Voith WSR-D80112-S User manual

Installation and Operating Manual
Way Valve
WSR-D80112-S
Version 1.5, 2016-02-26
91800271810, Protection Class: 0: Offen (public)

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ublic
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WSR-D80112-S
Contact
2
Contact
Voith Turbo GmbH & Co. KG
Voithstraße 1
74555 Crailsheim, GERMANY
Phone: + 49 7951 32-0
Fax + 49 7951 32-500
E-mail
www.voith.com
Voith Turbo GmbH & Co. KG
After-Sales Service of Business Unit
Electronic Drive Systems
Voithstraße 1
74555 Crailsheim, GERMANY
Phone: + 49 7951 32-470
Fax + 49 7951 32-605
E-mail
[email protected]
Please indicate type and serial number
(see nameplate).
This document describes the state of
design of the product at the time of the
editorial deadline on 2016-02-26.
Copyright © by
Voith Turbo GmbH & Co. KG
This document is protected by
copyright. It must not be translated,
duplicated (mechanically or electron-
ically) in whole or in part, or passed on
to third parties without the publisher's
written approval.

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Contents
Contents
1User Information 5
1.1Identification of text function 5
1.2Safety information 6
1.3Field of application 7
1.4General information 7
1.5Health and safety at work 8
1.5.1Accident prevention 9
1.5.2Environment 10
1.6General description of the way valve 10
1.7Proper use 10
2Technical Data 11
2.1Way Valve 11
3Packing, Storage, and Transportation 14
3.1Packaging 14
3.2Storage and preservation 14
3.3Transport 15
4Design and Functioning 16
4.1Design 16
4.2Function 17
5Installation 19
5.1Notes 19
5.2Mounting 20
5.3Hydraulic connection 21
5.4Electrical connection 22
6Commissioning 23

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Contents
6.1Test run 23
6.2Parameter settings 25
6.2.1Potentiometer effect 26
6.2.2Setting of X0 and X1 potentiometers 27
6.2.3Setting of proportional gains 29
6.2.4Adjustment of operating frequency SF 31
6.2.5Adjustment of the hydraulic center position 31
6.2.6Factory setting 31
7Operation 32
7.1Operation with manual operation knob 32
7.2Normal operation 33
7.3Troubleshooting 33
8Maintenance, Servicing and Inspection 35
8.1Maintenance and Servicing 35
8.2Inspection 36
8.3Spare parts information 37
8.4Seal replacement 37
8.5Replacing the control magnet 38
8.5.1Disassembly 38
8.5.2Mounting 40
8.6Replacement of the hydraulic part 41
8.6.1Disassembly 41
8.6.2Mounting 42
9Decommissioning 43
10Annex 44

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User Information
1 User Information
1.1 Identification of text function
Texts in this installation and operating manual are differentiated as to their function
and are identified accordingly. The following text functions are possible:
Text type Function
A
ction instruction
1st level
1., 2., etc. Prompts an action
A
ction instruction
1st level
a), b), etc. Denotes a section in a sequence of
actions
List

Indicates individual elements of the list
Highlighting

Identifies important comments
Cross-reference Refers the reader to another chapter or
document
Note For useful additional information for
proper handling of the product only
i

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User Information
1.2 Safety information
Safety information is classified as follows:
DANGER
DANGER indicates an immediate threat to a person's life or health. Failure to
observe this note will result in death or most serious injury.
WARNING
WARNING indicates a potentially hazardous situation to the life and health o
f
persons. Failure to observe this note could result in death or most serious
injury.
CAUTION
CAUTION indicates a potential threat to a person's health. Failure to observe
this note may result in minor injuries.
NOTICE
NOTICE indicates potentially imminent damages to property. Failure to
observe this note may result in damage to the product or to other objects.

