The Principle and User Manual For CVT-XX Digital Hydraulic Turbine Governor PDF

CVT/ZT-XX
The Principle and User Manual for

CVT/ZT-XX Digital Hydraulic Turbine Governor

Beijing IWHR Technology Co., Ltd
ADD: A-1 fuxing road Beijing China Post code 100038
TEL 010-68781925 FAX 010-68576176
010-68781923 E_mail gover@iwhr.com
Web http://aec.iwhr.com
2
The Principle and User Manual for Digital Hydraulic Turbine Governor
Catalogue
1 General
2 System Configuration
3 Main Technical Parameters
4 Working Principle
5 Operation
6 Installation of Equipment
7 The Fault Type and Processing
8 Maintaining Suggestion
Notice: We will reserve the rigths of revising this document. The information in this
document is subject to change without notice and should not be construed as a
commitment by BITC. BITC assumes no responsibility for any errors that may appear
in this document. Please based on the actual product as the criterion, if there has any
discrepancies between the actual product and this document. Welcome to contact us
at any time.
2
Beijing IWHR technology Co. Ltd
3
1 General
PLC +
The new type microcomputer-based governor system consisted of standard

PLC regulator + electro-hydraulic servo system is now widely used. The
microcomputer regulator section can execute following functions, such as signal
transmission, regulating rule synthesize , regulating parameter switch, status
indication, the output of control value,etc. The mechanical-hydraulic section adopt the
eletro-hydraulic servo system, it simply works as a power amplifier and servo control
actuator. The new type microcomputer-based governor system can improve the
performance and the flexibility of use.
CVT/ZTXX CVT/ZTXX
This manual will describe the princilpe and operating about the CVT/ZT
XXdigital hydraulic turbine governor. The CVT/ZTXX governor is a new type
governor based on the modern hydraulic digital logic cartridge technology. Its model
number are defined as follows,
CVT/ZT-XX-XX
Pressure grade code

Specification code, also called main valve
CVT is single regulating governor, CVZT is double
regulating governo

--
-/ +
3
4
This type governor is based on logic cartridge technology, that is combined with
high speed on-off valve and cartridge valve,via multi-level manifold block combination
and optimal design from components to subassembly to fluid loop, then proceed to
realize all the regulating and control functions of governor. It has successfully
breached the constraint of classic structure with electrical-mechanical/hydraulic
conveter or micro-motor plus main distributing valve, and it has also broken through
the constraint of manufacturing process and structural arrangement. It is without the
necessity for middle position and mechanical feedback to ensure the regulating and
control of system. That enable the design and manufacture of governor to be a
fundamental change. It make a compromise the motion reliability of mechanical
hydraulic section, applicability of micro-computer,and simplification of valve. It has
unique advantages of high reliability, quick response, smooth motion, and high
precision of positioning, high motion efficiency, save oil consumption,etc. It is unique
and place a position in the field of governor.
2 System Configulation
CVT/ZTXX
The CVT/ZTXX series turbine governor is mainly composed by two parts:

electrical regulator and hydraulic servo system. Components of each part are
presented as follows:
2.1
Electrical Regulator
//
Its core part includes PLC, input/output signal disposing module, the
amplifier/driver circuit; it provides high reliabilitya friendly man-machine surface, and
direct measuring and debugging and maintaining method.
CPU
4
5
The PLC is composed of CPU unit, digital input/output (I/O) modules, analog
input modules, high speed counter modules, remote communication modules and
power supply modules.
/ DC24V
The amplifier/driver circuit: After amplified TTL output signal of microcomputer,

the amplifier/driver circuit will drive the DC24V digital valve sets, and the output
signal is pulse signal.
Main characteristic
MTBF
150000
Adopting the PLC as the main part of the hardware, the equipment has high
reliability, and its MTBF (Mean Time between Failures) is more than 150000 hours;
//
The electrical regulator provides frequency(hydraulic turbine

speed)/opening/active power regulating modes, and it can adapt various operating
mode of hydraulic turbine unit;
05V 020mA,
,
Water head can be measured automatically (the electrical level standard: 0~5V
or 0~20mA), or set manually by operator. Its opening character and maximal power
character adapt well to water head;
bpbtTdTn bpKpKiKd
Regulating parameters (bp, bt, Td, Tn or bpKpKiKd) are adjusted through the
touch screen(or HMI);

Adopting large scale digital display tube, light diode (light brand), dial ammeter,
switch and touch screen as the interface with the operator, it has the advantages of
clarity, visual display and easy to operate;
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6
Electric accessories element (switch power supply, relay, control switch, signal
light) are imported high quality implement, and have high reliability;
PID PI
Adaptable and parameter variable PID regulating rules were adopted for the
frequency regulating mode, and PI regulating rules were adopted for the opening and
active power regulating mode;
RS-422/RS485/RS232
The communication interface (RS-422 / RS485 / RS232) with LCU has been
provided.

The shut-up opening and the maximal active power limit of the turbine unit can
be changed according to different water head. As water head increased, the governor
can automatically decrease the shut-up opening and the maximal active power limit,
so as to ensure the hydraulic turbine generator switched on line quickly and
effectively and run with safety.

Accelerating characteristic of hydraulic turbine unit startup process can be set
through the touch screen(HMI).
CVT/ZT /
The list of main hardware/components of microcomputer regulator in CVZT
governor

Serial number designation
PLC
1.
High reliable PLC controller
6
7

2.
Flat touch screen HMI

3.
Peripheral circuit board or signal transform module

4.
Unit frequency transmitter

5.
Net frequency transmitter

6.
Displacement transducer

7.
Amplifier/driver module

8.
Dual AC/ DC power supply

9.
Accessories such as relay and plug and socket

10.
Electric control cabinet skid
2.2 Hydraulic servo system

:
Its basic structure characteristic can be induced in the pilot control, main level
valve and cartridge connection. Each component part is combined together in module
structure. The hydraulic servo system mainly includes:

Digital (high frequency on/off) valve sets
()
The hydraulic power driver valve sets assembled with logical cartridge valve
basic units (serving as main distributing valve function)

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8
The adjusting screw for open/close time and quick shutdown or emergency
shutdown time of servomotor

The oil filter with replaceable filter core and signal sending instrument for oil filter
clogged

Manual air releasing valve

The by-pass relief valve acting when the oil filter is clogged, invalid or being
cutting off

The startup/shutdown pulse control valve

The quick shutdown or emergency shutdown valve sets
()
Flow control valve (linear transformer between flux and pressure difference).

ISO
The mechanical hydraulic servo system is designed as module construction, can

be flexible assembled and arranged according to the using purpose. Without pole,
steel rope and internal pipe, the whole hydraulic control device is highly integrated,
so the operating and maintaining demand to the user become lower. The mechanical
hydraulic servo system adopted large quantities of hydraulic components matched
the ISO standard, and have the characters of great standardization, modularization,
integration, generalization and interchangeability.
Main features include:

Replacing the electro-hydraulic converter/transducer with some high frequency
on/off valves, redundancy control becomes realizable.
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9
D/A
The hydraulic part of the governor has both the functions of D/A converter and
power amplification, thus the direct digital control can be realized.

The hydraulic components are not sensitive to working medium contamination:

the operating force on the valve core of high frequency valve is powerful, which
guarantees the anti-greasy performance and reliability of the components.

The logical cartridge valve techniques: the main distributing valve is replaced by
the combined logical cartridge control valves. The logic cartridge control valve is
driven by hydraulic power which is more than hundreds of kilograms, therefore the
action reliability is greatly improved. And those disadvantages of traditional main
distributing valve are also avoided, such as the low standardization degree, the
difficult consistency of capability and bad interchangeability. Besides, the logical
cartridge control valve units contain abrasion resistance material of high rigidity, it can
be hardly disabled after long-term working.

The high frequency valve is structured as redundancies construct with many

channels. Once one (or more) of the channels disabled, it can automatically keep
running through normally working channels.

The system has quick response, high regulating precision and low failure rate,
and its availability is also improved.

9
10
,
Even if the electrical part got to be absolutely failed, the main servomotor could
be kept the gate opening stable, and the system is automatically switched to run
manually, thus the fault extending and kickback of the fault could be avoided.

//
The mechanical-hydraulic part of the governor can realize not only all functions
of traditional mechanical-hydraulic equipment, but also fault tolerance running and
smooth switching between auto/manual/electrical- manual running.

Maintenance-free is ensured radically by special design of fault-tolerance control

function and oil filter circuit.

