Professional Documents
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M-020 Volume 2 Manual Belt Feeders
M-020 Volume 2 Manual Belt Feeders
Operation and
Maintenance Manual
VOLUME 2
Prepared by:
ThyssenKrupp Robins
December 2005
HYDRAULIC DRIVE SYSTEM
OPERATION AND INSTRUCTION
MANUAL
CUSTOMER INFORMATION
Name THYSSENKRUPP ROBINS
Reference
Notes B E LT F E ED ER
HÄGGLUNDS INFORMATION
Project 2 005 033
Notes
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 033
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
1 Project Specifications
Bill of Materials
Test Reports
2
Hydraulic Motor
Motor Accessories
3
Hägglunds Drives Inc. Hydraulic Power Unit
2275 International Street
Columbus, Ohio 43228 USA
5
Project Drawings
6
Spanish Documentation
Documentacion Espanol
NORTH AMERICAN SALES OFFICES
NORTHEAST EASTERN
1273 Bound Brook Road 87B Marie-Victorin
Suite 11 Suite 202
Middlesex, New Jersey 08846 Candiac, Quebec J5R 1C3
(732) 469-0411 (450) 659-4244
(732) 469-8047 (fax) (450) 659-3792 (fax)
MIDWEST CENTRAL
2275 International Street 5040 Mainway, Unit #7
Columbus, Ohio 43228 Burlington, Ontario L7L 7G5
(614) 527-7400 (905) 319-6338
(614) 527-7401 (fax) (905) 319-6615 (fax)
NORTHWEST WESTERN
19219 West Valley Highway #3 7201-72 Street
Suite M-101 Delta, British Columbia V4G 1H2
Kent, Washington 98032 (604) 940-8281
(425)-251-9661 (604) 940-8241 (fax)
(425)-251-9280 (fax)
SOUTHEAST
4335 South Lee Street
United States Headquarters
Suite F Hägglunds Drives Inc.
Buford, Georgia 30518 2275 International Street
(770) 945-6223 Columbus, Ohio 43228
(770) 945-6246 (fax) (614) 527-7400
(614) 527-7401 (fax)
NORTH-CENTRAL
(262) 594-3762 Canadian Headquarters
(262) 594-3764 (fax)
Hägglunds Drives (Canada) Inc.
CENTRAL 5040 Mainway, Unit #7
(913) 515-8047 Burlington, Ontario L7L 7G5
(913) 322-6910 (fax) (905) 319-6338
(905) 319-6615 (fax)
SOUTH-CENTRAL
220 Spring Hill Drive Worldw ide Headquarters
Suite 200 Hägglunds Drives AB
Spring, Texas 77386 SE-890 42
(281) 292-6700 Mellansel, Sweden
(281) 292-6768 (fax) +46 660 870 00
+46 660 871 60 (fax)
SOUTHWEST
(602) 790-4632
(480) 474-1039 (fax)
PROJECT INFORMATION
Hägglunds Salesperson: CHUCK SEITZ
Customer Name: THYSSENKRUPP ROBINS
Address: 7730 E. BELLEVIEW AVE. SUITE 404
GREENWOOD VILLAGE, CO. 80111
Contact Name: PETER SEHL
Phone: 303 793-2605 Fax: 303-770-8233
E-mail: [email protected]
Customer P.O. : 0507 001 5727 Customer Ref.: 507 001
Customer Spec. No. Copy Attached: yes/no
Spec. Exceptions List YES Copy Attached: yes/no
Equipment : BELT FEEDER 210-FE-001
Description :
Location : SAN CRISTOBAL, BOLIVA
NEMA Classification NEMA 4X (IP-65)
Ambient Temp. Range -10.3 C TO 21.6 C
Cooling Water Temp. N/A
Elev. Above Sea Level 3900 M
DESIGN INFORMATION
Drive Speed, Run 0-6.97 RPM
Drive Speed, Max 6.97 RPM
Nominal Torque 36,315 Ft. Lbs.
Starting Torque 62,337 Ft. Lbs.
Duty Cycle CONT
Flow Range: 43.7 GPM
Motor Case Flushing: 0.98 GPM
Nominal Pressure: 2484 PSI
Peak Pressure: 4203 PSI
Horsepower Installed: 100 HP, 1470 RPM
High Pressure Switch Setting: PSI
Max Volume Stop : GPM (Forward) GPM (Reverse)
Uni / Bi-Directional Drive: UNI W/JOG REVERSE
Port "A" of Pump to Port A MOTOR
SCOPE OF SUPPLY
Hydraulic Motor CB-400-320-C-A-O-N-O 178-5041-2602
Hydraulic Power Unit PBC-0202-073/XXX-100/XXX-21-1110-11B-0000-0-0380/50
Elec. Control System SPIDER II
Torque Arm TCA-40-2 278-5014-602
Mounting Tool MTMB 378-0846-801
Shaft Adaptor N/A
Speed Encoder SPDB-3600 378-5036-802
Encoder Mounting Set SMCB 178-5049-801
Axial Locking Set N/A
Customer Supplied
Hägglunds Drives, Inc.; 2275 International Street, Columbus,OH 43228; Tel: 614-527-7400; Fax: 614-527-7401
DESCRIPTION OF OPERATION
xx
xx LONG TERM STORAGE REQUIRED
xx PACKING FOR SEAWORTHY EXPORT
xx SPECIAL TAGGING REQUIREMENTS,PER SPEC AAPPENDIX B, AND M-020, 7.5
xx AND GD-11
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
HYDRAULIC NOTES
xx 25 FT. HOSE KITS REQUIRED
xx
xx
xx
xx
ELECTRICAL NOTES
xx
xx
xx
xx
xx
MECHANICAL NOTES
xx
xx
xx
xx
xx
DOCUMENTATION NOTES
Drawings: 2 copies For Approval and 2 copies of For Construction. Please specify other requirements.
Drawing Due Date: 3 weeks after receipt of Tech Clarified order
Manuals: TOTAL 8 MANUALS, IN ENGLISH, 8 MANUALS SPANISH
Manuals Due Date: 1 week after the ship date
Hägglunds Drives, Inc.; 2275 International Street, Columbus,OH 43228; Tel: 614-527-7400; Fax: 614-527-7401
PB C - 0 2 0 2 - 0 7 3 / X X X - 1 0 0 / X X X - 2 1 - 1 1 1 0 - 1 1 B - 0 0 0 0 - 0 - 0 3 8 0 / 5 0
PAC
PBC
PHS Electric Motor Frequency
PAX 60 Hz
50 Hz
Tank Size
Liter(Gallon) Voltage
1000 (264) = 100 200 (53) = 020 460/575 VAC
1200 (317) = 120 400 (106) = 040 2300/4160 VAC
Other (Specify) 600 (159) = 060
800 (211) = 080 Electric Motor Supplied By
1 = Customer
Number of Doors 0 = Hägglunds
2
3 000 = Standard Design
001-999 = Special Design
Pump Displacement
Left Door/Right Door Accumulator Package
cu. cm/rev cu. in./rev 1 = With
SP-40 = 040 P6S = 060 0 = Without
SP-71 = 071 P7S = 073
SP-125 = 125 P11S = 110 Control Box Voltage
SP-180 = 180 P14S = 140 A = 24 VDC
SP-250 = 250 P24S = 240 B = 110 VAC
SP-355 = 355 P30S = 300 C = 220 VAC
SP-500 = 500 9A2 Pump Stroker(5A2/9A2 for Denison, EP for SP pumps)
SP-750 = 750 1 = Air/ Oil Cooler
0 = Water/Oil Cooler
Electric Motor Size Water Valve Voltage X
Left Door/Right Door Air Cooler EM Voltage X
kW HP
22 = 022 30 = 030 1 = Oil Heater
30 = 030 40 = 040 0 = Without
37 = 037 50 = 050 Oil Heater Voltage 220V
45 = 045 60 = 060
55 = 055 75 = 075 1 = Duplex Filters
75 = 075 100 = 100 0 = Single Filters
90 = 090 125 = 125
110 = 110 150 = 150 1 = Cabinet Feet
132 = 132 200 = 200 0 = Without
160 = 160 250 = 250
200 = 200 300 = 300 1 = High Pressure Switch
250 = 250 350 = 350 0 = Without
315 = 315 400 = 400
450 = 450 1 = Pressure Transmitter
500 = 500 0 = Without
HP Specify HP or kW
Control Box Mounting
Control Box Options 0 = Shipped Loose
None = 0 1 = Mounted Inside Power Unit
Driver Card = 1 2 = Mounted in Power Unit Door
Spider = 2 3 = Supplied as Separate Item, with Bracket
Other = 3 4 = Supplied as Separate Item, with Flange
5 = Mounted outside of Power Unit (Specify)
XX ft.
XX ft.
XX ft.
XX ft.
0.00
hb2005033e.xls, Date Printed: 11/29/2005 Form No.: F10203-1 | Releae Date: 4/6/2001 | Revision: A
Bill of Material No.: CB2005033
Bill Of Material
Date Issued : 7-Jun-2005 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: RHW 2275 International Street; Columbus, Ohio 43228, USA P.O. 0507 001 5727
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: Assembly Ref(s) :
CONTROL CONSOLE Revised By : CC-2005 033
HYDRAULIC POWER UNIT CS-2005 033
PBC-202-073-100-21-1110-11B-0000-0-380/50 Rev. Date : Project No. :
2005 033
C
Item O Hägglunds Description Manufacturer Mfg. Part. No.
No. Qty. D Part No. Vendor
E
1 1 CB2005033-A CONTROL PANEL Industrial Solutions IP05-xxx
2 1 276 0023-801 SPIDER 2 CONTROL, FULL FUNCTION HDM 276 0023-801
3 1 H103-20469 ENCLOSURE NEMA 4X, 24 X 24 X 12 HOFFMAN C-SD242412SS
4 1 H103-20420 PANEL FOR ABOVE ITEM HOFFMAN C-P2424
5 1 H103-20394 ENCLOSURE MOUNTING KIT HOFFMAN C-MFKSS
6 1 H103-20415 DOOR LOCK KIT FOR ENCLOSURE HOFFMAN C-WHK
7 1 H153-15301 PUSHBUTTON, GREEN FLUSH HEAD, 1 N.O., 1 N.C. CONTACTS ALLEN BRADLEY 800T-A1A
8 1 H153-15302 PUSHBUTTON, RED EXT. HEAD, 1 N.O., 1 N.C. CONTACTS ALLEN BRADLEY 800T-B6A
9 1 H153-10363 INDICATING LIGHT, GREEN, FULL VOLTAGE, 120VAC ALLEN BRADLEY 800T-Q10G
10 1 H151-15318 MUSHROOM HEAD PUSH/PULL MAINTAINED PUSHBUTTON, 2 N.O. CONTACTS ALLEN BRADLEY 800T-FX6A5
11 1 155-10060 LEGEND PLATE, GRAY, E-MOTOR START ALLEN BRADLEY 800H-W100
12 1 155-10055 LEGEND PLATE, RED, E-MOTOR STOP ALLEN BRADLEY 800H-W100
13 1 H155-10487 LEGEND PLATE, GRAY, E-MOTOR STARTED ALLEN BRADLEY 800H-W100
14 1 155-10057 JUMBO LEGEND PLATE, RED, EMERGENCY STOP
15 62 123-75144 TERMINAL, UKK5 PHOENIX 2774017
16 6 123-75048 END ANCHOR, E/UK PHOENIX 1201442
17 4 ft. 123-75047 MOUNTING RAIL, NS 35/7.5 PHOENIX 0801681
18 3 123-75146 END COVER D-UKK 3/5 PHOENIX 2770024
19 3 123-75147 SPACER PLATE, DP-UKK 3/5 PHOENIX 2770794
20 3 H123-75421 END SPACER COVER, DG-UKK 3/5 PHOENIX 2770817
21 10 H123-75422 PARTITION PLATE, ATP-UKK 3/5 PHOENIX 2778521
22 10 H123-75453 ISOLATING BRIDGE BAR, ISSBI 10-6 PHOENIX 0301505
23 10 H123-75465 BRIDGE BAR ISOLATOR, IS-K 4 PHOENIX 1302338
24 2 H123-75477 DOUBLE TERMINAL BLOCK, UDK 4 PHOENIX 2775016
25 1 H123-75478 END COVER FOR DOUBLE TERMINAL BLOCK, D-UDK-4 PHOENIX 2775113
26 2 H123-75489 UNIVERSAL GROUNDING DOUBLE TERMINAL BLOCK, UDK-4-PE PHOENIX 2775184
27 2 123-75069 MARKER STRIP, 11-20
28 2 123-75070 MARKER STRIP, 21-30
29 2 123-75077 MARKER STRIP, 91-100
30 2 123-75086 MARKER STRIP, 121-130
31 2 123-75089 MARKER STRIP, 151-160
32 2 123-75126 MARKER STRIP, 301-310
33 2 123-75127 MARKER STRIP, 311-320
34 2 H123-75467 MARKER STRIP, 331-340
35 2 H123-75468 MARKER STRIP, 341-350
36 2 123-75162 MARKER STRIP, 401-410
37 2 123-75163 MARKER STRIP, 411-420
38 2 H123-75493 MARKER STRIP, 421-430
39 2 H123-75495 MARKER STRIP, 441-450
40 2 123-75139 MARKER STRIP, 501-510
41 2 123-75141 MARKER STRIP, 521-530
42 2 H123-75427 MARKER STRIP, L, N, GND
43 10 ft. 104-25020 WIRE DUCT, 2" X 3", WHITE HOFFMAN A 200 300 WH
44 10 ft. 104-25021 WIRE DUCT COVER, 2", WHITE HOFFMAN A 200 CWH
Installation
All Terminal Markers Installed: Function
All wires bundled and tied: Continuity Test:
Control Box P/N Tag Installed: Functional Check of Switches:
All Bill of Material Items Installed: Functional Check of Lights:
Grounding Lug Properly Installed: Functional Check of Pushbuttons:
Other Items
Control Voltage: 120 VAC
Make of Power Supply: HDI
Model of Power Supply: SPIDER
Spider Controller
Jumpers are in correct position:
All Parameters checked:
If the Spider is supplied as a loose item, is it temporarily wired to the Power Unit:
If there are any Parameter changes please list them all in the "NOTES" section of this report.
Page 1
F10208-2 l Revision: Orig.l Date: 10/10/02 www.hagglunds.com
Jupiter 900 Driver Card (S20-14078)
SW SW SW SW
Input Command: 1A 1B Ramp 1C 1D
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Bi-Directional Output
Unidirectional Output
Page 2
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Miscellaneous
Password ( If Spider is used): 0533
Tested By: WK
Date: 16SEP05
Engineering Release and Approval for Shipment:
Approval By:
Date:
Notes:
Page 3
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Power Unit Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
If motor has any other special options please list in “NOTES” section of this report.
Pump No. 1
Manufacturer: DENISON Model No. P7S 2R1A 9A2 B00 0A1 M2
Serial Number: 01043475 Part No.: 023-07706-0
Rotational Check: Left Hand (CCW looking at input shaft) Right Hand (CW looking at input shaft)
Internal Charge Relief valve setting: 450 psi Servo Pressure with Pump in Neutral: 480 psi
Charge Pressure with Pump in Neutral: 300 psi Servo Pressure at 50% max. flow: 400 psi
Charge Pressure at 50% max. flow: 220 psi
If pump has any other special options please list in “NOTES” section of this report.
Page 1
F10208-1 l Revision: Al Date: 7/31/02 www.hagglunds.com
Job Number: 2005 033 Serial Number: 517-2-21190
Power Unit Model Code: PBC-202-073-100-21-1110-11B-0000-0-380/50
Miscellaneous
Torque Seal applied to reservoir breather and all pressure switches: Yes No
Serial Number Plate installed: Yes No
Documentation Used for testing:
General Arrangement Rev. A Hydraulic Schematic Rev. A
Electrical Schematic Rev. - Power Unit Bill of Material Rev. B
List all other drawings used and their revision levels:
CS-2005 033 Rev. A
CD-2005 033 Rev. A
CC-2005 033 Rev. A
Rev. -
Rev. -
Rev. -
Rev. -
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 517D026559
*PS-4 (High System Pressure): Hydac EDS 3476-3-6000-400 / Rng.6000 Psig / Art No:908598 /
S/n 524D030726
"POWER UNIT TESTED WITH 250 HP TEST MOTOR @ 460 VAC / 60 HZ / 3 PHASE / 1770 RPM"
Page 3
F10208-1 l Revision: A l Date: 7/31/02 www.hagglunds.com
COMPACT CB MOTOR MANUAL
Installation and Maintenance Manual
Compact CB 280-840
EN683-2h 2002
Preface Installation and Maintenance Manual, Compact CB
Preface
Hägglunds Drives is one of the worlds leading manufacturers of large hydrau-
lic Drive Systems. A leading position, made possible by unbeatable service
spirit and of continuing development of both products and markets all over the
world. Our drives are to be found in most industrial and marine segments,
where there are extremely high demands for efficiency and reliability. Our main
office and production plant is in Mellansel, Sweden and we have our own
sales- and representation offices in some 40 different countries.
Our high quality Drive Systems, are based upon our unique hydraulic piston
motors, developed through a wealth of experience accumulated over 30 years
in marine and industrial areas.Today this ongoing development work has
resulted in the powerful COMPACT CB industrial motor. New, as well as esta-
blished technical solutions, contribute to the creation of this product. The most
desirable features and operating reliability have been designed in this hydrau-
lic motor.
2
Installation and Maintenance Manual, Compact CB Contents
Contents
1. GENERAL ....................................................................................................................... 4
1.1 Safety precautions .. ........................................................................................................ 4
1.2 Motor data ........................................................................................................................ 5
1.3 Functional description ...................................................................................................... 6
3. INSTALLATION ............................................................................................................. 11
3.1 Mounting instructions ..................................................................................................... 11
Thread for mounting tool ................................................................................................ 12
Spline ............................................................................................................................. 12
3.1.1 Lifting methods ............................................................................................................... 13
Standing the motor on a flat surface ............................................................................... 14
3.1.2 Mounting the coupling onto the motor shaft .................................................................... 15
3.1.3 Fitting the torque arm to the motor . ................................................................................ 17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling .............................................. 18
3.1.4b Mounting the motor onto the driven shaft - splines ......................................................... 21
3.1.5 Removing the motor from the driven shaft ..................................................................... 22
3.1.6 Mounting the reaction point . .......................................................................................... 23
3.2 Oil connections .............................................................................................................. 24
3.2.1 Direction of rotation of motor shaft ................................................................................. 26
3.2.2 Draining and venting the motor ...................................................................................... 36
3.2.3 Flushing .......................................................................................................................... 27
5. FAULT FINDING............................................................................................................ 32
DECLARATION OF CONFORMITY ............................................................................ 33
3
General Installation and Maintenance Manual, Compact CB
1. GENERAL
1.1 Safety precautions
It is of high importence that the Safety precautions are always followed, if you are
unsure about something, please don´t hesitate to contact your nearest HD-office
for advice.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal enjury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.
Application area
All new and rebuild applications, should always be approved and supervised by Hägglunds
personel.
Mounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.
Before starting up
Before starting up new, rebuild or just worked on applications, all accessories and safety
arrangements functions, should be controlled/tested.
Periodic maintenance
Notice the intervals in maintenance chart (4.4) and keep a record.
Dismounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.
4
Installation and Maintenance Manual, Compact CB General
Table 1.1
Metric
Specific Rated * Max. Max. ** Max. Max. power 3)
Displacement
torque speed 1) speed pressure torque 2) Intermittently
Motor type
Vi Ts n n p
kNm kW
cm3/rev Nm/bar rev/min rev/min bar
CB 280-240 15 100 240 53 68 350 79 530
CB 280 17 600 280 44 58 350 92 530
CB 400-240 15 100 240 94 125 350 79 970
CB 400-280 17 600 280 73 105 350 92 950
CB 400-320 20 100 320 71 94 350 110 970
CB 400-360 22 600 360 59 82 350 120 960
CB 400 25 100 400 58 75 350 130 970
CB 560-440 27 600 440 49 65 350 140 930
CB 560-480 30 200 480 48 62 350 160 970
CB 560-520 32 700 520 41 57 350 170 960
CB 560 35 200 560 40 53 350 180 970
CB 840-600 37 700 600 30 45 350 200 880
CB 840-640 40 200 640 28 41 350 210 850
CB 840-680 42 700 680 27 40 350 220 890
CB 840-720 45 200 720 25 37 350 240 870
CB 840-760 47 800 760 23 34 350 250 840
CB 840-800 50 300 800 23 34 350 260 890
CB 840 52 800 840 21 32 350 280 870
US
Specific Rated * Max. Max. ** Max. Max. power 3)
Displacement speed 1)
torque speed pressure torque 2) Intermittently
Motor type Vi Ts n n p
lbf·ft/1000 lbf·ft hp
in3/rev psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
*) Related to a required pressure of 12 bar/175 psi for motors in braking mode. (Special considerations regarding
charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used for higher
speed).
**) The motors are designed according to DNV-rules. Test pressure and peak pressure 420 bar/6000 psi is allowed.
1
) Special considerations regarding charge pressure, cooling and choice of hydraulic system for speed above rated.
2
) Calculated as : Metric= Ts·(350-15)·0,98 US= Ts·(5000-218)·0,98.
3
) Valid for minimum permissible oil viscosity 20 cSt in the motor case.
5
General Installation and Maintenance Manual, Compact CB
1
1. Cam ring
2. Cam roller
2 A, C
3. Piston
3
D 4. Shaft coupling
4 8
5. Cylinder block /
hollow shaft
5 6. Cylinder block / spline
7. Front end cover
8. Cylindrical roller bearing
11 9. Connection block
10. Valve plate
6 11. Axial bearing
6
Installation and Maintenance Manual, Compact CB Technical data
2. TECHNICAL DATA
2.1 Recommended charge There are two distinct cases:
pressure Case 1:
The hydraulic system must be such that the The motor works in braking mode. Required
motor will recieve sufficient charge pressure charge pressure at the inlet port is according
at the low-pressure port. This applies to all to diagram below.
types of installations.
Case 2:
The motor works in driving mode only. Required
back pressure at the outlet port corresponds
to 30% of value given in diagram below, but
may not be lower than 2 bar (29 psi).
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
Recommended charge pressure [bar]
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-port connection Speed [rpm]
Note:
The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge
pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing
pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5
seconds upto 8 bar (116 psi) are allowed). Max permitted case pressure at stand-still is 8 bar (116
psi).
7
Technical data Installation and Maintenance Manual, Compact CB
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
Table 2.1b Charge pressure
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
Recommended charge pressure [bar]
16
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Background noise
Remarks:
Background noise
Hydraulic motor
The background noise can not normally be
influenced but is usually known or easy to The hydraulic motor is a known noise level.
measure. (Tables of sound data - see subsection 4.9 in
the Engineering Manual).
Pump unit
Driven unit
The pump unit is a known noise level.
The driven unit is an unknown sound source
(for us) but can through certain information
Pipe noise probably be obtained from the supplier. When
The pipe noise is probably the source of the securing the torque arm of a hydraulic motor
majority of mistakes in installations: all pipe to the foundation or casing of a driven machine,
clamps should be of vibration insulating type it is highly important to study the construction
secured to concrete ceiling, wall or floor. of the foundation or casing. This may well be
Securing to non-rigid metal structures or the most important factor to consider, since
structures is likely to give resonance and many structures may give rise to resonance,
should be avoided. resulting in severe noise problems.
8
Installation and Maintenance Manual, Compact CB Technical data
9
Technical data Installation and Maintenance Manual, Compact CB
* Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids
must be controlled every 3 months and temperature shall be less than +45° (113°F) C to give good service life for
the fluid.
** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil.
Filtration Explanation of
"GRADE OF FILTRATION"
The oil in a hydraulic system must always be
filtered and also the oil from your supplier has Grade of filtration β 10=75 indicates the
to be filtered when adding it to the system. The following:
grade of filtration in a hydraulic system is a β 10 means the size of particle ≥10µm that will
question of service life v.s. money spent on filt- be removed by filtration.
ration.
=75 means the grade of filtration of above
In order to obtain stated service life it is mentioned size of particle. The grade of filt-
important to follow our recommendations ration is defined as number of particles in the
concerning contamination level. oil before filtration in relation to number of
When choosing the filter it is important to particles in the oil after filtration.
consider the amount of dirt particles that the Ex. Grade of filtration is β 10=75.
filter can absorb and still operate satisfactory.
For that reason we recommend a filter with an Before the filtration the oil contains N number
indicator that gives a signal when it is time to of particles ≥10µm and after passing the filter
change the filter cartridge.
once the oil contains number of particles
Before start-up, check that the system is This means that number of
thoroughly cleaned.
particles have been filtered (=98,6%).
1. In general the contamination level in our
motors should not exceed ISO 4406 19/15.
(NAS 10)
2. For heavy-duty industrial applications the
contamination level should not exceed ISO
4406 16/13. (NAS 7)
3. When filling the tank and motor housing, we
recommend the use of a filter with the grade
of filtration β 10=75.
10
Installation and Maintenance Manual, Compact CB Installation
3. INSTALLATION
3.1 Mounting instructions Design of driven shaft end on heavily-
loaded shaft
If the motor is to work properly it must be
installed with the greatest possible precision. Where the driven shaft is heavily loaded and
Every item connected to the motor that does is subject to high stresses, for example on
not meet the requirements of the following changes in the direction of rotation, it is
instructions may result in stresses that recommended that the driven shaft should
adversely affect the service life of the motor. have a stress relieving groove; see Fig. 3.1 and
tables 3.1 and 3.4.
Normally the motor must be completely filled
with oil. When the motor is installed with the
shaft in the horizontal plane, the drain ports G
must be positioned vertically. The higher of the F
four ports must be used: see fig. 3.25. Fig. 3.1 Max R 3,2
a
C
A
D
The drain line must be dimensioned so that
E
max. 3 bar (43.5 psi) motor housing pressure 30°
is not exceeded.
6±0,5 R 50
(0,24±0,02) (R 1,97)
The max housing pressure is 3 bar (43.5 psi). B±0,5
(B±0,02)
Brief peaks during operation up to 8 bar (116
psi) are permissible. The permitted housing
pressure when the motor is stationary is 8 bar Normally-loaded shaft
(116 psi). In drives with only one direction of rotation
The motor must always be connected in such where the stresses in the shaft are moderate,
a way as to give a sufficient boost, make-up the shaft can be plain, see Fig. 3.2 and tables
flow at the low pressure connection. This is 3.1 and 3.5
particularly important at high speeds and with Fig. 3.2
rapid reversing, see 2.1 "Recommended
charge pressure".
Max
11
Installation Installation and Maintenance Manual, Compact CB
Bidirectional drives
CB 280 - 840
Table 3.4
D M20 UNC 5/8"
Motor CB 280/400 CB 560/840
E >17 (0,67) >13,5 (0,53)
F 25 (0,98) 22 (0,87)
Toth profile and G 50 (1,97) 30 (1,18)
DIN 5480 DIN 5480
bottom form
Tolerance 8f 8f
Number of teeth 38 50 A
0 0
Minor diameter ø 188 ø 248
-1,201 -1,201
0 0
Major diameter ø 199 ø 259
-0,290 -0,320
-0,088 -0,103
Measure over
210,158 270,307
measuring pins -0,157 -0,181 0,15 A
(0,006) 0,4 A
Diameter of
ø 10 ø 10 (0,015)
measuring pins
Addendum
+2,25 +2,25
modification X M
12
Installation and Maintenance Manual, Compact CB Installation
Fig. 3.5
13
Installation Installation and Maintenance Manual, Compact CB
kg lb
Support
Table 3.7
Weight
Torque arm
kg lb
Support
NOTE:
The motor must not be placed on the end face
of the hollow shaft when the coupling is fitted,
since this may cause damage to the coupling.
When in storage, the motor must always be
placed on the end face to the hollow shaft. It is
also advisable to provide supports at the
mounting surface of the motor; see Fig. 3.7.
14
Installation and Maintenance Manual, Compact CB Installation
- You should note that the couplings are from the factory lubricated with MoS2 (Molycote) on the
conical surfaces and the bolts,see fig. 3.8. This lubricants shall remain on those surfaces but:
It is therefore important that you clean your hands free from Molycote. If those conditions are
fullfilled you may start the mounting.
- Clean the driven shaft and the out- and inside of the Compact motor hollow shaft.
- Remove the spacers between the two clamping rings of the coupling.
- Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the
stop of the shaft. Use a screwdriver to open the coupling ring for easier mounting.
- Mount the motor onto the driven shaft by following the instruction in the section 3.1.4. (With or
without using the mounting tool).
Remember:
-The conical surface between the coupling ring and the clamping rings + the bolts shall be coated
with MoS2 (Molycote), see Fig. 3.8. This is done from the factory at delivery! When a motor has
been in for overhaul or service and shall be reassembled it may be necessary to relubricate those
surfaces with Molycote again but remember only the specified surfaces!
-Absolutely No Molycote on the surfaces between shaft-motor. Clean the driven shaft and the
inside of the motor hollow shaft.
- Alignment of the motor on the shaft. (Dimensional check).
- Minimum variation in the gap between the clamping rings (Dimensional check).
- Right torque on the bolts. (Use torque wrench).
15
Installation Installation and Maintenance Manual, Compact CB
Clamping rings
Fig. 3.8
Centre of motor
16
Installation and Maintenance Manual, Compact CB Installation
Table 3.8
Tightening torque
Number
Motor Screw dimension
of screws
Nm lbf·ft
17
Installation Installation and Maintenance Manual, Compact CB
3.1.4a Mounting the motor onto the driven shaft - shaft coupling
The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of a
mounting tool is recommended since it makes the work easier.
It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft
of the motor.
Ensure that the full clamping length is used by, for example, measuring and marking the driven
shaft. This is of particular importance if the duty is so severe that a stress relieving groove has
been made on the driven shaft. See Fig. 3.11, 3.11a and the table 3.9.
Fig.3.10b
2 1; Bearing retainer
2; Plastic washer
3; Nut
4; Mounting tool
3
4
18
Installation and Maintenance Manual, Compact CB Installation
CB 560
153 6.02
CB 800
19
Installation Installation and Maintenance Manual, Compact CB
However for the tightening of the coupling Mark the screw heads at 12 o´clock with a pen
screws the following must be observed: or paint so that you can follow the turning
sequence of the screws.
Keep tension in your lifting wires to avoid
a skew setting of the motor on the shaft Set the torque wrench for the specified maxi-
during the tightening of the screws. mum torque. Tightening torque of the coupling
Wobbling caused by a skew setting of the screws; see the sign on the coupling, or table
motor gives extra forces on the main 3.10.
bearings.
Now start tightening the screws in sequence
In order to avoid the misalignment of the two shown in Fig. 3.14.
clamping rings during the screw tightening, the
Keep on doing this until you have reached the
gap between the rings must be measured in
stated torque. Several passes are required
several places during the process, see Fig.
before the screws are tightened to specified
3.14. The difference between the measured
torque. Keep checking the alignment of the
gaps must never vary more than 1 mm (0,04")
coupling. (15-20 passes may be necessary).
during any stage of the tightening process.
When the specified torque is reached it is
Pre-set the coupling screws in opposite pairs
important that all screws are tightened with
(12-6-3-9 o´clock) until you reach max. 50%
specified torque and that no further movement
of the torque specified for the screws. It is very
can be observed.
important that when you reach this stage the
misalignment is controlled as described above.
Table 3.10
Tightening torque
Motor No of Screw Strength Type of
type screws dim class head
Nm lbf·ft
CB 280 12 M20x80
CB 400 15 M20x90
10.9 490 362
Hexagon
CB 560 20
M20x100
CB 840 20
20
Installation Installation and Maintenance Manual, Compact CB
Fig. 3.14
Fig. 3.14a
21
Installation and Maintenance Manual, Compact CB Installation
1; Bearing retainer
2; Plastic Washer
3; Nut
4; Mounting tool
22
Installation Installation and Maintenance Manual, Compact CB
Alternative
Note: The toggle bearing must position
be dismounted during welding.
Steel:
EN 10113S355N
DIN St E39
BS 4360 Grade 50 C
Protected against corrosion, after welding.
Fig. 3.18
DANGER ZONE
Fig. 3.17 In case of failure of
torque arm installation
23
Installation Installation and Maintenance Manual, Compact
Fig. 3.25
T4
Table 3.11
F1,F2 Flushing connection For flushing of radial lip seal. Normally plugged.
T2, T3 Test connection Used to measure pressure and/or temperature in drain oil.
Table 3.12
D1, D2, F1, T1, y y x x
Motor A** C** D4 F3 T3 T4
D3 F2 T2 mm in mm in
**SAE coupling J 518 C, code 62, 414 bar (6000 psi). 1 1/4" or 1 1/2" can be used.
*** A2-connection and C2-connection is blocked at delivery. They are able to withstand max pressure.
24
Installation and Maintenance Manual, Compact CB Installation
Main connection A, C
Fig. 3.25b
Table 3.13
a c
Motor Connection b
mm (in) mm (in)
∅ 65
(2,56)
G
BSP
25
Installation Installation and Maintenance Manual, Compact CB
Vertical mounting
When the motor is mounted vertically, the highest of the four drain outlets D1, D2, D3 or D4 must
be used. Flushing of radial seal from low pressure is necessary.
26
Installation and Maintenance Manual, Compact CB Installation
Drain line
Low pressure
connection
Drain line
connection
G 1/2", Flushing
Low pressure connection F3
3.2.3 Flushing
27
Installation and Maintenance Manual, Compact CB Maintenance
4. OPERATING INSTRUCTIONS
4.1 Storage
The motor is delivered with internal protection in the form of an oil film and external protection in the form of an
anti-rust film. This provides sufficient protection for indoor storage in normal temperatures for about 12 months.
Note: the anti-rust protection must be touched-up after transport and handling.
If the motor is stored for more than 3 months in uncontrolled environment or more than 12 months in controlled
environment, it must be filled with oil and positioned as shown in Fig. 3.7.
Place the motor as shown in fig 4.1, fill the motor with filtered oil in the following order: D1, A1, C1. See 2.3,
"Filtration" and table 4.1.
Take extreme care to ensure that no contamination enters the motor.
Seal connections A and C with the cover plate fitted to the connection surface at delivery. Check that the O-
rings or rubber seals are in postion in the cover plate.
Fit the plug to D1, D2, D3 and D4, the table below states the amount of oil needed to fill the various types of
motors.
Table 4.1
Oil volume approx.
Motor
Litres US gal.
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
Maintenance Installation and Maintenance Manual, Compact CB
Maintenance chart
Oil Torque
In operation Oil
filters arm
After 3
months or Rpl.
500 hours
Once every 6
months
Rpl. Insp. Insp.
Once every
12 months
29
Maintenance Installation and Maintenance Manual, Compact CB
Motor Filters
If the motor is to be stored stationary for a Filters must be changed after the first 100
longer period than about 1 month, it must be working hours and the second change is to be
protected from internal rust. This can be done carried out after 3 months or 500 working hours
as follows: whichever is earlier. They must then be
1. Mix anti-rust additive with the hydraulic changed at regular intervals of 6 months or
fluid of the system. Use 5% of Rust Veto 4000 working hours.
Concentrate (manufactured by E F
Houghton & Co, Philadelphia, USA). This Oil (Se also 2.3)
additive gives rust protection for up to
about 1 year, after which time the motor Analysis
must be turned a few revolutions.
It is recommended that the oil should be analy-
2. If no additives are used, the motor must sed every 6 months. The analysis should cover
be regularly turned a few revolutions. viscosity, oxidation, water content, additives
3. If it is not possible to turn the motor, plug and contamination.
all connections, open drain outlet D1 or D2 Most oil suppliers are equipped to analyse the
on the port end housing (or if the motor is state of the oil and to recommend appropriate
mounted vertically, Flushing connection F1 action. The oil must be replaced immediately if
on the shaft end housing) and fill the motor the analysis shows that it is exhausted.
with hydraulic fluid.(See Fig. 4.3 and Fig.
4.3a). Viscosity
Many hydraulic oils become thinner with
Fig. 4.3
increasing use, and this means poorer
lubrication. The viscosity of the oil in service
must never fall below the minimum recom-
mended viscosity.
Oxidation
Hydraulic oil oxidizes with time of use and
temperature. This is indicated by changes in
colour and smell, increased acidity or the for-
mation of sludge in the tank. The rate of oxida-
Fig. 4.3a tion increases rapidly at surface temperatures
above 60°C (140°F), and the oil should then
be checked more often.
The oxidation process increases the acidity of
the fluid; the acidity is stated in terms of the
"neutralisation number". Typical oxidation is
slow initially and increases rapidly later.
A sharp increase (by a factor of 2 and 3) in the
neutralisation number between inspections is
a signal that the oil has oxidized too much and
should be replaced immediately.
30
Installation and Maintenance Manual, Compact CB Maintenance
Water content
Contamination of the oil by water can be Another method is to install an inline particle
detected by sampling from the bottom of the counter direct in your hydraulic system which
tank. Most hydraulic oils repel the water, which give you the contamination level according to
then collects at the bottom of the tank. This the international rules, the disadvantage with
water must be drained off at regular intervals. this method is that you only get the
Certain types of transmission oils and engine contamination level in the oil.
oils emulsify the water; this can be detected
by coatings on filter cartridges or a change in General
the colour of the oil. Obtain the advice of your The intention is to verify the condition of the oil
oil supplier in such cases. during operation.The motors should be running
Degree of contamination at normal operation while the sample is taken.
The cleanliness is extremely important during
Heavy contamination of the oil causes sampling.
increased wear of the hydraulic system Always use bottles adapted to oil samples,
components. The cause of the contamination they can be ordered from any fluid analysis
must be immediately investigated and re- laboratory.
medied. Never try to clean your own bottle if you want
a true value of the result.
The sample should be taken by using a mini-
mess hose connected to a mini-mess
coupling.
Always clean the connections carefully before
All hydraulic fluids are affected you connect the mini-mess hose to the
differently. Obtain the advice of coupling.
your oil supplier or by nearest Be careful when connecting the mini-mess
Hägglunds representative. hose because the oil beam can be dangerous
and should never point against any person or
other sensible object.
Check and be aware of the pressure you
4.5 Oil inspection mayhave on the connection before you
Purpose connect.
The purpose to take an oil sample is to check
the condition of the oil. How to do
With scheduled oil analysis, wear products can Bottle samples
be identified and corrective action can be taken The sample shall be taken at the mini-mess
before failure occurs. Oil analysis can indicate coupling on the charge pressure side of the
when an oil change is required, point out motor in the closed loop system. Never out of
shortcomings in maintenance and keep repair the tank using the ball valves.
cost to a minimum. Using oil analysis can Clean the coupling and the hose carefully.
create a “window of opportunity”, allowing the Connect the mini-mess hose to the coupling
user to schedule re-fittings or overhauls, but be careful and be aware of the direction of
maintenance or repairs, thus saving money on the oil beam.
equipment repairs and downtime. Let minimum 2 litres (0,6 gallon US) of oil flush
The most used method is to take samples in a into a bucket before you fill the bottle.
special bottle and send it to a fluid laboratory Remove the cap of the bottle as late as
for an analysis and from the laboratory you possible and don’t let any contamination be in
get a repor t, which follow a specific touch with the cap, bottle or the mini-mess hose
international standard. when the sample is taken.
You have to select what analysis the laboratory In dirty air area, use a soft plastic foil (normal
should take, but the most used analysis are as protection in laboratory bottles between
particle count, water content, oxidation and bottle and cap).
viscosity.
31
Fault finding Installation and Maintenance Manual, Compac CB
Do not remove the foil, prick the end of your Inline measure
mini-mess hose through the foil into the bottle The sample shall be taken at the mini-mess
and fill. coupling on the charge pressure side of the
To get a reliable result the system must run motor in of the closed loop system. Clean the
without moving any valves and the mini-mess coupling and the hose carefully.
hose should not touch the bottle. Connect the hoses according to the particle
Only ¾ of the bottle shall be filled because the counters manual.
laboratory has to shake the sample to get a To get a true value the contamination readings
mixed fluid when they analyse it. Minimum have to be stable about 10 min before you stop
200ml are needed for a good analysis. to measure.
When the bottled is filled close the cap as soon
as possible to prevent contamination from the
air that might enter the bottle and give you a
wrong result.
5. FAULT FINDING
Hydraulic motor
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pressure has
risen to the relief valve setting, remove the
load from the drive.
The motor does not deliver Investigate the pressure level in the system
enough torque because the and correct the setting of the pressure limiting
pressure difference across the valve if necessary.
motor is not great enough for
the load.
Motor rotates in wrong Oil supply connections to Connect the oil supply correctly.
direction. motor incorrectly connected.
Motor runs jerkily. Pressure or flow fluctuations Find the cause in the system or in the driven
in the hydraulic system. unit.
Noise in the motor. The motor is being operated Adjust the charge pressure to the correct
with the charge pressure too level. See 2.1 "Recommended charge
low. pressures".
Internal faults in the motor. Investigate the drain oil, if necessary. Put a
magnetic plug in the oil flow and check the
material that sticks to the magnet. Steel
particles indicate damage. Note that fine
material from the castings may be deposited
and does not mean internal damage in the
motor.
External oil leakage on The radial lip seal is worn. Replace the radial lip seal.
the motor.
32
Deklaration of conformity Installation and Maintenance Manual, Compact CB
DECLARATION OF CONFORMITY
Example of the Declaration of Conformity given by Hägglunds Drives AB
33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
740
4
(4,331)
(26,772 -0,0062)
45°
-0,0013
A
-0,024
-0,149
H (2:1)
B D1 30 B
C C (1,181)
D4 B B
680
223 (2x)
(8,780)
174 (4x)
(6,850)
(17,008 +0,00078)
C C
+0,00235
)
(29,213 -0,024)
+0,0029
+0,063
432 +0,023
+0,072
+0,023
6x15
742 ±0,6
(17,323)
(0,236)
440
200 0
(7,874 +0
117
(4,606)
D D
D2 T3
E A2 Not 1. E
A
C2 Note 1.
T4 A M20 (34x)
T4 1/2"UNC (16x) 31 (4x)
(1,220)
38
Equ 9° A
ally (1,496)
(1,063)
F F
(1,457)
divi 207 (4x)
27
ded
37
(8,150) 237 425
(9,331) (16,732)
489
782 101 (19,252)
G (30,787) G
B-B (1 : 1) (3,976)
250 224 = = = = A1 C1
25° 55°
(9.843) (8,819)
5/8"UNC (16x) T1 T1
D3 F1 D1 D3
H H
(1,378)
(1,772)
D4
35
45
F2
A F3
D2 F1
(3,346)
(2,874)
85
= = = =
73
T2
C-C (1 : 1)
I T3 I
99 A (1 : 2)
T4 T4
(2,126)
(3,898)
54
(13,976)
(17,559)
C1 MAIN CONNECTION SAE 1¼" AND 1½" ** without notice or obligation, unless certified
Contravention will be prosecuted.
446
A2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** referring to a certain purchase order.
C2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** Information contained herin should be confirmed
before placing orders.
D1 DRAIN CONNECTION BSP 1 ¼"
D2, D4 ALTERNATIVE DRAIN CONNECTION BSP 1 ¼" Measurements within brackets indicates
D3 ALTERNATIVE DRAIN CONNECTION BSP 1" measurements in inches.
K T1, T2 TEST CONNECTION M16 x 2 NOTE 1: For tightening torque see installation manual. K
T3 TEST CONNECTION BSP ¼" Must be verified on actual name plate.
A T4 PRESSURE CONNECTION BSP ½"
T1 T1 FLUSHING CONNECTION BSP ¼"
F1, F2 Item No. Qty Article No. Material, type, etc Dimensions Name of item
Part of
according to
SS-ISO 2768-1, class m Scale Presiding drawing no Control code
SS-ISO 965, class 6.
Other not indicated tol. 1:2.5
F2 ** SAE coupling J 518 C, code 62, 414 bar (6000 psi) Cad type
SW
Sheet size
A0
Drawn by
Knight/DVN
Description (English)
A40P
Prepared both for 1¼" and 1½". Accepted for prod by Iss by Dept. Year Week Description (Own language)
L
T2 99 A F3 Both UNC 1/2" for SAE 1¼" and UNC 5/8" for SAE 1½" Drawing checked by
D52 01 22 CB400
Rev ind Sheet
Similar drawing No.
1
(3,898) A 620 060 LFN 02 05
D52/BLL
Design checked by
078 5003 A No. of sheets
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Bill of Material No.: HK-2005033
Bill Of Material
Date Issued : 3-Jun-2005 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: JFD 2275 International Street; Columbus, Ohio 43228, USA - -
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: - Assembly Ref(s) :
HOSE KIT Revised By : -
25 FT. LONG, PBC-200 with 1 x P6S/P7S to 1 x CB-280/400 -
WITH MAINLINE, AND DRAINLINE HOSES Rev. Date : Project No. :
- 2005 033
C
Item O Hägglunds Description
No. Qty. D Part No.
E
NOTES:
Fill up motors all the way with following amount of oil and make
sure all drain and vent ports have metal plugs with o-rings:
Compact CA-50 - 0.53 gallons
Compact CA-70 - 0.66 gallons
Compact CA-100 - 0.98 gallons
Compact CA-140 - 1.32 gallons
Compact CA-210 - 1.80 gallons
Compact CB-280 - 4.0 gallons
Compact CB-400 - 5.6 gallons
Compact CB-560 - 5.0 gallons
Compact CB-840 - 6.6 gallons
HAS10392a.XLS
Bill of Material No.: HAS-10014
Bill Of Material
Date Issued : 10-Mar-1993 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: CBH 2275 International Street; Columbus, Ohio 43228, USA B
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: ECN-00000422 Assembly Ref(s) :
Revised By :
Long Term Storage Flange Kit, 1½" HDR
Used for Goldcup P6, P7, P11, P14 and Hagglunds SP250 and SP355 pumps Rev. Date : Project No. :
11-Apr-2008
C
Item O Hägglunds Description
No. Qty. D Part No.
E
2 NOT USED
4 1 LABOR TO UNCRATE PUMP AND INSTALL PROTECTIVE COVERS AND FILL WITH OIL
NOTE:
Install Items 1, 2 and 5 onto pump and then fill with oil
according to the following chart:
Goldcup P6 & P7 - 0.8 gallons
Goldcup P11 & P14 - 1.6 gallons
Hägglunds SP-250 - 2.6 gallons
Hägglunds SP-355 - 2.1 gallons
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 1(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
Speed encoder SPDB1:
Digital incremental hollow shaft encoder with torque
arm mounting.
MECHANICAL SPECIFICATION
Shaft, Stainless steel Hollow-shaft ø 12mm
Moment of inertia 5,4 x 10-6 kgm2
Load max Same direction as motor
Radial 20 N - clockwise
Axial 10 N
Speed max 6000 rpm
Code disc Unbreakable acrylic glass
Temperature
Operating -25°C...+70°C
Storage -25°C...+70°C
Housing Aluminium, anodized
Weight Approx. 250 g
Protection class IP 65 according to IEC 529
Vibration <100 m/s2 (50...2000 Hz)
Shock <1000 m/s2 (11 ms)
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 2(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
1 inv
2 inv
0 inv
Connection:
Encoder must be connected with shielded cable, max 0.5 mm2 which is to be solded in connector-pins.
The shield connects to connector-shell.
T-contact:
To be used for external measuring.
HD art. no: 378 5043-801
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 3(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
F/A converter:
- Frequence to Analogue converter is available as option.
- Analog output signal 4-20 mA.
- F/A-converter must be mounted externally. Technical data
Supply voltage DC 24 V (12-50 V)
HD art. no: 576 4057-001
Power consumption 3W
Operation temp. -20°C...+60°C
Humidity 0-90% RH, non condens-
ing
Temp. coefficient <0,01%/°C
Accuracy better than 0.3%
Resolution 0.1%
Mounting NS35 DIN rail
Size w45 x d70 d h117 mm
Electrical connections
Pulse input:
- Input high Vin > 15 V
- Input low Vin < 6 V
4-20mA output max. output load 500 Ohms
SW1
EMC approval EN 50081-1, EN 50082-2 SW2-1 on
Safety EN 60730 SW2-2 off
LED1 power on
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 4(4)
1 2 3 4 5 6 7 8
+0,009
635 M20 (40x)
68 - 0,021
A +0,00052 (25,000) A
(2,677 -0,00066)
(1,417)
(1,575)
A-A
36
40
1250
(49,213)
1330
(52,362)
1721
(67,756)
B B
R410
(16,142)
(12,070)
C
307
C
A A
19
(0,748) (29 742
,21
3)
D D
therof must not be imparted to a third party
nor be used for any unauthorized purpose.
This document must not be copied without
our written permission, and the contents
B
57 485 429
(2,244) (19,080) (16,890)
(17,717)
(21,457 -0,277)
+0,273
150
E referring to a certain purchase order. E
(5,906)
Information contained herein should be confirmed
before placing orders.
Figures within brackets indicate Item No. Qty Article No. Material, type, etc Dimensions Name of item
according to
SS-ISO 2768-1, class m Scale Preceding drawing no Control code
40
Other not indicated tol. 4 (0,157) SS-ISO 965, class 6.
Other not indicated tol. 1:5
(0,787)
210
Weight: 128 kg / 282 lb (arm) SW A2 Knight/DVN A00A
(8,268) Accepted for prod by Iss by Dept. Year Week Description (Own language) Type design/group
D522/TKN 1
B-B
Rev.Ind. Revision Appd. Year Week
Design checked by
1 TCA 40
1 2 3 4 5 6 7 8
A2 - Landscape ver. 2.0
PBC POWER UNIT MANUAL
Installation and
Maintenance Manual
PBC
Preface Installation and Maintenance Manual, Power Unit PBC
Preface
Hägglunds Drives is one of the world’s leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine custom-
ers all over the world. They know that when they seek solutions, support or
service, they can trust Hägglunds Drives to be there. The Hägglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.
Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PBC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating reli-
ability have been designed into this power unit, PBC.
Before starting the installation and/or maintenance, the manual must be read
and thoroughly understood in all respects. All involved personnel shall read
and acknowledge the safety precautions that are stated in section 1.1.
2
Installation and Maintenance Manual, Power Unit PBC Contents
Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6
2. TECHNICAL DATA .......................................................................................................... 7
2.1 Operating conditions .....................................................................................................................7
2.2 Cooling water ................................................................................................................................7
2.3 Requirements for hydraulic fluid cleanliness .................................................................................7
2.4 Choice of hydraulic fluid ................................................................................................................8
2.5 Power unit monitoring....................................................................................................................9
3. HANDLING OF THE PACKED POWER UNIT .............................................................. 10
3.1 Storage of the packed power unit ................................................................................................10
3.2 Lifting the packed power unit .......................................................................................................10
4. INSTALLATION ............................................................................................................. 11
4.1 Installation directions ................................................................................................................... 11
4.2 Lifting methods and weights ........................................................................................................12
4.3 Positioning the power unit ...........................................................................................................13
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor ...........................................................................................................14
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................15
4.7 Hydraulic connections .................................................................................................................15
4.8 Electric connections ....................................................................................................................16
4.9 Pipe work ....................................................................................................................................16
4.10 Extra filtration prior to start up ...................................................................................................19
4.11 Commissioning......................................................................................................... 20
4.11.1 Prior to commissioning ...........................................................................................................20
4.11.2 Filling up the system with hydraulic fluid .................................................................................20
4.11.3 Initial start up procedure .........................................................................................................22
4.12 Pump settings and adjustments ................................................................................................24
5. PREVENTIVE MAINTENANCE ..................................................................................... 25
5.1 Maintenance log ..........................................................................................................................25
5.2 Maintenance chart .......................................................................................................................25
5.3 Filter change ...............................................................................................................................26
5.4 Inspection of hydraulic fluid .........................................................................................................27
5.5 Lubrication of electric motor ........................................................................................................28
5.6 Air breather change .....................................................................................................................28
5.7 Cleaning of Air-Oil cooler.............................................................................................................29
5.8 Power unit out of service .............................................................................................................29
6. CORRECTIVE MAINTENANCE .................................................................................... 29
6.1 Common ......................................................................................................................................29
6.2 Change of hydraulic pump/electric motor assembly ....................................................................30
6.3 Troubleshooting ...........................................................................................................................31
7. DISPOSING OF POWER UNIT ..................................................................................... 32
3
General Installation and Maintenance Manual, Power Unit PBC
1. GENERAL
1.1 Safety precautions
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hägglunds Drives representative for advice.
Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:
DANGER
! DANGER is used to indicate the presence of a hazard, which will
cause severe personal injury, death, or substantial property damage
if the warning is ignored.
WARNING
! WARNING is used to indicate the presence of a hazard, which can
cause severe personal injury, death, or substantial property damage
if the warning is ignored.
!
CAUTION
CAUTION is used to indicate the presence of a hazard, which will or
can cause minor personal injury or property damage if the warning is
ignored.
General
Limit access to the equipment only to authorized personnel. Only perform measures on the PBC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional ser-
vice personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.
4
Installation and Maintenance Manual, Power Unit PBC General
Prior to troubleshooting
• Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
• Read the attached technical documentation (this manual included) and make yourself familiar
with the PBC (control system included) as well as the complete drive.
• Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
• Always ensure that there is no accumulated energy in the system prior to maintenance.
• Ensure that all electric power is off and locked out.
• Ensure that there is no entrapped pressure in the hydraulic system.
• Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
• If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
• Ensure that all accumulators are discharged.
Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.
Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.
Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.
Maintenance and service
Follow the maintenance intervals for your specific PBC or the maximum intervals on the maintenance
chart (section 5.2 “Maintenance Chart”) and keep a maintenance log. Regular and correct mainte-
nance is necessary for reliable and safe operation.
Only use spare parts recommended and supplied by the Hägglunds Drives organization.
Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.
Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.
Hot surfaces
Temperatures in the hydraulic system above 158° F (70° C) will create hot surfaces.
Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situa-
tion. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5
Operating Principle Installation and Maintenance Manual, Power Unit PBC
18
Main components
1. Hydraulic pump AIR
FLOW
2. Drain valve 20
3. Sight glass 19
8
4. Charge pressure gauge
5. Servo pressure gauge
6. Main pressure gauge ‘B’ port
7. Main pressure gauge ‘A’ port
8. Air breather 11
11 6
9. Drain filter 7 4
10. Return filter 5 5
4 7
11. Electric motor 6
12. Filter switch 12 3
6
Installation and Maintenance Manual, Power Unit PBC Technical Data
2. TECHNICAL DATA
2.1 Operating conditions
The standard PBC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hägglunds Drives representative with your specific require-
ments for special design considerations.
Ambient temperature: Minimum 32° F (0° C) to a maximum 85° F (30° C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hägglunds Drives representative for more details.
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.
7
Technical Data Installation and Maintenance Manual, Power Unit PBC
150 720
100 RECOMMENDED
VISCOSITY
40 187
VG VG
VG 100 150
46
VG
68
10
0 10 20 30 40 50 60 70 80 90 100
Temperature ºC (measured in the motor case)
8
Installation and Maintenance Manual, Power Unit PBC Technical Data
POWER UNIT
Maximum oil
Temperature switch
1
Minimum oil
Temperature switch
1
Minimum oil
level switch
Closed suction
1 1 STOP HYDRAULIC MOTOR
line switch
1
1s 0s STOP ELECTRIC MOTOR
Low charge Time delay off
pressure switch Time delay on
0s 0.5s
1
5s 0s
&
Time delay on
Warning oil
temperature switch
1
Low oil
level switch
1
Return filter Time delay off
switch
Drain filter
0s 5s
1 1 WARNING INDICATION
Time delay off
switch
0s 5s
1
High pressure Time delay off
switch
0s 5s
1
The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PBC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.
9
Technical Data Installation and Maintenance Manual, Power Unit PBC
If storage time exceeds the above mentioned limits, then the power
unit must be operated so that the hydraulic system is lubricated with
new fluid. (section 5.8 “Power unit out of service”)
!
CAUTION
•
•
Avoid rapid acceleration, deceleration and turns while
moving the equipment.
Position the forks according to the instructions below.
10
Installation and Maintenance Manual, Power Unit PBC Installation
4. INSTALLATION
4.1 Installation directions
If the PBC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical docu-
mentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.
H1
H1
B2 A2 B2
H2
H2
B1 M A1 B1 M
A3 A3
Cabinet Size 1 2 3 4 5
Type PBC 100 PBC 300 PBC 400D
PBC 200D PBC 800
Dimension PBC 200 PBC 400 PBC 600
H1 84 7/8 in. (2156mm) 84 7/8 in. (2156mm) 123 1/2 in. (3138mm) 123 1/2 in. (3138mm) 126 in. (3200mm)
H2 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 3 in. (76mm)
B1 55 1/8 in. (1400mm) 82 5/8 in. (2099mm) 66 in. (1676mm) 105 in. (2667mm) 121 3/4 in. (3092mm)
B2 51 1/8 in. (1299mm) 78 5/8 in. (1997mm) 62 in. (1575mm) 100 in. (2540mm) 117 3/4 in. (2991mm)
A1 39 3/8 in. (1000mm) 39 3/8 in. (1000mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm) 53 in. (1346mm)
A2 35 3/8 in. (899mm) 35 3/8 in. (899mm) 49 1/4 in. (1251mm) 48 1/2 in. (1232mm) 48 in. (1220mm)
A3 82 in. (2083mm) 111 in. (2820mm) 96 in. (2439mm) 138 in. (3505mm) 154 3/4 in. (3931mm)
M 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC
11
Installation Installation and Maintenance Manual, Power Unit PBC
MAX
90˚ O
! •
(check rating plate).
Do not lift the power unit with hydraulic fluid in the tank, or with the
DANGER front bar disassembled.
12
Installation and Maintenance Manual, Power Unit PBC Installation
32 [813mm] 32 [813mm]
FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM
DANGER
! •
•
beware that the cooler will start without notice and has sharp edges
Beware of airborne particles in the outgoing air flow
If the air-oil cooler becomes loose it can cause severe personal injury.
13
Installation Installation and Maintenance Manual, Power Unit PBC
[25mm-38mm]
1 [13mm]
ADJUSTABLE
Be careful while mounting the
2
2
1
! cabinet feet. Follow the safety
1-1
precautions in section “Lifting
WARNING methods and weights”
14
Installation and Maintenance Manual, Power Unit PBC Installation
!
DANGER
•
•
•
Use all lifting ears when the electric motor is hanging free.
Use only lifting equipment adapted to the weight on the rating plate.
No hands/fingers between electric motor and bell housing during assembly.
!
DANGER
or perform maintenance if the
hydraulic system is pressurized.
2
3
4
PBC 200D
PBC 300/400
PBC 400D/600
1 1/4" SAE
code 61 flange
1" SAE female
5 PBC 800
15
Installation Installation and Maintenance Manual, Power Unit PBC
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hägglunds Drives service representative for more information.
Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.
Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines to
check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.
Hoses
To avoid damage caused by vibrations it is important that the PBC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compres-
sion volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under “Pipe sizes.”
Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the PBC
unit to remove contamination introduced during assembly and/or welding. Please contact a Hägglunds
Drives service representative for proper cleaning and flushing procedure.
16
Installation and Maintenance Manual, Power Unit PBC Installation
Pipe sizes
It is important that lines between the main connections of the motor and PBC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s) Drain lines 5 ft/s (1.0 m/s)
4. Lower noise level.
In certain systems, where very small compression volumes are required, higher flow rates
are acceptable with possible increase in noise. Contact a Hägglunds Drives representative
in these specific cases.
When dimensioning hose and pipe lengths between the drain connections of the motor and the PBC,
keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5
PSI (1 bar). The pressure drop through the PBC is 7.25 PSI (0.5 bar).
Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:
Non-welded couplings are preferred
Non welded couplings provide the most clean piping installation as compared to a welded pipe system.
Welded couplings (socket or butt type)
When using welded couplings, the pipes should be machined, normalized, and pickled. The pipes
must then be brushed, rinsed internally and blown clean before flushing.
Pipe coupling
Type collar coupling as per SAE J 514.
Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the clamped
joint and have good vibration-absorbing properties.
17
Installation Installation and Maintenance Manual, Power Unit PBC
DANGER
! Use necessary safety equipment during installation of the pipe system.
Usual safety requirements for each step must be followed.
Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any dam-
ages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the seal (if any) is in its right position, free from cracks and that
it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.
18
Installation and Maintenance Manual, Power Unit PBC Installation
O
4.10 Extra filtration prior to start up
HYDRAULIC MOTOR
A pressure filter and check valve has to be con-
nected to the main line at the power unit. This
filter is connected on the return side of the drive Hoses
pump. connected
together
Recommended filtration degree ß10 = 75 or bet-
ter. Flow Direction
19
Installation Installation and Maintenance Manual, Power Unit PBC
4.11 Commissioning
4.11.1 Prior to commissioning
• Read and understand this complete manual and the other attached technical documentation.
• Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documen-
tation.
• Check that the coupling between the electric motor and pump is properly mounted.
• Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.
Cleanliness
• The hydraulic system must be flushed and thoroughly cleaned on the inside.
• If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.
Pipe work
• Are the couplings properly tightened?
• Is the pipe work properly cleaned?
• Is the pipe work mounted free of stress?
• Are the lines in accordance with installation drawing/piping plan?
Electrical System
• Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
• Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.
20
Installation and Maintenance Manual, Power Unit PBC Installation
Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connec-
tion is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.
RETURN FILTER
OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER
OIL HEATER
After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.
• Check caution sign on container and the warnings (section 2.4 “Choice
of hydraulic fluid”).
!
WARNING
•
•
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
21
Installation Installation and Maintenance Manual, Power Unit PBC
22
Installation and Maintenance Manual, Power Unit PBC Installation
23
Installation Installation and Maintenance Manual, Power Unit PBC
DANGER
! could be dangerous in case of
unforeseen failures.
CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
CHARGE PRESSURE VALVE
ADJUSTMENT
View from the back View from the back Front view
Charge pressure and Pump compensator pressure level are set before the PBC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in techni-
cal documentation. Professional service personnel familiar with the functions and risks involved
with the pump must perform setting of pressures on the pump(s). The pressures shall be set
during operation and with the system at operating temperature. Note that pressures can change with
different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact a Hägglunds Drives representative for consultation.
2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure
limiter setting. The pressure limiter setting is reached when the pressure stops increasing and
remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.
Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
24
Installation and Maintenance Manual, Power Unit PBC Maintenance
5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.
25
Maintenance Installation and Maintenance Manual, Power Unit PBC
Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:
• All points listed under frequent checks.
• Check all pressure levels.
• Check for stable temperature levels around the system.
• Drain water and sludge from the tank at the drain tap.
• Check the electric motor.
• Check the function of monitoring equipment/switches, etc.
• Clean areas where dirt is building up.
Note: never use a high pressure washing system to clean the power unit.
• Check the cables.
• Check accumulators (optional) for correct pre-charge.
• Check drain line flows and drain line oil condition.
• Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition.
• Check the shaft coupling through the inspection hole. Warning, rotating parts inside the
inspection hole.
• Check the flow of cooling water.
26
Installation and Maintenance Manual, Power Unit PBC Maintenance
Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Engage the switching lever and move to the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 2-3
turns.
4. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
5. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.
Vent screws
Pressure
• There are dangers associated equalizer
with hydraulic fluid. lever
• Store used hydraulic fluid
! and contaminated filter ele-
ments for proper disposal.
In this
position
you can Switching
lever
CAUTION • The fluid may be hot if the change
cooling is insufficient. this
element
27
Maintenance Installation and Maintenance Manual, Power Unit PBC
!
CAUTION
Check the warning label
on the grease cartridge. Frame
size
Lubrication schedule for electric motor (60 Hz)
Electric motor
HP (kW)
Lubrication
intervals
Volume of
grease
28
Installation and Maintenance Manual, Power Unit PBC Maintenance
Follow the safety precautions on the container of the cleaning agent used.
! Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
WARNING and waste water from rinsing should be disposed of in accordance to pre-
vailing local regulations.
6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recom-
mended safety procedures.
Before disassembly
• Troubleshoot the PBC and perform appropriate tests.
• Clean all assemblies and components, take all precautions necessary to prevent dirt entering
the system.
• Disassembly may only be done by professional service personnel.
29
Corrective Maintenance Installation and Maintenance Manual, Power Unit PBC
Disassembly
• Label all parts, and protect precision or machined surfaces.
• Inspect all parts during disassembly for wear or damage.
• If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and
covered when not in use.
• Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint
free cloth to drain.
Reassembly
• Lubricate with system hydraulic fluid.
• Replace all seals, gaskets and o-rings with new items of the correct size.
• Ensure complete sealing at pipe connections.
• Refill hydraulic fluid according to recommendations (section 4.11.2 “Filling up the system with
hydraulic fluid”).
• Always use all four lifting points when lifting the electric
motor/pump unit.
• Never use the lifting ears on the electric motor to lift the
!
DANGER
•
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
“Lifting methods and weights”).
• Do not stand underneath hanging load
• Take center of gravity into consideration during lifting.
30
Installation and Maintenance Manual, Power Unit PBC Troubleshooting
6.3 Troubleshooting
Pump/Motor baseplate
shipping bolts still installed Remove shipping bolts
31
Troubleshooting Installation and Maintenance Manual, Power Unit PBC
!
DANGER
•
•
•
The components may contain accumulated energy.
Take fire hazards into consideration during dismantling.
The accumulator (optional) must be empty and discharged.
32
AM326-1A Printer : Precision Printing 1999
Figure: M300
Threaded Ends Meets ANSI/NSF 61 Section 8
Non-rising Stem (1998)
Solid Wedge Disc and
California Proposition 65
Rating:
125 psi WSP
200 psi WOG
Figure: M300S
Sweat Ends
Non-rising Stem
Solid Wedge Disc Meets ANSI/NSF 61 Section 8
(1998)
Available with Waste and
(specify Fig. M300SW) California Proposition 65
Dimensions:
1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
A Center of Port to Top 3 3 1/16 3 3 1/2 4 1/16 4 3/4 5 3/16 6 3/16 7 l/2 9 10 1/4
B End to End 1 5/8 1 5/8 1 11/16 1 7/8 2 3/16 2 3/8 2 7/16 2 13/16 3 1/2 4 4 9/16
B1 End to End 1 5/8 1 3/4 2 3/8 2 3/16 3 1/16 3 1/16 4 1/8 4 3/4 4 3/4
C Overall Height 3 1/2 3 1/2 3 9/16 4 1/4 5 5 3/4 6 3/8 7 5/8 9 1/2 11 1/8 13 1/8
D Wheel Diameter 2 1/8 2 1/8 2 1/8 2 1/8 2 3/8 2 7/8 2 7/8 6 3/4 5 4 l/4 3 1/4
Weight lbs. Thd. .55 .53 .56 .81 1.10 1.80 2.l0 3.20 7.00 9.60 17.0
Weight lbs. Swt. .48 .51 .75 1.10 1.70 2.00 3.10 6.80 9.40
CABINET FEET
TF
Features
The TF mounting is installed in minutes by following the
instructions provided. There is no need to fix the machines
to the floor since the rubber base of the mounting keeps
the machine in place. Whenever necessary, the machine
can easily be re-positioned. The level is adjusted with load
applied.
Novibra® type TF
Novibra® type TF with level adjuster is suitable for a wide
range of free standing workshop machines, e.g.
• Lathes
• Milling machines
• Grinding machines G
• Multiple operation machinery
• Presses
• Plate shears
• Nibbling machines
• Punches and cutters
• Woodworking machines
• Plastic moulding machinery H
68 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
TF
Loading range per mounting (kg)
Mounting instructions
1 2 3
TFE
Mounting TFE is a simpler version of type TF without Both models also available in S/S
level adjuster. It is used for machines which do not require (ISO 2604/11,BS 3605:1 )
height adjustment or where such a feature is already pro-
vided, e.g. by an adjusting screw in the machine.
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 69
ISOLATION MOUNTS
Bobbins
Trelleborg Industrial AVS - Bobbins
A supplementary range of cylindrical mountings for a wide Manufactured in natural rubber hardness 40° IRH or
range of applications. They can be loaded either in com- 60° IRH.
pression or shear taking into consideration individual de-
mands for actual applications.
82 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
Bobbins
G ØD
L H
A 40/20 M8x20 318840 318850 275 632 34 170 534 1226 75 369
A 40/25 359 1076 58 369
A 40/30 M8x20 318860 318870 130 481 21 170 271 1002 47 369
A 40/40 M8x20 318880 318890 86 437 16 170 184 935 34 369
A 50/20 M10x25 318900 318910 564 1248 56 265 1042 2306 122 577
A 50/25 M10x25 318920 318930 335 976 42 265 652 1900 93 577
A 50/30 M10x25 1861540 1255870 234 846 34 265 472 1706 75 577
A 50/35 M10x25 318940 318950 180 774 29 265 371 1598 62 577
A 50/40 M10x25 318960 1255340 146 730 25 265 306 1533 54 577
A 50/45 M10x25 318970 1255880 123 701 22 265 261 1490 47 577
A 50/50 M10x25 318980 1255350 106 681 19 265 228 1460 42 577
A 75/40 M12x35 319000 319010 417 2032 57 596 827 4030 124 1299
A 75/50 M12x35 319020 319030 282 1766 44 596 579 3632 97 1299
A 75/55 M12x35 319040 319050 242 1689 40 596 504 3517 87 1299
A 100/40 M16x45 319060 319070 932 4541 102 1060 1755 8549 221 2309
A 100/55 M16x45 319080 319090 496 3455 71 1060 994 6929 155 2309
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 83
Bobbins
S
G ØD
L H
84 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
Bobbins
S
G ØD
60° IRH
Type D/H G(S) Art.No. Compression load Shear load
60° IRH
kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
C 15/15 M4(4) 1256210 86 112 13 52
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 85
Bobbins
G
Type D Type E
L G
H H
ØD ØD
Compression load
Type D/H GxL Art.No. Art.No. 40° IRH 60° IRH
40° IRH 60° IRH Fmax Fmax
(N) (N)
D 10/10 M4x10 319390 59
G(S)
E 30/17 M8(8) 1256930 1661280 225 500
E 50/20 M10(10) 319600 1700
E 50/36 M10(10) 1659990 319610 550 1100
E 50/45 M10(10) 1659870 1000
86 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
P6S, P7S & P8S PUMP MANUAL
DENISON HYDRAULICS
goldcup series
closed circuit piston pumps
P6, P7, P8S
service information
Publ. S1-AM025-A
PAGE
installation 3
typical characteristics 3
fluid connections 4
general 5
description 5
mounting 5
shaft information 5
piping 5
service information 5
recommended fluids 5
viscosity 6
viscosity index 6
temperature 6
alternate fluids 6
maintenance 6
fluid cleanliness for new installation 6
start-up procedure 6
comparison of solid contamination classification system 7
troubleshooting 7
assembly tool drawings, T1, T2, T3, T4, T5 9
disassembly 11
rework of wear parts 12
assembly 13
drive shaft and bearing 13
barrel and auxiliary drive shaft 13
rocker cam 15
pistons and shoes 16
mounting flange, cam & cradle 16
housing 17
housing, end cap, cam and barrel 17
port block 18
mounting port block to housing 18
gerotor and barrel holddown 19
valve block (before 7-93) 20
valve block (after 7-93) 22
valve block for special mounting of servo valve (before 7-93) 26
valve block for special mounting of servo valve (after 7-93) 29
output controls 32
input controls 32
shaft and seal installation 33
mechanical shaft seal assembly procedure 33
counter-balance servo stem 34
rear drive adapter 34
pilot valve 36
shuttle valve 36
shuttle valve mounting 37
important instructions 38
instructions for replenishing circuit isolation plug 38
hydraulic circuit 40
test procedure 41
general requirements 41
basic pump test 41
(refer to manual S1-AM030 for controls service information)
ordering code 43
seal kits
complete S23-15092
valve block S23-00135
HI-IQ valve block S13-04226
shaft seal replacement S23-44302
shaft seal 623-00006
shuttle valve S23-15089
2
INSTALLATION
• shaft-spline SAE C C C
keyed
Note: Any SAE-A or B mount pump may be used with the appropriate external drive
3
INSTALLATION
4 Revised
INSTALLATION
GENERAL The DENISON HYDRAULICS Goldcup 6, 7, and 8 axial piston pumps feature advance
design concepts which are time proven and provide for advance pumping and control
concepts. The instructions contained in this manual cover complete disassembly and
reassembly of the unit. Before proceeding with the disassembly or reassembly of any
unit, this manual should be studied in order to become familiar with proper order and
parts nomenclature.
DESCRIPTION The use of a rocker cam to control the pump displacement provides a small package
size, reduces wear, and speeds control response. The control vane actuator eliminates
linkage and backlash inherent in typical stroking cylinder designs.
Standard controls for the Goldcup units are Rotary Servo and Compensator Override.
Additional optional controls are also available.
MOUNTING This pump is designed to operate in any position. The mounting hub and four bolt mount-
ing flange are in full conformance with SAE standard. The pump shaft must be in align-
ment with the shaft of the driven load and should be checked with a dial indicator. The
mounting pad or adaptor into which the fluid pump pilots must be concentric with the pump
shaft to prevent bearing failure. This concentricity is particularly important if the shaft is
rigidly connected to the driven load without a flexible coupling.
SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.006" TIR (.15 mm).
Angular misalignment at the male and female spline axes must be less than ±.002” per
inch radius (.002 mm per mm radius). The coupling interface must be lubricated. DENI-
SON HYDRAULICS recommends lithium molybdenum disulfide or similar grease. The
female coupling should be hardened to 27-45 Rc and must conform to SAE-J498B
(1971) Class 1 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hard-
ened to 27-34 Rc. The key corners must be chamfered .030"-.040" (.75-1 mm) at 45° to
clear radii that exist in the keyway.
Splined or Keyed: Both types of shafts will accept a side load of 170 lbs. (77 kg) at the
center of the spline or key, with a B10 life of 10,000 hours at 1800 RPM.
PIPING Connect inlet and outlet lines to the port block of the pump.
The maximum case pressure is 75 PSI (5.17 bar) continuous, 125 PSI (8.6 bar) inter-
mittent. Case pressures must never exceed inlet pressure by more than 25 PSI (1.7 bar).
When connecting case drain line make certain that drain plumbing passes above high-
est point of the pump before passing to the reservoir. If not, install a 5 PSI (.3 bar) case
pressure check valve to be certain the case is filled with oil at all times.
The case leakage line must be of sufficient size to prevent back pressure in excess of 75
PSI (5.7 bar) and returned to the reservoir below the surface of the oil as far from the
supply suction as possible. All fluid lines, whether pipe, tubing, or hose must be adequate
size and strength to assure free flow through the pump. An undersized inlet line will pre-
vent the pump from reaching full speed and torque. An undersized outlet line will create
back pressure and cause improper operation. Flexible hose lines are recommended. If
rigid piping is used, the workmanship must be accurate to eliminate strain on the pump
port block or to the fluid connections. Sharp bends in the lines must be eliminated wher-
ever possible. All system piping must be cleaned with solvent or equivalent before
installing pump. Make sure the entire hydraulic system is free of dirt, lint, scale, or other
foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with
continued use.
SERVICE INFORMATION These hydraulic products are designed to give long dependable service when properly
applied and their systems properly maintained. These general instructions apply to typi-
cal systems. Specific instructions for particular equipment can be developed from them.
RECOMMENDED FLUIDS See DENISON HYDRAULICS bulletin SPO-AM305 for more details.
5 Revised
INSTALLATION
FILLING CASE It is essential to make certain that the case (pump housing) is as full of fluid as possible
and remains full during operation and at rest.
Always fill to the highest available point. Remove a plug or screw and allow the oil to
escape through this point.
MAINTENANCE This pump is self-lubricating and preventative maintenance is limited to keeping system
fluid clean by changing filters frequently. Keep all fittings and screws tight. Do not oper-
ate at pressures and speeds in excess of the recommended limit. If the pump does not
operate properly, check the Trouble Shooting Chart before attempting to overhaul the
unit. Overhauling is relatively simple and may be accomplished by referring to the
Disassembly, Rework Limits of Wear Parts and Assembly Procedures.
FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation by filters that maintain a
cleanliness level of NAS 1638 Class 8.
START UP PROCEDURE • Read and understand the instruction manual. Identify components and their function.
• Visually inspect components and lines for possible damage.
• Check reservoir for cleanliness and drain and clean as required.
• Check fluid level and fill as required with filtered fluid at least as clean as that recom-
mended. Fill pump case with clean oil prior to starting.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of relief valve. Make sure accurate pressure readings can be
made at appropriate places.
• If solenoids in system, check for actuation.
• Start pump drive. Make sure pump and motor fill properly.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines especially in
pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds, sys-
tem shocks and air in fluid.
• Equipment is operational.
6 Revised
TROUBLESHOOTING
TROUBLESHOOTING Component problems and circuit problems are often inter-related. An improper circuit
may operate with apparent success but will cause failure of a particular component with-
in it. The component failure is the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by
studying their effects:
7
TROUBLESHOOTING
8
ASSEMBLY TOOL DRAWINGS
T-1
MATERIAL
CRS 1" DIA. X 2 5/8"
(25.4mm) (66.68 mm)
T-2
9
ASSEMBLY TOOL DRAWINGS
T-3
T-4
T-5
Material:
OHTS 5 5/8 x 1 1/4 DIA
(130.17) x (31.75)
Hardened Tip RC 58-62
Note: Dimensions in ( ) are mm.
10
UNIT DISASSEMBLY
INTRODUCTION The instructions contained in this section cover a complete teardown of the subject
pump. Disassemble only as far as necessary to replace or repair any worn parts.
DISASSEMBLY Position pump unit so that valve block assembly is on top. A bench or similar suitable sur-
face capable of supporting unit should be used. Disassembly area should be clean.
VALVE BLOCK See figure 14. Remove the eight hex. head cap screws (17) and lift the entire block
assembly from the port block.
See figure 12/13. Remove the four hex. head cap screws (58) and four soc. hd. screws
(53) and lift the entire block assembly from the port block.
(before 7-93) See figure 10. Remove the four screws (39) to separate the cover (21) from the block
(11). Do not remove the check valves (19).
Remove plugs (43), (36) and pin (40). Remove the 8-32 nut from the bottom of cover (21)
to remove filter assembly (34).
Remove housing (29) and O-ring (28). Remove items (30), (31), (32) and (33) as a unit.
Insert a small brass rod thru the hole in the housing and tap out piston (27) and O-ring
(26).
Remove spring (25) and cone (24). Remove seat (23) and O-ring (22).
Note: Seat is made for hex. wrenching. Use 1/2" six point socket with 1/4" drive.
Remove O-ring (37) and replenishing relief valve (41). Inspect orifices (12) visually to
insure they are open. Do not remove unless damage or clogging is apparent.
Remove springs (16), (17) and (18). Remove retainer (15) and poppets (13) and (14).
Remove the four screws (4) from the plate (6) and (11). Remove gasket (7).
Remove seats (8) and (9). Do not remove roll pins (5) and (10) unless replacements are
needed.
(after 7-93) See figure 11. Remove plugs (20), (23) and pin (21). Remove the 8-32 nut from the bot-
tom of block (1) to remove filter assembly (14). Do not remove the check valves (2).
Remove housing (8), O-ring (9), piston seal (10), O-ring (11), screw (6), nut (7), and
acorn nut (45) as a unit.
Remove spring (12) and cone (13). Remove seat (5) and O-ring (4).
Note: Seat is made for hex. wrenching. Use 1/2" six point socket with 1/4" drive.
Remove O-rings (37), (48) and (47). Remove four screws (43) and remove the retainer
plate (42). Do not remove roll pins (46) unless replacements are needed.
Remove gasket (29) and seats (27) and (28). Remove poppets (30), (31) and springs
(32), (33), (35) and retainer (34).
Inspect orifices (3) visually to insure they are open. Do not remove unless damage or
clogging is apparent.
CONTROLS See figure 14. Remove the four screws (14) from the side cover (16) and remove the
input shear seal valve assembly
Note: The myltite washers (13) should be replaced at assembly.
Remove the four screws (14) from the side cover (15) and remove the counter balance
shear seal assembly.
Remove the two screws (12) and remove the balance stem (9) and balance plate (10)
EXTERNAL PUMP, SHUTTLE See figure 14. Remove two screws (20) and remove external pump (21).
VALVE AND REAR ADAPTER
Remove four screws (23) and remove shuttle valve (24).
BARREL HOLDDOWN AND See figure 9. Remove retainer ring (16), pin (14), holddown nut (13), insert (15), thrust
GEROTOR ASSEMBLY washers (10), bearing (11) and seal ring (12).
Remove pressure plate (9), Gerotor side plate (5) “O” rings (7) and (8).
Remove Gerotor assembly (3), dowel pin (4), key (2), and side plate (1).
11
UNIT DISASSEMBLY
PORT BLOCK See figure 8. Remove four screws (1) that secure the port block (2) to the housing (6). Use
caution when removing screws on valve block side to prevent marring valve block face.
Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3).
Note: port plate will in some instances adhere to port block upon disassembly.
See figure 7. Remove the check valve assemblies (7) from the port block.
Remove two screws (5), lockwashers (6), check rings (3), and clamps (4). Only one
check ring assembly in open circuit pumps.
BARREL AND AUXILIARY SHAFT Remove face plate (2, fig. 6) from face of barrel assembly.
BARREL AND AUXILIARY SHAFT
Remove the barrel assembly (1, fig. 4) by grasping the auxiliary shaft and lifting the com-
plete assembly out of the housing.
DRIVE SHAFT See figure 14. Remove the four screws (8) and gaskets (7). Remove seal retainer (6),
and the stationary part of the shaft seal (4). Refer to view of item 4.
Carefully remove the carbon ring and the remainder of the shaft seal from the shaft.
Caution: Do not scratch seal surface of shaft when removing seal.
Remove snap ring (3) and the shaft and bearing assembly (1). Remove shim (2).
HOUSING After shaft assembly has been removed, position the unit on end with the mounting
flange turned down.
Push the ends of the small tube lines away from the housing.
Lift the housing from the mounting flange, remove the gasket, and dowel pins from the
mounting flange.
Do not remove the roll pins and the bearing from the housing unless the bearing is dam-
aged and must be replaced.
ROCKER CAM AND CONTROL See figure 4. Remove the complete assembly (5) from the mounting cap (7) and posi-
STROKING ASSEMBLY tion on a clean flat surface with the two tubes (2) in a horizontal position and located at
the top. Mark the cam (24) and cradle (20) as indicated in Figure 3. These marks will
determine positioning of parts during reassembly.
Carefully remove the small tube lines (3) and (4) from the cradle.
Caution: Do not bend these lines
See figure 3. Position the assembly in an upright position on the flat surface of the cra-
dle (20). Remove the retaining ring (1) and thrust washer (2). Remove the piston and
shoe assembly (4) and the creep plate (5) from the cam (24). Carefully remove the two
set screws (6a) and two screws (6) that secure the servo plate to the cam (24) and
remove the servo input parts (7, 8 and 9).
Remove the four 7/16" screws (10) and eight 1/4" screws (11) and (12) from the control
covers (15R) and (15L). Remove the four dowel pins (16) and remove the two chambers
(17). Remove the two special seals (18) and the four steel balls (19). Remove the two
vane seal cartridge assemblies (23) and the four holddown vanes (22) from the rocker
cam (24).
Note: Some units may have thin shims under the holddown vanes.
12
UNIT DISASSEMBLY
IMPORTANT:
The port plate both faces finish must be 25 microinches (635 mm), flat within .00006
(0015 mm) and parallel within .001(0254 mm) T.I.R.
The creep plate wear face finish must be 10 microinches (254 mm), flat within .0002
(0381 mm) and parallel to the backside within .0005 (0127 mm)T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 mm), and flat within
.0015 (0381 mm) (must not be convex).
The piston shoes wear face finish must be 5 microinches (127 mm), and must be lapped
in a set with the retainer plate, all shoe sole thicknesses to be within .001 (0254 mm) after
lapping. The maximum permissible shoe and piston axial looseness is .010 (254 mm).
The special retaining ring service kit (S23-12461) may be required to control shoe
holddown clearance.
13
ASSEMBLY PROCEDURES
CLEANING AND INSPECTION All parts must be inspected and be free of material defects, dirt, scratches or any foreign
material.
All parts must be cleaned with a suitable cleaning solvent and all holes and passages
blown out with dry, clean, compressed air.
After cleaning and inspection, all parts must be covered with a light film of oil and pro-
tected from dirt and moisture. Excessive handling of internal parts should be avoided
prior to assembly.
During assembly, lapped and ground surfaces must be lubricated with clean oil and pro-
tected from nicks or surface damage.
DRIVE SHAFT AND BEARING See figure 1. Pass one retaining ring (3) over the internal end of drive shaft (1) and install
in the groove near the shaft seal surface.
Caution: Do not pass the ring over the seal surface.
Press the bearing (2) over the same end of the shaft and seat against the ring.
Support only the inner race of the bearing and press on the coupling end of the shaft.
Caution: Do not use excessive force and distort or damage the retaining ring.
Install the other retaining ring (3) in the other retaining ring groove. Be sure that both
rings are fully seated.
quantity
item description part no. #3 #2
1 #3 (splined shaft) 033-70567 1 -
#2 (keyed shaft) 033-70579 - 1
Figure 1 2 shaft bearing 230-82140 1 1
3 retaining ring 033-70817 2 2
4 square key 5/16 x 1-1/4 033-71348 - 1
BARREL AND AUXILIARY See figure 2. Position the barrel (1) in a press with the large end turned down and insert
DRIVE SHAFT tool figure T-1 in the splined shaft hole in the barrel.
Place stop (3) and spring (4) over shaft (2) in the same sequence as shown.
Insert shaft (2) in barrel (1) and rest on tool figure T-1. Position the spring retainer (5) over
the shaft (2) and against spring (4).
Carefully place tool figure T-2, with the large end of the tapered hole up, over the shaft
(2) and against the barrel face (1). Insert ring (6) around the shaft (2) and in the tool.
Position the ring with the gap within 5/8" (16 mm) of the notch in the barrel for easy
removal.
Place tool figure T-3 over the shaft (2) with the small end against ring (6). Press on the
end of the assembly tool and seat the ring (6) in the groove of the barrel (1).
Remove the assembly tools. Check to be sure that the ring is properly seated. Check bar-
rel face to be certain it is not marred.
quantity
item description part no. P6 P7 P8
1 barrel & sleeve ass’y (P6) S13-43657 1 - -
Figure 2 barrel & sleeve ass’y.(P7) S13-47511 - 1 -
barrel & sleeve ass’y (P8) S23-12718 - - 1
2 auxiliary drive shaft 033-91050 1 1 1
3 stop 033-53944 1 1 1
4 barrel holddown spring 033-70493 1 1 1
5 spring retainer 033-53945 1 1 1
6 retaining ring 033-70494 1 1 1
14
ASSEMBLY PROCEDURES
*Note: Item 10 through 24 can be ordered as a complete rocker cam & control stroking
assembly.
S23-12196 is for RH pumps
S23-12197 is for LH pumps
15
ASSEMBLY PROCEDURES
ROCKER CAM/PISTONS
AND RETAINER
Marks Designate
Top of Assembly
Figure 3
Note: Install items 6, 7, 8, and 9 on side shown of rocker
cam if pump model number has “B” suffix. Install on
opposite side if “A” suffix.
ROCKER CAM See figure 3. Position the cradle (20) on a clean flat surface with the large flat area down.
Position the rocker cam (24) on the cradle (20). Note marks made earlier to indicate top
of rocker cam & cradle.
Place O-ring (23c) around spacer (23d) and insert in the vane seal (23b).
Insert check valve (23e) inside of spacer (23d) and assemble between the two backup
plates (23a) with the notched V’s exposed.
Install assembled cartridge in slot in cam as indicated in Figure 3. Repeat steps 1, 2 and
3 on other side of cam.
Insert the four holddown vanes (22) in the slots on each side of the control vanes (23).
Position both control chambers (17) on a clean flat surface with seal grooves turned up.
Drop the four steel balls (19) in the four counterbored holes at each end of the seal
grooves.
Lubricate seals (18) and insert in seal grooves in control chamber (17).
The tapered side of the seals must be pushed into the grooves and the ends must cover
the steel balls.
Install the control chamber (17) with seal (18) and steel balls (19) assembled over the
control vane (23). The seal must be against the cam. Rotate the chamber until it passes
over the control vane assembly, then rotate in the opposite direction until the 1/4" dowel
pins (16) can be pushed through the chamber (17) and into the cradle (20). Install cham-
ber in the same manner on the other side of the cam.
Two sets of chamber covers are available. The set marked CW must be installed in the
right hand rotation pump and the set marked CCW must be used in the left hand rota-
tion pump. (Rotation is determined facing the shaft end of pump.) The covers must be
installed with the tubing holes and the tapped holes at the top of the unit. Install cham-
ber covers (15r) and (15l) on the control chambers (17) over the dowel pins (16). The
tapped holes must be at the top. Refer to the “T” marked on the rocker cam (24) and cra-
dle (20).
Install four 1/4-20 screws, two (11) and two (12), in each side and torque to 10 ft.-lbs.
(13.56 Nm)
Install two 7/16-14 screws (10) in each side and torque to 45 ft.-lbs. (61.0 Nm)
16
ASSEMBLY PROCEDURES
ROCKER CAM Install tubes (25) in reamed holes in each cover. These tubes must be a tight fit. If tubes
(continued) are loose, the ends can be expanded with a tapered punch.
Install servo plate with the end of the screws (6) through the servo stem. The orifice
screw end of the servo stem must be against the servo plate.
Position the stem and plate on the rocker cam input side at 9 o’clock position on “B” suf-
fix or 3 o’clock on “A” suffix models with the screws positioned over the 10-24 tapped
holes. Torque the screws (6) to 40 in. lbs. (4.5 Nm). Install setscrews (6a) and torque to
5 ft.-lbs. (6.8 Nm). Caution: The set screws must not protrude from the servo plate.
Install creep plate (5) over center post on rocker cam with small O.D. of plate turned
toward cam.
PISTONS AND SHOES See figure 3. Insert the seven piston and shoes (4b) in the shoe retainer (4a). Position
the assembly (4) over the center post and against the creep plate.
MOUNTING, FLANGE, CAM & Five different retaining rings (1) are available for the holddown assembly. Each ring is
CRADLE, BARREL marked; white dot .087 (2.21 mm) thick, blue dot .085 (2.16 mm) thick, yellow dot .083
(2.11 mm) thick, green dot .081 (2.06 mm) thick, and red dot .079 (2.01 mm) thick. Install
the thickest ring (1) with the dot up, that will fit in the groove on the center post and allows
a maximum clearance of .002-.004 (.051-.102 mm) between the shoe and creep plate
while grasping one piston and lifting tightly against shoe retainer.
The piston and shoe assembly (4) must be free to rotate easily by hand. The assembly
must be rotated through 360° to confirm there is no binding and that each shoe is always
free in the retainer plate. Oil the assembly thoroughly.
Position the cradle and cam assembly with the piston and shoe assembly attached with
T marked on the cradle turned up.
See figure 4. Insert tube line assemblies (3 and 4) in the holes provided in cradle.
Note: Tube assemblies (3 & 4, fig. 4) must be a snug fit into holes in cradle. Expand end
of tubes with a pointed tool to assure fit.
Position the mounting flange (7) with the large open end up, and install two dowel pins
(6) in the cradle mounting surface of the flange and two dowel pins (6) in the outer edge
of the flange.
See
Fig. 3 Install rocker cam and cradle assembly over the two dowel pins (6) in the mounting
flange. Be certain that cradle is seated over the pins and against the flange with the tube
lines (3) and (4) in the grooves in the flange.
Position the mounting flange with the rocker cam assembly installed on the top or bottom
side and install two or more 1/4-20 x 1-1/4" screws through the seal retainer area into the
cradle. Be certain the cradle is fully seated in flange. These screws are required to hold
the rocker cam assembly in place and will be removed later.
Return the assembly to an upright position with the mounting flange down.
Position the Barrel Assembly with Auxiliary Shaft (1) directly over the pistons. Start with
the uppermost piston and guide them one at a time into the barrel. Return the rocker cam
to a level position in the cradle.
Figure 4
17
ASSEMBLY PROCEDURES
HOUSING See figure 5. Position housing (1) on a clean flat surface with the large open end up.
S13-42335
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clear oil and protected from nicks or surface damage.
2
Clean housing, item #1, and barrel bearing, item #2. Apply loctite primer grade "T" & loc-
tite retaining compound #609 to bearing O.D. & bearing bore of housing. Rest housing
on mounting flange end.
Position notch on bearing (2) with hole in housing bore. Insert Pressing Plug tool (figure
Drive 1
T-4) in the bearing. With smooth and steady force, press the bearing into the housing
Shaft Right bore until seated. DO NOT HAMMER OR BEAT INTO PLACE.
End Side
Install bearing retainer (7) with O-ring (8). Torque to 50 lb.-ft. (68 Nm).
Bottom
3
Turn housing (1) on side and install roll pin (4) in the 1/4" through hole in the control cover
4 pad. The pin must be 3/8" below the pad surface. THE PIN END MUST NOT INTER-
FERE WITH THE INTERNAL BEARING CAGE. Install two dowel pins (3) in the blind
Left
holes in the same pad.
HOUSING, END CAP, CAM See figure 6. Insert the three face plate pins (1) in the holes provided in the barrel face.
AND BARREL
Apply heavy grease to the face of the barrel and install the face plate (2) over the pins
(1) in the barrel.
Make certain the face plate is properly seated on the barrel and pins with the steel
side towards the barrel face. The face plates have only one side bronzed and this
should be toward the port plate. If necessary, remove coating from edge of face plate
to determine bronze side.
Install gasket (3) over the two dowel pins (item 6 on Fig. 4) in the mounting flange.
Position the Housing Assembly (4) over the Barrel and Auxiliary Shaft Assembly and
carefully guide the pressure tubes and tube lines (items 2, 3 and 4 on Fig. 4) through the
Housing Assembly (4).
*Note: item 2: (Ref. only) Arcuate port width: 6 in3 is 13/32" (10,3 mm), 8.0 & 7.25 in3 is
1/2" (12.7 mm)
See
Fig. 4
Figure 6
18
ASSEMBLY PROCEDURES
PORT BLOCK See figure 7. Position the port block (1) on a clean flat surface with the two open ports up.
THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED. Position needle
bearing (2) on tool (Figure T-5) with the marked end of the bearing against the shoulder on
the tool and press the bearing (2) into the port block. The bearing must be .010-.025" (.254-
.635 mm) below the surface.
Slip check ring (3) into the two 1.50" (38 mm) ports and align holes in the ring with the
side holes in the port wall.
Place lock washers (6) on special screws (5). Insert (5) through port wall and drilled holes
in checks (3) and thread into clamps (4). Torque to 10 ft. lbs. (13.56 Nm).
Thread two check valve assemblies (7) into valve face of port block.
Figure 7 Place O-ring (10) on hollow hex plug (9) and thread into tapped hole in top of the port
block.
MOUNTING PORT See figure 8 on next page. Position the pump with the unplugged hole (top drainport) in
BLOCK TO HOUSING the housing assembly at 12 o'clock position.
Install the two special pins (3) in the face of the port block assembly. Apply petroleum jelly
or heavy grease to the plate (4) and position port plate over the pins (3) on the port block.
Port plate must be fully seated and indexed towards direction of rotation. (See port plate
view in figure 8.)
Slide the port block assembly and port plate over the end of the auxiliary shaft. Be cer-
tain that tubes 2, 3 and 4 shown on Fig. 4 are engaged and that the port plate (4) is still
on the pins (3).
When the pump is properly assembled, the valve mounting surface will be at the top of
the unit.
Install the four bolts (1), and torque to 225 ft.-lbs. (305 Nm). Caution: Use care to prevent
damage to the valve mounting surface while installing and torquing the two top bolts.
19
ASSEMBLY PROCEDURES
MOUNTING PORT
BLOCK TO HOUSING
(continued)
Rear View –
Width of Arcuate Ports
6 in.3 is 13/32" (10,3 mm)
7.25 and 8.0 in.3 is 1/2 (12,7 mm)
Figure 8
15
16 13
14
GEROTOR IN POSITION FOR RH ROTATION
Figure 9
GEROTOR AND BARREL See figure 9. Position the unit with the shaft in a horizontal position and the valve block
HOLDDOWN mounting surface turned up. Rotate the shaft until the small keyway in the auxiliary shaft
is at 12 o’clock.
If pump is being assembled for right hand rotation install dowel pin (4) in hole in port
block at the 9 o’clock position; if left hand pump, install at 3 o’clock position when view-
ing from port block end of unit.
Install side plate (1), steel side first, over dowel pin. Insert key (2) in shaft keyway. Install
the inner gear of the gerotor assembly (3b) on the shaft and over the key (2). Install the
eccentric ring (3a) on the dowel pin (4). Install the large outer gear of the gerotor assem-
bly (3b) inside the eccentric ring (3a) and over the inner gear.
Note: When changing pump rotation consult parts list for proper side plate.
Place O-rings (7) and (8) on side plate assembly. Lubricate the O-rings and slip the pres-
sure plate (9) over the O-rings on the side plate assembly. Slip the two plates over the
auxiliary shaft and position the gerotor side plate over the dowel pin (4).
Place seal ring (12) on auxiliary shaft. Position bearing (11) between the two thrust wash-
ers (10) and install around the seal ring (12). Install insert (15) over spline on shaft.
Thread holddown nut (13) on the shaft and tighten no more than 10 ft. lbs. (13.56 Nm)
max. Back off the nut (13) until second slot is aligned with pin hole in the shaft. Insert pin
(14) through nut and shaft and secure with ring (16).
Check the main shaft for smooth rotation. If not smooth, check the gerotor parts for posi-
tion and hold down nut for proper adjustment.
20
ASSEMBLY PROCEDURES
Lubricate the four orifice plugs (12) and insert in the top of valve block (11).
Check the pilot valve assembly (41) to be certain that approximately 1-1/2 threads are
exposed from this small nut on the bottom of the valve assembly. This setting will allow
the valve to function at about 200 PSI (14 bar). Each complete right hand turn of this
screw will increase the pressure about 50 PSI (3.4 bar). Torque hex lock nut to 20-25 in.
lbs. (2.26 to 2.82 Nm). Thread the check valve (41) into the 3/8-24 tapped hole into the
valve block (11) as shown.
Press the two dowel pins (10) into the holes provided in the bottom of the valve block
(11). The pins (10) must be .12" (.3 mm) below the surface.
Place the two sequence seats (8) in the sequence ports (SB, SA). Place the four valve
seats (9) in the ports marked RB, RA, RV and servo. Position the gasket (7) and retain-
er plate (6) over the seats and insert the four screws (4) in the block (11). Torque to 10
in.-lbs. (1.1 Nm).
Position the valve block and the attached parts with four orifices (12) turned up. Insert the
two 1-7/16 long springs (17) in the two sequence poppets (13) and install (13) and(17)
in the block and over the sequence seats (18) in ports SB and SA. Install the four valve
poppets (14) in the ports marked RB, RA,RV and servo. Servo and RV seats to seated
with grooved side down. Insert spring retainer (15), large end first, in the servo poppet.
Insert the light weight spring (18) 1-9/16" (39.7 mm) long in the RV poppet. Insert the
three 1" (25.4 mm) long springs (16) in poppets RB, RA and servo.
Lubricate the two check valves (19) and install in sides of cover (21).
Lubricate O-ring (22) and place on seat (23) and install in valve cover (21). Use a 1/2" 6
point 1/4" drive socket and torque to 15 ft-lbs. ((20.4 Nm). Do not use impact wrench.
Lubricate O-rings (26) and (28) and place on parts (27) and (29). Assemble parts 30, and
33 on (31) and start (31) into housing (29). Push seal piston (27) and O-ring (26) into
housing (29) with the small end of the piston exposed. Place spring (25) on cone (24) and
insert all these parts in the valve cover (21). Be certain that cone (24) enters seat (23).
Disassemble the strainer assembly (34) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in. (1.47 Nm).
21 Revised
ASSEMBLY PROCEDURES
VALVE BLOCK Lubricate O-rings 37. Install (37) in the block (11).
before 7-93 (continued)
Position the cover (21) over the springs and poppets and install the four screws (39). BE
CERTAIN THAT THE SPRINGS ARE IN THE RIGHT POSITION BEFORE TIGHTENING
THE SCREWS.
Install dowel pin or roller pin (40) in the hole over the servo poppet. Lubricate the four
O-rings (42) and place on the four plugs (43). Install the four plugs. Lubricate O-ring (35)
and place on plug (36) and install.
Caution: Use of other than SAE plugs will result in malfunction and possible pump
damage
Invert the complete assembly and install roll pins (5) thru plate (6) and into the valve
block. Install O-rings (2) and (3) in the plate (6).
22
ASSEMBLY PROCEDURES
Valve Block
(Before 7-93)
S23-00904
Figure 10
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two roll pins
(46) in position. (Roll pins to be .12" (3.04 mm) below surface of valve block).
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve block. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque #6-32 screw to 13 lb-in (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve block.
23
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
after 7-93 (continued) Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
groove side facing up, over poppets.
Place spring (32) 1.56" long (39.6 mm) into bore next to compensator valve side of block.
Install replenish poppet over spring. Position seat (28) with the groove side facing down,
over poppet.
Insert spring (35) 1.09" long (27.7 mm) into the remaining bore. Place spring retainer (34)
in spring. Place servo poppet (31) over the retainer and spring. Position seat (28) with
the groove side facing down, over poppet.
Carefully position the retainer plate over seats and poppets. Pressing with one hand on
the valve block, compress seats, poppets and springs far enough to alternately thread
two button head cap screws (43) in far enough to hold the retainer plate. Install the other
two screws and alternately tighten screws. Torque to 30 lb-in. (3.39 Nm).
Lubricate O-ring (4) and install on to seat (5), thread seat in valve block. (Be careful not
to damage bore in the seat.) Torque to 15 lb-ft (20.34 Nm).
Apply vaseline to shank of cone (13) and install spring (12) on cone. Carefully insert cone
and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11) install in groove of piston (10) and insert end into spring (12).
Lubricate O-ring (9) and install on housing guide (8) and thread into valve block. Tighten
in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring.
Using a small bladed screw driver, thread the pilot replenishing relief valve assembly (36)
into valve block and lightly tighten in place. (Do not over tighten. Over tightening can
cause sides of slot to break now or at next removal.)
Lubricate O-ring (4) and install on plug (25) and tighten plug in place.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tighten.)
Lubricate O-ring (22) and install on plug (23) and tighten in place.
Lubricate O-ring (19) and install on plug (20) and tighten plug in place.
Install pin (21). Lubricate O-ring (22) and install over plug (23) and tighten plug in place.
Lubricate O-ring (4) and install on plug (25) and tighten in place.
Lubricate two O-rings (22) and install over two plugs (25) and tighten in place.
Using a small hammer carefully tap roll pins (46) into and thru the retainer plate (42), the
pins should bottom out in hole leaving enough length sticking out for piloting into the port
block.
Lubricate O-ring (47), (48) and (37) and install in the bottom of retainer plate (42).
24
ASSEMBLY PROCEDURES
Valve Block
(After 7-93)
S23-12770
Seal Kit
S23-00135
Figure 11
25
ASSEMBLY PROCEDURES
26
ASSEMBLY PROCEDURES
VALVE BLOCK
for special mounting of servo valve
(before 7-93)
S23-11433
Figure 12
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on valve
block and retainer. Must have 60 rms finish with no grinding marks which might carry oil
to outside surface. If lapping is necessary, check depth of pockets for valve seats after
lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clearance for valve
seats.
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (25) with O-ring groove down and horizontal in order to press two roll
pins (26) in position. (Roll pins need to be .12" (3.05 mm) below surface of valve block).
Apply a liberal amount of vaseline or grease to the six counterbores in the face of the valve
block (25). Install two valve seats (27) tapered bore side first, into counterbores and
against roll pin (26), one required each end, (outer-most counterbores in block). Insert the
valve seats (28) and valve seat (44) in remaining counterbores as shown.
Press two roll pins (46) into retainer plate (42). Each roll pin should stick out approximately
.25" (6.35 mm) from each face of the retainer plate.
27
ASSEMBLY PROCEDURES
VALVE BLOCK Position valve block gasket (29) on valve block. Take care that none of the gasket is cov-
for special mounting of servo valve ering the valve seats.
before 7-93 (continued) a. Position retainer plate (42) with O-ring grooves facing up, over valve block gasket.