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User Information
1.3 Field of application
This installation and operating manual applies to the current state of design of the way
valve (see page 2). Subject to design modifications.
The version of this installation and operating manual is shown on the front page, for
the initial document it reads version 1. The version number is always increased by 1
throughout the entire installation and operating manual when the contents are revised.
The following table shows which chapters have been revised.
Version Revision in chapter Remarks
1.1 6.2.5 Adjustment of the hydr.
center position
Description for PI-controller
removed
1.2 10 Annex Outline drawing changed
1.3 Chapter 2.1 Add. installation dir. horizontal
1.4 all revised
1.5 all French speech added
1.4 General information
Installation and Operating Manual
The installation and operating manual contains important information regarding proper
handling of the way valve. Prior to installation and commissioning of the way valve,
carefully read the entire installation and operating manual and make sure you fully
understand its content.
Keep this installation and operating manual in a place that is accessible to the
operator's staff at all times.
In addition to this installation and operating manual, hold the rules governing accident
prevention and environmental protection available and observe the same.
Please keep for later reference.
Warranty
The terms and conditions stated in the General Terms and Conditions of Sale for
Industrial Engineering of Voith Turbo GmbH & Co. KG, Crailsheim shall apply.
Warranty claims are excluded, if these are due to one or several of the following
causes:
Improper transportation, storage, installation, connection, commissioning,
operation, maintenance and repair of the way valve.
Non-observance of the information contained in the installation and operating
manual with regard to safety at work and of the product.
Use of spare parts not approved by Voith Turbo, Crailsheim.

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User Information
NOTICE
During the warranty period, repair work on the way valve may be performed
only with the approval of Voith Turbo GmbH & Co. KG, Crailsheim.
Constructional modifications
Mounting work and structural modifications are not permitted.
The threaded joint of the cable gland on the control magnet (VRM) and the position
pickup is secured against distortion. Do not distort or slacken the threaded joint.
1.5 Health and safety at work
DANGER
For reasons of safety it is not allowed to perform any modifications,
attachments or conversions on the way valve without prior approval by Voith
Turbo GmbH & Co. KG, Crailsheim.
WARNING
Only trained and instructed staff is allowed to work on the way valve. This
staff must be sufficiently trained, instructed and authorized to properly mount,
operate and maintain the way valve in accordance with the safety standards.
The following notes apply to the entire manual and are to be observed in addition to
the individual instructions.

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User Information
1.5.1 Accident prevention
WARNING
Operating medium leaving/leaking out of the way valve may get in contac
t
with hot machine parts, posing a risk of fire.
The way valve is under pressure!
On operation with manual operation knob, uncontrolled piston rod movements
may result posing a risk to persons and property. This movement may pose a
risk to both individuals and objects.
During operation of the way valve, the output pressure may vary severely in
case of a failure of the electric energy or of malfunctions of the control
electronics integrated in the way valve. The piston rod of a hydraulic cylinder,
for example, may move uncontrolled posing a risk to persons or objects.
WARNING
The way valve is a hydraulic unit. In case of improper use, operating medium
being under pressure may leak out. The operating medium poses a risk to the
health and life of the operating staff. Prior to performing any work on the way
valve, switch off the hydraulic supply system.
In case of improper use, operating medium being under pressure may leak
out on the sealing surfaces.
On commissioning or operation of the way valve, spraying hydraulic oil ma
y
get into the eyes causing blindness. Wear safety goggles for all work
performed on the way valve.
During operation, the outer surfaces of the way valve and the hydraulic
connecting lines may become hot due to the operating medium. Any contac
t
may cause injuries by burning. Prior to performing any work on the way valve,
let the way valve cool down.
CAUTION
Prior to performing any work, switch off the hydraulic supply system.
On commissioning or operation of the way valve, the end of the piston rod
directly or indirectly driven by the way valve may move uncontrolled in case o
f
a failure of the hydraulic or electric energy, due to malfunctions in the maste
r
control or on the way valve. This movement may pose a risk to both
individuals and objects. Prior to performing any work on the way valve, switch
off the hydraulic and electric auxiliary energy.

