Hydraulic Power Unit Product Information Manual Model 506.82 Model 506.
Copyright information Trademark information © 2000 MTS Systems Corporation. All rights reserved. MTS is a registered trademark of MTS Systems Corporation. DTE is a registered trademark of Mobil Corporation. Tellus is a registered trademark of Shell Oil Corporation. Contact information Publication information MTS Systems Corporation 14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S.
Table of Contents Section 1 1.1 1.2 Section 2 2.1 2.2 2.3 Section 3 3.1 3.1.1 3.1.1.1 3.1.1.2 3.1.2 3.1.3 3.1.3.1 3.1.3.2 3.1.3.3 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 Section 4 4.1 4.2 4.2.1 4.2.2 4.3 Introduction Functional Description............................................................................. 1-2 Specifications........................................................................................... 1-3 Operation Controls and Indicators.................................
Section 5 5.1 5.2 5.2.1 5.2.2 Theory of Operation Hydraulic Operation................................................................................ 5-1 Electrical Operation ................................................................................. 5-3 Control.............................................................................................. 5-4 Interlocks ..........................................................................................
Section 1 Introduction Definition The Model 506.82/.92 Hydraulic Power Unit (HPU) uses two variablevolume (pressure compensated) main pumps, with a pressurized (supercharged) hydraulic fluid inlet, to provide pressure to systems with various flow requirements. The HPU is designed to be used with servocontrolled, electro-hydraulic systems. Model 506.82/.
1.1 Functional Description Front panel controls and indicators Front panel controls on the HPU include local operating controls and two running time meters. Front panel indicators show power on, low oil level, fluid over-temperature, motor overload and dirty filter conditions. Pressure output The output pressure is controlled by an adjustment on the main pumps and is monitored by the output pressure gage.
1.2 Specifications The required water pressure between the input and the output of the heat exchanger is 30 to 45 psi (0.2 to 0.3 MPa). The maximum allowable pressure is 120 psig (0.8 psid). The flow rate (±20%) at a given temperature is shown in the table below. Cooling water specifications Table 1-1. Cooling Water Requirements Cooling Water Inlet Required Water Flow Temperature 506.82B 506.92B 60°F (15.5°C) 30 gpm (114 l/min) 35 gpm (132 l/min) 65°F (18.
Table 1-2. HPU Specifications (Continued) Parameter Supercharge pump motor power rating Model 506.82B Model 506.92B 25 hp (19 kW) 40 hp (30 kW) Inrush 575 A 775 A Continuous 395 A 535 A Starter type Wye-delta Wye-delta 24 V external hydraulic control amps (with optional remote control) 6.8 A 6.
Section 2 Operation 2.1 Controls and Indicators Figure 2-1 and Table 2-1 identify and describe HPU controls and indicators. Fluid Level Gage Temperature Gage (These gages are located on the HPS rear panel) VW-G041C Figure 2-1.
Table 2-1. Controls and Indicators Control/Indicator Power On indicator* Description The Power On indicator lights to indicate that electrical power is applied to the HPU. Emergency Stop switch This switch operates in both local and remote control and is used during emergency situations only. When pressed, it immediately shuts down the HPU (the supercharge pump may continue to run briefly to supply the main pumps until they fully stop).
2.2 Operation Procedures This section provides the local and remote operating procedures for the 506.82/.92 Hydraulic Power Unit. ! WARNING Do not start the HPU if the servovalve command is not equal to feedback (that is, zero balanced). Failure to do this can result in sudden actuator movement which may cause injury to persons and/or damage to equipment. Ensure that the system is at zero balance before starting the HPU. Before you begin Before you begin operation complete the following steps: 1.
Remote Operation 1. Turn the Source Remote/Local switch to Remote. Make sure that the remote control cable is connected to the cable connector (the figure on the left shows the location of this connector) and to the remote control device. 2. Apply electrical power. 3. Press Reset (must be pressed whenever electrical power to the HPS has been interrupted). remote control connector 4. Use the remote control device to start the HPU at low pressure. 5. Check for leaks and unusual sounds. VW-G045A 6.
Section 3 Service This section contains service information for the Model 506.82/.92 Hydraulic Power Unit (HPU). It provides: Introduction • maintenance procedures • service adjustments • electrical information 3.1 Maintenance Procedures Maintenance overview The following sections provide the routine maintenance procedures for the HPU. Figure 3-1 shows the location of the components accessed for the maintenance procedures. Table 3-1 lists the maintenance schedule.
