Electro-hydraulic I/H Converters and WSR Way Valves ​
Actuator Technology for Positioning Cylinders on Turbomachinery
Well-established technology
Outstanding reliability
All the world‘s our home
Electro-hydraulic I/H converters
and WSR way valves are the ideal
eco­nomic solution for controlling
hy­draulic positioning cylinders. ​
This enables a valve to regulate the
mass flow (e.g. steam) in a precise
and highly dynamic manner.
The electro-hydraulic I/H converters
and WSR way valves design is a
simple one:
n Control magnet with integrated
electronics
n Hydraulic component
We are a reliable partner to manu­
facturers and operators of turbo ma­
chines in all international markets.
A current input signal (0/4 – 20 mA)
in the I/H converters or WSR way
valves is proportionally converted
into an output pressure or an oil
flow.
This simple and compact design
serves to ensure high operational
reliability coupled with availability of
the components, and your system.
Voith Turbo actuator technology
has established itself 10,000 times
over in power plants across the
globe and ensures economic oper­
ation of turbines and compressors.
I/H converters
Voith Turbo I/H converters convert a 0/4 – 20 mA current
input signal quickly and precisely into proportional output
pressure.
4
1
5
3
2
6
7
A Consumer terminal (output)
T Tank connection
P Oil supply terminal (input)
1 Control magnet housing
2 Tappet
3 Potentiometer
4 Manual adjustment
5 Electrical connection
6 Hydraulic component
7 Control piston
T
Design
A Voith I/H converter is an electric­
ally-controllable pressure regulating
valve, consisting of force-controlled
solenoid and a hydraulic component.
2
A
P
Simple design and well-established operating principle
Application principle 1:
Direct actuation of a
hydraulic cylinder
Application principle 3:
Operation of a pilot valve with
electronic position return
Application principle 2:
Operation of a pilot valve with
mechanical position return
Mechanical
position return
s
i
s
For
process
control
engineering
s
A
Steam
valve
Pilot
valve
Live
steam
Process control engineering
X0 X1
w
U
UHALL
F
Live
steam
P
Pilot
valve
A
T
P
X0, X1
A
+24V
+
T
FHydr
FMag
T
P
FMag
FHydr
UHall
U
s
i
w
Control magnet
Hydraulic pilot control
Electronic
position return
s
Position pick
up sensor
A
T
P
Live
steam
Consumer terminal (output)
Tank connection
Oil supply terminal (input)
Parameters for output
pressure range
(potentiometer)
Magnetic force
Hydraulic force
Hall voltage
Voltage
Stroke
Position pick up sensor
current signal
Nominal value for output
pressure
Function
Solenoid-force control generates a
magnetic force of FMag in a 24V d.c.
solenoid. This magnetic force is pro­
portional to the 0/4 – 20 mA input
signal (w), the limits are configured
using the X0 and X1 parameters.
The electronic control, magnetic
flux measurement, engineering de­
sign of the magnet and the hydraul­
ic pilot control together form a dy­
namic functional unit that is prac­
tically free of hysteresis.
The control magnet applies the
force FMag to the control piston. This
in turn counteracts hydraulic force
FHydr as generated by the pressure
at output A over the cross-sectional
area of the control piston (pressure
regulator).
As a result of this regulation, the
output line of the actuator always
receives the exact required pres­
sure and the oil quantity for pos­
itioning the steam or fuel valves.
3
Versatile application made possible by robust design
and maximum precision
Technical data
and characteristics
n Supply
voltage 24 VDC
consumption 1.0 A
n Input signal 0/4 – 20 mA
n Type of protection IP 65
n Input pressure up to 70 bar
n Ambient temperature - 20 to
+ 80 °C for standard design
n Explosion-proof design
EEx d IIC T4 available
n Current
Type
Maximum ​
input pressure
[bar]
Control range for
output pressure
[bar]
P ➞ A
A ➞ T
DSG-B03XXX
40
0–3
30
30
DSG-B05XXX
40
0–5
30
30
DSG-B05X48
20
0–5
100
140
DSG-B07XXX
40
1–7
30
30
DSG-B10XXX
40
0 – 10
30
30
DSG-B30XXX
70
0 – 30
30
30
DSG-B35XXX
70
10 – 35
30
30
Selection table
System-specific data must be taken
into consideration when defining a
suitable I/H converter. When select­
ing an I/H converter, please make
full use of our comprehensive know­
ledge. Our experienced sales staff
will be only too glad to be of assist­
ance.
