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Damcos™ Local Power Unit
Service Manual
Service Manual
Version: SM 8000-1000-01 Ed 04
Release: February, 2017
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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
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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
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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
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Damcos LPU: Safety Service Manual
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Safety
A description of issues concerning
personal safety when handling
Damcos
TM
VRC
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Service Manual Damcos LPU: Safety
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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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Service Manual Damcos LPU: Safety
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Damcos LPU: General Service Instructions for LPU Service Manual
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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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LPU-D and LPU-S on KF/KFR - Bleed valve positions
LPU-S on BRCF - Bleed valve positions
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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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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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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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LPU-S Top View with top cover made partly transparent.
LPU-S Bottom View
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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
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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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LPU-S Top View with top cover made partly transparent.
LPU-S Bottom View
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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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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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LPU-S-Ex-ia Top View with top cover made partly transparent.
LPU-S Bottom View
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Damcos LPU: LPU-D Overview Service Manual
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LPU-D Overview
This Chapter Describes the LPU-D with
Overview and Handling Instructions
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Overview LPU-D
LPU-D Front View
Emergency Operation
How to Operate the LPU-D
Fault Finding
Technical Data
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-D 2a” on page 75.
See “Troubleshooting Guide LPU” on page 43.
For technical data see “LPU Technical Data” on page 111.
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LPU-D Top View with top cover made partly transparent.
*)Pressure switch is not present in all versions of LPU-D!
LPU-D Bottom View
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Damcos LPU: LPU-D-Ex Overview Service Manual
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LPU-D-Ex Overview
This Chapter Describes the LPU-D-EX with
Overview and Handling Instructions
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Service Manual Damcos LPU: LPU-D-Ex Overview
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Overview LPU-D-Ex
LPU-D Front View
Emergency Operation
How to Operate the LPU-D
Fault Finding
Technical Data
Cable Glands
Cable
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-D 2a” on page 75.
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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LPU-D Top View with top cover made partly transparent.
LPU-D Bottom View
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Damcos LPU: LPU-D-Ex-ia Overview Service Manual
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LPU-D-Ex-ia Overview
This Chapter Describes the LPU-D-Ex-ia with
Overview and Handling Instructions
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Service Manual Damcos LPU: LPU-D-Ex-ia Overview
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Overview LPU-D-Ex-ia
LPU-D Front View
Emergency Operation
How to Operate the LPU-D
Fault Finding
Technical Data
Cable Glands
Cable
Zener barrier
See “Emergency Operation of LPU V.2” on page 77.
See “Operating LPU-D 2a” on page 75.
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.
See “Zener barrier LPU-Ex-ia” on page 117.
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LPU-D Top View with top cover made partly transparent.
LPU-D Bottom View
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Damcos LPU: Troubleshooting Guide LPU Service Manual
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Troubleshooting Guide LPU
This Chapter Describes how to Identify
and Correct minor Problems for LPU
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Service Manual Damcos LPU: Troubleshooting Guide LPU
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Fault Finding List LPU
ACTUATOR CONNECTED PROBLEM
“Actuator only running in one direction (the unit can either only open or only close)” on page 53
“LPU-D not maintaining pressure on actuator” on page 57
“Spring actuator only partly closing or not starting to close” on page 58
“Too little tank volume for operating actuator” on page 66
“Spring actuator do not close by emergency hand pump operation” on page 69
ELECTRICAL PROBLEM
“Unit drawing too much current” on page 65
EMERGENCY OPERATION
“Emergency operation by key giving oil spillage through breather valve” on page 59
“Emergency operation by key not possible, hydraulically locked” on page 59
“Emergency operation by hand pump giving oil spillage through breather valve” on page 59
“Emergency operation by hand pump not possible” on page 60
“Spring actuator do not close by emergency hand pump operation” on page 69
LPU-D
“LPU-D not maintaining pressure on actuator” on page 57
LPU-Ex
“LPU-Ex motor do not run” on page 70
“LPU-Ex has to be bulkhead mounted because of too little space or zone 0 at actuator” on page 71
LPU-S
“LPU-S frequently restarting in open position” on page 47
MOTOR
“LPU-Ex motor do not run” on page 70
“Motor not running and is hot” on page 49
“Motor not running and is Cold” on page 49
“Motor not stopping” on page 50
“Motor running hot, LPU is operating normally” on page 56
“Motor running for a short time and stops High pressure on the port to which oil is led” on page 62
“Motor running for a short time and stops” on page 62
“Motor ”diving” in RPM in end position ” on page 63
“Motor ”diving” in RPM as spring actuator opens” on page 63
OIL LEAKAGE
“LPU leaking from bleeder valve when hand pump is mounted” on page 68
“Oil spillage, generally” on page 64
“Oil in electronic connection box” on page 64
“Oil spillage from breather valve” on page 64
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POSITION INDICATOR
“Position indicator errors” on page 72
PUMP
“Pump rendering too low (or no) pressure in one or both directions” on page 51
“Noise from pump, but only at low pressure” on page 54
“Noise from pump, but only at high pressure” on page 55
“Noise from pump at both high and low pressure” on page 55
“Pump not rendering sufficient oil at high pressure (“valve running too slowly”)” on page 61
“Pump not rendering sufficient oil at low pressure (“valve running too slowly”)” on page 61
PRESSURE
“Pump rendering too low (or no) pressure in one or both directions” on page 51
“LPU-D not maintaining pressure on actuator” on page 57
“LPU cannot raise pressure after hand pump operation (but no problems after remote operation)” on
page 67
SOLENOID VALVE
“Solenoid valve not working” on page 52
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Damcos LPU: Troubleshooting Guide LPU Service Manual
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LPU-S frequently restarting in open position
Action: Place pressure gauge on quick connection B.
Read maximum pressure and observe if pressure drops when motor stops.
Then if: 1. Pressure is raised to approx. 150 bar, but drops to 95 - 105 bar before motor is restarted.
Goto “Leakage in the hydraulic system between check valve and actuator or in actuator” on
page 47.
2. Pressure is raised to approx. 150 bar and motor stops, but is restarted before pressure drops
below 115 bar.
Goto “Fault on pressure switch or wires, possibly on printed circuit board” on page 47.
3. Pressure is raised to below 120 bar and drops to 90 - 110 bar before motor is restarted.
Goto “Large leakage in the hydraulic system, or misadjusted safety valve” on page 48.
1. Leakage in the hydraulic system between check valve and actuator or in
actuator
Action: Mount hand pump, pressure gauge is already mounted (see above), and open actuator fully by hand
pump.
