m be certain. Series 505G2 SilentFlo™ Hydraulic Power Unit Product Information Model 505G2.20 Model 505G2.
Copyright information Trademark information © 2013 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. Molykote is a registered trademark of Dow Chemical Corporation. All other trademarks or service marks are property of their respective owners.
Contents Technical Support 5 How to Get Technical Support Before You Contact MTS 5 5 If You Contact MTS by Phone 7 Problem Submittal Form in MTS Manuals 8 Preface 9 Before You Begin Conventions 9 10 Documentation Conventions 10 Introduction 13 EU Declarations Intended Use 13 13 Product Information CD 14 505.20/.30 HPU Component Identification 505.20/.
Operator’s Panel 40 Main Screen 40 Status Screen 43 Operating the HPU Locally or Remotely Recovering from an Interlock Changing the Water Flow 45 46 47 Resetting the Thermal Overloads and Circuit Breakers Adjusting the Hydraulic Pressure 48 49 Adjusting the Auto-Cooling Level 50 Low/High Pressure Functionality 54 Maintenance 57 Routine Maintenance Overview Checklist Checking the Hydraulic Fluid 58 59 Replacing the Return Line Filter 61 Sampling the Hydraulic Fluid 62 Replacing the Hy
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 6 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 505G2.20 - 505G2.
Documentation Conventions 12 Preface Model 505G2.20 - 505G2.
EU Declarations Introduction Contents 505.20/.30 HPU Component Identification 505.20/.30 HPU Functional Description 15 16 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.
Product Information CD 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.
505.20/.30 HPU Component Identification 505.20/.
505.20/.30 HPU Functional Description Component Descriptions (Continued) Component Description Fluid Sample Port Access port for obtaining hydraulic fluid samples from the HPU. A quick disconnect port is provided. Use the optional sampling kit that includes a needle valve to regulate the flow through the sample port. Heat Exchanger Cools the hydraulic fluid by using an oil-to-water heat exchanger. The heat exchanger removes most of the heat generated by the HPU.
505.20/.30 HPU Functional Description Pressure The start/low/high switch on the electrical enclosure’s front panel controls the hydraulic pressure of the HPU. The start/low/high switch operates like an automotive ignition switch; turn and hold the switch in the start position until the motor starts running. The switch returns to the low position. The unit automatically starts in low pressure to reduce the amperage needed for starting, which will extend pump and motor life.
505.20/.30 HPU Functional Description The effective operating range of the auto-cooling circuit is between system pressures of 14 MPa (2000 psi) to 21 MPa (3000 psi). In order for the autocooling valve to function properly, it must be re-adjusted anytime the output pressure is changed and operation of the HPU at the new pressure is to be longer than 10 minutes. Note Electrical Control If the test condition requires a maximum pressure level less than 14 MPa (2000 psi), consult MTS.
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).
General Safety Practices: Hydraulic Power Units and 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. The following labels and placards are typically located on the HPU. Label Description Hydraulic Power Unit information label. Part # 100-263-702 Caution To prevent equipment damage and impede performance, remove red shipping plug under filler cap before operating.
General Safety Practices: Hydraulic Power Units and 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.
505.20/.30 HPU Connections Installation Contents 505.20/.30 HPU Connections Position the 505.20/.30 HPU Testing the 505.20/.30 HPU 27 30 30 Precharging the Surge Suppressor Accumulator 35 505.20/.30 HPU Connections Connecting the water lines For the purpose of cooling the hydraulic fluid, you must connect the HPU to a water supply capable of maintaining the water flow rate as listed in the following table.
505.20/.30 HPU Connections Connecting the controller cable Note If a controller is not used, the installed jumper plug must be used or the unit will not start. • The controller cable provides a means to connect your controller to the HPU. • The controller cable allows you to remotely start and stop the unit and switch between the low and high pressure selections. The controller cable also permits the controller to monitor the low level, over temperature, and dirty filter status.
