Danfoss 90 Concrete Pumps User guide
MAKING MODERN LIVING POSSIBLE
Technical Information
Concrete Pumps
Series 90
powersolutions.danfoss.com
Technical Information Series 90 Concrete Pumps
Revision history Table of revisions
Date Changed Rev
February 2016 minor edits - new installation drawings 0202
June 2014 Converted to Danfoss layout – DITA CMS BA
February 2014 First Edition AA
2 BC00000360en-US • Rev 0202 • February 2016
Technical Information
Contents
General Description
Technical specifications
Operating Parameters
System Design Parameters
Master Model Code
Control Options
Features and Options
Installation Drawings
Series 90 Concrete Pumps
Series 90 Concrete Pumps.............................................................................................................................................................4
General Specifications.................................................................................................................................................................... 5
Features and Options......................................................................................................................................................................5
Operating Parameters.....................................................................................................................................................................6
Fluid Specifications..........................................................................................................................................................................6
Overview..............................................................................................................................................................................................7
Input Speed........................................................................................................................................................................................ 7
System Pressure................................................................................................................................................................................7
Servo Pressure................................................................................................................................................................................... 7
Charge Pressure................................................................................................................................................................................ 8
Case Pressure..................................................................................................................................................................................... 8
External Shaft Seal Pressure..........................................................................................................................................................8
Temperature and Viscosity........................................................................................................................................................... 9
Filtration System.............................................................................................................................................................................10
Filtration Options...........................................................................................................................................................................10
Suction filtration – Option S................................................................................................................................................. 10
Fluid Selection.................................................................................................................................................................................10
Reservoir............................................................................................................................................................................................11
Case Drain.........................................................................................................................................................................................11
Pump Life..........................................................................................................................................................................................11
Understanding and Minimizing System Noise....................................................................................................................11
Sizing Equations............................................................................................................................................................................. 12
Mounting Flange Loads...............................................................................................................................................................12
Accumulator.................................................................................................................................................................................... 13
High Pressure Signal Output Port X10................................................................................................................................... 13
Master Model Code....................................................................................................................................................................... 14
Hydraulic Displacement Control (HDC), Option HD; H9..................................................................................................17
Operation.....................................................................................................................................................................................17
Features and Benefits..............................................................................................................................................................17
Pump output flow direction vs. control pressure.........................................................................................................18
Multi-Function Valves...................................................................................................................................................................19
Overpressure protection........................................................................................................................................................19
Bypass Function........................................................................................................................................................................ 19
Auxiliary Mounting Pads............................................................................................................................................................. 20
Mating pump requirements................................................................................................................................................. 20
Displacement Limiter................................................................................................................................................................... 21
Shaft Torque.....................................................................................................................................................................................22
Shaft Availibility and Torque Ratings......................................................................................................................................22
Charge Pump...................................................................................................................................................................................23
Charge pump sizing/selection.............................................................................................................................................23
Charge pump flow and power curves...............................................................................................................................24
Loop Flushing Valve......................................................................................................................................................................25
Frame Size 130................................................................................................................................................................................ 27
Frame Size 180................................................................................................................................................................................ 29
BC00000360en-US • Rev 0202 • February 2016 3
M3
S
X2
X1
P108958
TA
M5
M4
TB
S (B)
S (A)
P
M10
L1
L2
CW
2
1
flow out
M2
X9 (M22)
X9 (3/4)
X8 (M22)
X8 (3/4)
M1
X 10
M12
B
T
A
M3
S
X2 X1
TA
M5
M4
TB
S (B)
S (A)
P
M10
L1
L2
CW
2
1
M2
X9 (M22)
X9 (3/4)
X8 (M22)
X8 (3/4)
M1
X 10
M12
B
T
A
X12
X11
A
N
X3(M11)
N
X12
X11
flow out
A
X3(M11)
Technical Information Series 90 Concrete Pumps
General Description
Series 90 Concrete Pumps
The S90 concrete pumps are designed for 2 cylinder concrete pump applications. This Technical
Infomation only describes concrete pump specific information - General information about Series 90
pumps can be found in Series 90 Axial Piston Pumps Technical Information 520L0603.
