Self-Contained

Electro-Hydraulic
Actuator
EHC-AA

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E 2.800.2/ 04.11

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 Self-Contained
Electro-Hydraulic
Actuator
EHC-AA
Innovative drive concept
Electro-hydraulic actuators are used on process valves
with strict requirements for dynamics, positioning forces and safety.
On conventional actuators with a mechanical spring, the drive has to be designed and manufactured according
to the particular requirements of each individual process valve. Subsequent adaptation of the drive to a different
valve is not possible, leading eventually to a considerable number of models.
The basis of the innovative drive concept is a hydraulic accumulator which replaces the mechanical spring.
Its spring characteristics can be altered very simply by adjusting the operating pressure of the piston accumulator.
This drive concept has the effect of reducing the variety of models to a few basic types.
The use of the piston accumulator as a standard component also contributes to the cost reduction.
Similarly, given the capability to adjust its characteristics, common parts can be used,
thus supporting the modularisation of the valve actuators.
It is possible to monitor the piston accumulator easily during operation.
The drive concept on this basis complies with the requirements of Safety Integrity Level 2.
Safety Integrity Level 3 is achieved when a shut-off valve operated by an on/off-actuator
is configured in series with a control valve operated by a servo-actuator.
This innovative actuator contains all the components necessary for operation
and does not require a separate oil supply unit.

EHS
Axial piston pump
Electric motor

Pressure filter

Hydraulic accumulator

Pressure transmitter

Proportional valve with positioning module

I I I
p T s Pressure control device

Hydraulic cylinder
pressure Limit switch
control device
Position transmitter
I
p Temperature transmitter

Pressure transmitter

Hydraulic accumulator

M Safety control EHS

Cooler unit

Terminal box
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Note:
The information in this brochure relates to the operating conditions and applications described.
For applications and operating conditions not described, please contact the relevant technical department.
Subject to technical modifications.
2
Functional description
Cylinder
A key component of the compact drive is a hydraulic linear
cylinder with piston rod and flange on the rod-side end (8).
The rod is extended using a hydropneumatic spring.
Retraction is possible by filling the rod side with pressurised oil.
To do this, the rod side must be actively closed using
a safety device (14).
In the case of the servo-actuator, the stroke of the piston rod is
adjusted continuously by a proportional valve. In the case
of the on / off-actuator, the rod side is supplied with pressurised
oil by the control valve and the cylinder rod is retracted (100%
stroke).
The cylinder stroke is measured using an integrated position
sensor (10). The limits of the cylinder can be monitored
by contactless limit switches (9) as an option.
Piston accumulator
as hydropneumatic spring
The piston side of the cylinder is linked
to the pressurised oil side of the piston accumulator (13).
The pressurised oil is supported by the gas volume
of the accumulator. The oil pressure corresponds
to the gas pressure. During operation, the oil is pre-charged
by the pressure control device to a minimum pressure (7).
It corresponds to the minimum required positioning force
of the actuator when the piston rod is extended.
When the piston rod retracts, the pressure rises
on the piston side of the cylinder.
The cylinder position is already measured for position
control (10). Oil pressure and oil temperature are recorded
using integrated sensors (11, 12). These variables
are evaluated for condition monitoring of the actuator.