505.20/.30 HPU Connections CAUTION The first time a pump motor is started after electrical service is connected to the HPU, it is possible for the pump motor to rotate in the wrong direction. A pump motor rotating in the wrong direction at high pressure for longer than 10 seconds can cause severe damage to your HPU. If the output pressure does not increase within 10 seconds after High is selected, stop the unit.
Position the 505.20/.30 HPU Position the 505.20/.30 HPU You should determine where to put the HPU. Becauseit is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located anywhere. To position the HPU: • The HPU can fit through a standard 1-m or 36-in door. • The HPU can be moved by a fork lift, pallet jack, or dolly. • Placement considerations should include proximity to the facility electric power and the hydraulic components.
HPU Setup 6. Check for unusual noises or leaks. If a problem is found, press the Stop button. You must correct the problem before you continue. 7. Turn the High/Low/Start switch to the High position. 8. Verify the correct output pressure, as shown on the pressure gage. A. Adjust the pressure if necessary. B. If the pressure is adjusted, the auto-cooling function may need to be adjusted. 9. Press the Stop button to shut down the unit.
HPU Setup 4. On the user interface panel, press and hold the Setup button for five seconds to display the Setup HMI (human-machine interface) screen. 5. The following table describes the pushbuttons and indicators on the Setup screen. Name and Location Description Use Buttons Below To Change Parameters Indicator - blue-green: Provides instruction for the setup screen. Remote Fault Normal/Remote Fault Reverse Pushbutton /Indicator. The HPU generates fault signals for remote monitoring.
HPU Setup Name and Location Description Aux Contact: On/Off/Temp Aux Polarity Normal/Reverse Pushbuttons /Indicators. Aux Contact: On/Off - gray 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.
HPU Setup Name and Location Description Mean Temp/numeric display and Deadband/numeric display Mean Temp (deg) - blue-green: Indicator used as a label for the pushbutton switch below it. Deadband (deg) - blue-green: Indicator used as a label for the pushbutton switch below it. Mean Level numeric display - pushbutton/indicator - gray: Used to set the mean level operating temperature of the hydraulic fluid. Push the button to display a numeric keypad.
Precharging the Surge Suppressor Accumulator Precharging the Surge Suppressor Accumulator The surge suppressor 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. The surge suppressor is mounted to the output of the hydraulic pump inside the reservoir.
Precharging the Surge Suppressor Accumulator Checking the precharge pressure The nitrogen precharge should be about 50–60% of the output pressure. Monitor the pressure gage. If the pressure reading is outside the range of 10.3–12.5 MPa (1500–1800 psi), perform the procedure “Changing the precharge pressure.” Low Pressure Gage 0–2.
Precharging the Surge Suppressor Accumulator 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.
Precharging the Surge Suppressor Accumulator 38 Installation Model 505G2.20 - 505G2.
Operation Contents Operator’s Panel 40 Main Screen 40 Status Screen 43 Operating the HPU Locally or Remotely Recovering from an Interlock Changing the Water Flow 45 46 47 Resetting the Thermal Overloads and Circuit Breakers Adjusting the Hydraulic Pressure 49 Adjusting the Auto-Cooling Level 50 Low/High Pressure Functionality 54 Model 505G2.20 - 505G2.
Operator’s Panel 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. 40 Operation Model 505G2.20 - 505G2.
Main Screen Name and Location Description Faulted/Ready/Running/High Pressure/Alarm/Overtemp Bypass Indicator. Indicate the various state of the HPU Faulted - red: Initial condition. Also displayed 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. Running - green: Indicates the HPU is running in low pressure. High Pressure - green: Indicates the HPU is running in low pressure.
Main Screen Name and Location Description Oil Temp(erature) Indicator/Display: Indicates the temperature of the hydraulic fluid in the reservoir. Part of the Analog Option;only displayed if the Analog Option was purchased. Oil Level Part of the Analog Option;only displayed if the Analog Option was purchased. Indicator/Display: Displays the level of the hydraulic fluid in the reservoir in 1/8 increments. The level is relative to the bottom of the sensor, not the bottom of the reservoir.