Install four button-head cap screws (43), torque to 30 in.-lbs. (3.39 Nm).
b.Turn the assembly over so that it is resting with the retainer plate O-ring side down-
ward.
Place spring (33) (1.43" long) (36.3 mm) into poppet (30) and insert small hole end first
into outer-most bores at each end of the valve block (25).
Insert three poppets (31) and one poppet (34) in remaining bores as shown, small diam-
eter end first.
Insert two springs (35) (1.09" long) (27.7 mm) into remaining outer poppets (31).
Install spring (32) 1.56" long (39.6 mm) into remaining poppet located in center of valve
block.
Install four orifice plugs (3) in valve block (25) and tighten in place.
Thread pilot replenishing relief valve (36) into block (25). Valve must not extend below
lower surface of retainer plate.
Place O-ring (4) onto seat (5) and install in valve block cover (1). (Be careful not to dam-
age bore in seat.) Torque (5) to 15 ft.-lbs. (20.4 Nm). (Do not use impact wrench).
Lubricate O-ring (11) and insert into groove of seal piston (10) and slip spring (12) onto
end of seal piston and press into bore of housing guide (8).
c. Align cone with seat in valve cover and thread housing guide into bore and tighten
in place.
Thread nut (7) on soc. setscrew (6) and thread into housing guide (8) until it starts to
compress spring. Thread acorn nut (45) on soc. setscrew (6).
Coat check valve (2) threads with loctite removable thread locker #242 and thread into
end of valve cover (1). (Be sure check valve is properly installed and does not block pas-
sages from orifice plug (3). Lubricate O-ring (22) and install on plug (23) and tighten.
Repeat above step at the opposite end of the valve cover (1).
Disassemble the strainer assembly (14) in valve block and reassemble per the following:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 in.-lbs. (2.6 Nm).
b. Install the strainer support, filter screen and #6-32 x 1/4 lg. screw. Torque #6-32
screw to 13 in.-lbs. (1.47 Nm).
Place O-ring (37) and two (2) O-rings (47) into the grooves on the upper surface of the
valve block and secure with vaseline or grease.
Place valve cover (1) over valve block (25) positioning over springs (33), (32) and (35)
and secure in place with four (4) socket hd. cap screws (41).
Lubricate O-ring (22) and install on plug (23) and tighten in place.
Lubricate O-ring (19) and install over plug (20) and tighten plug in place.
Lubricate O-rings (47) and install in underside of manifold block (15). Carefully, place
manifold block (15) on top of the valve cover (1) making sure the O-rings are correctly
seated. Secure with four (4) soc. hd. cap screws (41) by threading into valve block (25).
Insert spring (16) and spool (38) into manifold (15) with the spring guide and spring
towards the left side of the manifold (15) when viewing from the top rear.
Install temporary plugs (49) and (50) in 1/2" tube and 1/4" tube ports, front and back and
side. Insert O-ring (19) and plug (20) in alternate drain port.
28
ASSEMBLY PROCEDURES
29
ASSEMBLY PROCEDURES
VALVE BLOCK
for special mounting of servo valve
(after 7-93)
S23-12776
Figure 13
See figure 13.
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two roll pins
(46) in position. (Roll pins to be .12" (3.04 mm) below surface of valve block).
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve block. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve block.
Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
30
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
for special mounting of servo valve step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
groove side facing up, over poppets.
after 7-93 (continued)
Place spring (32) 1.56" (39.6 mm) into bore next to com-pensator valve side of block.
Install replenish poppet over spring. Position seat (28) with the groove side facing down,
over poppet.
Insert spring (33) 1.43" (36.3 mm) into the remaining bore. Place servo poppet (37) over
the retainer and spring. Position seat (44) with the tapered bore facing down, over poppet.
Carefully position the retainer plate over seats and poppets. Pressing with one hand on
the valve block, compress seats, poppets and springs far enough to alternately thread
two button head cap screws (43) in far enough to hold the retainer plate. Install the other
two screws and alternately tighten screws. Torque to 30 lb-in. (3.39 Nm).
Lubricate O-ring (4) and install on to seat (5), thread seat in valve block. (Be careful not
to damage bore in the seat.) Torque to 15 lb-ft (20.34 Nm).
Apply vaseline to shank of cone (13) and install spring (12) on cone. Carefully insert cone
and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11) install in groove of piston (10) and insert end of piston into spring
(12).Lubricate O-ring (9) and install on housing guide (8) and thread into valve block.
Tighten in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring.
Using a small bladed screw driver, thread the pilot replenishing relief valve assembly (36)
into valve block and lightly tighten in place. (Do not over tighten. Over tightening can
cause sides of slot to break now or at next removal.)
Lubricate O-ring (4) install on plug (25) and tighten plug in place.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tighten.)
Lubricate O-ring (22) install on plug (23) and tighten in place.
Lubricate O-ring (19) install on plug (20) and tighten plug in place.
Lubricate O-rings (22) install over plugs (23) and tighten plugs in place.
Lubricate O-ring (19) install over plug (20) and tighten in place.
Lubricate O-rings (47) and install in underside of manifold block (15). Carefully, place
manifold block (15) on top of the valve cover (1) making sure the O-rings are correctly
seated. Secure with four (4) soc. hd. cap screws (41) by threading into valve block (25).
Insert spring (16) and spool (38) into manifold (15) with the spring guide and spring
towards the left side of the manifold (15) when viewing from the top rear. Install orifice
plug (61) in manifold (15).
Install temporary plug, (50) in 1/4" tube port. Insert O-ring (19) and plug (20) in alternate
drain port.
Using a small hammer carefully tap roll pins (46) into and thru the retainer plate (42), the
pins should bottom out in hole leaving enough length sticking out for piloting into the port
block.
Lubricate O-ring (47), (48) and (37) and install in the bottom of retainer plate (42).
31
ASSEMBLY PROCEDURES
32
ASSEMBLY PROCEDURES
33 Revised
ASSEMBLY PROCEDURES
Valve Block
See Fig.
10, 11,
12, 13
21
20
22
24
23 Figure 14
SHAFT AND SEAL INSTALLATION See figure 14. Stand the pump in an upright position with the port block inlet and outlet
pads turned down.
Install the shaft and bearing (1) assembly in the mounting flange and cradle. Be certain
that there are no burrs or sharp edges on shaft seal area of the shaft.
For a rigid shaft application use the shim (2) that results in least clearance around the
shaft bearing. Do not use a shim with a floating shaft.
Install the snap ring (3) in the mounting flange to retain the Shaft Assembly. Be certain
that the ring is fully seated in the groove. Use the ring that results in the tightest fit.
Warning: When installing a new mechanical shaft seal, exercise care to insure that
all of the parts fit together properly. This is particularly important if the seal was once
assembled and disassembled for some reason. If the rubber boot, item 4, grips the
shaft and doesn't slide on the shaft, as it is disassembled, then the spring, item 7, can
disengage the shell, item 5, from the band, item 6, so that they do not re-engage
properly when reassembled. Be sure the shell and the band are properly engaged
before reassembling the seal, and stays engaged during assembly.
Note: Lubricate seal and shaft with clean hydraulic fluid of the same type that will be
used in the system.
34
ASSEMBLY PROCEDURES
See figure 14. The seal assembly (4) is available as a complete unit only.
Caution: Before installing the seal assembly examine all the parts. The lapped seal
seat and the carbon ring have a precision finish that must be handled with care. Be
certain that both parts are free of scratches, marks and cracks.
Place the spring retainer (e) over the shaft and against the retaining ring on the shaft
assembly. Place the spring (d) against the retainer (e). Apply grease to the inner surface
of the rubber friction ring (f) and position the shell containing the rubber friction ring (f)
and carbon ring (c) over the shaft with the carbon ring exposed. Apply grease to the
square section rubber seal (a) and install on the ceramic seat (b). Insert the seat and seal
in the seal retainer (6) with the lapped side of the seat in position to contact the carbon
ring. Place the seal retainer assembly and O-ring (5) over the shaft with the lapped sur-
face against the carbon face. Place the four gaskets (7) on the four screws (8) and insert
the seal retainer (6). Depress the seal retainer only far enough to start the four screws
and tighten evenly. Torque to 10 ft.-lbs. (13.56 Nm).
Note: Seal installation must be completed quickly to avoid the rubber friction ring from
seizing on the shaft.
COUNTER-BALANCE SERVO Place the two spacers (11) on the two screws (12) and insert through the balance plate
STEM (10) and servo stem (9).
Insert these parts through the opening in the side of the housing assembly and position
the screws over the two #10-24 tapped holes in the rocker cam.
Hold these parts against the cam and alternately tighten the screws (12) to hold the
assembly firmly in place. Torque screws to 5 ft.-lbs. (6.78 Nm)
REAR DRIVE ADAPTER See figure 15. Place wave spring, (8) over isolation tube (4). Lube O-ring (7) and assem-
ble to isolation tube. Place isolation tube against pressure plate, item (9) Fig. 9.
Lube tetraseals (10). Insert into adapter block and carefully assemble adapter block to
port block. Using screws (9) and washers (12) to hold adapter block in place, torque to
150 ft-lbs. (203 Nm).
Coupling (2) with coupling insert (3) and retaining ring (6) may be installed to end of aux-
iliary shaft when external pump is mounted.
Adapter
Figure 15
35
ASSEMBLY PROCEDURES
36 Revised
ASSEMBLY PROCEDURES
Figure 16
PILOT VALVE See figure 16. Insert seat (2-8) into cap (2-3) and seat in bottom of bore.
Install small end first of block (2-7) into bore and against seat.
Install spacer (2-5) and secure in place with set screw (2-4).
Install spring (2-11) onto cone (2-9) . Install spring (2-10) over spring (2-11), and insert into
cap (2-3) and seat (2-8).
Install O-ring (2-14) in piston (2-13) and insert small end into springs.
Install plug (2-15), screw (2-17) & nut (2-16). Set per requirement and cover with acorn
nut. (2-18).
If externally drained, insert plug (2-19) into hole on spring end of cap.
If internally drained, insert plug (2-20) and O-ring (2-19) in cap drain port.
SHUTTLE VALVE See figure 16. Lube spool (3) and insert it into valve body (1). When the spool is fully
engaged, move the spool back and forth a few times to check for smooth operation. Spool
must move freely in body bore.
Install spring stop (4) into one end of valve body (1). Make sure it is seated properly.
Insert spring (8) into valve body (1) over the spool (3). Install plug (12) & O-ring (15) into
the valve body (1).
Lube O-ring (9) and install into valve body (1). Make sure it fits exactly.
Lube O-ring (9) and place over the sleeve (5) and install into bore of valve body (1). Be
careful not to jam sleeve in bore.
37
ASSEMBLY PROCEDURES
SHUTTLE VALVE Insert piston (6) into sleeve (5) and place spring (7) into piston (6).
(continued)
Lube O-ring (10) and place onto the sleeve (5).
Mount pilot valve cap sub-assembly (2) onto shuttle block (1). Use three S.H.C. screws
(14) and the one screw which comes with the pilot valve sub-assembly. Make sure that
the screw that comes with the valve cap sub-assembly is positioned on end closest to
acorn nut. Torque to 50 ft-lbs. (68 Nm) Run lead wire which comes with valve cap sub-
assembly through holes in special screw and acorn nut. Twist ends together.
SHUTTLE VALVE MOUNTING Lubricate tetraseals (11) figure 16 and place in C' bores of shuttle valve mounting surface.
Carefully attach shuttle valve to adapter (22) fig. 14, using hex hd. screws (13) figure 16.
Torque to 75 lb-ft. (102 Nm).
38
IMPORTANT INSTRUCTIONS
INSTRUCTIONS FOR CAUTION: The isolation plug enclosed is to be used ONLY if an external filter circuit
REPLENISHING CIRCUIT is provided. DO NOT operate this unit with the isolation plug installed unless an exter-
ISOLATION PLUG nal line has been provided.
When the external filter circuit IS NOT used discard the isolation plug.
When the external filter circuit IS used install the isolation plug between port G and H
(refer to appropriate installation drawing): use a 3/16 Hex. wrench by 4" minimum length
INSERTING THE ISOLATION PLUG INTO PORT H and tighten to 80 - 120 in.-lb. torque.
(9.04-13.56 Nm)
Isolation plug: Part No. 311-45032 (3/8-16 x 1/2 UNC Flat point set screw).
39
HYDRAULIC CIRCUIT
40 Revised
HYDRAULIC CIRCUIT
41 Revised
TEST PROCEDURES
GENERAL REQUIREMENTS 1. Maximum runout between pump shaft and electric motor shaft .003 (.076 mm) T.I.R.
A floating shaft must have a support in mounting bracket. A fixed shaft should not have
a support bearing in mounting bracket.
4. Inlet condition Main Pump 100 to 150 PSI. (6.9 to 10.3 bar)
Gerotor 10" HG to 5 PSI. (25.4 mm HG to .34 bar)
BASIC PUMP TEST 1. Mount pump on test stand. Connect system lines and gerotor inlet line to pump.
Connect case drain line to flowmeter. Connect shuttle return line to reservoir. If shuttle
pilot valve is externally drained, connect drain to max. 5 PSI (.34 bar) return line. If an
auxiliary pump is mounted, connect auxiliary pump inlet to reservoir. If auxiliary pump is
not mounted, remove coupling and seal auxiliary unit mounting surface.
3. Rotate pump input control shaft. The servo control should control pump displacement
through its full range. Set pump displacement for full volume, and adjust system pressure
for 1000 PSI (69 bar). Check and record system flow and case drain flow above and below
center.
4. Back out compensator adjusting screw until unit is fully compensated (count number
of turns). Observe volume indicator and stroke rotary servo input shaft from full to full
position on each side of center. Indicator should remain on or very near zero position
("O"). If compensator functions normally, return compensator adjusting screw to its orig-
inal position and proceed with Step 5.
5. Cycle pump at 10 sec. intervals-full volume above center to full volume below
center*—as follows:
5 minutes at 1000 PSI (69 bar)
3 minutes at 2500 PSI (172 bar)
3 minutes at 3500 PSI (241 bar)
2 minutes at 5000 PSI (345 bar)
6. Adjust system pressure to 5000 PSI (345 bar) and set pump displacement for full vol-
ume. Check and record system flow and case drain flow above and below center.
7. Set pump to compensate at 5000 PSI (345 bar). Servo pressure should be at least
650 PSI (45.5 bar). Check and record replenishing flow. (Case leakage flow).
Maximum flow-14.6 GPM (55.3 l/m) with Barnes auxiliary pump. 6.5 GPM (24.6 l/m)
without auxiliary pump.
8. Set pump to compensate at minimum PSI. Check and record replenishing and servo
pressure.
Servo pressure-Minus Case Pressure 455 to 570 PSI (31.3 to 39.3 bar).
Repl. pressure-Minus Case Pressure 350 PSI ± 20 PSI (24.1 ± 1.4 bar).
42
TEST PROCEDURES
BASIC PUMP TEST If pressures are incorrect, remove replenishing relief valve pilot and increase or decrease
pressure as required. (One full turn on adj. screw will cause pressure to change approx-
(continued)
imately 50 PSI) (3.4 bar). Re-torque locknut to 20-25 in-lbs. (2.3-2.8 Nm).
Note: There is no servo relief valve adjustment. Increasing or decreasing repl. pres-
sure will cause both servo and repl. pressure to change by the same amount.
9. Set pump to full displacement and set the test stand relief valve at approx. 2000 PSI
(138 bar). Set the pump compensator at 1000 PSI (69 bar). Set the shuttle relief valve
pilot cap to 220 ± 20 PSI (15.2 ± 1.4 bar) above case pressure and secure with locknut
and acorn nut.
10. Stroke pump to center position and observe repl. pressure. It should rise to the value
in step 8 above.
11. Slowly cycle the pump across center several times while observing repl. pressure
drops to 220 ± 20 PSI (15.2 ±1.4 bar) while on stroke, and rises to 350 ± 20 PSI (24.1 ±
1.4 bar) at zero stroke, to verify shuttle operation.
12. Set pump to compensate at 5000 PSI (345 bar). Record repl. and servo pressure.
13. Set pump to compensate at minumum PSI. Servo pressure should return to 455 to
570 PSI (3.3 to 39.3 bar).
Note: After completing step 13, proceed with pump control test and adjustment. Refer
to the goldcup control manual #S1-AM030 for your control type. Continue with step
14 after testing controls.
14. Adjust pump displacement for full volume and adjust system pressure to 6000 PSI
(413.8 bar).**Adjust compensator from 6000 PSI to 3000 PSI (413.8 to 206.9 bar) to min-
imum pressure. At each pressure, stroke rotary servo input shaft to the full position on
each side of center. Cam indicator should remain on or very near the zero position with
no oscillation. System pressure should not vary from Port "A" to Port "B" more than 150
PSI (10.3 bar) and not oscillate.
**Caution: DO NOT hold pump at 6000 PSI (413.8 bar) for longer than one minute at
any time. This is only an intermittent pressure rating.
15. Set compensator for 1000 PSI (69 bar) when fully compensated, UNLESS OTHER-
WISE SPECIFIED. Increase and decrease system pressure above and below compensa-
tor setting. When system pressure is above compensator setting, the pump should de-
stroke and not oscillate. When the system pressure is below the compensator setting, the
pump should stroke to full volume.
43
ORDERING CODE
Pump series
Displacements, Max.
6 = 6.0 in3/rev., 98 cc/rev.
7 = 7.25 in3/rev., 119 cc/rev.
8 = 8.0 in3/rev., 131 cc/rev.
Pump type
S = closed circuit, with shuttle valve
Shaft
SAE = C
2 = keyed
3 = spline
Rotation, shaft
viewed from shaft end
R = clockwise
L = counter-clockwise
Fluid class
1 = compatible w/Buna N
4 = compatible w/EPR
5 = compatible w/Viton
Designates special
44 Revised
NOTES
45
NOTES
46
NOTES
47
SALES AND SERVICE WORLDWIDE
Internet: http://www.denisonhydraulics.com
E-mail: [email protected]
900 PUMP CONTROL
DENISON HYDRAULICS
controls for
goldcup pumps & motors series 6. . .30
service information
valve block
"B" side
control
mounting
"A" side
control
mounting
rotation
viewed from shaft end
P 6 P -2 R 1 C -4 A 2 -A -00 -B 1 -M-XXXXX
Pump series Control Feature
500 Control
Primary Controls 00-with deadband
1-Screw Adjustment 01-without deadband
2-Cylinder Control
4-Rotary Servo (spring centered w/trimmer) 600 Control
5-Electrohydraulic Stroker 00-75-350 PSI (5-24 bar)
6-Hydraulic Stroker 01-75-435 PSI (5-30 bar)
7-Servovalve & Feedback Device 02-100-380 PSI (7-26 bar)
8-Proportional Hydraulic Stroker 03-150-400 PSI (10.3-27.6 bar)
9-Electrohydraulic Stroker
(All include rotary servo, pressure compensator 700 Control
override & displ. indicator) 00-w/o manual override shut-off
01-w/manual override shut-off
Primary Control Options
0-None 800 Control
A-Adjustable maximum volume stops 00-75-350 PSI (5-24 bar)
B-Automatic brake control 01-75-435 PSI (5-30 bar)
C-A & B above, together 02-100-380 PSI (7-26 bar)
D-10 GPM Servovalve w/feedback potentiometer 03-150-400 PSI (10.3-27.6 bar)
E-10 GPM Servovalve w/feedback RVDT 04-75-250 PSI (5-17 bar)
F-10 GPM Servovalve w/pot. & manual override
w/4A2 Control 900 Control
G-10 GPM Servovalve w/RVDT & manual override 00-24 VDC
w/4A2 Control 01-12 VDC
H-3 pos (Spring centered w/trimmer) ALL OTHER CONTROLS USE 00
M 6 H -2 N 1 C -2 A 0 -A -00 -M-XXXXX
Motor series Control Feature
500 Control
Primary Controls 1-without deadband
2-Cylinder with adjustable maximum & minimum stops
5-Electrohydraulic Stroker 600 Control
6-Hydraulic Stroker 0-170-350 PSI (11.7-24.1 bar)
8-Proportional Hydraulic Stroker 1-200-450 PSI (17.2-31 bar)
9-Electrohydraulic Stroker (without deadband) 2-150-380 PSI (10.3-26.2 bar)
(All include rotary servo stem and displacement indicator) 3-75-250 PSI (5-17 bar)
Control Location
A-Command on Port A side
B-Command on Port B side
4
GOLDCUP CONTROLS CHARACTERISTICS
*5A, 5C CONTROLS
*Note: If the driver uses Pulse Width Modulation, (PWM) the frequency must be 2000 Hz. or higher to avoid erratic operation.
Water Glycol, Phosphate Ester (including Skydrol), and Invert emulsions cannot be used with 5A and 5C controls.
5
GOLDCUP CONTROLS CHARACTERISTICS
6A MOTOR CONTROLS
Feature Control press. Control press. Max. hysteresis @ Max. hysteresis @
max. displacement min. displacement max. displacement min. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
0- 155-185 (10.7-12.7) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
1- 185-215 (12.8-14.8) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
2- 135-165 (9.3-11.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
3- 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
*With connector terminal B at +15 Volts, terminal D at - 15 Volts. This polarity must be maintained for D.C. RVDT, Polarity is optional
for potentiometer.
8A, 8C PUMP CONTROL
Code Control press. Control press Max. hysteresis @ Max. hysteresis @
min. displacement max. displacement min. displacement max. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
04 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
Torque for manual operation (no control pressure) begin stroke 7.5-20 in. lb. (0.8-2.2 N·m)
Torque for manual operation (no control pressure) end stroke 28-58 in. lb. (3.2-6.5 N·m)
8A MOTOR CONTROL
Code Control press. Control press Max. hysteresis @ Max. hysteresis @
min. displacement max. displacement min. displacement max. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
0* 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
1* 235-265 (16.2-18.3) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
Signal ports SAE - 4
Torque for manual operation (no control pressure) begin stroke 7.5-20 in. lb. (0.8-2.2 N·m)
Torque for manual operation (no control pressure) end stroke 28-58 in. lb. (3.2-6.5 N·m)
*Specifications above are based on using a Jupiter 900 Driver with a 24 VDC supply and set at 120 Hz pulse width modulation.
Performance will vary when other controls are used. 100 to 200 Hz pulse width modulation is recommended.
6
GOLDCUP CONTROLS SERIES 900
9A ELECTRIC STROKER
DESCRIPTION The 9A consists of one or two electric proportional pressure control valves mounted on
the 8A cover to provide the pilot pressure signal. It is a simple electrohydraulic control
with comparable performance to the 5A in most applications. Refer to 8A for stroker
description.
The Jupiter 900 Driver Card has been developed to accompany the 9A control with
24V coil.
ASSEMBLY All parts are to be inspected and be free of material defects, dirt, scratches, or any for-
eign material.
All parts are to be cleaned with a suitable cleaning solvent and all cores and passages
blown out with clean dry compressed air.
After cleaning and inspection, all parts are to be covered with a light film of oil and
should be protected from dirt and excessive handling until assembled onto the unit.
During assembly, lapped and ground surfaces should be kept lubricated and protected
from nicks or surface damage.
1. Apply pipe sealant to the 1/8” pipe plug (12) and install in the cover plate. Torque to
100 lbs-in. (11.3 Nm).
87
GOLDCUP CONTROLS SERIES 900
2. Thread trimmer locknut (22) all the way onto trimmer screw (23). Slip back-up
washer (21), small dia. first, onto trimmer screw and against locknut. Using a 3/4-16
hex nut with a 1.030” (26.2mm) dia. x .030/.035” (0.76/0.89mm) deep c’bore, crimp the
washer onto the stop. Washer must be free to rotate slightly. Remove crimping nut.
See Figure 8A-1 3. Compress spring (4) solid in order to remove spring set. This may be safely
accomplished using a 1/4” (6.35 mm) dia. bolt, nut and washers.
4. Assemble retaining ring (2), guide (3), spring (4) and guide (3) onto spool (1).
5. Tighten nut (7) till it just starts to load the spring, then tighten 2-5/6 additional turns.
6. Install locknut (5) onto spool and lock against nut (7) without changing adjustment.
See Figure 9A 7. Insert spool assembly (11), spring end first, into trimmer screw (23). Compress
snap ring on the spool assembly until it snaps into internal groove inside trimmer
screw. See that it is securely seated.
8. Thread spring stop locknut (24) all the way onto adjusting spring stop (25). Slip
back-up washer (26), small diameter first, onto stop and against locknut. Using a 9/16-
18 hex nut with a .810/.815” (20.6/20.7mm) dia. x .030-.035” (0.76-0.89mm) dp. c’bore,
crimp washer onto stop. Washer must be free to rotate slightly. Remove the crimping
nut.
9. Install O-ring (35) on plug (34) and insert into spring stop (25). Install O-ring (27)
onto stop (25) and against washer (26).
10. Thread adjusting spring stop (25) into trimmer screw (23) until it just touches the
spool assembly. Be sure spool assembly is against snap ring.
11. Determine the correct position of the spool assembly in the valve body. For 9A
standard pump controls, and for 9A motor controls mounted on the “B” port side, the
spool assembly is installed in the side of the control cap containing the 1/8” pipe plug
(12). For controls used on P*R pumps, and motor controls mounted on the “A” port
side, the spool assembly is installed on the side opposite the 1/8” pipe plug (12).
12. Place O-ring (14) on trimmer screw (23) and thread assembly into the cover plate,
as noted above.
13. Install adjusting screw (15) in plug (13). Install O-ring (14) on plug. Thread adjust-
ing screw in until it protrudes approximately 1/2” from top of plug (13). For motor con-
trols, install two nuts (36) on the inner end.
14. Thread cover nut (16) with O-ring (31) onto adjusting screw.
15. Install plug (28) and O-ring (29) into cover nut (16).
16. Install this assembly in body on the opposite side from the spool assembly (11).
17. Install nut (36) on adjusting screw (6). Thread adjusting screw into stop (25).
18. Install roll pins (30) into drilled holes in surface of cover, being careful not to dam-
age surface.
19. Install 0-ring (7) in groove of shear seal (8).
20. Install shear seal with o-ring in large hole on the servo link, on the servo shaft
side. Be certain that the shear seal is sitting with the flange flush against the servo
link surface.
Note: The shear seal will fit in one position only, otherwise one side will be held up
by the lip of the servo link. Shear seal (8) must be installed to face against the cover
plate (10). This shear seal (8) differs from shear seal (18) in that the face surface is
machined with two .094” (2.4mm) radius scallops.
21. Install thrust bearing (9) over servo shaft and seat against the servo link.
22. Slip washer (33) over the servo shaft and against the thrust bearing.
23. Using installation tool T-1, install O-ring (5) in the second groove from the end of
the shaft (1). Warm glyd ring (20) to make it pliable, and install over O-ring (5).
24. Install the servo shaft assembly in the cover plate (10). Pin must engage slot in
spool assembly (11).
25. Install retaining ring (4) into the groove of the servo shaft extending thru the cover
plate.
26. Apply loctite® 271 on threads of screw (43), and on threads of shaft assembly (1).
Assemble nut (44) on screw, insert screw into shaft assembly and turn in snugly. Hold
screw and arm. Torque nut to 14 lb.-ft. (19 Nm).
27. Place two spring washers (17), nested with the bent sections matching each other,
into the large hole in the servo link.
88
GOLDCUP CONTROLS SERIES 900
32. For controls with single valve, install soc. setscrew (54) in the tapped hole furthest
in from the unused opening. Torque to 70 in.-lb. (7.9 Nm). Install plug (53) and O-ring
(55) in the unused opening. Torque to 20 lb.-ft. (27 Nm).
33. Install coil(s) (52) on proportional valve (38). CAUTION! Torque to 20-25 in.-lb.
(2.2-2.8 Nm) max.
34. Install remaining parts.
35. If control is to be tested on unit, install stroker block assembly and control on
pump control pad with O-rings (3, 31, and 45), gasket (19), washers (49) and screws
(2). Torque to 30 Lb.-ft. (40.8 Nm).
9A CONTROL TEST SETUP Remove plug over input shaft. Insert T handle 3/16” Allen wrench into opening.
Connect proportional control driver to proportional valve. Connect pressure gage on
SAE-4 port adjacent to proportional valve or valves.
Rotate wrench handle to check for free play. Turn spring stop adjustment in or out till
it just contacts the spring and there is no free play. Lock in place. Note: this adjust-
ment is critical to accurate neutral adjustment!
9A PUMP TEST 1. Turn trimmer screw to place input shaft on the zero stroke position. Check for posi-
tive centering. Lock in place. For cross-center pumps, set max. volume stops so that
servo shaft link touches stop pins when handle is stroked each side of center. For one
side of center pumps, set max. stop so that servo shaft link touches the stop pin. Set
min stop to prevent crossing over center. Lock stops in place.
2. Apply signal current to one proportional valve. Adjust current from minimum to
maximum. Note the pressure and current value at which pump just starts to stroke,
and at which the pump reaches full stroke These must be within the following values:
3. If control pressure is off the same amount at start and end of stroke, the control
may be disassembled and the spring (Figure 2) readjusted. One flat (1/6 turn) of
adjustment will change the pressure by 4.6 psi (0.31 bar).
4. If the change in pressure from start to end of stroke is incorrect, the spring (Figure
2) is incorrect and must be replaced.
5. If pressures are correct but current is incorrect, then either the coil is incorrect or
the proportional valve is bad.
6. With minimum signal, pump shall return to zero stroke within 200 psi. (13.8 bar)
max.
7. For cross-center pumps, repeat test on opposite side of center.
8. Increase and decrease current between minimum and maximum several times.
Pump stroke should follow control pressure smoothly and proportionally. Full to zero or
zero to full stroke should be achieved in no more than two seconds. Adjust stroke up
to approximately 50% stroke from zero stroke, then adjust down from full stroke to the
same current value. The flow at the two settings shall not vary more than 25%.
9A MOTOR TEST 1. Turn trimmer screw to place input shaft on the full stroke position. Lock in position.
2. Rotate input handle to reduce motor displacement to minimum. CAUTION! do not
exceed motor rated speed! Adjust minimum stop screw to set minimum displacement
at 25% of full displacement. (4 times the rpm at maximum displacement.)
89
GOLDCUP CONTROLS SERIES 900
5. If control pressure is off the same amount at start and end of stroke, the control
may be disassembled and the spring (Figure 2) readjusted. One flat (1/6 turn) of
adjustment will change the pressure by 4.6 psi (0.31 bar).
6. If the change in pressure from start to end of stroke is incorrect, the spring (Figure
2) is incorrect and must be replaced.
7. If pressures are correct but current is incorrect, then either the coil is incorrect or
the proportional valve is bad.
8. With minimum signal, motor shall return to full stroke.
9. Increase and decrease current between minimum and maximum several times.
Motor stroke should follow control pressure smoothly and proportionally. Full to min. or
min. to full stroke should be achieved in no more than two seconds. Adjust stroke
down to approximately 50% stroke from full stroke, then adjust up from 25% stroke to
the same signal. The speed at the two settings shall vary no more than 25%.
10. When control has satisfactorily passed test, remove stop assembly, set and lock
the two nuts on the inside to prevent adjustment below 25% stroke. Re-install stop.
90
GOLDCUP CONTROLS SERIES 900
PARTS LIST
Figure 9A Electric stroker
Feature ➔ 00 00 01 00 0*
Option ➔ P*P, P*S 6R,7R,8R P*P,P*S P*V M*H, M*V
Pump Pump Pump Pump Motor
Assembly No. ➔ S23-12667 S23-12940 S23-12957 S23-12734 S23-15050
S23-12733 S23-15051
ITEM DESCRIPTION PT. NO. QTY. QTY. QTY. QTY. QTY.
1 Servo shaft S23-12267 1 1 1 1 1
2 HHCS 3/8-16 X 3.25” 306-40184 4 4 4 4 4
3 O-ring, 70- S-5 ARP 013 675 00013 9 9 9 9 9
4 Ring, Truarc #5144-50 356-65070 1 1 1 1 1
5 O-ring, 70 S-5 ARP 012 675-00012 5 5 5 5 5
6 HHCS, 5/16-24 X 1” 307-13160 1 1 1 1 -
Setscrew, 5/16-24 X 1.25” 312-13180 - - - - 1
7 O-ring, 70 S-5 ARP 017 675-00017 2 2 2 2 2
8 Shear Seal 033-71371 1 1 1 1 1
9 Bearing 230-82141 1 1 1 1 1
10 Cover-9A 033-91220 1 1 1 1 1
11 Spool Assy (Fig. 8A-1) S23-12956 1 1 1 1 1
12 Flush plug 1/8” 431-90204 1 1 1 1 1
13 SAE plug 033-91027 1 1 1 1 1
14 O-ring, 90 S-5 ARP 908 695-00908 3 3 3 3 3
15 Soc. setscrew, 5/16-24 X 2” 312-35062 1 1 1 1 -
Setscrew, 5/16-24 X 2.50” 312-35063 - - - - 1
16 Nut 033-91033 1 1 1 1 1
17 Finger Spring 350-10067 2 2 2 2 2
18 Shear seal 033-70525 1 1 1 1 1
19 Gasket 033-91058 1 1 1 1 1
20 Glyd ring 679-00004 1 1 1 1 1
21 Washer 350-10139 1 1 1 1 1
22 Nut 033-91115 1 1 1 1 1
23 Center trimmer 033-91028 1 1 1 1 1
24 Locknut 492-15353 1 1 1 1 1
25 Stop 033-91026 1 1 1 1 1
26 Washer 350-10126 1 1 1 1 1
27 O-ring, 90 S-5 ARP 906 695-00906 1 1 1 1 1
28 Plug, Parker 2P5N-S 488-35029 1 1 1 1 1
29 O-ring, 90 S-5 ARP 902 695-00902 1 1 1 1 1
30 Rollpin 3/16 X .75” 325-12120 2 2 2 2 2
31 O-ring, 70 S-5 ARP 014 675-00014 2 2 2 2 2
32 Washer 350-10064 1 1 1 1 1
33 Washer 350-10141 1 1 1 1 1
34 Piston 033-91099 1 1 1 1 1
35 O-ring, 70 S-5 ARP 010 675-00010 1 1 1 1 1
36 Nut, 5/16-24 335-13100 1 1 1 1 3
37 Orifice, .025” 033-91225 4 4 4 4 4
38 Valve- proportional 517-00085 2 2 2 1 1
38-a O-ring, 70 S-5 ARP 015 675-00015 2 2 2 1 1
38-b O-ring, 90 S-5 ARP 016 695-00016 2 2 2 1 1
91
GOLDCUP CONTROLS SERIES 900
PARTS LIST
Figure 9A Electric stroker
Feature ➔ 00 00 01 00 0*
Option ➔ P*P, P*S 6R,7R,8R P*P,P*S P*V M*H, M*V
Pump Pump Pump Pump Motor
Assembly No. ➔ S23-12667 S23-12940 S23-12957 S23-12734 S23-15050
S23-12733 S23-15051
ITEM DESCRIPTION PT. NO. QTY. QTY. QTY. QTY. QTY.
38-c O-ring, 90 S-5 ARP 116 695-00116 2 2 2 1 1
39 Stroker Block 033-54991 1 1 1 1 1
40 Plug, SAE-4 488-35061 2 2 2 2 2
41 O-ring, 90 S-5 ARP 904 695-00904 2 2 2 2 2
42 Plug. Parker 8HP N-S 488-35018 1 1 1 1 1
43 SHCS, 1/4-20 X 2.25” 358-12100 1 1 1 1 1
44 Nut, 1/4-20 333-12001 1 1 1 1 1
45 O-ring, 70 S-5 ARP 121 675-00121 1 1 1 1 1
46 Connector 167-01008 2 2 2 1 1
47 Guard 033-54994 1 1 1 1 1
48 SHCS, 1/4-20 X 2.25” 306-12260 2 2 2 2 2
49 Washer 350-10144 4 4 4 4 4
50 Plate 030-55002 1 - - - -
Plate 030-55003 - 1 1 1 1
51 Drive screw 320-10203 2 2 2 2 2
52 Coil, 24 VDC. 517-00086 2 2 - 1 1
Coil, 12 VDC 517-00087 - - 2 - -
53 Plug, Parker 10 P50N-S 488-35016 - - - 1 1
54 SHCS, 10-32 X .19” 312-09030 - - - 1 1
55 O-ring, 90 S-5 ARP 910 695-00910 - - - 1 1
56 Washer 345-10016 2 2 2 2 2
92
GOLDCUP CONTROLS SERIES 900
ELECTRIC STROKER
FIGURE 9A
93
NOTES
115
SALES AND SERVICE WORLDWIDE
Printed in U.S.A.
OPI 2M 10203
TB VANE PUMP
Vane Pumps
2
P S
1. TB-011-1R00-A100 .....................................Series
6. TB-011-1R00-A100 ....................................Design
2. TB-011-1R00-A100 ................................ Cam size
Size.........in3/rev Size.........in3/rev Size.........in3/rev
7. TB-011-1R00-A100 ..............................Seal Class
003..........0.54 006 ......... 1.26 011 ......... 2.17 Buna N : mineral oil 1
004..........0.78 008 ......... 1.59 012 ......... 2.42
005..........0.98 009 ......... 1.92
8. TB-011-1R00-A100 ................... Port Connections
3. TB-011-1R00-A100 .....................................Shafts Pressure port P Threaded SAE, 4 bolts
Suction port S SAE-12 ¾” NPTF ¾”
4. TB-011-1R00-A100 ..................................Rotation
SAE-20 00
CW R Threaded
1” ¼ NPTF 03 0X
CCW L
SAE, 4 bolts 1” ¼ 01
5. TB-011-1R00-A100 ....................................Porting
P & S : same side / opposite side 01 / 00
TB
E 1.22
F 3.39
G 5.72
J1 3.250
2
J2 3.248
N 4.19
O 5.13
P ∅ .44
Torque
Shafts in-lb
TB L1 L2 DIAMETER K1 x K2 H1 M1
1 Key : No SAE (∅.75) - ● 2.66 1.25 .750 - .749 .188 x.186 0.83 -
Dimensions (i n)
Ports Options Threads T1
A1 B1 C1 D1
Features
These soft seat (virtual zero leak), with guided poppet valves offer a wide variety of end fitting configurations and elastomers
and the option of 316 stainless steel construction. These options enable a valve to be configured to meet the needs of any
system. Snap-tite’s versatile 6C/3C Inline Check Valves are designed with a 4:1 safety factor at a maximum working
pressure of 6000 psi (415 bar) making them ideal for any application.
75.70
113.55
151.40
189.25
378.50
757.00
113.55
378.50
1892.50
11.36
15.14
18.93
37.85
75.70
1.36
1.51
1.89
3.79
7.57
.38
.76
100 6.90
3.45
PRESSURE DROP, bar
10 .69 200
/4"
13.79
"
1-1
1/4
"
3/8
5.0 .35
"
1/2
4.0 .28
/2"
"
100 6.90
3/4
3.0 .21
1-1
1"
2.0 .14
50 3.45
1.0 .07
40 2.76
.5 .034 30 2.07
.4 .028
2"
.3 .021 20 1.38
.2 .014
.1 .007 10 .69
.1
.2
.3
.4
.5
1.0
2.0
3.0
4.0
5.0
10
20
30
100
10
20
30
40
50
100
200
500
Note: Gallons shown are in U.S. gallons. *Dimensions shown are for NPTF ported valves; for other end fitting configurations consult factory.
Ordering Information
Series Inlet Outlet Port Size Thread Type Spring Pressure Seal
CPI - F- F- NPSF or BSP SAE RP - 05 - 5 psi (.35 bar) No letter for
Inline Female Female 2 - 1/4” Female 15 - 15 psi (1 bar) Viton (std.)
Check 3 - 3/8” British Parallel 25 - 25 psi (1.75 bar) A - Buna
Valve 4 - 1/2” 8 - 1/2” BS 2779 65 - 65 psi (4.50 bar) E - Ethylene
Poppet 6 - 3/4” 12 - 3/4” P - Female NPSF Propylene
Style 8 - 1” 16 - 1” S - Female SAE
CAV 10 - 3P - 15 A
*3/4” 6C SST working pressure - 5000 psi (345 bar), 1” 6C SST working pressure - 4000 psi (275 bar)
! WARNING !
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Snap-tite, Inc., its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having
technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to
the variety of operation conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Snap-tite, Inc. and its subsidiaries
at any time without notice.
Distributed by:
Table of Contents
1 Technical Data
2 Hints
2.1 General Hints
2.2 Safety and Advice Hints
2.3 General Hints to Danger
2.4 Proper Use
3 Storage
4 Assembly
4.1 Components of the Couplings
4.2 Hint regarding the finish bore
4.3 Taper Lock Clamping Sleeve
4.4 Assembly of the Hubs
4.5 Displacements - Alignment of the Couplings
5 Enclosure A
® ®
picture 1: ROTEX (material: Al-D) picture 2: ROTEX (material: GG 25 / GGG 40)
® ®
picture 3: ROTEX (material: steel) picture 4: ROTEX design DKM
®
picture 5: ROTEX design Taper-Lock
CAUTION !
For a continuous and troublefree operation of the coupling it must be designed according
! to the selection instructions (according to DIN 740 part 2) for the particular application
®
(see ROTEX catalogue).
If the operating conditions (performance, speed, changes at engine and machine) change,
the coupling selection must be checked again.
2 Hints
Please read through these mounting instructions carefully before you set the coupling into operation. Please pay
special attention to the safety instructions!
The ROTEX® coupling is approved for the use in hazardous areas.
When using the coupling in hazardous areas please observe the special hints and instructions
regarding safety in enclosure A.
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
DANGER !
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
You may only assemble, operate and maintain the coupling if you
• carefully read through the mounting instructions and understood them
• had technical training
• are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting
damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these mounting
instructions.
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years in case of favourable stock
conditions.
CAUTION !
The storage rooms may not include any ozone-generating devices, like e. g. fluorescent
! light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under
65%.
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
Compo-
Quantity Designation
nent
1 2 hub
2 1 spider
3 2 setscrew
®
picture 6: ROTEX
Compo-
Quantity Designation
nent
1 2 hub
2 2 spider
3 1 DKM - spacer
4 2 setscrew
®
picture 7: ROTEX DKM
Compo-
Quantity Designation
nent
hub for taper
1 2
clamping sleeve
taper lock clamping
2 2
sleeve
3 1 spider
4 4 setscrew
®
picture 8: ROTEX Taper-Lock-clamping sleeve
spider hardness
marking (colour)
(Shore)
92 Sh A yellow
95/98 Sh A red
natural white with green
64 Sh D-F
marking of teeth
DANGER !
STOP Valid for all materials !
The maximum permissible bore diameters d (see
table 1 to 5 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
Table 6: Setscrews
ROTEX® size 14 19 24 28 38 42 48 55 65
dimension G M4 M5 M5 M6 M8 M8 M8 M10 M10
tightening torque TA [Nm] 1,5 2 2 4,8 10 10 10 17 17
®
ROTEX size 75 90 100 110 125 140 160 180
dimension G M10 M12 M12 M16 M16 M20 M20 M20
tightening torque TA [Nm] 17 40 40 80 80 140 140 140
Table 7:
taper lock screw dimension
clamping G L SW TA quantity spanner
sleeve [inch] [inch] [mm] [Nm]
1008 1/4 1/2 3 5,7 2 SW 3
1108 1/4 1/2 3 5,7 2 SW 3
1610 3/8 5/8 5 20 2 SW 5
1615 3/8 5/8 5 20 2 SW 5
2012 7/16 7/8 6 31 2 SW 6
2517 1/2 7/8 6 49 2 SW 6
3020 5/8 1 1/4 8 92 2 SW 8 picture 10: withworth grub screw (BSW)
F
ATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION !
Please pay attention to the danger of ignition in hazardous areas.
DANGER !
STOP Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
CAUTION !
For the assembly please make sure that the distance dimension E (see table 1 to 5) is kept
! to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.
• Assemble the hubs onto the shaft of driving and driven side.
• Move the power packs in axial direction until the dimension E is achieved.
• If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for
adjusting the dimension E.
• Fasten the hubs by tightening the setscrews DIN 916 with cup point.
F
ATTENTION !
If the shaft diameters with inserted feather key are smaller than the dimension dH (see
table 1 to 5) of the spider, one or two shaft ends may protude into the spider.
The displacement figures shown in tables 8 and 9 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
CAUTION !
In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
! hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 8 and 9). If the
figures are exceeded, the coupling is damaged.
In case of a use in hazardous areas for the explosion group IIC (marking II 2G c IIC T4),
only the half displacement figures (see tables 8 and 9) are permissible.
Please note:
• The displacement figures mentioned in tables 8 and 9 are maximum figures which must not arise in parallel.
If radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 12).
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 8 and 9
can be observed.
Example 1:
∆KR = 30%
∆KW = 70%
Example 2:
∆KR = 60%
∆KW = 40%
ROTEX® DKM and ROTEX® ZS-DKM only with spacer made from steel.
ROTEX® Coupling
® ®
picture 13: ROTEX coupling picture 14: ROTEX spider
Here the backlash between coupling cams and the flexible spider must be checked by a feeler gauge.
When reaching the limit of wear of max. friction, the spider must be exchanged immediately, independent of the
inspection intervals.
In case of a backlash of more than x mm, the flexible spider must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating
parameters.
CAUTION !
In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
! hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 8 and 9). If the
figures are exceeded, the coupling is damaged.
picture 15: checking of the limit of wear picture 16: wear of spider
Table 10:
ROTEX® limits of wear (friction) ROTEX® limits of wear (friction)
size Xmax. [mm] size Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
In the explosion groups IIB and IIC only the following material combinations may be used:
GG 25 - GG 25
GGG 40 - GGG 40
steel - steel
stainless steel - stainless steel
Couplings for the use in hazardous areas are marked for the respectively permissible conditions of use.
Explosion group IIC: e. g. II 2G c IIC T4
In the marking II 2G c IIC T4 the explosion group IIB is included.
5.5 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and
the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated
tightening torques dependent on the type of coupling.
If used in hazardous areas, the setscrews must be additionally secured against self-loosening to fix
the hub, e. g. with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
The distance between the cover and the rotating parts must be at least 5 mm.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings made from
aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor if the
magnesium part is below 7,5 %. The cover may only be taken off after having stopped the unit.
CAUTION !
If you note any irregularities at the coupling during operation, the drive unit must be turned
! off immediately. The cause of the breakdown must be found out with the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.
F
ATTENTION !
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.
Certificate of Conformity
corresponding to EG Standard 94/9/EG dated 23 March 1994
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
FILTER ELEMENTS
HYDAC filters are tested according
to the following ISO test standards:
• ISO 3724, Verification of fatigue
characteristics
• ISO 4572, Filtration Efficiency
FLN In-Line Simplex Filter
• ISO 4572, Multi-pass method for
evaluating filtration performance Fluid Compatibility:
• ISO 3968, Evaluation of pressure Suitable for mineral oils,
drop versus flow characteristics lubrication oils, non-flammable
• ISO 2942, Bubble point test fluids, synthetic and rapidly
biodegradable oils. For use with
• ISO 2941, Verification of water, please contact our
collapse / burst resistance
technical sales department.
Reliable filter operation is only
• Clogging Indicator:
guaranteed with the original
For further types of clogging
HYDAC filter elements.
indicators and further details
The filter elements are also on indicators, please see
suitable for use in dynamic brochure no.: 02070327.
applications due to their high
• Seals:
pressure stability; maximum
FKM (Viton)
permissable ∆p across the element:
Betamicron® (BN/HC):
435 psi (30 bar)
Wire Mesh (W/HC):
435 psi (30 bar)
Model Code: Filter
FLN BN/HC 250 D E 10 A 1 . X / 12 - V - B3 .
Filter Type
FLN
Filter Material Element
BN/HC = Betamicron® (BN3HC)
W/HC = Stainless Steel Wire Mesh
Size
160, 250, 400
Operating Pressure
D = 360 psi (25 bar)
Type and Size of Port
E = SAE-20 (1 1/4”)
Filtration Rating (micron)
3 = 3µm
6 = 6µm
BN/HC
10 = 10µm
25 = 25µm
25 = 25µm
50 = 50µm
W/HC
100 = 100µm
200 = 200µm
Type of Clogging Indicator
A = no clogging indicator
B = with visual clogging indicator VM2B.0 for other
C = with electrical clogging indicator VM2C.0 clogging
D = with visual and electrical clogging indicator VM2D.0 indicators
see brochure
LE = visual-mechanical/electrical indicator VD2LE.0 # 02070327
LZ = visual-mechanical/electrical indicator with VD2LZ.0
75% and 100% switching contact
Type Code
1
Modification Number
X the latest version is always supplied
Port Configuration
12 = SAE straight thread inlet/outlet connections
Seals
V = Fluoro Rubber (FKM) (standard)
Bypass Valve
B3 = 43 psid (3 bar) (standard)
(omit) = no bypass (optional - consult factory)
Supplementary Details
L24 = Lamp for 24 volt
L48 = Lamp for 48 volt D-type clogging
L115 = Lamp for 110 volt indicator only
L230 = Lamp for 220 volt
W = suitable for oil-water emulsions (HFA, HFC), NBR seals,
(refers exclusively to the type of clogging indicator)
EV = knurled air bleed valve (replaces standard socket head plug)
A2.2 = 32 psi (2.2 bar) Indicator trip setting
30C = 30°C Indicator thermal lockout
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
2
Model Code: Replacement Element
0250 DN 010 BN/HC / - V
Size
0160 = size 160
0250 = size 250
0400 = size 400
Type
DN
Filtration Rating (micron)
003 = 3µm
006 = 6µm
BN/HC
010 = 10µm
025 = 25µm
025 = 25µm
050 = 50µm
W/HC
100 = 100µm
200 = 200µm
Filter Material
BN/HC = Betamicron®
W/HC = Stainless Steel wire mesh
Seals
V = FKM - Fluoro Rubber (standard)
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
Filtration Efficiency:
Filtration Rating Specification
3 µm ß 3 ≥ 200
6 µm ß 6 ≥ 200
10 µm ß 10 ≥ 200
25 µm ß 25 ≥ 200
Element Data:
Element Specifications
ISOMTD contamination
retention capacity in grams
at ∆p = 72 psi (5 bar) for BN/HC elements
Filter Type 3 µm 6 µm 10 µm 25 µm
160 27.5 29.3 33.1 36.7
250 46.0 49.0 55.2 61.3
400 76.2 81.3 91.4 101.5
Assembly Weight:
Filter Specifications
Weight lbs(kg)
Filter Type Port Element Size
with element
160 SAE 1 1/4” 0160 DN... 4.3 (9.5)
250 SAE 1 1/4” 0250 DN... 4.9 (10.8)
400 SAE 1 1/4” 0400 DN... 5.9 (13.0)
3
Engineering Data: FLN 160, 250, and 400
Design In-Line Low Pressure Filter
Mounting Method 2 Mounting Holes on top of Filter Housing
Connections Inlet: Outlet:
SAE-20 (1 7/8-12 UN-28) SAE-20 (1 7/8-12 UN-28)
Direction of Flow In-Line
Housing Pressure Ratings Operating: 360 psi (25 bar)
Proof: 540 psi (37.5 bar)
Fatigue: 360 psi (25 bar) @ 1 million cycles
Burst: Contact HYDAC office
Element Collapse Pressure Ratings Standard Elements: BN/HC: 435 psid (30 bar)
(ISO 2941) W/HC: 435 psid (30 bar)
Fluid Temperature Range -22°F to +210°F (-30°C to 100°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Fluid Compatibility Compatible with all petroleum oils and synthetic fluids rated for use
(ISO 2943) with Fluoro Rubber seals.
Contact HYDAC office for information on special for use with water
glycols,oil/water emulsions, and HWBF.
Flow Fatigue Resistance Filter medium is supported to achieve flow fatigue resistance.
(ISO 3724) Contact HYDAC office for information.
Trip Pressure of Differential Indicator 29 psi (2 bar) ± 10% (standard)
Cracking Pressure of ∆P = 43 psid (3 bar) bar ± 10% (standard)
Bypass Valve No Bypass (optional - consult factory)
Hydraulic Symbols
with bypass (standard) without bypass (optional)
A A
VA
VA
B B
4
Pressure Drop Calculations:
Assembly
To calculate the pressure drop of a filter assembly use the equation:
∆P Assembly = ∆P Housing + ∆P Element
Housing Curves
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases in
proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
0.40 6.0
0.30 4.5
0.20 3.0
0.10 1.5
0.00 0.0
0 13 26 40 52 66 79 92 106
Q in gpm
Elements ∆P Calculations
All element curves are based on test results using mineral oil with a kinematic viscosity of 141 SUS and a specific
gravity of 0.86. The differential pressure across the element changes proportionally to the viscosity and specific gravity.
1.4 21
p in bar
6µm
1.2 18
p in psid
p in bar
0.8 12
10µm 1.0 15
0.6 9 10µm
25µm 0.8 12
0.6 9 25µm
0.4 6
0.4 6
0.2 3
0.2 3
0.0 0 0.0 0
0 13 26 40 52 0 26 52 79 106
Q in gpm Q in gpm
0 50 100 150 200 0 100 200 300 400
Q in L/min Q in L/min
1.4 21
p in bar
size 250
1.0 15 0.04 0.60
0.8 12 6µm
0.03 0.45 size 400
0.6 9 10µm 0.02 0.30
0.4 6 25µm
0.2 3 0.01 0.15
0.0 0 0.00 0.00
0 26 52 79 106 0 13 26 40 52 66 79 92 106
Q in gpm Q in gpm
5
Dimensions: FLN 160, 250, and 400
1.7" SAE-2
43.5mm 1 1/4"
INLET OUTLET
3.0"
76mm
size 160
11.2"
285mm
size 250
14.3"
363mm
Drain Screw
size 400
20.2"
513mm
ø 3.9"
100mm
M10x8
2.4"
ø 5.1" ø
130mm 60mm
Indicator Plug/Port
5.9"
150mm
6
HYDAC FILTERTECHNIK
Inline Filter
FLN 160 / 250 / 400
SPARE PARTS LIST
MAINTENANCE INSTRUCTIONS
for customer Hägglunds
2. Maintenance
2.1 General
2.2 Maintenance procedures
2.3 Interval between changing elements
3. Element-changes
3.1 Removing the element
3.2 Element-mounting
4. Spare parts
4.1 Spare part-drawing FLN
4.2 Spare parts list FLN
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
1. Maintenance instructions
1.1 Safety-instructions
This pressure vessel complies with the provisions of article 3 paragraph 3 of the
pressure vessels directive (97/23/EC) and so must not have a CE-mark.
Information
The pressure vessel must be used only according to the operating instructions of
the machine or system.
Information
Information
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Warning
W i
Attention pressure vessel: please ensure for all works at the pressure vessel that the
referring side of the pressure vessel (filter housing) is released of pressure.
Danger
Modificatione of the pressure vessel are not allowed (welding, drilling, forced
opening..).
Danger
The operator/owner has to ensure adherence to the National Water Resources Act as
well as local water resources laws and other related regulations.
Information
Information
Follow the rules for prevention of accidents, safety regulations and data sheets for
fluids.
Smoking and open flames/fire are not allowed while working on or near hydraulic
systems.
Hydraulic media and water-polluting fluids are not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure an environmentally waste
management of hydraulic oils. Adherence is to be maintained to pertinent national
and local regulations pertaining to groundwater protection, disposal of waste/spent
oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
1.2 Installation
Before installation of the system it must be checked that the permissible operating pressure of
the system is not higher than the permissible operating pressure of the filter. Take a look at
the type code label!
1.3 Commissioning
Check whether the correct filter element (1) is fitted. Moisten thread and sealing surfaces on
the filter bowl and filter head, as well as the O-ring on bowl and element with clean system
fluid. Screw in the filter housing again fully and then unscrew by one quarter-turn (the sealing
effect will not be improved by over tightening). Switch on the hydraulic system and check the
filter for leakage. Vent filter.
2. MAINTENANCE
2.1 General
This section describes maintenance work, which should be carried out periodically. The
operational safety and the service-life of the filter, and whether it is ready for use, depend to a
large degree on regular and careful maintenance.
-Spare parts must fulfil the technical requirements specified by the manufacturer. This is
always guaranteed for HYDAC original spares.
-After disassembling the filter, clean all parts, check for damage or wear and change if
necessary.
-When changing a filter element it must be paid attention to the best cleanliness.
The filter can be equipped with a clogging indicator (visual and/or electrical or electronic) to
observe the filter element. If the clogging indicator reacts, it is necessary to change or clean
the filter element without delay. If no clogging indicator is installed, we recommend to change
the elements in intervals (the filter element change depends on the filter design and the
conditions).
Higher dynamic loads across the element might necessitate shorter intervals between
changes. Shorter intervals can also be necessary during commissioning, repairs, oil changes
etc, on the hydraulic system.
The standard clogging indicators only respond when fluid is flowing through the filter. With
electrical indicators the signal can also be converted into a continuous display on the control
panel. In this case the continuous display has to be switched off after a cold start or element
change. If the clogging indicator reacts during a cold start only, it is possible that the element
does not need to be changed yet.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
3. ELEMENT-CHANGES
3.1 Removing the element
2. Remove oil drain plug (collect fluid in a suitable container and clean or dispose of in accordance
with environmental regulations).
4. Remove filter element from element centering pivot (examine surface of element for dirt residue
and larger particles; these can indicate damage at the components).
5. Change or clean filter element (only W,W/HC, and V-elements can be cleaned)
Please request for cleaning instructions.
6. Clean filter bowl and filter head. Especially pay attention to the cleanliness of the threads.
7. Examine filter, especially sealing surfaces and thread, for mechanical damage.
1. Moisten thread and sealing surfaces on the filter bowl and filter head, as well as the o-ring with
clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
6. Switch on hydraulic system and vent filter on suitable part of the unit.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
Spare Parts Drawing FLN 160 bis 400
2.4/3.3/5.6
2.1
2.2/3.1/5.4
2.3/3.2/5.5
1.2/5.1
1.1
4.3/5.3
4.2/5.2
4.1
4.4/5.7
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
Spare Parts List FLN 160 bis 400
cons. Article-no. Hägglunds-
Item pc. Designation
of Dimension No.
Filter Element:
1 0160 DN 006 BN3HC /-VPN-SO378-SPARE 01271034 478 3233 628
1 0160 DN 010 BN3HC /-VPN-SO378-SPARE 01271036 478 3233 620
1 1 0250 DN 006 BN3HC /-VPN-SO378-SPARE 01271038 478 3233 629
1 0250 DN 010 BN3HC /-VPN-SO378-SPARE 01271040 478 3233 621
1 0400 DN 006 BN3HC /-VPN-SO378-SPARE 01271042 478 3233 630
1 0400 DN 010 BN3HC /-VPN-SO378-SPARE 01271044 478 3233 622
1.1 1 Filter Element DN... -
1.2 1 O-ring 40,87 x 3,53 -
Clogging Indicator:
2 01271999 478 3233 644
VD 2.2 LE.1 /-30C-SO378-03043225
2.1 1 Clogging Indicator VD 2.2 LE... -
2.2 1 Profile sealing ring VD... -
2.3 1 O-ring 16 x 1 -
2.4 2 O-ring 12 x 1 -
Sealkit Clogging Indicator:
3 01272003 478 3233 651
SEALKIT-E VD /-SO378
3.1 1 Profile sealing ring VD... -
3.2 1 O-ring 16 x 1 -
3.3 2 O-ring 12 x 1 -
Filter Bowl:
BOWL-ASS‘Y FLND160 W.0/-V 01274800
4 BOWL-ASS‘Y FLND250 W.0/-V -
01274801
BOWL-ASS‘Y FLND400 W.0/-V 01274950
4.1 1 Bowl FLN... FLN... -
4.2 1 Back-up-ring FLN... -
4.3 1 O-ring 102 x 3 -
4.4 1 Locking screw G 3/8 NA -
Repair-kit:
5 01272216 -
REPAIR-KIT-E FLN..160/250/400 W.0
5.1 1 O-Ring (element) 40,87 x 3,53 -
5.2 1 Back-up-ring (Topf) FLN... -
5.3 1 O-ring (Bowl) 102 x 3 -
5.4 1 Profile sealing ring (clogging indicator) VD... -
5.5 1 O-Ring (clogging indicator) 16 x 1 -
5.6 2 O-Ring (clogging indicator) 12 x 1 -
5.7 1 Locking screw G 3/8 NA -
Hägglunds_E_FLN/24.11.00/B. Schön
PRESSURE GAUGE
PRECISION INSTRUMENT COMPANY
MODEL '201L', LIQUID FILLED GAUGES
Our ‘200’ Series Gauge Line Is A High Quality Line Of Liquid Filled Gauges. The Glycerine Filling Helps
Dampen The Effects Of Pulsation And Vibration, While Also Perpetually Lubricating The Movement (And
Keeping Contaminates Such As Dirt Away From All Moving Parts) Which Will Extend The Life Of The Gauge.
This Gauge Has Been Specifically Designed With The Original Equipment Manufacturers In Mind And
Are Typically Used On Hydraulic & Pneumatic Systems As Well As Any Commercial Or Industrial Application
Not Corrosive To Brass And Bronze Wetted Parts Where Glycerine Filling Is Suitable For Use.
SPECIFICATIONS:
• Available Dial Sizes: 1 ½”, 2”, 2 ½”, 4", 6"
• Available Connection Sizes:
1/8”MNPT on 1 ½” and 2”
1/4"MNPT on 2”, 2 ½” and 4"
1/2"MNPT on 4" and 6"
• Stainless Steel Case And Bezel
• Brass Internals & Connection
• Phosphour Bronze Bourdon Tube
• Liquid Filled (Dry Available)
• Accuracy : 1 ½” and 2” Dial = 2 %
2½ ”Dial Size = 1.5 %
4” and 6” Dial Size = 1 %
• Dual Scale: PSI & Bar (x100=kPa)
Single Scale available from stock
• Ambient temperature: FILLED: 30’F to 160’F
DRY: -30’F to 180’F
30/0"VAC A 5 0.5
30/0/15 CB 5 0.5
30/0/30 CC 10 1
30/0/60 CD 10 1
30/0/100 CE 20 2
30/0/150 CF 20 2
30/0/300 CH 50 10
0/15 B 2 0.2
0/30 C 5 0.5
0/60 D 10 1
0/100 E 20 2
0/160 F 20 2
0/200 G 40 4
A B C D E
0/300 H 50 5
0/400 I 50 5 1 ½” In 1.88 1.06 .89 2.77 1/8”
0/500 J 100 10 Dial MM 48 27 23 58 Npt
0/600 K 100 10
2” In 2.24 1.27 .71 2.80 1/8” or
0/800 L 100 10
0/1000 M 200 20 Dial MM 57 32 23 71 ¼”npt
0/1500 N 200 20 2 ½" In 2.80 1.28 1.07 3.55 1/4“
0/2000 O 400 50 MM 71 33 27 90 Npt
Dial
0/3000 P 500 50
0/4000 Q 500 50 4" In 4.32 1.63 1.25 5.57 1/4" or
0/5000 R 1000 100 Dial MM 110 42 32 141 ½
”npt
0/6000 S 2000 200
6" In 6.54 1.70 1.68 8.22 1/4“ or
0/10,000 U 2000 200
0/15,000 V 2000 200 Dial MM 166 43 43 210 ½”npt
OIL LEVEL INDICATOR
FLUID LEVEL
INDICATORS FSA/FSK
APPLICATION
The HYDAC FSA-Visual Fluid
Level indicators and FSK-
Electrical Fluid Level Indicators
are used for monitoring fluid
levels and temperature in various
types of reservoirs. Typical
applications are hydraulic system
reservoirs and lubricating, cutting
and cooling fluid tanks. Visual and
Electrical Fluid Level Indicators
are suitable for service in mineral
oils and phosphate-ester based
hydraulic fluids. For Water Glycols
and High Water based fluids, the
sight tube must be ordered in
glass construction. Fluid Level
Indicators can be supplied with
various types of thermometers:
Built-in Tube (FSA only), Dial
Gauge with Thermometer Probe
or Electrical Thermo-Switch.
SPECIAL FEATURES
• Attractive appearance
• Transparent Polyamide sight tube
• Thermometers furnished with
dual range for both Celsius and
Fahrenheit
• Simple and rugged construction
• Available in several sizes
• Choice of seals
• Easy mounting
• Available with Thermo-Switch
DESCRIPTION controls the oil temperature in the
hydraulic reservoir. The Thermo
The HYDAC FSA Visual Fluid Level Switch opens when the nominal
Indicator is available in five sizes. temperature is reached. The switch
The HYDAC FSK Electrical Fluid closes when the temperature is
Level Indicator is available in four approximately 36˚F (20˚ below
sizes and provides an electrical nominal temperature.)
signal at a low fluid level. This
reliable magnetically-operated
reed relay circuit is available in
two single pole single throw
(SPST) contact arrangements:
normally closed (type “O”) or
normally open (type “C”). The
HYDAC TS Thermo-Switch
TECHNICAL DATA THERMO SWITCH SELECTION CODE
Thermo Switch Switch Mounting
Code Temperature Thread
Mounting Thread TS50 50˚C/122˚F M 12
FSK or FSA................M 12 or M 10 TS60 60˚C/140˚F M 12
TS ...................................M 12 only TS70 70˚C/158˚F M 12
TS80 80˚C/176˚F M 12
Material
Housing............Anodized Alumnum
Sight Tube............Polyamide,Glass
Seals................Fluorocarbon, NBR MODEL CODE
Fluid Temperature FS A -127- 1 . 1 - - T - 12 -
-4˚F/-20˚C to176˚F/80˚C
Maximum Pressure Fluid Level Indicator
14.5 PSI (1 BAR)
Type
Thermometer A = Visual
Type T K = Electrical
(FSA only)
68˚F/20˚C to 176˚F/80˚C Size (Mounting Hole Centers)
Type FT 76 = 3 inches (FSA Only)
32˚F/0˚C to 212˚F/100˚C 127 = 5 inches
176 = 7 inches
Bolting Torque 254 = 10 inches
Max. 8 LB-FT+1 (10 Nm +2) 381 = 15 inches
see installation instructions on page 4
Electric Switch Seals
1 = NBR (FSA)
FSK...C FSK...O
2 = Fluorocarbon (FSA and FSK)
2 2
3 3 Modification Number
1 1 1 = FSA (Determined by Manufacturer)
3 = FSK (Determined by Manufacturer)
Electrical Switch
(omit) = For FSA
Contact Ratings.................Max. 8W “C”(SPST) = Normally open at Normal Level
Maximium Voltage.....50 VAC or DC “O”(SPST) = Normally closed at Normal Level
Maximum Current...............200 mA
Connection 3 not used Thermometer
TYPE C TYPE O T = Built-in Tube (FSA Only)
Normally Normally FT 200 = Probe Thermometer (200mm-7.87”LG)
Open Closed FT 300 = Probe Thermometer (300mm-11.87”LG)
TS = Thermo Switch (See Chart Above)
FSK - C FSK - O
Hex Head Bolt
12 = M12 Bolt (Standard)
10 = M10 Bolt (Optional)(Not Available with TS)
Contacts are Contacts are Sight Tube
closed at lower open at lower (omit) = Polyamide construction (not suitable for water glycols or high water
level of fluid level of fluid based fluids)
Thermo Switch Glass = Glass construction-Special Order for FSA Only. Not Available with
FSK.
TS
When ordering probe thermometer separately, please order one (1) drilled bolt, item
12, in spare parts list.
1 2
See installation procedures on page 4 to determine whether a washer is needed.
If a washer is needed, order part # 00001689
M 12 or
M 10 M 12 or
M 10
1.97
50
.79 20
20 5 1.34
34
1.77
45
1.77
SCREW-TYPE CONDUIT
45
FITTING PG 9
Size L L1 L2 Size L L2
inch 4.25 1.46 2.99 inch 8.07 5.00
76 127
mm 108 37 76 mm 205 127
inch 6.26 2.99 5.00 inch 10.00 6.93
127 176
mm 159 76 127 mm 254 176
inch 8.19 4.92 6.93 inch 13.07 10.00
176 254
mm 208 125 176 mm 332 254
inch 11.26 7.99 10.00 inch 18.27 15.00
254 381
mm 286 203 254 mm 464 381
inch 16.26 12.99 15.00
381
mm 413 330 381
11
.67 SQ
SW 17
M 12
ø1.51
ø40
1.93
49
12
7.87" or 11.87"
200 or 300
.63 3.62
16 92
3
Recommended Installation Process
1. Drill mounting holes according to dimension L2 on page 3.
Mounting hole diameter is dependent on the bolt selected in the model code. see pages 2 & 3
2. Torque the Nut, item 9, to 8+ 1 LB-FT. If it is not possible to torque the nut, the bolt head must be torqued. To avoid
damaging the indicator a washer is recommended to be used under the bolt head.
This washer is available from HYDAC: Part Number 00001689.
Washer Dimensions: OD 18.8 mm, ID 13.10 mm, 0.5 mm thick
Spare Parts
FSA FSK
10 1
2
3
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - Fluid Level Indicators FSA/FSK #02068184 / 9.02
9 13
4
5
6
7 14
or
15
Quanity Quanity
Item Description FSA FSK
1 Housing 1 1
2 Name Plate 1 -
3 Tube 1 1
4 O-Ring 13x2.5 2 2
5 Tube Connector 2 2
6 O-Ring 12.3x2.4 2 2
7 Sealing Washer 2 2
8 Hex Bolt 2 2
9 Hex Nut 2 2
10 Thermometer in Indicator Tube 1 -
11 Probe Thermometer (see page 3) 1 1
12 Hex Bolt for Probe Thermometer 1 1
13 Magnetic Float - 1
14 Base Assembly with Type “C” Switch - 1
15 Base Assembly with Type “O” Switch - 1
16 Washer (optional - see note 2 above) 1 1
page 84
BF...30 25 SCFM 3 or 10 µm Threaded Durable Synthetic Material (PA 6)
200 GPM phenolic resin 3/8 to 3/4” BSPP Pressurized (optional)
impregnated paper (male)
page 85
BF...7 65 SCFM 3 or 10 µm Threaded Durable Synthetic Material (PA 6)
500 GPM phenolic resin 1” BSPP with optional differential gauge
impregnated paper (male)
Replaceable
page 86
BL... & BLT... 110 SCFM 3 or 10 µm Threaded, Flanged, Spin-on elements (BL...)
850 GPM phenolic resin or Welded Dehumidifying element (BLT...)
impregnated paper
page 88
BD... (Drymicron) 100 SCFM 2µm Threaded, Silica Gel Desiccant adsorbs water
750 GPM Disposable Flanged, or then changes color to indicate
Bayonet when breather should be changed
page 91
BF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel
1600 GPM phenolic resin 2 1/2” BSPP
impregnated paper (female)
Replaceable
page 87
page 81
Sizing: Maximum Flow is the greater of the maximum pump flow rate, or the maximum system return rate into
the reservoir. Flow rates given are based on a 0.6 psi initial pressure drop with a clean element in a normal
operating environment. Contact HYDAC for applications in extreme environmental conditions.
77 Accessories Catalog
Breathers
Breathers & Filler Breather Technical Overview
Importance of Breathers
Breathers are a integral component in any Hydraulic system. Breathers provide protection from contamination found in harsh industrial
environments. It is well advised to address both contaminant exclusion and removal. An old rule of thumb states that it cost 10 times
as much to REMOVE a particle from your system as it does to EXCLUDE it. Since this is true, it is easy to see that the benefits of
using a high quality breather greatly out-weigh the costs.
Recommendations
1) HYDAC recommends selecting a breather with a filtration rating (micron rating)
that is equivalent to or finer than your finest system filter.
2) Breathers do get clogged over time. HYDAC recommends the following change-out schedules:
For breathers without pressure gauges
• Change you breather annually or with every service interval
For breathers with pressure gauges
• Change your breathers at a 3 psi pressure drop, at 7 psi pressure drop the pump can cavitate
Pressurized Breathers
The use of pressurized breathers adds certain benefits:
• Provides additional protection from moisture which can condense in your tank, causing oil degradation and tank erosion
• Provides positive pressure to pump suction line
• Increased breather service life due to less breathing
• Performs anti-splash function
Tank Pressure
Atmospheric
No Breathing Takes Place Atmospheric
Pressure Pressure
Vacuum Vacuum
(tank breathes in) (tank breathes in)
Time Time
When fluid level rises, the tank pressure rises When fluid level rises, the existing air volume is
and air is immediately expelled through the compressed, and no air is expelled until the cracking
breather whenever positive pressure exists. pressure is surpassed.
When fluid level lowers, the tank pressure drops When fluid level lowers, the tank pressure drops
and air is immediately drawn in through the breather until a vacuum is created at which point, air will be
whenever a vacuum exists. drawn in through the breather.
Air is constantly moving through the breather Air is only expelled when the tank pressure is
in order to maintain atmospheric pressure. above the cracking pressure, and air is only
drawn in below atmospheric pressure.
The majority of the operational cycle will take place
between these two conditions.
0.18"
with relief valve (ELF3 only) standard ø
4.5mm
(6 places)
Size D1 D2 D3 H1 H2 H3
2.99” 3.27” 2.05” 6.26” 3.80” 2.46”
ELF 3 Ø Ø Ø
76mm 83mm 52mm 159mm 96.5mm 62.5mm
1.73” 1.97” 1.10” 5.32” 3.21” 2.11”
ELF 4 Ø Ø Ø
44mm 50mm 28mm 135mm 81.5mm 53.5mm
79 Accessories Catalog
Breathers
ELF 3 Series Filler Breather Parts
ELF 3 Breather Caps
Self Tapping
Bayonet Flange Kit
Screws
M5x10 (DIN 963)
Reservoir Wall
Hydraulic Symbol:
Mounting Hole Pattern
ELF 30
(Flange Interface to DIN 24557/T2)
0.18"
ø
4.5mm
standard
(6 places)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
81 Accessories Catalog
Breathers
ELF...7 Series Filler Breathers
Specifications: Dimensions:
• Maximum flow rate - 65 SCFM/500 GPM
• Durable synthetic material (PA6) ELF 7
• 3 or 10 micron
Optional
• 500 micron plastic filler basket Gauge
• Replaceable element
• Threaded connection to access fill port ø 4.72"
• Installs via 6-bolt circle (bolts included) 120mm
7.13"
with gauge ø 2.36" ø 2.87" 181mm
60mm 73mm Counter Sunk
3.82" Slotted Screw
97mm
ø 0.18" M5 x 10 (DIN 963)
4.5mm
(6 places)
ø 1.93"
49mm
without gauge
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
2.68"
Replacement Elements 68mm
G3
Micron Model Code Part No. (ELF5...3.0)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
83 Accessories Catalog
Breathers
BF...3 & BF...4 Series Breathers
Specifications: Dimensions:
• Maximum flow rate - 35 SCFM/250 GPM
• Epoxy coated steel cap
ø D1
• Zinc-plated internals
• 3 or 10 micron
• Threaded connection
• Pressurized breather H1
with relief valve (optional - BF3 only)
H3
Hydraulic Symbols: HEX
D2
standard
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
85 Accessories Catalog
Breathers
BF...7 Series Breathers
Specifications: Dimensions:
• Maximum flow rate - 65 SCFM/500 GPM
• Durable synthetic material Optional
• 3 or 10 micron Gauge
• Replaceable element
• Threaded breather cap connection ø 4.72"
120mm
• Differential gauge (optional)
Replacement Elements
Micron Model Code Part No. 2.36" Clearance Required for
3 0007L003P 00310948
60mm Element Removal
10 0007L010P 00310485
ø 4.57"
116mm
1.73"
Hydraulic Symbols: 44mm
4.33"
110mm
with gauge
1 5/8"
HEX
41mm
0.71"
18mm
G 1"
ISO 228
without gauge
male
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
G 2 1/2"
Hydraulic Symbol: (ISO 228)
female
Model Code
BF P 5 G 10 W 1 . 0
Filter Type
BF = Breather
Filter Element Material
P = Phenolic Resin Impregnated Paper
Size
5
Type of Connection
G = Threaded
Filtration Rating (micron)
3 = 3µm Air Filtration
10 = 10µm Air Filtration
Gauge Options
W = Without Indicator
Tank Thread Connection (ISO 228)
1 = G 2 1/2 (standard)
Modification Number (standard)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
87 Accessories Catalog
Breathers
BL Series Spin-on Breathers
Specifications: Dimensions:
• Maximum flow rate H3
Clearance needed
110 SCFM/850 GPM for removal Ø D1
• 3 or 10 micron Mounting Hole Pattern for Flange Connection (F)
(Flange Interface to DIN 24557/T2)
• Steel Canister
• 10 micron Betamicron® 2.87"
ø 73mm ø
2.36"
60mm
• Replaceable element H2
H1 ø 0.18"
4.5mm
(6 places)
Hydraulic Symbol:
D3
D2
Size D1 D2 D3 H1 (F or S) H1 (G) H2 H3
3.67” 7” 5.4” 0.75”
BL...80 3/4” NPT 1”-12UNF-2B -
Ø 93mm 178mm 137mm 19mm
5.00” 9.25” 8.75” 7” 1.00”
BL...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 235mm 222mm 178mm 25.4mm
5.00” 13.25” 12.75” 11” 1.00”
BL...180 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 337mm 324mm 279mm 25.4mm
5.33” 9.25” 8.75” 7” 1.00”
BLT...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 136mm 235mm 222mm 178mm 25.4mm
Dimensions are for general information only, all critical dimensions should be verified by requesting a certified print.
Adapters
Size G F S
Threaded Adapter Flanged Adapter Welded Adapter
ADAPTER BL 080G 3/4” NPT NBR
80 N/A N/A
02064393
160
ADAPTER BL 160/180 G 1 1/4” NPT NBR ADAPTER BL 160/180 F (PHOS) ADAPTER BL 160/180 S (PHOS)
02064394 00407646 00416311
180
89 Accessories Catalog
Breathers
Engineering Data
Mounting Position: ELF & BF Vertical (max. 30° off vertical axis)
BL, BLT, BLG, & BLS Vertical or Horizontal
Air Filter Material: Phenolic Resin Impregnated Paper
Note: None of the air filter elements can be cleaned.
Fluid Temperature Range: -15° to 250°F (-26° to 121°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils.
(ISO 2943) Contact HYDAC office for information.
Weights
Model lbs. kg.
ELF 3 0.55 0.25
ELF E RV 0.66 0.30
ELF 4 0.44 0.20
ELF 5 (TYPE NO. 2) 5.95 2.70
ELF 5 (TYPE NO. 3) 6.83 3.10
ELF 7 0.84 0.38
BF 3 0.62 0.28
BF 3 RV 0.73 0.33
BF 4 0.18 0.08
BF 5 4.41 2.00
BF 7 0.88 0.40
BL 160 4.63 2.10
BL 80G 1.40 0.60
BL 160G 2.60 1.20
BL 180G 3.48 1.58
BL 160S 3.86 1.75
BL 180S 4.22 1.91
BLT 160 5.31 2.41
Retention Value
dx
x refers to the percentage of particles of a particular size that the breather will filter.
i.e. d80 for a 10µm filter will capture 80% of 10 µm particles
REPLACE
design to ensure optimum protection by removing GOLD
ACTIVE
water vapor and solid contaminant before they enter
the fluid system. GREEN
DRYMICRON Breathers replace the standard breather
cap or vent tube on a tank or reservoir. They are easy Safety Sealed
to install using one of several adapters designed for • Seals keep moisture from entering the units until they
different applications. are placed in service. They are easily removed without
When the fluid in the system is lowered, or pressure tools or sharp instruments.
changes occur, air is drawn in through openings under
the breather cap. First, air passes through a fine, 2
Solid Contaminant
micron solid particle filter. The air then passes through Filter (2 µm)
a diffuser to ensure maximum effectiveness within the
Air Diffuser
silica gel chamber.
Next, water vapor is removed as the air travels through
360˚ Air Flow
a bed of silica gel — the highest capacity adsorbent
available. After being dried, the air passes through a
second 2 micron solid particle filter and enters the
reservoir clean and dry!
High Capacity
Advantages Water Vapor
Adsorbent
DRYMICRON Breathers protect expensive equipment, Solid Contaminant
increase Filter (2 µm)
operation efficiency, and reduce maintenance costs by:
• eliminating corrosion
• extending life of hydraulic, lubrication, and process
fluids CLEAN DRY AIR
91 Accessories Catalog
Breathers
Product Specifications
Performance Specification
Nominal Air Flow Rate BD 100-400 35 SCFM (990 l/min)
Equivalent of 260 gpm of fluid volume change
Nominal Air Flow Rate BD 800 100 SCFM (2850 l/min)
Equivalent of 750 gpm of fluid volume change
Solid Contamination Filtration Level 2 micron, 100% efficiency @ 35 SCFM air flow
Solid Contamination Filtration Surface area 20.6 in2 / 133 cm2
Operating Temperature Range -26˚ to 200˚F / -32˚ to 93˚C
Silica Gel: Adsorption Up to 40% of its weight of water
Chemical Resistance Resistant to alkalis, hydrocarbons, non-oxidizing
acids, salt water, and mineral or synthetic oils
Flow Rate vs Pressure Drop Unit Selection Guide (adapters sold separately)
GPM Max. H2 0
Height (A) Weight
Model Code Part No. Capacity
37 75 112 150 187 225 262 300 inches (mm) lbs (kg)
1.0 lbs (ltr)
BD 100 X 2 W 0.0 02074253 3.5 (90) 1.3 (0.6) 0.2 (0.1)
0.8
BD 200 X 2 W 0.0 02074254 5 (128) 1.9 (0.9) 0.4 (0.2)
∆P (PSI)
Adapters Selection Guide (adapters sold separately - Note: no adapter needed for BD 800)
Bayonet Adapter Threaded Adapter Threaded Standpipe Adapter Flange Adapter
Part No. 02074251 Part No. 02074248 (3/4" NPT) Part No. 02077124 Part No. 02074250 (not drilled)
Part No. 02074249 (1" NPT) Part No. 02075193 (pre-drilled)
Bayonet Flange Kit with 3.5" Steel Basket Bypass Adapter Part No. 01270816 ø 0.18"
4.5mm
Part No. 02079076 (6 places)
Press-Fit to
2.36"
Drymicron ø
60mm
1 Bayonet Fitting
2 gaskets Vent to
atmosphere
1 Filler Basket
Press-Fit to any
6 Screws Drymicron Adapter
for Installation
X
Description:
This compact plastic design has a sponge element and threaded
connection with anti-splash baffle. Dipsticks are available to the D
Ordering:
To order models without dipsticks, simply use the model code from the chart above. If a dipstick is required
(dipsticks are special order items and minimum quantities may apply), also include:
• Overall Length
• To Add Mark refer to dimension drawing above
• To Full Mark
93 Accessories Catalog
Breathers
HBRM Series
Specifications: Dimensions:
• Chrome-plated carbon steel
• 10 or 40 micron
• NPT threaded connection
• Optional dipstick
Description: Overall
These chrome plated breathers have a paper element and NPT Dipstick Length
threads. Dipsticks are available to the customer’s requirement. To Full Mark
See ordering information below.
To Add Mark
ØA
C B
HEX
SIZE
D
(NPT Male)
Ordering:
To order models without dipsticks, simply use the model code from the chart above. If a dipstick is required
(dipsticks are special order items and minimum quantities may apply), also include:
• Overall Length
• To Add Mark refer to dimension drawing above
• To Full Mark
ENS 3000
Operating Manual
2 ENS 3000 Manual
CONTENTS
2. Mounting
The electronic level sensor ENS 3000 is to be fastened as completely as possible to the metal tube of the connecting
piece with an assembly fitting. An assembly fitting can take and hold a metal tube with 22 mm in diameter. We recom-
mend a bulkhead union with an inserted sleeve fitting (see Accessories section). The active range is to rise up as freely as
possible into the container. For optimal function a part of the active range should be over the upper edge of the con-
tainer or over the overflow of the container.
mode
mode
mode
Device for
Metal Part Attachment
of ENS 3000 Device for
for Connection Attachment Structure
Active
Range
For safe and simple assembly use assembly accessories from HYDAC ELECTRONICS
Attention: The electronic level sensor ENS 3000 is not suitable for tanks with positive pressure. A brief pressure of up
to 3 bar is tolerated and is not harmful up to a time span of 1 minute
mode
min
0.78”
min
2.36”
Active
Range
Metallic
Tube
At the mechanical connecting piece is a grounding screw, which takes over the function of an electrical ground. The
earth ground must be attached, if no grounding connection is given (e.g.: with the plastic tank). It is recommended to use
as leads a cable with diameter of 1 mm2 and as short a conduit length as possible.
4-digit
display
Display for
level sensor SP1 in SP2
4. Digital Display
After switching on the supply voltage on the equipment the display shows ENS&niU briefly. Afterwards the value (level or
temperature) in the display appears indicated and begins with the display of the current value (basic adjustment).
2s 2s
A level below the measurable range of the electronic level sensor is recognizable by the following operational sequence
on the announcement:
2s 2s
Hint:
• If the current level exceeds the nominal level range of the equipment, then it cannot not be indicated any more and
the announcement begins to flash.
• If the level of liquid falls below the lower measuring range, the display shows the value of the off set and the display
in such a way begins to flash
• During the display of the actual level; the possibility exists through pressing the key first the maximum value of
the level will be indicated. With each press of the key, the minimum value of the level, the current value, the
maximum value of the temperature, and the minimum value of the temperature are cycled through the display.
OUT
Hi. 1 plus 3xincrement Switch-back value
Hi. 1 Safety Zone Switching value
IN
IN
Lo. 1 Switching value
Safety Zone Switch-back value
Lo. 1 minus 3xincrement
OUT
t
IN
OUT
Hint: The window function works (switching on and off) only if all switching values (including security zone) are over 0 cm or
0°C, and under the nominal measuring range.
References:
• If “LOC” appears when attempting changes, the programming is locked. Programming should be changed to “free”
(see chapter 7 “programming releases”)
• When changing, if the key or is held, the value will continue to increase or decrease automatically.
• After changing the settings “PROG” appears in the display. The settings will then be stored in the unit.
Switching Point
Hystersis and/or
Measuring Range and/or Upper Increment
Lower Switching
in cm Switching Value in cm
Point in cm*
in cm*
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
Switching Point
Hystersis and/or
Measuring Range and/or Upper Increment
Lower Switching
in inches Switching Value in inches
Point in inches*
in inches*
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
25 0 to 104 0.1
36 0 to 144 0.1
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
Hint: If no keys have been pressed for 25 seconds the menu is terminated automatically, without possible changes
becoming effective.
ON/ OFF ON
The adjustment procedure for switch point 2 is the same as described above.
Actual pressure
niv/ niv
Level-Peak value n.Top/
n.Min/
Temp/
T.Top/
Level-Min value T.Min/
S.P.1/
S.P.2/
OFF
Actual Tempurature
Tempurature-Peak value
Tempurature-Min value
or Switchpoint 1 or 2
Display off
Dark display (see section 4 for detail)
Display
Display reacts slowly to pressure changes. SLOW/ FAST
FAST
Level Offset
A positive offset is able to be programmed 0
to account for baseline level adjustment.
Tempurature indicated in °C
Software Version
Indicates the software version installed at time of manufacture.
If menu adjustments were changed, then upon exiting “ProG” will be displayed. This notifies the user changes have
been made and stored.
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
The equipment had 2 programming releases the two given to be must around attitudes change. The operating pro-
gramming release can be set and/or waived during the enterprise. It offers protection from unintentional changes.
Closing programming over the main programming release causes that during the enterprise no change of the attitudes
can be made. This serves e.g. as safety function or as protection from bad changes.
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
Hint: If a setting was changed, the display briefly changes to “ProG” after changing the setting. The new setting was
then stored in the equipment.
E.01 The setpoint and hysteresis were adjusted in such a way that the resulting reset point is not within the per-
mitted range of adjustment.
Example: Setpoint of 10 in. and hysteresis of 15 in.
Action: Change setpoint or hysteresis.
E.10 A data error was recognized within the stored settings. Possible causes are strong electromagnetic distur-
bance or a defective component.
Action: Examine all settings (programming releases, switching points, reset points and basic adjustments) and cor-
rect these if necessary. If the error should arise more frequently, contact our service department.
E.20 A communication error was recognized within the equipment. Possible causes are strong electromagnetic
disturbance or a defective component.
Action: Acknowledge error by depressing any key. If the error should remain, please contact our service department.
ENS 3X16-3
Imax 1.2 A
+ 1 4
SP 1
18 to 35 V
I = 4 to 40 mA
– 3 2
Analog
RL
General
Level Length of Probe 16.14” or 20.47”
Active Range 10.24” or 14.17”
Inactive Range 5.91” or 6.30”
Max. Vessel Pressure only for application without pressure
Output Data
Level Repeatability ± 2% FS
Accuracy at Switch Point ± 2% FS (at hydraulic oil)
Analog Output 0 to 10 V or 4 to 20 mA selectable
temperature or level selectable
Switching Outputs 2
Type PNP transister output
selectable N.O. / N.C.
Assigning of Switch Output selectable temperature or level
Switching Current Max. 1.2 A
Switching Cycles > 100 millions
Max. Speed of Change of Levels 130 mm/s
Ambient Conditions
Nominal temperature range 32° to 176°F (0° to 80˚C)
Ambient temperature range 32° to 176°F (0° to 80°C)
Storage temperature range -40° to 176°F (-40° to 80°C)
Fluid temperature range 32° to 176°F (0° to 80°C)
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
Vibration resistance to
approx. 10 g / 0 to 500 Hz
IEC 68-2-6 at 10 to 500Hz
Safety type to DIN 40050 IP 67
Shock Resistance approx. 50 g / 1ms
Other Data
Supply voltage 20 to 32 V
Dielectric coefficient of medium >2
Residual ripple supply voltage ≤ 5%
Reverse polarity protection of
the supply voltage, and short standard
circuit protection
Parts in Contact with Media PP (polypropylene)
Display 4 digit, 7 segment LED, red,
7mm character height
General
Level Length of Probe 16.14” or 20.47”
Active Range 10.24” or 14.17”
Inactive Range 5.91” or 6.30”
Max. Vessel Pressure only for application without pressure
Temperature Principle of Sensor semiconductor senor
Measuring Range 32° to 176°F (0° to 80˚C)
Output Data
Level Repeatability ± 2% FS
Accuracy at Switch Point ± 2% FS (at hydraulic oil)
Temperature Accuracy ± 2.7°F (± 1.5°C)
Analog Output 0 to 10 V or 4 to 20 mA selectable
temperature or level selectable
Switching Outputs 2
Type PNP transister output
selectable N.O. / N.C.
Assigning of Switch Output selectable temperature or level
Switching Current Max. 1.2 A
Switching Cycles > 100 millions
Max. Speed of Change of Levels 130 mm/s
Ambient Conditions
Nominal temperature range 32° to 176°F (0° to 80˚C)
Ambient temperature range 32° to 176°F (0° to 80°C)
Storage temperature range -40° to 176°F (-40° to 80°C)
Fluid temperature range 32° to 176°F (0° to 80°C)
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
Vibration resistance to
approx. 10 g / 0 to 500 Hz
IEC 68-2-6 at 10 to 500Hz
Safety type to DIN 40050 IP 67
Shock Resistance approx. 50 g / 1ms
Other Data
Supply voltage 20 to 32 V
Dielectric coefficient of medium >2
Residual ripple supply voltage ≤ 5%
Reverse polarity protection of
the supply voltage, and short standard
circuit protection
Parts in Contact with Media PP (polypropylene)
Display 4 digit, 7 segment LED, red,
7mm character height
1.10"
(28mm)
1.04"
ZBE 06-02 with 2m length (26.5mm)
Part #: 06006790
Colour code:
ZBE 06-05 with 5m length Pin 1: brown
Part #: 06006789 1.24"
(31.50mm)
Pin 2: white
Pin 3: blue
Pin 4: black
1.10"
(28mm)
1.50"
(38mm)
1.42"
(36mm)
3.15"
(80mm)
1.61"
(41mm)
0.74"
(19mm)
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.25" 2.13"
(32mm) (54mm)
G 3/4 BSPP
ø 1.65"
(42mm)
ø 2.15" M12x1
(54.5mm)
mode
3.68"
(93.5mm)
0162
19.82"
(503.5mm)
or
0205
24.15"
(613.5mm)
0.63" 1.13"
(16mm) (28.6mm)
Inactive Range
3.69"
(93.65mm)
0.87"
(22mm)
Active Range
10.24"
(260mm)
or
14.17”
0162 (360mm)
16.14"
(410mm)
or
0205
20.47"
(520mm) 15.02"
(381mm)
Inactive Range
1.09
(27.75mm)
Specifications
ANSI/ISO Pressure Rating: Dynamic applications with normal to moderate hydraulic Low Cycle, Non-pulsating Pressure Rating: Applications with lower cycle
shocks such as general industrial equipment, hydraulic presses, agricultural equip- life and no severe cyclic pressure fluctuations, essentially steady pressure during
ment, etc. Impulse tested at a multiple (125% to 133%) of rated pressure. an operating cycle. Typical applications include hydraulic jacks, mine roof
support systems, and high pressure fluid transfer (pumping water or slurry in
oil wells). Minor pump ripple is considered non-pulsating. Impulse tested at rated
pressure.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Pressure (PSI) Rated Pressure (PSI)
Brass 1000 1000 1000 1000 1000 1000 800 800 3000 3700 2700 3500 2200 1500 1500 1200
Stainless steel 2000 2000 1500 1500 1500 1000 1000 1000 5000 5000 5000 5000 3000 3000 1500 1500
Steel 5000 5000 4000 4000 2500 2000 1000 1000 5000 5000 4000 4000 2500 2000 1500 1500
Steel w / HD N/A 5000 4000 4000 3000 3000 N/A N/A 5000 5000 4000 4000 3000 3000 N/A N/A
nipple
Temperature Range: Standard seals (Buna-N) -40° to +250° F Optional Viton seals -10° to +400° F
Vacuum Data: 27.4 inches Hg. both connected and disconnected (1-1/2" and 2-1/2" body size 60 Series couplings are not reccommended for service in diconnected mode)
Note: Read the Safety Guide for Selecting and Using Quick Action Couplings and Related Accessories before making a coupling selection. It may be found in
Parker Hannifin Quick Coupling Divison catalogs and is available as Parker Publication No. 3800-B1.0.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Flow (GPM) .8 3 6 12 28 50 100 200
Performance
60 Series (1/8;1/4") 60 Series (3/8;1") 60 Series (11/2;21/2")
Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS
30 30 200 200
40 40
30 30
2-1/2"
20 20 100 100
80 80
20 20
1/8" 60 60
1/4" 50 50
1/2" 1" 40 40
10 10
Pressure Drop in PSID
3/8" 3/4"
9 9 30 30
8 8 10 10
9 9 1-1/2"
7 7 8 8 20 20
6 6 7 7
5 5 6 6
5 5 10 10
4 4 8 8
4 4
3 6 6
3
5 5
3 3
4 4
2 2 3 3
2 2
2 2
1 1 1 1 1
1
.2 .3 .4 .5 .6 .7 .8 .9 1 2 3 4 1 2 3 4 5 6 7 8 910 20 40 60 80 10 20 30 40 50 60 80 100 200 300
Flow in USGPM Flow in USGPM Flow in USGPM
Couplers A
Female Thread
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Flats Diameter
A B C
1/8 BH1-60 0.16 H1-62 0.16 SH1-62 0.16 SSH1-62Y** 0.15 1/8-27 – 1.90 0.68 0.96
1/8 – – H1-62-T4 0.18 SH1-62-T*4 0.10 SSH1-62Y-T4 0.17 – 7/16-20 2.06 0.68 0.96
1/4 BH2-60 0.32 H2-62 0.30 SH2-62 0.30 SSH2-62Y 0.30 1/4-18 – 2.26 0.81 1.14
1/4 – – H2-62-T6 0.31 SH2-62-T6 0.31 SSH2-62Y-T6 0.31 – 9/16-18 2.41 0.81 1.14
3/8 BH3-60 0.43 H3-62 0.40 SH3-62 0.40 SSH3-62Y 0.40 3/8-18 – 2.49 0.88 1.40
3/8 – – H3-62-T8 0.51 SH3-62-T8 0.51 SSH3-62Y-T8 0.51 – 3/4-16 2.75 1.00 1.40
1/2 BH4-60 0.80 H4-62 0.73 SH4-62 0.75 SSH4-62Y 0.76 1/2-14 – 2.87 1.12 1.77
1/2 – – H4-62-T10 0.78 SH4-62-T10 0.75 SSH4-62Y-T10 0.78 – 7/8-14 3.05 1.12 1.77
3/4 BH6-60 – H6-62 1.30 SH6-62 1.31 SSH6-62Y 1.33 3/4-14 – 3.56 1.31 2.14
3/4 – – H6-62-T12 1.39 SH6-62-T12 1.34 SSH6-62Y-T12 1.40 – 1-1/16-12 3.56 1.31 2.14
1 BH8-60 – H8-62 1.95 SH8-62 1.95 SSH8-62Y 1.95 1-11 1/2 – 4.18 1.62 2.52
1 – – H8-62-T16 1.95 SH8-62-T16 1.95 SSH8-62Y-T16 1.95 – 1-5/16-12 4.18 1.62 2.52
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Contact factory for seal options)
Contact division for BSPP port availability
Nipples D
Female Thread
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Exposed Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Length Flats Diameter
D E F G
1/8 BH1-61 0.04 H1-63 0.03 SH1-63 0.03 SSH1-63Y** 0.04 1/8-27 – 1.61 0.41 0.56 0.65
1/8 – 0.06 H1-63-T4 0.05 SH1-63-T*4 – SSH1-63Y-T4 0.06 – 7/16-20 1.32 0.57 0.69 0.79
1/4 BH2-61 0.09 H2-63 0.08 SH2-63 0.08 SSH2-63Y 0.08 1/4-18 – 1.39 0.65 0.75 0.87
1/4 – 0.11 H2-63-T6 0.10 SH2-63-T6 0.10 SSH2-63Y-T6 0.10 – 9/16-18 1.54 0.70 0.88 1.01
3/8 BH3-61 0.10 H3-63 0.12 SH3-63 0.12 SSH3-63Y 0.12 3/8-18 – 1.50 0.54 0.88 1.01
3/8 – 0.12 H3-63-T8 0.16 SH3-63-T8 0.16 SSH3-63Y-T8 0.14 – 3/4-16 1.76 0.80 1.00 1.15
1/2 BH4-61 0.25 H4-63 0.24 SH4-63 0.24 SSH4-63Y 0.24 1/2-14 – 1.75 0.69 1.12 1.30
1/2 – 0.28 H4-63-T10 0.27 SH4-63-T10 0.27 SSH4-63Y-T10 0.27 – 7/8-14 1.94 0.87 1.19 1.37
3/4 BH6-61 0.50 H6-63 0.46 SH6-63 0.45 SSH6-63Y 0.46 3/4-14 – 2.16 0.79 1.38 1.59
3/4 – 0.55 H6-63-T12 0.46 SH6-63-T12 0.50 SSH6-63Y-T12 0.50 – 1-1/16-12 2.27 0.90 1.34 1.59
1 BH8-61 0.76 H8-63 0.76 SH8-63 0.76 SSH8-63Y 0.76 1-11 1/2 – 2.91 0.99 1.62 1.88
1 – 0.80 H8-63-T16 0.80 SH8-63-T16 0.80 SSH8-63Y-T16 0.80 – 1-5/16-12 2.91 0.99 1.62 1.88*
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Contact factory for seal options)
Contact division for BSPP port availability
A
Couplers
Female Thread
C
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Flats Diameter
A B C
1 1/2 BH12-60L 4.58 H12-62L 4.70 SH12-62L 4.68 SSH12-62LY** 4.68 1 1/4-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 BH12-60N 4.58 H12-62N 4.70 SH12-62N 4.68 SSH12-62NY 4.68 1 1/2-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T20 4.72 SH12-62-T20 4.71 SSH12-62Y-T20 4.71 – 1 5/8-12 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T24 4.72 SH12-62-T24 4.71 SSH12-62Y-T24 4.71 – 1 7/8-12 4.86 2.38‡ 3.00
2 1/2 BH2016-60 11.06 H2016-62 10.58 SH2016-62 – SSH2016-62Y – 2-11 1/2 – 5.57 3.75 4.10
2 1/2 BH2020-60 11.42 H2020-62 10.91 SH2020-62 – SSH2020-62Y – 2 1/2-8 – 6.04 3.75 4.10
2 1/2 BH2024-60 – H2024-62 – SH2024-62 – SSH2024-62Y – 3-8 – 6.96 4.00 4.35
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Consult factory for seal options)
‡Wrench Flat on 303 Stainless is 2.50 in.
Contact division for BSPP port availability
D
Nipples E
Female Thread
G
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Exposed Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Length Flats Diameter
D E F G
1 1/2 BH12-61L 2.96 H12-63L 3.10 SH12-63L 3.06 SSH12-63LY** – 1 1/4-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 BH12-61N 2.96 H12-63N 3.10 SH12-63N 3.06 SSH12-63NY – 1 1/2-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T20 3.15 SH12-63-T20 3.14 SSH12-63Y-T20 – – 1 5/8-12 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T24 3.15 SH12-63-T24 3.14 SSH12-63Y-T24 – – 1 7/8-12 4.76 2.69 2.38‡ 2.75†
2 1/2 BH2016-61 7.78 H2016-63 7.90 SH2016-63 7.92 SSH2016-63Y – 2-11 1/2 – 5.48 2.90 3.75 4.10
2 1/2 BH2020-61 8.12 H2020-63 8.16 SH2020-63 8.16 SSH2020-63Y – 2 1/2-8 – 5.95 3.37 3.75 4.10
2 1/2 BH2024-61 – H2024-63 – SH2024-63 – SSH2024-63Y – 3-8 – 6.87 4.29 4.00 4.35
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Consult factory for seal options)
† Largest diameter on Brass is 2.96" across Hex Corners
‡Hex on 303 Stainless is 2.50 in.
Contact division for BSPP port availability
Specifications
Body Size (in.) 1/4 to 1
Rated Pressure (PSI)
with saturated steam at 338°F 100
Temperature Range (std seals) Ethylene Propylene
Continuous +250°F
Intermittent +400°F
Coupler
Female Pipe Thread
Body Part Thread Dimension (in.)
Size No. Size Overall Wrench Largest Wt. (LB.)
(in.) Brass NPTF Length Flats Diameter P/Piece
A B C G
1/4 BH2-60-STM 1/4-18 2.26 0.81 1.14 0.30
3/8 H3-68 3/8-18 2.50 0.88 1.77 0.50
1/2 BH4-60-STM 1/2-14 2.87 1.12 1.77 0.75
A
3/4 BH6-60-STM 3/4-14 3.56 1.31 2.14 1.31
1 BH8-60-STM 1-11 1/2 4.18 1.62 2.52 1.95
C
Nipple
Female Pipe Thread
Repair Kits
Body Repair Kit Used For
Steam Coupling Size Part No. Part No.
3/8 H68E-67K H3-68
3/8 H69E-67K H3-69
Applications
Parker offers a complete line of dust plugs and caps for their Protective dust plugs and caps play a crucial role in the use of
hydraulic quick couplings. Each series shown in this catalog quick couplings and no purchase of a hydraulic quick coupling
has a dust plug and cap specifically designed to be used with is complete without the selection of an appropriate dust plug
that style of coupling. and cap. When ordering the dust cap/plug body size must
correspond to that of the coupler or nipple.
