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Summary of Contents for Koso REXA Electraulic Xpac

  • Page 1 IOM 05/09...
  • Page 2 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives...
  • Page 3 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Contents: Safety Considerations INTRODUCTION 1 OVERVIEW 1.1 Actuator 1.2 Control Enclosure 1.3 Menu Calibration 1.4 Operational Summary 1.5 Optional Equipment 1.5.1 Position Transmitters 1.5.2 Manual Override 1.5.3 Limit Switches 1.5.4 Alarm Relay 1.5.5 Surge Control 1.5.6 Pulse Input...
  • Page 4: Table Of Contents

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.3.1 Actuator Power 5.3.2 Control Signals 6 OPERATION 6.1 Auto Mode 6.2 LOCAL Mode 6.3 SEtUP Mode 6.3.1 Cal - Calibration Sub-Menu 6.3.2 ACC - Acceleration Sub-Menu 6.3.3 CtL - Control Sub-Menu 7 START-UP CONSIDERATIONS 7.1 Wiring 7.1.1 Module Cable...
  • Page 5 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives APPENDICES A. Drawings B. Quick Reference C. Optional Features D. Canadian Standards Association (CSA) Approved for Hazardous Area Class I, Division 2, Groups B, C & D E91001 Relay Option Board, E91002 Position Transmitter Class I, Division 1, Groups B, C &...
  • Page 6 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives SAFETY CONSIDERATIONS SHOCK HAZARD: Hazardous voltage levels are present in the actuator. Only qualified service and installation personnel should install or adjust this device. ALIGNMENT: Insure that the actuator shaft is in line with the valve plug stem. Misalign- ment could damage the actuator and driven device or cause injury to installation personnel.
  • Page 7 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives ACCUMULATOR FAILURE OPTION: REXA actuators denoted by an A in the model number contain an accumulator charged with high-pressure nitrogen. These actuators also have an automatic recharging cycle for the accumulator. Failure to properly follow installation instructions may cause serious injury to maintenance personnel and/or dam- age to equipment.
  • Page 9 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives INTRODUCTION REXA Xpac actuators and drives are Electraulic (self-contained, electro-hydraulic) devices. They are controlled by a dedicated micro- processor located within the control enclosure and operated by a fluid power system in the power module.
  • Page 10 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives The model number provides a physical description of the mechanical portion of the actuator. The cyl- inder size, Power Modules and failure mode are described in this simple system. Model Number _ _ _ _ _ –...
  • Page 11 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1 THEORY OF OPERATION Overview The REXA Xpac is a microprocessor controlled, self contained, Electraulic (electro-hydraulic) actuator or drive designed specifi- cally for modulating service. Hydraulic, electronic and mechanical technologies are combined to achieve the state of the art in actuator design.
  • Page 12: B Linear Actuator Assembly

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1.1 Actuator The heart of the actuator is the Electraulic Power Module. Consisting of a motor, gear pump, flow match valve (FMV), make-up oil reser- voir, heater and bypass solenoid (spring fail units only), the Power Module delivers oil at a nominal 2000 psi to a hydraulic cylinder.
  • Page 13 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1.2 Control Enclosure The control enclosure contains the position control processor (PCP), power supplies, fuses and filters, motor drivers and a termination area. The PCP consists of an 8-bit, 80C52 microprocessor, a 32 Kbyte EEPROM memory for program storage, a 2 Kbyte EEPROM memory for data storage, a 12-bit A/D converter, and a 3-button/5- digit display user interface.
  • Page 14: C Hydraulic Schematic

