电液转换器使用说明书

电液转换器原理与调试电液转换器（Electro-Hydraulic Converter）是一种将电能转换为液压能的装置，广泛应用于工业控制系统中。

它的工作原理是通过电信号控制阀门的开关，从而改变液压系统中液压元件的工作状态，实现对液压系统的控制和调节。

液压系统中的元件包括液压缸、液压马达、液压阀等。

通过控制电动机的启动和停止，可以实现对液压泵的启动和停止。

而通过控制液压泵的工作状态和输出压力，可以实现对液压缸等液压元件的运行速度、位置和力度的调节。

为了能够更好地控制液压系统，通常还需要使用电子控制器。

电子控制器通过接收电信号，并进行处理、转换和放大等操作，将电信号转换为适合液压系统的控制信号。

控制信号通过控制液压阀的开关，从而实现对液压系统的精确控制。

调试电液转换器需要根据具体的应用需求和设计要求进行。

首先，需要检查液压系统中液压油的质量和量，确保系统正常工作。

同时，还需要检查液压泵的工作状态和压力参数，确保其输出符合要求。

在调试过程中，还需要对液压系统中的液压元件进行校准。

校准包括对液压阀的开关状态进行调节，以及对液压泵的输出压力和流量进行调节。

调节液压元件的工作参数可以通过改变电子控制器的工作状态和参数实现。

在进行调试时，还需要密切关注液压系统中的压力和流量参数。

通过检测压力和流量的变化情况，可以判断液压系统的工作状态是否正常，以及控制效果是否达到预期。

此外，在调试过程中还需要注意安全问题。

液压系统中会产生高压和高温的工作环境，需要采取相应的安全措施，防止事故发生。

总结起来，电液转换器通过电能转换为液压能，实现对液压系统的控制和调节。

在调试过程中，需要检查液压系统的各项参数，校准液压元件的工作状态，并关注压力和流量的变化情况。

同时，还需要注意安全问题，确保调试过程的顺利进行。

数字电液转换器DEH运行操作2.1 前言根据系统设计、组态结果及WoodWard505数字控制器操作程序，结合我厂提供的配置本产品的汽轮机启动要求，特编写运行规程仅供运行人员作为操作指导。

本章主要在以下几个方面，阐述控制器在机组控制中的基本操作：2.1.1启动前的准备检查；2.1.2升速控制；2.1.3并网、升负荷及负荷控制；2.1.4甩负荷；2.1.5超速试验；2.1.6停机。

2.2 启动前的准备、检查在控制器投入运行前以下的准备及检查工作必须进行且没有遗漏2.2.1确认控制电源为AC220V且已正确接入相应端子：L、N、G。

2.2.2确认与控制器相连的所有信号均正确无误，电缆符合要求，屏蔽线控制器内连接接地。

2.2.3控制器上电后，确认专业工程师已将最终的组态软件已存入控制器中。

2.2.4控制器上电后，确认无故障报警，机组已具备冲转条件，油动机符合静态试验要求：2.2.4.1油动机及油系统已具备试验条件；2.2.4.2汽机505复位,保护复归，磁力断路油门复位；2.2.4.3按伺服阀控制器说明书进行阀门校验；2.2.4.4校验完后，通过在伺服阀控制器端子上接入4-20mA信号校验，验入4mA 油动机是否刚开20mA时，验入20mA 油动机是否全开，若满足要求则油动机静态试验完成。

2.3 升速控制运行人员在控制器操作盘上按“RUN”前，先要就地将机组挂闸，自动主汽门开启操作，接下来确认控制器显示屏上无影响启机及运行安全的故障报警。

2.3.1按“RESET”清除跳机信号和故障报警信号。

2.3.2 在Controlling ParameterPush Run/Rrogram显示时按“RUN”后汽机冲转。

2.3.3显示屏将显示实际转速（Speed）及状态信息“Status Mvg Low Idle”即Speed xxxxRPM 实际转速Status messagel 信息（屏1）messagel “Mvg Low Idle”（正向第一暖机点升速。

VOITH电液转换器使用说明书型号：DSG-BXX113目录1.技术数据 (1)2.安全指示 (3)2.1 提示和标志的定义2.2 正确使用2.3 重要提示2.4 担保3.功能描述 (6)3.1 设计3.2 操作特点4.包装、储存、运输…………………………………………75.安装…………………………………………………………85.1 组装5.2 液压连接5.3 电器连接6. 试运行 (10)6.1 运行检测6.2 参数设定7.操作 (11)7.1 用手动旋钮操作7.2 用设定信号操作7.3 故障检修和排除8. 维护和检修…………………………………………………9. 停机…………………………………………………………1、技术数据：周围环境：储存温度－40 (90)工作环境温度－20 (85)保护IP65 to EN 60529适合于在工业空间内部安装电气数据：电压：24 VCD ±15%电流：大约0.7A（对DSG-B05…DSG-B10型）大约1A（对DSG-B30型）最大3A 时间t ‹1 Sec输入设置：0/4…20mA输入阻抗大约25欧姆，具有抑制电路。

