m be certain. Series 505 SilentFlo™ Hydraulic Power Unit Product Information Model 505.60 Model 505.90 Model 505.120 Model 505.150 Model 505.
Copyright information Trademark information © 1999–2010 MTS Systems Corporation. All rights reserved. MTS and SilentFlo are registered trademarks of MTS Systems Corporation within the United States. These trademarks may be protected in other countries. DTE is a registered trademark of Exxon Mobil Corporation. Tellus is a registered trademark of Shell Oil Corporation. Synasol is a registered trademark of Union Carbide Corporation. Molykote is a registered trademark of Dow Chemical Corporation.
Contents Technical Support 7 How to Get Technical Support Before You Contact MTS 7 7 If You Contact MTS by Phone 9 Problem Submittal Form in MTS Manuals 10 Preface 11 Before You Begin Conventions 11 12 Documentation Conventions 12 Introduction 15 EU Declarations 15 Model 505.60 HPU Component Identification HPU Functional Description 16 18 Options Available for the HPU 18 Model 505.60/.90 HPU Hydraulic Schematic 20 Model 505.120/.150/.180 HPU Hydraulic Schematic Model 505.
Installation 47 Model 505.60—505.180 HPU Electrical, Hydraulic, and Water Connections Model 505.60 HPU Setup 47 52 Testing Model 505.60 HPU Operation 56 Precharging the Optional Surge Suppressor Accumulator 59 Operation 63 Model 505.60 HPU Startup Panel 64 Model 505.60 HPU Main Display 66 Model 505.60 HPU Data 68 Model 505.60 HPU Status 69 Model 505.60 HPU Setup 70 ROD Setup 72 Operating the Model 505.
160 Hours/Biweekly 500 Hours 108 109 1000 Hours 110 2000 Hours 111 5000 Hours 112 10,000 Hours 113 Model 505.60 - 505.
Contents Model 505.60 - 505.
How to Get Technical Support Technical Support How to Get Technical Support Start with your manuals The manuals supplied by MTS provide most of the information you need to use and maintain your equipment. If your equipment includes software, look for online help and README files that contain additional product information. If you cannot find answers to your technical questions from these sources, you can use the Internet, e-mail, telephone, or fax to contact MTS for assistance.
Before You Contact MTS Know information from prior technical assistance Identify the problem Know relevant computer information Know relevant software information 8 Technical Support If you have contacted MTS about this problem before, we can recall your file based on the: • MTS notification number • Name of the person who helped you Describe the problem and know the answers to the following questions: • How long and how often has the problem occurred? • Can you reproduce the problem? • Were
If You Contact MTS by Phone If You Contact MTS by Phone A Call Center agent registers your call before connecting you with a technical support specialist. The agent asks you for your: • Site number • Name • Company name • Company address • Phone number where you can be reached If your issue has a notification number, please provide that number. A new issue will be assigned a unique notification number.
Problem Submittal Form in MTS Manuals Problem Submittal Form in MTS Manuals Use the Problem Submittal Form to communicate problems with your software, hardware, manuals, or service that are not resolved to your satisfaction through the technical support process. The form includes check boxes that allow you to indicate the urgency of your problem and your expectation of an acceptable response time. We guarantee a timely response—your feedback is important to us.
Before You Begin Preface Before You Begin Safety first! Other MTS manuals Before you use your MTS product or system, read and understand the Safety manual and any other safety information provided with your system. Improper installation, operation, or maintenance can result in hazardous conditions that can cause severe personal injury or death, or damage to your equipment and specimen. Again, read and understand the safety information provided with your system before you continue.
Conventions Conventions Documentation Conventions The following paragraphs describe some of the conventions that are used in your MTS manuals. Hazard conventions Hazard notices may be embedded in this manual. These notices contain safety information that is specific to the activity to be performed. Hazard notices immediately precede the step or procedure that may lead to an associated hazard. Read all hazard notices carefully and follow all directions and recommendations.
Documentation Conventions Hypertext links The electronic document has many hypertext links displayed in a blue font. All blue words in the body text, along with all contents entries and index page numbers, are hypertext links. When you click a hypertext link, the application jumps to the corresponding topic. Model 505.60 - 505.
Documentation Conventions 14 Preface Model 505.60 - 505.
EU Declarations Introduction Contents Model 505.60 HPU Component Identification HPU Functional Description Options Available for the HPU 16 18 18 Model 505.60/.90 HPU Hydraulic Schematic 20 Model 505.120/.150/.180 HPU Hydraulic Schematic Model 505.60 HPU Electrical Control 21 22 Model 505.60/.90 Electrical Schematic 23 Model 505.120/.150/.180 Electrical Schematic 26 Model 505.60–505.180 HPU General Specifications Model 505.60 HPU Specifications 33 Model 505.
