Industrial Hydraulics

Parker

Commission ng Instructions

Hydraulic Installations

Contents

1 General.3

1.1 Safety instructions.31

.2 Transport.31

.3 Storage.31

.4 Assembly.31

.5 Hydraulic fluids.31

.6 Warranty.3

2 Commissioning.4

2.1 Filling.4

2.2 Electrical connections .4

2.2

.1 Drive motor.4

2.2

.2 Solenoids.4

2.3 Pumps and equipment.4

2.3

.1 Pumps .42

.3

.2 Pressure valves.4

2.3

.3 Flow control valves.4

2.3

.4 Directional control valves.4

2.3

.5 Proportional valves.42

.3

.6 Accumulator .4

2.4 Pressure adjustment at pressure switching valves.4

2.5 Start-up.4

2.6 Bleeding .5

2.7 Filter.5

2.8 Flushing.5

3 Maintenance and service.5

3.1 Routine maintenance.5

3.2 Oil changes.5

3.3 Spare parts.5

4 Troubleshooting.6

4.1 Excessive noise in the installation.6

4.2 No pressure or insufficient pressure.7

4.3 Pressure and flow fluctuations.8

4.4 Insufficient or no defiveiy.8

4.5 Fluid temperature loo high.9

Parker Addresses:

Kaarst:

Parker Hannifin GmbH

GutenbergstraGe 38D-41564 Kaarst

Phone (+2131)5 13-0Fax (+2131)5 13-2 30

Vertriebsbûro

WeberstraBe 17

D-72622 NûrtingenPhone (+ 70 22) 7 03 - 0Fax (+ 70 22) 7 03 -1 81

Chemnitz:

Parker Hannifin GmbHVertriebsbûro

Otto-Schmerbach-StraBe 19D-09117 Chemnitz

Phone (+371)8141-0Fax (+3 71)81 41 -2 50

AL106BHyt*au(cs

1 General

Industrial Hydraulics

1 General

Careful planning together with correct as-sembly and commissioning are importantfactors in ensuring an economic, reliableand efficient hydraulic installation. Con-scientious maintenance will significantlyprolong the service life of all hydraulic ele-ments.

The following instructions should be obser-ved during commissioning and maintenan-ce. Useful tips on how to remedy faultshave been compiled in the troubleshootingsection.

1.1 Safety instructions

The hydraulic installation has beenplanned and designed so that the opera-ting personnel are not endangered by pos-sible faults. This assumes that the various

pumps and equipment are operated withintheir permissible working pressure ranges.Together with the electric control, any pos-sible damage to the installation must bekept to a minimum.

Hydraulic accumulators must only be filledwith nitrogen. The test documents for thehydraulic accumulator and safety valvesare included with the delivery and shouldbe kept separately. These are to be pre-sented to the safety officer if necessary.Sealed safety valves may not be opened -pay attention to the warning signs.

Accumulators with a pressure-litre product< 200 must be officially accepted by acompetent authority and > 200 by an ex-pert authority (TÙV).Any additional commissioning instructionsfrom the supplier of the accumulator takepriority over these instructions.

Attention: Hydraulic accumulators > 1 litrenominal volume may only be filled with amax. of 10 bar for transportation.

Subsequent welding work on hydraulicfluid tanks may only be carried out by ex-perts on their own responsibility. The oilcontents and manhole cover should al-

ways be removed.

Further measures have to be agreed de-pending on the place of insta ation for thehydraulic installation, e.g. an oil troughmust be provided in areas designated forthe preservation of groundwater. Or non-flammable fluids must be used in the event

of an increased risk of fire.

1.2 Transport

The hydraulic unit and the attached controlblocks have been packed and handed overto the carriers correctly. Please contact themanufacturer or your carriers in the eventof damages.

1.3 Storage

The hydraulic installation or control blockhas been checked and set to the values

specified in the circuit diagrams in the ma-nufacturer

'

s works. If stored before use, it

must be protected against contamination,mechanical damage and the effects ofweathering.

1.4 Assembly

The pipe unions of the unit are numberedaccording to the hydraulic plan and shouldbe connected to the external appliancesand control blocks or machine.

Pay attention to the following points:

. Use cold drawn precision steel pipes.

the only exception being internal dia-meters of more than 50 mm.

. Pay attention to the pipe cross secti-ons and permissible operating pressu-res.

. Only remove the plastic sealing plugsimmediately before connecting the pi-pes.

. Use a fixti.'5 :: ~ =

bends.

