Iyappan Engg Products

HP BYPASS SYSTEM
SERVO VALVES - QUICK STROKING

ST 10/4, ST-10/63 DEVICE SSB-10
BLOCKING STEPPING
ELEMENT BL 10 CONTROL APL-6
OIL SUPPLY FEEDBACK

UNIT TRANSMITTER
HYDRAULIC
ACTUATOR ASM
63, 100, 160, 200

250
electro hydraulic servo valves...
Electro Hydraulic Servo Valves
- An Introduction
Servo Valve -Feedback Mechanism
COLD
WATER
HOT
WATER
- A person wants to take bath.

- He opens both the control
valves of hot water & cold water
- He feels the temperature
- He is not comfortable with it
- An Introduction
COLD
WATER
HOT
WATER
- His brain gives feedback to his

hands
- And his hand in turn adjusts
the valves
- This process continues until he
feels comfortable
- An Introduction
COLD
WATER
HOT
WATER
- He is satisfied and continues

to have bath.
Simple Servo Valve Feedback System
IYAPPAN ENGINEERING INDUSTRIES PVT LTD

CHENNAI - 600 098
PUMP
INPUT ERROR HYD. CYLINDER OUTPUT

+ VALVE OR LOAD
- HYD.MOTOR
FEEDBACK
BLOCK DIAGRAM OF SERVO FEEDBACK MECHANISM

Electro hydraulic Actuator System - Continuous Control
Servo System - Uses
Servo system is used for

- POSITION CONTROL
- SPEED CONTROL
- TEMERATURE CONTROL
- PRESSURE CONTROL
Servo Valve - Applications
• CONTROL VALVES
• ROBOTS
•PLASTIC INJECTION MOULDING MACHINES
•AUTOMATIC GAUGE CONTROL FOR STEEL
ROLLING MILLS
•DEEP SEA RESEARCH MANIPULATOR
•SIX AXIS MOTION SYSTEM FOR FLIGHT
SIMULATOR
•STEERING SYSTEM FOR SHIP
•HONING MACHINE & MACHINE TOOL
INDUSTRIES
•TESTING MACHINES
Servo Valve - STAGES
Servo valve consists of 2 stages
SERVO VALVE
FIRST SECOND
STAGE STAGE
ELECTRICAL HYDRAULIC
blocking element...
Blocking Element
Blocking Element
maintenance of servo valves...
Maintenance - Servo Valves
Importance of oil cleanliness :

Hydraulic oil should conform to NAS Grade -6 for the
following reasons:
1. The control oil has to pass through 0.17mm & 0.25mm
diameter orifices - any blockage will cause malfunction
of the system.
2. The diameter clearance between the Spool & Bush is
6 to 8 microns.
- any dirt will cause scoring mark on the Spool & the
Bush.
- the Spool may also get stuck
Servo Valve
Servo Valve
Servo Valves
Servo Valve
Servo Valve
Servo Valve
Servo Valve
Servo Valve
Servo Valve
Servo Valve
Trouble shooting of Servo Valves
SL. FAULTS PROBABLE CAUSES REMEDIES
NO.
1 Actuator a) In spool dia. 0.25 hole a) Clean the spool
moves in one b) blocked. b) Clean the throttle
direction Throttle Pin dia.0.17 pin
c) hole blocked. c)
d) Balancing of R6z d) Balance the R6z
disturbed Clean it by Air
Torque Motor & R6z
struck up.
2 Actuator not a) Spool wrong assy. a) Assemble the spool

moving in correctly.
both directions b) In spool dia.0.25 hole b) Clean the spool
blocked in both sides
c) Torque Motor Rotary c) Clean it by air
part stuck up.
d) Connecting wires are d) Correct the wiring
loose and discontinued and loads properly.
NO.
3 Oil Leak a) 'O'Ring flat or damaged a) Change 'O'Ring
a) through Filter b) Scoring mark on dia.17.5 b) Change Filter
Support of Filter Support or Support
Filter Support damaged
c) Housing bore of Filter c) Change the valve
Support hole damaged
3b) Oil leak a) Diaphragm damaged a) Change the

through b) 'O'Ring flat or damaged Diaphragm
Torque Motor b) Change the 'O'Ring
3c) Oil leak a) Cover 'O'Ring or Piston, a) Change the 'O'Ring
through 'O'Ring damaged
Manual Cover b) Scoring Mark on Cover b) Change the Cover
Assembly Assy. ID or OD Assembly.
3d) Oil leak a) Hose, 'O'Ring damaged a) Change the 'O'Ring
through Stud
Coupling side b) Stud coupling Broken or b) Change the Stud
damaged Coupling
c) Hose connection c) Change hose
damaged
3e) Oil leak a) Face 'O'Ring flat or a) Change the 'O'Ring
through Servo damaged
Valve Face
side

