Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information Model 505G2.60, 505G2.90, 505G2.120, 505G2.150, 505G2.180 100-227-352 D be certain.
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Contents Technical Support 7 How to Get Technical Support.................................................................................................................7 Before You Contact MTS.........................................................................................................................7 If You Contact MTS by Phone.................................................................................................................9 Problem Submittal Form in MTS Manuals..............
Do not disable safety devices.....................................................................................................27 Use appropriately sized fuses.....................................................................................................27 Provide adequate lighting...........................................................................................................27 Provide means to access out-of-reach components................................................................
Adjust the Model 505.60 Hydraulic Pressure........................................................................................66 Low/High Pressure Functionality...........................................................................................................67 Low pressure..............................................................................................................................68 System commissioning.............................................................................
Service Every 160 Hours/Biweekly.......................................................................................................95 Service Every 500 Hours........................................................................................................................95 Service Every 1000 Hours......................................................................................................................96 Service Every 2000 Hours...........................................................
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. Technical support methods MTS provides a full range of support services after your system is installed. If you have any questions about a system or product, contact Technical Support in one of the following ways.
When you have more than one MTS system, the system job number identifies your system. You can find your job number in your order paperwork. Example system number: US1.
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.
After you call MTS logs and tracks all calls to ensure that you receive assistance for your problem or request. If you have questions about the status of your problem or have additional information to report, please contact Technical Support again and provide your original notification number.
Preface Before You Begin Safety first! Before you use your MTS product or system, read and understand the 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. It is very important that you remain aware of hazards that apply to your system.
Warning: Warning notices indicate the presence of a hazard with a medium level of risk which, if ignored, can result in death, severe personal injury, or substantial property damage. Caution: Caution notices indicate the presence of a hazard with a low level of risk which, if ignored, could cause moderate or minor personal injury or equipment damage, or could endanger test integrity.
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.
Introduction Topics: • HPU Models...........................................................................................................................................16 • EU Declarations.....................................................................................................................................16 • Intended Use..........................................................................................................................................
Introduction HPU Models Item Description 1 Models 505.60/.90 HPU 2 Models 505.120/.150/.180 HPU (Dual-Pressure Models) EU Declarations EC Declaration of Conformity (Machinery Directive 2006/42/EC Annex II 1A) If applicable, a Declaration of Conformity is supplied with the machinery; an example of the Declaration of Conformity is provided at the end of this manual. Intended Use The intended use of the Hydraulic Power Unit (HPU) is: • Hydraulic supply for servohydraulic testing systems.
Introduction Product Information CD A Product Information CD is supplied with the HPU (MTS part number 100-227-354). The Product Information CD includes the electrical and hydraulic schematics along with the configuration drawings. The Product Information CD also contains the product specifications and other reference documents to aid MTS qualified service personnel.
Introduction Drawing Number Description 700005252 505.180 Configuration Drawing (Right Hand) 700005254 505.180 Configuration Drawing (Left Hand) 700000232 505.180 Hydraulic schematic 700004936 505.60/90/120/150/180 Electrical Schematic (200 - 480 VAC) 700004943 505.
Introduction HPU Component Identification Component Locations (505.90 Shown) Component Descriptions Item Component Description 1 Heat Exchanger/ Cools the hydraulic fluid using a highly efficient, stainless steel oil-to-water heat exchanger. The heat exchanger removes most of the heat generated by the HPU. Manifold Combines the output of the individual pumps to deliver the full output of the HPU through a single port.
Introduction Item Component Description 2 Filter Filters particles out of the hydraulic fluid as it is returned to the HPU. 3 Pump Assemblies Produces the pressurized hydraulic fluid for system use. Each pump assembly includes a motor, pump, and electrical enclosure for connecting with the main starter. 4 Reservoir Holds the hydraulic fluid and houses the pump and motor. 5 Commoning Expansion Plate Allows the HPU to be commoned with another HPU.
Introduction HPU Functional Description Pump assemblies 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.
Introduction Run On Demand option The run on demand (ROD) option will turn individual pumps on and off as needed to accommodate the system’s demand for hydraulic fluid. The PLC monitors the fluid flow; when flow changes beyond preset limits for a preset time, a pump will be turned on or off as needed. The ROD option allows the HPU to turn individual pump motors on and off as your system flow demand changes.
