain the oil (if required) acc. to instruction.
- Disconnect the electrical power supply prior to any maintenance.
- Disconnect the cables in the motor terminal box.
- Turn the motor screws (1) out and put the motor aside; remove O-ring (2).
- Turn the screws (5) of the add. flange out and put the flange (3) aside; remove O-ring (4).
- Replace O-ring (4).
- Mount the additional flange (3) at the actuator housing and fasten it with the flange screws (5).
- Put new O-ring (2) into the flange groove and fasten the motor with the screws (1); consider tighten-
ing torque.
4.3.4 Motor disassembly / assembly
4.3.4.1 Motors without fan on rear shaft end
3
Fig. 11: Brake cover removal (I)
Additionally remove the brake for motor ball bearing replacement.

- Undo brake cover screws (1) and put cover (2) aside.
- Disconnect the two cables.
- Undo the brake fastening screws (3) and put brake body with disk aside.
Maintenance
32 1
Fig. 12: Brake removal (II)
- Use appropriate retaining ring pliers (1) to get the retaining ring (2) for the brake pinion (3) out.
- Pull the brake pinion (3) from the shaft.
1
Fig. 13: Removal of the motor flange
- Firstly pull the key (1) out of the motor shaft.

- Undo motor flange screws (2).
NOTICE - Use an appropriate extraction tool to pull the flange from the stator housing (see fig. 13 for details)
Maintenance
4.3.4.2 Motors with fan on rear shaft end
cover
cover
screws removal
tool
split
ring
split ring
pliers
fan
motor
Fig. 14: Cover removal Fig. 15: Split ring removal Fig. 16: Removal tool
- Undo cover screws and remove the cover.

- Use appropriate split ring pliers and removal tool to remove the split ring and the fan.
- Remove fan.
- Undo brake cover screws.
sealing ring
brake cover
rear end of
motor shaft
brake cover
screws
Fig. 17: (example; motor series 1) Fig. 18: (example; motor series 1)
- Remove brake cover.
Maintenance
shrinkable brake screws brake disk

tube
brake brake disk

disk pinion
brake body
Fig. 19: Brake (example; motor series 1) Fig. 20: Brake body removal Fig. 21: Brake disk removal
(example; motor series 1) (example; motor series 1)
- Undo brake screws.

- Open shrinkable tube and disconnect cable.
- Take brake body apart.
- Take brake disk apart.
- Remove retaining ring from brake disk pinion and pull the pinion from the shaft; see also fig. 12 (r. h.);
(see chpt. 4.4 for brake adjustment).
- Undo pinion screw (use appropriate glue to secure the screw when re-assembling).
motor front key key

housing flange hole
pinion screw pinion removal tool
Fig. 22: pinion removal Fig. 23:
- Use appropriate removal tool to pull the pinion from the shaft.
- Do not damage the threaded center hole.
- Remove the key; note the key position (key hole) before you take it out of the shaft groove.
- Pull front flange with motor shaft out of the housing.
Maintenance
retaining ring
pliers
spring washer front flange
Fig. 24: pinion removal Fig. 25:
- Remove bearing support washer (spring washer); take care to place it properly when re-assembling
the motor.
- Use appropriate retaining ring pliers to remove the bearing retaining ring out of the front flange.
- Pull the shaft out of the flange.
4.3.5 Exchange of motor bearings
2 3
Fig. 26: Removal of motor ball bearing (exemplified; illustration applies to all motors)
- Use an appropriate extraction tool (1) for bearing removal.

- Make sure that the extraction tool claws (2) pull at the inner ball bearing ring (3).
Maintenance
4.3.6 Exchange of motor shaft sealing ring

sealing ring seat
sealing ring shoulder with shoulder oil
motor flange
sleeve sealing ring
sealing ring seat

sealing without shoulder
ring oil
sleeve sealing ring
Fig. 27: Inside of the motor flange
- Take the old sealing ring out.

