USER MANUAL RKP-II Radial Piston Pump CA53461-001; Version 2, January 2010
Copyright © 2010 Moog GmbH Hanns-Klemm-Strasse 28 71034 Böblingen Germany Telephone: +49 7031 622-0 Fax: +49 7031 622-191 Email: sales@moog.com Website Address: http://www.moog.com/Industrial All rights reserved. No part of the User Manual may be reproduced in any way or form (print, photocopy, microfilm or by any other means) or edited, duplicated or distributed with electronic systems without our prior written consent. Offenders will be held liable for the payment of damages.
Table of Contents Table of Contents Copyright ................................................................................................................................................... A List of Tables .............................................................................................................................................iv List of Figures ............................................................................................................................................
Table of Contents 3 Product Description ................................................................................11 3.1 3.2 3.3 3.4 3.5 Configuration ............................................................................................................................. 11 Scope of Delivery....................................................................................................................... 12 Nameplate...........................................................................
Table of Contents 7 Operation .................................................................................................43 7.1 Initial Pump Set-Up.................................................................................................................... 43 7.1.1 Filling up the Pump....................................................................................................... 44 7.1.2 Adjusting the Compensator ..........................................................................
List of Tables List of Tables Tab. 1: Tab. 2: Tab. 3: Tab. 4: Tab. 5: Tab. 6: Tab. 7: Tab. 8: Tab. 9: Tab. 10: Tab. 11: Tab. 12: Tab. 13: Tab. 14: Tab. 15: Tab. 16: Tab. 17: Tab. 18: Tab. 19: Tab. 20: iv Supplemental Documentation............................................................................................................ 2 Description of the Compensator Options ......................................................................................... 15 General Technical Data .............
List of Figures List of Figures Fig. 1: Configuration Radial Piston Pump RKP-II ....................................................................................... 11 Fig. 2: Scope of Delivery............................................................................................................................. 12 Fig. 3: Nameplate for Radial Piston Pump RKP-II ...................................................................................... 13 Fig.
List of Figures For your Notes.
1 General Information Information on the User Manual 1 General Information 1.1 Information on the User Manual The User Manual at hand refers solely to the radial piston pumps in the series RKP-II and is an integral part of the product. It describes the intended use and safe application of the product in all phases of operation. Information on the User Manual 1.1.1 Target Groups 1.1.1.
Supplemental Documentation 1 General Information 1.1.5 Warning Labels Warning Labels DANGER Denotes safety instructions, which are meant to warn of an imminent danger of death or serious bodily injury or of significant property damage.
1 General Information Environmental Safety 1.3 Environmental Safety 1.3.1 Emissions If operated properly according to instructions, typically no dangerous emissions emanate from the radial piston pump. Environmental Safety: Emissions 1.3.
Responsibilities 1 General Information 1.
1 General Information Warranty and Liability 1.5 Warranty and Liability In principle, our general terms and conditions for delivery and payment apply. These shall be available to the buyer at the latest at the time the sales contract is completed.
Trademarks 1 General Information 1.6 Trademarks Trademarks Moog™ and Moog Authentic Repair Service™ are registered trademarks of Moog Inc. and its subsidiaries. All product and company names listed in the User Manual are possibly protected trademarks of their respective manufacturer, the use of which by third parties for their own purposes may be in violation of the manufacturer's rights. A missing ® or ™ symbol may not be interpreted to mean that the name is a brand name that can be used unrestricted.
2 Safety Intended Use 2 Safety 2.1 Intended Use The Radial Piston Pump RKP-II is a work machine used to produce hydraulic displacement. Certain versions of the radial piston pumps are fitted with an additional safety function for locking (not a hermetic sealing function) the hydraulic displacement. Intended Use Use Environment: The radial piston pump is designed to control and regulate pressures and displacements in commercial applications.
Organizational Measures 2 Safety For its intended use, the following applies: • Observance of the User Manual • Handling the Radial Piston Pump safely Ö Chap. "2.2.1 Safe Operation", Page 8 • Adhering to the inspection and maintenance instructions from the manufacturer and the operator of the machinery.