Safety Topics: • General Safety Practices: Hydraulic Power Units and Hydraulic Service Manifolds.............................
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.
Safety • Test specimens Because of these variables (and the possibility of others), your system can operate under unforeseen circumstances that can result in an operating environment with unknown hazards. Improper installation, operation, or maintenance of your system can result in hazardous conditions that can cause death, personal injury, or damage to the equipment or to the specimen.
Safety Remember, when hydraulic power is interrupted on a servohydraulic system, it is likely that stored accumulator pressure will persist for some time within the system. In addition, it is likely that as stored energy dissipates, gravity will cause portions of the system to move. Be aware of component movement with hydraulics off The actuator rod can also drift down when hydraulics are turned off hitting anything in its path.
Safety 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.
Safety Provide means to access out-of-reach components Make sure you can access system components that might be out of reach while standing on the floor. For example, ladders or scaffolding might be required to reach load cell connectors on tall load units. Wear appropriate personal protection Wear eye protection when you work with high-pressure hydraulic fluid, breakable specimens, or when anything characteristic to the specimen could break apart.
Safety Stay alert Avoid long periods of work without adequate rest. In addition, avoid long periods of repetitious, unvarying, or monotonous work because these conditions can contribute to accidents and hazardous situations. If you are too familiar with the work environment, it is easy to overlook potential hazards that exist in that environment. Contain small leaks Do not use your fingers or hands to stop small leaks in hydraulic or pneumatic hoses.
Safety a gas, remember that many gases cannot support life. Therefore, as the ratio of released gas to oxygen increases, so does the potential for suffocation. • Wear appropriate safety devices to protect your hearing. Escaping air or gas can create a noise level that can damage your hearing. • Ensure that all pressurized air or gas is bled out of a pneumatic or gas-charged device before you start to disassemble it.
Safety Label Description Voltage hazard. High voltage exists in the vicinity where this icon is located. Be aware of possible electrocution when working in areas noted with this icon. Part # 100-223-270 Explosion hazard; release of pressure. High pressure fluid or gasses. Do not tamper with fittings or hoses. Wear appropriate protection such as safety goggles and hearing protection. Maintain safe pressure levels. Disconnect from electrical power before servicing. Read the manuals.
Installation Topics: • Model 505.60—505.180 HPU Electrical, Hydraulic, and Water Connections........................................34 • HPU Setup.............................................................................................................................................40 • About the Optional Surge Suppressor Accumulator Precharge............................................................44 • Check the Precharge Pressure...............................................................
Installation 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. Do not lift the HPU in the middle of its chassis. Lift the HPU from each end of the chassis, as shown in the next figure. Item Description 1 When moving the HPU with an overhead lift, use a spreader bar to help balance the weight.
Installation • 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. • The HPU can fit through a standard 1.04-m or 41-in door.
Installation Item Description 1 PE GND (Protective Earth Ground) Lug 2 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. 4. Connect the hydraulic and water lines. 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.
Installation Item Description 1 2 inch (505G2.120-.180 1.5 inch (505G2.60-.90) Female NPT Water In 2 2 inch (505G2.120-.180 1.5 inch (505G2.60-.90) Female NPT Water Out 3 2 inch SAE Code 61 Pressure 4 2 inch SAE Code 61 Return 5 -16 JIC Drain a) Connect the hydraulic pressure and drain lines to the hydraulic fluid distribution system or directly to a hydraulic device. Use hydraulic line or hose that is rated to handle the maximum hydraulic pressure of the HPU.
Installation Water Temperature 21.1°C (70°F) 26.7°C (80°F) 32.2°C (90°F) Model Number 505.60 505.90 505.120 505.150 505.180 56.8 L/m (15 gpm 83.3 L/m (22 gpm) 177.9 L/m (47 gpm) 83.3 L/m (22 gpm) 128.7 L/m (34 gpm) 268.7 L/m (71 gpm) 113.6 L/m (22 gpm) 166.6 L/m (44 gpm) 355.8 L/m (494 gpm) 135 L/m (36 gpm) 210 L/m (55 gpm) 440 L/m (116 gpm) 166.5 L/m (44 gpm) 257.4 L/m (68 gpm) 537.5 L/m (142 gpm) 5. Add hydraulic fluid to the reservoir. The unit is shipped with a plug in the filler cap.
