Model 512.
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. Synasol is a registered trademark of Union Carbide 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.
Contents Introduction 5 Functional Description 6 Component Identification 8 Specifications 10 Dimensions 11 Installation Operation 13 17 Maintenance 19 Reducing the Fluid Temperature 20 Adding Hydraulic Fluid 21 Resetting the Thermal Overloads 22 Adjusting the Output Pressure 23 Changing the Filter 24 Changing the Hydraulic Fluid 25 Model 512.
Contents Model 512.
Introduction Contents Functional Description 6 Component Identification Specifications 8 10 This manual documents the Model 512.01 Hydraulic Power Unit (HPU), also called a hydraulic power supply, HPS, or pump. This compact hydraulic power unit is designed for use with low force testing systems. It includes an air cooled heat exchanger to maintain the operating temperature range. l Model 512.
Functional Description The hydraulic power unit (HPU) is the mechanical source of high-pressure hydraulic fluid required to operate the hydraulic components of a test system. See “Component Identification” on page 8 for more information about the components described in this section. Pump motor A motor drives a hydraulic pump which draws hydraulic fluid from a reservoir and pressurizes it to 6.9 MPa (1000 psi). The pressurized fluid is made available to the hydraulic components in your test system.
Hydraulic schematic Pressure Gage The hydraulic schematic shows how the hydraulic components are connected in the Model 512.01 Hydraulic Power Unit. Pressure -6 37° JIC Flare Pressure Reducing Valve Drain -06 37° JIC Flare Return -6 37° JIC Flare Set at 7 MPa (1000 psi) Set at 7.
Component Identification This table describes the components shown in the figure called “Component Identification” on page 9. Component Descriptions COMPONENT DESCRIPTION Filter Provides 3–micron filtration to fluid returning to the reservoir (see “Changing the Filter” on page 24). Low Fluid and Overtemperature Sensor Shuts the pump off if fluid becomes hotter than 55ºC (130ºF) or it detects a low fluid level.
Filter Low Fluid/Over Temp. Sensor Pump Motor Jumper Plug Fluid Thermometer Heat Exchanger Control Box Filter Change Gage Start Pressure Gage Stop Reset Reservoir l Sight Glass Component Identification Model 512.
Specifications Model 512.01 Specifications PARAMETER SPECIFICATION Environmental Operating temperature 18–35°C (65–95°F) Heat load* 480 kcal/hr (1900 BTU/hr) Noise rating† at 1 m 70 db (A) Flow capacity at 6.9 MPa (1000 psi) 3.8 l/m (1.0 gpm) @ 60 Hz Motor rating 0.56 kW (0.75 hp) Operating voltage 115 V (ac) @ 13.
Dimensions The following figure shows those dimensions which are useful when installing the HPU. 563 mm (22 in) 254 mm (10 in) 480 mm (19 in) l 406 mm (16 in) 584 mm (23 in) Model 512.
Introduction Model 512.
Installation This section describes how to install the Model 512.01 Hydraulic Power Unit (HPU). The following figure show the components referenced in the installation procedure. Lift Ring Dirty Filter Gage Heat Exchanger Pump Drain Line Connection Power Cord Breather Thermometer Output Pressure Gage Start Return Line Connection Stop Reset Pressure Line Connection E-Stop Connector l Lift Ring Sight Gage Component Identification Model 512.
1. Position the hydraulic power unit. You should determine where to put the hydraulic power unit (HPU). Since it is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located remotely. 2. • Use the lifting rings (with a crane or fork lift) to move the HPU unit into place. • The HPU must be located where adequate air movement is available. A clearance of 50 mm (2 ft) is required between the heat exchanger and a wall.
4. Test the HPU. A. Remove the 1/2” NPT pipe plug and install the breather in the reservoir cover. B. Make sure all the pressure, return, and drain port caps are in place. C. Press the Start button (be sure the Stop button is released). D. Check that the output pressure is less than 6.9 MPa (1000 psi). E. 5. Press the Stop button. Connect the hydraulic lines. See “Component Identification” on page 13 to determine the locations of the hydraulic connections to the HPU.
Installation Model 512.
Operation The following procedure is a guideline, and it assumes you are starting the hydraulic power unit (HPU) after it has been turned off for some time (the hydraulic fluid is considered cool). You may want to incorporate portions of this procedure into your system startup sequence. 1. Check the fluid level in the sight gage. The hydraulic fluid should be close to the top of the sight glass. If you need to add fluid, add 1 liter (1 quart) at a time.