2 Safety Organizational Measures Qualified users are skilled professionals, who have been trained to carry out these tasks and who have the required knowledge and experience. In particular, such skilled professionals must be licensed to operate, ground and label machines, systems and electric circuits in accordance with applicable safety standards. Project planners must be familiar with the safety concepts for automated technology. Qualified Users 2.2.
General Safety Instructions 2 Safety 2.3 General Safety Instructions • Any and all work to the Radial Piston Pump may only be performed by user's qualified to do so and those authorized. Ö Chap. "2.2.2 Selecting and Qualifying Staff", Page 8 General Safety Instructions • The technical data and especially the information shown on the Radial Piston Pump's nameplate are to be observed and adhered to. Ö Chap. "4 Technical Data", Page 27 2.3.
3 Product Description Configuration 3 Product Description 3.1 Configuration Configuration Pos. Description 1 Control piston 2 Rolling bearing 3 Drive shaft 4 Drain Port 5 SAE piping connection 6 Sliding stroke ring 7 Slipper pad with working piston 8 Housing 9 Compensator Fig.
Scope of Delivery 3 Product Description 3.2 Scope of Delivery Scope of Delivery Pos. Description 1 Radial Piston Pump RKP-II 2 Cap 3 Flange cover 4 Transport protection for shaft ends Fig. 2: Scope of Delivery When pump stages are delivered, the through-drive is closed with a cap. The caps are not suitable for operational purposes.
3 Product Description Nameplate 3.3 Nameplate Nameplate Pos. Marking Additional Information 1 Revision status 2 Rotation direction 3 Type key 4 displacement Ö Catalog Radial Piston Pump RKP-II 5 Maximum revolutions for low noise operation 6 Maximum operating pressure 7 Date of manufacture in the format MM/YY 8 Model number Fig. 3: Nameplate for Radial Piston Pump RKP-II In the case of multiple pumps, each individual pump has its own nameplate.
Functional Description 3 Product Description 3.4 Functional Description Functional Description The shaft (Pos. 11) transfers the drive torque to the star-shaped cylinder block (Pos. 7), free of any axial forces, via a crossdisc coupling (Pos. 10). The cylinder block is hydrostatically supported on the control journal (Pos. 6). The radial pistons (Pos. 5) in the cylinder block run against the stroke ring (Pos. 3) through hydrostatically balanced slipper pads (Pos. 4).
3 Product Description Compensator Operation 3.5 Compensator Operation The Radial Piston Pump RKP-II enables a variety of compensator options to be used. This ensures maximum flexibility. Compensator Operation The following options are described in more detail later on: No. Compensator Option Description/Characteristics/Application 1 Adjustable pressure compensator, F1, F2 For constant pressure systems with a fixed pressure settings Ö Chap. "3.5.
Compensator Operation 3 Product Description 3.5.1 Adjustable Pressure Compensator, F1, F2 Adjustable Pressure Compensator, F1, F2 Pressure range: F1: 30–150 bar F2: 80–350 bar Pos. Description 1 Safety valve p = pmax. + 30 bar 2 Control piston 2 3 Control piston 1 4 Adjustment of zero stroke 5 Valve spool 6 Valve spring 7 Adjustment screw 8 Locknut for the adjustment screw 9 Setting the adjustment screw Fig.
3 Product Description Compensator Operation 3.5.2 Hydraulically Driven Remote Pressure Compensator, H1 Pressure pilot valve: Manually adjustable or proportional pressure valve Q = 1–1.5 l/min. Pos. Hydraulically Driven Remote Pressure Compensator, H1 Description 1 Safety valve p = pmax. + 30 bar 2 Control piston 2 3 Control piston 1 4 Adjustment of zero stroke 5 Pilot pressure valve 6 Valve spool 7 Orifice 8 pmin.
Compensator Operation 3 Product Description 3.5.3 Remote Pressure Compensator with Mooring Control, H2 Remote Pressure Compensator with Mooring Control, H2 The pressure compensator with Mooring control has an intermediate plate inserted between the pump body and the pressure compensator. The intermediate plate enables the pump's absorption operation. Pos. Description 1 Control piston 2 2 Control piston 1 3 Intermediate plate 4 Pilot pressure valve: 5 Valve spool 6 Orifice 7 pmin.
