Electro-hydraulic I/H converter and WSR way valve, actuator

technology for positioning cylinders on turbo machinery

Well-established technology Outstanding reliability All the world‘s our home

Electro-hydraulic I/H converter and
WSR way valves are the ideal eco-
nomic solution for controlling hy-
draulic positioning cylinders. This
enables a valve to regulate the
mass flow (e.g. steam) in a precise
and highly dynamic manner.
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.
The electro-hydraulic I/H converter
and WSR way valve design is a
simple one:
■ Control magnet with integrated
electronics
■ Hydraulic component
This simple and compact design
serves to ensure high operational
reliability coupled with availability of
the components, and your system.
We are a reliable partner to manu-
facturers and operators of turbo ma-
chines in all international markets.
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 A P

Design

A Voith I/H converter is an electric-

ally-controllable pressure regulating
valve, consisting of force-controlled
solenoid and a hydraulic component.

2
Simple design and well-established operating principle

Application principle 1: Application principle 2: Application principle 3:

Direct actuation of a Operation of a pilot valve with Operation of a pilot valve with
hydraulic cylinder mechanical position return electronic position return

Mechanical Position pick Electronic

position return up sensor position return
s s
i
For s
s process
A control A
Steam engineering
valve

Live Live
Pilot T P steam Pilot T P steam
valve valve
Live
steam

A Consumer terminal (output)

T Tank connection
A
X0 X1 +24V P Oil supply terminal (input)
X0, X1 Parameters for output
Process control engineering

pressure range
w + U (potentiometer)
F FMag Magnetic force
- FMag FHydr
FHydr Hydraulic force
UHALL
UHall Hall voltage
U Voltage
s Stroke
T P i Position pick up sensor
current signal
w Nominal value for output
Control magnet Hydraulic pilot control pressure

Function

Solenoid-force control generates a The control magnet applies the As a result of this regulation, the
magnetic force of FMag in a 24V d.c. force FMag to the control piston. This output line of the actuator always
solenoid. This magnetic force is pro- in turn counteracts hydraulic force receives the exact required pres-
portional to the 0/4 – 20 mA input FHydr as generated by the pressure sure and the oil quantity for pos-
signal (w), the limits are configured at output A over the cross-sectional itioning the steam or fuel valves.
using the X0 and X1 parameters. area of the control piston (pressure
The electronic control, magnetic regulator).
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.

3
 Versatile application made possible by robust design
and maximum precision

Technical data
and characteristics

■ Supply voltage 24 VDC

■ Current consumption 1.0 A
■ Input signal 0/4 – 20 mA
■ Type of protection IP 65
■ Input pressure up to 70 bar
■ Ambient temperature - 20 to
+ 80 °C for standard design
■ Explosion-proof design
EEx d IIC T4 available

Type Maximum input Control range for

pressure [bar] output pressure* [bar]

DSG-B03XXX 40 0–3

DSG-B05XXX 40 0–5

DSG-B07XXX 40 1–7

DSG-B10XXX 40 0 – 10

DSG-B30XXX 70 2 – 30
* Flow rate at p = 1 bar: ~30 l / min to
consumer (P ➞ A) and to tank (A ➞ T)

Selection table Voith Turbo I/H converters to a 300 MW steam turbine

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
Customer benefits
Outstanding reliability and
availability
■ Well-established operating
principle
■ Dirt-resistant and robust design
Voith Turbo I/H converters to a
3.4 MW steam turbine
(Photo: AG KK&K – www.agkkk.de)
Dynamic and precise positioning
of the output pressure
■ Reproducibility < 0.1 %
■ Almost no hysteresis
■ Temperature compensation
■ No drifting
■ Input pressure at least 0.5 bar
higher than maximum output
pressure
■ Fast response time
Explosion-proof design (left) and standard design
Simple installation and initial
startup
■ Device inspected and configured
at factory (plug & play)
■ min. and max. Output pressures can
be changed simply using parameters
X0 and X1 (potentiometers)
■ Turbine lubricating oil can frequently
be used as an operating medium
■ Depending on the model in ques-
tion, adapter plates, flushing
plates and connecting cables are
available
5
 WSR way valve

Voith Turbo WSR way valves with integrated positioner convert a

4 – 20 mA current input signal quickly and precisely into a propor-
tional 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 A P

Design

A Voith Turbo WSR way valve (fuel-

quantity 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
Integrated control electronics for dynamic
and high-precision changes in flow rate

3/3-WSR way valve for single-acting hydraulic cylinders 4/3-WSR way valve for dual-acting hydraulic cylinders

Position pick Hydraulic Position pick Hydraulic

up sensor cylinder up sensor cylinder
s s
i Steam i Steam
control control
s valve s
valve

Live steam Live steam

- -
+ X0 + X0
X1 X1
Process control engineering

Process control engineering

+24V +24V
x A x A B
UMag FMag FF UMag FMag FF
- -
w U w U
+ F + F
KPU UHall KPU UHall
KPD KPD
T P T P T

Hydraulic pilot Hydraulic pilot

Control magnet Control magnet
control control

Function A, B Consumer terminals (outputs)

