Koso REXA Electraulic Xpac Installation And Operation Manual Download Page 17

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REXA

Electraulic Actuators & Drives

Xpac

Installation Manual -- Version 5.1 (5/08)

1.5.12 Split Clamps

On linear actuators mounted at unusual angles or with reduced ac-
cessibility, a split clamp connection between the actuator and driven
device is available. The difﬁculties of stem rotation, shaft insertion
and jam nuts are eliminated.

Summary of Contents for REXA Electraulic Xpac

Page 1: ...IOM 05 09...

Page 2: ...Xpac Installation Manual Version 5 1 5 08 REXA Electraulic Actuators Drives 2...

Page 3: ...ot 8 1 5 12 Split Clamps 9 2 DELIVERY 10 2 1 Receipt 10 2 2 Storage 10 2 3 Unpacking 10 3 OIL 11 3 1 Level Check 11 3 2 Filling 11 3 3 Oil Weeping 12 4 MECHANICAL INSTALLATION 13 4 1 R Series Rotary 1...

Page 4: ...itudinal Misalignment 41 7 4 Tuning 41 7 5 Output 42 7 5 1 Fail In Place Actuators 43 7 5 2 Spring Failure Actuators 43 7 6 Temperature 43 8 ERROR CODES 45 8 1 Loss of Feedback E Fb 45 8 2 Stall E St...

Page 5: ...1 Alarming Loop p 2 C A Flow Characteristics p 11 F A SLC Feedback Board p 2 P Pulse Auxiliary Board p 1 R 1 Single Enclosure Electronics p 4 R 2 Interconnection Wiring Diagram p 5 T 1 Screw Terminal...

Page 6: ...e from the enclosure before applying power HYDRAULIC OIL The standard oil used in REXA actuators or drives is Castrol Syntec SAE 5W 50 motor oil Oil for special applications such as food grade would b...

Page 7: ...sure nitrogen These actuators also have an automatic recharging cycle for the accumulator Failure to properly follow installation instructions may cause serious injury to maintenance personnel and or...

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Page 9: ...ries are quarter turn actuators designed to operate rotary devices ball valves butter y valves directly coupled louvers etc The L Series are designed for linear applications The D Series of drives are...

Page 10: ...st Rated Strokes lbs in inches 2 000 75 2 4 6 8 11 4 000 75 2 4 5 000 75 2 4 6 8 11 16 22 10 000 75 2 4 6 8 11 16 22 15 000 75 2 4 6 8 11 16 22 20 000 75 2 4 6 8 11 16 22 30 000 75 2 4 6 8 11 16 22 40...

Page 11: ...correct position is reached the motor shuts off Power is not required to maintain actuator position The hydraulics are con trolled by a dedicated microprocessor contained within the control enclosure...

Page 12: ...der is manufactured from a solid block of aluminum Larger size linear cylinders are made of a fabricated tie rod construction The third type used on rotary and drive units is a rack and pinion rotary...

Page 13: ...e power supplies are built into the motor drivers The control enclosure includes one motor driver for each power module The motor driver converts the low power logic signals from the PCP into high vol...

Page 14: ...ze FMV 2 through port A The spool in FMV 2 becomes unbalanced by the pressure differential and moves to the left lifting its check valve opening port D to port B and port A to port E High pressure uid...

Page 15: ...raulic circuit as the motor the required torque is low On actuators with high thrust or torque or long strokes a 5 16 hex drill drive may be substituted for the handwheel or a 5 1 geared hand crank on...

Page 16: ...hile still maintaining the control capability available in the stan dard Fail in Place version the spring failure provides a high degree of safety The spring is continuously engaged and is compressed...

Page 17: ...on 5 1 5 08 9 1 5 12 Split Clamps On linear actuators mounted at unusual angles or with reduced ac cessibility a split clamp connection between the actuator and driven device is available The dif cult...

Page 18: ...inal containers The ambient environment must be Clean no airborne particles or contaminants NonCorrosive minutequantitiesofgasescanconcentrate in a con ned area Dry relative humidity must be suf cient...

Page 19: ...position is shown by a scribe mark around the rod If the indicator protrudes less than inch beyond the housing then the actuator should be lled with oil 3 2 Filling The underside of the Electraulic po...