- Grease the new sealing ring and press it in the flange as shown in fig. 27; make sure that the „open“
part of the sealing ring points towards the oil (when the motor is mounted to the actuator); see fig. 27.
- Assemble in reverse order; use a customary sealant for both motor flanges.
- Check the brake gap after re-assembly; see chpt. 4.4 for details.
sleeve
sealing
ring
flange
Fig. 28: Mounting the sealing ring
Maintenance
4.4 Brake adjustment

4.4.1 Brake of motor series 1
STOP Note that the actuator position may be changed accidentally by the external load on the drive when
STOP Do not turn the slotted nut (1). It preloads the brake spring. Any disadjustment may reduce the brake
force and thus disable the brake to hold the actuator in position!
1
3 gap approx.
4 0.2+0.1 mm
5
d0130xa
Fig. 29: Brake
In automatic mode the brake is permanently released. Therefore, it is not exposed to wear and does
usually not require any re-adjustment. The gap between coil body and brake disk should be approx.
0.2+0.1 mm (0.008“ ... 0.012“). To check the gap switch-off the voltage supply and put a thickness
gauge between the coil body (3) and the brake disk (4). If the brake requires an adjustment (e. g. after
replacement) proceed as follows:
- disconnect the voltage supply
- remove the brake cover
- loosen the socket head screws (2)
- put a thickness gauge (0.2 mm) between the coil body (3) and the thrust plate (4)
- turn the counter nuts (5) until the thickness gauge is tautly between coil body (3) and thrust plate (4)
- tighten the socket head screws (2) evenly
Maintenance
4.4.2 Brake of motor series 2

STOP Note that the actuator position may be changed accidentally by the external load on the drive when
STOP
1
2
3
4
5
Fig. 30: Brake for motors; series 2
In automatic mode the brake is permanently released. Therefore, it is not exposed to wear and does
usually not require any re-adjustment. The gap between coil body and brake disk should be approx.
0.2+0.1 mm (0.008“ ... 0.012“). To check the gap switch-off the voltage supply and put a thickness
gauge between the coil body (2) and the brake disk (4). If the brake requires an adjustment (e. g. after
replacement) proceed as follows:
- disconnect the voltage supply
- remove the brake cover
- turn the socket head screws (1) completely out
- take the brake body (2) off
- turn the hexagon nuts (4) cw until they are in touch with the brake body (2)
- put the brake body (2) onto the shaft and tighten the screws (1); hand screwed
- turn the hexagon nuts (4) ccw until they are in touch with the base plate (5)
- evenly turn the socket head screws (1) approx 1/3 turn ccw (approx 120°); this also lifts the hexagon
nuts (4)
- turn the hexagon screws (4) until they are in touch with the brake body (5)
check the gap between brake body (2) and thrust plate (3) using a thickness gauge 0.2+0.1 mm (0.008“
... 0.012“)
Electrical Connection
5 Electrical Connection
5.1 General
The cable between actuator and electronic unit is connected to the electronic unit via terminals and
to the actuator via a plug. The plug housing may contain a carrier for terminals or for the cable ends
with crimp sockets.
terminal carrier
cables with
cable end
sleeve
female carrier
68d_0157
or
crimp carrier
cables with
crimp pins
10-pole
carrier only with male carrier
optional anti 68d_0218
(power + plug
condensation heater signals) 68d_0156
housing
Fig. 31: Exemplary illustration of cable connection to the actuator; plug housing may contain alternatively a terminal carrier or
a crimp carrier.
CAUTION Disconnect the actuator and electronic unit from the mains supply before you start working at the elec-
trical components. Make sure that switching off the actuator does not affect the process!
5.1.1 Covers
Terminal covers and other components at the Contrac 3 1
actuators and electronic units are fastened with 4 or cover or
more screws (only 2 screws for local control panel cov- similar
er). In some cases they are additionally sealed with a screws component
soft rubber gasket. In order to avoid a gap between the
housing and the cover (or the other component) tighten
these screws evenly crosswise according to the order
2 4
in the basic sketch in fig. 32 to get an even load
Fig. 32: Exemplary cover
Start with one screw and tighten it slightly. Then tighten
the 2nd, opposite screw in the same manner. Continue with the remaining screws. Finally tighten the
screws in the same order. This will ensure a tight seal.
5.2 Wiring diagrams

