Low Profile J Series Power Unit with Vane Pump

Transcription

1 Low Profile J Series Power Unit with Vane Pump

2 READ ALL INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN THE PRODUCT DESCRIBED. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION. FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE! RETAIN INSTRUCTIONS FOR FUTURE REFERENCE. WARNING: THIS INSTRUCTION MANUAL IS INTENDED FOR USE BY QUALIFIED INDIVIDUALS WITH A WORKING KNOWLEDGE OF HYDRAULIC AND ELECTRICAL PRINCIPLES. PROFESSIONAL INSTALLATION IS RECOMMENDED. Description The hydraulic power units detailed herein are designed to operate on 3 phase, AC electric power. Each power unit consists of a pressure balanced vane pump, powder coated reservoir, Premium Efficiency three phase electric motor, anti-vibration bars, spin-on type return filter, and a factory set System Safety Relief valve. Each unit is equipped with a Pressure port at the manifold and a Tank Return port at the return line filter head. The units are to be connected to remote mounted valving. The power units can be coupled via suitable hydraulic lines to a wide variety of directional control valves and hydraulically operated devices. Proper circuit design must be considered when selecting directional control valves and load control valves to ensure safe and predictable movement of all hydraulic actuators and connected devices. We recommend using Open Center or Tandem Center directional control valves. If the hydraulic unit is to be connected to Closed Center or Float Center valves, the circuit must include an unloading valve to avoid having the system running over the relief valve when the closed center directional control valves are not shifted. Specifications All units have: Totally enclosed fan cooled Premium Efficiency electric motor, rated for 60 Hz and 50 Hz voltages (see motor nameplate for full details of ratings) Anti-vibration mounts between the electric motor and the reservoir top plate Pressure balanced vane pump Powder coated reservoir plumbed for vertical only mounting Adjustable Safety Relief Valve preset at the factory Aluminum manifold with SAE #12 Pressure port and cartridge style air bleed valve Suction strainer at pump inlet SAE #16 ported return line filter with spin-on type, 10 micron canister and visual by-pass indicator Bayonette style filler / breather assembly with strainer basket Sight / level / temperature gauge Liquid filled pressure gauge with isolator ¾ NPT drain port on lower front of reservoir 1 P a g e Unpacking Check package for any external signs of damage that may have occurred during transit then unpack the unit and check for physical signs of damage. If components are missing or there is any noticeable damage, please contact the office where the item was purchased.

3 Figure 1 38VP30 Figure 4 38VP31 Figure 2 38VP30 Dimensions Figure 5 38VP31 Dimensions Figure 3 38VP30 Hydraulic schematic Figure 6 38VP31 Hydraulic schematic 2 P a g e

4 Assembly All the power units are packaged fully assembled. Customer is responsible to fill the reservoir with proper level of a quality hydraulic fluid suitable for use in the intended environment. Customer must also supply and install all directional control valves to be mounted remote from the hydraulic power unit. Figure 7 38VP33 Installation of Hydraulic Power Unit 1. Select a good location to mount the hydraulic power unit. It should be in a clean, level, dry area with adequate ventilation and preferably near the electric power source. NOTE: Although the units have totally enclosed fan cooled motors, they still need free air circulation around the motor and reservoir to displace heat. CAUTION Avoid dusty conditions that could clog the reservoir breather. Figure 8 38VP33 Dimensions 2. This hydraulic power unit is designed for vertical mounting with the reservoir feet down and the reservoir breather on the top. Choose a flat, level mounting surface to bolt the reservoir feet to. See unit dimensions for reservoir base bolt pattern. The hydraulic unit is plumbed For vertical mounting as noted above. Mounting the unit in an inclined plane or any other position will greatly reduce the available usable oil in the reservoir. This can cause the hydraulic oil to foam resulting in erratic movement of hydraulic components, and pump failure. CAUTION Figure 9 38VP33 Hydraulic schematic To minimize contamination problems, do not remove plastic shipping plugs from hydraulic unit until you are ready to install hoses and fittings. 3 P a g e

