Technical Information Intelligent Actuators for

30/68-104 EN
Process Automation
(Contrac)
System Description

Instrumentation-Solutions
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Content Page
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Part-turn actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Linear actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electronic units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FSK communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
RS232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Device Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engineering Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Configuration Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Basic settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Torque /Force: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Speed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Moving into the end position: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Leaving the end position: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Avoiding control movements close to the end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Input / Output: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Signal Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Alarms / Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Integrated PID controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Actuators in explosion-proof design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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General
Actuators are used for automation applications in many industries. In process control plants, they reg-
ulate the respective material, mass or energy flow by adjusting valves, flaps, dampers or slide valves.
The latest technology has now reached actua-
tors, as they become intelligent field devices.
Now, customers have improved CONtrol built
into an ACTuator… something ABB calls CON-
TRAC.
The Contrac actuator system is based on the
family of the conventional part-turn and linear
actuators that are built on more than 50 year of
success.
They feature:
■ Continuous positioning
■ Overload- proof in the end position without
torque dependent switch - off. Fig. 1 Power station Jaenschwalde; Cottbus/Germany
■ High protection class
■ Long service life (up to 10 years service life)
By combining proven mechanical actuator components with a processor controlled electronic unit, an
intelligent control actuator series has been developed that:
– Has fieldbus compatibility but which can also be operated conventionally
– Permits a diagnostic analysis and can be parameterized via a graphical user interface
– Offers self monitoring options
– Enables the fail-safe storage of technical data
In addition, the CONTRAC features innovative features for a reliable operation; including functions that
extend actuator availability by providing monitoring, maintainance and service information.
In addition to these advanced functions the actuator components are also highly innovative, including
an asynchronous three-phase motor with cage rotor. This type of motor was used due to its safe oper-
ation and reliability. Last but not least, this solution has been successful for decades in different actu-
ator applications all over the world due to its simple design and it's the well-known robustness and reli-
ability. In addition, it is proven technology after being used successfully for decades in different actuator
applications due to its simple design, robustness and reliability.
The secret to the asynchronous three-phase motor's success was the breakthrough of the frequency
converter technology. Now speed control became possible for three-phase motors, too.
Using the frequency converter principle, it is now possible to vary the torque or positioning time of the
intelligent actuators.
That means, both parameters can be adapted independently to the related final control element and to
the process.

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Operating philosophy
Y setpoint Y position signal
signal
DCS

electronic

process value
unit

M
Contrac
n1 (subordinated
= control loop)
actuator n2 Y
process =
force force P
process

Fig. 2 Operating philosophy Fig. 3 Continuous positioning

The actuator follows continuously to a setpoint signal. The
torque max.
(force) motor is permanently energized (operating mode S9 - 100%
acc. to IEC 34-1) and increases or decreases the torque
- + smoothly and proportionally to the ∆Y signal (difference
between Y-setpoint and Y-position) at the electronic unit
approx.
Y (see as well fig. 4). The actuator is not subjected to any tem-
0.4%
perature derating; i. e. there are no restrictions even at max.
approx. permissible ambient temperature. Finally the actuator force
± 0.05% and the process counter force are in balance and the actu-
Fig. 4 Deviation dependent torque / force ator holds the final control element in position. In this „bal-
anced“ condition the ∆Y signal is within the proportional
section of the torque / force characteristic (see fig. 4). However, this remaining deviation within the sub-
ordinated loop does not negatively affect the entire process, since the superimposed loop (transmitter,
DCS) compensates it (see fig. 5).

setpoint
position
setpoint actuator position

time

Fig. 5 Schematic diagram of a Contrac step response

Fig. 5 shows the dynamic behavior after a setpoint step. The actuator follows immediately the changing
setpoint with a slight offset.

