USER MANUAL

Pulptec

VBW-1000

VBW-1000 Basis Weight Valve

High Valve position % Limit Low

Open

Close

Man

Auto

Open

Close

Power

Ind

On Fuse 2,5 T Off

BTG Pulp & Paper Sensors AB

M2035/3en

Disclaimer The contents of this document are subject to revision without notice due to continued progress in methodology, design, and manufacturing. BTG shall have no liability for any error or damages of any kind resulting from the use of this document. BTG 2006.

BTG Pulp & Paper Sensors AB P.O. Box 602 SE-661 29 Sffle Sweden Phone: +46 533 426 00 www.btg.com

BTG Pulp & Paper Sensors AB

Table of contents 1 Product Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 1.2 1.3 1.4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CE-Declaration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Regulations for Dimensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Regulations for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Regulations for Commissioning, Operation, and Service . . . . . . 12

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 3.1.1 3.1.1.1 3.1.1.2 3.2 3.2.1 3.2.1.1 3.2.1.2 3.2.1.3 3.2.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electronics Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wall Mounting (Standard configuration) . . . . . . . . . . . . . . . . . . . . . . . . . 15 Panel Mounting (Optional Configuration) . . . . . . . . . . . . . . . . . . . . . . . . 15 Cabling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Actuator cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Signal cables (for Output, valve control, etc.): . . . . . . . . . . . . . . . . . . . . 16 Guidelines for Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Connection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electronics Unit Connection Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Actuator Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Controller Connections - Controller with Pulsed Closing Contact Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Controller Connections - Controller / Computer with Pulsed Signal Output for 24VDC Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Direct Connection Between Valve and Controller . . . . . . . . . . . . . . . . . 24

M2035/3en

VBW-1000 Table of contents BTG 2006

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the Manual Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Check the Automatic Control Functions. . . . . . . . . . . . . . . . . . . . . . . . . 27 Operating from the Electronics Unit (Standard) . . . . . . . . . . . . . . . . . . . 28 Manual control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Automatic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Operating using the Handwheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.3.1 5.2.4 5.2.5 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.4 5.4.1 Maintenance Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Change Electric Motor with Gear Box . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Separate/Open the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Check Mechanical Play Between Valve and Actuator . . . . . . . . . . . . . . 33 Locate and correct the source of the play . . . . . . . . . . . . . . . . . . . . . . . 33 Inspection and change of Harmonic Drive Gear . . . . . . . . . . . . . . . . . . 35 Change Valve Position Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Adjusting the Mechanical End Position Stop . . . . . . . . . . . . . . . . . . . . . 39 Adjusting the Valve Position Potentiometer . . . . . . . . . . . . . . . . . . . . . . 40 Adjusting the R/I Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjusting the Motor's End Position Switch and Limit Switches . . . . . . . 42 Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Simple Troubleshooting in the Electronics Unit Functions . . . . . . . . . . . 44

II

VBW-1000 Table of contents BTG 2006

M2035/3en

Parts List VBW-1000 Basis Weight Valve . . . . . . . . . . . . 47

6.1 6.2 6.3 Ball Segment/Sector Valve with Actuator . . . . . . . . . . . . . . . . . . . . . . . . 47 Electronics Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Remote Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.1 7.1.1 7.2 7.3 7.3.1 7.3.2 Remote Control Unit VBW-10RC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Valve Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Electronic Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electronic Circuits in the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Structure of the Electronics Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

M2035/3en

VBW-1000 Table of contents BTG 2006

III

IV

VBW-1000 Table of contents BTG 2006

M2035/3en

1.1 - General

Product Introduction
1.1 General

Fig

1 Basis weight valve VBW-1000 complete with electronics unit

High Valve position % Limit Low

Open

Close

Man

Auto

Open

Close

Power

Ind

On Fuse 2,5 T Off

The BTG Basis Weight Valve is designed for precision control of the pulp flow to the paper machine. It is distinguished by its extremely high accuracy and resolution in process conditions. The linear characteristic of the valve makes it ideal for precision control. The design has proven to be extremely reliable in numerous installations worldwide. The valve is either a ball segment valve from Somas, or a ball section valve from MKE, that is ideal for accurate flow control over the whole valve stroke.

M2035/3en

VBW-1000 Product Introduction BTG 2006

1.1 - General

Fig

2 Example of consistency, flow and basis weight control CRC = Consistency Controller/Recorder CT = BTG Consistency Transmitter type MEK FT = Flow Meter BTG Basis Weight Valve VBW-1000 Machine chest White water chest Consistency signal Flow signal Control signal to the basis weight valve Valve position signal 4 20 mA Control function for basis weight Basis weight Basis weight signal set point

& " 
.6 +4+ +6 +6

' 

% $

1 2 3 4 5 6 7 8 9 10

 !

The design of the valves are based on well-known standard design but are adapted for the basis weight valve application. To control the valve an electric actuator driven by a synchronous motor is used. The motor is connected to the valve spindle through a highly accurate gearbox (Harmonic Drive). The standard actuating time is 260 seconds at 50 Hz and 217 seconds at 60 Hz. The valve and actuator are connected by a special arrangement to provide a backlash (play) and striction free transmission. An electronics unit controls the valve and displays the valve position in %. A precision potentiometer in the valve generates a signal that is transformed into a current signal (4 - 20 mA) before sending it to the electronics unit. This conversion makes it less sensitive to disturbances. This signal is not intended to be used as a feedback signal in the control circuit, only as an indication of the valve position. The valve can be directly controlled by a controller/computer making potentialfree closing contacts, or open collector with pulse duration output. Via a separate relay box, not provided by BTG, a SCR (thyristor-pulsed output) can be connected.

VBW-1000 Product Introduction BTG 2006

M2035/3en

1.1 - General

Fig

3 Cut-away of BTG Basis weight valve VBW-1000 1 Ball segment/section valve 2 Actuator 3 Precision potentiometer for valve position signal 4 20 mA 4 Electric synchronous motor with planetary gear 5 Gear box, type Harmonic drive 6 Travel limit switches

M2035/3en

VBW-1000 Product Introduction BTG 2006

1.2 - Technical Data

1.2 Technical Data

General
Manufacturer

BTG, Sffle, Sweden

Quality Assurance

Quality-assured in accordance with ISO 9000:2000. Designed in accordance with relevant CE standards.
Factory Calibration

Basic calibration before delivery.

Function Specifications
Actuator Data
Control Function

Time-duration pulsed input.

Motor Type

High-precision synchronous single-phase AC motor with built-in planetary gear box.

Transmission

Harmonic drive gear box, firmly clamped to valve shaft.

End-limit Power Cut-off

Dual microswitches for redundancy.

Valve Data
Type

Ball segment valve (Somas) or ball section valve (MKE).

Linear characteristics

See fig 30 on page 58

Pressure Rating

Somas valve: PN 10 or ANSI 150 lb. (must be stated on order). MKE valve: PN 10 - 25
Capacity Factors

See Table 6 on page 59 for Somas valves, and Table 7 on page 59 for MKE valves.

Electronics Unit Data

Control

In Auto from computer/controller, or in Manual from electronics unit. One potential-free contact indicates manual/auto.
Input Signal

Time duration pulsed signal output from computer/controller Standard alternatives: Potential free closing contact, 24 VDC 50 mA. 24VDC supply from electronics unit. Open collector, 24 VDC, 50 mA. 24VDC supply from electronics unit. The input signal operation is solid state relays to operate the motor.

VBW-1000 Product Introduction BTG 2006

M2035/3en

1.2 - Technical Data

Output Signals

4 - 20 mA, limited to 20 mA. Two adjustable limit switches with potential free closing contacts.
Load Limitations

Maximum 950 at 20 mA output signal. The load dependency is negligible.

Support System Specifications

Power Supply
Actuator Motor

Supplied from standard electronics unit: 120 VAC, 50/60 Hz. Without electronics unit: 120 VAC 60 Hz or 240 VAC 50 Hz.
Electronics Unit

230/115 VAC 10%, 50/60 Hz.

Power Consumption

Maximum 60 VA

Process Specifications
Media Temperature

Somas valve: Maximum 150C/302F. MKE valve: Maximum 200C/392F

Performance Specifications
Actuator
Resolution

Better than 5000:1 for a pulse length of 0.05 s.

Backlash

< 0.01 (< 25 ms), (including valve).

Start Friction

Normally negligible. (Including valve).

Valve
Pulse Duration

See fig 31 on page 61

Physical Specifications
Wetted Parts
Valve Body Material

Stainless steel SS 2343 (corresponding to AISI 316, EN 1.4436).

Seat Material

Graphite-filled PTFE as standard. PTFE 53 (stainless steel powder filled PTFE) and stellite as option.
Stuffing Box

Double seal, radial seal ring and glide ring of PTFE.

M2035/3en

VBW-1000 Product Introduction BTG 2006

1.2 - Technical Data

Valve weight

See Table 8 on page 60 for Somas valves, and Table 9 on page 60 for MKE valves.

Non-wetted Parts
Actuator Degree of Protection

IP 55.
Actuator Material

Housing of cast silumin, epoxy polyurethane painted.

Actuator Weight

16 kg (35.2 lbs)
Electronics Unit Enclosure Material

Self-extinguishing thermoplastic type makrolon with transparent cover for wall mounting.
Electronics Unit Degree of Protection

IP 65 (corresponding to Nema 4X).