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User Information
NOTICE
Electrical components are integrated in the way valve. These components
may be destroyed, e.g. when performing electric welding work near the way
valve. Prior to performing any electric welding work near the way valve,
remove all electric connecting lines.
1.5.2 Environment
NOTICE
On assembly, disassembly or improper use of the way valve, operating
medium may leak out. Operating medium getting into the sewage system o
r
open soil causes severe environmental damages. Collect any leaking
operating medium and dispose of it in accordance with the national statutory
provisions.
1.6 General description of the way valve
In hydraulics, a "Voith way valve" serves to release, block or change the flow direction
of the hydraulic fluid by converting a setpoint signal, 4mA to 20mA, into a linear
movement of the control piston.
The way valves differ according to the following main features:
1. Number of positions
2. Number of flow routes
3. Number, size and kind of connections, e.g. nominal diameter, thread, ...
'Voith way valves' are suitable for fixing to hydraulic cylinders or to adapter plates and
4-way blocks.
1.7 Proper use
The way valve serves to transform an electric set signal, e.g. 4 - 20 mA into a flow rate
variable in direction and size. This allows, for example, remote-controlled, infinitely
variable adjustment of a hydraulic positioning cylinder with spring resetting for the
positioning of control valves on turbo machinery.
The maximum pressure indicated in the installation and operating manual must not be
exceeded.
Proper use also includes observing this installation and operating manual and
complying with the inspection and maintenance instructions.

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Technical Data
2 Technical Data
2.1 Way Valve
General data
Way valve type WSR-D80112-S
Article number 22000106810
Operating Manual No. 91800271810
Product identification See nameplate
Ingress
protection IP 65 as per EN 60529
Ambient temperature for operation TA -20 ... +70 °C
Ambient temperature (storage) -20 ... +80 °C
Installation conditions Indoor installation
Outdoor installation
Offshore
Industrial
atmosphere
Hydraulic Data
Supply pressure P
permissible pressure range 1 … 25 bar
Maximum pressure 25 bar
Return pressure T -0.05 … 0.2 bar
Flow rate P A,B at p = 4 bar 290 l/min
Flow rate A,B T at p = 4 bar 290 l/min
Operating medium
Type Hydraulic oil as per DIN 51524
Turbine oil as per DIN 51515
High-flash point fluid1)
Oil temperature during operation +10 … +70 °C
Cleanliness grade (ISO VG 4406) - / 16 / 13
Viscosity (DIN 51519) ISO VG 32 … ISO VG 46
Leakage (Toil = 50 °C at 10 bar) < 10 l/min
a) Important note:
The above-mentioned unit with -S marking is a SIL-certified version. Please refer to the nameplate on the
unit as to which type you are using. An additional safety manual is provided for SIL-certified way valves as
well as a Proof Test manual.

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Technical Data
Mechanical data
Way valve design 3/3 4/3
Installation positions
VRM…Voith control magnet
Recommended installation position:
Preferably vertically, control magnet at the bottom
Sealing material FPM2)
Special design4)
NBR
3)
Dimensions, fastening See Chapter 10
Hydraulic connection See Chapter 10
Weight approx. 21
kg
1) According to customer's request or especially for high-flash point fluids
2) Fluor-caoutchouc
3) Acrylnitril-Butadien-caoutchouc
4) According to the customer's specification and consultation with Voith Turbo GmbH & Co.KG

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Technical Data
Electrical data
Supply voltage (power) including residual ripple 24 (+10% / -15%) V DC
Current consumption 1 A, max. 3 A for t < 1 sec
Supply voltage (control) 24 (+10% / -15%) V DC
Current consumption 0.2 A
Control Parameters
Setpoint w for stroke 0% … 100% w = 4.0 … 20.0 mA
Actual value input for stroke 0% ... 100% 20…4 mA
Actual value remote indication for stroke
0% … 100% 4…20 (load 400 max.) mA
Magnetic force switch-off at w < 3 mA
Magnetic force switch-on at w 4 mA
Setpoint limitation
E506 Electronics
E524 Electronics
E530 Electronics
w > 20.2
w > 90
w > 21
mA
mA
mA
Input configuration
E506 Electronics
E524 / E530 Electronics
Applied, related to GND
Isolated (500 k)
Please see the outline drawing in Chapter 10 for further technical data.

