Hydraulic Supply and Return Piping

Transcription

1 Technical Brief Version 1.0 May 1, 2013 Hydraulic Supply and Return Piping Car Wash Hydraulics on a VFD The car wash industry uses a hydraulic pump with proportionators and priority valves to control the speed, or rpm, of rotary washing equipment. To effectively change or verify the rpm of a washer, a towel is tied to the washer or wash material is dislodged, the washer is turned on, a stopwatch is used to measure one minute while the revolutions of the washer are counted. This must be repeated for each piece of rotating wash equipment in the tunnel. Vehicle damage results when the washer rpm is too fast or too slow. Washer speed is always relative to conveyor speed. Higher rpm also create significant noise inside the vehicle and result in a customer feeling that his vehicle is being abused or in jeopardy of being damaged. Excessive heat is also created by the gear based proportionating equipment. Heat degrades the life of seals in the hydraulic components and is a result of the substantial amounts of electricity consumed in driving the proportionating equipment. We use a VFD and a flow meter to control the speed of a hydraulic motor. Our hydraulic system eliminates all the proportionating and flow control equipment. Each hydraulic motor has a published graph or formula of GPM and speed. Based on the flow meter, we can change the speed of the motor and hydraulic pump to ensure the correct washer rpm is achieved. The relay output, built into the VFD, is used to operate a normally open bypass valve. The pump starts and ramps to the desired flow rate prior to the vehicle reaching the washer. As the vehicle approaches the washer, the VFD relay output will be activated to close the bypass and force the correct GPM of hydraulic fluid to the hydraulic motor. A digital input in the VFD will be wired to an adjustable oil level switch. This switch should be adjusted to the very top of the oil level. If there is an oil leak, the float switch will drop out and voltage will not be present on the digital input causing the motor to immediately break (deaccelerate) and stop. A digital input can be used to measure the rpm of the shaft being driven by the hydraulic motor. This ensures that the washer is turning at the desired rpm and the coupling device between Copyright 2013 Innovative Control Systems, Inc. Portions of this document may contain information that is ICS proprietary

2 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 the hydraulic motor and the washer has not failed. Coupling failure can result in significant damage to a customer s vehicle. 1 Cleaning is improved by operating the washers at the correct speed at all times. 2 Customer experience is enhanced by reducing noise on the vehicle caused by washers operating too fast. Damages are reduced by maintaining the proper rpm at all times. Damage occurs more frequently when washer speed is too fast or too slow. 3 Electrical cost is significantly reduced by eliminating all the back pressure caused by the mechanical gears proportionating the hydraulic fluid. Electrical usage is also lowered by bypassing fluid between vehicles which effectively eliminates the load on the motor ABB Hydraulics Square D 2 Copyright Innovative Control Systems May 1, 2013

3 Technical Brief Version 1.0 Hydraulic Supply and Return Piping Installation Hydraulic Supply and Return Piping Installation The hydraulic pack unit is supplied with 37⁰ JIC fitting to connect flexible lines from the wash equipment. This section will describe the fitting locations and sizes needed to complete installation. High pressure line connection HY-1 and HY-4 are equipped with ½ 37⁰ JIC fittings located at the top right hand corner of the wire termination enclosure on the unit (Figure 1). Connect ½ flexible lines to fittings and torque to manufactures specs. Figure 1. Fittings located next to Wire Termination Enclosures May 1, 2013 Copyright Innovative Control Systems 3

4 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 HY-2, HY-3, HY-5, HY-6, HY-8 through HY-11 are equipped with ½ 37⁰ JIC fittings located at the right hand of the high pressure system gauge (Figure 2). Connect ½ flexible lines to fittings and torque to manufacturers specs. Figure 2. Fittings located next to High Pressure System Gauge 4 Copyright Innovative Control Systems May 1, 2013

5 Technical Brief Version 1.0 Hydraulic Supply and Return Piping Installation HY-7 has two flow control valves located top right hand corner of the hydraulic unit. The valves are equipped with ½ 37⁰ JIC fittings (Figure 3). Connect ½ flexible lines to fittings and torque to manufactures specs. Return line connections Figure 3. Flow Control Valves HY-1 is equipped with ¾ 37 ⁰ JIC fitting located at the right hand corner of the wire termination enclosure on the unit (Figure 4). Connect ¾ flexible line to fitting and torque to manufactures specs. May 1, 2013 Copyright Innovative Control Systems 5

6 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 Figure 4. Fitting located at Wire Termination Enclosure Hy-2, HY-3 are equipped with ¾ 37 ⁰ JIC fittings located at the lower right hand corner of the piping to the right of the filter housing (Figure 5). Connect ¾ flexible line to fitting and torque to manufactures specs, and clamp the line with the supplied clamp located at the top of the back panel. 6 Copyright Innovative Control Systems May 1, 2013

7 Technical Brief Version 1.0 Hydraulic Supply and Return Piping Installation Figure 5. Fittings located to right of the piping which is to the right of filter housing HY-4 is equipped with a ½ 37 ⁰ JIC fitting located at the right hand corner of the wire termination enclosure on the unit (Figure 6). Connect ½ flexible line to fitting and torque to manufactures specs. May 1, 2013 Copyright Innovative Control Systems 7

8 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 Figure 6. Fittings located at wire termination enclosure HY-5 through HY-11 are equipped with ½ 37 ⁰ JIC fittings located at the right hand side of the bypass solenoid block (Figure 7). Connect ½ flexible line to the fitting and torque to manufactures specs. 8 Copyright Innovative Control Systems May 1, 2013

9 Technical Brief Version 1.0 Hydraulic Supply and Return Piping Installation Figure 7. Fittings located at the bypass solenoid block All the units are equipped with a filter on the return side of piping (Figure 8). To assist in maintenance the filter housing has a pressure gauge to inform the user when it is time to change the element. The gauges are equipped with a color reference for the ease of replacement identification. May 1, 2013 Copyright Innovative Control Systems 9

10 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 Hydraulic Pump Tank Figure 8. Filter housing and pressure gauge Each hydraulic tank is equipped with an oil level sight gauge and level float switch (Figure 9). The site level gives the user a visual reference of fluid level in the tank. In the sight gauge, the level in the tank should be maintained at half way. The level float switch is connected to pump control circuit. 10 Copyright Innovative Control Systems May 1, 2013

11 Technical Brief Version 1.0 Hydraulic Supply and Return Piping Installation If the hydraulic level drops below a safe level, the pump will shut off protecting the Hydraulic pump from damage. Figure 9. Oil level sight gauge and level float switch May 1, 2013 Copyright Innovative Control Systems 11

12 Hydraulic Supply and Return Piping Installation Technical Brief Version 1.0 Notes Table 1: Document Change History Document Version Date(s) Contributor Initials Description /01/2013 B.F., B.M., W.S. First release. WashConnect, Auto Sentry, Lube Master and Tunnel Master are registered trademarks of Innovative Control Systems, Inc. Touch N Clean and Wash Valet are trademarks of Innovative Control Systems, Inc. All other company or product names are referenced for identification and may be trademarks of their respective owners. No part of this document may be reproduced in any form or by any means, including but not exclusive to electronic, mechanical, photocopying, etc., without the prior written permission of Innovative Control Systems. This document and the information contained within subject to change without notice. Hydraulic Requirements fm Innovative Control Systems, Inc Jacobsburg Road Wind Gap, PA Fax documentation@icscarwashsystems.com 12 Copyright Innovative Control Systems May 1, 2013