Instructions Manual Mod. CE-02 Rev.

0 of 01/05/07

INSTRUCTIONS MANUAL

HYDRAULIC POWER PACK Model CICI-S

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

INDEX
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. FRONT COVER TECHNICAL DATA BASIC FUNCTIONS INSTALLATION, USE AND DISCONNECTION INSTRUCTIONS FOR USERS MAINTENANCE AND REPAIR PRECAUTIONS INSTRUCTIONS FOR CRITICAL SITUATIONS DISMANTLING SERVICE TECHNICAL DATA SHEET MODEL CICI-S SUGGESTED PERIODICAL CHECK Pag. 1 3 4 6 6 7 7 8 8 8 9 10

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

2. TECHNICAL DATA Dimensions: see attached technical data sheet Power Pack model CI-S Weight: see attached technical data sheet Power Pack model CI-S Power supply: see attached technical data sheet Power Pack model CI-S Maximum oil pressure: see attached technical data sheet Power Pack model CI-S Oil flow: see following table. Type of oil: HM 46 or equivalent (4,2 ENGLER at 50C / 46 CST at 40C) Environmental Conditions: Temperature range: from 5C to 40C For higher temperature we suggest to use a cooling unit (air or water based). For lower temperature we suggest to use an heating unit. The cooling or heating units can be supplied as optional accessories. Maximum Humidity: 95% Maximum Noise: 70 dBA. We recommend to respect the environmental conditions above specified.
COMPONENT
Oil Tank Tank Gear Pump Electric Motor Oil level indicator with builtbuilt-in thermometer ReRe-fill cap with bleeding device Oil drain plug plug Oil suction filter Directional Valves Assembly Relief Valve (max. pressure) Heater Cooling Unit

CHARACTERISTICS
Capacity: 30 l Prevalence: Flow: 2 l/min Power: 0.75 kW 4P B5 Supply: 230/400V - 50Hz Scale: 0 - 90C In high position In low position 90 micron Number of valves per group: Type: M3-SE-6C20/315G24NZ5L Pressure range: 0250 Bar - (optional) - (optional) 1 1 1 1 1 1 1 1 1 -

QUANTITY

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

3. BASIC FUNCTIONS
The hydraulic power pack is designed to generate a flow of industrial oil with specified flow rate and pressure. The required flow is obtained through a volumetric pump powered by an electric motor (1); the oil is transferred from the tank (3) to the brake through a 3-ways solenoid ball valve (normally closed). Based on the enclosed data sheet Hydraulic Power Pack CI-S, we can define the following basic oprational procedure: - Start the electric motor (1). The pump (2), powered by the motor (1), aspires the oil from the tank (3) through the filter (5). The pressurized oil enters the block (15) through a rigid pipe: o The oil arrives to the maximum pressure relief adjustable valve (4) where the user can adjust the required maximum pressure [indicated on the pressure gauge (9) with the accumulator (12) loaded]. The valve will open if the pressure goes up over the set maximum pressure. Attention Attention: tion: the maximum pressure relief valve is pre-set. o The oil arrives to the first check valve (11) and then to the normally open unloading solenoid valve (13); this unloading valve is activated when one of the two pressure switches (8) [the switch set at the required minimum pressure] indicates that the accumulator (12) has a pressure below the set minimum pressure. In this situation the solenoid valve will close in order to allow the oil to load the accumulator (12). When the pressure achieves the maximum value [set on the second pressure switch (8)] the unloading solenoid valve (13) will open in order to let the oil go back to the tank. Attention Attention: tion: the pressure switches are pre-set. o The second check valve (11) avoids the accumulator (12) to be unloaded. o The pressure gauge (9) indicates the pressure in the accumulator (12). o At the end of the block (15) there is a normally closed solenoid ball valve (6) in order to send the oil to the brake when it is required. Attention Attention: tion: the ball valve (17) must be open and the valve of the manual pump (16) has to be closed. In case of electric power failure, the brake can be engaged with the manual pump (16). In this case the ball valve (17) must be closed. Attention Attention: tion: the ball valve (17) must be closed, otherwise the pumped oil will go back to the tank (3). Important: the valve of the manual pump (16) is strongly tightened by the manufacturer because it must be always closed.

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

In case its necessary to empty the accumulator, open the pin valve (20) which sends the oil back to the tank (3) through a rigid pipe. Important: the pin valve (20) must be always closed while the power pack is working. Important: the accumulator must be empty during normal maintenance operations.

The oil coming out from the brake thrusters goes back to the tank (3) when the solenoid ball valve (6) is disengaged. Attention Attention: tion: the ball valve 17 must be open and the valve of the manual pump (16) must be closed.

The thermostat switch (18) sends a signal when the pre-set maximum temperature of the oil is achieved. This signal is an alarm which must be followed by the interruption of electric power supply. Attention: Attention: the maximum temperature of the oil should not be more than 50C.

The level switch (19) sends a signal when the oil quantity in the tank (3) achieves the minimum level. This signal is an alarm which must be followed by the interruption of electric power supply.