-
The system structure is concise, the friction of internal liquid flow is small. From
the element to the system, the sealing is tight and with little leakage. The efficiency of
the system is extremely increased and the service life of oil pump and electromotor
are prolonged.
3 The main technique parameters
PID
Regulating rules: Adaptable and variable parameter PID
+
Frequency/speed measuring method: PT voltage frequency measuring or PT
voltage + toothed disc speed measuring;

The hydraulic turbine unit frequency/speed signal:

One way signal comes from PT voltage of generator;
0.6~100V
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The normal range of signal voltage: 0.6~100V sine wave

5~100Hz
The normal range of frequency measurement: 5~100Hz
0.001Hz
The resolution of frequency measurement: 0.001Hz
The other way signal comes from toothed disk proximity probe;
0~24V
The normal range of signal voltage: 0~24Vsquare wave
0~100Hz
0.002Hz
The signal of electrical network/grid frequency
Comes from PT voltage of low voltage side of main transformer

0.6~100V
The normal range of signal voltage: 0.6~100V sine wave
45~55Hz
0.001Hz
bp=(010)%
Permanent speed droop: bp=010%
K p = 0.5 : 20
:bt=(5%150)%
K p = 0.5 : 20
Temporary speed droop: bt=5%150%, or Proportional gain
:Td=(220)s K i = 0.05 : 10(1 s )
Damping time constant: Td=220s, or Integral gain K i = 0.05 : 10(1 s )
:Tn=(05)s K d = 0 : 5( s )
Accelerating time constant [derivative time constant]: Tn=05s or Derivative
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K d = 0 : 5( s )
gain ;
fG
=(4555)Hz
f
Frequency setting range G =(4555)Hz
P
G =(0120)%
P
Active power setting range G =0120%
H[] H (
0~10V 0~20mA)
Water head: Manually setting with [water head setting] button; or automatically
measuring the parameter H (Electrical level standard: 0~10V or 0~20mA).

Feedback signal of guide vane servomotor displacement:
+15V
Power supply voltage provided by microcomputer regulator: +15V
0~100%+0.35~+9.6V
Feedback voltage of guide vane servomotor displacement: the guide vane
opening range 0~100%, corresponding to the voltage+0.35~9.6V;

Contact between microcomputer regulator and secondary circuit

The isolated supplementary contact of the generator circuit breaker

Isolated supplementary contact of the line breaker at high voltage side

Isolated contact of the start-up relay

Isolated contact of the shut-down relay
/
Isolated contact of the increasing opening/speed/active power
/
Isolated contact of the decreasing opening/speed/active powe
Power supply
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~220V10%50HZ1000VA
AC: ~220V10%50HZ1000VA
220V10%1000W
DC: 220V10%1000W
E
() f =(00.5)Hz
E
Frequency(speed) artificial dead band f =(00.5)Hz, adjustable.
/E(Y-P)=(05)%
Power/opening artificial dead bandE(Y-P)=(05)%, adjustable

Regulating mode
()EF=0,E(Y-P)=0,PID
Frequency/speed regulatingEF=0, E(Y-P)=0, PID regulating
/ EF=(00.5)Hz, E(Y-P)=(05)%, PI
Power/opening regulatingEF=(00.5)Hz,E(Y-P)=(05)%, PI regulating.
1.6MPa31.5MPa
Rated operating pressureadaptable to 1.6MPa31.5MPa
(37500)L/min(P0.2MPa)
Maximum designed flow of the main controlled valve sets 3
7500L/min(P0.2MPa), adjustable
/(170)s
The full stroke start-up/shut-down time of the main servomotor 1 70s,
adjustable
24V10%
Rated working voltage of high frequency on-off valveDC: 24V10%
35W()
Maximum power of high frequency on-off valve: 35W (single)
15
Action durability of high frequency on-off valvemore than 1.5109 times
200Hz
Working frequency of high frequency on-off valvemore than 200Hz
-40135
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Allowed temperature range of high frequency on-off valve:-40135

24V15%
Rated working voltage of quick/emergency shut-down valve: DC,24V15%
0.35MPa
Maximum pressure difference durability of filter core0.35MPa
MTBF 2
MTBF(Mean Time Between Failures): MTBF> 20000 h
: ix<0.02%0.04%
Static characteristic speed dead band: ix<0.02%-0.04%
<0.15%
Automatic no-load speed swing<0.15%
25%Tq<0.2
Dead time of servomotor in 25% rated load rejectionTq<0.2
100%
Dynamic characteristics in 100% rated load rejection
a. 1.5Hz 2
The number of wave-crest departure from stable speed larger than 1.5Hz is no
more than two
b.0.5%
40s.
b. The period is no more than 40S, from the first time servomotor running
towards the opening direction, to speed swing below 0.5%.
c 100%1 t E
tM
8 10
15
0.9
c. The ratio of t E / t M is no more than 8 for reaction turbine of middle or lower
head; no more than 10 for adjustable-blade propeller turbine, the blade shut-down
time of which is relatively longer; no more than 15 for reaction turbine of high head,
t
where E is the regulating time ,after which the speed deviation from the speed
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tM
setpoint remains below 1; is the time , from the beginning of load rejection to
the speed up to the maximum value. For the unit supplying power to the station
service network after seperating from the grid, the lowest relative speed after load
rejection wont be below 0.9.
Working Principle
4.
1.
CVT D/A
See also Fig.1, the regulating rules synthesizing and control variable calculating
is realized by electrical regulator, the CVT/ZT hydraulic servo system is just as power
amplifier, followed the electrical controlled variable, and realizing D/A conversion,
then drive guide vane servomotor and turbine operating ring.
4.1 The working principle of microcomputer regulator
CVT/ZT LCU /
The CVT/ZT microcomputer regulator receive LCU command signal, according

to the signal of hydraulic turbine frequency/grid frequency, active power, water head,
opening, etc. synthesize regulating rules through software, then obtain corresponding
controlling variable that drive the digital valve sets of hydraulic servo system through
position control module; finally, it can control and regulate the guide vane servomotor
and hydro turbine unit.
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1.1 CVT/ZT
Figure1.1 The CVT/ZT structure principle diagram---Micro computer regulator&
Hydraulic servo system

4.1.1 Software Components
1 ()
Signal collecting and processing software: digital signal (command, status,etc.)

collecting software, hydro turbine unit frequency measurement software, grid
frequency measurement software, signal transmission software, digital filter software,
analog signal measurement software.
2
Regulating and control software: frequency control software, gate opening

control software, active power regulating software, shut-up process control software,
normal shut-down control software, condenser control software, load rejection control
software, operation condition translation software wicket gate opening control
software;
3
Signal output software: Wicket gate output control software, indication signal
output software, alarm signal output software;
4
Fault diagnostic and handling software: frequency measurement fault diagnosis,

wicket gate feedback fault diagnosis, digital signal fault diagnosis, analog signal fault
diagnosis, communication transmission fault diagnosis, system self-recover
software fault tolerance software.
5
Indication and parameter managing software: display software, parameter

setting software, fault alarm software, operating message software, debugging test
software, data communication software.
Operating Mode and regulating Rules
4.1.2
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()
Hydraulic turbine generator unit is usually operating under complicated
conditions, the translation of operation conditions is realized by the turbine governor,
the figure below is the main operation condition of hydraulic turbine generator unit,
some of states, stop standby, no load, load, condensor, are steady cycle states(long
time keep-working states), others are transient states.
1
Stop standby
.
In this congition, the hydro turbine unit has been shut down and standing by, the
hydro turbine unit speed is zero, wicket gate is closed completely and compressed
tightly.
2
Automatic close-loop start-up

Choosing a proper start-up strategy of hydraulic turbine unitthe items below can
achieve to the best effect
a.The time length of unit reaching rated speed
shorter
b.Small Axial thrust
c.. Small fluctuations of hydraulic turbine torque
and axial thrust
d.Pressure changing of penstocks is small
CVT/ZT
PID PLC
During the start-up period of unit, the frequency signal of CVT/ZT governor can
be accessible; the governor is under close-loop control mode. According to the
difference between the setting frequency and current unit frequency, wicket gate
control value can be calculated by PID operations, then, by PLC high-speed output
and power amplifier module acting on the electro-hydraulic servo system, the wicket
gate displacement changes with the control variables changing, which leading the
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unit speed reaches rated value, then, start-up program completes.
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3
No-load frequency tracking
50Hz
When the grid-frequency tracking mode exited, the default value of setting
frequency is 50Hz, the setting frequency value can be modified by using touch
screen(HMI), to make the unit frequency tracking setting frequency. When
grid-frequency tracking mode starting, the current grid frequency is taken as setting
frequency , the regulation object is tracking grid frequency, the unit frequency always
changes with the grid frequency, to make synchronization rapidly .
4
Load cycle