液压参数：最小进口油压P in min： 1.5bar＋最大输出P A max(对B05…B10型)5bar＋最大输出油压P A max(对B30型)最大进口油压P in max ：见表压力流体：不易燃烧的原油或压力油油粘度：根据DIN51519，ISO VG32…ISO VG48油温：＋10℃ (70)油纯度：根据NAS1638为7级根据ISO4406为-/16/13级泄漏量：当进口油压P in=10bar 时≤3 l/min (对DSG-B05…DSG-B10 ) 当进口油压P in=40bar 时≤5 l/min（对DSG-B30）P A最小值调整范围处决于P A最大值的设定值.。

上面表中所示P A最小值的调整范围参考P A max的最小调整值机械参数：安装尺寸：见第十章液压连接：见第十章安装位置：见第十章密封材料：FPM重量：大约12kg2.安全指示：2.1提示和标记的定义：危险：这标志标示对人的生命和健康带会带来危险，如不遵照此提示，将会对健康发生危害，甚至发生更加严重的损害。

E360电液转换器说明书1.0版1.0 电液转换器-选项2.0 功能介绍2.1 原理2.2 设计和操作3.0 技术资料4.0 连接4.1 机械/液力连接不带活塞阻尼器的电液转换器4.2 机械/液力连接带活塞阻尼器的电液转换器4.3 电力部分连接-标准设计4.4 电力部分连接-防爆设计5.0 安装规则6.0设备冲洗7.0安装位置8.0电力连接9.0试车运行9.1压力介质9.2滤网9.3泄口9.4最小输出压力10.0 调节11.0错误诊断附件1.0 电液转换器-选项*）超出调查范围图概要（看附件）：43.9862.21 不带活塞阻尼器标准设计43.9862.30 带活塞阻尼器标准设计43.9631.11 不带活塞阻尼器防爆设计43.9631.30 带活塞阻尼器防爆设计2.0 功能介绍2.1 原理电液转换器充当压力限制电磁阀。

依据一定的准则，电子输入信号被转换成相应的压力信号。

2.2 设计和操作通过两个位置控制器的配合，计算和控制电磁力到预设值。

输出压力作用在一控制动作方向是和电磁力相反的活塞上。

因为选择的控制因素，电磁力是以大约60Hz的频率围绕平均值波动的。

活塞增大或减小控制输入压力管和排管之间相交部分，达到稳定位置。

输出压力正确总是对应当前的信号数据。

手动执行器：电液转换器带手动执行旋钮，即使没有外部辅助电源，操作数据能被设置。

3.0 技术数据3.1 机械/液压数据：装置尺寸：标准设计：参看图no.43.9862.××防爆设计：参看图no.43.9631.××液压连接：参看图：“电液转换器-液压连接”最大输出压力。

（也是设计的可能的最高压力）：P=40barI E=0或4mA时最小输出压力：P A0=0barI E=20mA时最大输出压力：P A1=20bar在△P=1bar，T=50℃，粘度=30mm²/s最大排油流速（A→T1）大约45l/min油洁净等级：最大容许污秽等级为NAS1638等级7 或ISO4406 Class 16/13（我们建议滤网最小维持率β6≥200）因为液力振动，我们建议设计使用阻尼活塞。

与505/505E配套使用的电液转换器为两种：VOITH和CPC 1、VOITH1 - 控制磁性调节阀体P in －进口油压2 –动力传输杆P A －输出信号油压3 - ×0和×1电位计4 - 手动操作旋钮T1－回油5 - 电气接线T2 －回油6 - 控制壳体F Mag －磁力7 - 带阻尼活塞的控制活塞F Hyd－液压力8 –端盖F Fed－弹簧力9 –控制弹簧手动操作旋钮的功能：通过手动操作旋钮来控制电液转换器的磁铁，依靠这个旋钮，能设定一个可调的弹簧力以替代磁力F Mag。

弹簧力通过电枢和传输杆控制活塞，液压力F Hyd与输出信号压力P A成正比，但作用力方向与弹簧力相反，这样输出压力的调节不需要电气就可实现。

用手动旋钮操作时，由电液转换器控制的液压元件的行程位移不受控制，其输出发生变化是由于输出信号压力的增加。

只有把弹性挡圈从手动操作旋钮上移开时才能手动操作。

完成手动操作以后，顺时针转动计数器，使手动操作旋钮回到原来位置，再把弹性档圈推到原来位置。

作用方向：顺时针旋转输出压力增加。

电位计的作用：×0－在电位计×0 的帮助下，可以调节最小的输出压力P A min ,当设定值为4mA时。

电位计顺时针旋转，压力增加。

×1－在电位计×1 的帮助下，可以调节最大的输出压力P A max ,当设定值为20mA时。

电位计顺时针旋转，压力增加。

电位计×1先于×0 调整。

电位计×1的调节将影响×0的调整。

4~20mA对应油压为0.15MPa~0.45MPaVOITH接线CPC压力输出大小(LEVEL) 此调整量改变压力的输出大小，调整它对各个点都起作用，顺时针调整将增大压力输出。

