07 - Hyd2.0 Installation PDF

HydroCOM 2.
0
P
Installation
HOERBIGER
Assembly and Installation

General
For trouble-free operation of the HydroCOM

system
it is essential
that the installations is of top quality and
suitable for maintenance!

Good practice!

Terrible!!!!!!!!!!!!!!!!!!!!!!

HydroCOM2.0
General
Standards - abbreviations - system overview
Mechanical Installation
Wiring
Hydraulic System
Hydraulic unit - tubes & fittings
Piping:
Flare gas - oil leakage
Check List

Abbreviations
Actuator
CA
CAoff
CAon
CIU
CCM
DCS
EPS
GIM
HU
IA
IPS
IVD
MODBUS
SIM
SU
TDC
Unit for the actuation of the suction valves

Crank Angle
Crank angle where
opening of suction valve starts.
Crank angle where
closing of suction valve starts.
Compressor Interface Unit
Compressor Condition Monitoring Software
Distributed Control System
External Power Supply (power supply for the actuators)
General Interface Module
Hydraulic Unit
Isolation Amplifier
Internal Power Supply (power supply for the CIU)
Intelligent Valve Driver
Serial interface to DCS or CCM
Stage Interface Module
Service Unit
Top Dead Center

Standards
For trouble-free acceptance of the HydroCOM system
by the customer it is essential
that all standards are adhered.
The installation of the system must comply with the following
Ex-protection standards:
Europa
EN50154
Europa
IEC79-14
USA
ANSI/ISA RP12.6
USA
ANSI/ISA RP 12.1
USA
ANSI/NFPA 70
UK
BS5345 Parts 1,4 & 6 is replaced by EN50154
CSA
Class 2258 02
Cables, lines, connections, insulation and accessories must be

selected in compliance with the relevant standards.

System Overview HydroCOM
Field
Feld
Feld
Switchroom
Schaltraum
Schaltraum
DCS
Warte
EPS
48 VDC
TDC
IA
BUS
4...20 mA
Binre Signale
HOERBIGER
HOERBIGER
HOERBIGER
Valve#
Valve#
Valve#
Code#
Code#
Code#
Scroll/
Reset
Scroll/
Reset
Scroll/
Reset
SIM 1 SIM 2 SIM 3
HOERBIGE
HOERBIGE
HOERBIGE
Power
R
R
R
TDC
Enable
Ext.Sim.
P
Sensor
hy
Error
Ld
S oM
U O
D
B
U
S
5V
15V
GIM IPS
berwachung
Monitoring
berwachung
DEV:DISCH GAS TEMP 1 (%)
CIU
HYD
ROCO
M
SUNBURST: RECIP #1: DISCHARGE TEMPERATURE DEVIATIONS

40
30
40
20
20
10
0
-10
DEV:DISCH GAS TEMP 2 (%)
OIL
-20
-20
-30
-40
-40
98000
100000
101000
Operating Hours
OPERATING HOURS: 101157.2 DATE: 93/03/01 TIME: 14:00
NUMBER:
SEQUENCE
2
DEV:DISCH GAS TEMP 1-9.8
(%) =DEV:DISCH GAS TEMP 2 (%) = 3.08
TIM
HU
SU
99000
CCM
Assembly and Installation of an Actuator

Contents
General
Installation
Connections

General
Clarification during early stage
of quotation how to install valves
and actuators at the compressor
Standard design or special solution for

installation of both, valves and actuators?
Is it possible to adapt valve covers?

Costs of cover adaptation?
Influence on delivery time?
In general:
Special solutions should be avoided

Standard Design
230
Actuator No.
electric housing
Valve housing
110
44 xx M12
M12
on
on PCD
PCD 90
90
18,0 mm ( 2,0 mm)
Centering
Centering diameter
diameter
+0,1
72
72+0,1 ,, depth
depth min.
min. 5mm
5mm
Seal housing
O-ring
O-ring seal
seal
Unloader
Valve
3
2
87,0 mm ( 2,0 mm)
Check after assembly:
220
Actuator

Further Design Solutions
Seal housing in standard
design, mounted on
modified valve cover
Air vent
Oil leakage
Gas leakage
Oil leakage
Air vent
Oil leakage,
Gas leakage

Further Design Solutions
Standard seal housing
mounted on
modified valve cover
Oil leakage
Air vent
Oil leakage,
Gas leakage
Valve holder is secured by

Belleville spring washers

Special Solutions
Special solution of
the seal housing
mounted on
modified valve
cover
Special designs
should be avoided
because of high
costs!