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Packin
g
, Stora
g
e, and Trans
p
ortation
3 Packing, Storage, and
Transportation
3.1 Packaging
The way valve is supplied in special packaging. All hydraulic connections are
sealed with protective plugs.
NOTICE
Keep all protective plugs and covers for a possible repacking, furthe
r
transportation, or storage.
3.2 Storage and preservation
The outer surfaces of the way valve are electro-plated. On delivery, the surfaces
of the way valve which are not surface-coated are moistened with preservation
oil.
NOTICE
Within Europe, this preservation is sufficient as corrosion protection for about
8 months. A precondition is that the way valve is stored in a dry location.
If it is intended to store the way valve for a longer period of time, special
precautions have to be taken. Coordinate such precautions for each individual
case with Voith Turbo GmbH & Co. KG, Crailsheim.
NOTICE
The ambient conditions for storage must be within the limits indicated in
Chapter 2.

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Packin
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3.3 Transport
CAUTION
Improper transportation or lifting of the way valve may cause damage to
property and personal injuries.
Ensure, in particular, that no constraining forces act on the cable gland of the
control magnet.
Only use suitable lifting appliances that are in accordance with the safety
regulations to lift the way valve.
For transportation purposes, it is not allowed to keep the way valve connected
to the connecting line.
Never lift or carry the way valve on the cable gland or on the open cable end
of the control magnet.
WARNING
Do not stay below suspended loads.
When transporting the way valve, it may swing or tilt due to fast movements o
f
the lifting appliance or due to eccentricities of center of gravity.
When lifting or while transporting the way valve by means of a lifting
appliance, secure it against swinging and tilting.
NOTICE
Be careful with mounted pipes when lifting the way valve.
Using chains to lift the way valve is not recommended. Chains may damage
the painting or individual parts.
From a weight of 15kg, it is recommended no longer carrying the way valve by
hand.
Fig. 1: Illustration for the lifting

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Desi
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4 Design and Functioning
4.1 Design
The way valve comprises the main functional units:
Voith Control Magnet VRM
Manual operation knob
Retaining clip
Cable gland
Control housing
Control piston
Tappet for power transmission
Control spring
Cover
Fig. 2: Illustration of the way valve
Legend
P = Input pressre
A = Outlet A
B = Outlet B
T = Tank return line
FMag = Magnetic force
Fspring = Spring force
(1)
(1a)(1a)
(1b)
(1c)
(2)
(3)
(4)
(5)
(6)
Fmag
FFed

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4.2 Function
The way valve is an electro-hydraulic positioner with permanently activated way valve.
This enables variable and basically hysteresis-free positioning of a hydraulic cylinder
equipped with a position transmitter and spring resetting.
For way valve operation, an electric and a hydraulic auxiliary energy are required. All
electric controllers and connections necessary for the way valve operation are
integrated in the Voith control magnet (VRM). The control loop parameters and the
parameters to scale the position of the piston rod are set via potentiometers on the
VRM.
Block diagram - way valve
Fig. 3: Block diagram of way valve
Position control
The way valve is controlled by the control system with an electric signal (4 mA to 20
mA) as position setpoint (w) 0% to 100% for a piston rod. In the VRM position control
loop, this setpoint (w) is compared to the actual position (x) of the piston rod
measured by the position pick-up resulting in a change of the magnetic force (FMag)
of the VRM via the magnetic force controller. This magnetic force moves the control
piston of the gate valve against a control spring, thus changing the magnitude and
direction of the flow rate (Q) to the hydraulic cylinder working chamber. The hydraulic
force resulting from the flow rate effects a movement of the piston rod position (x) in
connection with the compression spring. The piston rod moves into or out of the
actuator with a velocity dependent on the flow rate.
The main control parameters can be adjusted at the VRM from the outside via
potentiometers, thus allowing optimum adjustment of the control for various cylinders
and allocation of the required stroke range to setpoint w.
Function of manual operation knob
Instead of the magnetic force FMag, a force can be set with the manual operation
knob that is transmitted to the tappet and thus to the control piston via the magnet
armature. This permits a movement of the control piston without electrical connection
to thus connect outlet A with P or T. Thus, the piston rod on a cylinder connected on
outlet A can be moved to a corresponding final position. However, it is not possible to
adjust any desired position.