Model 505.60 HPU Component Identification Model 505.60 HPU Component Identification Main Electrical Enclosure Heat Exchanger and Manifold Enclosure User Interface Panel Filter Assembly Emergency Stop Switch Pump Assemblies Power Disconnect Switch Level/Temperature Switch Level/Temperature Transducer Reservoir Fluid Level Gage Filler Cap Output Pressure Controls Commoning Expansion Plate Component Locations (505.90 Shown) 16 Introduction Model 505.60 - 505.
Model 505.60 HPU Component Identification Component Descriptions Component Description Commoning Expansion Plate Allows the HPU to be commoned with another HPU. Electrical Enclosure Houses the HPU’s electrical and control components. The wye-delta starters for the Model 505.60/.90 HPUs are located in the electrical enclosure. The wye-delta starters for the Model 505.120/.150/.180 HPUs are located in the pump assemblies. The main power lines enter the electrical enclosure at its top.
HPU Functional Description HPU Functional Description Pump assemblies Manifold Pump assemblies draw hydraulic fluid from the reservoir and pressurize it to a maximum preset pressure. Each pump assembly contains a variable volume pump, a motor, and an electrical enclosure. Each pump assembly has a flow capacity that contributes to the total hydraulic flow capacity of the HPU.
Options Available for the HPU The ROD option allows the HPU to turn individual pump motors on and off as your system flow demand changes. A minimum flow reserve is maintained and pump usage is equalized by sequentially turning on pumps starting with the pump with the least amount of run time, and turning the pumps off in reverse order.
Model 505.60/.90 HPU Hydraulic Schematic Model 505.60/.90 HPU Hydraulic Schematic The hydraulic schematic shows the functional layout of HPU models with two or three pump assemblies (505.60/.90). 20 Introduction Model 505.60 - 505.
Model 505.120/.150/.180 HPU Hydraulic Schematic Model 505.120/.150/.180 HPU Hydraulic Schematic The hydraulic schematic shows the functional layout of HPU models with four to six pump assemblies (505.120/.150/.180). Model 505.60 - 505.
Model 505.60 HPU Electrical Control Model 505.60 HPU Electrical Control The HPU can be controlled locally using the front panel controls, or remotely through a controller via the J1 connector. A PLC (programmable logic controller) manages the electrical systems within the HPU. The electrical system includes the following: • A user interface panel that contains a touch screen to program preferences and operational settings.
Model 505.60/.90 Electrical Schematic Model 505.60/.90 Electrical Schematic The electrical schematic shows the electrical layout of the Model 505.60/.90 HPU. Model 505.60 - 505.
Model 505.60/.90 Electrical Schematic 24 Introduction Model 505.60 - 505.
Model 505.60/.90 Electrical Schematic Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic Model 505.120/.150/.180 Electrical Schematic The electrical schematic shows the electrical layout of the Model 505.120/.150/ .180 HPU. 26 Introduction Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic 28 Introduction Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic 30 Introduction Model 505.60 - 505.
Model 505.120/.150/.180 Electrical Schematic Model 505.60 - 505.
Specifications Specifications Model 505.60–505.180 HPU General Specifications Parameter Environmental Specification For use in a controlled environment. Operating temperature 5–40°C (40–104°F) Humidity 0–85% noncondensing Hydraulic fluid Exxon Mobil DTE 25 or Shell Tellus 46 AW Typical operating temperature range 43–49°C (110–120°F) Filtration (microns) 3 microns nominal Output Pressure 21 MPa (3000 psi) Non-adjustable relief valve setting 22.
Model 505.60 HPU Specifications Model 505.60 HPU Specifications Parameter Specification Pump/Motor Wye-Delta starter configuration Number of pump/motors 2 Maximum continuous pressure 21 MPa (3000 psi) Maximum flow capacity 200 L/m (53.
Model 505.90 HPU Specifications Model 505.
Model 505.120 HPU Specifications Model 505.120 HPU Specifications Parameter Specification Pump/Motor Wye-Delta starter configuration Number of pump/motors 4 Maximum continuous pressure 21 MPa (3000 psi) Maximum flow capacity 400 L/m (106.
Model 505.150 HPU Specifications Model 505.
Model 505.180 HPU Specifications Model 505.
Model 505.180 HPU Specifications 38 Introduction Model 505.60 - 505.
General Safety Practices: Hydraulic Power Units and Safety General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds The hydraulic power unit (HPU) provides high pressure hydraulic fluid to system components for system operation. The hydraulic service manifold (HSM) controls distribution of that hydraulic fluid pressure. This section provides general information about safety issues that pertain to system hydraulic supply and distribution components.
General Safety Practices: Hydraulic Power Units and It is very important that you study the following safety information to ensure that your facility procedures and the system’s operating environment do not contribute to or result in a hazardous situation. Remember, you cannot eliminate all the hazards associated with this system, so you must learn and remain aware of the hazards that apply to your system at all times.
