Voith Electro Hydraulic Positioning Control

VEHS
Description

Version 09 / 2022-02-04
3626-015310 en / Protection Class 0 : public
Uncontrolled copy

Issued by: Glasbrenner, Michael Date: 2022-02-04

ID Number: 3626-015310

Version Changes Remarks

07 Update of Ex-Certification in chap. 5, Update to IP 66 in chap. 5 -

08 Update ambient temp. chap. 5, Typing error correct. actual pos. chap. 7.2 -
09 Update of power supply variation in chap. 5, chap. 7 omitted, update of -
chap. 8, New chap. 9 for Appendix A
 Voith Electro Hydraulic Positioning Control
Contents

Contents
1 General 3

2 Principle of Operation 4

3 Integrated Positioner Parameter Settings 5

4 Block Diagram of Voith Electro-Hydraulic Positioning Control – VEHS 6

5 Technical data 7

6 Electrical Connection 9

7 Commissioning of the VEHS Unit 10

7.1 Safety information with regard to the VEHS 10

7.2 Setting of the position pick-up 10

7.3 Setting the electromagnetic actuator 12

8 Options as to the VEHS 14

9 Appendix A 15
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 Voith Electro Hydraulic Positioning Control
General

1 General
The Voith electro-hydraulic positioning control serves to provide an exact and continuous position-
ing. The VEHS is used for positioning the scoop tube for geared variable speed couplings and for
positioning the guide vane for torque converters. The VEHS is a compact unit consisting of an elec-
tromagnetic actuator, a double-acting cylinder and the electronic position pickup.
The actual position is recorded by the electronic position pickup on the double-acting cylinder. The
electromagnetic actuator consists of a control magnet with integrated PD controller with subordi-
nated magnetic force control and a hydraulic 4/3-way valve. The excellent control quality of the
positioning control circuit results from the high sensitivity/responsiveness and accuracy in case of
short positioning times.
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 Voith Electro Hydraulic Positioning Control
Principle of Operation

2 Principle of Operation
The VEHS unit is a positioner with PD action. The actuator (e.g. scoop tube, guide vanes) is posi-
tioned as a function of the position setpoint of a master controller (control circuit). The internal posi-
tion control circuit compares the actual position value (position pickup: 4 .. 20 mA <=> 100 % .. 0%)
with the position setpoint of the master controller.
The difference signal acts on the subordinated magnetic force controller. The change in magnetic
force F results in an adjustment of the way valve (control pin). The control edges of the way valve
release an oil flow to and also from the double-acting cylinder.
The position pickup gives a signal of change in piston travel of the double-acting cylinder back to
the positioner. With decreasing difference signal (deviation) (w - x), the magnetic force F also re-
duces and at w = x, the way valve is in the hydraulic center position.
The electromagnetic actuator feeds the actual position (4 .. 20 mA <=> 0 .. 100 %) of the actuator
(scoop tube or guide vanes) back. This signal is not electrically isolated and can be used by the
master controller or a local indicating instrument.

The electromagnetic actuator does not contain a fault monitoring. The master controller has to
monitor the position setpoint with the actual position fed back; at the same time, all electrical and
hydraulic sources of error are recorded.
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 Voith Electro Hydraulic Positioning Control
Integrated Positioner Parameter
Settings

3 Integrated Positioner Parameter

Settings
The control response of the positioner is set via parameter Kp (proportional-action coefficient). All
other parameters are already factory-set and do not need to be changed.