Assembly
230
Valve housing
18,0 mm ( 2,0 mm)
Seal housing
3
2
Place suction valve with unloader

and unloader rod
into valve nest
Insert cage
Place valve cover
Tighten valve cover bolts - with
jacking bolts loose
Tighten valve cage jacking bolts
with prescribed torque
220
Check after assembly:

87,0 mm ( 2,0 mm)
Installation of a suction valve:
Actuator No.
electric housing
110
Installation of the actuator

starts with correct installation of
the suction valve

Assembly - Replacement of an Actuator
Electric housing shall
be removed 10 min or
later after power
supply (EPS) was
switched off
Removal of seal housing only while

compressor is stopped and depressurized
Assembly:
separate valve housing

and seal housing
place seal housing

onto valve cover
take care that the

temperature sensor
plug is free of dirt
flush hydraulic lines

for several hours
flush compression
and flare gas parts
using nitrogen
Insert unloader rod carefully

into seal housing, do not
damage sealing elements

Installation Height
remove O-ring
for measurement
Installation height of
18mm shall be
checked while valve
housing is removed.
18mm +/- 2mm

Hydraulic and Flare Gas Lines
Hydraulic Oil inlet
G1/2 female thread
hydraulic oil inlet
hydraulic
oil outlet:
G3/8 female
thread
leakage oil to collection vessel
2 connection points
(lowest one shall be chosen)
G1/8
G1/8 for flare gas line

Power Supply and Data Cable
Terminal box
Terminal box
A, B, GND
for bus cable
+ -
for power supply
Cable gland
PG 13,5 for
power supply
cable
Cable gland
PG 13,5
for bus cable
PE wire is attached to PE symbol

Power Supply and Data Cable
Cable glands mounted
with 8 Nm +/-1Nm for
water proof installation
HOERBIGER
Last actuator on a data bus cable:

A and B are connected with an RC-module.
Remaining unused cable gland is replaced by a stopping plug.
Assembly and Installation of the CIU

General - Installation Dimensions
The CIU
It is the interface between actuators, TIMs and a DCS (distributed

control system).
It consists of a 19 card frame which houses different modules (i.e.
IPS, GIM, SIMs).
It can control up to 48 actuators and up to 12 TIMs
It must be located in a safe zone (non hazardous zone)
132 (=3HE)
58
HOERBIGER
HOERBIGER
HOERBIGER
HOERBIGER
HOERBIGER
HOERBIGER
Valve #
Valve #
Valve #
Valve #
Valve #
Valve #
Code #
Code #
Code #
Code #
Code #
Code #
HOERBIGER
Run
TDC
Enable
Ext.Sim.
Phyd Lo
Sensor
Error
HOERBIGER
HOERBIGER
5V
15V
SU MODBUS
Scroll /
Reset
SIM 1
Scroll /
Reset
SIM 2
Scroll /
Reset
SIM 3
Scroll /
Reset
SIM 4
Scroll /
Reset
SIM 5
Scroll /
Reset
SIM 6
HYDROCOM
GIM
IPS
CIU
465
482 (=19)
slot 11 x 7,5
weight: 4 6 kg

Inputs - Outputs - State of the GIM
HOERBIGER
HOERBIGER
HOERBIGER
Valve #
Valve #
Valve #
Code #
Code #
Code #
HOERBIGER
Run
TDC
Enable
Ext.Sim.
Phyd Lo
Sensor
Error
HOERBIGER
HOERBIGER
5V
15V
SU MODBUS
Scroll /
Reset
SIM 1
Scroll /
Reset
SIM 2
Scroll /
Reset
SIM 3
HYDROCO
M
GIM
IPS
CIU
RUN : CIU-power supply active

TDC : input from isolation amplifier (IA)
ENABLE and externe SIMULATION :
binary signals from DCS
Phyd Lo, SENSOR, ERROR :
binary signals to DCS
SU Interface
HOERBIGER
Run
TDC
Enable
Ext.Sim.
P hyd Lo
Sensor
Error
SU
MODBUS
Interface RS232 9-pole sub-D plug

Connection to service unit (SU) for
HydroCOM diagnostics and configuration
Modbus Interface
Interface RS232 or RS485
Connection to DCS
or to CCM
GIM