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Due to the sophisticated electronics and control technology there is no need for temperature or torque
limit switches. This operation mode with smoothly increasing and decreasing mechanical loads is one
of the reasons for the long life and service intervals.
If the voltage is cut off, the motor is de-energized and a brake at the rear motor shaft end holds the
motor in its position, avoiding that restoring process forces drive the valve into an end position.
entire duty cycle = 100% (open end)
Load
+
permanently
energized

Time

-
Tmax. (perm.)
(steady-state temperature
of the device never exceeds
the max. permissible
Tamb Tmax. (device) temperature)

Time
Fig. 6
S9 specification:
The device (actuator) is permanently energized. The device temperature rises after the switch-on, but
never exceeds the maximum permissible temperature limit. The device may be energized 100% (even
at max. permissible ambient temperature with various speeds, various directions) without any time limit
and without the need for any protection or monitoring of components.
Operation mode S1 (100% duty cycle at constant load) is covered by mode S9!
No control loop restriction caused by the actuator!!!!

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Hardware
Part-turn actuators
motor
handwheel for
manual operation

plug for
electrical
connection

spur wheel position sensor

gearing
drive
shaft

lever (d0062rxa)

Fig. 7 Cut-away view of a part-turn actuator

Part-turn actuators are available from 50 Nm to 16000 Nm (40 lbf-ft to 12000 lbf-ft) rated torque and
they all feature a similar design. A motor drives the oil lubricated low-friction spur wheel gearing. At the
end of this gearing a shaft mounted lever transfers the torque to the final control element via a linkage.
Since the position transmitter is directly mounted on the rear shaft end it allows for a backlash-free
position feedback. This is one of the reasons for the high precision positioning with Contrac.

(ap68_0039)
(ap68_0045)

Fig. 8 Contrac part-turn actuator mounted Fig. 9 Contrac actuators work reliably under harshest conditions.
on a damper.

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Linear actuators
Linear actuators are available from 4 kN to 200 kN (900 lbf to 45000 lbf) rated force and they also feature
a similar design. The motor drives an integrated rotary / linear conversion unit, which runs on the actu-
ator stem. This moves out or in depending on the motor direction of rotation. The feature, which makes
these actuators unique is the technical detail for the rotary / linear conversion, where ABB uses a
re-circulating ball screw assembly with extremely low friction.

motor
integrated
rotary-linear

plug for
electrical connection
spur wheel
gearing

position
sensor

handwheel (d0118rxa)
recirculating
integrated ball screw assembly
thrus rod springs (d0119rxa)

Fig. 10 Cut-away view of a linear actuator and detailed view of recirculating ball screw assembly
Integrated springs absorb force peaks when the actuator runs into the end position and they also
absorb the possible thermal expansion, e. g. if the associated valve is mounted on a superheated steam
pipe.

actuator

yoke

valve

(ap68_0044)

(ap68_0068)

Fig. 11 Linear actuator RSD20 Fig. 12 Horizontally mounted linear actuator (Contrac)
(Contrac)

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Electronic units

(d0008rxa)
(d0138rxa)
electronic units for field installation electronic units for (d0110rxa)
rack installation local control panel
Fig. 13 Electronic units; the integrated version is only available for the smallest linear and part-turn actuators
Regarding the actuator and the valve as the
muscles of a control loop, the Contrac elec-
tronic unit is its brain. It may be installed in
the field (IP 66) close to the actuator or in a
mounting rack (IP 20). Integrated versions
are available for the smallest linear and
part-turn actuator.
Apart from the connection terminals and
power supply devices they also contain the
micro processor, the frequency converter
for the motor control, the digital input and
output contacts, the communication inter-
faces and the socket for PC-connection for
the local parameter setting and diagnosis.
(68ap_0046)
Regardless the motor power all electronic Fig. 14 Application photo of field mounted electronic units
units are fed from the 1~ AC 230 / 115 V
mains.
Electrical connection
A metal plug for the electrical connection of Contrac actuators ensures reliability even under harsh envi-
ronmental conditions and a high protection class. Depending on the selected options, it contains, one
or two terminal strips for the connection of signal and power cables. The terminals are available for
screw or crimp connection.
Actuator

female strip(s) in terminal strip for

plug housing crimp connection
of wires

(68d_0156)

terminal strip for

screw connection
of wires

(68d_0218)

male strip(s) in (68d_0157)