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives If the error exceeds the deadband (user set), then the PCP will initiate corrective action by starting the motor. A reversible hydraulic pump is driven by the motor. The pump can pressurize either side of a double acting cylinder through one of two Flow Matching Valves, FMV-1 and FMV-2.
  • Page 15 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1.5 Optional Equipment (see Appendices) The Xpac is available with a substantial list of optional equipment. Most items can be field retrofitted. Consult your local sales repre- sentative for details. 1.5.1 Position Transmitter (see Appendix C.1) The position transmitter provides a loop powered two-wire 4-20 mA...
  • Page 16 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1.5.6 Pulse Input (see Appendix P) In place of or in conjunction with the normal analog control signal, pulse or contact signals can provide control input to the actuator. Three or four wire, 24 to 120 volts, AC or DC, signals can be used.
  • Page 17 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 1.5.12 Split Clamps On linear actuators mounted at unusual angles or with reduced ac- cessibility, a split clamp connection between the actuator and driven device is available. The difficulties of stem rotation, shaft insertion and jam nuts are eliminated.
  • Page 18 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 2 DELIVERY 2.1 Receipt Inspect the crate and make note of any physical damage. If severe damage is present, then consideration should be given to rejecting the shipment and contacting the shipping company concerning in-transit damage claims.
  • Page 19 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 3 OIL The Xpac is a sealed, self-contained Electraulic actuator. During normal operation, the hydraulic oil is pumped from one side of a double acting cylinder to the other. An oil reservoir which provides a source of “make-up”...
  • Page 20 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives A reservoir relief valve is installed on the top of the power module on fail in place units and next to the oil fill valve on spring failure units.
  • Page 21 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 4 MECHANICAL INSTALLATION The Xpac can operate any device requiring force and stroke or Installation of an accumulator failure is explained in Appendix G. torque and rotation within its range. These include louvers, dampers, variable speed drives and valves.
  • Page 22: A Universal Spring Alignment

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives within 5° of this position is acceptable. Position the spring lever to the 45° location by extending the spring stop as shown in figure 4.A. Rotate the driven device to the required failure position.
  • Page 23 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives To Adjust: 1. Loosen Jam Nut #36 (figure 4.B). 2. Turn Stroke Adjusters, #34, CW to reduce stroke, CCW to increase stroke. 3. Tighten Jam Nut, #36. 4. Resume system pressure. 4.2 L Series (Linear) 4.2.1 Elastic Coupling For valve installations, linear Xpac actuators are provided with an...
  • Page 24 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 4.2.2 Fail In Place Installation CAUTION! When mounting linear actuators, take care to avoid mechanical misalignment that would cause side load to the actuator output shaft. Be sure that the valve stem is straight and not bent.
  • Page 25 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives mounted underneath the hydraulic cylinder and a normally open so- lenoid valve installed on top of the power module. The spring can be specified to extend or retract the stem upon power loss. It is not field reversible.
  • Page 26: C Drive Base Bolting

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives diameter and recommended bolt torques. Standard bolting or threaded studs are acceptable, but material strength must be an SAE Grade 3 or better. Hardened load washers and lock washers must be used. Figure 4.C Drive Base Bolting RECOMMENDED Model...
  • Page 27: E Ambient Temperature

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Rated Drive Torque Load = Effective Lever For most installations, the optimum alignment of the drive arm and the driven (damper) arm is when they are parallel to each other and perpendicular to the connecting linkage at mid-rotation.
  • Page 28 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5 ELECTRICAL INSTALLATION B, C and 2C Power Modules The Xpac consists of two major components, the Electraulic actuator Electrical installation of ½D, D and 2D Power Modules is contained within (cylinder &...
  • Page 29: D Module Connection

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.1.1 Enclosure Termination For B or C power modules connect the cable to the 24 PIN green Be sure to cut off excess lengths of terminal strip within the control enclosure per figure 5.A (p. 26). The wire within the control enclosure.
  • Page 30 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.2 Feedback Cable The standard cable consists of a red, white and black wire and a tinned copper ground wire. Each individual wire is 18 AWG. The feedback cable is not restricted by distance.
  • Page 31 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives On L series actuators with thrust of 10,000 lbs or less and strokes of 6 The O-ring should be properly seated in the cover with no cuts or other inches or less, the feedback connection is made directly to the screw discontinuities.
  • Page 32: Actuator Power

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.3 User Connections The minimum user connections to the Xpac are electric power and control signal. The standard power is 110 Vac ± 10%, 60 Hz for the B, C and ½D size Power Modules.
  • Page 33: Control Signals

