Tyco BIFFI EHAS Series Installation Instructions And Maintenance Manual
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Tyco BIFFI EHAS Series Installation Instructions And Maintenance Manual

Tyco BIFFI EHAS Series Installation Instructions And Maintenance Manual

Electro-hydraulic actuator with integral electronic position control
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EHAS
(OLGAS-M 35-2000-100-OP)
ELECTRO-HYDRAULIC ACTUATOR
with
INTEGRAL ELECTRONIC POSITION CONTROL
INSTALLATION INSTRUCTIONS AND
MAINTENANCE HANDBOOK
MDE 142E
CUSTOMER
Tyco Hong Kong ORDER
0235155/BB3606
VALVE MAKER
Vanessa srl VALVE SIZE
32"/150
ACTUATOR MAKER
Biffi italia ACKNOWLEDGE
02/3063/GKF
END USER
ANSHAN STEEL WORK ENGINEERING
tba
!@ç$ flow control
BIFFI ITALIA s.r.l. - Loc. Caselle S. Pietro - 29017 Fiorenzuola d'Arda -Piacenza - ITALY -
Tel. (0523) 944411 - Fax (0523) 941885 - e_mail: biffi_italia@biffi.it

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  • Page 1 EHAS (OLGAS-M 35-2000-100-OP) ELECTRO-HYDRAULIC ACTUATOR with INTEGRAL ELECTRONIC POSITION CONTROL INSTALLATION INSTRUCTIONS AND MAINTENANCE HANDBOOK MDE 142E CUSTOMER Tyco Hong Kong ORDER 0235155/BB3606 VALVE MAKER Vanessa srl VALVE SIZE 32”/150 ACTUATOR MAKER Biffi italia ACKNOWLEDGE 02/3063/GKF END USER ANSHAN STEEL WORK ENGINEERING !@ç$ flow control...
  • Page 2 INDEX 1. FOREWARD 2. ACTUATOR FUNCTIONAL DESCRIPTION 3. SYSTEM OPERATING PRINCIPLE 4. CONTROL SYSTEM FUNCTIONING 4.1. Control function 4.1.1. Position regulator and speed control 4.2. General function 4.2.1. Selection between turn clockwise to close or anti-clockwise to close 4.2.2. Stroke limit electronic setting 4.2.3.