10-pole strip 24-pole power
plug housing for heater (if applicable) and signal strip
Fig. 15 Plug for the electrical connection at the actuator and at the integrated electronic unit (if applicable)

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Electronic unit

terminals
signal in / out

cable motor
entries terminals
cable
entries
mains
supply

(68d_0145)
(68d_0184)
EBN853 EBS852
Fig. 16 Example of connection details at a Contrac electronic unit
All separately installed electronic units use terminals for the connection of the wires.
The terminal arrangement depends on the individual version (EAN823, EBN853; EBN861; EAS822,
EBS852 or EBS862). See fig. 16 for details.
Wiring diagram

Sub Distribution Board

mains supply ext. fuse screen grounded at both ends
AC115 / 230 V single sided screening
EBN861: in following wiring possible
only AC230 V

DI1 DI2 DI3 DO1 DO2 DO3 Uv setpoint transmitter act. value
end pos. end pos. +HART 4...20 mA 0/4...20mA
MAN/AUT MAN(+) MAN(-) ok/fail. 0% 100% out
0/4...20mA

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 10E 1 2 1 2 3 13 14 Han 24E

17 18 19 20 21 22 23 24

heater sensors
approx. 6 W M
3~
(option)
motor brake Contrac Actuator r00350x1

Fig. 17 Basic wiring diagram (example: field mounted units EBN853 / EBN861)

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Communication
As in the past, the new actuator generation can also be operated with the available conventional sig-
nals. The user in conventional plants must not to give up his current control concept when the intelligent
actuators are installed. But he can also be sure not to run into an dead-end with this new actuator gen-
eration. They can be operated later on with future plant concepts such as fieldbus.
The intelligent actuators are able to communicate either via an RS232 interface, an FSK communica-
tions with the HART protocol or via a fieldbus connection. FSK and fieldbus communication are option-
ally available and require the appropriate pcb.
Using a PC or notebook and the graphical user interface with the appropriate device type manager
(DTM), it is possible to configure all the actuator functions, to set parameters and to perform a diagnos-
tic analysis/ maintenance.
However, the basic actuator settings can also be done locally without additional hardware such as PC
or notebook. Push buttons and LEDs on the commissioning and service panel at the electronic unit
allow for fast and easy basic settings.
FSK communication
Contrac actuator 20 mA notebook with
setpoint Smart Vision and DTM
FSK modem
wiring between
actuator and
electronic unit
(d0035grxa)

COM
port
(15d_0034)
(d0224rxa)
(d0141rxa)

Fig. 18 Arrangement of Contrac components for the local communication via FSK modem.
RS232
Contrac actuator communication
cable

wiring between
actuator and
notebook
electronic unit
with
Smart Vision
and DTM

(d0178rxa)

(d0224rxa)
(15d_0034)

Fig. 19 Arrangement of Contrac components for the local communication using the RS232 interface
Contrac allows for pure HART communication via FSK modem or a HART supporting DCS. However,
with this communication mode, transmission is limited to 1200 baud. An additional RS232 interface
with a 9-pole socket guarantees up to 9600 baud using a special communication cable, which is con-
nected to the COM port at the locally used computer.

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Fieldbus
Take advantage from decentralized intelligence using fieldbus communication. Save on wiring, docu-
mentation and commissioning time and get more information out of the process.
Contrac actuators are available for PROFIBUS DP communication. This allows for
– Cyclic data traffic
– Diagnosis
– Configuration with GSD files

GSD
Operate Engineer
File

Ethernet/TCP-IP

Master
Control Class 1

Repeater

PROFIBUS DP (Segment 1) PROFIBUS DP (Segment...)