5.2.1 EBN853 / EBN861 / EBS862 (HART)
sub distribution board
mains
ext. fuse
screen grounded at both ends
one-sided screening in further
wiring possible
DI1 DI2 DI3 DO1 DO2 DO3 setpoint

end p. end p. + HART Transmitter act. pos.
MAN/AUT MAN (+) MAN (-) ok U out 4...20 mA 4...20 mA 0/4...20 mA
0% 100%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 26 27 28 29 30 31
L N
+ - + - + - + -+ - + + -
RB RB
I
24V + - + -
Uv
24V U
Contrac electronic unit

H1 H2 U V W Br Br PE 17 18 19 20 21 22 23 24
Han 10 E Han 24 E
plug 1 2 1 2 3 13 14 17 18 19 20 21 22 23 24 plug
heater Contrac actuator

approx. 6 W
(option) M
3~
sensors
motor brake (r0009xa)
Fig. 33: Wiring diagram for EBN853 / EBN861 / EBS862 (HART)
5.2.2 EBN853 / EBN861 (PROFIBUS DP)

mains
ext. fuse
Bus in Bus out
green
green
red
red
L N
Contrac electronic unit bus termination
B A B A
S1
bus terminals 28 29 30 31
H1 H2 PE 17 18 19 20 21 22 23 24
U V W Br Br
1 2 1 2 3 13 14 17 18 19 20 21 22 23 24
heater
approx. 6 W
M
(option) 3~ Contrac actuator
sensors
motor brake
Fig. 34: Wiring diagram for EBN853 / EBN861 / EBS862 (PROFIBUS DP)
5.2.3 EBS852 (HART)
sub distribution board

mains mains
ext. fuse
AC 110...250V
setpoint
DI1 DI2 DI3 DO1 DO2 DO3 Uv + HART
MAN (-) end p. end p. U out Transmitter act. pos.
MAN/AUT MAN (+) ok 4...20 mA 4...20 mA 0/4...20 mA
0% 100%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 28 29 26 27 30 31
L N
+ - + - + - + - + + - + -
RB RB
I
24V + - + -
Uv
24V U
Contrac
U V W Br Br PE electronic unit 17 18 19 20 21 22 23 24
Han 24 E Han 10 E
1 2 3 13 14 plug 17 18 19 20 21 22 23 24 plug 1 2
heater
M Contrac approx. 6 W
3~ (option)
actuator
sensors
motor brake r0363x1
Fig. 35: Wiring diagram for EBS852 (HART)
5.3 Fuses
5.3.1 Electronic unit for field installation
Electronic Fuse type Fuse dimens. Location U = 115 V U = 230 V 1)
Unit
EBN853 External fuse -- external 16 A, slow
12.5 A,
Mains fuse 5 x 20 mm in connection chamber 10 A, slow
slow
Analogue setpoint
5 x 20 mm in connection chamber 40 mA; fast
input
Motor brake 5 x 20 mm power board 0.315 A; medium
Intermediate circuit
6.3 x 32 mm power board 10 A, super-fast
fuse
Anti condensation 5 x 20 mm in connection chamber
2 A; slow
heater
EBN861 35 A fuse
External fuses1) -- external -- 16 A thermal
safety cutout
on board 0.315 A,
Motor brake 5 x 20 mm --
(power section) medium
Intermediate circuit 16 A, super fast
6.3 x 32 mm power board --
fuse
Fuse f. DO1, DO2, 3 x 0.2 A;
5 x 20 mm in connection chamber -----
DO3 medium
Table 9:
1)
The 35 A fuse and the thermal safety cutout (16 A) are included in the scope of delivery. They ensure
safe operation for the special switching conditions of power electronic units EBN861. Note that the
cable cross-sectional area between the fuse and the electronics must be at least 2.5 mm2
(#13 AWG).
5.3.2 Electronic units for rack installation
Electronic Fuse type Fuse dimens. Location U = 115 V U = 230
Unit
EBS852 External fuse -- external 16 A, slow
12.5 A
Mains fuse 5 x 20 mm connection chamber 10 A slow
slow
Motor brake 5 x 20 mm power board 315 mA; medium
Intermediate circuit
6.3 x 32 mm power board 10 A; super fast
fuse
Fuse f. DO1, DO2, DO3 5 x 20 mm connection chamber 200 mA; medium
EBS862 35 A fuse
External fuses1) -- external -- 16 A thermal
safety cutout
on board 0.315 A,
Motor brake 5 x 20 mm --
(power section) medium
Intermediate circuit 16 A,
6.3 x 32 mm power board --
fuse super fast
in connection 3 x 0.2 A;
Fuse f. DO1, DO2, DO3 5 x 20 mm -----
chamber medium
Table 10:
1) The 35 A fuse and the thermal safety cutout (16 A) are included in the scope of delivery. They ensure
safe operation for the special switching conditions of power electronic units EBS862. Note that the cable
cross-sectional area between the fuse and the electronics must be at least 2.5 mm2 (#13 AWG).
5.3.3 Fuse location EBN853

