Emerson Damcos Service Manual
Damcos™ Local Power Unit
Service Manual
Service Manual
Version: SM 8000-1000-01 Ed 04
Release: February, 2017
The content of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they are not to be construed
as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our
terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of our products at any time without notice. Damcos A/S accepts no responsibility for any errors that may appear in this publication.
As each system may be configured for each delivery, the content and illustrations in this manual may differ from your system.
Copyright © Damcos A/S, 2017
Service Manual for LPU in English
Damcos LPU: Table of Contents Service Manual
February 2017 SM 8000-100-01 Ed 04
Table of Contents
Abbreviation and Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warning Levels Used in Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Service Instructions for LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LPU and Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
LPU-S Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Overview LPU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LPU-S-Ex Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview LPU-S-Ex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LPU-S-Ex-ia Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Overview LPU-S-Ex-ia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LPU-D Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Overview LPU-D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
LPU-D-Ex Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Overview LPU-D-Ex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
LPU-D-Ex-ia Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Overview LPU-D-Ex-ia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Troubleshooting Guide LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Fault Finding List LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LPU-S frequently restarting in open position . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Motor not running and is hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Motor not running and is Cold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Motor not stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump rendering too low (or no) pressure in one or both directions . . . . . . . 51
Solenoid valve not working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Actuator only running in one direction
(the unit can either only open or only close) . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Noise from pump, but only at low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
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Noise from pump, but only at high pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Noise from pump at both high and low pressure. . . . . . . . . . . . . . . . . . . . . . . . 55
Motor running hot, LPU is operating normally . . . . . . . . . . . . . . . . . . . . . . . . . . 56
LPU-D not maintaining pressure on actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Spring actuator only partly closing or not starting to close . . . . . . . . . . . . . . . 58
Emergency operation by key giving oil spillage through breather valve . . . . 59
Emergency operation by key not possible, hydraulically locked. . . . . . . . . . . 59
Emergency operation by hand pump giving oil spillage through breather valve
59
Emergency operation by hand pump not possible . . . . . . . . . . . . . . . . . . . . . . 60
Pump not rendering sufficient oil at high pressure (“valve running too slowly”)
61
Pump not rendering sufficient oil at low pressure (“valve running too slowly”)
61
Motor running for a short time and stops
High pressure on the port to which oil is led. . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Motor running for a short time and stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Motor ”diving” in RPM in end position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Motor ”diving” in RPM as spring actuator opens . . . . . . . . . . . . . . . . . . . . . . . . 63
Oil spillage, generally . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil in electronic connection box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Oil spillage from breather valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Unit drawing too much current. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Too little tank volume for operating actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 66
LPU cannot raise pressure after hand pump operation
(but no problems after remote operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
LPU leaking from bleeder valve when hand pump is mounted . . . . . . . . . . . . 68
Spring actuator do not close by emergency hand pump operation. . . . . . . . 69
LPU-Ex motor do not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
LPU-Ex has to be bulkhead mounted because of too little space or zone 0 at ac-
tuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Position indicator errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Operating LPU-S 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Operating LPU-D 2a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Emergency Operation of LPU V.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Speed adjustment for Actuator on LPU (v.2) . . . . . . . . . . . . . . . . . . . . . . 83
Pump pressure adjustment for LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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Refill of Oil in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Replace Pump in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replace DPCV in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Replace release valve in LPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Setup new P-net LPU circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Setup new P-net LPU circuit board in VIEW ver. 3.16 . . . . . . . . . . . . . . 103
