Model 512.
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Contents Introduction 5 Component Identification Functional Description Specifications Dimensions 6 8 10 11 Installation 13 Operation 17 Running the HPU 18 Recovering From an Interlock Condition Reducing the Fluid Temperature Adjusting the Air Flow 20 21 22 Adjusting the Water Flow 23 Resetting the Thermal Overloads Adjusting the Output Pressure 24 25 Maintenance 27 Checking the Hydraulic Fluid Replacing the Filter 29 31 Sampling the Hydraulic Fluid Adding Hydraulic Fluid 35 Replacing th
Contents 512.
Introduction The Model 512.14 Hydraulic Power Unit (HPU) provides high-pressure hydraulic fluid for test system operation. 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. This section contains the functional description and specifications of the HPU (also called a hydraulic power supply, or pump).
Component Identification Component Identification Water-Cooled Pump Motor Control Box Filter Change Gage Filter Pressure Gage Sight Glass Reservoir Heat Exchanger Air-Cooled Control Box Pump Motor Pressure Gage Heat Exchanger (Detached) Sight Glass Reservoir Major Components (Side View) 6 Introduction 512.
Component Identification Component Descriptions Component Description Control Box Houses the electronic controls of the pump, including the Stop button, and Low/High switch. It also houses the thermal overloads to protect the pump motor. See “Resetting the Thermal Overloads” on page 24. Pressure Gage Shows the current output pressure from the hydraulic power unit. The output pressure is factory set to 21MPa (3000 psi). See “Adjusting the Output Pressure” on page 25 to change the output pressure.
Functional Description 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 6 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 21 MPa (3000 psi).
Functional Description 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.
Specifications Specifications Parameter Specification Environmental Operating temperature (ambient air) 18–40°C (65–104°F) Heat load* 1061 kcal/hr (4200 BTU/hr) Noise rating† at 1 m 74 dB (A) Flow capacity 12.5 lpm (3.3 gpm) @ 50 Hz 15.1 lpm (4 gpm) @ 60 Hz Motor rating 5.6 kW (7.5 hp) Operating voltage 208 V (AC) @ 24.2 A, 3 phase 230 V (AC) @ 22.0 A, 3 phase 460 V (AC) @ 11.
Dimensions Dimensions The following figure shows those dimensions which are useful when installing the hydraulic power unit. Air Cooled Water Cooled 610 mm (24 in) 671 mm (26.4 in) 610 mm (24 in) 864 mm (34 in) 335 mm (13.2 in) 559 mm (22 in) 406 mm (16 in) 508 mm (20 in) 512.
Dimensions 12 Introduction 512.
Installation This section describes how to install a Model 512.14 Hydraulic Power Unit. Note The HPU is designed for indoor use. The HPU should be stored and installed indoors. 1. Position the hydraulic power unit. Determine where to put the HPU. Since it is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located remotely. Considerations include: Emergency Stop Connection • The air cooled HPU must be located where adequate air movement for cooling can occur.
2. Connect the hydraulic lines. See “Connection Locations (Top View)” on page 13 to determine the locations of the hydraulic connections to the HPU. The following table lists the size of each hydraulic connection. Connector Size Pressure, 37º flare -8 Return, 37º flare -8 Drain, 37º flare -6 3. Connect the water lines to the heat exchanger. Note This applies only 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 X1 1A X2 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 M1 TAS T-1 Below 77° C (170° F) OL Low Fluid Switch (opens at 70% full) Fan and Motor (air-cooled only) Electrical Schematic 512.
Installation 512.
Operation This section describes the front panel controls and indicators, and provides operating instructions for the Series 505 Hydraulic Power Unit (HPU). Contents Running the HPU 18 Recovering From an Interlock Condition Reducing the Fluid Temperature Adjusting the Air Flow 21 22 Adjusting the Water Flow 23 Resetting the Thermal Overloads Adjusting the Output Pressure 512.
Running the HPU Running the HPU 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.
Running the HPU 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. Turn the HPU off when the filter gage reaches the red zone and change the filter. Red Zone (do not operate) Yellow Zone (warning to change) Green Zone (normal) Check the Filter Change Gage 5. Check the output pressure gage for the correct output pressure.
Recovering From an Interlock Condition Recovering From an Interlock Condition Abnormal shutdowns Any one of the following conditions can cause your HPU to suddenly shut down. You will not be able to restart your HPU until you correct the condition. Interlock Conditions Problem The hydraulic fluid exceeds 75ºC (160ºF). 20 Solution See “Reducing the Fluid Temperature” on page 21. The hydraulic fluid cannot be seen in the sight glass (or it is at a low level). page 35.
Reducing the Fluid Temperature 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. 512.14 Hydraulic Power Unit • If you have the air-cooled version go to “Adjusting the Air Flow” on page 22.
Reducing the Fluid Temperature 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. Turn the start switch to LOW PRESS and hold it there to override the shutdown. If overheated fluid caused the shutdown, the HPU will now start to run.
Reducing the Fluid Temperature 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). An out-of-adjustment water control valve can cause rapid overheating. Water Valve Check the Heat Exchanger Changes in your water supply’s temperature may require adjustment of this valve. 1. Start with the hydraulic fluid at room temperature.