Installation Note: The following step only applies when the HPU is first turned on after the electrical power has been connected (see Step 3 ). d) Verify the motor rotation (the pump motor can start with the wrong rotation). Press the High Pressure switch. • If pressure begins to increase, proceed to the next step. • If the oil pressure value shows no pressure, press the Stop button to shut down the unit (do not run more than 10 seconds in the wrong direction).
Installation Note: If a controller is not used, the installed jumper plug must be used or the unit will not start. HPU Setup The following procedure should only be performed at HPU installation to verify settings, when you replace the user interface panel, or if you need to change a selection. 1. Rotate the power disconnect switch to the on (|) position. 2. On the user interface Main Display, select the language. 3.
Installation 5. The following table describes the pushbuttons and indicators on the Setup screen. Name and Location Description Module #N Not Present/Module #N Present Pushbutton/Indicator. The pushbutton is used to select the availability of pump modules. Pressing the button alternates between the states. Module #N Not Present- yellow: Indicates the module is not installed in the HPU. Module #N Present- green: Indicates the module is installed in the HPU.
Installation Name and Location Description Pressure Display In (units) Pushbutton/Indicator: Used to select the units for pressure displays in either psi or MPa. Push to alternate between the two pressure units. Pressure Display in psi - gray. Pressure Display in MPa - black. Remote Fault Normal/Remote Fault Reverse Pushbutton /Indicator. The HPU generates fault signals for remote monitoring. This button is used to define the polarity of the output signal.
Installation Name and Location Description Aux Contact: Temp - black Aux Polarity Normal - gray Aux Polarity Reverse - black One of the auxiliary contacts can be used to control an external device such as a warning lamp or a remote cooling circuit.
Installation Name and Location Description shows factory settings that should not be changed by the user. About the Optional Surge Suppressor Accumulator Precharge The surge suppressor, if provided, smooths out the ripple caused by the pulsing action of the pump as it pressurizes the hydraulic fluid. The surge suppressor is a cylinder that has an outer sleeve that is pressurized with nitrogen. The gas pressurized sleeve dampens the pressure pulses.
Installation Charging Kit Item Description 1 Low Pressure Gage 0–2.1 MPa (0–300 psi) 2 Gage Protector (factory set to limit pressure to the gage to approximately 1.
Installation Item Description 14 Nitrogen Bottle 15 Nitrogen Bottle Valve 16 Regulator Output Pressure Valve 17 Regulator Shut-Off Valve 18 Nitrogen Bottle Pressure Gage 19 Regulator Output Pressure Gage 20 Nitrogen Supply Hose 21 Extension Hose 22 Close 23 Bleed Valve 24 Open 25 Input Check Valve 26 High Pressure Gage 0–21 MPa (0–3000 psi) Decrease the Pressure 1. Slowly open the bleed valve on the charging kit until gas begins to escape.
Installation Warning: Precharging with a gas other than dry nitrogen will cause the existing nitrogen within the surge suppressor to be mixed with the new gas. Mixing gases can produce unpredictable results. Use only dry nitrogen gas to precharge the surge suppressors. 3. Connect the nitrogen supply hose from the supply bottle pressure regulator output to the input check valve on the charging kit. 4. Open the nitrogen bottle valve. Check the nitrogen bottle pressure gage on the regulator.
Operation Topics: • Operator’s Panel....................................................................................................................................50 • Auto Setup.............................................................................................................................................56 • Setting Up Run On Demand (ROD).......................................................................................................58 • Run On Demand Detailed Example........
Operation Operator’s Panel Main Screen The Main screen is displayed initially when the HPU is powered up. The following table describes the pushbuttons and indicators on the Main screen. Main Screen Name and Location Description Faulted/Ready/Running/High Pressure/Alarm/Overtemp Bypass Indicator. Indicate the various state of the HPU Faulted - red: Indicates when an interlock has occurred and the HPU has been shut down. Ready - green: Indicates the interlocks are cleared and the HPU is ready to start.
Operation Name and Location Description Enable Module - blue: Indicates that no modules are enabled. It alerts the user to enable one or more modules before the HPU can be started. Enable Module #1 through #6 Module #1 through #6 Enabled Pushbutton/Indicator. Used to enable and disable the available pump modules. Pressing the button alternates between the two states. Enable Module #N - gray: Indicates the pump module is disabled and can not be started.