压力范围(RANGE) 此调整量改变压力输出的范围，即压力曲线的斜率，顺时针调整将增大压力输出曲线的斜率。

标定一、输入电流和输出压力1. 将输入电流置于12mA 测量输出压力2. 调整压力Level电位器将输出压力调整到所需值3. 将输入电流置于20mA 测量输出压力4. 调整压力范围Range 电位器将输出压力调整到所需值5. 再次将输入电流置于12mA 调整压力Level电位器6. 将输入电流置于4mA 调整压力 Range 电位器注意顺时针调整Range 电位器将减小输出压力7. 重复1-6 步操作直至输出压力在极限值的公差范围内注意压力Level电位器和压力 Range 电位器为多圈电位器, 25转二、动态调整1. 将输入电流置于12mA2. 顺时针慢慢将增益Gain 电位器至中间位置如果输出压力不稳定则逆时针调整电位器通常50%的增益将适用于各种类型的负载3. 对于小型或闭锁的伺服机构稳定电位器Stability 通常设定为10%-20% 对于大型的伺服机构通常设定为50%-60% 如果油温比较低或油的粘质比较大请适当增加稳定值的调整如果发现输出压力有高频抖动现象, 则应减小稳定值同时可适当增大增益4. 从4 mA 到20mA 逐步增大电流检查输出压力是否稳定4~20mA对应油压为0.25MPa~0.6MpaCPC与VOITH相比的优缺点：优点：反应灵敏，有超限报警缺点：调节麻烦，对油质要求高（5um滤网），无法脱机试验针对这一问题，woodward公司新研发了CPCII产品CPCII改进：1、去掉滤网2、提高功率，提高动作的灵敏性和可靠性。

电液转换器工作原理：（见图）
当信号电流为零时, 芯棒与滑阀处于左端极限位置, 压力油腔与控制油压之间节流口关闭.腔经阀芯中地内孔与回油腔相通,所以腔处于卸压状态.资料个人收集整理，勿做商业用途
当信号电流（）增加时，芯棒在磁场作用力下，或比例地产生一个向右作用力，推动滑阀向右移动，使控制油腔与回油腔地流通面积减小，与压力油腔地流通面积增大，根据流量平衡原理，控制油压升高，随着油压地升高，与油腔相通地腔压力也升高.当产生地油压力与相抵消时，滑阀达到平衡，控制油压稳定.腔油压值即是成比例地对应输入信号地相应值. 资料个人收集整理，勿做商业用途
当信号电流减小时，芯棒在磁场作用力下，产生一个向左作用力.这时，由于与油腔相通地腔油压力大于芯棒作用力，滑阀向左移动，使得控制油腔与回油腔地流通面积增大，与压力油腔地流通面积减小，控制油压降低.同时，腔油压亦降低，芯棒上地磁场力与油压力相等，滑阀达到平衡，控制油压稳定.资料个人收集整理，勿做商业用途
在手动工作状态，旋动手轮，经传动杆推动芯棒移动，即能调到所要求地控制油压.
一般对应－控制电流输出地二次脉冲油压为,在这一段范围内控制特性地线形度较高. 资料个人收集整理，勿做商业用途
电液转换器调试过程：。

有任何关于1/H型转换器的问题，根据转换器上的物品号和序列号，请联系V oith Turbo Gmbh & Co.KG公司电驱动系统的服务部。

V oith Turbo Gmbh & Co. KG邮政信箱15 55D-74555 Crailsheim总机：++49-7951/32-0传真：++49-7951/32-500电驱动系统产品服务部电话：++49-7951/32-470传真：++49-7951/32-605电子邮箱：****************V oith Turbo Gmbh & Co. KG供货地址Dept.ceV othstr.1D-74564 Crailsheim这个安装手册说明了从2003年9月以来交货的1/H转换器的技术条件。

在这之后交付产品所作的任何修改不写入本操作手册之内。

本安装手册版权所有未经许可，不得复制或翻译用作其他用途。

中国唯一代理：杭州怡林机电技术开发有限公司杭州市朝晖路182号国都发展大厦1幢19层H座邮编：310014电话：＋86-571-85808865传真：＋86-571-85808807内容1．技术数据2．安全信息2.1 标识符号说明2.2 使用范围2.3 重要说明2.4 授权3．功能描述3.1 构造设计3.2 操作特性4．包装、存储和运输5．安装5.1 装配5.2 液压连接5.3 电路连接6．试车6.1 测试运行6.2 参数设置7．操作7.1 用手动旋钮操作7.2 用设置信号操作7.3 问题解答和矫正措施8．维护和修理9．关闭10．接线略图11．附件1．技术数据环境条件：存储的环境温度-400C (900)环境温度-200C (850)保护IP 65 到EN 60529适合工业空气中的内部安装电路数据：电压24VDC±15％电源消耗接近0.7A 最大3A，对t<1秒给定值输入w＝0/4…20mA 抑制电路输入电阻25欧姆液压数据：最小输入压力 1.5bar大于P A最大值最大输入压力见表压力流体矿物油或液压油（不易燃烧的要求）压力流体粘性ISO VG 32…ISO VG 48 到DIN 51519压力流体温度+100C (700)油纯度推荐纯度等级：NAS1638等级7 ISO4406等级-/16/13A AP A最小值的调节范围显示了第一条线涉及的最小的可调整的P A最大值。