NO.
4. Irregular a) Electrical connecting a) Correct the connection
operation plug loose
b) b) Check and correct the
Discontinuity of supply supply.
5. Spool jammed Change the Servo valve

and rusted
a) Oil contamination a) Clean the oil
b) Water mixed in the oil b) Change the oil (send the

servo valve to Factory for
servicing.
maintenance of blocking
elements...
Blocking Element - Maintenance
TROUBLE SHOOTING OF BLOCKING ELEMENT
NO.
1. Irregular operation a) Electrical Plug loose a) Correct the
connection
b) Discontinuity of Electric b) Check and correct the
Supply Electric supply
2. Valve opening and a) Piston 'O'Ring damaged a) Change the 'O'Rings
Actuator drifting
b) Pistron Struck-up. b) Service and clean the
Piston & bore
c) Solenoid Valve not c) Check & service

functioning solenoid valve. (If
problem continues,
change the solenoid
valve)
3. Oil leak through a) Cover & Piston Rod a) Change the 'O'Ring
Manual Cover Assy. 'O'Ring damaged
b) Cover OD or Piston Rod b) Change the Manual

OD damaged Cover Assy.
4. Oil leak through a) Spring Cover, 'O'Ring a) Change the 'O'Ring

Spring Cover Assy. damaged
b) Improper seating of b) Correctly assemble
Cover Assy. the Spring Cover
Assy.
TROUBLE SHOOTING OF BLOCKING ELEMENT
SL.NO. FAULTS PROBABLE CAUSES REMEDIES

5. Oil leak through a) a) Change both 'O'Rings
Solenoid Valve 'O'Rings of Solenoid Valve
Connecting Plate Connection face damaged
6. Oil leak through the face a) Face 'O'Rings damaged a) Change the 'O'Rings
of the Connecting
Manifold and face of the b) Improper seating of Servo b) Correct and properly
Blocking Unit Valves, Blocking Element on assemble the Servo Valve
Connecting Manifold & Blocking Element on
the connecting Manifold
Change connecting
c) Threads of connecting c) Manifold
Manifold damaged
7. Piston Jammed a) Piston rusted a) Change the Blocking
Element (Send the
Blocking element for
servicing)
b) Mix up of water in the oil b) Change Oil
oil supply unit...
OIL SUPPLY UNIT
OIL SUPPLY UNIT
OIL SUPPLY UNIT
OIL SUPPLY UNIT
OIL SUPPLY UNIT
OIL SUPPLY UNIT
OIL SUPPLY UNIT
hydraulic actuator...
ACTUATOR
ON OF F CONTROL ASSY
QUICK STROKING ASSY
feedback transmitter...
Feedback Transmitter
FEEDBACK TRANSMITTER
electro hydraulic actuator…
Electro Hydraulic Actuator
Iyappan Engg Industries Pvt Ltd

Iyappan Engg Industries Pvt Ltd

List of Tests Conducted for E.H.A
EHA. TESTS - FINAL STAGE
(FULLY ASSEMBLED)
3 TANK & CYLINDER 9 TOP PLATE ASSY.

ASSY. TEST TEST
1 OIL TANK PRE. TEST 4 HAND PUMP ASSY. TEST 10 FEEDBACK

2 CYLINDER ASSY. 5 SAFETY VALVE ASSY. TRANSMITTER
PRE.TEST TEST TEST
6 SHUT OFF VALVE ASSY.

TEST
7 PRESSURE FILTER ASSY.
TEST
7 DIFFERNTIAL PRESSURE
a ASSY. TEST
8 CHECK VALVE ASSY.
TEST
ASSEMBLY CYCLIC TEST
All the assemblies are tested for a cyclic test for 3 days in our Test Bench
for the total stroke length at 54 cycles per minute. Totally 10000 cycles
in operation before taking out the final reading as per the data given.
IYAPPAN ENGINEERING INDUSTRIES PRIVATE LIMITED: CHENNAI-600098
TYPE TEST FOR EHA