General Safety Practices: Hydraulic Power Units and Have first aid available Accidents can happen even when you are careful. Arrange your operator schedules so that a properly trained person is always close by to render first aid. In addition, ensure that local emergency contact information is posted clearly and in sight of the system operator. Know potential crush and pinch points Be aware of potential crush and pinch points on your system and keep personnel and equipment clear of these areas.
General Safety Practices: Hydraulic Power Units and Practice good housekeeping Keep the floors in the work area clean. Hydraulic fluid that is spilled on any type of floor can result in a dangerous, slippery surface. Do not leave tools, fixtures, or other items not specific to the test, lying about on the floor, system, or decking. Protect hoses and cables Protect electrical cables from spilled hydraulic fluid and from excessive temperatures that can cause the cables to harden and eventually fail.
General Safety Practices: Hydraulic Power Units and Handle chemicals safely Whenever you use or handle chemicals (for example, cleaning fluids, hydraulic fluid, batteries, contaminated parts, electrical fluids, and maintenance waste), refer to the appropriate MSDS documentation for that material and determine the appropriate measures and equipment required to handle and use the chemical safely. Ensure that the chemical is disposed of appropriately.
General Safety Practices: Hydraulic Power Units and Know the causes of unexpected actuator motions Do not use RF transmitters Know compressed gas hazards The high force and velocity capabilities of MTS actuators can be destructive and dangerous (especially if actuator motion is unexpected).
Hazard Placard Placement Consult MTS when in doubt about the safety or reliability of any system-related procedure or modification that involves devices that contain any type of compressed gas. Hazard Placard Placement Hazard placards contain specific safety information and are affixed directly to the system so they are plainly visible. Each placard describes a system-related hazard.
Hazard Placard Placement Label Description Caution To prevent equipment damage and impede performance, remove red shipping plug under filler cap before operating. Replace with black plastic snap in strainer. Part # 050-174-101 Warning Disconnect unit from the electrical supply before opening enclosure. Part # 100-008-037 Wye-Delta Connections Use for single voltage 6 lead motors suitable for wye-delta starting. Part # 053-448-401 46 Safety Model 505.60 - 505.
Model 505.60—505.180 HPU Electrical, Hydraulic, and Installation Contents Model 505.60—505.180 HPU Electrical, Hydraulic, and Water Connections 47 Model 505.60 HPU Setup 52 Testing Model 505.60 HPU Operation 56 Precharging the Optional Surge Suppressor Accumulator 59 Model 505.60—505.180 HPU Electrical, Hydraulic, and Water Connections 1. Position the hydraulic power unit. CAUTION Lifting the HPU in the middle of its chassis can strain the structural integrity of the HPU.
Model 505.60—505.180 HPU Electrical, Hydraulic, 2. Determine where to put the HPU. Consider the following: • The room dimensions must be adequate to accommodate the HPU. – Refer to your local electrical codes for the required free space surrounding the HPU. – A minimum of 914.4 mm (36 in) between the ends of the HPU and any obstruction. – The rear of the HPU can be as close as 25.4 mm (1 in) to the wall. – A minimum of 2362.2 mm (93 in) from the floor to an overhead obstruction.
Model 505.60—505.180 HPU Electrical, Hydraulic, and B. Connect the grounding wire to the lug labeled PE GND (protective earth ground). HPU Power Requirement and Power Feed Phase Orientation Identifier Electrical Power Feed Lugs (shown labeled for counterclockwise phase orientation) Ensure that lugs are secure. They should be checked periodically; Refer to the Maintenance section. PE GND (Protective Earth Ground) Lug Power Disconnect 4. Connect the hydraulic and water lines. Model 505.60 - 505.
Model 505.60—505.180 HPU Electrical, Hydraulic, Note For hydraulic connections to air-cooled units, refer to the Air-Cooler to SilentFlo HPU Integration Product Information manual (MTS part number 100-135-073). Each port is labeled on the manifold. Take care to identify and correctly make these connections. Failure to make proper connection could lead to water in the hydraulic fluid, hydraulic fluid in the cooling water, or pressurization of low pressure lines.
Model 505.60—505.180 HPU Electrical, Hydraulic, and D. A regulating valve must be adjusted according to your water temperature. For a description of how to set the water regulating valve see, the “Changing the Water Flow” procedure. The water supply must also be capable of maintaining water flow at a rate listed in the following table. Water Temperature Model Number 505.60 505.90 505.120 505.150 505.180 10.0°C (50°F) 34.1 L/m (9.0 gpm) 56.0 L/m (14.8 gpm) 68.1 L/m (18.0 gpm) 87.8 L/m (23.
Model 505.60 HPU Setup 7. Connect the controller cable (if used). The controller cable provides a means to connect a remote controller to the HPU. When connected, your controller can remotely start and stop the unit and switch between the low and high pressure selections. The cable also permits the controller to monitor the low level, over temperature, and dirty filter status. For information about the connection, see the appropriate electrical schematics.