Self-contained electro-hydraulic Preferred 50 63 80 100 125 140 160

actuator EHC-AA models

Piston diameter D mm 50.00 63.00 80.00 100.00 125.00 140.00 160.00

Rod diameter D mm 25.00 28.00 36.00 45.00 50.00 56.00 63.00

Static force 210 bar Fn kN 41.23 65.46 105.56 164.93 257.71 323.27 422.23

Front view Rear view

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Oil supply unit
To supply the pressurised oil, actuators have
an axial piston pump with adjustable swash plate (1).
Its supply pressure is maintained at a constant value.
A hydraulic accumulator is connected to the pump (4).
The volume stored there corresponds to at least
one reserve stroke of the drive.
Within a position control circuit, a proportional
valve (6) is actuated and the piston rod is moved.
If there is a sudden requirement for oil, the accumulator
buffers the flow of the pump.
When holding the position of the actuator, this concept
minimises the energy consumption by cutting back
the supply to almost zero. The oil is stored
in a tank which is optimised through the use of flow
simulations. Below the tank is a drip tray with a monitoring
contact. The oil temperature and oil level in the tank are
also monitored.
Cooling systems
The cylinder and the hydraulic oil are cooled using an oil/
air heat exchanger (15). This means that the external heat
transfer from the process into the oil system is reduced
right from the point of entry.
Reliability
Tried and tested components are used which
can be configured to be redundant as an option.
The hydropneumatic spring can also be designed
to be redundant.
The innovative drive concept with hydropneumatic
spring guarantees a high level of reliability in operation.
Safety control for shut-off
The safety control (14) acts independently.
It relieves the rod side of the cylinder when de-energized.
When triggered, the piston rod
extends and closes the process valve.
As an option, the actuator can be equipped
with a 2-out-of-3 logic.

Terminal box
All sensors and solenoid valves are connected to a terminal
Simulation strip in a terminal box (16). This also contains the electronic
of the tank flow positioning module.

Model code

EHC-AA – XXX – D – G – E – X

Electro Hydraulic Control Actuator Autarchic

Piston diameter
XXX = mm

Cylinder type
D = Differential cylinder

Type of spring
G = Gas spring

Direction of movement
with spring assistance
E = Extension
R = Retraction

Measurement technology
(redundant versions available)
W = Position transmitter
E = Limit switch
P = Pressure transmitter
T = Temperature transmitter
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 Features Safety control
High degree of modularity and adaptability The patented electro-hydraulic safety control EHS
due to the hydropneumatic spring from HYDAC complies with the requirements of
IEC 61508 and IEC 61511.
Low number of actuator variants
many common parts

Possibility to increase the availability

due to redundancy

High level of flexibility since force level and, if necessary,

any force characteristics can be adapted during operation

One actuator suitable for use on different process valves

Continuous monitoring of the availability of

the closing force during the motion EHS 1oo1 EHS 2oo2

Energy saving pressure supply with pressure

controlled variable displacement or fixed displacement
pumps with accumulator charging circuit
Safety function is performed reliably
thanks to proven technology
Modular safety logic selectable
for example in a 1-out-of-2 or 2-out-of-3 voting
Partial stroke test can be carried out
SIL 2 for individual drive, SIL 3 for series circuit
The safety integrity level SIL of the system
is determined by the risk assessment. As part of the
control chain, on the one hand the hydraulic control
elements and their circuitry must satisfy the requirements.
On the other hand, the highest possible reliability
is expected, so the system must therefore have maximum
availability and must also be easy to maintain.
The electro-hydraulic safety control using
SIL-compliant control modules takes account
of these factors and, with the choice of different logic
modules, enhances the reliability of the safety control.

Technical specifications
Nominal pressure 210 bar
ISO VG 32, ISO VG 46, mineral oil to DIN 51 524, HFD-U
Operating fluids
HFD-R fire-resistant ISO 6743-4 – others on request
Temperature range of environment - 5 °C to + 60 °C
Atmosphere Dusty industrial environment, potentially explosive according to ATEX Directive (optional)
Relative air humidity up to 90 %
Electrical specifications
Control voltage 24 V DC
Power supply 400 V, 3 phase, 50 Hz – other on request
Nominal current of coil 1.45 A for 24 V DC (standard coil), 0.55 A for 24 V DC (ATEX)
Protection class IP54 (standard) – others on request
Nominal current for positioning module < 100 mA
Target position 0 - 100% 4 – 20 mA
Actual position 0 - 100% 4 – 20 mA
Positioning
Positioning accuracy <1%
Repeatability < 0.1 %
Hysteresis < 0.1 %
Actuating times
Control operation 3 s – 60 s
Controlled Open / Close 1 s – 30 s
Safety stroke Open / Close 0.04 s – 2.5 s
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Accumulator Technology 30.000
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Accessories 61.000

Head Office Industriegebiet

HYDAC SYSTEM GMBH 66280 Sulzbach /Saar
Electronics 180.000

Germany
Tel.: +49 6897 509-01
Fax: +49 6897 509-577
E-mail: info@hydac.com
Internet: www.hydac.com
E 2.163.0/07.13
Cooling Systems 5.700