Page 20: ...use a small amount of oil to weep from the relief valve The actuator is a closed hydraulic system and an increase in oil volume must be purged This action is a normal occurrence If the tempera ture is...

Page 21: ...4 1 2 Universal Rotary Spring Failure CAUTION REXA actuators denoted by an E R or U in the model number contain a spring under tension Fail ure to properly remove this force before disassembly can cau...

Page 22: ...ow mating of the shafts and alignment of the mounting bolts Figure 4 A Universal Spring Alignment Once mounted the spring stops should be withdrawn to a position that transfers torque onto the valve s...

Page 23: ...its rated mark when the valve is seated At that point the load on the valve seat is approximately the net rated output of the actuator Lower rated cou plings are available for applications that requir...

Page 24: ...rotated If the actuator is installed in a vertical position manually stroke it to allowthestemconnectiontoself align Securelytightenthemounting connection Visually inspect the stem for any noticeable...

Page 25: ...he button may be locked in the depressed condition The required clamping force is only 30 40 lbs Do not over tighten the clamp as damage to the nylon valve seat will result in actuator drifting Cautio...

Page 26: ...e driven device linkage is by means of the drive arm Itisusuallysuppliedmanufacturedtotheuser sspeci edlength pin diameter and end undercut as shown in gure 4 D The length of the arm is determined by...

Page 27: ...he major electrical components are located in a NEMA 4X or op tionally in a CSA approved CL I DIV 2 GRP B C D enclosure They have a wide temperature range gure 4 E and can be eld installed at a conven...

Page 28: ...ofacoloredwireandacolored black stripedwire These wires are used for the motor red and green pairs for the cartridge heater black white of the triad included in most actuators and for the optional by...

Page 29: ...ed through for the connections is a inch NPT Remove the four cap screws that retain the junction cavity cover g ure 5 D Feed the module cable through the inch NPT opening and into the cavity Figure 5...

Page 30: ...per ground wire to terminal 14 Earth Ground 5 2 2 Actuator Termination For L series actuators there are two types of feedback termination On units with tie rod hydraulic cylinders thrusts greater than...

Page 31: ...linder until it clears the internal components Feed the cable through the inch NPT opening Wiring connection is made directly to the feedback printed circuit board per gure 5 C p 28 Replace the cover...

Page 32: ...voltage is supplied to the actuator The power rating for each module is Watts B size Power Module 350 C size Power Module 700 2C size Power Modules 1400 Please see TM2 Power Consumption for complete d...

Page 33: ...control signals 4 20 mA 1 5Vdc etc are connected to pins 2 and 3 of the 24 PIN green connector on all actuators Connections for pulse input signals are made on a separate auxiliary board located on to...

Page 34: ...re 9 Spare 10 Solenoid 3 Blue 2 3 11 Solenoid 3 Blue Black 2 3 12 AC Line User Supplied 13 AC Neutral User Supplied 14 Earth Ground User Supplied and Feedback Ground1 15 Heater Black 2 16 Heater White...

Page 35: ...Connection 21 Solenoid Blue4 3 22 Solenoid Blue Black4 3 23 Motor 2 Phase A Green4 24 Motor 2 Phase A Green Black4 25 Motor 2 Phase B Red 26 Motor 2 Phase B Red Black 27 Act Earth Ground Green Yellow...

Page 36: ...lue 3 Solenoid Blue Black 2 3 Blue 3 FEEDBACK CABLE L Series right angle junction box Bullet Connectors 15Vdc Red 1 Red Feedback White 1 White Feedback Black 1 Black R or D Series Feedback Enclosure S...

Page 37: ...he user through the operation and calibration of an Xpac They are the Operating Parameter Sheet af xed to the cover of the Control Enclosure and the Setup Quick Reference contained in the Appendix Aft...

Page 38: ...manual mode is exited by pressing the E NTER key CONTROL SIGNAL The other two functions available in the LOCAL mode are accessed by pressing the Scroll Down key when the label P is not blinking The rs...

Page 39: ...Subsequent use of the Scroll Down key displays the next succeeding parameter until the end of the sub menu is reached The Scroll Up key does the reverse redisplaying the previous parameter until the...

