MTS 506-92 User Manual

Hydraulic Power Unit
Product Information Manual

Model 506.82
Model 506.92



011-770-700 F

Copyright information © 2000 MTS Systems Corporation. All rights rese rved.

Trademark information MTS is a registered trademark of MTS Systems Corporation.

DTE is a registered trademark of Mobil Corporation.
Tellus is a registered tradema r k of Shell Oil Corporation.

Contact information MTS Systems Corporation

14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: [phone] (within the U.S. or Canada)
Phone: [phone] (outside the U.S. or Canada)
Fax: [phone]
E-mail: [e-mail]
http://www.mts.com

Publication information

Manual Part Number Publication Date

011-770-700 F

June 1997

Table of Contents

Section 1 Introduction

1.1 Functional Description............................................................................. 1-2

1.2 Specifications........................................................................................... 1-3

Section 2 Operation

2.1 Controls and Indicators............................................................................ 2-1

2.2 Operation Procedures .............................................................................. 2-3

2.3 Supercharge Pump Operation .................................................................. 2-5

Section 3 Service

3.1 Maintenance Procedures.......................................................................... 3-1

3.1.1 Filters ................................................................................................ 3-2

3.1.1.1 High-Pressure Filter Replacement ................................................ 3-3

3.1.1.2 Low-Pressure Filter Replacement ................................................. 3-4

3.1.2 Hydraulic Fluid................................................................................. 3-5

3.1.3 Accumulators .................................................................................... 3-7

3.1.3.1 Precharge Pressure-Checking Intervals......................................... 3-7

3.1.3.2 Precharging the Accumulators..................................................... 3-8

3.1.3.3 Changing the Accumulator Seals.................................................. 3-8

3.2 Service Adjustments................................................................................. 3-9

3.2.1 Adjusting the Output Pressure........................................................... 3-10

3.2.2 Dual-Temperature Switch Adjustments.............................................. 3-12

3.2.3 Low-Level Switch Adjustment........................................................... 3-13

3.2.4 Main Pump Low-Inlet Pressure Switch Adjustment ........................... 3-14

3.3 Starter Assembly..................................................................................... 3-15

3.3.1 Abnormal HPS Shutdown................................................................. 3-16

3.3.2 Fuse Replacement............................................................................. 3-16

3.3.3 PLC Service...................................................................................... 3-17

Section 4 Installation

4.1 Hydraulic Connections............................................................................ 4-2

4.2 Electrical Connections.............................................................................. 4-3

4.2.1 Transformer Wiring ........................................................................... 4-4

4.2.2 Input Power ...................................................................................... 4-5

4.3 Cooling Water Connections ..................................................................... 4-6

Table of Contents i

Section 5 Theory of Operation

5.1 Hydraulic Operation................................................................................ 5-1

5.2 Electrical Operation ................................................................................. 5-3

5.2.1 Control.............................................................................................. 5-4

5.2.2 Interlocks .......................................................................................... 5-5

Index

List of Figures

Figure 2-1 Controls and Indicators ........................................................................... 2-1

Figure 3-1 Location of Maintenance Components (HPS Side View)........................... 3-1

Figure 3-2 Location of Accumulators........................................................................ 3-7

Figure 3-3 Location of Adjustment Components (HPS Side View) ............................. 3-9

Figure 3-4 Models 506.82/.92 Starter Assembly (Typical).......................................... 3-15

Figure 3-5 Fixed Controller with Remote Control Modules...................................... 3-16

Figure 4-1 Location of Remote Control Connector.................................................... 4-1

Figure 4-2 Hydraulic Connections............................................................................ 4-2

Figure 4-3 Models 506.82 and 506.92 Starter Assemblies ............................................ 4-3

Figure 4-4 Standard Transformer Wiring Configuration............................................. 4-4

Figure 4-5 Typical Multi-Tap Transformer Wiring Configuration............................... 4-4

Figure 5-1 Hydraulic Block Diagram........................................................................ 5-1