Status Screen Status Screen The Status screen is displayed by pressing the Status button on the Main screen. The following table describes the pushbuttons and indicators on the Status screen. 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.
Status Screen Name and Location Description Oil Temp OK/Oil Temp Fault Indicator. Used to indicate if the hydraulic fluid temperature is within acceptable limits. Oil Temp OK - gray: Indicates the hydraulic fluid temperature is within acceptable limits. Oil Temp Fault - red: Indicates the hydraulic fluid temperature is not within acceptable limits and an interlock is active. Motor OK/Motor Overload Indicator. Used to indicate if the pump motor is in an acceptable operating condition.
Operating the HPU Locally or Remotely Operating the HPU Locally or Remotely The HPU can be operated locally using the controls on the user interface panel or remotely using your system controller. Local operation 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.
Recovering from an Interlock 7. Run the HPU for about 30 minutes or until the hydraulic fluid is up to operating temperature [typically 43–49°C (110–120°F)] before using your test system. 8. Stop the HPU with the controller. Recovering from an Interlock This section describes how to reset each type of HPU interlock. If a fault occurs (Low Level, Over temperature, Dirty Filter), the HPU will not start. You must determine the source of the interlock and correct the cause before using the HPU.
Changing the Water Flow 2. If the there is no change in the Oil Temp reading after several minuets, determine if the hydraulic fluid is receiving adequate cooling. • The cooling water inlet temperature affects the efficiency of cooling the hydraulic fluid. • Check the cooling water inlet-to-outlet pressure differential. It should be between 0.24–0.31 MPa (35–45 psi). If necessary, adjust the water pressure at its source. 3.
Resetting the Thermal Overloads and Circuit Breakers The valve is adjusted at MTS Systems Corporation to maintain the hydraulic fluid temperature at 43°C (110°F). However, the temperature of your water may require you to readjust the regulator. Decrease Increase To set the operating temperature of the hydraulic fluid: 1. Start the HPU and switch to high-pressure mode. 2. Observe the temperature gage as the hydraulic fluid temperature rises. Note the temperature where the hydraulic fluid stabilizes. 3.
Adjusting the Hydraulic Pressure 2. Loosen the bolts securing the door of the electrical enclosure and open the door. 3. Locate the tripped thermal overload or circuit breaker; labeling is provided next to each component for identification. If necessary, press Reset to clear the switch. If the thermal overload or circuit breaker switch trips again after the cause has been remedied, wait until the switch/breaker cools.
Adjusting the Auto-Cooling Level CAUTION The pump and motor are designed to operate below a specified pressure. Setting the hydraulic pressure above 21 MPa (3000 psi) can damage the pump and its motor. Do not adjust the output pressure higher than 21 MPa (3000 psi). Adjusting the HPU output pressure 1. Turn on high hydraulic pressure. Ensure that there are no flow demands by the system. 2. Loosen the nut securing the output pressure control. 3.
Adjusting the Auto-Cooling Level An incorrect adjustment may cause one of two conditions: • An overtemperature interlock as indicated by the front panel indicator. A mis-adjustment of the auto-cooling valve may prohibit the flow of hydraulic fluid across the heat exchanger • Unexpectedly reduced system performance.
Adjusting the Auto-Cooling Level Important Adjustment of the auto-cooling valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting. This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage. Adjustment of the auto-cooling valve at or above the desired output pressure may prevent the valve from shifting and result in the HPU overheating.
Adjusting the Auto-Cooling Level C. Stop adjusting at this point. If no valve shift is audibly or visually detected and the valve has been fully closed go to Step 3. Important Adjustment of the auto-cooling valve to a level too close to the desired output pressure may cause an unstable condition characterized by rapid valve shifting. This condition will produce an audible flutter and can be seen as an erratic movement of the needle on the pressure gage.
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.