Dust plugs and caps serve a twofold function. They keep the
mating surface clean and free of contamination and protect Parker’s full line of dust plugs and caps can be found below
the critical mating elements of the coupling halves when they and on the following pages.
are disconnected. In this way the nipple is protected from
damage that would make the total coupling unusable. Dust Plug: Used on Coupler (female half)
Dust Cap: Used on Nipple (male half)
Dust Plugs
Body Dust Plug Dust Plug Dust Cap Dust Cap
60 Series Size Part No. Part No. Part No. Part No.
(in.) Aluminum Geolast Aluminum Geolast
1/8 H1-65 H1-65M H1-66 H1-66M
1/4 H2-65 H2-65M H2-66 H2-66M
3/8 H3-65 H3-65M H3-66 H3-66M
1/2 H4-65 H4-65M H4-66 H4-66M
3/4 H6-65 H6-65M H6-66 H6-66M
1 H8-65 H8-65M H8-66 H8-66M
1 1/2 H12-65 NA H12-66 NA
2 1/2 H20P-65 NA H20P-66 NA
NA = Not Available
25 Electronics Catalog
Model Code:
EDS 3 X X X - X - XXXX - 400 X 1
Series
EDS 3 = 3000 Series Electronic Sensor
Sensor Type
1 = Ceramic absolute
3 = Ceramic relative
4 = Thin-film relative
Mechanical Connection
4 = G 1/4 BSPP male thread*
8 = 1/4” - 18 NPT male thread
7 = SAE-6 male thread (9/16-18 UNF2A)
Electrical Connection
6 = M12x1 plug, 4 pole for output codes 1, 2, and 3 (connector not included)
8 = M12x1 plug, 5 pole for output code 5 (connector not included)
Output
1 = 1 Switch output (only with electrical connection 6)
2 = 2 Switch outputs (only with electrical connection 6)
3 = 1 Switch with analog output (only with electrical connection 6)
5 = 2 Switch with analog output (only with electrical connection 8)
Pressure Ranges
Type 1 (ceramic - absolute) Type 3 (ceramic - relative) Type 4 (thin-film, relative)
0015 = 0 to 15 psi 0015 = 0 to 15 psi 0250 = 0 to 250 psi 1000 = 0 to 1000 psi
0050 = 0 to 50 psi 0030 = 0 to 30 psi 0500 = 0 to 500 psi 3000 = 0 to 3000 psi
0050 = 0 to 50 psi 0089 = -14 to 75 psi 6000 = 0 to 6000 psi
0150 = 0 to 150 psi 9000 = 0 to 9000 psi
Modification Number
400 = standard in psi
Sealing Material (in contact with media)
F = FPM seal (to be used for example with hydraulic fluid)
E = EPDM seal (to be used for example with refrigerant coolant or fluids containing ammonia)
Material for Mechanical Connection / Housing (in contact with media)
1 = Stainless Steel
* G 1/4 port sizes are available upon request
Plug Connection:
EDS 3XX6 EDS 3XX8 use with ZBE 06 (4-pole) & ZBE 08 (5-pole)
(4-pole) (5-pole) (see page 60)
4 3 4 3
1 2 1 5 2
Circuit Connection:
Model with 1 switch output Model with 1 switch output
Plug 4-pol. M12x1 and signal output Dimensions: ø 1.65"
M12x1
(42mm)
Plug 4-pol. M12x1
ø 2.15" (54.5mm)
EDS 3X46-1 EDS 3X46-3
Imax 1.2 A
+ 1 + 1 4
Imax 1.2 A SP 1
9 to 35 V 4 18 to 35 V
SP 1 I = 4 to 20 mA
– 3 – 3 2
Analog
RL
3.68"
(93.5mm)
mode
2.95"
(75mm)
Model with 2 switch outputs Model with 2 switch outputs
Plug 4-pol. M12x1 and signal output
Plug 5-pol. M12x1
EDS 3X46-2 EDS 3X48-5 Imax 1.2 A
Imax 1.2 A
+ 1 4 + 1 4
SP 1 SP 1
9 to 35 V Imax 1.2 A
Imax 1.2 A 18 to 35 V 5 0.47"
2 SP 2 (12mm)
– 3 – I = 4 to 20 mA
3 2
SP 2
Analog ø 1.16"
RL SAE 6 (29.5mm)
0.63"
6kt-SW27 (16mm)
SERVICE REFERENCE
DIVISION 4 SECTION ARTM
SALES
REFERENCE (Supersedes PD419-8) PD419-9
161-058027-001
DATE SEPTEMBER, 2002
GENERAL
Chromalox types ARTM (copper sheath), ARTMO (steel sheath), (ARTMO) and stainless steel (ARTMS) and (ARTMI).
ARTMS (stainless steel sheath) and ARTMI (INCOLOY® sheath) C. Medium to high watt densities.
screwplug immersion heaters are designed for a wide variety of heat- D. Built-in thermostat standard with ranges of 0-127˚F, 60-180˚F
ing applications. and 60-240˚F.
E. Broad selection of sheath materials to operate successfully in
many corrosive solutions. Note: Proper selection of the sheath
material is the sole responsibility of the customer.
IMPORTANT: It is the responsibility of the purchaser F. E1 (General Purpose), E2 (Moisture Resistant/Explosion
of the heater to make the ultimate choice of sheath Proof) and E4 (Moisture Resistant, not shown) terminal hous-
material based upon his knowledge of the chemical ings are standard.
composition of the corrosive solution, character of the
materials entering the solution, and controls which he
maintains on the process.
Heater Construction Characteristics: The system designer is responsible for the safety of
A. High quality resistance wire held in place by compacted this equipment and should install adequate back-up
Magnesium Oxide refractory enclosed in a wide variety of controls and safety devices with their electric heating
sheath materials. equipment. Where the consequences of failure could
B. 1” NPT Screwplug is standard in brass (ARTM), steel result in personal injury or property damage, back-up
controls are essential.
INSTALLATION
This Portion of the Heater Above Liquid Level and
Expected Low Liquid Exposed to Air Will Lead to Premature Burnout of Element
ELECTRIC SHOCK HAZARD. Disconnect all power Level
before installing or servicing heater. Failure to do so
could result in personal injury or property damage.
Heater must be installed by a qualified person in accor- WRONG
dance with the National Electrical Code, NFPA 70.
RIGHT
1. Before installing, check your type ARTM immersion heater
for any damage that may have occurred during shipment. Expected Maximum
Sediment Level
2. Check to insure that the line voltage is the same as that stamped
on the nameplate. Note: Locate Heater as low as possible for maximum heated liquid storage
3. Do not bend the heating elements. If bending is necessary, capacity. Heat does not move downward.
check factory. Figure 1 - Open Tank Installation
4. IMPORTANT: Mount heater in the tank so the liquid level will
always be above the effective heated portion of the heater (see
Figure 1).
© 2002 Chromalox®, Inc
INSTALLATION
If the heater is not properly submerged, the heating elements will Drip loop recommended
overheat and create heater damage or a possible fire hazard due to to minimize passage of moisture
along wiring into terminal
Outlet
excessive sheath temperatures. wiring and connections
OPERATION
1. Do not operate heaters at voltages in excess of that stamped on the insulation resistance of less than twenty megohms. Normally, this
heater since excess voltage will shorten heater life. megohm value corrects itself after heatup and does not affect
2. Always maintain a minimum of 2” of liquid above the heated por- heater efficiency or life.
tion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat and A low megohm condition can be easily corrected by removing the
damage heating elements, tank or contents. DO NOT OPERATE terminal housing and baking the heater in an oven at 350˚F for sev-
HEATER IF DRY. eral hours, preferably overnight. Note: Before baking, the lid must
3. Be sure all trapped air is removed from a closed tank. Bleed the air be removed from an E2 housing. The housing and screwplug gas-
out of the liquid piping system and heater housing prior to ener- ket must be removed from E4 models.
gizing.
Note: The tank or heating chamber in closed tank systems An alternate procedure is to disconnect the thermostat and energize
must be kept filled with liquid at all times. the heater(s) at low voltage until the megohm reading returns to
4. Keep heating elements above sediment deposits. normal. When energizing heater(s) in air, the sheath temperatures
5. Low Megohm Condition — The refractory materials used in elec- should not exceed 400˚F for copper and 750˚F for steel and alloy
tric heaters may absorb moisture during transit or when subject to elements.
a humid environment. This moisture absorption results in a cold
MAINTENANCE
3. Remove any accumulated sludge deposits from heater and
from tank.
ELECTRIC SHOCK HAZARD. Disconnect all power 4. Check for loose terminal connections and tighten if necessary.
before installing or servicing heater. Failure to do 5. If corrosion is indicated in the E2 or E4 terminal housing,
so could result in personal injury or property dam- check terminal box gasket and replace if necessary. Check screw-
age. Heater must be installed by a qualified person plug gasket on E4 models and replace if necessary. Check conduit
in accordance with the National Electrical Code, layout to correct conditions that allow corrosion to enter the termi-
NFPA 70. nal housing.
1. Heaters should be checked periodically for coatings and corro- 6. Clean terminal ends of all contamination.
sion and cleaned if necessary. 7. Check thermostat for proper identification.
2. The tank should be checked regularly for sediment around
the heater as sediment can act as an insulator and shorten heater life.
AB 16 S 32 1 1/4" 1.19 2.31 1.38 1.42 M12 14 2.24 3.31 1.14 1.38 0.28 M6 2.28 13 9 41x3.5
AB 16 S 40 1 1/2" 1.41 2.75 1.75 1.81 M12 14 2.72 3.74 1.14 1.38 0.28 M6 2.28 13 9 52X3.5
AB 16 S 50 2" 1.69 3.06 2.13 2.20 M12 14 3.15 4.09 1.14 1.38 0.28 M6 2.28 13 9 62X3.5
AB 16 S 63 2 1/2" 2.00 3.50 2.62 2.68 M12 14 3.86 4.53 1.22 1.65 0.31 M6 2.52 13 12 75X4
AB 16 S 80 3" 2.44 4.19 3.25 3.35 M16 16 4.57 5.31 1.22 1.65 0.35 M8 2.52 17 12 92X4
AB 16 S 100 4" 3.06 5.13 4.17 4.17 M16 16 5.39 6.26 1.22 1.65 0.35 M8 2.52 17 12 114X4
AB 16 S 125 5" 3.63 6.00 5.16 5.16 M16 16 6.42 7.13 1.22 1.65 0.35 M8 2.52 17 12 140X4
Type W X
(in) (in)
AB 16 S 32 to 50 4.13 1.57
AB 16 S 63 to 125 4.33 1.57
90° to shut
Type E L1 SW1
UNC-2B in mm
AB 16 S 32 to 63 7/16 - 14 0.47 12
Threaded bushing AB 16 S 40 to 63 1/2 - 13 0.51 12
AB 16 S 80 to 125 5/8 - 11 0.51 17
to
to
2. Technical Data: 4
Working Pressure: 87 p.s.i.
2
Max. Pressure: 174 p.s.i.
Tank 2 3
Burst Pressure: 290 p.s.i.
Vacuum: 20" Hg
Temperature -4°F to 176°F
Acceptable Movement
Size
Table 1
Type [NG] Size A B D E F G H L Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 S 25 1" 1.03 2.06 1.69 0.43 0.43 2.17 2.76 2.56 ±0.20 in ±0.20 in 7.5° 0.8
K 16 S 32 1 1/4" 1.19 2.31 1.97 0.43 0.51 2.76 3.15 2.56 ±0.20 in ±0.20 in 7.5° 1.10
K 16 S 40 1 1/2" 1.41 2.75 2.44 0.51 0.51 3.15 3.54 3.94 ±0.39 in ±0.39 in 10° 1.76
K 16 S 50 2" 1.69 3.06 2.83 0.51 0.51 3.54 3.94 3.94 ±0.39 in ±0.39 in 10° 2.21
K 16 S 63 2 1/2" 2.00 3.50 3.43 0.55 0.51 4.13 4.53 3.94 ±0.39 in ±0.39 in 10° 2.65
K 16 S 80 3" 2.44 4.19 4.09 0.55 0.71 4.72 5.20 3.94 ±0.39 in ±0.39 in 10° 3.97
K 16 S 90 3 1/2" 2.75 4.75 4.09 0.55 0.71 5.12 5.75 3.94 ±0.39 in ±0.39 in 10° 4.19
K 16 S 100 4" 3.06 5.13 5.12 0.63 0.71 5.51 6.14 3.94 ±0.39 in ±0.39 in 10° 5.51
connecting sizes
after SAE-Norm
(J 518ci) and
after DIN 2633 - ND 16
Table 2
Type [NG] Size A B C D E F G H K L M N Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (in) Push/Pull Offset Angle (°) Weight (lbs.)
K16SD- 25 1" 1.031 2.062 4.53 1.69 0.43 0.43 2.17 2.76 3.35 2.56 4x14 0.63 ±0.20 in ±0.20 in 7.5° 3.31
K16SD- 32 1 1/4" 1.188 2.312 5.51 1.97 0.43 0.51 2.76 3.15 3.94 2.56 4x18 0.63 ±0.20 in ±0.20 in 7.5° 3.97
K16SD- 40 1 1/2" 1.406 2.750 5.91 2.44 0.51 0.51 3.15 3.54 4.33 3.94 4x18 0.63 ±0.39 in ±0.39 in 10° 4.85
K16SD- 50 2" 1.688 3.062 6.50 2.83 0.51 0.51 3.54 3.94 4.92 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 6.17
K16SD- 63 2 1/2" 2.00 3.500 7.28 3.43 0.55 0.51 4.13 4.53 5.71 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 7.06
K16SD- 80 3" 2.438 4.188 7.87 4.09 0.55 0.71 4.72 5.20 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 8.82
K16SD- 90 3 1/2" 2.750 4.750 7.87 4.09 0.55 0.71 5.12 5.75 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 9.04
K16SD- 100 4" 3.062 5.125 8.66 5.12 0.63 0.71 5.51 6.14 7.09 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 10.58
Table 3
The movement absorption in static and dynamic loads and the different types of movements must be added together and the totals
are not allowed to exceed the data given.
Attention: Pressure spikes are push loads which add to the axial movement. Do not exceed given data!
Table 4
Techincal Data:
Operating Pressure: 10,150 psi (lock pressure)
Proof Pressure: 40,600 psi
Temperature Range: -40°F to 176°F
Viscosity Range: 5 to 500 c St
Installation Position: Any direction
Flow Rate: See section 4
Stainless Steel on Request
Type G K d T U X
Notes:
E01PX10-2347.txt
Printout time: 2005-09-27 11:56:52
Printed by SpiderCom2 version: 4.1.4 Build 8
Parameter file name: E01PX10-2347.s2p
Parameter file version: 2
SpiderII software version: 4.1.2 2
Main settings
Function
MAA01 - System function BASIC
Configuration
MAB01 - E-motor connection for P1 E-motor 1
MAB02 - E-motor connection for P2 OFF
MAB03 - E-motor connection for P3 OFF
MAB04 - E-motor connection for P4 OFF
MAB05 - Drive connection for P1 Drive 1
MAB06 - Drive connection for P2 OFF
MAB07 - Drive connection for P3 OFF
MAB08 - Drive connection for P4 OFF
MAB09 - Separate or common Separate
MAB10 - Shutdown ramp time 0
MAB11 - Emerg. stop mem bypass off
Language
MAC01 - Display language selection English
Protection
MAD01 - Security code - setup menu yes (*)
MAD02 - Security code 0533 (*)
Pump outputs
Pump 1
POA01 - Forward min current 183 (*)
POA02 - Forward max current 315 (*)
POA03 - Reverse min current 175 (*)
POA04 - Reverse max current 305 (*)
POA05 - Coil resistance 41 (*)
POA06 - PWM-frequency 200
Pump 2
POB01 - Forward min current 0
POB02 - Forward max current 0
POB03 - Reverse min current 0
POB04 - Reverse max current 0
POB05 - Coil resistance 40
POB06 - PWM-frequency 200
Pump 3
POC01 - Forward min current 0
POC02 - Forward max current 0
POC03 - Reverse min current 0
POC04 - Reverse max current 0
POC05 - Coil resistance 40
POC06 - PWM-frequency 200
Pump 4
POD01 - Forward min current 0
POD02 - Forward max current 0
POD03 - Reverse min current 0
POD04 - Reverse max current 0
POD05 - Coil resistance 40
POD06 - PWM-frequency 200
Friction
POE01 - Pump friction Off
POE02 - Pump low friction limit 0
POE03 - Pump high friction limit 200
POE04 - Friction up ramp time 2.0
POE05 - Friction down ramp time 2.0
Page 1
E01PX10-2347.txt
Digital inputs
Digital in 1 - 22
DIN01 - Digital input 1, DI1:3 14 START 1 (*)
DIN02 - Digital input 2, DI1:4 15 REV 1 (*)
DIN03 - Digital input 3, DI1:5 21 OFF (*)
DIN04 - Digital input 4, DI1:6 07 MN LEVEL
DIN05 - Digital input 5, DI1:7 07 LO LEVEL
DIN06 - Digital input 6, DI1:8 06 DRF 100
DIN07 - Digital input 7, DI2:4 06 RF100 P1
DIN08 - Digital input 8, DI2:5 05 SUCTION1
DIN09 - Digital input 9, DI2:6 03 C PRA P1 (*)
DIN10 - Digital input 10, DI2:7 01 H APR P1
DIN11 - Digital input 11, DI2:8 21 OFF (*)
DIN12 - Digital input 12, DI2:9 21 OFF (*)
DIN13 - Digital input 13, DI2:10 21 OFF (*)
DIN14 - Digital input 14, DI2:11 21 OFF (*)
DIN15 - Digital input 15, DI2:12 21 OFF
DIN16 - Digital input 16, DI3:4 21 OFF (*)
DIN17 - Digital input 17, DI3:5 21 OFF (*)
DIN18 - Digital input 18, DI3:6 21 OFF (*)
DIN19 - Digital input 19, DI3:7 21 OFF (*)
DIN20 - Digital input 20, DI3:8 21 OFF (*)
DIN21 - Digital input 21, DI3:9 21 OFF (*)
DIN22 - Digital input 22, DI3:10 21 OFF (*)
Digital in 23 - 43
DIN23 - Digital input 23, DI3:11 21 OFF (*)
DIN24 - Digital input 24, DI3:12 21 OFF
DIN25 - Digital input 25, DI4:4 21 OFF
DIN26 - Digital input 26, DI4:5 21 OFF
DIN27 - Digital input 27, DI4:6 21 OFF
DIN28 - Digital input 28, DI4:7 21 OFF
DIN29 - Digital input 29, DI4:8 21 OFF
DIN30 - Digital input 30, DI4:9 21 OFF
DIN31 - Digital input 31, DI4:10 21 OFF
DIN32 - Digital input 32, DI4:11 21 OFF
DIN33 - Digital input 33, DI4:12 21 OFF
DIN34 - Digital input 34, DI5:3 21 OFF
DIN35 - Digital input 35, DI5:4 21 OFF
DIN36 - Digital input 36, DI5:5 21 OFF
DIN37 - Digital input 37, DI5:6 21 OFF
DIN38 - Digital input 38, DI5:7 21 OFF
DIN39 - Digital input 39, DI5:8 21 OFF
DIN40 - Digital input 40, DI5:9 21 OFF
DIN41 - Digital input 41, DI5:10 21 OFF
DIN42 - Digital input 42, DI5:11 21 OFF
DIN43 - Digital input 43, DI5:12 21 OFF
Digital outputs
Digital out 1
DOA01 - Digital output function 11 COOLCONI (*)
DOA02 - Inverted function no
DOA03 - Delay time for digital output 5.0
DOA04 - Delay function for output NO
Digital out 2
DOB01 - Digital output function 01 A1 (*)
DOB02 - Inverted function no
DOB03 - Delay time for digital output 5.0
DOB04 - Delay function for output NO
Digital out 3
DOC01 - Digital output function 01 W1 (*)
DOC02 - Inverted function no
DOC03 - Delay time for digital output 5.0
Page 2
E01PX10-2347.txt
DOC04 - Delay function for output NO
Digital out 4
DOD01 - Digital output function 02 START 1 (*)
DOD02 - Inverted function no
DOD03 - Delay time for digital output 5.0
DOD04 - Delay function for output NO
Digital out 5
DOE01 - Digital output function 04 REMOTE 1 (*)
DOE02 - Inverted function no
DOE03 - Delay time for digital output 5.0
DOE04 - Delay function for output NO
Digital out 6
DOF01 - Digital output function 03 READY 1 (*)
DOF02 - Inverted function no
DOF03 - Delay time for digital output 5.0
DOF04 - Delay function for output NO
Digital out 7
DOG01 - Digital output function 15 OFF
DOG02 - Inverted function no
DOG03 - Delay time for digital output 0.0 (*)
DOG04 - Delay function for output NO
Digital out 8
DOH01 - Digital output function 15 OFF
DOH02 - Inverted function no
DOH03 - Delay time for digital output 0.0 (*)
DOH04 - Delay function for output NO
Digital out 9
DOI01 - Digital output function 15 OFF
DOI02 - Inverted function no
DOI03 - Delay time for digital output 5.0
DOI04 - Delay function for output NO
Digital out 10
DOJ01 - Digital output function 15 OFF
DOJ02 - Inverted function no
DOJ03 - Delay time for digital output 5.0
DOJ04 - Delay function for output NO
Digital out 11
DOK01 - Digital output function 15 OFF
DOK02 - Inverted function no
DOK03 - Delay time for digital output 5.0
DOK04 - Delay function for output NO
Digital out 12
DOL01 - Digital output function 15 OFF
DOL02 - Inverted function no
DOL03 - Delay time for digital output 5.0
DOL04 - Delay function for output NO
Digital out 13
DOM01 - Digital output function 15 OFF
DOM02 - Inverted function no
DOM03 - Delay time for digital output 5.0
DOM04 - Delay function for output NO
Pulse inputs
Drive 1
P1I01 - Pulses/rev 3600 (*)
P1I02 - Units for REG109 rpm
P1I03 - Decimals for REG109 0
P1I04 - Scaling for REG109 1.00
P1I05 - Filter time for speed reading 0.0
P1I06 - Polarity - digital speed signal 1
P1I07 - Encoder type 1
Drive 2
P2I01 - Pulses/rev 1000
Page 3
E01PX10-2347.txt
P2I02 - Units for REG209 rpm
P2I03 - Decimals for REG209 0
P2I04 - Scaling for REG209 1.00
P2I05 - Filter time for speed reading 0.0
P2I06 - Polarity - digital speed signal 1
P2I07 - Encoder type 1
Analog inputs
Setpoint 1
AIA01 - Input type 4-20 mA
AIA02 - Zero point adjustment 0
AIA03 - Max point adjustment 0
AIA04 - Reading for REG101 %
Setpoint 2
AIB01 - Input type 4-20 mA
AIB02 - Zero point adjustment 0
AIB03 - Max point adjustment 0
AIB04 - Reading for REG201 %
Analog in 1
AIF01 - Input type 4-20 mA
AIF02 - Zero point adjustment 0
AIF03 - Max point adjustment 0
AIF04 - Min input, REG401 0
AIF05 - Max input, REG401 200
AIF06 - Units for REG401 bar
AIF07 - Decimals for REG401 0
AIF08 - Scaling for REG401 1.00
AIF09 - Function for input OFF
AIF10 - High indication level 200
AIF11 - Low indication level 0
AIF12 - Function for min indication OFF
AIF13 - Function for high indication OFF
AIF14 - Function for low indication OFF
Analog in 2
AIG01 - Input type 4-20 mA
AIG02 - Zero point adjustment 0
AIG03 - Max point adjustment 0
AIG04 - Min input, REG402 0
AIG05 - Max input, REG402 200
AIG06 - Units for REG402 bar
AIG07 - Decimals for REG402 0
AIG08 - Scaling for REG402 1.00
AIG09 - Function for input OFF
AIG10 - High indication level 200
AIG11 - Low indication level 0
AIG12 - Function for min indication OFF
AIG13 - Function for high indication OFF
AIG14 - Function for low indication OFF
Analog in 3
AIH01 - Input type 4-20 mA
AIH02 - Zero point adjustment 0
AIH03 - Max point adjustment 5 (*)
AIH04 - Min input, REG403 -25 (*)
AIH05 - Max input, REG403 100 (*)
AIH06 - Units for REG403 °C (*)
AIH07 - Decimals for REG403 1 (*)
AIH08 - Scaling for REG403 1.00
AIH09 - Function for input TANK A (*)
AIH10 - High indication level 60 (*)
AIH11 - Low indication level 0 (*)
AIH12 - Function for min indication OFF
AIH13 - Function for high indication OFF
AIH14 - Function for low indication OFF
Page 4
E01PX10-2347.txt
Analog in 4
AII01 - Input type 4-20 mA
AII02 - Zero point adjustment 0
AII03 - Max point adjustment 0
AII04 - Min input, REG404 0
AII05 - Max input, REG404 69 (*)
AII06 - Units for REG404 bar
AII07 - Decimals for REG404 0
AII08 - Scaling for REG404 1.00
AII09 - Function for input PR1 (*)
AII10 - High indication level 69
AII11 - Low indication level 0
AII12 - Function for min indication OFF
AII13 - Function for high indication OFF
AII14 - Function for low indication OFF
Analog in 5
AIJ01 - Input type 4-20 mA
AIJ02 - Zero point adjustment 0
AIJ03 - Max point adjustment 0
AIJ04 - Min input, REG405 0
AIJ05 - Max input, REG405 414 (*)
AIJ06 - Units for REG405 bar
AIJ07 - Decimals for REG405 0
AIJ08 - Scaling for REG405 1.00
AIJ09 - Function for input SP1 (*)
AIJ10 - High indication level 325 (*)
AIJ11 - Low indication level 10 (*)
AIJ12 - Function for min indication OFF
AIJ13 - Function for high indication OFF
AIJ14 - Function for low indication OFF
Analog in 6
AIK01 - Input type 4-20 mA
AIK02 - Zero point adjustment 0
AIK03 - Max point adjustment 0
AIK04 - Min input, REG406 0
AIK05 - Max input, REG406 200
AIK06 - Units for REG406 bar
AIK07 - Decimals for REG406 0
AIK08 - Scaling for REG406 1.00
AIK09 - Function for input OFF
AIK10 - High indication level 200
AIK11 - Low indication level 0
AIK12 - Function for min indication OFF
AIK13 - Function for high indication OFF
AIK14 - Function for low indication OFF
Analog in 7
AIL01 - Input type 4-20 mA
AIL02 - Zero point adjustment 0
AIL03 - Max point adjustment 0
AIL04 - Min input, REG407 0
AIL05 - Max input, REG407 200
AIL06 - Units for REG407 bar
AIL07 - Decimals for REG407 0
AIL08 - Scaling for REG407 1.00
AIL09 - Function for input OFF
AIL10 - High indication level 200
AIL11 - Low indication level 0
AIL12 - Function for min indication OFF
AIL13 - Function for high indication OFF
AIL14 - Function for low indication OFF
Analog in 8
AIM01 - Input type 4-20 mA
AIM02 - Zero point adjustment 0
Page 5
E01PX10-2347.txt
AIM03 - Max point adjustment 0
AIM04 - Min input, REG408 0
AIM05 - Max input, REG408 200
AIM06 - Units for REG408 bar
AIM07 - Decimals for REG408 0
AIM08 - Scaling for REG408 1.00
AIM09 - Function for input OFF
AIM10 - High indication level 200
AIM11 - Low indication level 0
AIM12 - Function for min indication OFF
AIM13 - Function for high indication OFF
AIM14 - Function for low indication OFF
Analog in 9
AIN01 - Input type 4-20 mA
AIN02 - Zero point adjustment 0
AIN03 - Max point adjustment 0
AIN04 - Min input, REG409 0
AIN05 - Max input, REG409 200
AIN06 - Units for REG409 bar
AIN07 - Decimals for REG409 0
AIN08 - Scaling for REG409 1.00
AIN09 - Function for input OFF
AIN10 - High indication level 200
AIN11 - Low indication level 0
AIN12 - Function for min indication OFF
AIN13 - Function for high indication OFF
AIN14 - Function for low indication OFF
Tank temp
AIP01 - Zero point adjustment 0
AIP02 - Max point adjustment 0
AIP03 - Units for REG410 °F (*)
Power limit
AIR01 - Power limitation E-motor 1 1101 (*)
AIR02 - Power limitation E-motor 2 400
AIR03 - Power limitation E-motor 3 400
Analog outputs
Analog out 1
AOA01 - Analog output REG109 (*)
AOA02 - 4-20mA or 2-10V ouput on
AOA03 - Zero point adjustment 0
AOA04 - Max point adjustment 0
Analog out 2
AOB01 - Analog output REG403 (*)
AOB02 - 4-20mA or 2-10V ouput on
AOB03 - Zero point adjustment 0
AOB04 - Max point adjustment 0
Analog out 3
AOC01 - Analog output REG405 (*)
AOC02 - 4-20mA or 2-10V ouput on
AOC03 - Zero point adjustment 0
AOC04 - Max point adjustment -15 (*)
Analog out 4
AOD01 - Analog output OFF
AOD02 - 4-20mA or 2-10V ouput off (*)
AOD03 - Zero point adjustment 0
AOD04 - Max point adjustment 0
Bus
Type && Function
BTF01 - Type of bus communication OFF
BTF02 - Max com. drop time 1
BTF03 - Function at com. drop Interlock
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E01PX10-2347.txt
Digital in
BDI01 - Digital input 1 21 OFF
BDI02 - Digital input 2 21 OFF
BDI03 - Digital input 3 21 OFF
BDI04 - Digital input 4 21 OFF
BDI05 - Digital input 5 21 OFF
BDI06 - Digital input 6 21 OFF
BDI07 - Digital input 7 21 OFF
BDI08 - Digital input 8 21 OFF
BDI09 - Digital input 9 21 OFF
BDI10 - Digital input 10 21 OFF
BDI11 - Digital input 11 21 OFF
BDI12 - Digital input 12 21 OFF
BDI13 - Digital input 13 21 OFF
BDI14 - Digital input 14 21 OFF
BDI15 - Digital input 15 21 OFF
BDI16 - Digital input 16 21 OFF
BDI17 - Digital input 17 21 OFF
BDI18 - Digital input 18 21 OFF
BDI19 - Digital input 19 21 OFF
BDI20 - Digital input 20 21 OFF
BDI21 - Digital input 21 21 OFF
BDI22 - Digital input 22 21 OFF
BDI23 - Digital input 23 21 OFF
BDI24 - Digital input 24 21 OFF
Analog in 1
BAA01 - Min input, REG501 0
BAA02 - Max input, REG501 200
BAA03 - Units for REG501 %
BAA04 - Decimals for REG501 0
BAA05 - Function for input OFF
Analog in 2
BAB01 - Min input, REG502 0
BAB02 - Max input, REG502 200
BAB03 - Units for REG502 %
BAB04 - Decimals for REG502 0
BAB05 - Function for input OFF
Analog in 3
BAC01 - Min input, REG503 0
BAC02 - Max input, REG503 200
BAC03 - Units for REG503 °
BAC04 - Decimals for REG503 0
BAC05 - Function for input OFF
Analog in 4
BAD01 - Min input, REG504 0
BAD02 - Max input, REG504 200
BAD03 - Units for REG504 bar
BAD04 - Decimals for REG504 0
BAD05 - Function for input OFF
Analog out
BAK01 - Analog output register OFF
BAK02 - Analog output register OFF
BAK03 - Analog output register OFF
BAK04 - Analog output register OFF
BAK05 - Analog output register OFF
BAK06 - Analog output register OFF
BAK07 - Analog output register OFF
BAK08 - Analog output register OFF
Pump monitor
Pump 1
PMA01 - Charge pr. interlock delay 5 sec
PMA02 - Delay, Charge pr. A 0.5 sec
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E01PX10-2347.txt
PMA03 - Delay, Charge pr. B 0.5 sec
PMA04 - Delay, Suction line 0.0 sec
PMA05 - Delay, Return filter 75% 7.0 sec
PMA06 - Delay, Return filter 100% 7.0 sec
PMA07 - Return filter alarm OFF
PMA08 - Delay, High work pr. A 7.0 sec
PMA09 - Mem bypass, work pr. A off
PMA10 - Delay, High work pr. B 7.0 sec
PMA11 - Mem bypass, work pr. B off
PMA12 - Signal plausibility check on
PMA13 - Error limits between in/out 50
PMA14 - Analog pressure sensor off
Pump 2
PMB01 - Charge pr. interlock delay 5 sec
PMB02 - Delay, Charge pr. A 0.5 sec
PMB03 - Delay, Charge pr. B 0.5 sec
PMB04 - Delay, Suction line 0.0 sec
PMB05 - Delay, Return filter 75% 7.0 sec
PMB06 - Delay, Return filter 100% 7.0 sec
PMB07 - Return filter alarm OFF
PMB08 - Delay, High work pr. A 7.0 sec
PMB09 - Mem bypass, work pr. A off
PMB10 - Delay, High work pr. B 7.0 sec
PMB11 - Mem bypass, work pr. B off
PMB12 - Signal plausibility check on
PMB13 - Error limits between in/out 50
PMB14 - Analog pressure sensor off
Pump 3
PMC01 - Charge pr. interlock delay 5 sec
PMC02 - Delay, Charge pr. A 0.5 sec
PMC03 - Delay, Charge pr. B 0.5 sec
PMC04 - Delay, Suction line 0.0 sec
PMC05 - Delay, Return filter 75% 7.0 sec
PMC06 - Delay, Return filter 100% 7.0 sec
PMC07 - Return filter alarm OFF
PMC08 - Delay, High work pr. A 7.0 sec
PMC09 - Mem bypass, work pr. A off
PMC10 - Delay, High work pr. B 7.0 sec
PMC11 - Mem bypass, work pr. B off
PMC12 - Signal plausibility check on
PMC13 - Error limits between in/out 50
PMC14 - Analog pressure sensor off
Pump 4
PMD01 - Charge pr. interlock delay 5 sec
PMD02 - Delay, Charge pr. A 0.5 sec
PMD03 - Delay, Charge pr. B 0.5 sec
PMD04 - Delay, Suction line 0.0 sec
PMD05 - Delay, Return filter 75% 7.0 sec
PMD06 - Delay, Return filter 100% 7.0 sec
PMD07 - Return filter alarm OFF
PMD08 - Delay, High work pr. A 7.0 sec
PMD09 - Mem bypass, work pr. A off
PMD10 - Delay, High work pr. B 7.0 sec
PMD11 - Mem bypass, work pr. B off
PMD12 - Signal plausibility check on
PMD13 - Error limits between in/out 50
PMD14 - Analog pressure sensor off
Tank monitor
Digital
TMA01 - Delay, Low oil level warn. 0.0 sec
TMA02 - Delay, Min oil level alarm 0.0 sec
TMA03 - Delay, Min temp alarm 0.0 sec
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E01PX10-2347.txt
TMA04 - Delay, High temp warn. 0.0 sec
TMA05 - Delay, Max temp alarm 0.5 sec
TMA06 - Delay, Drain 75% warn. 7.0 sec
TMA07 - Delay, Drain 100% warn. 7.0 sec
TMA08 - Drain filter alarm OFF
TMA09 - Min oil temp function A
Analog
TMB01 - Analog temp sensor on
TMB03 - Max oil temp alarm level 60
TMB04 - High oil temp warning level 55
TMB05 - Cooling temp on level (rise) 40
TMB06 - Cooling hysteresis 3
TMB07 - Filter interlock temp level 18 (*)
TMB08 - Heating temp on level (fall) 15
TMB09 - Heating hysteresis 3
TMB10 - Min oil temp alarm level 10
TMB11 - Flushing temp on level (fall) 30
TMB12 - Flushing hysteresis 3
Aux monitor
Aux 1
AMA01 - Aux function W D1
AMA02 - Aux delay time 0.1 (*)
AMA03 - Aux memory bypass on (*)
AMA04 - Aux configurable text Eng Stop (*)
AMA05 - Aux inverted input off
Aux 2
AMB01 - Aux function W D1
AMB02 - Aux delay time 1.0
AMB03 - Aux memory bypass off
AMB04 - Aux configurable text AUX 2
AMB05 - Aux inverted input off
Aux 3
AMC01 - Aux function W D1
AMC02 - Aux delay time 1.0
AMC03 - Aux memory bypass off
AMC04 - Aux configurable text AUX 3
AMC05 - Aux inverted input off
Aux 4
AMD01 - Aux function W D1
AMD02 - Aux delay time 1.0
AMD03 - Aux memory bypass off
AMD04 - Aux configurable text AUX 4
AMD05 - Aux inverted input off
Aux 5
AME01 - Aux function W D1
AME02 - Aux delay time 1.0
AME03 - Aux memory bypass off
AME04 - Aux configurable text AUX 5
AME05 - Aux inverted input off
Aux 6
AMF01 - Aux function W D1
AMF02 - Aux delay time 1.0
AMF03 - Aux memory bypass off
AMF04 - Aux configurable text AUX 6
AMF05 - Aux inverted input off
Aux 7
AMG01 - Aux function W D1
AMG02 - Aux delay time 1.0
AMG03 - Aux memory bypass off
AMG04 - Aux configurable text AUX 7
AMG05 - Aux inverted input off
Aux 8
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E01PX10-2347.txt
AMH01 - Aux function W D1
AMH02 - Aux delay time 1.0
AMH03 - Aux memory bypass off
AMH04 - Aux configurable text AUX 8
AMH05 - Aux inverted input off
Aux 9
AMI01 - Aux function W D1
AMI02 - Aux delay time 1.0
AMI03 - Aux memory bypass off
AMI04 - Aux configurable text AUX 9
AMI05 - Aux inverted input off
Aux 10
AMJ01 - Aux function W D1
AMJ02 - Aux delay time 1.0
AMJ03 - Aux memory bypass off
AMJ04 - Aux configurable text AUX 10
AMJ05 - Aux inverted input off
Aux 11
AMK01 - Aux function W D1
AMK02 - Aux delay time 1.0
AMK03 - Aux memory bypass off
AMK04 - Aux configurable text AUX 11
AMK05 - Aux inverted input off
Aux 12
AML01 - Aux function W D1
AML02 - Aux delay time 1.0
AML03 - Aux memory bypass off
AML04 - Aux configurable text AUX 12
AML05 - Aux inverted input off
Aux 13
AMM01 - Aux function W D1
AMM02 - Aux delay time 1.0
AMM03 - Aux memory bypass off
AMM04 - Aux configurable text AUX 13
AMM05 - Aux inverted input off
Aux 14
AMN01 - Aux function W D1
AMN02 - Aux delay time 1.0
AMN03 - Aux memory bypass off
AMN04 - Aux configurable text AUX 14
AMN05 - Aux inverted input off
Aux 15
AMO01 - Aux function W D1
AMO02 - Aux delay time 1.0
AMO03 - Aux memory bypass off
AMO04 - Aux configurable text AUX 15
AMO05 - Aux inverted input off
Aux 16
AMP01 - Aux function W D1
AMP02 - Aux delay time 1.0
AMP03 - Aux memory bypass off
AMP04 - Aux configurable text AUX 16
AMP05 - Aux inverted input off
Aux 17
AMQ01 - Aux function W D1
AMQ02 - Aux delay time 1.0
AMQ03 - Aux memory bypass off
AMQ04 - Aux configurable text AUX 17
AMQ05 - Aux inverted input off
Aux 18
AMR01 - Aux function W D1
AMR02 - Aux delay time 1.0
AMR03 - Aux memory bypass off
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AMR04 - Aux configurable text AUX 18
AMR05 - Aux inverted input off
Aux 19
AMS01 - Aux function W D1
AMS02 - Aux delay time 1.0
AMS03 - Aux memory bypass off
AMS04 - Aux configurable text AUX 19
AMS05 - Aux inverted input off
Aux 20
AMT01 - Aux function W D1
AMT02 - Aux delay time 1.0
AMT03 - Aux memory bypass off
AMT04 - Aux configurable text AUX 20
AMT05 - Aux inverted input off
Drive monitor
Start interlock
DMA01 - Start alternative, drive 1 and
DMA02 - Start delay time, drive 1 5 sec
DMA03 - Start alternative, drive 2 and
DMA04 - Start delay time, drive 2 5 sec
Drive 1
DMB01 - Delay, charge pressure A 0.5 sec
DMB02 - Delay, charge pressure B 0.5 sec
DMB03 - Delay, E-motor temp 0.0 sec
DMB04 - Delay, work pressure A 7.0 sec
DMB05 - Mem bypass, work pr. A off
DMB06 - Delay, work pressure B 7.0 sec
DMB07 - Mem bypass, work pr. B off
DMB08 - Analog pressure sensor off
Drive 2
DMC01 - Delay, charge pressure A 0.5 sec
DMC02 - Delay, charge pressure B 0.5 sec
DMC03 - Delay, E-motor temp 0.0 sec
DMC04 - Delay, work pressure A 7.0 sec
DMC05 - Mem bypass, work pr. A off
DMC06 - Delay, work pressure B 7.0 sec
DMC07 - Mem bypass, work pr. B off
DMC08 - Analog pressure sensor off
Emotor interlock
DMD01 - Delay, Interlock E-motor 1 1.0
DMD02 - Delay, Interlock E-motor 2 1.0
DMD03 - Delay, Interlock E-motor 3 1.0
Drive 1 basic
Setpoint
D1A01 - Speed setpoint Local/Remote (*)
D1A02 - Type of command signal Unidirectional (*)
D1A03 - Reset of local setpoint yes
D1A04 - Reverse input on (*)
D1A05 - Reverse command setpoint -10.0 (*)
D1A06 - Digital forward setpoint 10.0
D1A07 - Digital reverse setpoint -10.0
D1A08 - Drive front panel buttons on
Ramp
D1C01 - Up ramp time forward 2.0
D1C02 - Down ramp time forward 2.0
D1C03 - Up ramp time reverse 2.0
D1C04 - Down ramp time reverse 2.0
Regulator
D1D01 - Regulator on (*)
D1D02 - Feed forward function on
D1D03 - Proportional regulator on (*)
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E01PX10-2347.txt
D1D04 - Integrating regulator on (*)
D1D05 - Derivation regulator off
D1D06 - Proportional gain 0.1
D1D07 - Integration time 10.0
D1D08 - Derivation time 0.10
D1D09 - Derivation decline time 0.1
D1D10 - Max feedback deviation 50
D1D11 - Regulated or nonregulated Switching (*)
Feedback
D1E01 - Max motor shaft speed 8.0 (*)
D1E02 - Feedback selection Digital
D1E03 - Filter time for feedback 0.0
Power limitation
D1F01 - Delay time, power limitation 0.0 (*)
D1F02 - Ramp time, power limitation 20.0
Drive 2 basic
Setpoint
D2A01 - Speed setpoint Local
D2A02 - Type of command signal Bidirectional
D2A03 - Reset of local setpoint yes
D2A04 - Reverse input off
D2A05 - Reverse command setpoint -20.0
D2A06 - Digital forward setpoint 10.0
D2A07 - Digital reverse setpoint -10.0
D2A08 - Drive front panel buttons on
Ramp
D2C01 - Up ramp time forward 2.0
D2C02 - Down ramp time forward 2.0
D2C03 - Up ramp time reverse 2.0
D2C04 - Down ramp time reverse 2.0
Regulator
D2D01 - Regulator off
D2D02 - Feed forward function on
D2D03 - Proportional regulator off
D2D04 - Integrating regulator off
D2D05 - Derivation regulator off
D2D06 - Proportional gain 0.1
D2D07 - Integration time 10.0
D2D08 - Derivation time 0.10
D2D09 - Derivation decline time 0.1
D2D10 - Max feedback deviation 50
D2D11 - Regulated or nonregulated Non-regulated
Feedback
D2E01 - Max motor shaft speed 10.0
D2E02 - Feedback selection Digital
D2E03 - Filter time for feedback 0.0
Power limitation
D2F01 - Delay time, power limitation 0.5
D2F02 - Ramp time, power limitation 20.0
Shredder 1
Function
SHA01 - Reverse control Pressure, separate
SHA02 - Reverse stop function Going to forward
SHA03 - Delay before reversal 3.0
SHA04 - Reversal time 10.0
SHA05 - Reverse delay SHA02 3.0
SHA06 - Forward time 10.0
SHA07 - Shredder automatic dir. off
SHA08 - Forward time interval 60
SHA09 - Reverse time interval 60
SHA10 - Selection of regulated dr. Unregulated
Page 12
E01PX10-2347.txt
Setpoint
SHB01 - Reverse command setpoint Forward
SHB02 - Scale factor for reverse 100
SHB03 - Analog pressure sensor off
SHB04 - High pr. level, forward 200
SHB05 - High pr. level, reverse 200
Counter
SHC01 - Window time for counter 60
SHC02 - Reversal counter 5
Shredder 2
Function
SHG01 - Reverse control Pressure, separate
SHG02 - Reverse stop function Going to forward
SHG03 - Delay before reversal 3.0
SHG04 - Reversal time 10.0
SHG05 - Reverse delay SHG02 3.0
SHG06 - Forward time 10.0
SHG07 - Shredder automatic dir. off
SHG08 - Forward time interval 60
SHG09 - Reverse time interval 60
SHG10 - Selection of regulated dr. Unregulated
Setpoint
SHH01 - Reverse command setpoint Forward
SHH02 - Scale factor for reverse 100
SHH03 - Analog pressure sensor off
SHH04 - High pr. level, forward 200
SHH05 - High pr. level, reverse 200
Counter
SHI01 - Window time for counter 60
SHI02 - Reversal counter 5
Synchro
Function
SYA01 - Type of synchronisation RATIO
SYA02 - Master command D1 Master - D2 Slave
Drive 1 reset
SYB01 - Counter reset command Reset by start
SYB02 - Enable of counter reset E-motors start
Drive 2 setpoint
SYC01 - Drive 2 low friction limit 0
SYC02 - Drive 2 high friction limit 200
SYC03 - Offset reset by motor start off
SYC04 - Offset for Drive 2 0.0
Drive 2 indication
SYD01 - Synchro indication limit 5
SYD02 - Sync time 1.0
Drive 2 reset
SYE01 - Counter reset command Reset by start
SYE02 - Enable of counter reset E-motors start
Master setpoint
SYF01 - Up ramp time forward 2.0
SYF02 - Down ramp time forward 2.0
SYF03 - Up ramp time reverse 2.0
SYF04 - Down ramp time reverse 2.0
Drive 1 setpoint
SYG01 - Drive 1 low friction limit 0
SYG02 - Drive 1 high friction limit 200
Pressure 1
Function
PRA01 - Pressure control off
PRA02 - Reverse dir. of ctrl action off
Page 13
E01PX10-2347.txt
PRA03 - Low pressure control off
PRA04 - High pressure control off
PRA05 - Filter time, low pr. control 5
PRA06 - Filter time, high pr. control 5
Pr. setpoint
PRB01 - Pressure setpoint Local
PRB02 - Local pressure setpoint 200
PRB03 - Low limit, pressure setpoint 25
PRB04 - High limit, pressure setpoint 25
PRB05 - Low limit, PID output 10
PRB06 - High limit, PID output 10
PRB07 - Max pressure 250
Regulator
PRC01 - Proportional regulator off
PRC02 - Integrating regulator off
PRC03 - Derivation regulator off
PRC04 - Proportional gain 0.1
PRC05 - Integration time 10.0
PRC06 - Derivation time 0.10
PRC07 - Derivation decline time 0.1
PRC08 - Filter time for pr. feedback 0.0
Pressure 2
Function
PRG01 - Pressure control off
PRG02 - Reverse dir. of ctrl action off
PRG03 - Low pressure control off
PRG04 - High pressure control off
PRG05 - Filter time, low pr. control 5
PRG06 - Filter time, high pr. control 5
Pr. setpoint
PRH01 - Pressure setpoint Local
PRH02 - Local pressure setpoint 200
PRH03 - Low limit, pressure setpoint 25
PRH04 - High limit, pressure setpoint 25
PRH05 - Low limit, PID output 10
PRH06 - High limit, PID output 10
PRH07 - Max pressure 250
Regulator
PRI01 - Proportional regulator off
PRI02 - Integrating regulator off
PRI03 - Derivation regulator off
PRI04 - Proportional gain 0.1
PRI05 - Integration time 10.0
PRI06 - Derivation time 0.10
PRI07 - Derivation decline time 0.1
PRI08 - Filter time for pr. feedback 0.0
Reading 1
Scroll menu
R1A01 - Text for reading 1 HIGH PSI (*)
R1A02 - Reading 1 REG405 (*)
R1A03 - Text for reading 2 TANKTEMP (*)
R1A04 - Reading 2 REG403 (*)
R1A05 - Text for reading 3 READING3
R1A06 - Reading 3 OFF
R1A07 - Text for reading 4 READING4
R1A08 - Reading 4 OFF
R1A09 - Text for reading 5 READING5
R1A10 - Reading 5 OFF
R1A11 - Text for reading 6 READING6
R1A12 - Reading 6 OFF
R1A13 - Text for reading 7 READING7
Page 14
E01PX10-2347.txt
R1A14 - Reading 7 OFF
R1A15 - Text for reading 8 READING8
R1A16 - Reading 8 OFF
R1A17 - Text for reading 9 READING9
R1A18 - Reading 9 OFF
Left upper
R1B01 - Reading REG102
Right upper
R1C01 - Reading REG106
Left lower
R1D01 - Reading REG109
Right lower
R1E01 - Reading REG311
Reading 2
Scroll menu
R2A01 - Text for reading 1 READING1
R2A02 - Reading 1 OFF
R2A03 - Text for reading 2 READING2
R2A04 - Reading 2 OFF
R2A05 - Text for reading 3 READING3
R2A06 - Reading 3 OFF
R2A07 - Text for reading 4 READING4
R2A08 - Reading 4 OFF
R2A09 - Text for reading 5 READING5
R2A10 - Reading 5 OFF
R2A11 - Text for reading 6 READING6
R2A12 - Reading 6 OFF
R2A13 - Text for reading 7 READING7
R2A14 - Reading 7 OFF
R2A15 - Text for reading 8 READING8
R2A16 - Reading 8 OFF
R2A17 - Text for reading 9 READING9
R2A18 - Reading 9 OFF
Left upper
R2B01 - Reading REG202
Right upper
R2C01 - Reading REG206
Left lower
R2D01 - Reading REG209
Right lower
R2E01 - Reading REG321
Page 15
SPIDER USERS MANUAL
Users Manual
SPIDER 2
Program Release v 2
Software Version 4.1.2
SPIDER AS
Engineering manual
Preface
04-04-02, New
Preface
Hägglunds is one of the worlds leading manufacturers of large hydraulic Drive Systems. A leading position,
made possible by unbeatable service spirit and of continuing development of both products and markets
all over the world. Our drives are to be found in most industrial and marine segments, where there are
extremely high demands for efficiency and reliability. Our main office and production plant is in Mellansel,
Sweden and we have our own sales- and representation offices in some 40 different countries.
This Engineering manual provides necessary information for Spider control system. In order to find particular
information, just search for the wanted section as listed in the table of contents. However, changes in the
equipment may occur. We therefore reserve the right to introduce amendments in the manual as we deem
necessary without notice or obligations.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will cause
personal injury or substantial property damage. Depending on the probability of the hazard, and how
serious the injury or property damage could be, there are three levels of classification.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 1(1)
AS-1
Spider Introduction
Engineering manual 04-04-02
1.1 Description
The Spider unit is a microcontroller based system, configurable to suit different application
needs. It is designed to match the two or three door power unit also with one door unit added.
The control system can control pumps with double coil (Denison 9A, Brueninghaus EP, Sauer
Sundstrand KA or similar pumps) or single coil in one direction (Denison 5A).
The unit can be mounted inside the power unit, in the power unit door, on the outside of the
power unit or delivered separate with wall brackets or panel flange to be wired in by the
customer. Cable sets can be supplied as an option.
The configuration of the pre-programmed system functions is done using the front panel with
help from the text displays or via a serial connection from a laptop. The configuration mode can
be protected with a password.
The Spider unit can control the system with different settings of electric motor/pump
configuration.
EM EM EM EM
DRIVE P DRIVE P P P
EM EM EM EM EM
DRIVE P P
DRIVE P P
P P
EM EM
P P
DRIVE P P
DRIVE
EM EM
DRIVE P P
DRIVE
EM EM EM
DRIVE P P P
DRIVE
-------
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(7)
AS1, Introduction, Engineering manual 04-04-02
• Two to four pumps for two drives with common function. If one stops by a fault the other will
also stop:
EM EM EM
DRIVE P
DRIVE P
DRIVE P
DRIVE P
EM EM EM EM
DRIVE P P
DRIVE P P
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P
DRIVE P P
EM EM EM
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P P
DRIVE P
The Monitor function can health monitor the power unit switches and give information on the text
display about warnings or alarms. An alarm will stop the electric motor or motors if the digital
interlock output is connected via a relay to the starter interlock circuit. Up to 4 pumps can be
controlled in parallel for the same drive
M M M
M M
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(7)
AS1, Introduction, Engineering manual 04-04-02
The Basic function has added functions for power limitation and closed loop speed feedback via
a PID-regulator. Inputs are available for analog or digital speed encoders.
The unit can also monitor analog signals on the display such as speed, E-motor current,
pressure etc.
The Shredder function has the same functions as Basic and added functions for reversing by an
overload-stopped drive. It is possible to maximise the number of reversals within a time limit and
stop the drive when exceeded. The drive can be set to change direction after an adjustable time
interval.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(7)
AS1, Introduction, Engineering manual 04-04-02
The Friction function has the same functions as Basic and added functions for control of two
hydraulic drives driven together with a ratio between the motors.
The Friction slave function has the same functions as Basic and added functions for control of
two hydraulic drives driven together with a ratio in relation to the master setpoint.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(7)
AS1, Introduction, Engineering manual 04-04-02
The Synchro function has the same functions as Basic and added functions for position control
between two hydraulic drives. It is possible by an external signal to set the angle between the
rolls. Ratio drive is also possible. This mode requires digital speed encoders.
The pressure control function output is added to the ramped flow command. The function
compares actual pressure to a setpressure and gives a positive or negative output depending on
sign of the difference and action direction of regulation.
The Spider unit front has push-buttons for start and stop of the drive, local/remote, speed
setpoint by increase and decrease in local mode, inch reverse, regulated/non-regulated drive
and auto/manual drive in shredder mode. These push-button functions can be bypassed in the
configuration of the system functions.
All inputs and outputs are configurable and can be connected to pre-programmed functions in
the setup of the system. All signals are as standard wired to contact terminals or via fieldbus port
(optional).
The digital inputs can be configured to functions for eg. start/stop, reverse, reset, monitoring of
the power unit, auxiliary monitor where it is possible to set the function and display monitor text.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(7)
AS1, Introduction, Engineering manual 04-04-02
The digital outputs can be configured to functions for eg. common alarm/warning, ready to use,
drive started, shredder blocked, cooler and heater control. The outputs are of dry relay contact
type.
The analog inputs can be configured to functions for eg. tank temp, speed, pressure, power for
monitoring and control. The inputs can be configured for current loop or voltage.
The analog outputs can be configured to monitor eg. speed, pressure, temp. The outputs can be
configured for current loop or voltage.
The system includes a drive monitoring function with drive time counters, alarm/warning list and
8 scalable log channels with data download via serial interface. A remote drive monitoring
system with access via GSM can be added as an option.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(7)
AS1, Introduction, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(7)
AS-2
Spider Technical data
Engineering manual 04-04-02
2.1 Mechanical
2.1.1 Mechanical data
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(5)
AS2, Technical data, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(5)
AS2, Technical data, Engineering manual 04-04-02
2.3 Inputs
2.3.1 Analog inputs
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(5)
AS2, Technical data, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
2.3.2 Digital inputs
2.4 Outputs
2.4.1 Pump control
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(5)
AS2, Technical data, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
2.5 Communication
2.5.1 PC connection
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(5)
AS-3
Spider Connection
Engineering manual
04-04-02
3.1 Wiring
Shielded cables are preferred for the installation.
The wire must be min 0,5mm2 for input signals and min 1mm2 for supply and output cables.
Max distance between control system and power unit is 50m.
3.2 Supply
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(30)
AS-3 Connection, Engineering manual 04-04-02
SETPOINT DRIVE 1
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(30)
AS-3 Connection, Engineering manual 04-04-02
SETPOINT DRIVE 2
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(30)
AS-3 Connection, Engineering manual 04-04-02
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 11(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 12(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 15(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(30)
AS-3 Connection, Engineering manual 04-04-02
Pumps with separate coils for A and B side can be used. If pumps with a common coil for both
directions is used, the drive can only be controlled in one direction.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 17(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 19(30)
AS-3 Connection, Engineering manual 04-04-02
Note! All outputs must be protected against induced voltage at switch off by e.g. free wheeling
diode (see 3.4.2), varistor, RC circuit or other overvoltage protection device mounted close to
the load.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 21(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(30)
AS-3 Connection, Engineering manual 04-04-02
INTERCONNECTION TERMINAL
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(30)
AS-3 Connection, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
1 2 3 4 5
6 7 8 9
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not connected
Pin3 B-line, Pos TXD/RXD
Pin4 RTS, Request to send
Pin5 GND BUS
Pin6 +5V BUS
Pin7 Not connected
Pin8 A-line, Neg TXD/RXD
Pin9 Not connected
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(30)
AS-3 Connection, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not used
Pin3 Not used
Pin4 Not connected
Pin5 GND
Pin6 +5V
Pin7 RS485 B-line
Pin8 RS485 A-line
Pin9 Not connected
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(30)
AS-3 Connection, Engineering manual 04-04-02
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Spare terminals IC 6 For interconnection purpose
5 For interconnection purpose
4 For interconnection purpose
3 For interconnection purpose
2 For interconnection purpose
1 For interconnection purpose
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(30)
AS-4
Spider Indication and setting
Engineering manual 04-04-02
E-MOTOR STARTED
TESTING HARDWARE
SYSTEM READY TO USE
DRIVE MODE
OFF REM
-> TANKTEMP 34°C <-
0% 0%
0rpm 0Amp
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(14)
AS4, Indication and setting, Engineering manual 04-04-02
DRIVE INDICATION
WARN = Common Warning
ALARM = Common Alarm
INT = Interlock
ON = Drive Started
OFF = Drive Stopped
REM = Remote speed command
LOC = Local speed command
BUS = Fieldbus remote speed command
"Blank" = Open loop drive
REG = Closed loop speed feedback drive
WARN ON REM REG AUT MAN = Manual mode (Only in Shredder function)
AUT = Auto mode (only in Shredder function)
> TANKTEMP 35°C <
85 % 92 %
Scroll list shown
20.5 rpm 120 kW
INTERLOCK INDICATION
INTERLOCK DRIVE 1
NO EXT FEED
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(14)
AS4, Indication and setting, Engineering manual 04-04-02
RESET OF ALARMS/WARNINGS
ALARM OFF REM OFF REM
E-MOTOR STOPPED E-MOTOR STOPPED
0% 0% 0% 0%
0.0 rpm 0 mA 0.0 rpm 0 mA
DRIVE 1 3 sec.
DRIVE 1
OR
OR
DRIVE 2 3 sec.
DRIVE 2
ALARM DRIVE 1
LOW CHARGE PRESS P1
NO MORE ALARMS OR
WARNINGS
ALARM DRIVE 1
MIN OIL LEVEL
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(14)
AS4, Indication and setting, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(14)
AS4, Indication and setting, Engineering manual 04-04-02
4.4.2 Drive buttons
INCREASE
Increase speed setpoint when driving
in local mode (front panel setpoint).
FORWARD
Manual forward in Shredder function.
Same
button Switching between open and closed loop
REG/UNREG
speed control when speed feedback used.
(Not avaliable in Shredder function)
Inch reverse with fixed speed.
REVERSE Manual reverse in Shredder function.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(14)
P24
To displays
P23
P27
1 Jtag programming port for Microcontroller IC4
2 1 2
P25
Microcontroller TP2 1 2
TP5 TP4
1
Contact for Spidercom connection
TP23
SW1 5
TP21
TP22 P22
IC15 1
Jtag programming port for CPLD
4.5.1 Revision A
P28
TMS To memory card
CPLD TDI
TP3 TMO
TCK
GND To front keypad
+3V3
C137 C138
Watchdog
indicator TP19 TP16
TP18 TP15
D1 SW3
J1 2 TP17
TP20
W-DOG
1
ON
OFF
1
TP9 P47
4.5 Main card jumpers and indications
12
Logger connection
TP10
TP6
REL15
REL16
REL14
TP7
+
+ TP13
TP12
DC1
- TP11 Supply voltage
indicators
1
Jumpers for analog
P3
- Supply voltage indicators current loop inputs
Jumpers for analog TP8
REL17
current loop inputs
D170 D171 D172 D173 D174 D175 D176 D181
U
AS4, Indication and setting, Engineering manual
I Logger connections
AI6 I AI7 I AI8 I AI9 I AI3 I AI4 I AI5
DO EM EI DE DI1 DI2 AI DE D116 D117
12V 1 1 1 1 1 1 1
PO4
PO4
I I I I P43 P44 P45 P46 P40 P41 P42
SP SP AI_1 AI_2
D1 D2 + - 10V
P2
CA2
CA1
REL18
REL6
REL5
REL9
REL8
REL4
REL7
REL11
REL10
REL3
REL12
REL13
REL1
REL2
PO3
PO3
AO2
1
CA1
CA1
1
P21
P19
1
AO2
PO2
PO2
P1
IC1
IC1
P20
DO1 DO2 EO1 EI/ DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
EM
P14
PO1
PO1
P18
P9
P10
P16
P11
P15
P17
1
1
1
1
1
1
1
1
1
P7
P8
P12
P13
P6
P5
P4
1
1
1
1
1
1
DO1 DO2 EO1 EI/EM DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
05-01-21, replaces 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
6(14)
04-04-02
AS4, Indication and setting, Engineering manual 04-04-02
4.5.2 Jumpers
4.5.3 Indicators
4.5.4 Switches
SW3-2 No function
4.5.5 Contacts
DC supply DC1
Pump output 1 PO1 4 pole contact
Pump output 2 PO2 4 pole contact
Pump output 3 PO3 4 pole contact
Pump output 4 PO4 4 pole contact
Digital output 1 DO1 14 pole contact
Digital output 2 DO2 12 pole contact
Electric motor output EO1 8 pole contact
Electric motor input EI/EM 8 pole contact
Emergency stop input
Digital encoder 1 DE1 8 pole contact
Digital encoder 2 DE2 8 pole contact
Digital input 1 DI1 8 pole contact
Digital input 2 DI2 12 pole contact
Digital input 3 DI3 12 pole contact
Digital input 4 DI4 12 pole contact
Digital input 5 DI5 12 pole contact
Analog input 1 AI1 12 pole contact
Analog input 2 AI2 12 pole contact
Analog input 3 AI3 14 pole contact
Analog output 1 AO1 6 pole contact
Analog output 2 AO2 6 pole contact
Internal connection IC 6 pole contact
CAN bus 1 CA1 6 pole contact
CAN bus 2 CA2 6 pole contact
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(14)
AS4, Indication and setting, Engineering manual 04-04-02
24V OK
DC connection
Fuse
Main switch
Main connection
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(14)
AS4, Indication and setting, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
Profibus connector
Termination switch
D5
S1
ON
S3 S2
1 2
LED indicators
901 901
23
23
78
78
456 456
4 3
Address switches
4.7.1.1 Indicators
Indicator Description Function Information
name
D1 Not used Not used Normal function
Off No error.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(14)
AS4, Indication and setting, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
4.7.1.2 Switches
Indicator Function Information
name
S1 Terminating switch On= Enabled (if first or last in a network)
Off= Disabled
S2 Node Address x1 for the node address setting
4.7.2 Modbus
Modbus connector
Termination switch
S1
ON
S2 S3
1 2
LED indicators
3 4
1 2 3 4 5 6 7 8 1 2 3 4
Parity switches
Baudrate switches
Node Address switches
4.7.2.1 Indicators
Indicator Description Function Information
name
D1 Processing Green flashing Receiving Query and building
response.
Off No Query
D2 Bus error Red Bus error
4.7.2.2 Switches
Indicator Function Setting Information
name
S1 Terminating switch On Enabled (if first or last in a
network)
Off Disabled
S2: 1-7 Node Address Binary value:
Switch: 1234567
0000000 Not valid
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Baud rate Binary value:
S3: 1-2 Switch: 812
000 Not valid
001 1200
010 2400
011 4800
100 9600
101 19200 (Default)
110 38400
111 57600
S3: 1-2 Parity Binary value:
Switch: 34
00 Not valid
01 None(Default)
10 Even
11 Odd
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 12(14)
AS4, Indication and setting, Engineering manual 04-04-02
When the software stops both Hardware(M) time and Software(S) time is displayed in 1/10 sec so that
the times can be verified/corrected.
HW ERROR, FC 2
This test is to verify that the relay that feeds the PWM-outputs opens. If emergency stop is actuated
the Spider hardware for emergency stop open this relay. This test is performed when all e-motors are
stopped. If the relay doesn't open on this test, error message ”HW ERROR, FC 2” is displayed and
the software stops.
HW ERROR, FC 3
This test is to verify that the electric motor interlock relays opens. When electric motor interlock is
OK the relay is closed and open when interlock not is OK. If the relay not opens, error message ”HW
ERROR, FC 3” is displayed and the software stops. This test is performed at power on and once when all
electric motors are stopped.
HW ERROR, FC 4
Watchdog indication should not be acived during normal program execution. If it happens during normal
program execution, error message ”HW ERROR, FC 4” is displayed and the software stops. This test is
performed continiously.
HW ERROR, FC 5
If measured current is 50% greater than max configured current a shortcircuit is assumed,
error message ”HW ERROR, FC 5” is displayed and the software stops. This test is performed continiously.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(14)
AS4, Indication and setting, Engineering manual 04-04-02
4.9.4 Bus
BUS FAIL
Anybus function is selected but the communication does not function. This error is likely to occur if the bus
cable not is connected.
BUS HW FAIL
Anybus function is selected but the hardware is not functioning. This error is likely to occur if the bus module
is missing or defect.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(14)
AS-5
Spider Parameters V4.1.x
Engineering manual 05-01-21
Pump Monitor (23) Pump 1 PMA Reading 1 (39) Scroll menu R1A
Pump 2 PMB Left upper R1B
Pump 3 PMC Right upper R1C
Pump 4 PMD Left lower R1D
Right lower R1E
Tank Monitor (25) Digital TMA
Analog TMB Reading 2 (40) Scroll menu R2A
Left upper R2B
Right upper R2C
Left lower R2D
Right lower R2E
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Main settings-Configuration
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Main settings-Language
Switch Description Type Default Min Max
Main settings-Reset
Switch Description Type Default Min Max
Pump outputs-Pump1
Switch Description Type Default Min Max
Pump outputs-Pump2
Switch Description Type Default Min Max
Pump outputs-Pump3
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump outputs-Pump4
Switch Description Type Default Min Max
Pump outputs-Friction
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Digital Inputs
Switch Description Type Default
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
17 AUTO 1 Activated input = auto mode Drive 1, Open input = manual mode
17 AUTO 2 Activated input = auto mode Drive 2, Open input = manual mode
17 AUTO 1+2 Activated input = auto mode Drive 1 and 2, Open input = manual mode
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
18 REG 1 Activated input = Closed loop speed feedback active Drive 1, Open input = Open loop
18 REG 2 Activated input = Closed loop speed feedback active Drive 2, Open input = Open loop
18 REG 1+2 Activated input = Closed loop speed feedback active Drive 1+2, Open input = Open loop
18 ERR1 RES External reset of Error too large function, Drive 1
18 ERR2 RES External reset of Error too large function, Drive 2
18 ERR1+2 R External reset of Error too large function, Drive 1 and 2
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 11(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
03 READY 1 Ready to use, Drive1 (also to be used for Fail safe valve, Drive 1)
03 READY 2 Ready to use, Drive2 (also to be used for Fail safe valve, Drive 2)
03 READY1+2 Drive 1 or Drive 2 ready
03 READY1*2 Drive 1 and Drive 2 ready
08 C ZERO Indication for found zero position in Synchro counter function (synchro activated)
08 SYNCHRO Synchro within limits set in parameter L22
09 AOUT 1- Selected register reading for analogue output 1 has negative sign
09 AOUT 2- Selected register reading for analogue output 2 has negative sign
09 AOUT 3- Selected register reading for analogue output 3 has negative sign
09 AOUT 4- Selected register reading for analogue output 4 has negative sign
Pulse inputs-Drive 1
Switch Description Type Default Min Max
Pulse inputs-Drive 2
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 15(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
AIP01 Zero point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP02 Max point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP03 Units for REG410 **** °C
*** Possible units of measure settings: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
rps, lpm, gpm, mm, “, l, gal
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.8 Bus
Bus – Type&Function
Switch Description Type Default Min Max
Bus – Analog in 1
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Bus – Analog in 2
Switch Description Type Default Min Max
Bus – Analog in 3
Switch Description Type Default Min Max
Bus – Analog in 4
Switch Description Type Default Min Max
** Possible units of measure settings: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
A, kW, hp, °, rps, lpm, gpm
*** Possible function settings:
BSO = Synchro offset (Synchro function)
BP1 = Pressure setpoint, Drive 1 (Pressure function)
BP2 = Pressure setpoint, Drive 2 (Pressure function)
BMS = Master speed setpoint (Synchro function)
PF = Pump friction
OFF = Not used
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 21(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump monitor-Pump 1
Switch Description Type Default Min Max
Pump monitor-Pump 2
Switch Description Type Default Min Max
Pump monitor-Pump 3
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump monitor-Pump 4
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Tank monitor-Digital
Switch Description Type Default Min Max
Tank monitor-Analog
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux1
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux8
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux15
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive monitor-Drive 1
Switch Description Type Default Min Max
Drive monitor-Drive 2
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 1 basic-Setpoint
Switch Description Type Default Min Max
Drive 1 basic-Ramp
Switch Description Type Default Min Max
Drive 1 basic-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 1 basic-Feedback
Switch Description Type Default Min Max
D1E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D1E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D1E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 31(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 2 basic-Setpoint
Switch Description Type Default Min Max
Drive 2 basic-Ramp
Switch Description Type Default Min Max
Drive 2 basic-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 32(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 2 basic-Feedback
Switch Description Type Default Min Max
D2E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D2E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D2E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 33(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.15 Shredder 1
Shredder 1-Function
Switch Description Type Default Min Max
Shredder 1-Setpoint
Switch Description Type Default Min Max
Shredder 1-Counter
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 34(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.16 Shredder 2
Shredder 2-Function
Switch Description Type Default Min Max
Shredder 2-Setpoint
Switch Description Type Default Min Max
Shredder 2-Counter
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 35(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.17 Synchro
Synchro-Function
Switch Description Type Default Min Max
Synchro-Drive 2 setpoint
Switch Description Type Default Min Max
Synchro-Drive 1 setpoint
Switch Description Type Default Min Max
5.2.18 Pressure 1
Pressure 1-Function
Switch Description Type Default Min Max
Pressure 1-Pr.setpoint
Switch Description Type Default Min Max
Pressure 1-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 37(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.19 Pressure 2
Pressure 2-Function
Switch Description Type Default Min Max
Pressure 2-Pr.setpoint
Switch Description Type Default Min Max
Pressure 2-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 38(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.20 Reading 1
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 39(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.21 Reading 2
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 40(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 41(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 42(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 43(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 44(44)
AS-6
Spider Software settings and function
Engineering manual 04-04-02
Contents
Introduction ............................................................................................................. 2
6.1 General system setup ....................................................................................... 3
6.2 Speed command............................................................................................... 4
6.3 Ramp ................................................................................................................ 4
6.4 Output ............................................................................................................... 5
6.5 Speed feedback ................................................................................................ 6
6.6 Power limitation................................................................................................. 9
6.7 Monitoring ....................................................................................................... 10
6.8 Analog inputs .................................................................................................. 11
6.9 Digital inputs ................................................................................................... 12
6.10 Digital outputs ............................................................................................... 19
6.11 Signal monitor ............................................................................................... 21
6.12 Shredder ....................................................................................................... 23
6.13 Synchro......................................................................................................... 24
6.14 Pressure control............................................................................................ 25
6.15 Bus Communication...................................................................................... 28
6.16 Drive monitoring log ...................................................................................... 33
6.17 Analog outputs .............................................................................................. 35
6.18 Language selection....................................................................................... 35
6.19 Drive monitoring log ...................................................................................... 36
6.20 Emergency stop ............................................................................................ 37
6.21 Program update ............................................................................................ 38
6.22 Hardware calibration ..................................................................................... 38
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(38)
AS-6
Spider Software settings and function
Engineering manual 04-04-02
Introduction
Settings of the basic blocks in the software. All settings are for drive 1. The same procedure is done for
drive 2 but with the parameter letter in ().
This also describes the logical order for the system set up.
The list of parameters is found in AS5 and block diagrams with parameters are found in AS7.
The choice of parameters are made by using the directional buttons (◄, ►, ▲ & ▼) (see AS5.1). After a
change, the choice must be updated with the enter button (◄┘). The parameters are updated in the
memory when going back to the Main status reading in the display.
The settings can be protected by a password (MAIN SETTINGS Æ PROTECTION: MAD01-02).
The drive monitoring function is protected by a separate password under SETUP-LOG FUNCTION.
Setpoint(s)
Customer
Drive control
El.m. 1 El.m. 2 El.m. 3 Spider 2 Digital/analog
Stroker current(s)
indications
Analog indicators
Pump4
Function:
Drive 1 Basic
Friction
Syncro
Drive 2 Shredder
Pressure
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(38)
AS6, Software settings and function, Engineering manual 04-04-02
• BASIC – The basic and most common function. The function includes monitoring, speed feedback
and power limitation. This is the function that also is selected for monitoring type unit.
• SHREDDER – Same as for BASIC with added functions for reversing by an overload stopped
drive.
• SYNCHRO – Same as for BASIC with two drives driven together with FRICTION ratio or position
control between the motors.
The PRESSURE function can be used with BASIC, SHREDDER and FRICTION basic function.
The functions for the drive buttons at the front can be bypassed by setting parameter D1A08 (D2A08)
off.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.3 Ramp
The start ramp time is the time it takes for the signal to control the hydraulic pump, to go from zero to
100% if the speed setpoint is 100% and drive start is activated. The stop ramp is the time it takes to go
from 100% to zero when drive stop is activated.
Drive start and stop are ramped commands (as well as fixed forward, fixed reverse and inch reverse).
The start ramp is controlled by the parameters DxC01 in forward direction and DxC03in reverse direction.
The stop ramp is controlled by the parameters DxC02in forward direction and DxC04in reverse direction.
Example: If the ”up ramp” D1C01 is set to 10 sec. and the down ramp D1C02 is set to
5 sec. we will get the following output.
The example is based on 50 and 100% setpoint.
Speed
Drive start Drive stop
100 %
Stop ramp
50%
Start ramp
0 10 20 25 Time in sec.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.4 Output
6.4.1 PWM frequency
The individual settings for each pump are made in PUMP OUTPUTS ( See AS5.2.2)
The outputs are Pulse Width Modulated and the PWM frequency can be set with parameters POx06.
The normal setting is 200Hz but can be set 100 to 2000Hz in steps of 100Hz. If a 5A stroker is used
(can only be controlled in one direction) the frequency must be set to 2000Hz to avoid damaging of the
stroker.
D(J)07
Lower frquency then 2000Hz can destroy5A2 pump stroker
POx01-04
High current can destroy
pump stroker
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(38)
AS6, Software settings and function, Engineering manual 04-04-02
D1D01 Sets the regulator function ON or OFF. In this case ON, the regulator is enabled.
D1D02 Feed forward function is set ON or OFF. In this case ON, the speed set-point is put to the
stroker output as an initial value and the regulator compensates for deviations in speed.
If the parameter is set OFF the regulator output will be the only signal to the
stroker output.
D1D03 Sets the Proportional regulator stage function ON or OFF. In this case select ON. The
proportional stage reacts proportional to the Error input signal. Action of this stage is
determined by parameter D1D06.
D1D04 Sets the Integrator function ON or OFF. In this case select ON. This function gives the
drive a possibility to reach set-point speed over time. Action of this stage is determined
by parameter D1D07.
D1D05 Sets the Derivative function ON or OFF. In this case select OFF. The derivative stage is
used when very quick speed changes are to be expected at the drive. It reacts on the
rate of change at the Error input signal. The D stage is seldom used due to a difficult
tuning procedure. Action of this stage is set by parameters D1D08 and D1D09.
D1D06 Proportional gain parameter sets the gain of the P-stage. In this case set to 0.5 as a start
value. P gain 0.5 means that half the Error signal input value will be transferred to the
stage output. Proportional stage however, will not make the drive reach set-point speed.
There will always be a remaining Error. The remaining Error value is though depending
on the Proportional gain setting. If the Error signal is small, close to zero, P gain will not
produce any output at this stage output. The P stage always needs an Error signal to
modify.
D1D07 Integrator time parameter sets the integration time of the I-stage. In this case set to 10
seconds as a start value. Integrator time 10 seconds means that the output value of this
stage will reach 63% of the Error signal input value in 10 seconds. Introduction of
Integration will eliminate the remaining Error signal. The actual speed will over time
correspond to speed set-point. It can be compared with a Capacitor that is charged with
the Error signal.
D1D08 Derivative time parameter sets the Derivative time of the D stage. In this case it is left at
the default value, 10 seconds. Derivative time 10 seconds means that the derivative
“gain” is a factor 10. The output from this stage is the “gain” factor multiplied with the rate
of change of the Error signal.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(38)
AS6, Software settings and function, Engineering manual 04-04-02
D1D09 Derivative decline time parameter sets the Derivative decline time of the D stage. In this
case it is left at default value, 10 seconds. Derivative decline time 10 seconds means that
the output value from this stage will decline 63 % in 10 seconds.
D1D10 Max feedback deviation is the allowed difference between command and actual speed. If
this exceeds for 10sec., the drive will switch over to unregulated drive and give the
warning ERROR TOO LARGE.
The above settings give in most cases a good performance of the drive. However to optimise the
parameters the following method can be used.
In short words the method is as follows:
Increase the proportional gain until the drive starts to oscillate. Note the oscillation time. Reduce the
Proportional gain with 50 %. Set the Integrator time minimum to the double oscillation time value.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(38)
AS6, Software settings and function, Engineering manual 04-04-02
Example for power limitation setting Drive 2, Electric motor 3: Set function
Electric motor = 240A (from data sheet or motor rating plate) for input
Current transformer 400A = 20mA AIF-AIN09
We are using analog input 5 for this example.
We want to limit electric motor 3 in drive 2.
Set level
AIJ05, Max input = 400 for limitation
AIJ06, Units for indication = A AIR01-03
AIJ09, function => Power limitation = EC3
AIR03, Level for power limitation (e-motor 3) = 240
D2F01, Delay time = the time the power is allowed to be higher
then the level (AIR03) before the limit function starts Set filter time
D2F02, Ramp time = how fast the reaction will be for stroking D1(2)F01
down the pump to limitation level
Set downramp
The ramp time setting must be set by test with the drive. A too short time
time can cause oscillation in the system and a too long time will not D1(2)F02
(By test)
regulate the current to the max setting (same function as P regulation,
see AS6.5).
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.7 Monitoring
The monitoring function is available in all setups. The pre-defined digital inputs (for monitoring) must
be set to off if monitoring is not wanted. See setup of digital inputs under AS 5.2.3.
(If memory bypass = off: Warning indication will be activated if input is opened
Warning indication will remain if input is closed.
and must be reset in Alarm / warning menu).
(If memory bypass = on: Warning indication will be activated if input is opened
Warning indication will disappear if input is closed).
Set AMA02 to needed delay time between opened input and warning indication.
Set the text in AMA04 to HIGH OIL TEMP by using ∧, ∨ and ↵ buttons.
NOTE: The line has to be filled with blank characters by pushing ↵ until the line is filled.
Available characters are all possible characters for the display. For Chinese characters a VFD display
must be mounted and switch SW3-1 must be set to off.
Setup of this function can either be done on the spider front or via SpiderCom program.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Min 10 (TMB10) -- 10 10
Analogue input setpoint1, setpoint2 and analog in1-2 is isolated with it's own reference ground.
05-01-21, replaces 04-04-02
Analogue input 3-9 is isolated but with common reference ground with the power supply.
All analogue inputs can be connected to current or voltage signals. The function and the zero - and
maxpoint of the input must be set (see AS5.2.6).
The function settings are described for each function in AS6.5 for Analog speed feedback, AS6.6 for
power limitation AS6.12 for Shredder pressure, AS6.13 for Synchro offset and AS6.14 for
Pressure control.
Analog in 4 with a 4-20mA signal for power limitation drive 1. 20 mA corresponds to 200A, parameter
AII01=4-20mA and AII06=A
01 H BPR P1 High pressure B-side monitor function for pump 1 High, low at high W
For monitoring of pump high pressure in reverse pressure
direction.
01 H APR P2 High pressure A-side monitor function for pump 2 High, low at high W
see 01 H APR P1 pressure
01 H BPR P2 High pressure B-side monitor function for pump 2 High, low at high W
see 01 H BPR P1 pressure
01 H APR P3 High pressure A-side monitor function for pump 3 High, low at high W
see 01 H APR P1 pressure
01 H BPR P3 High pressure B-side monitor function for pump 3 High, low at high W
see 01 H BPR P1 pressure
01 H APR P4 High pressure A-side monitor function for pump 4 High, low at high W
see 01 H APR P1 pressure
01 H BPR P4 High pressure B-side monitor function for pump 4 High, low at high W
see 01 H BPR P1 pressure
02 H APR D1 High pressure A-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in forward direction. pressure
02 H BPR D1 High pressure B-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in reverse direction. pressure
02 H APR D2 High pressure A-side monitor function for drive 2 High, low at high W
see 02 H APR D1 pressure
02 H BPR D2 High pressure B-side monitor function for drive 2 High, low at high W
see 02 H BPR D1 pressure
02 H APR 12 High pressure A-side monitor function for drive 1 and 2 High, low at high W
see 02 H APR D1 pressure
02 H BPR 12 High pressure B-side monitor function for drive 1 and 2 High, low at high W
see 02 H BPR D1 pressure
03 C PRA P1 Low charge pressure A-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in forward pressure
direction
03 C PRB P1 Low charge pressure B-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in reverse pressure
direction
03 C PRA P2 Low charge pressure A-side monitor function for pump 2 High, low at low A
see 03 C PRA P1 pressure
03 C PRB P2 Low charge pressure B-side monitor function for pump 2 High, low at low A
see 03 C PRA P2 pressure
03 C PRA P3 Low charge pressure A-side monitor function for pump 3 High, low at low A
see 03 C PRA P1 pressure
03 C PRB P3 Low charge pressure B-side monitor function for pump 3 High, low at low A
see 03 C PRA P2 pressure
03 C PRA P4 Low charge pressure A-side monitor function for pump 4 High, low at low A
see 03 C PRA P1 pressure
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(38)
AS6, Software settings and function, Engineering manual 04-04-02
03 C PRB P4 Low charge pressure B-side monitor function for pump 4 High, low05-01-21,
at low replacesA04-04-02
see 03 C PRA P2 pressure
04 C PRA D1 Low charge pressure A-side monitor function for drive 1 High, low at low A
For monitoring of drive low charge pressure in reverse pressure
direction
04 C PRB D1 Low charge pressure B-side monitor function for drive 1 High, low at low A
For monitoring of drive low charge pressure in reverse pressure
direction
04 C PRA D2 Low charge pressure A-side monitor function for drive 2 High, low at low A
see 04 C PRA D1 pressure
04 C PRB D2 Low charge pressure B-side monitor function for drive 2 High, low at low A
see 04 C PRB D2 pressure
06 RF 75P1 Monitor of return filter for pump 1 clogged to 3/4 High, low on filter W
For monitoring of 3/4 clogged filter. clogged
Only applicable when using two level filter indicators.
06 RF 100P1 Monitor of return filter for pump 1 fully clogged High, low on filter W/(A)
For monitoring of fully clogged filter (must be exchanged) clogged
06 RF 75P2 Monitor of return filter for pump 2 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P2 Monitor of return filter for pump 2 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 RF 75P3 Monitor of return filter for pump 3 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P3 Monitor of return filter for pump 3 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 RF 75P4 Monitor of return filter for pump 4 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P4 Monitor of return filter for pump 4 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 DRF 100 Monitor of drain filter fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
07 LO LEVEL Low oil level monitor for tank High, low when W
Monitors Low oil level in PU tank below set level
07 MN LEVEL Min oil level monitor for tank High, low when A
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(38)
AS6, Software settings and function, Engineering manual 04-04-02
05-01-21, replaces 04-04-02
Monitors Min oil level in PU tank below set level
08 MAX TEMP Max oil temp monitor for tank High, low when A
Monitors max set temp. in PU tank above set temp
08 HI TEMP High oil temp monitor for tank High, low when W
Monitors high set temp. in PU tank above set temp l
08 MIN TEMP Low oil temp monitor for tank High, low when A
Monitors low set temp. in PU tank below set temp
09 BUS R Reset of alarms and warnings via bus High=Reset via bus C
10 SHR 1+2A Shredder forward stop, Drive 1 and 2 High, low at stop C
10 SHR 1+2B Shredder forward stop, Drive 1 and 2 High, low at stop C
12 RES EN2 External enable of counter reset in Synchro mode, Drive High=Enable of C
2 reset input
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(38)
AS6, Software settings and function, Engineering manual 04-04-02
15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2 High=Forward C
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2 High=Reverse C
16 SP RES1 Reset of set point in Local mode, Drive 1 High pulse = reset C
16 SP RES2 Reset of set point in Local mode, Drive 2 High pulse = reset C
18 REG 1+2 Closed loop speed feedback active, Drive 1 and 2 High=Active C
Low=Open loop
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 17(38)
AS6, Software settings and function, Engineering manual 04-04-02
18ERR2 RES Reset of error too large function, Drive 2 High pulse = reset C
18ERR1+2R Reset of error too large function, Drive 1 and 2 High pulse = reset C
20 PR HI 1 Set pressure control output to max speed-up level, Drive High=Max output C
1 Low=Normal control
20 PR LO 1 Set pressure control output to max slow-down level, Drive High=Min output C
1 Low=Normal control
20 PR HI 2 Set pressure control output to max speed-up level, Drive High=Max output C
2 Low=Normal control
20 PR LO 2 Set pressure control output to max slow-down level, Drive High=Min output C
2 Low=Normal control
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Output function
Abbreviation Function Normal status for
output
01 A(1,2, 1+2) Monitoring of common alarm Open, closed at
alarm
03 READY(1, 2, 1+2, 1*2) Drive ready to use after start delay Open, closed when
ready
04 REMOTE(1, 2) Drive in remote mode Open, closed in
remote mode
08 C ZERO Counters in Synchro counter function reset and synchro function Open, closed at
activated activated
synchronisation
09 AOUT(1...4) Register for analog output has negative sign Open, closed when
negative
11 LOW TEMP Indication for min oil temp active Open, closed when
active
11 HI TEMP Indication for high oil temp active Open, closed when
active
11 MAX TEMP Indication for max oil temp active Open, closed when
active
11 COOL CONI Start cooling interlocked with electric motor started Open, closed for
(with analog temp sensor) cooling
11 COOL COND Start cooling controlled directly from temp sensor Open, closed for
(with analog temp sensor) cooling
11 HEAT CON Start heating (with analog temp sensor) Open, closed for
heating
11 FLUSHCON Control of flushing circuit (with analog temp sensor) Open for cooling,
closed for heating
ON On delay From the moment when the function for the output is activated , the output will
not be active until the delay time is passed.
OFF Off delay From the moment when the function for the output is deactivated , the output
will not be inactive until the delay time is passed.
PULSE Output pulse From the moment when the function for the output is activated , the output will
be active only during the delay time.
OFF No delay
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 21(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Will give:
→ TANK TEMP 37.8ºC ←
PRESSURE 143bar
▲ or ▼ will alter between these two readings.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.12 Shredder
The selection of shredder function is made by setting parameter MAA01 to SHREDDER (see AS6.1).
The specific parameters are found in SETUP – SHREDDER 1(2).
In shredder all features described in 6.1.- 6.11 are avaliable except for the possibility to switch
between speed regulated and non-regulated drive. The selection of speed regulation has to be set
with parameter SHA(G)10.
The added functions are for the reversals by an overloaded drive.
The shredder has two drive modes, manual and auto.
In manual drive mode the forward button (or by configurable input set as L FORW1(2)) is used for
running forward and the reverse button (or by configurable input set as L REV1(2)) is used for running
reverse. The drive will run as long as the input is activated and stop when input is opened. The
reversing function is bypassed in manual drive.
In auto drive mode the start button (or by configurable input set as L START1(2)) starts the drive with
the automatic reversing function and is stopped with the stop button(or by configurable input set as L
STOP1(2)). A configurable digital input can be used for start in remote mode.
The switching between manual and auto is made with the MAN/AUT button or with a configurable
digital input (will bypass the button).
A digital output can be used for indication of auto mode.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.13 Synchro
The Synchro function set-up is to be found in the following parameter menus
"Synchro - Function"
"Synchro - Drive 1 reset"
"Synchro - Drive 2 setpoint"
"Synchro - Drive 2 indication"
"Synhcro - Drive 2 reset"
"Synchro - External Master"
"Synchro - Drive 1 setpoint"
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(38)
AS6, Software settings and function, Engineering manual 04-04-02
ratio drive can be activated by a configurable digital input, set to 12 FRICTION. The input can be
either a hardware signal, or in bus mode a bus signal.
By altering a parameter, PRA02 = On, reverse action is selected. The below diagram describes the
pressure control function, reverse action. If pressure is increasing the speed set point is decreasing.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(38)
AS6, Software settings and function, Engineering manual 04-04-02
PRC01 Sets the Proportional regulator stage function ON or OFF. The proportional stage reacts
proportional to the Error input signal. Action of this stage is determined by parameter
PRC04.
PRC02 Sets the Integrator function ON or OFF. This function gives the drive a possibility to reach
set-point pressure over time. Action of this stage is determined by parameter PRC05.
PRC03 Sets the Derivative function ON or OFF. The derivative stage is used when very quick
pressure changes are to be expected at the drive. It reacts on the rate of change at the
Error input signal. The D stage is seldom used due to a difficult tuning procedure. Action
of this stage is set by parameters PRC06 and PRC07.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(38)
AS6, Software settings and function, Engineering manual 04-04-02
PRC04 Proportional gain parameter sets the gain of the P-stage. P gain 0.5 means that half the
Error signal input value will be transferred to the stage output. Proportional stage
however, will not make the drive reach set-point pressure. There will always be a
remaining Error. The remaining Error value is though depending on the Proportional gain
setting. If the Error signal is small, close to zero, P gain will not produce any output at this
stage output. The P stage always needs an Error signal to modify.
PRC05 Integrator time parameter sets the integration time of the I-stage. An integrator time 10
seconds means that the output value of this stage will reach 63% of the Error signal input
value in 10 seconds. Introduction of Integration will eliminate the remaining Error signal.
The actual pressure will over time correspond to pressure set-point. It can be compared
with a Capacitor that is charged with the Error signal.
PRC06 Derivative time parameter sets the Derivative time of the D stage. A derivative time 10
seconds means that the derivative “gain” is a factor 10. The output from this stage is the
“gain” factor multiplied with the rate of change of the Error signal.
PRC07 Derivative decline time parameter sets the Derivative decline time of the D stage. A
derivative decline time 10 seconds means that the output value from this stage will
decline 63 % in 10 seconds.
PRC08 Filter time for pressure feedback parameter sets the filter time for the pressure. Useful
when the pressure signal contains a lot of noise, the filter will take away pressure peaks.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(38)
AS6, Software settings and function, Engineering manual 04-04-02
See block diagram AS7.2 and parameter list AS5.2.8 for further details.
6.15.1 General
The Bus function requires that a bus card is installed. The card is a profibus-DP slave following the
standard PROFIBUS-DP EN 50 170. It must be connected to a profibus-DP master. The card will only
respond to incoming commands, working as a slave.
The Bus function is activated when a digital input or a bus input is activated and remote mode is
selected via the keyboard. The digital inputs are BUS 1 and BUS 2, these inputs makes it possible to
select bus control separately for drive 1 and 2. Speed set-points are located at predefined bus
addresses. See chapter AS 6.15.9. The below sketch explains the possible mode changes.
BUS 1 (Drive 1)
REM 1 (Drive 1)
REM 2 (Drive 2)
Bus fail
Bus communication fail+timedelay (BTF02)
Alarm/Interlock (selectable via BTF03)
Hardware fail
Alarm/Interlock (selectable via BTF03) Prevents Bus mode
If the bus communication is lost, an alarm or Interlock is trigged. An adjustable timer determines the
filter time for the alarm/interlock. Local mode is activated if the bus is faulty. To be able to start bus
communication again the spider must be restarted by reset or power on.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(38)
AS6, Software settings and function, Engineering manual 04-04-02
REG/BIT 8 7 6 5 4 3 2 1
REG511 Din 8 Din 7 Din 6 Din 5 Din 4 Din 3 Din 2 Din 1
REG512 Din 16 Din 15 Din 14 Din 13 Din 12 Din 11 Din 10 Din 9
REG513 Din 24 Din 23 Din 22 Din 21 Din 20 Din 19 Din 18 Din 17
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(38)
AS6, Software settings and function, Engineering manual 04-04-02
The analog values are in "signed word" data format. Negative numbers are the 2's complement of the
positive ones. Below is a table with some examples
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(38)
AS6, Software settings and function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 31(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
20:0 Start1 21:0 P1HiCa 22:0 Forw2 23:0 ShBlck2 24:0 Ready2 25:0 Dummy
20:1 Remote1 21:1 P1CAct 22:1 Rev2 23:1 A1 24:1 EMot1 25:1 Dummy
20:2 Auto1 21:2 PLim 22:2 Reg2 23:2 A2 24:2 EMot2 25:2 Dummy
20:3 PLim1 21:3 ShBlck1 22:3 CZero 23:3 W1 24:3 CoolConI 25:3 Dummy
20:4 Forw1 21:4 Start2 22:4 Synchro 23:4 W2 24:4 HeatCon 25:4 Dummy
20:5 Rev1 21:5 Remote2 22:5 P2LoCa 23:5 Int1 24:5 CoolConD 25:5 Dummy
20:6 Reg1 21:6 Auto2 22:6 P2HiCa 23:6 Int2 24:6 Flush Con 25:6 Dummy
20:7 P1LoCa 21:7 PLim2 22:7 P2CAct 23:7 Ready1 24:7 Dummy 25:7 Dummy
DB20 to DB25 are signals to be found in the list of available functions for the digital relay outputs,
described in AS6.10.
DB26 to DB37 are partly signals to be found in the list of available functions for the digital inputs,
described in AS6.9.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 32(38)
AS6, Software settings and function, Engineering manual 04-04-02
The alarm lists are found in the menu under LOG READINGS – DRIVE 1 – ALARM and LOG
READINGS – DRIVE 2 – ALARM.
The warning lists are found in the menu under LOG READINGS – DRIVE 1 – WARNING and
LOG READINGS – DRIVE 2 – WARNING.
All four lists are 10 alarms or warnings long. The latest will be at the top and when a new warning
or alarm comes to an already filled list, the oldest will be removed. The alarms and warnings are
marked with date and time for the incident. For setting of actual time see TIME/DATE below.
The drive time counters are found in the menu under LOG READINGS – DRIVE 1 – TIME IN USE
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are DRIVE (the time with drive
started) and PUMPS (the time with started electric motor for each pump). The counters can be
reset , see RESET TIME below.
The settings for the drive monitoring log and clock and the reset of the time counters are made in
SETUP – DRIVE LOG and are protected by a password. The settings can only be done from the
front keypad.
TIME/DATE is the setting of actual date and time. The format is YYMMDD HH:MM and is
selected with > button and changed with ∧ and ∨ buttons. The date/time is used for alarm and
warning list time stamps and the clock is battery backed.
LOG1 to LOG 8 are for setting of the eight one dinensional scalable drive monitoring log channels.
The used analog inputs must be set before the log channels are configured, see AS6.8.
Each channel consists of a measuring area divided in 6 levels. The time the measured reading
has been within each of these levels is stored. The measuring is only active with drive started.
Total measuring time is 100 000 hours.
Parallel to the total time log, 4 shorter log registers with the same setting as the total is stored in
chronological order. The log time is adjustable.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 33(38)
AS6, Software settings and function, Engineering manual 04-04-02
Example: 90-100
- Log channel 2
70-90
50-70
30-50
10-30
Time MT 10-30
Period 2
AII06=bar for the reading units. 90-100
Time MT 70-90
50-70
30-50
2.Log setting:
10-30
0-10
Period 3
SETUP – DRIVE LOG – LOG 2:
STA=ON will activate the log function Time MT
90-100
70-90
50-70
30-50
RESET TIME for reset of the drive time counters. When the function is selected with > button
push ∧ to get a Y (yes) and then > button to reset.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 34(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
The spider card has four output channels. Each channel can be selected as 0-10V or 2-10V
voltage output or as 0-20mA or 4-20mA current output. The selection between current and
voltage is made by jumpers on the card and by using different terminals.
The selection between 0-10V and 2-10V or between 0-20mA and 4-20mA is made with
parameters in the setup menu.
Example for channel 1, 4-20mA for 0-20rpm speed from digital speed encoder.
1. Set parameter D1E01 to 20.0rpm (the speed that corresponds to 100%).
2. Connect a current meter in series with the output signal.
3. Parameter AOA02 must be ON for 4mA output.
4. Select parameter AOA03. The system gives 0% to the card. Adjust the parameter until
closest to 4mA output.
5. Select parameter AOA04. The system gives 100% to the card. Adjust the parameter
until closest to 20mA output.
6. Repeat 4 and 5 until the best result is achived.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 35(38)
AS6, Software settings and function, Engineering manual 04-04-02
The drive monitoring log consists of four parts, alarm/warning lists, drive time counters, six
scalable log channels and two scalable 3D-log channels. The alarm/warning lists and drive time
counters can be indicated on drive 1 display. The total drive log information must be downloaded
to a PC for examination. This requires null-modem cable 576 3521-003, a PC with windows XP
and SpiderCom2 software installed.
The alarm lists are found in the menu under LOG READINGS – DRIVE 1 – ALARM and LOG
READINGS – DRIVE 2 – ALARM.
The warning lists are found in the menu under LOG READINGS – DRIVE 1 – WARNING and
LOG READINGS – DRIVE 2 – WARNING.
All four lists are 10 alarms or warnings long. The latest will be at the top and when a new warning
or alarm comes to an already filled list, the oldest will be removed. The alarms and warnings are
marked with date and time for the incident. For setting of actual time see TIME/DATE below.
The drive time counters are found in the menu under LOG READINGS – DRIVE 1 – TIME IN USE
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are PUMP (the time with started
electric motor) and DRIVE (the time with drive started). The counters can be reset , see RESET
TIME below.
The settings for the drive monitoring log and clock and the reset of the time counters are made in
SETUP – LOG FUNCTION and are protected by a password.
TIME/DATE is the setting of actual date and time. The format is YYMMDD HH:MM and is
selected with > button and changed with ∧ and ∨ buttons. The date/time is used for alarm and
warning list time stamps and the clock is battery backed.
LOG1 to LOG 8 are for setting of the eight scalable drive monitoring log channels.
The used analog inputs must be set before the log channels are configured, see AS6.8.
Each channel consists of a measuring area divided in 6 levels. The time the measured reading
has been within each of these levels is stored. The measuring is only active with drive started.
Total measuring time is 100 000 hours.
Parallel to the total time log, 4 shorter log registers with the same setting as the total is stored in
chronological order. The log time is adjustable.
RESET TIME will reset the time counters for total drive time.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 36(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
At each power up and each time all electric motors are stopped, the system will check that the relays
for the electric motor interlock outputs not are stucked in closed position.
The emergency stop alarm is as default with memory and must be reset but can be set to automatic
reset with MAB11:ON.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 37(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Run Loader.exe. Select the file for download Start the procedure
Reset the Spider board by pushing the reset button or by switching on and off the power to the card to
start the download procedure.
When the download is ready, reset the Spider system and set new parameters.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 38(38)
AS-7.1
Spider Digital inputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.1, Digital inputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.1, Digital inputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.2
Spider Analog in- and outputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.2, Analog in- and outputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.2, Analog in- and outputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.3
Spider Pump outputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.4
Spider Monitor
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.4, Monitor, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.4, Monitor, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.5
Spider Basic function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.5, Basic function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.6
Spider Shredder function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.6, Shredder function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.7
Spider Synchro function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.7, Synchro function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.8
Spider Pressure function
Engineering manual 05-01-21
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.9
Spider Emergency stop
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.9
Spider Emergency stop
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
PAC MANUAL DE INSTALACIÓN Y MANTENIMIENTO
Manual de Instalación y
Mantenimiento
PAC
Prefacio Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Prefacio
Hagglunds Drives es uno de los fabricantes más importantes en el mundo
de sistemas hidráulicos de baja velocidad, alto torque y de uso pesado.
Ofrecemos un sistema de propulsión duradero que funcionará bajo las
condiciones más difíciles con un mínimo nivel de mantenimiento. Contamos
con clientes industriales y marítimos en todas partes del mundo quienes
saben que, al buscar soluciones, apoyo o servicio, pueden confiar en
Hagglunds Drives. La fábrica y oficinas principales de Hagglunds Drives
están ubicadas en Mellansel, Suecia. Además, contamos con oficinas de
ventas y servicio en 40 países.
sus representantes.
2
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Contenido
Contenido
1. GENERAL ........................................................................................................................ 4
1.1 Precauciones de seguridad ...........................................................................................................4
1.2 Principio operativo .........................................................................................................................6
2. DATOS TECNICOS ......................................................................................................... 7
2.1 Condiciones operativas .................................................................................................................7
2.2 Agua de enfriamiento ....................................................................................................................8
2.3 Requisitos para la limpieza del fluido hidráulico ............................................................................8
2.4 Selección del fluido hidráulico .......................................................................................................9
2.5 Monitoreo de la unidad de potencia ............................................................................................10
3. MANEJO DE LA UNIDAD DE POTENCIA EMPACADA............................................... 11
3.1 Almacenaje de la unidad de potencia empacada ........................................................................ 11
3.2 Levantamiento de la unidad de potencia empacada ................................................................... 11
4. INSTALACIÓN ............................................................................................................... 12
4.1 Instrucciones de instalación ........................................................................................................12
4.2 Métodos y pesos de levantamiento .............................................................................................14
4.3 Colocación de la unidad de potencia ..........................................................................................15
4.4 Ensamble de las patas del gabinete ...........................................................................................15
4.5 Ensamble del motor eléctrico ......................................................................................................16
4.6 Ensamble del enfriador de aire-aceite y ventilación del gabinete ...............................................18
4.7 Ensamble de la tapa superior......................................................................................................19
4.8 Conexiones hidráulicas ...............................................................................................................19
4.9 Conexiones eléctricas .................................................................................................................20
4.10 Tubería ......................................................................................................................................20
4.11 Filtración adicional antes del arranque ......................................................................................24
4.12 Puesta en servicio .................................................................................................... 25
4.12.1 Antes de la puesta en servicio ................................................................................................25
4.12.2 El llenado del sistema con fluido hidráulico ............................................................................ 25
4.12.3 Procedimiento inicial de arranque ..........................................................................................27
4.13 Ajuste de las bombas ................................................................................................................29
5. MANTENIMIENTO PREVENTIVO ................................................................................. 31
5.1 Registro de mantenimiento .........................................................................................................31
5.2 Tabla de mantenimiento ..............................................................................................................31
5.3 Reposición del filtro .....................................................................................................................32
5.4 Inspección del fluido hidráulico ...................................................................................................33
5.5 Lubricación del motor eléctrico....................................................................................................34
5.7 Limpieza del enfriador de aire-aceite ..........................................................................................35
5.8 Unidad de potencia fuera de servicio ..........................................................................................35
6. MANTENIMIENTO CORRECTIVO ................................................................................ 35
6.1 Mantenimiento común .................................................................................................................35
6.2 Reposición del ensamble de la bomba hidráulica / motor eléctrico.............................................36
6.3 Detección de fallas ......................................................................................................................37
7. DESECHO DE LA UNIDAD DE POTENCIA ................................................................. 38
3
General Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
1. GENERAL
1.1 Precauciones de seguridad
El cumplimiento de las precauciones de seguridad es de suma importancia. En caso de tener cualquier
duda, favor de comunicarse con su representante de Hagglunds Drives para pedir asesoría.
Señales de advertencia
En el presente manual, se incluyen las siguientes señales de advertencia, las cuales indican la existencia
de un peligro potencial que ocasionará o pudiera ocasionar lesiones corporales o daños a la propiedad.
Se han establecido tres categorías en lo que se refiere al nivel del peligro:
!
PELIGRO
Se utiliza el término PELIGRO para indicar la presencia de un riesgo
que ocasionará lesiones corporales severas, muerte o daños
significativos a la propiedad si se hace caso omiso de la advertencia.
!
ADVERTENCIA
Se utiliza el término ADVERTENCIA para indicar la presencia de un
riesgo que pudiera ocasionar lesiones corporales severas, muerte o
daños significativos a la propiedad si se hace caso omiso de la
advertencia.
PRECAUCION
! Se utiliza el término PRECAUCION para indicar la presencia de un
riesgo que ocasionará o pudiera ocasionar lesiones corporales
menores o daños a la propiedad si se hace caso omiso de la
advertencia.