3 Product Description Compensator Operation 3.5.4 Load Sensing Compensator, J1 Metering orifice: Manually remote adjustable orifice valve or proportional orifice valve. Load Sensing Compensator, J1 Pressure pilot valve: Manually remote adjustable proportional pressure valve Q = 1–1.5 l/min. Pos. Description Pos. Description 1 Metering orifice for flow control 8 Δp spring 2 Safety valve p = pmax.
Compensator Operation 3 Product Description 3.5.5 Load Sensing Compensator with p-T Control Notch, R1 Load Sensing Compensator with p-T Control Notch, R1 Metering orifice: Manually remote adjustable orifice valve or proportional orifice valve. Pressure pilot valve: Manually remote adjustable proportional pressure valve Q = 1–1.5 l/min. For multiple pumps feeding in one common line, only one compensator with a p-T control notch may be used. This compensator must be set to the higher Δp value. Pos.
3 Product Description Compensator Operation 3.5.6 Mechanical Stroke Adjustment, B1 Mechanical Stroke Adjustment, B1 Pos. Description 1 Adjustment screw 2 Seal nut Fig.
Compensator Operation 3 Product Description 3.5.7 Servo Control, C1 Servo Control, C1 Pos. Description Pos. 4 Description 1 Stroke ring Adjustment lever for control shaft 2 Pilot spool 5 Control piston 1 3 Spool sleeve 6 Control piston 2 Fig.
3 Product Description Compensator Operation 3.5.8 Power Control, S1 Power Control, S1 Pos. Description Pos. Description 1 Control piston 2 6 Pilot spool 2 Control piston 1 7 Rocker 3 Adjustment screw (fixed setting, do not modify) 8 Spring 1 4 Sensing piston 9 Spring 2 5 Adjusting screw (fixed setting, do not modify) Fig.
Compensator Operation 3 Product Description Characteristics for Power Control, S1 Fig. 13: Characteristic V = 32 cm3/U Fig. 14: Characteristic V = 63 cm3/U Fig. 15: Characteristic V = 100 cm3/U Approximation to the power hyperbola by means of two springs. Referenced on n = 1450 1/min.
3 Product Description Compensator Operation 3.5.9 Power Control, S2 Hydraulically operated power control with superimposed pressure and displacement limitation Power Control, S2 Pos. Description 1 Pressure p setting 2 Flow control Q setting 3 Control port Fig.
Compensator Operation 3 Product Description For your notes.
4 Technical Data General Technical Data 4 Technical Data 4.
Operating Conditions 4 Technical Data 4.2 Operating Conditions Operating Conditions Displacement [cm3/R] 19 32 45 63 80 100 140 Drive type Direct drive with coupling (for other drive types, please contact us) Ambient temperature range -15 °C up to 60 °C Max. speed at inlet pressure 0.8 bar abs. [min-1] 2700 2500 1800 2100 1500 1500 1500 Max. speed for inlet pressure 1 bar abs. [min-1] 2900 2900 2100 2300 1800 1800 1800 Max.
5 Transport and Storage Unpacking the Pump 5 Transport and Storage For pumps in explosive areas, observe the supplementary documentation as well: Ö User Manual RKP II Explosion-Proof Transport and Storage For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9 5.
Transporting the Pump 5 Transport and Storage CAUTION Damage to the attached parts! Any heavy weight on the attached parts, for example the compensator, during transport may result in damage to such. • Do not attach lifting tackle to the attached parts during transport. • Make sure that the attached parts do not collide with other objects during transport. For multiple pumps, add up the weights of the individual pumps. Procedure: 1. Determine the weight and the dimensions of the pump.
5 Transport and Storage Storing the Pump Fig. 18: Transporting Multiple Pumps with Lifting Tackle 5.3 Storing the Pump CAUTION Damage to Property! Storing the pump improperly may lead to property damage. Storing the Pump • Store the pump as instructed and if necessary, preserve it. Preservation Conditions Storage Duration Preservation up to twelve months not required > 1 year required Ö Chap. "5.4 Preserving the Pump", Page 32 Tab.