Installation of a new GIM
Prior to installation of a new GIM, binary inputs must be
configured (PULL-UP resistors on/off)
Prior to commissioning, compressor specific CIU

parameters must be downloaded to the GIM by a
HOERBIGER field engineer (using the service unit SU).
delivery state
as depicted:
Enable OFF
Ext. Sim OFF
TDC
ON
PULLUP ON-OFF
ON = jumper placed on left side OFF = jumper placed on right side

Inputs and Outputs of the GIM
Binary input signals, i.e. signal from TDC, enable EN and simulation SIM
can be implemented either as passive or active input signals.
Binary output signals are implemented as relay contacts.
Binary Inputs
Binary Outputs
TDC, EN, SIM
HY, ER, WA
isolated for active signal source
+20...30V
Input +
0V
Input -
PULLUP OFF
Output NO
not isolated for passive source

(isolated contact, open collector)
Input GND1
Input GND1
Contact open in case

of active signal (error
condition)
Output COM
Contact closed in
error-free operation
PULLUP ON
NO means normally open in
the event of an error.

The MODBUS-interface (9-pole Sub-D connection) can be configured
by the SU software as an RS232 or RS485:
Cable RS232 / single point communication:
HOERBIGER
1
2
3
4
5
6
7
8
9
not used
data lines
not used
ground
bridged
bridged
bridged
bridged
not used
pins
not used
1
2
3
4
5
6
7
8
9
pins
Bridges are only required in conjunction with modems.
Run
TDC
Enable
Ext.Sim.
P hyd Lo
Sensor
Error
SU
MODBUS
GIM

The MODBUS-interface (9-pole Sub-D connection) can be configured
by the SU software as an RS232 or RS485:
Cable RS485 / bus communication:
HOERBIGER
1
2
3
4
5
6
7
8
9
not used
data lines
not used
ground
bridged
bridged
bridged
bridged
not used
pins
not used
1
2
3
4
5
6
7
8
9
pins
Bridges are only required in conjunction with modems.
Run
TDC
Enable
Ext.Sim.
P hyd Lo
Sensor
Error
SU
MODBUS
GIM

Internal Power Supply Module (IPS)
HOERBIGER
HOERBIGER
HOERBIGER
Valve #
Valve #
Valve #
Code #
Code #
Code #
HOERBIGER
Run
TDC
Enable
Ext.Sim.
Phyd Lo
Sensor
Error
HOERBIGER
HOERBIGER
5V
15V
SU MODBUS
Scroll /
Reset
SIM 1
Scroll /
Reset
SIM 2
Scroll /
Reset
SIM 3
GIM
IPS
HYDROCO
M
CIU
Tasks of the IPS:
internal power supply of CIU.

IPS provids stabilized controlled
d/c voltage
Replacement:
disconnect CIU from power supply

unscrew fastening screws
remove the IPS board
While replacing any module of the CIU
necessary preventions have to be taken to
avoid electro-static damage to the CIU!

Internal Power Supply Module (IPS)
Supply voltage 110 VAC
or
230 VAC
Output
and
5 VDC
15 VDC
110VAC 230VAC
M2,00A M1,25A
Fuse is located on bottom

face of IPS

Backplane of the CIU
Connections for peripheral equipment are on back of the CIU

Standard plug connections for wires leading to both, control cabinet
and DCS.
Labelling corresponds to terminal box table provided to customers
binary
GIM-Inputs
power supply
of CIU
SIMinterfaces
binary GIM
outputs

4 different ground (GND)
potentials!
DO NOT MIX THEM!
4 different ground potentials,

however, they are coupled
by capacities, thus allowing
high-frequency transmission.
PE
Protective Earth
GND1
Digital inputs
GND1
Control output signals
GND2
Data transmission cable
GND3
Analogue outputs

GIM:
All SIMs:
load signal
digital
inputs
data bus
cable to
actuators
analogue
measurement
outputs
PE
protective
earth

Assembly - Commissioning
Assembly:
Ensure that the ventilation openings on top and bottom of the

19 card frame are not covered.
Ensure that no metallic objects get into the CIU when electrical
connections are being made.
Ensure that the connectors are plugged into the correct

positions: otherwise danger of faults.
Commissioning:
First the CIU must be configured specifically for the compressor

using the Service Unit.
The capacity control system cannot be commissioned without a

specifically configured CIU.
Warning:
Testing of dielectric strength may only be done
if modules have been removed from CIU card frame!
Assembly and Installation of the IA

Isolation Amplifier IA
The task of the 2 channel isolation amplifier is to transform
digital signals from hazardous area into save zone signals:
segregation of TDC sensor signal