General
Se debe limitar el acceso al equipo únicamente al personal autorizado. Se deben realizar operaciones
en relación con la PAC al estar totalmente familiarizado con las funciones de la unidad de potencia
(incluyendo el sistema de control), así como la transmisión en su totalidad.
El servicio y reparación de los sistemas eléctricos, hidráulicos y mecánicos requieren de los servicios
de personal profesional que entiende los riesgos involucrados.
Se deben utilizar los equipos de seguridad para la prevención de accidentes durante el ensamble y
mantenimiento, de acuerdo con los reglamentos vigentes en el país.
4
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC General
5
Principio Operativo Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Envoltura de la campana
Favor de tomar nota de que existen componentes rotatorios dentro de la envoltura de la campana
durante operaciones. Favor de tener cuidado al realizar inspecciones a través del registro. Reponer
la tapa del registro después de realizar una inspección.
Superficies calientes
Las temperaturas en el sistema hidráulico por encima de los 158º F (70º C) resultarán en superficies
calientes.
Situaciones de emergencia
Paro de emergencia: debe existir la posibilidad de apagar la energía eléctrica durante una situación
de emergencia. Se deben utilizar extintores de incendio que son aprobados para uso con productos
petroleros y equipos eléctricos.
Función
La función de la unidad de potencia es la de suministrar al motor hidráulico (u otros sistemas hidráulicos)
el flujo requerido de aceite y presión en el momento correcto. Todos los componentes están
ensamblados en uno o más gabinetes compactos. El PAC cuenta con una o más bombas, las cuales
son impulsadas por uno o más motores eléctricos. La bomba principal es de pistón axial con
desplazamiento variable para sistemas de circuito cerrado. El motor eléctrico está totalmente encerrado
y cuenta con un ventilador de enfriamiento. Dos sistemas de control están disponibles.
6
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Datos Tecnicos
2. DATOS TECNICOS
2.1 Condiciones operativas
La unidad estándar del PAC está diseñada para las condiciones que se establecen a continuación. Si
los requisitos están fuera de las condiciones que se establecen más adelante, favor de comunicarse
con su representante de Hagglunds Drives para explicar sus requisitos específicos para tomar en
cuenta consideraciones especiales en el diseño.
Temperatura ambiental: Un mínimo de 32º F (0º C) y un máximo de 85º F (30º C).
Altitud: Un máximo de 3,300 pies (1,000 metros).
Ubicación clasificada: La unidad está diseñada para una ubicación estándar. Las unidades
pueden ser construidas para uso en ubicaciones clasificadas como peligrosas. Favor de
comunicarse con su representante de Hagglunds Drives para mayores detalles.
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Datos Tecnicos Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
8
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Datos Tecnicos
Viscosidad n SSU
Viscosidad n cSt
150 720
Viscosidad
100 Recomendada
40 187
VG 100
VG 46 VG 150
VG 68
10
0 10 20 30 40 50 60 70 80 90 100
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Datos Tecnicos Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
UNIDAD DE POTENCIA
Interruptor máximo de
la temperatura de aceite
1
Interruptor mínimo de
la temperatura de aceite
1
Interruptor mínimo del
1
nivel de aceite
1
1s 0s PARO DEL MOTOR ELÉCTRICO
Interruptor de presión
Tiempo de retardo de apagado
de baja
Tiempo de retardo de encendido
0s 0.5s 1
5s 0s
&
Tiempo de retardo de encendido
Interruptor de advertencia
de la temperatura de aceite
1
Interruptor del
nivel bajo de aceite
1
Interruptor del filtro
Tiempo de retardo de apagado
1
de retorno
0s 5s 1 INDICACIÓN DE ADVERTENCIA
Interruptor del
Tiempo de retardo de apagado
filtro de drenaje
0s 5s 1
Interruptor de
Tiempo de retardo de apagado
alta presión
0s 5s 1
El monitoreo de los interruptores de la unidad de potencia está agrupado en dos niveles, de acuerdo
con el diagrama anterior.
La señal de advertencia le informa con respecto a la existencia de un problema en el PAC que no
requiere de atención inmediata.
El alarma indica la necesidad de parar la bomba. En lo que se refiere a la secuencia de paro, primero
se para el motor hidráulico sin rampa, al ajustar el ángulo oscilante de la bomba a cero. Posteriormente,
después de una pequeña demora, se para el motor eléctrico.
El interruptor de presión de baja carga debe estar enclavado durante el paro y arranque del motor
eléctrico para evitar una alarma y darle tiempo a la bomba para incrementar la presión de carga
después de su arranque.
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Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Datos Tecnicos
Etiqueta de centro
de gravedad.
• El centro de gravedad es alto, véase la etiqueta en la unidad de
potencia.
!
PRECAUCION
•
•
Evitar las aceleraciones, desaceleraciones y vueltas rápidas al
trasladar el equipo.
Se debe colocar el montacargas de acuerdo con las instrucciones
que se señalan a continuación.
Levantamiento con montacargas
• La longitud mínima de la plataforma del montacargas es de 51.2” (1300 mm).
• La distancia mínima entre las secciones de la plataforma del montacargas es de 31.5” (800 mm)
en el caso de un PAC de dos puertas y 43.3” (1100 mm) en el caso de una unidad de potencia
de tres puertas.
• Se debe colocar la plataforma de acuerdo con el centro de gravedad.
Componentes que se entregan por separado
• Siempre se indica el peso en el empaque.
• Los bultos empacados sobre patines están diseñados para manejo únicamente con
montacargas.
• Algunos otros bultos pueden ser levantados con una grúa, pero siempre se deben leer las
indicaciones que aparecen en la etiqueta colocada sobre el bulto.
!
PELIGRO
• Unicamente se debe utilizar equipo de levantamiento que tiene la
capacidad de manejar el peso que se indica en la etiqueta colocada
sobre el bulto.
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Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
4. INSTALACIÓN
4.1 Instrucciones de instalación
Para que el PAC funcione correctamente, se debe proceder con la instalación de acuerdo con estas
instrucciones. Se deben tomar en cuenta las condiciones bajo las cuales la unidad estará en operación.
La instalación incorrecta, al incumplir con las instrucciones establecidas en este manual y la
documentación técnica adjunta, puede afectar la operación y/o vida útil de la unidad de potencia.
Siempre se deben cumplir con las medidas de seguridad que se establecen en este manual.
H1
B2 A2 B2
H2
H2
B1 M A1 B1
A3
12
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
PRECAUCION
! la unidad de potencia, favor de tomar en cuenta que el
enfriador se arranca súbitamente y tiene bordos filosos.
OUT IN OUT IN
13
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Enfriador de aire-aceite
Tamaño Peso libras (kg)
B A A B AOVH-30 190 (86)
AOVH-40 350 (159)
AOL-950 221 (100)
AOL-1200 296 (134)
AOL-1600 355 (161)
Siempre se deben utilizar los cuatro puntos de
levantamiento al subir la unidad de potencia
!
PELIGRO •
manejar el peso de la unidad de potencia (según se indica en la placa de
identificación dentro del gabinete).
No se debe levantar la unidad de potencia con fluido hidráulico dentro del tanque
o cuando la barra frontal está desensamblada.
14
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
8 [203mm] 8 [203mm]
CONTORNO DEL PISO SIN CONTORNO DEL PISO SIN
EL ENFRÍADOR DE AIRE EL ENFRÍADOR DE AIRE
32 [813mm]
36 [914mm]
32 [813mm]
32 [813mm] 32 [813mm]
32 [813mm]
40 [1016mm]
40 [1016mm]
15
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
16
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
!
PELIGRO •
• Unicamente se debe utilizar equipo de levantamiento que tiene la capacidad
de manejar el peso, según se indica en la placa de identificación.
No se deben meter manos o dedos entre el motor eléctrico y la envoltura de
la campana durante el proceso de ensamble.
17
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
OUT IN OUT IN
FLUJO
DE AIRE FLUJO
DE AIRE
C C
A
1 1/4" SAE A B A B 1 1/4" SAE
B
E E
D D
B B
A A
Nota: Debe haber una apertura en la orilla • Hay que tener cuidado con las
inferior de la hoja de hule para permitir la
salida del aire de enfriamiento del ventilador
del motor eléctrico.
PELIGRO
! •
partículas en el aire de salida.
Si el enfriador de aire se afloja,
puede ocasionar graves lesiones
corporales.
18
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
¡NINGÚN
PEGAMENTO!
Tamaño de la Conexiones Hoyos con rosca ** * SAE brida J 518, código 62,
bomba principales A y 414 bar (6000 psi) conexiones
Denison B* Rosca Profundidad de 90º deben ser utilizadas.
P6/P7 ** Se requieren de 4 pernos /
1 1/2" 5/8-11 UNC
P11/P14 1.06 in. (27 mm) conexión, de preferencia,
tornillos prisioneros de Grado 8.
P24/P30 2" 3/4-10 UNC
19
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
4.10 Tubería
Al calcular el tamaño de las mangueras y la tubería hidráulica, entre el motor y la unidad de potencia,
se debe utilizar un factor de seguridad de, por lo menos, 4 veces la presión máxima del sistema en lo
que se refiere a la resistencia a la tensión. Favor de tomar en cuenta que el equipo puede volver a
ajustarse a una mayor presión al estar en operación. En términos generales, las pérdidas de presión
en el sistema de tubería deben mantenerse a un mínimo, pero existen excepciones en el caso de
ciertas aplicaciones. Favor de comunicarse con un representante de servicio de Hagglunds Drives
para mayores datos.
Tubería hidráulica
Las tuberías hidráulicas deben ser de acero de alta calidad, de acuerdo con ISO 3304, DIN 2391/C o
ANSI/B93.4
Mangueras
Para evitar daño a consecuencia de vibración, es importante que el PAC y el motor estén conectados
a las tuberías a través de mangueras.
Las mangueras deben ser cortas y del menor diámetro posible para obtener un pequeño volumen de
compresión. Sin embargo, se debe tomar en cuenta el radio mínimo de dobladura permitido, de
acuerdo con los datos proporcionados por el fabricante de la manguera. Además, se deben tomar en
cuenta las velocidades de flujo que se especifican en “Tamaño de los tubos”.
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Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
Prueba de presión
Se debe realizar una prueba de presión a 1.5 veces la presión máxima de trabajo en las líneas principales
para detectar posibles fugas.
Se recomienda la realización de las pruebas de presión con una bomba hidráulica manual.
Lavado de los tubos (flushing)
Antes de arrancar la unidad de potencia, se debe limpiar el sistema de tubería con una bomba de
lavado de un tamaño adecuado para eliminar los contaminantes que pueden haber entrado durante el
proceso de ensamble y/o soldadura. Favor de comunicarse con un representante de servicio de
Hagglunds Drives para determinar los procedimientos correctos de limpieza y lavado.
Tamaño de los tubos
Es importante que las líneas entre las conexiones principales el motor y el PAC sean lo más corto
posible.
Esto ofrece las siguientes ventajas:
1. Un pequeño volumen de compresión dentro del sistema hidráulico.
Esto es especialmente importante en el caso de sistemas hidráulicos con variaciones
grandes y rápidas en la carga y en el caso de transmisiones en donde la exactitud de la
velocidad es esencial.
2. Pequeñas pérdidas de pontentia en el sistema hidráulico.
3. Menores costos de instalación, puesto que tubos de menor diámetro y más cortos pueden
ser utilizados. En el caso de un sistema hidráulico normal, la caída total en la línea de presión y
de retorno no debe exceder del 5% de la presión normal de trabajo.
Se recomiendan los siguientes valores en lo que se refiere al flujo, los cuales no se
deben exceder:
Líneas principales: 15 pies/seg (4.5 m/s) Líneas de drenaje: 5 pies/seg (1.0 m/s)
4. Un menor nivel de ruido.
En el caso de ciertos sistemas, en donde se requieren de pequeños volúmenes de
compresión, flujos más altos son aceptables. Favor de comunicarse con un representante
de servicio de Hagglunds Drives para analizar estos casos específicos.
Al calcular el tamaño de las mangueras y la longitud de los tubos entre las conexiones de drenaje del
motor y el PAC, favor de tomar en cuenta que la caída total en la presión a las conexiones de drenaje
del motor no debe exceder de 14.5 psi (1 bar). La caída en la presión a través del PAC es de 7.25 psi
(0.5 bar).
Acoplamientos de los tubos
Es esencial que se seleccione un acoplamiento apretado y a prueba de presión.
Se recomiendan los siguientes tipos de acoplamientos:
Acoplamientos no soldados son preferibles
Los acoplamientos no soldados permiten la mayor limpieza durante la instalación del sistema de
tubería (en comparación con un sistema soldado).
Acoplamientos soldados (soldadura de boquilla y/o a tope)
Si se utilizan acoplamientos soldados, las tuberías deben ser maquinadas, estandarizadas, limpiadas
en un baño químico. Posteriormente, deben ser cepilladas, lavadas internamente y sopladas antes
del flushing.
Acoplamiento de tubos
Acoplamientos de collarín, de acuerdo con SAE J 514.
21
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
!
PELIGRO
el sistema hidráulico esta presurizado. Se debe utilizar el equipo de
seguridad necesario durante la instalación del sistema de tubería. Se
debe cumplir con los requisitos de seguridad normales durante cada etapa.
22
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
23
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Ejemplo de la instalación de la
tubería que es conveniente y en
donde fácilmente se puede instalar
en aislamiento contra ruido
24
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
25
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
FILTRO DE RETORNO
CONEXIÓN DE
ILENADO DE ACEITE
FILTRO DE DRENAJE DE
LA CARCAZA DE LA
BOMBA/MOTOR
CALENTADOR
DEL ACEITE
Después de llenar el sistema con fluido, se debe abrir la línea de drenaje y volver a conectar la línea de
drenaje del motor hidráulico.
!
ADVERTENCIA
•
•
(sección 2.4 “Selección del fluido hidráulico”).
Evitar el contacto prolongado del fluido hidráulico con su piel.
Para evitar lesiones, limpiar los derrames de fluido hidráulico de los
pisos, de inmediato.
26
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
27
Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
De inmediato, cerciorarse de
que la dirección de rotación de ROTACIÓN
28
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Instalación
ETAPA 5. Inspecciones
• Cerciorarse de que no existan ruidos o vibraciones anormales.
• Revisar la operación del equipo de seguridad.
• Verificar la temperatura dentro del tanque y el circuito cerrado. Cerciorarse de que el control del
enfriador sea estable. De ser que no, realizar una inspección del suministro de agua, los
controles, el enfriador de aire, etc.
• Cerciorarse de que no haya fugas.
• Cerciorarse de que los controles e interruptores (opcionales) del compensador de la bomba
estén ajustados a los niveles que corresponden a la transmisión especifica. En el momento de
su entrega, dichos niveles de presión están ajustados a los niveles especificados por el cliente
y, normalmente, no es necesario volver a ajustarlos. Dichos niveles están especificados en la
documentación técnica. Se puede revisar fácilmente el compensador del sistema al cerrar una
válvula de bola en la sección de alta presión y al permitir la operación de la bomba hasta que se
registre la presión en el medidor.
• Se debe verificar la presión de trabajo para cerciorarse de que corresponda a los valores
especificados.
ETAPA 6. Detener la operación del motor eléctrico
• Corregir cualesquiera fallas detectadas en los puntos anteriores.
• Revisar el indicador del filtro. No es inusual que se requiere su reposición durante la puesta en
servicio del sistema, ya que el sistema está eliminando las partículas de basura. Al reponer los
elementos del filtro, hay que seguir las instrucciones (sección 5.3 “Reposición del filtro”) para
evitar que basura entre en el sistema. Si aún permanece basura dentro del sistema, será
necesario un lavado adicional para evitar la falla prematura de los componentes del sistema.
• Realizar una inspección de todas las conexiones, pernos, etc., y apretarlos en caso de ser
necesario.
• Quitar todos los fluidos de desecho, pedazos de cable, etc., para mantener limpia la zona
alrededor de la unidad.
AJUSTE DE LA
PRESIÓN DE CARGA
VÁLVULA DE
AJUSTE DE LA COMPENSACIÓN
PRESIÓN DE CARGA
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Instalación Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Se ajustan la presión de carga y el nivel de presión del compensador de la bomba antes de que el PAC
salga de la fábrica y, por lo tanto, normalmente no existe la necesidad de volver a ajustarlos. Siempre
se deben verificar los niveles de presión en la documentación técnica. Personal profesional que
entiende los riesgos y funciones relacionados con la bomba debe realizar el ajuste de la presión
de la(s) bomba(s). Se deben ajustar las presiones durante operación y con el sistema a la temperatura
de operación. Favor de tomar nota de que las presiones pueden cambiar con distintos niveles de
viscosidad.
1. Ajuste de la presión de carga: Quitar la tuerca con cabeza de botón, aflojar la tuerca
prisionera y ajustar la presión con una llave Allen de 5/32”. Se incrementa la presión a dar la
vuelta en sentido de las manecillas del reloj. La presión de carga (en el medidor de la presión
de carga) debe estar dentro de los siguientes límites: 218 psi (15 bar) en el caso de P6S/P7S y
P11S/P14S y P24S y 261 psi (18 bar) en el caso de P30S.
Si se pretende utilizar otras cargas de presión, favor de consultar con su representante de Hagglunds Drives.
2. Después de ajustar la presión de carga: Apretar la tuerca prisionera y volver a colocar la
tuerca con cabeza de botón. Registrar el ajuste en la bitácora u otra documentación técnica.
3. En caso de incrementar los niveles de presión principales: Cerciorarse de que la tubería y
estructura de la máquina pueden aguantar la mayor presión/mayor torque que proviene del
motor hidráulico.
4. Ajuste de la presión del compensador: Aislar la bomba y, después, activar o mover la señal
de entrada al control de manera que se incremente la presión en el circuito cerrado de alta
presión al punto de ajuste en el limitador de presión. Se alcanza el ajuste en el limitador de
presión cuando la presión deja de incrementarse y permanece estable en un nivel de presión
(según se indica en los medidores).
Se establece el ajuste en el limitador de presión en el lado A- y B- en la válvula del compensador.
Quitar la tuerca con cabeza de botón, aflojar la tuerca prisionera y ajustar la presión con una llave
Allen de 5/32”. Se incrementa la presión a dar la vuelta en sentido de las manecillas del reloj.
5. Después de ajustar las presiones principales: Apretar la tuerca prisionera y volver a colocar
la tuerca con cabeza de botón. Registrar el ajuste en la bitácora u otra documentación técnica.
30
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Mantenimiento
5. MANTENIMIENTO PREVENTIVO
5.1 Registro de mantenimiento
Recomendamos se mantenga una bitácora de mantenimiento para registrar servicio / mantenimiento
/ reparaciones, adiciones y modificaciones de los equipos. Cada nota, observación o comentario
debe ser fechado.
31
Mantenimiento Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
Mantenimiento programado
Se debe realizar mantenimiento programado, a intervalos específicos, el cual debe incluir las siguientes
inspecciones y medidas:
• Todos los puntos mencionados en inspecciones frecuentes
• Verificar todos los niveles de presión
• Verificar la estabilidad de los niveles de la temperatura en todo el sistema
• Quitar el agua y lodo del tanque a través del tapón de drenaje
• Realizar una inspección del motor eléctrico
• Verificar la operación del equipo de monitoreo / interruptores, etc.
• Limpiar las áreas en donde existe una acumulación de suciedad
Nota: Nunca se debe usar un sistema de lavado de alta presión para limpiar la parte interna de
la unidad de potencia.
• Realizar una inspección de los cables
• Realizar una inspección de los acumuladores (opcionales) en lo que se refiere a la carga previa
• Realizar una inspección del flujo en las líneas de drenaje y la condición del aceite en la línea de
drenaje
• Realizar una inspección de las mangueras, acoplamientos y bomba(s) para detectar
agrietamientos, fugas y condiciones en general
• Realizar una inspección del acoplamiento de la flecha a través del registro de inspección.
Advertencia: existen componentes rotatorios dentro del registro de inspección
• Realizar una inspección del flujo del agua de enfriamiento
• Verificar que el aislamiento dentro del gabinete (especialmente en la campana) esté bien
sujetado
• Verificar que las puertas y la tapa de la unidad de potencia no han sufrido daño
Filtro simple
1. Detener las operaciones y parar el motor eléctrico.
2. Quitar el tazón del filtro y cambiar el cartucho del filtro.
Es muy importante que, durante el proceso de instalación, no se exponga el nuevo cartucho a
suciedad y, por lo tanto, debe mantenerse dentro de contenedor de plástico lo más que se
puede.
Realizar una inspección del anillo “O” y el anillo de respaldo para detectar cualquier daño. De ser
necesario, reponer las piezas.
3. Volver a instalar el tazón del filtro y apretarlo en forma manual hasta que se detenga y, luego,
regresar 1/8 de vuelta.
Nota: En el momento de quitar un cartucho, se debe realizar una inspección para detectar
contaminación inusual dentro de los pliegues. Favor de comunicarse con su oficina de Hagglunds
Drives para asesoría.
32
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Mantenimiento
Tornillos de
venteo
33
Mantenimiento Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
!
PRECAUCION
Leer la etiqueta de
advertencia en el
cartucho de grasa.
Programa de lubricación del motor eléctrico (60 Hz)
Tamaño
Motor eléctrico Intervalos de Volumen de
del
HP (kW) lubricación grasa
armazón
1.0 pulgada
286 30 (22)
cubica
40 (30)
6 to 12 meses
50 (37) 1.5 pulgada
324-365
60 (45) cubica
75 (56)
100 (75)
125 (93)
150 (112)
2.5 pulgada
404-449 200 (149) 6 meses
cubica
ENTRERROSCAS 509
DE LA GRASA 250 (186)
300 (224)
350 (261)
400 (298)
3 meses Revisar datos
5011 450 (336)
34
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Mantenimiento
6. MANTENIMIENTO CORRECTIVO
6.1 Mantenimiento común
Antes de quitar cualquier componente hidráulico/eléctrico, se debe desconectar la unidad de potencia.
Cerciorarse que ninguna energía se haya acumulado en el sistema y que el suministro de energía
eléctrica está desconectado del motor eléctrico. Seguir las precauciones de seguridad recomendadas.
35
Mantenimiento Correctivo Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
!
PELIGRO
•
subir la unidad completa del motor eléctrico / bomba.
Unicamente se debe utilizar equipo de levantamiento con la capacidad
de sostener el peso (sección 4.2 “Métodos de levantamiento y pesos”).
• Nadie debe pararse por debajo de la unidad después de subirla.
• Tomar en cuenta el centro de gravedad al realizar las maniobras de
levantamiento.
36
Manual de Instalación y Mantenimiento, Unidad de Potencia PAC Detección de Fallas
37
Detección de Fallas Manual de Instalación y Mantenimiento, Unidad de Potencia PAC
38
AM326-1A-SP 2000 Printer : Precision Printing 2000
Prólogo
Hägglunds Drives es uno de los primeros fabricantes del mundo de grandes
sistemas de accionamiento hidráulico, un primer puesto que ha sido posible
gracias a un imbatible espíritu de servicio y a un desarrollo continuo, tanto
de productos como de mercados, en el mundo entero. Nuestras unidades se
encuentran en casi todos los sectores industriales y marinos, en los que existen
altísimas exigencias de eficacia y fiabilidad. Nuestra oficina principal y nuestra
planta de fabricación se encuentran en Mellansel, Suecia, y contamos con
nuestras propias oficinas de ventas y representación en unos 40 países.
2
Manual de instalacíon y mantenimiento, Compact CB Índice
Índice
1. INFORMACIÓN GENERAL....................................................................................................4
1.1 Instrucciones de seguridad ....................................................................................................4
1.2 Datos sobre el motor .............................................................................................................5
1.3 Descripción de funcionamiento ..............................................................................................6
2. DATOS TÉCNICOS.................................................................................................................7
2.1 Presión de carga recomendada..............................................................................................7
2.2 Ruido de una instalación completa .........................................................................................8
2.3 Elección de fluido hidráulico ...................................................................................................9
Fluidos ecologicos adecuados para el medio ambiente .......................................................10
3. INSTALACIÓN......................................................................................................................11
3.1 Instrucciones de montaje......................................................................................................11
Rosca de la herramienta de montaje ....................................................................................12
Ejes estriados .......................................................................................................................12
3.1.1 Métodos de elevación ...........................................................................................................13
Colocación del motor en una superficie plana ......................................................................14
3.1.2 Montage del acoplamiento sobre el eje del motor ................................................................15
3.1.3 Montaje del brazo de par sobre el motor .............................................................................17
3.1.4a Montaje del motor sobre el eje conducido - eje de acoplamiento.........................................18
3.1.4b Montaje del motor sobre el eje conducido - estriado ...........................................................21
3.1.5 Desmontaje del motor del eje conducido .............................................................................22
3.1.6 Montaje del punto de reacción .............................................................................................22
3.2 Conexiones de aceite ..........................................................................................................24
3.2.1 Dirección de rotacíón del eje del motor ...............................................................................26
3.2.2 Drenaje y purga del motor ...................................................................................................26
3.2.3 Recirculacion de aceite en el motor......................................................................................27
3
Información general Manual de instalacíon y mantenimiento, Compact CB
1. INFORMACIÓN GENERAL
1.1 INSTRUCCIONES DE SEGURIDAD
Es de la máxima importancia seguir en todo momento las instrucciones de seguridad;
si tiene alguna duda al respecto, póngase en contacto con la oficina de HD más
cercana.
Señales de aviso
En este manual encontrará las siguientes señales de aviso, que indican un peligro potencial
que puede derivar en lesiones personales o importantes daños materiales. Dependiendo de
la probabilidad de peligro y de lo graves que pudieran ser las lesiones personales o los daños
materiales, existen tres niveles de clasificación:
Área de aplicación
El personal de Hägglunds siempre debe aprobar y supervisar todas las aplicaciones, ya sean
nuevas o reconstruidas.
Montaje
Siga atentamente las instrucciones y preste atención a los grandes pesos y fuerzas implicados
durante la elevación.
Mantenimiento periódico
Observe los intervalos del gráfico de mantenimiento (4.4) y lleve un registro de los mismos.
Desmontaje
Siga atentamente las instrucciones y preste atención a los grandes pesos y fuerzas durante la
elevación.
4
Manual de instalacíon y mantenimiento, Compact CB Información general
Tipo de motor Cilindrada Par nominal *Velocidad Velocidad **Presión Par máximo Potencia máxima
nominal 1) máxima máxima 2) 3)
EE.UU. intermitente
Vi Ts n n p lbf·ft hp
in3/rev lbf·ft/1000 psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
* Se requiere una presión de carga de 12 bares/175 psi para motores en modo de frenando. (Especiales consideraciones deben
ser tomadas, respecto a presión de carga, refrigeración y selección del sistema hidráulico, para velocidades superiores a las
nominales, las 4 vias deben ser utilizadas).
** Los motores han sido diseñados de acuerdo con las normas DNV. Se permite una presión de comprobación y una presión
máxima de 420 bares/psi.
1
) Consideraciones especiales con respecto a la presión de carga, refrigeración y elección de sistema hidráulico para la velocidad
anteriormente indicada.
2
) Calculado en: Métrico= Ts·(350-15)·0,98 EE.UU= Ts·(5000-218)·0,98.
3
) Válido para la mínima viscosidad del aceite permitida 20 cST en la carcasa del motor.
5
Información general
1 1. Anillo de leva
2. Podillo de leva
2 A, C 3. Pistón
3 4. Acoplamiento del eje
D
4 8 5. Bloque de cilindros /
eje hueco
6. Bloque de cilindros /
5 Estriado
7. Tapa delantera
8. Cilíndrico cojinete a
rodillos
11
9. Bloque de conexiones
6 10. Placa de distribución
11. Cojinete axial
7 9 A = Boca »A« entrada o
salida
10
C = Boca »C« entrada o
salida
D = Boca de purga
Datos técnicos
2. DATOS TÉCNICOS
2.1 Presión de carga Hay dos casos bien determinados:
recomendada
Caso 1:
El sistema hidráulico debe estar concebido de El motor funciona en modo de frenado. La
manera que el motor reciba suficiente presión presión de carga requerida en la boca de
de carga en la boca de baja presión. Esto se entrada es la que se indica en el diagrama
aplica a todo tipo de instalaciones. que vemos a continuación.
Caso 2:
El motor sólo funciona en modo de accio-
namiento. La contrapresión necesaria en la
boca de salida corresponde al 30% del valor
indicado en el diagrama que vemos a continua-
ción, pero puede no ser inferior a 2 bares (29
En aplicaciones con cargas sus-
psi).
pendidas, la presión de carga en las
conexiones de los motores, deben
ser las indicadas en el grafico de
abajo, en todas las condiciones.
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
Recommended charge pressure [bar]
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-portt connection
Velocidad [r pm](rpm)
Speed [rpm]
Nota:
El diagrama es válido para una presión en la carcasa de 1 bar (15 psi). Al incrementar la presión
en la carcasa, la presión de carga debe aumentar en consecuencia. El gráfico es válido para los
casos en los que se utilizan 4 bocas. La presión máxima en la carcasa es de 3 bares (43,5 psi)
(durante un 1% del tiempo de operación uniformemente dividido, se admiten puntas de presión
de 5 segundos máximo hasta 8 bares (116 psi)).
Datos técnicos Manual de instalacíon y mantenimiento, Compact CB
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
16
Recommended charge pressure [bar]
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Observaciones:
8
Manual de instalacíon y mantenimiento, Compact CB Datos técnicos
GENERALIDADES
El aceite debe ser conforme con FZG (90) fase de ensayo grado 11 descrito en IP 334 (DIN 51354).
El aceite debe contener también inhibidores para evitar la oxidación, corrosión y formación de
espuma. La viscosidad del aceite mineral depende en gran parte de la temperatura. La elección
definitiva del aceite debe depender de la temperatura de trabajo que se espera, o se conoce, en
el circuito y no en el depósito del aceite.
Las altas temperaturas del circuito reducen considerable-
VISCOSIDAD RECOMENDADA
mente la vida de servicio del aceite y de las juntas de A LA TEMPERATURA DE TRABAJO
goma.Asimismo dan como resultado una baja viscosidad 40-150 cSt/187-720 SSU.
que a su vez proporciona lubricación deficiente.
El contenido de agua deberá ser inferior al 0,1%. En aplica-
ciones industriales que exigen una larga vida de funciona-
Límites de temperature
miento, el contenido de agua será inferior al 0,05 %.
La temperatura normal de trabajo debe ser
Límites de viscosidad inferior a +50°C (122°F)
Indice de viscosidad =100 recomendada Juntas de nitrilo
=150* para funcionamiento (motor estándar) -35°C a +70°C
con grandes diferencias de Juntas de Viton -20°C a +100°C
temperatura Juntas de nitrilo
Mín. permitido en trabajo continuo 40 cSt/187 SSU (motor estándar) -31°F a +158°F
Mín. permitido en trabajo intermitente 20 cSt/98 SSU** Juntas de Viton -4°F a +212°F
Máx. permitido 10000 cSt/48000 SSU
* Muchos fluidos hidráulicos con mejoradores VI están sujetos temporal o permanentemente a reducciones de la viscosidad.
** Las viscosidades bajas reducen la vida de servicio de los motores “COMPACT CB”.
9
Datos técnicos Manual de instalacíon y mantenimiento, Compact CB
Fluidos ecológicos
10
Manual de instalacíon y mantenimiento, Compact CB Instalación
3. INSTALACIÓN
3.1 Instrucciones de montaje Diseño del extremo del eje conducido
de un eje sobrecargado
Para que el motor funcione correctamente,
Cuando el eje conducido está sobrecargado
debe instalarlo con la máxima precisión
y sujeto a grandes esfuerzos, por ejemplo, en
posible. Si conecta los elementos del motor
los cambios de la dirección de rotación, se
de forma que no cumplan los requisitos de las
recomienda que el eje tenga una ranura para
instrucciones que se indican a continuación,
eliminar los esfuerzos; consulte la figura 3.1 y
la vida de servicio del motor puede resultar
las tablas 3.1 y 3.4.
gravemente afectada.
Normalmente el motor debe estar totalmente
lleno de aceite. Cuando se instala el motor con Figura 3.1
el eje en el plano horizontal, las conexiones de G
C
A
D
del motor».
Debe dimensionar la tubería de drenaje de ma-
E
30°
nera que la presión de la carcasa del motor no
sea superior a 3 bares (43,5 psi). 6±0,5
(0,24±0,02)
R 50
(R 1,97)
La presión máxima de la carcasa es de 3 bares B±0,5
(B±0,02)
(43,5 psi). Se permiten breves picos de hasta
8 bares (116 psi) durante el trabajo. La presión Eje con carga normal
de la carcasa permitida cuando el motor está En aplicaciones con un solo sentido de
parado es de 8 bares (116 psi). rotación en las que los esfuerzos del eje son
El motor debe estar siempre conectado de moderados, éste puede ser liso, consulte la
tal manera que tenga suficiente presión de figura 3.2 y las tablas 3.1 y 3.5.
carga, en la conexión de baja presión. Esto
es especialmente im port an te a grandes
Figura 3.2
velo-cidades y con inversión de marcha
rápida, consulte 2.1 «Presión de carga Máx.
recomendada».
11
Instalación Manual de instalacíon y mantenimiento, Compact CB
Accionamientos bidireccionales
Acero con resistencia Relmin= 700 N/mm2 Tabla 3.5 Rosca alternativa
(figuras 3.1 y 3.2)
CB 280 - 840
D M20 UNC 5/8"
Tabla 3.4 E >17 (0,67) >13,5 (0,53)
Motor CB 280/400 CB 560/840 F 25 (0,98) 22 (0,87)
G 50 (1,97) 30 (1,18)
Perfil del diente y DIN 5480 DIN 5480
forma del fondo
Tolerancia 8f 8f
Guía Trasera Trasera
Ángulo de presión 30 ° 30°
Módulo 5 5
Número de 38 50
dientes Figura 3.3
Diámetro primitivo ø190 ø250
Diámetro menor ø188 0 ø248 0
A
-1,201 -1,201
Diámetro mayor ø199 0 ø259 0
-0,290 -0,320
ø
ø
12
Manual de instalacíon y mantenimiento, Compact CB Instalación
Figura 3.5
13
Instalación Manual de instalacíon y mantenimiento, Compact CB
Tabla 3.7
Brazo de par Peso
kg lb
TCA 40 128 282
Soporte
TCA 84 224 493
Figura 3.7
Soporte
NOTA:
El motor no debe apoyarse sobre el eje hueco,
cuando el acoplamiento está montado, ya que
este podría dañarse.
Al almacenar el motor, siempre debe colocarlo
sobre la superficie del eje hueco. También es
aconsejable instalar soportes en la superficie
de montaje del motor, consulte la figura 3.7.
14
Manual de instalacíon y mantenimiento, Compact CB Instalación
Por lo tanto, es importante que en las manos no quede ningún resto de Molycote. Una vez
cumplidas dichas condiciones, puede empezar el montaje.
- Limpie el eje conducido y la parte externa e interna del eje hueco del motor Compact.
- Quite los separadores entre los dos anillos de fijación del acoplamiento.
- Monte el acoplamiento sobre el eje hueco del motor. Debe empujar el acoplamiento hacia
arriba hasta el tope del eje. Utilice un destornillador para abrir el anillo de acoplamiento y
lograr así un montaje más fácil.
- Monte el motor en el eje conducido siguiendo las instrucciones de la sección 3.1.4 "Montaje
del motor sobre el eje conducido" (utilizando o sin utilizar la herramienta de montaje).
Recuerde:
- La superficie cónica entre el anillo de acoplamiento y los bridas de fijación + los tornillos debe
estar engrasados MoS2 (Molycote), consulte la figura 3.8. Esto se hace en fábrica a la entrega.
Cuando haya desmontado un motor para efectuar una revisión general o realizar un servicio,
y tenga que volver a montarlo, tal vez necesite lubricar de nuevo estas superficies con Molycote
pero, recuerde: sólo las superficies especificadas.
cadas
- Absolutamente nada de Molycote en las superficies de contacto entre el eje y el motor. Limpiar
el eje accionado y el interior del eje hueco del motor.
- La alineación del motor en el eje (comprobación dimensional).
- Una variación mínima en la separación entre los bridas de fijación (comprobación
dimensional).
- El par correcto en los tornillos (utilice una llave dinamométrica).
15
Instalación Manual de instalacíon y mantenimiento, Compact CB
Figura 3.8
Anillos de fijación
Labio
Anillo de acoplamiento
Arandela - - - - -= Superficie
engrasada
Superfície limpa
16
Manual de instalacíon y mantenimiento, Compact CB Instalación
Tabla 3.8
Motor Dimensión de los tornillos Número de Par de apriete
tornillos Nm lbf·ft
CB 280/400 M20 Strength class 10.9 34 540 400
17
Instalación Manual de instalacíon y mantenimiento, Compact CB
2 1; Soporte de fijación
2; Arandela de plástico
3; Tuerca
4; Herramienta de montaje
3
4
18
Manual de instalacíon y mantenimiento, Compact CB Instalación
Figura 3.11 Sin ranura para eliminar los esfuerzos Figura 3.12
19
Instalación Manual de instalacíon y mantenimiento, Compact CB
Tabla 3.10
20
Manual de instalacíon y mantenimiento, Compact CB Instalación
Separador
- Monte el separador en el eje. MV=450 Nm/300
lbf.ft.
- Montar el motor sobre el eje.
- Llenar de aceite por el tapon G1.
- Monte el tornillo de diseño especial.
- Apriete el tornillo. MV=385 Nm/280 lbf.ft.
Llenar de aceite antes
de apretar el tornillo - Montar la tapa. MV=81 Nm/59 lbt.ft.
M20 L=100 mm
21
Instalación Manual de instalacíon y mantenimiento, Compact CB
22
Manual de instalacíon y mantenimiento, Compact CB Instalación
Posición
alternativa
La totula debe ser
desmontada durante la
soldadura.
Acero:
EN 10113S355N
DIN St E39
BS 4360 Grade 50C
Protegido contra corrosión tras la soldadura.
ZONA DE PELIGRO
En caso de fallo de la instalación
del brazo de par
23
Instalación Manual de instalacíon y mantenimiento, Compact CB
Figura 3.25
T4
Tabla 3.11
Conexión Descripción Observaciones
C1, C2 Conexión principal Si se utiliza C como entrada, el eje del motor gira en el
sentido de las agujas del reloj, mirando desde el lado
del eje del motor*.
A1, A2 Conexión principal Si se utiliza A como entrada, el eje del motor gira en el
sentido contrario a las agujas del reloj, mirando desde
el lado del eje del motor*.
D1 Salida de drenaje Normalmente tapada a la entrega.
D2, D3, D4 Salidas de drenaje Normalmente tapada a la entrega.
alternativas
F1, F2 Conexión de recirculación aceite Para recircular el reten del eje. Normalmente tapado.
F3 Conexión de recirculación aceite Para purga de cojinete axial y de la carcasa del motor.
T1 Tomas de presión Se utilizan para medir la presión y la temperatura en
las conexiones principales.
T2, T3 Tomas de presión Utilizado para medir la presión y/o la temperatura del
aceite de drenaje.
T4 Conexión de presión Conexión para brazo de par de dos extremos.
Tabla 3.12
Motor A** C** D1, D2, D4 F1, F3 T1, T3 T4 y y x x
D3 F2 T2 mm in mm in
CB 280...840 1 1/4" 1 1/4" G G G G G1/4" G G 223 8.78 99 3,90
1 1/2" 1 1/2" 1 1/4" 1 1/4" 1/4" 1/2" M16 1/4" 1/2" 223 8.78 101 3.98
** Bridas SAE J518C, código 64, 414 bares (6000 psi). Se puede utilizar 1 1/4” o 1 1/2”.
*** La conexión A2 y la conexión C2 están bloqueadas a la entrega. Pueden soportar la máxima presión.
24
Manual de instalacíon y mantenimiento, Compact CB Instalación
Conexiones principales A, C
Tabla 3.13
Motor Conexión a b c
mm (in) mm (in)
CB 280 - 840 1 1/4" 31 (1,22) UNC 1/2" 27 (1.06)
1 1/4" UNC 5/8" 35 (1.38)
G
G1 1/4"
25
Instalación Manual de instalacíon y mantenimiento, Compact CB
Montaje vertical
Cuando el motor está montado verticalmente, se debe utilizar la salida de drenaje más alta D1,
D2, D3 o D4. Es necesaria la recirculación del retén radial de baja presión.
26
Manual de instalacíon y mantenimiento, Compact CB Mantenimiento
Conexiones
de la tubería
de drenaje Baja presión
Conexiones de la
tubería de drenaje
G 1/4", Conexión de
Figura 3.30 recirculacíon F1 Fig. 3.31
G 1/2", Conexión de
recirculacíon F3
Baja presión
27
Instalación Manual de instalacíon y mantenimiento, Compact CB
4. INSTRUCCIONES DE FUNCIONAMIENTO
4.1 Almacenamiento
El motor se entrega con una protección interna en forma de película de aceite y una protección externa en
forma de película anticorrosiva, lo que ofrece suficiente protección para su almacenamiento en interiores,
a temperaturas normales, durante unos 12 meses.
Nota: La protección anticorrosión debe retocarse después del transporte y la manipulación.
Si el motor permanece almacenado durante más de 3 meses en locales sin calefacción, o más de 12 meses
en locales con calefacción, debe llenarlo de aceite y colocarlo como se indica en la figura 3.7.
Coloque el motor como se indica en la figura 4.1, llénelo de aceite filtrado en el orden siguiente: D1, A1, C1.
Consulte 2.3, “Filtración” y tabla 4.1.
Tenga mucho cuidado para que no se introduzca ningún elemento contaminante en el motor con el aceite.
Cierre las conexiones A y C con la tapa protectora instalada en la superficie de conexión a la entrega.
Compruebe que todas las juntas tóricas o las juntas de caucho estén es su sitio en la tapa protectora. Ponga
el tapón en D1. En la tabla siguiente vemos la cantidad de aceite necesario para rellenar los distintos tipos
de motores.
Tabla 4.1
Motor Volumen de aceite aprox.
Litros Galones EE.UU
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
Manual de instalacíon y mantenimiento, Compact CB Mantenimiento
Tabla de mantenimiento
En Filtros Aceite Brazo
funcionamiento de de par
aceite
Después de las Camb. Inspec.
100 primeras
horas
Después de 3 Camp.
meses o 500
horas
Una vez cada 6 Camp. Inspec. Inspec.
meses
Una vez cada
12 meses
29
Mantenimiento Manual de instalacíon y mantenimiento, Compact CB
Motor Filtros
Si el motor va a permanecer almacenado du- Debe cambiar los filtros una vez transcurridas
rante más de 1 mes, debe protegerlo de la las 100 primeras horas de funcionamiento, y
corrosión interna, lo cual puede hacerse de la efectuar el segundo cambio tras 3 meses o
manera siguiente: 500 horas de funcionamiento, lo que primero
1. Mezcle un aditivo anticorrosivo con el ocurra. Después, debe cambiarlos a intervalos
líquido hidráulico del sistema. Utilice un 5% regulares de 6 meses o 4.000 horas de
de Rust Veto Concentrate (fabricado por funcionamiento.
EF Houghton & Co, Philadelfia, EEUU). Este
aditivo ofrece una protección anti-corrosión
durante aproximadamente un año, después Aceite (Consulte también 2.3)
de este tiempo, el motor debe ser girado una
pocas revoluciones
Análisis
2. Si no se utilizan aditivos, el motor debe ser
regularmiente girado unas, pocas revolu- Recomendamos analizar el aceite cada 6
ciones. meses. Dicho análisis debe incluir viscosidad,
oxidación, contenido de agua, aditivos y
3. Si no es posible girar el motor, tape todas contaminación.
las conexiones, abrir la boca de drenaje D1
o D2 en el extremo de la carcasa (o si el La mayoría de los distribuidores de aceite tienen
motor está montado verticalmiente, la boca un equipo que analiza el estado del aceite y
de purga F1 en la carcasa en el lado del recomienda las medidas oportunas a tomar.
eje) y llenar el motor con liquido hidráulico. Hay que cambiar el aceite inmediatamente si
(Consulte las figuras 4.3 y 4.3a). el análisis indica que se ha agotado.
Viscosidad
Muchos aceites hidráulicos se vuelven más
Figura 4.3
fluidos con el uso, lo que se traduce en una
lubricación más deficiente. La viscosidad del
aceite en servicio nunca debe ser inferior a la
viscosidad mínima recomendada.
Oxidación
El aceite hidráulico se oxida con el uso y la
temperatura, lo cual se hace patente por los
cambios de color y olor, una mayor acidez o
la formación de lodo en el depósito. El índice
de oxidación aumenta rápidamente a una
Figura 4.3a temperatura en la superficie superior a 60 °C
(140 °F); entonces debe comprobar el aceite
más a menudo.
El proceso de oxidación incrementa la acidez
del fluido. La acidez se indica en términos
del “número de neutralización”. La oxidación
típica es lenta al principio y después aumenta
rápidamente.
Un rápido incremento (en un factor de 2 y
3) del número de neutralización entre las
inspecciones es señal de que el aceite se ha
oxidado demasiado y hay que cambiarlo de
inmediato.
30
Manual de instalacíon y mantenimiento, Compact CB Localiczación de averías
Contenido de agua
La contaminación del aceite con agua puede El método más común de realizar el análisis es
detectarse haciendo un muestreo de la parte recoger una muestra de aceite en una botella
inferior del depósito. La mayoría de los aceites especial y enviarla a un laboratorio para que
hidráulicos repelen el agua, que se acumula en éste le remita el informe, que se atiene a las
la parte inferior del depósito. Este agua debe normas internacionales al respecto.
purgarse a intervalos regulares. Hay determi- Usted ha de decidir qué análisis debe realizar
nados tipos de aceites para transmisión y el laboratorio. El más común es un recuento
aceites para motor que emulsionan el agua, de partículas, contenido de agua, oxidación y
lo cual puede detectarse por la formación de viscosidad.
revestimientos en los cartuchos de filtro o
cambios del color del aceite. En dichos casos También puede instalar un contador de
deberá asesorarle su distribuidor de aceite. par tículas directamente en el sistema
hidráulico, que le informará de los niveles de
Grado de contaminación contaminación del aceite siguiendo las normas
internacionales. La única desventaja de ese
Una fuerte contaminación del aceite incrementa sistema es que sólo obtiene los niveles de
el desgaste de los componentes del sistema contaminación del aceite.
hidráulico. Debe investigar y solucionar in-
mediatamente la causa de la contaminación.
General
El objetivo es la verificación del estado del
aceite durante el funcionamiento del motor.
Los motores deben estar funcionando a un
régimen normal de trabajo cuando se tome
la muestra. Tenga en cuenta que es muy
importante operar con pulcritud a la hora
Todos los fluidos hidráulicos resultan de tomar la muestra.Utilice siempre botellas
afectados de manera distinta. Consulte especialmente preparadas para la recogida
de muestras de aceite, que puede adquirir en
con su dis-tribuidor de aceite o con el
cualquier laboratorio de análisis de fluidos.No
respresentante de Hägglunds Drives intente nunca depositar las muestras en una
más cercano. botella que haya limpiado previamente si desea
que el análisis sea preciso.La muestra se ha de
4.5 Revisión del aceite recoger con un latiguillo Minimess conectado
a un acoplador Minimess.Limpie con cuidado
todos los puntos de conexión antes de unir el
Finalidad latiguillo Minimess al acoplador.
La finalidad de la recogida de muestras de Tenga cuidado al conectar el latiguillo
aceite es comprobar su estado.Si se llevan a Minimess, ya que el chorro de aceite es
cabo análisis periódicos del aceite, se pueden peligroso. No lo dirija nunca hacia una persona
detectar los productos de desgaste y tomar las u objeto delicado.Compruebe la presión de la
medidas oportunas antes de que se produzca conexión antes de conectarla.
una avería. El análisis del aceite le ayuda a
establecer cuándo es necesario cambiarlo, le
Como efectuar
indica las deficiencias en el mantenimiento y
reduce al mínimo los gastos en reparaciones. Toma de muestras
Además, le brinda la oportunidad de programar Las muestras se han de tomar del acoplador
los reajustes o revisiones, los trabajos de Minimess situado en la parte de presión de
mantenimiento o reparaciones, y de este modo carga del motor en el circuito cerradoNo las
le permite ahorrar dinero y evitar períodos de tome nunca del depósito utilizando las válvulas
inactividad. esféricas.
Limpie con cuidado el acoplador y el
latiguillo.
31
Mantenimiento Manual de instalacíon y mantenimiento, Compact CB
5. LOCALIZACIÓN DE AVERÍAS
Motor hidráulico
Averiá Causa probable Acción
El motor no funciona. Parada mecánica del acciona- Compruebe la presión del sistema. Si ésta se ha
miento. elevado hasta el ajuste de la válvula limitadora de
presión, retire la carga del
accionamiento.
32
Manual de instalacíon y mantenimiento, Compact CB Declaración de conformidad
DECLARACIÓN DE CONFORMIDAD
Ejemplo de declaración de conformidad de Hägglunds Drives AB
33
SPIDER CONTOL SYSTEM
Manual para usuarios
SPIDER 2
Prólogo
Hägglunds es uno de los principales fabricantes de sistemas de control hidráulico de gran
tamaño del mundo. Ocupa una posición de liderazgo gracias a su inigualable espíritu de servicio
y al permanente desarrollo de productos y mercados en todo el mundo. Nuestros sistemas de
control se encuentran en la mayoría de los segmentos de la industria y la marina, donde las
demandas de eficiencia y confiabilidad son extremadamente altas. Nuestra oficina principal y
nuestra planta de producción se encuentran en Mellansel, Suecia, y tenemos nuestras propias
oficinas de ventas y representación en 40 países distintos.
Este manual de ingeniería proporciona información necesaria para operar el sistema de control
Spider. Para encontrar algún tipo de información en particular, simplemente busque la sección
deseada como figura en el índice. Sin embargo, es posible que haya cambios en los equipos.
Por consiguiente, nos reservamos el derecho de introducir modificaciones en el manual según
consideremos necesario sin aviso previo ni obligación alguna.
Símbolos de advertencia
En este manual encontrará los siguientes símbolos que indican un posible peligro que puede
provocar o provocará lesiones personales o daños materiales significativos. Dependiendo de la
probabilidad de peligro, y de la gravedad que puede tener la lesión personal o daño material, los
símbolos se clasifican en tres niveles.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(1)
AS-1
Spider Introducción
Manual de ingeniería 04-04-02
1.1 Descripción
La unidad Spider es un sistema basado en un microcontrolador, configurable para ajustarse a
diferentes necesidades de aplicación. Está diseñado para adaptarse a la unidad de potencia de
dos o de tres puertas, e incluso a una unidad de una puerta adicional. El sistema de control
puede controlar bombas con doble bobina (Denison 9A, Brueninghaus EP, Sauer Sundstrand
KA o bombas similares) o con bobina simple en una dirección (Denison 5A).
La configuración de las funciones preprogramadas del sistema se lleva a cabo usando el panel
delantero, con ayuda de las indicaciones que aparecen en la pantalla o mediante una conexión
en serie con una computadora portátil. Se puede proteger el modo de configuración con una
contraseña.
• De dos a cuatro bombas para dos sistemas de control con función independiente:
EM EM
P P
P P
EM EM
P P
EM EM EM
P P P
-------
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS1, Introducción, Manual de ingeniería 04-04-02
• De dos a cuatro bombas para dos sistemas de control con función común. Si uno se para por
una falla, el otro también se para:
EM EM EM
P P
P P
EM EM EM
P P
EM EM EM
P P P
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(7)
AS1, Introducción, Manual de ingeniería 04-04-02
La función Shredder (Triturador) tiene las mismas características que la función Basic (Básica) y
además cuenta con funciones adicionales de reversa a causa de un sistema de control parado
por sobrecarga. Es posible maximizar la cantidad de reversas dentro de un límite de tiempo y
parar el sistema de control cuando está excedido. El sistema de control puede configurarse para
cambiar de dirección, después de un intervalo de tiempo ajustable.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS1, Introducción, Manual de ingeniería 04-04-02
La función Friction (Fricción) tiene las mismas características que la función Basic (Básica) y
funciones adicionales para controlar dos sistemas de control hidráulicos accionados
conjuntamente, con una relación entre los motores.
La función subordinada Friction (Fricción) tiene las mismas características que la función Basic
(Básica) y funciones adicionales para controlar dos sistemas de control hidráulicos accionados
conjuntamente, con una relación respecto del valor de consigna maestro.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 4(7)
AS1, Introducción, Manual de ingeniería 04-04-02
La función Synchro (Sincronizar) tiene las mismas características que la función Basic (Básica)
y funciones adicionales para controlar la posición entre dos sistemas de control hidráulicos. Se
puede establecer el ángulo entre los cilindros mediante una señal externa. También es posible
el control en función de una relación. Este modo requiere codificadores de velocidad digitales.
El frente de la unidad Spider tiene botones pulsadores para arrancar y parar el sistema de
control, para configurar el modo local/remoto, para configurar el valor de consigna de velocidad
mediante los botones de aumento y reducción en el modo local, para configurar la reversa por
retrocesos sucesivos, para configurar el sistema de control regulado/no regulado y el sistema de
control automático/manual en el modo Shredder (Triturador). Estas funciones que se activan
mediante los botones pulsadores se pueden puentear en la configuración de las funciones del
sistema.
Todas las entradas y salidas son configurables y pueden conectarse con funciones
preprogramadas en la configuración del sistema. Todas las señales están cableadas en forma
estándar a los terminales de contacto o a través del puerto fieldbus (opcional).
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 5(7)
AS1, Introducción, Manual de ingeniería 04-04-02
Las entradas digitales pueden configurarse para funciones como arrancar/parar, reversa,
reiniciar, monitoreo de la unidad de potencia y monitor auxiliar, donde es posible configurar la
función y exhibir el texto del monitor.
Las salidas digitales pueden configurarse para funciones como alarmas/advertencias comunes,
listo para usar, sistema de control arrancado, triturador bloqueado, control del enfriador y del
calefactor. Las salidas son del tipo contacto seco de relé.
Las entradas analógicas pueden configurarse para funciones como temperatura del tanque,
velocidad, presión, potencia para monitoreo y control. También pueden configurarse para bucle
de corriente o voltaje.
Las salidas analógicas pueden configurarse para monitorear la velocidad, la presión y
temperatura. También pueden configurarse para bucle de corriente o voltaje.
El sistema incluye una función de monitoreo del sistema de control con contadores de tiempo
del sistema de control, lista de alarmas/advertencias y 8 canales de registro escalables, con
descarga de datos a través de una interfaz en serie. Como opción, se puede agregar un sistema
de monitoreo remoto para el sistema de control con acceso a través de GSM.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 6(7)
AS1, Introducción, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 7(7)
AS-2
Spider Datos técnicos
Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(5)
AS2, Datos técnicos, Manual de ingeniería 04-04-02
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confirmarse antes de colocar las órdenes de compra.
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AS2, Datos técnicos, Manual de ingeniería 04-04-02
2.3 Entradas
2.3.1 Entradas analógicas
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confirmarse antes de colocar las órdenes de compra.
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AS2, Datos técnicos, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
2.3.2 Entradas digitales
2.4 Salidas
2.4.1 Control de la bomba
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confirmarse antes de colocar las órdenes de compra.
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AS2, Datos técnicos, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
2.5 Comunicación
2.5.1 Conexión a PC
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confirmarse antes de colocar las órdenes de compra.
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AS-3
Spider Conexión
Manual de ingeniería
04-04-02
3.1 Cableado
Se prefieren cables blindados para la instalación.
El cableado debe tener como mínimo 0,5mm2 para las señales de entrada y como mínimo 1mm2 para los
cables de alimentación y salida.
La distancia máx. entre el sistema de control y la unidad de potencia es de 50m.
3.2 Alimentación
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confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 04-04-02
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confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 3(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 4(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 5(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 6(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 8(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 9(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 10(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 11(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
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confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 12(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 13(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 14(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
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confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 15(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
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confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 04-04-02
Se pueden usar bombas con bobinas separadas para los lados A y B. Si se usan bombas con
una bobina en común para ambas direcciones, el sistema de control sólo podrá ser controlado
en una dirección.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 17(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 18(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 04-04-02
¡Atención! Todas las salidas deben estar protegidas contra el voltaje inducido al apagar el
interruptor mediante, por ejemplo, un diodo de marcha libre (vea 3.4.2), un varistor, un circuito
RC u otro dispositivo de protección contra sobretensiones montado cerca de la carga.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 20(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 21(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 22(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
Alojamiento Blindaje
Pin1 No conectado
Pin2 No conectado
Pin3 Línea B, TXD/RXD pos
Pin4 RTS, Solicitud de envío
Pin5 Conexión a tierra BUS
Pin6 BUS +5V
Pin7 No conectado
Pin8 Línea A, TXD/RXD neg
Pin9 No conectado
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS-3 Conexión, Manual de ingeniería 05-01-21 reemplaza 04-04-02
04-04-02
Alojamiento Blindaje
Pin1 No conectado
Pin2 No se usa
Pin3 No se usa
Pin4 No conectado
Pin5 GND
Pin6 +5V
Pin7 Línea B RS485
Pin8 Línea A RS485
Pin9 No conectado
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 25(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 26(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 27(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 28(30)
AS-3 Conexión, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
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AS-3 Conexión, Manual de ingeniería 04-04-02
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Terminales extra IC 6 Para interconexión
5 Para interconexión
4 Para interconexión
3 Para interconexión
2 Para interconexión
1 Para interconexión
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Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 30(30)
AS-4
Spider Indicación y configuración
Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(14)
AS4, Indicación y configuración, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(14)
AS4, Indicación y configuración, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 3(14)
AS4, Indicación y configuración, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
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AS4, Indicación y configuración, Manual de ingeniería 04-04-02
4.4.2 Botones del sistema de control
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AS4, Indicación y configuración, Manual de ingeniería 04-04-02
05-01-21 reemplaza 04-04-02
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AS4, Indicación y configuración, Manual de ingeniería 04-04-02
4.5.2 Puentes
4.5.3 Indicadores
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04-04-02
4.5.4 Interruptores
4.5.5 Contactos
Alimentación de CC DC1
Salida de bomba 1 PO1 Contacto de 4 polos
Salida de bomba 2 PO2 Contacto de 4 polos
Salida de bomba 3 PO3 Contacto de 4 polos
Salida de bomba 4 PO4 Contacto de 4 polos
Salida digital 1 DO1 Contacto de 14 polos
Salida digital 2 DO2 Contacto de 12 polos
Salida de motor eléctrico EO1 Contacto de 8 polos
Entrada de motor eléctrico EI/EM Contacto de 8 polos
Entrada de parada de
emergencia
Codificador digital 1 DE1 Contacto de 8 polos
Codificador digital 2 DE2 Contacto de 8 polos
Entrada digital 1 DI1 Contacto de 8 polos
Entrada digital 2 DI2 Contacto de 12 polos
Entrada digital 3 DI3 Contacto de 12 polos
Entrada digital 4 DI4 Contacto de 12 polos
Entrada digital 5 DI5 Contacto de 12 polos
Entrada analógica 1 AI1 Contacto de 12 polos
Entrada analógica 2 AI2 Contacto de 12 polos
Entrada analógica 3 AI3 Contacto de 14 polos
Salida analógica 1 AO1 Contacto de 6 polos
Salida analógica 2 AO2 Contacto de 6 polos
Conexión interna IC Contacto de 6 polos
CAN bus 1 CA1 Contacto de 6 polos
CAN bus 2 CA2 Contacto de 6 polos
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
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Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 8(14)
AS4, Indicación y configuración, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
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04-04-02
4.7.1.1 Indicadores
Nombre Descripción Función Información
del
indicador
D1 No se usa No se usa Función normal
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04-04-02
4.7.1.2 Interruptores
Nombre Función Información
del
indicador
S1 Interruptor de On= Activado (si es primero o último en una red)
terminación Off= Desactivado
4.7.2 Modbus
4.7.2.1 Indicadores
Nombre del Descripción Función Información
indicador
D1 Procesando Verde parpadeando Recepción de Consulta y creación de
respuesta.
Apagado Sin consulta
D2 Error de bus Rojo Error de bus
Apagado Operación normal.
D3 Bus listo Rojo El módulo está Fuera de línea.
Apagado El módulo no está Fuera de línea.
D4 Estado de la Verde Bus listo. Operación normal.
configuració
n HW Rojo Error de tiempo límite del bus.
4.7.2.2 Interruptores
Nombre Función Configuración Información
del
indicador
S1 Interruptor de On Activado (si es primero o
terminación último en una red)
Off Desactivado
S2: 1-7 Dirección de nodo Valor binario:
Interruptor: 1234567
0000000 No válida
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Velocidad en baudios Valor binario:
S3: 1-2 Interruptor: 812
000 No válida
001 1200
010 2400
011 4800
100 9600
101 19200 (Predeterminada)
110 38400
111 57600
S3: 1-2 Paridad Valor binario:
Interruptor: 34
00 No válida
01 Ninguna (Predeterminada)
10 Par
11 Impar
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AS4, Indicación y configuración, Manual de ingeniería 04-04-02
Cuando el software se para aparecen en la pantalla los tiempos de Hardware(M) y de Software(S) en 1/10 s,
a fin de verificar o corregir los tiempos.
HW ERROR, FC 2 (ERROR DE HW, FC 2)
Esta prueba tiene como objetivo verificar que se abra el relé que alimenta las salidas de PWM. Si se acciona
la parada de emergencia, el hardware del Spider para parada de emergencia abre este relé. Esta prueba se
realiza cuando todos los motores eléctricos están parados. Si el relé no se abre durante esta prueba,
aparece el mensaje de error ”HW ERROR, FC 2” (ERROR DE HW, FC 2) y el software se para.
HW ERROR, FC 3 (ERROR DE HW, FC 3)
Esta prueba tiene como objetivo verificar que se abran los relés del enclavamiento de los motores eléctricos.
Cuando el enclavamiento del motor eléctrico está OK el relé se cierra, y se abre cuando el enclavamiento no
está OK. Si el relé no se abre, aparece el mensaje de error ”HW ERROR, FC 3” (ERROR DE HW, FC 3) y el
software se para. Esta prueba se realiza con la unidad encendida y una sola vez, cuando todos los motores
eléctricos están parados.
4.9.4 Bus
BUS FAIL (FALLA DEL BUS)
La función Anybus está seleccionada, pero no funciona la comunicación. Este error probablemente se
producirá si el cable del bus no está conectado.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 14(14)
AS-5
Spider Parámetros V4.1.x
Manual de ingeniería 05-03-15
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
Main settings-Configuration
Interruptor Descripción Tipo Predeterminado Min Max
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Main settings-Language
Interruptor Descripción Tipo Predeterminado Min Max
Main settings-Reset
Interruptor Descripción Tipo Predeterminado Min Max
Pump outputs-Pump1
Interruptor Descripción Tipo Predeterminado Min Max
Pump outputs-Pump2
Interruptor Descripción Tipo Predeterminado Min Max
Pump outputs-Pump3
Interruptor Descripción Tipo Predeterminado Min Max
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
Pump outputs-Pump4
Interruptor Descripción Tipo Predeterminado Min Max
Pump outputs-Friction
Interruptor Descripción Tipo Predeterminado Min Max
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Digital Inputs
Interruptor Descripción Tipo Predeterminado
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02 H APR D1 Función de monitoreo de presión alta del lado A para el sistema de control 1
02 H BPR D1 Función de monitoreo de presión alta del lado B para el sistema de control 1
02 H APR D2 Función de monitoreo de presión alta del lado A para el sistema de control 2
02 H BPR D2 Función de monitoreo de presión alta del lado B para el sistema de control 2
02 H APR 12 Función de monitoreo de presión alta del lado A para los sistemas de control 1 y 2
02 H BPR 12 Función de monitoreo de presión alta del lado B para los sistemas de control 1 y 2
03 C PRA P1 Función de monitoreo de presión de cebado baja del lado A para bomba 1
03 C PRB P1 Función de monitoreo de presión de cebado baja del lado B para bomba 1
03 C PRA P2 Función de monitoreo de presión de cebado baja del lado A para bomba 2
03 C PRB P2 Función de monitoreo de presión de cebado baja del lado B para bomba 2
03 C PRA P3 Función de monitoreo de presión de cebado baja del lado A para bomba 3
03 C PRB P3 Función de monitoreo de presión de cebado baja del lado B para bomba 3
03 C PRA P4 Función de monitoreo de presión de cebado baja del lado A para bomba 4
03 C PRB P4 Función de monitoreo de presión de cebado baja del lado B para bomba 4
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A para el sistema de control 1
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B para el sistema de control 1
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A para el sistema de control 2
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B para el sistema de control 2
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12 RES EN 1 Activación externa del reinicio del contador en modo Sincronizar, Sistema de control 1
12 RES EN2 Activación externa del reinicio del contador en modo Sincronizar, Sistema de control 2
12 FRICTION Sistema de control de fricción en modo contador de sincronización
12 INV M Inversión de comando de velocidad maestro en modo Sincronizar, Sistema de control 1
17 AUTO 1 Entrada activada = modo automático, Sistema de control 1 - Entrada abierta = modo manual
17 AUTO 2 Entrada activada = modo automático, Sistema de control 2 - Entrada abierta = modo manual
17 AUTO 1+2 Entrada activada = modo automático, Sistemas de control 1 y 2 - Entrada abierta = modo manual
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20 PR REM 1 Cambio entre valor de consigna de presión local y remoto, Sistema de control 1
20 PR REM 2 Cambio entre valor de consigna de presión local y remoto, Sistema de control 2
20 PR HI 1 Forzar la salida de la presión a nivel alto, Sistema de control 1
20 PR LO 1 Forzar la salida de la presión a nivel bajo, Sistema de control 1
20 PR ON 1 Encender el regulador de presión, Sistema de control 1
20 PR HI 2 Forzar la salida de la presión a nivel alto, Sistema de control 2
20 PR LO 2 Forzar la salida de la presión a nivel bajo, Sistema de control 2
20 PR ON 2 Encender el regulador de presión, Sistema de control 2
21 OFF No se usa
NOTA1
La entrada estará activa para el arranque/la parada del sistema de control en:
− modo local
− modo remoto si no se usa una entrada digital para el arranque
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 9(44)
AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 10(44)
AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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03 READY 1 Listo para usar, sistema de control 1 (también para usar como válvula a prueba de
fallos, sistema de control 1)
03 READY 2 Listo para usar, sistema de control 2 (también para usar como válvula a prueba de
fallos, sistema de control 2)
03 READY1+2 Sistema de control 1 o sistema de control 2 listo
03 READY1*2 Sistema de control 1 y sistema de control 2 listos
09 AOUT 1- La lectura de registro seleccionada para la salida analógica 1 tiene signo negativo
09 AOUT 2- La lectura de registro seleccionada para la salida analógica 2 tiene signo negativo
09 AOUT 3- La lectura de registro seleccionada para la salida analógica 3 tiene signo negativo
09 AOUT 4- La lectura de registro seleccionada para la salida analógica 4 tiene signo negativo
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OFF No se usa
Pulse inputs-Drive 2
Interruptor Descripción Tipo Predeterminado Min Max
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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AIP01 Zero point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP02 Max point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP03 Units for REG410 **** °C
02 H APR D1 Función de monitoreo de presión alta del lado A para el sistema de control 1
02 H BPR D1 Función de monitoreo de presión alta del lado B para el sistema de control 1
02 H APR D2 Función de monitoreo de presión alta del lado A para el sistema de control 2
02 H BPR D2 Función de monitoreo de presión alta del lado B para el sistema de control 2
02 H APR 12 Función de monitoreo de presión alta del lado A para los sistemas de control 1 y 2
02 H BPR 12 Función de monitoreo de presión alta del lado B para los sistemas de control 1 y 2
03 C PRA P1 Función de monitoreo de presión de cebado baja del lado A para bomba 1
03 C PRB P1 Función de monitoreo de presión de cebado baja del lado B para bomba 1
03 C PRA P2 Función de monitoreo de presión de cebado baja del lado A para bomba 2
03 C PRB P2 Función de monitoreo de presión de cebado baja del lado B para bomba 2
03 C PRA P3 Función de monitoreo de presión de cebado baja del lado A para bomba 3
03 C PRB P3 Función de monitoreo de presión de cebado baja del lado B para bomba 3
03 C PRA P4 Función de monitoreo de presión de cebado baja del lado A para bomba 4
03 C PRB P4 Función de monitoreo de presión de cebado baja del lado B para bomba 4
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A para el sistema de
control 1
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B para el sistema de
control 1
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A para el sistema de
control 2
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B para el sistema de
control 2
OFF No se usa
*** Configuraciones posibles de unidades de medida: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
rps, lpm, gpm, mm, “, l, gal
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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5.2.8 Bus
Bus – Type&Function
Interruptor Descripción Tipo Predeterminado Min Max
Bus – Analog in 1
Interruptor Descripción Tipo Predeterminado Min Max
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Bus – Analog in 2
Interruptor Descripción Tipo Predeterminado Min Max
Bus – Analog in 3
Interruptor Descripción Tipo Predeterminado Min Max
Bus – Analog in 4
Interruptor Descripción Tipo Predeterminado Min Max
** Configuraciones posibles de unidades de medida: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
A, kW, hp, °, rps, lpm, gpm
*** Configuraciones posibles de funciones:
BSO = Compensación de sincronización (función Sincronizar)
BP1 = Valor de consigna de presión, Sistema de control 1 (función Presión)
BP2 = Valor de consigna de presión, Sistema de control 2 (función Presión)
BMS = Valor de consigna de velocidad maestro (función Sincronizar)
PF = Fricción de la bomba
OFF = No se usa
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confirmarse antes de colocar las órdenes de compra.
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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Pump monitor-Pump 1
Interruptor Descripción Tipo Predeterminado Min Max
Pump monitor-Pump 2
Interruptor Descripción Tipo Predeterminado Min Max
Pump monitor-Pump 3
Interruptor Descripción Tipo Predeterminado Min Max
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Pump monitor-Pump 4
Interruptor Descripción Tipo Predeterminado Min Max
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Tank monitor-Digital
Interruptor Descripción Tipo Predeterminado Min Max
Tank monitor-Analog
Interruptor Descripción Tipo Predeterminado Min Max
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Aux monitor-Aux1
Interruptor Descripción Tipo Predeterminado Min Max
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Aux monitor-Aux8
Interruptor Descripción Tipo Predeterminado Min Max
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Aux monitor-Aux15
Interruptor Descripción Tipo Predeterminado Min Max
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Drive monitor-Drive 1
Interruptor Descripción Tipo Predeterminado Min Max
Drive monitor-Drive 2
Interruptor Descripción Tipo Predeterminado Min Max
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Drive 1 basic-Setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Drive 1 basic-Ramp
Interruptor Descripción Tipo Predeterminado Min Max
Drive 1 basic-Regulator
Interruptor Descripción Tipo Predeterminado Min Max
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Drive 1 basic-Feedback
Interruptor Descripción Tipo Predeterminado Min Max
D1E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D1E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D1E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
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Drive 2 basic-Setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Drive 2 basic-Ramp
Interruptor Descripción Tipo Predeterminado Min Max
Drive 2 basic-Regulator
Interruptor Descripción Tipo Predeterminado Min Max
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Drive 2 basic-Feedback
Interruptor Descripción Tipo Predeterminado Min Max
D2E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D2E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D2E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
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5.2.15 Triturador 1
Shredder 1-Function
Interruptor Descripción Tipo Predeterminado Min Max
Shredder 1-Setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Shredder 1-Counter
Interruptor Descripción Tipo Predeterminado Min Max
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5.2.16 Triturador 2
Shredder 2-Function
Interruptor Descripción Tipo Predeterminado Min Max
Shredder 2-Setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Shredder 2-Counter
Interruptor Descripción Tipo Predeterminado Min Max
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5.2.17 Sincronizar
Synchro-Function
Interruptor Descripción Tipo Predeterminado Min Max
Synchro-Drive 2 setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Synchro-Drive 1 setpoint
Interruptor Descripción Tipo Predeterminado Min Max
5.2.18 Presión 11
Pressure 1-Function
Interruptor Descripción Tipo Predeterminado Min Max
Pressure 1-Pr.setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Pressure 1-Regulator
Interruptor Descripción Tipo Predeterminado Min Max
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5.2.19 Presión 2
Pressure 2-Function
Interruptor Descripción Tipo Predeterminado Min Max
Pressure 2-Pr.setpoint
Interruptor Descripción Tipo Predeterminado Min Max
Pressure 2-Regulator
Interruptor Descripción Tipo Predeterminado Min Max
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5.2.20 Lectura 1
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5.2.21 Lectura 2
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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AS5, Parámetros V4.1.x, Manual de ingeniería 05-03-15
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AS-6
Spider Configuraciones y función del software
04-04-02
Manual de ingeniería
Índice
Introducción ............................................................................................................ 2
H H
6.13 Sincronizar.................................................................................................... 24
H H
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AS-6
Spider Configuraciones y función del software
04-04-02
Manual de ingeniería
Introducción
Configuraciones de los bloques básicos en el software. Todas las configuraciones son para el
sistema de control 1. El mismo procedimiento se aplica al sistema de control 2 pero con la letra de
parámetro entre ().
Esto también describe el orden lógico para la configuración del sistema.
La lista de parámetros se encuentra en AS5 y los diagramas de bloques con parámetros se
encuentran en AS7.
La elección de los parámetros se realiza usando los botones direccionales (◄, ►, ▲ y ▼) (vea AS5.1).
Después de un cambio, la elección debe ser actualizada con el botón Enter (◄┘). Los parámetros se
actualizan en la memoria cuando se regresa a la lectura Main Status (Estado principal) en la pantalla.
Las configuraciones se pueden proteger con una contraseña (MAIN SETTINGS Æ PROTECTION:
MAD01-02). (CONFIGURACIONES PRINCIPALES Æ PROTECCIÓN: MAD01-02).
La función de monitoreo del sistema de control está protegida por una contraseña independiente bajo la
FUNCIÓN SETUP-LOG (REGISTRO DE CONFIGURACIÓN).
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• BASIC (BÁSICA) – La función básica y más común. La función incluye monitoreo, realimentación
de velocidad y limitación de potencia. Esta es la función que también se selecciona para monitorear la
unidad tipo.
• SHREDDER (TRITURADOR) – Igual que para BASIC (BÁSICA) con funciones adicionales de
reversa a causa de un sistema de control parado por sobrecarga.
• SYNCHRO (SINCRONIZAR) – Igual que para BASIC (BÁSICA) con dos sistemas de control
accionados conjuntamente, con control de relación de FRICTION (FRICCIÓN) o posición entre
los motores.
La función PRESSURE (PRESIÓN) se puede usar con la función BASIC (BÁSICA), SHREDDER
(TRITURADOR) y FRICTION (FRICCIÓN).
Las funciones de los botones del sistema de control frontales se pueden puentear configurando el
parámetro D1A08 (D2A08) en off.
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6.3 Rampa
El tiempo de rampa de arranque es el tiempo que le toma a la señal controlar la bomba hidráulica, ir
desde cero hasta el 100% si el valor de consigna de velocidad es 100% y cuando se activa el arranque
del sistema de control. La rampa de parada es el tiempo que toma ir desde el 100% hasta cero cuando
se activa la parada del sistema de control.
El arranque y la parada del sistema de control son comandos con rampa (como el avance fijo, la reversa
fija y la reversa por retrocesos sucesivos). La rampa de arranque está controlada por los parámetros
DxC01 en dirección de avance y DxC03 en dirección de reversa. La rampa de parada está controlada
por los parámetros DxC02 en dirección de avance y DxC04 en dirección de reversa.
Ejemplo: Si la ”rampa de subida” D1C01 está configurada en 10 s y la rampa de bajada D1C02 está
configurada en 5 s obtendremos el siguiente resultado.
El ejemplo se basa en un valor de consigna de 50 y 100%.
Velocidad
Arranque del sistema de control Parada del sistema de control
100 %
Rampa de parada
50%
Rampa de arranque
0 10 20 25 Tiempo en s
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6.4 Salida
6.4.1 Frecuencia PWM
Las configuraciones individuales para cada bomba se realizan en PUMP OUTPUTS (SALIDAS
DE BOMBAS) (Vea AS5.2.2)
Las salidas están Moduladas en Anchura de Impulsos (Pulse Width Modulated) y la frecuencia
modulada en anchura de impulsos (Pulse Width Modulated, PWM) se puede configurar con los
parámetros POx06. La configuración normal es 200Hz pero se puede configurar de 100 a 2000Hz
en pasos de 100Hz. Si se usa un pistón 5A (sólo se puede controlar en una dirección), la frecuencia
debe ser configurada en 2000Hz para evitar dañar el pistón.
D(J)07
La frecuencia menor a 2000Hz puede destruir el pistón de bomba 5A2
POx01-04
La corriente alta puede destruir
el pistón de bomba
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Si se va a usar un codificador digital de velocidad, deben configurarse los parámetros P1I01 a P1I07.
El valor del parámetro P1I01 debe ser la cantidad de impulsos digitales que produce el codificador de
velocidad durante una rotación.
P1I06 puede configurarse si la rotación del motor hidráulico/codificador está dando una polaridad
errónea de la lectura. Si se configura en 1, cambiará la polaridad.
P1I07 determina el tipo de codificador de velocidad usado.
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Las configuraciones anteriores dan en la mayoría de los casos un buen rendimiento del sistema de
control. Sin embargo, para optimizar los parámetros se puede utilizar el siguiente método.
En pocas palabras, el método es el siguiente:
Aumente la ganancia proporcional hasta que el sistema de control comience a oscilar. Tome nota del
tiempo de oscilación. Reduzca la ganancia Proportional (Proporcional) con un 50 %. Configure el
tiempo Integrator (Integrador) mínimo al doble del valor del tiempo de oscilación.
Esta es una lista paso a paso recomendada de cómo ajustar el regulador PI:
1 Seleccione el modo UNREG (NO REGULADO).
2 Asegúrese de que las corrientes del pistón estén ajustadas correctamente.
3 Anule la selección de la etapa Integrator (Integrador), configurando el parámetro D1D04 en Off.
4 Reduzca la configuración del tiempo de rampa a cero o tanto como el sistema de control
pueda tolerar.
5 Arranque el sistema de control.
6 Dé un comando de velocidad de aproximadamente un 50 %.
7 Seleccione el modo REG (REGULADO). Esto activa el regulador. Controle el rendimiento del
sistema de control. Si el sistema de control comienza a oscilar, pare el sistema de control y
reduzca el valor del parámetro Proportional (Proporcional).
8 Aumente la ganancia Proportional (Proporcional) de a poco. Arranque y pare el sistema de
control. Controle la estabilidad del sistema de control. Cuando el sistema de control comienza a
oscilar, intente determinar el tiempo de ciclo de la oscilación (el tiempo desde un límite de
impulso hasta el próximo).
9 Reduzca el valor de ganancia proporcional a la mitad de lo que configuró en 8.
10 Active la parte Integral (Integral) configurando el parámetro D1D04 en On.
11 Configure el parámetro Integrator (Integrador), como mínimo, al doble del tiempo de oscilación.
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6.7 Monitoreo
La función de monitoreo está disponible en todas las configuraciones. Las entradas digitales
predefinidas (para monitoreo) deben configurarse en off si no se desea el monitoreo. Vea la
configuración de las entradas digitales incluida en AS 5.2.3.
Ejemplo: Entrada digital 25 como entrada de advertencia por alta temperatura Sistema
de control 1.
Configure AMA02 al tiempo de retardo que se necesite entre la entrada abierta y la indicación
de advertencia.
Configure el texto en AMA04 a HIGH OIL TEMP (TEMP. DE ACEITE ALTA) usando los
botones ∧, ∨ y ↵ .
NOTA: La línea debe ser completada con caracteres en blanco, pulsando ↵ hasta que se complete
la línea. Los caracteres disponibles son todos caracteres posibles para la pantalla. Para caracteres
chinos, se debe montar una pantalla VFD y el interruptor SW3-1 se debe configurar en off.
La configuración de esta función puede realizarse en el frente del Spider o mediante el programa de
SpiderCom.
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05-01-21
reemplaza
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04-04-02
Mín. 10 (TMB10) -- 10 10
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04-04-02
Todas las entradas analógicas pueden conectarse a señales de corriente o voltaje. Se deben
configurar la función y el punto cero y máximo de la entrada (vea AS5.2.6).
Las configuraciones de las funciones se describen para cada función en AS6.5 para la realimentación
de velocidad analógica, en AS6.6 para la limitación de potencia, en AS6.12 para la presión de
Shredder (Triturador), en AS6.13 para Synchro offset (Compensación de sincronización) y en AS6.14
para pressure control (control de presión).
Entrada analógica 4 con una señal 4-20mA para limitación de potencia sistema de control 1. 20 mA
corresponde a 200A, parámetro AII01=4-20mA y AII06=A
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03 C PRB P4 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para bomba 4, vea 03 C PRA P2 presión baja
04 C PRA D1 Función de monitoreo de presión de cebado baja del lado A Alta, baja a A
para el sistema de control 1 presión baja
Para monitorear la presión de cebado baja del sistema de
control en dirección de reversa.
04 C PRB D1 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para el sistema de control 1 presión baja
Para monitorear la presión de cebado baja del sistema de
control en dirección de reversa.
04 C PRA D2 Función de monitoreo de presión de cebado baja del lado A Alta, baja a A
para el sistema de control 2, presión baja
vea 04 C PRA D1
04 C PRB D2 Función de monitoreo de presión de cebado baja del lado B Alta, baja a A
para el sistema de control 2, presión baja
vea 04 C PRB D2
05 SUCTION1 Monitoreo de la línea de succión para la bomba 1 Alta, baja con A
Para monitorear el indicador de la línea de succión cerrada la línea de
aceite cerrada
05 SUCTION2 Monitoreo de la línea de succión para la bomba 2, Alta, baja con A
vea 05 SUCTION1 la línea de
aceite cerrada
05 SUCTION3 Monitoreo de la línea de succión de la bomba 3, Alta, baja con A
vea 05 SUCTION1 la línea de
aceite cerrada
05 SUCTION4 Monitoreo de la línea de succión para la bomba 4, Alta, baja con A
vea 05 SUCTION1 la línea de
aceite cerrada
06 RF 75P1 Monitoreo del filtro de retorno para la bomba 1 obstruido a 3/4 Alta, baja con W
Para monitorear el filtro obstruido a 3/4. filtro obstruido
Aplicable únicamente cuando se usan dos indicadores de nivel
de filtro.
06 RF 100P1 Monitoreo del filtro de retorno para la bomba 1 completamente Alta, baja con W/(A)
obstruido filtro obstruido
Para monitorear filtro completamente obstruido (debe ser
cambiado)
06 RF 75P2 Monitoreo del filtro de retorno para la bomba 2 obstruido a 3/4, Alta, baja con W
vea 06 RF 75P1 filtro obstruido
06 RF 100P2 Monitoreo del filtro de retorno para la bomba 2 completamente Alta, baja con W/(A)
obstruido, filtro obstruido
vea 06 RF 100P1
06 RF 75P3 Monitoreo del filtro de retorno para la bomba 3 obstruido a 3/4, Alta, baja con W
vea 06 RF 75P1 filtro obstruido
06 RF 100P3 Monitoreo del filtro de retorno para la bomba 3 completamente Alta, baja con W/(A)
obstruido, filtro obstruido
vea 06 RF 100P1
06 RF 75P4 Monitoreo del filtro de retorno para la bomba 4 obstruido a 3/4, Alta, baja con W
vea 06 RF 75P1 filtro obstruido
06 RF 100P4 Monitoreo del filtro de retorno para la bomba 4 completamente Alta, baja con W/(A)
obstruido, filtro obstruido
vea 06 RF 100P1
06 DRF 75 Monitoreo del filtro de drenaje obstruido a 3/4, vea Alta, baja con W
06 RF 75P1 filtro obstruido
06 DRF 100 Monitoreo del filtro de drenaje completamente obstruido, Alta, baja con W/(A)
vea 06 RF 100P1 filtro obstruido
06 F TEMP Entradas de advertencia de enclavamiento de filtro Alta, baja con W
Usadas cuando el enclavamiento de temp. externa deseada temp. superior
para el filtro funciona al valor de
consigna
07 LO LEVEL Monitoreo de nivel de aceite bajo para tanque Alta, baja W
Monitorea el nivel de aceite bajo en el tanque PU cuando es
inferior al nivel
de consigna
07 MN LEVEL Monitoreo de nivel mín. de aceite para tanque Alta, baja A
Monitorea el nivel mín. de aceite en el tanque PU cuando es
inferior al nivel
de consigna
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08 MAX TEMP Monitoreo de la temperatura máx. del aceite para el tanque Alta, baja A
Monitorea la temperatura máx. de consigna en el tanque PU cuando es
superior a la
temp. de
consigna
08 HI TEMP Monitoreo de la temperatura del aceite alta para el tanque Alta, baja W
Monitorea la temperatura alta de consigna en el tanque PU cuando es
superior a la
temp. 1
08 MIN TEMP Monitoreo de la temperatura del aceite baja para el tanque Alta, baja A
Monitorea la temperatura baja de consigna en el tanque PU cuando es
inferior a la
temp. de
consigna
09 ALARM R Reinicio remoto de alarmas y advertencias Baja, C
Alta=Reinicio
09 BUS R Reinicio de alarmas y advertencias mediante bus Alta=Reinicio C
mediante bus
09 BUS 1 Cambiar a señales de comando de Bus, Sistema de control 1 Alta=Sistema C
de control 1 de
bus
09 BUS 2 Cambiar a señales de comando de Bus, Sistema de control 2 Alta=Sistema C
de control 2 de
bus
09 BUS M Cambiar a señal de comando de Bus, External master (Maestro Alta=maestro C
externo) ext. de Bus
10 SHR A D1 Parada de Shredder (Triturador) en avance, Sistema de Alta, baja en la C
control 1 parada
10 SHR B D1 Parada de Shredder (Triturador) en reversa, Sistema de Alta, baja en la C
control 1 parada
10 SHR A D2 Parada Shredder (Triturador) en avance, Sistema de control 2 Alta, baja en la C
parada
10 SHR B D2 Parada de Shredder (Triturador) en reversa, Sistema de Alta, baja en la C
control 2 parada
10 SHR 1+2A Parada de Shredder (Trirurador) en avance, Sistemas de Alta, baja en la C
control 1 y 2 parada
10 SHR 1+2B Parada de Shredder (Trirurador) en avance, Sistemas de Alta, baja en la C
control 1 y 2 parada
14 L STOP1 Parada del sistema de control en modo Local (Local), Sistema Alta, impulso C
de control 1 bajo=parada
14 L START2 Arranque del sistema de control en modo Local (Local), Sistema Impulso C
de control 2 alto=Arranque
14 L STOP2 Parada del sistema de control en modo Local (Local), Sistema Alta, impulso C
de control 2 bajo=parada
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18ERR1 RES Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistema de control 1 reinicio
18ERR2 RES Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistema de control 2 reinicio
18ERR1+2R Reinicio de la función error too large (error demasiado grande), Impulso alto = C
Sistemas de control 1 y 2 reinicio
21 OFF No se usa
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Función de salida
Abreviatura Función Estado normal de la salida
01 A(1,2, 1+2) Monitoreo de alarma común Abierta, cerrada al momento de
la alarma
01 W(1,2, 1+2) Monitoreo de advertencia común Abierta, cerrada al momento de
la advertencia
01 INT(1, 2, 1+2) Monitoreo de enclavamiento común Abierta, cerrada al momento
del enclavamiento
02 START(1, 2, 1+2, 1*2) Sistema de control arrancado Abierta, cerrada al momento
del arranque
03 READY(1, 2, 1+2, 1*2) Sistema de control listo para usar después del retardo de Abierta, cerrada cuando está
arranque listo
04 REMOTE(1, 2) Sistema de control modo remoto Abierta, cerrada, en modo
remoto
05 AUTO(1, 2) Triturador en modo automático del sistema de control. Abierta, cerrada en modo
automático
05 REG(1, 2) Sistema de control con realimentación de velocidad Abierta, cerrada en modo
regulada. regulado
06 PLIM(1, 2, 1+2) Límite de potencia activo Abierta, cerrada en limitación
activa
07 FORW(1, 2) Sistema de control operando con comando de avance Abierta, cerrada operando
en avance
07REV(1, 2) Sistema de control operando con comando de reversa Abierta, cerrada operando
en reversa
08 C ZERO Contadores en reinicio de función contador Synchro Abierta, cerrada en
(Sincronizar) y función sincronizar activada sincronización activada
08 SYNCHRO Sincronización dentro de los límites de consigna. Abierta, cerrada cuando está
dentro de los límites
09 AOUT(1...4) El registro para una salida analógica tiene un signo Abierta, cerrada cuando es
negativo negativo
10 EMOTD(1, 2, 1+2, 1*2) Motores eléctricos arrancados Abierta, cerrada cuando están
arrancados
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11 LOW TEMP Indicación para temp. mín. del aceite activa Abierta, cerrada cuando está
activa
11 HI TEMP Indicación para temp. alta del aceite activa Abierta, cerrada cuando está
activa
11 MAX TEMP Indicación para temp. máx. del aceite activa Abierta, cerrada cuando está
activa
11 COOL CONI Enfriamiento del arranque enclavado con el motor eléctrico Abierta, cerrada para
arrancado enfriamiento
(con sensor analógico de temperatura)
11 COOL COND Enfriamiento del arranque controlado directamente desde Abierta, cerrada para
el sensor de temp. enfriamiento
(con sensor analógico de temperatura)
11 HEAT CON Calentamiento del arranque (con sensor analógico de Abierta, cerrada para
temperatura) calentamiento
11 FLUSHCON Circuito de control de lavado (con sensor analógico de Abierta para enfriamiento,
temperatura) cerrada para calentamiento
ON Retardo en On Desde el momento en que se activa la función para la salida, ésta no estará
activa hasta que haya pasado el tiempo de retardo.
OFF Retardo en Off Desde el momento en que se desactiva la función para la salida, ésta no estará
inactiva hasta que haya pasado el tiempo de retardo.
IMPULSO Impulso de salida Desde el momento en que se activa la función para la salida, ésta estará activa
únicamente durante el tiempo de retardo.
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Dará:
→ TANK TEMP 37.8ºC (Temp. del tanque 37.8ºC) ←
PRESSURE 143bar (Presión 143bar)
▲ o ▼ se alterará entre estas dos lecturas.
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6.12 Triturador
La selección de la función Triturador (shredder) se realiza configurando el parámetro MAA01 en
SHREDDER (vea AS6.1).
Los parámetros específicos se encuentran en SETUP – SHREDDER 1(2) (CONFIGURACIÓN –
TRITURADOR).
En Triturador están disponibles todas las características descritas en 6.1.- 6.11, excepto por la
posibilidad de cambiar entre sistema de control con y sin regulación de velocidad. La selección de la
regulación de velocidad debe configurarse con el parámetro SHA(G)10.
Las funciones adicionales son para las reversas a causa de un sistema de control sobrecargado.
El triturador tiene dos modos del sistema de control: manual y automático.
En el modo manual del sistema de control, el botón de avance (o por entrada configurable establecida
en L FORW1(2)) se utiliza para avanzar y el botón de reversa (o por entrada configurable establecida
en L REV1(2)) se utiliza para funcionar en reversa. El sistema de control funcionará mientras la
entrada esté activada y parará cuando se abra la entrada. La función de reversa se puentea en el
sistema de control manual.
En el modo automático del sistema de control, el botón de arranque (o por entrada configurable
establecida en L START1(2)) hace arrancar el sistema de control con la función de reversa
automática y para con el botón de parada (o por entrada configurable establecida en L STOP1(2)). Se
puede usar una entrada digital configurable para arrancar en modo remoto.
El cambio entre el modo manual y el modo automático se realiza con el botón MAN/AUT o con una
entrada digital configurable (que puentea el botón).
Se puede usar una salida digital para indicación del modo automático.
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6.13 Sincronizar
La configuración de la función Synchro (Sincronizar) se encontrará en los siguientes menús de
parámetros
"Synchro - Function" (Sincronizar - Función)
"Synchro - Drive 1 reset" (Sincronizar - Reinicio del sistema de control 1)
"Synchro - Drive 2 setpoint" (Sincronizar - Valor de consigna del sistema de control 2)
"Synchro - Drive 2 indication" (Sincronizar - Indicación del sistema de control 2)
"Synhcro - Drive 2 reset" (Sincronizar - Reinicio del sistema de control 2)
"Synchro - External Master" (Sincronizar - Maestro externo)
"Synchro - Drive 1 setpoint" (Sincronizar - Valor de consigna del sistema de control 1)
El control de la posición del sistema de control 2 se activa cuando se reinician ambos contadores. El
tiempo de rampa se puede ajustar para alcanzar una sincronización uniforme; esto se realiza con el
parámetro SYD02. La activación del regulador se puede indicar con una salida digital, establecida en
08 C ZERO. Mientras opera en modo de contador, el sistema de control de relación se puede activar
a través de una entrada digital configurable, establecida en 12 FRICTION. La entrada puede ser una
señal de hardware, o en modo bus, una señal del bus.
Alterando un parámetro, PRA02 = On, se selecciona la acción de reversa. El diagrama que aparece a
continuación describe la función de control de presión, acción de reversa. Si la presión aumenta, el
valor de consigna de velocidad disminuye.
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Vea el diagrama de bloques AS7.2 y la lista de parámetros AS5.2.8 para obtener más detalles.
6.15.1 General
La función Bus requiere la instalación de una tarjeta de bus. La tarjeta es un subordinado Profibus-DP
conforme al estándar PROFIBUS-DP EN 50 170. Debe conectarse a un Profibus-DP maestro. La
tarjeta sólo responderá a los comandos entrantes funcionando como subordinada.
La función Bus se activa cuando se activa una entrada digital o entrada de bus y se selecciona el
modo remoto con el teclado. Las entradas digitales son BUS 1 y BUS 2, estas entradas permiten
seleccionar el control de bus por separado para el sistema de control 1 y el sistema de control 2. Los
valores de consigna de velocidad se encuentran en direcciones de bus predefinidas. Vea el capítulo
AS 6.15.9. El esquema que aparece a continuación explica los posibles cambios de modo.
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REG/BIT 8 7 6 5 4 3 2 1
REG511 Din 8 Din 7 Din 6 Din 5 Din 4 Din 3 Din 2 Din 1
REG512 Din 16 Din 15 Din 14 Din 13 Din 12 Din 11 Din 10 Din 9
REG513 Din 24 Din 23 Din 22 Din 21 Din 20 Din 19 Din 18 Din 17
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Los valores analógicos se encuentran en formato de datos de "palabra con signo". Los números
negativos son el complemento 2 de los positivos. A continuación se incluye una tabla con algunos
ejemplos
Valor de palabra con signo, formato binario Valor decimal % del valor de la
señal
Byte más significativo Byte menos significativo
0010 0111 0001 0000 10000 100
1101 1000 1111 0000 -10000 -100
0001 0011 1000 1000 5000 50
1110 1100 0111 1000 -5000 -50
0000 1001 1100 0100 2500 25
1111 0110 0011 1100 -2500 -25
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20:0 Start1 21:0 P1HiCa 22:0 Forw2 23:0 ShBlck2 24:0 Ready2 25:0 Dummy
20:1 Remote1 21:1 P1CAct 22:1 Rev2 23:1 A1 24:1 EMot1 25:1 Dummy
20:2 Auto1 21:2 PLim 22:2 Reg2 23:2 A2 24:2 EMot2 25:2 Dummy
20:3 PLim1 21:3 ShBlck1 22:3 CZero 23:3 W1 24:3 CoolConI 25:3 Dummy
20:4 Forw1 21:4 Start2 22:4 Synchro 23:4 W2 24:4 HeatCon 25:4 Dummy
20:5 Rev1 21:5 Remote2 22:5 P2LoCa 23:5 Int1 24:5 CoolConD 25:5 Dummy
20:6 Reg1 21:6 Auto2 22:6 P2HiCa 23:6 Int2 24:6 Flush Con 25:6 Dummy
20:7 P1LoCa 21:7 PLim2 22:7 P2CAct 23:7 Ready1 24:7 Dummy 25:7 Dummy
DB20 a DB25 son señales que se encuentran en la lista de funciones disponibles para las salidas
digitales, descritas en AS6.10.
DB26 a DB37 son, en parte, señales que se encuentran en la lista de funciones disponibles para las
entradas digitales de relé, descritas en AS6.9.
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Las listas de alarma se encuentran en el menú bajo LOG READINGS – DRIVE 1 – ALARM
(LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ALARMA) y LOG READINGS –
DRIVE 2 – ALARM (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2 – ALARMA).
Las listas de advertencia se encuentran en el menú bajo LOG READINGS – DRIVE 1 –
WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ADVERTENCIA) y LOG
READINGS – DRIVE 2 – WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2
– ADVERTENCIA).
Las cuatro listas tienen una extensión de 10 alarmas o advertencias. La más reciente se
encontrará en la parte superior y cuando ingrese una nueva advertencia o alarma a una lista que
ya se encuentra llena, se eliminará la más antigua. Las alarmas y advertencias están marcadas
con la fecha y la hora del incidente. Para configurar la hora real, vea HORA/FECHA a
continuación.
Los contadores de tiempo del sistema de control se encuentran en el menú bajo LOG READINGS
– DRIVE 1 – TIME IN USE (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 –
TIEMPO EN USO) y LOG READINGS – DRIVE 2 – TIME IN USE (LECTURAS DEL REGISTRO
– SISTEMA DE CONTROL 2 – TIEMPO EN USO). Los contadores son DRIVE (SISTEMA DE
CONTROL) (el tiempo con el sistema de control arrancado) y PUMPS (BOMBAS) (el tiempo con
motor eléctrico arrancado para cada bomba). Los contadores pueden reiniciarse, vea REINICIAR
TIEMPO a continuación.
Las configuraciones para el registro de monitoreo del sistema de control, el reloj y el reinicio de
los contadores de tiempo se realizan en SETUP – DRIVE LOG (CONFIGURACIÓN – REGISTRO
DE SISTEMA DE CONTROL) y están protegidas por una contraseña. Las contraseñas sólo
pueden realizarse desde el teclado frontal.
LOG1 a LOG 8 son para configurar uno de los ocho canales de registro de monitoreo del sistema
de control escalables dimensionales.
Las entradas analógicas utilizadas deben configurarse antes de configurar los canales de
registro, vea AS6.8.
Cada canal consiste en un área de medición dividida en 6 niveles. Se almacena el tiempo que la
lectura medida se encuentra dentro de cada uno de estos niveles. La medición sólo está activa
con el sistema de control arrancado. El tiempo total de medición es de 100 000 horas.
Paralelamente con el registro total de tiempo, se almacenan 4 registros más cortos con la misma
configuración del total en orden cronológico. El tiempo de registro es ajustable.
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Ejemplo:
- Canal de registro 2
- Transductor de presión, 0-400 bar en Ain 4.
- Tiempo de medición de períodos de 200 horas
RESET TIME (REINICIAR TIEMPO) para configurar los contadores de tiempo del sistema de
control. Cuando se selecciona la función con el botón >, presione ∧ para obtener una Y (Sí) y
luego presione el botón > para reiniciar.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 34(38)
05-01-21
reemplaza
AS6, Configuraciones y función del software, Manual de ingeniería 04-04-02
04-04-02
Ejemplo para el canal 1, 4-20mA para una velocidad de 0-20rpm desde el codificador digital
de velocidad.
1. Configure el parámetro D1E01 en 20.0rpm (la velocidad que equivale al 100%).
2. Conecte un medidor de corriente en serie con la señal de salida.
3. El parámetro AOA02 debe estar en ON para una salida de 4mA.
4. Seleccione el parámetro AOA03. El sistema proporciona el 0% a la tarjeta. Ajuste el
parámetro hasta que se acerque lo más posible a la salida de 4mA.
5. Seleccione el parámetro AOA04. El sistema proporciona el 100% a la tarjeta. Ajuste el
parámetro hasta que se acerque lo más posible a la salida de 20mA.
6. Repita los pasos 4 y 5 hasta alcanzar los mejores resultados.
6.18 Selección de idioma
Se puede seleccionar el idioma para los textos de las listas de alarmas/advertencias y, en
algunos casos, los textos de las indicaciones de la pantalla principal en el menú (SETUP – MAIN
SETTINGS - LANGUAGE :MAC01) (CONFIGURACIÓN – CONFIGURACIONES PRINCIPALES -
IDIOMA :MAC01).
Los idiomas que se pueden seleccionar son: Inglés (Idioma predeterminado)
Alemán
Francés
Español
Italiano
Japonés (Requiere una pantalla de cristal
líquido (LCD) estándar)
Neerlandés
Finlandés
Sueco
Forma corta (abreviaciones)
Chino (Requiere una pantalla fluorescente de
vacío (VFD)
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 35(38)
AS6, Configuraciones y función del software, Manual de ingeniería 04-04-02
El registro de monitoreo del sistema de control está compuesto por cuatro partes: listas de
alarmas/advertencias, contadores de tiempo del sistema de control, seis canales de registro
escalables y dos canales de registro en 3D escalables. Las listas de alarmas/advertencias y los
contadores de tiempo del sistema de control se pueden indicar en la pantalla del sistema de
control 1. La información de registro total del sistema de control debe descargarse a una PC para
su examen. Esto requiere un cable módem nulo 576 3521-003, una PC con Windows XP y el
software de SpiderCom2 instalado.
Las listas de alarma se encuentran en el menú bajo LOG READINGS – DRIVE 1 – ALARM
(LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ALARMA) y LOG READINGS –
DRIVE 2 – ALARM (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2 – ALARMA).
Las listas de advertencia se encuentran en el menú bajo LOG READINGS – DRIVE 1 –
WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 – ADVERTENCIA) y LOG
READINGS – DRIVE 2 – WARNING (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 2
– ADVERTENCIA).
Las cuatro listas tienen una extensión de 10 alarmas o advertencias. La más reciente se
encontrará en la parte superior y cuando ingrese una nueva advertencia o alarma a una lista que
ya se encuentra llena, se eliminará la más antigua. Las alarmas y advertencias están marcadas
con la fecha y la hora del incidente. Para configurar la hora real, vea HORA/FECHA a
continuación.
Los contadores de tiempo del sistema de control se encuentran en el menú bajo LOG READINGS
– DRIVE 1 – TIME IN USE (LECTURAS DEL REGISTRO – SISTEMA DE CONTROL 1 –
TIEMPO EN USO) y LOG READINGS – DRIVE 2 – TIME IN USE (LECTURAS DEL REGISTRO
– SISTEMA DE CONTROL 2 – TIEMPO EN USO). Los contadores son PUMP (BOMBA) (el
tiempo con motor eléctrico arrancado) y DRIVE (SISTEMA DE CONTROL) (el tiempo con el
sistema de control arrancado). Los contadores pueden reiniciarse, vea REINICIAR TIEMPO a
continuación.
Las configuraciones para el registro de monitoreo del sistema de control, el reloj y el reinicio de
los contadores de tiempo se realizan en SETUP – LOG FUNCTION (CONFIGURACIÓN –
FUNCIÓN DE REGISTRO) y están protegidas por una contraseña.
LOG1 a LOG8 son para configurar ocho canales de registro de monitoreo del sistema de control
escalables.
Las entradas analógicas utilizadas deben configurarse antes de configurar los canales de
registro, vea AS6.8.
Cada canal consiste en un área de medición dividida en 6 niveles. Se almacena el tiempo que la
lectura medida se encuentra dentro de cada uno de estos niveles. La medición sólo está activa
con el sistema de control arrancado. El tiempo total de medición es de 100 000 horas.
Paralelamente con el registro total de tiempo, se almacenan 4 registros más cortos con la misma
configuración del total en orden cronológico. El tiempo de registro es ajustable.
RESET TIME (REINICIAR TIEMPO) reiniciará los contadores del tiempo total del sistema
de control.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 36(38)
05-01-21
reemplaza
AS6, Configuraciones y función del software, Manual de ingeniería 04-04-02
04-04-02
En cada encendido y cada vez que se paren los motores eléctricos, el sistema verificará que los relés
para las salidas del enclavamiento del motor eléctrico no estén trabados en la posición cerrada.
La alarma de parada de emergencia está predeterminada con la memoria y se debe reiniciar, pero se
puede configurar en reinicio automático con MAB11:ON.
