MTS 512-14 User Manual

Model 512.14 Hydraulic Power Unit Product Information

100-103-876 B

Trademark 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

Contact information 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

Publication information

Manual Part Number Publication Date

100-103-876 A March 2004

100-103-876 B November 2005

Contents

Introduction 5

Component Identification 6

Functional Description 8

Specifications 10

Dimensions 11

Installation 13

Operation 17

Running the HPU 18

Recovering From an Interlock Condition 20

Reducing the Fluid Temperature 21

Adjusting the Air Flow 22

Adjusting the Water Flow 23

Resetting the Thermal Overloads 24

Adjusting the Output Pressure 25

Maintenance 27

Checking the Hydraulic Fluid 29

Replacing the Filter 31

Sampling the Hydraulic Fluid 32

Adding Hydraulic Fluid 35

Replacing the Hydraulic Fluid 36

Lubricating the Motor 39

512.14 Hydraulic Power Unit Contents

Contents

512.14 Hydraulic Power Unit

Introduction

Contents Component Identification 6

The Model 512.14 Hydraulic Power Unit (HPU) provides high-pressure hydraulic fluid for test system operation. 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.

This section contains the functional description and specifications of the HPU (also called a hydraulic power supply, or pump).

Functional Description 8

Specifications 10

Dimensions 11

Water Cooled Air Cooled

Model 512.14 Hydraulic Power Unit

512.14 Hydraulic Power Unit Introduction

Component Identification

Water-Cool ed

Pressure Gage

Sight Glass

Control Box

Pump Motor

Reservoir

Air-Cooled

Filter Change Gage

Filter

Heat Exchanger

Control Box

Pressure Gage

Sight Glass

Pump Motor

Heat Exchanger (Detached)

Reservoir

Major Components (Side View)

Introduction

512.14 Hydraulic Power Unit

Component Descriptions

Component Description

Component Identification

Control Box

Pressure Gage

Sight Glass

Reservoir

Heat Exchanger

Filter

Low Fluid and Overtemperature Sensor

Filter Change Gage

Houses the electronic controls of the pump, including the Stop button, and Low/High switch. It also houses the thermal overloads to protect the pump

motor. See “Resetting the Thermal Overloads” on page 24.

Shows the current output pressure from the hydraulic power unit. The output pressure is factory set to 21MPa (3000 psi). See “Adjusting the Output

Pressure” on page 25 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 aircooled. See “Adjusting the Air Flow” on page 22 and “Adjusting the Water

Flow” on page 23 for more information.

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

the Filter” on page 31).

(Not shown) Shuts the pump off if fluid gets too low or becomes hotter than 75ºC (160ºF). See “Reducing the Fluid Temperature” on page 21 or “Adding

Hydraulic Fluid” on page 35 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

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 21 MPa (3.3 gpm at 3000 psi) @ 50 Hz.

Pumps a 15.1 lpm output at 21 MPa (4 gpm at 3000 psi) @ 60 Hz.

512.14 Hydraulic Power Unit Introduction

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 6 for more information about the

components discussed in this section.

Pump A motor drives a hydraulic pump which draws hydraulic fluid from a reservoir

and pressurizes it to 21 MPa (3000 psi). The pressurized fluid is made available to the hydraulic components in your test system.

Pressure 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 21 MPa (3000 psi) or less. High

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

Filtering The filtration system protects against silting by cleaning the hydraulic fluid to an

ISO particle count of 16/13/9 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.

Heat exchanger 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:

• 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.

Note For additional information, see the Heat Exchanger Care and Water

Quality Guide (MTS part number 015-164-000).

Introduction

512.14 Hydraulic Power Unit

Functional Description

Electronics 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

Hydraulic schematic The hydraulic schematic shows how the hydraulic components are connected in

the Model 512.14 Hydraulic Power Unit. Both types of heat exchangers are shown.