Low/High Pressure Functionality The effective range of the auto-cooling circuit is between system pressures of 14 MPa (2000 psi) to 21 MPa (3000 psi). In order for the auto-cooling valve to function properly, it must be re-adjusted anytime the output pressure will be changed for longer than 10 minutes. Note 56 Operation If the test condition requires a maximum pressure level less than 14 MPa (2000 psi), consult MTS. Model 505G2.20 - 505G2.
Maintenance Contents Routine Maintenance Overview Checklist Checking the Hydraulic Fluid 59 Replacing the Return Line Filter 61 Sampling the Hydraulic Fluid 62 Replacing the Hydraulic Fluid 64 Inspecting the Heat Exchanger Model 505G2.20 - 505G2.
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
Checking the Hydraulic Fluid 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 MTS Reco
Checking the Hydraulic Fluid To avoid these problems, you must maintain a clean hydraulic system. Regularly test samples of your hydraulic fluid and follow the recommended maintenance procedures described here. For more information on hydraulic fluid care, refer to the Hydraulic Fluid Care Guide (part number 050-000-536). Important Procedure To prevent problems with inconsistent and inferior fluids, MTS recommends only Exxon Mobil DTE 25 or Shell Tellus 46 to its customers.
Replacing the Return Line Filter Replacing the Return Line Filter The filter element of the HPU should be replaced for the following reasons: Prerequisite Procedure • When the dirty-filter indicator lights • Whenever the hydraulic fluid is changed • The filter manufacturer’s recommended maximum interval has passed (1000 hours or 6 months) You will need a filter element (MTS part number 010-053-349) or a filter kit (MTS part number 100-078-099).
Sampling the Hydraulic Fluid 4. Unscrew the filter housing and remove it from the HPU. Be careful not to spill any hydraulic fluid. 5. Remove the disposable element from the manifold. Discard any fluid contained in the filter housing and the filter element. 6. Wipe out any remaining sludge in the filter housing with a lint-free cloth. 7. Inspect the O-rings in the manifold for any sign of deterioration. If necessary, replace the defective O-ring(s). 8.
Sampling the Hydraulic Fluid Procedure Take a fluid sample from the reservoir to get a visual indication of the fluid level and relative contamination. Clean hydraulic fluid is clear and has an amber color. If the composition of the fluid appears to have changed, obtain a sample of the hydraulic fluid from the sample port and check the fluid qualities. Filler Cap Hose Valve Assembly Sample Port Control Manifold Fluid Level Sight Gage Needle Valve Control Manifold 1.
Replacing the Hydraulic Fluid 6. 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. 7. Close the needle valve and remove the hose and valve assembly. Open the needle valve.
Replacing the Hydraulic Fluid Recommended equipment Prerequisite • A transfer pump with a 10 micron filter (such as the Model 590.01 Fluid Transfer Pump) • ethanol or a similar cleaning solvent • Lint-free cloths or manufactured rags • A container for the used hydraulic oil and a small drain pan that will fit underneath the drain plug • A hydraulic fluid sampling kit (MTS part number 055-589-601) • A new filter Take a sample of the hydraulic fluid to determine if it should be replaced.
Inspecting the Heat Exchanger 6. Replace the HPU filter element. Refer to the related procedure. 7. Add new hydraulic fluid to the reservoir. A. Close the fluid drain. B. Replace the filter in the transfer pump and transfer fresh hydraulic fluid (filtered to 10 microns) into the reservoir. Stop when the fluid level gets close to the top of the sight glass. C. Reinstall the filter cap’s strainer assembly. 8. Run the HPU. A. Press the Start switch. B.
Inspecting the Heat Exchanger 6. Remove the end bonnet from the water intake side of the heat exchanger. If you have to remove a mounting bracket, use blocks of wood to support the exchanger. 7. Internally inspect the exchanger for: • Corrosion and erosion damage to the tubes and tube ends • Fouling and corrosion deposits on the tubes • Condition of the optional zinc anodes • Damaged threads 8. If no further cleaning is needed, reassemble the heat exchanger using new gaskets. 9.
Inspecting the Heat Exchanger 68 Maintenance Model 505G2.20 - 505G2.
