Well-established technology

Electro-hydraulic I/H converters

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.

Outstanding reliability

The electro-hydraulic I/H converters

and WSR way valves design is a

simple one:nControl magnet with integrated

electronicsnHydraulic component

This simple and compact design

serves to ensure high operational

reliability coupled with availability of

the components, and your system.

All the world‘s our home

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.

Electro-hydraulic I/H Converters and WSR Way Valves Actuator Technology for Positioning Cylinders on Turbomachinery

4 1 5 3 2 6 7

T A P

2

Design

A Voith I/H converter is an electric-

ally-controllable pressure regulating

valve, consisting of force-controlled

solenoid and a hydraulic component.

I/H converters

Voith Turbo I/H converters convert a 0/4 – 20 mA current

input signal quickly and precisely into proportional output

pressure.

A Consumer terminal (output)T Tank connectionP Oil supply terminal (input)1 Control magnet housing2 Tappet3 Potentiometer4 Manual adjustment5 Electrical connection6 Hydraulic component7 Control piston

+24V

T P T P

X1X0A

T P

Pilot valve

A

Proc

ess

cont

rol e

ngin

eerin

g

Control magnet Hydraulic pilot control

A

For process control engineering

FMag

is

FHydr

Position pick up sensor ss

s

Live steam

Electronic position return

Live steam

Live steam

Steam valve

3

w

Pilot valve

Mechanical position return

UF

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).

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.

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

Simple design and well-established operating principle

A Consumer terminal (output)T Tank connectionP Oil supply terminal (input)X0, X1 Parameters for output

pressure range (potentiometer)

FMag Magnetic forceFHydr Hydraulic forceUHall Hall voltageU Voltages Strokei Position pick up sensor

current signalw Nominal value for output

pressure

UHALL

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.

+

-

4

Versatile application made possible by robust design and maximum precision

Technical data

and characteristics

nSupply voltage 24 VDCnCurrent consumption 1.0 An Input signal 0/4 – 20 mAnType of protection IP 65n Input pressure up to 70 barnAmbient temperature - 20 to

+ 80 °C for standard designnExplosion-proof design

EEx d IIC T4 available

Voith Turbo I/H converters to a 300 MW steam turbineSelection 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.

Type Maximum input pressure

[bar]

Control range for output pressure

[bar]

Flow rate [l/min] at p = 1 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

5

Simple installation and initial

startup

nDevice inspected and configured

at factory (plug & play)nmin. and max. Output pressures can

be changed simply using parameters

X0 and X1 (potentiometers)nTurbine lubricating oil can frequently

be used as an operating mediumnDepending on the model in ques-

tion, adapter plates, flushing

plates and connecting cables are

available

Outstanding reliability and

availability

nWell-established operating

principlenDirt-resistant and robust design

Customer benefits

Voith Turbo I/H converters to a 3.4 MW steam turbine(Photo: AG KK&K – www.agkkk.de)

Explosion-proof design (left) and standard designVoith Turbo I/H converters to a 300 MW steam turbine

Dynamic and precise positioning

of the output pressure

nReproducibility < 0.1 %nAlmost no hysteresisnTemperature compensationnNo driftingn Input pressure at least 0.5 bar

higher than maximum output

pressurenFast response time

6

4 13 3 2 6 7 853/3 -WSR way valve

A Consumer terminal (output)T Tank connectionP Oil supply terminal (input)1 Control magnet housing2 Tappet3 Potentiometer4 Manual adjustment5 Electrical connection6 Hydraulic component7 Control piston8 Control spring

WSR way valves

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.

Voith Turbo WSR way valves with integrated positioner convert in

combination with an hydraulic cylinder a 4 – 20 mA current input

signal quickly and pre cisely 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.

T A P

7

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.

