Hydraulic Installation Guide Version 1.0 Hydraulic Installation Guide - Version 1.0
Change Log Date Change 03/11/2014 Initial Release ABT-TRAC 517-A Martin Avenue Rohnert Park, CA 94928 Tel: 707-586-3155 Fax: 707-586-3159 http://www.thrusters.com
Each hydraulic system provided by ABT-TRAC is engineered for the needs of the particular vessel into which it will be installed. In light of that, the number of configurations is nearly limitless. This manual addresses hydraulic system installation in a general way, and should only be used as a guide. Refer to your particular vessel s hydraulic plumbing diagram for specific installation information. Warnings Always refer to your vessel s hydraulic plumbing diagram for specific installation information. Never exceed the maximum hose or pipe operation pressures. Never raise the pressure in any part of the system over the maximum listed in your vessel s plumbing diagram. Always install components and interconnects so that a leak, however unlikely, cannot reach an area hot enough to cause a fire. Version 1.0 3 Hydraulic Installation Guide
Layout of a Basic Hydraulic System The typical fluid path in an ABT-TRAC hydraulic system is as follows: 1. Fluid is held in the hydraulic reservoir. 2. The hydraulic pump draws in fluid and then expels it into the pressure manifold. Feedback from the pressure manifold regulates the pump. 3. The pressure manifold distributes the fluid to the directional control valves. 4. The directional control valves move fluid into and out of the final consumer (thruster, stabilizer, windlass, capstan, and so on). 5. The returned fluid exits the directional control valves and is collected in the return combiner. 6. The fluid leaves the return combiner and enters the heat exchanger where it is cooled. 7. The cooled fluid is filtered and then returned to the hydraulic reservoir. Figure 1. Basic Hydraulic System Reservoir 1 7 6 2 Combiner 2 2 Universal Manifold DPPCM 5 5 3 3 Servo Manifold Thruster Manifold 4 Thruster 4 Hydraulic Installation Guide Version 1.0 4
Reservoirs In a typical system, the reservoir Holds hydraulic fluid for use by the system Cools the fluid when a heat exchanger is installed Filters returning fluid Displays fluid level and temperature Electronically reports fluid level and temperature Figure 2 and Figure 3 illustrate possible reservoirs, one with an attached heat exchanger and one without. Figure 2. Typical 11/20 Gallon Reservoir (with heat exchanger) Heat Exchanger Upper Anode Filter Fill Figure 3. Typical 4.7 Gallon Reservoir (w/o heat exchanger) Visual Temperature/Level Indicator Fill Filter Visual Temperature/Level Indicator Return Section Filter Main Tank Case Section Lower Anode Version 1.0 5 Hydraulic Installation Guide
s s receive unpressurized fluid and expel pressurized fluid. ABT-TRAC uses three general pump types: gear pumps, variable piston pumps, and variable vane pumps. Figure 4. Typical Gear Outlet Suction Figure 5. Typical Variable Piston Case Drain Sense Line High Standby Suction (outlet directly opposite on other side) Maximum Flow Figure 6. Typical Variable Vane High Sense Input Standby Case (There are two case ports. After pump is instalalled, attach hose to the higher one.) Maximum Volume Suction (outlet directly opposite on the other side) Hydraulic Installation Guide Version 1.0 6
Universal and System Manifolds Universal manifolds are containers that capture pressurized fluid from various pumps within the system through one-way valves (check valves). After the fluid is captured, it is distributed to components within the system through open general ports, or through a valve when isolation is required. Fluid pressure is regulated by components within universal manifolds, the receiving component, or not at all depending on the fluid s final use. Universal manifolds also contain a system pressure relief valve. Universal manifolds are used in conjunction with a dual pressure pump control manifold (DPPCM) when multiple feedback pressures to the pump are required. System manifolds combine the functionality of a universal manifold and a dual pressure pump control manifold into one assembly. Figure 7. Universal Manifold Figure 8. System Manifold Universal and System Manifold Families There are an infinite number of ways to configure universal and system manifolds, but they generally belong to a handful of families. The following sections describe the general functions of these assembly families. Version 1.0 7 Hydraulic Installation Guide