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 37(38)
05-01-21
reemplaza
AS6, Configuraciones y función del software, Manual de ingeniería 04-04-02
04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 38(38)
AS-7.1
Spider Entradas digitales
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(3)
AS7.1, Entradas digitales, Manual de ingeniería 05-01-21
EN DIGITAL BUS 1
EN DIGITAL BUS 2
EN DIGITAL BUS 3
EN DIGITAL BUS 4
EN DIGITAL BUS 5
EN DIGITAL BUS 6
EN DIGITAL BUS 7
EN DIGITAL BUS 8
EN DIGITAL BUS 9
EN DIGITAL BUS 10
EN DIGITAL BUS 11
EN DIGITAL BUS 12
EN DIGITAL BUS 13
EN DIGITAL BUS 14
EN DIGITAL BUS 15
EN DIGITAL BUS 16
EN DIGITAL BUS 17
EN DIGITAL BUS 18
EN DIGITAL BUS 19
EN DIGITAL BUS 20
EN DIGITAL BUS 21
EN DIGITAL BUS 22
EN DIGITAL BUS 23
EN DIGITAL BUS 24
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(3)
AS7.1, Entradas digitales, Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 3(3)
AS-7.2
Spider Entradas y salidas analógicas
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(3)
AS7.2, Entradas y salidas analógicas, Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(3)
AS7.2, Entradas y salidas analógicas, Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 3(3)
AS-7.3
Spider Salidas de la bomba
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(1)
AS-7.4
Spider Monitor
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(3)
AS7.4, Monitor, Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(3)
AS7.4, Monitor, Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 3(3)
AS-7.5
Spider Función Básica
Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(2)
AS7.5, Función Básica, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(2)
AS-7.6
Spider Función Triturador
Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(2)
AS7.6, Función Triturador, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(2)
AS-7.7
Spider Función Sincronizar
Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(2)
AS7.7, Función Sincronizar, Manual de ingeniería 04-04-02
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 2(2)
AS-7.8
Spider Función Presión
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(1)
AS-7.9
Spider Parada de emergencia
Manual de ingeniería 05-01-21
El contenido de este documento está sujeto a cambios sin aviso previo ni obligación alguna. La información especificada en el presente debe
confirmarse antes de colocar las órdenes de compra.
Hägglunds Drives AB. S-890 42 Mellansel, SUECIA 1(1)
HYDRAULIC DRIVE SYSTEM
OPERATION AND INSTRUCTION
MANUAL
CUSTOMER INFORMATION
Name THYSSENKRUPP ROBINS
Reference
Notes B E LT F E ED ER
HÄGGLUNDS INFORMATION
Project 2 005 032
Notes
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
2005 032
20053022
Hydraulic Drive System Operation And Instruction Manual
PBC-202-073-100-21-1110-11B-0000-0-380/50
THYSSENKRUPP ROBINS
1
Project Specifications
Bill of Materials
Test Reports
www.hagglunds.com
3
Project Drawings
NORTHEAST EASTERN
1273 Bound Brook Road 87B Marie-Victorin
Suite 11 Suite 202
Middlesex, New Jersey 08846 Candiac, Quebec J5R 1C3
(732) 469-0411 (450) 659-4244
(732) 469-8047 (fax) (450) 659-3792 (fax)
MIDWEST CENTRAL
2275 International Street 5040 Mainway, Unit #7
Columbus, Ohio 43228 Burlington, Ontario L7L 7G5
(614) 527-7400 (905) 319-6338
(614) 527-7401 (fax) (905) 319-6615 (fax)
NORTHWEST WESTERN
19219 West Valley Highway #3 7201-72 Street
Suite M-101 Delta, British Columbia V4G 1H2
Kent, Washington 98032 (604) 940-8281
(425)-251-9661 (604) 940-8241 (fax)
(425)-251-9280 (fax)
SOUTHEAST
4335 South Lee Street
United States Headquarters
Suite F Hägglunds Drives Inc.
Buford, Georgia 30518 2275 International Street
(770) 945-6223 Columbus, Ohio 43228
(770) 945-6246 (fax) (614) 527-7400
(614) 527-7401 (fax)
NORTH-CENTRAL
(262) 594-3762 Canadian Headquarters
(262) 594-3764 (fax)
Hägglunds Drives (Canada) Inc.
CENTRAL 5040 Mainway, Unit #7
(913) 515-8047 Burlington, Ontario L7L 7G5
(913) 322-6910 (fax) (905) 319-6338
(905) 319-6615 (fax)
SOUTH-CENTRAL
220 Spring Hill Drive Worldw ide Headquarters
Suite 200 Hägglunds Drives AB
Spring, Texas 77386 SE-890 42
(281) 292-6700 Mellansel, Sweden
(281) 292-6768 (fax) +46 660 870 00
+46 660 871 60 (fax)
SOUTHWEST
(602) 790-4632
(480) 474-1039 (fax)
PROJECT INFORMATION
Hägglunds Salesperson: CHUCK SEITZ
Customer Name: THYSSENKRUPP ROBINS
Address: 7730 EAST BELLEVIEW AVE. SUITE 404
GREENWOOD VILLAGE, CO. 80111
Contact Name: PETER SEHL
Phone: 303-793-2605 Fax: 303-770-8233
E-mail: [email protected]
Customer P.O. : 0507 001 5727 Customer Ref.: 507-001
Customer Spec. No. Copy Attached: NO
Spec. Exceptions List YES Copy Attached: NO
Equipment : BELT FEEDER 220 FE-006,007,008
Description :
Location : SAN CRISTOBAL,BOLIVA
NEMA Classification NEMA 4X (IP-65)
Ambient Temp. Range -10.3 C TO 21.6 C
Cooling Water Temp. N/A
Elev. Above Sea Level 3900 M
DESIGN INFORMATION
Drive Speed, Run 0-6.9 RPM
Drive Speed, Max 6.9 RPM
Nominal Torque 44,800 Ft. Lbs.
Starting Torque 79795 Ft. Lbs.
Duty Cycle CONT
Flow Range: 42.6 GPM
Motor Case Flushing: 1.11 GPM
Nominal Pressure: 2716 PSI
Peak Pressure: 4764 PSI
Horsepower Installed: 100 HP, 1470 RPM
High Pressure Switch Setting: PSI
Max Volume Stop : GPM (Forward) GPM (Reverse)
Uni / Bi-Directional Drive: UNI W/JOG REVERSE
Port "A" of Pump to Port A MOTOR
SCOPE OF SUPPLY
Hydraulic Motor 3 X CB-400-360-C-A-0-N-0 178-5041-1602
Hydraulic Power Unit 3 X PBC-0202-073/XXX-21-1110-11B-0000-0-0380/50
Elec. Control System 3 X SPIDER CONTROL II
Torque Arm 3 X TCA-40-2 278-5014-602
Mounting Tool 1 X MTMB 378-0846-801
Shaft Adaptor N/A
Speed Encoder 3 X SPDB-3600 378-5036-802
Encoder Mounting Set 3 X SMCB 178-5049-801
Axial Locking Set N/A
Hägglunds Drives, Inc.; 2275 International Street, Columbus,OH 43228; Tel: 614-527-7400; Fax: 614-527-7401
DESCRIPTION OF OPERATION
xx
xx LONG TERM STORAGE REQUIRED
xx PACKING FOR SEAWORTHY EXPORT
xx SPECIAL TAGGING REQUIREMENTS PER SPEC APPENDIX B AND M-020, 7.5 AND
xx GD-11
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
xx
HYDRAULIC NOTES
xx 3 X 25FT. HOSE KITS REQUIRED
xx
xx
xx
xx
ELECTRICAL NOTES
xx
xx
xx
xx
xx
MECHANICAL NOTES
xx
xx
xx
xx
xx
DOCUMENTATION NOTES
Drawings: 2 copies For Approval and 2 copies of For Construction. Please specify other requirements.
Drawing Due Date: 3 weeks after receipt of Tech Clarified order
Manuals: 8 TOTAL REQUIRED IN BOTH ENGLISH AND SPANISH PER SYSTEM
Manuals Due Date: 1 week after the ship date
Hägglunds Drives, Inc.; 2275 International Street, Columbus,OH 43228; Tel: 614-527-7400; Fax: 614-527-7401
P B CC - 0 2 0 2 - 0 7 3 / X X X - 1 0 0 / X X X - 2 1 - 1 1 1 0 - 1 1 B - 0 0 0 0 - 0 - 0 3 8 0 / 5 0
PAC
PBC
PHS Electric Motor Frequency
PAX 60 Hz
50 Hz
Tank Size
Liter(Gallon) Voltage
1000 (264) = 100 200 (53) = 020 460/575 VAC
1200 (317) = 120 400 (106) = 040 2300/4160 VAC
Other (Specify) 600 (159) = 060
800 (211) = 080 Electric Motor Supplied By
1 = Customer
Number of Doors 0 = Hägglunds
2
3 000 = Standard Design
001-999 = Special Design
Pump Displacement
Left Door/Right Door Accumulator Package
cu. cm/rev cu. in./rev 1 = With
SP-40 = 040 P6S = 060 0 = Without
SP-71 = 071 P7S = 073
SP-125 = 125 P11S = 110 Control Box Voltage
SP-180 = 180 P14S = 140 A = 24 VDC
SP-250 = 250 P24S = 240 B = 110 VAC
SP-355 = 355 P30S = 300 C = 220 VAC
SP-500 = 500 9A2 Pump Stroker(5A2/9A2 for Denison, EP for SP pumps)
SP-750 = 750 1 = Air/ Oil Cooler
0 = Water/Oil Cooler
Electric Motor Size Water Valve Voltage X
Left Door/Right Door Air Cooler EM Voltage X
kW HP
22 = 022 30 = 030 1 = Oil Heater
30 = 030 40 = 040 0 = Without
37 = 037 50 = 050 Oil Heater Voltage 220V
45 = 045 60 = 060
55 = 055 75 = 075 1 = Duplex Filters
75 = 075 100 = 100 0 = Single Filters
90 = 090 125 = 125
110 = 110 150 = 150 1 = Cabinet Feet
132 = 132 200 = 200 0 = Without
160 = 160 250 = 250
200 = 200 300 = 300 1 = High Pressure Switch
250 = 250 350 = 350 0 = Without
315 = 315 400 = 400
450 = 450 1 = Pressure Transmitter
500 = 500 0 = Without
HP Specify HP or kW
Control Box Mounting
Control Box Options 0 = Shipped Loose
None = 0 1 = Mounted Inside Power Unit
Driver Card = 1 2 = Mounted in Power Unit Door
Spider = 2 3 = Supplied as Separate Item, with Bracket
Other = 3 4 = Supplied as Separate Item, with Flange
5 = Mounted outside of Power Unit (Specify)
XX ft.
XX ft.
XX ft.
XX ft.
hb2005032e.xls, Date Printed: 11/29/2005 Form No.: F10203-1 | Releae Date: 4/6/2001 | Revision: A
Bill Of Material
Bill of Material No.: HB2005032
Date Issued : 31-May-2005 Hägglunds Drives Inc. Latest Rev. : Customer Ref(s) :
Issued By: JFDIII 2275 International Street; Columbus, Ohio 43228, USA E P.O. 0507 001 5727
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN : -
TITLE: ECN-00000642 Assembly Ref(s) :
Revised By : HS-2005 032
Power Unit Model JFDIII GA-2005 032
PBC-202-073-100-21-1110-11B-0000-0-380/50 Rev. Date : Project No. :
21-Nov-2005 2005 032
C
Item O Hägglunds Description
No. Qty. D Part No.
E
38 CB2005032-0 CONTROL BOX CONSISTING OF 38a, 38b, 38c:
38a 1 CB2005032-A CONTROL BOX
38b 1 276 0023-801 SPIDER II CONTROLS, 1 PUMP - SINGLE DRIVE
38c 1 576 7942-025 RUBBER FLANGE FL21 (USED WITH EVERY SPIDER II)
38d 1 HAS-10778-0 CONTROL BOX MOUNTING BRACKET
38e 1 276 0003-001 MOUNTING FRAME (FOR DOOR OR BOX MOUNTED SPIDER II)
38f 1 HU3 3872-801 HEATER ASSEMBLY
39 1 HDE-30988-0 MTG ANGLE, DRAIN/FLUSHING CONNECTION
40 1 HDE-30569-0 CHECK VALVE MANIFOLD, PAC/PBC 200-400 UNITS, 1-1/4" SAE
41 NOT USED
42 1 513-50133-0 CHECK VALVE, 1-1/4" SAE, 65 PSI
43 NOT USED
44 NOT USED
45 1 TAG-2005032-0 LOT OF LAMACOID TAGS PER CUSTOMER SPEC
46 1 SP-2005032-0 ENGRAVED PLATE OF HYDRAULIC SCHEMATIC: HS-2005032 (11 X 17)
47 2 HDE-30576-1 1/2" CONDUIT BRACKET
48 1 HDE-30576-2 3/4" CONDUIT BRACKET
49 1 038-54612-0 S/N PLATE
50 NOT USED
51 1 HAS-10014-0 LONG TERM OIL FILLING, GOLDCUP P6 THRU P14 AND HAGGLUNDS SP250, SP355
52 1 EXPORT CRATING, 200 UNIT
hb2005032e.xls, Date Printed: 11/29/2005 Form No.: F10203-1 | Releae Date: 4/6/2001 | Revision: A
Bill of Material No.: CB2005032
Bill Of Material
Date Issued : 7-Jun-2005 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: RHW 2275 International Street; Columbus, Ohio 43228, USA P.O. 0507 001 5727
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: Assembly Ref(s) :
CONTROL CONSOLE Revised By : CC-2005 032
HYDRAULIC POWER UNIT CS-2005 032
PBC-202-073-100-21-1110-11B-0000-0-380/50 Rev. Date : Project No. :
2005 032
C
Item O Hägglunds Description
No. Qty. D Part No.
E
1 1 CB2005032-A CONTROL PANEL
2 1 276 0023-801 SPIDER 2 CONTROL, FULL FUNCTION
3 1 H103-20469 ENCLOSURE NEMA 4X, 24 X 24 X 12
4 1 H103-20420 PANEL FOR ABOVE ITEM
5 1 H103-20394 ENCLOSURE MOUNTING KIT
6 1 H103-20415 DOOR LOCK KIT FOR ENCLOSURE
7 1 H153-15301 PUSHBUTTON, GREEN FLUSH HEAD, 1 N.O., 1 N.C. CONTACTS
8 1 H153-15302 PUSHBUTTON, RED EXT. HEAD, 1 N.O., 1 N.C. CONTACTS
9 1 H153-10363 INDICATING LIGHT, GREEN, FULL VOLTAGE, 120VAC
10 1 H151-15318 MUSHROOM HEAD PUSH/PULL MAINTAINED PUSHBUTTON, 2 N.O. CONTACTS
11 1 155-10060 LEGEND PLATE, GRAY, E-MOTOR START
12 1 155-10055 LEGEND PLATE, RED, E-MOTOR STOP
13 1 H155-10487 LEGEND PLATE, GRAY, E-MOTOR STARTED
14 1 155-10057 JUMBO LEGEND PLATE, RED, EMERGENCY STOP
15 62 123-75144 TERMINAL, UKK5
16 6 123-75048 END ANCHOR, E/UK
17 4 ft. 123-75047 MOUNTING RAIL, NS 35/7.5
18 3 123-75146 END COVER D-UKK 3/5
19 3 123-75147 SPACER PLATE, DP-UKK 3/5
20 3 H123-75421 END SPACER COVER, DG-UKK 3/5
21 10 H123-75422 PARTITION PLATE, ATP-UKK 3/5
22 10 H123-75453 ISOLATING BRIDGE BAR, ISSBI 10-6
23 10 H123-75465 BRIDGE BAR ISOLATOR, IS-K 4
24 2 H123-75477 DOUBLE TERMINAL BLOCK, UDK 4
25 1 H123-75478 END COVER FOR DOUBLE TERMINAL BLOCK, D-UDK-4
26 2 H123-75489 UNIVERSAL GROUNDING DOUBLE TERMINAL BLOCK, UDK-4-PE
27 2 123-75069 MARKER STRIP, 11-20
28 2 123-75070 MARKER STRIP, 21-30
29 2 123-75077 MARKER STRIP, 91-100
30 2 123-75086 MARKER STRIP, 121-130
31 2 123-75089 MARKER STRIP, 151-160
32 2 123-75126 MARKER STRIP, 301-310
33 2 123-75127 MARKER STRIP, 311-320
34 2 H123-75467 MARKER STRIP, 331-340
35 2 H123-75468 MARKER STRIP, 341-350
36 2 123-75162 MARKER STRIP, 401-410
37 2 123-75163 MARKER STRIP, 411-420
38 2 H123-75493 MARKER STRIP, 421-430
39 2 H123-75495 MARKER STRIP, 441-450
40 2 123-75139 MARKER STRIP, 501-510
41 2 123-75141 MARKER STRIP, 521-530
42 2 H123-75427 MARKER STRIP, L, N, GND
43 10 ft. 104-25020 WIRE DUCT, 2" X 3", WHITE
44 10 ft. 104-25021 WIRE DUCT COVER, 2", WHITE
Installation
All Terminal Markers Installed: Function
All wires bundled and tied: Continuity Test:
Control Box P/N Tag Installed: Functional Check of Switches:
All Bill of Material Items Installed: Functional Check of Lights:
Grounding Lug Properly Installed: Functional Check of Pushbuttons:
Other Items
Control Voltage: 120 VAC
Make of Power Supply: HDI
Model of Power Supply: SPIDER
Spider Controller
Jumpers are in correct position:
All Parameters checked:
If the Spider is supplied as a loose item, is it temporarily wired to the Power Unit:
If there are any Parameter changes please list them all in the "NOTES" section of this report.
Page 1
F10208-2 l Revision: Orig.l Date: 10/10/02 www.hagglunds.com
Jupiter 900 Driver Card (S20-14078)
SW SW SW SW
Input Command: 1A 1B Ramp 1C 1D
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Bi-Directional Output
Unidirectional Output
Page 2
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Miscellaneous
Password ( If Spider is used): 0532
Tested By: WK
Date: 6SEP05
Engineering Release and Approval for Shipment:
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Power Unit Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
If motor has any other special options please list in “NOTES” section of this report.
Pump No. 1
Manufacturer: DENISON Model No. P7S 2R1A 9A2 B00 0A1 M2
Serial Number: 01046867 Part No.: 023-07706-0
Rotational Check: Left Hand (CCW looking at input shaft) Right Hand (CW looking at input shaft)
Internal Charge Relief valve setting: 450 psi Servo Pressure with Pump in Neutral: 490 psi
Charge Pressure with Pump in Neutral: 300 psi Servo Pressure at 50% max. flow: 410 psi
Charge Pressure at 50% max. flow: 222 psi
If pump has any other special options please list in “NOTES” section of this report.
Page 1
F10208-1 l Revision: Al Date: 7/31/02 www.hagglunds.com
Job Number: 2005 032-1 Serial Number: 517-2-21187
Power Unit Model Code: PBC-202-073-100-22-1110-11B-0000-0-380/50
Miscellaneous
Torque Seal applied to reservoir breather and all pressure switches: Yes No
Serial Number Plate installed: Yes No
Documentation Used for testing:
General Arrangement Rev. - Hydraulic Schematic Rev. -
Electrical Schematic Rev. - Power Unit Bill of Material Rev. A
List all other drawings used and their revision levels:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 507C022881
*PS-4 (High System Pressure): Hydac EDS 3476-3-6000-400 / Rng.6000 Psig / Art No:908598 /
S/n 517D026703
"POWER UNIT TESTED WITH 250 HP TEST MOTOR @ 460 VAC / 60 HZ / 3 PHASE / 1770 RPM"
Page 3
F10208-1 l Revision: A l Date: 7/31/02 www.hagglunds.com
Control Box Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
Installation
All Terminal Markers Installed: Function
All wires bundled and tied: Continuity Test:
Control Box P/N Tag Installed: Functional Check of Switches:
All Bill of Material Items Installed: Functional Check of Lights:
Grounding Lug Properly Installed: Functional Check of Pushbuttons:
Other Items
Control Voltage: 120 VAC
Make of Power Supply: HDI
Model of Power Supply: SPIDER
Spider Controller
Jumpers are in correct position:
All Parameters checked:
If the Spider is supplied as a loose item, is it temporarily wired to the Power Unit:
If there are any Parameter changes please list them all in the "NOTES" section of this report.
Page 1
F10208-2 l Revision: Orig.l Date: 10/10/02 www.hagglunds.com
Jupiter 900 Driver Card (S20-14078)
SW SW SW SW
Input Command: 1A 1B Ramp 1C 1D
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Bi-Directional Output
Unidirectional Output
Page 2
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Miscellaneous
Password ( If Spider is used): 0532
Tested By: WK
Date: 6SEP05
Engineering Release and Approval for Shipment:
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Power Unit Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
If motor has any other special options please list in “NOTES” section of this report.
Pump No. 1
Manufacturer: DENISON Model No. P7S 2R1A 9A2 B00 0A1 M2
Serial Number: 01046866 Part No.: 023-07706-0
Rotational Check: Left Hand (CCW looking at input shaft) Right Hand (CW looking at input shaft)
Internal Charge Relief valve setting: 450 psi Servo Pressure with Pump in Neutral: 480 psi
Charge Pressure with Pump in Neutral: 300 psi Servo Pressure at 50% max. flow: 410 psi
Charge Pressure at 50% max. flow: 224 psi
If pump has any other special options please list in “NOTES” section of this report.
Page 1
F10208-1 l Revision: Al Date: 7/31/02 www.hagglunds.com
Job Number: 2005 032-2A Serial Number: 517-2-21188
Power Unit Model Code: PBC-202-073-100-22-1110-11B-0000-0-380/50
Miscellaneous
Torque Seal applied to reservoir breather and all pressure switches: Yes No
Serial Number Plate installed: Yes No
Documentation Used for testing:
General Arrangement Rev. - Hydraulic Schematic Rev. -
Electrical Schematic Rev. - Power Unit Bill of Material Rev. A
List all other drawings used and their revision levels:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 507C022880
*PS-4 (High System Pressure): Hydac EDS 3476-3-6000-400 / Rng.6000 Psig / Art No:908598 /
S/n 524D030724
Page 3
F10208-1 l Revision: A l Date: 7/31/02 www.hagglunds.com
Control Box Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
Installation
All Terminal Markers Installed: Function
All wires bundled and tied: Continuity Test:
Control Box P/N Tag Installed: Functional Check of Switches:
All Bill of Material Items Installed: Functional Check of Lights:
Grounding Lug Properly Installed: Functional Check of Pushbuttons:
Other Items
Control Voltage: 120 VAC
Make of Power Supply: HDI
Model of Power Supply: SPIDER
Spider Controller
Jumpers are in correct position:
All Parameters checked:
If the Spider is supplied as a loose item, is it temporarily wired to the Power Unit:
If there are any Parameter changes please list them all in the "NOTES" section of this report.
Page 1
F10208-2 l Revision: Orig.l Date: 10/10/02 www.hagglunds.com
Jupiter 900 Driver Card (S20-14078)
SW SW SW SW
Input Command: 1A 1B Ramp 1C 1D
± 5VDC OFF
± 10VDC 0.1 – 6 Sec.
± 0-20mA 0.4 – 40 Sec.
± 4-20mA
SW2
FUNCTION 1 2 3 4
0.1 – 6 Sec.
RAMP 0.4 – 40 Sec.
OFF
DITHER ON
OFF
Bi-Directional Output
Unidirectional Output
Page 2
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Miscellaneous
Password ( If Spider is used): 0532
Tested By: WK
Date: 13SEP05
Engineering Release and Approval for Shipment:
Approval By: JFDIII
Date: 10-28-2005
Notes:
Page 3
F10208-2 l Revision: Orig. l Date: 10/10/02 www.hagglunds.com
Power Unit Test Report
Hägglunds Drives Inc.
2275 International Street
Columbus, Ohio 43228
If motor has any other special options please list in “NOTES” section of this report.
Pump No. 1
Manufacturer: DENISON Model No. P7S 2R1A 9A2 B00 0A1 M2
Serial Number: 01043827 Part No.: 023-07706-0
Rotational Check: Left Hand (CCW looking at input shaft) Right Hand (CW looking at input shaft)
Internal Charge Relief valve setting: 450 psi Servo Pressure with Pump in Neutral: 490 psi
Charge Pressure with Pump in Neutral: 305 psi Servo Pressure at 50% max. flow: 410 psi
Charge Pressure at 50% max. flow: 220 psi
If pump has any other special options please list in “NOTES” section of this report.
Page 1
F10208-1 l Revision: Al Date: 7/31/02 www.hagglunds.com
Job Number: 2005 032-3 Serial Number: 517-2-21189
Power Unit Model Code: PBC-202-073-100-22-1110-11B-0000-0-380/50
Miscellaneous
Torque Seal applied to reservoir breather and all pressure switches: Yes No
Serial Number Plate installed: Yes No
Documentation Used for testing:
General Arrangement Rev. - Hydraulic Schematic Rev. -
Electrical Schematic Rev. - Power Unit Bill of Material Rev. A
List all other drawings used and their revision levels:
CS-2005 032 Rev. -
CD-2005 032 Rev. -
CC-2005 032 Rev. -
Rev. -
Rev. -
Rev. -
Rev. -
Notes:
*PS-1 (Charge): Hydac EDS 3476-3-1000-400 / Rng.1000 Psig / Art No:908841 / S/n 507C022878
*PS-4 (High System Pressure): Hydac EDS 3476-3-6000-400 / Rng.6000 Psig / Art No:908598 /
S/n 524D030722
"POWER UNIT TESTED WITH 250 HP TEST MOTOR @ 460 VAC / 60 HZ / 3 PHASE / 1770 RPM"
Page 3
F10208-1 l Revision: A l Date: 7/31/02 www.hagglunds.com
COMPACT CB MOTOR MANUAL
Installation and Maintenance Manual
Compact CB 280-840
EN683-2h 2002
Preface Installation and Maintenance Manual, Compact CB
Preface
Hägglunds Drives is one of the worlds leading manufacturers of large hydrau-
lic Drive Systems. A leading position, made possible by unbeatable service
spirit and of continuing development of both products and markets all over the
world. Our drives are to be found in most industrial and marine segments,
where there are extremely high demands for efficiency and reliability. Our main
office and production plant is in Mellansel, Sweden and we have our own
sales- and representation offices in some 40 different countries.
Our high quality Drive Systems, are based upon our unique hydraulic piston
motors, developed through a wealth of experience accumulated over 30 years
in marine and industrial areas.Today this ongoing development work has
resulted in the powerful COMPACT CB industrial motor. New, as well as esta-
blished technical solutions, contribute to the creation of this product. The most
desirable features and operating reliability have been designed in this hydrau-
lic motor.
2
Installation and Maintenance Manual, Compact CB Contents
Contents
1. GENERAL ....................................................................................................................... 4
1.1 Safety precautions .. ........................................................................................................ 4
1.2 Motor data ........................................................................................................................ 5
1.3 Functional description ...................................................................................................... 6
3. INSTALLATION ............................................................................................................. 11
3.1 Mounting instructions ..................................................................................................... 11
Thread for mounting tool ................................................................................................ 12
Spline ............................................................................................................................. 12
3.1.1 Lifting methods ............................................................................................................... 13
Standing the motor on a flat surface ............................................................................... 14
3.1.2 Mounting the coupling onto the motor shaft .................................................................... 15
3.1.3 Fitting the torque arm to the motor . ................................................................................ 17
3.1.4a Mounting the motor onto the driven shaft - shaft coupling .............................................. 18
3.1.4b Mounting the motor onto the driven shaft - splines ......................................................... 21
3.1.5 Removing the motor from the driven shaft ..................................................................... 22
3.1.6 Mounting the reaction point . .......................................................................................... 23
3.2 Oil connections .............................................................................................................. 24
3.2.1 Direction of rotation of motor shaft ................................................................................. 26
3.2.2 Draining and venting the motor ...................................................................................... 36
3.2.3 Flushing .......................................................................................................................... 27
5. FAULT FINDING............................................................................................................ 32
DECLARATION OF CONFORMITY ............................................................................ 33
3
General Installation and Maintenance Manual, Compact CB
1. GENERAL
1.1 Safety precautions
It is of high importence that the Safety precautions are always followed, if you are
unsure about something, please don´t hesitate to contact your nearest HD-office
for advice.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will
cause personal enjury or substantial property damage. Depending on the probability of the hazard,
and how serious the injury or property damage could be, there are three levels of classification.
Application area
All new and rebuild applications, should always be approved and supervised by Hägglunds
personel.
Mounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.
Before starting up
Before starting up new, rebuild or just worked on applications, all accessories and safety
arrangements functions, should be controlled/tested.
Periodic maintenance
Notice the intervals in maintenance chart (4.4) and keep a record.
Dismounting
Carefully follow the instructions and be aware of the high weights and forces during lifting.
4
Installation and Maintenance Manual, Compact CB General
Table 1.1
Metric
Specific Rated * Max. Max. ** Max. Max. power 3)
Displacement
torque speed 1) speed pressure torque 2) Intermittently
Motor type
Vi Ts n n p
kNm kW
cm3/rev Nm/bar rev/min rev/min bar
CB 280-240 15 100 240 53 68 350 79 530
CB 280 17 600 280 44 58 350 92 530
CB 400-240 15 100 240 94 125 350 79 970
CB 400-280 17 600 280 73 105 350 92 950
CB 400-320 20 100 320 71 94 350 110 970
CB 400-360 22 600 360 59 82 350 120 960
CB 400 25 100 400 58 75 350 130 970
CB 560-440 27 600 440 49 65 350 140 930
CB 560-480 30 200 480 48 62 350 160 970
CB 560-520 32 700 520 41 57 350 170 960
CB 560 35 200 560 40 53 350 180 970
CB 840-600 37 700 600 30 45 350 200 880
CB 840-640 40 200 640 28 41 350 210 850
CB 840-680 42 700 680 27 40 350 220 890
CB 840-720 45 200 720 25 37 350 240 870
CB 840-760 47 800 760 23 34 350 250 840
CB 840-800 50 300 800 23 34 350 260 890
CB 840 52 800 840 21 32 350 280 870
US
Specific Rated * Max. Max. ** Max. Max. power 3)
Displacement speed 1)
torque speed pressure torque 2) Intermittently
Motor type Vi Ts n n p
lbf·ft/1000 lbf·ft hp
in3/rev psi rev/min rev/min psi
CB 280-240 920 12 200 53 68 5000 57 000 710
CB 280 1070 14 200 44 58 5000 67 000 710
CB 400-240 920 12 200 94 125 5000 57 000 1300
CB 400-280 1070 14 200 73 105 5000 67 000 1300
CB 400-320 1230 16 300 71 94 5000 76 000 1300
CB 400-360 1380 18 300 59 82 5000 86 000 1300
CB 400 1530 20 300 58 75 5000 95 000 1300
CB 560-440 1690 22 400 49 65 5000 100 000 1300
CB 560-480 1840 24 400 48 62 5000 110 000 1300
CB 560-520 1990 26 400 41 57 5000 120 000 1300
CB 560 2150 28 500 40 53 5000 130 000 1300
CB 840-600 2300 30 500 30 45 5000 140 000 1200
CB 840-640 2450 32 500 28 41 5000 150 000 1100
CB 840-680 2610 34 600 27 40 5000 160 000 1200
CB 840-720 2760 36 600 25 37 5000 170 000 1200
CB 840-760 2910 38 700 23 34 5000 180 000 1100
CB 840-800 3070 40 700 23 34 5000 190 000 1200
CB 840 3220 42 700 21 32 5000 200 000 1200
*) Related to a required pressure of 12 bar/175 psi for motors in braking mode. (Special considerations regarding
charge pressure, cooling and choice of hydraulic system for speeds above rated, 4 ports must be used for higher
speed).
**) The motors are designed according to DNV-rules. Test pressure and peak pressure 420 bar/6000 psi is allowed.
1
) Special considerations regarding charge pressure, cooling and choice of hydraulic system for speed above rated.
2
) Calculated as : Metric= Ts·(350-15)·0,98 US= Ts·(5000-218)·0,98.
3
) Valid for minimum permissible oil viscosity 20 cSt in the motor case.
5
General Installation and Maintenance Manual, Compact CB
1
1. Cam ring
2. Cam roller
2 A, C
3. Piston
3
D 4. Shaft coupling
4 8
5. Cylinder block /
hollow shaft
5 6. Cylinder block / spline
7. Front end cover
8. Cylindrical roller bearing
11 9. Connection block
10. Valve plate
6 11. Axial bearing
6
Installation and Maintenance Manual, Compact CB Technical data
2. TECHNICAL DATA
2.1 Recommended charge There are two distinct cases:
pressure Case 1:
The hydraulic system must be such that the The motor works in braking mode. Required
motor will recieve sufficient charge pressure charge pressure at the inlet port is according
at the low-pressure port. This applies to all to diagram below.
types of installations.
Case 2:
The motor works in driving mode only. Required
back pressure at the outlet port corresponds
to 30% of value given in diagram below, but
may not be lower than 2 bar (29 psi).
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
CB 400 / CB 400-360
CB 560 / CB 560-520
CB 280-240
CB 400-320
CB 840-720
CB 840-600
CB 840
CB 280
20
18
250
16
Recommended charge pressure [bar]
14 200
12
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80
Recommended charge pressure - CB 280-840 2-port connection Speed [rpm]
Note:
The diagram is valid for 1 bar (15 psi) case pressure. With increasing case pressure the charge
pressure must be increased accordingly. The graph is valid when 4 ports are used. Max casing
pressure is 3 bar (43,5 psi)(for 1% of the operation time evenly divided, pressure peaks of max 5
seconds upto 8 bar (116 psi) are allowed). Max permitted case pressure at stand-still is 8 bar (116
psi).
7
Technical data Installation and Maintenance Manual, Compact CB
CB 840-680 / CB 840-640
CB 560-480 / CB 560-440
CB 840-800 / CB840-760
Table 2.1b Charge pressure
CB 560 / CB 560-520
CB 400 / CB 400-360
CB 840-720
CB 840-600
CB 280-240
CB 400-320
CB 840
CB 280
20
18
250
Recommended charge pressure [bar]
16
10 150
8
100
6
4
50
2
0 0
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Background noise
Remarks:
Background noise
Hydraulic motor
The background noise can not normally be
influenced but is usually known or easy to The hydraulic motor is a known noise level.
measure. (Tables of sound data - see subsection 4.9 in
the Engineering Manual).
Pump unit
Driven unit
The pump unit is a known noise level.
The driven unit is an unknown sound source
(for us) but can through certain information
Pipe noise probably be obtained from the supplier. When
The pipe noise is probably the source of the securing the torque arm of a hydraulic motor
majority of mistakes in installations: all pipe to the foundation or casing of a driven machine,
clamps should be of vibration insulating type it is highly important to study the construction
secured to concrete ceiling, wall or floor. of the foundation or casing. This may well be
Securing to non-rigid metal structures or the most important factor to consider, since
structures is likely to give resonance and many structures may give rise to resonance,
should be avoided. resulting in severe noise problems.
8
Installation and Maintenance Manual, Compact CB Technical data
9
Technical data Installation and Maintenance Manual, Compact CB
* Vegetable fluids give good lubrication and small change of viscosity with different temperature. Vegetable fluids
must be controlled every 3 months and temperature shall be less than +45° (113°F) C to give good service life for
the fluid.
** Environmental acceptabel fluid gives the same servicelife for the drive, as mineral oil.
Filtration Explanation of
"GRADE OF FILTRATION"
The oil in a hydraulic system must always be
filtered and also the oil from your supplier has Grade of filtration β 10=75 indicates the
to be filtered when adding it to the system. The following:
grade of filtration in a hydraulic system is a β 10 means the size of particle ≥10µm that will
question of service life v.s. money spent on filt- be removed by filtration.
ration.
=75 means the grade of filtration of above
In order to obtain stated service life it is mentioned size of particle. The grade of filt-
important to follow our recommendations ration is defined as number of particles in the
concerning contamination level. oil before filtration in relation to number of
When choosing the filter it is important to particles in the oil after filtration.
consider the amount of dirt particles that the Ex. Grade of filtration is β 10=75.
filter can absorb and still operate satisfactory.
For that reason we recommend a filter with an Before the filtration the oil contains N number
indicator that gives a signal when it is time to of particles ≥10µm and after passing the filter
change the filter cartridge.
once the oil contains number of particles
Before start-up, check that the system is This means that number of
thoroughly cleaned.
particles have been filtered (=98,6%).
1. In general the contamination level in our
motors should not exceed ISO 4406 19/15.
(NAS 10)
2. For heavy-duty industrial applications the
contamination level should not exceed ISO
4406 16/13. (NAS 7)
3. When filling the tank and motor housing, we
recommend the use of a filter with the grade
of filtration β 10=75.
10
Installation and Maintenance Manual, Compact CB Installation
3. INSTALLATION
3.1 Mounting instructions Design of driven shaft end on heavily-
loaded shaft
If the motor is to work properly it must be
installed with the greatest possible precision. Where the driven shaft is heavily loaded and
Every item connected to the motor that does is subject to high stresses, for example on
not meet the requirements of the following changes in the direction of rotation, it is
instructions may result in stresses that recommended that the driven shaft should
adversely affect the service life of the motor. have a stress relieving groove; see Fig. 3.1 and
tables 3.1 and 3.4.
Normally the motor must be completely filled
with oil. When the motor is installed with the
shaft in the horizontal plane, the drain ports G
must be positioned vertically. The higher of the F
four ports must be used: see fig. 3.25. Fig. 3.1 Max R 3,2
a
C
A
D
The drain line must be dimensioned so that
E
max. 3 bar (43.5 psi) motor housing pressure 30°
is not exceeded.
6±0,5 R 50
(0,24±0,02) (R 1,97)
The max housing pressure is 3 bar (43.5 psi). B±0,5
(B±0,02)
Brief peaks during operation up to 8 bar (116
psi) are permissible. The permitted housing
pressure when the motor is stationary is 8 bar Normally-loaded shaft
(116 psi). In drives with only one direction of rotation
The motor must always be connected in such where the stresses in the shaft are moderate,
a way as to give a sufficient boost, make-up the shaft can be plain, see Fig. 3.2 and tables
flow at the low pressure connection. This is 3.1 and 3.5
particularly important at high speeds and with Fig. 3.2
rapid reversing, see 2.1 "Recommended
charge pressure".
Max
11
Installation Installation and Maintenance Manual, Compact CB
Bidirectional drives
CB 280 - 840
Table 3.4
D M20 UNC 5/8"
Motor CB 280/400 CB 560/840
E >17 (0,67) >13,5 (0,53)
F 25 (0,98) 22 (0,87)
Toth profile and G 50 (1,97) 30 (1,18)
DIN 5480 DIN 5480
bottom form
Tolerance 8f 8f
Number of teeth 38 50 A
0 0
Minor diameter ø 188 ø 248
-1,201 -1,201
0 0
Major diameter ø 199 ø 259
-0,290 -0,320
-0,088 -0,103
Measure over
210,158 270,307
measuring pins -0,157 -0,181 0,15 A
(0,006) 0,4 A
Diameter of
ø 10 ø 10 (0,015)
measuring pins
Addendum
+2,25 +2,25
modification X M
12
Installation and Maintenance Manual, Compact CB Installation
Fig. 3.5
13
Installation Installation and Maintenance Manual, Compact CB
kg lb
Support
Table 3.7
Weight
Torque arm
kg lb
Support
NOTE:
The motor must not be placed on the end face
of the hollow shaft when the coupling is fitted,
since this may cause damage to the coupling.
When in storage, the motor must always be
placed on the end face to the hollow shaft. It is
also advisable to provide supports at the
mounting surface of the motor; see Fig. 3.7.
14
Installation and Maintenance Manual, Compact CB Installation
- You should note that the couplings are from the factory lubricated with MoS2 (Molycote) on the
conical surfaces and the bolts,see fig. 3.8. This lubricants shall remain on those surfaces but:
It is therefore important that you clean your hands free from Molycote. If those conditions are
fullfilled you may start the mounting.
- Clean the driven shaft and the out- and inside of the Compact motor hollow shaft.
- Remove the spacers between the two clamping rings of the coupling.
- Mount the coupling on the hollow shaft of the motor. The coupling must be pushed right up to the
stop of the shaft. Use a screwdriver to open the coupling ring for easier mounting.
- Mount the motor onto the driven shaft by following the instruction in the section 3.1.4. (With or
without using the mounting tool).
Remember:
-The conical surface between the coupling ring and the clamping rings + the bolts shall be coated
with MoS2 (Molycote), see Fig. 3.8. This is done from the factory at delivery! When a motor has
been in for overhaul or service and shall be reassembled it may be necessary to relubricate those
surfaces with Molycote again but remember only the specified surfaces!
-Absolutely No Molycote on the surfaces between shaft-motor. Clean the driven shaft and the
inside of the motor hollow shaft.
- Alignment of the motor on the shaft. (Dimensional check).
- Minimum variation in the gap between the clamping rings (Dimensional check).
- Right torque on the bolts. (Use torque wrench).
15
Installation Installation and Maintenance Manual, Compact CB
Clamping rings
Fig. 3.8
Centre of motor
16
Installation and Maintenance Manual, Compact CB Installation
Table 3.8
Tightening torque
Number
Motor Screw dimension
of screws
Nm lbf·ft
17
Installation Installation and Maintenance Manual, Compact CB
3.1.4a Mounting the motor onto the driven shaft - shaft coupling
The motor can be mounted onto the driven shaft with or without a mounting tool, but the use of a
mounting tool is recommended since it makes the work easier.
It is important to arrive at the correct clamping length between the driven shaft and the hollow shaft
of the motor.
Ensure that the full clamping length is used by, for example, measuring and marking the driven
shaft. This is of particular importance if the duty is so severe that a stress relieving groove has
been made on the driven shaft. See Fig. 3.11, 3.11a and the table 3.9.
Fig.3.10b
2 1; Bearing retainer
2; Plastic washer
3; Nut
4; Mounting tool
3
4
18
Installation and Maintenance Manual, Compact CB Installation
CB 560
153 6.02
CB 800
19
Installation Installation and Maintenance Manual, Compact CB
However for the tightening of the coupling Mark the screw heads at 12 o´clock with a pen
screws the following must be observed: or paint so that you can follow the turning
sequence of the screws.
Keep tension in your lifting wires to avoid
a skew setting of the motor on the shaft Set the torque wrench for the specified maxi-
during the tightening of the screws. mum torque. Tightening torque of the coupling
Wobbling caused by a skew setting of the screws; see the sign on the coupling, or table
motor gives extra forces on the main 3.10.
bearings.
Now start tightening the screws in sequence
In order to avoid the misalignment of the two shown in Fig. 3.14.
clamping rings during the screw tightening, the
Keep on doing this until you have reached the
gap between the rings must be measured in
stated torque. Several passes are required
several places during the process, see Fig.
before the screws are tightened to specified
3.14. The difference between the measured
torque. Keep checking the alignment of the
gaps must never vary more than 1 mm (0,04")
coupling. (15-20 passes may be necessary).
during any stage of the tightening process.
When the specified torque is reached it is
Pre-set the coupling screws in opposite pairs
important that all screws are tightened with
(12-6-3-9 o´clock) until you reach max. 50%
specified torque and that no further movement
of the torque specified for the screws. It is very
can be observed.
important that when you reach this stage the
misalignment is controlled as described above.
Table 3.10
Tightening torque
Motor No of Screw Strength Type of
type screws dim class head
Nm lbf·ft
CB 280 12 M20x80
CB 400 15 M20x90
10.9 490 362
Hexagon
CB 560 20
M20x100
CB 840 20
20
Installation Installation and Maintenance Manual, Compact CB
Fig. 3.14
Fig. 3.14a
21
Installation and Maintenance Manual, Compact CB Installation
1; Bearing retainer
2; Plastic Washer
3; Nut
4; Mounting tool
22
Installation Installation and Maintenance Manual, Compact CB
Alternative
Note: The toggle bearing must position
be dismounted during welding.
Steel:
EN 10113S355N
DIN St E39
BS 4360 Grade 50 C
Protected against corrosion, after welding.
Fig. 3.18
DANGER ZONE
Fig. 3.17 In case of failure of
torque arm installation
23
Installation Installation and Maintenance Manual, Compact
Fig. 3.25
T4
Table 3.11
F1,F2 Flushing connection For flushing of radial lip seal. Normally plugged.
T2, T3 Test connection Used to measure pressure and/or temperature in drain oil.
Table 3.12
D1, D2, F1, T1, y y x x
Motor A** C** D4 F3 T3 T4
D3 F2 T2 mm in mm in
**SAE coupling J 518 C, code 62, 414 bar (6000 psi). 1 1/4" or 1 1/2" can be used.
*** A2-connection and C2-connection is blocked at delivery. They are able to withstand max pressure.
24
Installation and Maintenance Manual, Compact CB Installation
Main connection A, C
Fig. 3.25b
Table 3.13
a c
Motor Connection b
mm (in) mm (in)
∅ 65
(2,56)
G
BSP
25
Installation Installation and Maintenance Manual, Compact CB
Vertical mounting
When the motor is mounted vertically, the highest of the four drain outlets D1, D2, D3 or D4 must
be used. Flushing of radial seal from low pressure is necessary.
26
Installation and Maintenance Manual, Compact CB Installation
Drain line
Low pressure
connection
Drain line
connection
G 1/2", Flushing
Low pressure connection F3
3.2.3 Flushing
27
Installation and Maintenance Manual, Compact CB Maintenance
4. OPERATING INSTRUCTIONS
4.1 Storage
The motor is delivered with internal protection in the form of an oil film and external protection in the form of an
anti-rust film. This provides sufficient protection for indoor storage in normal temperatures for about 12 months.
Note: the anti-rust protection must be touched-up after transport and handling.
If the motor is stored for more than 3 months in uncontrolled environment or more than 12 months in controlled
environment, it must be filled with oil and positioned as shown in Fig. 3.7.
Place the motor as shown in fig 4.1, fill the motor with filtered oil in the following order: D1, A1, C1. See 2.3,
"Filtration" and table 4.1.
Take extreme care to ensure that no contamination enters the motor.
Seal connections A and C with the cover plate fitted to the connection surface at delivery. Check that the O-
rings or rubber seals are in postion in the cover plate.
Fit the plug to D1, D2, D3 and D4, the table below states the amount of oil needed to fill the various types of
motors.
Table 4.1
Oil volume approx.
Motor
Litres US gal.
CB 280 15 4.0
CB 400 21 5.6
CB 560 19 5.0
CB 840 25 6.6
28
Maintenance Installation and Maintenance Manual, Compact CB
Maintenance chart
Oil Torque
In operation Oil
filters arm
After 3
months or Rpl.
500 hours
Once every 6
months
Rpl. Insp. Insp.
Once every
12 months
29
Maintenance Installation and Maintenance Manual, Compact CB
Motor Filters
If the motor is to be stored stationary for a Filters must be changed after the first 100
longer period than about 1 month, it must be working hours and the second change is to be
protected from internal rust. This can be done carried out after 3 months or 500 working hours
as follows: whichever is earlier. They must then be
1. Mix anti-rust additive with the hydraulic changed at regular intervals of 6 months or
fluid of the system. Use 5% of Rust Veto 4000 working hours.
Concentrate (manufactured by E F
Houghton & Co, Philadelphia, USA). This Oil (Se also 2.3)
additive gives rust protection for up to
about 1 year, after which time the motor Analysis
must be turned a few revolutions.
It is recommended that the oil should be analy-
2. If no additives are used, the motor must sed every 6 months. The analysis should cover
be regularly turned a few revolutions. viscosity, oxidation, water content, additives
3. If it is not possible to turn the motor, plug and contamination.
all connections, open drain outlet D1 or D2 Most oil suppliers are equipped to analyse the
on the port end housing (or if the motor is state of the oil and to recommend appropriate
mounted vertically, Flushing connection F1 action. The oil must be replaced immediately if
on the shaft end housing) and fill the motor the analysis shows that it is exhausted.
with hydraulic fluid.(See Fig. 4.3 and Fig.
4.3a). Viscosity
Many hydraulic oils become thinner with
Fig. 4.3
increasing use, and this means poorer
lubrication. The viscosity of the oil in service
must never fall below the minimum recom-
mended viscosity.
Oxidation
Hydraulic oil oxidizes with time of use and
temperature. This is indicated by changes in
colour and smell, increased acidity or the for-
mation of sludge in the tank. The rate of oxida-
Fig. 4.3a tion increases rapidly at surface temperatures
above 60°C (140°F), and the oil should then
be checked more often.
The oxidation process increases the acidity of
the fluid; the acidity is stated in terms of the
"neutralisation number". Typical oxidation is
slow initially and increases rapidly later.
A sharp increase (by a factor of 2 and 3) in the
neutralisation number between inspections is
a signal that the oil has oxidized too much and
should be replaced immediately.
30
Installation and Maintenance Manual, Compact CB Maintenance
Water content
Contamination of the oil by water can be Another method is to install an inline particle
detected by sampling from the bottom of the counter direct in your hydraulic system which
tank. Most hydraulic oils repel the water, which give you the contamination level according to
then collects at the bottom of the tank. This the international rules, the disadvantage with
water must be drained off at regular intervals. this method is that you only get the
Certain types of transmission oils and engine contamination level in the oil.
oils emulsify the water; this can be detected
by coatings on filter cartridges or a change in General
the colour of the oil. Obtain the advice of your The intention is to verify the condition of the oil
oil supplier in such cases. during operation.The motors should be running
Degree of contamination at normal operation while the sample is taken.
The cleanliness is extremely important during
Heavy contamination of the oil causes sampling.
increased wear of the hydraulic system Always use bottles adapted to oil samples,
components. The cause of the contamination they can be ordered from any fluid analysis
must be immediately investigated and re- laboratory.
medied. Never try to clean your own bottle if you want
a true value of the result.
The sample should be taken by using a mini-
mess hose connected to a mini-mess
coupling.
Always clean the connections carefully before
All hydraulic fluids are affected you connect the mini-mess hose to the
differently. Obtain the advice of coupling.
your oil supplier or by nearest Be careful when connecting the mini-mess
Hägglunds representative. hose because the oil beam can be dangerous
and should never point against any person or
other sensible object.
Check and be aware of the pressure you
4.5 Oil inspection mayhave on the connection before you
Purpose connect.
The purpose to take an oil sample is to check
the condition of the oil. How to do
With scheduled oil analysis, wear products can Bottle samples
be identified and corrective action can be taken The sample shall be taken at the mini-mess
before failure occurs. Oil analysis can indicate coupling on the charge pressure side of the
when an oil change is required, point out motor in the closed loop system. Never out of
shortcomings in maintenance and keep repair the tank using the ball valves.
cost to a minimum. Using oil analysis can Clean the coupling and the hose carefully.
create a “window of opportunity”, allowing the Connect the mini-mess hose to the coupling
user to schedule re-fittings or overhauls, but be careful and be aware of the direction of
maintenance or repairs, thus saving money on the oil beam.
equipment repairs and downtime. Let minimum 2 litres (0,6 gallon US) of oil flush
The most used method is to take samples in a into a bucket before you fill the bottle.
special bottle and send it to a fluid laboratory Remove the cap of the bottle as late as
for an analysis and from the laboratory you possible and don’t let any contamination be in
get a repor t, which follow a specific touch with the cap, bottle or the mini-mess hose
international standard. when the sample is taken.
You have to select what analysis the laboratory In dirty air area, use a soft plastic foil (normal
should take, but the most used analysis are as protection in laboratory bottles between
particle count, water content, oxidation and bottle and cap).
viscosity.
31
Fault finding Installation and Maintenance Manual, Compac CB
Do not remove the foil, prick the end of your Inline measure
mini-mess hose through the foil into the bottle The sample shall be taken at the mini-mess
and fill. coupling on the charge pressure side of the
To get a reliable result the system must run motor in of the closed loop system. Clean the
without moving any valves and the mini-mess coupling and the hose carefully.
hose should not touch the bottle. Connect the hoses according to the particle
Only ¾ of the bottle shall be filled because the counters manual.
laboratory has to shake the sample to get a To get a true value the contamination readings
mixed fluid when they analyse it. Minimum have to be stable about 10 min before you stop
200ml are needed for a good analysis. to measure.
When the bottled is filled close the cap as soon
as possible to prevent contamination from the
air that might enter the bottle and give you a
wrong result.
5. FAULT FINDING
Hydraulic motor
Fault Probable cause Action
The motor does not run. Mechanical stop in the drive. Check system pressure. If the pressure has
risen to the relief valve setting, remove the
load from the drive.
The motor does not deliver Investigate the pressure level in the system
enough torque because the and correct the setting of the pressure limiting
pressure difference across the valve if necessary.
motor is not great enough for
the load.
Motor rotates in wrong Oil supply connections to Connect the oil supply correctly.
direction. motor incorrectly connected.
Motor runs jerkily. Pressure or flow fluctuations Find the cause in the system or in the driven
in the hydraulic system. unit.
Noise in the motor. The motor is being operated Adjust the charge pressure to the correct
with the charge pressure too level. See 2.1 "Recommended charge
low. pressures".
Internal faults in the motor. Investigate the drain oil, if necessary. Put a
magnetic plug in the oil flow and check the
material that sticks to the magnet. Steel
particles indicate damage. Note that fine
material from the castings may be deposited
and does not mean internal damage in the
motor.
External oil leakage on The radial lip seal is worn. Replace the radial lip seal.
the motor.
32
Deklaration of conformity Installation and Maintenance Manual, Compact CB
DECLARATION OF CONFORMITY
Example of the Declaration of Conformity given by Hägglunds Drives AB
33
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
740
4
(4,331)
(26,772 -0,0062)
45°
-0,0013
A
-0,024
-0,149
H (2:1)
B D1 30 B
C C (1,181)
D4 B B
680
223 (2x)
(8,780)
174 (4x)
(6,850)
(17,008 +0,00078)
C C
+0,00235
)
(29,213 -0,024)
+0,0029
+0,063
432 +0,023
+0,072
+0,023
6x15
742 ±0,6
(17,323)
(0,236)
440
200 0
(7,874 +0
117
(4,606)
D D
D2 T3
E A2 Not 1. E
A
C2 Note 1.
T4 A M20 (34x)
T4 1/2"UNC (16x) 31 (4x)
(1,220)
38
Equ 9° A
ally (1,496)
(1,063)
F F
(1,457)
divi 207 (4x)
27
ded
37
(8,150) 237 425
(9,331) (16,732)
489
782 101 (19,252)
G (30,787) G
B-B (1 : 1) (3,976)
250 224 = = = = A1 C1
25° 55°
(9.843) (8,819)
5/8"UNC (16x) T1 T1
D3 F1 D1 D3
H H
(1,378)
(1,772)
D4
35
45
F2
A F3
D2 F1
(3,346)
(2,874)
85
= = = =
73
T2
C-C (1 : 1)
I T3 I
99 A (1 : 2)
T4 T4
(2,126)
(3,898)
54
(13,976)
(17,559)
C1 MAIN CONNECTION SAE 1¼" AND 1½" ** without notice or obligation, unless certified
Contravention will be prosecuted.
446
A2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** referring to a certain purchase order.
C2 ALTERNATIVE MAIN CONNECTION SAE 1¼" AND 1½" ** Information contained herin should be confirmed
before placing orders.
D1 DRAIN CONNECTION BSP 1 ¼"
D2, D4 ALTERNATIVE DRAIN CONNECTION BSP 1 ¼" Measurements within brackets indicates
D3 ALTERNATIVE DRAIN CONNECTION BSP 1" measurements in inches.
K T1, T2 TEST CONNECTION M16 x 2 NOTE 1: For tightening torque see installation manual. K
T3 TEST CONNECTION BSP ¼" Must be verified on actual name plate.
A T4 PRESSURE CONNECTION BSP ½"
T1 T1 FLUSHING CONNECTION BSP ¼"
F1, F2 Item No. Qty Article No. Material, type, etc Dimensions Name of item
Part of
according to
SS-ISO 2768-1, class m Scale Presiding drawing no Control code
SS-ISO 965, class 6.
Other not indicated tol. 1:2.5
F2 ** SAE coupling J 518 C, code 62, 414 bar (6000 psi) Cad type
SW
Sheet size
A0
Drawn by
Knight/DVN
Description (English)
A40P
Prepared both for 1¼" and 1½". Accepted for prod by Iss by Dept. Year Week Description (Own language)
L
T2 99 A F3 Both UNC 1/2" for SAE 1¼" and UNC 5/8" for SAE 1½" Drawing checked by
D52 01 22 CB400
Rev ind Sheet
Similar drawing No.
1
(3,898) A 620 060 LFN 02 05
D52/BLL
Design checked by
078 5003 A No. of sheets
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Bill of Material No.: HK-2005032
Bill Of Material
Date Issued : 3-Jun-2005 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: JFD 2275 International Street; Columbus, Ohio 43228, USA - -
Checked By: CBH Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: - Assembly Ref(s) :
HOSE KIT Revised By : -
25 FT. LONG, PBC-200 with 1 x P6S/P7S to 1 x CB-280/400 -
WITH MAINLINE, AND DRAINLINE HOSES Rev. Date : Project No. :
- 2005 032
C
Item O Hägglunds Description Manufacturer Mfg. Part. No. Cost, Each Cost, Total
No. Qty. D Part No.
E
1 2 Hose Assembly, 1-1/2" 5000 PSI Hose with, GATES/MOTION IND. GATES
1-1/2" Code 62 Flange 90° One End, HERSCH PARKER
1-1/2" Code 62 Straight Flange Other End, 25 Ft. Lg.
(Main Lines, Motor to Power Unit)
Gates : 24G5K-24FLH-24FLH90M-300".
Parker: 78C-6N-6A-24-24-24-300"
2 1 Hose Assembly, 1-1/4" Low Pressure Hose with GATES/MOTION IND. GATES
1-1/4" JIC 37° Straight Swivel One End, HERSCH PARKER
1-1/4" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Drain to Power Unit Drain)
Gates : 20G1(C1T)-20FJX-20FJX90M x 300"
Parker: 381-06-39-20-20-20-300"
4 1 Hose Assembly, 1/2" Low Pressure Hose with GATES/MOTION IND. GATES
1/2" JIC 37° Straight Swivel One End, HERSCH PARKER
1/2" JIC 37° Swivel 90° Other End, 25 Ft. Lg.
(Motor Case Flushing)
Gates : 08G1(C1T)-08FJX-08FJX90M x 300"
Parker: 381-06-39-08-08-08-300"
$2,274.00
NOTES:
Fill up motors all the way with following amount of oil and make
sure all drain and vent ports have metal plugs with o-rings:
Compact CA-50 - 0.53 gallons
Compact CA-70 - 0.66 gallons
Compact CA-100 - 0.98 gallons
Compact CA-140 - 1.32 gallons
Compact CA-210 - 1.80 gallons
Compact CB-280 - 4.0 gallons
Compact CB-400 - 5.6 gallons
Compact CB-560 - 5.0 gallons
Compact CB-840 - 6.6 gallons
HAS10392a.XLS
Bill of Material No.: HAS-10014
Bill Of Material
Date Issued : 10-Mar-1993 Hägglunds Drives, Inc. Latest Rev. : Customer Ref(s) :
Issued By: CBH 2275 International Street; Columbus, Ohio 43228, USA B
Checked By: Phone: (614)-527-7400; Fax: (614)-527-7401; www.hagglunds.com Latest ECN :
TITLE: ECN-00000422 Assembly Ref(s) :
Revised By :
Long Term Storage Flange Kit, 1½" HDR
Used for Goldcup P6, P7, P11, P14 and Hagglunds SP250 and SP355 pumps Rev. Date : Project No. :
11-Apr-2008
C
Item O Hägglunds Description
No. Qty. D Part No.
E
2 NOT USED
4 1 LABOR TO UNCRATE PUMP AND INSTALL PROTECTIVE COVERS AND FILL WITH OIL
NOTE:
Install Items 1, 2 and 5 onto pump and then fill with oil
according to the following chart:
Goldcup P6 & P7 - 0.8 gallons
Goldcup P11 & P14 - 1.6 gallons
Hägglunds SP-250 - 2.6 gallons
Hägglunds SP-355 - 2.1 gallons
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 1(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
Speed encoder SPDB1:
Digital incremental hollow shaft encoder with torque
arm mounting.
MECHANICAL SPECIFICATION
Shaft, Stainless steel Hollow-shaft ø 12mm
Moment of inertia 5,4 x 10-6 kgm2
Load max Same direction as motor
Radial 20 N - clockwise
Axial 10 N
Speed max 6000 rpm
Code disc Unbreakable acrylic glass
Temperature
Operating -25°C...+70°C
Storage -25°C...+70°C
Housing Aluminium, anodized
Weight Approx. 250 g
Protection class IP 65 according to IEC 529
Vibration <100 m/s2 (50...2000 Hz)
Shock <1000 m/s2 (11 ms)
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 2(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
1 inv
2 inv
0 inv
Connection:
Encoder must be connected with shielded cable, max 0.5 mm2 which is to be solded in connector-pins.
The shield connects to connector-shell.
T-contact:
To be used for external measuring.
HD art. no: 378 5043-801
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 3(4)
AC-3.4
04-03-30, Replaces 03-06-12 Accessories, ACB-3.4
F/A converter:
- Frequence to Analogue converter is available as option.
- Analog output signal 4-20 mA.
- F/A-converter must be mounted externally. Technical data
Supply voltage DC 24 V (12-50 V)
HD art. no: 576 4057-001
Power consumption 3W
Operation temp. -20°C...+60°C
Humidity 0-90% RH, non condens-
ing
Temp. coefficient <0,01%/°C
Accuracy better than 0.3%
Resolution 0.1%
Mounting NS35 DIN rail
Size w45 x d70 d h117 mm
Electrical connections
Pulse input:
- Input high Vin > 15 V
- Input low Vin < 6 V
4-20mA output max. output load 500 Ohms
SW1
EMC approval EN 50081-1, EN 50082-2 SW2-1 on
Safety EN 60730 SW2-2 off
LED1 power on
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 4(4)
1 2 3 4 5 6 7 8
+0,009
635 M20 (40x)
68 - 0,021
A +0,00052 (25,000) A
(2,677 -0,00066)
(1,417)
(1,575)
A-A
36
40
1250
(49,213)
1330
(52,362)
1721
(67,756)
B B
R410
(16,142)
(12,070)
C
307
C
A A
19
(0,748) (29 742
,21
3)
D D
therof must not be imparted to a third party
nor be used for any unauthorized purpose.
This document must not be copied without
our written permission, and the contents
B
57 485 429
(2,244) (19,080) (16,890)
(17,717)
(21,457 -0,277)
+0,273
150
E referring to a certain purchase order. E
(5,906)
Information contained herein should be confirmed
before placing orders.
Figures within brackets indicate Item No. Qty Article No. Material, type, etc Dimensions Name of item
according to
SS-ISO 2768-1, class m Scale Preceding drawing no Control code
40
Other not indicated tol. 4 (0,157) SS-ISO 965, class 6.
Other not indicated tol. 1:5
(0,787)
210
Weight: 128 kg / 282 lb (arm) SW A2 Knight/DVN A00A
(8,268) Accepted for prod by Iss by Dept. Year Week Description (Own language) Type design/group
D522/TKN 1
B-B
Rev.Ind. Revision Appd. Year Week
Design checked by
1 TCA 40
1 2 3 4 5 6 7 8
A2 - Landscape ver. 2.0
PBC POWER UNIT MANUAL
Installation and
Maintenance Manual
PBC
Preface Installation and Maintenance Manual, Power Unit PBC
Preface
Hägglunds Drives is one of the world’s leading manufacturers of low speed,
high torque and heavy-duty hydraulic drive systems. We supply a durable
drive system that will work under the toughest conditions with a minimum
level of maintenance requirements. We have industrial and marine custom-
ers all over the world. They know that when they seek solutions, support or
service, they can trust Hägglunds Drives to be there. The Hägglunds Drives
main office and manufacturing plant is located in Mellansel, Sweden. In
addition, there are sales and service offices in 40 countries worldwide.
Our high quality drive systems are based upon our unique hydraulic piston
motors, which were developed through experience accumulated over 30
years in marine and industrial areas. Today this ongoing development work
has resulted in our PBC power unit product line. This is what powers our
drive systems. New, as well as established technical solutions contribute to
the creation of this product. The most desirable features and operating reli-
ability have been designed into this power unit, PBC.
Before starting the installation and/or maintenance, the manual must be read
and thoroughly understood in all respects. All involved personnel shall read
and acknowledge the safety precautions that are stated in section 1.1.
2
Installation and Maintenance Manual, Power Unit PBC Contents
Contents
1. GENERAL ........................................................................................................................ 4
1.1 Safety precautions ........................................................................................................................4
1.2 Operating principle ........................................................................................................................6
2. TECHNICAL DATA .......................................................................................................... 7
2.1 Operating conditions .....................................................................................................................7
2.2 Cooling water ................................................................................................................................7
2.3 Requirements for hydraulic fluid cleanliness .................................................................................7
2.4 Choice of hydraulic fluid ................................................................................................................8
2.5 Power unit monitoring....................................................................................................................9
3. HANDLING OF THE PACKED POWER UNIT .............................................................. 10
3.1 Storage of the packed power unit ................................................................................................10
3.2 Lifting the packed power unit .......................................................................................................10
4. INSTALLATION ............................................................................................................. 11
4.1 Installation directions ................................................................................................................... 11
4.2 Lifting methods and weights ........................................................................................................12
4.3 Positioning the power unit ...........................................................................................................13
4.4 Mounting of the cabinet feet ........................................................................................................14
4.5 Mounting of electric motor ...........................................................................................................14
4.6 Mounting of air-oil cooler and cabinet ventilation ........................................................................15
4.7 Hydraulic connections .................................................................................................................15
4.8 Electric connections ....................................................................................................................16
4.9 Pipe work ....................................................................................................................................16
4.10 Extra filtration prior to start up ...................................................................................................19
4.11 Commissioning......................................................................................................... 20
4.11.1 Prior to commissioning ...........................................................................................................20
4.11.2 Filling up the system with hydraulic fluid .................................................................................20
4.11.3 Initial start up procedure .........................................................................................................22
4.12 Pump settings and adjustments ................................................................................................24
5. PREVENTIVE MAINTENANCE ..................................................................................... 25
5.1 Maintenance log ..........................................................................................................................25
5.2 Maintenance chart .......................................................................................................................25
5.3 Filter change ...............................................................................................................................26
5.4 Inspection of hydraulic fluid .........................................................................................................27
5.5 Lubrication of electric motor ........................................................................................................28
5.6 Air breather change .....................................................................................................................28
5.7 Cleaning of Air-Oil cooler.............................................................................................................29
5.8 Power unit out of service .............................................................................................................29
6. CORRECTIVE MAINTENANCE .................................................................................... 29
6.1 Common ......................................................................................................................................29
6.2 Change of hydraulic pump/electric motor assembly ....................................................................30
6.3 Troubleshooting ...........................................................................................................................31
7. DISPOSING OF POWER UNIT ..................................................................................... 32
3
General Installation and Maintenance Manual, Power Unit PBC
1. GENERAL
1.1 Safety precautions
It is of extreme importance that the safety precautions are always followed. If you are unsure about
anything, please contact your nearest Hägglunds Drives representative for advice.
Warning signs
In this manual, you will find the following signs, which indicate a potential hazard that can or will cause
personal injury or substantial property damage. There are three levels of hazard classification:
DANGER
! DANGER is used to indicate the presence of a hazard, which will
cause severe personal injury, death, or substantial property damage
if the warning is ignored.
WARNING
! WARNING is used to indicate the presence of a hazard, which can
cause severe personal injury, death, or substantial property damage
if the warning is ignored.
!
CAUTION
CAUTION is used to indicate the presence of a hazard, which will or
can cause minor personal injury or property damage if the warning is
ignored.
General
Limit access to the equipment only to authorized personnel. Only perform measures on the PBC when
you are completely familiar with the function of the power unit (including the control system) as well as
the complete drive.
Service and repair of the electrical, hydraulic, and the mechanical functions require professional ser-
vice personnel who are aware of risks involved.
Safety equipment necessary for the prevention of accidents during the mounting and maintenance
must be used in accordance with the regulations prevailing in the local country.
4
Installation and Maintenance Manual, Power Unit PBC General
Prior to troubleshooting
• Use the order code and other attached technical documentation to identify the features of your
unique power unit and system.
• Read the attached technical documentation (this manual included) and make yourself familiar
with the PBC (control system included) as well as the complete drive.
• Use safety equipment like hard hat, protective goggles, safety shoes and hearing protection.
• Always ensure that there is no accumulated energy in the system prior to maintenance.
• Ensure that all electric power is off and locked out.
• Ensure that there is no entrapped pressure in the hydraulic system.
• Ensure that no pressure will enter the hydraulic system in the power unit via the hydraulic motor,
for example loads on the shaft or winch drum.
• If the hydraulic system is used for lift devices such as elevators, winches, etc., these should be
secured, or in the rest position (hanging load).
• Ensure that all accumulators are discharged.
Electricity supply
Safety equipment necessary for the prevention of accidents must be provided in accordance with the
regulations prevailing in the local country.
All electrical supply levels shall be within the limits that the equipment is constructed for, see technical
documentation and maximum rating plates.
Mounting
Carefully follow the instructions and be aware of the large weights and forces involved during lifting.
Incorrect mounting and setting of electrical, hydraulic and the mechanical components can cause
personal injury or property damage.
Before starting up
Before starting up new, rebuilt or serviced drive systems, all accessories and safety arrangement
functions need to be checked and tested.
Maintenance and service
Follow the maintenance intervals for your specific PBC or the maximum intervals on the maintenance
chart (section 5.2 “Maintenance Chart”) and keep a maintenance log. Regular and correct mainte-
nance is necessary for reliable and safe operation.
Only use spare parts recommended and supplied by the Hägglunds Drives organization.
Hydraulic fluid
Be aware that most hydraulic fluids can cause personal injury and severe damage to the environment.
Check the caution sign on the container or consult the supplier. Used hydraulic fluid can contain
noxious contaminates. We recommend using the service of a professional oil company for supply and
disposal of used fluids. Never dump hydraulic fluid into water drainage or water supplies.
Bell housing
Note that there are rotating parts inside the bell housing during operation. Be careful during inspection
through the inspection hole. Replace inspection cover when finished.
Hot surfaces
Temperatures in the hydraulic system above 158° F (70° C) will create hot surfaces.
Emergency situations
Emergency shutdown: It has to be possible to turn off the electric power during an emergency situa-
tion. Only use a fire extinguisher that is approved for use on both oil products and electric equipment.
5
Operating Principle Installation and Maintenance Manual, Power Unit PBC
18
Main components
1. Hydraulic pump AIR
FLOW
2. Drain valve 20
3. Sight glass 19
8
4. Charge pressure gauge
5. Servo pressure gauge
6. Main pressure gauge ‘B’ port
7. Main pressure gauge ‘A’ port
8. Air breather 11
11 6
9. Drain filter 7 4
10. Return filter 5 5
4 7
11. Electric motor 6
12. Filter switch 12 3
6
Installation and Maintenance Manual, Power Unit PBC Technical Data
2. TECHNICAL DATA
2.1 Operating conditions
The standard PBC unit is designed for the conditions listed below. If the requirements are outside of
the conditions listed below, contact your Hägglunds Drives representative with your specific require-
ments for special design considerations.
Ambient temperature: Minimum 32° F (0° C) to a maximum 85° F (30° C).
Altitude: Maximum 3,300 feet (1000 m).
Classified Location: Unit is designed for a standard location. Units can be built for use in
classified hazardous locations. Contact your Hägglunds Drives representative for more details.
If cooling capacity is too low, the service life of hydraulic motor, the main
components in power unit, and the hydraulic fluid will be reduced.
7
Technical Data Installation and Maintenance Manual, Power Unit PBC
150 720
100 RECOMMENDED
VISCOSITY
40 187
VG VG
VG 100 150
46
VG
68
10
0 10 20 30 40 50 60 70 80 90 100
Temperature ºC (measured in the motor case)
8
Installation and Maintenance Manual, Power Unit PBC Technical Data
POWER UNIT
Maximum oil
Temperature switch
1
Minimum oil
Temperature switch
1
Minimum oil
level switch
Closed suction
1 1 STOP HYDRAULIC MOTOR
line switch
1
1s 0s STOP ELECTRIC MOTOR
Low charge Time delay off
pressure switch Time delay on
0s 0.5s
1
5s 0s
&
Time delay on
Warning oil
temperature switch
1
Low oil
level switch
1
Return filter Time delay off
switch
Drain filter
0s 5s
1 1 WARNING INDICATION
Time delay off
switch
0s 5s
1
High pressure Time delay off
switch
0s 5s
1
The monitoring of the power unit switches are grouped in two levels according to the above logic
diagram.
The warning indication is to inform about a problem in the PBC but does not need an immediate action.
The alarm indicates a need for stopping the pump. The stop sequence is to first stop the hydraulic
motor without ramp, by setting the pump swash angle to zero. Furthermore, after a short delay stop
the electric motor.
The low charge pressure switch must be interlocked during stop and start-up of the electric motor, to
avoid alarm and give the pump time to build up the charge pressure after start.
9
Technical Data Installation and Maintenance Manual, Power Unit PBC
If storage time exceeds the above mentioned limits, then the power
unit must be operated so that the hydraulic system is lubricated with
new fluid. (section 5.8 “Power unit out of service”)
!
CAUTION
•
•
Avoid rapid acceleration, deceleration and turns while
moving the equipment.
Position the forks according to the instructions below.
10
Installation and Maintenance Manual, Power Unit PBC Installation
4. INSTALLATION
4.1 Installation directions
If the PBC is to work properly, it must be installed in accordance with these instructions. The conditions
the unit will operate in must be taken into consideration.
Improper installation, not following the instructions in this manual and in the attached technical docu-
mentation, may affect the function and/or the service life of the power unit. It is important that the
safety precautions mentioned in this manual are always followed.
H1
H1
B2 A2 B2
H2
H2
B1 M A1 B1 M
A3 A3
Cabinet Size 1 2 3 4 5
Type PBC 100 PBC 300 PBC 400D
PBC 200D PBC 800
Dimension PBC 200 PBC 400 PBC 600
H1 84 7/8 in. (2156mm) 84 7/8 in. (2156mm) 123 1/2 in. (3138mm) 123 1/2 in. (3138mm) 126 in. (3200mm)
H2 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 1/2 in. (13mm) 3 in. (76mm)
B1 55 1/8 in. (1400mm) 82 5/8 in. (2099mm) 66 in. (1676mm) 105 in. (2667mm) 121 3/4 in. (3092mm)
B2 51 1/8 in. (1299mm) 78 5/8 in. (1997mm) 62 in. (1575mm) 100 in. (2540mm) 117 3/4 in. (2991mm)
A1 39 3/8 in. (1000mm) 39 3/8 in. (1000mm) 53 1/4 in. (1353mm) 53 1/4 in. (1353mm) 53 in. (1346mm)
A2 35 3/8 in. (899mm) 35 3/8 in. (899mm) 49 1/4 in. (1251mm) 48 1/2 in. (1232mm) 48 in. (1220mm)
A3 82 in. (2083mm) 111 in. (2820mm) 96 in. (2439mm) 138 in. (3505mm) 154 3/4 in. (3931mm)
M 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC 5/8-13 UNC
11
Installation Installation and Maintenance Manual, Power Unit PBC
MAX
90˚ O
! •
(check rating plate).
Do not lift the power unit with hydraulic fluid in the tank, or with the
DANGER front bar disassembled.
12
Installation and Maintenance Manual, Power Unit PBC Installation
32 [813mm] 32 [813mm]
FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM FLOOR OUTLINE DISTANCES SHOWN ARE MINIMUM
DANGER
! •
•
beware that the cooler will start without notice and has sharp edges
Beware of airborne particles in the outgoing air flow
If the air-oil cooler becomes loose it can cause severe personal injury.
13
Installation Installation and Maintenance Manual, Power Unit PBC
[25mm-38mm]
1 [13mm]
ADJUSTABLE
Be careful while mounting the
2
2
1
! cabinet feet. Follow the safety
1-1
precautions in section “Lifting
WARNING methods and weights”
14
Installation and Maintenance Manual, Power Unit PBC Installation
!
DANGER
•
•
•
Use all lifting ears when the electric motor is hanging free.
Use only lifting equipment adapted to the weight on the rating plate.
No hands/fingers between electric motor and bell housing during assembly.
!
DANGER
or perform maintenance if the
hydraulic system is pressurized.
2
3
4
PBC 200D
PBC 300/400
PBC 400D/600
1 1/4" SAE
code 61 flange
1" SAE female
5 PBC 800
15
Installation Installation and Maintenance Manual, Power Unit PBC
When sizing hoses and hydraulic piping between the motor and the power unit, a safety factor of at
least 4 times the maximum system pressure should be used for the tensile strength. Keep in mind that
the equipment may be readjusted to higher pressure in duty. Pressure losses in the pipe system
should generally be kept to a minimum but there are exceptions in certain applications. Contact a
Hägglunds Drives service representative for more information.
Hydraulic pipes
The hydraulic pipes should be of high-grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.
Pressure test
A pressure test to 1 1/2 times the maximum working pressure should be performed on the main lines to
check for possible leakage.
Pressure tests on the main lines are best carried out using a hydraulic hand pump.
Hoses
To avoid damage caused by vibrations it is important that the PBC and the motor be connected to
pipes by means of hoses.
The hoses must be short and have the smallest possible diameter in order to obtain a small compres-
sion volume. Nevertheless, allowance must be made for the minimum permissible bending radius
according to the data provided by the supplier of the hose. Allowance must also be made for the flow
velocities listed under “Pipe sizes.”
Pipe flushing
The piping system must be flushed with an adequately sized flushing pump prior to starting up the PBC
unit to remove contamination introduced during assembly and/or welding. Please contact a Hägglunds
Drives service representative for proper cleaning and flushing procedure.
16
Installation and Maintenance Manual, Power Unit PBC Installation
Pipe sizes
It is important that lines between the main connections of the motor and PBC are as short as possible.
This gives the following advantages:
1. Small compression volume in the hydraulic system.
This is particularly important in hydraulic systems with large and rapid load variations, and in
drives, where high speed accuracy is essential.
2. Small power losses in the hydraulic system.
3. Lower installation costs in that smaller pipe sizes and shorter pipe lengths can be used.
For a normal hydraulic system, the total pressure drop in the pressure and return line must
not be more than 5 percent of the normal working pressure.
The following flow rates are recommended values and should not be exceeded:
Main lines 15 ft/s (4.5 m/s) Drain lines 5 ft/s (1.0 m/s)
4. Lower noise level.
In certain systems, where very small compression volumes are required, higher flow rates
are acceptable with possible increase in noise. Contact a Hägglunds Drives representative
in these specific cases.
When dimensioning hose and pipe lengths between the drain connections of the motor and the PBC,
keep in mind that the total pressure drop to the drain connections of the motor must not exceed 14.5
PSI (1 bar). The pressure drop through the PBC is 7.25 PSI (0.5 bar).
Pipe couplings
It is essential that a tight and pressure rated coupling is chosen.
The following types of coupling are recommended:
Non-welded couplings are preferred
Non welded couplings provide the most clean piping installation as compared to a welded pipe system.
Welded couplings (socket or butt type)
When using welded couplings, the pipes should be machined, normalized, and pickled. The pipes
must then be brushed, rinsed internally and blown clean before flushing.
Pipe coupling
Type collar coupling as per SAE J 514.
Pipe clamps
Pipes should be clamped with uniformly spaced clamps.
The distance between the clamps may not exceed 6 ft (2 m) for pipes with outside diameters between
1/2 in. (15 mm) and 1 1/2 in. (38 mm). The distance between the clamps may not exceed 9 ft (3m) for
pipes with outside diameters greater than 1 1/2 in. (38 mm).
In addition, the pipes must be clamped immediately before and after a bend. The pipes must be
clamped immediately before transition to a hose as well.
The pipe clamps shall be secured to a stable and non-vibrating surface such as concrete structure.
The pipe clamps must be of a type permitting a certain amount of axial and radial motion in the clamped
joint and have good vibration-absorbing properties.
17
Installation Installation and Maintenance Manual, Power Unit PBC
DANGER
! Use necessary safety equipment during installation of the pipe system.
Usual safety requirements for each step must be followed.
Handling of fittings
Inspect the sealing surfaces on the couplings visually before mounting. It must be free of any dam-
ages such as scores and cracks. Handle the couplings with care. If you drop the coupling or it has
nicks on it inspect it visually. Check that the seal (if any) is in its right position, free from cracks and that
it is saturated with oil.
The protection and packing on the fittings must be kept on until final assembly.
18
Installation and Maintenance Manual, Power Unit PBC Installation
O
4.10 Extra filtration prior to start up
HYDRAULIC MOTOR
A pressure filter and check valve has to be con-
nected to the main line at the power unit. This
filter is connected on the return side of the drive Hoses
pump. connected
together
Recommended filtration degree ß10 = 75 or bet-
ter. Flow Direction
19
Installation Installation and Maintenance Manual, Power Unit PBC
4.11 Commissioning
4.11.1 Prior to commissioning
• Read and understand this complete manual and the other attached technical documentation.
• Visually check the whole system for signs of damage, incorrect circuitry, security of foundations,
and that the degree of filtration of the filters are according to the data in the technical documen-
tation.
• Check that the coupling between the electric motor and pump is properly mounted.
• Check that the pre charge pressure in the accumulator (optional) is in accordance with the
technical documentation.
Cleanliness
• The hydraulic system must be flushed and thoroughly cleaned on the inside.
• If you are uncertain about the cleanliness of the system, it must be checked prior to filling with
oil.
Pipe work
• Are the couplings properly tightened?
• Is the pipe work properly cleaned?
• Is the pipe work mounted free of stress?
• Are the lines in accordance with installation drawing/piping plan?
Electrical System
• Check that electric motor(s) and control system and other electrical components are connected
to the correct voltages.
• Check the function of electrical components and monitoring system manually. Instruments that
cannot be actuated can be checked for correct wiring and possibly operated manually. Level
switch and indication should be checked when filling the tank.
20
Installation and Maintenance Manual, Power Unit PBC Installation
Filling
Use a fluid filling pump unit, which has a filter with a filter rating of 10 microns, or better.
New fluid is normally not filtered and will introduce dirt into the system, the
fluid must therefore always be filled through a filter. Never pour hydraulic
fluid into the tank through the air breather filter.
Always pump the fluid in through the quick connection that is marked appropriately. The quick connec-
tion is a completely rustproof quick release coupling, see figure below. The fluid filled into the system
will be filtered through the drain filter for better results.
The tank must be filled with oil to 0.79 in. (20 mm) below the maximum level on the visual level gauge
on tank before starting for the first time.
Check the function of the level switch and indication during filling up of the tank.
RETURN FILTER
OIL FILL
CONNECTION
PUMP/MOTOR CASE
DRAIN FILTER
OIL HEATER
After filling the system with fluid, open the drain line and reconnect the drain line from the hydraulic motor.
• Check caution sign on container and the warnings (section 2.4 “Choice
of hydraulic fluid”).
!
WARNING
•
•
Avoid prolonged contact of hydraulic fluid with your skin.
Clean hydraulic fluid spills from floors immediately to prevent personal
injury.
21
Installation Installation and Maintenance Manual, Power Unit PBC
22
Installation and Maintenance Manual, Power Unit PBC Installation
23
Installation Installation and Maintenance Manual, Power Unit PBC
DANGER
! could be dangerous in case of
unforeseen failures.
CHARGE PRESSURE
ADJUSTMENT
COMPENSATOR
CHARGE PRESSURE VALVE
ADJUSTMENT
View from the back View from the back Front view
Charge pressure and Pump compensator pressure level are set before the PBC leaves the factory and
consequently there is normally no need for readjustment. Always check the pressure levels in techni-
cal documentation. Professional service personnel familiar with the functions and risks involved
with the pump must perform setting of pressures on the pump(s). The pressures shall be set
during operation and with the system at operating temperature. Note that pressures can change with
different viscosity.
1. Charge pressure adjustment: Remove acorn nut, loosen lock nut and adjust pressure with a
5/32" size Allen key. Clockwise adjustment will increase the pressure. The charge pressure (on
the charge pressure gauge) shall be within the following limits: 218 psi (15 bar) for P6S/ P7S &
P11S/P14S & P24S and 261 psi (18 bar) for P30S.
If other charge pressures are to be set, contact a Hägglunds Drives representative for consultation.
2. When charge pressure is set: Tighten lock nut and return acorn nut. Note in the logbook or
other technical documentation.
3. If the main pressure levels are to be increased: Make sure that the piping and machine
structure can take higher pressure/higher torque delivered from the hydraulic motor.
4. Compensator pressure adjustment: Dead head the pump, then activate or move the input
signal to the control so that pressure increases in the high pressure closed circuit to the pressure
limiter setting. The pressure limiter setting is reached when the pressure stops increasing and
remains steady at a given pressure level. (As shown on the gauges)
The pressure limiter setting for both A- and B-side is set on the compensator valve.
Remove acorn nut, loosen lock nut and adjust pressures with a 5/32" size Allen key, until the desired
pressure level is established. Clockwise rotation of the adjustment screw will increase the pressure.
5. When main pressures are set: Tighten lock nut and return acorn nut. Note the new pressure
level in logbook or technical documentation.
24
Installation and Maintenance Manual, Power Unit PBC Maintenance
5. PREVENTIVE MAINTENANCE
5.1 Maintenance log
We recommend that a maintenance log be kept to record service/maintenance/repair, addition and
alteration of the equipment. Each note, observation or comment should be dated.
25
Maintenance Installation and Maintenance Manual, Power Unit PBC
Scheduled maintenance
Planned maintenance at specific time intervals, including the following checks and actions:
• All points listed under frequent checks.
• Check all pressure levels.
• Check for stable temperature levels around the system.
• Drain water and sludge from the tank at the drain tap.
• Check the electric motor.
• Check the function of monitoring equipment/switches, etc.
• Clean areas where dirt is building up.
Note: never use a high pressure washing system to clean the power unit.
• Check the cables.
• Check accumulators (optional) for correct pre-charge.
• Check drain line flows and drain line oil condition.
• Check the hoses, couplings and pump(s), with regards to cracks, leaks and condition.
• Check the shaft coupling through the inspection hole. Warning, rotating parts inside the
inspection hole.
• Check the flow of cooling water.
26
Installation and Maintenance Manual, Power Unit PBC Maintenance
Duplex filter
1. Press in the pressure-equalizing lever on the underside of the switching lever and hold it, see
figure below.
2. Engage the switching lever and move to the other side.
3. Loosen the vent screw, only on the side where the filter is to be changed, (see picture below) 2-3
turns.
4. Remove the filter bowl and change filter cartridge.
It is very important during the mounting not to expose the cartridge to any dirt, therefore keep
it in the plastic cover as long as possible.
Check the O-ring and the backup ring for damage. Change parts if necessary.
5. Mount the filter bowl. Tighten by hand to stop and back off 1/8th of a turn.
6. Refill the filter by pressing the equalizing lever and hold it there until the vent screw bore is
bubble free.
7. Tighten the vent screw. Check the filter for leaks by pressing in the equalizing lever again.
Vent screws
Pressure
• There are dangers associated equalizer
with hydraulic fluid. lever
• Store used hydraulic fluid
! and contaminated filter ele-
ments for proper disposal.
In this
position
you can Switching
lever
CAUTION • The fluid may be hot if the change
cooling is insufficient. this
element
27
Maintenance Installation and Maintenance Manual, Power Unit PBC
!
CAUTION
Check the warning label
on the grease cartridge. Frame
size
Lubrication schedule for electric motor (60 Hz)
Electric motor
HP (kW)
Lubrication
intervals
Volume of
grease
28
Installation and Maintenance Manual, Power Unit PBC Maintenance
Follow the safety precautions on the container of the cleaning agent used.
! Disconnect the power unit before disconnecting the Water-oil/Air-oil cooler.
Make sure that electric power is cut off before cleaning! Cleaning agent
WARNING and waste water from rinsing should be disposed of in accordance to pre-
vailing local regulations.
6. CORRECTIVE MAINTENANCE
6.1 Common
Before removing any hydraulic/electric components, disconnect the power unit. Ensure that no energy
is accumulated in the system and the power is disconnected from the electric motor. Follow recom-
mended safety procedures.
Before disassembly
• Troubleshoot the PBC and perform appropriate tests.
• Clean all assemblies and components, take all precautions necessary to prevent dirt entering
the system.
• Disassembly may only be done by professional service personnel.
29
Corrective Maintenance Installation and Maintenance Manual, Power Unit PBC
Disassembly
• Label all parts, and protect precision or machined surfaces.
• Inspect all parts during disassembly for wear or damage.
• If hydraulic fluid is to be drained and reused, make sure that drain containers are clean and
covered when not in use.
• Clean all metal parts using a suitable solvent prior to reassembly, set aside on a clean and lint
free cloth to drain.
Reassembly
• Lubricate with system hydraulic fluid.
• Replace all seals, gaskets and o-rings with new items of the correct size.
• Ensure complete sealing at pipe connections.
• Refill hydraulic fluid according to recommendations (section 4.11.2 “Filling up the system with
hydraulic fluid”).
• Always use all four lifting points when lifting the electric
motor/pump unit.
• Never use the lifting ears on the electric motor to lift the
!
DANGER
•
complete electric motor/pump unit.
Use only lifting equipment adapted to the weight (section 4.2
“Lifting methods and weights”).
• Do not stand underneath hanging load
• Take center of gravity into consideration during lifting.
30
Installation and Maintenance Manual, Power Unit PBC Troubleshooting
6.3 Troubleshooting
Pump/Motor baseplate
shipping bolts still installed Remove shipping bolts
31
Troubleshooting Installation and Maintenance Manual, Power Unit PBC
!
DANGER
•
•
•
The components may contain accumulated energy.
Take fire hazards into consideration during dismantling.
The accumulator (optional) must be empty and discharged.
32
AM326-1A Printer : Precision Printing 1999
Figure: M300
Threaded Ends Meets ANSI/NSF 61 Section 8
Non-rising Stem (1998)
Solid Wedge Disc and
California Proposition 65
Rating:
125 psi WSP
200 psi WOG
Figure: M300S
Sweat Ends
Non-rising Stem
Solid Wedge Disc Meets ANSI/NSF 61 Section 8
(1998)
Available with Waste and
(specify Fig. M300SW) California Proposition 65
Dimensions:
1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
A Center of Port to Top 3 3 1/16 3 3 1/2 4 1/16 4 3/4 5 3/16 6 3/16 7 l/2 9 10 1/4
B End to End 1 5/8 1 5/8 1 11/16 1 7/8 2 3/16 2 3/8 2 7/16 2 13/16 3 1/2 4 4 9/16
B1 End to End 1 5/8 1 3/4 2 3/8 2 3/16 3 1/16 3 1/16 4 1/8 4 3/4 4 3/4
C Overall Height 3 1/2 3 1/2 3 9/16 4 1/4 5 5 3/4 6 3/8 7 5/8 9 1/2 11 1/8 13 1/8
D Wheel Diameter 2 1/8 2 1/8 2 1/8 2 1/8 2 3/8 2 7/8 2 7/8 6 3/4 5 4 l/4 3 1/4
Weight lbs. Thd. .55 .53 .56 .81 1.10 1.80 2.l0 3.20 7.00 9.60 17.0
Weight lbs. Swt. .48 .51 .75 1.10 1.70 2.00 3.10 6.80 9.40
CABINET FEET
TF
Features
The TF mounting is installed in minutes by following the
instructions provided. There is no need to fix the machines
to the floor since the rubber base of the mounting keeps
the machine in place. Whenever necessary, the machine
can easily be re-positioned. The level is adjusted with load
applied.
Novibra® type TF
Novibra® type TF with level adjuster is suitable for a wide
range of free standing workshop machines, e.g.
• Lathes
• Milling machines
• Grinding machines G
• Multiple operation machinery
• Presses
• Plate shears
• Nibbling machines
• Punches and cutters
• Woodworking machines
• Plastic moulding machinery H
68 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
TF
Loading range per mounting (kg)
Mounting instructions
1 2 3
TFE
Mounting TFE is a simpler version of type TF without Both models also available in S/S
level adjuster. It is used for machines which do not require (ISO 2604/11,BS 3605:1 )
height adjustment or where such a feature is already pro-
vided, e.g. by an adjusting screw in the machine.
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 69
ISOLATION MOUNTS
Bobbins
Trelleborg Industrial AVS - Bobbins
A supplementary range of cylindrical mountings for a wide Manufactured in natural rubber hardness 40° IRH or
range of applications. They can be loaded either in com- 60° IRH.
pression or shear taking into consideration individual de-
mands for actual applications.
82 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
Bobbins
G ØD
L H
A 40/20 M8x20 318840 318850 275 632 34 170 534 1226 75 369
A 40/25 359 1076 58 369
A 40/30 M8x20 318860 318870 130 481 21 170 271 1002 47 369
A 40/40 M8x20 318880 318890 86 437 16 170 184 935 34 369
A 50/20 M10x25 318900 318910 564 1248 56 265 1042 2306 122 577
A 50/25 M10x25 318920 318930 335 976 42 265 652 1900 93 577
A 50/30 M10x25 1861540 1255870 234 846 34 265 472 1706 75 577
A 50/35 M10x25 318940 318950 180 774 29 265 371 1598 62 577
A 50/40 M10x25 318960 1255340 146 730 25 265 306 1533 54 577
A 50/45 M10x25 318970 1255880 123 701 22 265 261 1490 47 577
A 50/50 M10x25 318980 1255350 106 681 19 265 228 1460 42 577
A 75/40 M12x35 319000 319010 417 2032 57 596 827 4030 124 1299
A 75/50 M12x35 319020 319030 282 1766 44 596 579 3632 97 1299
A 75/55 M12x35 319040 319050 242 1689 40 596 504 3517 87 1299
A 100/40 M16x45 319060 319070 932 4541 102 1060 1755 8549 221 2309
A 100/55 M16x45 319080 319090 496 3455 71 1060 994 6929 155 2309
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 83
Bobbins
S
G ØD
L H
84 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
Bobbins
S
G ØD
60° IRH
Type D/H G(S) Art.No. Compression load Shear load
60° IRH
kcomp Fmax kshear Fmax
(N/mm) (N) (N/mm) (N)
C 15/15 M4(4) 1256210 86 112 13 52
Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design and specification of our products without prior notification or alteration of literature 85
Bobbins
G
Type D Type E
L G
H H
ØD ØD
Compression load
Type D/H GxL Art.No. Art.No. 40° IRH 60° IRH
40° IRH 60° IRH Fmax Fmax
(N) (N)
D 10/10 M4x10 319390 59
G(S)
E 30/17 M8(8) 1256930 1661280 225 500
E 50/20 M10(10) 319600 1700
E 50/36 M10(10) 1659990 319610 550 1100
E 50/45 M10(10) 1659870 1000
86 Trelleborg Industrial AVS operates a policy of continuous improvement and development. We reserve the right to change design an d specification of our products without prior notification or alteration of literature
P6S, P7S & P8S PUMP MANUAL
DENISON HYDRAULICS
goldcup series
closed circuit piston pumps
P6, P7, P8S
service information
Publ. S1-AM025-A
PAGE
installation 3
typical characteristics 3
fluid connections 4
general 5
description 5
mounting 5
shaft information 5
piping 5
service information 5
recommended fluids 5
viscosity 6
viscosity index 6
temperature 6
alternate fluids 6
maintenance 6
fluid cleanliness for new installation 6
start-up procedure 6
comparison of solid contamination classification system 7
troubleshooting 7
assembly tool drawings, T1, T2, T3, T4, T5 9
disassembly 11
rework of wear parts 12
assembly 13
drive shaft and bearing 13
barrel and auxiliary drive shaft 13
rocker cam 15
pistons and shoes 16
mounting flange, cam & cradle 16
housing 17
housing, end cap, cam and barrel 17
port block 18
mounting port block to housing 18
gerotor and barrel holddown 19
valve block (before 7-93) 20
valve block (after 7-93) 22
valve block for special mounting of servo valve (before 7-93) 26
valve block for special mounting of servo valve (after 7-93) 29
output controls 32
input controls 32
shaft and seal installation 33
mechanical shaft seal assembly procedure 33
counter-balance servo stem 34
rear drive adapter 34
pilot valve 36
shuttle valve 36
shuttle valve mounting 37
important instructions 38
instructions for replenishing circuit isolation plug 38
hydraulic circuit 40
test procedure 41
general requirements 41
basic pump test 41
(refer to manual S1-AM030 for controls service information)
ordering code 43
seal kits
complete S23-15092
valve block S23-00135
HI-IQ valve block S13-04226
shaft seal replacement S23-44302
shaft seal 623-00006
shuttle valve S23-15089
2
INSTALLATION
• shaft-spline SAE C C C
keyed
Note: Any SAE-A or B mount pump may be used with the appropriate external drive
3
INSTALLATION
4 Revised
INSTALLATION
GENERAL The DENISON HYDRAULICS Goldcup 6, 7, and 8 axial piston pumps feature advance
design concepts which are time proven and provide for advance pumping and control
concepts. The instructions contained in this manual cover complete disassembly and
reassembly of the unit. Before proceeding with the disassembly or reassembly of any
unit, this manual should be studied in order to become familiar with proper order and
parts nomenclature.
DESCRIPTION The use of a rocker cam to control the pump displacement provides a small package
size, reduces wear, and speeds control response. The control vane actuator eliminates
linkage and backlash inherent in typical stroking cylinder designs.
Standard controls for the Goldcup units are Rotary Servo and Compensator Override.
Additional optional controls are also available.
MOUNTING This pump is designed to operate in any position. The mounting hub and four bolt mount-
ing flange are in full conformance with SAE standard. The pump shaft must be in align-
ment with the shaft of the driven load and should be checked with a dial indicator. The
mounting pad or adaptor into which the fluid pump pilots must be concentric with the pump
shaft to prevent bearing failure. This concentricity is particularly important if the shaft is
rigidly connected to the driven load without a flexible coupling.
SHAFT INFORMATION Splined: The shafts will accept a maximum misalignment of 0.006" TIR (.15 mm).
Angular misalignment at the male and female spline axes must be less than ±.002” per
inch radius (.002 mm per mm radius). The coupling interface must be lubricated. DENI-
SON HYDRAULICS recommends lithium molybdenum disulfide or similar grease. The
female coupling should be hardened to 27-45 Rc and must conform to SAE-J498B
(1971) Class 1 flat root side fit.
Keyed: High strength heat treated keys must be used. Replacement keys must be hard-
ened to 27-34 Rc. The key corners must be chamfered .030"-.040" (.75-1 mm) at 45° to
clear radii that exist in the keyway.
Splined or Keyed: Both types of shafts will accept a side load of 170 lbs. (77 kg) at the
center of the spline or key, with a B10 life of 10,000 hours at 1800 RPM.
PIPING Connect inlet and outlet lines to the port block of the pump.
The maximum case pressure is 75 PSI (5.17 bar) continuous, 125 PSI (8.6 bar) inter-
mittent. Case pressures must never exceed inlet pressure by more than 25 PSI (1.7 bar).
When connecting case drain line make certain that drain plumbing passes above high-
est point of the pump before passing to the reservoir. If not, install a 5 PSI (.3 bar) case
pressure check valve to be certain the case is filled with oil at all times.
The case leakage line must be of sufficient size to prevent back pressure in excess of 75
PSI (5.7 bar) and returned to the reservoir below the surface of the oil as far from the
supply suction as possible. All fluid lines, whether pipe, tubing, or hose must be adequate
size and strength to assure free flow through the pump. An undersized inlet line will pre-
vent the pump from reaching full speed and torque. An undersized outlet line will create
back pressure and cause improper operation. Flexible hose lines are recommended. If
rigid piping is used, the workmanship must be accurate to eliminate strain on the pump
port block or to the fluid connections. Sharp bends in the lines must be eliminated wher-
ever possible. All system piping must be cleaned with solvent or equivalent before
installing pump. Make sure the entire hydraulic system is free of dirt, lint, scale, or other
foreign material.
Caution: Do not use galvanized pipe. Galvanized coating can flake off with
continued use.
SERVICE INFORMATION These hydraulic products are designed to give long dependable service when properly
applied and their systems properly maintained. These general instructions apply to typi-
cal systems. Specific instructions for particular equipment can be developed from them.
RECOMMENDED FLUIDS See DENISON HYDRAULICS bulletin SPO-AM305 for more details.
5 Revised
INSTALLATION
FILLING CASE It is essential to make certain that the case (pump housing) is as full of fluid as possible
and remains full during operation and at rest.
Always fill to the highest available point. Remove a plug or screw and allow the oil to
escape through this point.
MAINTENANCE This pump is self-lubricating and preventative maintenance is limited to keeping system
fluid clean by changing filters frequently. Keep all fittings and screws tight. Do not oper-
ate at pressures and speeds in excess of the recommended limit. If the pump does not
operate properly, check the Trouble Shooting Chart before attempting to overhaul the
unit. Overhauling is relatively simple and may be accomplished by referring to the
Disassembly, Rework Limits of Wear Parts and Assembly Procedures.
FLUID CLEANLINESS Fluid must be cleaned before and continuously during operation by filters that maintain a
cleanliness level of NAS 1638 Class 8.
START UP PROCEDURE • Read and understand the instruction manual. Identify components and their function.
• Visually inspect components and lines for possible damage.
• Check reservoir for cleanliness and drain and clean as required.
• Check fluid level and fill as required with filtered fluid at least as clean as that recom-
mended. Fill pump case with clean oil prior to starting.
• Check alignment of drive.
• Check oil cooler and activate it, if included in circuit. Check fluid temperature.
• Reduce pressure settings of relief valve. Make sure accurate pressure readings can be
made at appropriate places.
• If solenoids in system, check for actuation.
• Start pump drive. Make sure pump and motor fill properly.
• Bleed system of air. Recheck fluid level.
• Cycle unloaded machine at low pressure and observe actuation (at low speed, if
possible).
• Increase pressure settings gradually in steps. Check for leaks in all lines especially in
pump and motor inlet lines.
• Make correct pressure adjustments.
• Gradually increase speed. Be alert for trouble as indicated by changes in sounds, sys-
tem shocks and air in fluid.
• Equipment is operational.
6 Revised
TROUBLESHOOTING
TROUBLESHOOTING Component problems and circuit problems are often inter-related. An improper circuit
may operate with apparent success but will cause failure of a particular component with-
in it. The component failure is the effect, not the cause of the problem.
This general guide is offered to help in locating and eliminating the cause of problems by
studying their effects:
7
TROUBLESHOOTING
8
ASSEMBLY TOOL DRAWINGS
T-1
MATERIAL
CRS 1" DIA. X 2 5/8"
(25.4mm) (66.68 mm)
T-2
9
ASSEMBLY TOOL DRAWINGS
T-3
T-4
T-5
Material:
OHTS 5 5/8 x 1 1/4 DIA
(130.17) x (31.75)
Hardened Tip RC 58-62
Note: Dimensions in ( ) are mm.
10
UNIT DISASSEMBLY
INTRODUCTION The instructions contained in this section cover a complete teardown of the subject
pump. Disassemble only as far as necessary to replace or repair any worn parts.
DISASSEMBLY Position pump unit so that valve block assembly is on top. A bench or similar suitable sur-
face capable of supporting unit should be used. Disassembly area should be clean.
VALVE BLOCK See figure 14. Remove the eight hex. head cap screws (17) and lift the entire block
assembly from the port block.
See figure 12/13. Remove the four hex. head cap screws (58) and four soc. hd. screws
(53) and lift the entire block assembly from the port block.
(before 7-93) See figure 10. Remove the four screws (39) to separate the cover (21) from the block
(11). Do not remove the check valves (19).
Remove plugs (43), (36) and pin (40). Remove the 8-32 nut from the bottom of cover (21)
to remove filter assembly (34).
Remove housing (29) and O-ring (28). Remove items (30), (31), (32) and (33) as a unit.
Insert a small brass rod thru the hole in the housing and tap out piston (27) and O-ring
(26).
Remove spring (25) and cone (24). Remove seat (23) and O-ring (22).
Note: Seat is made for hex. wrenching. Use 1/2" six point socket with 1/4" drive.
Remove O-ring (37) and replenishing relief valve (41). Inspect orifices (12) visually to
insure they are open. Do not remove unless damage or clogging is apparent.
Remove springs (16), (17) and (18). Remove retainer (15) and poppets (13) and (14).
