Tyco BIFFI EHAS Series Instructions for use

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. [phone] - Fax [phone] - e_mail: [email protected]

MDE142E0 2/60 06/04/04
INDEX
1. FOREWARD 6
2. ACTUATOR FUNCTIONAL DESCRIPTION 7
3. SYSTEM OPERATING PRINCIPLE 10
4. CONTROL SYSTEM FUNCTIONING 11
4.1. Control function 11
4.1.1. Position regulator and speed control 11
4.2. General function 12
4.2.1. Selection between turn clockwise to close or anti-clockwise to close 12
4.2.2. Stroke limit electronic setting 12
4.2.3. Open loop operation 12
4.2.4. Direct / Reverse action 12
4.2.5. Position failure (Jammed) 12
4.2.6. Opening high speed operation 12
4.2.7. ESD operation 12
4.2.8. Internal temperature monitoring 12
4.2.9. Accumulator nitrogen leakage 12
4.2.10. Motor/pump control 13
4.2.11. Language selection 13
4.2.12. Maintenance instruction 13
5. REMOTE CONNECTIONS14
5.1. Analogue input / output 14
5.1.1. Position signal request (input) 14
5.1.2. Process valve position signal (output) 14
5.1.3. Oil level transmitter (output) 14
5.1.4. Oil pressure transmitter (output) 14
5.1.5. Oil temperature transmitter (output) 14
5.2. Digital input / output 14
5.2.1. ESD control (input) 14
5.2.2. Monitor relay (output) 14
5.2.3. Auxiliary relays (output) 14
6. LOCAL OPERATOR INTERFACE 15
6.1. Local operator interface features 16
6.2. Variables, alarms and warnings visualisation 18
6.3. Configuration options 19
6.3.1. Actuator set-up 19
6.3.2. Name plate 19
6.3.3. Valve data 19
6.3.4. Maintenance 19
6.4. Entering the view mode 20
6.5. Entering the set-up mode 20
6.6. Exit from view and set-up mode 20
7. SET-UP MENU 22
8. VIEW MENU 24
9. SET-UP ROUTINES 26
9.1. Stroke limits 26
9.2. Purge 26
9.3. Positioner 27
9.4. ESD Control 27
9.5. Local control 28
9.6. OUTPUT Relays 28
9.6.1. Monitor relay 28
9.6.2. Auxiliary output relays 28
9.7. Fail safe 29

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9.8. Output 4-20 mA 30
9.9. Interlock 30
9.10. Miscellaneous 30
9.10.1. Time and date 30
9.10.2. Factory setting 31
9.10.3. Pump 31
9.10.4. Valve jammed (time) 31
9.10.5. Vem calib. 32
9.11. VALVE DATA ROUTINES 33
9.11.1. Tag name 33
9.11.2. Serial number 33
9.12. MAINTENANCE ROUTINES 33
9.12.1. Set password 33
9.12.2. Clear alarm log 33
9.12.3. Clear recent data log 34
9.12.4. Set maintenance date 34
9.13. Example of set-up routine (Local Control) 35
10.VIEW ROUTINES 36
10.1. Actuator set-up routines 36
10.2. Name plate routines 36
10.3. Valve data routines 36
10.4. Maintenance routines 37
10.5. Example of view routine 38
11.FACTORY TEST CONFIGURATION 39
11.1. Actuator set-up menu 39
11.2. Name plate menu 40
11.3. Valve data menu 40
11.4. Maintenance menu 40
12.EHAS SYSTEM DATA 41
12.1. Working condition 41
12.2. System performances 41
12.3. Electrical and hydraulic features 41
12.4. Hydraulic oil characteristics 41
12.5. Valve torque requirement 41
12.6. Actuator performances 41
13.INSTALLATION INSTRUCTIONS 42
13.1. Assembling the actuator on the valve 42
13.2. Setting of the mechanical stroke limits 43
13.3. Instruction for start up 43
13.3.1. Hydraulic controls 43
13.3.2. Electric connections 43
13.3.3. Start up 45
13.3.4. Purge operation 45
14.MAINTENANCE 46
14.1. Standard maintenance 46
14.2. Special maintenance 46
15.TROUBLE-SHOOTING 46
15.1. The display is off when the actuator is powered 46
15.2. The electronic control logic works but there is an alarm 47
16.MAIN COMPONENT PART LIST TABLE 49
16.1. Control cabinet 50
16.2. Hydraulic cylinder /quick exhaust valve 51
16.3. Actuator spring cartridge) 52

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16.4. Actuator scotch yoke mechanism 53
16.5. Position transmitter and limit switch assembly 54
16.6. Hydraulic Control Unit (HCU) 55
16.7. Motor Control Unit (MCU) 56
17.OPERATING DIAGRAM57
17.1. Hydraulic operating diagram SLASDOO2 57
17.2. Wiring diagram SE 89B-173A/B 58

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NOTES:
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REVISION LIST
018/10/2002 Issue document R.Z A.A.
Rev. Date Description Prepared Approved