. The pice r:s.; :educed dL"g oerdrc

. The pipes must be cut aacSy *>length, oeoj~ec arc ÿeanec

. Use p0e JManw .punfciy to thepressure and eaanKnlal conditionsof the instalafion: always follow the-

= t s asse-"structions.

. = Zt ÿ T-.

: :e aid and fixed free

from tension.

. -ea"-"ea:ea p ces must be mechani-cal v cteaned and descaled (this alsoape es after welding).

. Lea< oil lines should be laid to enter

the tank above the oil level wherever

possible, should have a suitable dropand present no restrictions to the flow.

. If hose lines have to be used, the ty-

pes should suit the pressure and envi-ronmental conditions of the installation

.

Pay attention to the wear resistance,

operating pressure and internal diame-ter.

. An adequate number of pipe clipsshould be used to prevent vibrations.

. We recommend providing a vent con-nection at the highest point of the pipegrid.

1.5 Hydraulic fluids

Please refer to brochure AL 103, Table ofLubricants, to facilitate a choice of suitable

hydraulic fluids.

This lists suitable oil grades from the bestknown mineral oil producers. In principle,the hydraulic fluid must meet the require-ments of DIN-51 524 Part 1 and 2.

Pay attention to separate instructionswhen using other hydraulic fluids (e.g.compatibility with the sealing materials).

1.6 Warranty

Rectification of faults, free of charge, is

only possible within the dscope of theaz-eez a-art\ The information in these

nstructions is only of a general nature andassumes a professional approach to work.Assistance from our personnel during as-sembly. commissioning and maintenancecan be agreed according to our serviceconditions.

IndustrialAL 106 B

2 Commissioning

2 CommissioningCommissioning may only be carried out byqualified personnel. It may be necessary toobserve certain special instructions of thesupplier.

The hydraulic plan, equipment list and fun-ctional plan must also be available. Theplanned pressure settings must be speci-fied in the hydraulic plan for all pressurevalves.

2.1 Filling

Before filling the tank with hydraulic fluidcheck and, if necessary, clean the insideof the tank.

Always fill the tank through a fine filter toguarantee the desired purity class of thehydraulic fluid at the start.

Special filling devices or equipment alrea-dy provided in the installation - e.g. thereturn filter - are ideal for filling purposes.

The grade of oil is specified on a separateplate alongside the filler opening.

2.2 Electrical connections

Are the right currents and voltagesavailable?

2.2

.1 Drive motor

Check the mains current against thatspecified on the electric motor's ratingsplate.

2.2

.2 Solenoids

Are the type of current (~ or =) and voltagecorrect? Check name plates onequipment.

2.3 Pumps and equipment

Pay attention to the special commissioninginstructions for pumps and hydraulic andelectrical equipment.

Only the most important instructions arelisted in the following.

2.3

.1 PumpsIt is best to keep the pressure setting towthe first time the pumps are started. In thecase of variable displacement pumps, thepressure compensator is set to 15-20 bar.and in the case of constant displacementpumps the pressure control valve shouldbe adjusted to this setting. However, oneexception here are the homologated andpre-set accumulator safety valves.

2.3

.2 Pressure valves

Start with the minimum pressure settingdepending on the machine function. Onlyenter the pressure in the measuring stationplate when the final pressure is reached.

2.3

.3 Flow control valves

Set each drive element (cylinder, etc.) tothe desired speed or stroke time in stagesusing restrictor or flow control valves.

2.3

.4 Directional control valves

In the case of electrically operated valves,select the direction directly via the electriccontrol.

Attention: Only activate the emergencyhand operation on the solenoid with suita-ble tools.

2.3

.5 Proportional valvesProportional pressure, flow and directionalcontrol valves should initially be operatedwith a low electric set point. Please refer tothe separate commissioning instructionsfor the amplifier system.

2.3

.6 Accumulator

If the installation contains acajraJafexs.

these should be checked for tie correct

gas charging pressure and tapped up asrequired. Suitable checking and changingequipment is required for this work.

Attention: Accumulators must only becharged with nitrogen for safety reasons.The charging pressure to provide the cor-rect working pressure is specified in thehydraulic plan.

The following applies in general:

Gas charging pressure = min. workingpressure x 0.9.

After testing or filling, the hydraulic accu-mulator can be switched into the installati-

on via the stop valve.

2.4 Pressure adjustment at

unloading valvesIn order to keep the heat generated byconstant déplacement pumps to a mini-mum. any delivery not required is switchedto depressurized circulation by unloadingvalves.