When the synchronization condition of hydraulic turbine unit is met, the

synchronization command is sent from the LCU, the unit will be connected to the grid,
and entering to the load cycle. The load opening limit is opened by governor
automatically, according to the regulation setting of governor and grid condition, it will
select the load regulation mode automatically: active power regulation, opening
regulation or frequency regulation. After switched on line, the governor will monitor
the real-time fluctuations of grid, and chooses the regulation mode automatically.
5
Opening regulating mode
50EfEf
50Ef
After the hydro turbine unit connected to the grid, frequency of grid is within the
scale of 50Ef (Ef is artificial speed dead band setting for the governor), if the
governor don't accord with the power regulation condition, it will judge that the unit is
in large interconnected grid , the governor will translate the operation condition to
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opening regulating mode. Actually, opening regulation mode is, when the grid
frequency fluctuates within the scale of 50Ef, the opening of servo motor do not
change with the changing of frequency, but keep a specific opening value.
50Ef
b
p
Under the opening regulating mode, if frequency of grid exceeds the scale of
50Ef, the governor will participate primary frequency regulating by itself, according
b
to the frequency variation and direction , and permanent speed droop p , change
the wicket gate opening of unit.
6
Active power regulating mode
AGC AGC
PI
This operating mode is applicable to the power station that has realized AGC
(Automatic Generation Control). After the hydraulic turbine unit of the power station
realized AGC is connected to the grid, the governor will receive the setting active
power as object value via computer network communication with LCU, and collect the
feedback value of active power automatically. Meanwhile the governor will compare
the active power setting value given by LCU with the feedback value of active power,
according to the compared result, regulate with PI rule, control the wicket gate
opening automatically, then ensure the active power of unit to the setting power
value.

50Ef
e
p
We call this regulating mode as power regulation mode which making active
power as closed-loop regulating. Under this regulating mode, if frequency of grid
exceed the scale of 50HzEf, the governor will participate primary frequency
regulating by itself, according to the variation value and direction of frequency , and
e
permanent droop p , change the active power of unit.
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7
Frequency regulation mode

50HzEf
b e
, p p /
50HZ(50Hz
0.033Hz) AGC AGC
It should be noted that the conception is strictly different between the frequency
regulation mode under generating condition and primary frequency regulating.
Primary frequency regulating applies in the opening regulating mode or power
regulating mode, for the frequency differential deviating from the rated frequency of
system (50HzEf), according to the static characteristic of permanent speed droop,
control the units opening/ power. Its characteristic is that the frequency regulating is
quick, but the regulating quantity differs from different units, and the regulating
quantity is limited , so the primary frequency control completed by the different unit
governor system cannot make up for the differential power value of grid, and the
regulating quantity is not enough for recovering the grid frequency to a allowable
range (50Hz0.033Hz) nearby the rated frequency (50 Hz). Moreover, its control
purpose is not in accordance with AGC, for example, AGC requires the unit operating
keeping a specific constant power value, but the primary frequency control need
change the power with the changing of frequency differential.
50Hz0.5Hz
When frequency deviate far from the rated frequency, as exceeds

50Hz0.5Hzin a long term, the governor will consider that the unit is operating in a
isolated network with local loads, for recovering the frequency to the nearby of rated
frequency and assuring the system stability, it will turn into the frequency regulation
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mode. So, the frequency regulation mode of generator connected to the grid is
equivalent to the isolated grid operating mode.
8
Condensor operating mode

After the unit switched on line, the condensor command sent out from LCU, the
wicket gate servo motor will be closed by governor, the unit is operated by which
translate from generator to electric motor, absorbing the active power from grid line,
the unit is under condensor operation condition. If the command of condensor
released, the opening of wicket gate will be increased to the position of no-load. The
condensor operation mode on the unit of Tishrin hydro power plant is cancelled, so
as to avoid the unit lifting.
9
Shut-down mode

The shut-down command has the highest priority. Under any operation condition,
if the shut-down command received, the governor will close wicket gate quickly, and
the unit speed decreasing to zero. For reliability, when shut-down process completed,
the governor will translate to stand-by mode, the unit is under standby condition.
4.1.3 Hardware components
PLC PLC Microcomputer Platform
1 CPU
The PLC microcomputer platform mainly is composed of CPU module and
software storage unit.
2 Components of peripheral sub-system
CVT/ZT
Peripheral components of CVZT mainly include:
(DI)
Digital Input module (DI);
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(DO)
Digital Output module (DO);

Hi-speed counter module, used for measuring frequency/speed in regulator
system;
(A/D)
Analog Input Module (A/D);
RS232RS422
RS485 CAN PROFIBUS
Communication Module (according to different communication objects,
communication modules use different ports: Serial port RS-232, RS-422 or RS-485,
CAN port, Ethernet communication processor, PROFIBUS communication processor,
etc.
/
Driver/Amplifier Module;

Power Supply Module;

Frequency signal reforming module;

Analog signal reforming module;
(HMI)
Human-Machine Interface (HMI), Here is touch screen;

Switch, button, meter circuit;

Relay circuit;
4.1.4 HMI Human-Machine Interface
HMI

About this part content, please refer to
Human-Machine Interface specifications.
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4.2 The working principle of hydraulic servo system

4.2.1 Working principle of main components
1
High frequency on-off valve
Brief Introduction of High frequency on-off valve
CVT/CVZT/YCVT/CJCVT
/(
)
/
0.5ms3ms
D/A
()
()
()
High speed on-off valve (also called digital valve) is the key component that
convert from electric signal to hydraulic signal, its function is receiving the pulse serial
control signal that electrical regulator output, and cause direct-acting valve core
moving, then the control pressure will be changed, this pressure signal then regulate
the main control valve liquid flow to operate the servomotor.
High speed on-off valve in CVT/CVZT/YCVT/CJCVT series of governors, makes
the function of converting the electric pulse signal to hydro-pressure/flow signal, just
as electric hydraulic converter, compared to the competitors, traditional electric
hydraulic converting devices/components (electric hydraulic converter, servo valve,
proportional valve, step motor-pilot valve, servo motor-pilot valve), its a new valve
type and a upgrade product. Nowadays, high speed on-off valve has been widely
applied to automobile, fuel injection, engineering machinery, aerospace control,
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metallurgy, medical devices, machine tool, robot fields. Its also of concern and has
some applications in the fields of hydraulic turbine governor. It is considered to have
the place of applications. It is classified pulse fluid control item, has only on-off status,
the response time is about 0.5ms~3ms. Its one of ideal project on the
computer-controlled hydraulic system, as the bridge between the computer and the
hydraulic system, it can access the interface of computer without D/A conversion,
then digitize the fluid control (obviously , high speed on-off valve used as digital
valve ). It has simple structure, high resistant oil contamination capability, good
repeatability, working stable and reliable, and energy-saving advantage. It should be
pointed out that, some people at our country think general electromagnetic valve as
high speed on-off valve (digital valve), its a misunderstanding. The performance of
general electromagnetic ball valve is far different from the high speed on-off valve.
Though it has some switch/digital features, but the response time constant is too
large, often between tens of milliseconds to hundreds of milliseconds, so it cannot
control the pressure/flow continuously and steady. If the general electromagnetic ball
valve used as digital valve, the regulating performance will be restricted greatly.
Additionally, the performance of materials and corrosion resistance is a problem. It
should be noticed that the conception of control of flow or pressure continuously
(that is the output flow or pressure is changing steady) is very important, it is the
most important characteristics that the high speed on-off valve distinguished from
general electromagnetic reverse valve, generally the output of common
electromagnetic valve is actually realizing the discontinuous control.

The high speed on-off valve with quality guaranteed should have the following
index:
11
Operation lifeMore than 1100 billion times
200Hz
Working frequency: More than 200Hz
0.5ms5ms
On-off regulating time: 0.5ms5ms
0.05ms
Repeatability precision 0.05ms

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Material : Anti-abrasion rigid ceramic alloy

The main components of high speed on-off valve
3
()
(
)
See also Figure 3, high speed on-off valve consists of valve bush, electromagnet,
control valve core and the reset spring in the core end. The integrated manifold block
shell is designed by the system integrators idea, and processed the fluid port. The
plug-in assembly of high speed on-off valve is trimmed in the pole to use. Here, the
aim of setting pressure compensation channel is inducing the operating force when
valve core moving, which can increase the responsibility performance.
HSV
()
HSV

T
T
K

P
3
Figure3. High speed on-off valve unit schematic diagram
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Working principle

(
)
High speed on-off valve controls the oil circuit on-off by the axial movement of
the valve core in the valve body, which controlled by the electromagnet push pole. It
is a sectional ring groove cylinder, the spool has several working cones or steel-balls,
and the valve bush has several grooves, each groove connects outside through the
corresponding hole and channel.
2 HSV
3 P K T
K
High speed on-off pulse valve has only two working position, when
electromagnet HSV is power off, valve core moves upward by the force of bottom
spring, the valve position state see figure 3, at this time, the pressure oil P links to
the control port K, the link of return oil T and the control ports K is broken.
HSV 4
P K T K
When electromagnet HSV is electrified, valve core moves down by the force of
electromagnet push pole, the valve position state see figure 4, the pressure oil P
doest not link to the control port K, return oil T links to the control ports K.