Figure 5-2 Typical Electrical Schematic..................................................................... 5-7

List of Tables

Table 1-1 Cooling Water Flow Requirements .......................................................... 1-3

Table 1-2 HPS Specifications ................................................................................... 1-3

Table 2-1 Controls and Indicators............................................................................ 2-2

Table 3-1 Maintenance Schedule ............................................................................. 3-2

Table 3-2 Starter Assembly Fuse Values.............................................................. ....3-16

Table 3-3 Fixed Controller Output Indicators.......................................................... 3-18

Table 3-4 Fixed Controller Input Indicators............................................................ 3-18

Table 3-5 Remote Control Module Output Indicators ............................................. 3-19

ii Table of Contents

Section 1

Introduction

Definition

The Model 506.82/.92 Hydraulic Power Unit (HPU) uses two variable­volume (pressure compensated) main pumps, with a pressurized
(supercharged) hydraulic fluid inlet, to provide pressure to systems with
various flow requirements. The HPU is designed to be used with servo­controlled, electro-hydraulic systems.

Model 506.82/.92 Hydraulic Power Unit

Introduction 1-1

1.1 Functional Description

Front panel controls
and indicators

Pressure output

Pressure
accumulation

Temperature
control

Fluid level indication

Front panel controls on the HPU include local operating controls and two
running time meters. Front panel indicators show power on, low oil
level, fluid over-temperature, motor overload and dirty filter conditions.

The output pressure is controlled by an adjustment on the main pumps
and is monitored by the output pressure gage. An adjustable back-up
relief valve limits output pressure by porting fluid back to the reservoir
when the output pressure rises above the relief valve setting.

High/low pressure operation is controlled by the high/low solenoid
valves. These valves control the main pressure control (pressure
compensator) vent ports and the backup relief valve vent port.

The pressure accumulator smoothes the HPU output pressure and
provides additional hydraulic flow for dynamic actuator demands. It is
precharged with dry nitrogen to a pressure proportional to HPU output
pressure. The slow turn-on accumulator slows the rate at which the
backup relief valve shifts from low to high pressure.

A temperature gage indicates hydraulic fluid temperature. An
oil-to-water heat exchanger controls the fluid temperature. When the
temperature exceeds a preset limit, a temperature sensitive switch turns off
the HPU and lights the front panel Over-Temperature indicator.

A transparent gage indicates the level of hydraulic fluid in the HPU
reservoir. A low-level switch automatically turns off the HPU and lights
the front panel Low Oil Level indicator if hydraulic fluid drops below a
preset level.

Programmable logic
controller

The PLC (programmable logic controller) located in the starter assembly
performs logic functions. The I/O (input/output) section of the PLC
provides an interface for various signals received from or sent to external
devices.

An optional module can be added to the PLC if remote control of the
HPU is required. This module provides the additional output indicators
needed for the remote control option.

Introduction 1-2

1 .2 Specifications

Cooling water
specifications

General HPU
specifications

The required water pressure between the input and the output of the heat
exchanger is 30 to 45 psi (0.2 to 0.3 MPa). The maximum allowable
pressure is 120 psig (0.8 psid). The flow rate (±20%) at a given temperature
is shown in the table below.

Table 1-1. Cooling Water Requirements

Cooling Water Inlet Required Water Flow

Temperature 506.82B 506.92B
60°F (15.5°C) 30 gpm (114 l/min) 35 gpm (132 l/min)

65°F (18.5°C) 35 gpm (132 l/min) 42 gpm (159 l/min)
70°F (21.0°C) 40 gpm (151 l/min) 51 gpm (193 l/min)
75°F (24.0°C) 46 gpm (174 l/min) 67 gpm (254 l/min)
80°F (26.5°C) 54 gpm (204 l/min) 90 gpm (341 l/min)
85°F (29.5°C) 70 gpm (269 l/min) 120 gpm (454 l/min)
90°F (32.0°C) 90 gpm (346 l/min) 160 gpm (606 l/min)

Table 1-2 lists the specifications for the Model 506.82/.92 Hydraulic Power
Unit.