5. Check to make sure the filter change gage’s needle stays in the green zone. NOTE Cold fluid may push it temporarily into the yellow or red zone. If the needle stays in the yellow or red zone, turn the HPU off and change its filter (see “Changing the Filter” on page 24). CAUTION Do not run the HPU if the filter gage is in the red region. When the gage needle stays in the red zone, some hydraulic fluid is bypassing the filter. This unfiltered fluid can wear or damage hydraulic components.
Maintenance Contents Reducing the Fluid Temperature 20 Resetting the Thermal Overloads Adjusting the Output Pressure Changing the Filter 22 23 24 Changing the Hydraulic Fluid 25 Maintenance Intervals WHAT TO DO WHEN TO DO IT Recover from an abnormal shutdown as needed–when the HPU suddenly stops running Lower the output pressure as required by your test needs Lubricate the pump motor every six months Change the filter when the filter gage needle stays in the yellow or red zone; whenever you
Reducing the Fluid Temperature The hydraulic power unit (HPU) will be shut down if the hydraulic fluid reaches a temperature of 55°C (130° F). 1. Check the thermometer. The HPU shuts down when fluid gets hotter than about 55ºC (130ºF). 2. Press the Start button. Hold it down to override the overtemperature sensor. • If overtemperature fluid caused the shutdown, the HPU will now start to run. • Keep holding the Start button until the HPU stays running when you let go of this button.
Adding Hydraulic Fluid 1. The hydraulic power unit (HPU) will shut down when fluid drops below the sight glass. Normally, it should be close to the top of the sight glass. Normal Level No Fluid Visible Check the Fluid Level CAUTION Do not mix different brands of hydraulic fluid. Mixing different brands of hydraulic fluid can contaminate your system. Call MTS if you are not sure what brand of hydraulic fluid your system uses. 2. Open the filler cap.
Resetting the Thermal Overloads The thermal overloads of the hydraulic power unit (HPU) can be tripped by the following conditions: • Poor motor ventilation • The output pressure is set too high • A pump or motor is seizing The thermal overloads are located in the control box. WARNING Do not open the control box unless the line voltage is turned off. When power is present in the control box, high voltage and amperages are also present.
Adjusting the Output Pressure The hydraulic power unit (HPU) comes with its output pressure set at 6.9 MPa (1000 psi) and a pressure relief setting of 7.9 MPa (1150 psi). Special testing needs may require you to lower this pressure. Pressure Relief Valve Factory Set to 7.9 MPa (1150 psi) Output Pressure Adjustment Factory Set to 6.9 MPa (1000 psi) Pressure Adjustment Locations CAUTION Do not set the output pressure higher than 6.9 MPa (1000 psi). Setting the output pressure above 6.
Changing the Filter Change the filter whenever the filter change gage’s needle stays in the yellow or red zone with the hydraulic fluid at operating temperature. Also, change the filter whenever you change the hydraulic fluid. Special equipment needed– • Oil filter wrench • 3–micron oil filter (part number 119515-21) 1. Press STOP to turn the hydraulic power unit (HPU) off. 2. Use an oil filter wrench to loosen the old filter. Screw the filter counterclockwise to remove it. Change Filter CCW 3.
Changing the Hydraulic Fluid As part of your regular HPU maintenance, change the hydraulic fluid every 2,500 hours of operation or if fluid analysis indicates the fluid should be changed. However, you must change it immediately if any of the following is true: • The fluid becomes very dark and has a strong burnt sugar smell (severe overheating). • Particles appear in the sight glass (indicate a collapsed pickup strainer). • Fluid becomes milky (water in the fluid–a possible leaking heat exchanger).
Lift the cover with these lift rings) Filler Cap Reservoir Cover Screws Pump Filter l Suction Strainer Drain Component Locations WARNING Synasol is toxic and flammable. Use the Synasol solvent in a ventalated area and keep it away from an open flame. Follow the cautions and warnings on its container. 26 Maintenance Model 512.
3. Clean the reservoir. A. Unscrew the cover screws attaching the cover plate to the reservoir. B. Attach scraps to the cover plate’s two lifting eyes. Lift the cover plate clear of the reservoir. C. Clean the inside of the reservoir using clean cloths dampened with Synasol. Clean the pump and bottom of the cover plate as well. D. Inspect the pump’s suction strainer. Replace this strainer if it is plugged or damaged. E. Lower the cover plate back down onto the reservoir. F.
