Annex to the CG4 Manual: HydraBrain

Transcription

1 Annex to the CG4 Manual: HydraBrain MOZELT GmbH & Co. KG Please observe the following safety information and recommendations before start-up!

2 Table of contents 1. Product Description Components used Determination of the required volumetric flow for the generator plant Determination of the additional volumetric flow for the generator plant Installation of the BELL CLUTCH with valve support Dimensional drawings HydraBrain Unit Proposed Connection Place of Installation (Recommendation) Electro-Hydraulic Drive Control Applications Function Dimensions: Drive Control valve Installation Standards and Safety Requirements Installation Remarks Electrical Connection Magnet Operation Switch 35 WARNING It is absolutely necessary to observe the following warnings. If these warnings are not observed, serious personal injuries with fatal result, severe injuries to health or considerable damage to property cannot be ruled out! WARNING A prerequisite is that the CoolGen4 and HydraBrain operating instructions have been read and understood. In particular, the safety notes shall be observed. Page 25

3 1. Product Description The novel HydraBrain system developed in intensive cooperation between Wessel Hydraulik and Mozelt Magnetanlagen immensely facilitates installation and driving of a generator for the customer; in the process, fuel and thus money is saved and, as a consequence, impact on the environment is reduced. Due to the electronic interaction of the generator with the novel and, as regards its efficiency, very good control valve - with integrated overpressure and overspeed safety device - the hydraulic system is not subjected to load when the magnet is switched off and the diesel engine has not to produce any drive power. Conventional systems are always subjected to a preload in the system and thus to an increased and unnecessary pressure level. Further, it is now also possible to install HydraBrain without any problems in construction machines whose manufacturers do not offer any support for installation of such systems, be that due to missing information or non-available technical implementation. This solution makes it possible for dealers and operators to get all components from a single source. There are no longer different sources of supply, technical adjustment or adaptation - if possible at all - is no longer necessary. 1.1 Components used Fig.: 1 HydraBrain add-on unit HydraBrain unit essentially consisting of: Synchronous generator CoolGen4 series Control Valve Electronic Control Device Hydraulic motor Flow line A Return line B Leakage oil hose Valve selection Valve selection Data transmission line for start, stop signal, 24-volt voltage and speed transmission 24-volt voltage line 24-volt on-board power supply system Magnet switch panel Page 26

4 1.2 Determination of the required volumetric flow for the generator plant Depending on its absorption volume (V) the hydraulic motor driving the generator requires the following input volumetric flow for the generator rated speed of 3000/min: Calculation of motor input volumetric flow: (Size of hydraulic motor) * 3 = (motor input volume) Example of a 17 ccm hydraulic motor: 17 ccm x 3 = motor input volumetric flow of 51 l/min Example of a 25 ccm hydraulic motor: 25 ccm x 3 = motor input volumetric flow of 75 l/min To be able to make this input volumetric flow available in a controlled condition the control valve requires an input volumetric flow which is by 10% to 20% higher: Calculation of the required control valve input volumetric flow: (calculatedmotor input volumetric flow) + (10 l//min of control volumetric flow) = control valve input volumetric flow Example of a 17 ccm hydraulic motor: 51 l/min + 10 litres of control volumetric flow = 61 l/min Example of a 25 ccm hydraulic motor: 75 l/min + 10 litres of control volumetric flow = 85 l /min This control valve input volumetric flow must be safely available across the entire operating range of the construction machine in which the generator operation will be allowed. The minimum value must never be undershot. If the maximum volumetric flow is exceeded, an unnecessary amount of energy will be wasted because also the excessive volumetric flow is generated under the same pressure and the construction machine is accordingly loaded with the total output. In case the calculated volumetric flow is not available on the construction machine a further reduction of the required volumetric flow can be obtained via a reduction of the generator rated speed.in this respect please contact Mozelt GmbH & Co. KG. 1.3 Determination of the additional volumetric flow for the generator plant The pressure in the generator hydraulic circuit adjusts itself through its electric load (output of the operated magnet). The pressure valve in the control valve serves to protect the pump. It is to be ensured that the pressure valve will not respond at normal operating conditions of the generator system because due to the effect of the pressure valve the control can be no longer carried out in the control valve. For this purpose it may be necessary to measure the pressure in the generator hydraulic circuit and to readjust the pressure valve in the control valve as well as other pressure valves, if necessary. If a change to a more efficient magnetic disc is made, a readjustment of the pressure valves may also be necessary. The additional maximum power demand for the generator plant can be calculated on an approximate basis as follows: L[kW] = P[bar] x Q[l/min] / 600 P = Q = L = gemessener Maximaldruck an der Pumpe Regelventil-Eingangsvolumenstrom Leistungbedarf During the operation of the generator plant it is to be ensured by an additional pump that the drive is designed for this additional output. It is also to be ensured that the admissible torque on the secondary drive is not exceeded by the additional pump. Page 27