Remove the four screws (4) from the plate (6) and (11). Remove gasket (7).
Remove seats (8) and (9). Do not remove roll pins (5) and (10) unless replacements are
needed.
(after 7-93) See figure 11. Remove plugs (20), (23) and pin (21). Remove the 8-32 nut from the bot-
tom of block (1) to remove filter assembly (14). Do not remove the check valves (2).
Remove housing (8), O-ring (9), piston seal (10), O-ring (11), screw (6), nut (7), and
acorn nut (45) as a unit.
Remove spring (12) and cone (13). Remove seat (5) and O-ring (4).
Note: Seat is made for hex. wrenching. Use 1/2" six point socket with 1/4" drive.
Remove O-rings (37), (48) and (47). Remove four screws (43) and remove the retainer
plate (42). Do not remove roll pins (46) unless replacements are needed.
Remove gasket (29) and seats (27) and (28). Remove poppets (30), (31) and springs
(32), (33), (35) and retainer (34).
Inspect orifices (3) visually to insure they are open. Do not remove unless damage or
clogging is apparent.
CONTROLS See figure 14. Remove the four screws (14) from the side cover (16) and remove the
input shear seal valve assembly
Note: The myltite washers (13) should be replaced at assembly.
Remove the four screws (14) from the side cover (15) and remove the counter balance
shear seal assembly.
Remove the two screws (12) and remove the balance stem (9) and balance plate (10)
EXTERNAL PUMP, SHUTTLE See figure 14. Remove two screws (20) and remove external pump (21).
VALVE AND REAR ADAPTER
Remove four screws (23) and remove shuttle valve (24).
BARREL HOLDDOWN AND See figure 9. Remove retainer ring (16), pin (14), holddown nut (13), insert (15), thrust
GEROTOR ASSEMBLY washers (10), bearing (11) and seal ring (12).
Remove pressure plate (9), Gerotor side plate (5) “O” rings (7) and (8).
Remove Gerotor assembly (3), dowel pin (4), key (2), and side plate (1).
11
UNIT DISASSEMBLY
PORT BLOCK See figure 8. Remove four screws (1) that secure the port block (2) to the housing (6). Use
caution when removing screws on valve block side to prevent marring valve block face.
Remove port block (2) and gasket (5). Remove port plate (4) and port plate pins (3).
Note: port plate will in some instances adhere to port block upon disassembly.
See figure 7. Remove the check valve assemblies (7) from the port block.
Remove two screws (5), lockwashers (6), check rings (3), and clamps (4). Only one
check ring assembly in open circuit pumps.
BARREL AND AUXILIARY SHAFT Remove face plate (2, fig. 6) from face of barrel assembly.
BARREL AND AUXILIARY SHAFT
Remove the barrel assembly (1, fig. 4) by grasping the auxiliary shaft and lifting the com-
plete assembly out of the housing.
DRIVE SHAFT See figure 14. Remove the four screws (8) and gaskets (7). Remove seal retainer (6),
and the stationary part of the shaft seal (4). Refer to view of item 4.
Carefully remove the carbon ring and the remainder of the shaft seal from the shaft.
Caution: Do not scratch seal surface of shaft when removing seal.
Remove snap ring (3) and the shaft and bearing assembly (1). Remove shim (2).
HOUSING After shaft assembly has been removed, position the unit on end with the mounting
flange turned down.
Push the ends of the small tube lines away from the housing.
Lift the housing from the mounting flange, remove the gasket, and dowel pins from the
mounting flange.
Do not remove the roll pins and the bearing from the housing unless the bearing is dam-
aged and must be replaced.
ROCKER CAM AND CONTROL See figure 4. Remove the complete assembly (5) from the mounting cap (7) and posi-
STROKING ASSEMBLY tion on a clean flat surface with the two tubes (2) in a horizontal position and located at
the top. Mark the cam (24) and cradle (20) as indicated in Figure 3. These marks will
determine positioning of parts during reassembly.
Carefully remove the small tube lines (3) and (4) from the cradle.
Caution: Do not bend these lines
See figure 3. Position the assembly in an upright position on the flat surface of the cra-
dle (20). Remove the retaining ring (1) and thrust washer (2). Remove the piston and
shoe assembly (4) and the creep plate (5) from the cam (24). Carefully remove the two
set screws (6a) and two screws (6) that secure the servo plate to the cam (24) and
remove the servo input parts (7, 8 and 9).
Remove the four 7/16" screws (10) and eight 1/4" screws (11) and (12) from the control
covers (15R) and (15L). Remove the four dowel pins (16) and remove the two chambers
(17). Remove the two special seals (18) and the four steel balls (19). Remove the two
vane seal cartridge assemblies (23) and the four holddown vanes (22) from the rocker
cam (24).
Note: Some units may have thin shims under the holddown vanes.
12
UNIT DISASSEMBLY
IMPORTANT:
The port plate both faces finish must be 25 microinches (635 mm), flat within .00006
(0015 mm) and parallel within .001(0254 mm) T.I.R.
The creep plate wear face finish must be 10 microinches (254 mm), flat within .0002
(0381 mm) and parallel to the backside within .0005 (0127 mm)T.I.R.
The shoe retainer wear face finish must be 32 microinches (813 mm), and flat within
.0015 (0381 mm) (must not be convex).
The piston shoes wear face finish must be 5 microinches (127 mm), and must be lapped
in a set with the retainer plate, all shoe sole thicknesses to be within .001 (0254 mm) after
lapping. The maximum permissible shoe and piston axial looseness is .010 (254 mm).
The special retaining ring service kit (S23-12461) may be required to control shoe
holddown clearance.
13
ASSEMBLY PROCEDURES
CLEANING AND INSPECTION All parts must be inspected and be free of material defects, dirt, scratches or any foreign
material.
All parts must be cleaned with a suitable cleaning solvent and all holes and passages
blown out with dry, clean, compressed air.
After cleaning and inspection, all parts must be covered with a light film of oil and pro-
tected from dirt and moisture. Excessive handling of internal parts should be avoided
prior to assembly.
During assembly, lapped and ground surfaces must be lubricated with clean oil and pro-
tected from nicks or surface damage.
DRIVE SHAFT AND BEARING See figure 1. Pass one retaining ring (3) over the internal end of drive shaft (1) and install
in the groove near the shaft seal surface.
Caution: Do not pass the ring over the seal surface.
Press the bearing (2) over the same end of the shaft and seat against the ring.
Support only the inner race of the bearing and press on the coupling end of the shaft.
Caution: Do not use excessive force and distort or damage the retaining ring.
Install the other retaining ring (3) in the other retaining ring groove. Be sure that both
rings are fully seated.
quantity
item description part no. #3 #2
1 #3 (splined shaft) 033-70567 1 -
#2 (keyed shaft) 033-70579 - 1
Figure 1 2 shaft bearing 230-82140 1 1
3 retaining ring 033-70817 2 2
4 square key 5/16 x 1-1/4 033-71348 - 1
BARREL AND AUXILIARY See figure 2. Position the barrel (1) in a press with the large end turned down and insert
DRIVE SHAFT tool figure T-1 in the splined shaft hole in the barrel.
Place stop (3) and spring (4) over shaft (2) in the same sequence as shown.
Insert shaft (2) in barrel (1) and rest on tool figure T-1. Position the spring retainer (5) over
the shaft (2) and against spring (4).
Carefully place tool figure T-2, with the large end of the tapered hole up, over the shaft
(2) and against the barrel face (1). Insert ring (6) around the shaft (2) and in the tool.
Position the ring with the gap within 5/8" (16 mm) of the notch in the barrel for easy
removal.
Place tool figure T-3 over the shaft (2) with the small end against ring (6). Press on the
end of the assembly tool and seat the ring (6) in the groove of the barrel (1).
Remove the assembly tools. Check to be sure that the ring is properly seated. Check bar-
rel face to be certain it is not marred.
quantity
item description part no. P6 P7 P8
1 barrel & sleeve ass’y (P6) S13-43657 1 - -
Figure 2 barrel & sleeve ass’y.(P7) S13-47511 - 1 -
barrel & sleeve ass’y (P8) S23-12718 - - 1
2 auxiliary drive shaft 033-91050 1 1 1
3 stop 033-53944 1 1 1
4 barrel holddown spring 033-70493 1 1 1
5 spring retainer 033-53945 1 1 1
6 retaining ring 033-70494 1 1 1
14
ASSEMBLY PROCEDURES
*Note: Item 10 through 24 can be ordered as a complete rocker cam & control stroking
assembly.
S23-12196 is for RH pumps
S23-12197 is for LH pumps
15
ASSEMBLY PROCEDURES
ROCKER CAM/PISTONS
AND RETAINER
Marks Designate
Top of Assembly
Figure 3
Note: Install items 6, 7, 8, and 9 on side shown of rocker
cam if pump model number has “B” suffix. Install on
opposite side if “A” suffix.
ROCKER CAM See figure 3. Position the cradle (20) on a clean flat surface with the large flat area down.
Position the rocker cam (24) on the cradle (20). Note marks made earlier to indicate top
of rocker cam & cradle.
Place O-ring (23c) around spacer (23d) and insert in the vane seal (23b).
Insert check valve (23e) inside of spacer (23d) and assemble between the two backup
plates (23a) with the notched V’s exposed.
Install assembled cartridge in slot in cam as indicated in Figure 3. Repeat steps 1, 2 and
3 on other side of cam.
Insert the four holddown vanes (22) in the slots on each side of the control vanes (23).
Position both control chambers (17) on a clean flat surface with seal grooves turned up.
Drop the four steel balls (19) in the four counterbored holes at each end of the seal
grooves.
Lubricate seals (18) and insert in seal grooves in control chamber (17).
The tapered side of the seals must be pushed into the grooves and the ends must cover
the steel balls.
Install the control chamber (17) with seal (18) and steel balls (19) assembled over the
control vane (23). The seal must be against the cam. Rotate the chamber until it passes
over the control vane assembly, then rotate in the opposite direction until the 1/4" dowel
pins (16) can be pushed through the chamber (17) and into the cradle (20). Install cham-
ber in the same manner on the other side of the cam.
Two sets of chamber covers are available. The set marked CW must be installed in the
right hand rotation pump and the set marked CCW must be used in the left hand rota-
tion pump. (Rotation is determined facing the shaft end of pump.) The covers must be
installed with the tubing holes and the tapped holes at the top of the unit. Install cham-
ber covers (15r) and (15l) on the control chambers (17) over the dowel pins (16). The
tapped holes must be at the top. Refer to the “T” marked on the rocker cam (24) and cra-
dle (20).
Install four 1/4-20 screws, two (11) and two (12), in each side and torque to 10 ft.-lbs.
(13.56 Nm)
Install two 7/16-14 screws (10) in each side and torque to 45 ft.-lbs. (61.0 Nm)
16
ASSEMBLY PROCEDURES
ROCKER CAM Install tubes (25) in reamed holes in each cover. These tubes must be a tight fit. If tubes
(continued) are loose, the ends can be expanded with a tapered punch.
Install servo plate with the end of the screws (6) through the servo stem. The orifice
screw end of the servo stem must be against the servo plate.
Position the stem and plate on the rocker cam input side at 9 o’clock position on “B” suf-
fix or 3 o’clock on “A” suffix models with the screws positioned over the 10-24 tapped
holes. Torque the screws (6) to 40 in. lbs. (4.5 Nm). Install setscrews (6a) and torque to
5 ft.-lbs. (6.8 Nm). Caution: The set screws must not protrude from the servo plate.
Install creep plate (5) over center post on rocker cam with small O.D. of plate turned
toward cam.
PISTONS AND SHOES See figure 3. Insert the seven piston and shoes (4b) in the shoe retainer (4a). Position
the assembly (4) over the center post and against the creep plate.
MOUNTING, FLANGE, CAM & Five different retaining rings (1) are available for the holddown assembly. Each ring is
CRADLE, BARREL marked; white dot .087 (2.21 mm) thick, blue dot .085 (2.16 mm) thick, yellow dot .083
(2.11 mm) thick, green dot .081 (2.06 mm) thick, and red dot .079 (2.01 mm) thick. Install
the thickest ring (1) with the dot up, that will fit in the groove on the center post and allows
a maximum clearance of .002-.004 (.051-.102 mm) between the shoe and creep plate
while grasping one piston and lifting tightly against shoe retainer.
The piston and shoe assembly (4) must be free to rotate easily by hand. The assembly
must be rotated through 360° to confirm there is no binding and that each shoe is always
free in the retainer plate. Oil the assembly thoroughly.
Position the cradle and cam assembly with the piston and shoe assembly attached with
T marked on the cradle turned up.
See figure 4. Insert tube line assemblies (3 and 4) in the holes provided in cradle.
Note: Tube assemblies (3 & 4, fig. 4) must be a snug fit into holes in cradle. Expand end
of tubes with a pointed tool to assure fit.
Position the mounting flange (7) with the large open end up, and install two dowel pins
(6) in the cradle mounting surface of the flange and two dowel pins (6) in the outer edge
of the flange.
See
Fig. 3 Install rocker cam and cradle assembly over the two dowel pins (6) in the mounting
flange. Be certain that cradle is seated over the pins and against the flange with the tube
lines (3) and (4) in the grooves in the flange.
Position the mounting flange with the rocker cam assembly installed on the top or bottom
side and install two or more 1/4-20 x 1-1/4" screws through the seal retainer area into the
cradle. Be certain the cradle is fully seated in flange. These screws are required to hold
the rocker cam assembly in place and will be removed later.
Return the assembly to an upright position with the mounting flange down.
Position the Barrel Assembly with Auxiliary Shaft (1) directly over the pistons. Start with
the uppermost piston and guide them one at a time into the barrel. Return the rocker cam
to a level position in the cradle.
Figure 4
17
ASSEMBLY PROCEDURES
HOUSING See figure 5. Position housing (1) on a clean flat surface with the large open end up.
S13-42335
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clear oil and protected from nicks or surface damage.
2
Clean housing, item #1, and barrel bearing, item #2. Apply loctite primer grade "T" & loc-
tite retaining compound #609 to bearing O.D. & bearing bore of housing. Rest housing
on mounting flange end.
Position notch on bearing (2) with hole in housing bore. Insert Pressing Plug tool (figure
Drive 1
T-4) in the bearing. With smooth and steady force, press the bearing into the housing
Shaft Right bore until seated. DO NOT HAMMER OR BEAT INTO PLACE.
End Side
Install bearing retainer (7) with O-ring (8). Torque to 50 lb.-ft. (68 Nm).
Bottom
3
Turn housing (1) on side and install roll pin (4) in the 1/4" through hole in the control cover
4 pad. The pin must be 3/8" below the pad surface. THE PIN END MUST NOT INTER-
FERE WITH THE INTERNAL BEARING CAGE. Install two dowel pins (3) in the blind
Left
holes in the same pad.
HOUSING, END CAP, CAM See figure 6. Insert the three face plate pins (1) in the holes provided in the barrel face.
AND BARREL
Apply heavy grease to the face of the barrel and install the face plate (2) over the pins
(1) in the barrel.
Make certain the face plate is properly seated on the barrel and pins with the steel
side towards the barrel face. The face plates have only one side bronzed and this
should be toward the port plate. If necessary, remove coating from edge of face plate
to determine bronze side.
Install gasket (3) over the two dowel pins (item 6 on Fig. 4) in the mounting flange.
Position the Housing Assembly (4) over the Barrel and Auxiliary Shaft Assembly and
carefully guide the pressure tubes and tube lines (items 2, 3 and 4 on Fig. 4) through the
Housing Assembly (4).
*Note: item 2: (Ref. only) Arcuate port width: 6 in3 is 13/32" (10,3 mm), 8.0 & 7.25 in3 is
1/2" (12.7 mm)
See
Fig. 4
Figure 6
18
ASSEMBLY PROCEDURES
PORT BLOCK See figure 7. Position the port block (1) on a clean flat surface with the two open ports up.
THE OPPOSITE FACE MUST NOT BE SCRATCHED OR DAMAGED. Position needle
bearing (2) on tool (Figure T-5) with the marked end of the bearing against the shoulder on
the tool and press the bearing (2) into the port block. The bearing must be .010-.025" (.254-
.635 mm) below the surface.
Slip check ring (3) into the two 1.50" (38 mm) ports and align holes in the ring with the
side holes in the port wall.
Place lock washers (6) on special screws (5). Insert (5) through port wall and drilled holes
in checks (3) and thread into clamps (4). Torque to 10 ft. lbs. (13.56 Nm).
Thread two check valve assemblies (7) into valve face of port block.
Figure 7 Place O-ring (10) on hollow hex plug (9) and thread into tapped hole in top of the port
block.
MOUNTING PORT See figure 8 on next page. Position the pump with the unplugged hole (top drainport) in
BLOCK TO HOUSING the housing assembly at 12 o'clock position.
Install the two special pins (3) in the face of the port block assembly. Apply petroleum jelly
or heavy grease to the plate (4) and position port plate over the pins (3) on the port block.
Port plate must be fully seated and indexed towards direction of rotation. (See port plate
view in figure 8.)
Slide the port block assembly and port plate over the end of the auxiliary shaft. Be cer-
tain that tubes 2, 3 and 4 shown on Fig. 4 are engaged and that the port plate (4) is still
on the pins (3).
When the pump is properly assembled, the valve mounting surface will be at the top of
the unit.
Install the four bolts (1), and torque to 225 ft.-lbs. (305 Nm). Caution: Use care to prevent
damage to the valve mounting surface while installing and torquing the two top bolts.
19
ASSEMBLY PROCEDURES
MOUNTING PORT
BLOCK TO HOUSING
(continued)
Rear View –
Width of Arcuate Ports
6 in.3 is 13/32" (10,3 mm)
7.25 and 8.0 in.3 is 1/2 (12,7 mm)
Figure 8
15
16 13
14
GEROTOR IN POSITION FOR RH ROTATION
Figure 9
GEROTOR AND BARREL See figure 9. Position the unit with the shaft in a horizontal position and the valve block
HOLDDOWN mounting surface turned up. Rotate the shaft until the small keyway in the auxiliary shaft
is at 12 o’clock.
If pump is being assembled for right hand rotation install dowel pin (4) in hole in port
block at the 9 o’clock position; if left hand pump, install at 3 o’clock position when view-
ing from port block end of unit.
Install side plate (1), steel side first, over dowel pin. Insert key (2) in shaft keyway. Install
the inner gear of the gerotor assembly (3b) on the shaft and over the key (2). Install the
eccentric ring (3a) on the dowel pin (4). Install the large outer gear of the gerotor assem-
bly (3b) inside the eccentric ring (3a) and over the inner gear.
Note: When changing pump rotation consult parts list for proper side plate.
Place O-rings (7) and (8) on side plate assembly. Lubricate the O-rings and slip the pres-
sure plate (9) over the O-rings on the side plate assembly. Slip the two plates over the
auxiliary shaft and position the gerotor side plate over the dowel pin (4).
Place seal ring (12) on auxiliary shaft. Position bearing (11) between the two thrust wash-
ers (10) and install around the seal ring (12). Install insert (15) over spline on shaft.
Thread holddown nut (13) on the shaft and tighten no more than 10 ft. lbs. (13.56 Nm)
max. Back off the nut (13) until second slot is aligned with pin hole in the shaft. Insert pin
(14) through nut and shaft and secure with ring (16).
Check the main shaft for smooth rotation. If not smooth, check the gerotor parts for posi-
tion and hold down nut for proper adjustment.
20
ASSEMBLY PROCEDURES
Lubricate the four orifice plugs (12) and insert in the top of valve block (11).
Check the pilot valve assembly (41) to be certain that approximately 1-1/2 threads are
exposed from this small nut on the bottom of the valve assembly. This setting will allow
the valve to function at about 200 PSI (14 bar). Each complete right hand turn of this
screw will increase the pressure about 50 PSI (3.4 bar). Torque hex lock nut to 20-25 in.
lbs. (2.26 to 2.82 Nm). Thread the check valve (41) into the 3/8-24 tapped hole into the
valve block (11) as shown.
Press the two dowel pins (10) into the holes provided in the bottom of the valve block
(11). The pins (10) must be .12" (.3 mm) below the surface.
Place the two sequence seats (8) in the sequence ports (SB, SA). Place the four valve
seats (9) in the ports marked RB, RA, RV and servo. Position the gasket (7) and retain-
er plate (6) over the seats and insert the four screws (4) in the block (11). Torque to 10
in.-lbs. (1.1 Nm).
Position the valve block and the attached parts with four orifices (12) turned up. Insert the
two 1-7/16 long springs (17) in the two sequence poppets (13) and install (13) and(17)
in the block and over the sequence seats (18) in ports SB and SA. Install the four valve
poppets (14) in the ports marked RB, RA,RV and servo. Servo and RV seats to seated
with grooved side down. Insert spring retainer (15), large end first, in the servo poppet.
Insert the light weight spring (18) 1-9/16" (39.7 mm) long in the RV poppet. Insert the
three 1" (25.4 mm) long springs (16) in poppets RB, RA and servo.
Lubricate the two check valves (19) and install in sides of cover (21).
Lubricate O-ring (22) and place on seat (23) and install in valve cover (21). Use a 1/2" 6
point 1/4" drive socket and torque to 15 ft-lbs. ((20.4 Nm). Do not use impact wrench.
Lubricate O-rings (26) and (28) and place on parts (27) and (29). Assemble parts 30, and
33 on (31) and start (31) into housing (29). Push seal piston (27) and O-ring (26) into
housing (29) with the small end of the piston exposed. Place spring (25) on cone (24) and
insert all these parts in the valve cover (21). Be certain that cone (24) enters seat (23).
Disassemble the strainer assembly (34) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in. (1.47 Nm).
21 Revised
ASSEMBLY PROCEDURES
VALVE BLOCK Lubricate O-rings 37. Install (37) in the block (11).
before 7-93 (continued)
Position the cover (21) over the springs and poppets and install the four screws (39). BE
CERTAIN THAT THE SPRINGS ARE IN THE RIGHT POSITION BEFORE TIGHTENING
THE SCREWS.
Install dowel pin or roller pin (40) in the hole over the servo poppet. Lubricate the four
O-rings (42) and place on the four plugs (43). Install the four plugs. Lubricate O-ring (35)
and place on plug (36) and install.
Caution: Use of other than SAE plugs will result in malfunction and possible pump
damage
Invert the complete assembly and install roll pins (5) thru plate (6) and into the valve
block. Install O-rings (2) and (3) in the plate (6).
22
ASSEMBLY PROCEDURES
Valve Block
(Before 7-93)
S23-00904
Figure 10
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two roll pins
(46) in position. (Roll pins to be .12" (3.04 mm) below surface of valve block).
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve block. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque #6-32 screw to 13 lb-in (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve block.
23
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
after 7-93 (continued) Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
groove side facing up, over poppets.
Place spring (32) 1.56" long (39.6 mm) into bore next to compensator valve side of block.
Install replenish poppet over spring. Position seat (28) with the groove side facing down,
over poppet.
Insert spring (35) 1.09" long (27.7 mm) into the remaining bore. Place spring retainer (34)
in spring. Place servo poppet (31) over the retainer and spring. Position seat (28) with
the groove side facing down, over poppet.
Carefully position the retainer plate over seats and poppets. Pressing with one hand on
the valve block, compress seats, poppets and springs far enough to alternately thread
two button head cap screws (43) in far enough to hold the retainer plate. Install the other
two screws and alternately tighten screws. Torque to 30 lb-in. (3.39 Nm).
Lubricate O-ring (4) and install on to seat (5), thread seat in valve block. (Be careful not
to damage bore in the seat.) Torque to 15 lb-ft (20.34 Nm).
Apply vaseline to shank of cone (13) and install spring (12) on cone. Carefully insert cone
and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11) install in groove of piston (10) and insert end into spring (12).
Lubricate O-ring (9) and install on housing guide (8) and thread into valve block. Tighten
in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring.
Using a small bladed screw driver, thread the pilot replenishing relief valve assembly (36)
into valve block and lightly tighten in place. (Do not over tighten. Over tightening can
cause sides of slot to break now or at next removal.)
Lubricate O-ring (4) and install on plug (25) and tighten plug in place.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tighten.)
Lubricate O-ring (22) and install on plug (23) and tighten in place.
Lubricate O-ring (19) and install on plug (20) and tighten plug in place.
Install pin (21). Lubricate O-ring (22) and install over plug (23) and tighten plug in place.
Lubricate O-ring (4) and install on plug (25) and tighten in place.
Lubricate two O-rings (22) and install over two plugs (25) and tighten in place.
Using a small hammer carefully tap roll pins (46) into and thru the retainer plate (42), the
pins should bottom out in hole leaving enough length sticking out for piloting into the port
block.
Lubricate O-ring (47), (48) and (37) and install in the bottom of retainer plate (42).
24
ASSEMBLY PROCEDURES
Valve Block
(After 7-93)
S23-12770
Seal Kit
S23-00135
Figure 11
25
ASSEMBLY PROCEDURES
26
ASSEMBLY PROCEDURES
VALVE BLOCK
for special mounting of servo valve
(before 7-93)
S23-11433
Figure 12
Note: Prior to assembly of reconditioned parts, check finish of gasket surface on valve
block and retainer. Must have 60 rms finish with no grinding marks which might carry oil
to outside surface. If lapping is necessary, check depth of pockets for valve seats after
lapping. Must be .085" (2.16 mm) minimum after lapping, to provide clearance for valve
seats.
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (25) with O-ring groove down and horizontal in order to press two roll
pins (26) in position. (Roll pins need to be .12" (3.05 mm) below surface of valve block).
Apply a liberal amount of vaseline or grease to the six counterbores in the face of the valve
block (25). Install two valve seats (27) tapered bore side first, into counterbores and
against roll pin (26), one required each end, (outer-most counterbores in block). Insert the
valve seats (28) and valve seat (44) in remaining counterbores as shown.
Press two roll pins (46) into retainer plate (42). Each roll pin should stick out approximately
.25" (6.35 mm) from each face of the retainer plate.
27
ASSEMBLY PROCEDURES
VALVE BLOCK Position valve block gasket (29) on valve block. Take care that none of the gasket is cov-
for special mounting of servo valve ering the valve seats.
before 7-93 (continued) a. Position retainer plate (42) with O-ring grooves facing up, over valve block gasket.
Install four button-head cap screws (43), torque to 30 in.-lbs. (3.39 Nm).
b.Turn the assembly over so that it is resting with the retainer plate O-ring side down-
ward.
Place spring (33) (1.43" long) (36.3 mm) into poppet (30) and insert small hole end first
into outer-most bores at each end of the valve block (25).
Insert three poppets (31) and one poppet (34) in remaining bores as shown, small diam-
eter end first.
Insert two springs (35) (1.09" long) (27.7 mm) into remaining outer poppets (31).
Install spring (32) 1.56" long (39.6 mm) into remaining poppet located in center of valve
block.
Install four orifice plugs (3) in valve block (25) and tighten in place.
Thread pilot replenishing relief valve (36) into block (25). Valve must not extend below
lower surface of retainer plate.
Place O-ring (4) onto seat (5) and install in valve block cover (1). (Be careful not to dam-
age bore in seat.) Torque (5) to 15 ft.-lbs. (20.4 Nm). (Do not use impact wrench).
Lubricate O-ring (11) and insert into groove of seal piston (10) and slip spring (12) onto
end of seal piston and press into bore of housing guide (8).
c. Align cone with seat in valve cover and thread housing guide into bore and tighten
in place.
Thread nut (7) on soc. setscrew (6) and thread into housing guide (8) until it starts to
compress spring. Thread acorn nut (45) on soc. setscrew (6).
Coat check valve (2) threads with loctite removable thread locker #242 and thread into
end of valve cover (1). (Be sure check valve is properly installed and does not block pas-
sages from orifice plug (3). Lubricate O-ring (22) and install on plug (23) and tighten.
Repeat above step at the opposite end of the valve cover (1).
Disassemble the strainer assembly (14) in valve block and reassemble per the following:
a. Install the orifice screw of strainer assembly (14) into valve cover. Thread elastic stop
nut onto the orifice screw and torque to 23 in.-lbs. (2.6 Nm).
b. Install the strainer support, filter screen and #6-32 x 1/4 lg. screw. Torque #6-32
screw to 13 in.-lbs. (1.47 Nm).
Place O-ring (37) and two (2) O-rings (47) into the grooves on the upper surface of the
valve block and secure with vaseline or grease.
Place valve cover (1) over valve block (25) positioning over springs (33), (32) and (35)
and secure in place with four (4) socket hd. cap screws (41).
Lubricate O-ring (22) and install on plug (23) and tighten in place.
Lubricate O-ring (19) and install over plug (20) and tighten plug in place.
Lubricate O-rings (47) and install in underside of manifold block (15). Carefully, place
manifold block (15) on top of the valve cover (1) making sure the O-rings are correctly
seated. Secure with four (4) soc. hd. cap screws (41) by threading into valve block (25).
Insert spring (16) and spool (38) into manifold (15) with the spring guide and spring
towards the left side of the manifold (15) when viewing from the top rear.
Install temporary plugs (49) and (50) in 1/2" tube and 1/4" tube ports, front and back and
side. Insert O-ring (19) and plug (20) in alternate drain port.
28
ASSEMBLY PROCEDURES
29
ASSEMBLY PROCEDURES
VALVE BLOCK
for special mounting of servo valve
(after 7-93)
S23-12776
Figure 13
See figure 13.
Wash and dry all parts. During assembly, lapped and ground surfaces should be kept
lubricated with clean oil and protected from nicks or surface damage.
Place valve block (1) with the six poppet valve bores up in order to press two roll pins
(46) in position. (Roll pins to be .12" (3.04 mm) below surface of valve block).
Install four orifice plugs (3) into valve block (1) and tighten in place.
Disassemble the strainer assembly (14) and reassemble per the following steps:
a. Install the orifice screw of the strainer assembly into valve block. Thread elastic stop
nut onto the orifice screw and torque to 23 lb-in. (2.6 Nm).
b. Install clean filter screen on strainer support and secure in place with socket head
cap screw, 6-32 x 1/4" long. Torque 6-32 screw to 13 lb-in (1.47 Nm).
Place valve block with poppet valve bores facing up. Position gasket (29) on valve block.
Place springs (33), 1.43" (36.3 mm) into outer most bores at each end of the valve block.
Place sequence poppets (30) over these springs. Position seats (27) small shoulder side
first over poppets.
30
ASSEMBLY PROCEDURES
VALVE BLOCK Place springs (35), 1.09" (27.7 mm) into bores next to the sequence poppet valves of
for special mounting of servo valve step 5. Place dual relief poppet (31) over these springs. Position seats (28) with the
groove side facing up, over poppets.
after 7-93 (continued)
Place spring (32) 1.56" (39.6 mm) into bore next to com-pensator valve side of block.
Install replenish poppet over spring. Position seat (28) with the groove side facing down,
over poppet.
Insert spring (33) 1.43" (36.3 mm) into the remaining bore. Place servo poppet (37) over
the retainer and spring. Position seat (44) with the tapered bore facing down, over poppet.
Carefully position the retainer plate over seats and poppets. Pressing with one hand on
the valve block, compress seats, poppets and springs far enough to alternately thread
two button head cap screws (43) in far enough to hold the retainer plate. Install the other
two screws and alternately tighten screws. Torque to 30 lb-in. (3.39 Nm).
Lubricate O-ring (4) and install on to seat (5), thread seat in valve block. (Be careful not
to damage bore in the seat.) Torque to 15 lb-ft (20.34 Nm).
Apply vaseline to shank of cone (13) and install spring (12) on cone. Carefully insert cone
and spring into valve block positioning point of cone into bore of seat.
Lubricate O-ring (11) install in groove of piston (10) and insert end of piston into spring
(12).Lubricate O-ring (9) and install on housing guide (8) and thread into valve block.
Tighten in place.
Thread nut (7) on socket set screw (6) and thread screw into housing guide (8) until it
starts to compress spring.
Using a small bladed screw driver, thread the pilot replenishing relief valve assembly (36)
into valve block and lightly tighten in place. (Do not over tighten. Over tightening can
cause sides of slot to break now or at next removal.)
Lubricate O-ring (4) install on plug (25) and tighten plug in place.
Thread check valve (2) into valve block and lightly tighten in place. (Do not over tighten.)
Lubricate O-ring (22) install on plug (23) and tighten in place.
Lubricate O-ring (19) install on plug (20) and tighten plug in place.
Lubricate O-rings (22) install over plugs (23) and tighten plugs in place.
Lubricate O-ring (19) install over plug (20) and tighten in place.
Lubricate O-rings (47) and install in underside of manifold block (15). Carefully, place
manifold block (15) on top of the valve cover (1) making sure the O-rings are correctly
seated. Secure with four (4) soc. hd. cap screws (41) by threading into valve block (25).
Insert spring (16) and spool (38) into manifold (15) with the spring guide and spring
towards the left side of the manifold (15) when viewing from the top rear. Install orifice
plug (61) in manifold (15).
Install temporary plug, (50) in 1/4" tube port. Insert O-ring (19) and plug (20) in alternate
drain port.
Using a small hammer carefully tap roll pins (46) into and thru the retainer plate (42), the
pins should bottom out in hole leaving enough length sticking out for piloting into the port
block.
Lubricate O-ring (47), (48) and (37) and install in the bottom of retainer plate (42).
31
ASSEMBLY PROCEDURES
32
ASSEMBLY PROCEDURES
33 Revised
ASSEMBLY PROCEDURES
Valve Block
See Fig.
10, 11,
12, 13
21
20
22
24
23 Figure 14
SHAFT AND SEAL INSTALLATION See figure 14. Stand the pump in an upright position with the port block inlet and outlet
pads turned down.
Install the shaft and bearing (1) assembly in the mounting flange and cradle. Be certain
that there are no burrs or sharp edges on shaft seal area of the shaft.
For a rigid shaft application use the shim (2) that results in least clearance around the
shaft bearing. Do not use a shim with a floating shaft.
Install the snap ring (3) in the mounting flange to retain the Shaft Assembly. Be certain
that the ring is fully seated in the groove. Use the ring that results in the tightest fit.
Warning: When installing a new mechanical shaft seal, exercise care to insure that
all of the parts fit together properly. This is particularly important if the seal was once
assembled and disassembled for some reason. If the rubber boot, item 4, grips the
shaft and doesn't slide on the shaft, as it is disassembled, then the spring, item 7, can
disengage the shell, item 5, from the band, item 6, so that they do not re-engage
properly when reassembled. Be sure the shell and the band are properly engaged
before reassembling the seal, and stays engaged during assembly.
Note: Lubricate seal and shaft with clean hydraulic fluid of the same type that will be
used in the system.
34
ASSEMBLY PROCEDURES
See figure 14. The seal assembly (4) is available as a complete unit only.
Caution: Before installing the seal assembly examine all the parts. The lapped seal
seat and the carbon ring have a precision finish that must be handled with care. Be
certain that both parts are free of scratches, marks and cracks.
Place the spring retainer (e) over the shaft and against the retaining ring on the shaft
assembly. Place the spring (d) against the retainer (e). Apply grease to the inner surface
of the rubber friction ring (f) and position the shell containing the rubber friction ring (f)
and carbon ring (c) over the shaft with the carbon ring exposed. Apply grease to the
square section rubber seal (a) and install on the ceramic seat (b). Insert the seat and seal
in the seal retainer (6) with the lapped side of the seat in position to contact the carbon
ring. Place the seal retainer assembly and O-ring (5) over the shaft with the lapped sur-
face against the carbon face. Place the four gaskets (7) on the four screws (8) and insert
the seal retainer (6). Depress the seal retainer only far enough to start the four screws
and tighten evenly. Torque to 10 ft.-lbs. (13.56 Nm).
Note: Seal installation must be completed quickly to avoid the rubber friction ring from
seizing on the shaft.
COUNTER-BALANCE SERVO Place the two spacers (11) on the two screws (12) and insert through the balance plate
STEM (10) and servo stem (9).
Insert these parts through the opening in the side of the housing assembly and position
the screws over the two #10-24 tapped holes in the rocker cam.
Hold these parts against the cam and alternately tighten the screws (12) to hold the
assembly firmly in place. Torque screws to 5 ft.-lbs. (6.78 Nm)
REAR DRIVE ADAPTER See figure 15. Place wave spring, (8) over isolation tube (4). Lube O-ring (7) and assem-
ble to isolation tube. Place isolation tube against pressure plate, item (9) Fig. 9.
Lube tetraseals (10). Insert into adapter block and carefully assemble adapter block to
port block. Using screws (9) and washers (12) to hold adapter block in place, torque to
150 ft-lbs. (203 Nm).
Coupling (2) with coupling insert (3) and retaining ring (6) may be installed to end of aux-
iliary shaft when external pump is mounted.
Adapter
Figure 15
35
ASSEMBLY PROCEDURES
36 Revised
ASSEMBLY PROCEDURES
Figure 16
PILOT VALVE See figure 16. Insert seat (2-8) into cap (2-3) and seat in bottom of bore.
Install small end first of block (2-7) into bore and against seat.
Install spacer (2-5) and secure in place with set screw (2-4).
Install spring (2-11) onto cone (2-9) . Install spring (2-10) over spring (2-11), and insert into
cap (2-3) and seat (2-8).
Install O-ring (2-14) in piston (2-13) and insert small end into springs.
Install plug (2-15), screw (2-17) & nut (2-16). Set per requirement and cover with acorn
nut. (2-18).
If externally drained, insert plug (2-19) into hole on spring end of cap.
If internally drained, insert plug (2-20) and O-ring (2-19) in cap drain port.
SHUTTLE VALVE See figure 16. Lube spool (3) and insert it into valve body (1). When the spool is fully
engaged, move the spool back and forth a few times to check for smooth operation. Spool
must move freely in body bore.
Install spring stop (4) into one end of valve body (1). Make sure it is seated properly.
Insert spring (8) into valve body (1) over the spool (3). Install plug (12) & O-ring (15) into
the valve body (1).
Lube O-ring (9) and install into valve body (1). Make sure it fits exactly.
Lube O-ring (9) and place over the sleeve (5) and install into bore of valve body (1). Be
careful not to jam sleeve in bore.
37
ASSEMBLY PROCEDURES
SHUTTLE VALVE Insert piston (6) into sleeve (5) and place spring (7) into piston (6).
(continued)
Lube O-ring (10) and place onto the sleeve (5).
Mount pilot valve cap sub-assembly (2) onto shuttle block (1). Use three S.H.C. screws
(14) and the one screw which comes with the pilot valve sub-assembly. Make sure that
the screw that comes with the valve cap sub-assembly is positioned on end closest to
acorn nut. Torque to 50 ft-lbs. (68 Nm) Run lead wire which comes with valve cap sub-
assembly through holes in special screw and acorn nut. Twist ends together.
SHUTTLE VALVE MOUNTING Lubricate tetraseals (11) figure 16 and place in C' bores of shuttle valve mounting surface.
Carefully attach shuttle valve to adapter (22) fig. 14, using hex hd. screws (13) figure 16.
Torque to 75 lb-ft. (102 Nm).
38
IMPORTANT INSTRUCTIONS
INSTRUCTIONS FOR CAUTION: The isolation plug enclosed is to be used ONLY if an external filter circuit
REPLENISHING CIRCUIT is provided. DO NOT operate this unit with the isolation plug installed unless an exter-
ISOLATION PLUG nal line has been provided.
When the external filter circuit IS NOT used discard the isolation plug.
When the external filter circuit IS used install the isolation plug between port G and H
(refer to appropriate installation drawing): use a 3/16 Hex. wrench by 4" minimum length
INSERTING THE ISOLATION PLUG INTO PORT H and tighten to 80 - 120 in.-lb. torque.
(9.04-13.56 Nm)
Isolation plug: Part No. 311-45032 (3/8-16 x 1/2 UNC Flat point set screw).
39
HYDRAULIC CIRCUIT
40 Revised
HYDRAULIC CIRCUIT
41 Revised
TEST PROCEDURES
GENERAL REQUIREMENTS 1. Maximum runout between pump shaft and electric motor shaft .003 (.076 mm) T.I.R.
A floating shaft must have a support in mounting bracket. A fixed shaft should not have
a support bearing in mounting bracket.
4. Inlet condition Main Pump 100 to 150 PSI. (6.9 to 10.3 bar)
Gerotor 10" HG to 5 PSI. (25.4 mm HG to .34 bar)
BASIC PUMP TEST 1. Mount pump on test stand. Connect system lines and gerotor inlet line to pump.
Connect case drain line to flowmeter. Connect shuttle return line to reservoir. If shuttle
pilot valve is externally drained, connect drain to max. 5 PSI (.34 bar) return line. If an
auxiliary pump is mounted, connect auxiliary pump inlet to reservoir. If auxiliary pump is
not mounted, remove coupling and seal auxiliary unit mounting surface.
3. Rotate pump input control shaft. The servo control should control pump displacement
through its full range. Set pump displacement for full volume, and adjust system pressure
for 1000 PSI (69 bar). Check and record system flow and case drain flow above and below
center.
4. Back out compensator adjusting screw until unit is fully compensated (count number
of turns). Observe volume indicator and stroke rotary servo input shaft from full to full
position on each side of center. Indicator should remain on or very near zero position
("O"). If compensator functions normally, return compensator adjusting screw to its orig-
inal position and proceed with Step 5.
5. Cycle pump at 10 sec. intervals-full volume above center to full volume below
center*—as follows:
5 minutes at 1000 PSI (69 bar)
3 minutes at 2500 PSI (172 bar)
3 minutes at 3500 PSI (241 bar)
2 minutes at 5000 PSI (345 bar)
6. Adjust system pressure to 5000 PSI (345 bar) and set pump displacement for full vol-
ume. Check and record system flow and case drain flow above and below center.
7. Set pump to compensate at 5000 PSI (345 bar). Servo pressure should be at least
650 PSI (45.5 bar). Check and record replenishing flow. (Case leakage flow).
Maximum flow-14.6 GPM (55.3 l/m) with Barnes auxiliary pump. 6.5 GPM (24.6 l/m)
without auxiliary pump.
8. Set pump to compensate at minimum PSI. Check and record replenishing and servo
pressure.
Servo pressure-Minus Case Pressure 455 to 570 PSI (31.3 to 39.3 bar).
Repl. pressure-Minus Case Pressure 350 PSI ± 20 PSI (24.1 ± 1.4 bar).
42
TEST PROCEDURES
BASIC PUMP TEST If pressures are incorrect, remove replenishing relief valve pilot and increase or decrease
pressure as required. (One full turn on adj. screw will cause pressure to change approx-
(continued)
imately 50 PSI) (3.4 bar). Re-torque locknut to 20-25 in-lbs. (2.3-2.8 Nm).
Note: There is no servo relief valve adjustment. Increasing or decreasing repl. pres-
sure will cause both servo and repl. pressure to change by the same amount.
9. Set pump to full displacement and set the test stand relief valve at approx. 2000 PSI
(138 bar). Set the pump compensator at 1000 PSI (69 bar). Set the shuttle relief valve
pilot cap to 220 ± 20 PSI (15.2 ± 1.4 bar) above case pressure and secure with locknut
and acorn nut.
10. Stroke pump to center position and observe repl. pressure. It should rise to the value
in step 8 above.
11. Slowly cycle the pump across center several times while observing repl. pressure
drops to 220 ± 20 PSI (15.2 ±1.4 bar) while on stroke, and rises to 350 ± 20 PSI (24.1 ±
1.4 bar) at zero stroke, to verify shuttle operation.
12. Set pump to compensate at 5000 PSI (345 bar). Record repl. and servo pressure.
13. Set pump to compensate at minumum PSI. Servo pressure should return to 455 to
570 PSI (3.3 to 39.3 bar).
Note: After completing step 13, proceed with pump control test and adjustment. Refer
to the goldcup control manual #S1-AM030 for your control type. Continue with step
14 after testing controls.
14. Adjust pump displacement for full volume and adjust system pressure to 6000 PSI
(413.8 bar).**Adjust compensator from 6000 PSI to 3000 PSI (413.8 to 206.9 bar) to min-
imum pressure. At each pressure, stroke rotary servo input shaft to the full position on
each side of center. Cam indicator should remain on or very near the zero position with
no oscillation. System pressure should not vary from Port "A" to Port "B" more than 150
PSI (10.3 bar) and not oscillate.
**Caution: DO NOT hold pump at 6000 PSI (413.8 bar) for longer than one minute at
any time. This is only an intermittent pressure rating.
15. Set compensator for 1000 PSI (69 bar) when fully compensated, UNLESS OTHER-
WISE SPECIFIED. Increase and decrease system pressure above and below compensa-
tor setting. When system pressure is above compensator setting, the pump should de-
stroke and not oscillate. When the system pressure is below the compensator setting, the
pump should stroke to full volume.
43
ORDERING CODE
Pump series
Displacements, Max.
6 = 6.0 in3/rev., 98 cc/rev.
7 = 7.25 in3/rev., 119 cc/rev.
8 = 8.0 in3/rev., 131 cc/rev.
Pump type
S = closed circuit, with shuttle valve
Shaft
SAE = C
2 = keyed
3 = spline
Rotation, shaft
viewed from shaft end
R = clockwise
L = counter-clockwise
Fluid class
1 = compatible w/Buna N
4 = compatible w/EPR
5 = compatible w/Viton
Designates special
44 Revised
NOTES
45
NOTES
46
NOTES
47
SALES AND SERVICE WORLDWIDE
Internet: http://www.denisonhydraulics.com
E-mail: [email protected]
900 PUMP CONTROL
DENISON HYDRAULICS
controls for
goldcup pumps & motors series 6. . .30
service information
valve block
"B" side
control
mounting
"A" side
control
mounting
rotation
viewed from shaft end
P 6 P -2 R 1 C -4 A 2 -A -00 -B 1 -M-XXXXX
Pump series Control Feature
500 Control
Primary Controls 00-with deadband
1-Screw Adjustment 01-without deadband
2-Cylinder Control
4-Rotary Servo (spring centered w/trimmer) 600 Control
5-Electrohydraulic Stroker 00-75-350 PSI (5-24 bar)
6-Hydraulic Stroker 01-75-435 PSI (5-30 bar)
7-Servovalve & Feedback Device 02-100-380 PSI (7-26 bar)
8-Proportional Hydraulic Stroker 03-150-400 PSI (10.3-27.6 bar)
9-Electrohydraulic Stroker
(All include rotary servo, pressure compensator 700 Control
override & displ. indicator) 00-w/o manual override shut-off
01-w/manual override shut-off
Primary Control Options
0-None 800 Control
A-Adjustable maximum volume stops 00-75-350 PSI (5-24 bar)
B-Automatic brake control 01-75-435 PSI (5-30 bar)
C-A & B above, together 02-100-380 PSI (7-26 bar)
D-10 GPM Servovalve w/feedback potentiometer 03-150-400 PSI (10.3-27.6 bar)
E-10 GPM Servovalve w/feedback RVDT 04-75-250 PSI (5-17 bar)
F-10 GPM Servovalve w/pot. & manual override
w/4A2 Control 900 Control
G-10 GPM Servovalve w/RVDT & manual override 00-24 VDC
w/4A2 Control 01-12 VDC
H-3 pos (Spring centered w/trimmer) ALL OTHER CONTROLS USE 00
M 6 H -2 N 1 C -2 A 0 -A -00 -M-XXXXX
Motor series Control Feature
500 Control
Primary Controls 1-without deadband
2-Cylinder with adjustable maximum & minimum stops
5-Electrohydraulic Stroker 600 Control
6-Hydraulic Stroker 0-170-350 PSI (11.7-24.1 bar)
8-Proportional Hydraulic Stroker 1-200-450 PSI (17.2-31 bar)
9-Electrohydraulic Stroker (without deadband) 2-150-380 PSI (10.3-26.2 bar)
(All include rotary servo stem and displacement indicator) 3-75-250 PSI (5-17 bar)
Control Location
A-Command on Port A side
B-Command on Port B side
4
GOLDCUP CONTROLS CHARACTERISTICS
*5A, 5C CONTROLS
*Note: If the driver uses Pulse Width Modulation, (PWM) the frequency must be 2000 Hz. or higher to avoid erratic operation.
Water Glycol, Phosphate Ester (including Skydrol), and Invert emulsions cannot be used with 5A and 5C controls.
5
GOLDCUP CONTROLS CHARACTERISTICS
6A MOTOR CONTROLS
Feature Control press. Control press. Max. hysteresis @ Max. hysteresis @
max. displacement min. displacement max. displacement min. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
0- 155-185 (10.7-12.7) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
1- 185-215 (12.8-14.8) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
2- 135-165 (9.3-11.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
3- 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
*With connector terminal B at +15 Volts, terminal D at - 15 Volts. This polarity must be maintained for D.C. RVDT, Polarity is optional
for potentiometer.
8A, 8C PUMP CONTROL
Code Control press. Control press Max. hysteresis @ Max. hysteresis @
min. displacement max. displacement min. displacement max. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
00 60-90 (4.1-6.2) 310-360 (21.3-24.8) 30 (2.1) 50 (3.4)
01 60-90 (4.1-6.2) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
02 100-120 (6.9-8.3) 350-400 (24.1-27.6) 30 (2.1) 50 (3.4)
03 135-165 (9.3-11.4) 375-425 (25.9-29.3) 30 (2.1) 50 (3.4)
04 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
Torque for manual operation (no control pressure) begin stroke 7.5-20 in. lb. (0.8-2.2 N·m)
Torque for manual operation (no control pressure) end stroke 28-58 in. lb. (3.2-6.5 N·m)
8A MOTOR CONTROL
Code Control press. Control press Max. hysteresis @ Max. hysteresis @
min. displacement max. displacement min. displacement max. displacement
psi (bar) psi (bar) psi (bar) psi (bar)
0* 60-90 (4.1-6.2) 225-275 (15.5-19.0) 30 (2.1) 50 (3.4)
1* 235-265 (16.2-18.3) 410-460 (28.3-31.7) 30 (2.1) 50 (3.4)
Signal ports SAE - 4
Torque for manual operation (no control pressure) begin stroke 7.5-20 in. lb. (0.8-2.2 N·m)
Torque for manual operation (no control pressure) end stroke 28-58 in. lb. (3.2-6.5 N·m)
*Specifications above are based on using a Jupiter 900 Driver with a 24 VDC supply and set at 120 Hz pulse width modulation.
Performance will vary when other controls are used. 100 to 200 Hz pulse width modulation is recommended.
6
GOLDCUP CONTROLS SERIES 900
9A ELECTRIC STROKER
DESCRIPTION The 9A consists of one or two electric proportional pressure control valves mounted on
the 8A cover to provide the pilot pressure signal. It is a simple electrohydraulic control
with comparable performance to the 5A in most applications. Refer to 8A for stroker
description.
The Jupiter 900 Driver Card has been developed to accompany the 9A control with
24V coil.
ASSEMBLY All parts are to be inspected and be free of material defects, dirt, scratches, or any for-
eign material.
All parts are to be cleaned with a suitable cleaning solvent and all cores and passages
blown out with clean dry compressed air.
After cleaning and inspection, all parts are to be covered with a light film of oil and
should be protected from dirt and excessive handling until assembled onto the unit.
During assembly, lapped and ground surfaces should be kept lubricated and protected
from nicks or surface damage.
1. Apply pipe sealant to the 1/8” pipe plug (12) and install in the cover plate. Torque to
100 lbs-in. (11.3 Nm).
87
GOLDCUP CONTROLS SERIES 900
2. Thread trimmer locknut (22) all the way onto trimmer screw (23). Slip back-up
washer (21), small dia. first, onto trimmer screw and against locknut. Using a 3/4-16
hex nut with a 1.030” (26.2mm) dia. x .030/.035” (0.76/0.89mm) deep c’bore, crimp the
washer onto the stop. Washer must be free to rotate slightly. Remove crimping nut.
See Figure 8A-1 3. Compress spring (4) solid in order to remove spring set. This may be safely
accomplished using a 1/4” (6.35 mm) dia. bolt, nut and washers.
4. Assemble retaining ring (2), guide (3), spring (4) and guide (3) onto spool (1).
5. Tighten nut (7) till it just starts to load the spring, then tighten 2-5/6 additional turns.
6. Install locknut (5) onto spool and lock against nut (7) without changing adjustment.
See Figure 9A 7. Insert spool assembly (11), spring end first, into trimmer screw (23). Compress
snap ring on the spool assembly until it snaps into internal groove inside trimmer
screw. See that it is securely seated.
8. Thread spring stop locknut (24) all the way onto adjusting spring stop (25). Slip
back-up washer (26), small diameter first, onto stop and against locknut. Using a 9/16-
18 hex nut with a .810/.815” (20.6/20.7mm) dia. x .030-.035” (0.76-0.89mm) dp. c’bore,
crimp washer onto stop. Washer must be free to rotate slightly. Remove the crimping
nut.
9. Install O-ring (35) on plug (34) and insert into spring stop (25). Install O-ring (27)
onto stop (25) and against washer (26).
10. Thread adjusting spring stop (25) into trimmer screw (23) until it just touches the
spool assembly. Be sure spool assembly is against snap ring.
11. Determine the correct position of the spool assembly in the valve body. For 9A
standard pump controls, and for 9A motor controls mounted on the “B” port side, the
spool assembly is installed in the side of the control cap containing the 1/8” pipe plug
(12). For controls used on P*R pumps, and motor controls mounted on the “A” port
side, the spool assembly is installed on the side opposite the 1/8” pipe plug (12).
12. Place O-ring (14) on trimmer screw (23) and thread assembly into the cover plate,
as noted above.
13. Install adjusting screw (15) in plug (13). Install O-ring (14) on plug. Thread adjust-
ing screw in until it protrudes approximately 1/2” from top of plug (13). For motor con-
trols, install two nuts (36) on the inner end.
14. Thread cover nut (16) with O-ring (31) onto adjusting screw.
15. Install plug (28) and O-ring (29) into cover nut (16).
16. Install this assembly in body on the opposite side from the spool assembly (11).
17. Install nut (36) on adjusting screw (6). Thread adjusting screw into stop (25).
18. Install roll pins (30) into drilled holes in surface of cover, being careful not to dam-
age surface.
19. Install 0-ring (7) in groove of shear seal (8).
20. Install shear seal with o-ring in large hole on the servo link, on the servo shaft
side. Be certain that the shear seal is sitting with the flange flush against the servo
link surface.
Note: The shear seal will fit in one position only, otherwise one side will be held up
by the lip of the servo link. Shear seal (8) must be installed to face against the cover
plate (10). This shear seal (8) differs from shear seal (18) in that the face surface is
machined with two .094” (2.4mm) radius scallops.
21. Install thrust bearing (9) over servo shaft and seat against the servo link.
22. Slip washer (33) over the servo shaft and against the thrust bearing.
23. Using installation tool T-1, install O-ring (5) in the second groove from the end of
the shaft (1). Warm glyd ring (20) to make it pliable, and install over O-ring (5).
24. Install the servo shaft assembly in the cover plate (10). Pin must engage slot in
spool assembly (11).
25. Install retaining ring (4) into the groove of the servo shaft extending thru the cover
plate.
26. Apply loctite® 271 on threads of screw (43), and on threads of shaft assembly (1).
Assemble nut (44) on screw, insert screw into shaft assembly and turn in snugly. Hold
screw and arm. Torque nut to 14 lb.-ft. (19 Nm).
27. Place two spring washers (17), nested with the bent sections matching each other,
into the large hole in the servo link.
88
GOLDCUP CONTROLS SERIES 900
32. For controls with single valve, install soc. setscrew (54) in the tapped hole furthest
in from the unused opening. Torque to 70 in.-lb. (7.9 Nm). Install plug (53) and O-ring
(55) in the unused opening. Torque to 20 lb.-ft. (27 Nm).
33. Install coil(s) (52) on proportional valve (38). CAUTION! Torque to 20-25 in.-lb.
(2.2-2.8 Nm) max.
34. Install remaining parts.
35. If control is to be tested on unit, install stroker block assembly and control on
pump control pad with O-rings (3, 31, and 45), gasket (19), washers (49) and screws
(2). Torque to 30 Lb.-ft. (40.8 Nm).
9A CONTROL TEST SETUP Remove plug over input shaft. Insert T handle 3/16” Allen wrench into opening.
Connect proportional control driver to proportional valve. Connect pressure gage on
SAE-4 port adjacent to proportional valve or valves.
Rotate wrench handle to check for free play. Turn spring stop adjustment in or out till
it just contacts the spring and there is no free play. Lock in place. Note: this adjust-
ment is critical to accurate neutral adjustment!
9A PUMP TEST 1. Turn trimmer screw to place input shaft on the zero stroke position. Check for posi-
tive centering. Lock in place. For cross-center pumps, set max. volume stops so that
servo shaft link touches stop pins when handle is stroked each side of center. For one
side of center pumps, set max. stop so that servo shaft link touches the stop pin. Set
min stop to prevent crossing over center. Lock stops in place.
2. Apply signal current to one proportional valve. Adjust current from minimum to
maximum. Note the pressure and current value at which pump just starts to stroke,
and at which the pump reaches full stroke These must be within the following values:
3. If control pressure is off the same amount at start and end of stroke, the control
may be disassembled and the spring (Figure 2) readjusted. One flat (1/6 turn) of
adjustment will change the pressure by 4.6 psi (0.31 bar).
4. If the change in pressure from start to end of stroke is incorrect, the spring (Figure
2) is incorrect and must be replaced.
5. If pressures are correct but current is incorrect, then either the coil is incorrect or
the proportional valve is bad.
6. With minimum signal, pump shall return to zero stroke within 200 psi. (13.8 bar)
max.
7. For cross-center pumps, repeat test on opposite side of center.
8. Increase and decrease current between minimum and maximum several times.
Pump stroke should follow control pressure smoothly and proportionally. Full to zero or
zero to full stroke should be achieved in no more than two seconds. Adjust stroke up
to approximately 50% stroke from zero stroke, then adjust down from full stroke to the
same current value. The flow at the two settings shall not vary more than 25%.
9A MOTOR TEST 1. Turn trimmer screw to place input shaft on the full stroke position. Lock in position.
2. Rotate input handle to reduce motor displacement to minimum. CAUTION! do not
exceed motor rated speed! Adjust minimum stop screw to set minimum displacement
at 25% of full displacement. (4 times the rpm at maximum displacement.)
89
GOLDCUP CONTROLS SERIES 900
5. If control pressure is off the same amount at start and end of stroke, the control
may be disassembled and the spring (Figure 2) readjusted. One flat (1/6 turn) of
adjustment will change the pressure by 4.6 psi (0.31 bar).
6. If the change in pressure from start to end of stroke is incorrect, the spring (Figure
2) is incorrect and must be replaced.
7. If pressures are correct but current is incorrect, then either the coil is incorrect or
the proportional valve is bad.
8. With minimum signal, motor shall return to full stroke.
9. Increase and decrease current between minimum and maximum several times.
Motor stroke should follow control pressure smoothly and proportionally. Full to min. or
min. to full stroke should be achieved in no more than two seconds. Adjust stroke
down to approximately 50% stroke from full stroke, then adjust up from 25% stroke to
the same signal. The speed at the two settings shall vary no more than 25%.
10. When control has satisfactorily passed test, remove stop assembly, set and lock
the two nuts on the inside to prevent adjustment below 25% stroke. Re-install stop.
90
GOLDCUP CONTROLS SERIES 900
PARTS LIST
Figure 9A Electric stroker
Feature ➔ 00 00 01 00 0*
Option ➔ P*P, P*S 6R,7R,8R P*P,P*S P*V M*H, M*V
Pump Pump Pump Pump Motor
Assembly No. ➔ S23-12667 S23-12940 S23-12957 S23-12734 S23-15050
S23-12733 S23-15051
ITEM DESCRIPTION PT. NO. QTY. QTY. QTY. QTY. QTY.
1 Servo shaft S23-12267 1 1 1 1 1
2 HHCS 3/8-16 X 3.25” 306-40184 4 4 4 4 4
3 O-ring, 70- S-5 ARP 013 675 00013 9 9 9 9 9
4 Ring, Truarc #5144-50 356-65070 1 1 1 1 1
5 O-ring, 70 S-5 ARP 012 675-00012 5 5 5 5 5
6 HHCS, 5/16-24 X 1” 307-13160 1 1 1 1 -
Setscrew, 5/16-24 X 1.25” 312-13180 - - - - 1
7 O-ring, 70 S-5 ARP 017 675-00017 2 2 2 2 2
8 Shear Seal 033-71371 1 1 1 1 1
9 Bearing 230-82141 1 1 1 1 1
10 Cover-9A 033-91220 1 1 1 1 1
11 Spool Assy (Fig. 8A-1) S23-12956 1 1 1 1 1
12 Flush plug 1/8” 431-90204 1 1 1 1 1
13 SAE plug 033-91027 1 1 1 1 1
14 O-ring, 90 S-5 ARP 908 695-00908 3 3 3 3 3
15 Soc. setscrew, 5/16-24 X 2” 312-35062 1 1 1 1 -
Setscrew, 5/16-24 X 2.50” 312-35063 - - - - 1
16 Nut 033-91033 1 1 1 1 1
17 Finger Spring 350-10067 2 2 2 2 2
18 Shear seal 033-70525 1 1 1 1 1
19 Gasket 033-91058 1 1 1 1 1
20 Glyd ring 679-00004 1 1 1 1 1
21 Washer 350-10139 1 1 1 1 1
22 Nut 033-91115 1 1 1 1 1
23 Center trimmer 033-91028 1 1 1 1 1
24 Locknut 492-15353 1 1 1 1 1
25 Stop 033-91026 1 1 1 1 1
26 Washer 350-10126 1 1 1 1 1
27 O-ring, 90 S-5 ARP 906 695-00906 1 1 1 1 1
28 Plug, Parker 2P5N-S 488-35029 1 1 1 1 1
29 O-ring, 90 S-5 ARP 902 695-00902 1 1 1 1 1
30 Rollpin 3/16 X .75” 325-12120 2 2 2 2 2
31 O-ring, 70 S-5 ARP 014 675-00014 2 2 2 2 2
32 Washer 350-10064 1 1 1 1 1
33 Washer 350-10141 1 1 1 1 1
34 Piston 033-91099 1 1 1 1 1
35 O-ring, 70 S-5 ARP 010 675-00010 1 1 1 1 1
36 Nut, 5/16-24 335-13100 1 1 1 1 3
37 Orifice, .025” 033-91225 4 4 4 4 4
38 Valve- proportional 517-00085 2 2 2 1 1
38-a O-ring, 70 S-5 ARP 015 675-00015 2 2 2 1 1
38-b O-ring, 90 S-5 ARP 016 695-00016 2 2 2 1 1
91
GOLDCUP CONTROLS SERIES 900
PARTS LIST
Figure 9A Electric stroker
Feature ➔ 00 00 01 00 0*
Option ➔ P*P, P*S 6R,7R,8R P*P,P*S P*V M*H, M*V
Pump Pump Pump Pump Motor
Assembly No. ➔ S23-12667 S23-12940 S23-12957 S23-12734 S23-15050
S23-12733 S23-15051
ITEM DESCRIPTION PT. NO. QTY. QTY. QTY. QTY. QTY.
38-c O-ring, 90 S-5 ARP 116 695-00116 2 2 2 1 1
39 Stroker Block 033-54991 1 1 1 1 1
40 Plug, SAE-4 488-35061 2 2 2 2 2
41 O-ring, 90 S-5 ARP 904 695-00904 2 2 2 2 2
42 Plug. Parker 8HP N-S 488-35018 1 1 1 1 1
43 SHCS, 1/4-20 X 2.25” 358-12100 1 1 1 1 1
44 Nut, 1/4-20 333-12001 1 1 1 1 1
45 O-ring, 70 S-5 ARP 121 675-00121 1 1 1 1 1
46 Connector 167-01008 2 2 2 1 1
47 Guard 033-54994 1 1 1 1 1
48 SHCS, 1/4-20 X 2.25” 306-12260 2 2 2 2 2
49 Washer 350-10144 4 4 4 4 4
50 Plate 030-55002 1 - - - -
Plate 030-55003 - 1 1 1 1
51 Drive screw 320-10203 2 2 2 2 2
52 Coil, 24 VDC. 517-00086 2 2 - 1 1
Coil, 12 VDC 517-00087 - - 2 - -
53 Plug, Parker 10 P50N-S 488-35016 - - - 1 1
54 SHCS, 10-32 X .19” 312-09030 - - - 1 1
55 O-ring, 90 S-5 ARP 910 695-00910 - - - 1 1
56 Washer 345-10016 2 2 2 2 2
92
GOLDCUP CONTROLS SERIES 900
ELECTRIC STROKER
FIGURE 9A
93
NOTES
115
SALES AND SERVICE WORLDWIDE
Printed in U.S.A.
OPI 2M 10203
TB VANE PUMP
Vane Pumps
2
P S
1. TB-011-1R00-A100 .....................................Series
6. TB-011-1R00-A100 ....................................Design
2. TB-011-1R00-A100 ................................ Cam size
Size.........in3/rev Size.........in3/rev Size.........in3/rev
7. TB-011-1R00-A100 ..............................Seal Class
003..........0.54 006 ......... 1.26 011 ......... 2.17 Buna N : mineral oil 1
004..........0.78 008 ......... 1.59 012 ......... 2.42
005..........0.98 009 ......... 1.92
8. TB-011-1R00-A100 ................... Port Connections
3. TB-011-1R00-A100 .....................................Shafts Pressure port P Threaded SAE, 4 bolts
Suction port S SAE-12 ¾” NPTF ¾”
4. TB-011-1R00-A100 ..................................Rotation
SAE-20 00
CW R Threaded
1” ¼ NPTF 03 0X
CCW L
SAE, 4 bolts 1” ¼ 01
5. TB-011-1R00-A100 ....................................Porting
P & S : same side / opposite side 01 / 00
TB
E 1.22
F 3.39
G 5.72
J1 3.250
2
J2 3.248
N 4.19
O 5.13
P ∅ .44
Torque
Shafts in-lb
TB L1 L2 DIAMETER K1 x K2 H1 M1
1 Key : No SAE (∅.75) - ● 2.66 1.25 .750 - .749 .188 x.186 0.83 -
Dimensions (i n)
Ports Options Threads T1
A1 B1 C1 D1
Features
These soft seat (virtual zero leak), with guided poppet valves offer a wide variety of end fitting configurations and elastomers
and the option of 316 stainless steel construction. These options enable a valve to be configured to meet the needs of any
system. Snap-tite’s versatile 6C/3C Inline Check Valves are designed with a 4:1 safety factor at a maximum working
pressure of 6000 psi (415 bar) making them ideal for any application.
75.70
113.55
151.40
189.25
378.50
757.00
113.55
378.50
1892.50
11.36
15.14
18.93
37.85
75.70
1.36
1.51
1.89
3.79
7.57
.38
.76
100 6.90
3.45
PRESSURE DROP, bar
10 .69 200
/4"
13.79
"
1-1
1/4
"
3/8
5.0 .35
"
1/2
4.0 .28
/2"
"
100 6.90
3/4
3.0 .21
1-1
1"
2.0 .14
50 3.45
1.0 .07
40 2.76
.5 .034 30 2.07
.4 .028
2"
.3 .021 20 1.38
.2 .014
.1 .007 10 .69
.1
.2
.3
.4
.5
1.0
2.0
3.0
4.0
5.0
10
20
30
100
10
20
30
40
50
100
200
500
Note: Gallons shown are in U.S. gallons. *Dimensions shown are for NPTF ported valves; for other end fitting configurations consult factory.
Ordering Information
Series Inlet Outlet Port Size Thread Type Spring Pressure Seal
CPI - F- F- NPSF or BSP SAE RP - 05 - 5 psi (.35 bar) No letter for
Inline Female Female 2 - 1/4” Female 15 - 15 psi (1 bar) Viton (std.)
Check 3 - 3/8” British Parallel 25 - 25 psi (1.75 bar) A - Buna
Valve 4 - 1/2” 8 - 1/2” BS 2779 65 - 65 psi (4.50 bar) E - Ethylene
Poppet 6 - 3/4” 12 - 3/4” P - Female NPSF Propylene
Style 8 - 1” 16 - 1” S - Female SAE
CAV 10 - 3P - 15 A
*3/4” 6C SST working pressure - 5000 psi (345 bar), 1” 6C SST working pressure - 4000 psi (275 bar)
! WARNING !
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH,
PERSONAL INJURY AND PROPERTY DAMAGE.
This document and other information from Snap-tite, Inc., its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having
technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to
the variety of operation conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of
the products and systems and assuring that all performance, safety and warning requirements of the application are met.
The products described herein, including without limitation, product features, specifications, designs, availability and pricing, are subject to change by Snap-tite, Inc. and its subsidiaries
at any time without notice.
Distributed by:
Table of Contents
1 Technical Data
2 Hints
2.1 General Hints
2.2 Safety and Advice Hints
2.3 General Hints to Danger
2.4 Proper Use
3 Storage
4 Assembly
4.1 Components of the Couplings
4.2 Hint regarding the finish bore
4.3 Taper Lock Clamping Sleeve
4.4 Assembly of the Hubs
4.5 Displacements - Alignment of the Couplings
5 Enclosure A
® ®
picture 1: ROTEX (material: Al-D) picture 2: ROTEX (material: GG 25 / GGG 40)
® ®
picture 3: ROTEX (material: steel) picture 4: ROTEX design DKM
®
picture 5: ROTEX design Taper-Lock
CAUTION !
For a continuous and troublefree operation of the coupling it must be designed according
! to the selection instructions (according to DIN 740 part 2) for the particular application
®
(see ROTEX catalogue).
If the operating conditions (performance, speed, changes at engine and machine) change,
the coupling selection must be checked again.
2 Hints
Please read through these mounting instructions carefully before you set the coupling into operation. Please pay
special attention to the safety instructions!
The ROTEX® coupling is approved for the use in hazardous areas.
When using the coupling in hazardous areas please observe the special hints and instructions
regarding safety in enclosure A.
The mounting instructions are part of your product. Please keep them carefully and close to the coupling.
The copyright for these mounting instructions remains with KTR Kupplungstechnik GmbH.
DANGER !
STOP With assembly, operation and maintenance of the coupling it has to be made sure that the
entire drive train is protected against unintentional engagement. You can be seriously hurt
by rotating parts. Please make absolutely sure to read through and observe the following
safety instructions.
• All operations on and with the coupling have to be performed taking into account "safety first".
• Please make sure to disengage the power pack before you perform your work.
• Protect the power pack against unintentional engagement, e. g. by providing hints at the place of engagement
or removing the fuse for current supply.
• Do not touch the operation area of the coupling as long as it is in operation.
• Please protect the coupling against unintentional touch. Please provide for the necessary protection devices
and caps.
You may only assemble, operate and maintain the coupling if you
• carefully read through the mounting instructions and understood them
• had technical training
• are authorized to do so by your company
The coupling may only be used in accordance with the technical data (see table 1 to 5 in chapter 1).
Unauthorized modifications on the coupling design are not admissible. We do not take any warranty for resulting
damages. To further develop the product we reserve the right for technical modifications.
The ROTEX® described in here corresponds to the technical status at the time of printing of these mounting
instructions.
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9
months.
The features of the coupling spiders (elastomers) remain unchanged for up to 5 years in case of favourable stock
conditions.
CAUTION !
The storage rooms may not include any ozone-generating devices, like e. g. fluorescent
! light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that there is no condensation. The best relative air humidity is under
65%.
4 Assembly
Basically the coupling is supplied in individual parts. Before assembly the coupling has to be controlled for
completeness.
Compo-
Quantity Designation
nent
1 2 hub
2 1 spider
3 2 setscrew
®
picture 6: ROTEX
Compo-
Quantity Designation
nent
1 2 hub
2 2 spider
3 1 DKM - spacer
4 2 setscrew
®
picture 7: ROTEX DKM
Compo-
Quantity Designation
nent
hub for taper
1 2
clamping sleeve
taper lock clamping
2 2
sleeve
3 1 spider
4 4 setscrew
®
picture 8: ROTEX Taper-Lock-clamping sleeve
spider hardness
marking (colour)
(Shore)
92 Sh A yellow
95/98 Sh A red
natural white with green
64 Sh D-F
marking of teeth
DANGER !
STOP Valid for all materials !
The maximum permissible bore diameters d (see
table 1 to 5 in chapter 1 - Technical Data) must not be
exceeded. If these figures are disregarded, the
coupling may tear. Rotating particles may cause
serious danger.
Table 6: Setscrews
ROTEX® size 14 19 24 28 38 42 48 55 65
dimension G M4 M5 M5 M6 M8 M8 M8 M10 M10
tightening torque TA [Nm] 1,5 2 2 4,8 10 10 10 17 17
®
ROTEX size 75 90 100 110 125 140 160 180
dimension G M10 M12 M12 M16 M16 M20 M20 M20
tightening torque TA [Nm] 17 40 40 80 80 140 140 140
Table 7:
taper lock screw dimension
clamping G L SW TA quantity spanner
sleeve [inch] [inch] [mm] [Nm]
1008 1/4 1/2 3 5,7 2 SW 3
1108 1/4 1/2 3 5,7 2 SW 3
1610 3/8 5/8 5 20 2 SW 5
1615 3/8 5/8 5 20 2 SW 5
2012 7/16 7/8 6 31 2 SW 6
2517 1/2 7/8 6 49 2 SW 6
3020 5/8 1 1/4 8 92 2 SW 8 picture 10: withworth grub screw (BSW)
F
ATTENTION !
We recommend to check bores, shaft, keyway and feather key for dimensional accuracy
before assembly.
Heating the hubs slightly (approx. 80 °C) allows for an easier installation onto the shaft.
PRECAUTION !
Please pay attention to the danger of ignition in hazardous areas.
DANGER !
STOP Touching the heated hubs causes burns.
We would recommend to wear safety gloves.
CAUTION !
For the assembly please make sure that the distance dimension E (see table 1 to 5) is kept
! to ensure that the spider can be moved axially.
Disregarding this hint may cause damage on the coupling.
• Assemble the hubs onto the shaft of driving and driven side.
• Move the power packs in axial direction until the dimension E is achieved.
• If the power packs are already firmly assembled, axial movement of the hubs on the shafts allows for
adjusting the dimension E.
• Fasten the hubs by tightening the setscrews DIN 916 with cup point.
F
ATTENTION !
If the shaft diameters with inserted feather key are smaller than the dimension dH (see
table 1 to 5) of the spider, one or two shaft ends may protude into the spider.
The displacement figures shown in tables 8 and 9 offer sufficient safety to compensate for environmental
influences like, for example, heat expansion or lowering of foundation.
CAUTION !
In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
! hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 8 and 9). If the
figures are exceeded, the coupling is damaged.
In case of a use in hazardous areas for the explosion group IIC (marking II 2G c IIC T4),
only the half displacement figures (see tables 8 and 9) are permissible.
Please note:
• The displacement figures mentioned in tables 8 and 9 are maximum figures which must not arise in parallel.
If radial and angular displacement arises at the same time, the permissible displacement values may only be
used in part (see picture 12).
• Please check with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 8 and 9
can be observed.
Example 1:
∆KR = 30%
∆KW = 70%
Example 2:
∆KR = 60%
∆KW = 40%
ROTEX® DKM and ROTEX® ZS-DKM only with spacer made from steel.
ROTEX® Coupling
® ®
picture 13: ROTEX coupling picture 14: ROTEX spider
Here the backlash between coupling cams and the flexible spider must be checked by a feeler gauge.
When reaching the limit of wear of max. friction, the spider must be exchanged immediately, independent of the
inspection intervals.
In case of a backlash of more than x mm, the flexible spider must be exchanged.
The reaching of the exchange values depends on the operating conditions and the existing operating
parameters.
CAUTION !
In order to ensure a long lifetime of the coupling and to avoid dangers regarding the use in
! hazardous areas, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures indicated (see tables 8 and 9). If the
figures are exceeded, the coupling is damaged.
picture 15: checking of the limit of wear picture 16: wear of spider
Table 10:
ROTEX® limits of wear (friction) ROTEX® limits of wear (friction)
size Xmax. [mm] size Xmax. [mm]
9 2 65 5
14 2 75 6
19 3 90 8
24 3 100 9
28 3 110 9
38 3 125 10
42 4 140 12
48 4 160 14
55 5 180 14
In the explosion groups IIB and IIC only the following material combinations may be used:
GG 25 - GG 25
GGG 40 - GGG 40
steel - steel
stainless steel - stainless steel
Couplings for the use in hazardous areas are marked for the respectively permissible conditions of use.
Explosion group IIC: e. g. II 2G c IIC T4
In the marking II 2G c IIC T4 the explosion group IIB is included.
5.5 Starting
Before putting the coupling into operation, check the tightness of the setscrews in the hubs, the alignment and
the distance dimension E and correct, if necessary, and also check all screw connections regarding the stipulated
tightening torques dependent on the type of coupling.
If used in hazardous areas, the setscrews must be additionally secured against self-loosening to fix
the hub, e. g. with Loctite (medium strength).
Last but not least, the coupling protection against unintended contact must be fixed.
The distance between the cover and the rotating parts must be at least 5 mm.
The cover must be electrically conductive and be included in the equipotential bonding. Bellhousings made from
aluminium and damping rings (NBR) can be used as connecting element between pump and electro motor if the
magnesium part is below 7,5 %. The cover may only be taken off after having stopped the unit.
CAUTION !
If you note any irregularities at the coupling during operation, the drive unit must be turned
! off immediately. The cause of the breakdown must be found out with the table
„Breakdowns“ and, if possible, be eliminated according to the proposals. The possible
breakdowns mentioned can be hints only. To find out the cause all operating factors and
machine components must be considered.
F
ATTENTION !
KTR does not assume any liabilities or guarantees regarding the use of spare parts and
accessories which are not provided by KTR and for the damages resulting herefrom.
Certificate of Conformity
corresponding to EG Standard 94/9/EG dated 23 March 1994
and to the legal regulations
The manufacturer - KTR Kupplungstechnik GmbH, D-48432 Rheine - states that the
According to article 8 (1) of Standard 94/9/EG the technical documentation is deposited with the:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
FILTER ELEMENTS
HYDAC filters are tested according
to the following ISO test standards:
• ISO 3724, Verification of fatigue
characteristics
• ISO 4572, Filtration Efficiency
FLN In-Line Simplex Filter
• ISO 4572, Multi-pass method for
evaluating filtration performance Fluid Compatibility:
• ISO 3968, Evaluation of pressure Suitable for mineral oils,
drop versus flow characteristics lubrication oils, non-flammable
• ISO 2942, Bubble point test fluids, synthetic and rapidly
biodegradable oils. For use with
• ISO 2941, Verification of water, please contact our
collapse / burst resistance
technical sales department.
Reliable filter operation is only
• Clogging Indicator:
guaranteed with the original
For further types of clogging
HYDAC filter elements.
indicators and further details
The filter elements are also on indicators, please see
suitable for use in dynamic brochure no.: 02070327.
applications due to their high
• Seals:
pressure stability; maximum
FKM (Viton)
permissable ∆p across the element:
Betamicron® (BN/HC):
435 psi (30 bar)
Wire Mesh (W/HC):
435 psi (30 bar)
Model Code: Filter
FLN BN/HC 250 D E 10 A 1 . X / 12 - V - B3 .
Filter Type
FLN
Filter Material Element
BN/HC = Betamicron® (BN3HC)
W/HC = Stainless Steel Wire Mesh
Size
160, 250, 400
Operating Pressure
D = 360 psi (25 bar)
Type and Size of Port
E = SAE-20 (1 1/4”)
Filtration Rating (micron)
3 = 3µm
6 = 6µm
BN/HC
10 = 10µm
25 = 25µm
25 = 25µm
50 = 50µm
W/HC
100 = 100µm
200 = 200µm
Type of Clogging Indicator
A = no clogging indicator
B = with visual clogging indicator VM2B.0 for other
C = with electrical clogging indicator VM2C.0 clogging
D = with visual and electrical clogging indicator VM2D.0 indicators
see brochure
LE = visual-mechanical/electrical indicator VD2LE.0 # 02070327
LZ = visual-mechanical/electrical indicator with VD2LZ.0
75% and 100% switching contact
Type Code
1
Modification Number
X the latest version is always supplied
Port Configuration
12 = SAE straight thread inlet/outlet connections
Seals
V = Fluoro Rubber (FKM) (standard)
Bypass Valve
B3 = 43 psid (3 bar) (standard)
(omit) = no bypass (optional - consult factory)
Supplementary Details
L24 = Lamp for 24 volt
L48 = Lamp for 48 volt D-type clogging
L115 = Lamp for 110 volt indicator only
L230 = Lamp for 220 volt
W = suitable for oil-water emulsions (HFA, HFC), NBR seals,
(refers exclusively to the type of clogging indicator)
EV = knurled air bleed valve (replaces standard socket head plug)
A2.2 = 32 psi (2.2 bar) Indicator trip setting
30C = 30°C Indicator thermal lockout
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
2
Model Code: Replacement Element
0250 DN 010 BN/HC / - V
Size
0160 = size 160
0250 = size 250
0400 = size 400
Type
DN
Filtration Rating (micron)
003 = 3µm
006 = 6µm
BN/HC
010 = 10µm
025 = 25µm
025 = 25µm
050 = 50µm
W/HC
100 = 100µm
200 = 200µm
Filter Material
BN/HC = Betamicron®
W/HC = Stainless Steel wire mesh
Seals
V = FKM - Fluoro Rubber (standard)
Model Codes Containing Red are non-stock items — Minimum quantities may apply – Contact HYDAC for information and availability
Filtration Efficiency:
Filtration Rating Specification
3 µm ß 3 ≥ 200
6 µm ß 6 ≥ 200
10 µm ß 10 ≥ 200
25 µm ß 25 ≥ 200
Element Data:
Element Specifications
ISOMTD contamination
retention capacity in grams
at ∆p = 72 psi (5 bar) for BN/HC elements
Filter Type 3 µm 6 µm 10 µm 25 µm
160 27.5 29.3 33.1 36.7
250 46.0 49.0 55.2 61.3
400 76.2 81.3 91.4 101.5
Assembly Weight:
Filter Specifications
Weight lbs(kg)
Filter Type Port Element Size
with element
160 SAE 1 1/4” 0160 DN... 4.3 (9.5)
250 SAE 1 1/4” 0250 DN... 4.9 (10.8)
400 SAE 1 1/4” 0400 DN... 5.9 (13.0)
3
Engineering Data: FLN 160, 250, and 400
Design In-Line Low Pressure Filter
Mounting Method 2 Mounting Holes on top of Filter Housing
Connections Inlet: Outlet:
SAE-20 (1 7/8-12 UN-28) SAE-20 (1 7/8-12 UN-28)
Direction of Flow In-Line
Housing Pressure Ratings Operating: 360 psi (25 bar)
Proof: 540 psi (37.5 bar)
Fatigue: 360 psi (25 bar) @ 1 million cycles
Burst: Contact HYDAC office
Element Collapse Pressure Ratings Standard Elements: BN/HC: 435 psid (30 bar)
(ISO 2941) W/HC: 435 psid (30 bar)
Fluid Temperature Range -22°F to +210°F (-30°C to 100°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Fluid Compatibility Compatible with all petroleum oils and synthetic fluids rated for use
(ISO 2943) with Fluoro Rubber seals.
Contact HYDAC office for information on special for use with water
glycols,oil/water emulsions, and HWBF.
Flow Fatigue Resistance Filter medium is supported to achieve flow fatigue resistance.
(ISO 3724) Contact HYDAC office for information.
Trip Pressure of Differential Indicator 29 psi (2 bar) ± 10% (standard)
Cracking Pressure of ∆P = 43 psid (3 bar) bar ± 10% (standard)
Bypass Valve No Bypass (optional - consult factory)
Hydraulic Symbols
with bypass (standard) without bypass (optional)
A A
VA
VA
B B
4
Pressure Drop Calculations:
Assembly
To calculate the pressure drop of a filter assembly use the equation:
∆P Assembly = ∆P Housing + ∆P Element
Housing Curves
The housing curve is based on test results using mineral oil with a specific gravity of 0.86. Differential pressure increases in
proportion to specific gravity of applicable fluid. To adjust the housing ∆P for the fluid being used, use the equation:
0.40 6.0
0.30 4.5
0.20 3.0
0.10 1.5
0.00 0.0
0 13 26 40 52 66 79 92 106
Q in gpm
Elements ∆P Calculations
All element curves are based on test results using mineral oil with a kinematic viscosity of 141 SUS and a specific
gravity of 0.86. The differential pressure across the element changes proportionally to the viscosity and specific gravity.
1.4 21
p in bar
6µm
1.2 18
p in psid
p in bar
0.8 12
10µm 1.0 15
0.6 9 10µm
25µm 0.8 12
0.6 9 25µm
0.4 6
0.4 6
0.2 3
0.2 3
0.0 0 0.0 0
0 13 26 40 52 0 26 52 79 106
Q in gpm Q in gpm
0 50 100 150 200 0 100 200 300 400
Q in L/min Q in L/min
1.4 21
p in bar
size 250
1.0 15 0.04 0.60
0.8 12 6µm
0.03 0.45 size 400
0.6 9 10µm 0.02 0.30
0.4 6 25µm
0.2 3 0.01 0.15
0.0 0 0.00 0.00
0 26 52 79 106 0 13 26 40 52 66 79 92 106
Q in gpm Q in gpm
5
Dimensions: FLN 160, 250, and 400
1.7" SAE-2
43.5mm 1 1/4"
INLET OUTLET
3.0"
76mm
size 160
11.2"
285mm
size 250
14.3"
363mm
Drain Screw
size 400
20.2"
513mm
ø 3.9"
100mm
M10x8
2.4"
ø 5.1" ø
130mm 60mm
Indicator Plug/Port
5.9"
150mm
6
HYDAC FILTERTECHNIK
Inline Filter
FLN 160 / 250 / 400
SPARE PARTS LIST
MAINTENANCE INSTRUCTIONS
for customer Hägglunds
2. Maintenance
2.1 General
2.2 Maintenance procedures
2.3 Interval between changing elements
3. Element-changes
3.1 Removing the element
3.2 Element-mounting
4. Spare parts
4.1 Spare part-drawing FLN
4.2 Spare parts list FLN
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
1. Maintenance instructions
1.1 Safety-instructions
This pressure vessel complies with the provisions of article 3 paragraph 3 of the
pressure vessels directive (97/23/EC) and so must not have a CE-mark.
Information
The pressure vessel must be used only according to the operating instructions of
the machine or system.
Information
Information
The user must ensure appropriate actions to avoid air formation (e.g. venting)
Warning
W i
Attention pressure vessel: please ensure for all works at the pressure vessel that the
referring side of the pressure vessel (filter housing) is released of pressure.
Danger
Modificatione of the pressure vessel are not allowed (welding, drilling, forced
opening..).
Danger
The operator/owner has to ensure adherence to the National Water Resources Act as
well as local water resources laws and other related regulations.
Information
Information
Follow the rules for prevention of accidents, safety regulations and data sheets for
fluids.
Smoking and open flames/fire are not allowed while working on or near hydraulic
systems.
Hydraulic media and water-polluting fluids are not be allowed to soak into the soil,
seep into bodies of water or the sewage system. Ensure an environmentally waste
management of hydraulic oils. Adherence is to be maintained to pertinent national
and local regulations pertaining to groundwater protection, disposal of waste/spent
oil and (hazardous) waste.
Work on filters may involve leaking hot oil which may cause injury and scalding as
result of its high pressure and/or temperature.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
1.2 Installation
Before installation of the system it must be checked that the permissible operating pressure of
the system is not higher than the permissible operating pressure of the filter. Take a look at
the type code label!
1.3 Commissioning
Check whether the correct filter element (1) is fitted. Moisten thread and sealing surfaces on
the filter bowl and filter head, as well as the O-ring on bowl and element with clean system
fluid. Screw in the filter housing again fully and then unscrew by one quarter-turn (the sealing
effect will not be improved by over tightening). Switch on the hydraulic system and check the
filter for leakage. Vent filter.
2. MAINTENANCE
2.1 General
This section describes maintenance work, which should be carried out periodically. The
operational safety and the service-life of the filter, and whether it is ready for use, depend to a
large degree on regular and careful maintenance.
-Spare parts must fulfil the technical requirements specified by the manufacturer. This is
always guaranteed for HYDAC original spares.
-After disassembling the filter, clean all parts, check for damage or wear and change if
necessary.
-When changing a filter element it must be paid attention to the best cleanliness.
The filter can be equipped with a clogging indicator (visual and/or electrical or electronic) to
observe the filter element. If the clogging indicator reacts, it is necessary to change or clean
the filter element without delay. If no clogging indicator is installed, we recommend to change
the elements in intervals (the filter element change depends on the filter design and the
conditions).
Higher dynamic loads across the element might necessitate shorter intervals between
changes. Shorter intervals can also be necessary during commissioning, repairs, oil changes
etc, on the hydraulic system.
The standard clogging indicators only respond when fluid is flowing through the filter. With
electrical indicators the signal can also be converted into a continuous display on the control
panel. In this case the continuous display has to be switched off after a cold start or element
change. If the clogging indicator reacts during a cold start only, it is possible that the element
does not need to be changed yet.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
3. ELEMENT-CHANGES
3.1 Removing the element
2. Remove oil drain plug (collect fluid in a suitable container and clean or dispose of in accordance
with environmental regulations).
4. Remove filter element from element centering pivot (examine surface of element for dirt residue
and larger particles; these can indicate damage at the components).
5. Change or clean filter element (only W,W/HC, and V-elements can be cleaned)
Please request for cleaning instructions.
6. Clean filter bowl and filter head. Especially pay attention to the cleanliness of the threads.
7. Examine filter, especially sealing surfaces and thread, for mechanical damage.
1. Moisten thread and sealing surfaces on the filter bowl and filter head, as well as the o-ring with
clean operating fluid.
2. When fitting a new element, check that the designation corresponds to that of the old element.
6. Switch on hydraulic system and vent filter on suitable part of the unit.
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
Spare Parts Drawing FLN 160 bis 400
2.4/3.3/5.6
2.1
2.2/3.1/5.4
2.3/3.2/5.5
1.2/5.1
1.1
4.3/5.3
4.2/5.2
4.1
4.4/5.7
Hägglunds_E_FLN/24.11.00/B. Schön
HYDAC FILTERTECHNIK
Spare Parts List FLN 160 bis 400
cons. Article-no. Hägglunds-
Item pc. Designation
of Dimension No.
Filter Element:
1 0160 DN 006 BN3HC /-VPN-SO378-SPARE 01271034 478 3233 628
1 0160 DN 010 BN3HC /-VPN-SO378-SPARE 01271036 478 3233 620
1 1 0250 DN 006 BN3HC /-VPN-SO378-SPARE 01271038 478 3233 629
1 0250 DN 010 BN3HC /-VPN-SO378-SPARE 01271040 478 3233 621
1 0400 DN 006 BN3HC /-VPN-SO378-SPARE 01271042 478 3233 630
1 0400 DN 010 BN3HC /-VPN-SO378-SPARE 01271044 478 3233 622
1.1 1 Filter Element DN... -
1.2 1 O-ring 40,87 x 3,53 -
Clogging Indicator:
2 01271999 478 3233 644
VD 2.2 LE.1 /-30C-SO378-03043225
2.1 1 Clogging Indicator VD 2.2 LE... -
2.2 1 Profile sealing ring VD... -
2.3 1 O-ring 16 x 1 -
2.4 2 O-ring 12 x 1 -
Sealkit Clogging Indicator:
3 01272003 478 3233 651
SEALKIT-E VD /-SO378
3.1 1 Profile sealing ring VD... -
3.2 1 O-ring 16 x 1 -
3.3 2 O-ring 12 x 1 -
Filter Bowl:
BOWL-ASS‘Y FLND160 W.0/-V 01274800
4 BOWL-ASS‘Y FLND250 W.0/-V -
01274801
BOWL-ASS‘Y FLND400 W.0/-V 01274950
4.1 1 Bowl FLN... FLN... -
4.2 1 Back-up-ring FLN... -
4.3 1 O-ring 102 x 3 -
4.4 1 Locking screw G 3/8 NA -
Repair-kit:
5 01272216 -
REPAIR-KIT-E FLN..160/250/400 W.0
5.1 1 O-Ring (element) 40,87 x 3,53 -
5.2 1 Back-up-ring (Topf) FLN... -
5.3 1 O-ring (Bowl) 102 x 3 -
5.4 1 Profile sealing ring (clogging indicator) VD... -
5.5 1 O-Ring (clogging indicator) 16 x 1 -
5.6 2 O-Ring (clogging indicator) 12 x 1 -
5.7 1 Locking screw G 3/8 NA -
Hägglunds_E_FLN/24.11.00/B. Schön
PRESSURE GAUGE
PRECISION INSTRUMENT COMPANY
MODEL '201L', LIQUID FILLED GAUGES
Our ‘200’ Series Gauge Line Is A High Quality Line Of Liquid Filled Gauges. The Glycerine Filling Helps
Dampen The Effects Of Pulsation And Vibration, While Also Perpetually Lubricating The Movement (And
Keeping Contaminates Such As Dirt Away From All Moving Parts) Which Will Extend The Life Of The Gauge.
This Gauge Has Been Specifically Designed With The Original Equipment Manufacturers In Mind And
Are Typically Used On Hydraulic & Pneumatic Systems As Well As Any Commercial Or Industrial Application
Not Corrosive To Brass And Bronze Wetted Parts Where Glycerine Filling Is Suitable For Use.
SPECIFICATIONS:
• Available Dial Sizes: 1 ½”, 2”, 2 ½”, 4", 6"
• Available Connection Sizes:
1/8”MNPT on 1 ½” and 2”
1/4"MNPT on 2”, 2 ½” and 4"
1/2"MNPT on 4" and 6"
• Stainless Steel Case And Bezel
• Brass Internals & Connection
• Phosphour Bronze Bourdon Tube
• Liquid Filled (Dry Available)
• Accuracy : 1 ½” and 2” Dial = 2 %
2½ ”Dial Size = 1.5 %
4” and 6” Dial Size = 1 %
• Dual Scale: PSI & Bar (x100=kPa)
Single Scale available from stock
• Ambient temperature: FILLED: 30’F to 160’F
DRY: -30’F to 180’F
30/0"VAC A 5 0.5
30/0/15 CB 5 0.5
30/0/30 CC 10 1
30/0/60 CD 10 1
30/0/100 CE 20 2
30/0/150 CF 20 2
30/0/300 CH 50 10
0/15 B 2 0.2
0/30 C 5 0.5
0/60 D 10 1
0/100 E 20 2
0/160 F 20 2
0/200 G 40 4
A B C D E
0/300 H 50 5
0/400 I 50 5 1 ½” In 1.88 1.06 .89 2.77 1/8”
0/500 J 100 10 Dial MM 48 27 23 58 Npt
0/600 K 100 10
2” In 2.24 1.27 .71 2.80 1/8” or
0/800 L 100 10
0/1000 M 200 20 Dial MM 57 32 23 71 ¼”npt
0/1500 N 200 20 2 ½" In 2.80 1.28 1.07 3.55 1/4“
0/2000 O 400 50 MM 71 33 27 90 Npt
Dial
0/3000 P 500 50
0/4000 Q 500 50 4" In 4.32 1.63 1.25 5.57 1/4" or
0/5000 R 1000 100 Dial MM 110 42 32 141 ½
”npt
0/6000 S 2000 200
6" In 6.54 1.70 1.68 8.22 1/4“ or
0/10,000 U 2000 200
0/15,000 V 2000 200 Dial MM 166 43 43 210 ½”npt
OIL LEVEL INDICATOR
FLUID LEVEL
INDICATORS FSA/FSK
APPLICATION
The HYDAC FSA-Visual Fluid
Level indicators and FSK-
Electrical Fluid Level Indicators
are used for monitoring fluid
levels and temperature in various
types of reservoirs. Typical
applications are hydraulic system
reservoirs and lubricating, cutting
and cooling fluid tanks. Visual and
Electrical Fluid Level Indicators
are suitable for service in mineral
oils and phosphate-ester based
hydraulic fluids. For Water Glycols
and High Water based fluids, the
sight tube must be ordered in
glass construction. Fluid Level
Indicators can be supplied with
various types of thermometers:
Built-in Tube (FSA only), Dial
Gauge with Thermometer Probe
or Electrical Thermo-Switch.
SPECIAL FEATURES
• Attractive appearance
• Transparent Polyamide sight tube
• Thermometers furnished with
dual range for both Celsius and
Fahrenheit
• Simple and rugged construction
• Available in several sizes
• Choice of seals
• Easy mounting
• Available with Thermo-Switch
DESCRIPTION controls the oil temperature in the
hydraulic reservoir. The Thermo
The HYDAC FSA Visual Fluid Level Switch opens when the nominal
Indicator is available in five sizes. temperature is reached. The switch
The HYDAC FSK Electrical Fluid closes when the temperature is
Level Indicator is available in four approximately 36˚F (20˚ below
sizes and provides an electrical nominal temperature.)
signal at a low fluid level. This
reliable magnetically-operated
reed relay circuit is available in
two single pole single throw
(SPST) contact arrangements:
normally closed (type “O”) or
normally open (type “C”). The
HYDAC TS Thermo-Switch
TECHNICAL DATA THERMO SWITCH SELECTION CODE
Thermo Switch Switch Mounting
Code Temperature Thread
Mounting Thread TS50 50˚C/122˚F M 12
FSK or FSA................M 12 or M 10 TS60 60˚C/140˚F M 12
TS ...................................M 12 only TS70 70˚C/158˚F M 12
TS80 80˚C/176˚F M 12
Material
Housing............Anodized Alumnum
Sight Tube............Polyamide,Glass
Seals................Fluorocarbon, NBR MODEL CODE
Fluid Temperature FS A -127- 1 . 1 - - T - 12 -
-4˚F/-20˚C to176˚F/80˚C
Maximum Pressure Fluid Level Indicator
14.5 PSI (1 BAR)
Type
Thermometer A = Visual
Type T K = Electrical
(FSA only)
68˚F/20˚C to 176˚F/80˚C Size (Mounting Hole Centers)
Type FT 76 = 3 inches (FSA Only)
32˚F/0˚C to 212˚F/100˚C 127 = 5 inches
176 = 7 inches
Bolting Torque 254 = 10 inches
Max. 8 LB-FT+1 (10 Nm +2) 381 = 15 inches
see installation instructions on page 4
Electric Switch Seals
1 = NBR (FSA)
FSK...C FSK...O
2 = Fluorocarbon (FSA and FSK)
2 2
3 3 Modification Number
1 1 1 = FSA (Determined by Manufacturer)
3 = FSK (Determined by Manufacturer)
Electrical Switch
(omit) = For FSA
Contact Ratings.................Max. 8W “C”(SPST) = Normally open at Normal Level
Maximium Voltage.....50 VAC or DC “O”(SPST) = Normally closed at Normal Level
Maximum Current...............200 mA
Connection 3 not used Thermometer
TYPE C TYPE O T = Built-in Tube (FSA Only)
Normally Normally FT 200 = Probe Thermometer (200mm-7.87”LG)
Open Closed FT 300 = Probe Thermometer (300mm-11.87”LG)
TS = Thermo Switch (See Chart Above)
FSK - C FSK - O
Hex Head Bolt
12 = M12 Bolt (Standard)
10 = M10 Bolt (Optional)(Not Available with TS)
Contacts are Contacts are Sight Tube
closed at lower open at lower (omit) = Polyamide construction (not suitable for water glycols or high water
level of fluid level of fluid based fluids)
Thermo Switch Glass = Glass construction-Special Order for FSA Only. Not Available with
FSK.
TS
When ordering probe thermometer separately, please order one (1) drilled bolt, item
12, in spare parts list.
1 2
See installation procedures on page 4 to determine whether a washer is needed.
If a washer is needed, order part # 00001689
M 12 or
M 10 M 12 or
M 10
1.97
50
.79 20
20 5 1.34
34
1.77
45
1.77
SCREW-TYPE CONDUIT
45
FITTING PG 9
Size L L1 L2 Size L L2
inch 4.25 1.46 2.99 inch 8.07 5.00
76 127
mm 108 37 76 mm 205 127
inch 6.26 2.99 5.00 inch 10.00 6.93
127 176
mm 159 76 127 mm 254 176
inch 8.19 4.92 6.93 inch 13.07 10.00
176 254
mm 208 125 176 mm 332 254
inch 11.26 7.99 10.00 inch 18.27 15.00
254 381
mm 286 203 254 mm 464 381
inch 16.26 12.99 15.00
381
mm 413 330 381
11
.67 SQ
SW 17
M 12
ø1.51
ø40
1.93
49
12
7.87" or 11.87"
200 or 300
.63 3.62
16 92
3
Recommended Installation Process
1. Drill mounting holes according to dimension L2 on page 3.
Mounting hole diameter is dependent on the bolt selected in the model code. see pages 2 & 3
2. Torque the Nut, item 9, to 8+ 1 LB-FT. If it is not possible to torque the nut, the bolt head must be torqued. To avoid
damaging the indicator a washer is recommended to be used under the bolt head.
This washer is available from HYDAC: Part Number 00001689.
Washer Dimensions: OD 18.8 mm, ID 13.10 mm, 0.5 mm thick
Spare Parts
FSA FSK
10 1
2
3
© Copyright 2001 HYDAC TECHNOLOGY CORPORATION - Brochure - Fluid Level Indicators FSA/FSK #02068184 / 9.02
9 13
4
5
6
7 14
or
15
Quanity Quanity
Item Description FSA FSK
1 Housing 1 1
2 Name Plate 1 -
3 Tube 1 1
4 O-Ring 13x2.5 2 2
5 Tube Connector 2 2
6 O-Ring 12.3x2.4 2 2
7 Sealing Washer 2 2
8 Hex Bolt 2 2
9 Hex Nut 2 2
10 Thermometer in Indicator Tube 1 -
11 Probe Thermometer (see page 3) 1 1
12 Hex Bolt for Probe Thermometer 1 1
13 Magnetic Float - 1
14 Base Assembly with Type “C” Switch - 1
15 Base Assembly with Type “O” Switch - 1
16 Washer (optional - see note 2 above) 1 1
page 84
BF...30 25 SCFM 3 or 10 µm Threaded Durable Synthetic Material (PA 6)
200 GPM phenolic resin 3/8 to 3/4” BSPP Pressurized (optional)
impregnated paper (male)
page 85
BF...7 65 SCFM 3 or 10 µm Threaded Durable Synthetic Material (PA 6)
500 GPM phenolic resin 1” BSPP with optional differential gauge
impregnated paper (male)
Replaceable
page 86
BL... & BLT... 110 SCFM 3 or 10 µm Threaded, Flanged, Spin-on elements (BL...)
850 GPM phenolic resin or Welded Dehumidifying element (BLT...)
impregnated paper
page 88
BD... (Drymicron) 100 SCFM 2µm Threaded, Silica Gel Desiccant adsorbs water
750 GPM Disposable Flanged, or then changes color to indicate
Bayonet when breather should be changed
page 91
BF...5 220 SCFM 3 or 10 µm Threaded Carbon Steel
1600 GPM phenolic resin 2 1/2” BSPP
impregnated paper (female)
Replaceable
page 87
page 81
Sizing: Maximum Flow is the greater of the maximum pump flow rate, or the maximum system return rate into
the reservoir. Flow rates given are based on a 0.6 psi initial pressure drop with a clean element in a normal
operating environment. Contact HYDAC for applications in extreme environmental conditions.
77 Accessories Catalog
Breathers
Breathers & Filler Breather Technical Overview
Importance of Breathers
Breathers are a integral component in any Hydraulic system. Breathers provide protection from contamination found in harsh industrial
environments. It is well advised to address both contaminant exclusion and removal. An old rule of thumb states that it cost 10 times
as much to REMOVE a particle from your system as it does to EXCLUDE it. Since this is true, it is easy to see that the benefits of
using a high quality breather greatly out-weigh the costs.
Recommendations
1) HYDAC recommends selecting a breather with a filtration rating (micron rating)
that is equivalent to or finer than your finest system filter.
2) Breathers do get clogged over time. HYDAC recommends the following change-out schedules:
For breathers without pressure gauges
• Change you breather annually or with every service interval
For breathers with pressure gauges
• Change your breathers at a 3 psi pressure drop, at 7 psi pressure drop the pump can cavitate
Pressurized Breathers
The use of pressurized breathers adds certain benefits:
• Provides additional protection from moisture which can condense in your tank, causing oil degradation and tank erosion
• Provides positive pressure to pump suction line
• Increased breather service life due to less breathing
• Performs anti-splash function
Tank Pressure
Atmospheric
No Breathing Takes Place Atmospheric
Pressure Pressure
Vacuum Vacuum
(tank breathes in) (tank breathes in)
Time Time
When fluid level rises, the tank pressure rises When fluid level rises, the existing air volume is
and air is immediately expelled through the compressed, and no air is expelled until the cracking
breather whenever positive pressure exists. pressure is surpassed.