Operation Name and Location Description Auto Pushbutton/Indicator. change between manual mode and auto mode. Auto mode will start the modules with the lowest hours first until the demand is satisfied. Rated Flow per Module (units) Auto - gray: Indicates the HPU is in manual mode. Auto- green: Indicates the HPU is in auto mode. When using the auto mode, you need to set the startup flow. Push the Startup Flow (units) button to display the keypad.
Operation Name and Location Description Status Pushbutton/Indicator. Pushbutton used to select the Status screen. Status - gray: In this state, one of the other screens is selected; for example the Main screen. Status - black: The Status screen is selected and displayed. Status - blue: A blue indicator means action is required. When the status indicator is blue, press the status button to go to the status screen and resolve any condition that requires action. Setup Pushbutton/Indicator.
Operation Name and Location Description Watchdog OK/Watchdog Fault Indicator. Used to indicate the status of the watchdog timer. Watchdog OK - gray: Indicates the PLC that controls the HPU is operating normally. Watchdog Fault - red: Indicates there is a problem with the hardware watchdog timer and the PLC is not operating correctly. A watchdog fault cause the HPU to shutdown. Reset Pushbutton /Indicator. Used to reset interlocks. Reset - gray: Indicates no active interlocks.
Operation Name and Location Description Press Filter OK - gray: Indicates the contamination in the pressure filter is within acceptable limits. Press Filter Dirty- yellow: Indicates the contamination in the pressure filter is not within acceptable limits. This state will not generate an active interlock, but alerts the user that the filter requires maintenance. The HPU cannot be started with an active pressure filter warning. Module #N Indicator.
Operation Auto Setup Note: ROD (Run On Demand) is a purchased option. To select this screen, press and hold the Auto Setup button for five seconds. Auto Setup Control Descriptions ROD Flow Buffer (units) ROD Flow Buffer (units) - blue-green: Indicator used as a label for the pushbutton switch below it. ROD Flow Buffer numeric display - pushbutton/indicator gray: Used to set the reserve flow capacity for run on demand. Push the button to display the numeric keypad.
Operation Control Descriptions ROD On Delay (sec) ROD On Delay (sec) - blue-green: Indicator used as a label for the pushbutton switch below it. ROD On Delay numeric display - pushbutton/indicator - gray: Used to set the delay in seconds. The flow must be at or above the trigger level for this amount of time before the next pump motor turns on. Push the button to display the numeric keypad.
Operation Control Descriptions Flow Meter Not Present- gray: In this state, there is no flow meter and the ROD option can not be used. However, the Auto feature can be used; see “Auto”. Flow Meter Present - black: In this state, the flow meter is present and the ROD option (if purchased) can be used. Flow Display In GPM/Flow Display in Pushbutton/Indicator. Pushbutton used to define which units LPM are displayed for hydraulic fluid flow. Pressing the button alternates between the states.
Operation 9. Press Run to start the HPU in low pressure. 10. Press High Pressure to select high pressure mode. The number of pumps running will be determined by the setting on the ROD Setup screen. 11. To disable run on demand after it is running, without turning off the HPU, pressing the ROD button will disable it. 12. Pressing the Stop button will turn off the HPU and disable run on demand.
Operation The HPU starts out with one module running to create 30 gpm of available flow. This satisfies both the Startup Flow requirement (10 gpm) and the Buffer Flow requirement (10 gpm). The demand rises and eventually hits 20 gpm. At this point the on delay is started because the 20 gpm of actual flow and 10 gpm of Buffer Flow meet or exceed the available 30 gpm. Because the flow stays above 20 gpm for the length of time Δton, another pump module is started and available flow goes to 60 gpm.
Operation Item Description 5 demand<20 Operate the HPU Locally or Remotely Local Operation The HPU can be operated locally using the controls on the user interface panel. 1. Make a general inspection of the HPU. Ensure that all cooling water valves are open. Ensure the Emergency Stop button is released. 2. If not already displayed, press the Main button to display the Main screen. 3. Verify that the Remote Operation button is gray.