The concrete pump system can be built up as Series 90 single or tandem pumps. Each pump can be
equipped with a loop flushing valve (LFV).
System Schematic
4 BC00000360en-US • Rev 0202 • February 2016
Technical Information Series 90 Concrete Pumps
Technical specifications
General Specifications
Design Axial piston pump of cradle swashplate design with variable displacement
Direction of rotation Clockwise, counterclockwise
Pipe connections Main pressure ports: ISO split flange boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation position Pump installation position is discretionary, however the recommended control position is on the top
or at the side, with the top position preferred.
Vertical input shaft installation is acceptable.
If input shaft is at the top 1 bar case pressure must be maintained during operation.
The pump housing must be filled with hydraulic fluid under all conditions; including after a long
period of shutdown. Before operating the machine, ensure the pump housing and case drain lines are
free of air.
Recommended mounting for a multiple pump stack is to arrange the highest power flow towards the
input source.
Consult Danfoss for nonconformance to these guidelines.
Auxiliary cavity pressure Will be inlet pressure with internal charge pump. For reference see Operating Parameters on page 6.
Will be case pressure with external charge supply.
Please verify mating pump shaft seal capability.
Features and Options
Feature Unit Frame
130 180
Displacement cm³/rev.
[in³]/rev.
Flow at rated speed (theoretical) l/min.
[US gal/min.]
Torque at maximum displacement (theoretical) N•m/bar
[lbf•in/1000 psi]
Mass moment of inertia of rotating components kg•m²
[slug•ft²]
Weight (with control opt. MA) kg [lb] 88 [195] 136 [300]
Mounting (per ISO 3019-1) Flange
Rotation
Main ports: 4-bolt split-flange
(per SAE J518 code 62)
Main port configuration Twin port
Case drain ports (SAE O-ring boss) UNF thread (in.) 1.3125–12 1.625–12
Other ports SAE O-ring boss
Shafts Splined, and tapered shafts available
Auxiliary mounting SAE-A, B, C, D SAE-A, B, C, D, E
mm
[in]
130
[7.93]
403
[106]
2.07
[1260]
0.023
[0.0170]
152-4 (SAE D)
31.75
[1.25]
180
[10.98]
468
[124]
2.87
[1750]
0.0380
[0.0280]
Flange
165-4 (SAE E)
31.75
[1.25]
BC00000360en-US • Rev 0202 • February 2016 5
Technical Information Series 90 Concrete Pumps
Technical specifications
Operating Parameters
Parameter Unit Frame
130 180
Input speed
Minimum min-1(rpm) 500 500
Rated Speed 3100 2600
Maximum 3400 2850
Operating parameters
System pressure Maximum working pressure bar [psi] 450 [6525]
Maximum pressure 480 [6960]
Maximum low loop 45 [650]
Minimum low loop pressure 10 [145]
Charge pressure Minimum bar [psi] 18 [261]
Maximum 34 [493]
Control pressure Minimum (at corner power for HDC) bar [psi] 14 [203]
Maximum 40 [580]
Charge pump inlet
pressure
Case pressure Rated bar [psi] 3.0 [44]
Lip seal external pressure Maximum bar [psi] 0.4 [5.8]
Rated bar (absolute) [in Hg vacuum] 0.7 [9]
Minimum (cold start) 0.2 [24]
Maximum bar [psi] 4.0 [58]
Maximum 12 [174]
Fluid Specifications
Feature Unit
Viscosity Intermittent
Minimum 7 [49]
Recommended range 12-80 [66-370]
Maximum 1600 [7500]
Temperature
range 2)
Minimum (cold start) 3) °C [°F] -40 [-40]
Recommended range 60-85 [140-185]
Rated 104 [220]
Maximum intermittent
Filtration
(recommended
minimum)
Cleanliness per ISO 4406-1999 22/18/13
Efficiency (charge pressure filtration) β-ratio β
Efficiency (suction and return line filtration) β
Recommended inlet screen mesh size µm 100 – 125
1)
Intermittent = Short term t < 1min per incident and not exceeding 2 % of duty cycle based load-life
2)
At the hottest point, normally case drain port
3)
Cold start = Short term t < 3min, p ≤ 50 bar [725 psi], n ≤ 1000 min-1(rpm)
1)
1)
mm2/s [SUS] 5 [42]
115 [240]
= 75 (β10 ≥ 10)
15-20
= 75 (β10 ≥ 2)
35-45
T000 129E
6 BC00000360en-US • Rev 0202 • February 2016
Technical Information
Operating Parameters
Overview
Input Speed
Series 90 Concrete Pumps
This section defines the operating parameters and limitations for Series 90 pumps with regard to input
speeds and pressures. For actual parameters, refer to the operating parameters for each displacement.