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.3.2 Control Signals Analog control signals (4-20 mA, 1-5 Vdc, etc.) are connected to pins 2 and 3 of the 24 PIN green connector on all actuators. Connections for pulse input signals are made on a separate auxiliary board located on top of the PCP.
  • Page 34: A Control Enclosure Connections (B&C Power Modules)

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Figure 5.A: Control Enclosure Connections B Power Module or C Power Module Connector Signal Wire Position Name Color +15Vdc Control Signal (+) User Supplied Control Signal (-) User Supplied Feedback (+) White Feedback (-)
  • Page 35: B Control Enclosure Connections (2C Power Modules)

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Figure 5.B: Control Enclosure Connections 2C Power Module Connector Signal Wire Position Name Color MODULE CABLE Motor 1 Phase A Green On actuators with two Power Mod- ules, two module cables are pro- Motor 1 Phase A Green/Black vided.
  • Page 36: C Actuator Connections

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Figure 5.C: Actuator Connections Signal Actuator Name Cable Wire Colors Wire Color MODULE CABLE Linear & Rotary Units - Junction Cavity ( On actuators with two Power Mod- Bullet Connectors) ules, two module cables are pro- Motor Phase A-...
  • Page 37: Operation

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 6 OPERATION There are three modes in which the actuator operates; Auto, LOCAL and SEtUP. As long as power is applied, the actuator will be in one of these modes. If power is removed and later restored, the actuator will resume operation in the last active mode.
  • Page 38: Local Mode

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives loop through each parameter and display the set value. The display will revert to position indication five seconds following the last scroll request. 6.2 LOCAL Mode In the LOCAL mode, the actuator is under the control of the three button keypad.
  • Page 39: Setup Mode

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 6.3 SEtUP Mode In the SEtUP mode, the actuator is under the control of the three button keypad. The actuator is off-line and does not respond to the control signal.
  • Page 40: Cal - Calibration Sub-Menu

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives When the SEtUP mode is entered, the display briefly shows"SEtUP" followed by the first sub-menu, CAL. However, if a passcode has been entered to restrict access, the "SEtUP" message is followed by PC in the left two digits.
  • Page 41 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives The operation of high speed actuators with low deadband can cause oscillation around the target position. This effect is controlled by reducing the actuator acceleration. REXA has developed a unique dual-acceleration method to eliminate oscillation while continuing to provide a fast, responsive actuator.
  • Page 42 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Position High is set by moving the stem to the actual high signal position. With PH on the display, press the (E)NTER key. PH will begin to blink. Using the Scroll Up and Scroll Down keys, position the actuator to the desired point and press (E)NTER again.
  • Page 43: Acc - Acceleration Sub-Menu

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives B/C Stepper Motor Software (V61SLSD1) with Gain Function: Recommended Initial Parameter Settings Model B Power Module C Power Module 2C Power Module L Series 2000 4000 10000 15000 20000 30000 40000...
  • Page 44: Ctl - Control Sub-Menu

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 6.3.3 CtL - Control Sub-Menu In LOCAL mode, both the actual posi- tion and control signal position may Bumpless Transfer (bt) provides a means by which process upsets be reviewed.
  • Page 45 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives PH - Move to the position specified by the parameter Position High. OFF- Override this feature for use with 0-20 mA signals. Control signals less than 2.5 mA are valid. If the control signal becomes invalid, the actuator seeks the selected failsafe position, displays error code E-CS and de-energizes the alarm relay.
  • Page 46: Start-Up Considerations

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 7 START-UP CONSIDERATIONS *Note: Refer to page 47 for Addendum: Cylinder End Stops. 7.1 Wiring The majority of problems encountered during initial start-up of REXA !IMPORTANT! actuators involve wiring or electrical power. Although the wiring is During assembly, Loctite 767 com- pound—or its equivalent—must be simple and straight forward, the quantity of wires and color coding...
  • Page 47: Electrical Noise

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 7.2 Electrical Noise Electrical noise can cause the actuator position to be unstable. That is, the motor will be constantly "hunting" for the target position. This is more likely for actuators with a tight deadband setting. To determine if an actuator is being affected by electrical noise, place the PCP into LOCAL control mode (section 6.2).
  • Page 48: Noise Pick-Up On Surrounding Equipment