  • Page 3: Table Of Contents

    9.8. Output 4-20 mA 9.9. Interlock 9.10. Miscellaneous 9.10.1. Time and date 9.10.2. Factory setting 9.10.3. Pump 9.10.4. Valve jammed (time) 9.10.5. Vem calib. 9.11. VALVE DATA ROUTINES 9.11.1. Tag name 9.11.2. Serial number 9.12. MAINTENANCE ROUTINES 9.12.1. Set password 9.12.2.
  • Page 4 16.4. Actuator scotch yoke mechanism 16.5. Position transmitter and limit switch assembly 16.6. Hydraulic Control Unit (HCU) 16.7. Motor Control Unit (MCU) 17.OPERATING DIAGRAM 17.1. Hydraulic operating diagram SLASDOO2 17.2. Wiring diagram SE 89B-173A/B MDE142E0 4/60 06/04/04...
  • Page 5 NOTES: ................................................................................................................................................................................................................................................................................................................................................................... ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. ………………………………………………………………………………………………………….. REVISION LIST 18/10/2002 Issue document A.A. Rev. Date Description Prepared Approved MDE142E0 5/60 06/04/04...
  • Page 6 FOREWARD EHAS are Electro-Hydraulic Linear Actuator series fitted with a new electronic units used to control the position of modulating linear valves in accordance with an external signal called ‘’position request’’.(REQ) The actuators system is consisting of an electro-hydraulic power unit (HPU) which generates the hydraulic pressure to fill an hydraulic accumulator (HA) in order to control, by means a microprocessor unit (MCU) and a solenoid valve control unit (HCU), the position of an hydraulic cylinder (HLA) connected by a suitable pedestal to a modulating valves (MV).
  • Page 7 ACTUATOR FUNCTIONAL DESCRIPTION EHAS actuators are equipped with the following main components: Oil pressure transmitter Oil temperature transmitter Oil level transmitter High pressure filter with clogging indicator junction box Oil reservoir Hydraulic accumulator Quick opening piloted valve Transmitter terminal block enclosure HCU Hydraulic solenoid valves Control Unit 10.
  • Page 8 The actuator functional description is referred to the simplified schematic reported here under: The electric motor (956) drives the pump (542) which send the pressurised oil, through the filter (361), to the hydraulic accumulator (34). When the pressure value reaches the set point value of the logic valve (395A), the discharge valve (998B) opens and the oil flow back the reservoir (555), at very low pressure value.
  • Page 9 a) Opening operation When the request signal requires to move the valve in opening direction (see Direct/Reverse action on par. 4.2.2) the MCU energise the solenoid valve (401B), which opens and reduces the cylinder chamber pressure value until the spring force start to move towards opening direction. b) Closing operation When the request signal requires to move the valve in closing direction (see Direct/Reverse action on par.
  • Page 10 SYSTEM OPERATING PRINCIPLE drives the solenoid valves and positions the valve in accordance with an external signal called ‘’position request (REQ)’’. The function is performed by the continuous comparison of the ‘’valve position (FB)’’ (REQ) signals: if they are different the solenoid valves are driven so as to move the actuator to the position indicated by the position request signal.
  • Page 11 CONTROL SYSTEM FUNCTIONING 4.1. Control function The functioning of the control system can be described by referring to the block diagrams represented on the following pages. Every block represents a function relevant to pressure and position control of the actuator. The function of each block is detailed as follows: DISPLAY RS232...
  • Page 12 4.2. General function 4.2.1. Selection between turn clockwise to close or anti-clockwise to close Via local operator interface it is possible to select between the following: “actuator turn CLOCKWISE or stem OUT for linear actuator, (CW/OUT) to close” or “actuator turn counter clockwise or stem IN for linear actuator (CCW/IN) to close”.
  • Page 13 The measure is not done during the first cycle after the power-up, or if the position request signal changes during the measuring time. The above warning condition is signalled only by the red LED (alarm/warning) located on the local operator interface.
  • Page 14 5. REMOTE CONNECTIONS EHAS system are provided of digital and analogue input / output, available from the terminal board, suitable for the remote control as described in the following: 5.1. Analogue input / output 5.1.1. Position signal request (input) The position request signal must be 4-20 mA, coming from an external generator or process controller. Impedance 250 Ω.
  • Page 15 Contact rating: max voltage 250Vac/30Vdc; max. current 5A min voltage 5Vdc; min current 5mA. LOCAL OPERATOR INTERFACE The following functions are available by the MCU local operator interface: Ø actuator control Ø system configuration Ø system status visualisation The below figure describes the function of each component of the local operator interface. MDE142E0 15/60 06/04/04...
  • Page 16 6.1. Local operator interface features Numeric display to indicate the present process valve position in % of the opening Three LED’s to indicate the actuator status according to the following logic: • green ON/ red OFF: the actuator is stopped in open position •...
  • Page 17 The following drawing shows the use of the OPEN / YES, CLOSE / NO STOP push buttons in function of the local selector position. LOCAL REMOTE OPEN / YES push-button = CLOSE / NO push-button = STOP push-button 37.5 % 37.5 % 37.5 % ALPHANUMERIC...
  • Page 18 6.2. Variables, alarms and warnings visualisation The following drawing shows the use of the OPEN/YES, CLOSE/NO and selector to visualise the VARIABLE, LOCAL REMOTE 3-POSITION SELECTOR OPEN / YES push-button = CLOSE / NO push-button = pulsante OPEN / YES = STOP push-button = pulsante CLOSE / NO 37.5 %...
  • Page 19 6.3. Configuration options DHAP system can be totally configured from the local interface by means of a series of menus that can be selected from the alphanumeric display. The operator is guided through the different displays by answering YES or NO at the appropriate prompt (change? OK?, view?, next?, etc.) present in the right corner of the lower row of the...
  • Page 20 6.4. Entering the view mode Before commissioning the actuator on the valve, the existing configuration should be checked. The parameters are configured in factory, according to a standard setting or alternatively to customer requirements. In view mode, no password is requested, but no change of parameters can be made. •...
  • Page 21 The figure below shows the procedure to enter VIEW and SET-UP mode From EXIT ? 37.5 % 37.5 % 37.5 % TO VIEW MENU Display YES STOP LANGUAGE xxxxxxx VIEW MODE ENGLISH OK ? STOP next ? 37.5 % LOCAL 37.5 % REMOTE Press NO until...
  • Page 22 SET-UP MENU 37.5 % display NORMAL STOP next? R% 37.5 37.5 % 37.5 % 37.5 % 37.5 % YES STOP 37.5 % LOCAL REMOTE SETUP MODE ACTUATOR SETUP VALVE DATA MAINTENANCE EXIT OK ? Change? Change? Change? SELECT LANGUAGE 3-position selector Routine: Routine: Routine:...
  • Page 23 The below figure shows the procedure to move in the set-up routines 37.5 % 37.5 % 37.5 % 37.5 % SETUP MODE MAINTENANCE XXXXXXXXX ACTUATOR change ? OK ? change ? SETUP change? 37.5 % 37.5 % 37.5 % STROKE FROM ENTER ROUTINE PASSWORD...
  • Page 24 VIEW MENU 37.5 % display NORMAL OFF R %37,5 next? YES STOP 37.5 % 37.5 % 37.5 % 37.5 % 37.5 % 37.5 % LOCAL REMOTE VALVE DATA NAME PLATE MAINTENANCE ACTUATOR SETUP EXIT ? VIEW MODE view? view? view ? view? SELECT LANGUAGE...
  • Page 25 The below figure shows the procedure to move in the view routine TO EXIT? 37.5 % 37.5 % 37.5 % 37.5 % 37.5 % MAINTENANCE ACTUATOR SETUP VIEW MODE NAME PLATE VALVE DATA vedi? view? view? view? 37.5 % 37.5 37.5 % 37.5 % ALARM...
  • Page 26 SET-UP ROUTINES 9.1. Stroke limits The routine allows the actuator to be configured according to the type of valve that it is mounted on and to set the stroke limits in automatic or manual mode. The stroke limits calibration shall be done after having performed the mechanical stroke limits setting (see par.15.1).
  • Page 27 9.3. Positioner The routine positioner allow to set the following parameters of the positioning control programme: Ø Dead band or positioning accuracy (range from 0 to 25.5%) Ø Opening control band (range from 0 to 25.5%), gain K (range from 0 to 100) and K2 (range from 0 to 100) Ø...
  • Page 28 9.5. Local control The routine allows: Ø to set the opening operational speed in manual local control (range from 0 to 100%); Ø to set the closing operational speed in manual local control (range from 0 to 100%) Ø to set the LED’s colour. The following options are available: open LED: green or red, close LED green or red, alarm LED: yellow or red Set-up procedure: •...
  • Page 29 Ø Ø main voltage failure valve position signal (FB) failure Ø Ø position request signal failure internal temperature alarm Ø Ø configuration error HW error Additional situation configured individually to switch-over the monitor relay: Ø Ø LOCAL/STOP pressed enabled Pump failure enabled Ø...