使用说明书（电池供电型）ABG仪表集团服务热线：400-666-5262目录1概述 (2)2性能指标 (2)3传感器配套要求 (3)4安装尺寸图 (4)4.1圆型一体立式 (4)4.2方型分体式 (5)5转换器图片 (5)6转换器信号线定义 (5)6.1圆表一体型端子接线与标示 (5)6.2方表分体端子接线与标示 (6)7流量检定 (7)7.1脉冲输出信号线 (7)7.2脉冲输出同标定系统的连线 (9)7.3脉冲输出参数设置 (10)7.4进入仪表检定模式 (10)8仪表参数设置 (11)8.1参数菜单 (11)8.2仪表详细参数说明 (13)9仪表报警显示 (15)10励磁方式选择 (16)11间隔测量模式 (16)12间隔测量时间 (16)13流量频测阈值 (16)附录1非线性修正功能说明 (17)附录2更换电池说明 (18)附录3各口径下脉冲宽度为1MS时设置参考表 (21)附录4W801转换器调节励磁电流的方法 (22)1概述Lmag_W801系我公司研发的电池供电型电磁水表转换器系列，该系列转换器能与普通电磁流量计传感器配套，并达到0.5级和0.2级流量测量精度。

也就是说，简单地将原普通电磁流量计，换上Lmag_W801转换器，用户就开发出了全新产品－电磁水表系列产品。

Lmag_W801电磁水表转换器标配一个常规锂电池组，可持续工作3--6年。

若配用高容量锂电池组，持续工作时间会更长。

Lmag_W801电磁水表转换器可采用基站式无线通讯网络系统，在区域中心建立通讯基站，覆盖半径为1000米。

各台电磁水表同基站进行近距通讯（ＳＲＤ模式），使用928MHZ开放频段（美国标准）。

基站通过GPRS 或CDMA手机通讯网络完成同管理计算机的数据通讯。

此外，Lmag_W801电磁水表转换器也可直接通过GPRS或CDMA手机通讯网络完成同管理计算机的数据通讯（GPRS通讯详见通讯说明书）。

Lmag_W801电磁水表转换器采用压铸铝表壳，IP68密封防护设计，可使用在井下等潮湿场合。

-N型电液转换器型号：SVA9--N 价格：18000.00使用说明书SVA9-N 型电液转换器是专为汽轮机电液调速器开发的关键电－位移转换元件，它能把微弱的电气信号通过液压放大转换为具有相当大作用力的位移输出。

SVA9-N型电液转换器主要由动圈式力马达、控制滑阀及随动活塞三大部分组成，控制滑阀与随动活塞之间采用直接位置反馈，安装方式采用板式连接。

SVA9-N型电液转换器是SV9型电液转换器的改进型，是我公司应用户要求改制的抗污染型电液转换器，它针对电站行业对电液转换器工作须绝对可靠的要求，在SV9型基础上改进零部件材质、提高加工精度，加大动圈出力，并在进油口处增设可反吹冲洗、反复使用的高效过滤器。

与SV9相比，抗污染能力更强，工作更可靠，是更适合于电站行业应用的新一代电液转换器。

除电气参数不同外，在连接尺寸上它与SV9完全一致，可以方便地替代SV9而不需对调速器作任何改动。

SVA9-N型电液转换器结构精密，工作可靠，灵敏度高，动特性好，对油液洁净度要求较低，在NAS8级的油液中能长期稳定地工作，除此之外，还具有液压应急控制功能，只要通过一个二位四通阀把进出油口（Ｐ、Ｔ）换向或在进出油口（Ｐ、Ｔ）同时通入压力油，随动活塞就能立即下推到底。

一、工作原理SVA9-N型电液转换器的电气――位移转换部分采用了动圈力马达结构，液压放大部分采用了具有直接位置反馈的三通控制滑阀控制差动缸（随动活塞）的典型结构。

其工作原理如下：磁钢在气隙中造成固定磁场，当动圈绕组中有控制电流通过时，动圈在气隙磁场中受电磁力的作用，此电磁力克服弹簧力使动圈及控制滑阀产生与控制电流成正比例的位移。

压力油从Ｐ口进入，流经控制滑阀与随动活塞的上下可变节流口，由Ｔ口回油。

油源压力直接作用在随动活塞下腔，使之始终有一个向上的恒力，而上下节流口间的控制油压则作用在随动活塞上腔（被控腔），使之产生一个向下的推力。

随动活塞上腔面积设计成是下腔面积的两倍，因此当控制滑阀静止时，随动活塞自动地稳定在一个平衡位置，在这个位置上，上、下节流口的过流面积相等上腔控制油压刚好等于下腔油源压力的一半，使作用在随动活塞两端的液压推力相等。