Resetting the Thermal Overloads 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. CAUTION 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 Adjusting the Output Pressure The HPU comes with its output pressure set at 21 MPa (3000 psi). Special testing needs may require you to lower this pressure. Output Pressure Adjustment CAUTION Do not set the output pressure higher than 21 MPa (3000 psi). Setting the output pressure above 21 MPa (3,000 psi) can damage the pump and its motor. Set the output pressure no higher than 21 MPa (3000 psi). Procedure To adjust the output pressure: 1.
Adjusting the Output Pressure Pressure Gage Locknut Setscrew 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. 26 Operation 512.
Maintenance This section describes preventive maintenance requirements and their recommended intervals for the Product Name. Contents Checking the Hydraulic Fluid Replacing the Filter 31 Sampling the Hydraulic Fluid Adding Hydraulic Fluid Lubricating the Motor 32 35 Replacing the Hydraulic Fluid Scheduling maintenance 29 36 39 The following table lists the recommended interval for each maintenance procedure.
Maintenance Schedule (part 2 of 2) What to Do When to Do It How to Do It Verify functionality of HPU interlocks† Every 1000 hours or 6 months Contact MTS Systems Corporation. Lubricate pump motor Every 1000 hours or 6 months Perform “Lubricating the Motor” on page 39. Check motor overload functionality† Every 1000 hours or 6 months Contact MTS Systems Corporation. Verify proper operation of hydraulic valves† Every 1000 hours or 6 months Contact MTS Systems Corporation.
Checking the Hydraulic Fluid Checking the Hydraulic Fluid Hydraulic fluid contamination and deterioration normally occur in most hydraulic systems. Failure to keep your fluid sufficiently free of contaminants or to change the fluid before severe fluid breakdown occurs will cause poor system performance and may lead to expensive system cleanups. Servovalves are especially susceptible to damage from dirty hydraulic fluid. To avoid these problems, you must maintain a clean hydraulic system.
Checking the Hydraulic Fluid 5. Check and adjust the hydraulic fluid delivery system so that: • Hydraulic fluid temperature stabilizes within the parameters given in “Specifications” on page 10 when the HPU is operating at high pressure. If you need to adjust the water-regulating valve, refer to “Adjusting the Water Flow” on page 23. • Pressure line reading is maintained at 21 MPa (3000 psi) maximum static value.
Replacing the Filter Replacing the Filter The filter element of the HPU should be replaced for the following reasons: Prerequisite Procedure • When the filter change gage’s needle stays in the yellow or red zone with the hydraulic fluid at operating temperature • Whenever the hydraulic fluid is changed • The filter manufacturer’s recommended maximum interval has passed (1000 hours or 6 months) You will need an oil filter wrench and a 3–micron oil filter (MTS part number 119515-21).
Sampling the Hydraulic Fluid Sampling the Hydraulic Fluid This section describes how to check the quality of the hydraulic fluid. Review the following hints before obtaining your sample: • Prerequisite Avoid contamination. – Keep the sample bottle in the storage box of the hydraulic fluid sampling kit until it is needed. – Do not remove the cap from the bottle until immediately before taking the sample. – Do not set the cap down on a dirty surface or in an area where airborne dust can settle.
Sampling the Hydraulic Fluid 4. Obtain a sample of the hydraulic fluid after flushing the valve hose assembly. A. Without closing the valve, quickly place the sample bottle into the fluid stream (keep the sample bottle sealed until the sample is to be taken). B. Fill the sample bottle (175 mL/6 oz) with fluid. C. Close the valve on the hose valve assembly and cap the sample bottle. 5. Check the fluid qualities of the sample by comparing it to a small jar of clean hydraulic fluid.
Sampling the Hydraulic Fluid Appearance of Hydraulic Fluid Sample (part 2 of 2) Fluid Properties Milky appearance Problem Indicates water is present in the fluid What to Do Check the heat exchanger for damage. Look for other water sources if the water does not appear to be coming from the heat exchanger. Identify and correct the source of the water leakage and replace the fluid if necessary.
Adding Hydraulic Fluid 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.
Replacing the Hydraulic Fluid Replacing the Hydraulic Fluid Replace the hydraulic fluid in the HPU reservoir whenever you have determined that the hydraulic fluid is no longer suitable for use. Recommended equipment: Prerequisite • A transfer pump with a 10 micron filter (such as the Model 590.
Replacing the Hydraulic Fluid 2. Remove the hydraulic fluid. A. Remove the transfer pump’s filter (you do not need to filter the dirty hydraulic fluid when removing it). B. Use the transfer pump to remove the old hydraulic fluid from the reservoir. C. Remove the drain plug to drain any remaining fluid. D. Drain the hydraulic fluid from hoses and accumulators in the system.
Replacing the Hydraulic Fluid CAUTION 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. 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.
Lubricating the Motor Lubricating the Motor The pump’s motor bearing needs lubrication every six months. Grease Fittings 1. Turn off the HPU. 2. Wipe off both grease fittings. 3. Using a grease gun, apply grease to each fitting. MTS recommends Shell Dolium R. Chevron SRI No. 2, or Texaco Premium RB grease. CAUTION Do not overgrease the motor. Too much grease could short out the motor. 512.
Lubricating the Motor 40 Maintenance 512.
m 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. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.