Page 40: ...times the difference between the current and traget positions Upper limits on the speed remains the value set for High Speed and the lower limit is the value set for Minimum Speed Figure 6 3A Integra...

Page 41: ...ed actuator position when the value for the control signal is low 4 mA Either end of the actuator travel extended retracted CW CCW is acceptable If a pulse input signal CtL St P is used then Position...

Page 42: ...t the signal source to the low level and press E NTER again The displayed value is recorded as Signal Low SL The Signal Type must be set to analog CtL St A for Signal Low or Signal High to be displaye...

Page 43: ...40 1 4 100 10 30 1 3 50000 NA NA NA NA 200 20 40 1 5 150 10 40 1 4 100000 NA NA NA NA NA NA NA NA 200 20 40 1 5 FIGURE 6 3B 6 3 2 ACC Acceleration Sub Menu Low Acceleration LA is the rate at which the...

Page 44: ...is set to any non zero value re entry into the SEtUP menu is prevented until the correct passcode is entered CAUTION When setting a passcode value be sure to record the entered value in a safe and sec...

Page 45: ...speci es a pulse input signal which is used in conjunction with the Pulse Input Board See Appendix P When Analog is selected sub menu CAL provides two setable parameters SL and SH which are used to ca...

Page 46: ...o the mother board is seated improperly 7 1 2 Feedback Cable Mis wiring of the feedback cable will cause the position display to remain constant during actuator motion or an E Fb error to occur 1 Veri...

Page 47: ...ground will not allow noise to drain off the cables The ground wire from the incoming power must be secure and true The motor power cable has a ground conductor green yellow It must be terminated at...

Page 48: ...3 Noise Pick up On Surrounding Equipment Although it is not common there have been situations where noise is picked up on surrounding equipment from the REXA actuator The noise is generated by the fre...

Page 49: ...but rather an installation problem With the actuator separated from the driven device rotate the driven device to the closed position Move the actuator in the same direction until the end of rotary p...

Page 50: ...conservativeapproach to actuator selection It is better to err on the side of safety than to provide a product that is too small for the job All REXA actuators are thoroughly tested to exceed their ra...

Page 51: ...hanical thrust or torque Because oil is essentially incompressible REXA actuators exhibit high stiffness and therefore can precisely posi tion large loads The viscosity of the oil is essential to the...

Page 52: ...es for additional details L Series thrust of 10 000 lbs or less and strokes of 6 inches or less SAE 5W 50 Standard Castrol Syntec 76 F 30 F 5 F 25 F 200 F 300 F 60 C 34 C 20 C 4 C 93 C 150 C R D Serie...

Page 53: ...ion E St is indicated Automatic corrective action consisting of ve motor restarts will occur Continued failure to resume motion will stop the unit trip the alarm relay and alternate the display betwee...

Page 54: ...ault low incoming voltage no power 8 6 Incorrect Direction E dr If the actuator moves in the direction opposite to the PCP command an incorrect direction error E dr will be indicated Motion of the uni...

Page 55: ...grees 1 2 3 Figure 5 5 Stroke Adjustment CAUTION Ensure that there is no hydraulic pressure in the system prior to cracking any hydraulic lines All pressure gauges should read 0 psi Note Each actuator...

Page 56: ...urn off the power breaker in the electronics 3 Locate the correct stroke adjuster refer to Figure 5 5 1 1 4 Locate the hydraulic tting 1 connected directly to the stroke adjuster cylinder cap as shown...

Page 57: ...to the hardware Figure 5 5 1 2 End Stop Detail 10 Use an allen wrench drive inserted into the hollow hex adjustment screw end to adjust the stroke adjustor Rotate clockwise to decrease the stroke of t...

Page 58: ...nd can be driven by using a standard wrench No special lubrica tion of the threads is needed during adjustment The unit is shipped from the factory with the stroke adjustor positioned at the full outw...

Page 59: ...tallation Manual Version 5 1 5 08 A 1 APPENDIX A Control Enclosures and Electrical Assembly Drawings For B C and 2C Power Modules EP96528 Rev5 A96525 Rev2 EP95837 Rev0 A96770 Rev1 EP96527 Rev2 A97217...

