Enclosure 1 - CPCS SS Ref Docs for GFE (Hagglunds-Instructions).pdf

DCUS-Clb Work instruction AA 38225-004 Appendix/Supplement

Drive System Start Up Edition: 2015-01-21 Editor: DCUS/SVE8-Clb

Reference: -

Ref.-Edition: -

Field Service Replacement for

Hägglunds 10308-1 : 2010-01-15

Target language: en Translation: en en Dept.: DCUS/SVE8-Clb DIS-Nr. 1234567890 Source language: en Date: 2015-01-21 Name: Randy Hipp In case of doubt the original language edition of this instruction applies. . 12345678901212

Bosch Rexroth Corporation created checked approved

Dept.: DCUS/SVE8-Clb DCUS/SVE8-Clb DCUS/SEL-Clb 2275 International Street Name: Randy Hipp Randy Hipp Ed Williams Columbus, OH 43228 BWN: US13 US13 US13 USA Signature on file Signature on file

Uncontrolled copy if printed; it is the user’s responsibility to verify that this document reflects the latest revision. Page 1 / 12

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Table of contents Page Amendments 1 Aim 2 Scope 3 Terminology and abbreviations 4 Responsibilities 5 Record Retention 6 Mechanical

6.1 Basic Inspections – Motor, Splined Shaft

6.2 Basic Inspections – Motor, Shrink Disk mounted

6.3 Basic Inspections – Motor, Viking

6.4 Power Unit

6.5 Piping

7 Electrical

7.1 Internal Wiring

7.2 External (customer supplied) wiring

8 Hydraulics and Controls

8.1 Pump Start up and check out

8.2 Controls

9 Supporting documents

Amendments

Compared to Hägglunds 10308-1 : 2010-01-15 following modifications were carried out:

a) Transferred process to current format; 2015-01-21

1 Aim The purpose of the work instruction is to provide an accurate process for start-up of hydraulic drive systems.

2 Scope This work instruction is valid for DCUS-Clb.

Page 2 / 12 Drive System Start Up AA 38225-004 : 2015-01-21

3 Terminology and abbreviations

Terms

Power Unit – An electro-hydraulic driven machine to provide pressure and flow to a hydraulic motor for operation.

Splined shaft – Splines are ridges or teeth on a drive shaft that mesh with grooves in a mating piece and transfer torque to it, maintaining the angular correspondence between them.

O-ring – An o-ring, also known as a packing, or a toric joint, is a mechanical gasket in the shape of a torus; it is a loop of elastomer with a round cross-section, designed to be seated in a groove and compressed during assembly between two or more parts, creating a seal at the interface.

Torque – A moment or moment of force, is the tendency of a forces to rotate an object about an axis or pivot.

Just as a force is a push or a pull, a torque can be thought of as a twist to an object.

Bill of Material – A formally developed listing for an object, which contains all belongings under indication of designation, material number, quantity and unit for the respective purpose. A bill of materials, which is created for a material is called a Material BOM within the SAP system. As a rule, the bill of materials represent the structure of products which are produced in our company. Besides materials, also different components like documents can be gathered (see ZN 01315).

Molykote – A brand of specialty lubricants manufactured by Dow Corning that can help control friction and wear to save energy, extend lubrication intervals to reduce maintenance and enhance equipment reliability to maintain productivity.

Disclaimer – Any statement intended to specify or delimit the scope of rights and obligations that may be exercised and enforced by parties in a legally recognized relationship.

Warranty – A guarantee or promise which provides assurance by one party to the other party that specific facts or conditions are true or will happen.

Dip switches – A manual electric switch that is packaged with others in a group in a standard dual in-line package (DIP).

Technical documentation – In engineering, technical documentation refers to any type of documentation that describes handling, functionality and architecture of a technical product or a product under development or use.

Manufacturer’s specification – Documented installation or maintenance instructions produced by a product manufacturer. Often these instructions must be carefully followed in order to maintain a product warranty.