Operation 2. If not already displayed, press the Main button to display the Main screen. 3. Verify that the Remote Operation button is green. If the button is not green, press the button to change it to green (indicating remote mode). 4. Verify that at least one pump is enabled. Enable additional pumps as necessary. 5. Start the HPU in low pressure at your controller. 6. Check the HPU for leaks and unusual sounds. Stop the HPU immediately if leaks or unusual sounds are noted.
Operation Hyd fluid overtemperature A hydraulic fluid overtemperature interlock is indicated on the Main screen by a flashing red Faulted indicator, a blue Bypass indicator, a red Oil Temp indicator, and a blue Status indicator. The interlock is generated when the temperature exceeds 55°C (131°F). The interlock will automatically shut down the HPU. The HPU cannot return to normal operation until the fluid has cooled. Perform the following to correct an overtemperature interlock: 1.
Operation Dirty filter A dirty filter interlock is indicated on the Main screen by a yellow Alarm indicator and a blue Status indicator. Press the Status button to display the Status screen and note the yellow Return Filter Dirty or Press(ure) Filter Dirty indicator(s). The interlock is generated when the filter capacity has reached a critical level. A dirty filter condition will prevent the HPU from being started, but it will not stop the HPU while it is running. 1.
Operation To set the operating temperature of the hydraulic fluid. 1. If not already selected, press the Main button on the user interface panel to select the Main Display. 2. Press Run to start the HPU in low pressure. 3. Press the High Pressure button to select the high-pressure mode. 4. Observe the Oil Temp on the Main Display screen as the hydraulic fluid temperature rises. Note the temperature where the hydraulic fluid temperature stabilizes. 5. Adjust the water-regulating valve.
Operation Adjust 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. Control Locations (505.69/90 shown) Item Description 1 2 3 User Interface Panel Pump Assemblies Output Pressure Controls Perform the following procedure to adjust the output pressure. Perform this procedure on one pump at a time.
Operation 2. Select Module #_ Enabled for the first pump module to be adjusted. Select Enable Module # for all the other pumps modules. 3. Press Run 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. Press the High Pressure button to select high pressure mode. 5. Loosen the nut securing the output pressure control. 6.
Operation Item Description 1 Flow to External System 2 Return Flow from System 3 High Pressure Flow 4 Circulation Pump 5 HPU Manifold 6 Heat Exchanger 7 Filter 8 Low Pressure Flow 9 Reservior Low pressure Series 505 HPUs are started in low pressure to reduce the amount of current inrush at motor start-up. A solenoid valve that opens a direct flow path to the return line commands the pressure setting.
Operation • With the HPU running in low pressure, acceptable particle counts are obtained in a relatively short time. • Keeping the HPU in low pressure effectively isolates the external or system flow because the relative back pressure is normally much higher in the external system circuit. • Running the HPU in low pressure maximizes fluid flow, allowing the HPU to circulate the reservoir contents across the filter more times per hour.
Maintenance Topics: • Routine Maintenance Overview Checklist.............................................................................................72 • Models 505.60/.90/.120/.150/.180 HPU Maintenance Schedule...........................................................74 • Spare parts............................................................................................................................................76 • Lockout/tagout........................................................
Maintenance Routine Maintenance Overview Checklist Important: When performing maintenance that requirers the cover be in a raised position, ensure the cover is preperly secured using the rod provided. Note: In the table below, an 'X' indicates service that should be perfromed by equipment operators. Most of these procedures involve visual checks that should not interfere with test systems operation. These checks are also completed by trained field service engineers on each routine maintenance visit.
Maintenance Calendar Time using 8 hour Daily Weekly Monthly Running Time rate per day Running Time-Hours 8 40 160 Annually 500 1000 1,500 2,000 Check HPU operating pressure and temperature MTS MTS MTS MTS Clean control cabinet air filter, replace if required MTS MTS MTS MTS Inspect heat exchanger for leaks or “flow (when off)” MTS MTS MTS MTS Inspect pump hoses for leaks MTS MTS MTS MTS Lubricate-grease motor bearings (non 505) MTS MTS MTS MTS Verify dirty filter indicators status MTS MTS
Maintenance Calendar Time using 8 hour Daily Weekly Monthly Running Time rate per day Running Time-Hours 8 40 160 Annually 500 1000 1,500 2,000 5,000 10,000 Determine if replacement or rebuild of pump requiredFootnote. MTS Determine if replacement or rewind of motor is requiredFootnote. MTS Recommend hydraulic fluid change & clean pump inlet strainer MTS Models 505.60/.90/.120/.150/.180 HPU Maintenance Schedule The following table lists the recommended interval for each maintenance procedure.