Field (parameter setting

Slave 1
via local RS232) Slave... Slave...

(d0224rxa) DTM
Slave 2 (e.g. Contrac)

Fig. 20 Basic arrangement of the components for the communication via PROFIBUS DP.

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Software
Three software applications are involved in the Contrac system:
– Device software; it is loaded into the electronic unit and contains the firmware, the motor character-
istics and the software objects and it is absolutely required to run a Contrac actuator.
– Engineering software (optionally)
– Configuration software (optionally)

Device Software
in electronic unit Configuration
Software
(firmware,
motor characteristic,
software objects)

Engineering
Software

Fig. 21 Contrac software applications

Device Software
Firmware
The firmware is the operating system of the actuator. It ensures its software functions, evaluates poten-
tial limits, coordinates the functions and manages the data traffic to / from the engineering and config-
uration software.
Motor characteristics
The individual power limits and the dynamic motor behavior is adapted to each motor / actuator com-
bination. The motor characteristics contain the relevant data.
Software Objects
All actuator relevant parameters such as torque / force limits, start behavior (e. g. with / without break-
away), limits are specified in the software objects.
Since the firmware, the motor characteristics and the software objects are saved in a flash memory of
the electronic unit they allow for both easy update in case of further developments and adaptation to
individual, non-standard applications.

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Engineering Software
The user cannot set these parameters individually, however, ABB provides the special engineering soft-
ware tool ECOM688. This enables the user to read the operating system, the motor characteristics and
the software objects and save them in any memory. The vice versa procedure is possible as well..
Electronic units Electronic units Electronic units
for lower power range for medium power range for upper power range

memory with PC loaded with

actuator specific data engineering tool
- firmware ECOM688
- motor characteristics and actuator data
- software objects

Fig. 22 Data handling via ECOM688

This allows the user to keep only one spare electronic unit available for each power range. If a faulty
electronic unit must be replaced, load the previously saved backup data into the new electronic unit.
The control loop will be ready for operation without the need for a new actuator setting.
Avoiding the need of driving the actuator through the entire operating range for the new endposition
settings enables the user to change the electronic unit while the process keeps on running.
Configuration Software
Configuration software, Device Type Manager (DTM),
enables the user to set the parameters within the limits, DTM
pre-defined by the operating system for the individual device A
actuator. Moreover the user gets a lot of diagnosis,
Frame application
service and maintenance information. The access to
(Smart Vision or DCS with
different functional areas can be protected using a FDT interface)
password. The device specific drivers can be loaded
into frame applications, which support the FDT / DTM DTM
technology, i. e. it can be used locally (e. g. in SMART device B
VISION) or within a DCS.
The ABB frame application (SMART VISION) and the
device specific drivers (DTM) are available in German
and English.
The actuators are delivered with a default configura- DTM
tion or with an individual, customer specific configura- device C
tion. There is no need for any software to do the basic
settings during the commissioning procedure. How-
ever, the user can use the software for a later adapta- Fig. 23 FDT / DTM philosophy
tion to a modified process. It also allows the immediate
use of the integrated diagnostic and test functions.