5 3. HYDRAULIC INSTALLATION Make sure that the work area and the hydraulic components are clean and free from dirt, debris,lint, etc. 4. Install properly sized tandem center or open center directional control valves and any required load control valves. 5. Connect your hoses and fittings to the hydraulic valves, actuator (hydraulic cylinder, hydraulic motor, or other devise) and when ready to connect the hydraulic power unit ports, remove and discard plastic shipping plugs from the P port of the aluminum manifold and from the T port of the return filter head. CAUTION! Do not use Teflon tape. This unit is equipped with SAE O-ring type ports. Do not over-tighten fittings. 6. Remove the reservoir breather and fill the hydraulic unit reservoir with a good quality hydraulic fluid. It is recommended that hydraulic fluids have a viscosity between 150 SUS and 225 SUS at 100 degrees F and the maximum operating temperature should not exceed 140 deg. F. The reservoir should be filled to the upper (blue) line of the sight / level / temperature gauge but not above. 7. Use of a filter cart to add fluid to the reservoir is highly recommended. Do not pour hydraulic fluid directly from a pail or drum as this can result in debris entering the reservoir. 8. Re-install the breather on the reservoir. Electrical Wiring 1. When wiring the motor, follow all local electrical and safety codes as well as the National electrical codes in your jurisdiction (i.e. NEC, ESA, etc) and all Occupational Safety and Health Act (OSHA) requirements. 2. Make certain that the wire size is adequate for the horsepower requirements (see chart on page 6). NOTE: Voltage drop increases with the length of power cord. Larger wire diameter may be required. 3. Motor nameplate voltage level must be available at the motor when it is operating under load. Avoid voltage drop by using adequate wire size. 4. DOUBLE CHECK ROTATION! Motor rotation is clockwise facing fan end of motor (which means the motor is wired to turn counter clockwise when facing the shaft of the motor). 5. On start-up, ensure an open flow path for the hydraulic circuit and jog the motor to ensure correct rotation and to prime the pump to ensure adequate lubrication. After the correct motor rotation is confirmed and the fluid is moving freely, motor may be operated at full speed. CAUTION! Never run the system without adequate levels of hydraulic fluid in the reservoir. New installations will require additional fluid to fill the lines, cylinders etc. so check the reservoir fluid levels frequently during initial operation to ensure the fluid level does not go below the minimum level on the sight gauge. 6. Keep all electrical lines as short as practical. 7. Never exceed the maximum operating pressure. 8. Do not over-tighten fittings, bolts, etc., as this can damage the units. 9. Provide adequate cooling for the hydraulic oil so as not to allow oil and/or component damage due to excessive temperatures. Excessively high operating temperatures will be hazardous and may cause property damage and/or personal injury. 4 P a g e

6 WARNING REPLACE OR REPAIR DAMAGED OR WORN POWER CORDS IMMEDIATELY. WARNING DO NOT OPERATE UNITS WITHOUT PROPER GROUNDING. WARNING DO NOT RUN THE HYDRAULIC UNIT DRY AS THIS WILL CAUSE SEVERE PUMP DAMAGE. PRIOR TO OPERATION: 1. Double check all hydraulic and electric connections. 2. Confirm that reservoir is filled with hydraulic fluid. 3. Put all equipment guards in place 4. Clear all persons from work area 5. Check for loose tools, equipment, or anything that might interfere with operation of equipment. OPERATION 1. Start Up When initially starting unit up, be sure to jog the unit (intermittently run unit) several times. This will prime the pump and fill the hydraulic lines. CAUTION Check motor fan rotation again at this time to avoid damaging pump or pump shaft seal. WARNING IF MOTOR IS TURNING IN THE WRONG ROTATION, SHUT OFF ELECTRICAL POWER BEFORE ATTEMPTING TO CHECK OUT MOTOR WIRING. Maintenance 1. Keep the reservoir filled to the proper level with hydraulic fluid. Use a good quality hydraulic fluid that is suitable for use in the intended environment. 2. Check the reservoir fluid level and return line filter condition on a regular basis and use new, filtered hydraulic fluid when adding fluid. Most pump/fluid motor failures, valve malfunctions, and short unit life can be traced directly or indirectly to dirt or other foreign materials (water, debris, lint, etc.) entering or already in the hydraulic system. 3. Make a frequent inspection of hydraulic fluid and change if contaminated. 4. Check the return line filter indicator on a regular basis and replace the spin-on canister before the indictor reaches the red area. 5. Regularly inspect hydraulic hoses and fittings for wear or leakage. 6. Keep the unit and surrounding area clear of dirt and foreign materials. 7. Keep electrical connections clean. 5 P a g e