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

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

4/3-WSR way valve for dual-acting hydraulic cylinders3/3-WSR way valve for single-acting hydraulic cylinders

X1

X0

Position pick up sensor

sSteam control valve

Live steam

A+24V

T P

FMag FF

x

Proc

ess

cont

rol e

ngin

eerin

g

Proc

ess

cont

rol e

ngin

eerin

g

sSteam control valve

Live steam

Hydraulic cylinder

w

A+24V

T

FMag

x

w

P T

B

Control magnetHydraulic pilot

controlControl magnet

A, B Consumer terminals (outputs)T Tank connectionP Oil supply terminal (input)X0, X1 Parameters for stroke

adjustment (potentiometers)KPU, KPD Control gains (potentiometers)w Position nominal value

(4 – 20 mA)x Position actual value

(4 – 20 mA)FMag Magnetic forceFF Force for control springUHall Hall voltageUMag Reference variable for solenoid

force FMag

U Voltages Strokei Position pick up sensor

current signal

is

is

UF

UF

UHall

UMag FF

Hydraulic pilot control

KPU

KPD

KPU

KPD

UMag

Hydraulic cylinder

Position pick up sensor

UHall

+

-

+

-

X1

X0+

-

+

-

8

Large flow rates and maximum accuracy enable versatile applicationTechnical data

and characteristics

n Supply voltage 24 VDCn Current consumption 1.0 An Input signal 4 – 20 mAn Remote display 4 – 20 mAn Type of protection IP 65n Input pressure up to 160 barnAmbient temperature - 20 to

+ 80 °C for standard designnExplosion-proof design

EEx d IIC T4 available

Selection table for 4/3-WSR way valveSelection 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.

Type Maximum input pressure

[bar]

Flow rate [l/min] at p = 1 bar

P ➞ A A ➞ T

WSR-C25XXX 200 17 62

WSR-C45XXX up to 40 22 75

WSR-C60XXX up to 40 35 150

WSR-E60XXX up to 40 30 350

WSR-E80XXX up to 40 50 600

WSR-K120XXX 25 600 600

Type Maximum input pressure

[bar]

Flow rate [l/min] at p = 2 bar

P ➞ A/B A/B ➞ T

WSR-D16XXX up to 160 14 14

WSR-D24XXX 40 40 40

WSR-D45XXX up to 40 80 80

WSR-D60XXX 40 130 130

WSR-D80XXX 40 180 180

WSR-K120XXX 25 600 600

9

Dynamic and high-precision

control

nResolution < 10 µmnAlmost no hysteresisnTemperature compensationnLoad shedding < 300 ms can be

realized

Outstanding reliability and

availability

nWell-established operating

principlenDirt-resistant and robust design

Customer benefits

Voith Turbo WSR way valves to a 40 MW steam turbine (photo: MAN Turbo)

Standard version, explosion-proof version optional

Simple installation and initial

startup

nDevice inspected and configured

at factory (plug & play)nThe stroke range and control re-

sponse of the working cylinder can

be easily changed and optimized

using the potentiometers (X0, X1,

KPU, KPD)nTurbine lubricating oil can frequent-

ly be used as an operating medium

For process control engineering

is

UF

pA1

pA2

A

T P

is

is

UF

10

Proc

ess

cont

rol e

ngin

eerin

g

Redundant actuator technology – maximum availability I/H converter module = 2 x I/H converter + maximum selection

w1

X1X0

2 x Control magnet Hydraulic pilot control

w2

x1

x2

x3

X1X0

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-

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.

x1

x2

x3

Steam control valve

Live steam

s

Position pick up sensor

Hydraulic cylinder

FHydrFMag

FMag

+24V

+24VFHydr

UHall

UHall

+

+

-

-

Maximum selection

UF

UF

is

is

11

Tandem WSR way valve = 2 x control magnet + hydraulic component

Proc

ess

cont

rol e

ngin

eerin

g

FF

A+24V

T

FMag

w2 P

Control magnet 1 Hydraulic pilot control

FMagw1

+24Vx1out

x2out

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.

UHall

s

A Consumer terminal (output)T Tank connectionP Oil supply terminal (input)pA1, pA2 Output pressure for I/H converterX0, X1 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)FMag Magnetic forceFHydr Hydraulic forceFF Force for control springUHall Hall voltageU Voltages Strokei Position pick up sensor current

signal

X1X0

X1

X0

x1in

x2in

Steam control valve

Live steam

Position pick up sensor

Hydraulic cylinder

UHallKPDKPUKPDKPU

+

-

+

-

+

-

+

-

Control magnet 2

cr30

4en,

S&

F /W

A, 0

6.20

10, 1

500.

Dim

ensi

ons

and

illu

stra

tions

with

out

ob

ligat

ion.

Sub

ject

to

mo

difi

catio

ns.

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