INSTRUCTION MANUAL

I/P Converter

DSG BXXY3Z
DSG BXXY4Z
Revision 2.0

Voith Turbo GmbH & Co. KG D-74564 Crailsheim

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 Should you have any questions concerning the I/P converter,
please contact the Service Department of the Product Group
Electric Actuators and Controllers
Voith Turbo GmbH & Co. KG, Crailsheim.

Voith Turbo GmbH & Co. KG

P.O. Box 15 55
74555 Crailsheim / Germany

Switchboard: ..49-7951/32-0
Telefax No.: ..49-7951/32-500

Electric Actuators and Controllers:

Direct dial No.: ..49-7951/32-470
Direct fax No.: ..49-7951/32-605
Email: turbinenstelltechnik@voith.de

Address for goods supplied:

Voith Turbo GmbH & Co. KG
ce Dept.
Brunnenstr. 51
74564 Crailsheim / Germany

This Instruction Manual describes the technical condition of the:

- I/P converter DSG-BXXY3Z and

- I/P converter DSG-BXXY4Z for delivery from August 1999

Voith Turbo GmbH & Co. KG 1999

This Instruction Manual is protected by copyright.

It is not allowed to be copied or translated by mechanical or
electronic process as a whole or in parts, nor submitted to third
parties without the publisher's written approval.

Date of issue: 09/00

Order No.: 3 626 016136 en
Revision: 2.0
Document No.: 9 117419 0

Printed in Germany

Voith Turbo GmbH & Co. KG D-74564 Crailsheim

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 Contents
1 Technical Data

2 Safety Information
2.1 Definition of symbols and notes
2.2 Use in accordance with regulations
2.3 General information
2.4 Warranty

3 Functional Description
3.1 Mechanical design
3.2 Operation

4 Transport and Storage

5 Installation and Connection
5.1. Hydraulic connection
5.2 Electric connection

6 Commissioning and Adjustments

6.1 Commissioning
6.2 Adjustments

7 Operation
7.1 Operation with manual operation knob
7.2 Operation with set signal

8 Switching-off
9 Servicing
10 Trouble-Shooting
11 Enclosures

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 1 Technical Data

Electric data:

- Supply voltage 24 VDC

(permissible range 20...30 VDC,
incl. residual ripple)
- Rated power consumption 17.6 W
- Max. power consumption 60 W
- Setpoint input w = 4...20 mA
Coupled against 24 VDC and protected against
overload.
Max. permissible electric potential to 24 VDC
and GND 50 V.
Input resistor approx. 36 ohms with suppressor
circuit.
- Emergency switching-off At w < 2 mA, quick de-energizing of magnet
coil. Result: PA 0 bar.
At w > 3 mA, normal operation again.
- Monitoring switching-off At f = 0 Hz (failure of control frequency),
downward regulation to and memory of
PA 0 bar.
Reset by:
w < 2 mA for t 1 ms or
interruption of 24 VDC for t 2 ms
- OK signal Output signals response of monitoring
switching-off.
(see chapter 11, outline drawings)
- Types of protection IP65 to DIN40050 to EN60529
- Ex-protection EEx d IIC T4 to EN50018

Hydraulic data:

- Pressure fluid mineral oil or hydraulic oil

- Oil purity class Recommended purity class:
to NAS1638 class 7
to ISO4406 class 16/13
- Input pressure (min.) 1,5 bar + PA (max.)
- Leakage 4 l/min
- Viscosity 10...400 cSt
- Attenuation adjustable by closing max. 3 attenuation
holes with set screws M3x5 in the
magnet armature
- Design free from non-ferrous heavy metal

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 Type DSG-

B05... B07... B10... B14... B20... B30... B35...

Pressure regulating
range 0..5 1..7 0..10 1.5..14 0..20 0..30 2..35
PA [bar]
Input pressure
40 40 40 40 40 70 70
P(MAX) [bar]
Flow rate
QP A [l/min] 18.6 18.6 16.8 16.8 9.8 20.5 20.5
at P = 1 bar
Flow rate
QA T [l/min] 20.5 20.5 18.8 18.8 12.0 22.3 22.3
at P = 1 bar
Regul. range approx
PA(MAX) [bar] 2.5..5 3.5..7 2.5..10 5.5..14 8..20 4..30 11..35
at setpoint 20 mA
Regul. range approx
0..1.5 1..2 0..2 1..3 0 0 1..6
PA(MIN) [bar]
0..2.5 1.5..4 0..7.5 2..9 0..5 0..14 2..20
at setpoint 4 mA

The regulating range of PA (MIN) depends on the set pressure PA (MAX).

