Vexve Hydrox hcu remote Manual

Hydrox™ HCU Remote

Installation, operation and

maintenance instructions

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Contents

1. Safety instructions 3

1.1 Oil storage and handling 6

2. General information 7

2.1. General instructions 7

2.2. Important 7

2.3, Risks 7

2.4. Handling 7

2.4.1. Delivery inspection 7

2.4.2. Storage instructions 7

2.4.3. Preparations before

installation 7

2.5. Regular inspections and

maintenance 8

2.5.1. Oil level in the reservoir 8

2.5.2. Temperature and possible

leakage of the pumps, motors

and valves 8

2.5.3. Condition of piping and

hoses 8

2.5.4. Sound of pumps and motors 8

3. HCU Remote Introduction 9

4. Control cabinet overview 11

4.1. Cabinet contents and components 11

4.2. Electrical cabinet overview 12

5. Function description 13

5.1. Overview 13

5.2. Valve control and position indication 13

5.2.1. Valve Selection 14

5.2.2. Opening the valve 14

5.2.3. Closing the valve 15

5.2.4. To stop valve moment 15

5.2.5. Local control buttons 15

5.2.6. Remote control buttons 15

5.2.7. Position indication 16

5.3. Using the manual pump 17

5.3.1. Opening the valve 17

5.3.2. Closing the valve 17

5.3.3. To stop the valve moment 17

5.4. Alarms, information and notiﬁcations 18

5.4.1. Alarm messages 18

5.4.2. Notiﬁcation messages 19

5.4.3. Information messages 19

6. Installation and Commissioning 20

6.1. General information 20

6.2. Control cabinet installation 20

6.3. Power connection 20

6.4. Installation of hydraulic hoses from

control cabinet to actuator 21

6.5. Adding ﬂuid and bleeding

the system 22

6.6. Position transmitter 22

6.7. Conﬁguration 23

6.7.1. Safety valve 23

7. HMI & Control 24

7.1. Control architecture 24

7.2. HMI Navigation and usage 25

7.2.1 Home screen 26

7.2.2 Process diagram and valve

information 27

7.2.3 Valve characteristics and

curve settings 30

7.2.4 Diagnostics 31

7.2.5 Administrator/

User operation level 38

8. Remote-control connection 40

8.1. Physical remote control 40

8.2. Modbus TCP remote control 42

8.3. WebApp remote control 42

9. Troubleshooting 43

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1. Safety instructions

Note

Danger

Harmful / irritating

Use safety glasses

Use protective footwear

Use ear protection

Use protective gloves

Use protective clothing

Use safety helmet

Read user manual

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Personnel

All hydraulic system installation, maintenance and repair work must be overseen by a supervisor and per-

formed by a skilled hydraulic system ﬁtter who is familiar with the operation and structure of the system.

Anyone working with these systems must be made aware of the special requirements of the work, such

as cleanliness.

General safety instructions

Health hazards

Repeated skin contact with mineral oils and certain additives can cause eczema, rash or oil

acne. Inhaled oil mist may also cause respiratory irritation, headache and nausea.

Oil mist spreading into the working area and oil leaking on the ﬂoor and other platforms

increase the risk of slipping.

Noise level in hydraulic systems can be quite high. Always use hearing protection when in

close vicinity of systems in operation. Use ear protection when noise level is over 85 dB.

Burn hazards

The temperature of oil may rise above 60°C. Oil as hot as this may cause burns.

Fire hazard

Oil mist mixed with air may explode even at temperatures below 200°C. Oil may also cause a ﬁre when it

comes into contact with hot machine parts. Oil leaking on the ﬂoor and machine frames and mixed with

dust causes an extremely great ﬁre hazard.

Oil jet hazard

Never handle pressurized hydraulic hoses and similar components with bare hands, since

high-pressure leaks may penetrate the skin.

Always wear eye protection, particularly when working with systems in operation.

Hydraulic pipelines convey pressurized ﬂuid. Any pipe, hose or coupling failure and the

resulting oil burst can create a hazardous situation that may lead to serious injury.

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Hose impact hazard

Pressurized bent hoses tend to straighten and straight hoses start to yaw due to the react-

ing force of the free ﬂuid discharge. Hoses are the weakest components of a hydraulic

system. Always replace old hoses in due time.

Safety during maintenance and repair

The hydraulic system must primarily be depressurized for maintenance and repair. Maintenance during

operation is permitted only where the hydraulic system is designed for such maintenance.

If the system includes pressure accumulators, disassemble the accumulators prior to starting any mainte-

nance work.