Electronics Unit Connection Cable

Connection cable between basis weight valve and electronics unit, 10 x 0.5 mm (equivalent to 10 x AWG 20), common shield. Approximate maximum length is 100 m/ 330' (not included in delivery).
Electronics Unit Weights

Electronics unit. 3.9 kg / 8.7 lbs Remote control unit. 1 kg / 2.2 lb

VBW-1000 Product Introduction BTG 2006

M2035/3en

1.3 - Dimensions

1.3 Dimensions
Fig 4 Dimensions Basis weight valve VBW-1000

430 16.9

158 6.2"

158 6.2"

210 8.3"

Table 1:

Dimensions - Somas ball segment valves Dimensions in mm (inch) (see fig above) A 64 (2.6) 65 (2.6) 72 (2.8) 74 (2.8) 108 (4.3) 108 (4.3) 102 (4) 102 (4) 116 (4.5) 151 (5.9) 186 (7.3) B 198 (7.8) 198 (7.8) 208 (8.2) 208 (8.2) 271 (10.7) 271 (10.7) 243 (9.6) 243 (9.6) 268 (10.6) 217 (8.5) 249 (9.8) C 85 (3.4) 190 (7.5) 95 (3.7) 216 (8.5) 120 (4.7) 120 (4.7) 111 (4.4) 111 (4.4) 125 (4.9) 170 (6.7) 215 (8.5) Free Throughput Diameter mm (inch) 40 (1.6) 40 (1.6) 50 (2) 50 (2) 65 (2.6) 60 (2.4) 75 (3) 75 (3) 92 (3.6) 124 (4.9) 156 (6.1)

Valve Size Diameter mm (inch) 40 (1.5) 40(1.5) (ANSI 150) 50 (2) 50 (2) (ANSI 150) 65 (2.5) 65 (2.5) (ANSI 150) 80 (3) 80 (3) (ANSI 150) 100 (4) 150 (6) 200 (8)

M2035/3en

VBW-1000 Product Introduction BTG 2006

1.3 - Dimensions

Table 1:

Dimensions - Somas ball segment valves Dimensions in mm (inch) (see fig above) A 228 (9.0) 340 (13.4) 385 (15.2) B 289 (11.4) 433 (17) 473 (18.6) C 260 (10) 500 (19.7) 550 (21.7) Free Throughput Diameter mm (inch) 189 (11.4) 282 (11.1) 326 (12.8)

Valve Size Diameter mm (inch) 250 (10) 300 (12) 350 (14)

Table 2:

Dimensions - MKE ball section valves Dimensions in mm (inch) (see fig above) A 85 (3.3) 100 (4) 110 (4.3) 120 (4.7) 160 (6.3) 185 (7.3) 210 (8.3) B 129 (5.1) 144 (5.7) 149 (5.9) 164 (6.5) 209 (8.2) 234 (9.2) 274 (10.8) C 100 (4) 105 (4.1) 122 (4.8) 140 (5.5) 190 (7.5) 243 (9.6) 297 (11.7) Free Throughput Diameter mm (inch) 50 (2) 65 (2.5) 75 (3) 90 (3.5) 121 (4.8) 160 (6.3) 195 (7.7)

Valve Size Diameter mm (inch) 50 (2) 65 (2.5) 80 (3.2) 100 (4) 150 (6) 200 (8) 250 (10) s Fig 5 Dimensions Electronics unit (standard)
175 7"

196 7.7 164 6.5"

Hig h Valve positi on %

AP P AR E NT P OWE R INS TA LLA TI ON CAT E GOR Y VOL T AGE TY P E

Limi t Low

VBW-1000

Max 60 VA III

230 / 115 V 50 / 60 Hz

BT G Pulp & Paper Sensors A B Bo x 602 66129 Sffle SW EDEN www. btg.se

FR E QUE NCY

NO

N1619

Open

Close

278 300 11.9" 12"

Man

Auto

Open

Close

Power

Ind

On Fus e 2,5 T Off

VBW-1000 Product Introduction BTG 2006

M2035/3en

1.3 - Dimensions

Fig

6 Dimensions Remote control unit, type VBW-10RC

Fig

7 Dimensions Electronics unit for panel mounting

220 8.6" ~110 4.3" 192 6.5"

*
Hig h Limi t Low

Valve positi on %
AP P AR E NT P OWE R INS TA LLA TI ON CAT E GOR Y VOL T AGE TY P E

VBW-1000

Max 60 VA III

230 / 115 V 50 / 60 Hz

BT G Pulp & Paper Sensors A B Bo x 602 66129 Sffle SW EDEN www. btg.se

FR E QUE NCY

NO

N1619

Open

Close

288 11.3"

315 12.4"

Man

Auto

Open

Close

Power

Ind

On Fus e 2,5 T Off

Required dimension of hole in panel

M2035/3en

VBW-1000 Product Introduction BTG 2006

1.4 - CE-Declaration

1.4 CE-Declaration

CE-Declaration of Conformity
According to EN 45014

Manufacturers Name Manufacturers Address declares that the product: Product Name Model Number complies, where applicable, with the amendments and requirements of the:

BTG Pulp & Paper Sensors AB P.O. Box 602 S- 661 29 SFFLE, Sweden Basis Weight Valve
VBW-1000

Machinery Directive 89/392/EEC Low Voltage Directive 73/23/EEC EMC Directive 89/336/EEC PED Directive 97/23/EEC

and conforms, where applicable, with the following product standards and PED conformity assessment procedure Safety LVD PED

EN 292/1-2 EN 61010-1 Pressure accessory for piping in accordance to: Guideline related to Article 1, 2.1.4 Accepted by WPG on: 1998-11-26 Accepted by Working Group "pressure" on: 1999-01-2 Must not bear CE-marking EN 50081-2, Aug.93 EN 61000-6-2, May 99 ISO 9001 monitored by Lloyd`s Register Quality Assurance

EMC Quality System

Sffle June, 2003

Tom Gustavsson, MD

10

VBW-1000 Product Introduction BTG 2006

M2035/3en

2.1 - General

Safety Instructions
2.1 General
These safety regulations are based on a risk analysis carried out in accordance with the requirements of relevant CE directives and in order to comply with European standards for CE marking. Read these safety regulations before installing. Be careful to follow the safety routines when installing, starting up, and carrying out service. Use warning signs for safety information! Mounting parts are dealt with in accordance with standards of the countries in question. Always take precautions when handling equipment in pressurized pipes. All installation, operation, service, and other handling must be carried out by trained and authorized personnel and according to valid standards. NOTE! For good personal and functional safety: Use only parts which have been manufactured or approved by BTG.

2.2 Conventions
The following conventions are used in this manual: DANGER! A DANGER! admonition is used when there is a hazard with a risk for injury or possible death to a person. WARNING! A WARNING! admonition is used when there is a risk for damage to program, device, machine, sampler and so on. CAUTION! A CAUTION! admonition is used when there is a risk for system failure, service interruption, disturbances to plant operation, a measuring application and so on. The admonitions above are hierarchic. A DANGER! admonition includes the possibility of both a WARNING! and a CAUTION! admonition.

M2035/3en

VBW-1000 Safety Instructions BTG 2006

11

2.3 - Safety Regulations

2.3 Safety Regulations

2.3.1 Safety Regulations for Dimensioning

Pressurized parts must be suited for the current maximum pipe pressure in relation to the temperature. Select a material for the parts which come in contact with the medium in order to avoid corrosion. See section 2.1.

2.3.2
DANGER
CHECK PIPES!
Risk for corrosive, toxic, or aggressive liquids or gases with high pressure or high temperature.

Safety Regulations for Installation

Welding and subsequent inspection must take place in accordance with current standards and regulations. All handling of electrical units must take place in accordance with current standards and regulations.

DANGER
Hazardous voltage in the equipment

2.3.3

Safety Regulations for Commissioning, Operation, and Service

DANGER
High pressure in the equipment

After installation, perform a pressure test using water in the pipeline. The test pressure is adapted to standards and regulations in each country. For lines there inspection is required, a pressure test must be carried out before the product can be commissioned. Verify the following points before starting up and performing service: Before removing the product from the pipeline, verify that the line is empty. If the product is exposed to dangerous basic or acidic corrosive media, it must be removed from the pipeline regularly for inspection. Replace any damaged seals. If the product or pressurized parts have corroded, verify that the material is correct for the application.

DANGER
CHECK PIPES!
Risk for corrosive, toxic, or aggressive liquids or gases with high pressure or high temperature.

DANGER
Hazardous voltage in the equipment

All handling of electrical units must take place in accordance with current standards and regulations.

12

VBW-1000 Safety Instructions BTG 2006

M2035/3en

Installation Instructions
To ensure correct operation of the installation, follow the instructions provided. The valve is normally supplied with the actuator fitted. The valve is tested in accordance with BTG's quality standards before being shipped. The following have been carried out: Inspection of the motor and gear function. Adjustment of the limit and end position switches. Testing of the electronics unit function. Transmission between motor shaft and valve spindle checked and found free of play according to predetermined standards.

Basis weight valves in sizes 50 - 250 mm (2" - 10") can be installed either horizontally, at an angle or vertically. These valves are completely sealed in their closed positions. Larger valves - sizes 300 - 350 mm (12" - 14") should be installed in horizontal lines or possibly at a slight angle (almost horizontally) with the actuator pointing upwards to limit actuating forces. The valves in these sizes are not always completely sealed in the closed position. This should not normally constitute a problem when regulating basis weight.

Fig

8 Recommended installation of basis weight valve VBW-1000 (applies only to sizes 300-350 mm (12"-14"))

M2035/3en

VBW-1000 Installation Instructions BTG 2006

13

3.1 - Mounting Instructions

3.1 Mounting Instructions

3.1.1 Electronics Unit

Depending on the type of installation the electronics unit is supplied in any of the following two configurations: Fig 9 Electronics Unit Standard Configuration The standard configuration has a splash-proof enclosure - IP65 (corresponding to NEMA 4X) - and brackets for wall mounting.
196 7.7 164 6.5"

175 7"

Hig h Valve positi on %

AP P AR E NT P OWE R INS TA LLA TI ON CAT E GOR Y VOL T AGE TY P E

Limi t Low

VBW-1000

Max 60 VA III

230 / 115 V 50 / 60 Hz

BT G Pulp & Paper Sensors A B Bo x 602 66129 Sffle SW EDEN www. btg.se

FR E QUE NCY

NO

N1619

Open

Close

278 300 11.9" 12"

Man

Auto

Open

Close

Power

Ind

On Fus e 2,5 T Off

Fig 10 Electronics Unit Panel Configuration Panel configuration for drip-proof enclosure, quick-opening cover and special fasteners for mounting in an instrument panel.

