Electro Hydraulic Actuator

Transcription

Models 12 or 24Volt FS or FIP, DM
Installation and Maintenance
IM0001
September 2012
CONTENTS
PAGE
Introduction1
Scope1
Description1
Specification 1
EHA Installation 2
DIP Switch Settings
8
Air Purge12
Wiring Diagram14
INTRODUCTION
CAUTION
Prior to installing, the instructions provided
herein should be completely reviewed and
understood before operating or repairing this
equipment . All CAUTION and WARNING
notes must be strictly observed to prevent
personal injury or equipment damage.
Scope
This installation manual includes instructions
and maintenance information for the 1” or 2”
Kimray electro hydraulic actuator.
Do not install, operate, or maintain an EHA
actuator without being fully trained and qualified with Kimray valves, actuators for operation and maintenance. To avoid personal
injury or property damage, it is important to
carefully read, understand, and follow all the
contents of this manual, including all safety
cautions and warnings. if you have any
questions about these instructions, contact
your Kimray applications support group
before proceeding.
Description
Used on all Kimray HPCV’s , topworks or any
30 psi maximum single acting spring return
valve actuators. The electro hydraulic actuator (EHA) is used for field automation where
electrical signals or communications are
used to actuate or position a spring return
control valve. (12VDC or 24VDC) Options
are available
Specification
See product bulletin PB0008 and instruction
manual KIM0001 electro hydraulic actuator
KA7502 control board discrete / MODBUS
version.
EHA MANIFOLD
Table 1 - Specifications
Voltage
12 or 24V
Current
4A Max
25 Seconds to Pressure
15 Seconds to De-Pressure
Max
30 PSI Output
Hydraulic Fluid:
Kimray P/N: 6927
MODBUS RTU Communication over RS-485
lines
CAUTION
When ordered, the valve configuration and
construction materials were selected to meet
specific pressure, temperature, pressure
drop and fluid conditions. Since some body/
trim material combinations are limited in their
pressure drop and temperature ranges, do
not subject the valve to any other conditions
without first contacting the Kimray Inc, sales
office or a sales / applications representative
WARNING
Do not exceed the maximum supply pressure
specified on the valve nameplate. Under no
circumstances should the actuator supply
pressure ever exceed 30 psig.
Kimray Inc.- 52 NW 42nd Street Oklahoma City, Ok 73118 USA - Ph: (405) 525-6601, Fax: (405) 525-7520 - Kimray.com
Printed in U.S.A.
© 2012 Kimray, Inc. All rights reserved.
1
EHA Installation
Wiring
Before installing the EHA actuator, inspect it
for shipment damage and for foreign material
that may have collected during crating and
shipment.
VIN - GND: Power input (12VDC or 24VDC options are available). The positive (+)
supply connects to VIN, the negative (-) supply con
nects to GND. There are two VIN and two GND termi
nals available. This
allows for direct feed from the control board to
the I.S barrier when
controlled by an
intrinsically safe electronic GEN II backmount controller.
1. Pressurize actuator using non-compress
ible fluid.
2. Use atmospheric side of actuator as reservoir.
3. Low-power pump provides pressure to open.
4. Solenoid valve bypass to relieve pres
sure and close valve.
5. Pressure transducer monitors actuator pressure.
D1-G:
Connect to relay outputs of electronic level controller (top-
level). These terminals are intended for dry relay contacts only. The “G” terminal is
equivalent to the GND poten
tial when these terminals are
shorted through dry relay contacts, the valve is told to open.
D2-G:
Connect to relay outputs of electronic level controller (span). These terminals are intended for dry relay contacts only. The “G” is equivalent to the GND potential of the control board. When these terminals are shorted through the dry relay contacts, the valve is told to close.
Note
CLOSE has precedence over OPEN
A- : Connect to MODBUS RS485- input (optional).
B+ : Connect to MODBUS RS485+ input (optional).
C : Connect to MODBUS RS485 common input (optional).
Valve Opening
Figure 1 2
Top Level
О
O
Span
О
O
User Connections
Figure 2 Valve Closing
Figure 3 3
Optional RS-485
Communication
MODBUS RTU
TXD0/DATA TXD1/DATA +
COMMON
Figure 4 120 Ohm load for
RS-485
Enable
Communication
LED indicators
Offers optional
internal load for
RS485
implementation
May be helpful for
bench debug of
communication
setup
Figure 5 4
Discrete Input
LED indicators
Can be helpful for
setting level
controller
Green = top level
Red = span
Close has
precedence over
open
Figure 6 OPEN
When in manual
Mode – opens
the valve
OP-CAL
Used to set Full
Open on P.O.
valves
CL-CAL
Used to set Full
Close on P.C.
valves
CLOSE
When in manual
Mode – closes
the valve
Figure 7 5
DIP switch settings