Pressure

Gage

Pressure

Motor

Pressure -8

37° JIC Flare

Relief Valve

0.714 MPa

(1002000 psi)

Check

Valve

Pump

Return -8

37° JIC Flare

0.125

See Heat

Exchangers

High/Low

Pressure Solenoid

Drain -06

SAE

Water Out

1/2 ID Hose

Water-Cooled Heat Exchanger

Fan and Motor

Water In

1/2 ID Hose

1/2 NPT

Strainer

Reservior

512.14 Hydraulic Power Unit Introduction

Filter

Overtemperature

Switch

Low Fluid

Switch

Air-Cooled Heat Exchanger

Specifications

Environmental

Parameter Specification

Operating temperature (ambient air)

Heat load

Noise rating† at 1 m

Pump

Flow capacity

Motor rating

Operating voltage

Hydraulic fluid

Nominal temperature

Filtration (microns)

Reservoir capacity

Maximum pressure

Heat exchanger

18–40°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

5.6 kW (7.5 hp)

208 V (AC) @ 24.2 A, 3 phase 230 V (AC) @ 22.0 A, 3 phase 460 V (AC) @ 11.0 A, 3 phase

Mobil DTE 25

63°C (145°F)

3 microns absolute

57 liters (15 gallons)

20.7 MPa (3000 psi)

Water cooled or air cooled

or Shell Tellus® 46 AW

Introduction

Flow requirements

Water pressure (differential)

Max input pressure

Cooling

Water hose

Hydraulic connections

Pressure Return Drain

Weight 115 kg (250 lb)

Specification is for 60 Hz operation.

†

Free field value [74 db. Your readings may be up to 10 db (A) more.

13 lpm @ 21°C (3.5 gpm @ 70°F)

0.2 MPa (30 psi)

1 MPa (150 psi)

4892 Kcal/hr (19,410 BTU/hr)

12.7 mm (0.5 in)—inside diameter

each requires a 37° flare

-8

-6

512.14 Hydraulic Power Unit

Dimensions

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

Water Cooled

610 mm

(24 in)

610 mm

(24 in)

Air Cooled

671 mm (26.4 in)

406 mm

(16 in)

335 mm (13.2 in)

864 mm

(34 in)

559 mm

(22 in)

508 mm

(20 in)

512.14 Hydraulic Power Unit Introduction

Dimensions

Introduction

512.14 Hydraulic Power Unit

Installation

This section describes how to install a Model 512.14 Hydraulic Power Unit.

Note The HPU is designed for indoor use. The HPU should be stored and

installed indoors.

1. Position the hydraulic power unit.

Determine where to put the HPU. Since it is connected to the other hydraulic equipment through hydraulic lines, the HPU can be located remotely. Considerations include:

• The air cooled HPU must be located where adequate air movement for

cooling can occur.

• The water cooled HPU requires a source of water.

• The HPU can be moved by a forklift, pallet jack or dolly.

• The HPU produces 74 dB of sound pressure level in a free field acoustic

environment.

• The base of the HPU has four holes that may be used to secure the unit in

place.

Emergency Stop

Connection

Return Line Connection

Cooling Water In

Water Valve

Drain Line Connection

Pressure Line Connection

Connection Locations (Top View)

512.14 Hydraulic Power Unit Installation

Cooling Water Out

2. Connect the hydraulic lines.

See “Connection Locations (Top View)” on page 13 to determine the locations of the hydraulic connections to the HPU. The following table lists the size of each hydraulic connection.

Connector Size

Pressure, 37º flare -8

Return, 37º flare -8

Drain, 37º flare -6

3. Connect the water lines to the heat exchanger.

Note This applies only to the water-cooled version of the HPU.

The HPU requires connection to a suitable water supply, equipped with an appropriate shutoff valve, to cool the hydraulic fluid. The differential pressure required between the HPU water inlet and outlet connections is 0.2 MPa (30 psi). The maximum allowable water inlet pressure is 1 MPa (150 psi).

The water supply must be capable of maintaining the water flow rate given in the table, “Specifications” on page 10.

See “Connection Locations (Top View)” on page 13 to determine the locations of the water connections.

4. Connect an external Emergency Stop switch.

An optional Emergency Stop switch can be connected to the 14–pin CPC connector located on the control box. Before you can use this connector, remove the jumper from pins 1 and 3 located on the terminal block in the control box (see “Electrical Schematic” on page 15).

5. Connect the electrical service to the HPU.

Note Electrical connections must be made by qualified personnel and conform

to local codes and regulations. Local electrical codes supersede any information found here.

A. Open the control box.

B. Open a knock-out hole.

C. Install a wire grommet.

D. Feed the line through the grommet into the control box.

E. Connect the power source lines (L1–L3) to the terminal blocks

according to the required line voltage. See “Electrical Schematic” on page 15.

Installation

F. Connect the ground to the lug identified with a sticker showing the

ground symbol.

512.14 Hydraulic Power Unit

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