使用说明书 OPERATIONAL MANUAL版本：AVersion:A电液转换器Elec-hydr. ConverterVOITH TURBO GMBH ＆ CO.KGI/H ConverterType DSG-B03212Type DSG-B07212 Instruction ManualVersion 1.005 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 1 / 20Should you have any questions concerning the I/H converter, please contactthe Service Department of the product group Electronic Drive Systems,Voith Turbo GmbH & Co. KG, Crailsheim, indicatingarticle number and serial number of the I/H converter.Voith Turbo GmbH & Co. KGP.O. Box 15 55D-74555 CrailsheimSwitchboard:++49 – 7951 / 32 - 0Fax:++49 – 7951 / 32 – 500Service department of the product groupElectronic Drive SystemsDirect dial:++49 – 7951 / 32 - 470Direct fax: ++49 – 7951 / 32 - 605E-mail: turcon@Address for goods supplied:Voith Turbo GmbH & Co. KGDept. ceVoithstr. 1D-74564 CrailsheimThis instruction manual describes the technical condition of theI/H converter on delivery from May 2003.Any modifications following the delivery are not considered in this operating manual.Ó Voith Turbo GmbH & Co. KG 2003This instruction manual is protected by copyright.It may not be reproduced or translated in any form or by anymeans (mechanical or electronic) or submitted tothird parties, without the publisher’s written approval.Issued:03-05Order No.: 3.626- 018861 enVersion: 1.00Printed in Germany05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 2 / 20Contents1.Technical data2.Safety Information2.1Definition of notes and symbols2.2Proper use2.3Important notes2.4Warranty3.Functional Description3.1Mechanical design3.2Operating characteristics4.Packing, Storage and Transport5.Installation5.1Mounting5.2Hydraulic connection5.3Electric connection6. Commissioning6.1Test run6.2Parameter setting7. Operation7.1 Operation with manual operation knob7.2 Operation wit set signal7.3 Trouble shooting and remedial action8.Maintenance and Repair9.Shutdown10.Outline drawing with Wiring Diagram11.Annex05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 3 / 201.Technical DataAmbient conditions:Ambient temperature for storage-40 °C ... +90 °CAmbient temperature:- Normal operation-20 °C ... +85 °C- Potentially explosive atmos.-20 °C ... +60 °CExplosion protection EEx d IICTemperature class T4, at Ta = -20 °C ... +60 °CDevice group IICategory2GProtection IP 65 to EN 60529suitable for internal installation in industrial airElectric data:Supply voltage24 VDC ± 10%Power consumption approx. 0.7 Amax. 3 A, for t < 1 secSetpoint input w = 0/4...20 mAinput resistor 25 Ohmwith suppressor circuit05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 4 / 20Hydraulic data:Input pressure P in min 1.5 bar more than P A max Input pressure P in max see tablePressure fluid mineral oil or hydraulic oil(hardly combustible fluids onrequest)Viscosity pressure fluid ISO VG 32... ISO VG 48 toDIN 51519Temperature pressure fluid:+10 °C...+60 °COil purity recommended purity class:To NAS1638 class 7To ISO4406 class -/16/13 Leakage£ 5 l/minDSG-BXX212TypeB03...B07... Output pressure regulating rangeP A[bar]0..30..7 Input pressureP(max) [bar]4040Flow rate line P ® AQ1[l/min]at D P = 1 bar1717Flow rate line A ® TQ2[l/min]at D P = 1 bar1818Regulating range approx.P A max [bar]at setpoint w = 20 mA1..3 5..7Regulating range approx.P A min [bar] at setpoint w = 4 mA 0..0.80..21..31.5..5The regulating range of P A min depends on the set pressure P A max.The regulating range of P A min indicated in the first line refers to the minimumadjustable pressure P A max .Mechanical data:Dimensions, fitting see chapter 10Hydraulic connection see chapter 10Mounting position see chapter 10Sealing material FPMWeight approx. 12 kg05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 5 / 202.Safety Information2.1Definition of notes and symbolsDanger !This symbol signals an imminent danger to the life and health of individuals.If this note is not observed, injury to health and even mostserious injuries may be the consequence.Warning !This symbol signals a harmful situation.If this note is not observed, the product may be damaged.Note !This symbol refers to proper handling of the product. It does not refer toor indicate a dangerous situation.2.2Proper useThe I/H converter serves to transform an electric set signalinto a related hydraulic output pressure reduced to feed-in pressure. Thisallows, for example, adjusting control pistons at hydraulic cylinders whichare used to position the valves of steam turbines.The I/H converter is suitable for usage in potentially explosiveatmospheres according to the explosion protection mentioned inchapter 1.2.3Important notesThe following notes refer to the entire instruction manual and have to beobserved in addition to the individual notes.Accident prevention·In any case observe the relevant standards and regulations when connecting an I/H converter in ex-design.·Improper use may cause operating agent under pressure to leak at the sealing surfaces. There is a risk of fire around hot components.·Isolate the hydraulic supply prior to working on the I/H converter.05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 6 / 20·Failure of electric power or disturbance of the control electronics integrated in the I/H converter may cause strong variations of theoutput pressure when operating the I/H converter. Thus e.g. thepiston rod of a hydraulic cylinder may move uncontrolled, causing danger to individuals or equipment.·During operation, the outer surfaces of the I/H converter may heat up due to the pressure fluid. Contact may cause skin burns. Make sureto cool down the I/H converter prior to working on it.