When starting maintenance and repair work where the system is ﬁrst depressurized, to avoid indirect

damage, make sure that it is safe to stop the hydraulic system.

After stopping the pumps and prior to starting any work, always eliminate the possibil-

ity of accidental start-up by locking the safety switches of electric motors or, in the

absence of safety switches, by removing the motor fuses. Always place nameplates

at the secured safety switches and removed fuses, identifying the person who carried

out the procedure. Safety locks may only be removed by the person who put them in

place.

Prior to starting any work, make sure that the system section to be serviced is depres-

surized, i.e. the pressure accumulators, pipeline and actuators are unpressurized.

The system is not allowed to be under load during maintenance situations!

Use appropriate tools and methods for all repair and maintenance work. Avoid spilling oil on the ﬂoor and

remove all oil from the ﬂoor immediately. Tighten disconnected pipe and hose couplings immediately after

installation. Prior to completing your work, check and retighten all couplings of the system section that

was serviced or repaired.

Prior to starting any pumps, make sure that the system is not undergoing any other maintenance work.

Maintain a safety distance to the items repaired when starting up the pumps. Before switching the hy-

draulic system on, make sure that there are no open connections in the system anymore. Make sure also

that no one is working between dierent parts because pressuring the system might cause movements in

the system.

When the system is again under pressure, the repaired system section must be tested.

Check the system for possible leaks after repair. Do not tighten leaking couplings while the system is

pressurized.

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1.1. Oil storage and handling

Storage

New oils must be stored in a covered, dry and dust-free space that has a constant temperature. Contain-

ers must be tightly sealed during storage. Barrels must be stored in a horizontal position.

Oil grades must be clearly marked on the containers to avoid confusion.

Substances that will cause a hazardous reaction if they come into contact with each other must not be

stored in the same storage room. The release of chemicals into a sewer system outside the storage room,

or to any other areas where they might create a hazard, must be prevented in a reliable way.

All required absorption agents and other equipment needed to recover leaked chemicals and clean con-

taminated areas must be available.

Handling

Waste oil must be stored in accordance with general and mill-speciﬁc instructions on storing of hazardous

waste.

Used hydraulic oil must be collected in separate containers. All waste oil transport containers must be

sealable, and they must withstand normal storage and transportation. Transport containers must be

clearly marked indicating the type of waste they contain.

All waste must be delivered to the appropriate collection points or for handling.

Used ﬁlters, research equipment, oil samples and waste oil must be handled in accordance with general

and mill-speciﬁc instructions for handling of hazardous waste. Used ﬁlters and ﬁlter diaphragms used in

analyses must be packed into containers. The containers must be marked in accordance with the ap-

plicable instructions on hazardous waste.

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2.1. General instructions

These instructions contain information relating to

the installation of HCU Remote and its handling

in order that the functionality and safety are en-

sured. For situations not covered by this manual

please contact Vexve Oy. The manufacturer

reserves the right to make technical changes

and improvements. This instruction manual

assumes that the user is thoroughly familiar with

the control unit and its components. Installation

of the control cabinet and related work should

be carried out by a professional.

2.2. Important

Before the system is taken into operation, the

following items should be taken into considera-

tion:

· Make sure that the hydraulic system is not

pressurised, and power is turned o before

any work is carried out to the control unit or

its components.

· Do not ever leave any part of the hydraulic

system open to contamination to prevent

damage to the internal components.

· The HCU Remote warranty period is one year

from installation date. (The installation must

be carried out within six months from the

acquisition date. The control cabinet should

be stored according to the instructions)

2.3. Risks

HCU Remote can be used only if the control

cabinet is properly installed and serviced by a

professional. The control cabinet user should be

thoroughly familiar with these instructions. These

instructions are in addition to existing regulations

at the customer’s premises regarding electric-

ity, pipelines and work. It is also essential to use

proper tools and safety equipment.

2.4. Handling

2.4.1. Delivery inspection

· Examine the control cabinet to ensure that

it, or internal components have not been

damaged during transport.

2.4.2. Storage instructions

· Protect the internal parts of the cabinet

from dirt, dust, water and moisture or other

contaminants.

· When the cabinet is supplied with a heater/

cooler and either of these cannot be

installed immediately, the cabinet should be

stored at room temperature. This will avoid

condensation/overheating which could

damage electronic components.

· If the control unit is installed and it is

not possible to connect power supply

immediately, electricity should be applied to

control unit for a while before operating any

valves in order to heat up/cool down the

components before use. Vexve does not take

responsibility of any damage to the control

unit resulting in the missing power supply in

outside environment.