Goldcup – A closed loop hydrostatic transmission pump with a 5A or 9A2 control manufactured by Parker Denison.

Transfer cart – A portable unit that can transfer hydraulic fluid from one container into another.

Servo – Or servomechanism is a device to provide control of a desired operation through the use of feedback.

Relief valve – A type of valve used to control or limit the pressure in a system or vessel which can build up by a process upset, instrument or equipment failure.

Interlocks – A device or operational control used to prevent undesired states in a machine, which in a general sense can include any electrical, electronic, or mechanical device or system.

Ball valves – A valve with a spherical disc, the part of the valve which controls the flow through it.

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Linearity – Refers to a mathematical relationship or function that can be graphically represented as a straight line, as in two quantities that are directly proportional to each other, such as voltage and current in a simple DC circuit, or the mass and weight of an object.

Encoders – A device, circuit, transducer, software program, algorithm or person that creates information from one format or code to another, for the purpose of standardization, speed or position measurement, security or compressions.

As-built – Use this after a component/power unit has been built and changes were made to the “For Construction” and “Working Copy” drawings. This should indicate any variances that happened during the construction and start up phases of the project. Major changes should get prior written confirmation from the customer , prior to changes being made.

Abbreviations AA = Work instruction of DC BOM = Bill of Material ISO = International Standards Organization PSI = Pounds per square inch (gauge) SP = Superior Performance I&M = Installation and Maintenance (manual) en = English PAC = Power Unit American Revision C DIN = German Institution for Standardization ANSI = American National Standards Institute ft/sec = Feet per second m/sec = Meter per second cm = Centimeter mm = Millimeter HS = Hydraulic Schematic NAS = National Aerospace Standard SAE = Society of Automotive Engineers BSP = British Standard Pipeform TAC = Torque Arm Complete ES = Electrical Schematic CD = Connection Diagram RTD = Resistance Temperature Detector PS = Project Specification F = Fahrenheit C = Celsius In = inch Max = Maximum SAP = Systems, Applications and Products in Data Processing

DC organizational units DC = Drive and Control Technology DCUS = Drive and Control Technology United States Clb = Columbus SVE8 = Field Service SEL = Mining and Bulk Material Handling

4 Responsibilities DCUS/SVE8-Clb is responsible for the preparation and care of the work instruction.

5 Record Retention Refer to Corporate Policy No. 112 for the appropriate retention deadline.

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6 Mechanical Provide customer with Start-Up Checklist (FR 38225-004) prior to conducting start-up of drive system.

6.1 Basic Inspections – Motor, Splined Shaft

6.1.1 The splines are to be lubricated with oil per the I&M manual. Insure that the o-ring on the leading edge of the motor shaft is in place.

Note: Motors subjected to radial load must have the spline cavity filled with oil.

6.1.2 Verify that the axial locking bolt is installed and torqued per the I&M manual.

6.1.3 For flanged mounted motors insure that the mounting bolts are torqued per the I&M manual.

6.1.4 For torque arm mounted motors, insure that the mounting bolts are torqued per the I&M manual.

6.1.5 Insure that the pivot attachment is installed and aligned per tolerances permitted in the I&M manual. i.e. torque arm perpendicular to pivot links within 25 degrees, less than 15 mm movement of links (axially on pins) when operating.

6.1.6 Insure that all other bill of material top-level (shipped loose) items and accessories are installed properly per Engineering drawings and manuals.

6.2 Basic Inspections – Motor, Shrink Disk mounted

6.2.1 Verify driven shaft and inside of the motor hollow shaft have been cleaned. Insure motor has been properly aligned and mounted (use of mounting tool recommended).

6.2.2 Verify that the correct clamping length between the driven shaft and the motor shaft has been obtained per the I&M manual.

6.2.3 Verify the shaft coupling has been properly coated with Molykote, and bolts torqued per value on coupling nameplate or I&M manual if no name plate exists. Torque bolts in proper sequence and increments per I&M manual, while checking and insuring proper alignment of coupling while tightening.