Maintenance What to Do When to Do It How to Do It Check the precharge pressure Every 160 hours or 1 Footnote. in optional accumulator month (whichever occurs first). Refer to the accumulator product information manual for complete instructions. If installed, check the precharge Every 160 hours or 1 pressure in the surge month (whichever suppressor occurs first). Refer to the procedure for precharging the surge suppressor accumulator. Conduct external inspection of Every 500 hours or 3 Footnote.
Maintenance What to Do When to Do It How to Do It occurs first), or sooner sample be analyzed by our contracted if duty is severe. service. Ask your Field Service Engineer for information. Replace hydraulic fluid If fluid analysis is not to Refer to procedure for replacing specifications. hydraulic fluid. Conduct internal inspection of Every 2000 hours or Footnote., Footnote. heat exchanger yearly (whichever occurs first).
Maintenance 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. About Checking the Hydraulic Fluid Hydraulic fluid contamination and deterioration normally occur in most hydraulic systems.
Maintenance 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).
Maintenance Item Description 4 Head Assembly 5 Cable 6 Locknut 7 Top of Reservoir 8 Shaft How to check the low level switch 1. Note the distance between the head assembly of the fixture and the top of the reservoir. 2. Turn on power to the hydraulic power unit. 3. Loosen the locknut on top of the reservoir that holds the assembly in place. 4. Raise the low level assembly high enough to cause the HPU Run Status to flash between Faulted and Low Level.
Maintenance 2. Turn off the water flow to the HPU (this prevents the heat exchanger from working). 3. Monitor the temperature on the Main Display on the user interface. When the hydraulic fluid temperature exceeds 55°C (131°F), HPU Run Status should flash between Faulted and Over Temp. If Over Temp does not display, replace the low level assembly. 4. Turn on the water flow to the HPU. 5. Press the Reset button to clear the interlock and turn the indicator off.
Maintenance Filter Components Item Description 1 Clamp 2 Cover 3 Seal 4 Head Assembly 5 Gasket 6 Filter Tube 7 Cartridge Rod 8 Filter Cartridge 9 Bypass Valve Assy 10 Seal Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information 81
Maintenance Item Description 11 “T” Handle 2. Unlock and open the small cover next to the electrical enclosure to access the filter assembly. 3. Release the clamp securing the cover to the head assembly. Important: You will need a minimum clearance of 712 mm (28 in) above the filter housing to remove the filter. 4. Place a drain pan nearby to catch drippings from the filter. 5. Use the “T” handle to pull the filter cartridge out of the filter tube. Be careful not to spill any hydraulic fluid. 6.
Maintenance About Capscrew-Style Housing Filter Replacement Capscrew-Style Housing Filter Item Description 1 Filter Housing 2 Capscrews (4) 53 N-M (39 ft-lb) 3 Filter Cap 4 O-Ring 5 Spring 6 Bypass Valve Assembly 7 Filter Element The return-line filter element of the HPU should be replaced for the following reasons: • When the dirty-filter detector trips • Whenever the hydraulic fluid is changed • The filter manufacturer’s recommended maximum interval (1000 hours or 6 months) Requir
Maintenance Replace the Capscrew-Style Housing Filter 1. Turn off the HPU. Ensure that the hydraulic pressure is at zero before proceeding. Caution: 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. 2. Unlock and open the small cover next to the electrical enclosure to access the filter assembly. 3.
Maintenance Required equipment You will need filter elements (MTS part number 010-053-305); quantity 2 for the 505.60/.90, quantity 4 for 505.120/.180) and seal kit (MTS part number 011-425-803). Also available is the O-ring used at the base inlet and outlet (MTS part number 010-010-907).
Maintenance 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) Remove the spring, spring plate, and two dirty filter elements. c) Save the plastic union that commons the two filter elements. Discard the dirty elements, following applicable environmental guidelines.
Maintenance • 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. • For additional information on hydraulic fluid care, see the Hydraulic Fluid Care Guide (part number 050-000-536) found in the documentation package inside the electrical control box.