Minimum speed is the lowest input speed recommended during engine idle condition. Operating below
minimum speed limits the pump's ability to maintain adequate flow for lubrication and power
transmission.
Rated speed is the highest input speed recommended at full power condition. Operating at or below
this speed should yield satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product
life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed
limit under any operating conditions.
Operating conditions between Rated speed and Maximum speed should be restricted to less than full
power and to limited periods of time.
For more information consult Pressure and Speed Limits, BLN-9884, when determining speed limits for a
particular application.
System Pressure
Servo Pressure
System pressure is the differential pressure between high pressure system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from high load,
reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted
average, pressure that can only be determined from a duty cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally defined within the
order code of the pump. This is the applied system pressure at which the drive-line generates the
maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended Application pressure. Maximum working
pressure is not intended to be a continuous pressure. Propel systems with application pressures at, or
below, this pressure should yield satisfactory unit life given proper component sizing.
Maximum pressure is the highest allowable Application pressure under any circumstance. Application
pressures above maximum working Pressure will only be considered with duty cycle analysis and factory
approval.
Pressure spikes are normal and must be considered when reviewing maximum working pressure.
Minimum low loop pressure must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop
pressure from gauge readings to compute the differential.
Servo pressure is the pressure in the Servo-system needed to position and hold the pump on stroke. It
depends on system pressure and speed.
At minimum servo pressure the pump will run at reduced stroke depending on speed and pressure.
Minimum servo pressure at corner power holds the pump on full stroke at max speed and max pressure.
Maximum servo pressure is the highest pressure typically given by the charge pressure setting.
BC00000360en-US • Rev 0202 • February 2016 7
C
C
Technical Information
Operating Parameters
Charge Pressure
Series 90 Concrete Pumps
An internal charge relief valve regulates charge pressure. Charge pressure supplies the control with
pressure to operate the swashplate and to maintain a minimum pressure in the low side of the
transmission loop. The charge pressure setting listed in the order code is the set pressure of the charge
relief valve with the pump in neutral, operating at 1800 min-1 [rpm], and with a fluid viscosity of 32 mm2/s
[150 SUS]. Pumps configured with no charge pump (external charge supply) are set with a charge flow of
30 l/min. [7.93 US gal/min.] and a fluid viscosity of 32 mm2/s [150 SUS].
The charge pressure setting is referenced to case pressure. Charge pressure is the differential pressure
above case pressure.
Minimum charge pressure is the lowest pressure allowed to maintain a safe working condition in the
low side of the loop. Minimum control pressure requirements are a function of speed, pressure, and
swashplate angle, and may be higher than the minimum
charge pressure shown in the Operating parameters tables.
Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment, and
which provides normal component life. Elevated charge pressure can be used as a secondary means to
reduce the swashplate response time.