When fluid level lowers, the tank pressure drops When fluid level lowers, the tank pressure drops
and air is immediately drawn in through the breather until a vacuum is created at which point, air will be
whenever a vacuum exists. drawn in through the breather.
Air is constantly moving through the breather Air is only expelled when the tank pressure is
in order to maintain atmospheric pressure. above the cracking pressure, and air is only
drawn in below atmospheric pressure.
The majority of the operational cycle will take place
between these two conditions.
0.18"
with relief valve (ELF3 only) standard ø
4.5mm
(6 places)
Size D1 D2 D3 H1 H2 H3
2.99” 3.27” 2.05” 6.26” 3.80” 2.46”
ELF 3 Ø Ø Ø
76mm 83mm 52mm 159mm 96.5mm 62.5mm
1.73” 1.97” 1.10” 5.32” 3.21” 2.11”
ELF 4 Ø Ø Ø
44mm 50mm 28mm 135mm 81.5mm 53.5mm
79 Accessories Catalog
Breathers
ELF 3 Series Filler Breather Parts
ELF 3 Breather Caps
Self Tapping
Bayonet Flange Kit
Screws
M5x10 (DIN 963)
Reservoir Wall
Hydraulic Symbol:
Mounting Hole Pattern
ELF 30
(Flange Interface to DIN 24557/T2)
0.18"
ø
4.5mm
standard
(6 places)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
81 Accessories Catalog
Breathers
ELF...7 Series Filler Breathers
Specifications: Dimensions:
• Maximum flow rate - 65 SCFM/500 GPM
• Durable synthetic material (PA6) ELF 7
• 3 or 10 micron
Optional
• 500 micron plastic filler basket Gauge
• Replaceable element
• Threaded connection to access fill port ø 4.72"
• Installs via 6-bolt circle (bolts included) 120mm
7.13"
with gauge ø 2.36" ø 2.87" 181mm
60mm 73mm Counter Sunk
3.82" Slotted Screw
97mm
ø 0.18" M5 x 10 (DIN 963)
4.5mm
(6 places)
ø 1.93"
49mm
without gauge
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
2.68"
Replacement Elements 68mm
G3
Micron Model Code Part No. (ELF5...3.0)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
83 Accessories Catalog
Breathers
BF...3 & BF...4 Series Breathers
Specifications: Dimensions:
• Maximum flow rate - 35 SCFM/250 GPM
• Epoxy coated steel cap
ø D1
• Zinc-plated internals
• 3 or 10 micron
• Threaded connection
• Pressurized breather H1
with relief valve (optional - BF3 only)
H3
Hydraulic Symbols: HEX
D2
standard
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
85 Accessories Catalog
Breathers
BF...7 Series Breathers
Specifications: Dimensions:
• Maximum flow rate - 65 SCFM/500 GPM
• Durable synthetic material Optional
• 3 or 10 micron Gauge
• Replaceable element
• Threaded breather cap connection ø 4.72"
120mm
• Differential gauge (optional)
Replacement Elements
Micron Model Code Part No. 2.36" Clearance Required for
3 0007L003P 00310948
60mm Element Removal
10 0007L010P 00310485
ø 4.57"
116mm
1.73"
Hydraulic Symbols: 44mm
4.33"
110mm
with gauge
1 5/8"
HEX
41mm
0.71"
18mm
G 1"
ISO 228
without gauge
male
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
G 2 1/2"
Hydraulic Symbol: (ISO 228)
female
Model Code
BF P 5 G 10 W 1 . 0
Filter Type
BF = Breather
Filter Element Material
P = Phenolic Resin Impregnated Paper
Size
5
Type of Connection
G = Threaded
Filtration Rating (micron)
3 = 3µm Air Filtration
10 = 10µm Air Filtration
Gauge Options
W = Without Indicator
Tank Thread Connection (ISO 228)
1 = G 2 1/2 (standard)
Modification Number (standard)
Model Codes containing selections listed in red italics are non-standard items – Minimum quantities may apply – Contact HYDAC for information and availability
Not all combinations are available
87 Accessories Catalog
Breathers
BL Series Spin-on Breathers
Specifications: Dimensions:
• Maximum flow rate H3
Clearance needed
110 SCFM/850 GPM for removal Ø D1
• 3 or 10 micron Mounting Hole Pattern for Flange Connection (F)
(Flange Interface to DIN 24557/T2)
• Steel Canister
• 10 micron Betamicron® 2.87"
ø 73mm ø
2.36"
60mm
• Replaceable element H2
H1 ø 0.18"
4.5mm
(6 places)
Hydraulic Symbol:
D3
D2
Size D1 D2 D3 H1 (F or S) H1 (G) H2 H3
3.67” 7” 5.4” 0.75”
BL...80 3/4” NPT 1”-12UNF-2B -
Ø 93mm 178mm 137mm 19mm
5.00” 9.25” 8.75” 7” 1.00”
BL...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 235mm 222mm 178mm 25.4mm
5.00” 13.25” 12.75” 11” 1.00”
BL...180 1 1/4” NPT 1 1/2”-16UN-2B
Ø 127mm 337mm 324mm 279mm 25.4mm
5.33” 9.25” 8.75” 7” 1.00”
BLT...160 1 1/4” NPT 1 1/2”-16UN-2B
Ø 136mm 235mm 222mm 178mm 25.4mm
Dimensions are for general information only, all critical dimensions should be verified by requesting a certified print.
Adapters
Size G F S
Threaded Adapter Flanged Adapter Welded Adapter
ADAPTER BL 080G 3/4” NPT NBR
80 N/A N/A
02064393
160
ADAPTER BL 160/180 G 1 1/4” NPT NBR ADAPTER BL 160/180 F (PHOS) ADAPTER BL 160/180 S (PHOS)
02064394 00407646 00416311
180
89 Accessories Catalog
Breathers
Engineering Data
Mounting Position: ELF & BF Vertical (max. 30° off vertical axis)
BL, BLT, BLG, & BLS Vertical or Horizontal
Air Filter Material: Phenolic Resin Impregnated Paper
Note: None of the air filter elements can be cleaned.
Fluid Temperature Range: -15° to 250°F (-26° to 121°C)
Based on Nitrile Seals under maximum continuous operating pressure.
Please contact HYDAC for information on extreme low
temperature applications (below -15°F.)
Fluid Compatibility: Compatible with all petroleum oils.
(ISO 2943) Contact HYDAC office for information.
Weights
Model lbs. kg.
ELF 3 0.55 0.25
ELF E RV 0.66 0.30
ELF 4 0.44 0.20
ELF 5 (TYPE NO. 2) 5.95 2.70
ELF 5 (TYPE NO. 3) 6.83 3.10
ELF 7 0.84 0.38
BF 3 0.62 0.28
BF 3 RV 0.73 0.33
BF 4 0.18 0.08
BF 5 4.41 2.00
BF 7 0.88 0.40
BL 160 4.63 2.10
BL 80G 1.40 0.60
BL 160G 2.60 1.20
BL 180G 3.48 1.58
BL 160S 3.86 1.75
BL 180S 4.22 1.91
BLT 160 5.31 2.41
Retention Value
dx
x refers to the percentage of particles of a particular size that the breather will filter.
i.e. d80 for a 10µm filter will capture 80% of 10 µm particles
REPLACE
design to ensure optimum protection by removing GOLD
ACTIVE
water vapor and solid contaminant before they enter
the fluid system. GREEN
DRYMICRON Breathers replace the standard breather
cap or vent tube on a tank or reservoir. They are easy Safety Sealed
to install using one of several adapters designed for • Seals keep moisture from entering the units until they
different applications. are placed in service. They are easily removed without
When the fluid in the system is lowered, or pressure tools or sharp instruments.
changes occur, air is drawn in through openings under
the breather cap. First, air passes through a fine, 2
Solid Contaminant
micron solid particle filter. The air then passes through Filter (2 µm)
a diffuser to ensure maximum effectiveness within the
Air Diffuser
silica gel chamber.
Next, water vapor is removed as the air travels through
360˚ Air Flow
a bed of silica gel — the highest capacity adsorbent
available. After being dried, the air passes through a
second 2 micron solid particle filter and enters the
reservoir clean and dry!
High Capacity
Advantages Water Vapor
Adsorbent
DRYMICRON Breathers protect expensive equipment, Solid Contaminant
increase Filter (2 µm)
operation efficiency, and reduce maintenance costs by:
• eliminating corrosion
• extending life of hydraulic, lubrication, and process
fluids CLEAN DRY AIR
91 Accessories Catalog
Breathers
Product Specifications
Performance Specification
Nominal Air Flow Rate BD 100-400 35 SCFM (990 l/min)
Equivalent of 260 gpm of fluid volume change
Nominal Air Flow Rate BD 800 100 SCFM (2850 l/min)
Equivalent of 750 gpm of fluid volume change
Solid Contamination Filtration Level 2 micron, 100% efficiency @ 35 SCFM air flow
Solid Contamination Filtration Surface area 20.6 in2 / 133 cm2
Operating Temperature Range -26˚ to 200˚F / -32˚ to 93˚C
Silica Gel: Adsorption Up to 40% of its weight of water
Chemical Resistance Resistant to alkalis, hydrocarbons, non-oxidizing
acids, salt water, and mineral or synthetic oils
Flow Rate vs Pressure Drop Unit Selection Guide (adapters sold separately)
GPM Max. H2 0
Height (A) Weight
Model Code Part No. Capacity
37 75 112 150 187 225 262 300 inches (mm) lbs (kg)
1.0 lbs (ltr)
BD 100 X 2 W 0.0 02074253 3.5 (90) 1.3 (0.6) 0.2 (0.1)
0.8
BD 200 X 2 W 0.0 02074254 5 (128) 1.9 (0.9) 0.4 (0.2)
∆P (PSI)
Adapters Selection Guide (adapters sold separately - Note: no adapter needed for BD 800)
Bayonet Adapter Threaded Adapter Threaded Standpipe Adapter Flange Adapter
Part No. 02074251 Part No. 02074248 (3/4" NPT) Part No. 02077124 Part No. 02074250 (not drilled)
Part No. 02074249 (1" NPT) Part No. 02075193 (pre-drilled)
Bayonet Flange Kit with 3.5" Steel Basket Bypass Adapter Part No. 01270816 ø 0.18"
4.5mm
Part No. 02079076 (6 places)
Press-Fit to
2.36"
Drymicron ø
60mm
1 Bayonet Fitting
2 gaskets Vent to
atmosphere
1 Filler Basket
Press-Fit to any
6 Screws Drymicron Adapter
for Installation
X
Description:
This compact plastic design has a sponge element and threaded
connection with anti-splash baffle. Dipsticks are available to the D
Ordering:
To order models without dipsticks, simply use the model code from the chart above. If a dipstick is required
(dipsticks are special order items and minimum quantities may apply), also include:
• Overall Length
• To Add Mark refer to dimension drawing above
• To Full Mark
93 Accessories Catalog
Breathers
HBRM Series
Specifications: Dimensions:
• Chrome-plated carbon steel
• 10 or 40 micron
• NPT threaded connection
• Optional dipstick
Description: Overall
These chrome plated breathers have a paper element and NPT Dipstick Length
threads. Dipsticks are available to the customer’s requirement. To Full Mark
See ordering information below.
To Add Mark
ØA
C B
HEX
SIZE
D
(NPT Male)
Ordering:
To order models without dipsticks, simply use the model code from the chart above. If a dipstick is required
(dipsticks are special order items and minimum quantities may apply), also include:
• Overall Length
• To Add Mark refer to dimension drawing above
• To Full Mark
ENS 3000
Operating Manual
2 ENS 3000 Manual
CONTENTS
2. Mounting
The electronic level sensor ENS 3000 is to be fastened as completely as possible to the metal tube of the connecting
piece with an assembly fitting. An assembly fitting can take and hold a metal tube with 22 mm in diameter. We recom-
mend a bulkhead union with an inserted sleeve fitting (see Accessories section). The active range is to rise up as freely as
possible into the container. For optimal function a part of the active range should be over the upper edge of the con-
tainer or over the overflow of the container.
mode
mode
mode
Device for
Metal Part Attachment
of ENS 3000 Device for
for Connection Attachment Structure
Active
Range
For safe and simple assembly use assembly accessories from HYDAC ELECTRONICS
Attention: The electronic level sensor ENS 3000 is not suitable for tanks with positive pressure. A brief pressure of up
to 3 bar is tolerated and is not harmful up to a time span of 1 minute
mode
min
0.78”
min
2.36”
Active
Range
Metallic
Tube
At the mechanical connecting piece is a grounding screw, which takes over the function of an electrical ground. The
earth ground must be attached, if no grounding connection is given (e.g.: with the plastic tank). It is recommended to use
as leads a cable with diameter of 1 mm2 and as short a conduit length as possible.
4-digit
display
Display for
level sensor SP1 in SP2
4. Digital Display
After switching on the supply voltage on the equipment the display shows ENS&niU briefly. Afterwards the value (level or
temperature) in the display appears indicated and begins with the display of the current value (basic adjustment).
2s 2s
A level below the measurable range of the electronic level sensor is recognizable by the following operational sequence
on the announcement:
2s 2s
Hint:
• If the current level exceeds the nominal level range of the equipment, then it cannot not be indicated any more and
the announcement begins to flash.
• If the level of liquid falls below the lower measuring range, the display shows the value of the off set and the display
in such a way begins to flash
• During the display of the actual level; the possibility exists through pressing the key first the maximum value of
the level will be indicated. With each press of the key, the minimum value of the level, the current value, the
maximum value of the temperature, and the minimum value of the temperature are cycled through the display.
OUT
Hi. 1 plus 3xincrement Switch-back value
Hi. 1 Safety Zone Switching value
IN
IN
Lo. 1 Switching value
Safety Zone Switch-back value
Lo. 1 minus 3xincrement
OUT
t
IN
OUT
Hint: The window function works (switching on and off) only if all switching values (including security zone) are over 0 cm or
0°C, and under the nominal measuring range.
References:
• If “LOC” appears when attempting changes, the programming is locked. Programming should be changed to “free”
(see chapter 7 “programming releases”)
• When changing, if the key or is held, the value will continue to increase or decrease automatically.
• After changing the settings “PROG” appears in the display. The settings will then be stored in the unit.
Switching Point
Hystersis and/or
Measuring Range and/or Upper Increment
Lower Switching
in cm Switching Value in cm
Point in cm*
in cm*
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
Switching Point
Hystersis and/or
Measuring Range and/or Upper Increment
Lower Switching
in inches Switching Value in inches
Point in inches*
in inches*
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
25 0 to 104 0.1
36 0 to 144 0.1
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
*All ranges indicated in the table are adjustable in the raster of the incrementation and are valid with an offset-value of zero.
Hint: If no keys have been pressed for 25 seconds the menu is terminated automatically, without possible changes
becoming effective.
ON/ OFF ON
The adjustment procedure for switch point 2 is the same as described above.
Actual pressure
niv/ niv
Level-Peak value n.Top/
n.Min/
Temp/
T.Top/
Level-Min value T.Min/
S.P.1/
S.P.2/
OFF
Actual Tempurature
Tempurature-Peak value
Tempurature-Min value
or Switchpoint 1 or 2
Display off
Dark display (see section 4 for detail)
Display
Display reacts slowly to pressure changes. SLOW/ FAST
FAST
Level Offset
A positive offset is able to be programmed 0
to account for baseline level adjustment.
Tempurature indicated in °C
Software Version
Indicates the software version installed at time of manufacture.
If menu adjustments were changed, then upon exiting “ProG” will be displayed. This notifies the user changes have
been made and stored.
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
The equipment had 2 programming releases the two given to be must around attitudes change. The operating pro-
gramming release can be set and/or waived during the enterprise. It offers protection from unintentional changes.
Closing programming over the main programming release causes that during the enterprise no change of the attitudes
can be made. This serves e.g. as safety function or as protection from bad changes.
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
mode mode
Display
(arrow keys
released)
Press and hold both with or choose:
arrow keys for 6 seconds.
FrEE = programming free
Loc = programming locked
Hint: If a setting was changed, the display briefly changes to “ProG” after changing the setting. The new setting was
then stored in the equipment.
E.01 The setpoint and hysteresis were adjusted in such a way that the resulting reset point is not within the per-
mitted range of adjustment.
Example: Setpoint of 10 in. and hysteresis of 15 in.
Action: Change setpoint or hysteresis.
E.10 A data error was recognized within the stored settings. Possible causes are strong electromagnetic distur-
bance or a defective component.
Action: Examine all settings (programming releases, switching points, reset points and basic adjustments) and cor-
rect these if necessary. If the error should arise more frequently, contact our service department.
E.20 A communication error was recognized within the equipment. Possible causes are strong electromagnetic
disturbance or a defective component.
Action: Acknowledge error by depressing any key. If the error should remain, please contact our service department.
ENS 3X16-3
Imax 1.2 A
+ 1 4
SP 1
18 to 35 V
I = 4 to 40 mA
– 3 2
Analog
RL
General
Level Length of Probe 16.14” or 20.47”
Active Range 10.24” or 14.17”
Inactive Range 5.91” or 6.30”
Max. Vessel Pressure only for application without pressure
Output Data
Level Repeatability ± 2% FS
Accuracy at Switch Point ± 2% FS (at hydraulic oil)
Analog Output 0 to 10 V or 4 to 20 mA selectable
temperature or level selectable
Switching Outputs 2
Type PNP transister output
selectable N.O. / N.C.
Assigning of Switch Output selectable temperature or level
Switching Current Max. 1.2 A
Switching Cycles > 100 millions
Max. Speed of Change of Levels 130 mm/s
Ambient Conditions
Nominal temperature range 32° to 176°F (0° to 80˚C)
Ambient temperature range 32° to 176°F (0° to 80°C)
Storage temperature range -40° to 176°F (-40° to 80°C)
Fluid temperature range 32° to 176°F (0° to 80°C)
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
Vibration resistance to
approx. 10 g / 0 to 500 Hz
IEC 68-2-6 at 10 to 500Hz
Safety type to DIN 40050 IP 67
Shock Resistance approx. 50 g / 1ms
Other Data
Supply voltage 20 to 32 V
Dielectric coefficient of medium >2
Residual ripple supply voltage ≤ 5%
Reverse polarity protection of
the supply voltage, and short standard
circuit protection
Parts in Contact with Media PP (polypropylene)
Display 4 digit, 7 segment LED, red,
7mm character height
General
Level Length of Probe 16.14” or 20.47”
Active Range 10.24” or 14.17”
Inactive Range 5.91” or 6.30”
Max. Vessel Pressure only for application without pressure
Temperature Principle of Sensor semiconductor senor
Measuring Range 32° to 176°F (0° to 80˚C)
Output Data
Level Repeatability ± 2% FS
Accuracy at Switch Point ± 2% FS (at hydraulic oil)
Temperature Accuracy ± 2.7°F (± 1.5°C)
Analog Output 0 to 10 V or 4 to 20 mA selectable
temperature or level selectable
Switching Outputs 2
Type PNP transister output
selectable N.O. / N.C.
Assigning of Switch Output selectable temperature or level
Switching Current Max. 1.2 A
Switching Cycles > 100 millions
Max. Speed of Change of Levels 130 mm/s
Ambient Conditions
Nominal temperature range 32° to 176°F (0° to 80˚C)
Ambient temperature range 32° to 176°F (0° to 80°C)
Storage temperature range -40° to 176°F (-40° to 80°C)
Fluid temperature range 32° to 176°F (0° to 80°C)
EN 61000-6-1, EN 61000-6-2,
mark
EN 61000-6-3 and EN 61000-6-4
Vibration resistance to
approx. 10 g / 0 to 500 Hz
IEC 68-2-6 at 10 to 500Hz
Safety type to DIN 40050 IP 67
Shock Resistance approx. 50 g / 1ms
Other Data
Supply voltage 20 to 32 V
Dielectric coefficient of medium >2
Residual ripple supply voltage ≤ 5%
Reverse polarity protection of
the supply voltage, and short standard
circuit protection
Parts in Contact with Media PP (polypropylene)
Display 4 digit, 7 segment LED, red,
7mm character height
1.10"
(28mm)
1.04"
ZBE 06-02 with 2m length (26.5mm)
Part #: 06006790
Colour code:
ZBE 06-05 with 5m length Pin 1: brown
Part #: 06006789 1.24"
(31.50mm)
Pin 2: white
Pin 3: blue
Pin 4: black
1.10"
(28mm)
1.50"
(38mm)
1.42"
(36mm)
3.15"
(80mm)
1.61"
(41mm)
0.74"
(19mm)
1.40"
(36mm)
0.87"
(22mm)
1.50"
(38mm)
1.25" 2.13"
(32mm) (54mm)
G 3/4 BSPP
ø 1.65"
(42mm)
ø 2.15" M12x1
(54.5mm)
mode
3.68"
(93.5mm)
0162
19.82"
(503.5mm)
or
0205
24.15"
(613.5mm)
0.63" 1.13"
(16mm) (28.6mm)
Inactive Range
3.69"
(93.65mm)
0.87"
(22mm)
Active Range
10.24"
(260mm)
or
14.17”
0162 (360mm)
16.14"
(410mm)
or
0205
20.47"
(520mm) 15.02"
(381mm)
Inactive Range
1.09
(27.75mm)
Specifications
ANSI/ISO Pressure Rating: Dynamic applications with normal to moderate hydraulic Low Cycle, Non-pulsating Pressure Rating: Applications with lower cycle
shocks such as general industrial equipment, hydraulic presses, agricultural equip- life and no severe cyclic pressure fluctuations, essentially steady pressure during
ment, etc. Impulse tested at a multiple (125% to 133%) of rated pressure. an operating cycle. Typical applications include hydraulic jacks, mine roof
support systems, and high pressure fluid transfer (pumping water or slurry in
oil wells). Minor pump ripple is considered non-pulsating. Impulse tested at rated
pressure.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Pressure (PSI) Rated Pressure (PSI)
Brass 1000 1000 1000 1000 1000 1000 800 800 3000 3700 2700 3500 2200 1500 1500 1200
Stainless steel 2000 2000 1500 1500 1500 1000 1000 1000 5000 5000 5000 5000 3000 3000 1500 1500
Steel 5000 5000 4000 4000 2500 2000 1000 1000 5000 5000 4000 4000 2500 2000 1500 1500
Steel w / HD N/A 5000 4000 4000 3000 3000 N/A N/A 5000 5000 4000 4000 3000 3000 N/A N/A
nipple
Temperature Range: Standard seals (Buna-N) -40° to +250° F Optional Viton seals -10° to +400° F
Vacuum Data: 27.4 inches Hg. both connected and disconnected (1-1/2" and 2-1/2" body size 60 Series couplings are not reccommended for service in diconnected mode)
Note: Read the Safety Guide for Selecting and Using Quick Action Couplings and Related Accessories before making a coupling selection. It may be found in
Parker Hannifin Quick Coupling Divison catalogs and is available as Parker Publication No. 3800-B1.0.
Body Size (in.) 1/8 1/4 3/8 1/2 3/4 1 1 1/2 2 1/2
Rated Flow (GPM) .8 3 6 12 28 50 100 200
Performance
60 Series (1/8;1/4") 60 Series (3/8;1") 60 Series (11/2;21/2")
Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS Test Fluid: Oil - 200 SUS
30 30 200 200
40 40
30 30
2-1/2"
20 20 100 100
80 80
20 20
1/8" 60 60
1/4" 50 50
1/2" 1" 40 40
10 10
Pressure Drop in PSID
3/8" 3/4"
9 9 30 30
8 8 10 10
9 9 1-1/2"
7 7 8 8 20 20
6 6 7 7
5 5 6 6
5 5 10 10
4 4 8 8
4 4
3 6 6
3
5 5
3 3
4 4
2 2 3 3
2 2
2 2
1 1 1 1 1
1
.2 .3 .4 .5 .6 .7 .8 .9 1 2 3 4 1 2 3 4 5 6 7 8 910 20 40 60 80 10 20 30 40 50 60 80 100 200 300
Flow in USGPM Flow in USGPM Flow in USGPM
Couplers A
Female Thread
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Flats Diameter
A B C
1/8 BH1-60 0.16 H1-62 0.16 SH1-62 0.16 SSH1-62Y** 0.15 1/8-27 – 1.90 0.68 0.96
1/8 – – H1-62-T4 0.18 SH1-62-T*4 0.10 SSH1-62Y-T4 0.17 – 7/16-20 2.06 0.68 0.96
1/4 BH2-60 0.32 H2-62 0.30 SH2-62 0.30 SSH2-62Y 0.30 1/4-18 – 2.26 0.81 1.14
1/4 – – H2-62-T6 0.31 SH2-62-T6 0.31 SSH2-62Y-T6 0.31 – 9/16-18 2.41 0.81 1.14
3/8 BH3-60 0.43 H3-62 0.40 SH3-62 0.40 SSH3-62Y 0.40 3/8-18 – 2.49 0.88 1.40
3/8 – – H3-62-T8 0.51 SH3-62-T8 0.51 SSH3-62Y-T8 0.51 – 3/4-16 2.75 1.00 1.40
1/2 BH4-60 0.80 H4-62 0.73 SH4-62 0.75 SSH4-62Y 0.76 1/2-14 – 2.87 1.12 1.77
1/2 – – H4-62-T10 0.78 SH4-62-T10 0.75 SSH4-62Y-T10 0.78 – 7/8-14 3.05 1.12 1.77
3/4 BH6-60 – H6-62 1.30 SH6-62 1.31 SSH6-62Y 1.33 3/4-14 – 3.56 1.31 2.14
3/4 – – H6-62-T12 1.39 SH6-62-T12 1.34 SSH6-62Y-T12 1.40 – 1-1/16-12 3.56 1.31 2.14
1 BH8-60 – H8-62 1.95 SH8-62 1.95 SSH8-62Y 1.95 1-11 1/2 – 4.18 1.62 2.52
1 – – H8-62-T16 1.95 SH8-62-T16 1.95 SSH8-62Y-T16 1.95 – 1-5/16-12 4.18 1.62 2.52
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Contact factory for seal options)
Contact division for BSPP port availability
Nipples D
Female Thread
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Exposed Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Length Flats Diameter
D E F G
1/8 BH1-61 0.04 H1-63 0.03 SH1-63 0.03 SSH1-63Y** 0.04 1/8-27 – 1.61 0.41 0.56 0.65
1/8 – 0.06 H1-63-T4 0.05 SH1-63-T*4 – SSH1-63Y-T4 0.06 – 7/16-20 1.32 0.57 0.69 0.79
1/4 BH2-61 0.09 H2-63 0.08 SH2-63 0.08 SSH2-63Y 0.08 1/4-18 – 1.39 0.65 0.75 0.87
1/4 – 0.11 H2-63-T6 0.10 SH2-63-T6 0.10 SSH2-63Y-T6 0.10 – 9/16-18 1.54 0.70 0.88 1.01
3/8 BH3-61 0.10 H3-63 0.12 SH3-63 0.12 SSH3-63Y 0.12 3/8-18 – 1.50 0.54 0.88 1.01
3/8 – 0.12 H3-63-T8 0.16 SH3-63-T8 0.16 SSH3-63Y-T8 0.14 – 3/4-16 1.76 0.80 1.00 1.15
1/2 BH4-61 0.25 H4-63 0.24 SH4-63 0.24 SSH4-63Y 0.24 1/2-14 – 1.75 0.69 1.12 1.30
1/2 – 0.28 H4-63-T10 0.27 SH4-63-T10 0.27 SSH4-63Y-T10 0.27 – 7/8-14 1.94 0.87 1.19 1.37
3/4 BH6-61 0.50 H6-63 0.46 SH6-63 0.45 SSH6-63Y 0.46 3/4-14 – 2.16 0.79 1.38 1.59
3/4 – 0.55 H6-63-T12 0.46 SH6-63-T12 0.50 SSH6-63Y-T12 0.50 – 1-1/16-12 2.27 0.90 1.34 1.59
1 BH8-61 0.76 H8-63 0.76 SH8-63 0.76 SSH8-63Y 0.76 1-11 1/2 – 2.91 0.99 1.62 1.88
1 – 0.80 H8-63-T16 0.80 SH8-63-T16 0.80 SSH8-63Y-T16 0.80 – 1-5/16-12 2.91 0.99 1.62 1.88*
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Contact factory for seal options)
Contact division for BSPP port availability
A
Couplers
Female Thread
C
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Flats Diameter
A B C
1 1/2 BH12-60L 4.58 H12-62L 4.70 SH12-62L 4.68 SSH12-62LY** 4.68 1 1/4-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 BH12-60N 4.58 H12-62N 4.70 SH12-62N 4.68 SSH12-62NY 4.68 1 1/2-11 1/2 – 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T20 4.72 SH12-62-T20 4.71 SSH12-62Y-T20 4.71 – 1 5/8-12 4.86 2.38‡ 3.00
1 1/2 – 4.61 H12-62-T24 4.72 SH12-62-T24 4.71 SSH12-62Y-T24 4.71 – 1 7/8-12 4.86 2.38‡ 3.00
2 1/2 BH2016-60 11.06 H2016-62 10.58 SH2016-62 – SSH2016-62Y – 2-11 1/2 – 5.57 3.75 4.10
2 1/2 BH2020-60 11.42 H2020-62 10.91 SH2020-62 – SSH2020-62Y – 2 1/2-8 – 6.04 3.75 4.10
2 1/2 BH2024-60 – H2024-62 – SH2024-62 – SSH2024-62Y – 3-8 – 6.96 4.00 4.35
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Consult factory for seal options)
‡Wrench Flat on 303 Stainless is 2.50 in.
Contact division for BSPP port availability
D
Nipples E
Female Thread
G
Body Part Part Part No. Part No. Thread Thread Dimensions (in.)
Size No. Wt. (LB.) No. Wt. (LB.) Type 303 Wt. (LB.) Type 316 Wt. (LB.) Size Size Overall Exposed Wrench Largest
(in.) Brass P/Piece Steel* P/Piece Stainless* P/Piece Stainless* P/Piece NPTF ORB Length Length Flats Diameter
D E F G
1 1/2 BH12-61L 2.96 H12-63L 3.10 SH12-63L 3.06 SSH12-63LY** – 1 1/4-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 BH12-61N 2.96 H12-63N 3.10 SH12-63N 3.06 SSH12-63NY – 1 1/2-11 1/2 – 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T20 3.15 SH12-63-T20 3.14 SSH12-63Y-T20 – – 1 5/8-12 4.76 2.69 2.38‡ 2.75†
1 1/2 – – H12-63-T24 3.15 SH12-63-T24 3.14 SSH12-63Y-T24 – – 1 7/8-12 4.76 2.69 2.38‡ 2.75†
2 1/2 BH2016-61 7.78 H2016-63 7.90 SH2016-63 7.92 SSH2016-63Y – 2-11 1/2 – 5.48 2.90 3.75 4.10
2 1/2 BH2020-61 8.12 H2020-63 8.16 SH2020-63 8.16 SSH2020-63Y – 2 1/2-8 – 5.95 3.37 3.75 4.10
2 1/2 BH2024-61 – H2024-63 – SH2024-63 – SSH2024-63Y – 3-8 – 6.87 4.29 4.00 4.35
* T = Designator for SAE Straight Thread
** Suffix 'Y' designates Viton Seal. (Consult factory for seal options)
† Largest diameter on Brass is 2.96" across Hex Corners
‡Hex on 303 Stainless is 2.50 in.
Contact division for BSPP port availability
Specifications
Body Size (in.) 1/4 to 1
Rated Pressure (PSI)
with saturated steam at 338°F 100
Temperature Range (std seals) Ethylene Propylene
Continuous +250°F
Intermittent +400°F
Coupler
Female Pipe Thread
Body Part Thread Dimension (in.)
Size No. Size Overall Wrench Largest Wt. (LB.)
(in.) Brass NPTF Length Flats Diameter P/Piece
A B C G
1/4 BH2-60-STM 1/4-18 2.26 0.81 1.14 0.30
3/8 H3-68 3/8-18 2.50 0.88 1.77 0.50
1/2 BH4-60-STM 1/2-14 2.87 1.12 1.77 0.75
A
3/4 BH6-60-STM 3/4-14 3.56 1.31 2.14 1.31
1 BH8-60-STM 1-11 1/2 4.18 1.62 2.52 1.95
C
Nipple
Female Pipe Thread
Repair Kits
Body Repair Kit Used For
Steam Coupling Size Part No. Part No.
3/8 H68E-67K H3-68
3/8 H69E-67K H3-69
Applications
Parker offers a complete line of dust plugs and caps for their Protective dust plugs and caps play a crucial role in the use of
hydraulic quick couplings. Each series shown in this catalog quick couplings and no purchase of a hydraulic quick coupling
has a dust plug and cap specifically designed to be used with is complete without the selection of an appropriate dust plug
that style of coupling. and cap. When ordering the dust cap/plug body size must
correspond to that of the coupler or nipple.
Dust plugs and caps serve a twofold function. They keep the
mating surface clean and free of contamination and protect Parker’s full line of dust plugs and caps can be found below
the critical mating elements of the coupling halves when they and on the following pages.
are disconnected. In this way the nipple is protected from
damage that would make the total coupling unusable. Dust Plug: Used on Coupler (female half)
Dust Cap: Used on Nipple (male half)
Dust Plugs
Body Dust Plug Dust Plug Dust Cap Dust Cap
60 Series Size Part No. Part No. Part No. Part No.
(in.) Aluminum Geolast Aluminum Geolast
1/8 H1-65 H1-65M H1-66 H1-66M
1/4 H2-65 H2-65M H2-66 H2-66M
3/8 H3-65 H3-65M H3-66 H3-66M
1/2 H4-65 H4-65M H4-66 H4-66M
3/4 H6-65 H6-65M H6-66 H6-66M
1 H8-65 H8-65M H8-66 H8-66M
1 1/2 H12-65 NA H12-66 NA
2 1/2 H20P-65 NA H20P-66 NA
NA = Not Available
25 Electronics Catalog
Model Code:
EDS 3 X X X - X - XXXX - 400 X 1
Series
EDS 3 = 3000 Series Electronic Sensor
Sensor Type
1 = Ceramic absolute
3 = Ceramic relative
4 = Thin-film relative
Mechanical Connection
4 = G 1/4 BSPP male thread*
8 = 1/4” - 18 NPT male thread
7 = SAE-6 male thread (9/16-18 UNF2A)
Electrical Connection
6 = M12x1 plug, 4 pole for output codes 1, 2, and 3 (connector not included)
8 = M12x1 plug, 5 pole for output code 5 (connector not included)
Output
1 = 1 Switch output (only with electrical connection 6)
2 = 2 Switch outputs (only with electrical connection 6)
3 = 1 Switch with analog output (only with electrical connection 6)
5 = 2 Switch with analog output (only with electrical connection 8)
Pressure Ranges
Type 1 (ceramic - absolute) Type 3 (ceramic - relative) Type 4 (thin-film, relative)
0015 = 0 to 15 psi 0015 = 0 to 15 psi 0250 = 0 to 250 psi 1000 = 0 to 1000 psi
0050 = 0 to 50 psi 0030 = 0 to 30 psi 0500 = 0 to 500 psi 3000 = 0 to 3000 psi
0050 = 0 to 50 psi 0089 = -14 to 75 psi 6000 = 0 to 6000 psi
0150 = 0 to 150 psi 9000 = 0 to 9000 psi
Modification Number
400 = standard in psi
Sealing Material (in contact with media)
F = FPM seal (to be used for example with hydraulic fluid)
E = EPDM seal (to be used for example with refrigerant coolant or fluids containing ammonia)
Material for Mechanical Connection / Housing (in contact with media)
1 = Stainless Steel
* G 1/4 port sizes are available upon request
Plug Connection:
EDS 3XX6 EDS 3XX8 use with ZBE 06 (4-pole) & ZBE 08 (5-pole)
(4-pole) (5-pole) (see page 60)
4 3 4 3
1 2 1 5 2
Circuit Connection:
Model with 1 switch output Model with 1 switch output
Plug 4-pol. M12x1 and signal output Dimensions: ø 1.65"
M12x1
(42mm)
Plug 4-pol. M12x1
ø 2.15" (54.5mm)
EDS 3X46-1 EDS 3X46-3
Imax 1.2 A
+ 1 + 1 4
Imax 1.2 A SP 1
9 to 35 V 4 18 to 35 V
SP 1 I = 4 to 20 mA
– 3 – 3 2
Analog
RL
3.68"
(93.5mm)
mode
2.95"
(75mm)
Model with 2 switch outputs Model with 2 switch outputs
Plug 4-pol. M12x1 and signal output
Plug 5-pol. M12x1
EDS 3X46-2 EDS 3X48-5 Imax 1.2 A
Imax 1.2 A
+ 1 4 + 1 4
SP 1 SP 1
9 to 35 V Imax 1.2 A
Imax 1.2 A 18 to 35 V 5 0.47"
2 SP 2 (12mm)
– 3 – I = 4 to 20 mA
3 2
SP 2
Analog ø 1.16"
RL SAE 6 (29.5mm)
0.63"
6kt-SW27 (16mm)
SERVICE REFERENCE
DIVISION 4 SECTION ARTM
SALES
REFERENCE (Supersedes PD419-8) PD419-9
161-058027-001
DATE SEPTEMBER, 2002
GENERAL
Chromalox types ARTM (copper sheath), ARTMO (steel sheath), (ARTMO) and stainless steel (ARTMS) and (ARTMI).
ARTMS (stainless steel sheath) and ARTMI (INCOLOY® sheath) C. Medium to high watt densities.
screwplug immersion heaters are designed for a wide variety of heat- D. Built-in thermostat standard with ranges of 0-127˚F, 60-180˚F
ing applications. and 60-240˚F.
E. Broad selection of sheath materials to operate successfully in
many corrosive solutions. Note: Proper selection of the sheath
material is the sole responsibility of the customer.
IMPORTANT: It is the responsibility of the purchaser F. E1 (General Purpose), E2 (Moisture Resistant/Explosion
of the heater to make the ultimate choice of sheath Proof) and E4 (Moisture Resistant, not shown) terminal hous-
material based upon his knowledge of the chemical ings are standard.
composition of the corrosive solution, character of the
materials entering the solution, and controls which he
maintains on the process.
Heater Construction Characteristics: The system designer is responsible for the safety of
A. High quality resistance wire held in place by compacted this equipment and should install adequate back-up
Magnesium Oxide refractory enclosed in a wide variety of controls and safety devices with their electric heating
sheath materials. equipment. Where the consequences of failure could
B. 1” NPT Screwplug is standard in brass (ARTM), steel result in personal injury or property damage, back-up
controls are essential.
INSTALLATION
This Portion of the Heater Above Liquid Level and
Expected Low Liquid Exposed to Air Will Lead to Premature Burnout of Element
ELECTRIC SHOCK HAZARD. Disconnect all power Level
before installing or servicing heater. Failure to do so
could result in personal injury or property damage.
Heater must be installed by a qualified person in accor- WRONG
dance with the National Electrical Code, NFPA 70.
RIGHT
1. Before installing, check your type ARTM immersion heater
for any damage that may have occurred during shipment. Expected Maximum
Sediment Level
2. Check to insure that the line voltage is the same as that stamped
on the nameplate. Note: Locate Heater as low as possible for maximum heated liquid storage
3. Do not bend the heating elements. If bending is necessary, capacity. Heat does not move downward.
check factory. Figure 1 - Open Tank Installation
4. IMPORTANT: Mount heater in the tank so the liquid level will
always be above the effective heated portion of the heater (see
Figure 1).
© 2002 Chromalox®, Inc
INSTALLATION
If the heater is not properly submerged, the heating elements will Drip loop recommended
overheat and create heater damage or a possible fire hazard due to to minimize passage of moisture
along wiring into terminal
Outlet
excessive sheath temperatures. wiring and connections
OPERATION
1. Do not operate heaters at voltages in excess of that stamped on the insulation resistance of less than twenty megohms. Normally, this
heater since excess voltage will shorten heater life. megohm value corrects itself after heatup and does not affect
2. Always maintain a minimum of 2” of liquid above the heated por- heater efficiency or life.
tion of the element to prevent exposure of the effective heated
length. If the heater is not properly submerged, it may overheat and A low megohm condition can be easily corrected by removing the
damage heating elements, tank or contents. DO NOT OPERATE terminal housing and baking the heater in an oven at 350˚F for sev-
HEATER IF DRY. eral hours, preferably overnight. Note: Before baking, the lid must
3. Be sure all trapped air is removed from a closed tank. Bleed the air be removed from an E2 housing. The housing and screwplug gas-
out of the liquid piping system and heater housing prior to ener- ket must be removed from E4 models.
gizing.
Note: The tank or heating chamber in closed tank systems An alternate procedure is to disconnect the thermostat and energize
must be kept filled with liquid at all times. the heater(s) at low voltage until the megohm reading returns to
4. Keep heating elements above sediment deposits. normal. When energizing heater(s) in air, the sheath temperatures
5. Low Megohm Condition — The refractory materials used in elec- should not exceed 400˚F for copper and 750˚F for steel and alloy
tric heaters may absorb moisture during transit or when subject to elements.
a humid environment. This moisture absorption results in a cold
MAINTENANCE
3. Remove any accumulated sludge deposits from heater and
from tank.
ELECTRIC SHOCK HAZARD. Disconnect all power 4. Check for loose terminal connections and tighten if necessary.
before installing or servicing heater. Failure to do 5. If corrosion is indicated in the E2 or E4 terminal housing,
so could result in personal injury or property dam- check terminal box gasket and replace if necessary. Check screw-
age. Heater must be installed by a qualified person plug gasket on E4 models and replace if necessary. Check conduit
in accordance with the National Electrical Code, layout to correct conditions that allow corrosion to enter the termi-
NFPA 70. nal housing.
1. Heaters should be checked periodically for coatings and corro- 6. Clean terminal ends of all contamination.
sion and cleaned if necessary. 7. Check thermostat for proper identification.
2. The tank should be checked regularly for sediment around
the heater as sediment can act as an insulator and shorten heater life.
AB 16 S 32 1 1/4" 1.19 2.31 1.38 1.42 M12 14 2.24 3.31 1.14 1.38 0.28 M6 2.28 13 9 41x3.5
AB 16 S 40 1 1/2" 1.41 2.75 1.75 1.81 M12 14 2.72 3.74 1.14 1.38 0.28 M6 2.28 13 9 52X3.5
AB 16 S 50 2" 1.69 3.06 2.13 2.20 M12 14 3.15 4.09 1.14 1.38 0.28 M6 2.28 13 9 62X3.5
AB 16 S 63 2 1/2" 2.00 3.50 2.62 2.68 M12 14 3.86 4.53 1.22 1.65 0.31 M6 2.52 13 12 75X4
AB 16 S 80 3" 2.44 4.19 3.25 3.35 M16 16 4.57 5.31 1.22 1.65 0.35 M8 2.52 17 12 92X4
AB 16 S 100 4" 3.06 5.13 4.17 4.17 M16 16 5.39 6.26 1.22 1.65 0.35 M8 2.52 17 12 114X4
AB 16 S 125 5" 3.63 6.00 5.16 5.16 M16 16 6.42 7.13 1.22 1.65 0.35 M8 2.52 17 12 140X4
Type W X
(in) (in)
AB 16 S 32 to 50 4.13 1.57
AB 16 S 63 to 125 4.33 1.57
90° to shut
Type E L1 SW1
UNC-2B in mm
AB 16 S 32 to 63 7/16 - 14 0.47 12
Threaded bushing AB 16 S 40 to 63 1/2 - 13 0.51 12
AB 16 S 80 to 125 5/8 - 11 0.51 17
to
to
2. Technical Data: 4
Working Pressure: 87 p.s.i.
2
Max. Pressure: 174 p.s.i.
Tank 2 3
Burst Pressure: 290 p.s.i.
Vacuum: 20" Hg
Temperature -4°F to 176°F
Acceptable Movement
Size
Table 1
Type [NG] Size A B D E F G H L Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) Push/Pull Offset Angle(°) Weight (lbs.)
K 16 S 25 1" 1.03 2.06 1.69 0.43 0.43 2.17 2.76 2.56 ±0.20 in ±0.20 in 7.5° 0.8
K 16 S 32 1 1/4" 1.19 2.31 1.97 0.43 0.51 2.76 3.15 2.56 ±0.20 in ±0.20 in 7.5° 1.10
K 16 S 40 1 1/2" 1.41 2.75 2.44 0.51 0.51 3.15 3.54 3.94 ±0.39 in ±0.39 in 10° 1.76
K 16 S 50 2" 1.69 3.06 2.83 0.51 0.51 3.54 3.94 3.94 ±0.39 in ±0.39 in 10° 2.21
K 16 S 63 2 1/2" 2.00 3.50 3.43 0.55 0.51 4.13 4.53 3.94 ±0.39 in ±0.39 in 10° 2.65
K 16 S 80 3" 2.44 4.19 4.09 0.55 0.71 4.72 5.20 3.94 ±0.39 in ±0.39 in 10° 3.97
K 16 S 90 3 1/2" 2.75 4.75 4.09 0.55 0.71 5.12 5.75 3.94 ±0.39 in ±0.39 in 10° 4.19
K 16 S 100 4" 3.06 5.13 5.12 0.63 0.71 5.51 6.14 3.94 ±0.39 in ±0.39 in 10° 5.51
connecting sizes
after SAE-Norm
(J 518ci) and
after DIN 2633 - ND 16
Table 2
Type [NG] Size A B C D E F G H K L M N Acceptable Movement
SAE (in) (in) (in) (in) (in) (in) (in) (in) (in) (in) (mm) (in) Push/Pull Offset Angle (°) Weight (lbs.)
K16SD- 25 1" 1.031 2.062 4.53 1.69 0.43 0.43 2.17 2.76 3.35 2.56 4x14 0.63 ±0.20 in ±0.20 in 7.5° 3.31
K16SD- 32 1 1/4" 1.188 2.312 5.51 1.97 0.43 0.51 2.76 3.15 3.94 2.56 4x18 0.63 ±0.20 in ±0.20 in 7.5° 3.97
K16SD- 40 1 1/2" 1.406 2.750 5.91 2.44 0.51 0.51 3.15 3.54 4.33 3.94 4x18 0.63 ±0.39 in ±0.39 in 10° 4.85
K16SD- 50 2" 1.688 3.062 6.50 2.83 0.51 0.51 3.54 3.94 4.92 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 6.17
K16SD- 63 2 1/2" 2.00 3.500 7.28 3.43 0.55 0.51 4.13 4.53 5.71 3.94 4x18 0.71 ±0.39 in ±0.39 in 10° 7.06
K16SD- 80 3" 2.438 4.188 7.87 4.09 0.55 0.71 4.72 5.20 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 8.82
K16SD- 90 3 1/2" 2.750 4.750 7.87 4.09 0.55 0.71 5.12 5.75 6.30 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 9.04
K16SD- 100 4" 3.062 5.125 8.66 5.12 0.63 0.71 5.51 6.14 7.09 3.94 4x18 0.79 ±0.39 in ±0.39 in 10° 10.58
Table 3
The movement absorption in static and dynamic loads and the different types of movements must be added together and the totals
are not allowed to exceed the data given.
Attention: Pressure spikes are push loads which add to the axial movement. Do not exceed given data!
Table 4
Techincal Data:
Operating Pressure: 10,150 psi (lock pressure)
Proof Pressure: 40,600 psi
Temperature Range: -40°F to 176°F
Viscosity Range: 5 to 500 c St
Installation Position: Any direction
Flow Rate: See section 4
Stainless Steel on Request
Type G K d T U X
Notes:
E01PX10-2258.txt
Printout time: 2005-09-27 11:55:37
Printed by SpiderCom2 version: 4.1.4 Build 8
Parameter file name: E01PX10-2258.s2p
Parameter file version: 2
SpiderII software version: 4.1.2 2
Main settings
Function
MAA01 - System function BASIC
Configuration
MAB01 - E-motor connection for P1 E-motor 1
MAB02 - E-motor connection for P2 OFF
MAB03 - E-motor connection for P3 OFF
MAB04 - E-motor connection for P4 OFF
MAB05 - Drive connection for P1 Drive 1
MAB06 - Drive connection for P2 OFF
MAB07 - Drive connection for P3 OFF
MAB08 - Drive connection for P4 OFF
MAB09 - Separate or common Separate
MAB10 - Shutdown ramp time 0
MAB11 - Emerg. stop mem bypass off
Language
MAC01 - Display language selection English
Protection
MAD01 - Security code - setup menu yes (*)
MAD02 - Security code 0532 (*)
Pump outputs
Pump 1
POA01 - Forward min current 184 (*)
POA02 - Forward max current 320 (*)
POA03 - Reverse min current 180 (*)
POA04 - Reverse max current 320 (*)
POA05 - Coil resistance 41 (*)
POA06 - PWM-frequency 200
Pump 2
POB01 - Forward min current 0
POB02 - Forward max current 0
POB03 - Reverse min current 0
POB04 - Reverse max current 0
POB05 - Coil resistance 40
POB06 - PWM-frequency 200
Pump 3
POC01 - Forward min current 0
POC02 - Forward max current 0
POC03 - Reverse min current 0
POC04 - Reverse max current 0
POC05 - Coil resistance 40
POC06 - PWM-frequency 200
Pump 4
POD01 - Forward min current 0
POD02 - Forward max current 0
POD03 - Reverse min current 0
POD04 - Reverse max current 0
POD05 - Coil resistance 40
POD06 - PWM-frequency 200
Friction
POE01 - Pump friction Off
POE02 - Pump low friction limit 0
POE03 - Pump high friction limit 200
POE04 - Friction up ramp time 2.0
POE05 - Friction down ramp time 2.0
Page 1
E01PX10-2258.txt
Digital inputs
Digital in 1 - 22
DIN01 - Digital input 1, DI1:3 14 START 1 (*)
DIN02 - Digital input 2, DI1:4 15 REV 1 (*)
DIN03 - Digital input 3, DI1:5 21 OFF (*)
DIN04 - Digital input 4, DI1:6 07 MN LEVEL
DIN05 - Digital input 5, DI1:7 07 LO LEVEL
DIN06 - Digital input 6, DI1:8 06 DRF 100
DIN07 - Digital input 7, DI2:4 06 RF100 P1
DIN08 - Digital input 8, DI2:5 05 SUCTION1
DIN09 - Digital input 9, DI2:6 03 C PRA P1 (*)
DIN10 - Digital input 10, DI2:7 01 H APR P1
DIN11 - Digital input 11, DI2:8 21 OFF (*)
DIN12 - Digital input 12, DI2:9 21 OFF (*)
DIN13 - Digital input 13, DI2:10 21 OFF (*)
DIN14 - Digital input 14, DI2:11 21 OFF (*)
DIN15 - Digital input 15, DI2:12 21 OFF
DIN16 - Digital input 16, DI3:4 21 OFF (*)
DIN17 - Digital input 17, DI3:5 21 OFF (*)
DIN18 - Digital input 18, DI3:6 21 OFF (*)
DIN19 - Digital input 19, DI3:7 21 OFF (*)
DIN20 - Digital input 20, DI3:8 21 OFF (*)
DIN21 - Digital input 21, DI3:9 21 OFF (*)
DIN22 - Digital input 22, DI3:10 21 OFF (*)
Digital in 23 - 43
DIN23 - Digital input 23, DI3:11 21 OFF (*)
DIN24 - Digital input 24, DI3:12 21 OFF
DIN25 - Digital input 25, DI4:4 21 OFF
DIN26 - Digital input 26, DI4:5 21 OFF
DIN27 - Digital input 27, DI4:6 21 OFF
DIN28 - Digital input 28, DI4:7 21 OFF
DIN29 - Digital input 29, DI4:8 21 OFF
DIN30 - Digital input 30, DI4:9 21 OFF
DIN31 - Digital input 31, DI4:10 21 OFF
DIN32 - Digital input 32, DI4:11 21 OFF
DIN33 - Digital input 33, DI4:12 21 OFF
DIN34 - Digital input 34, DI5:3 21 OFF
DIN35 - Digital input 35, DI5:4 21 OFF
DIN36 - Digital input 36, DI5:5 21 OFF
DIN37 - Digital input 37, DI5:6 21 OFF
DIN38 - Digital input 38, DI5:7 21 OFF
DIN39 - Digital input 39, DI5:8 21 OFF
DIN40 - Digital input 40, DI5:9 21 OFF
DIN41 - Digital input 41, DI5:10 21 OFF
DIN42 - Digital input 42, DI5:11 21 OFF
DIN43 - Digital input 43, DI5:12 21 OFF
Digital outputs
Digital out 1
DOA01 - Digital output function 11 COOLCONI (*)
DOA02 - Inverted function no
DOA03 - Delay time for digital output 5.0
DOA04 - Delay function for output NO
Digital out 2
DOB01 - Digital output function 01 A1 (*)
DOB02 - Inverted function no
DOB03 - Delay time for digital output 5.0
DOB04 - Delay function for output NO
Digital out 3
DOC01 - Digital output function 01 W1 (*)
DOC02 - Inverted function no
DOC03 - Delay time for digital output 5.0
Page 2
E01PX10-2258.txt
DOC04 - Delay function for output NO
Digital out 4
DOD01 - Digital output function 02 START 1 (*)
DOD02 - Inverted function no
DOD03 - Delay time for digital output 5.0
DOD04 - Delay function for output NO
Digital out 5
DOE01 - Digital output function 04 REMOTE 1 (*)
DOE02 - Inverted function no
DOE03 - Delay time for digital output 5.0
DOE04 - Delay function for output NO
Digital out 6
DOF01 - Digital output function 03 READY 1 (*)
DOF02 - Inverted function no
DOF03 - Delay time for digital output 5.0
DOF04 - Delay function for output NO
Digital out 7
DOG01 - Digital output function 15 OFF
DOG02 - Inverted function no
DOG03 - Delay time for digital output 0.0 (*)
DOG04 - Delay function for output NO
Digital out 8
DOH01 - Digital output function 15 OFF
DOH02 - Inverted function no
DOH03 - Delay time for digital output 0.0 (*)
DOH04 - Delay function for output NO
Digital out 9
DOI01 - Digital output function 15 OFF
DOI02 - Inverted function no
DOI03 - Delay time for digital output 5.0
DOI04 - Delay function for output NO
Digital out 10
DOJ01 - Digital output function 15 OFF
DOJ02 - Inverted function no
DOJ03 - Delay time for digital output 5.0
DOJ04 - Delay function for output NO
Digital out 11
DOK01 - Digital output function 15 OFF
DOK02 - Inverted function no
DOK03 - Delay time for digital output 5.0
DOK04 - Delay function for output NO
Digital out 12
DOL01 - Digital output function 15 OFF
DOL02 - Inverted function no
DOL03 - Delay time for digital output 5.0
DOL04 - Delay function for output NO
Digital out 13
DOM01 - Digital output function 15 OFF
DOM02 - Inverted function no
DOM03 - Delay time for digital output 5.0
DOM04 - Delay function for output NO
Pulse inputs
Drive 1
P1I01 - Pulses/rev 3600 (*)
P1I02 - Units for REG109 rpm
P1I03 - Decimals for REG109 0
P1I04 - Scaling for REG109 1.00
P1I05 - Filter time for speed reading 0.0
P1I06 - Polarity - digital speed signal 1
P1I07 - Encoder type 1
Drive 2
P2I01 - Pulses/rev 1000
Page 3
E01PX10-2258.txt
P2I02 - Units for REG209 rpm
P2I03 - Decimals for REG209 0
P2I04 - Scaling for REG209 1.00
P2I05 - Filter time for speed reading 0.0
P2I06 - Polarity - digital speed signal 1
P2I07 - Encoder type 1
Analog inputs
Setpoint 1
AIA01 - Input type 4-20 mA
AIA02 - Zero point adjustment 0
AIA03 - Max point adjustment 0
AIA04 - Reading for REG101 %
Setpoint 2
AIB01 - Input type 4-20 mA
AIB02 - Zero point adjustment 0
AIB03 - Max point adjustment 0
AIB04 - Reading for REG201 %
Analog in 1
AIF01 - Input type 4-20 mA
AIF02 - Zero point adjustment 0
AIF03 - Max point adjustment 0
AIF04 - Min input, REG401 0
AIF05 - Max input, REG401 200
AIF06 - Units for REG401 bar
AIF07 - Decimals for REG401 0
AIF08 - Scaling for REG401 1.00
AIF09 - Function for input OFF
AIF10 - High indication level 200
AIF11 - Low indication level 0
AIF12 - Function for min indication OFF
AIF13 - Function for high indication OFF
AIF14 - Function for low indication OFF
Analog in 2
AIG01 - Input type 4-20 mA
AIG02 - Zero point adjustment 0
AIG03 - Max point adjustment 0
AIG04 - Min input, REG402 0
AIG05 - Max input, REG402 200
AIG06 - Units for REG402 bar
AIG07 - Decimals for REG402 0
AIG08 - Scaling for REG402 1.00
AIG09 - Function for input OFF
AIG10 - High indication level 200
AIG11 - Low indication level 0
AIG12 - Function for min indication OFF
AIG13 - Function for high indication OFF
AIG14 - Function for low indication OFF
Analog in 3
AIH01 - Input type 4-20 mA
AIH02 - Zero point adjustment 0
AIH03 - Max point adjustment 6 (*)
AIH04 - Min input, REG403 -25 (*)
AIH05 - Max input, REG403 100 (*)
AIH06 - Units for REG403 °C (*)
AIH07 - Decimals for REG403 1 (*)
AIH08 - Scaling for REG403 1.00
AIH09 - Function for input TANK A (*)
AIH10 - High indication level 60 (*)
AIH11 - Low indication level 0 (*)
AIH12 - Function for min indication OFF
AIH13 - Function for high indication OFF
AIH14 - Function for low indication OFF
Page 4
E01PX10-2258.txt
Analog in 4
AII01 - Input type 4-20 mA
AII02 - Zero point adjustment 0
AII03 - Max point adjustment 0
AII04 - Min input, REG404 0
AII05 - Max input, REG404 69 (*)
AII06 - Units for REG404 bar
AII07 - Decimals for REG404 0
AII08 - Scaling for REG404 1.00
AII09 - Function for input PR1 (*)
AII10 - High indication level 69
AII11 - Low indication level 0
AII12 - Function for min indication OFF
AII13 - Function for high indication OFF
AII14 - Function for low indication OFF
Analog in 5
AIJ01 - Input type 4-20 mA
AIJ02 - Zero point adjustment 0
AIJ03 - Max point adjustment 0
AIJ04 - Min input, REG405 0
AIJ05 - Max input, REG405 414 (*)
AIJ06 - Units for REG405 bar
AIJ07 - Decimals for REG405 0
AIJ08 - Scaling for REG405 1.00
AIJ09 - Function for input SP1 (*)
AIJ10 - High indication level 325 (*)
AIJ11 - Low indication level 10 (*)
AIJ12 - Function for min indication OFF
AIJ13 - Function for high indication OFF
AIJ14 - Function for low indication OFF
Analog in 6
AIK01 - Input type 4-20 mA
AIK02 - Zero point adjustment 0
AIK03 - Max point adjustment 0
AIK04 - Min input, REG406 0
AIK05 - Max input, REG406 200
AIK06 - Units for REG406 bar
AIK07 - Decimals for REG406 0
AIK08 - Scaling for REG406 1.00
AIK09 - Function for input OFF
AIK10 - High indication level 200
AIK11 - Low indication level 0
AIK12 - Function for min indication OFF
AIK13 - Function for high indication OFF
AIK14 - Function for low indication OFF
Analog in 7
AIL01 - Input type 4-20 mA
AIL02 - Zero point adjustment 0
AIL03 - Max point adjustment 0
AIL04 - Min input, REG407 0
AIL05 - Max input, REG407 200
AIL06 - Units for REG407 bar
AIL07 - Decimals for REG407 0
AIL08 - Scaling for REG407 1.00
AIL09 - Function for input OFF
AIL10 - High indication level 200
AIL11 - Low indication level 0
AIL12 - Function for min indication OFF
AIL13 - Function for high indication OFF
AIL14 - Function for low indication OFF
Analog in 8
AIM01 - Input type 4-20 mA
AIM02 - Zero point adjustment 0
Page 5
E01PX10-2258.txt
AIM03 - Max point adjustment 0
AIM04 - Min input, REG408 0
AIM05 - Max input, REG408 200
AIM06 - Units for REG408 bar
AIM07 - Decimals for REG408 0
AIM08 - Scaling for REG408 1.00
AIM09 - Function for input OFF
AIM10 - High indication level 200
AIM11 - Low indication level 0
AIM12 - Function for min indication OFF
AIM13 - Function for high indication OFF
AIM14 - Function for low indication OFF
Analog in 9
AIN01 - Input type 4-20 mA
AIN02 - Zero point adjustment 0
AIN03 - Max point adjustment 0
AIN04 - Min input, REG409 0
AIN05 - Max input, REG409 200
AIN06 - Units for REG409 bar
AIN07 - Decimals for REG409 0
AIN08 - Scaling for REG409 1.00
AIN09 - Function for input OFF
AIN10 - High indication level 200
AIN11 - Low indication level 0
AIN12 - Function for min indication OFF
AIN13 - Function for high indication OFF
AIN14 - Function for low indication OFF
Tank temp
AIP01 - Zero point adjustment 0
AIP02 - Max point adjustment 0
AIP03 - Units for REG410 °F (*)
Power limit
AIR01 - Power limitation E-motor 1 1101 (*)
AIR02 - Power limitation E-motor 2 400
AIR03 - Power limitation E-motor 3 400
Analog outputs
Analog out 1
AOA01 - Analog output REG109 (*)
AOA02 - 4-20mA or 2-10V ouput on
AOA03 - Zero point adjustment 0
AOA04 - Max point adjustment 0
Analog out 2
AOB01 - Analog output REG403 (*)
AOB02 - 4-20mA or 2-10V ouput on
AOB03 - Zero point adjustment 0
AOB04 - Max point adjustment 0
Analog out 3
AOC01 - Analog output REG405 (*)
AOC02 - 4-20mA or 2-10V ouput on
AOC03 - Zero point adjustment 0
AOC04 - Max point adjustment -15 (*)
Analog out 4
AOD01 - Analog output OFF
AOD02 - 4-20mA or 2-10V ouput off (*)
AOD03 - Zero point adjustment 0
AOD04 - Max point adjustment 0
Bus
Type && Function
BTF01 - Type of bus communication OFF
BTF02 - Max com. drop time 1
BTF03 - Function at com. drop Interlock
Page 6
E01PX10-2258.txt
Digital in
BDI01 - Digital input 1 21 OFF
BDI02 - Digital input 2 21 OFF
BDI03 - Digital input 3 21 OFF
BDI04 - Digital input 4 21 OFF
BDI05 - Digital input 5 21 OFF
BDI06 - Digital input 6 21 OFF
BDI07 - Digital input 7 21 OFF
BDI08 - Digital input 8 21 OFF
BDI09 - Digital input 9 21 OFF
BDI10 - Digital input 10 21 OFF
BDI11 - Digital input 11 21 OFF
BDI12 - Digital input 12 21 OFF
BDI13 - Digital input 13 21 OFF
BDI14 - Digital input 14 21 OFF
BDI15 - Digital input 15 21 OFF
BDI16 - Digital input 16 21 OFF
BDI17 - Digital input 17 21 OFF
BDI18 - Digital input 18 21 OFF
BDI19 - Digital input 19 21 OFF
BDI20 - Digital input 20 21 OFF
BDI21 - Digital input 21 21 OFF
BDI22 - Digital input 22 21 OFF
BDI23 - Digital input 23 21 OFF
BDI24 - Digital input 24 21 OFF
Analog in 1
BAA01 - Min input, REG501 0
BAA02 - Max input, REG501 200
BAA03 - Units for REG501 %
BAA04 - Decimals for REG501 0
BAA05 - Function for input OFF
Analog in 2
BAB01 - Min input, REG502 0
BAB02 - Max input, REG502 200
BAB03 - Units for REG502 %
BAB04 - Decimals for REG502 0
BAB05 - Function for input OFF
Analog in 3
BAC01 - Min input, REG503 0
BAC02 - Max input, REG503 200
BAC03 - Units for REG503 °
BAC04 - Decimals for REG503 0
BAC05 - Function for input OFF
Analog in 4
BAD01 - Min input, REG504 0
BAD02 - Max input, REG504 200
BAD03 - Units for REG504 bar
BAD04 - Decimals for REG504 0
BAD05 - Function for input OFF
Analog out
BAK01 - Analog output register OFF
BAK02 - Analog output register OFF
BAK03 - Analog output register OFF
BAK04 - Analog output register OFF
BAK05 - Analog output register OFF
BAK06 - Analog output register OFF
BAK07 - Analog output register OFF
BAK08 - Analog output register OFF
Pump monitor
Pump 1
PMA01 - Charge pr. interlock delay 5 sec
PMA02 - Delay, Charge pr. A 0.5 sec
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E01PX10-2258.txt
PMA03 - Delay, Charge pr. B 0.5 sec
PMA04 - Delay, Suction line 0.0 sec
PMA05 - Delay, Return filter 75% 7.0 sec
PMA06 - Delay, Return filter 100% 7.0 sec
PMA07 - Return filter alarm OFF
PMA08 - Delay, High work pr. A 7.0 sec
PMA09 - Mem bypass, work pr. A off
PMA10 - Delay, High work pr. B 7.0 sec
PMA11 - Mem bypass, work pr. B off
PMA12 - Signal plausibility check on
PMA13 - Error limits between in/out 50
PMA14 - Analog pressure sensor off
Pump 2
PMB01 - Charge pr. interlock delay 5 sec
PMB02 - Delay, Charge pr. A 0.5 sec
PMB03 - Delay, Charge pr. B 0.5 sec
PMB04 - Delay, Suction line 0.0 sec
PMB05 - Delay, Return filter 75% 7.0 sec
PMB06 - Delay, Return filter 100% 7.0 sec
PMB07 - Return filter alarm OFF
PMB08 - Delay, High work pr. A 7.0 sec
PMB09 - Mem bypass, work pr. A off
PMB10 - Delay, High work pr. B 7.0 sec
PMB11 - Mem bypass, work pr. B off
PMB12 - Signal plausibility check on
PMB13 - Error limits between in/out 50
PMB14 - Analog pressure sensor off
Pump 3
PMC01 - Charge pr. interlock delay 5 sec
PMC02 - Delay, Charge pr. A 0.5 sec
PMC03 - Delay, Charge pr. B 0.5 sec
PMC04 - Delay, Suction line 0.0 sec
PMC05 - Delay, Return filter 75% 7.0 sec
PMC06 - Delay, Return filter 100% 7.0 sec
PMC07 - Return filter alarm OFF
PMC08 - Delay, High work pr. A 7.0 sec
PMC09 - Mem bypass, work pr. A off
PMC10 - Delay, High work pr. B 7.0 sec
PMC11 - Mem bypass, work pr. B off
PMC12 - Signal plausibility check on
PMC13 - Error limits between in/out 50
PMC14 - Analog pressure sensor off
Pump 4
PMD01 - Charge pr. interlock delay 5 sec
PMD02 - Delay, Charge pr. A 0.5 sec
PMD03 - Delay, Charge pr. B 0.5 sec
PMD04 - Delay, Suction line 0.0 sec
PMD05 - Delay, Return filter 75% 7.0 sec
PMD06 - Delay, Return filter 100% 7.0 sec
PMD07 - Return filter alarm OFF
PMD08 - Delay, High work pr. A 7.0 sec
PMD09 - Mem bypass, work pr. A off
PMD10 - Delay, High work pr. B 7.0 sec
PMD11 - Mem bypass, work pr. B off
PMD12 - Signal plausibility check on
PMD13 - Error limits between in/out 50
PMD14 - Analog pressure sensor off
Tank monitor
Digital
TMA01 - Delay, Low oil level warn. 0.0 sec
TMA02 - Delay, Min oil level alarm 0.0 sec
TMA03 - Delay, Min temp alarm 0.0 sec
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E01PX10-2258.txt
TMA04 - Delay, High temp warn. 0.0 sec
TMA05 - Delay, Max temp alarm 0.5 sec
TMA06 - Delay, Drain 75% warn. 7.0 sec
TMA07 - Delay, Drain 100% warn. 7.0 sec
TMA08 - Drain filter alarm OFF
TMA09 - Min oil temp function A
Analog
TMB01 - Analog temp sensor on
TMB03 - Max oil temp alarm level 60
TMB04 - High oil temp warning level 55
TMB05 - Cooling temp on level (rise) 40
TMB06 - Cooling hysteresis 3
TMB07 - Filter interlock temp level 18 (*)
TMB08 - Heating temp on level (fall) 15
TMB09 - Heating hysteresis 3
TMB10 - Min oil temp alarm level 10
TMB11 - Flushing temp on level (fall) 30
TMB12 - Flushing hysteresis 3
Aux monitor
Aux 1
AMA01 - Aux function W D1
AMA02 - Aux delay time 0.1 (*)
AMA03 - Aux memory bypass on (*)
AMA04 - Aux configurable text Eng Stop (*)
AMA05 - Aux inverted input off
Aux 2
AMB01 - Aux function W D1
AMB02 - Aux delay time 1.0
AMB03 - Aux memory bypass off
AMB04 - Aux configurable text AUX 2
AMB05 - Aux inverted input off
Aux 3
AMC01 - Aux function W D1
AMC02 - Aux delay time 1.0
AMC03 - Aux memory bypass off
AMC04 - Aux configurable text AUX 3
AMC05 - Aux inverted input off
Aux 4
AMD01 - Aux function W D1
AMD02 - Aux delay time 1.0
AMD03 - Aux memory bypass off
AMD04 - Aux configurable text AUX 4
AMD05 - Aux inverted input off
Aux 5
AME01 - Aux function W D1
AME02 - Aux delay time 1.0
AME03 - Aux memory bypass off
AME04 - Aux configurable text AUX 5
AME05 - Aux inverted input off
Aux 6
AMF01 - Aux function W D1
AMF02 - Aux delay time 1.0
AMF03 - Aux memory bypass off
AMF04 - Aux configurable text AUX 6
AMF05 - Aux inverted input off
Aux 7
AMG01 - Aux function W D1
AMG02 - Aux delay time 1.0
AMG03 - Aux memory bypass off
AMG04 - Aux configurable text AUX 7
AMG05 - Aux inverted input off
Aux 8
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E01PX10-2258.txt
AMH01 - Aux function W D1
AMH02 - Aux delay time 1.0
AMH03 - Aux memory bypass off
AMH04 - Aux configurable text AUX 8
AMH05 - Aux inverted input off
Aux 9
AMI01 - Aux function W D1
AMI02 - Aux delay time 1.0
AMI03 - Aux memory bypass off
AMI04 - Aux configurable text AUX 9
AMI05 - Aux inverted input off
Aux 10
AMJ01 - Aux function W D1
AMJ02 - Aux delay time 1.0
AMJ03 - Aux memory bypass off
AMJ04 - Aux configurable text AUX 10
AMJ05 - Aux inverted input off
Aux 11
AMK01 - Aux function W D1
AMK02 - Aux delay time 1.0
AMK03 - Aux memory bypass off
AMK04 - Aux configurable text AUX 11
AMK05 - Aux inverted input off
Aux 12
AML01 - Aux function W D1
AML02 - Aux delay time 1.0
AML03 - Aux memory bypass off
AML04 - Aux configurable text AUX 12
AML05 - Aux inverted input off
Aux 13
AMM01 - Aux function W D1
AMM02 - Aux delay time 1.0
AMM03 - Aux memory bypass off
AMM04 - Aux configurable text AUX 13
AMM05 - Aux inverted input off
Aux 14
AMN01 - Aux function W D1
AMN02 - Aux delay time 1.0
AMN03 - Aux memory bypass off
AMN04 - Aux configurable text AUX 14
AMN05 - Aux inverted input off
Aux 15
AMO01 - Aux function W D1
AMO02 - Aux delay time 1.0
AMO03 - Aux memory bypass off
AMO04 - Aux configurable text AUX 15
AMO05 - Aux inverted input off
Aux 16
AMP01 - Aux function W D1
AMP02 - Aux delay time 1.0
AMP03 - Aux memory bypass off
AMP04 - Aux configurable text AUX 16
AMP05 - Aux inverted input off
Aux 17
AMQ01 - Aux function W D1
AMQ02 - Aux delay time 1.0
AMQ03 - Aux memory bypass off
AMQ04 - Aux configurable text AUX 17
AMQ05 - Aux inverted input off
Aux 18
AMR01 - Aux function W D1
AMR02 - Aux delay time 1.0
AMR03 - Aux memory bypass off
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E01PX10-2258.txt
AMR04 - Aux configurable text AUX 18
AMR05 - Aux inverted input off
Aux 19
AMS01 - Aux function W D1
AMS02 - Aux delay time 1.0
AMS03 - Aux memory bypass off
AMS04 - Aux configurable text AUX 19
AMS05 - Aux inverted input off
Aux 20
AMT01 - Aux function W D1
AMT02 - Aux delay time 1.0
AMT03 - Aux memory bypass off
AMT04 - Aux configurable text AUX 20
AMT05 - Aux inverted input off
Drive monitor
Start interlock
DMA01 - Start alternative, drive 1 and
DMA02 - Start delay time, drive 1 5 sec
DMA03 - Start alternative, drive 2 and
DMA04 - Start delay time, drive 2 5 sec
Drive 1
DMB01 - Delay, charge pressure A 0.5 sec
DMB02 - Delay, charge pressure B 0.5 sec
DMB03 - Delay, E-motor temp 0.0 sec
DMB04 - Delay, work pressure A 7.0 sec
DMB05 - Mem bypass, work pr. A off
DMB06 - Delay, work pressure B 7.0 sec
DMB07 - Mem bypass, work pr. B off
DMB08 - Analog pressure sensor off
Drive 2
DMC01 - Delay, charge pressure A 0.5 sec
DMC02 - Delay, charge pressure B 0.5 sec
DMC03 - Delay, E-motor temp 0.0 sec
DMC04 - Delay, work pressure A 7.0 sec
DMC05 - Mem bypass, work pr. A off
DMC06 - Delay, work pressure B 7.0 sec
DMC07 - Mem bypass, work pr. B off
DMC08 - Analog pressure sensor off
Emotor interlock
DMD01 - Delay, Interlock E-motor 1 1.0
DMD02 - Delay, Interlock E-motor 2 1.0
DMD03 - Delay, Interlock E-motor 3 1.0
Drive 1 basic
Setpoint
D1A01 - Speed setpoint Local/Remote (*)
D1A02 - Type of command signal Unidirectional (*)
D1A03 - Reset of local setpoint yes
D1A04 - Reverse input on (*)
D1A05 - Reverse command setpoint -10.0 (*)
D1A06 - Digital forward setpoint 10.0
D1A07 - Digital reverse setpoint -10.0
D1A08 - Drive front panel buttons on
Ramp
D1C01 - Up ramp time forward 2.0
D1C02 - Down ramp time forward 2.0
D1C03 - Up ramp time reverse 2.0
D1C04 - Down ramp time reverse 2.0
Regulator
D1D01 - Regulator on (*)
D1D02 - Feed forward function on
D1D03 - Proportional regulator on (*)
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E01PX10-2258.txt
D1D04 - Integrating regulator on (*)
D1D05 - Derivation regulator off
D1D06 - Proportional gain 0.1
D1D07 - Integration time 10.0
D1D08 - Derivation time 0.10
D1D09 - Derivation decline time 0.1
D1D10 - Max feedback deviation 50
D1D11 - Regulated or nonregulated Switching (*)
Feedback
D1E01 - Max motor shaft speed 6.9 (*)
D1E02 - Feedback selection Digital
D1E03 - Filter time for feedback 0.0
Power limitation
D1F01 - Delay time, power limitation 0.0 (*)
D1F02 - Ramp time, power limitation 20.0
Drive 2 basic
Setpoint
D2A01 - Speed setpoint Local
D2A02 - Type of command signal Bidirectional
D2A03 - Reset of local setpoint yes
D2A04 - Reverse input off
D2A05 - Reverse command setpoint -20.0
D2A06 - Digital forward setpoint 10.0
D2A07 - Digital reverse setpoint -10.0
D2A08 - Drive front panel buttons on
Ramp
D2C01 - Up ramp time forward 2.0
D2C02 - Down ramp time forward 2.0
D2C03 - Up ramp time reverse 2.0
D2C04 - Down ramp time reverse 2.0
Regulator
D2D01 - Regulator off
D2D02 - Feed forward function on
D2D03 - Proportional regulator off
D2D04 - Integrating regulator off
D2D05 - Derivation regulator off
D2D06 - Proportional gain 0.1
D2D07 - Integration time 10.0
D2D08 - Derivation time 0.10
D2D09 - Derivation decline time 0.1
D2D10 - Max feedback deviation 50
D2D11 - Regulated or nonregulated Non-regulated
Feedback
D2E01 - Max motor shaft speed 10.0
D2E02 - Feedback selection Digital
D2E03 - Filter time for feedback 0.0
Power limitation
D2F01 - Delay time, power limitation 0.5
D2F02 - Ramp time, power limitation 20.0
Shredder 1
Function
SHA01 - Reverse control Pressure, separate
SHA02 - Reverse stop function Going to forward
SHA03 - Delay before reversal 3.0
SHA04 - Reversal time 10.0
SHA05 - Reverse delay SHA02 3.0
SHA06 - Forward time 10.0
SHA07 - Shredder automatic dir. off
SHA08 - Forward time interval 60
SHA09 - Reverse time interval 60
SHA10 - Selection of regulated dr. Unregulated
Page 12
E01PX10-2258.txt
Setpoint
SHB01 - Reverse command setpoint Forward
SHB02 - Scale factor for reverse 100
SHB03 - Analog pressure sensor off
SHB04 - High pr. level, forward 200
SHB05 - High pr. level, reverse 200
Counter
SHC01 - Window time for counter 60
SHC02 - Reversal counter 5
Shredder 2
Function
SHG01 - Reverse control Pressure, separate
SHG02 - Reverse stop function Going to forward
SHG03 - Delay before reversal 3.0
SHG04 - Reversal time 10.0
SHG05 - Reverse delay SHG02 3.0
SHG06 - Forward time 10.0
SHG07 - Shredder automatic dir. off
SHG08 - Forward time interval 60
SHG09 - Reverse time interval 60
SHG10 - Selection of regulated dr. Unregulated
Setpoint
SHH01 - Reverse command setpoint Forward
SHH02 - Scale factor for reverse 100
SHH03 - Analog pressure sensor off
SHH04 - High pr. level, forward 200
SHH05 - High pr. level, reverse 200
Counter
SHI01 - Window time for counter 60
SHI02 - Reversal counter 5
Synchro
Function
SYA01 - Type of synchronisation RATIO
SYA02 - Master command D1 Master - D2 Slave
Drive 1 reset
SYB01 - Counter reset command Reset by start
SYB02 - Enable of counter reset E-motors start
Drive 2 setpoint
SYC01 - Drive 2 low friction limit 0
SYC02 - Drive 2 high friction limit 200
SYC03 - Offset reset by motor start off
SYC04 - Offset for Drive 2 0.0
Drive 2 indication
SYD01 - Synchro indication limit 5
SYD02 - Sync time 1.0
Drive 2 reset
SYE01 - Counter reset command Reset by start
SYE02 - Enable of counter reset E-motors start
Master setpoint
SYF01 - Up ramp time forward 2.0
SYF02 - Down ramp time forward 2.0
SYF03 - Up ramp time reverse 2.0
SYF04 - Down ramp time reverse 2.0
Drive 1 setpoint
SYG01 - Drive 1 low friction limit 0
SYG02 - Drive 1 high friction limit 200
Pressure 1
Function
PRA01 - Pressure control off
PRA02 - Reverse dir. of ctrl action off
Page 13
E01PX10-2258.txt
PRA03 - Low pressure control off
PRA04 - High pressure control off
PRA05 - Filter time, low pr. control 5
PRA06 - Filter time, high pr. control 5
Pr. setpoint
PRB01 - Pressure setpoint Local
PRB02 - Local pressure setpoint 200
PRB03 - Low limit, pressure setpoint 25
PRB04 - High limit, pressure setpoint 25
PRB05 - Low limit, PID output 10
PRB06 - High limit, PID output 10
PRB07 - Max pressure 250
Regulator
PRC01 - Proportional regulator off
PRC02 - Integrating regulator off
PRC03 - Derivation regulator off
PRC04 - Proportional gain 0.1
PRC05 - Integration time 10.0
PRC06 - Derivation time 0.10
PRC07 - Derivation decline time 0.1
PRC08 - Filter time for pr. feedback 0.0
Pressure 2
Function
PRG01 - Pressure control off
PRG02 - Reverse dir. of ctrl action off
PRG03 - Low pressure control off
PRG04 - High pressure control off
PRG05 - Filter time, low pr. control 5
PRG06 - Filter time, high pr. control 5
Pr. setpoint
PRH01 - Pressure setpoint Local
PRH02 - Local pressure setpoint 200
PRH03 - Low limit, pressure setpoint 25
PRH04 - High limit, pressure setpoint 25
PRH05 - Low limit, PID output 10
PRH06 - High limit, PID output 10
PRH07 - Max pressure 250
Regulator
PRI01 - Proportional regulator off
PRI02 - Integrating regulator off
PRI03 - Derivation regulator off
PRI04 - Proportional gain 0.1
PRI05 - Integration time 10.0
PRI06 - Derivation time 0.10
PRI07 - Derivation decline time 0.1
PRI08 - Filter time for pr. feedback 0.0
Reading 1
Scroll menu
R1A01 - Text for reading 1 HIGH PSI (*)
R1A02 - Reading 1 REG405 (*)
R1A03 - Text for reading 2 TANKTEMP (*)
R1A04 - Reading 2 REG403 (*)
R1A05 - Text for reading 3 READING3
R1A06 - Reading 3 OFF
R1A07 - Text for reading 4 READING4
R1A08 - Reading 4 OFF
R1A09 - Text for reading 5 READING5
R1A10 - Reading 5 OFF
R1A11 - Text for reading 6 READING6
R1A12 - Reading 6 OFF
R1A13 - Text for reading 7 READING7
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E01PX10-2258.txt
R1A14 - Reading 7 OFF
R1A15 - Text for reading 8 READING8
R1A16 - Reading 8 OFF
R1A17 - Text for reading 9 READING9
R1A18 - Reading 9 OFF
Left upper
R1B01 - Reading REG102
Right upper
R1C01 - Reading REG106
Left lower
R1D01 - Reading REG109
Right lower
R1E01 - Reading REG311
Reading 2
Scroll menu
R2A01 - Text for reading 1 READING1
R2A02 - Reading 1 OFF
R2A03 - Text for reading 2 READING2
R2A04 - Reading 2 OFF
R2A05 - Text for reading 3 READING3
R2A06 - Reading 3 OFF
R2A07 - Text for reading 4 READING4
R2A08 - Reading 4 OFF
R2A09 - Text for reading 5 READING5
R2A10 - Reading 5 OFF
R2A11 - Text for reading 6 READING6
R2A12 - Reading 6 OFF
R2A13 - Text for reading 7 READING7
R2A14 - Reading 7 OFF
R2A15 - Text for reading 8 READING8
R2A16 - Reading 8 OFF
R2A17 - Text for reading 9 READING9
R2A18 - Reading 9 OFF
Left upper
R2B01 - Reading REG202
Right upper
R2C01 - Reading REG206
Left lower
R2D01 - Reading REG209
Right lower
R2E01 - Reading REG321
Page 15
SPIDER CONTROL SYSTEM [E01P X10-2511]
DOCUMENTATION FOR SPIDER CONTROL SYSTEM
E01P X10-2511
Notes:
E01PX10-2511.txt
Printout time: 2005-09-27 11:56:01
Printed by SpiderCom2 version: 4.1.4 Build 8
Parameter file name: E01PX10-2511.s2p
Parameter file version: 2
SpiderII software version: 4.1.2 2
Main settings
Function
MAA01 - System function BASIC
Configuration
MAB01 - E-motor connection for P1 E-motor 1
MAB02 - E-motor connection for P2 OFF
MAB03 - E-motor connection for P3 OFF
MAB04 - E-motor connection for P4 OFF
MAB05 - Drive connection for P1 Drive 1
MAB06 - Drive connection for P2 OFF
MAB07 - Drive connection for P3 OFF
MAB08 - Drive connection for P4 OFF
MAB09 - Separate or common Separate
MAB10 - Shutdown ramp time 0
MAB11 - Emerg. stop mem bypass off
Language
MAC01 - Display language selection English
Protection
MAD01 - Security code - setup menu yes (*)
MAD02 - Security code 0532 (*)
Pump outputs
Pump 1
POA01 - Forward min current 175 (*)
POA02 - Forward max current 305 (*)
POA03 - Reverse min current 180 (*)
POA04 - Reverse max current 325 (*)
POA05 - Coil resistance 41 (*)
POA06 - PWM-frequency 200
Pump 2
POB01 - Forward min current 0
POB02 - Forward max current 0
POB03 - Reverse min current 0
POB04 - Reverse max current 0
POB05 - Coil resistance 40
POB06 - PWM-frequency 200
Pump 3
POC01 - Forward min current 0
POC02 - Forward max current 0
POC03 - Reverse min current 0
POC04 - Reverse max current 0
POC05 - Coil resistance 40
POC06 - PWM-frequency 200
Pump 4
POD01 - Forward min current 0
POD02 - Forward max current 0
POD03 - Reverse min current 0
POD04 - Reverse max current 0
POD05 - Coil resistance 40
POD06 - PWM-frequency 200
Friction
POE01 - Pump friction Off
POE02 - Pump low friction limit 0
POE03 - Pump high friction limit 200
POE04 - Friction up ramp time 2.0
POE05 - Friction down ramp time 2.0
Page 1
E01PX10-2511.txt
Digital inputs
Digital in 1 - 22
DIN01 - Digital input 1, DI1:3 14 START 1 (*)
DIN02 - Digital input 2, DI1:4 15 REV 1 (*)
DIN03 - Digital input 3, DI1:5 21 OFF (*)
DIN04 - Digital input 4, DI1:6 07 MN LEVEL
DIN05 - Digital input 5, DI1:7 07 LO LEVEL
DIN06 - Digital input 6, DI1:8 06 DRF 100
DIN07 - Digital input 7, DI2:4 06 RF100 P1
DIN08 - Digital input 8, DI2:5 05 SUCTION1
DIN09 - Digital input 9, DI2:6 03 C PRA P1 (*)
DIN10 - Digital input 10, DI2:7 01 H APR P1
DIN11 - Digital input 11, DI2:8 21 OFF (*)
DIN12 - Digital input 12, DI2:9 21 OFF (*)
DIN13 - Digital input 13, DI2:10 21 OFF (*)
DIN14 - Digital input 14, DI2:11 21 OFF (*)
DIN15 - Digital input 15, DI2:12 21 OFF
DIN16 - Digital input 16, DI3:4 21 OFF (*)
DIN17 - Digital input 17, DI3:5 21 OFF (*)
DIN18 - Digital input 18, DI3:6 21 OFF (*)
DIN19 - Digital input 19, DI3:7 21 OFF (*)
DIN20 - Digital input 20, DI3:8 21 OFF (*)
DIN21 - Digital input 21, DI3:9 21 OFF (*)
DIN22 - Digital input 22, DI3:10 21 OFF (*)
Digital in 23 - 43
DIN23 - Digital input 23, DI3:11 21 OFF (*)
DIN24 - Digital input 24, DI3:12 21 OFF
DIN25 - Digital input 25, DI4:4 21 OFF
DIN26 - Digital input 26, DI4:5 21 OFF
DIN27 - Digital input 27, DI4:6 21 OFF
DIN28 - Digital input 28, DI4:7 21 OFF
DIN29 - Digital input 29, DI4:8 21 OFF
DIN30 - Digital input 30, DI4:9 21 OFF
DIN31 - Digital input 31, DI4:10 21 OFF
DIN32 - Digital input 32, DI4:11 21 OFF
DIN33 - Digital input 33, DI4:12 21 OFF
DIN34 - Digital input 34, DI5:3 21 OFF
DIN35 - Digital input 35, DI5:4 21 OFF
DIN36 - Digital input 36, DI5:5 21 OFF
DIN37 - Digital input 37, DI5:6 21 OFF
DIN38 - Digital input 38, DI5:7 21 OFF
DIN39 - Digital input 39, DI5:8 21 OFF
DIN40 - Digital input 40, DI5:9 21 OFF
DIN41 - Digital input 41, DI5:10 21 OFF
DIN42 - Digital input 42, DI5:11 21 OFF
DIN43 - Digital input 43, DI5:12 21 OFF
Digital outputs
Digital out 1
DOA01 - Digital output function 11 COOLCONI (*)
DOA02 - Inverted function no
DOA03 - Delay time for digital output 5.0
DOA04 - Delay function for output NO
Digital out 2
DOB01 - Digital output function 01 A1 (*)
DOB02 - Inverted function no
DOB03 - Delay time for digital output 5.0
DOB04 - Delay function for output NO
Digital out 3
DOC01 - Digital output function 01 W1 (*)
DOC02 - Inverted function no
DOC03 - Delay time for digital output 5.0
Page 2
E01PX10-2511.txt
DOC04 - Delay function for output NO
Digital out 4
DOD01 - Digital output function 02 START 1 (*)
DOD02 - Inverted function no
DOD03 - Delay time for digital output 5.0
DOD04 - Delay function for output NO
Digital out 5
DOE01 - Digital output function 04 REMOTE 1 (*)
DOE02 - Inverted function no
DOE03 - Delay time for digital output 5.0
DOE04 - Delay function for output NO
Digital out 6
DOF01 - Digital output function 03 READY 1 (*)
DOF02 - Inverted function no
DOF03 - Delay time for digital output 5.0
DOF04 - Delay function for output NO
Digital out 7
DOG01 - Digital output function 15 OFF
DOG02 - Inverted function no
DOG03 - Delay time for digital output 0.0 (*)
DOG04 - Delay function for output NO
Digital out 8
DOH01 - Digital output function 15 OFF
DOH02 - Inverted function no
DOH03 - Delay time for digital output 0.0 (*)
DOH04 - Delay function for output NO
Digital out 9
DOI01 - Digital output function 15 OFF
DOI02 - Inverted function no
DOI03 - Delay time for digital output 5.0
DOI04 - Delay function for output NO
Digital out 10
DOJ01 - Digital output function 15 OFF
DOJ02 - Inverted function no
DOJ03 - Delay time for digital output 5.0
DOJ04 - Delay function for output NO
Digital out 11
DOK01 - Digital output function 15 OFF
DOK02 - Inverted function no
DOK03 - Delay time for digital output 5.0
DOK04 - Delay function for output NO
Digital out 12
DOL01 - Digital output function 15 OFF
DOL02 - Inverted function no
DOL03 - Delay time for digital output 5.0
DOL04 - Delay function for output NO
Digital out 13
DOM01 - Digital output function 15 OFF
DOM02 - Inverted function no
DOM03 - Delay time for digital output 5.0
DOM04 - Delay function for output NO
Pulse inputs
Drive 1
P1I01 - Pulses/rev 3600 (*)
P1I02 - Units for REG109 rpm
P1I03 - Decimals for REG109 0
P1I04 - Scaling for REG109 1.00
P1I05 - Filter time for speed reading 0.0
P1I06 - Polarity - digital speed signal 1
P1I07 - Encoder type 1
Drive 2
P2I01 - Pulses/rev 1000
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E01PX10-2511.txt
P2I02 - Units for REG209 rpm
P2I03 - Decimals for REG209 0
P2I04 - Scaling for REG209 1.00
P2I05 - Filter time for speed reading 0.0
P2I06 - Polarity - digital speed signal 1
P2I07 - Encoder type 1
Analog inputs
Setpoint 1
AIA01 - Input type 4-20 mA
AIA02 - Zero point adjustment 0
AIA03 - Max point adjustment 0
AIA04 - Reading for REG101 %
Setpoint 2
AIB01 - Input type 4-20 mA
AIB02 - Zero point adjustment 0
AIB03 - Max point adjustment 0
AIB04 - Reading for REG201 %
Analog in 1
AIF01 - Input type 4-20 mA
AIF02 - Zero point adjustment 0
AIF03 - Max point adjustment 0
AIF04 - Min input, REG401 0
AIF05 - Max input, REG401 200
AIF06 - Units for REG401 bar
AIF07 - Decimals for REG401 0
AIF08 - Scaling for REG401 1.00
AIF09 - Function for input OFF
AIF10 - High indication level 200
AIF11 - Low indication level 0
AIF12 - Function for min indication OFF
AIF13 - Function for high indication OFF
AIF14 - Function for low indication OFF
Analog in 2
AIG01 - Input type 4-20 mA
AIG02 - Zero point adjustment 0
AIG03 - Max point adjustment 0
AIG04 - Min input, REG402 0
AIG05 - Max input, REG402 200
AIG06 - Units for REG402 bar
AIG07 - Decimals for REG402 0
AIG08 - Scaling for REG402 1.00
AIG09 - Function for input OFF
AIG10 - High indication level 200
AIG11 - Low indication level 0
AIG12 - Function for min indication OFF
AIG13 - Function for high indication OFF
AIG14 - Function for low indication OFF
Analog in 3
AIH01 - Input type 4-20 mA
AIH02 - Zero point adjustment 0
AIH03 - Max point adjustment 6 (*)
AIH04 - Min input, REG403 -25 (*)
AIH05 - Max input, REG403 100 (*)
AIH06 - Units for REG403 °C (*)
AIH07 - Decimals for REG403 1 (*)
AIH08 - Scaling for REG403 1.00
AIH09 - Function for input TANK A (*)
AIH10 - High indication level 60 (*)
AIH11 - Low indication level 0 (*)
AIH12 - Function for min indication OFF
AIH13 - Function for high indication OFF
AIH14 - Function for low indication OFF
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Analog in 4
AII01 - Input type 4-20 mA
AII02 - Zero point adjustment 0
AII03 - Max point adjustment 0
AII04 - Min input, REG404 0
AII05 - Max input, REG404 69 (*)
AII06 - Units for REG404 bar
AII07 - Decimals for REG404 0
AII08 - Scaling for REG404 1.00
AII09 - Function for input PR1 (*)
AII10 - High indication level 69
AII11 - Low indication level 0
AII12 - Function for min indication OFF
AII13 - Function for high indication OFF
AII14 - Function for low indication OFF
Analog in 5
AIJ01 - Input type 4-20 mA
AIJ02 - Zero point adjustment 0
AIJ03 - Max point adjustment 0
AIJ04 - Min input, REG405 0
AIJ05 - Max input, REG405 414 (*)
AIJ06 - Units for REG405 bar
AIJ07 - Decimals for REG405 0
AIJ08 - Scaling for REG405 1.00
AIJ09 - Function for input SP1 (*)
AIJ10 - High indication level 325 (*)
AIJ11 - Low indication level 10 (*)
AIJ12 - Function for min indication OFF
AIJ13 - Function for high indication OFF
AIJ14 - Function for low indication OFF
Analog in 6
AIK01 - Input type 4-20 mA
AIK02 - Zero point adjustment 0
AIK03 - Max point adjustment 0
AIK04 - Min input, REG406 0
AIK05 - Max input, REG406 200
AIK06 - Units for REG406 bar
AIK07 - Decimals for REG406 0
AIK08 - Scaling for REG406 1.00
AIK09 - Function for input OFF
AIK10 - High indication level 200
AIK11 - Low indication level 0
AIK12 - Function for min indication OFF
AIK13 - Function for high indication OFF
AIK14 - Function for low indication OFF
Analog in 7
AIL01 - Input type 4-20 mA
AIL02 - Zero point adjustment 0
AIL03 - Max point adjustment 0
AIL04 - Min input, REG407 0
AIL05 - Max input, REG407 200
AIL06 - Units for REG407 bar
AIL07 - Decimals for REG407 0
AIL08 - Scaling for REG407 1.00
AIL09 - Function for input OFF
AIL10 - High indication level 200
AIL11 - Low indication level 0
AIL12 - Function for min indication OFF
AIL13 - Function for high indication OFF
AIL14 - Function for low indication OFF
Analog in 8
AIM01 - Input type 4-20 mA
AIM02 - Zero point adjustment 0
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AIM03 - Max point adjustment 0
AIM04 - Min input, REG408 0
AIM05 - Max input, REG408 200
AIM06 - Units for REG408 bar
AIM07 - Decimals for REG408 0
AIM08 - Scaling for REG408 1.00
AIM09 - Function for input OFF
AIM10 - High indication level 200
AIM11 - Low indication level 0
AIM12 - Function for min indication OFF
AIM13 - Function for high indication OFF
AIM14 - Function for low indication OFF
Analog in 9
AIN01 - Input type 4-20 mA
AIN02 - Zero point adjustment 0
AIN03 - Max point adjustment 0
AIN04 - Min input, REG409 0
AIN05 - Max input, REG409 200
AIN06 - Units for REG409 bar
AIN07 - Decimals for REG409 0
AIN08 - Scaling for REG409 1.00
AIN09 - Function for input OFF
AIN10 - High indication level 200
AIN11 - Low indication level 0
AIN12 - Function for min indication OFF
AIN13 - Function for high indication OFF
AIN14 - Function for low indication OFF
Tank temp
AIP01 - Zero point adjustment 0
AIP02 - Max point adjustment 0
AIP03 - Units for REG410 °F (*)
Power limit
AIR01 - Power limitation E-motor 1 1101 (*)
AIR02 - Power limitation E-motor 2 400
AIR03 - Power limitation E-motor 3 400
Analog outputs
Analog out 1
AOA01 - Analog output REG109 (*)
AOA02 - 4-20mA or 2-10V ouput on
AOA03 - Zero point adjustment 0
AOA04 - Max point adjustment 0
Analog out 2
AOB01 - Analog output REG403 (*)
AOB02 - 4-20mA or 2-10V ouput on
AOB03 - Zero point adjustment 0
AOB04 - Max point adjustment 0
Analog out 3
AOC01 - Analog output REG405 (*)
AOC02 - 4-20mA or 2-10V ouput on
AOC03 - Zero point adjustment 0
AOC04 - Max point adjustment -15 (*)
Analog out 4
AOD01 - Analog output OFF
AOD02 - 4-20mA or 2-10V ouput off (*)
AOD03 - Zero point adjustment 0
AOD04 - Max point adjustment 0
Bus
Type && Function
BTF01 - Type of bus communication OFF
BTF02 - Max com. drop time 1
BTF03 - Function at com. drop Interlock
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Digital in
BDI01 - Digital input 1 21 OFF
BDI02 - Digital input 2 21 OFF
BDI03 - Digital input 3 21 OFF
BDI04 - Digital input 4 21 OFF
BDI05 - Digital input 5 21 OFF
BDI06 - Digital input 6 21 OFF
BDI07 - Digital input 7 21 OFF
BDI08 - Digital input 8 21 OFF
BDI09 - Digital input 9 21 OFF
BDI10 - Digital input 10 21 OFF
BDI11 - Digital input 11 21 OFF
BDI12 - Digital input 12 21 OFF
BDI13 - Digital input 13 21 OFF
BDI14 - Digital input 14 21 OFF
BDI15 - Digital input 15 21 OFF
BDI16 - Digital input 16 21 OFF
BDI17 - Digital input 17 21 OFF
BDI18 - Digital input 18 21 OFF
BDI19 - Digital input 19 21 OFF
BDI20 - Digital input 20 21 OFF
BDI21 - Digital input 21 21 OFF
BDI22 - Digital input 22 21 OFF
BDI23 - Digital input 23 21 OFF
BDI24 - Digital input 24 21 OFF
Analog in 1
BAA01 - Min input, REG501 0
BAA02 - Max input, REG501 200
BAA03 - Units for REG501 %
BAA04 - Decimals for REG501 0
BAA05 - Function for input OFF
Analog in 2
BAB01 - Min input, REG502 0
BAB02 - Max input, REG502 200
BAB03 - Units for REG502 %
BAB04 - Decimals for REG502 0
BAB05 - Function for input OFF
Analog in 3
BAC01 - Min input, REG503 0
BAC02 - Max input, REG503 200
BAC03 - Units for REG503 °
BAC04 - Decimals for REG503 0
BAC05 - Function for input OFF
Analog in 4
BAD01 - Min input, REG504 0
BAD02 - Max input, REG504 200
BAD03 - Units for REG504 bar
BAD04 - Decimals for REG504 0
BAD05 - Function for input OFF
Analog out
BAK01 - Analog output register OFF
BAK02 - Analog output register OFF
BAK03 - Analog output register OFF
BAK04 - Analog output register OFF
BAK05 - Analog output register OFF
BAK06 - Analog output register OFF
BAK07 - Analog output register OFF
BAK08 - Analog output register OFF
Pump monitor
Pump 1
PMA01 - Charge pr. interlock delay 5 sec
PMA02 - Delay, Charge pr. A 0.5 sec
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PMA03 - Delay, Charge pr. B 0.5 sec
PMA04 - Delay, Suction line 0.0 sec
PMA05 - Delay, Return filter 75% 7.0 sec
PMA06 - Delay, Return filter 100% 7.0 sec
PMA07 - Return filter alarm OFF
PMA08 - Delay, High work pr. A 7.0 sec
PMA09 - Mem bypass, work pr. A off
PMA10 - Delay, High work pr. B 7.0 sec
PMA11 - Mem bypass, work pr. B off
PMA12 - Signal plausibility check on
PMA13 - Error limits between in/out 50
PMA14 - Analog pressure sensor off
Pump 2
PMB01 - Charge pr. interlock delay 5 sec
PMB02 - Delay, Charge pr. A 0.5 sec
PMB03 - Delay, Charge pr. B 0.5 sec
PMB04 - Delay, Suction line 0.0 sec
PMB05 - Delay, Return filter 75% 7.0 sec
PMB06 - Delay, Return filter 100% 7.0 sec
PMB07 - Return filter alarm OFF
PMB08 - Delay, High work pr. A 7.0 sec
PMB09 - Mem bypass, work pr. A off
PMB10 - Delay, High work pr. B 7.0 sec
PMB11 - Mem bypass, work pr. B off
PMB12 - Signal plausibility check on
PMB13 - Error limits between in/out 50
PMB14 - Analog pressure sensor off
Pump 3
PMC01 - Charge pr. interlock delay 5 sec
PMC02 - Delay, Charge pr. A 0.5 sec
PMC03 - Delay, Charge pr. B 0.5 sec
PMC04 - Delay, Suction line 0.0 sec
PMC05 - Delay, Return filter 75% 7.0 sec
PMC06 - Delay, Return filter 100% 7.0 sec
PMC07 - Return filter alarm OFF
PMC08 - Delay, High work pr. A 7.0 sec
PMC09 - Mem bypass, work pr. A off
PMC10 - Delay, High work pr. B 7.0 sec
PMC11 - Mem bypass, work pr. B off
PMC12 - Signal plausibility check on
PMC13 - Error limits between in/out 50
PMC14 - Analog pressure sensor off
Pump 4
PMD01 - Charge pr. interlock delay 5 sec
PMD02 - Delay, Charge pr. A 0.5 sec
PMD03 - Delay, Charge pr. B 0.5 sec
PMD04 - Delay, Suction line 0.0 sec
PMD05 - Delay, Return filter 75% 7.0 sec
PMD06 - Delay, Return filter 100% 7.0 sec
PMD07 - Return filter alarm OFF
PMD08 - Delay, High work pr. A 7.0 sec
PMD09 - Mem bypass, work pr. A off
PMD10 - Delay, High work pr. B 7.0 sec
PMD11 - Mem bypass, work pr. B off
PMD12 - Signal plausibility check on
PMD13 - Error limits between in/out 50
PMD14 - Analog pressure sensor off
Tank monitor
Digital
TMA01 - Delay, Low oil level warn. 0.0 sec
TMA02 - Delay, Min oil level alarm 0.0 sec
TMA03 - Delay, Min temp alarm 0.0 sec
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TMA04 - Delay, High temp warn. 0.0 sec
TMA05 - Delay, Max temp alarm 0.5 sec
TMA06 - Delay, Drain 75% warn. 7.0 sec
TMA07 - Delay, Drain 100% warn. 7.0 sec
TMA08 - Drain filter alarm OFF
TMA09 - Min oil temp function A
Analog
TMB01 - Analog temp sensor on
TMB03 - Max oil temp alarm level 60
TMB04 - High oil temp warning level 55
TMB05 - Cooling temp on level (rise) 40
TMB06 - Cooling hysteresis 3
TMB07 - Filter interlock temp level 18 (*)
TMB08 - Heating temp on level (fall) 15
TMB09 - Heating hysteresis 3
TMB10 - Min oil temp alarm level 10
TMB11 - Flushing temp on level (fall) 30
TMB12 - Flushing hysteresis 3
Aux monitor
Aux 1
AMA01 - Aux function W D1
AMA02 - Aux delay time 0.1 (*)
AMA03 - Aux memory bypass on (*)
AMA04 - Aux configurable text Eng Stop (*)
AMA05 - Aux inverted input off
Aux 2
AMB01 - Aux function W D1
AMB02 - Aux delay time 1.0
AMB03 - Aux memory bypass off
AMB04 - Aux configurable text AUX 2
AMB05 - Aux inverted input off
Aux 3
AMC01 - Aux function W D1
AMC02 - Aux delay time 1.0
AMC03 - Aux memory bypass off
AMC04 - Aux configurable text AUX 3
AMC05 - Aux inverted input off
Aux 4
AMD01 - Aux function W D1
AMD02 - Aux delay time 1.0
AMD03 - Aux memory bypass off
AMD04 - Aux configurable text AUX 4
AMD05 - Aux inverted input off
Aux 5
AME01 - Aux function W D1
AME02 - Aux delay time 1.0
AME03 - Aux memory bypass off
AME04 - Aux configurable text AUX 5
AME05 - Aux inverted input off
Aux 6
AMF01 - Aux function W D1
AMF02 - Aux delay time 1.0
AMF03 - Aux memory bypass off
AMF04 - Aux configurable text AUX 6
AMF05 - Aux inverted input off
Aux 7
AMG01 - Aux function W D1
AMG02 - Aux delay time 1.0
AMG03 - Aux memory bypass off
AMG04 - Aux configurable text AUX 7
AMG05 - Aux inverted input off
Aux 8
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AMH01 - Aux function W D1
AMH02 - Aux delay time 1.0
AMH03 - Aux memory bypass off
AMH04 - Aux configurable text AUX 8
AMH05 - Aux inverted input off
Aux 9
AMI01 - Aux function W D1
AMI02 - Aux delay time 1.0
AMI03 - Aux memory bypass off
AMI04 - Aux configurable text AUX 9
AMI05 - Aux inverted input off
Aux 10
AMJ01 - Aux function W D1
AMJ02 - Aux delay time 1.0
AMJ03 - Aux memory bypass off
AMJ04 - Aux configurable text AUX 10
AMJ05 - Aux inverted input off
Aux 11
AMK01 - Aux function W D1
AMK02 - Aux delay time 1.0
AMK03 - Aux memory bypass off
AMK04 - Aux configurable text AUX 11
AMK05 - Aux inverted input off
Aux 12
AML01 - Aux function W D1
AML02 - Aux delay time 1.0
AML03 - Aux memory bypass off
AML04 - Aux configurable text AUX 12
AML05 - Aux inverted input off
Aux 13
AMM01 - Aux function W D1
AMM02 - Aux delay time 1.0
AMM03 - Aux memory bypass off
AMM04 - Aux configurable text AUX 13
AMM05 - Aux inverted input off
Aux 14
AMN01 - Aux function W D1
AMN02 - Aux delay time 1.0
AMN03 - Aux memory bypass off
AMN04 - Aux configurable text AUX 14
AMN05 - Aux inverted input off
Aux 15
AMO01 - Aux function W D1
AMO02 - Aux delay time 1.0
AMO03 - Aux memory bypass off
AMO04 - Aux configurable text AUX 15
AMO05 - Aux inverted input off
Aux 16
AMP01 - Aux function W D1
AMP02 - Aux delay time 1.0
AMP03 - Aux memory bypass off
AMP04 - Aux configurable text AUX 16
AMP05 - Aux inverted input off
Aux 17
AMQ01 - Aux function W D1
AMQ02 - Aux delay time 1.0
AMQ03 - Aux memory bypass off
AMQ04 - Aux configurable text AUX 17
AMQ05 - Aux inverted input off
Aux 18
AMR01 - Aux function W D1
AMR02 - Aux delay time 1.0
AMR03 - Aux memory bypass off
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AMR04 - Aux configurable text AUX 18
AMR05 - Aux inverted input off
Aux 19
AMS01 - Aux function W D1
AMS02 - Aux delay time 1.0
AMS03 - Aux memory bypass off
AMS04 - Aux configurable text AUX 19
AMS05 - Aux inverted input off
Aux 20
AMT01 - Aux function W D1
AMT02 - Aux delay time 1.0
AMT03 - Aux memory bypass off
AMT04 - Aux configurable text AUX 20
AMT05 - Aux inverted input off
Drive monitor
Start interlock
DMA01 - Start alternative, drive 1 and
DMA02 - Start delay time, drive 1 5 sec
DMA03 - Start alternative, drive 2 and
DMA04 - Start delay time, drive 2 5 sec
Drive 1
DMB01 - Delay, charge pressure A 0.5 sec
DMB02 - Delay, charge pressure B 0.5 sec
DMB03 - Delay, E-motor temp 0.0 sec
DMB04 - Delay, work pressure A 7.0 sec
DMB05 - Mem bypass, work pr. A off
DMB06 - Delay, work pressure B 7.0 sec
DMB07 - Mem bypass, work pr. B off
DMB08 - Analog pressure sensor off
Drive 2
DMC01 - Delay, charge pressure A 0.5 sec
DMC02 - Delay, charge pressure B 0.5 sec
DMC03 - Delay, E-motor temp 0.0 sec
DMC04 - Delay, work pressure A 7.0 sec
DMC05 - Mem bypass, work pr. A off
DMC06 - Delay, work pressure B 7.0 sec
DMC07 - Mem bypass, work pr. B off
DMC08 - Analog pressure sensor off
Emotor interlock
DMD01 - Delay, Interlock E-motor 1 1.0
DMD02 - Delay, Interlock E-motor 2 1.0
DMD03 - Delay, Interlock E-motor 3 1.0
Drive 1 basic
Setpoint
D1A01 - Speed setpoint Local/Remote (*)
D1A02 - Type of command signal Unidirectional (*)
D1A03 - Reset of local setpoint yes
D1A04 - Reverse input on (*)
D1A05 - Reverse command setpoint -10.0 (*)
D1A06 - Digital forward setpoint 10.0
D1A07 - Digital reverse setpoint -10.0
D1A08 - Drive front panel buttons on
Ramp
D1C01 - Up ramp time forward 2.0
D1C02 - Down ramp time forward 2.0
D1C03 - Up ramp time reverse 2.0
D1C04 - Down ramp time reverse 2.0
Regulator
D1D01 - Regulator on (*)
D1D02 - Feed forward function on
D1D03 - Proportional regulator on (*)
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D1D04 - Integrating regulator on (*)
D1D05 - Derivation regulator off
D1D06 - Proportional gain 0.1
D1D07 - Integration time 10.0
D1D08 - Derivation time 0.10
D1D09 - Derivation decline time 0.1
D1D10 - Max feedback deviation 50
D1D11 - Regulated or nonregulated Switching (*)
Feedback
D1E01 - Max motor shaft speed 6.9 (*)
D1E02 - Feedback selection Digital
D1E03 - Filter time for feedback 0.0
Power limitation
D1F01 - Delay time, power limitation 0.0 (*)
D1F02 - Ramp time, power limitation 20.0
Drive 2 basic
Setpoint
D2A01 - Speed setpoint Local
D2A02 - Type of command signal Bidirectional
D2A03 - Reset of local setpoint yes
D2A04 - Reverse input off
D2A05 - Reverse command setpoint -20.0
D2A06 - Digital forward setpoint 10.0
D2A07 - Digital reverse setpoint -10.0
D2A08 - Drive front panel buttons on
Ramp
D2C01 - Up ramp time forward 2.0
D2C02 - Down ramp time forward 2.0
D2C03 - Up ramp time reverse 2.0
D2C04 - Down ramp time reverse 2.0
Regulator
D2D01 - Regulator off
D2D02 - Feed forward function on
D2D03 - Proportional regulator off
D2D04 - Integrating regulator off
D2D05 - Derivation regulator off
D2D06 - Proportional gain 0.1
D2D07 - Integration time 10.0
D2D08 - Derivation time 0.10
D2D09 - Derivation decline time 0.1
D2D10 - Max feedback deviation 50
D2D11 - Regulated or nonregulated Non-regulated
Feedback
D2E01 - Max motor shaft speed 10.0
D2E02 - Feedback selection Digital
D2E03 - Filter time for feedback 0.0
Power limitation
D2F01 - Delay time, power limitation 0.5
D2F02 - Ramp time, power limitation 20.0
Shredder 1
Function
SHA01 - Reverse control Pressure, separate
SHA02 - Reverse stop function Going to forward
SHA03 - Delay before reversal 3.0
SHA04 - Reversal time 10.0
SHA05 - Reverse delay SHA02 3.0
SHA06 - Forward time 10.0
SHA07 - Shredder automatic dir. off
SHA08 - Forward time interval 60
SHA09 - Reverse time interval 60
SHA10 - Selection of regulated dr. Unregulated
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E01PX10-2511.txt
Setpoint
SHB01 - Reverse command setpoint Forward
SHB02 - Scale factor for reverse 100
SHB03 - Analog pressure sensor off
SHB04 - High pr. level, forward 200
SHB05 - High pr. level, reverse 200
Counter
SHC01 - Window time for counter 60
SHC02 - Reversal counter 5
Shredder 2
Function
SHG01 - Reverse control Pressure, separate
SHG02 - Reverse stop function Going to forward
SHG03 - Delay before reversal 3.0
SHG04 - Reversal time 10.0
SHG05 - Reverse delay SHG02 3.0
SHG06 - Forward time 10.0
SHG07 - Shredder automatic dir. off
SHG08 - Forward time interval 60
SHG09 - Reverse time interval 60
SHG10 - Selection of regulated dr. Unregulated
Setpoint
SHH01 - Reverse command setpoint Forward
SHH02 - Scale factor for reverse 100
SHH03 - Analog pressure sensor off
SHH04 - High pr. level, forward 200
SHH05 - High pr. level, reverse 200
Counter
SHI01 - Window time for counter 60
SHI02 - Reversal counter 5
Synchro
Function
SYA01 - Type of synchronisation RATIO
SYA02 - Master command D1 Master - D2 Slave
Drive 1 reset
SYB01 - Counter reset command Reset by start
SYB02 - Enable of counter reset E-motors start
Drive 2 setpoint
SYC01 - Drive 2 low friction limit 0
SYC02 - Drive 2 high friction limit 200
SYC03 - Offset reset by motor start off
SYC04 - Offset for Drive 2 0.0
Drive 2 indication
SYD01 - Synchro indication limit 5
SYD02 - Sync time 1.0
Drive 2 reset
SYE01 - Counter reset command Reset by start
SYE02 - Enable of counter reset E-motors start
Master setpoint
SYF01 - Up ramp time forward 2.0
SYF02 - Down ramp time forward 2.0
SYF03 - Up ramp time reverse 2.0
SYF04 - Down ramp time reverse 2.0
Drive 1 setpoint
SYG01 - Drive 1 low friction limit 0
SYG02 - Drive 1 high friction limit 200
Pressure 1
Function
PRA01 - Pressure control off
PRA02 - Reverse dir. of ctrl action off
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E01PX10-2511.txt
PRA03 - Low pressure control off
PRA04 - High pressure control off