4
Flow rate [l/min]
at p = 1 bar
Voith Turbo I/H converters to a 300 MW steam turbine
Customer benefits
Outstanding reliability and
Dynamic and precise positioning
Simple installation and initial
availability
of the output pressure
startup
n Reproducibility
n Device
n Well-established
operating
principle
n Dirt-resistant
< 0.1 %
no hysteresis
n Temperature compensation
n No drifting
n Input pressure at least 0.5 bar
higher than maximum output
pressure
n Fast response time
n Almost
and robust design
Voith Turbo I/H converters to a
3.4 MW steam turbine
(Photo: AG KK&K – www.agkkk.de)
inspected and configured
at factory (plug & play)
n min. and max. Output pressures can
be changed simply using parameters
X0 and X1 (potentiometers)
n Turbine lubricating oil can frequently
be used as an operating medium
n Depending on the model in ques­
tion, adapter plates, flushing
plates and connecting cables are
available
Explosion-proof design (left) and standard design
5
WSR way valves
Voith Turbo WSR way valves with integrated positioner convert in
combination with an hydraulic cylinder a 4 – 20 mA current input
signal quickly and pre­cisely into a propor­tional stroke.
3/3-WSR way valves or 4/3-WSR way valves can be used to position
hydraulic cylinders in a highly dynamic manner.
4
3
1
3
5
2
6
7
8
3/3 -WSR way valve
A Consumer terminal (output)
T Tank connection
P Oil supply terminal (input)
1 Control magnet housing
2 Tappet
3 Potentiometer
4 Manual adjustment
5 Electrical connection
6 Hydraulic component
7 Control piston
8 Control spring
T
Design
A Voith Turbo WSR way valve (fuelquantity positioner) is an electric­
ally-controllable directional control
valve, consisting of force-controlled
solenoids and a 3/3-WSR way valve
hydraulic unit for single-acting cylin­
ders or 4/3-WSR way valve hydraul­
ic unit for dual-acting cylinders.
6
A
P
Integrated control electronics for dynamic
and high-precision changes in flow rate
3/3-WSR way valve for single-acting hydraulic cylinders
Position pick
up sensor
Hydraulic
cylinder
Position pick
up sensor
s
i
4/3-WSR way valve for dual-acting hydraulic cylinders
Steam
control
valve
s
Hydraulic
cylinder
s
i
Steam
control
valve
s
Live steam
Live steam
-
+ X0
X1
+24V
x
w
-
UMag
+
KPU
KPD
U
A
FMag
FF
F
UHall
T
Control magnet
P
Hydraulic pilot
control
Process control engineering
Process control engineering
+ X0
X1
+24V
x
w
UMag
+
KPU
KPD
FMag
FF
F
UHall
T
Control magnet
Function
The specific system deviation (nom­
inal value w - actual value x) and the
set control gain KPU resp. KPD,
yields a reference variable UMag for
the solenoid force control. The mag­
netic force FMag generated in the
magnet system is monitored indir­
ectly through measurement of the
magnetic flux over UHall and sent
back to the controller. FMag acts via
the tappet on the control piston of
the hydraulic pilot control. This is
deflected against the control spring
U
B
A
until the travel-specific spring force
FF balances out against the force
FMag. This results in a volumetric
flow that can be changed in both
direction and size, and which can
adjust the stroke s of an externally
mounted hydraulic cylinder. The
actual position is monitored by
means of a position pick up sensor
and sent to the positioner inte­
grated into the WSR way valve. The
adjustment of hydraulic cylinder
occurs position controlled.
P
T
Hydraulic pilot
control
A, B
T
P
X0, X1
Consumer terminals (outputs)
Tank connection
Oil supply terminal (input)
Parameters for stroke
adjustment (potentiometers)
KPU, KPD Control gains (potentiometers)
w
Position nominal value
(4 – 20 mA)
x
Position actual value
(4 – 20 mA)
Magnetic force
FMag
Force for control spring
F F
Hall voltage
UHall
Reference variable for solenoid
UMag
force FMag
U
Voltage
s
Stroke
i
Position pick up sensor
current signal
7
Large flow rates and maximum accuracy
enable versatile application
Technical data
and characteristics
nSupply
voltage 24 VDC
consumption 1.0 A
nInput signal 4 – 20 mA
nRemote display 4 – 20 mA
nType of protection IP 65
nInput pressure up to 160 bar
n Ambient temperature - 20 to
+ 80 °C for standard design
n Explosion-proof design
EEx d IIC T4 available
nCurrent
Type
Maximum
input pressure
[bar]
P ➞ A
A ➞ T
Type
Maximum
input pressure
[bar]
Flow rate [l/min]
at p = 2 bar
P ➞ A/B
A/B ➞ T
WSR-C25XXX
200
17
62
WSR-D16XXX
up to 160
14
14
WSR-C45XXX
up to 40
22
75
WSR-D24XXX
40
40
40
WSR-C60XXX
up to 40
35
150
WSR-D45XXX
up to 40
80
80
WSR-E60XXX
up to 40
30
350
WSR-D60XXX
40
130
130
WSR-E80XXX
up to 40
50
600
WSR-D80XXX
40
180
180
WSR-K120XXX
25
600
600
WSR-K120XXX
25
600
600
Selection table for 3/3-WSR way valve
System-specific data must be taken
into consideration when defining a
suitable WSR way valve. When se­
lecting a WSR way valve, please
make full use of our comprehensive
knowledge. Our experienced sales
staff will be only too glad to be of
assistance.