5 1.4 Installation of the BELL CLUTCH with valve support Fig.: 2 Fastening of the manometric balance to the end shield Support control valve Fastening screw A end shield / support control valve Service fastening This type of fastening is used, if fastening screws Item 2 have to be loosened for servicing. It ensures that the support and manometric balance at the end shield form a unit and thus, the clutch bell with control valve and electronic control device can be pulled off Through-hole for fastening of the electronic control device Page 28

6 MOZELT GmbH & Co. KG 1.5 Dimensional drawings HydraBrain Unit Please note that the assembly kits mentioned below may vary in height and length due to the different hosing possibilities! Fig.: 3 HydraBrain 13 kw with 17-ccm Sunfab hydraulic motor Fig.: 4 HydraBrain 13 kw with 25-ccm Sunfab hydraulic motor Fig.: 5 HydraBrain 20 kw with 25-ccm Sunfab hydraulic motor Page 29

7 1.6 Proposed Connection P 3 T A L B L 5 1 2a 2b T L Piping: L P T A B Leakage-Oil hose Pump-Oil hose Tank-Oil hose Flow line Return line Components: 1 Control line 2a Variant A: Switch line 2b Variant B: Switch line V Power line 4 Load lifting magnet 5 Unit HydraBrain 4 Fig.: 6 Proposed connection 1.7 Place of Installation (Recommendation) Fig.: 7 Possible place of installation Fig.: 8 Possible place of installation variant B Page 30

8 MOZELT GmbH & Co. KG 2. Electro-Hydraulic Drive Control 2.1 Applications Used for single acting rotary actuators which must be operated with a precise controlled speed and reactions of load changes have to be dampened dynamically. Fig.: 9 Control valve Fig.: 10 Electronic control device General Electrics Installation position: Hydraulics Environmental temperature: Weight: any -20 to +50 C Connections: A ; B G1/2 ISO P ; T G3/4 ISO L ; LSA G1/4 ISO MB ; M min. M8x1 Power supply voltage: Tolerance of voltage: Maximum current (controler and solenoids) Maximum solenoid current: Digitale Inlet ports 24 VDC +/- 10 % VDC 1600 ma (at 24 VDC) 2x 750 ma logic 0: < 2V logic 1: >10V Maximum operating pressure: Maximum allowable input volume flow : 420 bar (6000 psi) at port A, P, T 350 bar (5080 psi) at port B port L unpressurized 250 l/min (66 gpm) Minimum inlet volume flow: Volume flow of the consumer +20% Load volume flow: l/min (...26 gpm), adjusted by software Hydraulic fluid: Mineral Oil (HL, HLP) conforming DIN 51524, different fluids upon request Hydraulic fluid temperature range: -20 to +80 C Viscosity range: 20 to 500mm²/s (preferably 30 to 46) Contamination grade: Filtering conforming with NAS 1638, class 8 Page 31