Then if: • Pressure remains constant
Leakage in solenoid valve or leakage at check valve in valve block:
– Check for leakage in solenoid valve.
– Check valve in valve block for external leakage, e.g. at pressure switch or closing speed adjust-
ment. Check for external leakage and if no leakage is found replace solenoid valve or check
valve.
• Pressure drops
Leakage in bypass valve at actuator, release valve, shuttle valve, emergency valve or actuator.
– Check o-rings on emergency slide and shuttle valve, possibly replace release valve or shuttle
valve if shuttle valve is version with internal slide.
– Check that bypass valve in actuator is closed.
– Possibly dismount LPU from actuator and check if actuator has leakage, internal or external.
2. Fault on pressure switch or wires, possibly on printed circuit board
Action: Wires to pressure switch are dismounted from pressure switch and connected to each others, simu-
lating high pressure.
Caution! For LPU power these wires are supplied by 230 V. When the LPU is energized, the motor
must run for 7 - 12 seconds, then stop, and not start until the wires are disconnected
from each other.
Pressure Switch is electrically measured fully pressurized for short breaks (loose connections). Pressure gauge is mounted on quick connection for B and pressure is read when pressure switch breaks.
Then if: • Pressure switch breaks above 105 bar
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– Pressure switch is adjusted, so that pressure switch breaks by falling pressure at
100 ±5 bar. Pressure switch must close below 125 bar by rising pressure.
• Short breaks of pressure switch
– Replace pressure switch! See “Replace pressure switch” on page 109.
• Pressure switch breaks below 105 bar, no short breaks
– Check electrical connections from pressure switch. If no other faults are detected, replace
printed circuit board. See “Replace Printed Circuit Board” on page 105.
3. Large leakage in the hydraulic system, or misadjusted safety valve
Action: Mount hand pump, actuator is fully opened by hand pump, pressure gauge is mounted.
Then if: • Pressure remains constant
Leakage in solenoid valve, quick connection B or external leakage, e.g. at pressure switch. Possibly too low adjusted pressure at pump relief valve (pump safety valve).
– Check for external leakage, if no leakage, adjust pump pressure (see “Pump pressure adjust-
ment for LPU” on page 85). If this cannot be adjusted any higher, check internal sealings and
flow reducing valve (opening speed adjustment).
– Replace solenoid valve (see “Replace Solenoid Valve in LPU-D” on page 107), flow reducing
valve or sealings. Then safety valve is readjusted to 150 bar (see “Pump pressure adjustment
for LPU” on page 85).
Note! If oil has too low viscosity or is very hot this might be the reason for a too low pressure.
• Pressure drops
Leakage in actuator, or possibly bypass valve, release valve, emergency valve or shuttle valve.
– Check o-rings on shuttle valve and emergency valve, possibly replace release valve, see
“Replace release valve in LPU” on page 99.
– Check for external leakage.
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Motor not running and is hot
Action: Check that electrical connections to motor and capacitor are OK! Open bypass to release possible
pressure on pump and try to run the motor with opened bypass.
Then if: • Motor is running, but stops when bypass is closed.
Incorrectly connected motor or fault on motor or wires.
– Low supply voltage.
– Defective flow reducing valve, see “Motor ”diving” in RPM in end position ” on page 63.
• Motor is not running at all, even though bypass is opened.
– Disconnect current to LPU for measurement of resistance from N to CL and from N to OP on
printed circuit board (the easiest way is to disconnect the capacitor). Resistance must be
15
. The capacitor can on rare occasions be defective.
If connections and resistance are OK, the pump has stuck. New pump set is then mounted,
see “Replace Pump in LPU” on page 93. Reason for defective pump should be found, e.g.
insufficient quantity of oil, no stop of motor, impurities in oil etc.
Note! For LPU-Ex the temperature cut-off box might have interrupted power to motor due to too
high motor temperature. If this is the case the motor needs time to cool down, then 24 V
to LPU-Ex is interrupted for 10 seconds and LPU-Ex should be ready to run again.
Motor not running and is Cold
Action: • Check that there is 220 - 230 V AC over “N” and “open” or “close”, respectively when trying to
operate.
• Check that electrical connections to motor are OK. If the black wire is not connected, motor can-
not run.
• Dismount the motor wires. Check the resistance on the printed circuit board from “N” to the
centre motor wire, and from “open” and “close”, respectively to the two other motor connections. There must not be a measurable resistance.
• Check the resistance in the motor itself, there must be approximately 15
wire and each of the others. If the resistance differs widely, the motor is to be replaced.
Note! For LPU-Ex the temperature cut-off box will interrupt power to motor if 24 V is not present
or bounces when it is connected.
. between the black
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Motor not stopping
Action: • The pressure on B-port is measured.
If the pressure is below 120 bar, while motor is running, see “Pump rendering too low (or no)
pressure in one or both directions” on page 51.
• Wires to the pressure switch are dismounted and connected to each others, simulating high
pressure.
Caution! LPU-Power wires are supplied by 230 V. When LPU terminal (“open”) is energized in the
relevant direction, motor must stop after 7 - 12 seconds.
LPU-S-power must not be restarted before wires are disconnected.
LPU-D-power must not be restarted before power is disconnected and reconnected
again.
• If pressure switch is correctly connected, and the pressure is correct, check that pressure switch
is closing as required. Pressure switches must close at maximum 125 bar and break between 95
to 105 bar.
Adjust and if necessary replace pressure switches, see “Replace pressure switch” on page 109.
LPU-D-P-Net
If motor does not stop at all, the printed circuit board must be replaced, see “Replace Printed Circuit
Board” on page 105.
If the motor runs longer than normal, but then stops, the fault should be found in the position indicator, the calibration of the analogue indicator or setup of extra time in circuit board. Check, that the
position signal is really “0” or “100”.
LPU-S-P-Net
If motor does not stop at all and pressure on B-port is above 125 bar, the printed circuit board must
be replaced, see “Replace Printed Circuit Board” on page 105.
If the motor runs longer than normal, but then stops, the fault should be found in the position indicator, the pressure switch, the calibration of the analogue indicator or setup of extra time in circuit
board. Check that the position signal really is “100”.
LPU Power Control
Check that the pressure switch is correctly connected. See “Pump rendering too low (or no) pressure
in one or both directions” on page 51.
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Pump rendering too low (or no) pressure in one or both
directions
Action: • Check that solenoid valve is clicking at connection. If not see “Solenoid valve not working” on
page 52.
• If pump does not render any pressure at all check oil level.