The correct adjustment of such a unloa-ding valve operation according to the pres-sures indicated on the hydraulic plan isbest carried out as follows:

Turn unloading valve fully to the left. Setpressure control valve of the pressuremaintenance pump to the desired reliefpressure. Now turn the unloading valveclockwise until the valve pressurizes thedelivery. Set the pressure relief valve onthe pump approx. 8-10 bars higher. Checkwhether the pressure in the delivery hasbeen relieved by measuring the pressureat the test point of the unloading valve. Ifthe measured pressure is higher than3 bar, set the unloading valve slightly hig-her.

2.5 Start-up

The drive motor should initially only beoperated in jog-skip mode to determine thedirection of rotation. The correct direction

of rotation is indicated by an arrow on thepump casing. Change the phases of theelectric motor if necessary. Start the pumpby repeated jogging. The working pressurecan be set to its nominal value after approx.1 min running. (See also Chapter 4, Trou-

bleshooting, in particular 4.1 and 4.2)

The starting instructions of the pump ma-nufacturer should be given priority overthese instructions.

4 AL106 Bindustrial Hyb-aJcs

2 Commissioning3 Maintainance and service

Industrial Hydraulics

2.6 Bleeding

Air in hydraulic installations affects thecontrol behaviour and is thus undesirable.

The installation must be carefully bled du-ring initial commissioning, after oil changesor after opening lines and valves. All fun-ctions should hereby be performed in suc-cession, over the full stroke of the cylinderwithout load, and keeping the pressure aslow as possible. The installation should bebled at the highest point of the pipe grid.Loosen the pipe union slightly so that aircan escape with a small quantity of oil. Assoon as the escaping fluid shows no signsof air bubbles, tighten the union. If thehydraulic cylinder has a bleeding screwthis should be used for bleeding. However.care must be taken to ensure that the pi-ston is moved several times over the entire

stroke. In horizontally-mounted c> ndersthe bleeding screws should be at the top.After filling the cylinders chec< and ifnecessary top up, the oil leve in the tank.

2.7 Filter

The function and life of pumps and hydrau-lic equipment depends to a arge extent onthe cleanliness of the hydraulic fluid.

Contamination is the biggest enemy of hy-draulic installations.

There are three main sources of contami-

nation:

. the contamination produced during as-sembly - assembly contamination

. the contamination produced duringoperation - operating contamination

. contamination from the environment.

The correct filter concept is specified du-ring planning of the installation or is deter-mined by the necessary purity class.

Pressure or return filters are used depen-ding on the requirements. In the case ofuncritical installations a return filter with a

mesh of B25 > 75 (25 um filter) is usuallyused. This prevents contamination of thetank and the pump only draws in clean 0Pressure filters are used in installations

with high requirements - e.g. very small cflows (Q < 200 cm3/min) or a constant highpressure in pressure valves. Filter gaugesof B10 < 75 (10 urn) or B3 > 75 (3 um) aretypically used. Filters can only fulfil theirtask if the filter cartridges used are cleanedor replaced in due time, particularly duringthe initial period of operation. The degreeof filter contamination can be checked

using mechanical or electrical indicatorsduring operation.

For further information please refer toSection 3.2, Oil changes.

2.8 Flushing

Long pipelines, particularly in large centralpressure oil stations, should be flushed byshort circuiting the pressure and return li-nes. This prevents the assembly contami-nation from reaching the control valves(very important with servo or proportionalvalves) and the drive elements (cylinder,hydraulic motors, etc.). The various mea-sures should be co-ordinated in the pro-ject,s circuitry.

3 Maintenance and service

Maintenance work may only be carried outby qualified personnel. This assumes aknowledge of the machine,s function whenswitched on and off and the safety measu-res.

3.

1 Routine maintenance

The hydraulic installation should be sub-jected to simple checks at regular, shortintervals.

An automatic, electrical monitoring systemmay already been provided for somechecks.

These include:

. Oil level in ta"»

. Operating temperahxe. This shotid

not exceed a -.= = zf f I: I

. State c; c -_c . s-a

check of cotour and smefl of of)

. C-e:- s ~e : - ~_ e;

. Check of tie gas charging pressure inthe accÿr-ijator.

. Leaks in pumps, valves and pipelines.

. Che:- : easi ness of filter elements

(see Section 2.7).

. CrecK hose lines.