Model 505.60 HPU Setup Note This selection can also be made from the HPU Setup panel. Platform Selection Button Main Display Selection Button Startup Screen (505.120/150/180 Platform selection shown) 3. On the user interface Main Display ensure that the Remote button under the Master Unit Control is not selected (gray), indicating the HPU is in local mode. Remote not selected 4. Press the Reset button to clear the interlock conditions that are the result of initially applying power to the HPU.
Model 505.60 HPU Setup 5. On the user interface panel, press and hold the HPU Setup button for five seconds to display the HPU Setup panel. 6. Verify that the correct pumps are present for the HPU model installed. • For Model 505.60, typically two pumps are present (three buttons are displayed). • For Model 505.90, typically three pumps are present (three buttons are displayed). • For Model 505.120, typically four pumps are present (six buttons are displayed). • For Model 505.
Model 505.60 HPU Setup C. If you are controlling the HPU with an external device connected to the 14-pin MS connector, select the polarity of the remote interlock signals from the HPU to the controller. Press the Remote Logic button to select: Remote Logic Normal (active high) or Remote Logic Reverse (active low). D. If a watchdog timer is present, press the Watchdog button to display Watchdog Present. If a watchdog timer is not present, press the Watchdog button to display Watchdog Not Present. E.
Testing Model 505.60 HPU Operation F. An auxiliary contact is available for the Model 505.120, 505.150, or 505.180 HPUs. This contact can be used to control an external device such as a warning lamp or a remote cooling circuit. This contact has two adjustment parameters. One controls the polarity of the active states of the contact: Normal (active high) and Reverse (active low).
Testing Model 505.60 HPU Operation 2. Verify that the platform displayed corresponds with the HPU model you are installing. • 505.60/.90 Selected—for a Model 505.60 or 505.90 HPU. • 505.120/.150/.180 Selected—for a Model 505.120 or 505.150 or 505.180 HPU. If the displayed platform is not correct, press and hold the platform selection button until the selection changes (5 seconds). Note This selection can also be made from the HPU Setup panel.
Testing Model 505.60 HPU Operation 4. Press the Reset button to clear any active interlock conditions. For interlocks that do not clear, determine and correct the cause and then press Reset. 5. Press the Pump #1 Enabled button to enable the first pump. Note The following step only applies when the HPU is first turned on after the electrical power has been connected. 6. Verify the motor rotation (the pump motor can start with the wrong rotation).
Precharging the Optional Surge Suppressor A. Enable the first pump. B. Press the Run/Low Pressure button. The enabled pump will sequence on and start running in low pressure. C. Press the High Pressure button. The enabled pump will sequence to high pressure. D. Check for unusual noises or leaks. If a problem is found, press the Stop button. You must correct the problem before you continue. E. Verify that the Hyd Fluid Pressure display indicates high pressure [typically 21 MPa (3000 psi)]. F.
Precharging the Optional Surge Suppressor When you have established a regular interval for checking the precharge pressure, note the amount of pressure loss that occurs each time the pressure is checked. An increase in pressure loss during the period between checks might indicate that the surge suppressor seals or bladder require replacement. Checking the precharge pressure The nitrogen precharge should be about 50–60% of the output pressure. To check the accumulator precharge: 1.
Precharging the Optional Surge Suppressor Changing the precharge pressure The nitrogen precharge should be within the range of 10.3–12.5 MPa (1500– 1800 psi) which is 50–60% of the output pressure (21 MPa or 3000 psi). Perform one of the following procedures to change the precharge pressure. Decreasing pressure To decrease the precharge pressure: 1. Slowly open the bleed valve on the charging kit until gas begins to escape.
Precharging the Optional Surge Suppressor 6. Slowly open the regulator shut-off valve until gas is heard escaping from the accumulator charging kit bleed valve. Allow gas to slowly escape for approximately ten seconds, and then close the bleed valve. Immediately close the regulator shut-off valve before the pressure reading on either the high or low charging kit pressure gage exceeds the pressure level of the accumulator. 7. Open the locknut.
Operation Contents Model 505.60 HPU Startup Panel 64 Model 505.60 HPU Main Display 66 Model 505.60 HPU Data 68 Model 505.60 HPU Status 69 Model 505.60 HPU Setup 70 ROD Setup 72 Operating the Model 505.60 HPU Locally or Remotely Recovering From an Interlock Changing the Water Flow 76 78 Resetting the Thermal Overloads 79 Adjusting the Model 505.60 Hydraulic Pressure Low/High Pressure Functionality Setting Up Run-On-Demand Model 505.60 - 505.
Model 505.60 HPU Startup Panel Model 505.60 HPU Startup Panel The Series 505.60/.90 and 505.120–.180 HPUs have similar user interface panels. The primary difference is the number of pumps that are displayed. This is determined by the HPU Model. The controls for the various panels are shown and described on the following page. 505.60/90 Platform 505.120/150/180 Platform 64 Operation Model 505.60 - 505.