MDE142E0 6/60 06/04/04
1. FOREWARD
The 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).
The units are provided with display and non intrusive push-buttons/selector to allow local actuator
control, configuration and diagnosis operations. A powerful, memory resident, diagnostic function
monitor the correct operation of the actuator and generates an alarm when failure occurs.
HPU
Hydraulic Power Unit HCU
solenoid valve control unit
MCU
Microprocessor Control Unit
OLGAS
Hydraulic Spring return
Actuator
MV
Modulating Valve
PT
PositionTransmitter
Valve position request(REQ)
Electric supply
Valveposition (FB)
EHAS
push-buttondisplay
Hydraulic HA Accumulator

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2. ACTUATOR FUNCTIONAL DESCRIPTION
The EHASactuators are equipped with the following main components:
1. Oil pressure transmitter
2. Oil temperature transmitter
3. Oil level transmitter
4. High pressure filter with clogging indicator junction box
5. Oil reservoir
6. Hydraulic accumulator
7. Quick opening piloted valve
8. Transmitter terminal block enclosure
9. HCU Hydraulic solenoid valves Control Unit
10. Hydraulic power unit electric motor
11. MCU local interface operator with pushbutton/selector and display
12. Hydraulic power unit pump
13. Hydraulic suction filter
14. Actuator position transmitter/limit switches enclosure
15. MCU Microprocessor Control Unit with terminal block enclosure
16. Hydraulic power unit cabinet

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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.
When the pressure value, due to the actuator movement, slow down at the logic valve lower set point, the
discharge valve closes and the oil is send again to the hydraulic accumulator.
The movement and the direction of the motion occurs by controlling the oil pressure value of the cylinder
chamber of the OLGAS ACTUATOR.
The speed of operation is controlled by the MCU (954) in function of the difference (ERROR) between
the actuator position signal EPT (41), called feed-back (FB) and the position request signal (REQ) as
described on par.4.2.1.

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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.
4.2.2) the (MCU) energise the solenoid valve (401A) which opens allowing the oil flows from the
accumulator to the cylinder chamber, the pressure value in this chamber increases and the piston force
compress the spring and moves the actuator towards closing direction.
c) Stop in position
When, during the movement, the position of the actuator approaches the requested position, the MCU
adjust the pressure in the cylinder chambers to minimise the speed of operation.
As soon as the position of the actuator reaches the range of permitted error (DEAD BAND), the MCU de-
engines all solenoid valves causing the actuator to stop.
d) Opening high speed operation
When the 4-20 mA signal (REQ) change from low to higher value with a variation speed higher than 32
mA/sec, the MCU energise the solenoid valve (399) which allows that the pilot valve (998B) opens
discharging quickly the cylinder chamber pressure. In this condition the actuator speed reaches a speed of
180°/sec (equal to 0,5 sec from fully close to fully open position).
e) ESD operation
When a dry contact in the control room is opens (ESD) the MCU ignore the 4-20 mA signal (REQ) and
moves the actuator to the open position with a speed of 13-15°/sec (equal to 6-7 sec from fully close to
fully open position).

MDE142E0 10/60 06/04/04
3. SYSTEM OPERATING PRINCIPLE
The MCU drives the HCU 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)’’ and (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.
The following figure represents the block diagram of the positioning system.
The modulating operation is performed as follows:
⇒-if the (REQ) signal decreases in comparison with the ‘’present valve position’’ signal, the position
regulator generates the voltage (see paragraph 4.2.1) that, through a power module, will power the
coil of the proportional solenoid valve, in close direction, to decrease the position and close the valve.
⇒- if the (REQ) signal increases in comparison with the ‘’present valve position’’ signal, the position
regulator generates the voltage that, through a power module, will power the coil of the proportional
solenoid valve, in open direction, to increase the position and open the valve.
⇒if the “ position request variation ” is greater than 32 mA/sec., the high speed solenoid valve is
energised to open the valve in a short time.
⇒When a dry contact in the control room is opens (ESD) the MCU cut-off the 4-20 mA signal (REQ)
and moves the actuator to the open position with an established speed (equal to 6-7 sec from fully
close to fully open position).
When the (ESD) contact is restored, the control returns to the (REQ).
⇒If the (REQ) signal do not change for 15 minutes the MCU stop the motor. The motor will restart as
soon as the (REQ) signal change or when the accumulator pressure slow down to the minimum and
the pressure switch (PS) change over its contact.
⇒a pressure switch monitors the hydraulic pressure and generates an alarm if the pressure do not
increases within an established time
⇒in case of loss of 3ph 380 V power supply the actuator remains in service until the hydraulic pressure
is available
⇒in case of UPS supply failure the actuator remains in stay-put.
High speed
control
HPU control
ESDCONTROL
open
close
Valve
position
signal (FB)
POSITION LOOP
PS
Pressure Switch
PT
PositionTransmitter
HCU
Proportional solenoid
valves
OLGAS
Spring return Hydraulic
Actuator
MCU
Microprocessor
Electronic Control
Position request (REQ)
Power supply 3ph 380 V
PIPELINE
MODULATING
VALVE
POSITION RE-TRANSMISSION
AUTOMATIC NOT AVAILABLE
OR WARNING
HPU
Hydraulic Power Unit
EHAS BLOCK DIAGRAM
High speed
solenoid valve
END of TRAVEL CONTACTS
Supply from UPS 230 V