NOTICE Remove the cover of the connection chamber carefully in order to avoid any damage of the fuses or
the fuse holder.
fuse for analogue

setpoint input
cable
glands signal terminals
(not supplied
by ABB) terminals and
fuse for anti
condensation heater
(available only when
heater installed)
tapholes motor terminals
mains fuse
(spare fuse
not shown)
terminals for
mains supply
Fig. 36: Fuses in connection-housing part
intermed.
circuit fuse
brake fuse
Fig. 37: Fuses in control-housing part
5.3.4 Fuse location EBN861 / EBS862
DO1
DO2
DO3
D0113rxa
Fig. 38:
brake fuse
interm.
circuit
fuse
Fig. 39: Fuses in EBN861 / EBS 862
5.3.5 External fuses for EBN861 / EBS862

One 35 A fuse and the 16 A thermal circuit breaker are supplied together with the electronic unit
EBN861 / EBS862. They ensure a safe operation with respect to the switch-on characteristic of these
electronic units. The wire cross section must be at least 2.5 mm2 (#13 AWG).
35 A 16 A (ϑ)
L
electronic
AC 230 V 1~ N unit
PE
Fig. 40: External fuses
Fig. 41: External fuse; 35 A Fig. 42: Thermal circuit breaker; 16 A
5.3.6 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.
dig. interm.
output circuit
fuses fuse
brake
fuse
mains
fuse
Details: digital output fuses
fuse f. DO3
fuse f. DO2
fuse f. DO1
brake
fuse
(detail view)
Fig. 43: Fuses in EBS852; connection area (left) and main pcb (right)
Exchange of position sensor
6 Exchange of position sensor

6.1 Dismounting
- Drive actuator into 50% position (referred to rated actuator operating range).
- Delete the current position settings by pressing the 2 drive buttons on the LCP for at least 5 sec until
both LED on the local control panel of the electronic unit flash.
- Switch-off the voltage supply and disconnect the plug (supply cables).
- Remove position transmitter hood and male connector carrier.
- Loosen both fastening screws of position sensor (fig. 45) and take the sensor out.
- Detach plug from sensor pcb.
6.2 Mounting
The toothed gear pair of the position sensor is held in place by a tension spring (1), to ensure backlash-
free motion when the direction of rotation is reversed.
- Set the stop pin to the center position, as shown in Figure 44.
- Align the sensor and its gears with the actuator; set the first toothed gear in 03:00 o’clock position
(fig. 45) onto the gear of the conversion gearing.
- Slightly move the sensor back and forth to pre-tension the toothed gears with the difference “z“ until
the second toothed gear snaps in.
- Fasten the screws (2) tightly.
- Fasten sensor cable plug on sensor pcb.
position
sensor cable
position
sensor
fastening
screws (2)
conversion
1 gearing
(d0181rxa)
male connector carrier
Fig. 44: Position sensor Fig. 45: Mounting position
Position sensor conversion gearing
7 Position sensor conversion gearing