6.2.4 Verify that no Molykote or lubrication was used on the drive shaft or inside of the hollow shaft on the motor.

6.2.5 After removing the installation tool, refit the plug, end cover and torque the screws per the I&M manual.

6.2.6 Insure that all other BOM top-level (shipped loose) items and accessories are installed properly per the Engineering drawings and manuals.

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6.3 Basic Inspections – Motor, Viking

6.3.1 The motor should be normally filled with oil at least to the shaft center and completely filled for low speed operation. Bleed the motor with 1 ¼” BSP plug on front end cover.

6.3.2 For mounting shaft adapter and/or rope drum, carefully clean the mounting surfaces.

Lubricate and torque the bolts per the I&M manual. Insure that the eccentricity and axial wobble of mounting surfaces of mating equipment, such as shaft and rope drums are within

0.15 mm (0.006 in) for the inner and outer flanges.

6.3.3 For V46-0 valve mounting (44 and 64 series motors) insure motor is mounted with “D₂” port facing downwards. For V46-C valve mounting (44 and 64 series motors) insure motor is mounted with “D₂” port facing upwards.

6.3.4 Remove cover and plugs from motor mounting surface, install a 2-speed plug in port A per the I&M manual. Position the greased o-rings on the valve mounting surface, and install the valve per the I&M manual with the ports in corresponding position.

6.3.5 For torque arm mounting (44 and 64 series motors), insure the connection “D₂” is upwards

(unless valve V46-0 is used. If used the “D₂” connection on the motor must be facing downwards). For TAC 1000-K, insure that the hub and keys are lubricated and installed correctly, insure that there is no damage on the wear ring from knocking the keys in too far.

6.3.6 For torque arm mounting (84 series motors), insure that the connection “D₁” is upwards.

Lubricate and torque the bolts per the I&M manual. Insure that the welding of the fixed attachments meets the class and tolerances as specified in the I&M manual. Insure the installation of the pivoted attachment meets the position and tolerance requirements of the I&M manual.

6.3.7 Insure that all of the other BOM top-level (shipped loose) items and accessories are installed properly as per the Engineering drawings and manuals.

6.4 Power Unit

6.4.1 Insure that the forklift forks extend completely through the frame, or that all of the lifting points are used when crane lifting/positioning.

6.4.2 Verify that the power unit is placed on a firm and level foundation.

6.4.3 Verify that the cabinet feet (if supplied, see BOM) are installed on the power unit.

6.4.4 Insure that the minimum required space around the power unit has enough clearance for maintenance and ventilation, as per general arrangement drawing or the I&M manual.

6.4.5 Verify that the electric motor(s) have been installed in the correct position according to the general arrangement drawing. Verify that the coupling has been installed according to the manufacturer’s specifications.

6.4.6 Reinstall the power unit cabinet top cover, heat baffle and hood riser according to the drawing if so equipped (PAC units).

6.4.7 Insure that the air or water cooler has been installed properly, if shipped loose.

6.4.8 Locate and properly store any spare filter elements that were shipped loose with the power unit.

6.4.9 Verify that the electric motor bearing grease fittings (both the drive end and non-drive end) have been greased according to the manufacturer’s specifications. On PAC units, an extension tube or hose is recommended to allow easy access to the non-drive end grease fittings.

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6.5 Piping

6.5.1 A non-welded piping system of either phosphate cold drawn seamless pipe or stainless steel pipe is recommended. Carbon steel pipe should be of high grade steel as per ISO 3304, DIN 2391/C or ANSI/B93.4.

6.5.2 Piping size and wall thickness shall be selected to provide a 4:1 safety factor over the maximum system pressure. ANSI standard B31.3 is recommended for design. Line velocities can vary per design requirements but in general should be designed for system pressure lines at 15-25 ft/sec (4.5-7.5 m/s) and return lines sized for 10-15 ft/sec (3-4.5 m/s).