The regulating range for PA (MIN) indicated in the first line refers to the minimum
adjustable pressure PA (MAX).

Control characteristics:
- Hysteresis 0.01 bar

Dimensions and installation position:

Please see chapter 11, outline drawings.

Electric and hydraulic connection:

Please see chapter 11, outline drawings.

Ambient conditions:
- Ambient temperature -25...+85 C
- Shock resistance 50 g for 0.005 s (total 18 impulses)
- Vibration 18...500 Hz at 4.2 g
- Atmospheric humidity 100% condensing
- Pressure fluid temperature +10...+70 C

Weight: approx. 12 kg

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 2 Safety Information

2.1 Definition of symbols and notes

Danger!
This symbol signals an imminent danger to the life and health of people.
If this note is not observed, serious 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 to or indicate
a dangerous situation.

2.2 Use in accordance with regulations

The I/P converter serves to transform an electric set signal (e.g. 4-20 mA) to the
relevant hydraulic pressure. This allows, for example, a continuous adjustment of the
control piston or working piston.

2.3 General information

Instruction Manual:
The instruction manual contains important information for proper handling of the
I/P converter. Prior to installation and commissioning of the I/P converter, read
the manual carefully. Keep this instruction manual in a location convenient to the
operating staff.

Prevention of accidents / environmental protection:

The I/P converter is an electro-hydraulic unit.
In case of improper use, oil under pressure may leak out.

In the event of improper mounting, connection or commissioning, the type

of protection indicated will no longer be guaranteed.

In addition to the instruction manual: Have the regulations for prevention of accidents
and environmental protection available.

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 Staff:
Only trained personnel is allowed to perform installation and commissioning.

Please obligatorily observe the applicable standards and regulations when working
on units with explosion protection.

Constructional modifications:
Construction modifications are allowed only with the approval of Voith Turbo,
Crailsheim.

2.4 Warranty
The 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, set-up, commissioning, operation, maintenance

and repair of the servomotor.

Not observing the safety regulations and guidelines included in this instruction
manual.

Using spare parts not approved by Voith.

Note!
It is only allowed to perform repair work on the I/P converter after obtaining Voith Turbo
GmbH & Co. KG, Crailsheim approval.

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 3 Functional Description

3.1 Mechanical design

Picture 3.1.1

1 - control magnet P - input pressure

2 - tappet for power transmission PA - output signal pressure
3 - potentiometer X0 and X1
4 - manual operation knob T1 - tank return line
5 - electric connection T2 - tank return line
6 - control housing FMag - magnetic force
7 - control piston FHyd - hydraulic force
8 - cover

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 3.2 Operation
see picture 3.1.1

A set signal w = 4...20 mA generates a magnetic force FMag in the control magnet the
limits of which can be adjusted by means of the potentiometers X0 and X1 and which
is then transmitted to the control piston via the tappet.
The hydraulic force FHyd being proportional to the output signal pressure PA acts
against this force.
When both forces are identical, the control piston is located in the "hydraulic centre
position" shown and the output signal pressure PA corresponds to the set signal. The
"hydraulic centre position" is the control piston position where this piston performs
minimum oscillating movements in the area of the control edges P PA and PA T
until the output signal pressure PA corresponds to the value set by FMag.
When increasing, for example, the set signal and thus FMag from this condition, the
control piston position changes so that the output PA is connected to the feed
pressure P and PA is blocked to the tank return line T1. Now the pressure PA
increases until the control piston returns to the "hydraulic centre position" and PA
corresponds to the new set signal.

Function of manual operation knob:

The control magnet of I/P converter is provided with manual operation knob. With help
of this manual operation knob, a spring force can be adjusted and set, instead of the
magnetic force FMag, which acts on the control piston via the magnet armature and
tappet. The hydraulic force FHydr. being proportional to the output signal pressure PA
also acts against this spring force here. So the output signal pressure can be adjusted
without electric connection.