SL.NO. IY-14
STROKE 40MM
BEFORE STARTING THE CYCLE TEST
OUTPUT OF
TRAVEL OF OUTPUT OF
TRAVEL OF FEEDBACK
SERVO VALVE PISTON FEEDBACK
PISTON UPWARD TRANSMITTER -
INPUT (mA) DOWNWARD TRANSMITTER -
(mm) DOWNWARD
(mm) UPWARD (mA)
(mA)
4.00 0.00 0.00 4.00 4.01
6.00 5.12 5.18 5.97 6.00
8.00 10.33 10.50 7.97 8.04
10.00 15.65 15.80 10.13 10.17
12.00 20.47 20.60 12.07 12.11
14.00 25.44 25.48 14.02 14.06
16.00 30.41 30.48 16.00 16.03
18.00 35.25 35.30 17.94 17.96
20.00 40.15 40.15 19.94 19.94
CONCLUSION: Hysterisis in Travel - 0.17mm

Hysterisis in Feedback - 0.07mA
GRAPH PLOTTED BEFORE STARTING THE CYCLE TEST
Input Current vs Piston Travel
(Sl.No.IY-14, Stroke - 40mm)
45.00
40.00
35.00
Piston Travel (mm)
30.00
25.00
20.00
15.00
10.00
5.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00
Input Current (mA)
TRAVEL OF PISTON UPWARD (mm) Piston down (mm)

GRAPH PLOTTED BEFORE STARTING THE CYCLE TEST
Input Current vs Feedback Transmitter Output
Feedback Transmitter Output (mA)
25.00
20.00
15.00
10.00
5.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00
Input Current (mA)
OUTPUT OF FEEDBACK TRANSMITTER - UPWARD (mA)

OUTPUT OF FEEDBACK TRANSMITTER - DOWNWARD (mA)
IYAPPAN ENGINEERING INDUSTRIES PRIVATE LIMITED: CHENNAI-600098
TYPE TEST FOR EHA

SL.NO. IY-14
STROKE 40MM
AFTER COMPLETING 10000 CYCLES
OUTPUT OF OUTPUT OF
TRAVEL OF TRAVEL OF
SERVO VALVE FEEDBACK FEEDBACK
PISTON UPWARD PISTON
INPUT (mA) TRANSMITTER - TRANSMITTER -
(mm) DOWNWARD (mm)
UPWARD (mA) DOWNWARD (mA)
4.00 0.00 0.00 3.98 3.97
6.00 5.12 5.12 5.93 5.92
8.00 10.24 10.35 7.87 7.90
10.00 15.48 15.61 9.97 10.03
12.00 20.60 20.75 12.04 12.09
14.00 25.65 25.75 14.02 14.04
16.00 30.58 30.72 16.00 16.05
18.00 35.48 35.58 17.94 17.97
20.00 40.20 40.20 19.94 19.94
CONCLUSION: Hysterisis in Travel - 0.15mm

Hysterisis in Feedback - 0.06mA
GRAPH PLOTTED AFTER THE CYCLE TEST
Input Current vs Piston Travel
45.00
40.00
35.00
30.00
Piston Travel (mm)
25.00
20.00
15.00
10.00
5.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00
Input Current (mA)
TRAVEL OF PISTON UPWARD (mm) TRAVEL OF PISTON DOWNWARD (mm)

GRAPH PLOTTED AFTER THE CYCLE TEST
Input Current vs Feedback Transmitter Output
25.00
Feedback Transmitter Output
20.00
15.00
(mA)
10.00
5.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00
Input Current (mA)
OUTPUT OF FEEDBACK TRANSMITTER - UPWARD (mA)

OUTPUT OF FEEDBACK TRANSMITTER - DOWNWARD (mA)
SECTIONAL VIEW OF EHA - HSA-1-K-02
4-PD-E5(1)-SPEC-006
MODIFIED ELECTRO HYDRAULIC ACTUATOR ASSEMBLY.
02
01
MODIFIED ITEMS:-
ELECTRO HYDRAULIC ACTUATOR

ASSY. (MODEL HSA-1-K-02) 4-PD-E5(1)-SPEC-006
SECTIONAL VIEW
HYDRAULIC CIRCUIT DIAGRAM OF EHA - HSA-1-K-02
4-PD-E5(1)-SPEC-005
IYAPPAN ENGG. INDUSTRIES PVT.LTD.
HYDRAULIC CIRCUIT DIAGRAM