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Limitation of maximum value
In case of incorrect connection of the setpoint, e.g. by unintentional connection of 24
VDC to the plus-port of the setpoint input, the setpoint current is limited to an uncritical
value by means of an overload protector integrated in the VRM, thus protecting the
way valve control against damage.
24V Control and 24V Power function
During normal operation, both 24V connections have to be connected to the 24V
supply. To switch off the way valve, both 24V connections can be simultaneously
disconnected from the 24V supply.
However, if only the hydraulic part is to be switched into its preferential position with
the way valve and its actual value remote indication remaining active, it is sufficient to
switch off the 24V power; the 24V control may remain connected with the 24V supply.
Thus, a remote indication is available even in a switched-off condition, e.g. for
observation purposes.
Magnetic force switch-off
At setpoint w < 3 mA (wmin) the magnetic force FMag = 0 N and the control piston of
the slide valve are moved uncontrolled into the appropriate end position by the spring
tension FF. This connects outlet A with T and, for example, a valve that is coupled to
the actuator is kept safely in its closed position.

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Installation
5 Installation
5.1 Notes
WARNING
Only staff satisfying the qualifications according to Chapter 1.5 is allowed to
work on the way valve.
Work performed improperly could result in severe injuries.
CAUTION
Electric lines, cable glands, cable entries and electric connections must not be
damaged.
NOTICE
Improper installation of the way valve may cause malfunctioning and
premature failure of the way valve.
Cleanliness is imperative during both installation and connection. Prevent any
impurities (dust, metal chips, etc.) from getting into the interior of the wa
y
valve or into the piping system. Any such impurities may cause damage to the
way valve.
During the installation period, cover and protect the way valve and, in
particular, the electric and hydraulic connections.
Prior to the installation, check the way valve for possible damages.
Hydraulic connections and flange surfaces must not be damaged.
Installation according to the latest design standard.
For dimensions of the way valve, the flange arrangement, and the positions of the
hydraulic connections, please see the outline drawing in Chapter 10.
Please observe, among others, Standard EN ISO 4413 "General rules and safety
requirements for hydraulic systems and their components".

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Installation
5.2 Mounting
DANGER
Any work on the way valve may only be performed in de-energized condition
and with the oil supply system switched off. During installation, the oil and
power supply for the way valve has to be secured against unintentional
switching-on.
WARNING
During mounting, always secure the way valve against tilting, swinging, o
r
falling down!
CAUTION
Wear safety goggles when mounting the way valve.
NOTICE
Mount the way valve in accordance with the permissible installation position
described in Chapter 2.
Flange on the way valve to a hydraulic consumer via the connecting bores
being at the way valve bottom. Use O-rings to the flange surface for sealing.
For position and dimensions of the connecting bores, please see Chapter 10.
Mounting procedure
Unpack and transport the way valve (see Chapter 3).
Transport the way valve as described in Chapter 3.
Observe the installation position (see Chapter 2).
Remove the plug.
Position the way valve on the suitable wiring diagram. Use O-rings on the way
valve for sealing. The customer's connecting surface has to correspond to Ra 
1.6µm and Rmax 6.3µm.
Tighten the fastening bolts. (Observe the tightening torque!)
NOTICE
When mounting ensure that the flange surfaces are clean and the sealing
rings are at their proper position.