PRA05 - Filter time, low pr. control 5
PRA06 - Filter time, high pr. control 5
Pr. setpoint
PRB01 - Pressure setpoint Local
PRB02 - Local pressure setpoint 200
PRB03 - Low limit, pressure setpoint 25
PRB04 - High limit, pressure setpoint 25
PRB05 - Low limit, PID output 10
PRB06 - High limit, PID output 10
PRB07 - Max pressure 250
Regulator
PRC01 - Proportional regulator off
PRC02 - Integrating regulator off
PRC03 - Derivation regulator off
PRC04 - Proportional gain 0.1
PRC05 - Integration time 10.0
PRC06 - Derivation time 0.10
PRC07 - Derivation decline time 0.1
PRC08 - Filter time for pr. feedback 0.0
Pressure 2
Function
PRG01 - Pressure control off
PRG02 - Reverse dir. of ctrl action off
PRG03 - Low pressure control off
PRG04 - High pressure control off
PRG05 - Filter time, low pr. control 5
PRG06 - Filter time, high pr. control 5
Pr. setpoint
PRH01 - Pressure setpoint Local
PRH02 - Local pressure setpoint 200
PRH03 - Low limit, pressure setpoint 25
PRH04 - High limit, pressure setpoint 25
PRH05 - Low limit, PID output 10
PRH06 - High limit, PID output 10
PRH07 - Max pressure 250
Regulator
PRI01 - Proportional regulator off
PRI02 - Integrating regulator off
PRI03 - Derivation regulator off
PRI04 - Proportional gain 0.1
PRI05 - Integration time 10.0
PRI06 - Derivation time 0.10
PRI07 - Derivation decline time 0.1
PRI08 - Filter time for pr. feedback 0.0
Reading 1
Scroll menu
R1A01 - Text for reading 1 HIGH PSI (*)
R1A02 - Reading 1 REG405 (*)
R1A03 - Text for reading 2 TANKTEMP (*)
R1A04 - Reading 2 REG403 (*)
R1A05 - Text for reading 3 READING3
R1A06 - Reading 3 OFF
R1A07 - Text for reading 4 READING4
R1A08 - Reading 4 OFF
R1A09 - Text for reading 5 READING5
R1A10 - Reading 5 OFF
R1A11 - Text for reading 6 READING6
R1A12 - Reading 6 OFF
R1A13 - Text for reading 7 READING7
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R1A14 - Reading 7 OFF
R1A15 - Text for reading 8 READING8
R1A16 - Reading 8 OFF
R1A17 - Text for reading 9 READING9
R1A18 - Reading 9 OFF
Left upper
R1B01 - Reading REG102
Right upper
R1C01 - Reading REG106
Left lower
R1D01 - Reading REG109
Right lower
R1E01 - Reading REG311
Reading 2
Scroll menu
R2A01 - Text for reading 1 READING1
R2A02 - Reading 1 OFF
R2A03 - Text for reading 2 READING2
R2A04 - Reading 2 OFF
R2A05 - Text for reading 3 READING3
R2A06 - Reading 3 OFF
R2A07 - Text for reading 4 READING4
R2A08 - Reading 4 OFF
R2A09 - Text for reading 5 READING5
R2A10 - Reading 5 OFF
R2A11 - Text for reading 6 READING6
R2A12 - Reading 6 OFF
R2A13 - Text for reading 7 READING7
R2A14 - Reading 7 OFF
R2A15 - Text for reading 8 READING8
R2A16 - Reading 8 OFF
R2A17 - Text for reading 9 READING9
R2A18 - Reading 9 OFF
Left upper
R2B01 - Reading REG202
Right upper
R2C01 - Reading REG206
Left lower
R2D01 - Reading REG209
Right lower
R2E01 - Reading REG321
Page 15
SPIDER CONTROL SYSTEM [E01P X10-2526]
DOCUMENTATION FOR SPIDER CONTROL SYSTEM
E01P X10-2526
Notes:
E01PX10-2526.txt
Printout time: 2005-09-27 11:56:20
Printed by SpiderCom2 version: 4.1.4 Build 8
Parameter file name: E01PX10-2526.s2p
Parameter file version: 2
SpiderII software version: 4.1.2 2
Main settings
Function
MAA01 - System function BASIC
Configuration
MAB01 - E-motor connection for P1 E-motor 1
MAB02 - E-motor connection for P2 OFF
MAB03 - E-motor connection for P3 OFF
MAB04 - E-motor connection for P4 OFF
MAB05 - Drive connection for P1 Drive 1
MAB06 - Drive connection for P2 OFF
MAB07 - Drive connection for P3 OFF
MAB08 - Drive connection for P4 OFF
MAB09 - Separate or common Separate
MAB10 - Shutdown ramp time 0
MAB11 - Emerg. stop mem bypass off
Language
MAC01 - Display language selection English
Protection
MAD01 - Security code - setup menu yes (*)
MAD02 - Security code 0532 (*)
Pump outputs
Pump 1
POA01 - Forward min current 173 (*)
POA02 - Forward max current 301 (*)
POA03 - Reverse min current 165 (*)
POA04 - Reverse max current 290 (*)
POA05 - Coil resistance 41 (*)
POA06 - PWM-frequency 200
Pump 2
POB01 - Forward min current 0
POB02 - Forward max current 0
POB03 - Reverse min current 0
POB04 - Reverse max current 0
POB05 - Coil resistance 40
POB06 - PWM-frequency 200
Pump 3
POC01 - Forward min current 0
POC02 - Forward max current 0
POC03 - Reverse min current 0
POC04 - Reverse max current 0
POC05 - Coil resistance 40
POC06 - PWM-frequency 200
Pump 4
POD01 - Forward min current 0
POD02 - Forward max current 0
POD03 - Reverse min current 0
POD04 - Reverse max current 0
POD05 - Coil resistance 40
POD06 - PWM-frequency 200
Friction
POE01 - Pump friction Off
POE02 - Pump low friction limit 0
POE03 - Pump high friction limit 200
POE04 - Friction up ramp time 2.0
POE05 - Friction down ramp time 2.0
Page 1
E01PX10-2526.txt
Digital inputs
Digital in 1 - 22
DIN01 - Digital input 1, DI1:3 14 START 1 (*)
DIN02 - Digital input 2, DI1:4 15 REV 1 (*)
DIN03 - Digital input 3, DI1:5 21 OFF (*)
DIN04 - Digital input 4, DI1:6 07 MN LEVEL
DIN05 - Digital input 5, DI1:7 07 LO LEVEL
DIN06 - Digital input 6, DI1:8 06 DRF 100
DIN07 - Digital input 7, DI2:4 06 RF100 P1
DIN08 - Digital input 8, DI2:5 05 SUCTION1
DIN09 - Digital input 9, DI2:6 03 C PRA P1 (*)
DIN10 - Digital input 10, DI2:7 01 H APR P1
DIN11 - Digital input 11, DI2:8 21 OFF (*)
DIN12 - Digital input 12, DI2:9 21 OFF (*)
DIN13 - Digital input 13, DI2:10 21 OFF (*)
DIN14 - Digital input 14, DI2:11 21 OFF (*)
DIN15 - Digital input 15, DI2:12 21 OFF
DIN16 - Digital input 16, DI3:4 21 OFF (*)
DIN17 - Digital input 17, DI3:5 21 OFF (*)
DIN18 - Digital input 18, DI3:6 21 OFF (*)
DIN19 - Digital input 19, DI3:7 21 OFF (*)
DIN20 - Digital input 20, DI3:8 21 OFF (*)
DIN21 - Digital input 21, DI3:9 21 OFF (*)
DIN22 - Digital input 22, DI3:10 21 OFF (*)
Digital in 23 - 43
DIN23 - Digital input 23, DI3:11 21 OFF (*)
DIN24 - Digital input 24, DI3:12 21 OFF
DIN25 - Digital input 25, DI4:4 21 OFF
DIN26 - Digital input 26, DI4:5 21 OFF
DIN27 - Digital input 27, DI4:6 21 OFF
DIN28 - Digital input 28, DI4:7 21 OFF
DIN29 - Digital input 29, DI4:8 21 OFF
DIN30 - Digital input 30, DI4:9 21 OFF
DIN31 - Digital input 31, DI4:10 21 OFF
DIN32 - Digital input 32, DI4:11 21 OFF
DIN33 - Digital input 33, DI4:12 21 OFF
DIN34 - Digital input 34, DI5:3 21 OFF
DIN35 - Digital input 35, DI5:4 21 OFF
DIN36 - Digital input 36, DI5:5 21 OFF
DIN37 - Digital input 37, DI5:6 21 OFF
DIN38 - Digital input 38, DI5:7 21 OFF
DIN39 - Digital input 39, DI5:8 21 OFF
DIN40 - Digital input 40, DI5:9 21 OFF
DIN41 - Digital input 41, DI5:10 21 OFF
DIN42 - Digital input 42, DI5:11 21 OFF
DIN43 - Digital input 43, DI5:12 21 OFF
Digital outputs
Digital out 1
DOA01 - Digital output function 11 COOLCONI (*)
DOA02 - Inverted function no
DOA03 - Delay time for digital output 5.0
DOA04 - Delay function for output NO
Digital out 2
DOB01 - Digital output function 01 A1 (*)
DOB02 - Inverted function no
DOB03 - Delay time for digital output 5.0
DOB04 - Delay function for output NO
Digital out 3
DOC01 - Digital output function 01 W1 (*)
DOC02 - Inverted function no
DOC03 - Delay time for digital output 5.0
Page 2
E01PX10-2526.txt
DOC04 - Delay function for output NO
Digital out 4
DOD01 - Digital output function 02 START 1 (*)
DOD02 - Inverted function no
DOD03 - Delay time for digital output 5.0
DOD04 - Delay function for output NO
Digital out 5
DOE01 - Digital output function 04 REMOTE 1 (*)
DOE02 - Inverted function no
DOE03 - Delay time for digital output 5.0
DOE04 - Delay function for output NO
Digital out 6
DOF01 - Digital output function 03 READY 1 (*)
DOF02 - Inverted function no
DOF03 - Delay time for digital output 5.0
DOF04 - Delay function for output NO
Digital out 7
DOG01 - Digital output function 15 OFF
DOG02 - Inverted function no
DOG03 - Delay time for digital output 0.0 (*)
DOG04 - Delay function for output NO
Digital out 8
DOH01 - Digital output function 15 OFF
DOH02 - Inverted function no
DOH03 - Delay time for digital output 0.0 (*)
DOH04 - Delay function for output NO
Digital out 9
DOI01 - Digital output function 15 OFF
DOI02 - Inverted function no
DOI03 - Delay time for digital output 5.0
DOI04 - Delay function for output NO
Digital out 10
DOJ01 - Digital output function 15 OFF
DOJ02 - Inverted function no
DOJ03 - Delay time for digital output 5.0
DOJ04 - Delay function for output NO
Digital out 11
DOK01 - Digital output function 15 OFF
DOK02 - Inverted function no
DOK03 - Delay time for digital output 5.0
DOK04 - Delay function for output NO
Digital out 12
DOL01 - Digital output function 15 OFF
DOL02 - Inverted function no
DOL03 - Delay time for digital output 5.0
DOL04 - Delay function for output NO
Digital out 13
DOM01 - Digital output function 15 OFF
DOM02 - Inverted function no
DOM03 - Delay time for digital output 5.0
DOM04 - Delay function for output NO
Pulse inputs
Drive 1
P1I01 - Pulses/rev 3600 (*)
P1I02 - Units for REG109 rpm
P1I03 - Decimals for REG109 0
P1I04 - Scaling for REG109 1.00
P1I05 - Filter time for speed reading 0.0
P1I06 - Polarity - digital speed signal 1
P1I07 - Encoder type 1
Drive 2
P2I01 - Pulses/rev 1000
Page 3
E01PX10-2526.txt
P2I02 - Units for REG209 rpm
P2I03 - Decimals for REG209 0
P2I04 - Scaling for REG209 1.00
P2I05 - Filter time for speed reading 0.0
P2I06 - Polarity - digital speed signal 1
P2I07 - Encoder type 1
Analog inputs
Setpoint 1
AIA01 - Input type 4-20 mA
AIA02 - Zero point adjustment 0
AIA03 - Max point adjustment 0
AIA04 - Reading for REG101 %
Setpoint 2
AIB01 - Input type 4-20 mA
AIB02 - Zero point adjustment 0
AIB03 - Max point adjustment 0
AIB04 - Reading for REG201 %
Analog in 1
AIF01 - Input type 4-20 mA
AIF02 - Zero point adjustment 0
AIF03 - Max point adjustment 0
AIF04 - Min input, REG401 0
AIF05 - Max input, REG401 200
AIF06 - Units for REG401 bar
AIF07 - Decimals for REG401 0
AIF08 - Scaling for REG401 1.00
AIF09 - Function for input OFF
AIF10 - High indication level 200
AIF11 - Low indication level 0
AIF12 - Function for min indication OFF
AIF13 - Function for high indication OFF
AIF14 - Function for low indication OFF
Analog in 2
AIG01 - Input type 4-20 mA
AIG02 - Zero point adjustment 0
AIG03 - Max point adjustment 0
AIG04 - Min input, REG402 0
AIG05 - Max input, REG402 200
AIG06 - Units for REG402 bar
AIG07 - Decimals for REG402 0
AIG08 - Scaling for REG402 1.00
AIG09 - Function for input OFF
AIG10 - High indication level 200
AIG11 - Low indication level 0
AIG12 - Function for min indication OFF
AIG13 - Function for high indication OFF
AIG14 - Function for low indication OFF
Analog in 3
AIH01 - Input type 4-20 mA
AIH02 - Zero point adjustment 0
AIH03 - Max point adjustment 5 (*)
AIH04 - Min input, REG403 -25 (*)
AIH05 - Max input, REG403 100 (*)
AIH06 - Units for REG403 °C (*)
AIH07 - Decimals for REG403 1 (*)
AIH08 - Scaling for REG403 1.00
AIH09 - Function for input TANK A (*)
AIH10 - High indication level 60 (*)
AIH11 - Low indication level 0 (*)
AIH12 - Function for min indication OFF
AIH13 - Function for high indication OFF
AIH14 - Function for low indication OFF
Page 4
E01PX10-2526.txt
Analog in 4
AII01 - Input type 4-20 mA
AII02 - Zero point adjustment 0
AII03 - Max point adjustment 0
AII04 - Min input, REG404 0
AII05 - Max input, REG404 69 (*)
AII06 - Units for REG404 bar
AII07 - Decimals for REG404 0
AII08 - Scaling for REG404 1.00
AII09 - Function for input PR1 (*)
AII10 - High indication level 69
AII11 - Low indication level 0
AII12 - Function for min indication OFF
AII13 - Function for high indication OFF
AII14 - Function for low indication OFF
Analog in 5
AIJ01 - Input type 4-20 mA
AIJ02 - Zero point adjustment 0
AIJ03 - Max point adjustment 0
AIJ04 - Min input, REG405 0
AIJ05 - Max input, REG405 414 (*)
AIJ06 - Units for REG405 bar
AIJ07 - Decimals for REG405 0
AIJ08 - Scaling for REG405 1.00
AIJ09 - Function for input SP1 (*)
AIJ10 - High indication level 325 (*)
AIJ11 - Low indication level 10 (*)
AIJ12 - Function for min indication OFF
AIJ13 - Function for high indication OFF
AIJ14 - Function for low indication OFF
Analog in 6
AIK01 - Input type 4-20 mA
AIK02 - Zero point adjustment 0
AIK03 - Max point adjustment 0
AIK04 - Min input, REG406 0
AIK05 - Max input, REG406 200
AIK06 - Units for REG406 bar
AIK07 - Decimals for REG406 0
AIK08 - Scaling for REG406 1.00
AIK09 - Function for input OFF
AIK10 - High indication level 200
AIK11 - Low indication level 0
AIK12 - Function for min indication OFF
AIK13 - Function for high indication OFF
AIK14 - Function for low indication OFF
Analog in 7
AIL01 - Input type 4-20 mA
AIL02 - Zero point adjustment 0
AIL03 - Max point adjustment 0
AIL04 - Min input, REG407 0
AIL05 - Max input, REG407 200
AIL06 - Units for REG407 bar
AIL07 - Decimals for REG407 0
AIL08 - Scaling for REG407 1.00
AIL09 - Function for input OFF
AIL10 - High indication level 200
AIL11 - Low indication level 0
AIL12 - Function for min indication OFF
AIL13 - Function for high indication OFF
AIL14 - Function for low indication OFF
Analog in 8
AIM01 - Input type 4-20 mA
AIM02 - Zero point adjustment 0
Page 5
E01PX10-2526.txt
AIM03 - Max point adjustment 0
AIM04 - Min input, REG408 0
AIM05 - Max input, REG408 200
AIM06 - Units for REG408 bar
AIM07 - Decimals for REG408 0
AIM08 - Scaling for REG408 1.00
AIM09 - Function for input OFF
AIM10 - High indication level 200
AIM11 - Low indication level 0
AIM12 - Function for min indication OFF
AIM13 - Function for high indication OFF
AIM14 - Function for low indication OFF
Analog in 9
AIN01 - Input type 4-20 mA
AIN02 - Zero point adjustment 0
AIN03 - Max point adjustment 0
AIN04 - Min input, REG409 0
AIN05 - Max input, REG409 200
AIN06 - Units for REG409 bar
AIN07 - Decimals for REG409 0
AIN08 - Scaling for REG409 1.00
AIN09 - Function for input OFF
AIN10 - High indication level 200
AIN11 - Low indication level 0
AIN12 - Function for min indication OFF
AIN13 - Function for high indication OFF
AIN14 - Function for low indication OFF
Tank temp
AIP01 - Zero point adjustment 0
AIP02 - Max point adjustment 0
AIP03 - Units for REG410 °F (*)
Power limit
AIR01 - Power limitation E-motor 1 1101 (*)
AIR02 - Power limitation E-motor 2 400
AIR03 - Power limitation E-motor 3 400
Analog outputs
Analog out 1
AOA01 - Analog output REG109 (*)
AOA02 - 4-20mA or 2-10V ouput on
AOA03 - Zero point adjustment 0
AOA04 - Max point adjustment 0
Analog out 2
AOB01 - Analog output REG403 (*)
AOB02 - 4-20mA or 2-10V ouput on
AOB03 - Zero point adjustment 0
AOB04 - Max point adjustment 0
Analog out 3
AOC01 - Analog output REG405 (*)
AOC02 - 4-20mA or 2-10V ouput on
AOC03 - Zero point adjustment 0
AOC04 - Max point adjustment -15 (*)
Analog out 4
AOD01 - Analog output OFF
AOD02 - 4-20mA or 2-10V ouput off (*)
AOD03 - Zero point adjustment 0
AOD04 - Max point adjustment 0
Bus
Type && Function
BTF01 - Type of bus communication OFF
BTF02 - Max com. drop time 1
BTF03 - Function at com. drop Interlock
Page 6
E01PX10-2526.txt
Digital in
BDI01 - Digital input 1 21 OFF
BDI02 - Digital input 2 21 OFF
BDI03 - Digital input 3 21 OFF
BDI04 - Digital input 4 21 OFF
BDI05 - Digital input 5 21 OFF
BDI06 - Digital input 6 21 OFF
BDI07 - Digital input 7 21 OFF
BDI08 - Digital input 8 21 OFF
BDI09 - Digital input 9 21 OFF
BDI10 - Digital input 10 21 OFF
BDI11 - Digital input 11 21 OFF
BDI12 - Digital input 12 21 OFF
BDI13 - Digital input 13 21 OFF
BDI14 - Digital input 14 21 OFF
BDI15 - Digital input 15 21 OFF
BDI16 - Digital input 16 21 OFF
BDI17 - Digital input 17 21 OFF
BDI18 - Digital input 18 21 OFF
BDI19 - Digital input 19 21 OFF
BDI20 - Digital input 20 21 OFF
BDI21 - Digital input 21 21 OFF
BDI22 - Digital input 22 21 OFF
BDI23 - Digital input 23 21 OFF
BDI24 - Digital input 24 21 OFF
Analog in 1
BAA01 - Min input, REG501 0
BAA02 - Max input, REG501 200
BAA03 - Units for REG501 %
BAA04 - Decimals for REG501 0
BAA05 - Function for input OFF
Analog in 2
BAB01 - Min input, REG502 0
BAB02 - Max input, REG502 200
BAB03 - Units for REG502 %
BAB04 - Decimals for REG502 0
BAB05 - Function for input OFF
Analog in 3
BAC01 - Min input, REG503 0
BAC02 - Max input, REG503 200
BAC03 - Units for REG503 °
BAC04 - Decimals for REG503 0
BAC05 - Function for input OFF
Analog in 4
BAD01 - Min input, REG504 0
BAD02 - Max input, REG504 200
BAD03 - Units for REG504 bar
BAD04 - Decimals for REG504 0
BAD05 - Function for input OFF
Analog out
BAK01 - Analog output register OFF
BAK02 - Analog output register OFF
BAK03 - Analog output register OFF
BAK04 - Analog output register OFF
BAK05 - Analog output register OFF
BAK06 - Analog output register OFF
BAK07 - Analog output register OFF
BAK08 - Analog output register OFF
Pump monitor
Pump 1
PMA01 - Charge pr. interlock delay 5 sec
PMA02 - Delay, Charge pr. A 0.5 sec
Page 7
E01PX10-2526.txt
PMA03 - Delay, Charge pr. B 0.5 sec
PMA04 - Delay, Suction line 0.0 sec
PMA05 - Delay, Return filter 75% 7.0 sec
PMA06 - Delay, Return filter 100% 7.0 sec
PMA07 - Return filter alarm OFF
PMA08 - Delay, High work pr. A 7.0 sec
PMA09 - Mem bypass, work pr. A off
PMA10 - Delay, High work pr. B 7.0 sec
PMA11 - Mem bypass, work pr. B off
PMA12 - Signal plausibility check on
PMA13 - Error limits between in/out 50
PMA14 - Analog pressure sensor off
Pump 2
PMB01 - Charge pr. interlock delay 5 sec
PMB02 - Delay, Charge pr. A 0.5 sec
PMB03 - Delay, Charge pr. B 0.5 sec
PMB04 - Delay, Suction line 0.0 sec
PMB05 - Delay, Return filter 75% 7.0 sec
PMB06 - Delay, Return filter 100% 7.0 sec
PMB07 - Return filter alarm OFF
PMB08 - Delay, High work pr. A 7.0 sec
PMB09 - Mem bypass, work pr. A off
PMB10 - Delay, High work pr. B 7.0 sec
PMB11 - Mem bypass, work pr. B off
PMB12 - Signal plausibility check on
PMB13 - Error limits between in/out 50
PMB14 - Analog pressure sensor off
Pump 3
PMC01 - Charge pr. interlock delay 5 sec
PMC02 - Delay, Charge pr. A 0.5 sec
PMC03 - Delay, Charge pr. B 0.5 sec
PMC04 - Delay, Suction line 0.0 sec
PMC05 - Delay, Return filter 75% 7.0 sec
PMC06 - Delay, Return filter 100% 7.0 sec
PMC07 - Return filter alarm OFF
PMC08 - Delay, High work pr. A 7.0 sec
PMC09 - Mem bypass, work pr. A off
PMC10 - Delay, High work pr. B 7.0 sec
PMC11 - Mem bypass, work pr. B off
PMC12 - Signal plausibility check on
PMC13 - Error limits between in/out 50
PMC14 - Analog pressure sensor off
Pump 4
PMD01 - Charge pr. interlock delay 5 sec
PMD02 - Delay, Charge pr. A 0.5 sec
PMD03 - Delay, Charge pr. B 0.5 sec
PMD04 - Delay, Suction line 0.0 sec
PMD05 - Delay, Return filter 75% 7.0 sec
PMD06 - Delay, Return filter 100% 7.0 sec
PMD07 - Return filter alarm OFF
PMD08 - Delay, High work pr. A 7.0 sec
PMD09 - Mem bypass, work pr. A off
PMD10 - Delay, High work pr. B 7.0 sec
PMD11 - Mem bypass, work pr. B off
PMD12 - Signal plausibility check on
PMD13 - Error limits between in/out 50
PMD14 - Analog pressure sensor off
Tank monitor
Digital
TMA01 - Delay, Low oil level warn. 0.0 sec
TMA02 - Delay, Min oil level alarm 0.0 sec
TMA03 - Delay, Min temp alarm 0.0 sec
Page 8
E01PX10-2526.txt
TMA04 - Delay, High temp warn. 0.0 sec
TMA05 - Delay, Max temp alarm 0.5 sec
TMA06 - Delay, Drain 75% warn. 7.0 sec
TMA07 - Delay, Drain 100% warn. 7.0 sec
TMA08 - Drain filter alarm OFF
TMA09 - Min oil temp function A
Analog
TMB01 - Analog temp sensor on
TMB03 - Max oil temp alarm level 60
TMB04 - High oil temp warning level 55
TMB05 - Cooling temp on level (rise) 40
TMB06 - Cooling hysteresis 3
TMB07 - Filter interlock temp level 18 (*)
TMB08 - Heating temp on level (fall) 15
TMB09 - Heating hysteresis 3
TMB10 - Min oil temp alarm level 10
TMB11 - Flushing temp on level (fall) 30
TMB12 - Flushing hysteresis 3
Aux monitor
Aux 1
AMA01 - Aux function W D1
AMA02 - Aux delay time 0.1 (*)
AMA03 - Aux memory bypass on (*)
AMA04 - Aux configurable text Eng Stop (*)
AMA05 - Aux inverted input off
Aux 2
AMB01 - Aux function W D1
AMB02 - Aux delay time 1.0
AMB03 - Aux memory bypass off
AMB04 - Aux configurable text AUX 2
AMB05 - Aux inverted input off
Aux 3
AMC01 - Aux function W D1
AMC02 - Aux delay time 1.0
AMC03 - Aux memory bypass off
AMC04 - Aux configurable text AUX 3
AMC05 - Aux inverted input off
Aux 4
AMD01 - Aux function W D1
AMD02 - Aux delay time 1.0
AMD03 - Aux memory bypass off
AMD04 - Aux configurable text AUX 4
AMD05 - Aux inverted input off
Aux 5
AME01 - Aux function W D1
AME02 - Aux delay time 1.0
AME03 - Aux memory bypass off
AME04 - Aux configurable text AUX 5
AME05 - Aux inverted input off
Aux 6
AMF01 - Aux function W D1
AMF02 - Aux delay time 1.0
AMF03 - Aux memory bypass off
AMF04 - Aux configurable text AUX 6
AMF05 - Aux inverted input off
Aux 7
AMG01 - Aux function W D1
AMG02 - Aux delay time 1.0
AMG03 - Aux memory bypass off
AMG04 - Aux configurable text AUX 7
AMG05 - Aux inverted input off
Aux 8
Page 9
E01PX10-2526.txt
AMH01 - Aux function W D1
AMH02 - Aux delay time 1.0
AMH03 - Aux memory bypass off
AMH04 - Aux configurable text AUX 8
AMH05 - Aux inverted input off
Aux 9
AMI01 - Aux function W D1
AMI02 - Aux delay time 1.0
AMI03 - Aux memory bypass off
AMI04 - Aux configurable text AUX 9
AMI05 - Aux inverted input off
Aux 10
AMJ01 - Aux function W D1
AMJ02 - Aux delay time 1.0
AMJ03 - Aux memory bypass off
AMJ04 - Aux configurable text AUX 10
AMJ05 - Aux inverted input off
Aux 11
AMK01 - Aux function W D1
AMK02 - Aux delay time 1.0
AMK03 - Aux memory bypass off
AMK04 - Aux configurable text AUX 11
AMK05 - Aux inverted input off
Aux 12
AML01 - Aux function W D1
AML02 - Aux delay time 1.0
AML03 - Aux memory bypass off
AML04 - Aux configurable text AUX 12
AML05 - Aux inverted input off
Aux 13
AMM01 - Aux function W D1
AMM02 - Aux delay time 1.0
AMM03 - Aux memory bypass off
AMM04 - Aux configurable text AUX 13
AMM05 - Aux inverted input off
Aux 14
AMN01 - Aux function W D1
AMN02 - Aux delay time 1.0
AMN03 - Aux memory bypass off
AMN04 - Aux configurable text AUX 14
AMN05 - Aux inverted input off
Aux 15
AMO01 - Aux function W D1
AMO02 - Aux delay time 1.0
AMO03 - Aux memory bypass off
AMO04 - Aux configurable text AUX 15
AMO05 - Aux inverted input off
Aux 16
AMP01 - Aux function W D1
AMP02 - Aux delay time 1.0
AMP03 - Aux memory bypass off
AMP04 - Aux configurable text AUX 16
AMP05 - Aux inverted input off
Aux 17
AMQ01 - Aux function W D1
AMQ02 - Aux delay time 1.0
AMQ03 - Aux memory bypass off
AMQ04 - Aux configurable text AUX 17
AMQ05 - Aux inverted input off
Aux 18
AMR01 - Aux function W D1
AMR02 - Aux delay time 1.0
AMR03 - Aux memory bypass off
Page 10
E01PX10-2526.txt
AMR04 - Aux configurable text AUX 18
AMR05 - Aux inverted input off
Aux 19
AMS01 - Aux function W D1
AMS02 - Aux delay time 1.0
AMS03 - Aux memory bypass off
AMS04 - Aux configurable text AUX 19
AMS05 - Aux inverted input off
Aux 20
AMT01 - Aux function W D1
AMT02 - Aux delay time 1.0
AMT03 - Aux memory bypass off
AMT04 - Aux configurable text AUX 20
AMT05 - Aux inverted input off
Drive monitor
Start interlock
DMA01 - Start alternative, drive 1 and
DMA02 - Start delay time, drive 1 5 sec
DMA03 - Start alternative, drive 2 and
DMA04 - Start delay time, drive 2 5 sec
Drive 1
DMB01 - Delay, charge pressure A 0.5 sec
DMB02 - Delay, charge pressure B 0.5 sec
DMB03 - Delay, E-motor temp 0.0 sec
DMB04 - Delay, work pressure A 7.0 sec
DMB05 - Mem bypass, work pr. A off
DMB06 - Delay, work pressure B 7.0 sec
DMB07 - Mem bypass, work pr. B off
DMB08 - Analog pressure sensor off
Drive 2
DMC01 - Delay, charge pressure A 0.5 sec
DMC02 - Delay, charge pressure B 0.5 sec
DMC03 - Delay, E-motor temp 0.0 sec
DMC04 - Delay, work pressure A 7.0 sec
DMC05 - Mem bypass, work pr. A off
DMC06 - Delay, work pressure B 7.0 sec
DMC07 - Mem bypass, work pr. B off
DMC08 - Analog pressure sensor off
Emotor interlock
DMD01 - Delay, Interlock E-motor 1 1.0
DMD02 - Delay, Interlock E-motor 2 1.0
DMD03 - Delay, Interlock E-motor 3 1.0
Drive 1 basic
Setpoint
D1A01 - Speed setpoint Local/Remote (*)
D1A02 - Type of command signal Unidirectional (*)
D1A03 - Reset of local setpoint yes
D1A04 - Reverse input on (*)
D1A05 - Reverse command setpoint -10.0 (*)
D1A06 - Digital forward setpoint 10.0
D1A07 - Digital reverse setpoint -10.0
D1A08 - Drive front panel buttons on
Ramp
D1C01 - Up ramp time forward 2.0
D1C02 - Down ramp time forward 2.0
D1C03 - Up ramp time reverse 2.0
D1C04 - Down ramp time reverse 2.0
Regulator
D1D01 - Regulator on (*)
D1D02 - Feed forward function on
D1D03 - Proportional regulator on (*)
Page 11
E01PX10-2526.txt
D1D04 - Integrating regulator on (*)
D1D05 - Derivation regulator off
D1D06 - Proportional gain 0.1
D1D07 - Integration time 10.0
D1D08 - Derivation time 0.10
D1D09 - Derivation decline time 0.1
D1D10 - Max feedback deviation 50
D1D11 - Regulated or nonregulated Switching (*)
Feedback
D1E01 - Max motor shaft speed 6.9 (*)
D1E02 - Feedback selection Digital
D1E03 - Filter time for feedback 0.0
Power limitation
D1F01 - Delay time, power limitation 0.0 (*)
D1F02 - Ramp time, power limitation 20.0
Drive 2 basic
Setpoint
D2A01 - Speed setpoint Local
D2A02 - Type of command signal Bidirectional
D2A03 - Reset of local setpoint yes
D2A04 - Reverse input off
D2A05 - Reverse command setpoint -20.0
D2A06 - Digital forward setpoint 10.0
D2A07 - Digital reverse setpoint -10.0
D2A08 - Drive front panel buttons on
Ramp
D2C01 - Up ramp time forward 2.0
D2C02 - Down ramp time forward 2.0
D2C03 - Up ramp time reverse 2.0
D2C04 - Down ramp time reverse 2.0
Regulator
D2D01 - Regulator off
D2D02 - Feed forward function on
D2D03 - Proportional regulator off
D2D04 - Integrating regulator off
D2D05 - Derivation regulator off
D2D06 - Proportional gain 0.1
D2D07 - Integration time 10.0
D2D08 - Derivation time 0.10
D2D09 - Derivation decline time 0.1
D2D10 - Max feedback deviation 50
D2D11 - Regulated or nonregulated Non-regulated
Feedback
D2E01 - Max motor shaft speed 10.0
D2E02 - Feedback selection Digital
D2E03 - Filter time for feedback 0.0
Power limitation
D2F01 - Delay time, power limitation 0.5
D2F02 - Ramp time, power limitation 20.0
Shredder 1
Function
SHA01 - Reverse control Pressure, separate
SHA02 - Reverse stop function Going to forward
SHA03 - Delay before reversal 3.0
SHA04 - Reversal time 10.0
SHA05 - Reverse delay SHA02 3.0
SHA06 - Forward time 10.0
SHA07 - Shredder automatic dir. off
SHA08 - Forward time interval 60
SHA09 - Reverse time interval 60
SHA10 - Selection of regulated dr. Unregulated
Page 12
E01PX10-2526.txt
Setpoint
SHB01 - Reverse command setpoint Forward
SHB02 - Scale factor for reverse 100
SHB03 - Analog pressure sensor off
SHB04 - High pr. level, forward 200
SHB05 - High pr. level, reverse 200
Counter
SHC01 - Window time for counter 60
SHC02 - Reversal counter 5
Shredder 2
Function
SHG01 - Reverse control Pressure, separate
SHG02 - Reverse stop function Going to forward
SHG03 - Delay before reversal 3.0
SHG04 - Reversal time 10.0
SHG05 - Reverse delay SHG02 3.0
SHG06 - Forward time 10.0
SHG07 - Shredder automatic dir. off
SHG08 - Forward time interval 60
SHG09 - Reverse time interval 60
SHG10 - Selection of regulated dr. Unregulated
Setpoint
SHH01 - Reverse command setpoint Forward
SHH02 - Scale factor for reverse 100
SHH03 - Analog pressure sensor off
SHH04 - High pr. level, forward 200
SHH05 - High pr. level, reverse 200
Counter
SHI01 - Window time for counter 60
SHI02 - Reversal counter 5
Synchro
Function
SYA01 - Type of synchronisation RATIO
SYA02 - Master command D1 Master - D2 Slave
Drive 1 reset
SYB01 - Counter reset command Reset by start
SYB02 - Enable of counter reset E-motors start
Drive 2 setpoint
SYC01 - Drive 2 low friction limit 0
SYC02 - Drive 2 high friction limit 200
SYC03 - Offset reset by motor start off
SYC04 - Offset for Drive 2 0.0
Drive 2 indication
SYD01 - Synchro indication limit 5
SYD02 - Sync time 1.0
Drive 2 reset
SYE01 - Counter reset command Reset by start
SYE02 - Enable of counter reset E-motors start
Master setpoint
SYF01 - Up ramp time forward 2.0
SYF02 - Down ramp time forward 2.0
SYF03 - Up ramp time reverse 2.0
SYF04 - Down ramp time reverse 2.0
Drive 1 setpoint
SYG01 - Drive 1 low friction limit 0
SYG02 - Drive 1 high friction limit 200
Pressure 1
Function
PRA01 - Pressure control off
PRA02 - Reverse dir. of ctrl action off
Page 13
E01PX10-2526.txt
PRA03 - Low pressure control off
PRA04 - High pressure control off
PRA05 - Filter time, low pr. control 5
PRA06 - Filter time, high pr. control 5
Pr. setpoint
PRB01 - Pressure setpoint Local
PRB02 - Local pressure setpoint 200
PRB03 - Low limit, pressure setpoint 25
PRB04 - High limit, pressure setpoint 25
PRB05 - Low limit, PID output 10
PRB06 - High limit, PID output 10
PRB07 - Max pressure 250
Regulator
PRC01 - Proportional regulator off
PRC02 - Integrating regulator off
PRC03 - Derivation regulator off
PRC04 - Proportional gain 0.1
PRC05 - Integration time 10.0
PRC06 - Derivation time 0.10
PRC07 - Derivation decline time 0.1
PRC08 - Filter time for pr. feedback 0.0
Pressure 2
Function
PRG01 - Pressure control off
PRG02 - Reverse dir. of ctrl action off
PRG03 - Low pressure control off
PRG04 - High pressure control off
PRG05 - Filter time, low pr. control 5
PRG06 - Filter time, high pr. control 5
Pr. setpoint
PRH01 - Pressure setpoint Local
PRH02 - Local pressure setpoint 200
PRH03 - Low limit, pressure setpoint 25
PRH04 - High limit, pressure setpoint 25
PRH05 - Low limit, PID output 10
PRH06 - High limit, PID output 10
PRH07 - Max pressure 250
Regulator
PRI01 - Proportional regulator off
PRI02 - Integrating regulator off
PRI03 - Derivation regulator off
PRI04 - Proportional gain 0.1
PRI05 - Integration time 10.0
PRI06 - Derivation time 0.10
PRI07 - Derivation decline time 0.1
PRI08 - Filter time for pr. feedback 0.0
Reading 1
Scroll menu
R1A01 - Text for reading 1 HIGH PSI (*)
R1A02 - Reading 1 REG405 (*)
R1A03 - Text for reading 2 TANKTEMP (*)
R1A04 - Reading 2 REG403 (*)
R1A05 - Text for reading 3 READING3
R1A06 - Reading 3 OFF
R1A07 - Text for reading 4 READING4
R1A08 - Reading 4 OFF
R1A09 - Text for reading 5 READING5
R1A10 - Reading 5 OFF
R1A11 - Text for reading 6 READING6
R1A12 - Reading 6 OFF
R1A13 - Text for reading 7 READING7
Page 14
E01PX10-2526.txt
R1A14 - Reading 7 OFF
R1A15 - Text for reading 8 READING8
R1A16 - Reading 8 OFF
R1A17 - Text for reading 9 READING9
R1A18 - Reading 9 OFF
Left upper
R1B01 - Reading REG102
Right upper
R1C01 - Reading REG106
Left lower
R1D01 - Reading REG109
Right lower
R1E01 - Reading REG311
Reading 2
Scroll menu
R2A01 - Text for reading 1 READING1
R2A02 - Reading 1 OFF
R2A03 - Text for reading 2 READING2
R2A04 - Reading 2 OFF
R2A05 - Text for reading 3 READING3
R2A06 - Reading 3 OFF
R2A07 - Text for reading 4 READING4
R2A08 - Reading 4 OFF
R2A09 - Text for reading 5 READING5
R2A10 - Reading 5 OFF
R2A11 - Text for reading 6 READING6
R2A12 - Reading 6 OFF
R2A13 - Text for reading 7 READING7
R2A14 - Reading 7 OFF
R2A15 - Text for reading 8 READING8
R2A16 - Reading 8 OFF
R2A17 - Text for reading 9 READING9
R2A18 - Reading 9 OFF
Left upper
R2B01 - Reading REG202
Right upper
R2C01 - Reading REG206
Left lower
R2D01 - Reading REG209
Right lower
R2E01 - Reading REG321
Page 15
SPIDER USERS MANUAL
Users Manual
SPIDER 2
Program Release v 2
Software Version 4.1.2
SPIDER AS
Engineering manual
Preface
04-04-02, New
Preface
Hägglunds is one of the worlds leading manufacturers of large hydraulic Drive Systems. A leading position,
made possible by unbeatable service spirit and of continuing development of both products and markets
all over the world. Our drives are to be found in most industrial and marine segments, where there are
extremely high demands for efficiency and reliability. Our main office and production plant is in Mellansel,
Sweden and we have our own sales- and representation offices in some 40 different countries.
This Engineering manual provides necessary information for Spider control system. In order to find particular
information, just search for the wanted section as listed in the table of contents. However, changes in the
equipment may occur. We therefore reserve the right to introduce amendments in the manual as we deem
necessary without notice or obligations.
Warning signs
In this manual you will find the following signs which indicate a potential hazard, which can or will cause
personal injury or substantial property damage. Depending on the probability of the hazard, and how
serious the injury or property damage could be, there are three levels of classification.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB, S-890 42 Mellansel, SWEDEN 1(1)
AS-1
Spider Introduction
Engineering manual 04-04-02
1.1 Description
The Spider unit is a microcontroller based system, configurable to suit different application
needs. It is designed to match the two or three door power unit also with one door unit added.
The control system can control pumps with double coil (Denison 9A, Brueninghaus EP, Sauer
Sundstrand KA or similar pumps) or single coil in one direction (Denison 5A).
The unit can be mounted inside the power unit, in the power unit door, on the outside of the
power unit or delivered separate with wall brackets or panel flange to be wired in by the
customer. Cable sets can be supplied as an option.
The configuration of the pre-programmed system functions is done using the front panel with
help from the text displays or via a serial connection from a laptop. The configuration mode can
be protected with a password.
The Spider unit can control the system with different settings of electric motor/pump
configuration.
EM EM EM EM
DRIVE P DRIVE P P P
EM EM EM EM EM
DRIVE P P
DRIVE P P
P P
EM EM
P P
DRIVE P P
DRIVE
EM EM
DRIVE P P
DRIVE
EM EM EM
DRIVE P P P
DRIVE
-------
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(7)
AS1, Introduction, Engineering manual 04-04-02
• Two to four pumps for two drives with common function. If one stops by a fault the other will
also stop:
EM EM EM
DRIVE P
DRIVE P
DRIVE P
DRIVE P
EM EM EM EM
DRIVE P P
DRIVE P P
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P
DRIVE P P
EM EM EM
DRIVE P P
DRIVE P
EM EM EM
DRIVE P P P
DRIVE P
The Monitor function can health monitor the power unit switches and give information on the text
display about warnings or alarms. An alarm will stop the electric motor or motors if the digital
interlock output is connected via a relay to the starter interlock circuit. Up to 4 pumps can be
controlled in parallel for the same drive
M M M
M M
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(7)
AS1, Introduction, Engineering manual 04-04-02
The Basic function has added functions for power limitation and closed loop speed feedback via
a PID-regulator. Inputs are available for analog or digital speed encoders.
The unit can also monitor analog signals on the display such as speed, E-motor current,
pressure etc.
The Shredder function has the same functions as Basic and added functions for reversing by an
overload-stopped drive. It is possible to maximise the number of reversals within a time limit and
stop the drive when exceeded. The drive can be set to change direction after an adjustable time
interval.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(7)
AS1, Introduction, Engineering manual 04-04-02
The Friction function has the same functions as Basic and added functions for control of two
hydraulic drives driven together with a ratio between the motors.
The Friction slave function has the same functions as Basic and added functions for control of
two hydraulic drives driven together with a ratio in relation to the master setpoint.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(7)
AS1, Introduction, Engineering manual 04-04-02
The Synchro function has the same functions as Basic and added functions for position control
between two hydraulic drives. It is possible by an external signal to set the angle between the
rolls. Ratio drive is also possible. This mode requires digital speed encoders.
The pressure control function output is added to the ramped flow command. The function
compares actual pressure to a setpressure and gives a positive or negative output depending on
sign of the difference and action direction of regulation.
The Spider unit front has push-buttons for start and stop of the drive, local/remote, speed
setpoint by increase and decrease in local mode, inch reverse, regulated/non-regulated drive
and auto/manual drive in shredder mode. These push-button functions can be bypassed in the
configuration of the system functions.
All inputs and outputs are configurable and can be connected to pre-programmed functions in
the setup of the system. All signals are as standard wired to contact terminals or via fieldbus port
(optional).
The digital inputs can be configured to functions for eg. start/stop, reverse, reset, monitoring of
the power unit, auxiliary monitor where it is possible to set the function and display monitor text.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(7)
AS1, Introduction, Engineering manual 04-04-02
The digital outputs can be configured to functions for eg. common alarm/warning, ready to use,
drive started, shredder blocked, cooler and heater control. The outputs are of dry relay contact
type.
The analog inputs can be configured to functions for eg. tank temp, speed, pressure, power for
monitoring and control. The inputs can be configured for current loop or voltage.
The analog outputs can be configured to monitor eg. speed, pressure, temp. The outputs can be
configured for current loop or voltage.
The system includes a drive monitoring function with drive time counters, alarm/warning list and
8 scalable log channels with data download via serial interface. A remote drive monitoring
system with access via GSM can be added as an option.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(7)
AS1, Introduction, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(7)
AS-2
Spider Technical data
Engineering manual 04-04-02
2.1 Mechanical
2.1.1 Mechanical data
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(5)
AS2, Technical data, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(5)
AS2, Technical data, Engineering manual 04-04-02
2.3 Inputs
2.3.1 Analog inputs
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(5)
AS2, Technical data, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
2.3.2 Digital inputs
2.4 Outputs
2.4.1 Pump control
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(5)
AS2, Technical data, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
2.5 Communication
2.5.1 PC connection
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(5)
AS-3
Spider Connection
Engineering manual
04-04-02
3.1 Wiring
Shielded cables are preferred for the installation.
The wire must be min 0,5mm2 for input signals and min 1mm2 for supply and output cables.
Max distance between control system and power unit is 50m.
3.2 Supply
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(30)
AS-3 Connection, Engineering manual 04-04-02
SETPOINT DRIVE 1
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(30)
AS-3 Connection, Engineering manual 04-04-02
SETPOINT DRIVE 2
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(30)
AS-3 Connection, Engineering manual 04-04-02
I I
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(30)
AS-3 Connection, Engineering manual 04-04-02
I I
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 11(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 12(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 15(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(30)
AS-3 Connection, Engineering manual 04-04-02
Pumps with separate coils for A and B side can be used. If pumps with a common coil for both
directions is used, the drive can only be controlled in one direction.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 17(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 19(30)
AS-3 Connection, Engineering manual 04-04-02
Note! All outputs must be protected against induced voltage at switch off by e.g. free wheeling
diode (see 3.4.2), varistor, RC circuit or other overvoltage protection device mounted close to
the load.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 21(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(30)
AS-3 Connection, Engineering manual 04-04-02
INTERCONNECTION TERMINAL
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(30)
AS-3 Connection, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
1 2 3 4 5
6 7 8 9
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not connected
Pin3 B-line, Pos TXD/RXD
Pin4 RTS, Request to send
Pin5 GND BUS
Pin6 +5V BUS
Pin7 Not connected
Pin8 A-line, Neg TXD/RXD
Pin9 Not connected
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(30)
AS-3 Connection, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
5 4 3 2 1
9 8 7 6
Housing Shield
Pin1 Not connected
Pin2 Not used
Pin3 Not used
Pin4 Not connected
Pin5 GND
Pin6 +5V
Pin7 RS485 B-line
Pin8 RS485 A-line
Pin9 Not connected
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(30)
AS-3 Connection, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(30)
AS-3 Connection, Engineering manual 04-04-02
17 CAN1 CA 8 DATA2-
7 NC
6 DATA2+
5 0VCAN2
CAN2 4 DATA1-
3 NC
2 DATA1+
1 0VCAN1
Spare terminals IC 6 For interconnection purpose
5 For interconnection purpose
4 For interconnection purpose
3 For interconnection purpose
2 For interconnection purpose
1 For interconnection purpose
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(30)
AS-4
Spider Indication and setting
Engineering manual 04-04-02
E-MOTOR STARTED
TESTING HARDWARE
SYSTEM READY TO USE
DRIVE MODE
OFF REM
-> TANKTEMP 34°C <-
0% 0%
0rpm 0Amp
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(14)
AS4, Indication and setting, Engineering manual 04-04-02
DRIVE INDICATION
WARN = Common Warning
ALARM = Common Alarm
INT = Interlock
ON = Drive Started
OFF = Drive Stopped
REM = Remote speed command
LOC = Local speed command
BUS = Fieldbus remote speed command
"Blank" = Open loop drive
REG = Closed loop speed feedback drive
WARN ON REM REG AUT MAN = Manual mode (Only in Shredder function)
AUT = Auto mode (only in Shredder function)
> TANKTEMP 35°C <
85 % 92 %
Scroll list shown
20.5 rpm 120 kW
INTERLOCK INDICATION
INTERLOCK DRIVE 1
NO EXT FEED
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(14)
AS4, Indication and setting, Engineering manual 04-04-02
RESET OF ALARMS/WARNINGS
ALARM OFF REM OFF REM
E-MOTOR STOPPED E-MOTOR STOPPED
0% 0% 0% 0%
0.0 rpm 0 mA 0.0 rpm 0 mA
DRIVE 1 3 sec.
DRIVE 1
OR
OR
DRIVE 2 3 sec.
DRIVE 2
ALARM DRIVE 1
LOW CHARGE PRESS P1
NO MORE ALARMS OR
WARNINGS
ALARM DRIVE 1
MIN OIL LEVEL
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(14)
AS4, Indication and setting, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(14)
AS4, Indication and setting, Engineering manual 04-04-02
4.4.2 Drive buttons
INCREASE
Increase speed setpoint when driving
in local mode (front panel setpoint).
FORWARD
Manual forward in Shredder function.
Same
button Switching between open and closed loop
REG/UNREG
speed control when speed feedback used.
(Not avaliable in Shredder function)
Inch reverse with fixed speed.
REVERSE Manual reverse in Shredder function.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(14)
P24
To displays
P23
P27
1 Jtag programming port for Microcontroller IC4
2 1 2
P25
Microcontroller TP2 1 2
TP5 TP4
1
Contact for Spidercom connection
TP23
SW1 5
TP21
TP22 P22
IC15 1
Jtag programming port for CPLD
4.5.1 Revision A
P28
TMS To memory card
CPLD TDI
TP3 TMO
TCK
GND To front keypad
+3V3
C137 C138
Watchdog
indicator TP19 TP16
TP18 TP15
D1 SW3
J1 2 TP17
TP20
W-DOG
1
ON
OFF
1
TP9 P47
4.5 Main card jumpers and indications
12
Logger connection
TP10
TP6
REL15
REL16
REL14
TP7
+
+ TP13
TP12
DC1
- TP11 Supply voltage
indicators
1
Jumpers for analog
P3
- Supply voltage indicators current loop inputs
Jumpers for analog TP8
REL17
current loop inputs
D170 D171 D172 D173 D174 D175 D176 D181
U
AS4, Indication and setting, Engineering manual
I Logger connections
AI6 I AI7 I AI8 I AI9 I AI3 I AI4 I AI5
DO EM EI DE DI1 DI2 AI DE D116 D117
12V 1 1 1 1 1 1 1
PO4
PO4
I I I I P43 P44 P45 P46 P40 P41 P42
SP SP AI_1 AI_2
D1 D2 + - 10V
P2
CA2
CA1
REL18
REL6
REL5
REL9
REL8
REL4
REL7
REL11
REL10
REL3
REL12
REL13
REL1
REL2
PO3
PO3
AO2
1
CA1
CA1
1
P21
P19
1
AO2
PO2
PO2
P1
IC1
IC1
P20
DO1 DO2 EO1 EI/ DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
EM
P14
PO1
PO1
P18
P9
P10
P16
P11
P15
P17
1
1
1
1
1
1
1
1
1
P7
P8
P12
P13
P6
P5
P4
1
1
1
1
1
1
DO1 DO2 EO1 EI/EM DE1 DE2 DI1 DI2 DI3 DI4 DI5 AI1 AI2 AI3 AO1
05-01-21, replaces 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
6(14)
04-04-02
AS4, Indication and setting, Engineering manual 04-04-02
4.5.2 Jumpers
4.5.3 Indicators
4.5.4 Switches
SW3-2 No function
4.5.5 Contacts
DC supply DC1
Pump output 1 PO1 4 pole contact
Pump output 2 PO2 4 pole contact
Pump output 3 PO3 4 pole contact
Pump output 4 PO4 4 pole contact
Digital output 1 DO1 14 pole contact
Digital output 2 DO2 12 pole contact
Electric motor output EO1 8 pole contact
Electric motor input EI/EM 8 pole contact
Emergency stop input
Digital encoder 1 DE1 8 pole contact
Digital encoder 2 DE2 8 pole contact
Digital input 1 DI1 8 pole contact
Digital input 2 DI2 12 pole contact
Digital input 3 DI3 12 pole contact
Digital input 4 DI4 12 pole contact
Digital input 5 DI5 12 pole contact
Analog input 1 AI1 12 pole contact
Analog input 2 AI2 12 pole contact
Analog input 3 AI3 14 pole contact
Analog output 1 AO1 6 pole contact
Analog output 2 AO2 6 pole contact
Internal connection IC 6 pole contact
CAN bus 1 CA1 6 pole contact
CAN bus 2 CA2 6 pole contact
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(14)
AS4, Indication and setting, Engineering manual 04-04-02
24V OK
DC connection
Fuse
Main switch
Main connection
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(14)
AS4, Indication and setting, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
Profibus connector
Termination switch
D5
S1
ON
S3 S2
1 2
LED indicators
901 901
23
23
78
78
456 456
4 3
Address switches
4.7.1.1 Indicators
Indicator Description Function Information
name
D1 Not used Not used Normal function
Off No error.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(14)
AS4, Indication and setting, Engineering manual 05-01-21, replaces 04-04-02
04-04-02
4.7.1.2 Switches
Indicator Function Information
name
S1 Terminating switch On= Enabled (if first or last in a network)
Off= Disabled
S2 Node Address x1 for the node address setting
4.7.2 Modbus
Modbus connector
Termination switch
S1
ON
S2 S3
1 2
LED indicators
3 4
1 2 3 4 5 6 7 8 1 2 3 4
Parity switches
Baudrate switches
Node Address switches
4.7.2.1 Indicators
Indicator Description Function Information
name
D1 Processing Green flashing Receiving Query and building
response.
Off No Query
D2 Bus error Red Bus error
4.7.2.2 Switches
Indicator Function Setting Information
name
S1 Terminating switch On Enabled (if first or last in a
network)
Off Disabled
S2: 1-7 Node Address Binary value:
Switch: 1234567
0000000 Not valid
0000001 1
0000010 2
0000011 3
… …
… …
1111111 127
S2: 8 Baud rate Binary value:
S3: 1-2 Switch: 812
000 Not valid
001 1200
010 2400
011 4800
100 9600
101 19200 (Default)
110 38400
111 57600
S3: 1-2 Parity Binary value:
Switch: 34
00 Not valid
01 None(Default)
10 Even
11 Odd
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 12(14)
AS4, Indication and setting, Engineering manual 04-04-02
When the software stops both Hardware(M) time and Software(S) time is displayed in 1/10 sec so that
the times can be verified/corrected.
HW ERROR, FC 2
This test is to verify that the relay that feeds the PWM-outputs opens. If emergency stop is actuated
the Spider hardware for emergency stop open this relay. This test is performed when all e-motors are
stopped. If the relay doesn't open on this test, error message ”HW ERROR, FC 2” is displayed and
the software stops.
HW ERROR, FC 3
This test is to verify that the electric motor interlock relays opens. When electric motor interlock is
OK the relay is closed and open when interlock not is OK. If the relay not opens, error message ”HW
ERROR, FC 3” is displayed and the software stops. This test is performed at power on and once when all
electric motors are stopped.
HW ERROR, FC 4
Watchdog indication should not be acived during normal program execution. If it happens during normal
program execution, error message ”HW ERROR, FC 4” is displayed and the software stops. This test is
performed continiously.
HW ERROR, FC 5
If measured current is 50% greater than max configured current a shortcircuit is assumed,
error message ”HW ERROR, FC 5” is displayed and the software stops. This test is performed continiously.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(14)
AS4, Indication and setting, Engineering manual 04-04-02
4.9.4 Bus
BUS FAIL
Anybus function is selected but the communication does not function. This error is likely to occur if the bus
cable not is connected.
BUS HW FAIL
Anybus function is selected but the hardware is not functioning. This error is likely to occur if the bus module
is missing or defect.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(14)
AS-5
Spider Parameters V4.1.x
Engineering manual 05-01-21
Pump Monitor (23) Pump 1 PMA Reading 1 (39) Scroll menu R1A
Pump 2 PMB Left upper R1B
Pump 3 PMC Right upper R1C
Pump 4 PMD Left lower R1D
Right lower R1E
Tank Monitor (25) Digital TMA
Analog TMB Reading 2 (40) Scroll menu R2A
Left upper R2B
Right upper R2C
Left lower R2D
Right lower R2E
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Main settings-Configuration
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Main settings-Language
Switch Description Type Default Min Max
Main settings-Reset
Switch Description Type Default Min Max
Pump outputs-Pump1
Switch Description Type Default Min Max
Pump outputs-Pump2
Switch Description Type Default Min Max
Pump outputs-Pump3
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump outputs-Pump4
Switch Description Type Default Min Max
Pump outputs-Friction
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Digital Inputs
Switch Description Type Default
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 6(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
17 AUTO 1 Activated input = auto mode Drive 1, Open input = manual mode
17 AUTO 2 Activated input = auto mode Drive 2, Open input = manual mode
17 AUTO 1+2 Activated input = auto mode Drive 1 and 2, Open input = manual mode
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
18 REG 1 Activated input = Closed loop speed feedback active Drive 1, Open input = Open loop
18 REG 2 Activated input = Closed loop speed feedback active Drive 2, Open input = Open loop
18 REG 1+2 Activated input = Closed loop speed feedback active Drive 1+2, Open input = Open loop
18 ERR1 RES External reset of Error too large function, Drive 1
18 ERR2 RES External reset of Error too large function, Drive 2
18 ERR1+2 R External reset of Error too large function, Drive 1 and 2
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 11(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
03 READY 1 Ready to use, Drive1 (also to be used for Fail safe valve, Drive 1)
03 READY 2 Ready to use, Drive2 (also to be used for Fail safe valve, Drive 2)
03 READY1+2 Drive 1 or Drive 2 ready
03 READY1*2 Drive 1 and Drive 2 ready
08 C ZERO Indication for found zero position in Synchro counter function (synchro activated)
08 SYNCHRO Synchro within limits set in parameter L22
09 AOUT 1- Selected register reading for analogue output 1 has negative sign
09 AOUT 2- Selected register reading for analogue output 2 has negative sign
09 AOUT 3- Selected register reading for analogue output 3 has negative sign
09 AOUT 4- Selected register reading for analogue output 4 has negative sign
Pulse inputs-Drive 1
Switch Description Type Default Min Max
Pulse inputs-Drive 2
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 15(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
AIP01 Zero point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP02 Max point adjustment Tank temp 1bit 0bit -102bit 102bit
AIP03 Units for REG410 **** °C
*** Possible units of measure settings: rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm, A, kW, hp, °, %
rps, lpm, gpm, mm, “, l, gal
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.8 Bus
Bus – Type&Function
Switch Description Type Default Min Max
Bus – Analog in 1
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Bus – Analog in 2
Switch Description Type Default Min Max
Bus – Analog in 3
Switch Description Type Default Min Max
Bus – Analog in 4
Switch Description Type Default Min Max
** Possible units of measure settings: %, rpm, m/m, m/s, f/m, f/s, bar, psi, MPa, °C, °F, kNm,
A, kW, hp, °, rps, lpm, gpm
*** Possible function settings:
BSO = Synchro offset (Synchro function)
BP1 = Pressure setpoint, Drive 1 (Pressure function)
BP2 = Pressure setpoint, Drive 2 (Pressure function)
BMS = Master speed setpoint (Synchro function)
PF = Pump friction
OFF = Not used
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 21(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump monitor-Pump 1
Switch Description Type Default Min Max
Pump monitor-Pump 2
Switch Description Type Default Min Max
Pump monitor-Pump 3
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Pump monitor-Pump 4
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Tank monitor-Digital
Switch Description Type Default Min Max
Tank monitor-Analog
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux1
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux8
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Aux monitor-Aux15
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive monitor-Drive 1
Switch Description Type Default Min Max
Drive monitor-Drive 2
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 1 basic-Setpoint
Switch Description Type Default Min Max
Drive 1 basic-Ramp
Switch Description Type Default Min Max
Drive 1 basic-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 1 basic-Feedback
Switch Description Type Default Min Max
D1E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D1E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D1E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 31(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 2 basic-Setpoint
Switch Description Type Default Min Max
Drive 2 basic-Ramp
Switch Description Type Default Min Max
Drive 2 basic-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 32(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
Drive 2 basic-Feedback
Switch Description Type Default Min Max
D2E01 Max hydraulic motor shaft speed 0.1rpm 10.0 0.1 300.0
D2E02 Feedback selection
1=Digital feedback 1 1
2=Analogue feedback 2
3=No feedback 3
D2E03 Filter time for speed feedback 0.1sec 0.0 0.0 5.0
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 33(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.15 Shredder 1
Shredder 1-Function
Switch Description Type Default Min Max
Shredder 1-Setpoint
Switch Description Type Default Min Max
Shredder 1-Counter
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 34(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.16 Shredder 2
Shredder 2-Function
Switch Description Type Default Min Max
Shredder 2-Setpoint
Switch Description Type Default Min Max
Shredder 2-Counter
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 35(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.17 Synchro
Synchro-Function
Switch Description Type Default Min Max
Synchro-Drive 2 setpoint
Switch Description Type Default Min Max
Synchro-Drive 1 setpoint
Switch Description Type Default Min Max
5.2.18 Pressure 1
Pressure 1-Function
Switch Description Type Default Min Max
Pressure 1-Pr.setpoint
Switch Description Type Default Min Max
Pressure 1-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 37(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.19 Pressure 2
Pressure 2-Function
Switch Description Type Default Min Max
Pressure 2-Pr.setpoint
Switch Description Type Default Min Max
Pressure 2-Regulator
Switch Description Type Default Min Max
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 38(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.20 Reading 1
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 39(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
5.2.21 Reading 2
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 40(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 41(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 42(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 43(44)
AS5, Parameters V4.1.x, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 44(44)
AS-6
Spider Software settings and function
Engineering manual 04-04-02
Contents
Introduction ............................................................................................................. 2
6.1 General system setup ....................................................................................... 3
6.2 Speed command............................................................................................... 4
6.3 Ramp ................................................................................................................ 4
6.4 Output ............................................................................................................... 5
6.5 Speed feedback ................................................................................................ 6
6.6 Power limitation................................................................................................. 9
6.7 Monitoring ....................................................................................................... 10
6.8 Analog inputs .................................................................................................. 11
6.9 Digital inputs ................................................................................................... 12
6.10 Digital outputs ............................................................................................... 19
6.11 Signal monitor ............................................................................................... 21
6.12 Shredder ....................................................................................................... 23
6.13 Synchro......................................................................................................... 24
6.14 Pressure control............................................................................................ 25
6.15 Bus Communication...................................................................................... 28
6.16 Drive monitoring log ...................................................................................... 33
6.17 Analog outputs .............................................................................................. 35
6.18 Language selection....................................................................................... 35
6.19 Drive monitoring log ...................................................................................... 36
6.20 Emergency stop ............................................................................................ 37
6.21 Program update ............................................................................................ 38
6.22 Hardware calibration ..................................................................................... 38
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(38)
AS-6
Spider Software settings and function
Engineering manual 04-04-02
Introduction
Settings of the basic blocks in the software. All settings are for drive 1. The same procedure is done for
drive 2 but with the parameter letter in ().
This also describes the logical order for the system set up.
The list of parameters is found in AS5 and block diagrams with parameters are found in AS7.
The choice of parameters are made by using the directional buttons (◄, ►, ▲ & ▼) (see AS5.1). After a
change, the choice must be updated with the enter button (◄┘). The parameters are updated in the
memory when going back to the Main status reading in the display.
The settings can be protected by a password (MAIN SETTINGS Æ PROTECTION: MAD01-02).
The drive monitoring function is protected by a separate password under SETUP-LOG FUNCTION.
Setpoint(s)
Customer
Drive control
El.m. 1 El.m. 2 El.m. 3 Spider 2 Digital/analog
Stroker current(s)
indications
Analog indicators
Pump4
Function:
Drive 1 Basic
Friction
Syncro
Drive 2 Shredder
Pressure
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(38)
AS6, Software settings and function, Engineering manual 04-04-02
• BASIC – The basic and most common function. The function includes monitoring, speed feedback
and power limitation. This is the function that also is selected for monitoring type unit.
• SHREDDER – Same as for BASIC with added functions for reversing by an overload stopped
drive.
• SYNCHRO – Same as for BASIC with two drives driven together with FRICTION ratio or position
control between the motors.
The PRESSURE function can be used with BASIC, SHREDDER and FRICTION basic function.
The functions for the drive buttons at the front can be bypassed by setting parameter D1A08 (D2A08)
off.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.3 Ramp
The start ramp time is the time it takes for the signal to control the hydraulic pump, to go from zero to
100% if the speed setpoint is 100% and drive start is activated. The stop ramp is the time it takes to go
from 100% to zero when drive stop is activated.
Drive start and stop are ramped commands (as well as fixed forward, fixed reverse and inch reverse).
The start ramp is controlled by the parameters DxC01 in forward direction and DxC03in reverse direction.
The stop ramp is controlled by the parameters DxC02in forward direction and DxC04in reverse direction.
Example: If the ”up ramp” D1C01 is set to 10 sec. and the down ramp D1C02 is set to
5 sec. we will get the following output.
The example is based on 50 and 100% setpoint.
Speed
Drive start Drive stop
100 %
Stop ramp
50%
Start ramp
0 10 20 25 Time in sec.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 4(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.4 Output
6.4.1 PWM frequency
The individual settings for each pump are made in PUMP OUTPUTS ( See AS5.2.2)
The outputs are Pulse Width Modulated and the PWM frequency can be set with parameters POx06.
The normal setting is 200Hz but can be set 100 to 2000Hz in steps of 100Hz. If a 5A stroker is used
(can only be controlled in one direction) the frequency must be set to 2000Hz to avoid damaging of the
stroker.
D(J)07
Lower frquency then 2000Hz can destroy5A2 pump stroker
POx01-04
High current can destroy
pump stroker
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 5(38)
AS6, Software settings and function, Engineering manual 04-04-02
D1D01 Sets the regulator function ON or OFF. In this case ON, the regulator is enabled.
D1D02 Feed forward function is set ON or OFF. In this case ON, the speed set-point is put to the
stroker output as an initial value and the regulator compensates for deviations in speed.
If the parameter is set OFF the regulator output will be the only signal to the
stroker output.
D1D03 Sets the Proportional regulator stage function ON or OFF. In this case select ON. The
proportional stage reacts proportional to the Error input signal. Action of this stage is
determined by parameter D1D06.
D1D04 Sets the Integrator function ON or OFF. In this case select ON. This function gives the
drive a possibility to reach set-point speed over time. Action of this stage is determined
by parameter D1D07.
D1D05 Sets the Derivative function ON or OFF. In this case select OFF. The derivative stage is
used when very quick speed changes are to be expected at the drive. It reacts on the
rate of change at the Error input signal. The D stage is seldom used due to a difficult
tuning procedure. Action of this stage is set by parameters D1D08 and D1D09.
D1D06 Proportional gain parameter sets the gain of the P-stage. In this case set to 0.5 as a start
value. P gain 0.5 means that half the Error signal input value will be transferred to the
stage output. Proportional stage however, will not make the drive reach set-point speed.
There will always be a remaining Error. The remaining Error value is though depending
on the Proportional gain setting. If the Error signal is small, close to zero, P gain will not
produce any output at this stage output. The P stage always needs an Error signal to
modify.
D1D07 Integrator time parameter sets the integration time of the I-stage. In this case set to 10
seconds as a start value. Integrator time 10 seconds means that the output value of this
stage will reach 63% of the Error signal input value in 10 seconds. Introduction of
Integration will eliminate the remaining Error signal. The actual speed will over time
correspond to speed set-point. It can be compared with a Capacitor that is charged with
the Error signal.
D1D08 Derivative time parameter sets the Derivative time of the D stage. In this case it is left at
the default value, 10 seconds. Derivative time 10 seconds means that the derivative
“gain” is a factor 10. The output from this stage is the “gain” factor multiplied with the rate
of change of the Error signal.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 7(38)
AS6, Software settings and function, Engineering manual 04-04-02
D1D09 Derivative decline time parameter sets the Derivative decline time of the D stage. In this
case it is left at default value, 10 seconds. Derivative decline time 10 seconds means that
the output value from this stage will decline 63 % in 10 seconds.
D1D10 Max feedback deviation is the allowed difference between command and actual speed. If
this exceeds for 10sec., the drive will switch over to unregulated drive and give the
warning ERROR TOO LARGE.
The above settings give in most cases a good performance of the drive. However to optimise the
parameters the following method can be used.
In short words the method is as follows:
Increase the proportional gain until the drive starts to oscillate. Note the oscillation time. Reduce the
Proportional gain with 50 %. Set the Integrator time minimum to the double oscillation time value.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 8(38)
AS6, Software settings and function, Engineering manual 04-04-02
Example for power limitation setting Drive 2, Electric motor 3: Set function
Electric motor = 240A (from data sheet or motor rating plate) for input
Current transformer 400A = 20mA AIF-AIN09
We are using analog input 5 for this example.
We want to limit electric motor 3 in drive 2.
Set level
AIJ05, Max input = 400 for limitation
AIJ06, Units for indication = A AIR01-03
AIJ09, function => Power limitation = EC3
AIR03, Level for power limitation (e-motor 3) = 240
D2F01, Delay time = the time the power is allowed to be higher
then the level (AIR03) before the limit function starts Set filter time
D2F02, Ramp time = how fast the reaction will be for stroking D1(2)F01
down the pump to limitation level
Set downramp
The ramp time setting must be set by test with the drive. A too short time
time can cause oscillation in the system and a too long time will not D1(2)F02
(By test)
regulate the current to the max setting (same function as P regulation,
see AS6.5).
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 9(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.7 Monitoring
The monitoring function is available in all setups. The pre-defined digital inputs (for monitoring) must
be set to off if monitoring is not wanted. See setup of digital inputs under AS 5.2.3.
(If memory bypass = off: Warning indication will be activated if input is opened
Warning indication will remain if input is closed.
and must be reset in Alarm / warning menu).
(If memory bypass = on: Warning indication will be activated if input is opened
Warning indication will disappear if input is closed).
Set AMA02 to needed delay time between opened input and warning indication.
Set the text in AMA04 to HIGH OIL TEMP by using ∧, ∨ and ↵ buttons.
NOTE: The line has to be filled with blank characters by pushing ↵ until the line is filled.
Available characters are all possible characters for the display. For Chinese characters a VFD display
must be mounted and switch SW3-1 must be set to off.
Setup of this function can either be done on the spider front or via SpiderCom program.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 10(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Min 10 (TMB10) -- 10 10
Analogue input setpoint1, setpoint2 and analog in1-2 is isolated with it's own reference ground.
05-01-21, replaces 04-04-02
Analogue input 3-9 is isolated but with common reference ground with the power supply.
All analogue inputs can be connected to current or voltage signals. The function and the zero - and
maxpoint of the input must be set (see AS5.2.6).
The function settings are described for each function in AS6.5 for Analog speed feedback, AS6.6 for
power limitation AS6.12 for Shredder pressure, AS6.13 for Synchro offset and AS6.14 for
Pressure control.
Analog in 4 with a 4-20mA signal for power limitation drive 1. 20 mA corresponds to 200A, parameter
AII01=4-20mA and AII06=A
01 H BPR P1 High pressure B-side monitor function for pump 1 High, low at high W
For monitoring of pump high pressure in reverse pressure
direction.
01 H APR P2 High pressure A-side monitor function for pump 2 High, low at high W
see 01 H APR P1 pressure
01 H BPR P2 High pressure B-side monitor function for pump 2 High, low at high W
see 01 H BPR P1 pressure
01 H APR P3 High pressure A-side monitor function for pump 3 High, low at high W
see 01 H APR P1 pressure
01 H BPR P3 High pressure B-side monitor function for pump 3 High, low at high W
see 01 H BPR P1 pressure
01 H APR P4 High pressure A-side monitor function for pump 4 High, low at high W
see 01 H APR P1 pressure
01 H BPR P4 High pressure B-side monitor function for pump 4 High, low at high W
see 01 H BPR P1 pressure
02 H APR D1 High pressure A-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in forward direction. pressure
02 H BPR D1 High pressure B-side monitor function for drive 1 High, low at high W
For monitoring of drive high pressure in reverse direction. pressure
02 H APR D2 High pressure A-side monitor function for drive 2 High, low at high W
see 02 H APR D1 pressure
02 H BPR D2 High pressure B-side monitor function for drive 2 High, low at high W
see 02 H BPR D1 pressure
02 H APR 12 High pressure A-side monitor function for drive 1 and 2 High, low at high W
see 02 H APR D1 pressure
02 H BPR 12 High pressure B-side monitor function for drive 1 and 2 High, low at high W
see 02 H BPR D1 pressure
03 C PRA P1 Low charge pressure A-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in forward pressure
direction
03 C PRB P1 Low charge pressure B-side monitor function for pump 1 High, low at low A
For monitoring of pump low charge pressure in reverse pressure
direction
03 C PRA P2 Low charge pressure A-side monitor function for pump 2 High, low at low A
see 03 C PRA P1 pressure
03 C PRB P2 Low charge pressure B-side monitor function for pump 2 High, low at low A
see 03 C PRA P2 pressure
03 C PRA P3 Low charge pressure A-side monitor function for pump 3 High, low at low A
see 03 C PRA P1 pressure
03 C PRB P3 Low charge pressure B-side monitor function for pump 3 High, low at low A
see 03 C PRA P2 pressure
03 C PRA P4 Low charge pressure A-side monitor function for pump 4 High, low at low A
see 03 C PRA P1 pressure
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 13(38)
AS6, Software settings and function, Engineering manual 04-04-02
03 C PRB P4 Low charge pressure B-side monitor function for pump 4 High, low05-01-21,
at low replacesA04-04-02
see 03 C PRA P2 pressure
04 C PRA D1 Low charge pressure A-side monitor function for drive 1 High, low at low A
For monitoring of drive low charge pressure in reverse pressure
direction
04 C PRB D1 Low charge pressure B-side monitor function for drive 1 High, low at low A
For monitoring of drive low charge pressure in reverse pressure
direction
04 C PRA D2 Low charge pressure A-side monitor function for drive 2 High, low at low A
see 04 C PRA D1 pressure
04 C PRB D2 Low charge pressure B-side monitor function for drive 2 High, low at low A
see 04 C PRB D2 pressure
06 RF 75P1 Monitor of return filter for pump 1 clogged to 3/4 High, low on filter W
For monitoring of 3/4 clogged filter. clogged
Only applicable when using two level filter indicators.
06 RF 100P1 Monitor of return filter for pump 1 fully clogged High, low on filter W/(A)
For monitoring of fully clogged filter (must be exchanged) clogged
06 RF 75P2 Monitor of return filter for pump 2 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P2 Monitor of return filter for pump 2 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 RF 75P3 Monitor of return filter for pump 3 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P3 Monitor of return filter for pump 3 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 RF 75P4 Monitor of return filter for pump 4 clogged to 3/4 High, low on filter W
see 06 RF 75P1 clogged
06 RF 100P4 Monitor of return filter for pump 4 fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
06 DRF 100 Monitor of drain filter fully clogged High, low on filter W/(A)
see 06 RF 100P1 clogged
07 LO LEVEL Low oil level monitor for tank High, low when W
Monitors Low oil level in PU tank below set level
07 MN LEVEL Min oil level monitor for tank High, low when A
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 14(38)
AS6, Software settings and function, Engineering manual 04-04-02
05-01-21, replaces 04-04-02
Monitors Min oil level in PU tank below set level
08 MAX TEMP Max oil temp monitor for tank High, low when A
Monitors max set temp. in PU tank above set temp
08 HI TEMP High oil temp monitor for tank High, low when W
Monitors high set temp. in PU tank above set temp l
08 MIN TEMP Low oil temp monitor for tank High, low when A
Monitors low set temp. in PU tank below set temp
09 BUS R Reset of alarms and warnings via bus High=Reset via bus C
10 SHR 1+2A Shredder forward stop, Drive 1 and 2 High, low at stop C
10 SHR 1+2B Shredder forward stop, Drive 1 and 2 High, low at stop C
12 RES EN2 External enable of counter reset in Synchro mode, Drive High=Enable of C
2 reset input
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 16(38)
AS6, Software settings and function, Engineering manual 04-04-02
15 FORW 1+2 Forward drive with fixed speed, Drive 1 and Drive 2 High=Forward C
15 REV 1+2 Reverse drive with fixed speed, Drive 1 and Drive 2 High=Reverse C
16 SP RES1 Reset of set point in Local mode, Drive 1 High pulse = reset C
16 SP RES2 Reset of set point in Local mode, Drive 2 High pulse = reset C
18 REG 1+2 Closed loop speed feedback active, Drive 1 and 2 High=Active C
Low=Open loop
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 17(38)
AS6, Software settings and function, Engineering manual 04-04-02
18ERR2 RES Reset of error too large function, Drive 2 High pulse = reset C
18ERR1+2R Reset of error too large function, Drive 1 and 2 High pulse = reset C
20 PR HI 1 Set pressure control output to max speed-up level, Drive High=Max output C
1 Low=Normal control
20 PR LO 1 Set pressure control output to max slow-down level, Drive High=Min output C
1 Low=Normal control
20 PR HI 2 Set pressure control output to max speed-up level, Drive High=Max output C
2 Low=Normal control
20 PR LO 2 Set pressure control output to max slow-down level, Drive High=Min output C
2 Low=Normal control
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 18(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Output function
Abbreviation Function Normal status for
output
01 A(1,2, 1+2) Monitoring of common alarm Open, closed at
alarm
03 READY(1, 2, 1+2, 1*2) Drive ready to use after start delay Open, closed when
ready
04 REMOTE(1, 2) Drive in remote mode Open, closed in
remote mode
08 C ZERO Counters in Synchro counter function reset and synchro function Open, closed at
activated activated
synchronisation
09 AOUT(1...4) Register for analog output has negative sign Open, closed when
negative
11 LOW TEMP Indication for min oil temp active Open, closed when
active
11 HI TEMP Indication for high oil temp active Open, closed when
active
11 MAX TEMP Indication for max oil temp active Open, closed when
active
11 COOL CONI Start cooling interlocked with electric motor started Open, closed for
(with analog temp sensor) cooling
11 COOL COND Start cooling controlled directly from temp sensor Open, closed for
(with analog temp sensor) cooling
11 HEAT CON Start heating (with analog temp sensor) Open, closed for
heating
11 FLUSHCON Control of flushing circuit (with analog temp sensor) Open for cooling,
closed for heating
ON On delay From the moment when the function for the output is activated , the output will
not be active until the delay time is passed.
OFF Off delay From the moment when the function for the output is deactivated , the output
will not be inactive until the delay time is passed.
PULSE Output pulse From the moment when the function for the output is activated , the output will
be active only during the delay time.
OFF No delay
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 20(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
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AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Will give:
→ TANK TEMP 37.8ºC ←
PRESSURE 143bar
▲ or ▼ will alter between these two readings.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 22(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.12 Shredder
The selection of shredder function is made by setting parameter MAA01 to SHREDDER (see AS6.1).
The specific parameters are found in SETUP – SHREDDER 1(2).
In shredder all features described in 6.1.- 6.11 are avaliable except for the possibility to switch
between speed regulated and non-regulated drive. The selection of speed regulation has to be set
with parameter SHA(G)10.
The added functions are for the reversals by an overloaded drive.
The shredder has two drive modes, manual and auto.
In manual drive mode the forward button (or by configurable input set as L FORW1(2)) is used for
running forward and the reverse button (or by configurable input set as L REV1(2)) is used for running
reverse. The drive will run as long as the input is activated and stop when input is opened. The
reversing function is bypassed in manual drive.
In auto drive mode the start button (or by configurable input set as L START1(2)) starts the drive with
the automatic reversing function and is stopped with the stop button(or by configurable input set as L
STOP1(2)). A configurable digital input can be used for start in remote mode.
The switching between manual and auto is made with the MAN/AUT button or with a configurable
digital input (will bypass the button).
A digital output can be used for indication of auto mode.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 23(38)
AS6, Software settings and function, Engineering manual 04-04-02
6.13 Synchro
The Synchro function set-up is to be found in the following parameter menus
"Synchro - Function"
"Synchro - Drive 1 reset"
"Synchro - Drive 2 setpoint"
"Synchro - Drive 2 indication"
"Synhcro - Drive 2 reset"
"Synchro - External Master"
"Synchro - Drive 1 setpoint"
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 24(38)
AS6, Software settings and function, Engineering manual 04-04-02
ratio drive can be activated by a configurable digital input, set to 12 FRICTION. The input can be
either a hardware signal, or in bus mode a bus signal.
By altering a parameter, PRA02 = On, reverse action is selected. The below diagram describes the
pressure control function, reverse action. If pressure is increasing the speed set point is decreasing.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 25(38)
AS6, Software settings and function, Engineering manual 04-04-02
PRC01 Sets the Proportional regulator stage function ON or OFF. The proportional stage reacts
proportional to the Error input signal. Action of this stage is determined by parameter
PRC04.
PRC02 Sets the Integrator function ON or OFF. This function gives the drive a possibility to reach
set-point pressure over time. Action of this stage is determined by parameter PRC05.
PRC03 Sets the Derivative function ON or OFF. The derivative stage is used when very quick
pressure changes are to be expected at the drive. It reacts on the rate of change at the
Error input signal. The D stage is seldom used due to a difficult tuning procedure. Action
of this stage is set by parameters PRC06 and PRC07.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 26(38)
AS6, Software settings and function, Engineering manual 04-04-02
PRC04 Proportional gain parameter sets the gain of the P-stage. P gain 0.5 means that half the
Error signal input value will be transferred to the stage output. Proportional stage
however, will not make the drive reach set-point pressure. There will always be a
remaining Error. The remaining Error value is though depending on the Proportional gain
setting. If the Error signal is small, close to zero, P gain will not produce any output at this
stage output. The P stage always needs an Error signal to modify.
PRC05 Integrator time parameter sets the integration time of the I-stage. An integrator time 10
seconds means that the output value of this stage will reach 63% of the Error signal input
value in 10 seconds. Introduction of Integration will eliminate the remaining Error signal.
The actual pressure will over time correspond to pressure set-point. It can be compared
with a Capacitor that is charged with the Error signal.
PRC06 Derivative time parameter sets the Derivative time of the D stage. A derivative time 10
seconds means that the derivative “gain” is a factor 10. The output from this stage is the
“gain” factor multiplied with the rate of change of the Error signal.
PRC07 Derivative decline time parameter sets the Derivative decline time of the D stage. A
derivative decline time 10 seconds means that the output value from this stage will
decline 63 % in 10 seconds.
PRC08 Filter time for pressure feedback parameter sets the filter time for the pressure. Useful
when the pressure signal contains a lot of noise, the filter will take away pressure peaks.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 27(38)
AS6, Software settings and function, Engineering manual 04-04-02
See block diagram AS7.2 and parameter list AS5.2.8 for further details.
6.15.1 General
The Bus function requires that a bus card is installed. The card is a profibus-DP slave following the
standard PROFIBUS-DP EN 50 170. It must be connected to a profibus-DP master. The card will only
respond to incoming commands, working as a slave.
The Bus function is activated when a digital input or a bus input is activated and remote mode is
selected via the keyboard. The digital inputs are BUS 1 and BUS 2, these inputs makes it possible to
select bus control separately for drive 1 and 2. Speed set-points are located at predefined bus
addresses. See chapter AS 6.15.9. The below sketch explains the possible mode changes.
BUS 1 (Drive 1)
REM 1 (Drive 1)
REM 2 (Drive 2)
Bus fail
Bus communication fail+timedelay (BTF02)
Alarm/Interlock (selectable via BTF03)
Hardware fail
Alarm/Interlock (selectable via BTF03) Prevents Bus mode
If the bus communication is lost, an alarm or Interlock is trigged. An adjustable timer determines the
filter time for the alarm/interlock. Local mode is activated if the bus is faulty. To be able to start bus
communication again the spider must be restarted by reset or power on.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 28(38)
AS6, Software settings and function, Engineering manual 04-04-02
REG/BIT 8 7 6 5 4 3 2 1
REG511 Din 8 Din 7 Din 6 Din 5 Din 4 Din 3 Din 2 Din 1
REG512 Din 16 Din 15 Din 14 Din 13 Din 12 Din 11 Din 10 Din 9
REG513 Din 24 Din 23 Din 22 Din 21 Din 20 Din 19 Din 18 Din 17
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 29(38)
AS6, Software settings and function, Engineering manual 04-04-02
The analog values are in "signed word" data format. Negative numbers are the 2's complement of the
positive ones. Below is a table with some examples
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 30(38)
AS6, Software settings and function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 31(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
20:0 Start1 21:0 P1HiCa 22:0 Forw2 23:0 ShBlck2 24:0 Ready2 25:0 Dummy
20:1 Remote1 21:1 P1CAct 22:1 Rev2 23:1 A1 24:1 EMot1 25:1 Dummy
20:2 Auto1 21:2 PLim 22:2 Reg2 23:2 A2 24:2 EMot2 25:2 Dummy
20:3 PLim1 21:3 ShBlck1 22:3 CZero 23:3 W1 24:3 CoolConI 25:3 Dummy
20:4 Forw1 21:4 Start2 22:4 Synchro 23:4 W2 24:4 HeatCon 25:4 Dummy
20:5 Rev1 21:5 Remote2 22:5 P2LoCa 23:5 Int1 24:5 CoolConD 25:5 Dummy
20:6 Reg1 21:6 Auto2 22:6 P2HiCa 23:6 Int2 24:6 Flush Con 25:6 Dummy
20:7 P1LoCa 21:7 PLim2 22:7 P2CAct 23:7 Ready1 24:7 Dummy 25:7 Dummy
DB20 to DB25 are signals to be found in the list of available functions for the digital relay outputs,
described in AS6.10.
DB26 to DB37 are partly signals to be found in the list of available functions for the digital inputs,
described in AS6.9.
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Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 32(38)
AS6, Software settings and function, Engineering manual 04-04-02
The alarm lists are found in the menu under LOG READINGS – DRIVE 1 – ALARM and LOG
READINGS – DRIVE 2 – ALARM.
The warning lists are found in the menu under LOG READINGS – DRIVE 1 – WARNING and
LOG READINGS – DRIVE 2 – WARNING.
All four lists are 10 alarms or warnings long. The latest will be at the top and when a new warning
or alarm comes to an already filled list, the oldest will be removed. The alarms and warnings are
marked with date and time for the incident. For setting of actual time see TIME/DATE below.
The drive time counters are found in the menu under LOG READINGS – DRIVE 1 – TIME IN USE
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are DRIVE (the time with drive
started) and PUMPS (the time with started electric motor for each pump). The counters can be
reset , see RESET TIME below.
The settings for the drive monitoring log and clock and the reset of the time counters are made in
SETUP – DRIVE LOG and are protected by a password. The settings can only be done from the
front keypad.
TIME/DATE is the setting of actual date and time. The format is YYMMDD HH:MM and is
selected with > button and changed with ∧ and ∨ buttons. The date/time is used for alarm and
warning list time stamps and the clock is battery backed.
LOG1 to LOG 8 are for setting of the eight one dinensional scalable drive monitoring log channels.
The used analog inputs must be set before the log channels are configured, see AS6.8.
Each channel consists of a measuring area divided in 6 levels. The time the measured reading
has been within each of these levels is stored. The measuring is only active with drive started.
Total measuring time is 100 000 hours.
Parallel to the total time log, 4 shorter log registers with the same setting as the total is stored in
chronological order. The log time is adjustable.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 33(38)
AS6, Software settings and function, Engineering manual 04-04-02
Example: 90-100
- Log channel 2
70-90
50-70
30-50
10-30
Time MT 10-30
Period 2
AII06=bar for the reading units. 90-100
Time MT 70-90
50-70
30-50
2.Log setting:
10-30
0-10
Period 3
SETUP – DRIVE LOG – LOG 2:
STA=ON will activate the log function Time MT
90-100
70-90
50-70
30-50
RESET TIME for reset of the drive time counters. When the function is selected with > button
push ∧ to get a Y (yes) and then > button to reset.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 34(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
The spider card has four output channels. Each channel can be selected as 0-10V or 2-10V
voltage output or as 0-20mA or 4-20mA current output. The selection between current and
voltage is made by jumpers on the card and by using different terminals.
The selection between 0-10V and 2-10V or between 0-20mA and 4-20mA is made with
parameters in the setup menu.
Example for channel 1, 4-20mA for 0-20rpm speed from digital speed encoder.
1. Set parameter D1E01 to 20.0rpm (the speed that corresponds to 100%).
2. Connect a current meter in series with the output signal.
3. Parameter AOA02 must be ON for 4mA output.
4. Select parameter AOA03. The system gives 0% to the card. Adjust the parameter until
closest to 4mA output.
5. Select parameter AOA04. The system gives 100% to the card. Adjust the parameter
until closest to 20mA output.
6. Repeat 4 and 5 until the best result is achived.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 35(38)
AS6, Software settings and function, Engineering manual 04-04-02
The drive monitoring log consists of four parts, alarm/warning lists, drive time counters, six
scalable log channels and two scalable 3D-log channels. The alarm/warning lists and drive time
counters can be indicated on drive 1 display. The total drive log information must be downloaded
to a PC for examination. This requires null-modem cable 576 3521-003, a PC with windows XP
and SpiderCom2 software installed.
The alarm lists are found in the menu under LOG READINGS – DRIVE 1 – ALARM and LOG
READINGS – DRIVE 2 – ALARM.
The warning lists are found in the menu under LOG READINGS – DRIVE 1 – WARNING and
LOG READINGS – DRIVE 2 – WARNING.
All four lists are 10 alarms or warnings long. The latest will be at the top and when a new warning
or alarm comes to an already filled list, the oldest will be removed. The alarms and warnings are
marked with date and time for the incident. For setting of actual time see TIME/DATE below.
The drive time counters are found in the menu under LOG READINGS – DRIVE 1 – TIME IN USE
and LOG READINGS – DRIVE 2 – TIME IN USE. The counters are PUMP (the time with started
electric motor) and DRIVE (the time with drive started). The counters can be reset , see RESET
TIME below.
The settings for the drive monitoring log and clock and the reset of the time counters are made in
SETUP – LOG FUNCTION and are protected by a password.
TIME/DATE is the setting of actual date and time. The format is YYMMDD HH:MM and is
selected with > button and changed with ∧ and ∨ buttons. The date/time is used for alarm and
warning list time stamps and the clock is battery backed.
LOG1 to LOG 8 are for setting of the eight scalable drive monitoring log channels.
The used analog inputs must be set before the log channels are configured, see AS6.8.
Each channel consists of a measuring area divided in 6 levels. The time the measured reading
has been within each of these levels is stored. The measuring is only active with drive started.
Total measuring time is 100 000 hours.
Parallel to the total time log, 4 shorter log registers with the same setting as the total is stored in
chronological order. The log time is adjustable.
RESET TIME will reset the time counters for total drive time.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 36(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
At each power up and each time all electric motors are stopped, the system will check that the relays
for the electric motor interlock outputs not are stucked in closed position.
The emergency stop alarm is as default with memory and must be reset but can be set to automatic
reset with MAB11:ON.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 37(38)
AS6, Software settings and function, 05-01-21, replaces04-04-02
Engineering manual 04-04-02
Run Loader.exe. Select the file for download Start the procedure
Reset the Spider board by pushing the reset button or by switching on and off the power to the card to
start the download procedure.
When the download is ready, reset the Spider system and set new parameters.
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 38(38)
AS-7.1
Spider Digital inputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.1, Digital inputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.1, Digital inputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.2
Spider Analog in- and outputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.2, Analog in- and outputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.2, Analog in- and outputs, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.3
Spider Pump outputs
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.4
Spider Monitor
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(3)
AS7.4, Monitor, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(3)
AS7.4, Monitor, Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 3(3)
AS-7.5
Spider Basic function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.5, Basic function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.6
Spider Shredder function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.6, Shredder function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.7
Spider Synchro function
Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(2)
AS7.7, Synchro function, Engineering manual 04-04-02
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 2(2)
AS-7.8
Spider Pressure function
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.9
Spider Emergency stop
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)
AS-7.9
Spider Emergency stop
Engineering manual 05-01-21
The contents of this information are subject to change without notice or obligation. Information herein should be confirmed before placing orders.
Hägglunds Drives AB. S-890 42 Mellansel, SWEDEN 1(1)