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Page 71: ...REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 8 00 APPENDIX B Quick Reference...

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Page 75: ...Alarm Indication p 5 C 5 Auxiliary Control p 6 C 5 1 External Control Option p 6 C 5 2 Remote Manual Control p 7 C 6 Advanced Control Options p 7 C 6 1 0 05 Deadband p 8 C 6 2 Minimum Control Point p...

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Page 77: ...diagrams is not required Maximum external resistor load is 700 ohms Also included in the transmitter is an Alarm Relay which may be used in series with the 4 20 mA signal loop or as an independent ala...

Page 78: ...oop power to the LOOP Complete the loop by connecting the positive side of the loop power to the LOOP COM External Load Resistor Alarming Loop Determine the minimum and maximum supply voltage to power...

Page 79: ...in of rated torque B 75 200 C 25 65 C 2 2 Declutchable Drill Drive The drill drive is mounted at the back of the motor on B C size modules in place of the handwheel To operate connect the chuck of an...

Page 80: ...devices and will provide a limit indication regardless of the electric power status of the unit Up to four switches may be installed On linear actuators they are GO style proximity switches mounted t...

Page 81: ...tivationpointofeachrelay inpercent of calibrated stroke is specified by the corresponding menu entry r1 for relay K1 and r2 for relay K2 For relay K1 r1 specifies the actuator position below which K1...

Page 82: ...to the top of the PCP The common terminal and either the normally open or normally closed connection may be used C 5 Auxiliary Control Configuration and local operation of the actuator is accomplished...

Page 83: ...ion Terminal strip Dx Material Fiberglass one Remote Auto switch two position one Open switch Momentary Push to operate one Close switch Momentary Push to operate Position indicator 0 100 includes Act...

Page 84: ...cavitation or low noise valves reduce the fluid energy by staged pressure reduction within a labyrinth cage These designs are only effective if there is sufficient fluid flow through the resistive el...

Page 85: ...able for a control valve to behave in a quick responsive manner As the valve is closed this type of motion will rapidly stop the fluid flow and may cause damaging pulsations The REXA two speed operati...

Page 86: ...ly be undertaken with a thorough understanding of the effect An 11 point 10 line segment characterization provides the ability to simulate most common control curves or to linearize the actuator to wi...

Page 87: ...REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 09 C 13 Figure C A...

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Page 89: ...ulic Actuators Drives Xpac Installation Manual Version 5 1 5 98 D 1 APPENDIX D Canadian Standards Association CSA Approved for Hazardous Area Class I Division 2 Groups A B C D and Class I Division 1 G...

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Page 91: ...trical code and CEC II NEC or CEC listed hubs suitable for the intended location must be installed III Wiring of Connecting Cables must be performed in ac cordance with NEC and CEC Wiring Methods for...

Page 92: ...rameters for Relay Option Board are as follows Vmax 30 Vdc Ci 0 F Imax 100 mA Li 0 mH 2 For Canadian installations energy to the hazardous location is to be limited by CSA certified ap paratus with ou...

Page 93: ...able inductance shall not exceed La of the apparatus Nonincendive field wiring parameters for Relay Option Board are as follows Vmax 30 Vdc Ci 0 F Imax 100 mA Li 0 mH 2 For Canadian installations ener...

Page 94: ...ccordance with article 250 of the National Electrical code and CEC code II NEC or CEC listed hubs suitable for the intended location must be installed III Wiring of Connecting Cables must be performed...

Page 95: ...APPENDIX E Mechanical Limit Switches REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98...

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Page 97: ...ronmental NEMA 4X FM CL I DIV 1 GRP A B C D Connection 14 NPT screw terminals Rotary Quantity 2 only or 2 of 4 Manufacturer Proximity Controls Type Single Pole Double Throw SPDT Rating 10 amp 24 vdc 0...

Page 98: ...he NPT fitting and make connections directly to the microswitches The cable should be grounded in accordance with Local and National Electrical Code Make sure that the O ring gasket is in place and ti...

Page 99: ...REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 08 F 1 APPENDIX F Seat Loading Cylinder...