Replace Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replace Solenoid Valve in LPU-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replace pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
LPU Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
LPU Power Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
LPU Power Control Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Operation LPU-S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Operating LPU-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
LPU with LED Position Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
LPU P-NET System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
LPU P-Net Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PCB Diagram for Local Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
PCB Diagram for Stand Alone Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Hydraulic Hand Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Hydraulic Diagram for Direct Mounted LPU Handpump . . . . . . . . . . . . . . . . 138
Hydraulic Diagram for Bulkhead Mounted LPU Handpump . . . . . . . . . . . . . 139
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
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Damcos LPU: Abbreviation and Denomination Service Manual
February 2017 SM 8000-100-01 Ed 04
Abbreviation and Denomination
DPCV Double Pilot Operated Check Valve
HP Hand Pump
ISC Integrated Ship Control
LPU Local Power Unit
LPU-D LPU for double-acting actuator
LPU-S LPU for single-acting spring operated actuator
LPU-Ex LPU approved for mounting in hazardous area
PLC Programmable Logic Controller
BB-VPI Bulkhead mounted Valve Position Indicator
VPI Valve Position Indicator
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Service Manual Damcos LPU: Abbreviation and Denomination
SM 8000-100-01 Ed 04 February 2017
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Damcos LPU: Safety Service Manual
February 2017 SM 8000-100-01 Ed 04
Safety
A description of issues concerning
personal safety when handling
Damcos
TM
VRC
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Service Manual Damcos LPU: Safety
SM 8000-100-01 Ed 04 February 2017
Warning Levels Used in Manuals
The following warning levels are used in the documentation of Damcos A/S for the safety of people
and equipment.
Warning! Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Caution! Indicates a potentially hazardous situation which, if not avoided, may result in prop-
erty damage.
Note! Indicates important information regarding the product.
Warnings
All personnel that handles Damcos LPU shall take part of and understand the following information
prior to handling the system. See warnings on next page.
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Damcos LPU: Safety Service Manual
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Service Manual Damcos LPU: Safety
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Damcos LPU: General Service Instructions for LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
General Service Instructions for LPU
This Chapter Describes the General Requirements
and Service Recommendations for the LPU
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Service Manual Damcos LPU: General Service Instructions for LPU
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General Considerations
Important notes on LPU equipment and systems:
• use original spare parts and tools
• use lifting facilities and transport equipment
• use handling instructions
• electrical cables are only to be connected by qualified personnel
Note! Read Safety chapter before handling any equipment!
Bleeder valve positions on LPU
It is extremely important that bleeder valve position is correctly chosen when mounting LPU with
actuator on pipe. Other positions are plugged when not used! This is normally done at installation.
Note! The choice of bleeder valve position is always selected at the highest point on LPU or actu-
ator tank!
For KC/KF/KFR bleed valve on top of actuator has no connection to LPU tank and must
always be present!
See next page for illustrated examples.
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Damcos LPU: General Service Instructions for LPU Service Manual
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LPU-D and LPU-S on KF/KFR - Bleed valve positions
LPU-S on BRCF - Bleed valve positions
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Service Manual Damcos LPU: General Service Instructions for LPU
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LPU and Optional Equipment
The LPU can be equipped with additional equipment, such as switches, indicators etc. Further more
the LPU can be bulkhead mounted, mounted with blocks or otherwise mounted in respect to customer requirements and system. Always check your specific system drawings and documents for
correct information. This manual is a guide on how to perform the service parts of your system. For
further information please contact Emerson service engineer or appointed agent.
Description
The LPU offers installation in both safe and hazardous area in two basic versions:
• LPU-S (fail safe) for single acting actuator
• LPU-D (fail set) for double acting actuator
Depending on safety zone requirements the LPU’s can be of Ex or Ex-ia, designed to meet the
requirements for mounting in hazardous areas. Be sure to use the designated equipment and spare
parts when performing service on your system.
The LPU system is designed to be controlled by two electrically different types of controls:
• Power controlled
• P-NET® bus controlled
The LPU can also be used as a stand-alone system.
LPU with an LED Position Indicator
LPU (except the Ex version) with an IP 68 LED indicator, showing clear RED or GREEN light when the
valve is CLOSED respectively OPEN is available in Power controlled and P-NET controlled LPU systems.
