M040-104 Series Portable Valve Tester

M040-104 Series Portable Valve Tester
APPLICATION NOTES
PORTABLE VALVE TESTER
M040-104
AUSTRALIA PTY. LTD.
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C.doc
APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
1 of 15
Contents
Section
Title
Page
1.
General Description
3
2.
Technical Details
4
3.
Features
5
4.
Panel Description
6
5.
Operation
9
6.
Application
14
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
2 of 15
1.
General Description
The Moog Portable Valve Tester (M040-104) has been developed from practical
field experience to provide an essential aid to commissioning, servicing and
troubleshooting control systems using:
1.1 Electrical feedback (e.f.b.) valves with integral electronis such as
-
D64X, D66X proportional valves
D769 servovalves
2.2 Mechanical feedback (m.f.b.) valves such as :
-
62 Series servovalves
760 Series servovalves
631 Series servovalves
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
3 of 15
2. Technical Details
Output
:
0 to ± 10V and 0 to ± 10 mA
command for e.f.b. valves.
0 to ± 10mA and 0 to ± 60mA for m.f.b. valves
± 15 V at ± 200 mA regulated supply.
Power
:
Switched mode power supply powered
by six D cell primary batteries.
Battery
:
Six 1.5V D cell Duracell alkaline battery,
or equivalent. Battery life is approximately six hours.
Note : use only alkaline cells
Dimensions :
270 W x 245 D x 125 H
3.0 kg (includes batteries)
Accessories :
1 x Operator's Manual
P.N. B63326
Optional
:
Accessories
m.f.b. valve cable, 1.5m,
P.N. B63336
e.f.b. valve cable, 6 pin,
1.5m,
P.N. B63337
5 to 6 pin adapter pair
P.N. D129-015-A001
e.f.b. valve cable, 12 pin,
1.5m,
P.N. B63341
12 pin socket to 6 pin plug adapter
P.N. A48997-001
12 pin plug to 6 pin socket adapter
P.N. A48997-002
AUSTRALIA PTY. LTD.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
4 of 15
3. Features
*
Suitable for D64X, D66X, proportional valves, D769
servovalve, and 62, 760, 631 etc. servovalves.
*
Fully portable, light and compact with a rugged polycarbonate
plastic carry case
*
Power supply
- batteries : commonly available D cell
disposable type.
-`in-line' : the valve uses normal plant
electronics supply.
*
Economical price - less than the cost of a spare valve
*
Analogue meters for ease of tracking command and spool
position signals.
*
Wide range of control options for commissioning and testing:
'in-line' monitoring of normal valve control electronics
*
-
tester generated commands for 'ramp', plus/minus
command magnitude, automatic cycling and polarity
switching.
-
step input emergency shut-off switch
Battery test via front panel meter.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
5 of 15
4. Panel Description
1
ON/BAT. TEST SWITCH
ON
- in the up position the internal batteries power the ± 15V power supply
OFF - in the centre position the ± 15V power supply is off.
BAT.TEST- hold down to test battery on SPOOL SIGNAL/AUXILIARY
METER 5. The ± 15V power supply is powered during this test.
2
Test points for + 15V and -15 V power supply. Measure with a separate
voltmeter.
3
Power supply L.E.D.'s - ON if supply > ± 13 V
4
Input range selection switch for SPOOL SIGNAL/AUXILIARY METER 5 for
e.f.b. valves
Position 1 for spool signal monitoring with D64X
Position 2 for spool voltage signal monitoring with D66X, D769
Position 3 for spool current signal monitoring with D66X.
5
SPOOL SIGNAL/AUXILIARY METER for monitoring spool position signal
and battery condition.
6
VALVE COMMAND signal meter.
7
Test point for METER 5 can be connected to external X-Y recorder,
oscilloscope or digital voltmeter.
8
`e.f.b. valve cable' connection point. The cable has two MS connectors, one
for connecting to the valve and the other for connecting to the cable that
normally connects the plant electronics to the valve (in-line).
9
Valve command signal selection for input via PIN 'd' or PIN 'e'.
10
COMMAND ON/OFF switch for isolating all valve commands during start up,
in emergencies or to provide step inputs. It is used to isolate commands
from the Tester or during in-line monitoring.
11
Test point for METER 6 can be connected to external X-Y recorder,
oscilloscope or digital voltmeter.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
6 of 15
Panel Description (cont.)
12
Command polarity selection switch
'NORMAL' for regular operation based on correct pin selection (switch 9).
'OFF' switches off the manual command at the 'RAMP' 14 rate selected.
'REVERSE' - reverses the manual command at the 'RAMP' 14 rate selected.
13
Selects manual command or automatic cycling at the range 15 and 'RAMP'
14 selected.
14
RAMP varies the rate of increase of commands under either
'NORMAL/OFF/REV' switch 12 or automatic cycle. (see selector switch 13).
Where '10' = steepest ramp rate, ie. shortest ramp time.
15
Amplitude Potentiometer for manual valve control and automatic cycle
peak to peak amplitude.
16
Selects Tester control or in-line monitoring. In-line monitoring enables the
Tester to follow commands from the in-plant electronics/PLC and the plant
power supply (± 15 VDC).
17
DEADBAND COMPENSATION SWITCH can be used for valves with
overlap to switch the command quickly through the deadband area.
18
OV (ground return) point for the m.f.b. valve test cable.
19
± 10mA current output point for m.f.b. valve testing. Meter 6 shows the
actual current.