At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure
(vacuum).
Minimum charge inlet pressure is only allowed at cold start conditions. In some applications it is
recommended to warm up the fluid (e.g. in the tank) before starting the engine and then run the engine
at limited speed.
Maximum charge pump inlet pressure may be applied continuously.
Case Pressure
External Shaft Seal Pressure
Under normal operating conditions, the rated case pressure must not be exceeded. During cold start
case pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly.
Auxiliary Pad Mounted Pumps. The auxiliary pad cavity of S90 pumps configured without integral
charge pumps is referenced to case pressure. Units with integral charge pumps have auxiliary mounting
pad cavities referenced to charge inlet (vacuum).
Caution
Possible component damage or leakage
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings,
causing external leakage. Performance may also be affected since charge and system pressure are
additive to case pressure.
In certain applications the input shaft seal may be exposed to external pressure. In order to prevent
damage to the shaft seal the maximum differential pressure from external sources must not exceed 0.4
bar (5.8 psi) over pump case pressure. The case pressure limits of the pump must also be followed to
ensure the shaft seal is not damaged.
Caution
Regardless of the differential pressure across the shaft seal, the shaft seal has been known to pump oil
from the external source (e. g. gear box) into the pump case.
8 BC00000360en-US • Rev 0202 • February 2016
Technical Information Series 90 Concrete Pumps
Operating Parameters
Temperature and Viscosity
Temperature
The high temperature limits apply at the hottest point in the transmission, which is normally the motor
case drain. The system should generally be run at or below the quoted rated temperature.
The maximum intermittent temperature is based on material properties and should never be
exceeded.
Cold oil will generally not affect the durability of the transmission components, but it may affect the
ability of oil to flow and transmit power; therefore temperatures should remain 16 °C [30 °F] above the
pour point of the hydraulic fluid.
The minimum temperature relates to the physical properties of component materials.
Size heat exchangers to keep the fluid within these limits. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Viscosity
For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range.
The minimum viscosity should be encountered only during brief occasions of maximum ambient
temperature and severe duty cycle operation.
The maximum viscosity should be encountered only at cold start.
BC00000360en-US • Rev 0202 • February 2016 9
Charge pump
Filter
Hydraulic fluid reservoir
Adjustable
charge pressure relief valve
To pump case
To low
loop and
control
Manometer
P102 003E
C
Technical Information
System Design Parameters
Filtration System
Filtration Options
Series 90 Concrete Pumps
To prevent premature wear, ensure only clean fluid enters the hydrostatic transmission circuit. A filter
capable of controlling the fluid cleanliness to ISO 4406 class 22/18/13 (SAE J1165) or better, under normal
operating conditions, is recommended.
These cleanliness levels can not be applied for hydraulic fluid residing in the component housing/case or
any other cavity after transport.
Filter efficiency can be measured with a Beta ratio (βX). For suction filtration, a filter with a β-ratio within
the range of β
Filter βx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number
of particles greater than a given diameter (“x” in microns) upstream of the filter to the number of these
particles downstream of the filter.
Because each system is unique, only a thorough testing and evaluation program can fully validate the
filtration system. Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information,
520L0467 for more information.
= 75 (β10 ≥ 2) or better has been found to be satisfactory.
35-45
Fluid Selection
Suction filtration – Option S
Suction filtration is the only option available for concrete pumps.
The suction filter is placed in the circuit between the reservoir and the inlet to the charge pump, as
shown below.
The use of a filter contamination monitor is recommended.
Suction filtration
Caution
Clogged filters can cause cavitation, which damages the charge pump. We recommend a filter bypass
with a filter bypass sensor to prevent damage due to blocked suction filters.
Ratings and performance data are based on operating with hydraulic fluids containing oxidation, rust
and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear,
erosion, and corrosion of pump components.
Never mix hydraulic fluids of different types.
10 BC00000360en-US • Rev 0202 • February 2016
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