Model 505.60 HPU Startup Panel The Startup Screen displays whenever power is first applied to the HPU through the power disconnect switch on the starter box. Startup Screen Controls Descriptions Control Description Language buttons Select user interface language. Language can be re-selected at HPU power up. 505.60/.90 Selected, 505.120/.150/.180 Selected toggle button Selects the HPU platform. The selected platform corresponds to the Model of the HPU installed.
Model 505.60 HPU Main Display Model 505.60 HPU Main Display Display Selector Buttons Master Unit Controls Pump Disabled Buttons Pump Enabled Buttons Main Panel Display Controls Control Descriptions Master Unit Controls Stop button Turns off hydraulic pressure to the system. The button turns red when the HPU is stopped. Run/Low Pressure button Turns each enabled pump on in low pressure mode. The button turns green when it is on.
Model 505.60 HPU Main Display Main Panel Display Controls (Continued) Control Descriptions Pump Enable/Disable The number of buttons displayed is determined by the model of the HPU and the selection made on the HPU Setup screen. Pump #1 through 6 Disabled buttons Disables the associated pump. The button is green if the pump is disabled. Pump #1 through 6 Enabled buttons Enables the associated pump. The button is green if the pump is enabled.
Model 505.60 HPU Data Model 505.60 HPU Data HPU Data Control Descriptions Pump Hours display Displays the running hours for each pump. The green bar indicates those pumps that are currently enabled but not running (blinking green) and those pumps currently enabled and running (solid green). The running hour display for each pump can be changed if desired. Hyd Fluid Pressure display Displays the highest pressure of the running pumps.
Model 505.60 HPU Status Model 505.60 HPU Status HPU Status Screen Control Descriptions HPU Fault Status All these indicators should be green if they are within normal operating parameters. Normal display Indicator the HPU is operating properly. Hyd Fluid Temp display Displays Hyd Fluid Temp Normal (green) when the temperature of the hydraulic fluid in the reservoir is within normal limits.
Model 505.60 HPU Setup HPU Status Screen (Continued) Control Descriptions Pressure Filter display Indicates yellow when the filter needs replacement. The signal can be monitored from the system controller. Refer to the appropriate filter replacement procedure if necessary. After replacing the filter, press the Reset button to clear the indication. The indicator returns to Pressure Filter Normal (green).
Model 505.60 HPU Setup To select this screen you must press and hold the HPU Setup button for five seconds. HPU Setup Control Descriptions Pump Motor Selection The number of buttons displayed is determined by the HPU model. Pump Present/ Pump Not Present buttons These buttons are used to place pumps online or take pumps offline. A pump is online when the button is green and indicates Pump #_ Present. A pump is offline when the button is red and indicates Pump #_ Not Present.
ROD Setup HPU Setup (Continued) Control Descriptions Temp Setting display button This button displays the temperature setting, in °F and °C, that will activate the auxiliary contact. To change the temperature setting, click on the button and use the four-button window that displays to change the setting. Click on the up arrow to increment or the down arrow to decrement the temperature in 1.0°F (1.8°C) increments. Click on ESC to close to window without accepting the changes.
ROD Setup To select this screen, press and hold the ROD Setup button for five seconds. ROD Setup Control Descriptions Minimum # of Pumps on Startup display and button Displays the adjustment range (in pumps) and how many of those pumps will be running at startup for run-on-demand. Next Stage On Delay display and button Displays the adjustment range (in seconds) for the on delay and the current delay setting.
Operating the Model 505.60 HPU Locally or Remotely You begin testing using two 7-gpm testing stations. The total hydraulic fluid flow for the HPU is now 14 gpm. When a third 7-gpm test station starts, the system flow increases to 21 gpm. This leaves nine gpm of available flow for the HPU. The available flow is below the 10 gpm set for the Minimum Avail Flow Trigger, so after 5 seconds at this flow level, the HPU starts the enabled pump motor with the next lowest number of running hours on it.
Operating the Model 505.60 HPU Locally or Remotely 4. Verify that at least one pump is enabled. Enable additional pumps as necessary. 5. Press Run/Low Pressure to start the pumps. The pumps start sequentially to prevent an electrical overload. Each pump starts in low pressure mode. 6. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if leaks or unusual sounds are noted. Determine the cause and fix the problem before restarting the HPU. 7.
Recovering From an Interlock Power save mode If the user interface is unused for 30 minutes, it will enter a power save mode. The display screen will go dark. The green power indicator on the bezel will remain lit. Touch and release anywhere on the display screen to reactivate the screen at the last accessed panel. Power On Indicator Recovering From an Interlock This section describes how to reset each type of HPU interlock.