Mount a plug giving a possibility of connecting compressed air instead of breather valve and
pressurize tank with maximum 2.5 bar, while the pump is running. If air pressure in tank does not
solve the problem, or if the pump renders pressure (but too low), hand pump with pressure
gauge is mounted and actuator is fully opened by hand pump.
LPU-D
If no opening pressure check that by-pass for tank filling (in front of LPU) is closed.
LPU-Power
Check that power supply is connected to terminal “open” and that terminal “close” is not connected.
If pressure remains constantly low
At too low pressure in one direction (LPU-S) or both directions (LPU-D) the safety valve is adjusted
according to instruction (see “Pump pressure adjustment for LPU” on page 85). If higher pressure
cannot be obtained, there is a possible leakage in the solenoid valve, or at DPCV-slide (LPU-D), or at
clearance between pump stator and rotor.
De-airing the flow reducing valve may be necessary, see “Pump not rendering sufficient oil at low
pressure (“valve running too slowly”)” on page 61.
If pressure drops quickly
Leakage in bypass valve (actuator), shuttle or emergency valve (LPU-S) or release valve. Check o-rings
on valves and if necessary replace release valve (see “Replace release valve in LPU” on page 99) or
shuttle valve.
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Solenoid valve not working
Action: • Check that solenoid valve is energized (230 V on terminals “N” and “SV”).
• If coil is energized, but solenoid valve does not work, the resistance of the coil is measured (LPU-
D). The coil must have a resistance of approximate 520
tance cannot be measured for LPU-S coil. Another way to check the coil is to loosen it and try to
lift the coil when energized. If coil does not work, it is replaced.
• If coil works, the valve is to be replaced. See “Replace Solenoid Valve in LPU-D” on page 107.
for LPU-D. Due to a diode bridge resis-
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Actuator only running in one direction
(the unit can either only open or only close)
LPU-D
If LPU-D can close, but not open check by-pass valve for oil filling. Check that solenoid valve is powered and working and that free travel of solenoid valve slide is OK.
LPU-S
If actuator can close, but not open see “Pump rendering too low (or no) pressure in one or both directions” on page 51. If actuator can open, but not close, see “Spring actuator only partly closing or not
starting to close” on page 58.
Note! BRCF and KF can always be closed by opening bypass valve at actuator. KFR can be closed
opening bypass valve and lifting valve for emergency operation by hand pump.
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Noise from pump, but only at low pressure
Action: Adjust speed from maximum to minimum (see “Speed adjustment for Actuator on LPU (v.2)” on
page 83). If possible, place key on emergency operation shaft of the actuator and hold against rotating direction (i.e. operating pressure must be approximate 30 bar) (only possible for BRC 125, 250,
500).
Warning! Beware of huge force, actuator cannot be stopped by hand!
Then if: • Sound disappears
Too low compression of O-ring on motor shaft, so that rotor is vibrating on coupling.
Replace O-ring.
• Sound is unchanged
A pump piston is operating too tightly and does not follow the ball bearing curve during movement. At relatively high pressure it is pressed out hydraulically. The sound can disappear at starting-up. Otherwise pump is dismounted and pistons and rotor are checked for coverings or burrs.
Note! If pump rotor has to be replaced the stator version has to be checked (check placement
and number of expanding plugs). If stator versions are different both rotor and stator must
be exchanged (complete pump set, see “Replace Pump in LPU” on page 93).
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Noise from pump, but only at high pressure
Reason: • Air in the pump if actuator has not been properly de-aired. Check oil level in tank.
• Too small tank volume for large actuators or long pipes in system.
• Piston in pump is sticking.
A pump piston is operating too tightly and does not follow the ball bearing curve during movement. At relatively high pressure it is pressed out hydraulically. The sound can disappear at starting-up. Otherwise pump is dismounted and pistons and rotor are checked for coverings or burrs.
Note! If pump rotor has to be replaced the stator version has to be checked (check placement
and number of expanding plugs). If stator versions are different both rotor and stator must
be exchanged (complete pump set, see “Replace Pump in LPU” on page 93).
Noise from pump at both high and low pressure
Reason: Motor and pump are not co-axial, pump stator is not mounted firmly in the block.
Action: • Check steering pins between blocks.
• Dismount pump and check that remounted stator is perpendicular to valve block.
See “Replace Pump in LPU” on page 93 for more information.
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Motor running hot, LPU is operating normally
Caution! Motor is designed for 25% duty cycle only.
Action: • LPU-S
Observe that LPU does not restart.
If it is restarting frequently, the motor is running hot. See“LPU-S frequently restarting in open
position” on page 47.
• Measure the supply voltage (220 - 230 V AC) to LPU.
If it differs widely from the required voltage, the voltage must be modified.
• Measure the resistance over the motor windings, on the terminal (easiest with disconnected
capacitor). There must be approximately 15
tively.
If this resistance is not observed, the motor is to be replaced.
• The mechanical resistance of the motor can be too high.
If it cannot be turned easily with the fingers, it is to be replaced.
• The mechanical resistance of the pump can be too high, if ball bearing is blocked.
Dismount valve block and pump rotor as to change pump (see “Replace Pump in LPU” on
page 93) and check if ball bearing can rotate freely.
between “N” and “OPEN” and “CLOSE” respec-
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LPU-D not maintaining pressure on actuator
Pressure drops only on 1 port
• Leakage in check valves for DPCV or release valve.
Change check valves for DPCV.
• A leakage in actuator might give pressure drop on only one port.
Replace the seal set in actuator with a new one.
Pressure drops on both ports
Leakage in bypass valve (actuator) or actuator.
• Check bypass valve, possibly replace release valve (see “Replace release valve in LPU” on
page 99).
• Check actuator.
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Spring actuator only partly closing or not starting to close
Action: Check that throttle valve for adjustment of closing speed is not blocked.
Open bypass while motor is not operated.
Then if: • Spring actuator closes
Solenoid valve coil is still energized while valve is required to be closed!
This might be due to that valve has been opened by hand pump or filter below pressure switch is
blocked or too fast closing speed so that emergency valve has no pressure and is closing before
actuator is closed.
If this is the case then:
– repeat opening and closing command (by remote operation) for LPU.
If closing does not function check that the power for the solenoid valve is turned off.
If not check relay in control cabinet (power controlled with separately connected solenoid
valve), or on printed circuit board (P-Net).
Else remove coil from solenoid valve. Check filter below pressure switch (valve must be
closed). Adjust closing speed valve to fully closed, open it 1 revolution and check again. If the
actuator now closes closing speed can be increased step by step. If closing speed cannot be
sufficient then B-line between LPU and actuator is checked for blocks that can throttle oil flow.