The position sensor shaft is horizontally shifted by 90° to the vertical drive sleeve. A position sensor
conversion gearing takes care of this conversion. A spring pre-stresses this gearing internally, in order
to avoid any backlash in case the direction of rotation reverses.
pinion
O-ring
position sensor spring

drive gear
fastening
screws
Fig. 46: sectional view Fig. 47:
7.1 Removal
In order to remove the entire gearing or to change the O-ring proceed as follows:
- Disconnect the actuator from any electrical supply and make sure this does not impact the process.
- Drain the oil.
- Remove the position sensor (see as well 6.1).
- Undo the fastening screws.
- Pull the gearing carefully out.
- Replace the O-ring if necessary.
7.2 Assembly
- Drive the actuator thrust rod completely in before you start the reassembly.
- Fix the sensor drive gear.
- Turn the pinion clockwise until the internal spring is completely pre-stressed.
- Turn the pinion 1/4 turn back.
- Keep the sensor drive gear fixed and push the conversion gearing carefully into its position until the
pinion is engaged with the toothing of the drive sleeve.
- Pay attention the O-ring is properly placed.
- Tighten the fastening screws.
- Refill the oil.
Electrical Test Values
pinion
sensor drive
gear
O-ring
Fig. 48: Pre-stress the spring Fig. 49: Mounting the conversion gearing
8 Electrical Test Values

NOTICE Check wiring and proper terminal connections before you start the test procedure.
8.1 Test values (position sensor)
The in- / output signals are assigned to terminals of the electronic unit as follows:
term. 17: DC +15 V; +/- 15% (supply); refer to
term 22
term. 18: not used
signal
term. 19: clock
terminals
term. 20: data
term. 21: reference potential for position signal
term. 22: reference potential for temp. signal
and supply voltage
term. 23: position proportional voltage signal
(0.4... 4.4 V); refer to term. 21; end po-
sitions of actuator must be adjusted
term. 24: temperature proportional voltage sig-
nal; refer to term. 22;
(∆ V approx. 22.4 mV / °C;
approx. 1.8 V at 20°C)
(see fig. 50 for terminal position)
Fig. 50: Signal terminal location; exemplified for EBN853
8.2 Test values

Brake voltage: DC 135 V with AC 115/AC230 V mains supply
Motor voltage: check for currents symmetry (i. e. with clip-on ammeter)
8.3 Winding resistance (motor)
CAUTION Disconnect the voltage supply and the actuator plug prior to any resistance measuring. Make sure that
switching off the actuator does not affect the process. Disconnect the cables (no. 1, 2, 3, 5, 6) in the
terminal box in order to avoid any measurement error.
Open the motor terminal box. Refer to the values in table 11 for proper resistance values of motor and
brake windings.
Electrical Test Values
term. 6 for cable 6

term. 3 for cable 3
term. 5 for cable 5
term. 2 for cable 2
ground term. 1 for cable 1
term. 4
(d0166rxa))
Fig. 51: Motor terminal box for MCS71BA; position of the cable gland may vary; cable numbers are printed on the cable; termi-
nal no. only for reference purpose
.
term. 2 for cable 2 term. 3 for cable 3
term. 1 for cable 1
term. 4
ground
(68de_0018)
term. 5 for cable 5 term. 6 for cable 6
Fig. 52: Motor terminal box for; MCS80BA, MC90BA, MC100BA; position of the cable gland may vary; cable numbers are print-
ed on the cable; terminal no. only for reference purpose
MCS 71 BA MCS 80 BA MC 90 BA MC 100 BA MC 112 BA