·Electrical components are installed in the I/H converter. These components can be destroyed by e.g. welding in its surrounding.Therefore make sure to disconnect all electric connections prior toelectrical weldings in the surrounding of the I/H converter.Environment protection·During mounting, dismounting or improper use of the I/H converter pressure fluid may leak out. Operating agent reaching the sewagesystem or the open soil, causes severe environmental damages.Leaking pressure fluid has to be collected and deposited inaccordance with the national legal regulations.Instruction manual·The instruction manual contains important information for proper handling of the I/H converter. Prior to installation and commissioningof the I/H converter, read the manual carefully and make sure it iscompletely understood.·Keep this manual in a location convenient to the operating staff.·In addition to this operating manual: Have the relevant regulations for prevention of accidents and environmental protection available andobserve these.05 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 7 / 2005 / 03cet - Ochs Voith Turbo GmbH & Co, KGPage: 8 / 20Staff qualification· Only trained and instructed staff is allowed to perform any work on theI/H converter. This personnel has to be trained and authorized to mount I/H converters professionally.· Installation, commissioning and operation have to be performed by anelectronic expert with experiences and knowledge in explosion protection.Constructional modifications· Mounting and constructional modifications are not permitted.· The screwing of the cable inlet is secured against distortion. Do notdistort or loosen the screwing.2.4WarrantyThe terms and conditions mentioned in the General Conditions of Sale of Voith Turbo GmbH & Co. KG, Crailsheim, are applicable.Warranty claims are excluded, if these are due to one or several of the following causes:· Improper transportation, storage, mounting, set-up, commissioningand operation of the I/H converter.· Not observing the safety instructions and guidelines included in thisinstruction manual.· Use of spare parts not approved byVoith Turbo GmbH & Co. KG, Crailsheim.Repair works on the I/H converter are to be performed or approved by Voith Turbo GmbH & Co. KG, Crailsheim.05 / 03cet - Ochs Voith Turbo GmbH & Co, KGPage: 9 / 203.Function3.1DesignFig. 3.1.11 – Control magnet VRMP - Input pressure2 – Tappet for power transmission P A - Output signal pressure3 - Potentiometer X0 und X14 – Manual operation knob T 1- Tank return line5 – Electric connection T 2- Tank return line int. leakage6 – Control housing F Mag - Magnetic force7 – Control piston F Hyd - Hydraulic force8 - CoverF Fed- Spring force9 - Control spring3.2 Operatingcharacteristics(see fig. 3.1.1)A set signal w = 0/4...20 mA generates a magnetic force F Mag in theVRM, the limits of which can be adjusted by means of the X0 and X1potentiometers and which is then transmitted onto the control piston viatappet.The hydraulic force F Hyd being proportional to the output signal pressureP A acts against this force.In the case of the two forces being equal, the control piston is positionedin the “hydraulic center” as shown in fig. 3.1.1 and the output signalpressure P A corresponds to the set signal. In the “hydraulic center“position the control piston performs minimum oscillating movements inthe area of the guiding edges P®P A and P A®T , in order to keep theoutput pressure P A on the value set by F Mag.When increasing the set signal and thus F Mag from this condition, thecontrol piston position changes and thus connects the output pressure P Ato the feed pressure P in and blocks P A towards the tank return line T1.Now the pressure P A will increase until the control piston returns to the”hydraulic center“ and P A corresponds to the new set signal.The spring force F Fed of the control spring generates a force-offset inorder to guarantee the I/H converter function for output pressures ofapprox. 0 bar, too.The internal leakage is fed back via tank return line T2.Function of manual operation knobThe control magnet of the I/H converter is provided with a manualoperation knob, by means of which an adjustable spring force can be setinstead of the magnetic force F Mag . This spring force affects the controlpiston via magnet armature and tappet. The hydraulic force F Hyd , beingproportional to the output signal pressure P A also acts against this springforce here. Thus adjustment of output pressure is possible withoutelectric connection.4.Packing, Storage and TransportPackingThe I/H converter is delivered in a special packing.The openings for the hydraulic connections are sealed with plugs toprevent penetration of impurities and humidity.Storage and preservingThe outer surfaces of the I/H converter are protected by means of apreserving surface coat.The internal parts are preserved by oil.Within Europe the anticorrosion protection is sufficient for approx. 8months in industrial air, presuming storage of the I/H converter in a drylocation.In case the I/H converter is supposed to be stored for a longer period oftime, special precautions will have to be taken.In each specific case, these precautions have to be agreed withVoith Turbo GmbH & Co, KG, Crailsheim.The storage ambient conditions have to be within the limits as indicatedin chapter 1.TransportImproper transport may cause personal injuries and damages toproperty.Pack the I/H converter in a way that prevents housing damages duringtransport. In particular make sure that no compulsive forces affect theelectric cable fitting and the electric feed in cable are not kinked ordamaged. Do not hold the I/H converter at the electric feed in cable fortransport.5.Installation·Improper installation of the I/H converter may cause malfunctions and premature failure of the operation of the I/H converter.