Model 512.
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Contents Contents 3 Introduction 5 Functional Description 6 Component Identification 8 Specifications 10 Dimensions 11 Installation Operation 13 17 Maintenance 21 Reducing the Fluid Temperature 22 Adjusting the Air Flow 23 Adjusting the Water Flow 24 Adding Hydraulic Fluid 25 Resetting the Thermal Overloads 26 Changing the Output Pressure 27 Lubricating the Motor 29 Changing the Filter 30 Changing the Hydraulic Fluid Model 512.
Contents Model 512.
Introduction Contents Functional Description 6 Component Identification Specifications 8 10 This manual documents the Model 512.04 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. The HPU is available with a water–cooled or an air–cooled heat exchanger. Water Cooled Air Cooled 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 discussed in this section. Pump Pressure Filtering A motor drives a hydraulic pump which draws hydraulic fluid from a reservoir and pressurizes it to 13.8 MPa (2000 psi).
Electronics The HPU has basic controls to turn it on to low pressure or high pressure and to turn it off. The HPU includes an Emergency Stop switch that is connected to the interlock chain of your test system.
Component Identification This table describes the components shown in the figure on page 9. Component Descriptions COMPONENT DESCRIPTION Control Box Houses the electronic controls of the pump, including the Stop button, Low/High switch, and Reset button. It also houses the thermal overloads to protect the pump motor. See “Resetting the Thermal Overloads” on page 26. Pressure Gage Shows the current output pressure from the hydraulic power unit. The output pressure is factory set to 13.8 MPa (2000 psi).
Pump Motor Control Box Water-Cooled Filter Change Gage Filter Pressure Gage Sight Glass Heat Exchanger Reservoir Pump Motor Filter Change Gage Air-Cooled Filter Control Box Pressure Gage Heat Exchanger Sight Glass Reservoir Major Components Model 512.
Specifications Model 512.04 Specifications PARAMETER SPECIFICATION Environmental Operating temperature (ambient air) 18–49°C (65–104°F) Heat load* 1061 kcal/hr (4200 BTU/hr) Noise rating† at 1 m 74 db (A) Flow capacity at 13.8 MPa (2000 psi) 12.5 lpm (3.3 gpm) @ 50 Hz 15.1 lpm (4 gpm) @ 60 Hz Motor rating 3.7 kW (5.0 hp) Operating voltage 208 V (ac) @ 16.7 A, 3 phase 230 V (ac) @ 15.2 A, 3 phase 460 V (ac) @ 7.
Dimensions The following figure shows those dimensions which are useful when installing the hydraulic power unit. Air Cooled Water Cooled 355 mm (14 in) 457 mm (18 in) 584 mm (23 in) 787 mm (31 in) 889 mm (35 in) Model 512.
Introduction Model 512.
Installation Perform the following to install the Model 512.04 Hydraulic Power Unit. 1. Position the hydraulic power unit. You should determine where to put the hydraulic power unit. Since it is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located remotely. • The air cooled HPU must be located where adequate air movement for cooling can occur. • The water cooled HPU requires a source of water.
2. Connect the hydraulic lines. See “Connection Locations” on page 13 to determine the locations of the hydraulic connections to the HPU. See the following table to identify the size of each hydraulic connection. Hydraulic Connectors 3. CONNECTOR SIZE Pressure, 37º flare -8 Return, 37º flare -8 Drain, 37º flare -6 Connect the water lines to the heat exchanger. NOTE This only applies to the water-cooled version of the HPU.
Three Phase L1 L2 L3 Remove Jumper if Remote Emergency Stop Switch Connected H4 H1 1 FU 1 3 X2 X1 1A 115 V (ac) 8 Varistor 9 Remote Emergency Stop Switch CPC-14S Varistor Stop Switch Start Switch Low High Pressure Pressure 1M SOV FS SS1 TAS M–1 T-1 Below 77° C (170° F) OL Low Fluid Switch (opens at 70% full) Fan and Motor (air-cooled only) Electrical Schematic Model 512.
Installation Model 512.
Operation The following procedure is a guideline, and it assumes you are starting the hydraulic power unit (HPU) after the 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.
3. At your test controller, make sure hydraulic pressure is turned off. NOTE 4. Some controllers can remotely control the HPU. The Model 512.04 Hydraulic Power Unit does not support this feature. Turn the start switch to START/LOW PRESS. and wait for the motor to get up to speed. Turn this switch to HIGH PRESS. START LOW PRESS. 5. HIGH PRESS. START LOW PRESS. HIGH PRESS. Check to make sure the filter change gage’s needle stays in the green zone.
