Vexve Hydrox HCU Remote User manual

Hydrox™ HCU Basic
installation, operation and maintenance manual

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Contents
1. General 4
2. Control unit identification 5
3. Unloading and storage 6
4. Control unit installation 7
5. Maintenance 8
5.1 Oil change 8
5.2 Battery replacement 9
5.3. Spare components list 10
6. Operation 11
6.1 Manual operation with Hydrox Control Unit (HCU) Basic 11

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NOTE:
This manual must be read and its instructions must be followed when installing,
operating and/or performing maintenance on the control unit or its equipment.
These instructions are of general nature and do not cover all possible operating scenarios. For more
specific guidance on the installation, operation and maintenance of the control unit or its suitability for
an intended use, please contact the manufacturer.
Vexve Oy reserves the right to make alterations to these instructions.
Vexve Oy is not responsible for damages caused by incorrect transportation, handling, installation,
operation or maintenance. Furthermore, Vexve Oy is not responsible for damage caused by foreign
objects or impurities.
Warranty
Warranty according to Vexve Oy’s “General terms and conditions of sale”.
The warranty covers manufacturing and material faults. The warranty does not apply to damages
caused by inappropriate installation, operation, maintenance, or storage ie. these instructions must be
followed for the warranty to apply. Vexve Oy requires that any faulty products under warranty are to
be returned to the factory for inspection. Only after the product has been found faulty, Vexve Oy can
grant compensation.
Please refer to Vexve Oy’s “General terms and conditions of sale” for detailed warranty clauses. The
document is available from the manufacturer.
Warnings and symbols
Ignoring the warnings and symbols may lead to serious injury or equipment damage. Persons
authorized to use the equipment must be familiar with the warnings and instructions.
Appropriate transportation, storage and installation as well as careful commissioning are essential to
ensure faultless and stable operation.
The following symbols are used in this manual to draw attention to actions essential to ensure the
proper use and safety of the device.
Meaning of the symbol: NOTE
The NOTE symbol is used for actions and functions that are essential for the proper use
of the device. Ignoring this symbol may have harmful consequences.
Meaning of the symbol: WARNING
The WARNING symbol is used for actions and functions that, if carried out incorrectly,
may lead to injury or equipment damage.

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1. General
Vexve Oy’s Hydrox control units are the best
solutions for controlling the Hydrox actuators.
Control units are specifically designed to
operate seamlessly with Hydrox actuators
and therefore with Vexve and Naval ball and
butterfly valves. The Hydrox control unit is the
perfect solution for easy and reliable operation
with minimum need of maintenance and with
maximum safety at all times.
NOTE:
When intending to use the control unit with actuators from other manufacturers than
Vexve Oy please contact Vexve Oy to ensure its suitability.
For detailed technical information including dimensions and weights, pressures etc. please refer to
Hydrox Product catalogue or data sheets (www.vexve.com).

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2. Control unit identification
Figure 1. Identification plate.
The identification plate locates at the control unit’s side. It has the following information:
1. Control unit type
2. Product no
3. No. of control valves
4. Max. pressure
5. Fluid viscosity
6. Casing IP-rating
7. Dry weight
8. Producer
9. Trademark
10. Producer’s website
11. Manufacturing year
Type: Hydrox Control Unit Basic
Product no:
No. of control valves:
Max pressure:
Fluid viscosity:
Casing IP-rating:
Dry weight
814000
4 pcs.
350 bar
10–500 mm2/s
IP34
54 kg
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3. Unloading and storage
Check that the content of the delivery is as
ordered. Check that the control unit and related
equipment have not been damaged during
transportation.
Store the control unit carefully before
installation, preferably in a well-ventilated, dry
place, on a shelf or a wooden grid to protect it
from rising damp.
Protect the cabinet’s ingoing components
from sand, dust, water, moist and other
contamination.
Protect bare metal surfaces with anti-corrosive
agent before storage.
The control unit must be transported to the
installation site in a sturdy package. Do not
remove any protectors before installation.
Protect the control unit from dust and other
impurities.
Take the weight of the control unit and its
equipment into account when handling them.
The maximum storage time is two years.
Packaging:
Vexve’s products are protected during
transportation with special packaging. The
packaging consists of environmentally friendly
materials that are easy to sort and recycle.
Recycling the packaging materials at
designated waste collection points is
recommended.
The following packaging materials are used:
wood, cardboard, paper, and polyethylene
sheets.
Recycling and disposal
Nearly all parts of the control unit are made
of recyclable materials. The material type is
marked on most parts. Separate recycling and
disposal instructions are available from the
manufacturer. The control unit can also be
returned to the manufacturer for recycling and
disposal against a fee.