Maintenance Location of Sample Port on Control Manifold Item Description 1 Hose Valve Assembly 2 Needle Valve 3 Sample Port 4 Control Manifold 5 Open panel to access manifold 4. Open the needle valve, and flush 1 liter (1 quart) of hydraulic fluid though the sampling assembly. This fluid can be directed to a waste container or back into the HPU reservoir. 5. Obtain a sample of the hydraulic fluid after flushing the valve hose assembly.
Maintenance 7. If there still is any uncertainty regarding fluid quality, obtain another sample of the fluid and have it analyzed. The fluid tests should include chemical analysis, particle count, and viscosity checks. Most oil companies have facilities for performing these tests, or consult MTS Systems Corporation. 8. Remove the hose and valve assembly.
Maintenance About 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 • A transfer pump with a 10 micron filter (such as the Model 590.01 Fluid Transfer Pump) with 915 mm (36 inch) suction tube.
Maintenance a) Use the transfer pump to remove the old hydraulic fluid from the reservoir and into an appropriate container. b) Remove the motor/pump cover assembly as needed to clean the reservoir. c) Drain the hydraulic fluid from hoses and accumulators in the system. 3. Clean the inside of the reservoir using clean cloths dampened with ethanol. Clean the pump, motor, and bottom of the cover plate as well. 4. Use a dry, lint-free cloth to wipe away the solvent. 5. Install the motor/pump cover assembly. 6.
Maintenance Important: This procedure requires special training and familiarity with heat exchanger operation. You must unbolt and remove the heat exchanger from the reservoir in order to inspect it. Consult MTS before you perform an internal inspection or any maintenance on the heat exchanger. Procedure To inspect the heat exchanger: 1. Shut off the HPU and the cooling water supply. 2.
Hydraulic Power Unit Maintenance and Service Logs Topics: • Service Every 8 Hours/Daily..................................................................................................................94 • Service Every 40 Hours/Weekly............................................................................................................94 • Service Every 160 Hours/Biweekly........................................................................................................
Hydraulic Power Unit Maintenance and Service Logs Service Every 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation Date Check Console Verification Check Dirty Filter Indicators Check for Leaks Check oil Level Check Pressure Performed by Performed by Performed by Performed by Performed by Notes Service Every 40 Hours/Weekly 40 Hours/Weekly Service Interval Recommendation Check Fluid Check Interlock Color and Odor Devices Date Performed by Performed by Notes 94 Series 505G2 SilentFlo™ H
Hydraulic Power Unit Maintenance and Service Logs Service Every 160 Hours/Biweekly 160 Hours/Monthly Service Interval Recommendation Date Check Cables and Connectors Check Console Air Filter Performed by Performed by Notes Service Every 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 Tempera
Hydraulic Power Unit Maintenance and Service Logs 500 Hours Service Interval Recommendation Inspect Lubricate-Grease Verify Dirty Pump Hoses motor Filter for Leaks Bearings Indicators (non-505) Status Date Verify HPU Hydraulic Fluid Level Verify Warning and Interlock Devices Performed by Performed by Performed by Performed by Performed by Notes Service Every 1000 Hours 1000 Hours Service Interval Recommendation All 500 hr Maintenance Procedures Date Replace All Filters Performed by Performed by Veri
Hydraulic Power Unit Maintenance and Service Logs Service Every 2000 Hours 2000 Hours Service Interval Recommendation All 1000 hr Check Check Pump Check Case Maintenance Pump/Motor Voltage and Drain Flow Procedures Coupling for Current Wear and Debris Date Performed by Performed by Performed by Recommend MTS Hydraulix Oil Sample Performed by Performed by Notes Service Every 5000 Hours 5000 Hours Service Interval Recommendation Recommend R/R Heat Exchanger Date Performed by Notes Series 505G2 Silen
Hydraulic Power Unit Maintenance and Service Logs Service Every 10,000 Hours 10,000 Hours Service Interval Recommendation Recommend Recommend Inspect R/R Heat Replacement Motor Exchanger of Hoses Bearings Date Performed by Performed by Determine if Replacement or Rebuild of Pump needed Determine if Replacement or Rebuild of Motor needed Performed by Performed by Performed by 98 Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information Recommend Hydraulic Fluid Change & Clean Pump Inlet Perfo
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