  • Page 30: Output 4-20 Ma

    UP MODE OK?” press YES. Press YES to select actuator set-up menu, and then press NO to scroll the list of available routines and then press YES to select the Fail safe routine. • Press YES to see the configured action, press NO to scroll the available list (off, go to xx%, close, open and stayput) and then YES to confirm the choice •...

  • Page 31: Factory Setting

    9.10.2. Factory setting The routine allows to re-set the parameters, here reported, with the following factory base setting. ROUTINES PARAMETERS STROKE LIMITS Close direction CCW / IN Dead band 0,1%; POSITIONER Control band OP 5 %, K=10, K2=20; Control band CL 5 %, K=10, K2=20;...

  • Page 32: Vem Calib

    Set-up procedure: • Move the local selector to OFF and then press simultaneously OPEN and STOP. Select the language and then enter the password according to the instructions “entering the set-up mode”. When the message of display is “SET-UP MODE OK?” press YES. Press YES to select actuator set-up menu, and then press NO to scroll the list of available routines and then press YES to select the Miscellaneous routine.

  • Page 33: Valve Data Routines

    9.11. VALVE DATA ROUTINES The valve data allow identifying the valve and its function in the process. The valve manufacturer and the end user can enter the data. The following data can be entered: Ø tag name (max. 28 char.) Ø...

  • Page 34: Clear Recent Data Log

    “SET-UP MODE OK?” press YES. Press NO to scroll the list of available menus and then press YES to select maintenance menu. • Press NO to scroll the list of available routines and then press YES to select clear alarm log. •...

  • Page 35: Example Of Set-Up Routine (Local Control)

    9.13. Example of set-up routine (Local Control) TO NEXT REMOTE 37.5 % 37.5 % 37.5 % 37.5 % 37.5 % LOCAL CONTROL SETUP MODE XXXXXXXXXXXX STROKE LIMITS ACTUATOR SETUP 3-position selector 37.5 % Press NO until the desired value appears and then press YES Display NORMAL 37.5 %...

  • Page 36: View Routines

    VIEW ROUTINES 10.1. Actuator set-up routines The above menu allows viewing the present actuator configuration. No change can be made at the present data. The following data can be viewed: ROUTINE PARAMETERS Ø Ø STROKE LIMITS close direction, Ø Ø POSITIONER dead band;...