Winding resistance ± 5% at
20° C (motor); 21 Ohm 7.7 Ohm 3.7 Ohm 3.7 Ohm 1.4 Ohm
term. 4 - 1; 4 - 2; 4 - 3
Winding resistance ± 5% at
2180 Ohm 1660 Ohm 1290 Ohm 1079 Ohm 1020 Ohm
20° C (brake); term. 5 - 6
Table 11: Winding resistance
WARNING 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.
Failure detection
9 Failure detection
9.1 LED signals at the local control panel
Provided the electronic unit is supplied with voltage (green LED on LCP „ON“), the red LED on the
local control panel provide some basic status information:
both LED are „OFF“ actuator is ok
both LED are „ON“ actuator is in bootstrap mode (e. g. during data loading procedure); in
this case the actuator is not available for the positioning loop
both LED flash simultaneously actuator end positions are not set; actuator does not accept com-
mands to the digital inputs and can only be moved via drive buttons
on the local control panel (see also electronic unit instruction)
both LED flash alternatively actuator failure (e. g. out of adjusted range); actuator can not be
moved via command buttons or commands from the process control
system; reset is only possible once the failure reason is eliminated.
„Out of range“ may require re-centering the position sensing potenti-
ometer (see section 6).
Fig. 53: Local Control Panel (LCP)
10 Trouble Shooting
NOTICE Check wiring, polarity and all plug and terminal connections before you start detailed trouble shooting.
The following chapter specifies various possible failure events or conditions, which should be
checked. Follow the block diagrams to find the associated reason, result or measure to solve the mal-
function.
The following chapter specifies various possible failure events or conditions, which should be
checked. Follow the block diagrams to find the associated reason, result or measure to solve the mal-
function.
Example:
condition: E6.1 LED signal: Failure
possible failure: E6.3 sensor memory failure
one reason / measure to solve the malfct. R6.2 replace sensor; see chpt. 6
(in this case the user will find more detailed in-
formation about the sensor replacement in
chapter 6)
Trouble Shooting
10.1 General
Actuator does not move
E1.1: LEDs signalize „malfunction“

(see chpt. 9)
No Yes R1.1: see chpt. 10.6
E1.2: Power LED on local control panel is „ON“
No Yes
R1.2: see chpt. 10.2
E1.3: Internal mains fuse ok?
No Yes
E1.4: Power supply „ON“?
No Yes
E1.5: Voltage level acc. to data label?
No Yes
R1.3: Replace fuse R1.4. Hook-up the volt- R1.5: Use electronic unit R1.6: Electronic unit
(see E1.5 if the fuse blows age supply; for appropriate voltage defective;
again) check external fuse level or ensure appropri- replace electronic unit
ate voltage level
Trouble Shooting
10.2 Failures at brake, fuse or wiring

E1.1: Yes E 2.1: Actuator can be moved over entire range via
drive buttons on LCP
No Yes
R 2.1 See 10.3
E2.2: Motor / brake wiring acc. to wiring diagram? (see chpt. 5.2)
No Yes
E 2.3: Disconnect actuator and valve. Actuator can be moved?
No Yes
E3.3: Brake fuse ok?
No Yes
E3.4: Motor winding resistance

acc. to table 11
No Yes
E 3.5: Check brake. „Click sound“ audible?
No Yes
E 3.6: Fuse of interm.

circuit ok?
No Yes
E 3.7: Remove motor (Oil!) Gearing

smoothly rotable over entire range?
No Yes
R 2.2: R 2.3: R 2.4: R 2.5: R 2.6: R 2.7: R 2.8: R 2.9:

Correct wir- Replace Motor de- Adjust Repl. Act. runs Motor / Valve runs
ing fuse fective brake gap fuse mech. brake hard
hard defective
Trouble Shooting
10.3 Operation mode (MAN / AUT)
E 2.1: Yes E 3.1: Actuator is set to AUTO mode

via software (A 1 chpt. 10.9)
No Yes
E 3.2: „Simulation“ mode

active? (D 3 chpt. 10.9)
Yes No
E 3.3: „Test“ mode

active? (D 2 chpt. 10.9)
Yes No
R 3.1: Set actuator to AUTO R 3.2: De-activate R 3.3: De-activate R 3.4 R 3.5
mode via config. software. „Simulation“ mode „Test“ mode see chpt. 10.4 see chpt. 10.5
(D 3 chpt. 10.9) (D 2 chpt. 10.9) (pos. after set- (pos. after step
If the actuator is still in MAN point) controller)
mode after switching on (C 4 chpt. 10.9) (C 4 chpt. 10.9)
again, change the settings
for „Behaviour after voltage
recovery“ to „Switch to
AUTO“
(C 2 chpt. 10.9)
Trouble Shooting
10.4 Input configuration
E 3.3: No E 4.1: Actuator is set to AUTO mode

(A 1 chpt. 10.9)
No Yes
E4.2: Fuse for setpoint signal ok? see chpt. 5.3
No Yes
E4.3: Setpoint signal measurable and polarity ok?
No Yes
E4.4: Setpoint function

adjusted to „analog setpoint“?
(C 4 chpt. 10.9)
No Yes
E4.5: Permanent drive

command at dig. input 2
or 3?
No Yes
R4.1: R4.2: R4.3: R4.4: R4.5: R4.6:

De-activate digital Replace Provide Select „analog set- Electronic De-activate per-
input contacts fuse setpoint signal and / point“ in user inter- unit manent drive
(C 4 chpt. 10.9) or or change polarity face defective command
provide „DC 24 V (C 4 chpt. 10.9)
„high“ signal to dig.
input 1
Trouble Shooting
10.5 Operation behind step controller
R 3.5: No E5.1: Actuator is set to MAN mode (user

interface; A 1 chpt. 10.9)
No Yes
E4.2: Pulses are measurable and

polarity ok?
No Yes
R5.1: Provide controller R5.2: Electronic unit R5.3: Select „AUTO“ mode
signal and check wiring defective in user interface
(A 1 chpt. 10.9)
10.6 Failure Diagram
E 1.1: Yes E6.1: LED signal: Failure
E6.2 Sensor E6.3: E6.4 E6.5: E6.6: E6.7: E6.8:

failure Sensor RAM Flash CPU Frequency Pos. loop
memory failure failure failure converter monitoring
failure failure
R6.1 R6.2 R6.3 R6.4

Check wiring Replace Replace electronic unit See 10.7
between elec- sensor
tronic unit and see chpt. 6
actuator
pos. sensor out
of oper. range
see. chpt. 6
Trouble Shooting
10.7 Failure due to response of positioning loop monitoring
R 6.4: E 7.1: Failure due to positioning loop monitoring

(C 5 chpt. 10.9)
E7.2 E7.3 E7.4 E7.5

Speed monitoring Stand still Wrong moving Moves too heavy in
monitoring direction end position
(rough-running)
R7.1 R7.2 R7.3 R7.4

Actuator can not fol- Actuator has left the Actuator has moved Check end position
low the setpoint with position without com- into wrong direction conditions (deposits
adjusted speed mand may cause friction
rough-running and slow down the
actuator, valve or actuator)
damper
(see 2.3 for further
action)
10.8 General
Actuator runs with creeping speed in one or both end positions
- check the software settings for leaving the end position; if „break-away“ is activated, the actu-
ator moves with increased torque / force but with reduced speed
Imprecise behaviour in step-control mode
- use graphical user interface to check function assignment of digital input settings; select „step
controller“
Actuator over-runs end position(s)
- change the software settings for the end position behaviour 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 set point
- de-activate „close tight“ in the software settings for modulating control near the end position
Actuator position does not correspond to setpoint although the position signal corresponds
to the setpoint
- de-activate the progammable set point in the software settings for the setpoint characteristic
Actuator follows the setpoint only within a limited range
- de-activate „split range“ in the software settings for the setpoint characteristic
10.9 User Interface Menus
Fig. 54: Trouble shooting related menus in the user interface (digitally manipulated screen shot)
The following table represents the first 2 menu levels (see also fig. 54) of the graphical user interface
as far as the trouble shooting is concerned. Some of the subjects in chpt. 10 refer to the user inter-
face. Use the numbering in table 12 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 position behaviour D 3 Signal Simulation
B 4 Load C 4 Input / Output D 4 Calibration of anal. output
C 5 Monitoring
C 6 Controller
C 7 Actuator specific data
C 8 Data overview
Table 12: Trouble shooting related menus of the user interface
ABB has Sales & Customer Support The Company’s policy is one of continuous product
expertise in over 100 countries worldwide. improvement and the right is reserved to modify the
information contained herein without notice.
www.abb.com/instrumentation
Printed in the Fed. Rep. of Germany (12.05)
© ABB 2005
43/68-14 EN
ABB Ltd. ABB Inc. ABB Automation Products GmbH