• Spring actuator remains open
The fault is to be found outside the LPU.
For KFR push button for emergency operation might be blocked. Valve is sticking, or fault on
spring actuator.
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Emergency operation by key giving oil spillage through
breather valve
Reason: When valve is emergency operated by key, oil is pumped from actuator to LPU tank and further on to
the actuator. If the oil flow from LPU tank to actuator gives more than 3 bar pressure drop, the oil can
be pressed through the breather valve instead of back to actuator.
Action: Carrying out emergency operation at the same opening and closing speed to which the valve is set at
remote operation can solve the problem.
Caution! Avoid replacement of breather valve with plug, as this might result in too high pressure
at motor shaft sealing.
Emergency operation by key not possible, hydraulically
locked
Reason: Bypass not active or bypass valve is blocked.
Action: Open bypass valve and keep it opened during emergency operation. If emergency operation is still
locked - bypass valve is to be dismounted and checked. If bore contains dirt, it has to be removed.
Emergency operation by hand pump giving oil spillage
through breather valve
Reason: Tank pressure in LPU is too high. The pressure drop over quick connections due to very fast operation
or defective or not properly connected quick connections. If LPU is bulkhead mounted the pressure
drop might be in piping as well if they are long or if the inside diameter is narrow.
If oil cannot return to the hand pump tank, an LPU-S may be opened without problems. When valve
closes again, the LPU tank overflows.
When LPU’s closed system is filled with oil, the exceeding oil is let out through the breather valve to
prevent overpressure in the LPU.
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Emergency operation by hand pump not possible
Reason: • Hand pump is building up pressure, but actuator is not moving
– Slide for shuttle valve is sticking, so that change over to emergency operation cannot take
place (LPU-S).
– Outlet from actuator blocked so that return oil cannot pass.
– Fault on quick connections, so that check valve in hand pump quick connection is not open-
ing.
• Hand pump is pumping oil, but cannot build up pressure
– Leakage in DPCV (LPU-D), bypass valve, release valve, emergency valve (LPU-S) or actuator
• After a few strokes, hand pump is not pumping oil
– Insufficient oil in hand pump tank
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Pump not rendering sufficient oil at high pressure (“valve
running too slowly”)
Reason: LPU is built up, so that oil quantity from pump, independent of adjusted speed, is reduced to approx-
imate 240 cm
“Pump rendering too low (or no) pressure in one or both directions” on page 51.
The pressure should only exceed 65 bar for a few seconds, when breaking valve away or clo sing
valve.
3
/min from pressure exceeding 75 bar. If flow is considerably below this quantity, see
Pump not rendering sufficient oil at low pressure (“valve
running too slowly”)
Action: • Check adjustment of opening and closing speed (see “Speed adjustment for Actuator on LPU
(v.2)” on page 83).
• While pump is running at high pressure in end position, valve housing for speed adjustment is
loosened by a 19 mm wrench (must be turned maximum 3 turns, as there is full pump pressure
below housing), until airless oil is running from it. Then valve housing is tightened, and pump
flow is checked again. If pump flow is still not OK, dismount adjusting screw for speed control,
check with a screw driver that the ball bearing behind this can be moved back and forth by pressing it. Check mobility of the piston in valve housing for speed adjustment.
• Dismount tank and check if filter in suction pipe is blocked.
• Dismount tank and valve block, check the mobility of the bearing, and observe if any pistons in
rotor are sticking. Stator is dismounted (pressed out from the tan side), and blown through, to
remove plugging, if any, in the longitudinal holes.
• Remounting of stator: stator must be pressed in until direction pin is below surface of block.
When seated correctly, the free stator length is approximate 19 mm. Do not use metal hammer
directly on the stator. (See “Replace Pump in LPU” on page 93).
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Motor running for a short time and stops
High pressure on the port to which oil is led
Action: Mount pressure gauge on quick connection on return oil from actuator (LPU-D). At the same time
check that actuator is moving.
Then if: • High pressure on return oil. Actuator is not moving, or is hardly moving
DPCV does not open check valve for return oil. Check slide, sealings and check-valves for DPCV.
• Low pressure on return oil. Actuator is running, but not to end position
Operating pressure for actuator too high due to blocking in return, could be dirt in holes near the
port surface or in actuator.
• Low pressure on return oil. Actuator is not moving, or is hardly moving
Operating pressure for actuator too high due to blocking in return, could be dirt in holes near the
port surface or in actuator.
Fault in actuator, valve (requires a too high torque or more than 7 seconds before breaking away
from the seat), or choice of actuator for the valve in question.
Motor running for a short time and stops
Reason: Pressure switch does not break, or fault on control print.
Action: • Try dismounting a wire for the pressure switch in question. LPU shall then operate as long as ter-
minal is energized. If not so, there is a fault on the printed circuit board which is then replaced
(see “Replace Printed Circuit Board” on page 105).
• Control card receives a signal for stop of motor from pressure switch. For LPU-S and LPU-D-
Power, pressure switch connections and adjustment are to be checked. Pressure switch is possibly replaced (see “Replace pressure switch” on page 109).
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Motor ”diving” in RPM in end position
Reason: Voltage too low, pump relief valve misadjusted, defective flow reducing valve (the displacement of
the pump is not reduced at high pressure), fault in motor, or faulty connection of motor. Possibly
fault in capacitor/connection.
Action: • Check voltage over the terminals during operation. If it is considerably below 220 V AC, the fault
is to be found here. Take corrective measures. (LPU can operate down to 185V at
60 Hz, but such a low voltage is an indication of something being wrong).
• Check connection of motor.
• Check connection of capacitor.
• Check the maximum pressure (connect a pressure gauge to the quick connection pressurised).
Possibly adjust relief valve to 150 bar.
• Dismount adjusting screw for speed control, check with a screwdriver that the ball bearing
behind this can be moved back and forth by pressing it.
Motor ”diving” in RPM as spring actuator opens
Reason: Voltage too low, mechanical resistance in ball bearing around pump, faulty connected motor or fault
in capacitor.
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Oil spillage, generally
Avoid starting motor until the correct level in tank has been ensured. After elimination of faults,
replenish tank with the correct oil for the specific system.
Oil in electronic connection box
Action: • At a large oil volume in electric connection box: Avoid starting the motor until having ensured
that the oil level in tank is OK.
• Check pressure switch and solenoid valve for visible leakage, possibly by starting pump.