  • Page 37: Maintenance Routines

    10.4. Maintenance routines Alarm log The alarm log routine allows visualising the list of the last 5 alarms and 5 warnings and the data when they occurred. The “clear alarm log” routine of the set-up menu should be used to clear the list. View procedure: •...

  • Page 38: Example Of View Routine

    10.5. Example of view routine REMOTE 37.5 % 37.5 % 37.5 % 37.5 % 37.5 % LOCAL CONTROL VIEW MODE XXXXXXXXXX ACTUATOR STROKE LIMITS view? 3-position view? SETUP view? selector 37.5 % Display NORMAL 37.5 % R 37,5 % change? 37.5 % ALARM LED YELLOW...

  • Page 39: Factory Test Configuration

    FACTORY TEST CONFIGURATION Status, variables and parameters set during a factory test are reported in the following table: 11.1. Actuator set-up menu PARAMETERS RUOTINES EHAS Serial N° 023063G01001 023063G01002 (OLGAS-M 35-2000-100-OP) STROKE LIMITS CLOSE DIRECTION CCW / IN; PURGE OUTPUT PWM POSITIONER DEAD BAND 0,1 %;...

  • Page 40: Name Plate Menu

    11.2. Name plate menu RUOTINES PARAMETERS SERIAL NUMBER 023063G01001, 023063G01002 ACTUATOR TYPE EHAS (OLGAS-M 3S-2000-100-OP) TORQUE/THRUST Torque 11611 Nm POWER SUPPLY AC 1Ph 230 V, 50Hz MOTOR DATA AC 3Ph/762W/1.9A TEST DATE 15/10/02 WIRING DIAGRAM SF/SE SLASD002/SE89B173A/173B HW VERSION SW VERSION LUBRICANT FLUID AGIP ARNICA 22 or EQUIVALENT 11.3.

  • Page 41: Ehas System Data

    EHAS SYSTEM DATA 12.1. Working condition -ambient temperature from –30 C to +60 C -area classification safe area -enclosure protection, waterproof IP 67 12.2. System performances -Accuracy +/- 0,5% -frequency response 1 Hz 12.3. Electrical and hydraulic features a) Electric voltage supply (admissible voltage drop 15%) 400 V 50 Hz 3Ph b) Electric power supply 0,75 kW...

  • Page 42: Installation Instructions

    INSTALLATION INSTRUCTIONS 13.1. Assembling the actuator on the valve The actuator can be assembled onto the valve flange by using the actuator housing flange with threaded holes. The actuator drive sleeve is connected to the valve stem by an insert bush. The assembly position of the actuator, with reference to the valve, must comply with the plant requirements (cylinder axis parallel or perpendicular to the pipeline axis).

  • Page 43: Setting Of The Mechanical Stroke Limits

    13.2. Setting of the mechanical stroke limits Note. To stroke the actuator it is necessary to electrically power the control system, put the 3 position selector in OFF and select the routine PURGE, following the relevant procedure, in order to stroke the actuator by means the OPEN/CLOSE push-buttons.
  • Page 44 The following figure shows the position and the size of electric entries. Entry Thread type Connection description Cable type 3/4” NPT Analogue signals to control room 1 Armoured/screened 3/4” NPT Analogue signals to control room 2 Armoured/screened 1/2” NPT Position request signal Armoured/screened 3/4”...

  • Page 45: Start Up

    The OLGAS actuator is also fitted with direct acted limit switches (SPDT type) that are connected to the switches junction box. Once the connections are completed, check that the controls and signals work properly. NOTE: Before energising the actuator put the local remote selector on “OFF” position. 13.3.3.

  • Page 46: Maintenance

    MAINTENANCE 14.1. Standard maintenance condition Under normal operating , the EHAS is maintenance free system. No formal actuator maintenance is required. Although visual inspection for oil leakage or external visible damages is recommended every two years. 14.2. Special maintenance The system is provided with different counters, as already mentioned on par.13.4, to records operations, alarms and warning in order to provide information to assist in the maintenance program and trouble-shooting.

  • Page 47: The Electronic Control Logic Works But There Is An Alarm

    15.2. The electronic control logic works but there is an alarm In this case the information available on the local display help the operator in the trouble-shooting. The alarm / warning table help the operator in understanding the reason of the alarm. The below table, used in conjunction with the alarm / warning table (see par 6.2) shows the procedure to be used to remove the alarm / warning.
  • Page 48 WARNING LIST Display Message Condition for Available Controls (*) Actions alarm/Warning Local Remote The temperature sensor switched Check the electric and mechanical THERMOSTAT on for motor over temperature. functionality of the motor pump available available available Temperature inside the actuator Find the heat source and insulate INT.