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives from another circuit at the breaker panel. Otherwise, install a line filter. Be sure the filter is rated for the proper current and voltage. CONTROL SIGNAL Although milliamp control signals are generally not noisy, it is possible for this signal to be corrupted by an outside source.
  • Page 49: Longitudinal Misalignment

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives In most cases, lateral alignment is corrected by stroking the actuator with the mounting or mating connection in a loosened condition. This will allow the connection to self-align. If there is insufficient clearance, then the appropriate bore diameters must be increased.
  • Page 50: Output

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 7.5 Output The most important concern in actuator sizing is adequate knowledge of the application. Factors such as pressure drop, packing friction, valve size and valve type affect the required output. These condi- tions may change with time or temperature.
  • Page 51: Fail In Place Actuators

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives In general, the REXA power modules will develop their nominal pres- sure (2000 PSI) over a wide range of temperatures (0° to 160° F) and speed settings (40% to 100%). It is only in the extreme where output drops below the ratings.
  • Page 52 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Ambient Temperature Range for Various Configurations L Series (thrust of 10,000 lbs or less and strokes of 6 inches or less) SAE 5W-50 (Standard –Castrol Syntec) High Temp. Option -76°F -30°F -5°F...
  • Page 53: Error Codes

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 8 ERROR CODES The PCP is able to provide various diagnostics for actuator malfunc- tion. These ERROR CODES are two letters preceded by an E- on the five digit display. Except for loss of feedback, E-Fb, the display will alternate between the error codes and actual position.
  • Page 54: Bumpless Transfer, E-Bt

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives The Fail Safe feature can be turned of ([CtL:FS] = OFF). In such instances, E-CS has no meaning and will not occur. 8.4 Bumpless Transfer, E-bt E-bt will automatically clear when the control signal and actuator position are within 5%.
  • Page 55: Addendum: Cylinder End Stops

    Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Addendum: Cylinder End Stops 5.5 CYLINDER END STOPS Cylinder end stops provide the actuator the means to prevent over-travel during a fail safe condition. If the driven device does not limit over-rotation or over-travel, cylinder end stops can be utilized for this purpose.
  • Page 56 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 5.5.1 End Stop Adjustment Counter Clockwise Adjuster Clockwise Adjuster Figure 5.5.1-1 Cylinder End Stops WARNING: The Calibrated end points PL and PH must not be set with the actua- tor against the cylinder end stop.
  • Page 57 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 8. The actuator stroke adjustment can now be made using the threaded adjust- ment rod. This rod has a hollow hex in the end to allow easy adjustment. WARNING: As the stroke adjusters are turned in, fluid will be displaced and need to leak out of the system.
  • Page 58 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives Table 5.5.1 Stroke Adjustor One Turn Adjustment Jam Nut Final Torque Model (degrees) (lb·ft) R600/R1 200 R2 500/R5 000 R10 000/R20 000 R50 000/R100 000 R200 000/R400 000 5.5.2 R200 000/R400 000 End Stroke Adjustments R200 000/R400 000 actuators do not use an external thread seal arrangement.
  • Page 59 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives APPENDIX A Control Enclosures and Electrical Assembly Drawings For B, C and 2C Power Modules EP96528 Rev5 A96525 Rev2 EP95837 Rev0 A96770 Rev1 EP96527 Rev2 A97217 Rev0 EP96526 Rev2 A97218 Rev0 D96935...
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  • Page 71 Xpac Installation Manual -- Version 5.1 (8/00) REXA Electraulic Actuators & Drives APPENDIX B Quick Reference...
  • Page 75 Xpac Installation Manual -- Version 5.1 (5/09) REXA REXA Electraulic Actuators & Drives Electraulic Actuators & Drives APPENDIX C Optional Features C.1 Position Transmitter .............. p. 1 C.2 Manual Override ..............p. 3 C.2.1 Declutchable Handwheel ..........p. 3 C.2.2 Declutchable Drill Drive ..........p. 3 C.2.3 Geared Hand Crank ............
  • Page 77: Optional Features

