240SS Power Unit Installation Manual AMKUS, Inc. is an ISO 9001 registered company. 4735 AMKUS, Inc., 2700 Wisconsin Avenue, Downers Grove, IL 60515-4226 Website: www.amkus.com E-mail: experts@amkus.com Tel.(630) 515-1800 Fax (630) 515-8866
Installation Procedures 1. Remove the unit from the packing cartons and carefully inspect for damage. Damage that occurs during shipment should be reported immediately to the carrier. 2. There are 4 major components included in the 240SS Super Simo Power Unit. 1. Remove the black cover from the power unit by removing the bolts on either end of the unit. 2. Determine the location for the power unit. Make sure the black cover is accessible so it is able to be removed for service. The sight gauge should be accessible for service as well. A template is provided to assist in marking the location of the mounting holes. 1. VFD (Variable Frequency Drive) Panel 2. Control Panel 3. Heat Exchanger 4. Power Unit Optional Wireless Receiver 3. The power unit has been shipped with the kinetic bushings and mounting brackets installed. A 2X4 is used between the mounting brackets to prevent them from spreading. Heat Exchanger VFD Panel Control Panel 4. Install and tighten the 4 mounting bolts. Power Unit Installing the 240SS Power Unit Remove bolt Remove bolt Sight Gauge 5. Remove the 4 bolts securing the 2X4 from each end of the 2X4. Remove the 2X4 and discard. Wiring Instructions Please refer to the following diagram for wiring instructions. Please note that each cable has a matching cable and plug. Do not remove or alter any connections. Each connector has one matching mate. 1
2 2 2 2 8 PIN DEUTSCH (DT) 2 EH-EX400-25 EH-SK100 PC-FD200 PC-FD300 EH-FD200 MA 3 PIN WEATHERPACK C410 M F OPTIONAL C720 EH-EX500-25 C610 R P PC-FD310 C620 P R OPTIONAL MA C510 F M HOT LOW OIL OIL PC-EK100 (-) PC-EK100 (+) C500 EH-EX500-25 R P 2 PIN DEUTSCH (DTP) C710 C130 PC-FD210 O - OFF O - OFF O - OFF O - OFF Note: Each cable has a matching cable and plug. Do not remove or alter any connections. Each connector only has one matching mate. PC-FD100 L1 = BLACK L2 = WHITE GND = GREEN 60 AMP Double Pole Breaker AC Input 240Vac - 1~ C140 C120 EH-SK110 EH-SK120 P P C125H C125V R P R C110 C125 EH-EK500 C B A C300 EH-RC300 A B C A B C400 EH-EX400-25 A B M F 2 PIN WEATHERPACK P R 16 PIN AMP (CPC) WB-EK400 C200 C200 EH-EX200-10 EH-FD200 R P 12 PIN DEUTSCH (DT) R P 12 PIN DEUTSCH (DT) C100 C100 EH-EX100-10 WB-EK100 R P 8 PIN DEUTSCH (DT) P R C600 60 AMP Breaker OPTIONAL WB-EK600 R P 4 PIN DEUTSCH (DT) Radio Receiver (+) (-) DC Input 12Vdc M1 V1 M2 V2 MASTER MASTER CONTROLS COOLER O - OFF O - OFF O - OFF WB-EK300 B A B A EH-EK100 WB-EK200 2
Connecting the Reels Red Hose Reel Pressure Red Hose Reel Return Blue Hose Reel Return Blue Hose Reel Pressure 1. Connect the pressure and return hoses. 2. The heat exchanger supply utilizes a check valve. The flow direction can be determined by the arrow stamped on the check valve. Connect this hose to an installer provided #8 SAE 100 R2 hose and connect the other end to the inlet side of the heat exchanger. The inlet side is the port closest to the temperature sending unit. If AMKUS standard couplers are being used, be sure the pressure line has a male coupler at the end of the reel. The return line will have a female coupler at the end of the reel. If AMKUS Mono Couplers are being used, be sure the pressure line is connected to the pressure port (P) of the female Mono Coupler and the return line is connected to the tank port (T) of the female Mono Coupler. Installing the Heat Exchanger (HEA11) Inlet Heat Exchanger Return (Outlet) 3. The heat exchanger return utilizes a check valve. The flow direction can be determined by the arrow stamped on the check valve. Connect this hose to an installer provided #8 SAE 100 R2 hose and connect the other end to the outlet side of the heat exchanger. The outlet side is the port farthest from the temperature sending unit. Installing the Control Panel and VFD Panel (EKDP Control System) Temperature Sending Unit 1. The heat exchanger should be mounted in a location that allows the intake of fresh air. Caution should be taken to prevent recirculation of the heated air. The air intake side of the heat exchanger should have a minimum of 3 inches from any obstruction. The exhaust (fan) side of the heat exchanger should exhaust into free air (no back pressure). 1. The 240SS Control Panel (shown above) houses the green power switch, red and blue motor switches, red and blue reel circuit switches, LED read out, control panel circuit breakers, low oil and temperature high heat indicators. The adjustable mounting brackets (supplied as pictured) can be configured to suit virtually all mounting situations. 3