3.2 Oil changes

The frequency of an oil change dependson:

. The type of hydraulic fluid (ageing)

. Filtration

. The working and ambient conditions(operating temperature)

Oil change periods. Installations used continuously over a

number of shifts must include workingfilters to guarantee the specified purityclass for the hydraulic fluid.The required purity class in accord-ance with ISO 4406 or NAS 1638 de-

pends on the use of the hydrauliccomponents. It assumes a certain plan-ning of the filtration and a regularcheck of the hydraulic fluid so as toguarantee the desired service life ofthe pumps and equipment. Under the-se conditions, an oil change can be si-gnificantly delayed or may even bedispensed with completely followingevaluation of the laboratory tests.

. We refer you to the services of theknown suppliers of oil and filters in con-nection with laboratory testing of thehydraulic fluid.

3.3 Spare parts

Only use original spare parts for repairs.

Please consult our service departmentshould you have questions relating to spa-re parts or faults.

Please specify hydraulic plan no. HRP ...and order no. A ... (see ratings plate onunit).

IndustrialAL 106 B 5

4 Troubleshooting

4.

1 Excessive noise in installation

Cause Reason Remedy

4.1.1 Cavitation in the pump

1/

. Suction filter clogged (if present) Clean or replace

. Internal diameter of suction line too

small or foreign bodies in suction lineFit pipes with greater internal diameter

j. Too many bends in suction line Lay pipes anew or use pipes with larger

internal diameter

. Local restrictions in the suction line,

e.g. partly closed valves, excessiveresistance in return valve, damagedpipe or bent hose

Open valves or change pipes or repairor replace hoses

. Hydraulic fluid too cold Fit electric heater to heat hydraulic fluidto recommended temperature

. Viscosity of hydraulic fluid too high Check hydraulic fluid

. Generation of vapour Reduce operating temperature to correctlevel: top up hydraulic fluid or replacewith correct fluid

. Feed pt*np failure Repair or replace feed pump

. Pimp rus at too high a speed Check speed of drive motor (see alsodata in hydraulic plan)

. Seaieciar* Fit a vent filter

4.1

.2 Hydraulic fluid foams orcontains air

. Hydraulic llud level r îantt nc o« Top up oil. In installations with greatlyfluctuating oil levels: only top up betweenmax. and min. level

. Wrong layout of tank Improve the design

. Return line ends above the hydra-jic

fluid level in the tankLay entry of return line below thelydraulic fluid level

. Wrong hydraulic fluid Replace with correct hydraulic fluid,

: _

-

3- : "stallation supplier if necessary

. Air enters through shaft seal on pump Reptece seal

. Air enters through unions in suction line Tighten or replace unions

. Porous suction hose Replace hose

. Incorrect bleeding Bleed the installation

j ; ! !___!

6 AL106BHytraJcs

4 Troubleshooting

Industrial Hydraulics

4.

1 Excessive noise in installation

Cause Reason Remedy

4.1

.3 Mechanical vibrations . Coupling incorrectly aligned or loose Re-align or tighten

. Pipeline vibration Tighten or improve the pipe clips

. Pump faulty or damaged Repair or replace

. Unsuitable type of pump Replace by suitable type

. Drive faulty or damaged Repair or replace

. Unsuitable type of drive Replace by suitable type

. Pressure valve unstable (flutters) Adjust correctly or replace bya suitable valve

4.2 No pressure or insufficient pressure

Cause Reason Remedy

4.2

.1 Incorrect pump delivery . Air enters suction line See fault 4.1.2

4.2

.2 High pump temperature . Worn or damaged pump Repair or replace

. Viscosity of hydraulic fluid too low See Fault 4.1.1

. Insufficient or incorrectly adjustedcooling

Improve or adjust cooling line correctly.Ensure flow of cooling water

4.2

.3 Speed of pump too lowor insufficient drive power

. Coupling c zets : :;e : e -defective

Repair defect

. Drive motor too smai Use correct drive motor

4.2

.4 Leaks from pressure sideto return line

. Incorrectry set pressure Correct setting

. Safety valve does not dose becauseof conta'-atxx! of faulty part

Clean, determine damage, repair orreplace

. Directional control or other valve openbecause of contamination or other

faulty part or electrical failure

Find the damaged appliance, adjust,clean, repair or replace

. Damaged cylinder bore, piston rods orpiston seal

Repair or replace damaged parts

. Piston ring failure since materialunsuitable for hydraulic fluid used

Fit seals made of correct material

4.2

.5 Feed pump failure(only reciprocating pump used)

. Damaged pump, faulty drive,unsuitable viscosity of fluid

See fault 4.1.3

AL 106 B

4 Troubleshooting

4.3 Pressure and flow fluctuations

Cause Reason Remedy

4.3

.1 Cavitation in the pump . See fault 4.1.