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives C OPTIONAL FEATURES To complement the standard capabilities found in the Xpac, various options are available to fulfill specific applications. C.1 Position Transmitter The position transmitter provides a two-wire 4-20 mA signal that is proportional to actuator position.
  • Page 78 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives CONNECTION The position transmitter mounts to the top of the PCP. All wiring connections are made directly to this option board. Non-Alarming Loop: Determine the minimum and maximum supply voltage to power the external load.
  • Page 79: Manual Override

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives C.2 Manual Override The Xpac has available three types of manual operators: Declutch- Operation of the spring failure inhibits able Handwheel, Declutchable Drill Drive and Geared Hand Crank. movement by a manual override.
  • Page 80: Geared Hand Crank

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives C.2.3 Geared Hand Crank The geared hand crank consists of a separate power module with a 5:1 gear reducer and crank arm replacing the motor. To operate, simply turn the crank.
  • Page 81: Alarm Indication

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives GENERAL SPECIFICATION Quantity: 2 Type: Single Pole, Double Throw (SPDT) Rating: 1 amp @ 30 vdc, 0.3 amp @ 120 vac - resistive Differential Travel (Hysteresis): 0.1% Connection: terminal strip on the auxiliary board CONNECTION The electronic limit switch board mounts to the top of the PCP.
  • Page 82: Auxiliary Control

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives The relay on the position transmitter board may be wired in series with the transmitter. In this mode, an alarm would be indicated without an additional pair of wires. The transmitter output would drop to 0.0 mA to indicate an alarm.
  • Page 83: Remote Manual Control

    Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives C.5.2 Remote Manual Control The actuator may be equipped to connect to a remotely located manual station. Operation of this option requires a two position switch (Auto/Manual) and two (normally open) push-button switches, extend (CCW) and retract (CW).
  • Page 84: 0.05% Deadband

    Xpac Installation Manual -- Version 5.1 (5/09) REXA C-10 Electraulic Actuators & Drives C.6.1 0.05% Deadband The 0.05% deadband option will double the standard precision and provide resolution within one half the thickness of a piece of paper on a 2 inch rated stroke. The control of an Xpac actuator with this setting is remarkable.
  • Page 85: Water Hammer (Two Speed Operation)

    Xpac Installation Manual -- Version 5.1 (5/09) REXA C-11 Electraulic Actuators & Drives the product of the signal span (Signal High - Signal Low) and this percent of stroke. = SL + (SH – SL) x CP C.6.3 Water Hammer (two speed operation) The phenomenon known as “Water Hammer”...
  • Page 86: Flow Characterization