DIP switch 1 - Manual /Calibration mode
“OFF” - default position. The control board will receive input only from the
descrete inputs and/or MODBUS.
Note
When DIP switch is moved to then “ON” position, the discrete inputs are temporarily disabled and the control board receives input from the manual buttons:
OPEN button: When pressed, the valve
is manually actuated in the OPEN direction.
CLOSE button: When pressed, the valve
is manually actuated in the CLOSE direction.
OP-CAL button: When pressed, the
current valve position is saved as the maximum open position on a PO (Pressure to Open) valve. This button has no effect
on a PC (Pressure Close) valve.
CL-CAL button: When pressed, the
current valve position is saved as the closed
position on a PC (Pressure Close) valve. This
button has no effect on a PO (Pressure to Open) valve.
DIP switch 2 - Pressure to OPEN/CLOSE.
“OFF” - indicates a PO (Pressure to OPEN) valve is in use (DEFAULT).
“ON” - indicates a PC (Pressure to Close) valve is in use.
DIP switch 2 is read only on power-up
Note
This switch setting does not make the valve
a P.O. or P.C. valve, it simply allows the
control board to identify which type of valve
is in use.
DIP switch 3 - Maximum pressure settings.
“OFF” - allows the maximum pressure to be
changed through manual calibration (see DIP
SWITCH 1) or through MODBUS communication.
“ON” - is used to force the valve to a 20
psi maximum pressure. When DIP switch
3 is “ON”, the maximum pressure is always
20 psi. The maximum pressure cannot
be changed through manual calibration or
through MODBUS when DIP switch 3 is in
the “ON” position.
The default settings is 30 psi maximum. By
moving this SWITCH to ON, the maximum
pressure is changed to 20 psi. If the board
is under power while the switch is moved
from the ON to OFF position, the maximum
pressure is changed back to 30 psi through
manual calibration or through MODBUS
communication.
If power is off when DIP switch 3 is turned
to the OFF position, it will retain its previous
maximum pressure setting.
DIP switch 4 - SOLENOID type
“OFF” - is used to indicate the installed
solenoid is of normally-open type. This type
of solenoid is installed on EHA’s that require
fail-open or fail-close operation.
“ON” - is used to indicate the installed solenoid is of normally-closed type. This type
of solenoid is installed on EHA’s that require
fail-in-place operation.
DIP switch 4 is read only on power-up.
Note
This switch setting does not make
the solenoid act as fail-open or fail-in-place,
it simply allows the control board to identify
which type of solenoid is in use.
Optional Jumpers
Jumper J1 - Use internal RS-485 termination
When JumperJ1 is shorted, a 120 Ohm
resistor in series with a 0.1uF capacitor is
placed across the A- and B+ inputs.
DIP1 ON:
MANUAL MODE
DIP1 OFF:
AUTOMATIC MODE
*Monitors D1/D2
*Monitors S1
*Operates PUMP and
SOLENOID accordingly
* Ignores discrete ins
* No pressure feedback
* Manual open/close
* Calibrate full open with
PO valve and full close
in a PC valve
Default = all OFF
Figure 8 6
Jumper J2 - MODBUS LED indicators
When Jumper J2 is shorted, optional MODBUS LED indicators are activated.
“ON” - Lit when power is applied to the control board.
“RX” - Lit when the microprocessor is receiving a MODBUS communication.
“TX” - Lit when the microprocessor is transmitting a MODBUS communication.
“ER” - Lit when there has been a communication error - such as incomplete MODBUS
message received or parity error. This LED
is cleared on the next successful MODBUS
read.
Jumper J3 - DISCRETE LED indicators
When jumper J3 is shorted, optional DISCRETE LED indicators are activated. A
green LED is lit when the D1 input is shorted
to G (ground) indicating an OPEN signal has
been received. A red LED is lit when the D2
input is shorted to G (ground) indicating a
CLOSE Signal has been recieved
Figure 9 DIP3 OFF:
DIP3 ON:
30 PSI Preset and
adjustable with manual
buttons
20 PSI Preset
Default = all OFF
Figure 10 7
DIP4 OFF:
FAIL SAFE
DIP4 ON:
FAIL-IN-PLACE
N.O. Solenoid is
installed
N.C. Solenoid is
installed
Default = all OFF
NOTE:
Only read during
power up
Figure 11 8
Control Signals
EHA control board receives input
and reacts by energizing pump or
solenoid valve until desired output
from the pressure transducer
EHA
CONTROL
BOARD
Instrument Side
Figure 12 PRESSURE
TRANSDUCER
PUMP
SOLENOID
VALVE
Power Side
Figure 13 9
Internal Porting
Integrated pressure relief valve to protect
from overpressure.
Internal check valve to eliminate backflow.
PRESSURE
RELIEF VALVE
CHECK
VALVE
Internal Porting
Figure 14 10
Fill topworks and reservoir.
Open bleed valve.
Cycle valve until oil is detected at BV.
Close BV and add oil to reservoir.
Actuator is purged.
BLEED
VALVE (BV)
Internal Porting
Figure 15 11
Air Purge
Retrofit
Air must be purged from the actuator to