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Functions
In the past most of the positioning loop related functions have been handled within the DSC. However,
with the growing number of functions it became more important to relieve the DCS (and the bus com-
munication, if applicable). With Contrac, a wide range of functions for parameter setting, diagnosis, ser-
vice, maintenance and information moved from the DCS into the electronic unit. The advantage is that
regardless which DCS is used the user benefits from the process optimizing options, which Contrac
offers.
The following chapters provide a rough overview. Screenshots of the dialogs and menus of the user
interface illustrate the description where applicable.
Basic settings
Contrac actuators do not require any torque switches or similar pro-
tection devices due to their unique operating mode. Once the actuator
is mechanically and electrically connected, all the user has to do is to
carry out the basic settings, i. e. to adjust the end positions. This does
not require any special tools or software.
Simply proceed as follows:
– open the cover of the commissioning and service panel at the elec-
tronic unit
– select the „Adjustment mode“
– drive the actuator in both end positions one after the other using the
appropriate push button
– confirm each position separately as 0% and 100%
– close the „Adjustment mode“
– close the cover of the commissioning and service panel at the elec-
tronic unit
Fig. 24 Local control panel
See the actuator instructions for details.
Configuration
Operating mode
Positioner after continuous setpoint
In the most common operating mode for Contrac, the actuator follows continuously an analog setpoint
signal. Since the torque / force increases or decreases smoothly, the mechanical components are not
exposed to load peaks and allow for long service intervals and a long actuator life.
Positioner behind a step controller process
setpoint Integration
Contrac can run in this smooth and material
Contrac
protecting operating mode, even if the posi- electronic unit
step analog
tioning commands are provided as pulses controller
by a step controller. Once it is set to the
mode „Operation behind step controller“
continuous positioning
potentially incoming pulses at the digital
inputs 2 and 3 (DI2 and DI3) are integrated M
within an internal memory. This memory Contrac
then provides an „artificial“ internal analog actuator n1 =
= transmitter n2 Y
setpoint. So even in old facilities or simple P
control systems, which often use step con-
trollers or simple ON / OFF commands, the
user can benefit from Contrac’s unique Fig. 25 Integration of pulse commands with „Operation behind a
operating mode. step controller“

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Torque /Force:
Torque and force can be set individually and
independently from the moving direction.
Select either „Constant“ to determine a con-
stant value from 0% to 100% (or vv) or select
„Characteristics“ to adjust an individual torque
/ force characteristic between the end posi-
tions.

Fig. 26 Screenshot of the menu for torque setting

Speed:
Options similar to „Torque / Force“.
Moving into the end position:
The menus allow an individual adjustment for each end position. Select from the menu either:
Keeping tight with (torque / force):
Position dependent switch-off:
Switch-off with 1x or 2x torque/force: As soon as the actuator reaches its end position, the motor
Leaving the end position:
Break-away option:
If the setpoint demands the endposition, the actuators remains
energized and holds the valve „electrically“ in position.
As soon as the actuator reaches a defined position, the motor is
de-energized and the brake freezes the actuator mechanically in
its current position.
increases the torque / force up to the selected value (1x or 2x the
rated value), is de-energized and the brake freezes the actuator
in its end position.
Final control elements, which had been in the end position for a
long time may be jammed due to deposits, etc. In order to
release them, they often require a higher torque / force than the
rated actuator value. Usually the required torque / force
decreases as soon as the final control element has left the end
position and then the rated torque / force value meets the
requirements. Contrac can provide up to 200% of its rated value
for a short time at reduced speed close to the 0% or 100% end
position or close to both end positions.

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Avoiding control movements close to the end position

Modulating control close to end pos.: Minor valve movements close to the end position (e. g. at 97%
or 2%) do not make sense for some processes; however, if the
valve is in this position and the process variables change, the
actuator will follow the resulting commands and might touch /
release the valve seat with a certain frequency. Moreover valve
positions close to the end of the range may cause cavitation. In
order to avoid the „hammer“ behaviour or cavitation the user can
define a small range close to the end position. As soon as the
actuator reaches this range, it runs as defined in the menu:
„Moving into the end position.
Input / Output:
Signal Range: For the start and end values of the setpoint select any value
between 0 and 20 mA with a span of at least 8 mA.
Select either 0...20 mA or 4...20 mA for the position feedback
signal range. Regardless which range you select, the output
level corresponds to 0...100%.
Example: setpoint: 6...14 mA
selected feedback range: 4...20 mA
feedback signal: 4...20 mA (0...100%)
Digital Input: Contrac offers 3 digital input contacts. The functions are
assigned via a „group assignment“ and 4 selectable group com-
mands. Selecting one of these commands automatically assigns
the defined function to each input.
- Off: The inputs are switched off
- Manual operation: DI1 is used for MAN/AUT mode; DI2 +
DI3 are used for +/- commands
- Rapid traverse: DI1 is used for MAN/AUT mode; high signals
to DI2 + DI3 let the actuator run with doubled speed at
reduced torque / force.
- Step controller: DI1 is used for MAN/AUT mode; „step com-
mands“ (e. g. coming from a step controller) to DI2 + DI3 are
internally integrated. Contrac uses this integrated result to
create an „artificial“ internal setpoint. Contrac follows this
setpoint smoothly in AUT mode. This allows the benefit from
all Contrac features even it is used in old facilities with step
controller signals. See fig. 25 for details.
Digital Output: Contrac offers 3 digital output contacts. One of the following
functions can be assigned individually to each of the outputs:
- ready for operation
- signal in 0% position
- signal in 100% position
- signal when exceeding (rising) a defined position
- signal when exceeding (falling) a defined position
- general alarm
- general failure