T Tank connection
The specific system deviation (nom- until the travel-specific spring force P Oil supply terminal (input)
X0, X1 Parameters for stroke
inal value w - actual value x) and the FF balances out against the force
adjustment (potentiometers)
set control gain KPU resp. KPD, FMag. This results in a volumetric KPU, KPD Control gains (potentiometers)
yields a reference variable UMag for flow that can be changed in both w Position nominal value
(4 – 20 mA)
the solenoid force control. The mag- direction and size, and which can
x Position actual value
netic force FMag generated in the adjust the stroke s of an externally (4 – 20 mA)
magnet system is monitored indir- mounted hydraulic cylinder. The FMag Magnetic force
FF Force for control spring
ectly through measurement of the actual position is monitored by
UHall Hall voltage
magnetic flux over UHall and sent means of a position pick up sensor UMag Reference variable for solenoid
back to the controller. FMag acts via and sent to the positioner inte- force FMag
U Voltage
the tappet on the control piston of grated into the WSR way valve. The
s Stroke
the hydraulic pilot control. This is adjustment of hydraulic cylinder i Position pick up sensor
deflected against the control spring occurs position controlled. current signal

7
 Large flow rates and maximum accuracy
enable versatile application
Technical data
and characteristics

■ Supply voltage 24 VDC

■ Current consumption 1.0 A
■ Input signal 4 – 20 mA
■ Remote display 4 – 20 mA
■ Type of protection IP 65
■ Input pressure up to 160 bar
■ Ambient temperature - 20 to
+ 80 °C for standard design
■ Explosion-proof design
EEx d IIC T4 available

Type Maximum input Flow rate [l/min] Type Maximum input Flow rate [l/min]
pressure [bar] at p = 1 bar to … pressure [bar] at p = 2 bar

Consumer Tank WSR-D16XXX up to 160 12

WSR-C45XXX up to 40 22 75 WSR-D24XXX 40 28

WSR-C60XXX up to 40 35 150 WSR-D45XXX up to 40 75

WSR-E60XXX 25 30 350 WSR-D60XXX 40 130

WSR-K120XXX 20 600 600 WSR-L120XXX 20 600

Selection table for 3/3-WSR way valve Selection table for 4/3-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
Customer benefits
Outstanding reliability and
availability
■ Well-established operating
principle
■ Dirt-resistant and robust design
Voith Turbo WSR way valves to a
40 MW steam turbine (photo: MAN Turbo)
Dynamic and high-precision
control
■ Resolution < 10 µm
■ Almost no hysteresis
■ Temperature compensation
■ Load shedding < 300 ms can be
realized
Standard version, explosion-proof version optional
Simple installation and initial
startup
■ Device inspected and configured
at factory (plug & play)
■ The stroke range and control re-
sponse of the working cylinder can
be easily changed and optimized
using the potentiometers (X0, X1,
KPU, KPD)
■ Turbine lubricating oil can frequent-
ly be used as an operating medium
9
 Redundant actuator technology – maximum availability
I/H converter module = 2 x I/H converter
+ maximum selection

Position pick
up sensor
x1 i
s Hydraulic cylinder
s
x2 Steam
i control
s
valve
x3 i
s
For process control
engineering Live
steam

x1 A
x2
x3 X0 X1 +24V pA1
FMag FHydr Maximum
w1 + U selection
F
Process control engineering

-
UHall

X0 X1 +24V
FMag FHydr
w2 +
U
- F
UHall pA2
T P

2 x Control magnet 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
monitored with the aid of additional- output pressure. The output pres-
ly-integrated pressure sensors under sure of the correctly operating I/H
normal operating conditions through converter is switched through. The
ramp-shaped lowering of the turbine process then continues smoothly.
controller‘s nominal value. This pres- The faulty device can be replaced
sure variation enables diagnosis of during operation.
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

10
Tandem WSR way valve = 2 x control magnet
+ hydraulic component
Position pick
up sensor
x1in i Hydraulic cylinder
s
s Steam
control
x2in i valve
s

Live
steam

- -
x2out + X0 + X0
X1
Process control engineering

X1 +24V +24V
x1out A
w1 - FMag - U FMag FF
U
+ F F
+
UHall UHall
KPU KPD KPU KPD

w2 T P

Control magnet 1 Control magnet 2 Hydraulic pilot control

Function A Consumer terminal (output)

T Tank connection
Both control magnets are given a and control magnet 2 is activated P Oil supply terminal (input)
pA1, pA2 Output pressure for I/H converter
separate nominal value (w1 and w2) over the nominal value (w2) using a
X0, X1 Parameters for stroke or pressure
and a separate position pick up specific transit time („warm redun- adjustment (potentiometers)
sensor (x1in and x2in) is connected to dancy“). The switching logic is lo- KPU, KPD Control gains (potentiometers)
w Stroke or pressure nominal value
each control magnet. The control cated externally in the control engin-
(4 – 20 mA)
magnet 1 armature moves the con- eering and it monitors the control x Position actual value (4 – 20 mA)
trol piston of the hydraulic pilot magnets (position pick up sensor FMag Magnetic force
FHydr Hydraulic force
control via the control magnet 2 displays x1out and x2out). It also gener-
FF Force for control spring
armature. If control magnet 1 is ates the switchover signals. UHall Hall voltage
active then control magnet 2 is Tandem WSR way valves are also U Voltage
s Stroke
inactive, although switched on. available as 3/3 and 4/3 versions.
i Position pick up sensor current
In the event of a malfunction, the signal
control magnet 1 is switched off

11
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

Cr 304 en, 02.2007, 1500, aik / K&E. Dimensions and illustrations without obligation. Subject to modifications.