Recovering From an Interlock Click on the HPU Status button to display the HPU Status screen and identify the fault conditions (see the next figure). Hyd fluid low level The HPU Fault Status on the user interface panel displays Hyd Fluid Low Level when the hydraulic fluid falls below the setting of the low level/over temperature sensor mounted through the top of the reservoir. Perform the following steps to correct a low level interlock: 1. Determine the cause for the low fluid level and correct it. 2.
Changing the Water Flow A. Press the Main Display button to select the Main Display screen. B. Ensure that pump #1 is present (the Pump #1 Enabled and Pump #1 Disabled button will be visible on the Main Display screen). If these buttons are not visible, go to the HPU Setup screen and press the Pump #1 Not Present button to change it to Pump #1 Present. C. Press and hold the Run/Low Pressure button.
Resetting the Thermal Overloads The water-regulating valve is adjusted at MTS Systems Corporation to maintain the hydraulic fluid temperature within the range of 43–49°C (110–120°F). However, the temperature of your water might require you to readjust the regulator. Water Inlet Water Regulating Valve Solenoid Valve Filter Assembly To set the operating temperature of the hydraulic fluid. 1. If not already selected, press the Main Display button on the user interface panel to select the Main Display. 2.
Resetting the Thermal Overloads Additional protection is provided by line fuses (FU1–FU9 for the Model 505.60/ .90 and FU1-FU18 for the Model 505.120–.180) and transformer fuses (FU10– FU12 for the Model 505.60/.90 and FU19–FU21 for the Model 505.120–.180). These cartridge-type fuses must be replaced with fuses of the same size, type, and rating, which vary according to the voltage configuration.
Adjusting the Model 505.60 Hydraulic Pressure Adjusting the Model 505.60 Hydraulic Pressure The output pressure can be adjusted from a low pressure value of 1 MPa (145 psi) to the maximum setting of 21 MPa (3000 psi). If you have a special testing requirement, you can reduce the HPU output pressure. User Interface Panel Pump Assemblies Output Pressure Controls Control Locations (505.69/90 shown) Perform the following procedure to adjust the output pressure. Perform this procedure on one pump at a time.
Adjusting the Model 505.60 Hydraulic Pressure 1. If not already selected, press the Main Display button on the user interface panel to select the Main Display. 2. Press the Pump #_ Enabled for the first pump to be adjusted. Press Pump #_ Disabled for all the other pumps. 3. Press Run/Low Pressure to start the HPU in low pressure. Ensure that there are no flow demands by the system. Run the pump in this mode until the hydraulic fluid is at normal operating temperature. 4.
Low/High Pressure Functionality Low/High Pressure Functionality This section clarifies the low and high pressure functionality of the HPU. There are certain cases where it is advantageous to use the HPU in low pressure versus high pressure.
Low/High Pressure Functionality Once the HPU has cleaned the reservoir hydraulic fluid, sections of the system should be isolated and sequentially cleaned. Flushing of hard line sections takes place in high pressure mode. If the HPU is run in low pressure, flow losses in the system will minimize the external flow and reduce the effectiveness of the system flushing and fluid conditioning.
Setting Up Run-On-Demand Setting Up Run-On-Demand The run-on-demand (ROD) option automatically starts or stops pumps to meet the hydraulic flow demand from the system. The PLC monitors the hydraulic fluid flow. When the flow changes beyond a trigger point for a set period of time, one of the pumps is turned on or off. From the current screen, press and hold the ROD Setup button on the user interface for five seconds.
Setting Up Run-On-Demand 5. Check the Rated Full Flow Per Pump. This value should only require change if the HPU is provided with pumps that have a different full flow rating. 6. Select as required Auto Reset ROD Upon HPU Stop or Do Not Reset ROD Upon HPU Stop. Model 505.60/.90 only After you have defined the run-on-demand parameters: 1. Press the HPU Data button. On the HPU Data screen, identify the enabled pump with the least number of hours. 2.
Maintenance Contents Models 505.60/.90/.120/.150/.180 HPU Maintenance Schedule Checking the Hydraulic Fluid 92 Checking the Low Level/Temperature Detector Replacing the Return-line Filter 93 94 Clamp-Style Housing Filter Replacement 94 Capscrew-Style Housing Filter Replacement 96 Replacing the Optional High-Pressure Filter 97 Sampling the Hydraulic Fluid 99 Replacing the Hydraulic Fluid 101 Inspecting the Heat Exchanger Model 505.60 - 505.