4 Transport and Storage

The outer surfaces of I/P converter are protected by means of a preserving
surface coat.
The inner parts are preserved by oil prior to shipment.
This preservation ensures the I/P converter's protection against corrosion for a
short storage under normal ambient temperatures.

The I/P converter is shipped in a special packing.

All holes are sealed by means of plugs or protective caps.

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 5 Installation and Connection
Perform any connection and installation work on the I/P converter only when it is
deenergized and the oil supply system is turned off.
When removing the seals from the I/P converter, existing residual oil may leak out.
Collect any oil leaking out in an appropriate receptacle.

When assembling the piping, ensure that it is fastened to fixed structures, free from
vibration and not to moving equipment.
Temperature variations of the piping (thus alterations in length) should not apply
external forces to the I/P converter.
Fibrous or hardening sealing compounds, such as hemp or adhesive cement, must
not be used.
Prior to mounting the piping, clean them from dirt, scale, sand, chips etc. Pickle or
flush welded pipes.
After having mounted the piping and hose lines, clean and flush them thoroughly.
Make sure that the I/P converter is not connected.
Maximum cleanliness is imperative for all work. Prior to loosening unions, clean the
external environment. Close all holes by means of protective caps. Make sure that
impurities cannot enter the I/P converter or the piping.
=> For flushing, a flushing plate, art. No. 43.8565.10, is available.

5.1 Hydraulic connection

The hydraulic connection on the I/P converter is made by means of connecting bores
on the I/P converter bottom. Sealing is made by O-rings.
Dimensions and position of connecting bores, please see chapter 11.
=> To connect the I/P converter to a piping system, adapters, art. No. 43.9299.80,
43.9300.11 and 91865632 are available.

5.2 Electric connection

Connecting wires to the I/P converter provided by the customer shall be screened lines.
Connect the screens on the infeed point to the reference potential.
Avoid that the connecting wires to the I/P converter run parallel to the wires of load-
commutated inverters.
If an I/P converter with ex-protection is connected, observe the requirements stipulated
in the relevant standards and regulations.
Please refer to the outline drawings of chapter 11 with regard to the connecting
diagrams.

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 6 Commissioning and Adjustments
6.1 Commissioning
The I/P converter was adjusted and tested at Voith Turbo's works by means of the
potentiometers X0 and X1. The test results as well as the parameters set are
documented in an attached test certificate.
The set potentiometers are provided with a protective cap to avoid any unintentional
maladjustment.

Observe the following on commissioning of the I/P converter:

Check the line mounting, connection and flow direction to and on the I/P converter.
Check the electric connection of I/P converter.
Check the oil cleanliness.
Specified oil cleanliness, see chapter 1: Technical Data.

Impurities in the oil reduce the service life and reliability of the hydraulic components
used and also impair the control behaviour of I/P converter.

Switch on the 24 VDC power supply.

Switch on the oil supply.
Set the signal 4...20 mA and check the output signal pressure.

Now commissioning is complete.

6.2 Adjustments
With help of the potentiometers X0 and X1, the pressure range can be easily adjusted
to the respective requirements within the limits indicated in chapter 1.

When doing so, observe that X1 should be adjusted before X0.

Adjustment of max. output signal pressure:

During this adjustment and on operation, make sure that the input pressure exceeds
the set output signal pressure at 20 mA by approx. 1.5 bar.

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 At a set signal of 20 mA, adjust the potentiometer X1 so that the max. output signal
pressure is on the I/P converter output.
Direction of control action:
Pressure increase by turning the potentiometer X1 clockwise (cw).

Adjustment of minimum output signal pressure:

At a set signal of i=4mA, adjust the potentiometer X0 so that the min. output signal
pressure is on the I/P converter output.
Direction of control action:
Pressure increase by turning the potentiometer X0 clockwise (cw).

7 Operation
7.1 Operation with manual operation knob

Operation with manually controlled rotary knob is possible without electric energy.

On operation with manually actuated rotary knob, uncontrolled stroke movements of

the hydraulic components controlled by the I/P converter output might produce due
to the increase in the output signal pressure.

Operation with manual operation knob is only possible when the circlip is removed
from the manual operation knob.
On completion of operation with manual operation knob, move the manual operation
knob in its final position by turning it counterclockwise and pushing in
the circlip to its final position.