CVZT
()
By pulse modulating to the on-off signals of high speed on-off valve, that is ,
controlling the pulse frequency and pulse width, we can realize the continuous
control of flow or pressure. As the output flow is small, in the CVZT series of
governors, it makes as pilot hydraulic pressure signal, and then drives the main
control valve (large scale cartridge valve). As far as its function, it makes electric
hydraulic converter actually.
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P
4. (HSV)
Figure4. Valve position when high speed on-off valve electromagnet (HSV)
electrified
The high speed on-off valve have main characteristic as following

24V10%
Rated working voltageDC: 24V10%
35W()
The maximum power: 35W (single)
11
The durability of actionmore than 1109order
200Hz
The frequency of actionMore than 200HZ
-40135
The allowable temperature range:-40135
1.031.5MPa
The adaptable operating pressure1.0MPa31.5MPa
29
30
13380cSt
Adaptable medium viscosity13380cSt
1.560L/min
The maximum working flow1.5~60L/min
/: 0.53ms
Rapid action response, regulating time of on-off is about 0.53ms
--- D/A
Similar to technique standard that D/A conversion circuit formative time.

Directly controlled by digital information, no signal distortion.
0.05ms
Repeated precision0.05ms
()
The material (cemented ceramics carbide) have enough rigidity, abrasion
resistance, anti-jamming

High capability of replacement, big electromagnetism driven force, good stability
and reliability of action
( 500
)
No else special demand for oil quality, and good anti-greasy

Simple structure, perfect manufaturability

Without disabled unit for abrasion in a long period
2
Main Control Valve

/
Main control valvelogical cartridge control valveis the key component that
realize governor main class control, its function is receiving the pressure signal that
high speed on-off valve provided, and cause main valve core to move, then control
working oil circuit changing, and control the displacement of main servomotor.
30
31
DIN24342 ISO7368GB/T2877 DIN24342

There is structure principle in fig.5. The characteristic of the valve is that power
stage uses a cartridge structure, hence the name cartridge control valve. The
cartridge structure consists of valve core, valve bush, springs accessory, and seal
components. At installation, plug it into the standard hole of integrated manifold block,
and screws it by the connection of cover and integrated block. The dimensions are
based on DIN 24342, ISO7368, GB/ T2877 now are taken almost all from DIN24342.
31
32
5 ()
Figure5. Main Control Valve (logical cartridge control valve) Structure diagram

ABK A/B
K
K
Generally, working state of the cartridge assembly is determined by the resultant
force and its direction of valve core. If resultant force is greater than zero, valve
closed; if resultant force is less than zero, valve opened, when resultant force is
equal to zero, the valve core stayed in a balanced position. It should be pointed that,
the stress status and open/close process of valve core is much more complex than
the theoretical analysis in the relevant data. But the pressure relationship among the
ABK chambers is still to play a leading role, the pressure of chamber A/B is
determined by the working load condition, which cannot change at will, so ,we realize
the control of logical cartridge valve by changing the pressure of chamber K.
Obviously, we can change the opening of main valve by changing the control
pressure of chamber K.
()
Compared to the four-channels slide valve (as main distributing valve), it can
make pilot control by receiving different type of switch signals, analog and digital
signals, and integrate pressure, flow, direction and many functions in the same main
class, much more, is compatible to the switch valve, proportional valve, digital valve.
32
33
If we regulate the pilot signal continuously or in proportional, main class of valve

seat can realize the function of controlling the servo valve/proportional valve, it has
excellent controllability and flexibility . The structure of valve seat overcomes the
shortcomings that slide valve processing property is poor and diametral clearance
make leakage. the main class of valve seat uses linear sealing and zero lap, as the
axial structure size is shorter, the weight of valve core is light, it provides the
possibility of improving the dynamic quality, realizing the multi-formed, large scale,
flexible integration. See from the control method side, cartridge unit is easy to use
complex control forms, which can be called Soft-control, like logical control,
proportional control, digital control and so on. thus it can be seen that Multi-function,
Soft-control is the outstanding characteristic of logical cartridge valve.
>>
Using logical cartridge control valve as main control valve, it has main
characteristic as following:

High standardization, good consistency of capability

Simple structure, easy to manufacture

Action reliability

Multipurpose with one valve

Low leaking and high efficiency

System integrating easily

Suit to work in large flow
3 Startup/Shutdown pulse valve
>> Startup/Shutdown pulse valve components
6(1)(2)(3)
33
34
See figure 6, Startup/Shutdown pulse valve mainly consists of valve body (1),
two electromagnets (2), control valve core (3), and the positioning devices in both
ends of valve core, etc.
P
TJL=OFF KJL=ON
T
T T
P
A P B
2. 1. 3. 2.
6.
Figure6. Structure diagram of Startup/Shutdown pulse valve
>> Working Principle

Startup/Shutdown pulse valve connects or disconnects the oil circuit by the axial
moving of valve core in the body, which controlled by the electromagnet push pole. It
is a sectional ring groove cylinder, the valve core has several shoulders, the valve
body has several grooves, each groove connects outside through the corresponding
hole and channel.
2 KJL TJL
(3) KJL
KJL
6 P A T
B
Startup/Shutdown pulse valve has only two working position, when right
34
35
electromagnet KJL is energized, and left (TJL) is not, valve core (3) moves left by the
force of right electromagnet KJL, at the same time, the positioning devices on the left
side of valve core keep it in the working position; even if the electromagnet KJL is
de-energized, the positing devices can keep the valve core not moving, the valve
position state just like figure 6, the pressure oil P links to the control port A, return oil
T links to the control port B.
TJL KJL (3) TJL
TJL 7
P B T A
When Left electromagnet TJL is energized, and right (KJL) is not, valve core (3)
will move right by the force of left electromagnet TJL, at the same time, the
positioning device on the right side of valve core keep it in the working position; even
if the electromagnet TJL is de-energized, the positing device can keep the valve core
not moving, the valve position state just like figure 7, the pressure oil P links to the
control port B, return oil T links to the control ports A.
TJL=ON KJL=OFF
T P T
A P B
7. (TJL)
Figure7. The Startup/Shutdown pulse valve position after left electromagnet (TJL)
energized
>> Main Technique Parameters
80L/min
35
36
Maximum discharge: 80L/min

()
Working medium: mineral oil, biodegradable substances (Canola oil,
polyethylene glycol, Synthetic ester)
2080
Temperatures range: 2080
2 2
2.8 mm / s 500 mm / s
2 2
Viscosity range: 2.8 mm / s 500 mm / s
DC24V10%
Voltage supply: DC 24V 10%
20N
Valve core control force: 20N
30W
Electromagnet power: 30W
150
Maximum temperature rising which electromagnet coil can endure: 150
4.2 System working principle

(CAD )
See the system schematic diagram showed in attached drawing (CAD drawing)
wicket gate servo system consists of high speed on-off valve, flow control valve,
cartridge valve, startup/shutdown pulse valve, quick/emergency shut-down valve,
step closing valve, blade servo system is exactly similar to the wicket gate servo
system ,except for startup/shutdown pulse valve, quick/emergency shut-down valve,
step closing valve.

36
37
At automatic mode, while microcomputer regulator send regulating signal, the

signal would be converted and amplified, then act on pilot control high speed on-off
valve. At the same time, the liquid flow signal that have been demodulated by digital
valve board act on hydraulic power drive board that combined by logical cartridge
valve control units, the liquid that have been converted and amplified by power drive
board enter main servo motor, and control the increasing/decreasing of signal, it
would keep until the regulating process ending.

And manual operation is most similar to automatic action above; it operates by

control pilot valve manually. Actually, it is degraded of automatic method (reducing
response capability slightly), but the displacement precision of the governor
controlling servo motor is much higher than that of general governor. Because logical
cartridge valve unit no need lapping, in theory, it has not displacement control dead
zone, so the displacement governing error were limited to dozens of microns, but to
the general governor, the manual governing error can reach millimeter level.
Compare with traditional governor, it is very convenient for operating that just moving
the switch and cutting off control output of electrical regulator cubicle, and it is with
smooth and no disturbance switch.