• For LPU-S, leakage at pressure switch or solenoid valve will result in a pressure drop, so that the
LPU motor / pump restarts if this function is engaged.
• Possible leakage from safety valve cannot be positively identified, until electronic connection
box has been dismounted.
• Leakage from actuator, led through the position indicator can occur at leakage from actuator to
indicator. In special cases, oil may even be led through the power/bus cables from one LPU to the
next.
• At leaking shaft seal on the electrical motor, the oil can run through motor and up in electronic
connection box.
• After repair of defects, the tank is replenished with the correct oil for the specific system.
Oil spillage from breather valve
• Oil spillage at emergency operation: see “Emergency operation by key giving oil spillage through
breather valve” on page 59 or “Emergency operation by hand pump giving oil spillage through
breather valve” on page 59.
• Oil spillage during operation when motor is changing direction: Compressed air in actuator.
Actuator is to be de-aired.
Especially linear actuators (KC, KF and KFR) may have to be loosened from valve to be able to
close completely before de-airing of actuator.
• Oil spillage when BRCF closes: Possibly air in actuator, actuator is to be de-aired. Breather valve
shall only be placed in BRCF or in LPU, not in both. Breather valve to be placed at highest possible
tank level. Too fast closing of actuator giving a high return pressure at closing letting oil out of
breather valve. Adjust closing speed to slower closing.
• Oil spillage when KF or KFR closes: Possibly air in actuator, actuator is to be de-aired. Breather
valve must always be placed on top of KFR, and in LPU, where breather valve has to be placed at
highest possible tank level. Too fast closing of actuator giving a high return pressure at closing
letting oil out of breather valve. Adjust closing speed to slower closing.
• Oil spillage at temperature rise in LPU-system: Oil tank overfilled or too great expansion at heat-
ing up, dependent on oil volume. At a large oil spillage due to heating up, an extended tank
should be used.
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Unit drawing too much current
Reason: • Mechanical resistance in motor
• Mechanical resistance in pump
• Too small winding resistance in motor meaning a 110 V motor has been used instead of 230 V
motor
• Too high or too low supply voltage
• Too low frequency
• Faulty electrical connection of motor
• Defective capacitor
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Too little tank volume for operating actuator
LPU
• Incorrect oil filling and de-airing of actuator. Check oil filling.
• Too high compressibility of oil in pipes between hand pump and LPU or between LPU and actua-
tor. Try more carefully de-airing of piping. It might be necessary to use an expansion tank at LPU.
Expansion tank at hand pump is not allowed as it gives risk of oil spillage at breather valve.
LPU-S
No connection from LPU-tank and hand pump tank to actuator tank/spring chamber. Hand pump
tank and LPU tank need tank connection to actuator to maintain constant oil volume in system for
mix of emergency and remote operation.
For large actuators
Oil compression by pressurizing actuator needs more oil than a standard tank can give. Use pressure
tank for LPU. This is the case for e.g. BRC/BRCF 16000, BRC 32000, BRCF 4000 HT, BRCF 8000 HT,
KC 325 and KC 400.
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LPU cannot raise pressure after hand pump operation
(but no problems after remote operation)
Reason: • Leakage from LPU to hand pump.
– Portable hand pump must be disconnected.
– Make sure that by-pass at possible bulkhead hand pump is closed.
– Try to operate valve in the selected direction by hand pump first, then by LPU. If LPU can raise
pressure now, the DPCV valve slide has too high friction. If problem is not solved DPCV is leaking due to defect non return valve or slide is sticking.
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Service Manual Damcos LPU: Troubleshooting Guide LPU
SM 8000-100-01 Ed 04 February 2017
LPU leaking from bleeder valve when hand pump is
mounted
Reason: For LPU-S
• Bad T-connection from LPU to hand pump:
– Check piping and connections.
– Check that no by-pass valve is placed in T-side of hand pump, as free T-flow is essential for
function of hand pump.
For LPU-D
• At remote operating LPU is compressing oil in piping for hand pump or, when bulkhead mounted
LPU, for actuator. The oil volume needed for compressing this oil is depending on oil volume in
pipes and proper de-airing. This oil volume will be taken from hand pump tank and cannot be
returned because of DPCV in hand pump.
– If de-airing of piping is OK a pressure tank at LPU has to be mounted.
Caution! Pressure tank at hand pump is not allowed.
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Damcos LPU: Troubleshooting Guide LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Spring actuator do not close by emergency hand pump
operation
Reason: • Spring actuators will not close by changing bulkhead hand pump to close, as there will be no
pressure rise to open the DPCV.
– Close actuator through by-pass valve at hand pump or actuator instead. Close by-pass valve
when the actuator is fully closed.
For KFR
If KFR is emergency opened at the actuator, an opening operation followed by closing the actuator is
necessary. Opening operation can be made by hand pump or remote control.
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Service Manual Damcos LPU: Troubleshooting Guide LPU
SM 8000-100-01 Ed 04 February 2017
LPU-Ex motor do not run
Reason: LPU-Ex-motors contain temperature sensors that have to be reset manually. After motor cut-off by
temperature sensors they have to be reset by turning off 24 V power for at least 10 sec.
If this don’t solve the problem, see “Motor not running and is hot” on page 49 and “Motor not run-
ning and is Cold” on page 49.
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Damcos LPU: Troubleshooting Guide LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
LPU-Ex has to be bulkhead mounted because of too little
space or zone 0 at actuator
Like other LPU’s LPU-Ex can be bulkhead mounted by means of BB-block or BB-VPI, but then needs an
intrinsically safe position indicator. All LPU-Ex can be delivered with integrated intrinsically safe outlet
for position indicator (ia) to solve the problem.
Note! For LPU-Ex with ia-outlet the hole for DPI in LPU must contain a special plug to ensure that
flameproof enclosure of LPU-Ex is maintained. This plug is delivered with ia-parts and
must always be used for ia-versions.
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Service Manual Damcos LPU: Troubleshooting Guide LPU
SM 8000-100-01 Ed 04 February 2017
Position indicator errors
Fault: • ON/OFF position indicator is not functioning correctly:
– Check the control cable connections.
– Check the function of the position indicator, measured on the position indicator wire connec-
tion. Possibly replace position indicator.
• Analogue position indicator cannot be calibrated
– Disconnect the wires from the position indicator, check the adjustment of the potentiometer,
and possibly re-adjust the indicator according to the relevant instruction
• Analogue position indicator not functioning correctly
For power controlled LPU:
– Check supply voltage at 4 - 20 mA transmitter which has to be 15 - 27 VDC.
– Disconnect the wires from the position indicator.