220 8.6" ~110 4.3" 192 6.5"

*
Hig h Limi t Low

Valve positi on %
AP P AR E NT P OWE R INS TA LLA TI ON CAT E GOR Y VOL T AGE TY P E

VBW-1000

Max 60 VA III

230 / 115 V 50 / 60 Hz

BT G Pulp & Paper Sensors A B Bo x 602 66129 Sffle SW EDEN www. btg.se

FR E QUE NCY

NO

N1619

Open

Close

288 11.3"

315 12.4"

Man

Auto

Open

Close

Power

Ind

On Fus e 2,5 T Off

* Required dimension of hole in panel

14

VBW-1000 Installation Instructions BTG 2006

M2035/3en

3.1 - Mounting Instructions

Wall Mounting (Standard configuration)

1. Mount the electronics unit on a wall, where it is not exposed to mechanical damage or direct water spray. 2. Install a roof to protect from water and pulp overflow according to fig 11. The roof is supplied by the customer. Fig 11 Protection Roof

75
APPARENT POWER INSTALLATION CATEGORY VOLTAGE TYPE

Panel Mounting (Optional Configuration)

1. Cut a hole 288 x 192 mm (11.34 x 7.56") in the instrument panel, refer to Fig 10. Install the electronics unit. 2. Remove the bracket from the back of the electronics unit, and insert the unit into the panel. 3. Re-attach the bracket to the electronics unit to lock the unit into position in the panel.

Max 60 VA III

VBW-1000
NO

230 / 115 V 50 / 60 Hz

BTG Pulp & Paper Sensors AB Box 602 66129 S ffle SWEDEN www.btg.se

FREQUENCY

N1619

M2035/3en

VBW-1000 Installation Instructions BTG 2006

15

3.2 - Cabling Instructions

3.2 Cabling Instructions

3.2.1 Cable Types

BTG recommends properly dimensioned cables as described below for connections to the electronics box.

Power supply cable

Shielded (80%) 3 x 0.75 mm2 (3 x AWG18) with PE. The power cable should be in accordance with the IEC 227/245 standard.

NOTE! BTG recommends that the power supply cable has a 2 A slow blow fuse.

Actuator cable
Shielded (85%) 10 x 0.5 mm2 (10 x AWG20) Maximum 100 m (320 ft)

Signal cables (for Output, valve control, etc.):

Shielded (100%) twisted pair: Min. 2 x 0.3 mm2 (2 x AWG24). Recommended size is 2 x 0.75 mm2 (2 x AWG18). Multiconductor cables can be used.

3.2.2

Guidelines for Cable Connections

Do not place signal cables and power supply cables close together! This may cause interference. Always avoid loops of cable leads in the electronics box and make the leads as short as possible. To avoid interference, the shields for all cables must be connected to PE on the circuit board.

16

VBW-1000 Installation Instructions BTG 2006

M2035/3en

3.3 - Connection Instructions

3.3 Connection Instructions

The valve is supplied with a separate electronics unit, and all electrical connections are normally made directly to the terminal blocks on the circuit board, inside the electronics unit. To access the circuit card, unscrew the two screws on the front panel of the electronics unit, and open the panel. Optionally, the actuator can also be connected directly to the controller. The connections for this scenario are made according to the instructions in section 3.3.6 on page 24.

M2035/3en

VBW-1000 Installation Instructions BTG 2006

17

3.3 - Connection Instructions

3.3.1

Electronics Unit Connection Overview

The connection diagram in fig 12 shows all possible electrical connections to the electronics unit. Further connection instructions are found in the following chapters: Fig 12 Electronics Unit VBW-1000 Diagram of Connections Power connections - section 3.3.2 on page 20 Actuator connections - section 3.3.3 on page 21 Controller connections for Controllers with pulsed closing contact output section 3.3.4 on page 22 Controller connections for Controllers/Computers with pulsed signal output for 24 VDC - section 3.3.5 on page 23

SK4
PE N L 1 2 3 4 5 6 7 8 9

Power supply

Actuator cable

SK5
10 11 12 13 14 15 16 17 18 19
Close Open Com Man Com
Man/Auto Status Output

SK6
20 21 22 23 24 25 26 27 28 29

+ Valve Limit Status Output

Valve Control + Input B

18

VBW-1000 Installation Instructions BTG 2006

+ Internal 24 V DC Output

24 V DC Indicator Input +

Valve pos. Output +

Valve Control Input A

Auto
-

M2035/3en

3.3 - Connection Instructions

Table 3: Signal

VBW-1000 electronics unit connections Terminal Function SK4

Power supply PE N L Actuator Cable 1-9

Mains supply. 230/115 V AC 10%, 50/60 Hz

Cable for communication between the actuator and the electronics box. See Table 4 on page 24 for function descriptions for each terminal. SK5

Valve position output

10 11 +

Valve position output signal. 4-20 mA, max. load 900 (short circuit when not used). Valve Control input for controllers with pulsed closing contact outputs.

Valve Control 12 Close Input A 13 Common 14 Open 24 V DC Indicator Input Man/Auto Status Output 15 16 + 17 Manual 18 Common 19 Auto

24 V DC input to a green LED indicator.

Status output signal for the MAN/AUTO control switch. Max. load: 250 V AC / 1 A

SK6 Valve Limit Status Output 20 21 + 22 23 + Valve Control 24 Input B 25 + 26 27 + Internal 24 V DC Output 28 + 29 High Limit status output signal. Indicates that the valve high limit position is reached, i.e. the valve is 98.5% open. Low Limit status output signal. Indicates that the valve low limit position are reached, i.e. the valve is 1.5% open. Open Valve input signal for controllers/ computerized control systems with a pulsed signal output for 24 VDC supply. Nominal 35 mA indication load. Closed Valve input signal for controllers/ computerized control systems with a pulsed signal output for 24 VDC supply. Nominal 35 mA indication load. Internal 24 V DC output. Max. 250 mA.

M2035/3en

VBW-1000 Installation Instructions BTG 2006

19

3.3 - Connection Instructions

3.3.2
DANGER
Hazardous voltage in the equipment

Power Connections

NOTE! Before installation, ensure that all power to the system has been turned off. Connect the power cable to terminal block SK4 in the electronics unit as shown in fig 13.

Fig 13 Power connection

SK4
PE N L 1 2 3 4 5 6 7 8 9

230/115 V AC 50/60 Hz

The electronics unit is prepared for either 230 V AC/50 Hz or 115 V AC/60 Hz. Check the type sign to ensure that correct power supply is used. Cabling must be made according to section 3.2: Cabling Instructions.

20

VBW-1000 Installation Instructions BTG 2006

M2035/3en

3.3 - Connection Instructions

3.3.3

Actuator Connections

Connect the actuator cable between terminal SK4 in the electronics unit, and terminal TB1 in the actuator, as shown in fig 14. Terminal 1 on SK4 is connected to terminal 1 on TB1, terminal 2 on SK4 to terminal 2 on TB1, and so on. Fig 14 Connections between the electronics unit and the valve
Electronics unit VBW-1000

SK4
PE N L 1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9

TB1
Actuator (valve) VBW-1000

Cabling must be made according to section 3.2: Cabling Instructions.

M2035/3en

VBW-1000 Installation Instructions BTG 2006

21

3.3 - Connection Instructions

3.3.4

Controller Connections - Controller with Pulsed Closing Contact Output

Electronics unit VBW-1000

Fig 15 Controller connections for controller with pulsed closing contact output
+

SK5
10 11 12 13 14 15 16 17 18 19
Close Open Com

Controller

1. Connect the 4-20 mA output signal for the valve position, to terminals 10 and 11 on SK5. 2. Connect the controller's contact output directly (relay box not required) to terminals 12, 13, and 14 on SK5. Closed contacts between 12 and 13 closes the valve Closed contacts between 13 and 14 opens the valve

In this scenario, other connections than those specified above are normally not used. See Table 3 on page 19 for a more detailed description of each terminal. Cabling must be made according to section 3.2: Cabling Instructions.

22

VBW-1000 Installation Instructions BTG 2006

M2035/3en

3.3 - Connection Instructions

3.3.5

Controller Connections - Controller / Computer with Pulsed Signal Output for 24VDC Supply

The internal 24 V DC, available at terminals 28 and 29 on SK6, can be used for the 24 V supply required in most connections below. If an insulated input/output is required, an external 24 V DC supply must be used. Fig 16 Controller connections for controller with pulsed closing contact output
Electronics unit VBW-1000

SK5
10 11 12 13 14 15 16 17 18 19
Man Com

SK6
20 21 22 23 24 25 26 27 28 29
+ + + + + -

Auto

+24 V

Controller

1. Connect the cable for the 4-20 mA output signal, for the valve position, to terminals 10 and 11 on SK5. 2. Connect the controller/computer output, for controlling the valve, to terminals 24, 25, 26, and 27 on SK6. 3. External indication of the MAN/AUTO switch position is available from terminals 17, 18, and 19 on SK5. A voltage supply of 24 V DC for the internal supply is needed to power a suitable indicator device, for example, a lamp, LED, or computer function. 4. The valve limit positions are available from terminals 20 and 21 (HIGH LIMIT) or 22 and 23 (LOW LIMIT) on SK6, using integral signal isolating relays. A voltage supply of 24 V DC for the internal supply is needed to power a suitable indicator device, for example, lamp, LED, or computer function. 5. Indication of the 24 V DC supply is obtained by connecting 24 V DC to terminals 15 and 16 on SK5. This lights up the green LED, marked IND, on the front panel. See Table 3 on page 19 for a more detailed description of each terminal. Cabling must be made according to section 3.2: Cabling Instructions.