Then we will make some brief introductions for the different local circuits, if we
make a compression for the local circuits, we can handle the whole working principle
exactly. Blade servo motor system is similar to the wicket gate servo motor system,
37
38
so we take wicket gate servo motor system for example. The part of blade, please
refers to the attached drawing, and analyzes by yourself.
1
Opening Increasing Automatic Operation
8
WZ(7) K T T
(12) WZ(7)
(12)
(12) B
K K
Figure 8 shows the working principle of opening increasing automatically. While

regulating signal of regulator make high speed on-off valve WZ(7) power on, then the
valve core will move down, the control port K connects to the return oil port T, and the
return oil port T connects the oil tank by selector valve. So the oil flow through flow
control valve (12), high speed valve WZ (7), selector valve, at last, reach the oil tank.
While oil flow through the flow control valve (12), a pressure drop which was linear
with discharge will be produced. So the outlet pressure of the flow control valve (12)
is linear with the discharge of high speed valve, which linked to the control chamber
of cartridge valve (K). Then, by controlling the discharge of high speed valve, we can
control the control chamber pressure of cartridge valve; also, make the opening of
the cartridge valve is linear with the discharge of high speed valve.
WZ(7) 2
From above, it is well known, when high speed valve WZ (7) power on, both of
the cartridge valves could be opened, then main pressure oil is linked to the left side
of servo motor through the left cartridge valve, the right side oil of servo motor will
discharge by the right side cartridge valve, the servo motor move to the side of
opening increasing.
38
39
8
Figure 8 Opening Automatic Increasing Local Principle Diagram
WZ(7)
K T (12)
K, 2 /
When the displacement of servo motor accords with the needed control value,
high speed valve WZ (7) cut off, and the control port K and return oil port T close.
Then the pressure control oil flows through the flow control valve (12), directly effect
on the control chamber of cartridge valve (K), close both the cartridge valves, and
also close the oil route lead to the control chamber of servo motor open/close side.
The servo motor will then stop moving, and keep the position accords with control
value. So we can see that the motion control and steady regulation are not based on
the middle-position of control valve.
39
40
(12)
It should be pointed that the title of flow control valve (12) may be less stringent.
Considering its function, it may be called discharge- pressure differential linear
conversion component exactly. From the point of view of hydrodynamic, the energy
conversion of Bernoulli equation shows, we can express the correspondence
between the discharge and differential pressure of throttle devices by any throttle
devices, a typical example as we well-known is Venturi tube and orifice meter. But
this type of throttle devices cannot acquire the linear conversion of discharge and
differential pressure. If we can make special design for the modeling of valve outlet of
throttle device, and make the valve core movable during the period of fluid flowing,
then we can get the linear conversion of discharge versus displacement and
discharge versus differential pressure. Swiss Berlingel, U.S Weeks, Germany
RWTH-Aachen have adopted the similar scheme. For the redundancy of the
theoretical derivation and equation formula, here is no more discussion.
2
Opening Decreasing Automatic Operating

Opening decreasing automatic operation is similar to opening increasing action

above, no more introduction provided, you can make self-analysis referring to the
attached drawing.
3 / Principle of Opening Manual
Increasing/Decreasing
/
/
40
41
Wicket gate opening manual increasing/decreasing is realized by operating high

speed valve manual button or operating electromagnet manually, its working principle
is similar with opening automatic increasing/decreasing by operating high speed
valve, so here is no more introduction, please make self-analysis by referring to the
attached drawing .
4
Startup/Shutdown Pulse Valve Circuit
9 (8)(KJL=ON)
Refer to figure 9 and attached drawing. During the normal regulating process,
startup/shutdown pulse valve (8) is in ON (KJL=ON), it do not mean opening the
servo motor, at the moment, piloted control oil line is under normal oil supply state,
the servo motor can be operated normally.
(8)(TJL=ON) 9
When the on/off pulse valve (8) is in OFF (TJL=ON), the oil line as is shown in
the figure 9, wicket gate is compressed in this state. Generally, it occurs in the stop
standby condition. Here an analysis of the oil line is as follows:
41
42
9
Figure9. The local principle diagram when startup/shutdown pulse valve in TJL
(8)(TJL=ON) A
Pr K (12) B A
(10) K Pc (8) A 2
When startup/shutdown pulse valve (8) is in OFF (TJL=ON), the oil returns from
the control port A, but it is closed by the pilot control pressure oil Pr, so, control
chamber of cartridge valve (K) is linked to the port B of flow control valve (12),then
port A, then port K of emergency stop valve (10), then outlet of Pc, port A of
startup/shutdown pulse valve (8), at last connect to the oil return tank, and will open
the left and right cartridge valves. So main pressure oil will connect to the right
chamber of servo motor through the left cartridge valve, the left chamber of servo
motor is linked to the return oil through the right cartridge valve, this can ensure the
servo motor is in the fully closed position, and a certain pressing force exists.
5 Quick/Emergency Shut Down Circuit
42
43
10
Figure10. The Local working principle diagram of Emergency stop valve acting
10(10) K T
Pc K (12) B A
(10) K T 2
Refer to Figure 10, when emergency stop valve is energized, the control port K
will link to return oil T , but it is closed with control port Pc, then control chamber of
cartridge valve (K) is linked to the port B of flow control valve (12), then port A, then
port K of emergency stop valve (10), then port T, at last reaches the oil return tank,
and will open the left and right cartridge valves, then main pressure oil will connect to
the right chamber of servo motor through the left cartridge valve, the left chamber of
servo motor is linked to the return oil through the right cartridge valve, this can
ensure the servo motor is in the fully closed position
43
44
1
Attached Figure 1: Principle Diagram of Wicket Gate Servo System
44
45
2
Attached Figure 2: Principle Diagram of Blade Servo System
45
46
5 Operation
5.1 CVT/ZT-XX Operation conditions of CVT/ZT-XX
governor

46#
The electric regulator, mechanical hydraulic servo system,oil pressure supply

unit and ect. have been installed. There has no foreign matter in control cubicle, and
the wiring and piping is correct. It meet the requirement to fill oil and air, electrify. The
needed 46# turbine oil, compressed air and power supply is conforming to relevant
technical requirements, and oil level indicator is normal. It is cleared on site, and not
allowed any construction work affecting operation at hydro turbine area of governor
system equipment.

According to the technical drawing, all wiring connection must be checked

validity. Then turn on the power and open pressure oil source, observe whether the
signal and indicator of power supply, pressure display, microcomputer, displayer,
frequency feedback, displacement feedback, driver/amplifier ,etc. is normal.

It will be specially indicated, the startup/shutdown pulse valve must be set at

shutdown side, before open oil source first. This gist is very important, so the
operator must pay high attention to it.
5.2 Operating panel of governor
10
The operating panel of governor is as Fig.10(If there has any discrepancies

between the actual panel and this panel figure, please based on the actual panel as
46
47
the criterion.)
10. CVZT-XX Operating panel of governor

5.3
Inspecting, operating and maintaining
Inspecting and patroling
stop standby mode
[]/[][]
The selecting switch [Gate Man./Aut.] & [Blade Man./Aut.] place in Aut.
Position.
[ 24V]
The indicator light [DC 24V] is lighten.
[]
The [Gate Openning] meter indicate to zero, the [Blade Openning] meter indicate
to start-up angle.
47
48

Each relational indicator of governor panel is normal.

The oil pressure is normal.

The oil filter blocked indicator light is off.
;
The generator potential transformer(PT) is normal, and high/low fuse of PT put
into use and not disconnected.

The indicator value of water head is corresponding to the current actual head.
Normal load operating condition
[]/[][]
The selecting switch [Gate Man./Aut.] & [Blade Man./Aut.] place in Aut.
Position.
[ 24V]
The indicator light [DC 24V] is lighten.
[]
The [Gate Openning] meter indicate to a relative value corresponding the current
position of wicket gate servomotor, the [Blade Openning] meter indicate to a relative
value corresponding the current angle of runner blade.
[]
The indicator light [Break ON] is lighten.

The oil pressure is normal.

The oil filter blocked indicator light is off.