– Check the adjustment of the potentiometer, and possibly re-adjust the indicator according to
the relevant instruction
– Check the function of the potentiometer, measured on the indicator.
– Check the cable entry in cable glands. Shield has to be connected in both ends. If the indicator
and cable mounting is OK, replace the printed circuit board (see “Replace Printed Circuit
Board” on page 105). Otherwise replace the position indicator.
(*
.
(*
.
*) 300-350 Ohm between the "closed" and the "wiper" connection, while the valve is fully closed.
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Damcos LPU: Operating LPU-S 2 Service Manual
1. Tank for hydraulic oil
2. Suction filter
3. Electrical motor
4. Pressure controlled flow adjustment
5. Pump safety valve
6. Actuator relief valve
7. Quick connection for hand pump suction
8. Fail safe actuator, single-acting
9. Quick connection for hand pump,
opening w/filter
10.Shuttle valve for hand pump, opening
11.Throttle for closing speed adjustment
12.Pressure switch
13.Pressure filter
14.Solenoid valve
15.Non-return valve
16.Opening speed adjustment
17.Variable displacement pump
February 2017 SM 8000-100-01 Ed 04
Operating LPU-S 2
Hydraulic Diagram LPU-S
To open valve
To move the valve towards open, the motor (3) is activated.
The oil is led from tank through the pump and through the non-return valve (15), directly to the
actuator B port. To prevent the oil from flowing back to tank, the solenoid valve (14) must be energized. When the valve is fully open, the pressure rises to 150 bar which causes the pump safety valve
(5) to open and the oil flows back to tank. The motor is de-energized.
The actuator is now hydraulically locked in position by the solenoid valve.
Safety/Actuator relief valve
In case of a major increase of temperature, the pressure may rise. This will not cause any problems
because of the safety valve (6) which will open at approximately 225 bar.
To stop valve in intermediate position
The valve can be stopped (and hydraulically locked) in any intermediate position simply by de-energizing the motor.
If the pressure drops while valve is fully open - due to a minor leakage in the solenoid valve or due to
temperature variations -, the pressure switch (12) will detect this. The motor may then be activated
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Service Manual Damcos LPU: Operating LPU-S 2
SM 8000-100-01 Ed 04 February 2017
for some seconds in order to keep up the pressure, and prevent the valve from leaving the open position. - This may take place automatically.
Close valve
To move the valve towards closed, the solenoid valve is de-energized. The springs then move the
actuator, pressing the oil back from the actuator B port, through the throttle valve (11) and the solenoid valve (14) to the LPU tank.
Note! For power controlled LPU please see also “Operation LPU-S” on page 123.
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Damcos LPU: Operating LPU-D 2a Service Manual
1. Tank for hydraulic oil
2. Suction filter
3. Electrical motor
4. Pressure switch
5. Double pilot operated check valve,
closing side
6. Actuator relief valve, closing side
7. Quick connection for hand pump,
closing w/filter
8. By-pass valve
9. Double-acting actuator
10.Quick connection for hand pump,
opening w/filter
11.Actuator relief valve, opening side
12.Tank filling valve
13.Double pilot operated check valve,
opening side
14.Solenoid valve
15.Pump safety valve
16.Pressure controlled flow adjustment
17.Variable displacement pump
February 2017 SM 8000-100-01 Ed 04
Operating LPU-D 2a
Hydraulic Diagram LPU-D
To open valve
When the motor and solenoid valve are activated the oil is sucked from tank through the suction filter to the pump and pumped through the solenoid valve and the pilot operated check valve (13) to
the actuator port B. This causes the actuator to open the valve. The oil from actuator port A flows
back through the pilot operated check valve (5) (which is opened by the pressure in the B-line) and
returns through the solenoid valve to the tank.
When the valve is fully open, the pressure rises to 150 bar, which causes the pump safety valve to
open so that the oil flows back to tank. The motor and the solenoid valve are then de-energized.
The actuator is now hydraulically locked in position by the pilot operated check valves.
Safety/Actuator relief valve
In case of a major rise in temperature, the pressure may rise. This will not cause any problems
because of the actuator relief valve (6) and (11), which will open at approx. 225 bar.
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Service Manual Damcos LPU: Operating LPU-D 2a
SM 8000-100-01 Ed 04 February 2017
Close valve
Closing the valve follows exact the same procedure, except that the solenoid valve is not activated
which causes the ports A and B to be reversed.
When the motor is running the direction of oil- flow is solely determined by the activation of the solenoid valve.
Note! For power controlled LPU please see also “Operating LPU-D” on page 124.
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Damcos LPU: Emergency Operation of LPU V.2 Service Manual
February 2017 SM 8000-100-01 Ed 04
Emergency Operation of LPU V.2
For all operations: When the hand pump is disconnected and the by-pass valve is closed, the remote
control is allowed to operate the system again.
Note! For LPUv.2 emergency operation with hydraulic hand pump, a hand pump unit with reser-
voir can be used. To avoid overfilling of the LPU, both quick connections have to be
mounted.
Note! To close emergency opened actuator by remote, open the actuator first to release shuttle
valve and then close.
LPU with LED Position Indicator
LPU (except Ex version) with IP 68 LED indicator will show clear red or green light when the valve is
closed respectively open.
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Service Manual Damcos LPU: Emergency Operation of LPU V.2
SM 8000-100-01 Ed 04 February 2017
Firmly mounted hand pump
With a firmly mounted hand pump the following applies:
Emergency open a fail-open LPU
1. Open by-pass at the actuator or at the firmly mounted hand pump until the valve has reached
the desired position. Then close by-pass valve again.
2. If the actuator has been closed by remote control and power is still on “the keep closed” function
is activated and the LPU may start up trying to keep the actuator closed. You have to disconnect
power or remove close-command before manual operation is started.
The valve will now stay in position until operated with hand pump again or by remote control.
Emergency closing a fail-close actuator
1. Open by-pass at the actuator or at the firmly mounted hand pump until the valve has reached
the desired position. Then close by-pass valve again.
2. If the actuator has been opened by remote control and power is still on, “the keep open” func-
tion is activated and the LPU may start up trying to keep the actuator open. You have to disconnect power or remove open-command before manual operation is started.
The valve will now stay in position until operated with hand pump again or by remote control.
Emergency closing a fail-open LPU
or
Emergency opening of actuator
1. Turn the directional valve at the hand pump to position “OPEN”
2. Operate hand pump until the valve has reached the desired position.
The valve will now stay in position until operated with hand pump again or by remote control.