ensure proper operation.
- Air will cause sluggish response from actua tor due to its compressibility
Non-invasive retrofit
- Remove existing tubing and accessories.
Two purging methods:
- New units will have a bleed valve port on yoke.
- Retrofit units will need the retrofit purge valve.
- Mount EHA to topworks and plumb inlet and outlet ports.
- Install INLET PURGE VALVE onto the topworks inlet.
- Fill the topworks through the upper adjustment screw and the reservoir.
- Fully cycle the valve a few times adding fluid to the reser
voir as needed.
- Burp the air out of the topworks by bleeding through the upper adjustment screw.
EHA
INLET
PURGE
VALVE
EHA
OUTLET
Retrofit Purge Valve
Figure 16 12
RETRACTED
VALVE CLOSED
Retracted Valve Closed
Figure 17 EXTENDED
VALVE OPEN
Retracted Valve Open
Figure 18 13
NC
WB
SC
NC
WB
SC
12V
Supply
2
1
DIP SW
I.S. Barrier
+
-
7
10
8
9
12
11
4
1
5
2
GND
VIN
VIN
GND
G
D2
G
D1
BRN
BLUE
BRN
BLUE
NON-HAZARDOUS LOCATION
Class I, Div 2 or less
RED
BLK
Level Application - Liquid Dump
Figure 19 Wires from I.S. Barrier to EHA must be in
conduit and sealed no more than 18 inches
from the EHA
EHA DIP SW
1 2 3 4
ON
ELECTRONIC
GenII
Intrinsically Safe wires must be isolated from
other wiring. They can be run
without conduit.
HAZARDOUS LOCATION
Class I, Div 1
14
Models 12 or 24 Volt FS or FIP, DM
12V
Supply
+
-
EHA DIP SW
1 2 3 4
ON
Low Power
Horizontal
Level Switch
Figure 20 EHA operated with Horizontal level switch
GND
VIN
Black
White
Red
15
HAZARDOUS LOCATION
Class I, Div 1
All wires must be in conduit.
Use seals within 18in of each
fitting.
12V
Supply
GND
VIN
White (bot)
Red (top)
White (top)
Black (bot)
EHA DIP SW
1 2 3 4
ON
Low Power
Horizontal
Level Switches
HAZARDOUS LOCATION
Class I, Div 1
Use seals within 18in of each
fitting.
Figure 21 Models 12 or 24 Volt FS or FIP, DM
16
EHA operated with Two Horizontal level switches
+
-
Warning Light
Warning Light
Power supply
24V
Supply
GND
24V SPDT RELAY
+
VIN
Level Application - High Liquid Alarm
Low Power
Horizontal
Level Switch
Use seals within 18 inches of each fitting.
RED (N.O.)
WHITE (COM)
BLK (N.C.)
HAZARDOUS LOCATION
Class I, Div 1
Figure 22 17
EHA operated with Horizontal Level Switch
COIL
Power
Supply
+
GND
VIN
The valve will CLOSE when
power is lost
The valve will CLOSE when
the switch is closed
The valve will OPEN when
the switch is open.
Figure 23 EHA operated with a simple switch
HAZARDOUS LOCATION
Class I, Div 1
18
Maintenance
How often does the KIMZOIL need to be replaced?
Replacement is only needed if the oil is somehow contaminated by an external source. Occasional addition may be required (but is to rare to
be predictable). Over time the red tint will fade, so replacement may be warranted after a few years to maintain a good level indication, but the
oil lasts almost indefinitely.
How often does the check valve and the electric pump need to be replaced?
Several years of maintenance free service is expected
Does the electric board require any type of yearly checks?
No, again several years of maintenance free service is expected.
Table 2 - Internal Leakage Problems
Problem
The valve does not open or close when the
appropriate relay signals are given.
Possible Cause(s)
The EHA may have entered Safety Lockout
Mode were the pressure is not changing as
expected, a safety mode kicks in which removes
power from both the pump and the solenoid. A
timer is started and pressure is compared every
60 seconds. If the pump has run continuously
for any 60 second period without an increase
in pressure, then power is removed from both
the pump and solenoid and enters a safety lock
phase.
Possible Solution
1.) Verify that minimum input voltage is
met. VIN ≥ 11.0 volts for a 12 volt system,
VIN ≥ 22 volts for a 24 volt system..
2.) Reset the actuator on of three ways 1) Cycle power.
2) Place in manual mode.
3) Clear the safety lockout through
MODBUS.
Any of these methods will reset the safety
lockout.
3.) Verify that all air is purged from the
topworks.
19
Kimray is an ISO 9001- certified manufacturer.
Kimray quality assurance process maintains strict controls
of materials and the certification of parts used in Kimray Electro Hydraulic Actuators.
All contents of this publication including illustrations are believed to be reliable. And while efforts have been made to ensure their accuracy, they are not to be construed as warranties for guarantees, express or
implied, regarding Kimray products or services described herein or their use or application. All sales are governed by our terms and conditions, which are available on request. Kimray reserves the right to modify
or improve the designs or specifications of such products at any time without prior notice.
IM0001
20

Electro Hydraulic Actuator

Transcription

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