M2035/3en

VBW-1000 Installation Instructions BTG 2006

23

3.3 - Connection Instructions

3.3.6

Direct Connection Between Valve and Controller

The valve can be connected directly to the controller without usage of the electronics unit. The connection is made to terminal TB1 on the actuator as shown in fig 17. The following external voltage supplies are required for this installation: 120 VAC, 60 Hz or 240 VAC, 50 Hz to the motor.

NOTE! The motor for 240 VAC is an option and must be specified at order. 24 VDC to the valve position transducer (R/I).

It is the responsibility of the customer to provide the required relay box in this case. We do, however, recommend that the electronics unit is used in all cases. Fig 17 VBW-1000 Actuator Direct Connection to Computer 1 Connections for motor operation 2 External voltage supply, 24 V DC 3 Valve position output signal, 4-20 mA

TB1
1 2 3 4 5 6 7 8 9
+ + + + 24 V DC - +
24 V DC

2
-

12 3

Table 4: Terminal 0 1 2 3 4 5 6 7 8 9

VBW-1000 Actuator Connections Function Protective Earth (PE) Common Open Close Stop switch for motor, open valve Stop switch for motor, closed valve Limit switch, open valve Limit switch, closed valve Common (-) 24 VDC (+) Valve position, output signal 4 - 20 mA Motor operation 120 VAC, 50/60 Hz

24

VBW-1000 Installation Instructions BTG 2006

M2035/3en

4.1 - Conventions

Operating Instructions
4.1 Conventions
The operating instructions in this chapter assumes that the electronics unit is connected and used for operation. Operating instructions for direct connection between the valve and a controller/computer are not included in this manual. Numbers within parenthesis in the instructions in this chapter refer to the callouts in fig 18.

Fig 18 VBW-1000 front panel 1 Valve high limit status indicator - valve is open. 2 Valve low limit status indicator - valve is closed. 3 Valve position display (0-100%) 4 Valve operation indicator - valve is opening 5 Valve operation indicator - valve is closing 6 Switch for Manual/Auto control 7 Switch for manual opening/closing of the valve 8 Power LED 9 Indicator for 24 V DC 10 Main power switch 11 Main fuse

1 2 3
High Valve position % Limit Low

4
Open

5
Close

6 7
Man Auto Open o Close

Power

Ind

8 9 10 11

On Fuse 2,5 T Off

M2035/3en

VBW-1000 Operating Instructions BTG 2006

25

4.2 - Commissioning

4.2 Commissioning
NOTE! Make sure the pipe is empty and pressureless during commissioning.

4.2.1

Startup

1. Turn on the main power switch (10). NOTE! For safety reasons, the lever must be pulled outwards before it can be switched. 2. Check that the power LED (8) and the valve position display (3), on the front panel of the electronics unit, lights up. 3. If a controller/computer with pulsed signal output for 24 V DC supply is connected, check that the indicator LED for 24 V DC (9) lights up. If any of the above mentioned indicators fails, check all connections, and that the main fuse (11) is intact.

4.2.2

Check the Manual Control Functions

1. Set the MAN/AUTO switch (6) to MAN. 2. Open the valve manually by holding the OPEN/CLOSE switch (7) in the OPEN position. 3. Check on the valve position display (3) that the valve opens (the valve position value increases) and that the indicator LED for OPEN (4) is lit. When the valve is approximately 98.5% open, the valve HIGH limit indicator (1) should be lit. At approximately 99.5% open, the motor should stop automatically and the indicator LED for OPEN will go out. 4. While the valve is fully open, check the external indications (if used) for valve HIGH limit and MANUAL control switch position as follows: Check that a closing contact function is obtained across terminals 20 and 21 on SK6. This occurs when the valve has reached above the valve HIGH limit, i.e. approximately 98.5% open. Check that a closing contact function is obtained across terminals 17 and 18 on SK5. A closing contact function should be obtained when the MAN/AUTO switch (6) is in the MAN position.

5. Close the valve manually by holding the OPEN/CLOSE switch (7) in the CLOSE position. 6. Check on the valve position display (3) that the valve closes (the valve position value decreases) and that the indicator LED for CLOSE (5) is lit. When the valve has reached below approximately 1.5% open, the valve LOW limit indicator (2) should be lit. At approximately 0.5% open, the motor should stop automatically and the indicator LED for CLOSE will go out.

26

VBW-1000 Operating Instructions BTG 2006

M2035/3en

4.2 - Commissioning

7. While the valve is completely closed, check the external indication (if used) for valve LOW limit: Check that a closing contact function is obtained across terminals 22 and 23 on SK6. This occurs when the valve has reached below the valve LOW limit, i.e. approximately 1.5%.

These functional checks show that the valve is operating as intended during manual control. NOTE! If any of the above checks fail, see section 5.4: Troubleshooting.

4.2.3

Check the Automatic Control Functions

1. Set the MAN/AUTO switch (6) to Auto. 2. Open and close the valve, using the connected controller or computer. Check on the valve position display (3) that the valve responds correctly. 3. Check that the 4-20 mA output signal corresponds to what is shown on the display. 4. Check the external indication (if used) for AUTO control switch position: Check that a closing contact function is obtained across terminals 18 and 19 on SK5. A closing contact function should be obtained when the MAN/AUTO switch (6) is in the AUTO position.

These functional checks show that the valve is operating as intended during auto control. NOTE! If any of the above checks fail, see section 5.4: Troubleshooting.

M2035/3en

VBW-1000 Operating Instructions BTG 2006

27

4.3 - Operating from the Electronics Unit (Standard)

4.3 Operating from the Electronics Unit (Standard)

The valve is supplied as standard with a separate electronics unit, which allows potential-free end position indication. The current valve position can be seen on the display (3). The valve is controlled manually or automatically using a signal from the controller or computer.

4.3.1

Manual control

1. Set the MAN/AUTO switch (6) on the front panel to MAN. 2. Control the valve using the OPEN/CLOSE switch (7). The valve will open, and remain open, as long as the switch is held in the OPEN position, and will close, and remain closed, as long as it is held in the CLOSE position.

4.3.2

Automatic control

1. Set the MAN/AUTO switch (6) on the front panel to AUTO. (The valve cannot now be reset manually using the OPEN/CLOSE switch). Automatic control can be done in the following two ways depending on the selected connection configuration. In both cases, the valve opens/closes depending on the time during which the motor's relay is activated. Controllers with pulsed closing contact output When the contact is closed, the motor's relay is actuated and the valve opens or closes. Controllers/Computers with pulsed signal output for 24 VDC A current loop (24 VDC) is closed in the computer output, after which a relay coil in the electronics unit is activated and the relay closes. This in turn activates the relay for the current to the actuator. The input signal is then isolated. The current loop can be closed in different ways depending on the computer's output. Common signal outputs are: open collector, relay contacts etc. These are directly suited to VBW-1000.

4.4 Operating using the Handwheel

The valve can also be reset using the hand wheel if there is a fault in the power supply which prevents the valve being closed electrically. The numbers in parenthesis corresponds to the figures in section 6.1. Remove the motor protective cover (47) and rotate the motor using the hand wheel (21).

28

VBW-1000 Operating Instructions BTG 2006

M2035/3en

5.1 - Maintenance Recommendations

Service Instructions
5.1 Maintenance Recommendations
Long-term maintenance includes: Inspection of harmonic drive gear, and change of lubrication every 10 years. The lubrication used in the VBW-1000 gearbox is of high-quality containing molybdendisulphide of type Molub Alloy BRB 572 and can be used for 10 years of operation. Therefore change lubrication every 10 years and at the same time, make a simple inspection of the harmonic drive gear as described in section 5.2.4: Inspection and change of Harmonic Drive Gear.

M2035/3en

VBW-1000 Service Instructions BTG 2006

29

5.2 - Actuator

5.2 Actuator
Minor service work can be carried out on the actuator without taking the valve out of the line. More extensive repairs should however be carried out in the workshop. NOTE! Clean the actuator before dismantling it, and keep it clean while the work is in progress so that contamination cannot reach sensitive parts. The actuator is a precision device and should be treated accordingly.

5.2.1
DANGER
Hazardous voltage in the equipment

Change Electric Motor with Gear Box

For terminal numbers in this section, see fig 32 on page 63. The numbers within parenthesis in this section corresponds to the figures in section 6.1. Before replacing the electric motor, check that the fault is actually in the motor. Remove the cover and measure the voltage at TB3. It should be 100 VAC when measured across terminals 1 and 2 when the valve is opened manually and across terminals 1 and 3 when it is closed manually. If no voltage is registered, check that the actuator is supplied with power from the electronics unit. Remove the cover and measure at TB1 across terminals 1 and 2 when the valve opens, and across terminals 1 and 3 when the valve closes. If a voltage can be measured here, the fault is in the limit switch contacts for direct disconnection of the motor current. If no voltage can be measured here the fault may be in: The limit contacts for switching across the relay (RE1/RE2). The cable between the electronics unit/actuator. The electronics unit.

If the fault is in the limit switches, replace them as instructed in section 5.2.5 on page 37. If the fault is in the motor, continue with the instructions below. 1. Disconnect the power supply to the motor/electronics unit. 2. Remove the protective cover (47) from the motor. 3. Remove the hand wheel (21). 4. Disconnect the input wires to the motor at TB3. 5. Undo the screws and remove the motor with the gear box (18) and capacitor. Remove the Harmonic Drive gear excenter unit (15A) from the motor shaft.

30

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.2 - Actuator

6. Fit the excenter unit (15A) to the new motor. Tighten the components. Lock the screws with Loctite 242. Connect the motor to TB2. 7. Refit the remainder of the parts in the reverse order. 8. Locate and rectify the cause of the motor failure. The motor should not normally be damaged if, for example, the valve sticks so that the motor remains stationary with the power supply switched on. 9. Test the valve.

5.2.2
DANGER
Hazardous voltage in the equipment

Separate/Open the Actuator

For terminal numbers in this section, see fig 32 on page 63. The numbers within parenthesis in this section corresponds to the figures in section 6.1. The actuator device must be separated when service is carried out on the following parts: The Harmonic Drive gear. The valve position potentiometer. The microswitches for the motor's limit switching. The microswitches for limit indication.