·Cleanliness is imperative during installation an connection. Prevent that any impurities ( dust, metal chips etc.) can get into the I/Hconverter or pipe system which may cause damage to the I/Hconverter.Cover and protect the I/H converter and in particular the electric linesduring construction time.5.1MountingPerform any work on the I/H converter only when it is in deenergizedcondition and with switched off oil supply system.Protect oil and power supply against unintentional switching-on duringmounting.Install the I/H converter in accordance with the permissible installationposition as shown in chapter 10.Recommended fastening bolts:2 pieces hexagonal screws M10, strength category 8.8.tightening torque MA=35 Nm, thread slightly oiled.Select screw length according to mounting situation.connection5.2 HydraulicThe hydraulic connection on the I/H converter is made by means ofconnection bores at its bottom. The connection flange is sealed witho-rings. Please refer to chapter 10 for position and dimensions of theconnections.Surface roughness of connecting flange:Ra = 1.6 m m, Rmax = 6.3 m mOnly pressure-less return of the operating medium through the return lineT2 to the tank, ensures proper work of the I/H converter.In practise the tank lines for the connections T1 and T2 are joinedtogether and laid downgrade towards the tank in one common pipe line.Requirements to this pipe line:Nominal size 20 mm or bigger for I/H converters with an output pressureup to 10 bar.Nominal size 30 mm or bigger for I/H converters with an output pressureof more than 10 bar.Observe the correct pressure range when selecting pipes, hoses,screwings and flanges.Immediately replace damaged pipes and hose lines.When assembling the pipe lines, ensure that it is fastened to fixedstructures, free from vibration and not to moving equipment. Temperaturevariations of the piping (thus alterations in length) must not applyconstraining forces to the I/H converter.Clean pipe lines from dirt, cinder, sand, chips etc. prior to installation.Pickle or flush welded pipes.Clean and flush carefully all pipe and hose lines prior to attaching theI/H converter.=> For flushing, a flushing plate (Art. No. 43.8565.10) is available.See chapter 11.=> To connect the I/H converter to the piping system an adapter (Art. no.43.9300.11) is available. See chapter 11.·Residual oil may leak when removing the plug (max. 0,1 l). Collect the oil in a suitable container and deposit it properly.·Do not use fibrous or hardening sealing compounds, such as e.g.hemp or mastic to seal the connections and screwings.5.3Electric connectionThe electric system has to be connected in accordance with electricalengineering standards and legal regulations of the manufacturingcountry. The works have to be performed by an electric specialist withexperience and knowledge in explosion protection.When connecting the I/H converter within the explosion hazardous area ,the electric feed in line have to be connected in housings according toprotection type EN 50014, section 1.2.When connecting customer´s lines, avoid parallel run of the I/H converterlines with the lines of current converter assemblies.The customer`s signals and supply lines running to the I/H convertermust be screened.Please refer to chapter 10 for the wiring diagram.missioningThe I/H converter was adjusted and tested at Voith Turbo’s works bymeans of the potentiometers X0 and X1. The test result is documented inan attached test certificate.The potentiometers are provided with a protective cap to avoidunintentional maladjustment and impurities.6.1Test runMake sure that pipe lines and hydraulic system are cleaned prior toperforming a test run. The operating fluid has to be in accordance withthe purity class as indicated in chapter 1. Do not flush or clean thepressure fluid with the I/H converter being hydraulically connected.Operation of the I/H converter with contaminated pressure fluid is notpermitted, the I/H converter may be damaged.·Check the line mounting, connection and flow direction to and on the I/H converter.·Check the electric connection.·Switch on the 24 VDC power supply.·Switch on the oil supply and check input pressure.The minimum input pressure has to be 1.5 bar more than the maximumoutput pressure required at 20 mA.·Set the signal w = 0/4.. 20mA and check output pressure.During the test run, check all hydraulic connections for leakages. Incase of leakage, immediately switch off the hydraulic supply andeliminate leakages.6.2Parameter settingDue to unintentional maladjustment of the parameters or changedoperating conditions, new setting of one or both parameters may becomenecessary.We recommend to document adjustment of the parameters as well as theset values.The parameters are adjusted by means of potentiometers X0 and X1.Please refer to chapter 10 for the position of the potentiometers.Potentiometer effects:X0-With help of potentiometer X0 the minimum output pressureP A min is adjusted at a setpoint of 0 mA or 4 mA.Pressure increase by turning the potentiometer clockwise.X1-With help of potentiometer X1 the maximum output pressureP A max is adjusted at a setpoint of 20 mA.Pressure increase by turning the potentiometer clockwiseX1 should be adjusted before X0.The X1- adjustment influences the adjustment of X0.Manufacturer-provided adjustments:At the works, the I/H converter has been adjusted as indicated in theorder.7.Operation7.1 Operation with manual knobOperation with manually controlled rotary knob is possible without electricenergy.On operation with manually actuated rotary knob, uncontrolled strokemovements of the hydraulic components controlled by the I/H converteroutput might occur due to the increase in the output signal pressure.Manual operation is only possible when the circlip is removed from themanual operation knob.On completion of operation with manual operation knob, move themanual operation knob in its final position by turning it counter clockwiseand pushing in the circlip to its final position.