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

4. INSTALLATION, USE AND DISCONNECTION

4.1 Installation and Use 1. Connect the output of the power pack block (15) through connections that can work safely at the maximum operational pressure. 2. Fill the tank (3) from the re-fill cap (14) with specified oil until reaching 75% of the tank capacity; the oil level can be seen on the indicator (7) positioned on the tank side. 3. Connect the electric motor (1) to the power supply line. Ensure the sense of rotation is the same as indicated by the arrow positioned on the motor (1). All the electric connections must be done by authorized qualified technicians. 4. Connect the solenoid valves (6) and (13) according to safety regulations related to the specific electric tension. 5. The maximum pressure relief valve (4) is pre-set at pressure = 200 Bar. Bar Attention Attention: tion: The required maximum pressure value set by the user cant be higher than the maximum pressure considered in the design of the power pack. 6. The pressure switch (8) for the maximum pressure is pre-set at pressure = 175 Bar. Bar 7. The pressure switch (8) for the minimum pressure is pre-set at pressure = 145 Bar. Bar Attention Attention: tion: The pressure switches (8) must be re-set if the maximum pressure value of the valve (4) is changed by the user. 8. Test accurately the basic functions of the power pack. 4.2 Disconnection 1. Disconnect the power pack from the electric power supply line. 2. Disconnect the power pack from the brakes. The oil can be discharged through the valve (17). Do not disperse the oil in the environment. environment 3. If the power pack has to be transported, the oil has to discharged from the tank (3) through the oil drain plug (10). Otherwise, if the oil is not discharged before transportation, ensure the re-fill cap (14) is tightly closed. During transportation, the power pack has to be safely fixed and kept in vertical position.

5. INSTRUCTIONS FOR USERS

The use of the power pack is related to the design of the main machine where the power pack will be installed. The user of the main machine has to follow the instructions of the supplier of the main machine. When in doubt, please contact the supplier of the power pack.

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

6. MAINTENANCE AND REPAIR

1. Before using the power pack, check that the oil level is at least 75% of the tank capacity. If its lower, re-fill the tank with prescribed oil. 2. While using the power pack, check the oil level (minimum 75% of the tank capacity) and the oil temperature (maximum 50 C). The temperature is indicated by the indicator (7) positioned on the side of the tank (3). In case the oil temperature is over 50 C, stop the machine and contact the supplier. The oil has to be always clean (yellow colour), if the colour turns darker the oil has to be replaced. 3. Every 500 hours of work, check the oil suction filter (5); if the filter is dirty, clean it or replace it if necessary. 4. Every 1000 hours of work, check carefully the oil and the bottom of the tank (3). In case there is about 1 cm of dirt on the bottom of the tank, replace the oil and clean the tank. Important: before any maintenance operation, empty the accumulator through the pin valve (20). 6. For any other necessary repair, contact the supplier of the power pack. In general, refer to the periodical check operations suggested by the supplier of the power pack. 5.

7. PRECAUTIONS
1. Oil at high pressure and high temperature All the pipelines are protected with a cover guard. When connecting the power pack to the brakes, use flexible or rigid pipes which can work at the maximum pressure. All of the pipes have to be protected and positioned not too close to the operators. Protective gloves must be used by the operators during maintenance operations in order to avoid to touch the oil, even at low temperature. 2. Tank with industrial oil We suggest to build an auxiliary tank as big as the main tank, in order to ensure the discharge of the oil towards a safe place, especially in case of failures and damages. Do not breathe oil vapours which might come out of the tank through the re-fill cap. In case of accidental breathing of oil vapours, call for medical assistance. Keep a data sheet with the oil characteristics close to the location of the power pack so a doctor can read it in case of accidents. 3. Electricity All the parts with electrical tension are clearly marked and covered. Switch off the tension before removing the cover guards. In case of tests with the tension on and without the cover guards, the maintenance technicians have to check that nobody is close to the power pack during the tests. ATTENTION ATTENTION: TION: The power pack is not equipped equipped with devices which can avoid the automatic rere-start of the machine, for example when the electric power comes back after a power failure. Eventua Eventual ual safety devices, devices, as well as warning signs and instructions labels for the operators, has to be installed installed by the manufacturer of the main machine. machine.

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

8. INSTRUCTIONS FOR CRITICAL SITUATIONS

Never use water on the parts wrking with electric tension or on the cabins containing these parts. In case of fire, switch off the power supply and use powder extinguishers.

9. DISMANTLING
Discharge the industrial oil and deliver it to authorized collection locations. The power pack is made of standard electric materials as well as iron and aluminium parts. The scraps have to be delivered to authorized demolition and recycling locations. Do not disperse oil and scraps in the environment.

10. SERVICE
The service is ensured by the supplier of the power pack.

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

11. TECHNICAL DATA SHEET MODEL CICI-S

Instructions Manual Mod. CE-02 Rev. 0 of 01/05/07

12. SUGGESTED PERIODICAL CHECK

Check if the coils of the electrovalves (6) and (13) are not shortcircuited. Check if the electric motor (1) is not shortcircuited or not blocked anyway. Check the correct position of the valves (17) and (20) and of the manual pump (16). In case of pressure failure: o Check if the valve of the pressure gauge (9) is open. o Check if the pressure gauge (9) is not broken. o Check if the valve (20) is open. o Check the nitrogen charge of the accumulator pre-loaded at 130 bar. o Check if the solenoid unloading valve (13) is not blocked in open position. o Check on the pressure gauge if the required pressure can be achieved acting on the relief valve (4). Check if the gear pump (2) is not blocked. Check if the suction filter (5) is not blocked by dirt. Check if there is no oil spilling through the solenoid ball valve (6). Check if there is not oil leaking from the connections. Check if the hoses are not damaged. Check if the signals sent by the level switch (19) and the temperature switch (18) are correct. Check if the double pressure switch (8) is correctly set and the signals are correct.

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