2. Mount the 240SS Control Panel (EKDP Control System) in a compartment using the supplied mounting brackets. The unit should be mounted in a compartment that will be accessible to tool operators. Optional Wireless Receiver Mount the optional wireless receiver using the supplied bolt. The receiver signal range is 300 without an optional antenna. This unit should be installed in a compartment out of the elements. Plug the supply cable into the matching plug from the control panel. Set-Up Procedures 3. Mount the 240SS VFD Panel in a compartment using the supplied mounting brackets. Installing the Optional Wireless Receiver Vent Cap Reservoir Fill Cap Sight Gauge Wireless Remote Controls Receiver The optional Wireless Receiver ships with two remote controls. 1. Remove the black vent cap with a 12mm Hex Key. Unscrew the red reservoir fi ll cap and fi ll the hydraulic fl uid reservoir until the sight gauge is completely full. Replace the black vent cap and the red reservoir fi ll cap. 4
Initial Start-Up 1. Connect the hose reel hoses together before starting the system. 5. The upper section of the Control Panel houses the master on power switch (green label), motor 1 switch (blue label), motor 2 switch (red label), valve 1 (blue label activates the blue hydraulic reel), valve 2 (red label activates the red hydraulic reel) and the heat exchanger breaker on/off switch. Turn on the green master switch. 2. Remove the VFD cover. 6. Activate red reel circuit motor. The motor is timecontrolled. Once activated, the indicator will blink for approximately 5 seconds when the motor has reached maximum RPM. 3. The VFD is shipped with the circuit breakers in the OFF position. 7. Activate blue reel circuit motor. The motor is timecontrolled. Once activated, the indicator will blink for approximately 5 seconds when the motor has reached maximum RPM. 4. Place the VFD circuit breakers in the ON position by fl ipping each black switch up. 5
Verify Hose Connections Return Line Pressure Line 8. Activate the valve 2 switch to energize the red hydraulic reel. Fluid Flows from Pressure Line 1. To verify which hose is the pressure hose, remove both couplings from the end of the hoses and place the hose ends in a bucket. Charge the appropriate valve. Fluid will fl ow from the pressure line. Turn off the valve once the pressure line is identifi ed. 9. Activate the valve 1 switch to energize the blue hydraulic reel. Sight Gauge Female Coupling Male Coupling 2. If AMKUS standard couplers are being used, place the male coupler on the pressure line and the female coupler on the return line. Repeat for the other reel. 10. Allow the power unit to fl ow through the reels for several minutes while monitoring the fl uid sight gauge level. Shut the power unit off. If AMKUS Mono Couplers are being used, be sure the pressure line is connected to the pressure port (P) of the female Mono Coupler and the return line is connected to the tank port (T) of the female Mono Coupler. 3. Check the sight gauge and add fl uid until the sight gauge is completely full again. 4. Put the black cover back in place and tighten the bolts on both ends. Installation Questions For installation questions, please contact Chuck Sheaffer at 630-330-5167 or csheaffer@amkus.com 6
1 Wireless Remote Control 2 Remote Control Operation 1. Pull Emergency Stop (1) (red) thumb wheel down or counter clockwise to be sure the remote is in the operation mode. 3 4 5 6 2. Move and hold the ON/OFF switch (2) to the Start position. When you release the switch, it will return to the ON position. When held in the Start position the remote is linking up to the receiver mounted in the apparatus so it is best to hold it in the start position briefl y to insure a good signal. 3. Push the Blue (3) and/or Red (4) motor button(s). The motors are programmed to reach full operating range in 5 seconds. 4. Push the Blue (5) and/or Red (6) valve button(s) to activate the red or blue reel circuits. 5. To shut off a circuit, push the appropriate valve (5) and/or (6) button. 6. To quickly shut down the entire system including the power, motors and reel circuits, push the Emergency Stop. To re-activate the system, repeat these instructions starting at number 1. Remote Control Features 1. Emergency Stop (Red) Shuts both circuits and system down. Depress to activate Emergency Stop. Pull thumb wheel down for normal operation. 2. On/Off Start (Black)- ON/OFF turns controller on or off. Start sends signal and links to the truck mounted receiver. 3. Blue Motor Switch Depress to activate motor for blue circuit. Depress again to turn motor off. Note: When motor switch is activated, wait for 5 seconds before activating control valve. 4. Red Motor Switch Depress to activate motor for red circuit. Depress again to turn motor off. Note: When motor switch is activated, wait for 5 seconds before activating control valve. 5. Blue Reel Switch Depress to activate control valve for blue circuit. Depress again to turn control valve off. 6. Red Reel Switch Depress to activate control valve for red circuit. Depress again to turn control valve off. 240SS INSTALL 05/2011 REV. 1 7