(ex-zone) to CIU and power supply
location in safe zone, e.g. control room,

control cabinet, etc.
converting of TDC sensor signal into

rectangular shaped impulse.
second channel for other binary signal

Power supply: 24 VDC

Functional Check: Yellow LED
Front View
Housing type C
LED yellow:
Transistor output I
LED green:
Power supply
LED red:
LB channel I
Switch S1:
Mode of operation channel I
LED yellow:
Transistor output II
Switch S2:
Mode of operation channel II
LED red:
LB channel II
Switch S3:
LB-monitoring

Installation Dimensions
screw mounted :
2 screws on 90 mm grid
snap mounted:
on 35mm standard rail DIN EN50022
Proper grounding must be ensured!
118
115
111
20
Assembly and Installation of TDC Sensor

Installation of the Inductive Proximity Switch
The top dead center sensor (TDC-sensor) is based on an inductive

proximity switch principle. It is available in two-wire Namur design.
The TDC-sensor generates an impulse per revolution of the crank
shaft of the compressor.
This impulse is forwarded to the isolation amplifier (IA)

Installation of the Inductive Proximity Switch
uncovered - no metal cover
20
4
35
flywheel cover
or fixture with
bore / thread
13 DIA / M12x1
recommended
clearance (mm)
2-3
10
flywheel
WS17
LED
thread M12x1

Installation - Adjustments - Commissioning
Installation :
next to flywheel by M12x1- thread

TDC sensor location needs not to coincide with real TDC position
needs not to be installed inside the cylinder
crank angel offset to TDC sensor must be known
connected to IA
Adjustments and Commissioning:

Measurement of TDC position as accurate as possible (+/- 2 crank
angle) as precission of TDC signal influences perfomance of control
It is not possible to use the HydroCOM system without knowing TDC
Angel difference between TDC-signal and real TDC of the reference
cylinder has to be measured in degrees (360 = one revolution)
If the TDC signal appears before real TDC then the offset is assigned a
positive value e.g. +30
If the TDC signal appears after real TDC then the offset is assigned a
positive value which is calculated by e.g 360 30 = +330
Functionality of the TDC sensor has to be verified by flashing yellow
LED on sensor, IA and CIU
Assembly and Installation of the TSI

Transmitter Supply Isolatoer (Transmitter Driver)
This device is suited for 2- and 3-wire transmitters and is used
for the temeprature transmitter installed on the HU.
segregation of 4..20mA sensor signal

(ex-zone) to PLS and power supply
location in safe zone, e.g. control room,

control cabinet, etc.
Power supply: 24 VDC
Assembly and Installation of the 24VDC

24 VDC Power supply
The output voltage of the 24VDC power supply is controlled and
stable independent of the power supply voltage.
Power supply voltage: 115/230VAC

Maximum load current: 500mA
Supplies 24VDC for:
- Isolation Amplifier (IA)
- Transmitter Driver (TSI)
- Protronic 500 controller (optional)
- etc.
Assembly & Installation of the EPS

External Power Supply EPS
Photograph:
big
size
input
clamps
output
clamps
External Power Supply EPS for the actuators and the solenoid
valves of the actuators:
Output voltage 48Vdc
Connection to mains 110V or 230V, 50 or 60Hz
Installation in the control cabinet in the instrumentation room
Two different EPS-sizes for different capacities, depending on the
number of actuators. Parallel operation of EPS is possible.

Mechanical design
and dimensions:
The EPS is suited for
35mm rail mounting
as well as installation
on a wall.
up to 10 actuators / TIMs:
KX000693

up to 20 actuators / TIMs:
KX000694
Parallel operation of two
KX000694, if more than
20 actuators are used.

Connection
The terminals on the EPS are marked
Assembly
Ensure that no metal parts get into the EPS when electrical
connections are being made
Commissioning
After installation check that there is 48VDC voltage at all
actuators
Wiring
Table of Contents
Safe area
Hazardous area
Supplied by customer
Supplied by
HOERBIGER
General Notes
Wiring CIU
Wiring IA
Wiring EPS
Wiring HU
practical training: the use of a training model is recommended
Wiring
General
Comments on cables:
The HydroCOM-System uses cables as standardized in chemical
plants and refineries.
In case of ambient temperatures >65C at the compressor area
cables must be used that have permissible operating temperatures
>80C (90 for the FM approval).
It is recommended to fit all stranded wires with wire end sleeves
presenting a gas tight connection. The quoted maximum wire
diameters are inclusive of any such end sleeves.
The wiring specifications are a recommendation, please consult
HOERBIGER if you wish to modify wiring.
USE CORRECT BUS CABLE (RS485, 1.5 twisted pairs,