How to adjust the output signal pressure:

Remove the circlip.

Slowly adjust the manual operation knob and observe the output signal pressure.
Direction of control action:
Pressure increase on the I/P converter output by clockwise (cw) rotation.

7.2 Operation with set signal

Operation with set signal is only possible after having turned the manual operation
knob counterclockwise in its final position and pushing in the circlip to its final position.

When the supply voltage is switched on, the output signal pressure can be adjusted
continuously by the set signal 4...20 mA, within the limits set by the potentiometers X0
and X1.

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 8 Switching-off

If an I/P converter is switched off for reasons of repair or unit shutdown, proceed as
follows:
Switch off the oil supply system and reduce the pressure in the existing
accumulators if necessary.
Switch off the 24VDC supply voltage and the set signal.
Clean the I/P converter, location of installation and particularly the area around
the installation surface of the hydraulic component.
Remove the I/P converter and collect the residual oil leaking out of the piping
and I/P converter.
Close all holes on the hydraulic component and pack the I/P converter carefully and
with clean material to avoid any damage, in particular of the electric connections.

In the event of a possible disposal of I/P converter, observe the local applicable
regulations regarding the environmental protection.
The I/P converter contains:
synthetic materials
copper
electronic components
residual oil

9 Servicing
For a trouble-free and reliable operation of the I/P converter, it is necessary to perform
supervision, maintenance and repair work in certain intervals.

Continuous monitoring:
Monitoring of lines, unions and connections on the I/P converter with regard to
leakage, impurities and damage.
Eliminate any leakage, impurity and damage noticed, if required, during appropriate
operating modes.

Monitor the I/P converter's control behaviour for any changes.

Analyse and eliminate the causes, if required, during appropriate operating modes.

Monitoring after approx. 740 operating hours, max. one / month:

Take an oil sample from the oil tank and analyse for impurities by solid and
suspended matters, water content, discolouration and air bubbles.
Check the oil sample cleanliness.
If required, clean or change the oil during an appropriate operating mode.

Monitoring after approx. 8000 operating hours, max. one / year:

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 Take 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 I/P converter's electric connections.

10 Trouble-Shooting
Malfunction: Pressure variations
Cause: low or considerably varying input pressure
Under load and in particular in case of a higher output signal
pressure, a lower input pressure may lead to pressure
variations.

Remedy:
Increase and/or stabilise the input pressure by taking
appropriate measures (e.g. accumulator).
See also chapter 6.2.

Malfunction: Pressure variations

Cause: air inclusion in the I/P converter
On first commissioning, air inclusion may lead to output
pressure variations.

Remedy:
By means of changing the set signal periodically (approx.
0.5 Hz) by +/- 6 mA over a few minutes, the air in the anchor
chamber of control magnet escapes.

Malfunction: Pressure variations

Cause: dirt particles in the hydraulic component
On first commissioning or after longer operation with a
contaminated oil, dirt particles might get inside the I/P
converter thus impairing the control piston function due to
increased abrasion.

Remedy:
Open the hydraulic component and clean the inner elements.
Examine the inner elements and replace them in case of
damage.

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 Malfunction: Output signal pressure PA 0bar
Cause: monitoring system causes shutdown
Shutdown by the monitoring system can be recognized only if
the OK signal is evaluated in accordance with the connecting
diagram.

Remedy:
If the malfunction cannot be remedied by the reset described in
chapter 1, please try to adjust the output signal pressure with
help of the manually controlled rotary knob.
If the pressure can be adjusted by the manually controlled
rotary knob, the control magnet is defective and the I/P
converter needs to be replaced by new one or repaired.
If the pressure cannot be adjusted by the manually controlled
rotary knob, please check the input pressure.

11 Enclosures

Outline Drawing 3623-017369 (normal design without hydr. attenuation)

Outline Drawing 3623-017370 (ex-protected design without hydr. attenuation)
Outline Drawing 3623-017449 (normal design with hydr. attenuation)
Outline Drawing 3623-017464 (ex-protected design with hydr. attenuation)
Flushing plate 43.8565.10
Adapter 43.9300.11
Adapter 43.9299.80
Adapter 91865632

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