    Xpac Installation Manual -- Version 5.1 (5/09) REXA C-12 Electraulic Actuators & Drives Speed Breakpoint (Sb) specifies the transition point, in percent of stroke, from Low Speed to High Speed . Operation of the actuator at strokes below the Speed Breakpoint will be at the Low Speed setting. Operation of the actuator at strokes above the Speed Breakpoint SPEED BREAKPOINT will be at the High Speed setting.
  • Page 87 Xpac Installation Manual -- Version 5.1 (5/09) REXA C-13 Electraulic Actuators & Drives Figure C.A...
  • Page 89 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX D Canadian Standards Association (CSA) Approved for Hazardous Area Class I, Division 2, Groups A, B, C & D Class I, Division 1, Groups B, C & D...
  • Page 91 Wiring of Connecting Cables must be performed in ac- cordance with NEC and CEC, “Wiring Methods for Class I Divisions 2 locations.” Replacement parts must be supplied by KOSO AMER- ICA. Installation procedures and final testing must be in accordance with KOSO AMERICA’s recommended practices.
  • Page 92 D - 4 ADDENDUM TO SUPPLEMENT REXA PRODUCTS RELAY OPTION BOARD FOR USE IN HAZARDOUS LOCATIONS. DOCUMENT NO. E91001 The Relay Option Board consists of three (3) NC-NO-COM relays. Each relay connection shall be used as specified in this document. NOTES For United States Installations, energy is to be limited by a CSA Approved apparatus with non- incendive field cirduits.
  • Page 93 D - 5 ADDENDUM TO SUPPLEMENT REXA PRODUCTS LOOP POWERED POSITION TRANSMITTER WITH ALARM RELAY FOR USE IN HAZARDOUS LOCATIONS. DOCUMENT NO. E91002 The Position Transmitter incorporates a NO Alarming Loop and a NC-NO Alarm Relay on the board. The relay connections shall be used as specified in this document.
  • Page 94 Wiring of Connecting Cables must be performed in ac- cordance with NEC and CEC, “Wiring Methods for Class I Divisions 1 locations.” Replacement parts must be supplied by KOSO AMER- ICA. Installation procedures and final testing must be in accordance with KOSO AMERICA’s recommended practices.
  • Page 95 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX E Mechanical Limit Switches...
  • Page 97 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives E. MECHANICAL LIMIT SWITCHES The mechanical limit switches are independent devices in- For heavy or inductive loads, arc stalled on the yoke in linear units and in the feedback housing suppression devices such as resis- area of rotary or drive units.
  • Page 98 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives E.2 Wiring E.2.1 Go Switches Remove the access plate by unscrewing the four slotted screws on the bottom of the unit. Thread the cable through the ½” NPT fitting and connect to the appropriate Normally Open (NO), Nor- mally Closed (NC) and Common (C) screw terminals.
  • Page 99 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives APPENDIX F Seat Loading Cylinder...
  • Page 101 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives F. SEAT LOADING CYLINDER Linear actuators which must come up against a hard stop (valve seat) use a spring loaded element between the actuator and valve stems. This elastic coupling provides a controlled loading of the seat without over stressing mating parts.
  • Page 102 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives F.2.2 Seat Loading Cylinder Termination The feedback connection is made directly to the screw terminals For best noise immunity, the feedback on the feedback printed circuit board. Remove the four cap screws ground wire should be kept as short as that hold the upper cover.
  • Page 103 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives APPENDIX G Accumulator Failure G.1 Description of Operation G.2 Handwheel Operation G.3 Oil Filling and Level Check G.4 Nitrogen Filling & De-Pressurizing Instructions Wiring Drawing D97189 Rev1 p. G-5...
  • Page 105 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G. ACCUMULATOR FAILURE G.1 Description of Operation G.1.1 OPERATION System operation is based on a piston type accumulator with nitrogen gas on one side of the piston and oil on the other. The accumula- tor is sized to provide a minimum of 2000-PSI oil pressure to the cylinder during failure, thus insuring that the actuator will always produce its rated output.
  • Page 106 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G.1.2 ADDED FUNCTIONALITY TO THE ELECTRONICS These four parameters are fac- Four new parameters have been added to the PCP to accommodate tory set. Do not change without consulting REXA.
  • Page 107 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G.1.3 RECHARGING The recharge cycle will only occur if: 1. The PCP is in the Auto mode, For normal operation, the ac- 2. The pressure transducer output is less than rl cumulator does not require the 3a.
  • Page 108 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G.2 HANDWHEEL OPERATION Accumulator actuators are equipped with solenoid manual override levers. This feature enables use of the handwheel with electrical power off or in trip mode. Units are shipped from the factory with the sole- noid override levers safety wired in the open position (see figure G1).
  • Page 109 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G.3 OIL FILLING AND LEVEL CHECK G.3.1 OIL LEVEL CHECK It is necessary to check the level after a recharge cycle as the unit may perform several partial stroke failures that will cause the rod to protrude beyond the normal (fully re-charged) position.