100..130 Ohm char. Impedance, shielded, etc.)
The HOERBIGER cable listings contain the exact specification of the
cables and connection points.
Wiring
Cables between SIM and Actuator or TIM
Actuators and TIMs belonging to one stage are
connected by a data line (bus).
hazardous zone
Actuator M1
SIM-M
A
B
GND
Connector
X M1
A
B
GND2
Hoerbiger Supply
ferrite core:
bus cable
PE
Actuator MN
or TIM MX
A
B
GND
PE
PE
Hoerbiger Supply
RC
safe zone
PE
Hoerbiger Supply
RC module on last
actuator / TIM connected
to the HydroCOM data bus
Note: M stands for 1..6 (stage)
N stands for 2..8 (actuator number)
X stands for 9..A (TIM number)
Wiring
BUS CABLE - Specification
Cable Type:
RS-485 compatible: characteristic impedance 100...130 ,
suitable for Zone 1, wire cross section 0,22 ... 1,5 mm
(AWG24...16), outer diameter 6...12 mm.
BELDEN-cabel, type 3106A

without armoring
BELDEN-Kabel, Type 133106A

with steel interlocked armoring
Wiring
Cables between SIM and Process Control System
SIM-M
connector
X M4
SIM-M
connector
X M3
SIM-M
connector
X M2
CIU (SIM-M)
distributed control system
or controller; control signal
for compressor stage M
4..20 mA = 0 .. 100 % load
GND1
C+
CT1
GND3
T2
GND3
T3
GND3
T4
GND3
valve cover temperatures

of valves 1 to 4
4..20 mA = -25 .. 125C
T5
GND3
T6
GND3
T7
GND3
T8
GND3
Hoerbiger Supply
valve cover temperatures

of valves 5 to 8
4..20 mA = -25 .. 125C
non hazardous zone
Wiring
Cables between GIM and PLS
Connection of the wires to the terminals at the rear of the CIU for the
binary Inputs EN and SIM
binary Outputs ER, WA, HY
CIU - GIM
dry contacts
Connector
X71
0 or 20...30VDC
Enable command
Simulation command
Hoerbiger Supply
Connector
X72
(dry contacts)
error signal
warning signal
oil pressure low signal
non hazardous zone

Cable type: twisted pair, wire cross section 0.22-1.5mm2 (AWG24..16)
Wiring
Cables between CIU and Isolation Amplifier IA
Connection of the TDC impulse signal to the
corresponding terminal at the rear of the GIM
in the CIU
IA
Connector
X71
CIU
TDCGND1
Hoerbiger Supply
7 (output 1)
8 (COM)
9 (output 2)
Hoerbiger Supply
non hazardous zone
Cable type:
twisted pair, wire cross section 0.22-1.5mm2 (AWG24..16)
Wiring
CIU Power Supply
110VAC or 230VAC (as specified in the order)
Connection of the mains to the rear of the CIU
Connector
X81
CIU
F1=4A
N
L1
PE
230 or 110 VAC

Protective Earth
Hoerbiger Supply
non hazardous zone

Cable type:
wire cross section 1,5 - 25 mm2 (AWG16..4)
Wiring
Top Dead Center Sensor to Isolation Amplifier IA
24VDC
3 x 1,5
IA
INPUT
TDCsensor
twisted
pair
Output
to CIU
safe area
The IA requires a
24VDC power supply
The TDC-signal is sent

to the CIU via the IA
hazardous area
proximity switch
(2-wire NAMUR)
supplied by customer
supplied by
crank shaft / flywheel
HOERBIGER
Wiring
Isolation Amplifier IA Power Supply
24VDC
Terminals: 14 and 15
IA
14
15
L (L+)
N (L-)
Hoerbiger Supply
non hazardous zone
Cable type:
wire cross section 1,5 - 2,5 mm2 (AWG16..11)
Wiring
Cables between IA and TDC-Sensor
The existing cable on the sensor is connected to a terminal box in the
field, which is appropriate for the intrinsically safe circuit. A cable is used
for the connection of the terminal box to the IA in the control room.
safe zone
IA
hazardous area
connection
box
1+
3-
Hoerbiger Supply
TDC-sensor
length < 2m
Hoerbiger Supply
Cable type:
blue cable, appropriate for the intrinsically safe circuit in zone 1,
wire cross section 0,22 - 2,5 mm2 (AWG24..11)
Wiring
Wiring of a second IA channel
Input of a second IA channel:
safe zone
hazardous zone
IA
(dry contact)
4+
6-
Hoerbiger Supply
Cable type for input:

blue cable suitable for intrinsically safe circuits in zone 1.
Wire cross section: 0,22- 2,5 mm (AWG 24...11)
Wiring
Wiring of a second IA channel
Output of a second IA channel:
Stecker
X71
CIU
IA
TDC-
7 (output 1)
GND1
8 (COM)
9 (output 2)
usage of second
output (optional)
Hoerbiger Supply
-
non hazardous zone