·Remove the circlip.·Slowly turn the manual operation knob clockwise and observe the output pressure.Effective direction: Output pressure increase by clockwise rotation.7.2Operation with set signalWhen the supply voltage is switched on, the output signal pressure canbe adjusted continuously by the set signal 0/4...20 mA within the limitsset by the potentiometers X0 und X1.7.3Trouble shooting and remedial actionPrior to all works, make sure that the I/H converter was commissionedaccording to chapters 5 and 6.Malfunction: Pressure variationsThe output signal pressure P A may vary now and then orperiodically with low or high frequency and amplitude.Cause: 1. air inclusions in the hydraulic component2. low or considerably varying input pressure.3. dirt particles in the hydraulic component4. pressure on return lineRemedy: 1.On first commissioning air inclusions in the VRM may causepressure variations. Due to periodic setpoint changes(approx. 0.5 Hz) of approx. +/- 6 mA, the air will escape outof the VRM after some minutes causing the hydraulicdamping to become effective.2. Under load and in particular in case of higher outputsignal pressure, a lower input pressure may lead topressure variations.Increase and / or stabilize the input pressure by takingappropriate measures (e.g. accumulator). See also chapter1.3. Contaminated pressure fluid results in increased friction atthe control piston, thus causing hysteresis and pressurevariations.Open hydraulic component and clean the inner elements. Incase of damaged surfaces and guiding edges replace theI/H converter.4. The dimensions of the return line have to be sufficient.In case of additional consumers of the output pressureconnected to this line, make sure they do not create anypressure in the return line. See also chapter 5.2.Malfunction:Output pressure PA ® 0 bar or ® P (input pressure)Due to a defective control valve VRM or blockage of thecontrol piston the output pressure may fall to 0 bar orincrease to the input pressure.Remedy:The function of the hydraulic component can be checked using the manually controlled knob with the supply voltage beingswitched off. See chapter 7.1.If the output pressure cannot be adjusted manually, the controlpiston, e.g., may be blocked by particles.Open hydraulic component and clean inner parts.If the surfaces and guiding lines are damaged, exchangethe I/H converter.Should output pressure adjustment be possible with manualoperation knob, but not with the control magnet, the controlmagnet VRM is defective.Repairs on the control magnet VRM are not allowed, otherwiseexplosion protection is no longer guaranteed.Replace any defective I/H converter completely.8.Maintenance and RepairFor a trouble-free and reliable operation of the I/H converter, it isnecessary to perform inspection, maintenance and repair work incertain intervals.Routine inspectionCheck the pipes, screw connections and connections on theI/H converter for leakage, impurities and damage.Eliminate any leakage, impurity and damage noticed, if required, duringappropriate operating modes.Monitor the control behavior of the I/H converter for any changes.Analyse and eliminate the causes, if required, during appropriateoperating modes.Inspection after approx. 740 operating hours / max. 1 monthTake an oil sample from the oil tank and analyse it for solid andsuspended matters, water content, shadings and air bubbles.Analyse oil purity of the oil sample. Clean or exchange the oil, ifrequired, in an appropriate operating mode.Inspection after approx. 8000 operating hours / max. 1 yearTake an oil sample from the oil tank and analyse it chemically.If required, clean or change the oil during an appropriate operating mode.Check and retighten, if necessary, the electric connections of the I/Hconverter.9.ShutdownIf the I/H converter is switched off for reasons of repair, inspection orunit shutdown, switch off the oil supply system and relieve all pressurereservoirs, if effective. Switch off the 24 VDC supply voltage andremove the lines as well as piping and hose connections. Doing so, anconsiderable oil quantity may leak out. Collect the oil in a suitablecontainer and deposit it properly. Close all holes. Now clean and packthe I/H converter.DisposalIn the event of disposal of the I/H converter, observe the local applicableregulations regarding the environmental protection. The I/H converteressentially contains steel, copper, synthetic materials, electroniccomponents and residual oil.Instruction Manual I/H Converter DSG-B03212I/H Converter DSG-B0721205 / 03cet - OchsVoith Turbo GmbH & Co, KG Page: 19 / 203.626 - 018861 en D – 74564 Crailsheim 10.Outline and Wiring DiagramInstruction ManualI/H Converter DSG-B03212I/H Converter DSG-B07212 11.AnnexFlushing plate43.8565.10Adapter plate43.9300.1105 / 03cet - Ochs Voith Turbo GmbH & Co, KG Page: 20 / 20 3.626 - 018861 en D – 74564 Crailsheim。