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting There are four steps necessary to convert the AMK-240SS Power Unit from the Horizontal Mounting Configuration to the Vertical Mounting Configuration as follow: 1. Remove the fill plug and extension from one end of the power unit and swap it with the plastic hex plug at the same end of the power unit. Note: you will need to remove the plastic cap from the solenoid before removing the fill plug and extension. Note: This end of the power unit will become the top end of the unit when it is mounted vertically. Figure 1 Unscrew and remove Plastic Cap from Solenoid Figure 2 Remove Fill Cap and Extension, then swap them with the Plastic Hex Plug Figure 3 After swapping Fill Cap and Hex Plug Page 1 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting 2. From the opposite end of the power unit, remove the quick coupler assembly from the end cap and swap it with the Plastic Hex Plug. Figure 4 Before swapping Quick Coupler Assembly and Plastic Hex Plug Figure 5 After swapping Quick Coupler Assembly and Plastic Hex Plug Page 2 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting 2. Remove cap from wiring connector and swap positions with second connector set. Figure 6 Locate the cable that is connected to the sight gage and is terminated with a blank cap. Figure 7 Remove the blank cap. Figure 8 Shown with blank cap removed. Page 3 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting Figure 9 Locate the adjacent connector with a single green wire. Figure 10 Disconnect the two halves of the connector, Figure 11 Place the blank cap onto the connector half with the green wire. Page 4 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting Figure 12 Shown with cap installed. Figure 13 Connect the two remaining connector halves together. Each half should have one black wire and one white wire. Figure 14 Shown with the two halves connected. Page 5 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting 4. Add two vibration mounts and arrange mounting hardware as necessary for your mounting location. Figure 15 Shown as shipped, hanging vertically. Notice four vibration mounts and 2 Z-bracket assemblies. Figure 16 Close-up view of vibration mounts. Figure 17 Lower side vibration mounts removed. Four vibration mounts installed on bottom of unit. Page 6 January 24, 2012
Converting AMKUS AMK-240SS Power Unit from Horizontal Mounting to Vertical Mounting Figure 18 Four vibration mounts installed in the bottom of the unit. Figure 19 Note: it is absolutely essential that the two vibration mounts installed on the side near the top of the unit be facing the front of the truck and supported by a wall! Page 7 January 24, 2012
16.09 29.84 30.94 10.71
38 0 [ 14.96 ] # 1 6 S A E O - R in g ( 2 x ) ( 1 5 / 1 6 " U NF ) 3 60 [ 1 4.1 7 ] 1 73 ± 5 [ 6.8 2 ±. 2 0 ] 65 [ 2.56 ] 187 [ 7.3 5 ] 1 / 2 " BS PP ( 2 x ) T e m p S w it c h In l e t B l o c k 10 0 100 [ 3.94 ] [ 3.94 ] 3 80 [ 1 4.9 6 ] 3 40 [ 1 3.3 9 ] 4 20 [ 1 6.5 4 ] s lo t 9 x 1 2 ( 6x ) s l o t.3 5 x.5 33 9 [ 13.35 ] = = b l i n d fl a n g e ( 2 x ) c o n n e c to r ( 2 x ) 128 59 [ 2.32 ] [ 5.02 ] each connector can be mounted on two different positions and in three different directions: T h i s d r a w in g a n d a t t a c h e d w r it t e n d i s c lo s u r e, i f a n y, i s o u r in t e ll e c t u a l p r o p e r t y a n d m u s t n o t b e u s e d o r d i s c lo s e d t o t h i r d p a r t ie s w i t h o u t o u r e x p lic i t c o n s e n t. A ll r ig h t s r e s e r v e d. free size tolerance surface 17.09.10 m o d if. 2 1. 0 4. 1 1 r e v ie w. 2 1. 0 9. 1 0 r e le as e 2 4. 0 9. 1 0 w e ig h t H E A -8 0 6 0/2 4 0S S L. H. JONES EQUIPMENT COMPANY s et up 1:1 item number(s): D i n 2 7 6 8 -v d a te s c a le nam e description LH H LH H ML LH H OIL/AIR COOLER 240 AC POWER UNIT 12VDC drawing number page A -8 0 6 0 R E V 1 U S index modification d a te nam e d r a w in g f ile : BC MC MTC u p da te. E R P.: 1 of. pg s.
O - OFF O - OFF O - OFF MASTER MOTOR VALVE MOTOR VALVE COOLER #1 #1 #2 #2 14.22 HOT LOW MASTER CONTROLS COOLER OIL OIL 10.00 4.85
22.00 7.74 12.48 5.51