Cable type for output:
twisted pair; wire cross section: 0,22 - 1,5 mm (AWG 24...16)
Wiring
Cables between EPS and Actuator or TIM
All actuators are supplied with 48VDC by a distribution box.
connection box
EPS
+
Actuator M1
+
Hoerbiger Supply
Hoerbiger Supply
Actuator MN
or TIM MN
Hoerbiger Supply
safe zone
hazardous area
Wire cross section varies according to the distance (cable length) between
the EPS and the actuators and number of actuators - refer to the manual!
Wiring
Power Supply EPS
The EPS has to be supplied with 110VAC or 230VAC.
All types of EPS have an auto-switching input.
F3: Fuses type C of slow response

Fuse sizing see Tab. 6 in manual
EPS
N
L
PE
230 or 110 VAC

Protective Earth
Hoerbiger Supply
non hazardous area
Wiring
Wiring of HU
The HU motor is of single speed, 3 phase, EEx de IIC T4 design.
Grounding is done as per local regulations and standards before
power supply is connected.
DELTA
jumpers
delta - connection
L1
W1
W2
U1
W2
U2
V2
Examples:
U2
U1
L2
L3
V2
Voltage and connection type

are specified on the motors
rating plate.
V1
V1
L1
W1
L2
L3
400 V
indicates delta
connection
required for 400 V.
660 VY
indicates star
connection
required for 660 V.
PE
jumpers
L1
STAR
star - connection
U1
W2
U2
V2
U2
U1
W2
W1
V1
W1
V2
L1
V1
L2
L2
L3
PE
Wiring
Wiring of Temperature Transmitter and Driver
The temperature transmitter is used to monitor the oil temperature of
the HU.
Temperature range: 4..20mA corresponds: -25C to +125C.
safe zone
hazardous zone
Transmitter Supply
Isolator
to
DCS
L+ (24V)
L- (0V)
8+
711+
12-
1+
3-
Temperature
Transmitter
+
Hoerbiger Supply
Hoerbiger Supply
Similarily, the pressure transmitter of the Hydraulic Unit is connected

the same way as the temperature transmitter.
Furthermore, these transmitters can be also connected directly to a TIM.
Wiring
Wiring of Oil Level Switch
The Mode shall be set to DRY = ON!
Power Supply
Output Signal
Mode Switch of
Output Signal
safe zone
Isolation
Amplifier
Hoerbiger Supply
hazardous zone
Oil Level Switch

4+
2+
6-
1-
Hoerbiger Supply
Hydraulics - Fittings - Lines

Contents
Hydraulic Lines and Fittings

Flare gas and Oil Leakage Lines
Hydraulics - Fittings - Lines

Components of the Hydraulic System
diaphragm reservoir
pressure lines
actuators
return oil lines
Hydraulic-Unit HU
Hydraulic Lines & Hydraulic Fittings

General Specification
Hydraulic pipes: seamless, cold-drawn, stainless steel
DO NOT USE conical screw-in threads (i.e. NPT)
Pressure energy stored in diaphragm reservoirs must

be released. Wait for a minute after switching off the
hydraulic unit.
Hydraulic hoses: with steel wire layer

Connections: strait screw sockets with sealing lip
(according to DIN 3852, type B) at
actuator, HU and diaphragm cylinders.
Only work on the Hydraulic Unit

when the system is depressurized

General
Installation
keep tubes and hoses as clean as possible
if welded tubes are used deburing is recommended
cotton waste or wool waste must not be used for cleaning
follow the instructions of the manufacturer of the fittings

DO NOT USE hemp and putty, teflon tapes or liquid thread
sealing material
before assembling clean all tubes, do not leave any dirt, scale,
sand, swarf, etc. inside the entire system
piping must be installed free of any mechanical stress

distance between pipe clips or support brackets are 2m maximum

General
Before commissioning:
bypass all actuators

flush each pipe circuit individually for at least 2 hours
replace all oil filters after flushing
reconnect all actuators
great care should be taken
to ensure that there is no dirt
in the supply lines to the actuators

Valve Housing
Inlet line: HU - distribution point - actuators
On the pressure side actuators are connected to the diaphragm
reservoirs using flexible hoses DN10 (outside diameter 19mm) or
12x1.5mm piping (DIN2391) .
Connections to the actuators are made of G1/2 female threads.
Return line: Actuators - distribution point - HU

Installation is similar to inlet lines using flexible hoses DN10 or
12x1.5mm pipes (connection female thread G3/8).