Table 1-2. HPU Specifications

Parameter Model 506.82B Model 506.92B

Maximum continuous pressure 3000 psi (20.7 MPa) 3000 psi (20.7 MPa)
Maximum flow capacity (60 Hz) 150 gpm (568 l/min) 200 gpm (757 l/min)
Maximum flow capacity (50 Hz) 150 gpm (568 l/min) 185 gpm (710 l/min)
Noise rating at 3 ft. (0.9 m) 90 dBa 90 dBa
Reservoir capacity:

Maximum full to top plate (no air) 571 gal ( 2161l) 571 gal ( 2161l)
Nominal running level, 28 in. (711 mm) above tank

bottom
Low-pressure filtration, absolute/nominal 3.0/0.45 microns 3.0/0.45 microns
High-pressure filtration 10 microns 10 microns
Fluid hose connections:

Pressure (SAE 4 bolt) -24 (1), -32 (1) -24 (1), -32 (1)
Return (SAE 4 bolt) -24 (1), -32 (1) -24 (1), -32 (1)
Drain (37° flare) -16 (1), -12 (1),

Main pump motor power rating (2 each) 150 hp (112 kW) 200 hp (150 kW)

*

463 gal (1753 l) 463 gal (1753 l)

-16 (1), -12 (1),

-8 (2)

-8 (2)

Introduction 1-3

Table 1-2. HPU Specifications (Continued)

Parameter Model 506.82B Model 506.92B

Supercharge pump motor power rating 25 hp (19 kW) 40 hp (30 kW)
3-phase current 460V/60 Hz:

†

Inrush 575 A 775 A

Continuous 395 A 535 A
Starter type Wye-delta Wye-delta
24 V external hydraulic control amps (with optional

6.8 A 6.8 A

remote control)
Maximum cooling water heat load:

BTU per hour 760,000 1,020,000

Kilocalories per hour 192,000 257,600
Atmospheric heat load (BTU per hour) 56,900 87,800
Atmospheric heat load (Kilocalories per hour) 14,400 22,200
Water inlet/outlet size 1.5 in. (38 mm) NPT 2 in. (51 mm) NPT
Maximum ambient operating temperature 104°F (40°C) 104°F (40°C)
Minimum ambient operating temperature 40°F (4.4°C) 40°F (4.4°C)
Height with casters 78 in. (1981 mm) 78 in. (1981 mm)
Length 111 in. (2819 mm) 111 in. (2819 mm)
Width 68 in. (1727 mm) 68 in. (1727 mm)
Weight with oil 12,500 lb (5669 kg) 12,500 lb (5669 kg)

* The number of connections are shown in parentheses.
†

Currents listed are typical theoretical values based on data outlined in the NEPA-70 (national
electrical code). Supply conductors and disconnect switch sizing must be done using the
customer’s local and state codes.

Specifications subject to change without notice. Contact MTS for verification of any critical specifications.

Introduction 1-4

2.1 Controls and Indicators

Figure 2-1 and Table 2-1 identify and describe HPU controls and indicators.

Section 2

Operation

Fluid Level Gage

Temperature Gage

(These gages are located on the
HPS rear panel)

Figure 2-1. Controls and Indicators

VW-G041C

Operation 2-1

Table 2-1. Controls and Indicators

Control/Indicator Description
Power On indicator* The Power On indicator lights to indicate that electrical power is

applied to the HPU.

Emergency Stop switch This switch operates in both local and remote control and is

used during emergency situations only. When pressed, it
immediately shuts down the HPU (the supercharge pump may
continue to run briefly to supply the main pumps until they
fully stop).

Local Mode switch If the Local Mode switch is activated, you can operate the HPU

with the front panel controls. If it is not activated, use a remote
control device to operate the HPU. Activation lights an LED in
the upper right corner of the switch.