1. Disconnect the power supply to electronics unit/actuator. 2. Remove the cover (37) from the junction box for the actuator. 3. Disconnect all wires to the motor on the TB2 terminals 11 and 12, the ground connection, and terminal 1 on TB1. Undo the cable fitting and draw out the cable for the motor's junction box. 4. Unscrew the nine screws (33) holding the two main parts of the actuator together. 5. Screw in the two screws in the threaded holes on the drive motor housing flange (10) so that the drive motor housing and the end piece (8) separates. NOTE! Tighten the screws alternately and by equal amounts. The Harmonic Drive gear, the potentiometer, the microswitches and the valve's spindle coupling are now accessible for service. Refer to the instructions in the relevant section. NOTE! After carrying out service on the potentiometer, the microswitches and the spindle coupling, adjustments must be carried out in accordance with section 5.3: Adjustments.

M2035/3en

VBW-1000 Service Instructions BTG 2006

31

5.2 - Actuator

6. Re-assemble the parts in the reverse order when service is completed. Pay attention to the following points during the assemble: Hold the drive motor housing firmly and align it at the same time so that the Harmonic Drive gear meshes in the correct manner and so that the sealing ring (12) enters the protective sleeve (32) for the gear. Lubricate where necessary with a suitable grease containing molybdenum disulfide such as Molub Alloy BRB 572. When the drive motor housing is pressed in, turn the motor's hand wheel (21) so that the housing is turned to align the screws.

NOTE! Be careful during assembly of precision parts.

NOTE! Tighten the screws alternately so that they are equally tight.

32

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.2 - Actuator

5.2.3

Check Mechanical Play Between Valve and Actuator

The numbers within parenthesis in this section corresponds to the figures in section 6.1. The normal play is usually so small that it is hardly measurable using normal instruments and is therefore of no practical importance during basis weight control. Before a valve is shipped from BTG, a check is performed to ensure that the play is within normal limits. The mechanical play can be measured as follows: 1. Fit a dial indicator, preferable fitted with a rocker arm, to the valve housing. Direct the tip of the indicator towards the valve's position indicator. The indicator must be firmly mounted. If the VBW-1000 is taken out of the pipe, it is best to measure against the edge of the ball segment/sector since the ball segment/sector's mounting against the spindle is also included in this case. 2. Remove the cover from the motor (47) and rotate the motor a few turns using the handwheel (21). Zero the dial indicator. Observe the exact position of the handwheel and then carefully turn the handwheel back again. Observe when the dial indicator's needle starts to move. The needle usually starts to move directly - in other words, there is no play to be measured. Even when the valves are large - sizes 300 - 350 (12 - 14") - the needle responds directly, but a certain amount of torsion in the gears can be seen. Pay special attention to the clearance at the valve's normal opening position. The actuator should be checked according to section 5.2.3.1 below if play measured in accordance with the above is greater than approximately 1/4 turn of the motor shaft. The gear ratio in the motor's planetary gear is 1:4 1/3 and in the Harmonic Drive gear it is 1:260 (at an actuating time of 280 s - at 50 Hz). This means that play at the motor is 1126 times greater than at the valve shaft. (The gear ratio varies according to the type of motor).

5.2.3.1

Locate and correct the source of the play

Systematically locate any play beginning with the ball segment/sector of the valve and go through the motor according to the following points: 1. First check that the play is actually mechanical and lies in the valve or actuator. If the play is merely shown on the display and cannot be measured using a dial indicator, it is advisable to check that the valve position potentiometer is properly attached, see section 5.3.2 on page 40. Electrical time delays that may be interpreted as play are unavoidable. These occur in motors and relays. The internal delay in VBW-1000 is < 30 - 40 ms depending on the selected input. The time delay in external relays must be added to this figure. 2. Check that the valve is properly tightened against the actuator. 3. Check for any play between valve shaft and ball segment/sector (for larger size, valves only) or if the valve is equipped with a separate spindle cou-

M2035/3en

VBW-1000 Service Instructions BTG 2006

33

5.2 - Actuator

pling, check for tightening of the coupling and screws for the bracket. 4. Check that the clamping piece (66) and the spindle coupling (11) are properly tightened against the shoulder on the valve spindle (torque = 40 Nm). 5. Check that screw (13) which retain the Harmonic Drive gear flexible cog wheel (15) (torque = 15 Nm) are properly tightened. 6. Check that screw (5) which retain the gear's circular spline (15C) (torque = 9 Nm, maximum 6 Nm if the screws are 40 mm/1.57 long) are properly tightened. 7. Check that the motor's mounting screws are tight. 8. Check that the Harmonic Drive gear cogs are undamaged. See section 5.2.4: Inspection and change of Harmonic Drive Gear. 9. Check that the spindle coupling and thus the Harmonic Drive gear flexspline (15B) are correctly mounted on the valve spindle. Misaligned mounting can cause the gear to fail. 10. Check the motor's planetary gear. The planetary gear and the motor shaft key fitting in the drive shaft always have a certain amount of play. This is however insignificant since gear ratio is small in this case.

34

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.2 - Actuator

5.2.4

Inspection and change of Harmonic Drive Gear

Before inspection can be performed the motor must be removed according to step 1-5 in section 5.2.1 on page 30, and the actuator must be separated according to section 5.2.2 on page 31. The numbers within parenthesis in this section corresponds to the figures in section 6.1. 1. Remove the Harmonic Drive gear excenter unit (15A) from the motor shaft. 2. Unscrew the screws (31). Remove the protective sleeve (32) and the Harmonic Drive gear circular spline (15C). 3. Unscrew the screws (13) and remove the Harmonic Drive gear Flexspline (15B). 4. Inspect the three separate parts of the Harmonic Drive gear according to the instructions for each part below: Fig 19 Harmonic Drive gear parts 1 Excenter unit 2 Flexspline 3 Circular spline
2

Inspection of Excenter unit

A. Remove all grease (lubricant) B. Check if the unit is discolored. If so, change the gear. C. Check the ball bearing. Change the gear if the bearing has an uneven motion (small irregulations in the path where the ball roll). If you speed up the bearing it shall make several turns and sound normal. Replace the gear in case of a jarring sound.

Inspection of Flexspline
A. Remove all grease (lubricant) B. Check if the unit is discolored. If so, change the gear. C. Inspect all cogs by means of a magnifier. Change the gear if the cogs are unevenly thick or pointed

M2035/3en

VBW-1000 Service Instructions BTG 2006

35

5.2 - Actuator

D. Check the metal for cracks. Change the gear if any cracks are found.

Inspection of Circular Spline

A. Remove all grease (lubricant) B. Inspect all cogs by means of a magnifier. Change the gear if the cogs are unevenly thick or pointed. The top of each cog shall be evenly wide and have no marks.

Possible errors
The reason for the Harmonic Drive parts being discolored is poor lubrication. Pointed or uneven cogs are due to overload. Break of rear part of the Flexspline depends on ingoing or outgoing shaft not being concentric. Cracks in the Flexspline indicates overload several times. Ratcheting might occur at heavy overloads (more than 650 Nm).

5. Check the sealing ring (12), replace it if it is worn. 6. Re-assemble the gear in the reverse order. Tighten the screws using a torque wrench (torque 15 Nm), and lock them with Loctite 242. Fig 20 Tighten the Screws

7. Lubricate the gear using a molybdenum disulfide lubricant such as Molub Alloy BRB 572 grease. Fig 21 Lubricate the Gear

36

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.2 - Actuator

5.2.5

Change Valve Position Potentiometer

Before service can be performed the actuator must be separated according to section 5.2.2 on page 31. For terminal numbers in this section, see fig 32 on page 63. The numbers within parenthesis in this section corresponds to the figures in section 6.1. Fig 22 The Position Potentiometer

1. Desolder the wires from the potentiometer (25). 2. Remove the clamping washers (53, 54) that retain the potentiometer. 3. Undo the clamping sleeve (24) and remove the cogwheel (22) from the potentiometer. 4. Fit the cogwheel and the clamping sleeve on the new potentiometer. 5. Perform an adjustment of the potentiometer according to section 5.3.2 on page 40. 6. Solder the wires to the new potentiometer: Black wire to potentiometer connection 1 from terminal 13, TB2. Blue wire to potentiometer connection 2 from terminal 14, TB2. Red wire to potentiometer connection 3 from terminal 15, TB2. Attach the wires to the retainer wire (52) using cable strips.

7. Perform all remaining adjustments according to section 5.3: Adjustments.

M2035/3en

VBW-1000 Service Instructions BTG 2006

37

5.3 - Adjustments

5.3 Adjustments
The numbers within parenthesis in this section corresponds to the figures in section 6.1. NOTE! All adjustments in this section must be performed when ball valves, potentiometers or microswitches has been changed. The adjustments are important to get the correct indication. Large valves may be difficult to turn by hand without the use of a tool when adjustment needs to be carried out. A tool is not necessary for small valves. Fig 23 Tool for Rotating the Valve Spindle
~ 35 (1.38")

26.5 (1.04")

Two holes 6.5 (0.26")

20 20 (0.79") (0.79") ~ 500 (19.7")

A tool as illustrated in Fig 23 should be manufactured for rotating large valves. If this tool is used, the Harmonic Drive gear flexspline (15B) must be removed, see section 5.2.4 on page 35. Screw the tool tight in the spindle coupling. Fig 24 Using the Tool for Rotating the Valve Spindle

NOTE! Never use a tool such as a pipe wrench on the outside of the Harmonic Drive gear flexible cogwheel for rotating the valve since this could cause damage.