Valve Housing - Inlet Lines
diaphragm
reservoir
G3/8
female thread
HP1..6
HU
connection M28x1,5
for filling device
female thread G1/2
hose DN10 length <2 m
or pipe 12 x 1,5
pipe 12x1,5
distribution point
(1 X or 2 Those DN10
fittings)
to avoid
vibrations
actuators N1..NM
G1/2 female thread
Hoerbiger supply

Valve Housing - Return Line
G3/8
female thread
Hoerbiger supply
HU
Hr 1..6
hose DN10
to avoid
vibrations
actuators
N1..NM
distribution point
(1 X or 2 Tfittings)
pipe 12x1,5
hose DN10 length <2 m
or pipe 12 x 1,5
G3/8
female thread
female thread G1/2

diaphragm
reservoir
connection M28x1,5
for filling device

Diaphragm Reservoirs
M28 x 1,5
Installation
ca 23
Diaphragm reservoirs are

screwed on to the hydraulic
lines.
They can be installed in any
position.
The filling connection must be
easily accessible.
103
74 DIA
In case of heavy vibration the

reservoirs must be secured
against breaking loose.
Commissioning
1
Reservoirs on the pressure

side to be filled with nitrogen
at half of the hydraulic oil
pressure.
key
width 30
21
14
Sealing
surface
G 1/2
34 DIA

Diaphragm Reservoirs
M28 x 1,5
Maximum pressure
210 bar
74 mm
Weight
0,8 kg
74 DIA
Diameter
103
approx. 124 mm
key
width 30
21
14
Height
ca 23
Technical data
Sealing
surface
G 1/2
34 DIA
Piping
Oil Leakage Line
Actuators
Hoerbiger supply
Hoerbiger supply
1.1
6.1
1.2
1.8
pipe 8x1
2 connections LO,
female thread G1/8 :
6.2
pipe 8x1 pipe 8x1
pipe 8x1
pipe 8x1
pipe 8x1
venting to
environment
Use the lower one

Close 2nd connection
with a screw plug, but
do not plug both vent
holes!
6.8
drain valve
plastic
vessel
Piping
Flare Gas Line
Actuators
Hoerbiger supply
Hoerbiger supply
1.1
6.1
1.2
pipe 8x1
2 connections LG,
female thread G1/8
Actuators Inner DIA
1.8
6.2
pipe 8x1 pipe 8x1
pipe 8x1
pipe ??x1
pipe ??x1
Pipe Size
1 to 8
6mm
e.g. 8x1
9 to 16
9mm
e.g. 12x1.5
17 to 24
12mm
e.g. 16x1.5
6.8
check valve
to flare
Piping
Seal Housing with Seal Gas
For H2S and other extremely aggressive gases
a seal housing with Seal Gas is used.
Connection SG
Connection LG
G1/8: Nitrogen into seal housing

G1/8: Flare gas out of seal housing
Hoerbiger supply
1.1
1.2
Hoerbiger supply
1.8
6.1
6.2
6.8
Actuators
seal gas
housing
pipe 8x1
pipe 8x1
pipe 8x1
pressure
controller
check valve
valve
seal gas inlet
to flare
Check List
HydroCOM 2.0
Before commissioning
the system has to be checked:
Valve and unloader assembly

Actuators
CIU
EPS
IA
TDC-Sensor
Transmitters& Drivers
HU
Diaphragm reservoirs
Data cables
Power supply
Hydraulic Lines
Flare line and oil leakage line
6.5.0
Check List
At the Compressor
With reference to the actuators number the actuators are installed

at the correct stage / cylinder end.
The distance upper edge seal housing to upper edge unloader rod
amounts to 18 +/- 2 mm.
Hydraulic supply and return lines are connected and tightened.
bus cables are connected to the actuators.

In the actuator where the bus cable ends
the RC-module must be already installed.
48 V power cable is connected to the actuators.
Flare gas lines are connected.