Table 3-1. Maintenance Schedule Procedure Interval Subsection Check output pressure on gage* daily Replace high-pressure filter whenever the indicator points to change 3.1.1 Replace low-pressure filter whenever Dirty Filter indicator lights 3.1.1 Check hydraulic fluid level on gage daily 3.1.2 Check hydraulic fluid in reservoir 150 operating hours 3.1.2 Analyze hydraulic fluid 500 operating hours 3.1.2 Check accumulator precharge at established interval 3.1.
3.1.1.1 High-Pressure Filter Replacement KO CHA NG E Replace the high-pressure filter elements whenever the DIRT ALARM indicator mounted on the base of each high-pressure filter housing points to CHANGE (red or yellow zone) or whenever the hydraulic fluid is replaced. DIRT ALARM VW-GO46 1. Press Stop on the HPU. The output pressure gage must read zero. End Cap – Top View unscrew to remove endcap 2. Loosen the air-bleed screw on top of the filter housing endcap.
3.1.1.2 Low-Pressure Filter Replacement The low-pressure filter element requires replacement whenever hydraulic fluid in the HPU reservoir is replaced, or the Filter Dirty indicator on the HPU front control panel lights.1 See Figure 3-1 for the location of the filter. Refer to the figure on the left to locate the components accessed for the following procedure. bleed screw with O-ring 1. Press Stop on the HPU. The output pressure gage must read zero. 2. Disconnect the cable from the filter manifold. 3.
3.1.2 Hydraulic Fluid Regular maintenance of hydraulic fluid maximizes the service life of the system and its components. Daily fluid checks Monthly fluid checks Yearly (every 500 operating hours) fluid checks Check the fluid-level in the transparent gage. A low level can indicate a leak. A high level can indicate water contamination from the heat exchanger.
Replacing hydraulic fluid HPS – Rear View Perform this procedure to replace the hydraulic fluid. You will need a Model 590.01 Fluid Transfer Pump or a pump which provides at least 10-micron filtration. 1. Turn off electrical power to the HPU. Remove the reservoir filler cap assembly. 2. Drain the hydraulic fluid into a container, while hot, through the drain valve. Close the valve. drain Then drain the oil from the entire system (such as from the hoses and accumulators).
3.1.3 Accumulators For more information about accumulators See the Series 111 Accumulator product manual (MTS part number 115533XX). For other accumulators, refer to the vendor literature or the Procedure for Checking Piston and Bladder Type Accumulator Precharge and Precharging (MTS part number 408266-XX). pressure accumulator pressure gage filter drain back-up relief valve slow turn-on accumulator Figure 3-2. Location of Accumulators 3.1.3.
Precharge pressure of the slow turn-on accumulator (Figure 3-2) must be checked at regular intervals. To establish an interval time, follow this procedure: Slow Turn-on Accumulator 1. Initially, check the precharge pressure after 2 weeks or 100 operating hours. 2. If there is a pressure-level change of more than 50%, check the precharge pressure every week or 50 operating hours. If there is a pressure-level change of less than 50%, check the precharge pressure every four weeks or 200 operating hours.
3.2 Service Adjustments Service overview Figure 3-3 shows the location of the service components accessed for the following procedures. • • • • output pressure adjustment dual-temperature switch adjustments low-level switch adjustment main pump low-inlet pressure switch adjustment pressure control - pump no. 1 pressure control - pump no. 2 low-level switch dual-temperature switch adjustment back-up relief valve low-inlet presssure switch VW-G043G Figure 3-3.
3.2.1 Output Pressure Adjustment Refer to Figure 3-2 for the location of the components indicated in the following procedure. 1. Turn off the HPU. 2. Make sure that the output pressure gage reads zero (Figure 3-2 shows the location of the pressure gage). 3. Remove the plastic cap on both pump pressure controls. Loosen the locknuts and turn both pressure controls fully counterclockwise. 4. Loosen the locknut on the back-up relief valve and turn the adjustment knob fully counterclockwise.
11. Press Pump 2 Select on the HPU Control Panel. 12. Press Start to run the HPU at low pressure, then press High Pressure. 13. Turn the pressure control on pump 2 clockwise until output pressure on the pressure gage reads approximately 100 psi (0.5 MPa) lower than the pressure control 1 setting. NOTE After you have finished A differential pressure between the pressure setting of pump 1 and pump 2 prevents crosstalk between the two hydraulic circuits Replace the plastic caps removed in step 3.