2.4.3. Preparations before installation

· Make sure that the hydraulic connections are

clean.

· Check that all electrical connections are

intact.

2. General information

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2.5. Regular inspections and

maintenance

2.5.1. Oil level in the reservoir

The oil level should be high enough to operate

all the actuators from open to close position and

vice-versa, if problems are suspected due to

lack of pressure or other problems, the oil level

may be low.

2.5.2. Temperature and possible

leakage of the pumps, motors and

valves

The temperature of the pump, motor and valves

is checked by hand contact. If the target is so

hot that the hand cannot be held for longer than

1-2 seconds, temperature is too high. When

the temperature is too high, pumps must be

stopped. The reason for high temperature needs

to be investigated and the fault repaired, or the

component replaced before restarting the pump.

2.5.3. Condition of piping and hoses

The piping must be monitored for pipe and ﬁt-

ting tightness. If the attachment of the pipes has

loosened, they must be tightened. If tightening

does not securely fasten the pipe, the clamp

must be replaced. The ﬁtting must be tightened

if the pipe ﬁtting leaks. If tightening does not

stop the leak, the ﬁtting and possibly the pipe

connected to it must be replaced.

When replacing the ﬁtting and the pipe, they

must be cleaned from the inside to be com-

pletely free of all impurities, including burrs prior

to insertion. Replacement must be carried out

with absolute purity.

When observing the hose, attention should be

paid to the tightness of the attachment and pos-

sible abrasion.

If the hose attachment has become loose, they

must be tightened immediately.

Hoses must be replaced if the tightening does

not help. If rubbing is detected, it is necessary

to secure them in such a way that they will no

longer be rubbed.

The worst-scratched hoses must be replaced.

Before installing a new hose, it must be cleaned

from the inside until completely clean. Replace-

ment must be carried out with absolute purity.

When changing pipes and hoses, open open-

ings must be sealed with a clean plug. The

plug is only removed as late as possible due

to impurities in the ambient air, which must be

prevented from accessing the open hydraulic

circuit.

2.5.4. Sound of pumps and motors

The sound of pumps and motors is heard

by ear. If the sound intensiﬁes or its tone has

changed, it may be a sign of possible damage

of the component. The pumps must be stopped

immediately, and the damaged component

replaced.

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3. HCU Remote introduction

At operational changes, or emergencies, it is necessary to quickly close the valves. Therefore there is

a need to be able to remotely control valves from control centers. HCU Remote is meant for the most

demanding locations where remote control is required. All components are located in a rugged metal

enclosure and the electronics to electrical cabinet with high protection class.

HCU Remote is an electro-hydraulic control unit designed for remote and local operating of valves

equipped with hydraulic actuators. The control unit is equipped with a hand pump, so that actuators can

also be operated without electricity.

Technical properties:

Control unit

· Dimensions 1310 x 895 x 312mm (W x H x D)

· Control unit protection classiﬁcation: IP34

· Inner electrical cabinet protection: IP65

· Fluid viscosity: 10-500 mm2/s

· Filtration: ISO code 16/13;

SAE class 4 or better

· Fluid temperature: -20 °C +80 °C ·

· Ambient temperature range: -25 °C +35 °C

(heating, optional cooling)

Pump

· Motor 0,75kW

· Power supply voltage 400v/3-phase, 50 Hz

· Pump ﬂow rate: 0,1 – 1,26 l/min

· Maximum recommended pressure 210 bar·

· Pressure limiter 150 bar (adjustable)

Oil reservoir

Capacity: 2 liters

Control valve block

· Number of valves: 2-6

· Max. pressure: 210 bar

· 3 valve positions (open – neutral – close)

Electrical cabinet

· Local and remote access switch, safety

switch

· Control panel

· Common operating buttons: Open, close,

stop, emergency stop

Control panel

· Size: 7’’ Simatic

· Valve conﬁguration window

· Position indication: Diode indication for

position 0-100 % open and end positions

· Alarms: Active and old ones

· Diagnostics

Pressure gauge

· Range: 0…250 bar

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Hydrox model Runtime 0-100% (s)

Hydrox 035BP 23

Hydrox 2 65

Hydrox 4 150

Hydrox 8 271

Hydrox 16 504

Hydrox 32 579

Hydrox 64 608

Table 1. Default operation times

The default closing time for each actuator size is

calculated to give a slow closing to minimize the

risk of water hammer in the pipe.

Options Product

no.