Preserving the Pump 5 Transport and Storage Procedure: 1. Inspect to assure that all openings have been closed using flange covers or caps. 2. Check to assure that transportation protection means are attached to the pump's drive shaft. 3. Make certain that the storage space - Is clean, dry, frost-protected and free of corrosives and vapors. - Has a consistent temperature (temperature difference < 10 °C). 4. Depending on storage duration: preserve the pump Ö Tab. 5, Page 31 5.
6 Mounting Preparing for mounting 6 Mounting For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-Proof Mounting For any and all tasks to be performed on the pump, suitable personal protective equipment should be worn. Ö Chap. "2.2.
Installing the Pump 6 Mounting 6.2 Installing the Pump Installing the Pump WARNING Risk of Crushing! During mounting, the pump may topple over and crush body parts. • Select lifting tackle to correspond with the overall weight of the pump. • Attach the lifting tackle to the pump properly. Ö Chap. "5.2 Transporting the Pump", Page 29 • Avoid all areas below the floating load.
6 Mounting Planning Lines Procedure: 1. Mount the specified half of the coupling to the pump's drive shaft as per the information provided by the coupling manufacturer. The threaded bore on the pump's drive shaft can be used to mount the coupling. 2. Make sure that the connection and mounting surfaces are clean. - If not, clean the connection and mounting surfaces using suitable cleaning agents. - Use suitable cleaning rags.
Connecting Pipes 6 Mounting • Avoid sharp angles and screwed pipe joints (danger of air intake and dispersion, high flow resistance). Use curved pipes or hoses instead. • Maintain the minimum inlet pressure. • Only reduce the length of the suction line at the pump entry. • If a suction filter (min. 0.15 mm mesh aperture) or a shut-off valve is used, install the devices below the fluid level. Pressure Line • Ensure sufficient stability. • Inspect the tightening torques of the screws.
6 Mounting Electrically connecting the pump 6.5 Electrically connecting the pump The pump's electrical is connected through the control unit: Ö Application Instruction RKP-D with CAN Bus Interface Electrically connecting the pump 6.6 Arranging Multiple Pumps 6.6.1 Determining the through drive torque Additional pump stages can be mounted axially to the pump and as a result, all pumps can be driven by the same shaft.
Arranging Multiple Pumps 6 Mounting Design of the first through drive The pressure and the current flow for the first pump have no effect on the torque transferred by the through drive.
6 Mounting Arranging Multiple Pumps Fig. 20: Radial piston pump with tandem mounted gear pump using SAE-A adapter Fig.
Arranging Multiple Pumps 6 Mounting 6.6.2 Attaching the Adapter Flange Pre-Conditions: Attaching the Adapter Flange • The centering diameters of both the adapter flange and the add-on pump match. • The dimensions of the through drive shaft match with the add-on pump. • The flange diameters of both the adapter flange and the add-on pump match. • The connection surfaces are clean. Procedure: 1. Attach the adapter flange to the add-on pump without damaging the O-rings. 2.
6 Mounting Arranging Multiple Pumps Adapter flange SAE-B with 13-tooth shaft Profile Bolt Thread Thread Shaft end for add-on pump Fig. 23: Adapter flange SAE-B with 13-tooth shaft Flange Code: Shaft Code: Spline as per: Conditions for attachment: 101-2 22-4 ANSI B92.1 13T 16/32 DP Flat root side fit RKP with heavy-duty through drive The adapter includes through drive shaft, seals (HNBR), intermediate ring for RKP 63–140 and four fastening screws.
Arranging Multiple Pumps 6 Mounting Adapter flange SAE-C with 14-tooth shaft Fig. 24: Adapter flange SAE-C with 14-tooth shaft Flange Code: Shaft Code: Toothing to: Conditions for attachment: 127-2 32-4 ANSI B92.114T 12/24DP Flat root side fit RKP with heavy-duty through-drive Adaptor including through-drive shaft, seals (HNB-R), intermediate ring for RKP 140 and 4 fastening screws and special nut.
7 Operation Initial Pump Set-Up 7 Operation For pumps in explosive areas, observe the supplementary documentation as well: Ö User Manual RKP II Explosion-proof Operation For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9 7.1 Initial Pump Set-Up CAUTION Damage to the pump! Setting up the pump for initial operation without the required basic mechanical and hydraulic knowledge may result in damage to the pump.