FM: Setting of hydraulic control pin center position, for w - x = 0

x0: Control pin setting at s = min, w = 4 mA
x1: Control pin setting at s = max. w = 20 mA
Kp: Setting of proportional-action coefficient -> increases in clockwise direction
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 Voith Electro Hydraulic Positioning Control
Block Diagram of Voith Electro-Hydraulic Positioning Control – VEHS

4 Block Diagram of Voith Electro-

Hydraulic Positioning Control – VEHS

VEHS-Unit
eletromagnetic actuator
control magnet 4/3-way valve
magnetic force p1
position controller
controller control pin
T
+ + I
PD - F
-
B A

FM
x0 x1 Kp,TD F0 Final controlling element:
F1
Scoop tube
varaible speed coupling
actual position
I
from postion pickup s
20 .. 4 mA <=> 0 .. 100 % Guide vanes torque converter
double acting
position pickup cylinder

X Actual postion feedback 100 % 0%

4 .. 20 mA <==> 0 .. 100 %
W
Position setpoint
4 .. 20 mA <==> 0 .. 100 %

p1 = Control oil pressure

T = Tank return pipe
A = Consumer
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B = Consumer
Wposition setpoint = Position setpoint of master controller: 4 .. 20 mA <=> 0 .. 100 %
Xactual position = Actual position feedback: 4 .. 20 mA <=> 0 .. 100 %

x0, x1
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Parameter setting through potentiometer

KP, FM

F1 and F0 factory-set and sealed Potentiometers are located

TD factory-set and sealed behind the black cap.

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 Voith Electro Hydraulic Positioning Control
Technical data

5 Technical data
Supply voltage - stabilized: 24 VDC -15 % / +10 % *1
(residual ripple at rated load < 1 %) [input resistance: ∞Ω]
Maximum current consumption (temporarily) 3.0 A

Current consumption during normal closed-loop

control: approx. 1.2 A

Time constant (electro-hydraulic conversion): approx. 20 msec

Settling time at 0 <=> 100 % setpoint step change

on geared variable speed coupling and torque converter: typically 5 - 10 s *2

Settling time at 0 <=> 100 % setpoint step change typically 30 s *2

on the Vorecon:

Sensitivity of positioning control: < 0.1 %

Actual position of position pickup: 20 .. 4 mA = 0 ... 100% *3

[input load 332 Ω]

Analog output actual position feedback -: 4 .. 20 mA = 0 .. 100 %

"Xactual position" (non-isolated) [input resistance: ∞Ω]
must not be supplied with 24 VCD (-> 4-wire system). max. load: 400 Ω

Analog input for position setpoint – "Wposition setpoint“: 4 .. 20 mA = 0 .. 100 %

(from the master controller), mA signal has to be provided max. 25 mA, [input load
with voltage as common for a power source. 155 Ω, @25°C], with suppressor circuit

Grade of filtration for control oil: 25 µm

Ambient temperature during operation: -20 °C ... +60 °C standard
-30 °C ... +70 °C optional, depending on
used type / thermal link

Protection: IP 66
VEHS Description / Version 09 / ID No. 3626-015310 en / 2022-02-04

Electromagnetic actuator for hazardous area (optional):

ATEX II 2 G Ex db eb IIC T4 Gb
IECEx (only for electrical part) Ex db eb IIC T4 Gb
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CSA approval (cCSAus) Class I, Divisions 1 and 2,

Groups B,C and D T4
Other approvals like KOSHA or EAC on request.

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 Voith Electro Hydraulic Positioning Control
Technical data

Remarks:

*1 Nominal current consumption is at approx. 1.2 A. The 24 VDC auxiliary energy supply line
is to be dimensioned so that the terminal voltage does not fall below the value of 20.4 V on
current consumption.
On switch-on or settling of greater disturbances, the current consumption may temporarily
(2 sec) rise up to 3.0 A.

*2 This short settling time is required for the rapid start function.
To guarantee a sufficient control stability in case of a closed-loop control circuit, the master
controller is required to output the position setpoint via a ramp function. In this case it is
necessary to set the ramp time as a function of the process.

*3 Regarding circuit logic, the positioner is designed to correct the 0 % position on failure of
the position pickup signal: xd = Wposition setpoint – inverted actual position of position pickup.
On failure, the actual position of the position pickup is greater than 100 %.
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 Voith Electro Hydraulic Positioning Control
Electrical Connection

6 Electrical Connection
The technical data regarding voltages, currents, powers, cable lengths (voltage drop) and toleranc-
es are to be observed.