The indicator value of water head is corresponding to the current actual head.
/
E
/ f
48
49
The main servomotor may be stationary or increasing/decreasing a certain

opening value , depending on the inc./dec. command from LCU and the frequency
variation range.(When the frequency variation exceeds the artificial speed dead band
Ef
, the servomotor will move the corresponding stroke, so as to meet the
requirement of Primary Frequency Regulation. )

Generally, the opening of servomotor is basically unchanged in opening
operating mode or basic load mode.
/
/
It should be pointed out that the active power/opening will be automatically
regulated with the frequency changing in hydraulic turbine unit of bearing power
system frequency regulation.
Operating and maintaining
Normal operation (Micro-computer automatic regulation)
[]/[][]
Micro-computer automatic regulation is the normal operation mode. The
selecting switch [Gate Man./Aut.] & [Blade Man./Aut.] place in Aut. Position.
Start-up and switch on line(connect to the grid)

Before automatic start-up,the generator potential transformer(PT) is normal, and

high/low fuse of PT put into use and not disconnected, the governor is at stop
standby mode. The indicator value of water head is corresponding to the current
actual head.
[]
When governor receiving start-up command, the [Start-up] indicator lamp lighten,
wicket gate wiil be opened to no-load opening corresponding to the current actual
head, meanwhile the hydraulic turbine unit frequency track the grid frequency.
49
50
[
]
After meeting the automatic synchronization condition, the synchronization
device will operate the breaker switched on line, the [Breaker on] indicator lamp
lighten.
Disconnected from line and shut-down

Decreasing the hydraulic turbine unit load to zero.
[]
The hydraulic turbine unit breaker will be switched off via LCU operating, the
[Breaker on] indicator lamp is off, the unit is at no-load operating mode.
[]
When governor receiving shut-down command, the [Shut-down] indicator lamp
lighten, wicket gate wiil be full closed, meanwhile the hydraulic turbine unit speed will
gradually decrease.
[]
When the air pressure of brake is released, the [Stop standby] indicator lamp in
HMI will be lightened, the governor translate the operation condition to standby
mode.
/ Load increasing/decreasing operating
/ LCU
LCU /
/
The load increasing/decreasing operation generally operated by LCU Inc./Dec.
pulse signal of active power setting. About the detail content, please see also the
LCU information. At special circumstances, if LCU chance fault, the operator can
switch over the governor to manual mode, then Inc./Dec. the unit load to the object
value via Inc./Dec. switch, finally switch to Aut. Mode.
Y+Y- LCU
/
50
51
Y+/Y-
Y+/Y-
Y0.5/Tmin Tmin LCU

Y3.8%10%.
Notice: The Inc./Dec. velocity Y+/Y- of active power must be tuned and set
together with LCU and governor. Generally, it will be set to a certain value via HMI,
when the governor equipment first debugging and running. The tuning principle is
that the active power Inc./Dec process response is fast and with no overshoot, and
the deviation between object and actual power value is small. When daily using, this
parameter cant be changed casually, if you want change it, you must coordinate and
validate with LCU, so as to avoid accidents. Overall, the smaller the Y+/Y- value,
the higher the resolution of load regulation, but the load regulating velocity will be
slow; the greater the Y+/Y- value, the lower the resolution of load regulation, but
the load regulating velocity will be fast, if the value is too large then overshoot may
be caused. General recommendations by the formula, Y0.5/Tmin, here Tmin is
the minimum pulse width time of LCU Inc./Dec. pulse signal. The default value range
isY3.8%10%.
Y/ P E(Y/P)=(05)%
L1+L1-
Y/ P
Y/ P
In addition, the range of artificial opening/power dead band is E(Y/P)=(05)%,

and can also be tuned; this value expressed by the symbol L1+/L1- at HMI. The
value shall be determined according to the control requirements actual effect. The
smaller the value, the higher the control precision, but may be caused frequent
movement and increasing the consumption of oil source; the larger the value, the
lower the control precision, but conducive to stability of servomotor and decreasing
the consumption of oil source.
51
52
/()
LCU
It must be pointed out, when voltage/current increasing test of main transformer,

governor shall be minitored by operator, if LCU sending Inc. signal to governor and
turbine unit speed higher then rated speed, you should switch over governor to
manual mode immediately, and decrease the opening, so as to keep the unit speed
nearby the rated speed and avoid to cause chaos control, lrge-scale fluctuation of
servomotor or overspeed.
/
Manual/Automation switch over
CVT/ZT-/
The Man./Aut. switch over for CVT/ZT- governor is very simple, without any of
conditions to prepare before switch over. If you want switch over Aut. to Man. , just
whirl the Man./Aut. switch pointing Man. Position; if you want switch over Man. to
Aut. , just similarly whirl the Man./Aut. switch pointing Aut. Position;
Manual operation
.
Whirling the Man./Aut. switch to point Man. position, the governor will be
translated the operating mode to Manual mode. When Manual operating mode,
governor shall be minitored by operator.
. Increasing opening operation
/
Operating the Inc./Dec. switch allocating to Inc. side, the opening increase
operating can be executed.
(
)[] 2
52
53
It should be pointed out, before manual increasing opening, if governor is just in

Stop standby mode, your must press the [Release] button at HMI and keeping 2
seconds(this operating purpose is enable the increasing oil cuicuit to recover normal);
in other operation condition, this preparations is not necessary.
. Decreasing opening operation
/
This operation is very similar to opening increase operating. Operating the

Inc./Dec. switch allocating to Dec. side, the opening decrease operating can be
executed.
Quick shutdown/Emergency shutdown
. LCU
Generally, if quick shutdown/emergency shutdown command signal is tripped

by LCU, the quick shutdown/emergency shutdown valve will be energized, then the
wicket gate will be full closed quickly with rated time.
. LCU 24V
At special circumstances, if there has no LCU protection or DC24V power supply,

the operator may manually push forward the emergency button inside the quick
shutdown/emergency shutdown solenoid valve, then the quick shutdown/emergency
shutdown process can also be executed.
Quit or standby recovery operation of governor
. Out of standby
Whirling the Man./Aut. switch to point Man.
position.
2
Press the [Impacting] button at panel and keeping 2 seconds(this operating
purpose is disable the increasing oil cuicuit.);

Making lock engageg(Notice: Before lock engaged, confirming the
53
54
[Impacting] button pressed in 2 seconds. )

Cut off the main isolate valve of pressure oil supply
unit.
. Recover standby mode

Before recover standby mode, you must confirm the following conditions are met,
the generator potential transformer(PT) is normal, and high/low fuse of PT put into
use and not disconnected, the main isolate valve of oil source is opened, the
indicator value of water head is corresponding to the current actual head.
Whirling the Man./Aut. switch to point Aut.
position.
/ 220V 24V AC/DC220V, DC24V power supply are normal
Making lock released
Filter replacement
11
See also the oil circuit Fig.11, generally, as long as the filter blocked indicator
lamp is not lightened, that neednt to execute this operation. If the filter blocked
indicator lamp lightened, and the filter red plunger push out, then indicating the filter
blocked, at this case, you need to replace the filter. Please refer to the recommended
following steps while replacing filter.
JZ1JZ2First, cut off the check valve
JZ1, JZ2, then unscrew the filter cartridge and disassemble the filter core.
Replace and assemble the new filter core, screw the filter
cartridge.
JZ1 JZ2 Open the check valve JZ1, but the check
valve JZ2 is still closed.

Rotate counterclockwise the air exhaust valve threaded
54
55
sleeve at the top of the filter cartridge, remove the isolation pads; then rotate
clockwise the threaded sleeve to the lower position, executing exhaust operating.
After exhaust operation fulfilled, recover filter
device to the original status.
JZ2Open the check valve JZ2.

11. The oil circuit schematic diagram of filter assembly
6 Installation of equipment

The installation of equipment is avery important working procedure during

operation of the equipment. It is related to the equipment security, reliability and
performance of normal play.
CVT/ZT-
Like other automatic equipment, CVT/ZT series governor has its special
installation demand. Therefor, before installation, the whole technical information
must be known well by customer, especially the content of this section. When you are
familiar with the technical documents, you must draft installation project according to
the site actual situation, then excute the installation work.
6.1 Preparations for installation

Installation preparations include technical preparation and materials preparation.
55
56
Technical preparation before installation

The whole technical information about this equipment must be known well by
customer, especially the content of this section. The tagname definition of external
wiring of this equipment must be learned more.

The center, levels and elevation should be fully reviewed, then pouring the
foundation and bolt of the equipment.

You must do the comprehensive analysis and synthesis about unit automatic
operating loop and the demand of this governor equipment, determine the connection
project between the unit automatic operating loop and this governor equipment, and
plot the corresponding principle drawing. Then you need to cross-check the
process action from start-up, load, shut-down, etc. operation condition translation,
check whether the design is realistic.

According to the external wiring drawing, plot the the appropriate cable wiring
diagram.

The external wiring demand of this governor equipment
CVT/ZT-XX Refer
to the terminal drawing provided with the equipment, the external wiring of
CVT/ZT-XX governor cubicle can be devided into the following sections.
The power supply section
Digital input section
Digital output section
Frequency/speed measurement section
Opening signal input section
56
57
Active power input section

Water head input section
The corresponding requirements are described as follows,
The power supply section
CVT/ZT-XX / 220V The governor
used AC/DC220V dual power supply, please carefully check the voltage before
wiring.
Digital input section
Start-up command dry contact

40 CVT/ZT-XX
Start-up command dry contact is needed normal open dry contact, and keep
more than 40s during start-up process.
Normal shut-down command dry contact

40 CVT/ZT-XX
Normal shut-down command dry contact is needed normal open dry contact, and
keep more than 40s during normal shut-down process.