Hydrox Control Unit (HCU) Remote -

Locked control cabinet

812010

Hydrox Control Unit (HCU) Remote -

Analogue pressure measurement

812011

Hydrox Control Unit (HCU) Remote -

Wireless remote control

812012

Hydrox Control Unit (HCU) Remote -

For six valves

812013

Hydrox Control Unit (HCU) Remote -

For two valves

812014

Hydrox Control Unit (HCU) Remote -

Cooling

812015

Table 3. Options and product numbers

Model Flow rate Product no.

Hydrox Control Unit

(HCU) Remote

1,27 l/min 812100

Table 2. HCU Remote product number

Product numbers

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4. Control cabinet overview

4.1. Cabinet contents and its components

Part

1 Electrical cabinet

2 HMI

3 Pressure transmitter (optional)

4 Valve block

5 Hand pump pressure adjustment

6 Hand pump

7 Electric Motor

8 Hydraulic Pump

9 System cabinet

10 Safety valve

11 Pressure gauge

12 Oil reservoir

13 Plinth (purchased separately)

Table 4. Contents and componets of cabinet

Figure 1. Cabinet overview

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4.2. Electrical cabinet overview

Figure 2. Electrical cabinet overview

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5.1. Overview

The Hydrox HCU Remote is designed to control between 2 and 6 valves operated with hydraulic actuators

and used in dierent applications. These actuators are operated by a semi-closed loop system which al-

lows the operation of speciﬁc valves by opening/closing them in a controlled manner through the manipula-

tion of oil pressure using an inverter-controlled pump. For control of the hydraulic pump and the solenoid

valves by inverter, programmable logic is used. The operational behaviours of the valves are conﬁgurable.

The system is enclosed in a cabinet which is a compound hydraulic/electrical system. Inside this cabinet

there is a pump with a small oil container and variable number of selector valves (2-6) as seen in section 4.

This unit can be controlled both locally and remotely. Local control relies on buttons located on electri-

cal cabinet door and a Human Machine Interface (HMI) that allows monitoring of valve position as well as

control and conﬁguration of the system. For more information on how to control the system via HMI please

refer to section 5.2. Remote control can be enabled through various means:

· Modbus Holding Registers (HR)

- Through physical Modbus TCP connection

- Through VPN Modbus TCP connection

· Physical remote I/O

· PLC WebApp directly available via VPN connection

For more information on remote control options, please refer to section 8.

5.2. Valve control and position indication

A Local/Remote selector can be found on the side of the electrical control cabinet. This allows the user

to change the operational mode of the system. If “Local” is selected all remote operations are blocked, if

“Remote” is selected the system may be operated remotely. Disabling remote operation when in “Local”

operation is a critical safety feature for operating personnel.

Regardless of whether the user is controlling the system locally or remotely, there will be a “User Interface”

(UI) available to the user. While some aspects of the UI may be dierent in dierent control modes; the

manner of interaction will generally be the same. This section of the manual addresses only the general op-

eration of valves, for speciﬁc details on the usage of the HMI or remote operations please refer to sections

7 and 8 respectively.

Only one valve may be operated at a time, which is selected via an HMI screen that provides an interface

to the operator. Local control relies on buttons located on electrical cabinet door. There are common but-

tons for open, close and stop. Valve selection is usually achieved by clicking on the valve icon that the user

wishes to operate or by pressing the button associated to said valve, regardless of the UI used. The UI will

look similar to the image seen in Figure 3.

NOTE:

For simplicity, many other elements usually present in the UI were removed from

the following ﬁgure. The reader can get acquainted with these elements in the afore-

mentioned sections.

5. Function description

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Element 3 as in table 5 can be either a representation of a physical function button to press, as it would

be in the case of the HMI, or an actual button to click on in the case of the WebApp. Clicking on either

option will select the valve and enable access to the open/close functions.

5.2.2. Opening the valve:

1. Once the valve is selected, press the OPEN button.

2. The pump starts to open the valve according to the conﬁgured operational behaviour curve

(see section 7.2.3).

3. The pump will automatically stop when the valve reaches the open position.

Element

1 Valve number

2 Valve representation

3 Valve button

Table 5. Generic UI description

5.2.1. Valve Selection

Figure 3. Generic UI

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5.2.3. Closing the valve:

1. Once the valve is selected, press the CLOSE button.

2. The pump starts to close the valve according to the conﬁgured operational behaviour

curve. (see section 7.2.3).

3. The pump will automatically stop when the valve reaches the closed position.

5.2.4. To stop valve movement

1. If you wish to stop the control process, press the STOP button.

2. The valve stops at its current position until a new signal is given (OPEN/CLOSE)*

*Hydraulic actuators, which are equipped with a control block.