Start switch Pressing Start sequences supercharge and main motors on, then

applies low pressure when in local control.

High Pressure Pressing High Pressure applies high pressure in local control.

Start must be pressed before applying high pressure. Activation

lights an LED in the upper right corner of the switch. The LED
also lights if high pressure is requested remotely.

Stop switch When Stop is pressed (in either local or remote mode), the HPU

first ramps to low pressure and then goes to zero pressure. The
supercharge pump continues to run for approximately 15
seconds.

Reset switch This switch resets the interlock circuit if the condition causing

the interlock has been corrected.

Low Oil Level indicator When this indicator lights, the hydraulic fluid level has dropped

below a preset value.

Fluid level gage This gage indicates the level of hydraulic fluid in the reservoir.

Over-Temperature

indicator

Temperature gage This gage indicates the temperature of the hydraulic fluid in the

Dirty Filter indicator When this indicator lights, the low-pressure filter needs

Pump 1 Select Pressing this switch selects Pump 1 for operation. Activation

Pump 2 Select Pressing this switch selects Pump 2 for operation. Activation

Hour Meter
Pump No. 1

Hour Meter
Pump No. 2

When this indicator lights, hydraulic fluid temperature has
exceeded a preset value.

HPU reservoir.

replacement. See Subsection 3.1.1.

lights an LED in the upper right corner of the switch.

lights an LED in the upper right corner of the switch.

This front panel meter indicates the total operating hours of
pump 1.

This front panel meter indicates the total operating hours of
pump 2.

Operation 2-2

2.2 Operation Procedures

WARNING

!

This section provides the local and remote operating procedures for the

506.82/.92 Hydraulic Power Unit.

Do not start the HPU if the servovalve command is not equal to feedback
(that is, zero balanced).

Failure to do this can result in sudden actuator movement which may
cause injury to persons and/or damage to equipment.

Ensure that the system is at zero balance before starting the HPU.

Before you begin

Local operation

Before you begin operation complete the following steps:

1. Make sure that the external hydraulic system is ready for operation.

2. Press the Pump 1 Select or Pump 2 Select switch to select main pump
operation.

NOTE

To operate the HPU in local control mode complete the following steps:

1. Press the Local Mode switch to run the HPU in local control.
Activating this switch lights an LED in its upper right corner.

2. Apply electrical power to the HPU (the Power On indicator will
light).

3. Press Reset (must be pressed whenever electrical power to the HPS
has been interrupted).

The Dirty Filter indicator may light during a cold-start. It
should turn off when the HPU reaches its normal
operating temperature. If the indicator fails to turn off,
correct the condition (Subsection 3.1.1.2) and press Reset.

4. Press the Start switch to apply low pressure to the system.

5. Check the HPU and external hydraulic system for leaks and unusual
sounds.

6. Press the High Pressure to apply high pressure to the system.

7. Press Stop on the HPU front panel to stop the HPU and remove
output pressure.

Operation 2-3

Remote Operation

1. Turn the Source Remote/Local switch to Remote. Make sure that
the remote control cable is connected to the cable connector (the
figure on the left shows the location of this connector) and to the
remote control device.

2. Apply electrical power.

remote control

connector

has been interrupted).

4. Use the remote control device to start the HPU at low pressure.

5. Check for leaks and unusual sounds.

3. Press Reset (must be pressed whenever electrical power to the HPS

VW-G045A

6. Select high pressure at the remote control device.

7. Use the Off switch on the remote control device to stop the HPU
and remove output pressure.

2.3 Supercharge Pump Operation

When to use the
supercharge pump

Cooling procedure

When the temperature of the hydraulic fluid in the HPU reservoir exceeds
140˚F (60˚C), the fluid over-temperature switch automatically shuts down
the HPU. The HPU main pumps cannot be restarted in local or remote
until the hydraulic fluid cools.