Oil leakage lines are connected.
Diaphragm cylinders in supply lines are filled with nitrogen
to the correct pressure.
continued ...
Check List
At the Compressor
continued ...
The TDC-sensor is correctly mounted in top dead center position

and wired (respectively the offset angle between the sensor
signal and the actual TDC is measured).
TDC-sensor is connected to IA.

Hydraulic oil of mineral type, ISO VG 10 is filled into the HU tank.
HU motor power supply is connected as per rating plate.
Option: Level switch is wired.
Option: Solenoid valve for HU heating is wired.
Check List
Instrumentation room (CIU, EPS, IA)
All pugs are correctly mounted (no offset position).
TDC signal connected.
Grounds are connected to the correct ground level.

The CIU is configured for the supply voltage (110 or 230 VAC).
Controller inputs are connected for each stage.
Measuring signals are connected.
Binary signals are connected (Warning, Error, P_hyd low,
Enable, Simulation).
Bus lines to actuators / TIMs connected.
Ferrite cores are installed close to the CIU.
Power supply connected to EPS.
48 VDC lines to actuators correctly sized.
Power supply connected to IA, 24VDC supply, transmitter driver
TDC signal checked with yellow LED at IA and LED at GIM.
Check List
DCS
Programming of DCS completed and tested.
Check List
Hydraulic Unit
Short-circuits hydraulic lines at actuator in- and outlet connection.

Start-up of HU. Stop HU if direction of rotation is incorrect and
change two phases.
Adjust pressure control valve for main hydraulic circuit as per
hydraulic data sheet.
Option: If heating is provided for the HU adjust pressure control
valve for heating circuit to 70 bar.
Flush hydraulic system for several hours.
Change hydraulic oil filters.
Check tightness of hydraulic fittings.
Connect hydraulic lines to the actuators.
Check List
Preparations for Start - Up
CIU is configured by HOERBIGER using the SU.

Option: Modbus connected and configured (HOERBIGER).
All loops checked.
Simulation run successfully performed.
Compressor pressurized and tightness of covers and flanges
checked.
Check List
Compressor Start - Up
Note: Before compressor start up all works mentioned
above have to be completed.
Watch suction valve cap temperatures.

Optimization of control parameters and
determination of minimum and maximum limits.
Test runs for total operating range.
HydroCOM 2.0
End of File
Installation on the Compressor
Installation of the System

07 - Hyd2.0 Installation PDF

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HydroCOM 2.

Assembly and Installation

Assembly and Installation

For trouble-free operation of the HydroCOM

Assembly and Installation

Assembly and Installation

Assembly and Installation

Assembly and Installation

Unit for the actuation of the suction valves

Assembly and Installation

BS5345 Parts 1,4 & 6 is replaced by EN50154

Cables, lines, connections, insulation and accessories must be

Assembly and Installation

SIM 1 SIM 2 SIM 3

SUNBURST: RECIP #1: DISCHARGE TEMPERATURE DEVIATIONS

DEV:DISCH GAS TEMP 2 (%)

Assembly and Installation of an Actuator

Assembly and Installation of an Actuator

Standard design or special solution for

Is it possible to adapt valve covers?

Assembly and Installation of an Actuator

87,0 mm ( 2,0 mm)

Check after assembly:

Assembly and Installation of an Actuator

Assembly and Installation of an Actuator

Valve holder is secured by

Assembly and Installation of an Actuator

Assembly and Installation of an Actuator

18,0 mm ( 2,0 mm)

Place suction valve with unloader

Check after assembly:

Installation of a suction valve:

Installation of the actuator

Assembly and Installation of an Actuator

Removal of seal housing only while

separate valve housing

place seal housing

take care that the

flush hydraulic lines

Insert unloader rod carefully

Assembly and Installation of an Actuator

18mm +/- 2mm

Assembly and Installation of an Actuator

hydraulic oil inlet

Assembly and Installation of an Actuator

for power supply

PE wire is attached to PE symbol

Assembly and Installation of an Actuator

Last actuator on a data bus cable:

Assembly and Installation of the CIU

It is the interface between actuators, TIMs and a DCS (distributed

Assembly and Installation of the CIU

RUN : CIU-power supply active

Interface RS232 9-pole sub-D plug

Assembly and Installation of the CIU

Prior to commissioning, compressor specific CIU

ON = jumper placed on left side OFF = jumper placed on right side

Assembly and Installation of the CIU

TDC, EN, SIM

isolated for active signal source

not isolated for passive source

Contact open in case