The breaker auxiliary contact is needed normal open dry contact. If condition
allowed, we recommend the generator breaker and main transformer high voltage
side breaker auxiliary contact are both provided.
LCU .
The Increase/Decrease pulse signal from LCU is needed normal open dry
contact.

CVT/ZT-XX
LCU DO
The Increase/Decrease speed pulse signal from synchronizer is needed normal
open dry contact, if this pair signal cancelled, it will not affect the normal regulation of
57
58
governor. And this pair contact signal is permitted parallel connection with the
Inc./Dec. signal from LCU DO module.
/()
LCU
The position signal(lock engaged/lock released) of lock servomotor is needed
normal open dry contact, and it can also be provided from LCU translation relay
contact of DO module.

Quick shut-down/Emergency shut-down command dry contact is needed normal
open dry contact.
The digital output section
CVT/ZT-XX
PFR PFR
The digital output signal of governor includes: governor fault, power failure,
manual mode, PFR engaged, PFR acting, etc.
Frequency/speed measurement

AB CB AC PT
The turbine unit frequency signal source can use generator PT or toothed disk.
()
PT
The grid frequency signal source is PT voltage from low voltage side of main
transformer.

The generator and grid PT secondary coil used for frequency measurement must
be current isolated from all circuit, this secondary coil is only used for governor
controling and regulating.
: Opening signal input

58
59
The displacement sensor must be fixed on rigid support, the locking nut of
handspike must be locked, any radial or axial offset will cause the signal instability
and distortion; the power supply and wiring of conditioning circuit must be highly
reliable, otherwise it will cause the signal instability , distortion and disturbance,
implicate stability and reliability of the whole governor system.

The adjustment of feedback signal for gate opening and runner blade

Adjusting the gate opening feedback sensor and additional potentiometer, to
achieve:
Y=0% Gate full closed Y=0%
feedback voltage U YF =0.3~0.35V
Y=100% Gate full opened (Y=100%)
feedback voltage U YF =9.5~9.7V
Finally, fixing the displacement sensor reliably.

It is very similar between the runner blade angle sensor with gate
displacement sensor.
: Active power measurement
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CVT/ZT-XX 420mA
The active power measurement is realized by active power transducer, voltage
level standard: 420mA.
: Water head measurement
CVT/ZT-XX ()4
20mA
The net water head signal can be collected automatically(water head transducer
provided by customer), voltage level standard: 420mA.
Preparation of installation materials and tools
Cable and shielded wire
Standard fasteners
Rubber seal
Manifold flange
Seamless steel tube
Multimeter

Within six wrench, ordinary wrench, screwdriver, etc.
The box out checking program and main content

First, affirm if the box has any serious external damage after transport. If there
no serious external damage, please carefully open the box.

Check the variety and quantity of packing items, whether it is corresponding to
the packing list.

Check the exterior of the equipment, it shouldnt exist any serious injuries.

Open the door of the equipment, check and affirm if there have any abnormal
phenomenon, such as wire broken, components injury, loose fasteners, loose
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terminals ,etc.
The installation of equipment
6.

The installation of noumenon equipment, flange and steel pipe will be described
at this section content. The key factor is the standard installation of flange and pipe.
The quality of the installation will relate to oil medium pollution, reliability and safe
operation, so it must be given sufficient attention.
The installation of noumenon
The installation progress is as follows

Place: When placing the noumenon, you should pay attention to preventing the
panel and component damage, and giving solid and reliable connection to plant
foundation.
Wiring: The wiring must be accurate, solid and
reliable.
The installation of flange and steel pipe

CVT/ZT-XX O
O
Flange: We use NBR rubber as sealing material in CVT/ZT governor system.

While welding flange, the sealing materials must be removed, so as to avoid
high-temperature produced during welding burn damage.
Steel pipe

The steel pipe must have sufficient strength, smooth
and clean wall, and with no defect such as sticky sand, corrosion, oxide, etc. If there
is one of the following conditions, you cannot use such pipe.
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The pipe wall has corrosion or significant

discoloration
With wound and rift
Surface indentation
Surface separation or scarring
While bending the pipe, there shouldnt
exist following defects.
Inner side of bending part has been twisted or
crushed;
Inner side of bending part has uneven ripple.

Bracket should be installed for long pipeline, so as to be shockproof. At

right-angle bend section, both ends must be added fixed bracket, and pipe should be
installed on a solid place, and block or hard rubber liner should be fixed on bracket,
so as to avoid the foundation directly connecting the pipe.

The entire pipeline should be as short as possible ,
and pipe bend quantity is as little as possible. Any section of pipeline should be free
disassembly, and dont affect the other components.

All pipeline is required secondary installation. After first
installation, disassemble pipeline, thoroughly clean pipe, and then reinstall all pipe. If
site condition is permited, it would be best to do acid pickling treatment.

Taking into account that if pipeline cleaning is not strict, it will easily cause
secondary pollution to oil medium by solid pollutants. The solid pollutants has great
harm, it will accelerate wearing ,aging and performance degradation of hydraulic
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components, or plug the orifice leading to control failure and reducing the system
reliability. The requirements on oil cleanliness not only consider the security and
reliability of system, but also ensure the long life work of hydraulic components.
7. The fault type and processing
7.1 Fault type
The governor send out fault alarm signal
Unit frequency disappeared or broken
Grid frequency disappeared or broken
The active power signal is bad quality
()The runner blade angle feedback signal is bad quality
The wicket gate opening feedback signal is bad quality
Lithium cell with low voltage
Oil filter blocked
Fault type display: The specific
fault information will be shown at HMI screen.
7.2 Fault analyzing and processing
(1) Unit frequency fault
Reason: Signal wire broken, or frequency
measurement damaged.
,
Phenomenon: The indicator lamp Fj Disappear is lightened,
the fault alarm signal is sent to LCU. The servomotor is motionless and maintaining
the original position during load mode operation, or full closed during start-up process
or no-load mode operation.
Processing steps
(
)First,
it would be best to switch over the governor to manual operation mode.(During
start-up process, if unit frequency fault occurred, please shut-down the turbine at
once. During load operation mode , if unit frequency fault occurred, the governor
system can still remain automatic running; and also allowed to switch to manual
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mode, but you must find out the cause of the malfunction as quickly as possible.)
15V
Check whether the frequency
measurement module is normal: If the output voltage of frequency measurement
module is below 15V or external resistor is very hot, the frequency measurement
module may have been damaged, you must replace it to reserve module.
PT Signal
disappeared or wire broken: According to the principle drawing, find fault point by
point from frequency measurement module to PT .
After troubleshooting, the
governor is all normal, then it can be switched to automatic running.
(2)
Grid frequency fault
Reason: Signal wire broken, or frequency
measurement damaged.
Phenomenon: The indicator lamp Fw
Fault is lightened, the fault alarm signal is sent to LCU.
Processing steps
(
)First, it would be best to switch over the governor to

manual operation mode.( No matter what operation condition,grid frequency fault will
not affect the normal running of governor system, if the function "grid-frequency
tracking is removed from HMI. This fault can be dealed with at any time and not
urgent.)
15V
Check whether the frequency
measurement module is normal: If the output voltage of frequency measurement
module is below 15V or external resistor is very hot, the frequency measurement
module may have been damaged, you must replace it to reserve module.
PT Signal
disappeared or wire broken: According to the principle drawing, find fault point by
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point from frequency measurement module to PT .

After troubleshooting, the
governor is all normal, then it can be switched to automatic running.
(3) The active power signal is bad quality
Reason: Signal wire broken, or active power
transducer damaged.

Phenomenon: The indicator lamp P_in Fault is lightened. The governor
switch from Power operation mode to Opening operation mode.
()
No matter what operation condition, active power signal fault will not affect the normal
running of governor system
Processing steps
Check the power transducer and signal wire
PLC According to
the principle drawing, find fault point by point from active power transducer to PLC
AD module .
(4) (
CVZT )
The runner blade angle feedback
signal is bad quality
Reason: Displacement
sensor signal wire broken, or sensor damaged, or external terminal affected with
water.
Displacement sensor signal wire broken, or
sensor damaged.
Zero and full-scale of sensor is not
proofreaded.
Phenomenon: The indicator lamp
Y_ Fault is lightened.

If external terminal affected with water, there is no alarm signal, but the
servomotor will close continuously.
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Processing steps: According to

different fault reason, the following steps will be adopted,
() 0.3V
0.33V
If zero-scale voltage(the feedback voltage at full closed position of servomotor)
below 0.33V, the sensors zero position must be readjusted, enable the feedback
voltage bigger than 0.33V.
/
If the sensor damaged, after repaired or replaced, the zero and full-scale of
sensor should be proofreaded again. The proofreading method can see also section
6 contents.