  • Page 110 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives 4. Loosen the tube fitting where it attaches to the auxiliary cylinder. 5. Continue filling and purging until clear oil drains out of the loosened fitting. 6. Tighten the loose fitting. 7.
  • Page 111 Xpac Installation Manual -- Version 5.1 (5/08) REXA Electraulic Actuators & Drives G.4 NITROGEN FILLING & DEPRESSURIZING CAUTION! THE ACCUMULATOR CONTAINS HIGH PRESSURE NITRO- GEN GAS. FAILURE TO PROPERLY FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT. REXA accumulators are shipped pre-charged from the factory.
  • Page 112 Xpac Installation Manual -- Version 5.1 (5/08) REXA G-10 Electraulic Actuators & Drives G.4.2 ACCUMULATOR DEPRESSURIZATION INSTRUCTIONS 1. Remove gas valve guard and gas valve cap. 2. Back gas chuck “T” handle all the way out (counter clockwise) before attaching charging assembly to accu- mulator gas valve.
  • Page 113 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives APPENDIX H Booster Pump Configuration...
  • Page 115 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives BOOSTER PUMP CONFIGURATION Introduction Our philosophy of precise positioning, actuator mounted components, minimum power consumption and reduced maintenance directed product design to smaller size (1.5 horsepower) power modules. As users became more familiar with our capabilities, a need for larger pumping systems became evident.
  • Page 116 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives H1 MECHANICAL INSTALLATION An Xpac with the Booster Pump Configuration is installed in the same manner as an actuator with any other size Power Module (see Section 4). H1.1 Actuator Please refer to Section 4.1 for a rotary actuator, 4.2 for a linear actua- tor and 4.3 for a D series drive.
  • Page 117 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives H2 ELECTRICAL INSTALLATION The Xpac consists of two major components, the Electraulic actuator (cylinder and power module) and the control enclosure. The actua- For simplicity, reference is made to the Xpac actuator, L series or R se- tor is installed on the driven device, while the enclosure is remotely ries.
  • Page 118 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives H2.1.1 Enclosure Termination The motor cables are terminated to the screw connector terminal blocks in the top left section of the control enclosure (DWG A97134). Connect the cables by following DWG D97135 for the ½D,P9 or DWG D97135-P40 for the D,P40.
  • Page 119 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives H2.4 Module Cable A cable consisting of 3 twisted A thermostatically controlled cartridge heater and solenoid power pairs and a triad is supplied as the (optional; only connected on spring fail units) are installed in the ½D module cable.
  • Page 120 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives H3 SETUP FEATURES Please refer to Section 6 for a detailed explanation of REXA actuator operation. Section 6.3 should be thoroughly understood and followed before proceeding. The booster pump requires one new parameter. The D power module redefines two parameters (Low Acceleration and Acceleration Breakpoint) and requires two new parameters (gain and minimum speed) in the CAL branch.
  • Page 121 Xpac Installation Manual -- Version 5.1 (4/09) REXA Electraulic Actuators & Drives The speed of the unit is equal to the Gain times the difference be- Gain and minimum speed will ap- pear in the CAL Branch only if a tween the current and target positions.
  • Page 122 Xpac Installation Manual -- Version 5.1 (4/09) REXA H-10 Electraulic Actuators & Drives Acceleration Breakpoint (Ab) specifies the position at which the actua- tor will start accelerating from the minimum speed(dL). This position is the difference between the current position and the target position. Values from 0.1% to 5.0% difference may be selected.
  • Page 123 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX P Pulse Operating System...
  • Page 125 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives P. Pulse Operating System The pulse operating system developed for the Xpac makes opti- mum use of the actuator’s capabilities. Dual acceleration, minimum modulating and water hammer features are available. In addition, Both Pulse inputs active simultaneous- the error diagnosis and alarm function are active.
  • Page 126 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives SIGNAL INPUT RANGE Voltage: OFF: 0 to 8 volts, AC or DC ON: 22 to 120 volts, AC or DC Undefined: 8 to 22 volts, AC or DC Current: OFF: less than 1 mA ON: 1.8 mA to 10 mA;...
  • Page 127 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives The OFF time between successive input pulses must be greater than 1 Parameter Failsafe has no meaning millisecond. Long input pulses; that is, input pulses which remain ON with a pulse control signal.
  • Page 129 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX R Redundant Construction...
  • Page 131 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives R. REDUNDANT CONSTRUCTION Introduction The modular construction of the Xpac allows the duplication of the critical components without a major redesign or sacrificing operational charac- teristics. Two Power Modules, two complete control electronics and two feedback assemblies are used to operate a single hydraulic cylinder.