Routine Maintenance Overview Checklist Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted Calendar Time using 8 hour Running Time rate per day Daily Weekly Monthly Running Time-Hours 8 40 160 Check electronic enclosure ventilation X* Check dirty filter indicators X Check for leaks X Check oil level X Check pressure X Annually 500 1000 1,500 2,000 Check all accumulators for proper precharge pressure and oil MTS MTS MTS MTS
Routine Maintenance Overview Checklist Recommended service to be performed at each running time interval noted Calendar Time using 8 hour Running Time rate per day Daily Weekly Monthly Running Time-Hours 8 40 160 Annually 500 1000 1,500 2,000 Replace all filters MTS MTS Verify operation and settings of psi control and relief valves MTS MTS Check pump/motor coupling for wear and debris MTS Check pump voltage and current MTS Check case drain flow MTS Recommend MTS Hydraulix oil sample
Models 505.60/.90/.120/.150/.180 HPU Maintenance Models 505.60/.90/.120/.150/.180 HPU Maintenance Schedule The following table lists the recommended interval for each maintenance procedure. Maintenance Schedule What to Do When to Do It How to Do It Make daily visual inspections Before the start of each day’s testing. Check electronic enclosure ventilation. Check dirty filter indicators. Look for signs of fluid leakage. Check the fluid level in the sight gage and replenish as required.
Models 505.60/.90/.120/.150/.180 HPU Maintenance Maintenance Schedule (Continued) What to Do When to Do It How to Do It Check motor overload functionality‡ Every 1000 hours or 6 months (whichever occurs first). Contact MTS Systems Corporation. Verify proper operation of hydraulic valves§ Every 1000 hours or 6 months (whichever occurs first). Contact MTS Systems Corporation. Conduct a hydraulic fluid analysis Every 1000 hours or 6 months (whichever occurs first), or sooner if duty is severe§.
Checking the Hydraulic Fluid Operating the HPU When running the HPU, become familiar with the sounds and smells of the HPU. Changes in the sounds and smells of the HPU might indicate that maintenance or service is needed. Checking the Hydraulic Fluid Hydraulic fluid contamination and deterioration normally occur in most hydraulic systems.
Checking the Low Level/Temperature Detector 5. Check and adjust the hydraulic fluid delivery system so that: • Hydraulic fluid temperature stabilizes within the parameters given in the Specifications table when the HPU is operating at high pressure. • Pressure line reading is maintained at 21 MPa (3000 psi) maximum static value. • Maximum drain line back pressure is limited to 0.1 MPa (15 psi).
Replacing the Return-line Filter 5. Detach the cable and remove the existing low level/temperature fixture. Install the replacement fixture and attach the cable. Note Ensure that the new fixture has the same length as the old one. Raise the low level assembly high enough to cause the operator interface to flash Low Level. 6. Lower the fixture back into the reservoir to match the distance between the head assembly of the fixture and the top of the reservoir. 7.
Clamp-Style Housing Filter Replacement Required equipment • Filter element (MTS part number 100-015-519) • O-rings (MTS part number 100-030-032 and 100-030-053) OR • Procedure MTS Filter Element Seal Kit part number (100-030-199) Note The dirty-filter indicator may light when the HPU is first started due to low hydraulic fluid temperature. When the HPU is at normal operating temperature, recheck the indicator to determine if the element actually needs replacement. 1. Turn off the HPU.
Capscrew-Style Housing Filter Replacement 6. Replace the O-ring(s) seals in the bypass valve assembly and under the cover. (Reference MTS part number 100-030-032 and 100-030-053.) 7. Unscrew the “T” handle from the cartridge rod and remove the filter cartridge. 8. Install a new filter on the cartridge rod and secure it with the “T” handle. 9. Install the filter cartridge assembly into the head assembly and into the filter tube. 10. Replace the cover and clamp it to the head assembly. 11.
Replacing the Optional High-Pressure Filter Required equipment Procedure • Filter element (MTS part number 100-029-989) • O-ring (MTS part number 010-010-927) To change the filter element: WARNING The system pressure does not immediately drop to zero when the HPU is turned off. Residual pressure can produce a high pressure spray that can hurt you. Do not start this procedure until all pressure gages read zero 1. Turn off the HPU. Ensure that the hydraulic pressure is at zero before proceeding. 2.
Replacing the Optional High-Pressure Filter Procedure To change the filter element: Filter Cap Electric Dirt Alarm O-ring and Backup Ring Spring Spring Plate Filter Element Filter Housing Plastic Union Filter Components 1. Turn off the HPU. Ensure that the hydraulic pressure is at zero before proceeding. Wait until all pressure gages read zero before starting the next step. 2. Remove the dirty filter element. A. Use a 7/8 inch socket or wrench to unscrew the filter cap. B.
Sampling the Hydraulic Fluid C. Look inside the housing for signs of serious contamination such as pieces of grit, rubber particles, and metal shards. Correct the cause of this contamination before operating your system again. 4. Install the new elements. A. Insert two clean elements, with the plastic union between them, into the filter housing. B. Insert the spring plate and spring. C. Screw down the filter cap. Take care not to damage its O-ring and backup ring.
Sampling the Hydraulic Fluid 1. Operate the HPU until the hydraulic fluid is at normal operating temperature (about 30 minutes). 2. Open the bottom side panel to access the control manifold. 3. Close the needle valve. Connect the hose valve assembly to the sample port located on the control manifold. Hose Valve Assembly Needle Valve Sample Port Control Manifold Open panel to access manifold Location of Sample Port on Control Manifold 4.