7 Troubleshooting Chart SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION Motor won t start 1. Loose connection 2. Circuit breaker tripped 3. Voltage drop 4. Seized pump 1. Check wiring 2. Reset circuit breaker 3. Use heavier gauge wire 4. Replace pump Will not pump oil (Motor runs but cylinder does not move, or moves slowly) Pump motor unit is noisy Unit does not develop full pressure 1. No oil in reservoir 2. Motor rotation incorrect 3. Oil level low 4. Relief valve is held open 5. Suction strainer is clogged 6. Hydraulic cylinder (or motor etc) seals are cut or worn out. 7. Reservoir breather is dirty or clogged. 1. Low oil level 2. Air in system 3. Suction strainer or inlet filter is clogged 1. System relief valve set too low, or leaking 2. Pump worn out 3. Air in system 4. Oil temperature is too high HYDRAULIC POWER UNIT PERFORMANCE 1. Check oil level, refill 2. Rewire 3. Add oil as needed 4. Flush relief valve 5. Clean suction strainer 6. Replace or repair cylinder (or motor etc) 7. Clean reservoir breather and reinstall 1. Add oil as needed 2. Bleed air from highest fitting in system by loosening fitting very slightly and operating unit until bubbling of air stops, then tighten 3. Clean suction strainer or inlet filter 1. Check system relief valve for proper setting 2. Replace the pump 3. Bleed air from systems 4. Let oil cool well below 140 F MODEL Reservoir Capacity HP Nominal Flow Max. Pressure Voltage Phase Hz Full Load Amps 38VP30 20GAL GPM /460 VAC 3 60/ / VP31 20GAL GPM /460 VAC 3 60/ / VP33 30GAL GPM /460 VAC 3 60/ / P a g e

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9 NO. DESCRIPTION 38VP30 38VP31 38VP33 QTY 1.1 Reservoir Nut, Multi-thread U, 5/16UNC FOR 38VP30 & 38VP31 14 FOR 38VP Plug, Steel, 3/4" NPT Gauge, 5" Sight-Temperature Nipple, 1 NPT X 16 Long Fitting,street elbow,1 NPT,black pipe Suction strainer,1 NPT,15gpm Top plate Gasket, thickness,10feet long Screw,Hex washer hd,5/16unc X FOR 38VP30 & 38VP31 14 FOR 38VP Tube,return,3/4 NPT X 11-1/2 lg Tube,return,1 NPT X 11-1/2 lg suction flange Screw,washer style h.h., 5/16-18x3/4 lg Anti-Vibration bar,,bolt down, 213/ Screw,SHCS,3/8-16 X 1 plated Spring washer, for SHCS 3/ Vane pump,sae A,7.5gpm@1800rpm Manifold,P&T pts c/w two C10-2 cavities Relief,10,2w,P.O Velocity fuse / Air Bleed valve, C Valve,shut-off,1/4 NPTF Gauge 0~2000 l.f. ¼ NPT,back mount Screw,SHCS,3/8-16X1-3/4lg Washer,internal tooth lock,3/ Washer,13/32 IDX3/4 OD X.091 thick Adapter,#12 SAEM union Fitting adapter,#12jic-#12saem Hose ass y,#12jicf to #12 JICF Adapter,#12 JIC male-#12npt male #6 SAE plug #12 SAE plug Adapter,P/M,254/256TC-SAE A Screw,hex head,1/2-13 x 1-1/2 lg Washer,1/2 internal tooth lock Washer,1/2 SAE flat plated Coupling,3/4 dia. X 3/16 key Coupling,1-3/8 dia. X 5/16 key Insert, nitrile Motor Screw,hx. Hd. Cap. 3/8-16x1-1/ Washer, internal tooth lock,3/ Washer,13/32 IDx ¾ ODX Filter head with 15PSI by-pass Gauge,pressure,color indicator Filter element,spin on,0~34gpm Nipple,1 NPT X 12 lg adapter #16 ORBMX1"NPTF Filter Breather Cap Assembly Screw, 10-32UNC X3/4" P a g e