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Page 101: ...When the spring is compressed to the full nominal working pres sure the power module will shut off The rated actuator output is now applied to the driven device and retained within the cylinders by t...

Page 102: ...ce the cover on the cylinder and securely fasten Figure F A SLC Feedback Board SLC inch NPT on cylinder Screw Termination signal name wire colors terminal 15VDC Red R Feedback White W Feedback Black B...

Page 103: ...Installation Manual Version 5 1 5 08 G 1 G 1 Description of Operation G 2 Handwheel Operation G 3 Oil Filling and Level Check G 4 Nitrogen Filling De Pressurizing Instructions Wiring Drawing D97189 Re...

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Page 105: ...goilunderpressurefromthe accumulator to enter the failure side of the actuator and the other allowing the oil displaced from the opposite side of the actuator into a holding reservoir auxiliary cylind...

Page 106: ...ip condition then Fd should be set to PH This parameter is typically factory set The contact input P1 P3 provides a trip signal input When the trip signal is active the PCP will de energize the soleno...

Page 107: ...cer output equals rH the motor is stopped and the solenoids are closed The actuator will then begin tracking the normal control signal Note The actuator is shipped in the failed or tripped condition T...

Page 108: ...h solenoids with override levers in the closed position for handwheel use Figure G1 Solenoid override lever wired in the open position Once both overrides are closed the handwheel may be operated in a...

Page 109: ...cycle the auxiliary cylinder rod should protrude beyond the bronze bushing see figure G3 with the unit at 68 70 F 21 C according to the following R2500 1 6 in 1 in 53 mm 2 mm R5000 2 1 in 1 in 40 mm 2...

Page 110: ...auxiliary cylinder 5 Continue filling and purging until clear oil drains out of the loosened fitting 6 Tighten the loose fitting 7 Continue adding oil until the auxiliary cylinder rod ex tends to the...

Page 111: ...guard and gas valve cap 2 Back gas chuck T handle all the way out counter clockwise before attaching charging assembly to accumulator gas valve 3 Close bleed valve 4 Making sure not to loop or twist...

Page 112: ...ly to accumulator gas valve 5 Turn gas chuck T handle all the way down clockwise This will depress core in gas valve 6 Crack open bleed valve and slowly empty accumulator Shut off when gauge indicates...

Page 113: ...APPENDIX H Booster Pump Configuration REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 4 09...

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Page 115: ...ity Booster Pump The power module provides fine positioning while a volume booster pump provides the speed Duty cycle for the booster pump is low because it is only needed for gross position changes O...

Page 116: ...r a D series drive H1 2 Control Enclosure The major electrical components are located in a NEMA 4X enclosure They have a wide temperature range 40 F to 120 F1 and can be field installed at a convenien...

Page 117: ...control signals are made at the enclosure IMPORTANT Motor power and motor resolver cables for the power module and booster pump motors must be shielded The shield of each is connected to the green gro...

Page 118: ...1 Enclosure Termination The cables are terminated to screw connectors located at the right side of the enclosure Connect the cables by following DWG D97135 for the D P9 or DWG D97135 P40 for the D P40...

Page 119: ...s Minimum user connections to the actuator are the electric power and control signal Connections for other option contained on the auxiliaryboards positiontransmitter alarm electroniclimitswitches are...

Page 120: ...power up to increase the speed Any value between 10 and 100 may be set A 100 setting will disable Booster Pump opera tion Parameter bP is the third item in submenu Obd Inordertoinsuresmoothfinalposit...

Page 121: ...lected The higher the value the closer the unit will be to the target position before the calculated motor speed begins to drop below High Speed Recommended initial settings are shown in Figure H 2 Th...

Page 122: ...mended Initial Parameter Settings Model D and D size 2D size Power Module Power Module L Series dG dL LA Ab dG dL LA Ab 2000 10 5 10 0 5 5 5 5 0 5 4000 15000 25 10 20 1 0 20 5 10 1 0 20000 or larger 5...

Page 123: ...APPENDIX P Pulse Operating System REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98...

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Page 125: ...is added to the PCP This board accepts 3 or 4 wire signals in the range of 24 to 120 volts AC or DC The pulses are interpreted by the PCP based on the values set for the two pulse control parameter Pu...