4-PD-E5(1)-SPEC-005
FOR E.H.A MODEL HSA-1-K-02
COMBINED PRESSURE RELIEF AND CONTROL VALVE ASSEMBLY
COMBINED PRESSURE RELIEF AND CONTROL VALVE ASSEMBLY
TROUBLE SHOOTING OF ELECTRO HYDRAULIC ACTUATOR
SL.
NO FAULTS PROBABLE CAUSES REMEDIES
.
I Oil pressure 1) Pressure gauge not working 1) Change the pressure
gauge indicates gauge
little or no oil 2) Insufficient oil in sump 2) Fill oil upto sight glass
pressure level
3) Leak in pressure line 3) Tighten up all
connections
(Check for pipe fracture
if require change)
4) Suction Filter clogged 4) Clean the filter
5) a) Motor Running in 5) a) Correct the supply
wrong direction or two and direction as per
phase supply the indication mark.
b) Defective Motor b) Replace the Motor

6) Coupling between Motor and 6) Replace the coupling
pump defective
7) Pump not pumping oil 7) Replace Pump (send the
pump for servicing)
8) Pressure limiting valve 8) Adjust the pressure
incorrectly adjusted limiting valve correctly
9) Accumulator Safety Block 9) Change the Safety Block
not working properly (Send the Safety Block
for servicing
SL.
.
II Piston moves to 1) Feed Back Spring or 1) Replace the spring and
one end and Retaining spring of the Servo readjust the range
remains valve damaged
stationary
2) Feed back rod not rigidly 2) Tighten and secure the
secured feed back rod correctly.
3) One Restrictor blocked 3) Clean the restrictor with
compressed air.
4) Dirt between flappor and one 4) Clean the Nozzle
of the nozzle
5) Leakage in oil line to 5) Tighten oil line
cylinder connection and to be leak
free
III The stroke of the 1) Change the ambient 1) The displacement can
actuator shifts temperature in over a wide only be in the order of
range, ie. Between summer 3% and should be
and winter corrected by means of
fine adjustment screw
2) Iron particles between the 2) Clean the pole shoes
pole shoes armature and magnet.
SL.
.
IV Stroke time for 1) Filter element blocked 1) Clean the Filter.
the operating 2) More Load on the Actuator 2) Deflect the servo valve
range too long fully and note pressure
gauge reading. This
must always fall. The
maximum working
pressure atleast 3 bar
below the set oil
pressure.
Hand pump is Hand pump blocked due to dirt in Clean the restrictor
not operative return flow restrictor
V Hunting of the 1) Pressure filter choked 1) Clean the filter
Actuator 2) Blockage in Nozzle of 2) Clean the Nozzle of
Restrictor assy. restrictor assy.
3) Feed back spring and 3) Mount the springs
Retaining spring mounting is properly. If required,
improper and spring change the Feed Back
touching the body. Spring
4) 4)
The pressure on both side of To send to Factory for
the flapper is not equal. caliberation.
SL.
.
VI Oil leakage in 1) Wiper seal damaged 1) Change the wiper seal
Piston Rod 2) Cylinder seat 'O'Ring 2) Change the 'O'Ring
damaged
VII Oil leakage in Gasket damaged Change the Gasket
sight glass
mounting
VIII Accumulator not 1) Shut-off valve not open 1) Open the shut off valve
operating during 2) 4/3 way valve or movable 2) Set 4/3 way valve to
power failure plate set for incorrect correct direction
direction
3) Non-return valve to pump 3) Change the Non-return
does not close and valve
Accumulator oil is forced
through Pump
4) Leakage in oil pipe 4) Correct the oil line
IX During Power 1) Oil in the Accumulator is Correct the Nitrogen gas
failure the low due to Nitrogen gas pressure in the Accumulator
Actuator not pressure is high by charging.
operating to full 2) Accumulator envelop
stroke defective Change the Accumulator
(Return the defective
Accumulator to the
Manufacturer for repair)
SL.
.
X Accumulator Load on Actuator too great Discuss with manufacturer.
operates slowly Possibility of increasing oil
pressure
XI Irregular feed 1) Feed Back Transmitter 1) Clean the stem (if
back from the Stem Struck up. required change the FBT
Feed Back
Transmitter 2) Guide plate dislocated 2) Correct the guide plate
and mount correctly.
IYAPPAN ENGINEERING INDUSTRIES PRIVATE LIMITED: CHENNAI-600 098
IMPROVEMENT DONE ON EHA FROM THE FEED BACK
Sl. Description of item Earlier used Used atpresent Improvement