This may especially be useful if LPU is operated from a local hand pump, were the LPU is mounted in a
distance so the indication of the actuator is not visible. The LED must be supplied with 24 VDC.
LPU Mounting
The LPU can be mounted in the following ways:
• Direct mounting on BRC 250 - 16000, BRCF 250 - 16000, KC 65 - 400 and KF 65-250.
• Mounting on BRC 052, 072 and 092 is via inter-mediate block and with external position indica-
tion cable.
• Mounting on BRCF Fail Open and KF Fail Open is via special intermediate block.
• Mounting on BRC 125 and BRCF 125 has to be bulkhead mounted or supported otherwise.
• LPU may be bulk-head mounted via a standard B-block. - It is possible to use a B-block with inte-
grated VPI, (please see illustration). No external indication cable.
When decided on mounting method the pipe dimensions has to be considered as well.
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Damcos LPU: General Service Instructions for LPU Service Manual
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B-VPI Block for bulk-head mounted LPU.
Note! If bulk-head mounted:
Oil level must be checked before starting up the LPU.
LPU must be placed with motor pointing down and breather valve on top, short suction
pipe recommend.
The LPU may be emergency operated as if mounted direct on actuator.
Properly de-airing via quick connections on the LPU.
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Service Manual Damcos LPU: General Service Instructions for LPU
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Damcos LPU: LPU-S Overview Service Manual
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LPU-S Overview
This Chapter Describes the LPU-S with
Overview and Handling Instructions
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Service Manual Damcos LPU: LPU-S Overview
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Overview LPU-S
LPU-S Front View
Emergency Operation
How to Operate the LPU-S
Fault Finding
Technical Data
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-S 2” on page 73.
See “Troubleshooting Guide LPU” on page 43.
For technical data see “LPU Technical Data” on page 111.
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Damcos LPU: LPU-S Overview Service Manual
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LPU-S Top View with top cover made partly transparent.
LPU-S Bottom View
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Service Manual Damcos LPU: LPU-S Overview
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Damcos LPU: LPU-S-Ex Overview Service Manual
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LPU-S-Ex Overview
This Chapter Describes the LPU-S-Ex with
Overview and Handling Instructions
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Service Manual Damcos LPU: LPU-S-Ex Overview
SM 8000-100-01 Ed 04 February 2017
Overview LPU-S-Ex
LPU-S Front View
Emergency Operation
How to Operate the LPU-S-Ex
Fault Finding
Technical Data
Cable Glands
Cable
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-S 2” on page 73.
See “Troubleshooting Guide LPU” on page 43.
For technical data see “LPU Technical Data” on page 111.
See “Cable Gland” on page 116.
See “Cables” on page 116.
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Damcos LPU: LPU-S-Ex Overview Service Manual
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LPU-S Top View with top cover made partly transparent.
LPU-S Bottom View
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Service Manual Damcos LPU: LPU-S-Ex Overview
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Damcos LPU: LPU-S-Ex-ia Overview Service Manual
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LPU-S-Ex-ia Overview
This Chapter Describes the LPU-S-Ex-ia with
Overview and Handling Instructions
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Service Manual Damcos LPU: LPU-S-Ex-ia Overview
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Overview LPU-S-Ex-ia
LPU-S Front View
Emergency Operation
How to Operate the LPU-S
Fault Finding
Technical Data
Cable Glands
Zener barrier
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-S 2” on page 73.
See “Troubleshooting Guide LPU” on page 43.
For technical data see “LPU Technical Data” on page 111.
See “Cable gland LPU-Ex and LPU-Ex-ia” on page 116.
See “Zener barrier LPU-Ex-ia” on page 117.
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Damcos LPU: LPU-S-Ex-ia Overview Service Manual
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LPU-S-Ex-ia Top View with top cover made partly transparent.
LPU-S Bottom View
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Service Manual Damcos LPU: LPU-S-Ex-ia Overview
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