7. Run the HPU for 20–30 minutes to get the hydraulic fluid up to operating temperature of 64–68°C (147–155°F). Once the hydraulic fluid is up to the operating temperature, you can use the hydraulic system. 8. To turn the HPU off, switch to low pressure then press the STOP switch. STOP In the event of an emergency, press the STOP switch or the optional Emergency Stop switch. 9. If your HPS is water cooled, make sure its heat exchanger’s water valves are closed. Model 512.
Operation Model 512.
Maintenance Contents Reducing the Fluid Temperature Adjusting the Air Flow 22 23 Adjusting the Water Flow 24 Resetting the Thermal Overloads Changing the Output Pressure Lubricating the Motor Changing the Filter 26 27 29 30 Changing the Hydraulic Fluid 31 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.
Reducing the Fluid Temperature The hydraulic power unit (HPU) will be shut down if the hydraulic fluid reaches a temperature of 77°C (170° F). 77ºC (170ºF) NOTE The thermometer is for reference only. Use a calibrated thermometer submersed in the reservoir for an accurate reading. To reduce the fluid temperature, you need to make adjustments to the heat exchanger. 22 Maintenance • If you have the air-cooled version go to “Adjusting the Air Flow” on page 23.
Adjusting the Air Flow Air-cooled heat exchangers use louvers to control airflow through the exchanger. You may have to adjust them to keep the fluid’s temperature between 64 and 68ºC (147 and 155ºF). Adjust Adjust the Louvers Make sure the louvers are fully open. 1. START LOW PRESS. Turn the start switch to START/LOW PRESS. Hold it there (this overrides the shutdown). If overtemperature fluid caused the shutdown, the HPU will now start to run. HIGH PRESS.
Adjusting the Water Flow On water-cooled heat exchangers, the water control valve regulates the flow of water through the exchanger. MTS sets this valve to keep the hydraulic fluid temperature between 64 and 68ºC (147 and 155ºF). If you have a water-cooled HPU, make sure both water supply valves are open. An out of adjustment water control valve can cause rapid overheating.
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’re not sure what brand of hydraulic fluid your system uses. NOTE New fluid should be prefiltered since it may not be clean. 2.
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.
Changing the Output Pressure The hydraulic power unit (HPU) comes with its output pressure set at 13.8 MPa (2000 psi). Special testing needs may require you to lower this pressure. Output Pressure Adjustment CAUTION Do not set the output pressure higher than 13.8 MPa (2000 psi). Setting the output pressure above 13.8 MPa (2,000 psi) can damage the pump and its motor. Set the output pressure no higher than 13.8 MPa (2000 psi). Model 512.
1. Set the HPU’s output to HIGH PRESS. Put the HPU into a no-flow condition (where no fluid is flowing to other hydraulic equipment). 2. Wait for the fluid to reach the operating temperature of 64 and 68ºC (147 and 155ºF). Pressure Gage Locknut Setscrew 28 Maintenance 3. Hold the setscrew with a 5/32–inch hex key. Loosen the locknut with a 9/16–inch wrench. 4. Turn the setscrew while watching the gage until you get the output pressure you want. 5. Hold the setscrew and tighten down the locknut.
Lubricating the Motor This pump’s motor bearing of the hydraulic power supply (HPU) needs lubrication every six months. Use Shell Dolium R. Chevron SRI No. 2, or Texaco Premium RB grease. Grease Fittings CAUTION 1. Turn off the HPU. 2. Wipe off both grease fittings. Do not overgrease the motor. Too much grease could short out the motor. 3. Using a grease gun, apply grease to each fitting. Model 512.
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 2500 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 (indicates severe overheating). • Particles appear in the sight glass (indicates the suction filter may need cleaning).
Filler Cap Hydraulic Fluid Hoses (to the heat exchanger) Reservoir Cover Screws Stop Switch Pump Filter Drain Component Locations WARNING Synasol is toxic and flammable. Use the Synasol solvent in a ventilated area and keep it away from an open flame. Follow the cautions and warnings on its container. 32 Maintenance Model 512.
3. Clean the reservoir. A. Disconnect the heat exchanger’s two hydraulic fluid lines. B. Unscrew the cover screws attaching the cover plate to the reservoir. C. Attach straps to the cover plate’s two lifting eyes. Lift the cover plate clear of the reservoir. D. Clean the inside of the reservoir using clean cloths dampened with Synasol. Clean the pump and bottom of the cover plate as well. E. Inspect the pump’s suction strainer. Replace this strainer if it is plugged or damaged. F.
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