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4. Control unit installation
Figure 2. Mounting holes.
See figure 2.
Control units must always be installed securely to the plinth with four screws from the corners (1). The
plinth must be installed to the ground according to the instructions on the plinth. Cabinets must be
mounted and used in the position according to the drawing below.
Preparations before comissioning:
·Make sure the hydraulic connections are clean.
·Keep all protective caps on the hydraulic connections until hoses are connected. This is for
preventing the system and its components against contamination.
·Check that all bolts and hydraulic couplings are fastened. The control cabinets are always pressure
tested and verified before delivery. However, during delivery, the threaded connections can loosen
and therefore this should be controlled before pressurizing the system.
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Hydrox control units need only little maintenance.
The correct choice of control unit, valve and actuator combination as well as careful installation,
commissioning and use significantly reduce any need for maintenance.
We recommend checking the following periodically to ensure long-term operational reliability, even
when seldom used (around ten times a year or less):
Approximately six months after commissioning and then once a year, check the functionality of the
control unit, inspect the control unit for oil leaks (carefully tighten if any leakages occurred) and ensure
the tightness of the hydraulic hoses between the control unit and actuator. Test also the functionality
of the position indication box.
5. Maintenance
5.1 Oil change
Oil changes are necessary and depend on the size of the system. Under clean conditions, it is
recommended that the condition of the oil is inspected approximately every two years and that the
oil is replaced at every second inspection. If dirty/low-quality oil is used, oil changes are necessary at
shorter intervals. Because the small oil volume in part-turn actuators compared to the volume in the
pipework, there is no oil change during the operating cycles. Because of this, it is recommended to
change the hydraulic oil so that the oil changes also inside the part-turn actuator and hoses not only in
the hydraulic pump.

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5.2 Battery replacement
See figure 3.
Battery must be tested by pressing the test button on the indication box during the maintenance
periods.
Following steps are needed to replace the battery:
1. Loosen the corner screws (1) of the position indication box and pull the front plate gently. Note
that the wires inside the box should not be loosened.
2. Replace the battery (2) with a similar one.
3. Close the indication box by mounting the front plate and tightening the corner screws.
Figure 3. Battery replacement.

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5.3. Spare components list
Figure 4. Parts.
Part
1 Control block with directional control valves
2 Lever
3 Position indication box
4 Battery for the position indication box
5 Plinth
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6. Operation
6.1 Manual operation with Hydrox Control Unit (HCU) Basic
Part numbers mentioned in this chapter refer to the figure 5.
Up to four valves can be connected and
operated with the Hydrox Control Unit (HCU).
Following initial steps are needed for taking the
system into use:
Systems without position transmitter:
1. Connect the hydraulic hoses to the
actuator’s connections “A” and “B”. Do
not tighten them fully.
2. Connect the hydraulic hose from actuator
port “A” to the first cabinet control block
port “A” and for port “B” vice versa. Check
figure 5.
3. Fill in the portable pump tank with
hydraulic oil.
4. Connect the hoses of portable pump to
the first couplings of the control block
with quick couplings.
5. Connect the power cable of portable
pump unit to electric grid and start the
pump with the green button.
6. To bleed the system, switch the hand
levers of the first valves (2) A and B in the
control valve block into the open position.
The port that is connected to the pressure
side hose of the portable pump unit is
pressurized. Let the air bleed out of the
loosened hydraulic connector on the
actuator. Repeat the foregoing procedure
for the hose connected in the port B by
switching the hoses to dierent ports or
by turning the lever in the portable pump
unit to change the pumping direction
depending on the portable pump type.
7. During bleeding process check the oil
level of the portable pump’s tank and refill
the tank if necessary.
8. Tighten the hose connections on the
actuator.
9. Repeat the foregoing steps (4-8) with the
other valves.
When commissioning of the system has
successfully finished you can continue with the
operational steps to open or close the valves:
10. Choose the valve to be operated and
switch valves for both A and B ports to
the open position.
11. By operating the portable pump unit
the valve turns in the chosen position.
Pressure to port A closes the valve and
pressure to port B opens the valve.
12. Actuator’s indicator slot (4) will show the
valve’s position.
13. When shutting the valve observe that the
actuator’s indicator slot turns into close
position and the pressure level starts
to increase. To ensure that the valve is
closed, continue pumping for a while after
the pressure rises. Pressure can be seen
from the pressure gauge at the pump
unit.
14. When opening the valve observe that the
actuator’s indicator slot turns into open
position and the pressure level starts to
increase.
15. After the wanted operations are done,
stop the portable pump unit with the red
button.
NOTE:
Please contact Vexve Oy if you intend to use the control unit with other actuators than
Hydrox.
When bleeding the system the hydraulic connectors must be loosened in the hydraulic
actuator. Otherwise the valve could change its position.