  • Page 49: Main Component Part List Table

    MAIN COMPONENT PART LIST TABLE Item Qty. Description Code Number Ref. Table Control cabinet 2110403000 18.1 Control cabinet terminal enclosure 2349960105 Hydraulic accumulator 24.5 l 8802012500 Hydraulic cylinder/quick exhaust valve 2281004100 18.2 Actuator scotch yoke mechanism 229A030S00 18.4 Position transmitter and limit switch assembly 2340001092 18.5 Hydraulic Control Unit (HCU)

  • Page 50: Control Cabinet

    16.1. Control cabinet Item Qty. Description Code Number SLASD002 Pressure transmitter 8960298485 item 267 Temperature transmitter 8960295660 item 565 Oil level transmitter 8960279302 item 562 Protection cabinet 4110403060 item 301 Oil filling plug 8960047001 Oil reservoir 4110403010 item 555 Pressure gauge 8880223800 item 621 Electric motor...

  • Page 51: Hydraulic Cylinder /Quick Exhaust Valve

    16.2. Hydraulic cylinder /quick exhaust valve Item Qty. Description Code Number Note Tie rod nut 8111016000 End flange 3281002130 Stopper counternut 8131130000 Stopper seal ring 3200150330 Stopper 30x2x140 8355735000 Piston 3281001950 Piston guide sliding ring 3281000080 Piston seal ring 3281000070 O-Ring 8092238000 Tie rod...

  • Page 52: Actuator Spring Cartridge)

    16.3. Actuator spring cartridge) Item Qty. Description Code Number Note 3201200210 Washer 8160156000 Sealing washer 3201200330 Stop setting screw 3273300130 Spring container 427A020002 Spring B3084680010 8111016000 Shoulder washer 3272330160 Rod bushing 8183005000 Guide rod 327A020003 Spring thrust flange 3273920040 Rod bushing 8183005000 Container rod 327A040006...
  • Page 53 16.4. Actuator scotch yoke mechanism Item Qty. Description Code Number Note O-Ring 8092168000 Yoke bushing 329A030003 Retainer ring 8065028000 Housing 329A030001 Guide bar 329A030008 Yoke 329A030014 Cover gasket 329A030009 Guide block 329A030005 Bushing 8183051000 Sliding block 329A030007 Vent valve 4272690150 Screw 8031262000 Cover...
  • Page 54 16.5. Position transmitter and limit switch assembly Item Qty. Description Code Number Note SPDT switch 8890018000 Switch cam 3500005031 Potentiometer support plate 3349160160 Position transmitter potentiometer 8960286060 Cover box gasket 3342070030 Switch support plate 3349160110 Driver shaft 3348670010 Shaft driver gear M1/Z78 3349160120 Potentiometer gear M1/Z26 3349160130...
  • Page 55 16.6. Hydraulic Control Unit (HCU) Item Qty. Description Code Number SLASD002 Closing solenoid valve 2261811H20 item 401A Coil spare 2B00012M00 Opening solenoid valve 2261811H20 item 401B Coil spare 2B00012M00 Quick opening solenoid valve 2154631000 item 562 Coil spare 2B00035M00 O-Ring 8092011000 Protection housing base 3141410030...
  • Page 56 16.7. Motor Control Unit (MCU) Item Qty. Description Code number Local interface operator 4800000010 MCU housing 3110403030 Terminal box cover 3800000020 Display mask 3800000270 Push-buttons (2 black + 1 red) 4800000060-70 3-position selector LOCAL/OFF/REMOTE 4800000080 O’ring 8092166000 Terminal block 4800000030 4-20 mA card 493IEHASI02 Transformer 400/230 with support...
  • Page 57 OPERATING DIAGRAM 17.1. Hydraulic operating diagram SLASD002 MDE142E0 57/60 06/04/04...
  • Page 58 17.2. Wiring diagram SE 89B-173A/B MDE142E0 58/60 06/04/04...
  • Page 59 MDE142E0 59/60 06/04/04...
  • Page 60 ELECTRO-HYDRAULIC ACTUATOR EHAS View of the hydraulic power unit cabinet, hydraulic control unit and microprocessor control unit with local operator interface. !@ç$ flow control BIFFI ITALIA s.r.l. - Loc. Caselle S. Pietro - 29017 Fiorenzuola d’Arda -Piacenza - ITALY - Tel.

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