Replacing the Hydraulic Fluid 8. Remove the hose and valve assembly. Appearance of Hydraulic Fluid Sample Fluid Properties Problem What to Do Dark colored fluid Indicates chemical breakdown or the hydraulic fluid has been allowed to rise above the maximum recommended temperature (severe overheating) Analyze the fluid and replace as required by the analysis.
Replacing the Hydraulic Fluid Prerequisites • Sample the hydraulic fluid to determine if the hydraulic fluid should be replaced. • Identify and correct any sources of contamination. CAUTION Mixing different brands of hydraulic fluid can contaminate your system. Contaminated hydraulic fluid can cause premature wear of the hydraulic components in your system. Do not mix different brands of hydraulic fluid. MTS Systems Corporation recommends using Exxon Mobil DTE-25 or Shell Tellus 46 AW hydraulic fluid.
Inspecting the Heat Exchanger A. Turn on power to the HPU. Rotate the power disconnect switch to the on (|) position. B. Select Main Panel from the Startup screen. C. Press Reset on the Main Panel to clear interlock conditions resulting from applying power to the HPU. D. Press Run/Low Pressure on the Main Panel. E. Run the HPU at low pressure for about three hours to filter the new hydraulic fluid. F. Press the High Pressure button to select the high pressure mode. Check the HPU for fluid leaks.
Inspecting the Heat Exchanger 6. Begin with an external inspection of the heat exchanger. Visually inspect for: • Corrosion • Signs of a previous repair • Leakage 7. A marked decrease in pressure and/or reduction in performance usually indicates cleaning is necessary. The following are suggested methods of cleaning either side of the heat exchanger.
Hydraulic Power Unit Maintenance and Service Logs Contents 8 Hours/Daily 106 40 Hours/Weekly 107 160 Hours/Biweekly 500 Hours 108 109 1000 Hours 110 2000 Hours 111 5000 Hours 112 10,000 Hours 113 Hydraulic Power Unit Maintenance and Service Logs 105
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation Date 106 Check Console Verification Check Dirty Filter Indicators Check for Leaks Check oil Level Check Pressure Performed by Performed by Performed by Performed by Hydraulic Power Unit Maintenance and Service Logs Performed by Notes
40 Hours/Weekly 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation Date Check Fluid Color and Odor Check Interlock Devices Performed by Performed by Notes Hydraulic Power Unit Maintenance and Service Logs 107
160 Hours/Biweekly 160 Hours/Biweekly 160 Hours/Monthly Service Interval Recommendation Date 108 Check Cables and Connectors Check Console Air Filter Performed by Performed by Notes Hydraulic Power Unit Maintenance and Service Logs
500 Hours 500 Hours 500 Hours Service Interval Recommendation Date Check All Accumulators for Proper Precharge Pressure and Oil Check Condition of All Electrical Cables and Cable Connections Check HPU Hydraulic Fluid Color, and Odor Check HPU Operating Pressure and Temperature Clean Control Cabinet Air Filter, Replace if Required Inspect Heat Exchanger for Leaks or “flow (when off)” Performed by Performed by Performed by Performed by Performed by Performed by Notes 500 Hours Service Interval
1000 Hours 1000 Hours 1000 Hours Service Interval Recommendation Date 110 All 500 hr Maintenance Procedures Replace All Filters Verify Operation and Settings of psi Control and Relief Valves Performed by Performed by Performed by Hydraulic Power Unit Maintenance and Service Logs Notes
2000 Hours 2000 Hours 2000 Hours Service Interval Recommendation Date All 1000 hr Maintenance Procedures Check Pump/ Check Pump Motor Coupling Voltage and for Wear and Current Debris Check Case Drain Flow Recommend MTS Hydraulix Oil Sample Performed by Performed by Performed by Performed by Performed by Notes Hydraulic Power Unit Maintenance and Service Logs 111
5000 Hours 5000 Hours 5000 Hours Service Interval Recommendation Date 112 Recommend R/R Heat Exchanger Recommend Replacement of Motor Bearings Performed by Performed by Notes Hydraulic Power Unit Maintenance and Service Logs
10,000 Hours 10,000 Hours 10,000 Hours Service Interval Recommendation Date Recommend R/R Heat Exchanger Recommend Replacement of Hoses Recommend Replacement of Motor Bearings Recommend Replacement or Rebuild of Pump Recommend Replacement or Rebuild of Motor Recommend Hydraulic Fluid Change & Clean Pump Inlet Performed by Performed by Performed by Performed by Performed by Performed by Notes Hydraulic Power Unit Maintenance and Service Logs 113
10,000 Hours 114 Hydraulic Power Unit Maintenance and Service Logs
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.