3.2.2 Dual-Temperature Switch Adjustments The dual-temperature switch has two adjustment screws behind its front protective cover. The Over Temperature adjustment turns off the HPU if hydraulic fluid reaches a temperature of 140˚F (60˚C). Definition The Water Solenoid Control adjustment allows water flow to the heat exchanger when an oil temperature of 105°F (40°C) is exceeded. The water solenoid control is only used if the optional water solenoid valve is required.
1. Start this procedure when the temperature gage shows that the hydraulic fluid is below 90°F (32°C). Water control adjustment 2. Start the HPU. 3. Make sure the square shaft on top of the water regulating valve is turned fully counterclockwise to shut off water flow. 4. Monitor the temperature gage as the hydraulic fluid heats up. 5. When the fluid temperature reaches approximately 120°F (49°C), turn the adjustment screw clockwise until water starts to flow.
3.2.4 Main Pump Low-Inlet Pressure Switch Adjustment The main pump low-inlet-pressure switch shown in the figure below monitors the pressure level supplied by the supercharge pump at the input to the main pumps. The switch protects the main pumps by turning off the HPU if the supercharge pump pressure drops below the minimum level required by the main pumps. Pressure Switch – Cover Off adjustment knob VW-G052 The switch is set at the factory to activate at 30 psi (0.21 MPa).
3.3 Starter Assembly The starter assembly is located behind the starter box door. Figure 3-4 shows the location of the starter assembly components. ! WARNING High voltage is present in the starter assembly. Do not open the starter box door when power is applied to the HPU. Touching components with high voltage can cause death. Remove electrical power at the power disconnect switch before you open the front starter box door. Control Relays Transformer PLC Fuses Motor Relays Figure 3-4 Models 506.82/.
3.3.1 Abnormal HPU Shutdown Motor overload Sudden shutdown of the HPU may be due to circuit protection elements in the pump motor starter assembly. If the supercharge motor overloads, the relay opens and de-energizes the motor starter coils to shut down the HPU. If either pump 1 or pump 2 motor overloads, the associated pump shuts down. Reset procedure If a motor overloads, follow this procedure to reset it. 1. Turn off ac power at the HPU disconnect switch.
3.3.3 PLC Service The programmable logic controller (PLC) in the 506.82/.92 HPU starter assembly has a fixed controller with both output and input indicators. These indicators are described in Tables 3-3 and 3-4. Optional modules with additional output indicators can be added for remote control of your HPU. These additional output indicators are described in Table 3-5.
Table 3-3. Fixed Controller Output Indicators Output Indicator Ch0 Description 0 Turns on to energize pump motor 1 start control relay CR1. 1 Turns on to energize pump motor 1 run control relay CR2. 2 Turns on to energize pump motor 2 start control relay CR3. 3 Turns on to energize pump motor 2 run control relay CR4. 4 Turns on to energize pump motor 1 high- pressure solenoid SOL1. 5 Turns on to energize pump motor 2 high- pressure solenoid SOL2.
Table 3-4 Fixed Controller Input Indicators (Continued) Input Indicator Ch0 Description 11 Spare 12 Turns off if motor overload relay contact OL1, OL3, or OL5 opens indicating that the respective pump motor 1, pump motor 2, or the supercharge pump has tripped its respective overload. This event indicates excessive current draws. 13 Turns on if motor relay M5 closes to show the supercharge pump is running. 14 Turns on if motor relay M2 closes to indicate pump motor 1 is running.
Section 4 Installation Introduction This section provides the following installation information for the Model 506.82/.92 Hydraulic Power Unit (HPU). • • • Before you complete connections hydraulic connections electrical connections water connections Perform these steps before you make any connections to the HPU. 1. Remove the shipping plate located under the hydraulic fluid filler cap. 2.
4.1 Hydraulic Connections The pressure, return and drain connections are located on the HPU manifold shown in Figure 4-2. Refer to the system hydraulic distribution drawing in the system Reference Manual for hydraulic connections that are specific to your system. Hydraulic hose connections from the HPU are made to the ports labeled P (pressure) and R (return) on the HPU manifold.
4.2 Electrical Connections The HPU is operated from a three-phase electrical power source. Operating voltage is labeled on the starter assembly and pump motor. Electrical connections must be made by qualified personnel and conform to local codes and regulations. Before you begin Install a fused power disconnect switch (customer supplied) following local codes. This switch removes electrical power to the HPU.
4.2.1 Transformer Wiring One of two types of transformers is installed in the starter assembly. Check the wiring configuration of the transformer before applying ac power to the HPU. Standard transformer wiring Figure 4-4 shows the jumper wiring required on a standard transformer for source voltages of 460. 460 Vac H1 H3 H2 H4 X2 X1 VW-C036 Figure 4-4. Standard Transformer Wiring Configuration An optional multi-tap transformer may be used for source voltages other than 230 Vac and 460 Vac.