1 See fault 4.1.1

4.3

.2 Foam or air inclusions in fluid . See fault 4

.1

.2 See fault 4.1.2

4.3

.3 Mechanical vibrations . See fault 4

.1

.3 See fault 4.1.3

4.3

.4 Pressure relief valve of safetyvalve flutters

. See fault 4.1

.3 See fault 4.1.3

. Damaged valve seat Repair or replace

. Valve has insufficient or no cushion Fit a more suitable component orprovide a cushion

4.3

.5 Valves stick . Contamination Drain hydraulic fluid, clean installation

and parts, fill with clean fluid

. Damaged or distorted Replace device, remove the reason forthe distortion

4.3

.6 Unequal pump delivery . Unsuitable pump type or pump design Replace with a suitable pump afterconsultation with manufacturer of

installation or pumps

4.3

.7 Air inclusions in installation . Installation not completely bled Bleed installation ,see 2.6 Bleeding

which produce an uneven orstick-slip motion . Electrical system faulty, e.g. valves

switch constantlyFind and remedy the fault

4.4 Insufficient or no delivery

Cause Reason Remedy

4.4

.1 Cavitation in the pump . See fault 4.1.

1 See fault 4.1.1

4.4

.2 Foam or air inclusions in fluid . See fault 4

.1

.2 See fault 4.1.2

4.4

.3 Faulty pump . See fault 4.1

.2 See fault 4.1.2

4.4

.4 Pump speed too low orinsufficient drive power

. See fault 4.2

.3 See fault 4.2.3

4.4

.5 Leaks from pressure sideto return line

. See fault 4.2

.4 See fault 4.2.4

4.4

.6 Wrong direction of rotationof pump

. Incorrect direction of rotation for motor Change phases of electric connection

8 AL 106 BHVj

4 Troubleshooting

Hydraulics

4.5 Fluid temperature too high

Cause Reason Remedy

4.5

.1 Bypass losses . Pressure set at pump too high orat safety valve too low

Correct pressure setting

. Oil flows out of accumulator safetyblock

Close accumulator drain valve at

accumulator safety block

4.5

.2 Leakage losses from pressureside to return line

. Incorrect function of valves and faultyseals

See fault 4.2.4

. Wrong viscosity of hydraulic fluid(too low)

Drain hydraulic fluid and fill installationwith fluid which has the viscosityrecommended by the manufacturer

4.5

.3 Hydraulic fluid flows underpressure through safety orpressure relief valve to tankalthough no hydraulic f - a isrequired

. Incorrect control of the installation Provide correct control, for instance

changeover to circulation without

pressure

. Incorrect function of bleedinginstallation due to contamination

or faulty parts

Clean or, if necessary, repair

. Safety pressure set too low Correct setting

4.5

.4 Insufficient cooling . Failure of cooling water supply or fan Remedy fault

. Sediment in the cooling water line Clean

4.5

.5 Insufficient heat removal . The installation has insufficient cooling

surfaces to remove the generated heatFit a cooling system and/or enlarge tanksize and area

. Increase in machine power with nocorresponding increase in coolingoutput

Improve cooling system and/or enlargetank size and area

4.5

.6 Overheated puÿc . Worn pump Repa' or replace

. Use of hydraulic fiutd at iliuft ÿ liviscosity

See fault 4.5.2

4.5

.7 Excessive recirculation speedof hydraulic fluid

. Insufficient fluid .odume Enlarge hydraulic fluid tank

. Hydraulic'- - eve r nstailation

is too lowTop up to recommended level

4.5

.8 Excessive fluid friction . Cross section of pipelines and valvestoo small

Fit pipes and valves of correct size

IndustrialAL106 B

raulics

Parker Addresses:

Kaarst:

Parker Hannifin GmbHGutenbergstraBe 38D-41564 KaarstPhone (+ 21 31) 5 13 - 0Fax (+21 31)513-230

Niirtingen:

Parker Hannifin GmbHVertriebsburoWeberstraBe 17D-72622 NudingenPhone (+7022) 7 03 - 0Fax (+7022)703-181

Chemnitz:

Parker Hannifin GmbHVeftriebsburoOtto-Schmerbach-StraBe 1 9D-09117 ChemnitzPhone (+ 3 71) 81 41 - 0Fax (+ 3 71) 81 41 -250