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Failure message via pos. value: In case of a failure, the signal level rises or falls beyond the
adjusted range limit. The DSC reacts accordingly.
This 2-fold use of the feedback signal saves wiring costs and
reduces the required input channels at the DCS.
Monitoring
Setpoint monitoring: Enter the upper and lower limit to determine the permissible set-
point range. Contrac generates a failure message a soon as the
setpoint exceeds this range and the actuator reacts as pre-
adjusted (locks in the last position or moves into a pre-defined
safety position; the safety position is freely selectable).
Positioning loop monitoring: Contrac monitors various selectable parameters of the position-
ing loop for coherent reaction. Contrac generates a failure mes-
sage, if the values exceed the defined limit. The actuator stops.
This allows for early information before the process reacts.
Service
Test
Contrac allows for testing some of its own compo-
nents such as brake, gearing, etc. as well as of
associated components such as linkage, etc.
Repeating a running time test in various time inter-
vals allows for conclusions about the wear or the
increased friction within the linkage.
One of the key test functions is the ability to docu-
ment the provided torque / force. On starting the
function Contrac divides the selected operating
range into 21 section. On passing through the
defined range with a fixed test speed, Contrac cal-
culates internally the provided torque / force and
displays the results in the menu of the configura-
tion software. Print or archive the results for further Fig. 27 Menu of „Torque / Force Test“
evaluation.
This function allows the user to check the Contrac power within the operating range and with the final
control element coupled to the actuator.
Signal Simulation
Contrac can simulate a high/low signal on the digital input and output and a signal level on the analog
input to check the wiring to the DCS without any actuator movement.
Diagnosis
Status
A non-editable windows informs about the status of:
- operating mode (MAN/AUT)
- function (positioner / controller)
- test mode (yes / no)
- simulation mode (yes / no)
- local operation (yes / no)
- general alarm (yes / no)
- general failure (yes / no)

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Alarms / Failures
Contrac provides detailed information about cur-
rently existing or previous alarms and failures. It
generates an alarm, if the actuator faces critical
conditions which, however, do currently not
endanger a safe process operation (e. g. high
temperature). It generates a failure, if the actua-
tor faces a critical situation, which, however,
does not allow to continue a safe operation (e. g.
CPU failure). The user interface displays the cur-
rently existing alarms and failures as well as the
previous alarms and failures. All messages can
be archived in order to have them available for
further evaluation.
Maintenance
Various parameters have an impact on the actu-
ator life time. Contrac evaluates these impacts Fig. 28 Screenshot of the detailed „Alarms / Failure“ menu
such as temperatures, motor reversals, torque
and force peaks and calculates the remaining time until they need maintenance. This „maintenance on
demand“ allows for an exact plant maintenance management.
Load
Some error patterns require more detailed information in order to fathom them. Contrac records the life-
time related parameters such as no. of motor reversals, max. temperature values for gearing and elec-
tronic units and torque / force, temperature and dynamic characteristics the actuator has been exposed
to. Use the configuration software to display these values or to save them for further / later evaluation.
Protocol
Every technician knows the difficulty to find the reason for non-reproducible failure. They come and go
and nobody knows when and why. In order to reduce the failure detecting effort, Contrac is able to
record the control loop related parameters such as setpoint, pos. value, temperature, motor frequency,
etc. The recording happens while the actuator is running in its process.
Integrated PID controller
The optionally integrated PID process controller allows to set up an isolated loop for closed-loop-con-
trol without a DCS. The parameter setting of the values for the PID behavior as well as the configuration
of the controller function as a fixed value or follow-up controller are also done via the graphical user
interface.
Contrac electronic unit
process setpoint controller
parameter setting
(from superimposed system
or isolated)
position motor
feedback control
process
value