4.2.2 Electrical connection procedure Polarity check Input Power See Figure 4-3 and perform the following procedure to make the electrical connections. 1. Connect a solid earth ground from the power disconnect switch to the starter assembly. 2. Connect the three input leads from the disconnect switch to the three terminals located on the starter assembly. Perform this procedure to ensure that electrical power is properly connected to the HPU: 1. Apply ac power to the HPU.
4.3 Cooling Water Connections Specifications The differential pressure required between the water inlet and outlet connections is 30 to 45 psid (0.2 to 0.3 MPa). The maximum allowable water pressure is 120 psi (0.83 MPa). The water supply must be capable of providing water flow at a rate indicated in Table 1-1. See Table 1-2 for the maximum cooling water heat load. Water connections To connect the water supply and drain to the heat exchanger water connections , use a 1.5 in.
Section 5 Theory of Operation This section describes the hydraulic and electrical operation of Model 506.82/.92 Hydraulic Power Unit (HPU). 5.1 Hydraulic Operation The figure below is a block diagram of the HPU hydraulic operation.
Main and supercharge pumps The HPU uses two variable-volume pressure compensated main pumps, with a pressurized (supercharged) hydraulic fluid inlet to provide fluid flow. The supercharge pump draws hydraulic fluid from the reservoir and forces it through a heat exchanger and a low-pressure filter. Fluid not required by the main pumps returns to the reservoir through check valves in the low-pressure filter manifold. The supercharge pump is mounted vertically inside the reservoir.
Pressure accumulation The pump-outlet pressure accumulator smoothes the HPU output and provides additional hydraulic pressure for high instantaneous flow demands. It is precharged with dry nitrogen to a pressure proportional to HPU output pressure. The optional slow turn-on accumulator slows the rate at which the backup relief valve shifts from low to high pressure. The precharge must be adjusted proportionally to the HPU output pressure.
5.2.1 Control When the disconnect switch is closed, the HPU control panel Power On indicator lights to show that electrical power to the HPU is on. Inlet pressure Pressing Start with Pump 1 Select , Pump 2 Select , or both pumps selected energizes relay CR5 at PLC output 15 to start the supercharge motor. Contacts M5 provide the supercharge motor status to PLC input 13. The supercharge motor provides inlet pressure for pumps 1 and 2.
When the stop switch at PLC input 3 is pressed, the two pump motors are shut down after a one second delay. The supercharge pump motor, however, continues to run for approximately five seconds. Stop control Pressing Emergency Stop turns off the HPU by de-energizing relay CRM. CRM contacts open to cut off power to the motor starters. The supercharge pump may continue to run briefly while the main pumps wind down. 5.2.
Motor overload Thermal overload sensors detect excessive current and open the normally closed contacts connected to the motor starter coil. Motor overload relay contacts OL1, OL3, or OL5, all at PLC input 12, open to turn off the HPU if the respective pump motor 1, pump motor 2, or supercharge pump motor is drawing excessive current. The LED lights from PLC output 10 When an overload condition occurs, the reset button on the motor overload relay must be pressed (see Subsection 3.3.1).
Figure 5-2.
Figure 5-2.
Figure 5-2.
Figure 5-2.
Index abnormal shutdown 3-16 accumulators functional description 1-2 location 3-7 maintenance 3-7 seals 3-8 theory of operation 5-3 adjustments location of components 3-7 low fluid level 3-12 low-inlet pressure 3-14 output pressure 3-10 temperature 3-12 water control 3-13 component location front panel controls 2-1 maintenance 3-1 service 3-9 connections electrical 4-3 hydraulic 4-2 specifications 1-3 water 4-6 controls 1-1, 2-1, 2-2 electrical connection procedure 4-5 connections 4-3 fuses 3-15 installatio
schematic electrical 5-6 hydraulic 5-1 service adjustments location of components 3-9 low-inlet pressure 3-14 output pressure 3-10 water control 3-13 local mode switch 2-1, 2-2 specifications 1-3 starter assembly fuses 3-16 installation 4-3 location of components 3-15 motor overload 3-16 programmable logic controller 3-17 specifications 1-2 stop switch 2-1, 2-2 supercharge pump operation procedure 2-4 specifications 1-3 theory of operation 5-2 temperature adjustment 3-12 control 1-2, 2-1, 2-2 fluid cooling
