Standard Power Units - Eaton

1 Standard Power UnitsStart-Up and MaintenanceSystem-Pak IISystem Pak-PlusProfile-PakSystem-CenterSystem-O verheadSystem-L2 Eaton Vickers Standard Power Units Start-Up and Maintenance Manual V-POPO-TS001-E1 June 2006 Table of ContentsGeneral Information.. 2 General Safety Information.. 3 Power unit Installation and Start-Up Information.. 4-5 Unpacking & Setup .. 4 Operation .. 5 Adjusting Relief Valve/Compensator Setting .. 5 General Operating Specifications.. 5 System Pressure Limitations.. 6-91500 RPM.. 6-71800 RPM.. 8-9 Maintenance.. 10 Troubleshooting Guide.. 11-15 Excessive Noise .. 11 Excessive Heat .. 12 Incorrect Flow .. 13 Incorrect Pressure .. 14 Faulty Operation.. 15 Installation Drawings.. 16-27 PSSP System-Pak II 3 & 5 gallon .. 16 PSSP System-Pak II 10, 15, 20, 30 gallon .. 17 PSPP System-Pak Plus.

2 18-19 PSLP Profile-Pak .. 20-21 PSSC System-Center Non-JIC .. 22-23 PSSC System-Center JIC Tank .. 24-25 PSSL System-L Series .. 26 PSSO System Overhead .. 27 General Information This manual outlinesinstallation, operation,and troubleshootingpractices for the Vickersstandard Power II, PSSPS ystem Pak-Plus, PSPPP rofile-Pak, PSLPS ystem-Center, PSSCS ystem-Overhead PSSO System-L, PSSL 3 Eaton Vickers Standard Power Units Start-Up and Maintenance Manual V-POPO-TS001-E1 June 2006 General SafetyInformationWARNING:Read General Safety Information carefullybefore attempting to assemble, install,operate, or maintain these to comply with these instructionsmay result in personal injury and/orproperty damage. Retain these instructionsfor future Make all electrical connections in accordance withthe National Electrical Code (NEC) and OccupationalSafety and Health Act (OSHA) regarding branchcircuit protection and means of motor disconnectionto avoid electric shock and fire Avoid the potential for oil spills and slippery floorconditions by: Maintaining oil reservoir on a level surface Maintaining leak-free hydraulic hose or pipeconnections to the unit Not overfilling the unit with hydraulic Exceeding the recommended operatingtemperatures may cause system components tobecome too hot to handle.

3 Overheated componentscreate a potential for burns, leaks, and prematurecomponent Ensure that the relief valve setting does notexceed the pressure rating of the unit or of thelowest rated component connected to the powerunit. The system pressure setting should be withinthe horsepower specifications of the unit s electricmotor. Use the formula HP = PSI * GPM * for a general guideline. Refer to tables on Page 9 forspecific operation Ensure all pressure is released from the systembefore attempting to remove or repair any valve,pump, or component of the system. Failure tofollow this procedure may result in the release ofpressurized hydraulic fluid that has the potential tocause severe personal Ensure that all electrical Power is disconnected atthe junction box before attempting removal or repairof any electric motor starter, valves, or pumps, orother components in the Vickers Standard Power Units Start-Up and Maintenance Manual V-POPO-TS001-E1 June 2006 Power UnitInstallation and Start-UpInformation Unpacking & Setup1.

4 Unpacking: All Power Units are tested andinspected before shipment. Any damage orshortages evident when the equipment is receivedshould be reported immediately reported to thecommercial carrier that transported the is available from your Eatonrepresentative, if required. Always refer to thepurchase order number and Eaton model and serialnumbers when contacting Eaton . 2. Select a clean and well-ventilated area to install thepower unit . Level the Power unit before bolting thereservoir to the floor. Mounting hole dimensions canbe found in the instal-lation drawings in the Fill the reservoir through the filler-breather with ahigh-quality hydraulic oil: For ambient temperature 18 C to 70 C (0 to160 F), use SAE 10 grade oil, For ambient temperature 0 C to 90 C (32 to200 F), use SAE 20 grade hydraulic oil is often highly the oil is filtered through a high efficiencyfilter when Fill oil to the top of the full mark on fluid levelgauge on the reservoir.