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B
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Systems with position transmitter:
1. Connect the hydraulic hoses to the
actuator’s connections “A” and “B”. Do
not tighten them fully.
2. Connect the hydraulic hose from actuator
port “A” to the first cabinet control block
port “A” and for port “B” vice versa. Check
figure 5.
3. Fill in the portable pump tank with
hydraulic oil.
4. Connect the hoses of portable pump to
the first couplings of the control block
with quick couplings.
5. Connect the power cable of portable
pump unit to electric grid and start the
pump with the green button.
6. To bleed the system, switch the hand
levers of the first valves (2) A and B in the
control valve block into the open position.
The port that is connected to the pressure
side hose of the portable pump unit is
pressurized. Let the air bleed out of the
loosened hydraulic connector on the
actuator. Repeat the foregoing procedure
for the hose connected in the port B by
switching the hoses to dierent ports or
by turning the lever in the portable pump
unit to change the pumping direction
depending on the portable pump type.
7. During bleeding process check the oil
level of the portable pump’s tank and refill
the tank if necessary.
8. Tighten the hose connections on the
actuator.
9. Repeat the foregoing steps (4-8) with the
other valves.
10. Connect the position transmitter (5)
cables to the indication box (3).
11. Turn on the valve limit position indication
box.
12. Test the functionality of the LEDs by
switching the “TEST” knob (3).
When commissioning of the system has
successfully finished you can continue with the
operational steps to open or close the valves:
13. If there has been a lot of time of the
commissioning, test the functionality of
the LEDs by switching the “TEST” knob
(3).
14. Choose the valve to be operated and
switch valves for both A and B ports
to the open position.By operating the
portable pump unit the valve turns in the
chosen position. Pressure to port A closes
the valve and pressure to port B opens
the valve.
15. The limit position indication box will show
the valve’s position. RED shut; YELLOW
travelling; GREEN open.
16. When shutting the valve observe that
the RED lights up and the pressure level
starts to increase. To ensure that the valve
is closed, continue pumping for a while
after the pressure rises. Pressure can
be seen from the pressure gauge at the
pump unit.
17. When opening the valve observe that the
GREEN lights up and the pressure level
starts to increase.
18. After the wanted operations are done,
stop the portable pump unit with the red
button.
NOTE:
Please contact Vexve Oy if you intend to use the control unit with other position
transmitter than provided by Vexve Oy.
When bleeding the system the hydraulic connectors must be loosened in the hydraulic
actuator. Otherwise the valve could change its position.

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Figure 5. Hydrox Control Unit (HCU) Basic

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TP
www.vexve.com
Vexve Oy
Pajakatu 11
FI-38200 Sastamala
Finland
Tel. [phone]
Riihenkalliontie 10
FI-23800 Laitila
Finland
[e-mail] www.vexve.com
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