20
± 100mA current output point for m.f.b. valve testing. Meter 6 shows the
actual current. Note that the maximum current available on this range setting
is ± 60mA
21
Screw fasterner for hinged front panel to give access for cable storage and
battery changing.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
7 of 15
AUSTRALIA PTY. LTD.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
8 of 15
5. Operation
5.1 e.f.b. valve
The standard PV cable suits D66X voltage command valves, all D64X and D769
valves and D66X curent command valves.
Plug the PV cable into connector 8 and slide the lock
up to hold the connector securely in place.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
9 of 15
5. Operation (Cont.)
Switch the COMMAND switch 10 to the OFF position.
This is important. It ensures the valve being tested will not
receive a command when powering up and so activate the
plant it controls.
Connect the in-plant cable that is normally connected to the
test valve to the IN-LINE socket connector of the PV cable. If
the installed valve has five pins, use 5/6 PIN adapter (D129015-A001).
Connect the test valve to the VALVE socket of the PV cable. If
the valve has 5 pins, use a 6/5 PIN adapter (D129-015-A001).
BATTERY POWER
Hold switch 1 down to test battery condition on
meter 5. This will also switch on the Tester.
-
If the battery voltage is low, replace the batteries,
gaining access via the front panel.
-
Place switch 1 up to switch on the Tester.
Select valve command (switch 9) at PIN d or e according
to the existing installation.
Position 1. spool signal for D64X, D769
Position 2. spool signal for D66X, voltage, (V)
Position 3. spool signal for D66X, current (mA)
-select "in-line" and ensure wiring to the plant
electronics is complete. (This is because the Valve
Tester on its own does not provide the path
necessary for the load current to flow)
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
10 of 15
5. Operation (Cont.)
Select either the internally generated command or the
command from the plant electronics via the IN-LINE MONITOR
with switch 16.
Tester generated command.
Switch 13 selects, in the down position, a continuous automatic
cycling of the command, the rate of which is set by the RAMP
potentiometer 14. 10 is the quickest ramp. With switch 13 in
the up position the command is a non-cyclic level set by
potentiometer 15.
Switch 12 in the OFF position sets the non-cyclic command to
zero. In the NORMAL position the output is positive when
command potentiometer 15 is clockwise and negative when
counter clockwise. The polarities are opposite when REV is
selected.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
11 of 15
5. Operation (Cont.)
The command potentiometer 15 also sets
the peak to peak amplitude of the
automatic
cycle
signal.
RAMP
potentiometer 14 also controls the ramp
of the static command when changing
from NORMAL to REV.
DEADBAND COMPENSATION SWITCH, 17 can be used for
valves with overlap, to switch the command quickly through
the deadband area. Compensation is approximately ± 10%
of maximum command (ie. ± 1V or ± 1mA).
When the setup is complete the red command switch 10 can
be turned on to allow control of the valve being tested.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
12 of 15
5.2
m.f.b. valve
Set switch 4 to D64X. The command for m.f.b. current
drive outputs is generated in the same way as the
command for the e.f.b. valve via controls 12 to 15. See
page 11 for details.
Meter 6 shows the output current, either ± 10mA or ±
100mA, depending on which output point is connected
to the valve. Note that on the ± 100mA range setting
the maximum current available is ± 60mA.
Connect the black plug of the SV cable to the black OV
point 18 and the white plug to either 19 or 20, depending
on the current requirement of the valve.
Note that the Tester cannot power and e.f.b. valve and
test an m.f.b. valve simultaneously. Only one valve at a
time can be tested.
AUSTRALIA PTY. LTD.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
13 of 15
6. Application
6.1
Commissioning
6.1.1 The valve tester is particularly useful during early stages of commissioning, prior to
connection of plant electrical power and control. This means that the hydraulics
can be fully tested at the earliest possible stage with the following checks:
-
tests hydraulic functions
-
preliminary speed and ramp rates established for initial setting of the
in-plant electronics.
-
machine can be progressed through its complete cycle under manual
control.
-
slow ‘inching’ for critical adjustments.
-
emergency shut-off is available at all times via COMMAND ON/OFF
switch 10.
6.1.2 After the in-plant electronics have been installed and connected to the valve the
portable tester provides:
6.2
-
in-line monitoring of in-plant electronics with emergency isolation
available via COMMAND ON/OFF switch 10.
-
manual control via the valve tester can be used if ‘inching’ or ‘resetting’
of the cycle is needed due to failure part way through the automatic
operation.
Maintenance Monitoring
Routine maintenance of an e.f.b. valve requires only a periodic check that the valve
is correctly following the command signals. The Tester provides a simple means
of performing this check. It is achieved by plotting command versus spool position
with an external X-Y recorder for a permanent record of performance.
Correct performance of an m.f.b valve can be gauged by observing the reaction of
the controlled plant to varying valve drive levels. Actuator speed can be compared
to valve drive to verify that the valve is correctly following the command signal.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
14 of 15
6.3
Troubleshooting
The following tests can be carried out:
-
e.f.b. and m.f.b. valve operation fully independent of in-plant eclectronics.
-
monitoring of in-plant electronics during normal cycling.
valve command and spool position can be simultaneously monitored for
e.f.b. valves with 6 or 12 pin connectors.
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APPLICATION NOTES
CN 13.7.92
PORTABLE VALVE TESTER
JJ 17.9.92
M040-104
Rev C KC 2.2.01
B63326
15 of 15
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