Salterbeck Trading Estate 125 E. County Line Road Schillerstr. 72
Workington, Cumbria Warminster, PA 18974 32425 Minden
CA14 5DS USA Germany
UK Tel: +1 215 674 6000 Tel: +49 551 905-534
Tel: +44 (0)1946 830 611 Fax: +1 215 674 7183 Fax: +49 551 905-555
Fax: +44 (0)1946 832 661

43 68 14 en 12 2005

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Service Instruction Electrical Linear Actuators for

Tel: +49 551 905-534

© Copyright 2005 by ABB Automation Products GmbH

Symbol Signal Word Definitions

WARNING WARNING indicates a potentially hazardous situation which, if not

To ensure proper performance, use qualified personnel who have

1.3 Transport and storage

hand wheel drive sleeve

Fig. 1: RSD...; main components

2.1 Safety and precautions

IMV 1 IMV 3 IMB 5 1) IMB 5

Fig. 2: oil level; 1) = inspection screw, 2) = venting screw

Type RSD10 / RSD20 RSD10 / RSD20 RSD10 / RSD20 RSD10 / RSD20

oil quantity, approx. [ltr]

oil level [mm] below

IMV 1 IMV 3 IMB 5 1) IMB 5 (r00262xa)

Fig. 3: oil level; 1) = inspection screw, 2) = venting screw

Type RSD 50 RSD 50 RSD 50 RSD 50

oil quantity, appr. [ltr]

oil level [mm] below

IMV 1 IMV 3 IMB 5 IMB 5 (r00263x2)

Fig. 4: oil level; 1) = inspection screw, 2) = venting screw

oil quantity, approx. [ltr]

oil level [mm] below

oil quantity, approx. [ltr]

oil level [mm] below

3.2 Oil specifications

3.2.1 Oil change

4.1.1 RSD10 / RSD20

thrust rod (sc68_008)

- Drain the oil.

thrust rod (sc68_009)

RSD50 RSD100 RSD200

4.2 Sealing ring of hand wheel drive / hand wheel shaft

Table 8: Tightening torque for motor screws

4.3.2 Motor removal

Fig. 9: Rear motor view (exemplified; motor series 1)

- Disconnect the motor / actuator from any electrical supply.

4.3.3 Motor flange O-ring

In order to change the flange O-ring proceed as follows:

Additionally remove the brake for motor ball bearing replacement.

Fig. 12: Brake removal (II)

Fig. 13: Removal of the motor flange

- Firstly pull the key (1) out of the motor shaft.

4.3.4.2 Motors with fan on rear shaft end

- Undo cover screws and remove the cover.

- Remove brake cover.

shrinkable brake screws brake disk

brake brake disk

- Undo brake screws.

motor front key key

Fig. 22: pinion removal Fig. 23:

Fig. 24: pinion removal Fig. 25:

- Use an appropriate extraction tool (1) for bearing removal.

4.3.6 Exchange of motor shaft sealing ring

sleeve sealing ring

sealing ring seat

sleeve sealing ring

Fig. 27: Inside of the motor flange