Emergency closing of a double acting actuator
1. Turn the directional valve at the hand pump to position “CLOSE”
2. Operate hand pump until the valve has reached the desired position.
The valve will now stay in position until operated with hand pump again or by remote control.
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Damcos LPU: Emergency Operation of LPU V.2 Service Manual
February 2017 SM 8000-100-01 Ed 04
LPU-D
Emergency operation of double acting actuator with key
Actuators that can be opened by emergency operation actuator:
BRC 125 - BRC 500
1. Open the crossover valve by turning counter clockwise.
2. Use the emergency operation key on the actuator.
3. Open by-pass valve at the actuator and turn
the key counter clockwise to open valve and
clockwise to close valve.
4. After emergency operation by key the
crossover valve is closed.
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Service Manual Damcos LPU: Emergency Operation of LPU V.2
SM 8000-100-01 Ed 04 February 2017
Emergency opening of double acting actuator with hand pump
1. Connect hand pump P-line with B-line quick connection at the LPU.
2. Connect hand pump T-line with A-line quick connection at the LPU.
3. Operate hand pump and actuator will open.
4. Disconnect hand pump
Emergency closing of double acting actuator with hand pump
1. Connect hand pump P-line with A-line quick connection at the LPU.
2. Connect hand pump T-line with B-line quick connection at the LPU.
3. Operate hand pump and actuator will close.
4. Disconnect hand pump
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Damcos LPU: Emergency Operation of LPU V.2 Service Manual
February 2017 SM 8000-100-01 Ed 04
LPU-S
Emergency opening of single acting actuator with hand pump
1. Connect hand pump P-line with B-line quick connection at the LPU.
2. Connect hand pump T-line with T-line quick connection at the LPU.
With suction to T and pressure to B the shuttle valve will change over and prevents the oil from
flowing to tank.
3. Operate hand pump and actuator will open.
4. Disconnect hand pump
Note! This procedure applies to fail-close actuators.
For Fail-open actuators please contact Emerson Process Management.
Emergency closing of single acting fail-close actuator
1. Open cross-over valve on actuator and let it stay open until the required position is reached.
2. When the valve is fully closed, the shuttle valve will be reset.
Emergency opening of single acting fail-open actuator
1. Open cross-over valve on actuator and let it stay open until the required position is reached.
2. When the valve is fully closed, the shuttle valve will be reset.
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Service Manual Damcos LPU: Emergency Operation of LPU V.2
SM 8000-100-01 Ed 04 February 2017
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Damcos LPU: Speed adjustment for Actuator on LPU (v.2) Service Manual
February 2017 SM 8000-100-01 Ed 04
Speed adjustment for Actuator on LPU (v.2)
Speed adjustment for double acting actuators
Speed will be adjusted by means of a 3 mm Allen key, see picture below where to adjust. By turning
the screw clockwise (fasten screw), the actuator will run slower, turning the screw counterclockwise
it runs faster. If the actuator has to run with maximum or minimum speed, the adjustment screw
shall only be tightened slightly (max 1.5 Nm).
Speed adjustment for single acting actuators
Opening and closing speed will be adjusted by means of a 3 mm Allen key, see picture below where
to adjust. By turning the screw clockwise (fasten screw), the actuator will run slower, turning the
screw counterclockwise it runs faster. If the actuator has to run with maximum or minimum speed,
the adjustment screw shall only be tightened slightly (max 1.5 Nm).
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Service Manual Damcos LPU: Speed adjustment for Actuator on LPU (v.2)
SM 8000-100-01 Ed 04 February 2017
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Page 85
Damcos LPU: Pump pressure adjustment for LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Pump pressure adjustment for LPU
Warning! Parts inside housing of LPU are connected to 230 Volts, please do not touch these parts
without power supply securely OFF.
1. The pressure gauge is mounted on quick connection B (nearest to the motor) of the LPU. For
LPU-D the adjustment can also be carried out with the pressure gauge on quick connection A,
and thus the LPU shall only receive a ”Close”-command during adjustment.
2. Adjustment of the pump pressure is carried out with a 5 mm Allen key with ball head. The adjust-
ment screw is placed near the pressure switch (the one near the LPU-front in LPU-D).
3. The pressure has to be set to 150 bar. As there are some tolerances in the system, the pressure
might be varying, that’s why the pressure is set to 150 bar to assure a running pressure of 135
bar at the actuator. Tightening the screw will rise the pressure, loosening the screw will lower the
adjusted pressure.
4. For Power- controlled LPU: To obtain a longer operating time of the motor than standard 7 sec-
onds, the pressure switch cables to the specific pressure switch (for “B” it is the pressure switch
near the pressure adjustment) can possibly be dismounted from the print. These lines are from
print card connected to 220 Volt. The motor must be operated for max. 10 minutes.
5. For P-NET controlled LPU: To obtain a longer operating time of the motor than standard 7 sec-
onds, the indicator cables to the specific terminal can possibly be dismounted from the print.
The motor must be active for max. 10 minutes.
6. When the actuator is in end position, the pressure can be read on the pressure gauge, while the
motor is running.
7. The pressure is adjusted to approx. 150 bar. Then the motor is stopped, pressure released and
motor is started again for fine adjustment, if any.
8. After final adjustment the pressure gauge is dismounted, and the cables to the pressure switch/
indicator are mounted again.
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Service Manual Damcos LPU: Pump pressure adjustment for LPU
SM 8000-100-01 Ed 04 February 2017
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Page 87
Damcos LPU: Refill of Oil in LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Refill of Oil in LPU
Refilling of oil is normally done when needed. Refill of oil should also be done when parts are
changed in LPU or if LPU starts to make special noises at operation.
The LPU seen from above and below.
Recommended refill oil
Use an hydraulic oil, as specified for the system. The LPU is normally pre-filled with Shell Tellus T S2 V
32, for deck mounting Shell Tellus S4 VX.
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Service Manual Damcos LPU: Refill of Oil in LPU
SM 8000-100-01 Ed 04 February 2017
Procedures
LPU without pressurised reservoir using direct level control
1. Remove the breather valve, placed on top or bottom of the LPU or end of oil tank, depending on
the LPU mounting direction, see picture on page 87. For LPU-S on BRCF the breather valve might
be placed on top of BRCF.
2. Oil level must be max 15 mm below breather valve or plug in LPU.
For LPU-S on BRCF oil level in LPU tank must be above suction pipe at fully opened actuator.
3. If oil level is low, fill the reservoir with hydraulic oil as specified for the system. Oil filling may be
done directly through the hole for breather valve or with a hand pump.