Stage 1 Universal Manifold Assembly Family The Stage 1 Universal Manifold Assembly Family is the smallest family. The base manifolds used for this family are 36863 (aluminum) and 37350 (steel). Figure 9. Stage 1 Universal Manifold 2 In General To Cooling Cooling Circuit Cooling Circuit Cooling Circuit Flow 2 Check Return to Tank System Relief 3-way 1 Check To Compensator 1 In General Main Cavity Hydraulic Installation Guide Version 1.0 8
Stage 2 Universal Manifold Assembly Family The base manifold for the Stage 2 Universal Manifold Assembly Family is 34480 (aluminum). Figure 10. Stage 2 Universal Manifold (top/front) Main Cavity Forward Isolation #3 Check Cooling Circuit Forward Isolation On/Off Switch #1 In To Switch Cooling Circuit Flow Control To Cooling System Relief On/Off Version 1.0 9 Hydraulic Installation Guide
Figure 11. Stage 2 Universal Manifold (back) Forward Isolation #3 In Cooling Circuit Return to Tank #2 Check #1 Check General s #2 In Hydraulic Installation Guide Version 1.0 10
Stage 3 Universal Manifold Assembly Family The base manifolds for the Stage 3 Universal Manifold Assembly Family are 35136 (aluminum) and 36251 (steel). Figure 12. Stage 3 Universal Manifold (top/front) Forward Isolation #1 Check #2 Check Stabilize Cooling Circuit Main Cavity #1 Forward Isolation Cooling Circuit Flow General Switch Cooling Circuit Flow Control On/Off Switch Version 1.0 11 Hydraulic Installation Guide
Figure 13. Stage 3 Universal Manifold (back) System Relief Return to Tank #2 Check #3 Check #2 In Cooling Circuit General s #1 In #1 Check Hydraulic Installation Guide Version 1.0 12
Stage 2 System Manifold Assembly Family The base manifolds for this family are 38677 (aluminum) and 37944 (steel). Figure 14. Stage 2 System Manifold (top/front) #1 In System #2 In General s Control High Forward Isolation On/Off Forward Isolation Normally Open On/Off for VPV Control Low #3 Indpendent Cooling Circuit Output Output Cooling Circuit Return s Version 1.0 13 Hydraulic Installation Guide
Figure 15. Stage 2 System Manifold (back) Switch Control High Cooling Circuit Control Low Control #3 In System Relief General N/O Return s N/O (for VPV) #1 Tandem Control #2 Tandem Control #3 Independent Output Hydraulic Installation Guide Version 1.0 14
Stage 3 System Manifold Assembly Family The base manifolds for this family are 37955 (aluminum) and 38139 (steel). Figure 16. Stage 3 System Manifold (top/front)) #1 In System #2 In General s Cooling Circuit Cooling Circuit Flow Sense Control High Forward Isolation Forward Isolation Cooling Circuit #3 and #4 Independent On/Off s Control Low #1 and #2 Independent On/Off s Output On/Off Return s System Relief Return s Version 1.0 15 Hydraulic Installation Guide
Figure 17. Stage 3 System Manifold (back) Control Low Cooling Circuit Switch System Relief General #1 Independent Outlet #2 Independent Outlet Rear Isolation #3 Independent Outlet #3 In General #4 Independent Outlet Hydraulic Installation Guide Version 1.0 16
Dual Control Manifolds Dual pressure pump control manifolds (DPPCMs) are used along with universal manifolds to send one of three signals to variable piston pumps. No signal Energize low pressure valve Energize high pressure valve idles at standby pressure emits and maintains an interim pressure equal to the low pressure adjust plus the standby pressure emits the highest pressure for which it is set Figure 18. Dual Control Manifold Low Inlet Case Drain High On/Off Low Output 1 Ouput 2 Output 3 On/Off (controls output 1) On/Off (controls output 2 and 3) Version 1.0 17 Hydraulic Installation Guide
Directional Control s Directional control valves (DCVs) turn on and move linear (stabilizer, crank cylinder, etc.) or rotary (thruster, windlass, capstan motors, and so on) actuators forward or reverse. DCVs can be mounted to base manifolds singly or in groups of two or more. DCV base manifolds have an input port P, an output port T, and an A and B port pair for each valve. Fluid enters a DCV through port P, and depending on which of the two coils on the valve is energized, goes out through port A, is used by an actuator, and then returns through port B; or goes out through port B and returns through port A. After the fluid returns through port A or B, it flows to the return combiner through port T. The following figures illustrate typical DCVs. Figure 19. Typical Large Single-device DCV Assembly Figure 20. Typical Dual-device DCV Assembly Figure 21. Typical Single-device DCV Assembly Hydraulic Installation Guide Version 1.0 18