38

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.3 - Adjustments

5.3.1

Adjusting the Mechanical End Position Stop

The numbers within parenthesis in this section corresponds to the figures in section 6.1. The valve must be removed from the line so that the ball segment/sector can be inspected. The actuator's drive side can be dismantled but this is not necessary. 1. Adjust the valve with the ball segment/sector fully open. Screw tight and lock the screw (49) for the end position stop using the locknut (50) see, Fig 25. Fig 25 Adjust the Valve for End Position Stop

2. Check that the end position stop's pointer shows a 90 opening. Adjust the pointer as required by bending it carefully. 3. Reset the end position stop for a closed valve in the corresponding manner.

M2035/3en

VBW-1000 Service Instructions BTG 2006

39

5.3 - Adjustments

5.3.2

Adjusting the Valve Position Potentiometer

Before the adjustment can be performed the actuator must be separated according to section 5.2.2 on page 31. The numbers within parenthesis in this section corresponds to the figures in section 6.1. Fig 26 The Position Potentiometer

1. Remove the clamping washers (53, 54) that retain the potentiometer, and lift out the potentiometer (25). 2. Turn the valve towards the closed position until the mechanical stop is felt. 3. Connect an ohmmeter across the Potentiometers connections 2 and 3. 4. Set the potentiometer so that the ohmmeter shows a value between 0 - 10 . 5. Carefully place the potentiometer in position. Set the Potentiometers cogwheel against the position indicator cogwheel (7) before tightening the clamping washers. NOTE! This is important in order to eliminate play in the potentiometer drive. 6. Check that the measured value is 0 - 10 ., adjust if necessary. 7. Open the valve completely until the mechanical stop is felt. Check that the measured value is between 900 - 1000 .

40

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.3 - Adjustments

5.3.3
DANGER
Hazardous voltage in the equipment

Adjusting the R/I Transducer

See the wiring diagram in fig 32 on page 63 for terminal numbers in this section. The numbers within parenthesis in this section corresponds to the figures in section 6.1. The R/I transducers output signal 4 - 20 mA can be checked directly on the transducer at the actuator's connection terminal or on the electronics unit display, shown as 0 - 100%. For measuring directly on the R/I transducer, disconnect the outgoing wire at terminal 8 at TB1 and connect an ampere meter in series with the wire and terminal 8. NOTE! The output signal on SK5, terminals 10/11 must be strapped. The transducer is powered with 24 VDC from the electronics unit. If the electronics unit is not used, it is necessary to have an external 24 VDC supply, see section 3.3.6: Direct Connection Between Valve and Controller. When adjusting the R/I transducer, the actuator's motor section can be removed. If this is the case, the valve must be rotated by hand. It is preferable for the actuator to be fitted. 1. Turn the valve by hand to the fully closed position until the mechanical stop is felt. The stop must be adjusted as described in section 5.3.1 on page 39. 2. The display should now show 00,0 - 00,1 - the instrument displays 4,00 4,016 mA. If this is not the case, adjust the R/I transducer's ZERO. 3. Turn the valve to the fully open position. 4. The display should now show 99,9 - EEE, the instrument displays 19,98 mA. If this is not the case, adjust the R/I transducer's SPAN. NOTE! 0 and 100% signals are not used since they fall outside the range of the display.

M2035/3en

VBW-1000 Service Instructions BTG 2006

41

5.3 - Adjustments

5.3.4

Adjusting the Motor's End Position Switch and Limit Switches

DANGER
Hazardous voltage in the equipment

The numbers within parenthesis in this section corresponds to the figures in section 6.1. The following must be done before the microswitches are adjusted: The actuator must be separated as described in section 5.2.2 on page 31. The potentiometer must be adjusted as described in section 5.3.2 on page 40. The R/I transducer must be adjusted as described in section 5.3.3 on page 41.

Closed Valve
A. Limit position indication marked LOW LIMIT 1. Turn the valve by hand until the display shows approximately 1.5% valve opening. The instrument shows 4.24 mA. 2. Undo the screws (59) which fasten the switches' retainer. Adjust the retainer so that limit switch B closes and the green LED indication for LOW LIMIT is ON at approximately 1.5% opening. Tighten the retainer. 3. Check that the switch actually closes at approximately 1.5% valve opening. B. Motor switching 4. Turn the valve to approximately 0.5% opening, the instrument will show 4.08 mA. 5. Adjust the tandem lever (61) by gently bending it with a pair of flat pliers so that the middle switch D (the end position switch across the electronics unit's relay) operates just before safety switch E. 6. Undo the screw (16) and adjust the cam sector (56) so that the motor switch opens at approximately 0.5% valve opening. 7. Check the switching function at approximately 0.5% valve opening. This can be seen by setting the MAN/AUTO switch to MAN and pressing the CLOSE switch. If all is operating correctly, the CLOSE indicator must go off when motor switch D closes and the motor stops. If the motor stops and the CLOSE indicator does not go out, switch E has incorrectly switched off the current before D.

Open Valve
Carry out the corresponding adjustments as when the valve is closed. The following should occur when the valve is open: A. The HIGH LIMIT position limit indicator comes on when the valve is approximately 98,5% open (switch A). B. Motor switching occurs at 99.5% valve opening. Switch C (the end position switch across the -electronics unit's relay) opens just before safety switch F. 8. Assemble the actuator and lastly check its operation according to section 5.3.5 on page 43.

42

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.3 - Adjustments

5.3.5

Final Inspection

When the final inspection is carried out, the potentiometer, the R/I transducer, the mechanical end position switches and all switches must be adjusted according to the relevant sections. Actuator must be fitted and connected. The motor cover must be removed. 1. Switch on the power supply to the electronics unit. 2. Set the MAN/AUTO switch to MAN. 3. Open the valve manually by holding the OPEN/CLOSE switch in the OPEN position. When the valve is approximately 98.5% open, the HIGH LIMIT indicator should be lit, and when the valve is approximately 99.5% open, the motor should stop. 4. Open the valve carefully a bit more by hand. At approximately 100% the mechanical stop must come into action. Check according to the relevant section if any function is inoperable. 5. Close the valve manually by holding the OPEN/CLOSE switch in the CLOSE position. When the valve is approximately 1.5% open, the LOW LIMIT indicator should be lit, and when the valve is approximately 0.5% open, the motor should stop. 6. Close the valve carefully a bit more by hand. At approximately 00.0 - 00.1% the mechanical stop must come into action. Check according to the relevant section if any function is inoperable.

M2035/3en

VBW-1000 Service Instructions BTG 2006

43

5.4 - Troubleshooting

5.4 Troubleshooting
If there is a fault, check first that all the electrical connections in the electronics unit or the actuator are properly tightened and that the fault is not caused by a loose electrical connection. See the wiring diagram in section 7.3: Electronic Functions, fig 32 on page 63. NOTE! The nearest BTG office should be contacted if a fault cannot be located after implementing the following instructions.

5.4.1

Simple Troubleshooting in the Electronics Unit Functions

See the wiring diagram, fig 32 on page 63, for terminal numbers in this section. Undo the connections to the actuator, terminals 1 - 9 on SK4. Mains power supply fuse S4 (2.5 A. fast): fitted on the front panel. Power supply to the motor: Check that the transformer supplies 110 VAC. Measure across terminals 3 and 4 on SK3. Power supply (24 VDC) to relay coils, the R/I transducer and the display unit: Fuse S3 (1A, fast): Fitted before voltage controller IC4. Measure the unregulated input voltage across terminals 5 and 6 on SK3. The normal voltage is approximately 30 V. Fuse S1 (1A, fast): Fitted after the voltage controller. Check the voltage across the fuse holder (+) and terminals 5 (-) on SK3. The reading should be 24 0.5 VDC. LED Ld9, marked POWER, comes on when there is 24 VDC.

Relay functions: RE1/RE2: These 24 VDC operate the motor (110 VAC supply). RE1 opens and RE2 closes the valve. The relay contacts are protected against sparking by two varistors V1 and V2, fitted in parallel across the relay contacts. At emergency cases, if a solid state relay is not available, two mechanical relays can be fitted instead of the solid state relay.

Proceed as follows after checking the relay functions (valve disconnected): 1. Short circuit terminals 4, 5 and 9 on SK4. (This is equivalent to having the end position switches across the relays switched on, within the valve's operating range). 2. Set the AUTO/MAN switch to MAN. 3. RE1 function (valve opening) checks by manually opening the valve: OPEN. RE1 should then be activated and a 110 VAC control voltage for the motor is obtained across terminals 1 and 2 on SK4. 4. RE2 function (valve closing) checks by manually closing the valve: CLOSE. RE2 should then be activated and a 110 VAC control voltage for the motor is obtained across terminals 1 and 3 on SK4.

44

VBW-1000 Service Instructions BTG 2006

M2035/3en

5.4 - Troubleshooting

5. Replace the relays if they are faulty. RE3/RE4: RE4 opens the valve by connecting a 24 VDC voltage to terminals 24 (-) and 25 (+) on SK6 (The AUTO/MAN switch to AUTO. The 24 VDC voltage can be taken from terminals 28 (+) and 29 (-) on SK6). RE4 then activates RE1 in turn, and this supplies a voltage of 110 VAC to the motor.

6. RE3 is checked by connecting a 24 VDC voltage to terminals 26 (-) and 27 (+) on SK6. RE3 should now activate RE2. 7. RE5 and RE6 provides a potential free output signal for indicating the positions of the limit position switches. 8. RE5 produces LOW LIMIT, i.e. when the valve is closed, and RE6 HIGH LIMIT, i.e. when the valve is opened. 9. RE5 is checked by strapping across terminal 28 on SK6 and terminal 7 on SK4. (The electronics unit's internal 24 VDC voltage is used when the actuator is fitted. This goes across the limit switch of the actuator). The relay should now be activated so that there are closed contacts between terminals 22 and 23 on SK6. The LOW LIMIT LED should now be ON (green). 10. RE6 is checked in the same way by strapping across terminal 28 on SK6 and terminal 6 on SK4. Contacts are then closed between terminals 20 and 21 on SK6. The HIGH LIMIT LED should now be ON (red). The display unit: Fuse S2 (1A, fast): Protects the display unit against voltage spikes. If the display does not light up, check S2, the 5 VDC voltage at S2 (+) / terminal 5 (-) on SK3. If the display shows an incorrect value, check that the outer loop, terminals 10 and 11 on SK5, is under 900 . If the resistance is correct, check the R/I transducer as described in section 5.3.3 on page 41.