4. LPU-S hand pump filling: Apply pressure from hand pump directly to T-quick connection of the
LPU. See “LPU-S mounted on BRCF oil filling with hand pump” on page 90
alt.
LPU-D hand pump filling: Open stop valve at front of LPU and apply pressure from hand pump
directly to B-quick connection. Close stop valve after filling. See “LPU-D Oil Filling Instruction
with hand pump” on page 91.
5. Remount the breather valve.
LPU with pressurised reservoir
1. Oil level is controlled by measuring the distance from cap to piston with closed or fully opened
actuator, see drawing next page.
2. If refill is demanded, close the actuator, connect pressure connection from hand pump to T-
quick connection for LPU-S, see “LPU-S mounted on BRCF oil filling with hand pump” on page 90
or to B-quick connection for LPU-D, see “LPU-D Oil Filling Instruction with hand pump” on
page 91.
3. For LPU-D open by-pass valve at front of LPU.
4. Use hand pump to fill the LPU reservoir. For LPU-D close by-pass valve at front of LPU.
5. When recommended oil level is reached, disconnect hand pump and close the cap at the reser-
voir with breather valve.
6. Activate the LPU a few times and control oil level again.
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Damcos LPU: Refill of Oil in LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
LPU with permanently mounted hand pump
If the LPU is mounted with a permanently mounted hand pump, the oil level control has to be done in
the LPU and in the hand pump, as malfunction is possible in an empty hand pump.
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Service Manual Damcos LPU: Refill of Oil in LPU
breather valve
quick connection B
(OPEN)
quick connection T
by-pass valve
SM 8000-100-01 Ed 04 February 2017
LPU-S mounted on BRCF oil filling with hand pump
1. Connect hand pump pressure hose to quick connection T.
2. Dismount breather valve or upper-most plug in LPU tank.
3. Apply oil to T-port until tank is full (oil is just about to pour out of tank).
4. Remount breather valve/plug in LPU tank.
5. Dismount breather valve or upper-most plug at top of BRCF.
6. Apply oil to T-port until oil is just about to pour out of BRCF spring chamber.
7. Remount breather valve/plug in BRCF.
8. Disconnect hand pump.
9. Open/close actuator a few times by remote control.
Note! For LPU-S do not operate the directional slide of hand pump to release pressure. The oil
inside actuator will flow back to hand pump, but oil will not flow from hand pump to tank
line of actuator. Thus oil will be emptied out of LPU if LPU-S is closed by operating the
directional slide of hand pump.
10.Resume step 1 to 8 until oil level is stable at correct level.
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Damcos LPU: Refill of Oil in LPU Service Manual
breather valve
tank filling valve
quick connection B
(OPEN)
breather valve
tank filling valve
quick connection B
(OPEN)
February 2017 SM 8000-100-01 Ed 04
LPU-D Oil Filling Instruction with hand pump
1. Close the actuator fully.
2. Connect the hand pump pressure hose B to quick connection B (open).
3. Open the tank filling valve.
4. Pump the hand pump to fill the LPU reservoir and stop pumping when the oil is pouring out of
the breather valve.
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Service Manual Damcos LPU: Refill of Oil in LPU
SM 8000-100-01 Ed 04 February 2017
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Damcos LPU: Replace Pump in LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Replace Pump in LPU
Note! If permanently mounted hand pump is connected, close stop valves for hand pump if
mounted in system.
Replace Pump in LPU
1. Oil tank is emptied by removing plug at bottom of
tank or valve block.
3. Valve block with pump is removed from LPU. 4. Remove suction pipe from valve block by means of
5. Press out the pump stator through suction pipe
hole.
2. Remove 4 pcs M8-screw and remove the tank.
Allen key.
6. Remove the rotor.
cont...
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Service Manual Damcos LPU: Replace Pump in LPU
It is essential
that the height
of stator is
exactly 19 mm!
SM 8000-100-01 Ed 04 February 2017
Replace Pump in LPU
7. Oil the new stator and place it with slot for pin in
same direction as slot in valve block
Be sure the small pin is in place on stator!
9. Check the height of stator.
Stator is pressed until extension above valve block
surface is 19 mm. This should correlate with the
height of mounting tool as of point 8.
8. Turn in the stator. When stator is turned to correct
rotational position press it down to same level as
mounting tool.
10.Check suction pipe filter for contamination. If nec-
essary clean the filter.
Mount the suction pipe.
94
.
11.Rotor with pistons is placed on stator or in LPU
block depending on mounting direction of LPU.
Rotor coupling must be placed in same direction as
corresponding slot in motor shaft.
Page 95
Damcos LPU: Replace Pump in LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Replace Pump in LPU
12.Check O-rings and exchange them if necessary. 13.Mount the disc on stator.
14.All pistons are kept in place in rotor while valve
block with pump is mounted on LPU.
16.Mount the filter on suction pipe. 17.Mount tank. Screws are cross-tightened.
18.Refill with clean oil. See “Refill of Oil in LPU” on page 87.
19.Open actuator by-pass and start pump for 10-15 sec.
By-passing the actuator ensures de-airing of the pump
20.Control oil level, if necessary replenish. Close by-pass valve and run a full open/close cycle if possible.
Check oil level again.
15.Fasten suction pipe.
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Service Manual Damcos LPU: Replace Pump in LPU
SM 8000-100-01 Ed 04 February 2017
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Damcos LPU: Replace DPCV in LPU Service Manual
2 pcs
February 2017 SM 8000-100-01 Ed 04
Replace DPCV in LPU
Replace DPCV in LPU
1. Remove plug. 2. Use the correct tool or an M2 screw.
3. Dismount NRV front. 4. Dismount NRV back.
5. Remove slide and spring. 6. Old DPCV:
New DPCV:
7. Mount new DPCV.
cont...
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Service Manual Damcos LPU: Replace DPCV in LPU
SM 8000-100-01 Ed 04 February 2017
Replace DPCV in LPU
8. Mount NRV back. 9. Mount plug at back.
10.Mount NRV in front. 11.Mount plug in front.
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Damcos LPU: Replace release valve in LPU Service Manual
February 2017 SM 8000-100-01 Ed 04
Replace release valve in LPU
Replace release valve in LPU
1. Remove plug. 2. Use the correct tool or an M2 screw.
3. Remove release valve. Note that LPU-D has two
release valves, check drawings for exact positions.
5. Use tool to mount the valve. 6. Mount plug.
4. Change the valve.
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Service Manual Damcos LPU: Replace release valve in LPU
SM 8000-100-01 Ed 04 February 2017
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