- A power supply protection is to be provided by the customer.

- All signal lines are to be shielded.
- Motor lines and signal lines to run separately.
- It is mandatory to ground the reference potential of the VEHS unit.
- For order-specific information, please refer to the wiring diagram.
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 Voith Electro Hydraulic Positioning Control

7 Commissioning of the VEHS Unit

7.1 Safety information with regard to the VEHS
1. The 24 VDC power supply for the VEHS should basically be protected against power
failure to obtain a high availability of the complete unit (security of supply, Uninter-
rupted Power Supply).

2. In case of the following sources of failure, it is standard to move to the 0 % position

(a customer-specific 100 % position is also possible):

• Failure of the whole 24 VDC power supply.

• Failure of the actual position value of position pickup (20 .. 4 mA <=> 0 .. 100 %).

• Failure of the position setpoint (4 .. 20 mA <=> 0 .. 100 %) of the master controller.

3. Monitoring measures of the master process controller.

The VEHS does not perform an internal self-test. It is not provided with an output "unit
ready for operation". The following monitoring measures can be performed by the pro-
cess controller:

• Absolute value: | Wposition setpoint - Xposition actual value | is greater than 3 .. 5 %

The VEHS unit does not correct the preset position setpoint within the ramp time.

• Monitoring of the 24 VTD power supply for the VEHS unit.

7.2 Setting of the position pick-up

For setting the position pick-up, separate the electromagnetic actuator from the 24 VDC supply
voltage. The control oil pressure must be available on the VEHS so that the controlling element
(scoop tube or guide vanes) can be positioned by the handwheel of the electromagnetic actuator
(see page 10).

Please observe the following for balancing the position pickup:

Position pickups of different manufacturers are used in order to observe the regulations required for
VEHS Description / Version 09 / ID No. 3626-015310 en / 2022-02-04

the respective field of application:

a) Position pickup for the non-hazardous area.
b) Position pickup for the hazardous area.

Balancing differs for the respective position pickup, dependent on the manufacturer. Please see the
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separately attached operating instructions for the position pickup.

The following process has to be met for balancing the position pickup by all differing manufactur-
ers.

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 Voith Electro Hydraulic Positioning Control
Commissioning of the VEHS Unit

Balancing procedure:

• A current measuring instrument is to be connected in series in the output of the position pickup.
• Move the final controlling element to the zero position of the position pickup using the hand-
wheel located on the electromagnetic actuator:
Set the zero point in the zero position of position pickup, according to the instruction manual of
the position pickup.

Move the final controlling element to the end position of the position pickup using the handwheel
located on the electromagnetic actuator:
Set the end point in the end position of the position pickup according to the operating instruc-
tions of the position pickup.

• Check the zero and end position of the position pickup repeatedly and rebalance, if necessary.

• After balancing, secure the handwheel of the electromagnetic actuator using the retaining clip.

Zero position End position

Rising signal: Rising signal:
Output value Actual position Output value Actual position
4 mA 100 % 20 mA 0%

Falling signal: Falling signal:

Output value Actual position Output value Actual position
20 mA 0% 4 mA 100 %

Position pickup

Magnet - elemet
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 Voith Electro Hydraulic Positioning Control
Commissioning of the VEHS Unit

7.3 Setting the electromagnetic actuator

The electromagnetic actuator has been set in the factory according to the following points 1 to 5 so
that normally no other setting is necessary. The position pickup should already be set for setting
the electromagnetic actuator and the VEHS unit is to be supplied with 24 VDC.

The positioner is adjusted by the four potentiometers on the control magnets:

1. Optimization of positioner:
• The positioner is optimized using potentiometer Kp (and possibly TD) when presetting Wposition
setpoint steps,

e.g. Wposition setpoint 2 = 15 mA < Wposition setpoint 1 = 10 mA.