M2035/3en

VBW-1000 Service Instructions BTG 2006

45

5.4 - Troubleshooting

46

VBW-1000 Service Instructions BTG 2006

M2035/3en

6.1 - Ball Segment/Sector Valve with Actuator

Parts List
VBW-1000 Basis Weight Valve 6.1 Ball Segment/Sector Valve with Actuator
The instructions in this manual corresponds to the numbers in the tables, and in the figures in this chapter.

1 1

Item no. 1

Somas ball segment valves. Including brackets and spindle coupling, standard model with PTFE seat. Other types on request. Always state pressure rating of the counter flanges. Valve KVTW, wafer type Valve KVTF, ANSI 150 flanged type Valve KVTW, wafer type Valve KVTF, ANSI 150 flanged type Valve KVTW, wafer type Valve KVTW, ANSI 150 wafer type Valve KVTW, wafer type Valve KVTW, ANSI 150 wafer type Valve KVTW, wafer type Valve KVTW, wafer type Valve KVTW, wafer type Valve KVTW, wafer type Valve KVTF, flanged type Valve KVTF, flanged type

Size

Order no.

40 mm (1.5) 40 mm (1.5) 50 mm (2) 50 mm (2) 65 mm (2.5) 65 mm (2.5) 80 mm (3) 80 mm (3) 100 mm (4) 150 mm (6) 200 mm (8) 250 mm (10) 300 mm (12) 350 mm (14)

A0069104 A0069112 A0069120 A0069138 A0069146 A0093757 A0069153 A0083477 A0069187 A0069195 A0069203 A0069211 A0069229 A0069237

M2035/3en

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

47

6.1 - Ball Segment/Sector Valve with Actuator

Item no. 1

MKE ball sector valves. Ball sector valve VBG-30 P-PO, complete

Size 50 mm (2) 65 mm (2.5) 80 mm (3) 100 mm (4) 150 mm (6) 200 mm (8) 250 mm (10)

Order no. 84192467 84192475 84186667 84186675 84186683 84186691 84186709

48

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

M2035/3en

M2035/3en

A B
5 6 7 8 9 10 2 3 4

19

11 16

12 13 14 15

14

17

18

20

21

6.1 - Ball Segment/Sector Valve with Actuator

C
B AC

29 30 16 67 27
HIGH VOL

C B

33

31

32

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

F
DANG

34 35

16

45

46

47

28

36 37 38

39

42 43 44

35 40

41

38

49

6.1 - Ball Segment/Sector Valve with Actuator

49

50

68

51 26 52 53 54 16
D
OPEN

55 51 16 56 57 58

A-A

59
C/E
D/F

60 61 66

B-B

65

22 23 24 25

D-D

62 63 48 64

C-C

10

11 12 13 14 15 16 17

18

50

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

+ +
M2035/3en

6.1 - Ball Segment/Sector Valve with Actuator

Item no. 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Description Screw MC6S 12 x (included in item 1) lock with LOCTITE 242 Bearing cover Outer lip seal UNA 32 x 24 x 6 Washer Thrust bearing Position indicator cogwheel End piece Packing Drive motor housing Spindle coupling Sealing ring (VARISEAL M S-55604-0850-109-S) Screw MC6S 6 x 16 tighten to torque of 15 Nm lock with LOCTITE 242 Radial ring SgA 14 Harmonic drive gear HDUC: A Excenter unit B Flexspline C Circular spline Screw MCS 4 x 8 Screw MC6S 5 x 45 Electric motor complete with planatery gear 120 VAC 50/60 Hz Electric motor complete with planatery gear 240 VAC 50/60 Hz

Quantity 4 1 1 1 1 1 1 1 1 1 1 6 2 1

Order no.

14186449 27004548 14186472 14186480 14186464 11004751 12046512 11004769 13259494 27004506 15017593 25000068 28000453

16 17 18

11 2 1 1 2 2 1 1 1 1 1 1 1 1 4

15002033 15017288 53139333 83345413 14425847 15000961 14186597 74186289 15000797 14186308 46013223 15002041 84261148 54335740 15011455

19 20 21 22 23 24 25 26 27 28 29

Sign warning-triangle Screw MC6S 5 x 20 Hand wheel Cogwheel complete with hub Screw MC6S 3 x 10 Clamping sleeve Potentiometer SAKAE SFCP 50A-2724 1 k Screw MCS 4 x 10 Terminal (TB2) Warning sign Screw MCS 2.3 x 6

M2035/3en

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

51

6.1 - Ball Segment/Sector Valve with Actuator

Item no. 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

Description Spacer tube Screw MC6S 5 x 45 tighten to torque of 9 Nm Protective sleeve for Harmonic Drive Screw MC6S 8 x 25 Blind plug with O-ring M16 x 1.5 Cable fitting M16 x 1.5 Packing cover (TB2) Cover (TB2) Screw MC6S 5 x 12 Terminal (TB3) Packing cover (TB3) Cover (TB3) RC-circuit 0.25 F, 100 Type sign Screw KDS 2 x 5 O-ring 183.5 x 5 Nitrile Screw Protective cover Electrolytic capacitor 2.2 F, 63V Screw M6S 8 x 50 full thread Nut ML6M Washer BRB 4.3 x 8 Wire Clamping washer Clamping washer Cam sector Spacer washer Cylindrical pin CPK 5m6 x 20 Retainer Screw MC6S 4 x 25 Microswitch Honeywell 411 SM1

Quantity 4 6 1 9 2 3 1 1 8 1 1 1 2 1 2 1 4 1 1 2 2 8 1 1 2 2 1 1 2 4 4

Order no. 14257091 15017288 13078027 15001191 46028148 46028213 14186647 14186621 15000938 84186394 14186654 14186639 46004305 14429450 15011976 27009778 14216360 12133302 46014585 15007594 16000226 17000522 14189062 14186548 14186555 14186316 14186324 18001602 14257083 15000862 46014130

52

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

M2035/3en

6.1 - Ball Segment/Sector Valve with Actuator

Item no. 61 62 63 64 65 66 67 68

Description Tandem lever Honeywell JS-31 Microswitch Honeywell 411 SM1 Arm JS-5 Screw MCS 2.3 x 10 Screw MC6S 8 x 45 tighten to torque of 40 Nm lock with LOCTITE 242 Clamping piece R/I transducer Mechanical stop with pointer

Quantity 2 2 2 4 2 1 1 1

Order no. 46011862 46014130 46014148 15016157 15011810 14186589 74437534 74186511

M2035/3en

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

53

6.2 - Electronics Unit

6.2 Electronics Unit

18 19 1 32 2

3 4

26
Hig h Valve positi on % Limi t Low

5 6 7

25

S3

S2

27 28

Open

16

Close

17
S1

SK3 S3

29
6

Man

Auto

Open

Close

13

14 15

B1-15

24 23 20 21
RE3 RE4 RE5 RE6 RE1 RE2

20 21

A1-15
1

23
15 1

SK4

30 31

Power

Ind

SK5

On Fus e 2,5 T Off

22

10

11 12 13 14 15 16 17 18

19

SK6
20 211 22 23 24 25 26 27 28 29

12 10 11 8 9

Item no. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Description Electronics unit, complete Electronics enclosure, complete Panel design, complete modification kit (comprises 4, 5, 6, 7) Frame Screw MC6S 6 x 30 Nut M6M Retainer Cable fitting Pr 18.6 Nut Pr 18.6 msg Cable fitting Pr 22.5 Nut Pr 22.5 msg Installation bar (for wall mounting, standard) Power switch, SW3 Fuse holder

Quantity 1 1 1 1 4 8 2 2 2 1 1 2 1 1

15

Order no. A0068999 13194436 83262162 12056750 15001126 16000028 13114285 46021416 46000048 46021424 46000683 13093000 46012563 46000444

54

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

M2035/3en

6.2 - Electronics Unit

Item no. 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Description Fuse, S4, (5 x 20 2.5A T) Switch, SW1, MAN/AUTO Switch, SW2, OPEN/CLOSE Blade screw, bayonet fitting Cage, for blade screw with bayonet fitting Socket connector Cover Circuit card, solid state relay Spacer DHM M3050x15 Relay, Re3, 4, 5, 6 (24/24 VDC) Fuse, S1, 2, Spare (5 x 20 1A Fast) Main circuit card complete Transformer 110/220 Capacitor Rectifier bridge Fuse, S3 (5 x 20 1A Fast) Circuit card Front film Cable between actuator and electronics unit. Length according to order (maximum 100 m / 328 ft).

Quantity 1 1 1 2 2 4 4 1 8 4 3 1 1 1 1 1 1 1 m

Order no. 46012761 46012415 46012894 46012522 46012530 46009817 46009825 74384686 25002080 46011953 46012340 73118739 74445529 46009742 46009759 46012340 74257023 A0068031 46013496

M2035/3en

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

55

6.3 - Remote Control Unit

6.3 Remote Control Unit

Fig 27 Remote Control Unit VBW-10RC with Main Circuit Card

3
D1 Ld1 SPAN P2 R1 R2 R7 R6 IC2 DVM1 C4 R4 D4 Re1 C5 D3 R3 P1 D2 Ld2 ZERO R5 C6 +

5
6 7 8
S1 J1 5 4 3 2 1 J4 Sw1 Ld4

Ld3

Sw3 J3 Re2 + C3 Sw2 C2 5 4 3 2 1 J5 + Db1 _ + C1 _ IC1 J2

Table 5: Item no. 1 2 3 4 5 6 7 8 9

Spare Part List Remote Control Unit VBW-10 RC Description Remote control unit, complete Clamp Connection card, complete Main circuit card, complete Relay, Re1 and Re2 Switch (SW3) Switch (SW2) Fuse (5 x 20 500mA Fast) Transformer Quantity 1 2 1 1 2 1 1 1 1 Order no. 83141374 46014692 74290271 74290446 46014346 46012894 46012415 46014528 74437476

56

VBW-1000 Parts List VBW-1000 Basis Weight Valve BTG 2006

M2035/3en

7.1 - Remote Control Unit VBW-10RC

Appendix
7.1 Remote Control Unit VBW-10RC
The remote control unit allows duplicated control and indication of the valve's functions. The unit is fitted into the instrument panel whereas the valve's electronics unit is located close to the valve. The remote control unit is connected between the electronics unit (this is always necessary) and the computer/controller inputs.