High Pressure Filter Kit Accessories Contents High Pressure Filter Kit 69 Replacing the Pressure Line Filter Element Accumulator Kit 71 Commoning Kit 73 Caster Kit 70 75 High Pressure Filter Kit This section describes how to install the high pressure filter kit (part number 054-728-8XX). To install the high pressure filter kit: 1. Ensure that system hydraulic pressure has been reduced to zero before proceeding.
Replacing the Pressure Line Filter Element 6. Mount the filter assembly to the support with the 3/8-16 UNC screws, nuts and washers. 7. Use the filter assembly to determine where the filter support should be installed. Mount the filter support to the base of the HPU with the four 3/8 x 1-1/2 inch lag screws and washers. 8. Connect the high pressure hose between the filter assembly and the high pressure output port. 9. Turn on the hydraulic pressure and check for leaks.
Accumulator Kit 10. If you are changing the filter because the dirty filter indicator tripped, run the HPU for two to four hours to remove contaminants. Then take a fluid sample and have it analyzed. Clean or change the fluid if it does not meet an ISO cleanliness level of 13/9 or better. 11. Press the Reset button on the HPU control panel to reset any interlocks and turn off the Dirty Filter indicator. Accumulator Kit This section describes how to install the accumulator kit (MTS part number 054729-1xx).
Accumulator Kit The accumulator kit is used to reduce pump pressure ripple and supplies shortduration peak flows in excess of pump capacity. Flange Adapter Brackets O-Ring Accumulator Split Flange 1/4-20 UNC Nut Washer Headless Screw Straight Adapter Control Manifold Straight Adapter Spacers 1/4-20 UNC Nut Washer Headless Screw Hose 1/2-13 UNC Hex-head Screw Assembly of Accumulator Kit Components 72 Accessories Model 505G2.20 - 505G2.
Commoning Kit Installation procedure 1. Stop the HPU and ensure that the system hydraulic pressure is zero. 2. Remove the existing plug from the port labeled PO in the bottom of the control manifold. Install a straight adapter in this port. 3. Slide the accumulator support brackets onto the accumulator. Mount the flange adapter, split flange halves, and bolts to the accumulator. 4. Attach a straight adapter into the flange adapter. 5.
Commoning Kit 9. Install the new rear sheet metal panel with the commoning opening, existing front sheet metal panel, and plastic cover. Washer 5/8-11UNC Nut 5/8-11UNC Hex-head Screw Gasket HPU Back Panel Butterfly Valve Flange Washer 5/8-11UNC Hex-Head Screw Commoning Spool 74 Accessories Model 505G2.20 - 505G2.
Caster Kit Caster Kit The caster kit (part number 055-334-501) is a angle-weldment support with casters (two rigid, two locking swivel). The caster kit allows the hydraulic power unit to be easily moved. The caster kit is designed to hold the Model 505.20 or Model 505.30. Model Approximate Weight (with fluid) 505.20 717 kg (1580 lb) 505.30 762 kg (1680 lb) Caster Kit Model 505G2.20 - 505G2.
Caster Kit 76 Accessories Model 505G2.20 - 505G2.
Hydraulic Power Unit Maintenance and Service Logs Contents 8 Hours/Daily 78 40 Hours/Weekly 79 160 Hours/Biweekly 500 Hours 80 81 1000 Hours 82 2000 Hours 83 5000 Hours 84 10,000 Hours 85 Hydraulic Power Unit Maintenance and Service Logs 77
8 Hours/Daily 8 Hours/Daily 8 Hours/Daily Service Interval Recommendation Date 78 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 79
160 Hours/Biweekly 160 Hours/Biweekly 160 Hours/Monthly Service Interval Recommendation Date 80 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 82 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 Current for Wear and 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 83
5000 Hours 5000 Hours 5000 Hours Service Interval Recommendation Date 84 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 Inspect Motor Bearings Determine if Replacement or Rebuild of Pump needed Determine if Replacement or Rebuild of Motor needed 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 85
10,000 Hours 86 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.