5.2.5. Local buttons

In the case of local control, the OPEN/CLOSE/STOP buttons are physical and look as shown in ﬁgure 4.

5.2.6. Remote control buttons

In the case of remote control (WebApp VPN), the OPEN/CLOSE/STOP buttons are virtual and look as

shown in ﬁgure 5.

Open Close Stop

OPEN

VALVE

VALVE STOP

Figure 5. Remote buttons

Figure 4. Local buttons

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Valve indication can be observed mainly from elements 1 and 2. These elements show the percentage

of valve opening as well as visually represent an approximation of the current position of the valve. The

open/closed indicators in element 3 light up when the valve reaches its end position. The other elements

show other relevant values of the valve during operation. These values are addressed in more detail in

other sections of this document. Digital signals are used to stop the opening/closing cycle. The analogue

position signal (4-20mA) is used for indicating the continuous position of the valve.

Element

1 Valve open percentage (0-100%)

2 Valve open/close indicator ﬂap

3 Valve and general status

4 Valve operational values

Table 6. Valve indicators

Figure 6. valve position indication

5.2.7. Position indication

In a similar manner to valve control, position indication is addressed in the same way via dierent UI’s.

Figure 6 shows a generic view that will be available to the user for both local and remote (WebApp) visu-

alization.

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5.3. Using the manual pump

In the event of a power failure, or some other

kind of partial control failure, valves can be

operated locally using the manual pump. This is

accomplished by using a hand operated pump

and control lever located above the valve block

and next to the hydraulic pump.

NOTE: The control levers are

spring return and thus keep

their position. The user must

hold the push-pin nut in the

desired position throughout

the operation. This is a safety

feature, which ensures that

the directional control valve

is returned to neutral position

when the operating cycle is

completed.

5.3.1. Opening the valve:

1. Select the desired valve.

2. Press the control push-pin nut on the top

of the valve down, (See ﬁgure 7, arrow 1)

towards the valve block and hold it.

3. Pump the hand pump.

4. The pressure increases signiﬁcantly when

the valve reaches the open position. Make

sure that the valve has reached the end

position by watching the position indicator

in the HMI on the electrical cabinet. If there

is no power, continue pumping for a brief

period after the pressure has risen.

5.3.2. Closing the valve:

1. Select the desired valve.

2. Press the control push-pin nut on the

bottom of the valve up, towards the valve

block (see ﬁgure 7 arrow 2), and hold it.

3. Pump the hand pump.

4. The pressure increases signiﬁcantly when

the valve reaches the closed position.

Make sure that the valve has reached the

end position by watching the position indi-

cator in the HMI on the electrical cabinet. If

there is no power, continue pumping for a

brief period after the pressure has risen.

5.3.3. To stop valve movement:

1. Stop pumping and release the control

lever, if you want to stop valve movement.

2. The valve stops at its current position until

operation of the hand pump continues. *

* Hydraulic actuators, which are equipped with a

control block

Figure 7. Control push-pin nut

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5.4. Alarms, information and notiﬁcations

The HCU Remote system manages alarms, information and notiﬁcation messages dierently. Each of

these provides a speciﬁc type of information and can be triggered by either a user action or a fault in the

system. Depending on this category, an acknowledgment is required or not. Table 7 clariﬁes the dier-

ence between these three categories. Please note that these categories apply only to the Local HMI.

5.4.1. Alarm messages

Alarms in the Hydrox HCU Remote system vary depending on the point of access. Table 8 shows the ex-

isting alarms, their descriptions and their availability depending on the remote installation, should it apply.

Alarms must be acknowledged in the Local HMI and the WebApp, but not in remote applications. When

an alarm is triggered a message will popup and the user must acknowledge the message by pressing the

appropriate button. Only then will the message disappear from the screen. Troubleshooting, see section 9.

Message category Acknowledgement required

Alarm Yes

Notiﬁcation Yes

Information No

Table 7. Message categories

Alarm Description Local Remote

(WebApp)

Remote

Modbus

Remote

Physical

E-Stop Alarm E-Stop button is triggered X X X

Motor Fault A problem occurred with the motor X X

Tmax Alarm Maximum operating time when opening/closing

valve has elapsed X X

Pmax Alarm Maximum setup pressure exceeded X X

Duplicate Valve

Operation

User attempted to operate another valve

at the same time X X

Global system fault

alarm There is some sort of error in the system X X

Global process

fault alarm There is some sort of error in the process X X

Valve 1 position