Fig 28 Remote Control Unit, type VBW-10RC

7.1.1

Installation

1. Cut a 138 x 67 mm / 5.43x2.64 hole in the instrument panel. The depth required is 170 mm / 6.7. 2. Check that the unit is connected for the correct supply voltage. The 110/220 VAC switch is located inside the unit. 3. Fit the unit using the attachment clamps. 4. See Fig 29, and connect the remote control unit VBW-10RC in the same way as the standard electronics unit described in section 3: Installation Instructions. All the functions in the standard electronics unit are also available on the remote control unit. 5. Check the function in the same way as for the standard electronics unit, see section 3: Installation Instructions. The standard electronics unit's MAN/AUTO switch must always be in the AUTO position for the valve to be controlled using the remote control unit. NOTE! Protect the remote control unit from being splashed by water.

M2035/3en

VBW-1000 Appendix BTG 2006

57

7.2 - Valve Data

Fig 29 Remote Control Unit, VBW-10RC Diagram of Connections

Electronics Unit VBW-1000

SK4
L1 L2 1 2 3 4 5 6 7 8 9

SK5
10 11 12 13 14 15 16 17 18 19

SK6
20 21 22 23 24 25 26 27 28 29

IN

+
IN REMOTE CONTROL

L1 L2

10 11 12 13 14 15 16 17 18 19

20 21 22 23 24 25 26 27 28 29

OUT

10 11 12 13 14 15 16 17 18 19

OUT

20 21 22 23 24 25 26 27 28 29

Alternative connections for the user

TB1
1 2 3 4 5 6 7 8 9

Valve VBW-1000

7.2 Valve Data

Somas valve

MKE valve 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0%

Fig 30 Linear Characteristics

Flow

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0 10 20 30 40 50 60 70 80 90
Opening angle

0 10 20 30 40 50 60 70 80 90
Opening angle

58

VBW-1000 Appendix BTG 2006

M2035/3en

7.2 - Valve Data

Table 6: Valve Size Diameter mm (inch) 40 (1.5) 40 (1.5) (ANSI 150) 50 (2) 50 (2) (ANSI 150) 65 (2.5) 65 (2.5) (ANSI 150) 80 (3) 80 (3) (ANSI 150) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) Table 7: Valve Size Diameter mm (inch) 50 (2) 65 (2.5) 80 (3) 100 (4) 150 (6) 200 (8) 250 (10)

Capacity factors for Somas valves Capacity Factor Kv Opening Angle Kv 10 4.3 4.3 4.3 6.8 9.8 9.8 15 15 23 43 66 97 219 308 Kv 20 11 11 11 17 25 25 39 39 58 109 167 245 552 780 Kv 30 19 19 19 30 43 43 67 67 101 189 288 425 959 1355 Kv 40 29 29 29 45 65 65 102 102 154 288 439 646 1459 2058 Kv 50 39 39 39 61 87 87 138 138 208 390 594 875 1977 2793 Kv 60 53 53 53 82 113 113 184 184 276 519 790 1162 2626 3708 Kv 70 66 66 66 103 139 139 231 231 348 652 994 1463 3303 4667 Kv 80 84 84 84 131 171 171 295 295 444 817 1268 1866 4216 5952 Kv 90 96 96 96 150 191 191 340 340 510 925 1450 2150 4850 6843

Capacity factors for MKE valves Capacity Factor Kv Opening Angle Kv 75 130 205 280 390 675 1020 1430 Kv 90 160 300 410 570 990 1500 2100

M2035/3en

VBW-1000 Appendix BTG 2006

59

7.2 - Valve Data

Table 8: Valve Size Diameter mm (inch) 40 (1.5) 40 (1.5) (ANSI 150) 50 (2) 50 (2) (ANSI 150) 65 (2.5) 65 (2.5) (ANSI 150) 80 (3) 80 (3) (ANSI 150) 100 (4) 150 (6) 200 (8) 250 (10) 300 (12) 350 (14) Table 9: Valve Size Diameter mm (inch) 50 (2) 65 (2.5) 80 (3.2) 100 (4) 150 (6) 200 (8) 250 (10)

Somas valves weights Weight incl. Actuator kg (lbs) 28 (62) 34 (75) 30 (66) 36 (79) 37 (82) 37 (82) 32 (70) 32 (70) 35 (77) 42 (93) 62 (137) 89 (196) 235 (518) 325 (717) Weight Valve kg (lbs) 12 (24) 18 (40) 14 (31) 20 (44) 21 (46) 21 (46) 16 (35) 16 (35) 19 (42) 26 (57) 46 (101) 73 (161) 219 (483) 309 (681)

MKE valves weights Weight incl. Actuator kg (lbs) 21 (46) 23 (51) 26 (57) 30 (66) 42 (93) 62 (137) 90 (198) Weight Valve kg (lbs) 6 (13) 8 (18) 10 (22) 14 (31) 26 (57) 46 (101) 74 (163)

60

VBW-1000 Appendix BTG 2006

M2035/3en

7.2 - Valve Data

Fig 31 Pulse duration dependency for the resolution at some different valve travel times, according to practical tests. The graph shows the possible number of adjustments for the valve from closed to opened (opening angle 0 to 90). Valve travel times: 1 260 s Standard at 50 Hz /217 s at 60 Hz 2 131 s at 50 Hz /109 s at 60 Hz 3 78 s at 50Hz /65 s at 60 Hz

Pulse length, s

1 2 3

Resolution factor

M2035/3en

VBW-1000 Appendix BTG 2006

61

7.3 - Electronic Functions

7.3 Electronic Functions

7.3.1 Electronic Circuits in the Actuator

The electronic circuits in the actuator simply comprise an R/I transducer built into TB2. The R/I transducer converts the resistance signal 0 - 1000 from the precision potentiometer to a 4 - 20 mA current signal. A 24 VDC supply is required and this can normally be taken from the electronics unit. An external supply is required only if the basis weight valve is supplied without the electronics unit. ZERO/SPAN setting of the R/I transducer is carried out in accordance with section 5.3 on page 38. Supplementary Equipment: The actuator can be fitted with an additional precision potentiometer (can be fitted afterwards). In this case, a resistance signal is obtained at terminals 16, 17, and 18 on TB2. The valve position indicator with an output signal of 4 - 20 mA, such as Camille-Bauer SW-1. This can be powered from the electronics unit.

NOTE! This equipment requires considerable modification and must therefore be installed by BTG These produce double output signals for increased safety.

7.3.2

Structure of the Electronics Unit

The electronics unit has two circuit cards. There is a circuit card on the bottom plate where all connections to the electronics unit are made. The transformer, rectifier and, capacitor are mounted separately on the bottom plate. Two cable looms link the bottom plate with the front panel's main circuit card where most of the functions are assembled. See Fig 32 for more information. A complete circuit diagram is available on request. NOTE! It is recommended that a main circuit card is kept in stock as a spare for quick replacement in the event of a fault. Unserviceable cards should be returned to BTG for repair

62

VBW-1000 Appendix BTG 2006

M2035/3en

7.3 - Electronic Functions

External connections

SK 4
230/115 VAC 50/60 Hz 60 VA mA

Electronics Unit
POWER

SK3
S4 1 SW3 2 3 4
CLOSE

L1 L2 5V DC

S2
V REG +24 VDC

+5 VDC

SK5
10 11 12 13

S1

4 - 20 mA

V REG 24 V DC

S3

CLOSE

Ld9

5 6
OPEN

Ld7

DISPLAY UNIT
Ld9

OPEN

SK4
9 8

14
IND

15 16
Ld8
IND

7 6 5 4 3
LOW LIMIT HIGH LIMIT CLOSE OPEN

MAN

17 18
AUTO

19
HIGH LIMIT

SK6
20 21
Re5 Re6

2 1

Re2

Re1

LOW LIMIT

22 23

Ld5 Ld4

OPEN

24 25

SW1

Solid State
AUTO MAN CLOSE OPEN

CLOSE
FOR INSULATED INPUT/OUTPUT

26 27 + + -

Relay Card

SW 2
Re3 Re4
OPEN

24 VDC
Alternative Connections for the User

28 29

CLOSE

SK3
1 2 3 4 5 6 + 9 8 7 6 5 4 3 2 1

[230 VAC] + -

Actuator
Mechanical Actuation

[24 VDC]

+ (h)

R/I
TB2
(c) +

SK4 +24 VDC

4-2o mA
LOW LIMIT

9 8 7
(a) (i) (h) (f) (b)

18 17
A B C D E F (k) (g) 2

3
OPTION CLOSE

G
C1

M
F

115 VAC 50/60 Hz

HIGH LIMIT

6 5 4 3 2

(c) (g) (f)

15 14 13 12 11

(h) (c) 2
(a)

3 (d) 1 (b) 1

OPEN

16

COMMON

CLOSED

(h) (a) 2 3

OPENED CLOSE OPEN

TB3

(m) (a) (a) (d)

(c) (b)

COMMON

TB1

Fig 32 VBW-1000 Wiring Diagram

NOTE! Simplified schematics, not all components are shown in the wiring diagram.

M2035/3en

VBW-1000 Appendix BTG 2006

63

7.3 - Electronic Functions

64

VBW-1000 Appendix BTG 2006

M2035/3en