Initial Pump Set-Up 7 Operation WARNING Risk of injury and property damage as a result of fire! Easily inflammable operating fluid may cause fire. • Keep the pump away from any open flames. WARNING Risk of Burns! Pump parts run hot while in operation. • Do not touch the pump while it is running.
7 Operation Initial Pump Set-Up 7.1.2.1 Hydraulically Driven Remote Pressure Compensator, H1 Information on the compensator: Ö Chap. "3.5.2 Hydraulically Driven Remote Pressure Compensator, H1", Page 17 The information in this section also applies to: Ö Chap. "3.5.4 Load Sensing Compensator, J1", Page 19 When high dynamics are required for flow control, orifice and control flow volume, contact us to discuss application specific compensator adjustments.
Initial Pump Set-Up 7 Operation 7.1.2.3 Mechanical Stroke Adjustment Information on stroke adjustments: Ö Chap. "3.5.6 Mechanical Stroke Adjustment, B1", Page 21 When adjusting the required flow volume, make sure that the stroke ring is held tight between the two adjustment screws. Upon delivery, the pump is set to Vmax.. The information in the following table refers to Ö Fig. 10, Page 21 Displacement V [cm3/U] 19 Pos.1 32 45 63 WS 8 = 15 Nm + 5 Nm Pos.
7 Operation Initial Pump Set-Up 7.1.2.4 Servo Control, C1 Information about the Servo Control: Ö Chap. "3.5.7 Servo Control, C1", Page 22 The zero position and the end position are set at the factory. Manual or mechanical operations are performed using the adjustment lever. Pos. Description 1 Zero position (set at the factory) 2 End position / ±Vmax. (set at the factory) Fig. 25: Servo Control, C1 Displacement V [cm3/R] 19 32 45 63 80 100 Angle α [°] 44 47 57 44 56 56 2.4 2.
Initial Pump Set-Up 7 Operation 7.1.2.5 Power Control, S1, S2 Information on the power control: Ö Chap. "3.5.8 Power Control, S1", Page 23 Ö Chap. "3.5.9 Power Control, S2", Page 25 The power control settings are set at the factory and may not be changed! Pos. 1 Description Power control setting (set at the factory; may not be changed) 2 Pressure decrease (set at the factory Δp = 10 bar + 2 bar) 3 Control port G 1/4" Fig.
7 Operation Performing Functions Tests 7.1.2.6 Limiting the Maximum Flow Pos. Description 1 Adjustment mandrel 2 Cap nut 3 Lock nut Fig. 27: Limiting the Maximum Flow Displacement V [cm3/R] 19 32 45 63 80 100 140 Pos.1 WS 8 WS 12 WS 10 Pos. 2 WS 24 = 40 Nm + 10 Nm WS 32 = 80 Nm + 10 Nm WS 27 = 80 Nm + 10 Nm Pos. 3 WS 24 = 50 Nm + 10 Nm WS 32 = 90 Nm + 10 Nm WS 27 = 90 Nm + 10 Nm ΔV for 1 mm adjusting screw travel (pitch 1.5 mm/R) 3.6 5.6 6.5 8.9 11.3 11.5 Tab.
Operating the Pump 7 Operation 2. In doing so, watch especially for: - Noise development - Any exterior leaks 7.3 Operating the Pump Operating the Pump DANGER Bodily injuries and property damage! Incorrectly setting the pump in operation may lead to unexpected and uncontrolled movements of the machine / equipment and as a result may lead to bodily injuries or property damage. • Only trained personnel should be allowed to operate the pump.
7 Operation Operating the Pump 7.3.1 Start up Pre-Conditions: Start up • Pump has been filled. Ö Chap. "7.1.1 Filling up the Pump", Page 44 • The temperature of the operating fluid in the tank does not exceed the pump temperature by more than 25 °C. Procedure: If the temperature of the operating fluid in the tank exceeds the pump temperature by more than 25 °C, the pump should only be switched on in short intervals of 1 to 2 seconds until it has heated up.