Page 126: ...ut signal terminals will bypass the current PULSE CONTROL PARAMETERS When pulse control is indicated CtL St P the analog control signals Signal Low and Signal High will not appear in the CAL sub menu...

Page 127: ...cifiestheamount inpercentofcalibratedstroke that the actuator will adjust its target position for each valid input pulse received Pulse Increment may be set to any value from 0 1 to 5 0 The Signal Typ...

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Page 129: ...APPENDIX R Redundant Construction REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98...

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Page 131: ...at 1 6 A control signal change of less than 1 6 would result in only the main module taking action to change position A change greater than 1 6 would have both modules operating Regardless of the cha...

Page 132: ...connected in the conventional manner per Appendix C R 2 2 1 Alarm Indication The alarm relay is used to indicate the online status of the main Power Module Power for the alarm is obtained from the ma...

Page 133: ...these parameters will be different because of separate feedback readings and variations in internal resistors Position Low PL Position High PH and Control Point CP require repo sitioning of the actuat...

Page 134: ...Xpac Installation Manual Version 5 1 5 98 R 6 REXA Electraulic Actuators Drives Figure R 1 Single Enclosure...

Page 135: ...REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98 R 7 Figure R 2 Wiring Diagram...

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Page 137: ...APPENDIX S Surge Control Option REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98...

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Page 139: ...signal is greater than the Surge Breakpoint and in the surge motion direction then the solenoid opens and the actuator is moved at high speed to the new position Various configurations of the spring p...

Page 140: ...Place the PCP into the SEtUP mode and step over to the Option Board Sub Menu Obd Push the DOWN key three times The parameter should now read SG Surge Breakpoint Activate the parameter by pressing E NT...

Page 141: ...APPENDIX T Screw Terminals REXA Electraulic Actuators Drives Xpac Installation Manual Version 5 1 5 98...

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Page 143: ...on 5 2 T 1 Termination Remove the four cap screws that retain the enclosure cover Feed the module cable through the inch NPT opening into the terminal area Figure T 2 shows the wiring connections to t...

Page 144: ...Xpac Installation Manual Version 5 1 5 98 T 4 REXA Electraulic Actuators Drives Figure T 2 Wiring Connections...

Page 145: ...ac Installation Manual Version 5 1 5 09 X 1 APPENDIX X D Size Power Module Control Enclosures and Electrical Assembly Drawings D97103 Rev2 A97101 Rev0 EP97055 Rev0 A97099 Rev0 EP97076 Rev0 S96502 Rev4...

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Page 147: ...2 5 hz C 3 2 5 hz B 1 2 5 hz Toaccomplishthisdramaticincreaseinperformance theDmoduleutilizes a larger pump a 2 horsepower servo motor and a 240 VAC servo driver The D pump module utilizes a larger p...

Page 148: ...for a D series drive X1 2 Control Enclosure The major electrical components are located in a NEMA 4X enclosure They have a wide temperature range 40 F to 120 F1 and can be field installed at a conven...

Page 149: ...the enclosure IMPORTANT Motor power and motor resolver cables for the D power module must be shielded The shield of each is connected to the green ground screw on the back panel of the control enclos...

Page 150: ...ure to the driver This information is used to sequence the motor power pulsing The cable is shielded and consists of 4 shielded twisted pairs 20 AWG Maximum length is 700 ft X2 2 1 Enclosure Terminati...

Page 151: ...the D D97096 and A97099 for the D or D97097 and A97100 for the 2D The green yellow wire of the triad should connect to the green ground screw on the metal backplane X2 4 2 Actuator Termination The cab...

Page 152: ...ze power module is 2200 VA and for a 2D is 4400 VA Power connections are made to the main circuit breaker as shown in drawings D97103 D97096 and D97097 X2 5 2 Control Signals The analog control signal...

Page 153: ...shoot The speed of the unit is equal to the Gain times the difference between the current and target positions Upper limits on the speed remains the value set for High Speed and the lower limit is the...

Page 154: ...n in Figure X 2 The effect of this parameter on performance is indicated in Figure X 3 Figure X 2 Recommended Initial Parameter Settings Model D and D size 2D size Power Module Power Module L Series d...

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