no.
1 Tank Alumionium sand casting Aluminium fabricated out of plates Contamination from the casting is
and anodized completely eliminated
2 Internal Pipelines Seamless Steel carbon SS Tube after acid cleaning is used This prevents contamination of particles
Steel Tube from the pipelines
3 Feed Back Transmitter Linear variable Transmitter Direct mounting imported Siemens Avoided all linkage mechanism and play
with cam was used Angular Transducer is used is completely removed . Now, Hysterisis
is found less and repeatability is good
4 'O'Rings and seals Nitrile was used Viton O rings and seals are used Withstanding higher temperature
5 D P Switch Differential pressure gauge Clogging indicator imported from More accurate and compact. Damage
of Indian make was used MAHLE-GERMANY is used during transit of pressure gauges avoided
6 Motor 0.25 KW 0.33KW Tripping is totally avoided and heating of
the motor is reduced.
7 Hand pump operation Suction was less Suction Area was increased. Suction was increased and it takes only
25 strokes instead of 45 strokes taken
earlier for the movement of Actuator for
40mm.
8 Tests Only assembly test and Assembly stage inspection was After cyclical tests repeatability is
final test was conducted introduced and all the actuators are checked and found well within the limit
individually checked cyclically for including hysterisis.
10000 times
NOW, FOR THE NEW SERIES UNDER DEVELOPMENT, FOLLOWING WERE INTRODUCED.
1. Double filteration system - this enables to change the filter during the operation without stopping the actuator.
2. Tandem Pump with combined pressure relief valve is used- this reduces volume of pressurised oil and hence, heat generated is less during idle
condition..
3. Yoke length is increased. This reduces conduction of heat from the valve of the actuator.
FINALLY TO CONCLUDE, ALL THE DIFFICULTIES WERE OVERCOME AND NOW THE EHA IS PERFORMING VERY WELL.
ELECTRO HYDRAULIC ACTUATOR
IMPORTANT POINTS TO NOTE

1. Electro Hydraulic Actuator Assembly is selective assembly.
2. Spool is not interchangeable
3. Spool is to be fit in correct direction only
4. Oil contamination to be maintained to NAS 6 level
5. While dismantling the nozzle, care should be taken to
reassemble in the same position and also locking screw
position should not be disturbed.
bypass limit controller...
Bypass Limit Controller
Bypass Limit Controller
electro hydraulic converter...
Electro Hydraulic Converter
Electro Hydraulic Converter

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HP BYPASS SYSTEM

SERVO VALVES - QUICK STROKING

OIL SUPPLY FEEDBACK

63, 100, 160, 200

- A person wants to take bath.

- His brain gives feedback to his

- He is satisfied and continues

IYAPPAN ENGINEERING INDUSTRIES PVT LTD

INPUT ERROR HYD. CYLINDER OUTPUT

BLOCK DIAGRAM OF SERVO FEEDBACK MECHANISM

Servo system is used for

Importance of oil cleanliness :

2 Actuator not a) Spool wrong assy. a) Assemble the spool

3b) Oil leak a) Diaphragm damaged a) Change the

SL. FAULTS PROBABLE CAUSES REMEDIES

5. Spool jammed Change the Servo valve

b) Water mixed in the oil b) Change the oil (send the

c) Solenoid Valve not c) Check & service

b) Cover OD or Piston Rod b) Change the Manual

4. Oil leak through a) Spring Cover, 'O'Ring a) Change the 'O'Ring

SL.NO. FAULTS PROBABLE CAUSES REMEDIES

Iyappan Engg Industries Pvt Ltd

Iyappan Engg Industries Pvt Ltd

3 TANK & CYLINDER 9 TOP PLATE ASSY.

1 OIL TANK PRE. TEST 4 HAND PUMP ASSY. TEST 10 FEEDBACK

6 SHUT OFF VALVE ASSY.

TYPE TEST FOR EHA

BEFORE STARTING THE CYCLE TEST

CONCLUSION: Hysterisis in Travel - 0.17mm

TRAVEL OF PISTON UPWARD (mm) Piston down (mm)

OUTPUT OF FEEDBACK TRANSMITTER - UPWARD (mA)

TYPE TEST FOR EHA

AFTER COMPLETING 10000 CYCLES

CONCLUSION: Hysterisis in Travel - 0.15mm

TRAVEL OF PISTON UPWARD (mm) TRAVEL OF PISTON DOWNWARD (mm)

OUTPUT OF FEEDBACK TRANSMITTER - UPWARD (mA)

MODIFIED ELECTRO HYDRAULIC ACTUATOR ASSEMBLY.

ELECTRO HYDRAULIC ACTUATOR

IYAPPAN ENGG. INDUSTRIES PVT.LTD.

HYDRAULIC CIRCUIT DIAGRAM

b) Defective Motor b) Replace the Motor

IMPROVEMENT DONE ON EHA FROM THE FEED BACK

Sl. Description of item Earlier used Used atpresent Improvement

IMPORTANT POINTS TO NOTE

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