Placing the Pump out of Operation 7 Operation 7.4 Placing the Pump out of Operation Placing the Pump out of Operation DANGER Risk of injury and property damage as a result of blows or impact! Unexpected and uncontrolled movement of the machine / equipment may lead to severe injury or property damage. • Only trained personnel should be allowed to remove the pump. • Have the equipment manufacturer or operator assure that no uncontrolled signals are being transmitted to the pump.
8 Maintenance and Repairs Monitoring 8 Maintenance and Repairs For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-proof Maintenance and Repairs For any and all tasks to be performed on the pump, suitable personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9 8.
Trouble-shooting 8 Maintenance and Repairs 8.2 Trouble-shooting Should repairs be needed because of any trouble with the pump, these should only be carried out by one of our service technicians or by an authorized service location. Ö Chap. "2.2.3 Structural Modifications", Page 9 Ö Chap. "8.
9 Demounting Demounting the Pump 9 Demounting For pumps in explosive areas, the supplementary documentation should also be observed: Ö User Manual RKP II Explosion-Proof Demounting For any and all tasks to be performed on the pumps, appropriate personal protective equipment should be worn. Ö Chap. "2.2.4 Work Safety", Page 9 9.
Demounting the Pump 9 Demounting Pre-Conditions: • The pump is idle: Ö Chap. "7.4 Placing the Pump out of Operation", Page 52 • Demounting location is freely accessible. • Machine / equipment is at zero pressure and zero voltage. • Operating fluid has been inspected for risks and any necessary safety precautions have been taken. • Standard tools are available. • Supplementary documentation is available. Procedure: 1.
10 Spare Parts, Accessories, Repairs 10 Spare Parts, Accessories, Repairs The operator is not authorized to install spare parts and accessories. Repairs or other structural modifications to the pump may only be carried out by us or by an authorized service repair shop. Ö Chap. "2.2.3 Structural Modifications", Page 9 Spare Parts, Accessories For all tasks described in this User Manual, commercially available standard tools may be used.
10 Spare Parts, Accessories, Repairs For your notes.
11 Index A…P A B C D E F G H I J K L M N O P Q R S T U V W X Y Z 11 Index A M Accessories 57 Arranging multiple pumps Attaching the adapter flange 40 Determining the through drive torque 37 Demounting 55 Demounting the Pump 55 Duplication of the User Manual is strictly prohibited A Maintenance and Repairs 53 Monitoring 53 Moog Service Addresses • 54 Trouble-shooting 54 Manufacturer's Address A Moog GmbH Address A Mounting 33 Arranging multiple pumps 37 Connecting pipes 36 Electrically connecting pump
R…W 11 Index A B C D E F G H I J K L M N O P Q R S T U V W X Y Z R Repairs 57 Reproduction of the User Manual is strictly prohibited A Responsibilities 4 S Spare parts 57 T Technical Data 27 General Technical Data 27 Operating Conditions 28 Tools 57 Trademarks 6 Transport and Storage 29 Preserving the Pump 32 Storing the pump 31 Transporting the Pump 29 Unpacking the Pump 29 U User Manual Copyright A Duplication strictly prohibited. A Protected by Copyright A Reproduction strictly prohibited.
12 Appendix Abbreviations, Symbols and Code Letters 12 Appendix 12.1 Abbreviations, Symbols and Code Letters Abbreviations, Symbols and Code Letters Abb. Explanation βx Symbol for filter efficiency Δp Symbol for pressure change ΔpN Symbol for nominal pressure change ν Symbol for viscosity A Connection port (consumer load connection) ANSI American National Standards Institute (http://www.ansi.
Abbreviations, Symbols and Code Letters Abb. 12 Appendix Explanation Vmax. Symbol for maximum delivery volume ΔV Change in pump displacement VDI Verein Deutscher Ingenieure e. V. (http://www.vdi.de) VDE Verband der Elektrotechnik Elektronik Informationstechnik e. V. (http://www.vde.de) X Connection port (control pressure connection) L Connection port (leakage connection) Tab.
12 Appendix Tightening Torque 12.2 Tightening Torque The data on the tightening torque in this segment is considered as reference values only. Preference should be given to the data provided by each manufacturer of the particular machine part! Tightening Torque Flange for Suction and Pressure Connection Flanges with corresponding screws and sealing elements are to be used in accordance with the information provided by the flange manufacturer.
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