If external terminal affected with water, you can drying it with hair dryer.
(5) The wicket gate opening feedback signal is bad quality
Reason: Displacement
sensor signal wire broken, or sensor damaged, or external terminal affected with
water.
Displacement sensor signal wire broken, or
sensor damaged.
Zero and full-scale of sensor is not proofreaded.

Phenomenon: The indicator lamp Y_ Fault is lightened. The servomotor is

motionless when governor received start-up command. During no-load mode
operation, the servomotor is full closed. The servomotor is motionless and
maintaining the original position during load mode operation
If external terminal
affected with water, there is no alarm signal, but the servomotor will close
continuously.
Processing steps: According to different
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fault reason, the following steps will be adopted,

() 0.3V
0.33VIf zero-scale voltage(the feedback voltage at full closed position of
servomotor) below 0.33V, the sensors zero position must be readjusted, enable the
feedback voltage bigger than 0.33V.
/
If the sensor damaged, after repaired or replaced, the zero and full-scale of
sensor should be proofreaded again. The proofreading method can see also section
6 contents.
If external terminal affected
with water, you can drying it with hair dryer.
(6) /

If driver/amplifier module failure, please
replace the module at once.
(7)
The automatic start-up is
failed by unit frequency or gate opening signal fault.
LCU
Phenomenon: After the governor received start-up command from LCU, during
automatic start-up process, first the gate servomotor moving toward open direction, if
unit frequency or gate opening signal fault occurred at this time, the governor will
voluntarily close the servomotor, to ensure the equipment security.

LCU
Processing: The checking and processing for frequency or gate opening signal
fault is as reference to the above. If the failure has been discharged after processing,
then you want to execute the turbine unit start-up operation, you can switch the
governor to manual mode to operate start-up process. If you want to automatically
execute start-up process, in the first place, the normal shutdown command signal to
governor should be sent out by LCU, after the governor translate to stop standby
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mode, then send start-up command signal to governor.

Lithium cell with low voltage
If lithium
cell with low voltage, the indicator lamp Cell Fault is lightened. Please replace the
lithium cell at once.
Oil filter blocked

5
If oil filter blocked, the indicator lamp Filter Jammed is lightened. Then your
should arrange a time to replace the filter core.The replacing method can see also
section 5 contents.
Maintaining suggestion
8.

CVT/ZT 10
The following maintaining suggestion is just for reference, please draw up detail
maintenance specification combined with the your actual power plant.
Regular maintenance
8.
()Clean once the dust in
control cubicle at every minor repairs period(In the case of power off).
()Fasten every wiring termals at
every heavy repairs period.
/
(0%100%)
Check gate
opening and runner blade angle feedback sensor at every minor/heavy repairs,
manual open/close the servomotor with the slowest velocity in the whole stroke
range(0%100%), observe whether the feedback voltage changing with
continuous and monotone, otherwise the sensor should be replaced. And proofread
the voltage at full close/open position.
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Inspect relay,
active power transducer, water head transducer and frequency wave module at every
minor/heavy repairs period.
Inspect toothed disk speed detecting device at
every minor/heavy repairs period.
PLC ( 30
)We suggest that it is better to replace the Lithium
Battery/Cell at every heavy repairs period.(Dont power off the PLC controller power
supply source, when you replace the Lithium Battery/Cell , and execute the battery
replacing operation within 30s, otherwise may cause data loss.)
Replace the filter core at every heavy repairs
period.
O We suggest to replace the O ring of
hydraulic component at every heavy repairs period.
/()
Stab each electromagnet putter of solenoid valve component with screwdriver or

steel bar at every heavy repairs period, so as to test and verify whether the valve
assembly is normal. If abnormal, the solenoid valve component should be repaired or
replaced.
Unscheduled maintenance
8.

If gate opening sensor reference position changed, the location and zero/
full-scale of sensor should be proofreaded again.

If runner blade angle sensor reference position changed, the location and zero/
full-scale of sensor should be proofreaded again.

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(0%100%)
After the servomotor displacement sensor position readjusted ,you must check
whether the sensor is normal? The suggestion method is: manual open/close the
servomotor with the slowest velocity in the whole stroke range(0%100%),
observe whether the feedback voltage changing with continuous and monotone.
Then proofread the voltage at full close/open position.

If active power display value is inaccurate, recalibrate the signal zero/ full-scale.

If water head display value is inaccurate, recalibrate the signal zero/ full-scale.
HMI
If HMI(touch screen) is abnormal, press HMI Reset button, then recover it.If it is still
abnormal, replace the screen.
PLC / PLC
/
If PLC controller or input/output module is abnormal, power off and then power
on, if still abnormal, replace PLC controller or input/output module.
AC220V
AC220V power disappeared: Check whether the AC relay damaged? Whether

the AC power isolation transformer is normal? Whether rectifier bridge damaged?
Then replace corresponding damaged component.
DC220V
DC220V power disappeared: Check whether the DC relay damaged? Whether

rectifier bridge damaged? Then replace corresponding damaged component.

The active power transducer failure: Check whether the wiring correct or wire
broken or poor contact or AC power supply normal or output signal normal? Power off
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and then power on, if still abnormal, replace the transducer.

The water head transducer failure: Check whether the wiring correct or wire
broken or poor contact or DC power supply normal or output signal normal? Power
off and then power on, if still abnormal, replace the transducer.

Sending out alarm signal while running
8.3.
7 About the treatment
of the common possible fault phenomenon while running, that can see also the
content of section 7.
71

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CVT/ZT-XX

The Principle and User Manual for

3 Main Technical Parameters

7 The Fault Type and Processing

The new type microcomputer-based governor system consisted of standard

Pressure grade code

The CVT/ZTXX series turbine governor is mainly composed by two parts:

The amplifier/driver circuit: After amplified TTL output signal of microcomputer,

The electrical regulator provides frequency(hydraulic turbine

2.2 Hydraulic servo system

The mechanical hydraulic servo system is designed as module construction, can

The hydraulic components are not sensitive to working medium contamination:

The high frequency valve is structured as redundancies construct with many

Maintenance-free is ensured radically by special design of fault-tolerance control

The normal range of signal voltage: 0.6~100V sine wave

The signal of electrical network/grid frequency

Comes from PT voltage of low voltage side of main transformer

Allowed temperature range of high frequency on-off valve:-40135

The CVT/ZT microcomputer regulator receive LCU command signal, according

Signal collecting and processing software: digital signal (command, status,etc.)

Regulating and control software: frequency control software, gate opening

Fault diagnostic and handling software: frequency measurement fault diagnosis,

Indication and parameter managing software: display software, parameter

unit speed reaches rated value, then, start-up program completes.

When the synchronization condition of hydraulic turbine unit is met, the

When frequency deviate far from the rated frequency, as exceeds

4.2 The working principle of hydraulic servo system

Material : Anti-abrasion rigid ceramic alloy

The high speed on-off valve have main characteristic as following

DIN24342 ISO7368GB/T2877 DIN24342

If we regulate the pilot signal continuously or in proportional, main class of valve

Maximum discharge: 80L/min

4.2 System working principle

At automatic mode, while microcomputer regulator send regulating signal, the

And manual operation is most similar to automatic action above; it operates by

Figure 8 shows the working principle of opening increasing automatically. While

Opening decreasing automatic operation is similar to opening increasing action

Wicket gate opening manual increasing/decreasing is realized by operating high

The electric regulator, mechanical hydraulic servo system,oil pressure supply

According to the technical drawing, all wiring connection must be checked

It will be specially indicated, the startup/shutdown pulse valve must be set at

The operating panel of governor is as Fig.10(If there has any discrepancies

10. CVZT-XX Operating panel of governor

The main servomotor may be stationary or increasing/decreasing a certain

Before automatic start-up,the generator potential transformer(PT) is normal, and

Y0.5/Tmin Tmin LCU

In addition, the range of artificial opening/power dead band is E(Y/P)=(05)%,

It must be pointed out, when voltage/current increasing test of main transformer,

It should be pointed out, before manual increasing opening, if governor is just in

This operation is very similar to opening increase operating. Operating the

Generally, if quick shutdown/emergency shutdown command signal is tripped

At special circumstances, if there has no LCU protection or DC24V power supply,

[Impacting] button pressed in 2 seconds. )

JZ2Open the check valve JZ2.

The installation of equipment is avery important working procedure during

Technical preparation before installation

Active power input section

Flange: We use NBR rubber as sealing material in CVT/ZT governor system.

The pipe wall has corrosion or significant

Bracket should be installed for long pipeline, so as to be shockproof. At

)First, it would be best to switch over the governor to

point from frequency measurement module to PT .

Processing steps: According to