Contrac
transmitter

Fig. 29 Components within the control / positioning loop

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Actuators in explosion-proof design

Hazardous areas such as gas pipe-

lines, refineries, mining applications
etc. require devices in explosion-
proof design.
The Contrac system meets these
requirements with explosion-proof
actuators acc. to ATEX (II 2 GD ck
EEx de [ib] ib II B T4 or IP6x
T=130°C ZELM 04 ATEX 0209 X)
installed within the hazardous area
and standard electronic units
installed in the non-hazardous area
(see fig 33).
The actuators feature a servo motor
(flame-proof enclosure) and an
EExe wiring chamber.
Fig. 30 Pipeline
An additional motor temperature
monitoring unit cuts off the power supply, if the motor temperature exceeds the permissible motor tem-
perature limit.
Contrac actuators in explosion-proof design cover all
the functions and customer benefits which are offered
by the standard version.

(68ap_0066)
Fig. 31 Contrac RSDE20 used at a gas pipeline

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AC 115 / 230 V 1~

motor temperature
monitoring unit ϑ DCS / controller
(e. g. SD241B)

signal cable from / to

DCS / controller
(screened)
temperature sensor cable
Contrac power electronic unit non
explosive area

sensor cable
(screened)

motor
/ brake
brake cable explosive
(screened) area

sensor wiring chamber

(anti
condensation heater as option)
sensor electronics
motor with
temperature sensor position sensor

motor gearing
wiring
chamber
Contrac actuator
in explosion-proof design

Fig. 32 Arrangement of Contrac components in an „EX-application“

SD241B

Contrac
electronic unit
(68ap_0067)

Fig. 33 Contrac electronic unit and motor temperature monitoring unit installed in the non-hazardous area.

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Installation Examples
Power station

Fig. 34 Exhaust gas control with part-turn actuator and

multiple-flap
Fig. 37 Air control wit part-turn actuator
Cement Industry

Fig. 38 Mill air control with a part-turn actuator RHDE250

(rated torque 250 Nm)
Fig. 35 Linear actuator at feedwater pre-heater
Gas distribution

Fig. 36 Horizontally mounted linear actuator (air control)

Fig. 39 Explosion-proof linear actuator RSDE10

21

ABB has Sales & Customer Support
expertise in over 100 countries worldwide..
www.abb.com/instrumentation
ABB Ltd.
Salterbeck Trading Estate
Workington, Cumbria
CA14 5DS
UK
Tel: +44 (0)1946 830 611
Fax: +44 (0)1946 832 661
30/68-104 EN
The Company’s policy is one of continuous product
improvement and the right is reserved to modify the
information contained herein without notice.
Printed in the Fed. Rep. of Germany (02.06)
© ABB 2006
30/68-104 EN Rev. A
ABB Inc. ABB Automation Products GmbH
125 E. County Line Road Schillerstr. 72
Warminster, PA 18974 32425 Minden
USA Germany
Tel: +1 215 674 6000 Tel: +49 551 905-534
Fax: +1 215 674 7183 Fax: +49 551 905-555
CCC-support.deapr@de.abb.com