MTS 512-04 User Manual

Model 512.04 Hydraulic Power Unit Product Information

015-206-401 C

Trademark information

Contact information

Publication information

MTS is a registered trademark of MTS Systems Corporation.

DTE is a registered trademark of Mobil Corporation.

Tellus is a registered trademark of Shell Oil Corporation.

Synasol is a registered trademark of Union Carbide Corporation

MTS Systems Corporation

14000 Technology Drive Eden Prairie, Minnesota 55344-2290 USA Toll Free Phone: 800-328-2255 (within the U.S. or Canada) Phone: 952-937-4000 (outside the U.S. or Canada) Fax: 952-937-4515 E-mail: info@mts.com http://www.mts.com

ANUAL

ART

UMBER

152064 -01A October 1998

UBLICATION

ATE

015-206-401 B November 1999

015-206-401 C August 2000

Contents 3

Introduction 5

Functional Description 6 Component Identiﬁcation 8 Speciﬁcations 10 Dimensions 11

Installation 13

Operation 17

Maintenance 21

Reducing the Fluid Temperature 22

Adjusting the Air Flow 23

Adjusting the Water Flow 24 Adding Hydraulic Fluid 25 Resetting the Thermal Overloads 26 Changing the Output Pressure 27 Lubricating the Motor 29 Changing the Filter 30 Changing the Hydraulic Fluid 31

Model 512.04 Hydraulic Power Unit Contents

Contents

Model 512.04 Hydraulic Power Unit

Introduction

Contents

Functional Description 6 Component Identiﬁcation 8 Speciﬁcations 10

This manual documents the Model 512.04 Hydraulic Power Unit (HPU), also called a hydraulic power supply (HPS), or pump. This compact hydraulic power unit is designed for use with low force testing systems. The HPU is available with a water–cooled or an air–cooled heat exchanger.

Water Cooled Air Cooled

Model 512.04 Hydraulic Power Unit

What you need to

know

Model 512.04 Hydraulic Power Unit Introduction

MTS Systems Corporation assumes that you know how to use your controller. See the appropriate manual for information about performing any controller-related step in this manual’s procedures. You are expected to know how to perform the following procedures

• Using the controller HPU controls in conjunction with the control

located on the HPU

• Controlling hydraulic ﬂuid ﬂow to other hydraulic equipment

Functional Description

The hydraulic power unit (HPU) is the mechanical source of high-pressure hydraulic ﬂuid required to operate the hydraulic components of a test system. See “Component Identiﬁcation” on page 8 for more information about the components discussed in this section.

Pump

Pressure

Filtering

Heat exchanger

A motor drives a hydraulic pump which draws hydraulic ﬂuid from a reservoir and pressurizes it to 13.8 MPa (2000 psi). The pressurized ﬂuid is made available to the hydraulic components in your test system.

The HPU can produce low and high pressure outputs:

• The low pressure output is approximately 1.4 MPa (200 psi). Low

pressure is normally used while installing a specimen.

• The high pressure can be adjusted to 13.8 MPa (2000 psi) or less. High

pressure is used for an actual test. When operating in high pressure, the low-pressure vent is blocked.

The ﬁltration system protects against silting by cleaning the hydraulic ﬂuid to an ISO particle count of 14/11 or better. The ﬁlter change gage indicates when the ﬁlter needs to be replaced.

A suction strainer protects the pump from larger particles when the ﬂuid is pumped from the reservoir. It is located in the bottom of the hydraulic ﬂuid reservoir.

Hydraulic ﬂuid temperature is maintained with a heat exchanger that cools the ﬂuid. The heat exchanger helps keep the temperature of the hydraulic ﬂuid between 64–68°C (147–155°F). The temperature of the ﬂuid is monitored by an overtemperature switch. If the ﬂuid temperature exceeds 75ºC (170ºF), a switch opens and shuts down the HPU. The system cannot be restarted until the ﬂuid cools. There are two kinds of heat exchangers:

Introduction

• The water-cooled heat exchanger cools the hydraulic ﬂuid as it passes

over water-ﬁlled tubes. A regulating valve can adjust the ﬂow of water through the tubes, and this affects the amount of cooling the heat exchanger can accomplish.

• The air-cooled heat exchanger cools the hydraulic ﬂuid as it passes

through a radiator. A fan blows air through the radiator to transfer heat from the radiator to the air. Louvers control the airﬂow over the hydraulic radiator, and this affects the amount of cooling the heat exchanger can accomplish.

Model 512.04 Hydraulic Power Unit

Pressure

Gage

Electronics

Hydraulic

schematic

Pressure -8

37° JIC Flare

The HPU has basic controls to turn it on to low pressure or high pressure and to turn it off. The HPU includes an Emergency Stop switch that is connected to the interlock chain of your test system.

A hydraulic interlock can be generated by the hydraulic power supply if one of the following occurs:

• Low hydraulic ﬂuid level

• High hydraulic ﬂuid temperature

• Dirty hydraulic power supply ﬁlter (optional)

The hydraulic schematic shows how the hydraulic components are connected in the Model 512.04 Hydraulic Power Unit. Both types of heat exchangers are shown.