8
Flow rate [l/min]
at p = 1 bar
Selection table for 4/3-WSR way valve
Customer benefits
Outstanding reliability and
Dynamic and high-precision
Simple installation and initial
availability
control
startup
n Resolution
n Device
n Well-established
operating
principle
n Dirt-resistant and robust design
Voith Turbo WSR way valves to a
40 MW steam turbine (photo: MAN Turbo)
< 10 µm
n Almost no hysteresis
n Temperature compensation
n Load shedding < 300 ms can be
realized
inspected and configured
at factory (plug & play)
n The stroke range and control re­
sponse of the working cylinder can
be easily changed and optimized
using the potentiometers (X0, X1,
KPU, KPD)
n Turbine lubricating oil can frequent­
ly be used as an operating medium
Standard version, explosion-proof version optional
9
Redundant actuator technology – maximum availability
I/H converter module =2 x I/H converter
+ maximum selection
Position pick
up sensor
x1
i
x2
i
x3
i
Hydraulic cylinder
s
s
s
For process control
engineering
x1
x2
x3
Live
steam
A
X0
X1
+24V
+
w1
Process control engineering
Steam
control
valve
s
U
UHall
X0
+
U
UHall
pA1
FHydr
F
+24V
X1
w2
FMag
FMag
Maximum
selection
FHydr
F
pA2
T
2 x Control magnet
P
Hydraulic pilot control
Function
Dual-channel conversion of electrical
actuating signals into a hydraulic
pressure with maximum selection:
The two electrical actuator signals
w1 and w2 (4 – 20 mA) of a redundant
turbine controller are each converted
separately by a well-established
Voith I/H converter into a propor­
tional hydraulic pressure pA1 and pA2.
Both pressures act on a hydraulic
maximum selection. The higher pres­
sure is switched through (A). The hy­
draulic function can be continuously
10
monitored with the aid of additional­
ly-integrated pressure sensors under
normal operating conditions through
ramp-shaped lowering of the turbine
controller‘s nominal value. This pres­
sure variation enables diagnosis of
each sub-system to be conducted
during operation.
Each I/H converter receives an elec­
tronic monitoring circuit which
serves to ensure that in the event of
any malfunction the I/H converter
then regulates towards minimum
output pressure. The output pres­
sure of the correctly operating I/H
converter is switched through. The
process then continues smoothly.
The faulty device can be replaced
during operation.
Tandem WSR way valve = 2 x control magnet
+ hydraulic component
Position pick
up sensor
x1in
i
x2in i
Hydraulic cylinder
s
s
Steam
control
valve
s
Live
steam
-
Process control engineering
+ X0
X1
X1
x1out
w1
-
+ X0
x2out
+24V
-
U
+
KPU KPD
UHall
+24V
FMag F
U
+
KPU KPD
A
FMag
FF
F
UHall
w2
T
Control magnet 1
Control magnet 2
Function
Both control magnets are given a
separate nominal value (w1 and w2)
and a separate position pick up
sensor (x1in and x2in) is connected to
each control magnet. The control
magnet 1 armature moves the con­
trol piston of the hydraulic pilot
control via the control magnet 2
armature. If control magnet 1 is
active then control magnet 2 is
inactive, although switched on.
In the event of a malfunction, the
control magnet 1 is switched off
and control magnet 2 is activated
over the nominal value (w2) using a
specific transit time („warm redun­
dancy“). The switching logic is lo­
cated externally in the control engin­
eering and it monitors the control
magnets (position pick up sensor
displays x1out and x2out). It also gener­
ates the switchover signals.
Tandem WSR way valves are also
available as 3/3 and 4/3 versions.
P
Hydraulic pilot control
A
T
P
pA1, pA2
X0, X1
Consumer terminal (output)
Tank connection
Oil supply terminal (input)
Output pressure for I/H converter
Parameters for stroke or pressure
adjustment (potentiometers)
KPU, KPD Control gains (potentiometers)
w
Stroke or pressure nominal value
(4 – 20 mA)
x
Position actual value (4 – 20 mA)
Magnetic force
FMag
Hydraulic force
FHydr
Force for control spring
F F
Hall voltage
UHall
U
Voltage
s
Stroke
i
Position pick up sensor current
signal
11
cr304en, S&F /WA, 06.2010, 1500. Dimensions and illustrations without obligation. Subject to modifications.
Voith Turbo GmbH & Co. KG
Electronic Drive Systems
Voithstr. 1
74564 Crailsheim, Germany
Tel. +49 7951 32-470
Fax +49 7951 32-605
turcon@voith.com
www.voithturbo.com/actuation-control-turbomachinery