5 Do not Fill the case of external horizontally mountedpiston pumps. Open pump inlet valves, if Connect the powerunit s hydraulic pressuresupply and return connections using proper linesizing and cleanliness practices. Connect all othermodel auxiliary functions per manufacturer s datasheets included with Power unit informationpacket, temperature switches, pressureswitches, water coolers Check the motor nameplate and motor starteridentification tag, if your unit is so equipped, forproper voltage requirements. Connect the powerunit to a proper electrical source. Jog the motor tocheck rotation. Rotation must match the directionof the arrow decal(s) affixed to the unit , or thepump may be damaged. Polyphase motors are bi-directional, and proper rotation can be establishedby reversing any two Power System pressures should be set as low aspossible to prevent unnecessary fluid heating.

6 Onsome applications, this setting may be from 3,5 to14 bar (50 to 200 psi) above necessary staticpressures to overcome dynamic pressure drop orto achieve proper acceleration. 9. Pump noise and crackle are most often causedby air entering the pump suction inlet. Tiighteningthe suction fittings will usually eliminate suchproblems. If the pump fails to the prime, vent thepump discharge to atmosphere to establish fluidflow. Continue to jog the electric motor to initiallyprime the pump and lines. Completion of the jogmode will be achieved when the pressure gaugeindicates a positive pressure. The Power unit is nowready for The fluid level should be rechecked and maintainedso it always registers in the sight The first few hours of operation are critical to thelife of the system. The system should be run atminimum pressure and maximum flow for aminimum of two hours to remove contaminationintroduced during installation.

7 After the first fewhours of operation, any foreign material from thesystem will be flushed to the return filter. It is goodpractice to replace filter elements to maintain fluidcleanliness. Fluid temperature should be monitoredto achieve stability below 54 C (130 F) rangeduring the initial start-up and commissioningperiod. 12. For most industrial applications, an operatingtemperature of 66 C (150 F) is consideredmaximum. At higher temperatures, reliable andconsistent hydraulic control is reduced,component service life is compromised, hydraulicfluid deteriorates and a potential danger tooperation personnel is created. Note: At leastonce a year or every 4,000 operating hours, theair vent filter should be replaced and the entiresystem checked for possible future difficulties. Afluid sample should be taken and analyzed forparticle contamination and chemical Fluid Analysis part number 894277 isrecommended.

8 Some applications orenvironmental conditions may dictate suchmaintenance be performed at more frequentintervals. See the Maintenance Section of thisbrochure for more details. 5 Eaton Vickers Standard Power Units Start-Up and Maintenance Manual V-POPO-TS001-E1 June 2006 Power UnitInstallation and Start-UpInformation OPERATIONWARNING:Read General Safety Information section on Page 3prior to starting any maintenance run unit without At initial startup, start and stop the motor severaltimes to allow the pump to prime before full Bleed all air from the hydraulic system to preventerratic operation of the Re-check reservoir oil level after a few completecycles of the hydraulic system and refill, Relief Valve/Compensator SettingThe relief valve and/or compensator on this unit isfactory set at 0 - 25 bar (0-350 psi), unless otherwisespecified at time of order.

9 Use the formula HP = PSI * GPM * a general guideline before adjusting the reliefvalve or compensator to ensure you are within theoperating limits of the electric motor being to the tables on Page for specific operationlimitations. Set the relief valve at least 9 bar (120 psi)higher than the compensator if this unit has apressure compensated pump (see note below). It isrecommended that the compensator (or relief valvein the case of a non-compensated pump) beapproximately 7 bar (100 psi) higher than theoperating pressure required. To adjust the setting,refer to the following steps:1. Turn unit Block supply port or extend cylinder to full strokeso oil is going over the relief valve for fixed volumepumps or compensation is reached for variablepiston pumps. Note the pressure settings shownon Pages 6-8 for the maximum suggestedpressure Check system pressure Loosen lock nut on relief valve or compensatoradjustment Turn the adjustment screw: Clockwise (CW) to increase pressure setting.

10 Counterclockwise (CCW) to decrease pressure When the desired pressure is reached on thepressure gauge, tighten lock nut. Note: To set the relief valve on a unit that has apressure compensator: Close the compensatorCW all the way before adjusting the relief. Setthe relief to no more than 16 bar (220 psi)above the maximum recommended operatingpressure. Open the compensator CCW to thelower of 9 bar (120 psi) below the reliefsetting, or 7 bar (100psi) above the desiredoperating Operating Specifications Maintain fluid cleanliness at an ISO code of 18/16/14 or better. Use original equipmentreplacement filter elements Filtration return line 18/16/14 or better Operating temperature 66 C (150 F) maximum Fluid viscosity 70-250 SUS (13-54 cSt) Inlet pressure 5 In. Hg. vacuum atmospheric When looking at the fan end of the motor orshaft end of the pump, the typical motor rotationis clockwise.