9 2.2 Function The drive control system contains of a 3-direction flow valve with pressure cut-off, which is piloted by the electronic control device. The hydraulic valve regulates the inlet flow and the return flow of the consumer by means of two proportional hydraulic spools, piloted independently. The inlet spool regulates the volume flow to the consumer to a constant value. An electrical speed signal is produced by the consumer and regulates the inlet spool. The return spool is dampening the hydraulics in order not to allow oscillation to influence the system. Especially when load changes (e.g. switching ON or OFF of an electrical load in a generator application) occure this dampening is controlled dynamically. Therefore the consumer has to submit a START/STOP signal to the control device way Flow Control Valve with pressure cut off (Pressure Compensator) 2 controlled mainvalve fort he supply of the hydromotor 4 Pressure reducing valve. Generates piloting pressure (30 bar) for the supply of the proportional valves 5 and 6 Fig.: 11 Hydraulic diagram control valve 5 Electrical-proportional piloting valve for the inlet spool (2) 6 Electrical-proportional piloting valve for the return spool (7) The valves 5 and 6 are operated by the electronic control inside a regulating circuit 7 controlled mainvalve for the throtteling of the hydromotor s return line 8 safety pressure valve fort he hydromotor 9 anti-cavitation valve fort he hydromotor Page 32

10 MOZELT GmbH & Co. KG 2.3 Dimensions: Drive Control valve hole-punch Fig.: 12 Dimensions: Drive Control valve Page 33

11 3. Installation 3.1 Standards and Safety Requirements WARNING It is absolutely necessary to observe the following warnings. If these warnings are not observed, serious personal injuries with fatal result, severe injuries to health or considerable damage to property cannot be ruled out! WARNING CAUTION A prerequisite is that the CoolGen4 and HydraBrain operating instructions have been read and understood. In particular, the safety notes shall be observed. Hydraulic hoses are not to come into contact with the load holding valve because otherwise they might be subject to thermal damaging. Ensure that standards EN 563 and EN 982 are observed. WARNING The following standards are to be observed because of the surface temperatures on the load holding valve: EN 563: Temperatures on surfaces that can be touched. EN 982: Safety-technical requirements for fluid-technical systems and their components. 3.2 Installation Remarks WARNING Observe all installation and safety information of the construction machine manufacturer. Only technically permitted changes are to be made on the construction machine. The user has to ensure that the device is suitable for the respective application. Application exclusively for the range of application specified by the manufacturer. Before installation or de-installation, the hydraulic system is to be depressurized. Settings are to be made by qualified personnel only. Opening of the device is only to be performed with the approval of the manufacturer, otherwise the warranty is in validated. The included connection recommendations are not guaranteed. The functionality and the technical specifications of the construction machine must be checked. Page 34

12 3.3 Electrical Connection Data transmission line Electronic control device 1 Do not connect Power generator CG4 2 Do not connect 1 Input (0 VDC) Valve selection to connection no. 7 Voltage line 24 V 3 Do not connect 2 Input (24 VDC) 4 Speed signal 3 Output speed signal Valve selection to connection no. 6 Outgoing line on the electronic control dev. Control valve Connection 5 Conductor 1 Conductor 2 5 GND 0 VDC 6 Do not connect 7 Start-, stopsignal 8 Do not connect 9 Do not connect 10 Control valve 4 Output start, stop signal 5-11 See CG4 manual Connection 6 Conductor 1 Conductor 2 11 Control valve 12 GND 0 VDC supply voltage 13 Do not connect 14 Control valve Magnet Operation Switch 15 Control valve VDC supply voltage + - On-board power supply system Legend: = Data transmission line = Voltage line 24 V = Valve selection = Valve selection Terminal block on the CG4 power generator Terminal blocks on the electronic control device Fig.: 13 Terminal diagram 3.4 Magnet Operation Switch The switch for magnet operation is arranged on the operator panel of the operator cabin and activates magnet operation. Depending on the excavator manufacturer and excavator type, these switches differ and are not included in the HydraBrain scope of supply. As regards this matter, please contact your construction equipment dealer or excavator manufacturer. The magnet operation switch activates the following system functions: voltage supply HydraBrain electronic control system Deactivation of the speed control Prevents automatic or manual reduction of the diesel engine speed and thus also of the generator speed If for any reasons the magnet operation switch does not properly perform one of the above mentioned functions, there is the danger of load shedding during operation! Page 35