In case of a too high system deviation, it is necessary to correct the Kp factory setting.
• In order to optimally set Kp, at first rotate the Kp potentiometer counterclockwise until sensing a
slight noise; then the Kp value is at 0. Now rotate the Kp potentiometer clockwise for about 10
to 15 rotations. When rotating the KP potentiometer in clockwise direction, this increases the
proportional gain of the positioner. After proceeding accordingly, the KP is set optimally and
does not need to be readjusted. The VEHS positioning closed-loop circuit is extremely stable
and instabilities due to incorrect settings are not possible.

2. Adjustment of hydraulic center position of control pin:

• Run the unit with the factory setting until reaching operating temperature.
• Check the control oil pressure.
• Preset Wposition setpoint = 12 mA,
• Trim the feedback of the actual position value with potentiometer FM
until exactly 12 mA result.

3. Setting the 0 % position:

• Preset Wposition setpoint = 4 mA,
• set the feedback of the actual position value to the related 0 % position by means of poten-
tiometer x0.

4. Setting the 100 % position:

• Preset Wposition setpoint = 20 mA,
• set the feedback of the actual position value to the related 100 % position by means of poten-
tiometer x1.
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5. Repeat points 2. to 4. until reaching the smallest possible deviation (typically ≤ 0.1 mA).
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 Voith Electro Hydraulic Positioning Control
Commissioning of the VEHS Unit

Electromagnetic actuator (top view):

1: Handwheel with retaining clip
2: Connector plug
x0, x1, FM, Kp: Potentiometers used for setting
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 Voith Electro Hydraulic Positioning Control
Options as to the VEHS

8 Options as to the VEHS

1. It is also possible to supply the VEHS unit in explosion-proof design.
Please see Chapter 5.

2. A customer-specific auxiliary device can be supplied in addition to the VEHS unit, with the
following options:

• W_position setpoint limitation:

Adjustable ramp function for separate presetting of ramp-up and ramp-down time.
The acting time limitation performs an electronic damping of the final controlling element.
• Linearization unit
Conversion of a non-linear process variable into a linear position setpoint function.
• Local control station with selector switch:
- Local / remote changeover switch
- Min./max. pushbutton for local positioning of final controlling element.

• Check of analog VEHS signals:

- Monitoring of actual position by the position pickup. In case of a malfunction, a signal is given to
the master control system.
- Monitoring of Wposition setpoint by the master controller. In case of a malfunction, the last position
setpoint (Wposition setpoint) is retained.
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 Voith Electro Hydraulic Positioning Control
Appendix A

9 Appendix A
VEHS monitoring processes by the master process controller.

The VEHS does not perform an internal self-test. An output "Unit ready for operation" does not
exist. The following monitoring measures can be taken by the process controller:

1. The absolute value of | Wposition setpoint - Xactual position | has to be less than 5 % within a specified
time.

The process controller has to monitor whether the preset 4 .. 20 mA position setpoint will be
reached within e.g. 15 seconds.
The time period depends on the max. VEHS positioning time for 0 % <=> 100 % position.
However, it should not be selected too short (< 10 sec.) to avoid false trippings.
The process controller has to form the positive difference of the position setpoint and the feedback
signal (| Wposition setpoint - Xactual position |).
- If the difference is <= 5 %, VEHS functioning is given.
- If the difference is > 5 %, a timer has to be started with 15 s operating time.
If the difference is still > 5 % after timer operation, i.e. after 15 s, there is a malfunction at the
VEHS.

Causes:
- Auxiliary lube oil pump not in operation, control oil pressure not available.
- 4/3-way valve is not adjusted properly.
- Incorrect wiring (e.g. wire breakage).

2. If the feedback signal of the VEHS is > 22 mA, the position pickup is faulty.

Causes:
- Position pickup is not adjusted properly.
- Position pickup is defective.
- Incorrect wiring (e.g. wire breakage).
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