The following procedure uses the supercharge pump to hasten the cooling
of the hydraulic fluid:

1. Ensure the water supply to the heat exchanger is turned on.

2. Press the Start switch without pump motor 1 or 2 selected. The
supercharge pump operates independently of the main pumps and
circulates hydraulic fluid through the heat exchanger to cool the
fluid.

Operation 2-4

3. When the temperature gage reads approximately 130˚F (54˚C), press
the Stop switch to turn off the supercharge pump.

4. To restart the HPU, first press the Reset control on the local or remote
control panel to clear the hydraulic interlock circuit, and then start
the HPU in low pressure.

Section 3

Service

Introduction

This section contains service information for the Model 506.82/.92
Hydraulic Power Unit (HPU). It provides:

• maintenance procedures

• service adjustments

• electrical information

3.1 Maintenance Procedures

Maintenance
overview

The following sections provide the routine maintenance procedures for
the HPU. Figure 3-1 shows the location of the components accessed for
the maintenance procedures. Table 3-1 lists the maintenance schedule.

low pressure filter

supercharge pump/motor

high pressure filters

pressure accumulator

filter drain

manifold drain

heat exchanger

VW-G043E

Figure 3-1. Location of Maintenance Components (HPU Side View)

Service 3-1

Table 3-1. Maintenance Schedule

WARNING

!

Procedure Interval Subsection

Check output pressure on gage

*

daily

Replace high-pressure filter whenever the indicator points to

change

Replace low-pressure filter whenever Dirty Filter indicator lights 3.1.1

Check hydraulic fluid level on gage daily 3.1.2

Check hydraulic fluid in reservoir 150 operating hours 3.1.2

Analyze hydraulic fluid 500 operating hours 3.1.2

Check accumulator precharge at established interval 3.1.3

Check hydraulic hoses monthly

*

See Subsection 3.2.1 to adjust the output pressure.

3.1.1 Filters

Fluid filtration is provided by two 10-micron high-pressure filters (one for
each pump), and one 3-micron low-pressure filter. See Figure 3-1 for the
location of the filters and their drains.

3.1.1

3-2 Service

High-pressure release occurs if the system is pressurized.

High-pressure release may cause personal injury or damage equipment.

Ensure that the output pressure gage reads zero before replacing the
filters.

3.1.1.1 High-Pressure Filter Replacement

6

End Cap – Top View

r

g

O-ring and backup ring

CHANGE

OK

DIRT ALARM

unscrew to

remove endcap

unscrew to

bleed



Replace the high-pressure filter elements whenever the DIRT ALARM
indicator mounted on the base of each high-pressure filter housing
points to CHANGE (red or yellow zone) or whenever the hydraulic
fluid is replaced.

VW-GO4

1. Press Stop on the HPU. The output pressure gage must read zero.

2. Loosen the air-bleed screw on top of the filter housing endcap.

With a container under the manifold drain port (Figure 3-1), open
the port to drain the fluid for both filters (the pressure accumulator
also drains).

When the fluid is drained, close the drain port and tighten the air­bleed screw. Discard the fluid according to company policy.

VW-GO47

3. Unscrew and remove the endcap. Remove the compression spring
plate on top of the filter elements and remove the filter elements.

4. Remove and save the grommet between the two filter elements.
Discard the filter elements.

spring

spring

plate

After you have
finished

filte

filter housin

VW-GO48

5. Inspect the O-ring and back-up washer in the end-cap. If
replacement is not required, clean and lubricate them with clean
hydraulic fluid.

6. Inspect the filter housing for any remaining contamination.

7. Insert two clean filter elements (MTS part number 100533-05), with
the grommet between the two elements, into the filter housing.

8. Inspect the compression spring plate and replace the end-cap.
Taking care not to damage the O-ring and the back-up washer,
tighten the end-cap.

Operate the HPU in low pressure for 5 minutes to remove air from the
filter housing. Check for leaks while doing this.

Service 3-3