Return -8

37° JIC Flare

0.125

Drain -06

SAE

Motor

Pressure

Relief Valve

1/2 NPT Strainer

0.7–14 MPa

(100–2000 psi)

Check

Valve

Pump

Filter

See Heat

Exchangers

Overtemperature

High/Low

Pressure Solenoid

Switch

Low Fluid

Switch

Water Out

1/2 ID Hose

Water-Cooled

Heat Exchanger

Air-Cooled Heat

Fan and Motor

Water In

1/2 ID Hose

Exchanger

Reservior

Model 512.04 Hydraulic Power Unit Introduction

Component Identiﬁcation

This table describes the components shown in the ﬁgure on page 9.

Component Descriptions

OMPONENT

Control Box

Pressure Gage

Sight Glass

Reservoir

Heat Exchanger

Filter

Low Fluid and Overtemperature Sensor

Filter Change Gage

ESCRIPTION

Houses the electronic controls of the pump, including the Stop button,

Low/High switch, and Reset button. It also houses the thermal

overloads to protect the pump motor. See “Resetting the Thermal

Overloads” on page 26.

Shows the current output pressure from the hydraulic power unit. The output pressure is factory set to 13.8 MPa (2000 psi). See “Changing the

Output Pressure” on page 27 to change the output pressure.

Combines a thermometer with a sight glass. You can quickly check the hydraulic ﬂuid’s temperature, level, and condition (by its color).

Stores the hydraulic ﬂuid. The reservoir has a 57 L (15 gal) capacity. It includes a magnetic drain plug to help catch metal particles.

Cools the hydraulic ﬂuid. The heat exchanger can be either water-cooled or air-cooled.

Provides 3–micron ﬁltration to ﬂuid returning to the reservoir (see

“Changing the Filter” on page 30).

(Not shown) Shuts the pump off if ﬂuid gets too low or becomes hotter than 75ºC (160ºF). See “Reducing the Fluid Temperature” on page 22 or

“Adding Hydraulic Fluid” on page 25 for more information.

Shows when it’s time to change the hydraulic ﬁlter. The gage is marked with three zones; green, yellow, and blue.

Pump Motor

Introduction

Green—The ﬁlter is good to use.

Yellow—Change the ﬁlter soon.

Red—Do not run the HPU until you have replaced the hydraulic ﬁlter element.

Drives a ﬁxed displacement gear pump.

Pumps a 12.5 lpm output at 13.8 MPa (3.3 gpm at 2000 psi) @ 50 Hz.

Pumps a 15.1 lpm output at 13.8 MPa (4 gpm at 2000 psi) @ 60 Hz.

Model 512.04 Hydraulic Power Unit

Control Box

Pressure Gage

Sight Glass

Reservoir

Pump Motor

Water-Cooled

Filter Change Gage

Filter

Heat Exchanger

Control Box

Pressure Gage

Sight Glass

Reservoir

Pump Motor Filter Change Gage

Air-Cooled

Filter

Heat Exchanger

Major Components

Model 512.04 Hydraulic Power Unit Introduction

Speciﬁcations

Model 512.04 Speciﬁcations

ARAMETER

Environmental

Operating temperature (ambient air)

Heat load

Noise rating

Pump

Flow capacity at 13.8 MPa (2000 psi)

Motor rating

Operating voltage

Hydraulic ﬂuid

Nominal temperature

Filtration (microns)

Reservoir capacity

†

at 1 m

PECIFICATION

18–49°C (65–104°F)

1061 kcal/hr (4200 BTU/hr)

74 db (A)

12.5 lpm (3.3 gpm) @ 50 Hz

15.1 lpm (4 gpm) @ 60 Hz

3.7 kW (5.0 hp)

208 V (ac) @ 16.7 A, 3 phase 230 V (ac) @ 15.2 A, 3 phase 460 V (ac) @ 7.6 A, 3 phase

Mobil DTE 26

or Shell Tellus

63°C (145°F)

3 µ absolute

57 liters (15 gallons)

Heat exchanger

Flow requirements

Water pressure (differential)

Max input pressure

Cooling

Water hose

Hydraulic connections

Pressure Return Drain

Weight

Specification is for 60 Hz operation.

†

Free field value [75 db (A) may be up to 10 db (A) more.

Water cooled or air cooled

13 lpm @ 21°C (3.5 gpm @ 70°F)

0.2 MPa (30 psi)

1 MPa (150 psi)

3276 Kcal/hr (13,000 BTU/hr)

12.7 mm (0.5 in)—inside diameter

each requires a 37° ﬂare

-8

-6

115 kg (250 lb)

» heavy traffic at 17 m]. Your readings

Introduction

Model 512.04 Hydraulic Power Unit

Dimensions

The following ﬁgure shows those dimensions which are useful when installing the hydraulic power unit.

Water Cooled

355 mm

(14 in)

584 mm

(23 in)

Air Cooled

457 mm

(18  in)

787 mm

(31 in)

889 mm

(35 in)

Model 512.04 Hydraulic Power Unit Introduction

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