  • Page 132 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives Wiring is accomplished as two separate units. A Power Module and feedback circuit is connected to a single electronics. Please refer to Section 5 for a single B or single C connection and to Appendix X for a single D connection. R.2.1 User Connections Electrical power and control signal are wired in the conventional manner (Section 5.3).
  • Page 133 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives R.4 Simultaneous SEtUP Both PCPs should be calibrated at the same time on a step by step basis. Follow the procedure indicated in Section 6.3. With the exception of the Position Low (PL), Position High (PH), Control Point (CP), Signal Low (SL) and Signal High (SH), all values in the SEtUP Mode will be identical.
  • Page 134 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives Figure R.1 Single Enclosure...
  • Page 135 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives Figure R.2 Wiring Diagram...
  • Page 137 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX S Surge Control Option...
  • Page 139 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives S. SURGE CONTROL OPTION High speed operation in one direction during upset conditions can best be handled with the REXA Surge Control Option. The standard actuator is augmented with three additional components: Mechanical Spring - provides the force to move the actuator in the surge direction.
  • Page 140 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives SURGE BREAKPOINT Only the Surge Breakpoint must be included during calibration of the SEtUP parameters. Place the PCP into the SEtUP mode and step over to the Option Board Sub-Menu, Obd. Push the DOWN key SURGE BREAKPOINT three times.
  • Page 141 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives APPENDIX T Screw Terminals...
  • Page 143 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives T. SCREW TERMINALS A screw terminal junction enclosure (figure T.1) can be added to the B or C size Power Modules. The cable connection is made to the terminals by #8 ring lugs. Connections for the feedback cable is unchanged (Section 5.2).
  • Page 144 Xpac Installation Manual -- Version 5.1 (5/98) REXA Electraulic Actuators & Drives Figure T.2 Wiring Connections...
  • Page 145 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives APPENDIX X D Size Power Module Control Enclosures and Electrical Assembly Drawings D97103 Rev2 A97101 Rev0 EP97055 Rev0 A97099 Rev0 EP97076 Rev0 S96502 Rev4 D97097 Rev3 A97100 Rev0 D97096 Rev2...
  • Page 147 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives D SIZE POWER MODULE Introduction The D size power module is installed on larger size actuators and drives or applications requiring rapid operation. Its output as compared to the B and C size modules can be summarized as follows: Power Module Speed...
  • Page 148 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X1 MECHANICAL INSTALLATION An Xpac with ½D, D or 2D size Power Modules is installed in the same manner as an actuator with any other size Power Module (see Section 4).
  • Page 149 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X2 ELECTRICAL INSTALLATION D Power Modules Only For simplicity, reference is made to The Xpac consists of two major components, the Electraulic actuator the Xpac actuator, L series or R se- (cylinder and power module) and the control enclosure.
  • Page 150 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X2.1 Motor Power Cable The standard cable consists of 4 conductor, overall foil shield. Each individual wire is 14 AWG. Maximum length of the cable run is 700 ft. SHOCK HAZARD HAZARDOUS VOLTAGE LEVELS ARE PRESENT IN THE MOTOR POWER CABLE.
  • Page 151 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X2.3.2 Actuator Termination Feedback termination at the actuator for the D size Power Module is the same as for the other size modules (section 5.2.2). X2.4 Module Cable A thermostatically controlled cartridge heater and solenoid power (optional;...
  • Page 152 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X2.5.1 Actuator Power The minimum wire gauge providing power must be of sufficient size to insure that rated voltage is supplied to the units. The required power for a ½D size power module is 1200 VA, for a D size power module is 2200 VA and for a 2D is 4400 VA.
  • Page 153 Xpac Installation Manual -- Version 5.1 (5/09) REXA Electraulic Actuators & Drives X3 SETUP FEATURES Please refer to Section 6 for a detailed explanation of REXA actuator operation. Section 6.3 should be thoroughly understood and followed before proceeding. In addition to the standard parameters, the D power module redefines two parameters (Low Acceleration and Ac- celeration Breakpoint).
  • Page 154 Xpac Installation Manual -- Version 5.1 (5/09) REXA X-10 Electraulic Actuators & Drives Figure X.1 Speed Profile INTEGRAL Low Acceleration (LA) is the rate at which the speed increases from the Low Acceleration and Accelera- minimum (dL) until either High Speed or the target position is reached. tion Breakpoint provide different Values from 1 to 99 may be selected.
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