Drain lines should be sized to match the motor or pump case port size from port to reservoir without reduction.

6.5.3 Use of welded piping for Hägglunds Drive systems is not recommended. If used, the guidelines of DCUS-Clb Work instruction AA-38225-010, Piping Installation, for construction, flushing and cleaning should be followed.

6.5.4 The use of proper o-rings (material compatible with system fluid, 90 durometer for system pressure lines), seals, inserts, split flanges, couplings, etc. shall be used. All flange fasteners shall be tightened according to the manufacturer recommendations.

6.5.5 Pipe clamps should be uniformly spaced with distances between the clamps, normally to be

6 ft (1.8 m) max up to 1.5 in (38 mm) in diameter, and 9 ft (2.75 m) max for sizes over 1.5 in (38 mm). Pipe clamps should be used before and after bends, before transition to a hose, and be secured to stable and non-vibrating surfaces. Use of rubber isolation mounts to reduce noise and vibration is recommended.

6.5.6 All installed piping shall be pressure tested to a minimum of 1.5 times the maximum working pressure and be checked for leaks. A pressure test report shall be attached to the Startup checklist.

6.5.7 The hydraulic motor and pump should be connected to the piping with hoses. The hoses should be marked as rated for at least the maximum possible working pressure. In general, hoses should be as short and small of diameter as feasible while meeting the design velocity requirements.

6.5.8 Shut-off valves of the correct size and working pressure are recommended, where the pump main line hoses connect to the piping, and can also be installed where the hydraulic motor main line hoses connect to the piping. Use of locking handles or position switches are acceptable. It is never recommended to use a shut-off valve on any drain lines, as inadvertent closure can damage equipment.

6.5.9 The piping/hose system shall be verified as routed per the Engineering hydraulic schematic, usually drawing number HS-(project number).

6.5.10 Flushing and Cleanliness

6.5.10.1 The entire hose/piping system should be flushed and cleanliness verified prior to system startup. For a welded piping system, a pre-flush cleaning procedure per DCUS-Clb Work instruction AA-38225-010, Piping Installation, should be completed.

6.5.10.2 Flushing can be carried out by interconnecting system hoses together to facilitate flushing as much hose and piping at once, and can be completed in sections if needed. The flushing pump shall provide flow of at least as and preferably greater than the maximum design line velocities. Filtration during flushing should be 10 microns or better.

6.5.10.3 The flushing shall continue until the fluid sample cleanliness meets NAS 1638 Class 7, or

18/16/13 per ISO 4406.

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6.5.10.4 A copy of the fluid sample cleanliness report shall be attached to the Startup Checklist Form (FR-38225-004). One sample report is required for each separate section of piping/hose system flushed.

6.5.11 Disclaimer - Customers who refuse to verify piping/hose system cleanliness per section

5.5.10 must sign the Startup Checklist form (FR-38225-004) indicating that they authorize an override to the fluid cleanliness requirements. Bosch Rexroth reserves the right to deny warranty on any failures we consider to be caused by insufficient system fluid cleanliness.

7 Electrical

7.1 Internal Wiring

7.1.1 Control system type: Note if control system is a Spider controller or driver card type.

7.1.2 Spider or control box supply voltage: Measure and record the supply voltage to the Spider controller for systems so equipped or to the control box for driver card systems.

7.1.3 Verify that all internal jumpers are wired as per the project ES and CD drawings as applicable.

7.1.4 Verify that the dip switches are set per the project ES drawing.

7.1.5 Verify that the termination lugs have been used and that all connections are tight.

7.1.6 Verify that all of the internal wiring has been completed per the project ES drawing.

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7.2 External (customer supplied) wiring

7.2.1 The customer supplied electric motor starter circuit shall provide a dry contact, normally closed, that opens upon electric motor start.

7.2.2 The electric motor circuit must contain an electric motor interlock that is connected to the stop circuit of the electric motor.

7.2.3 The speed encoder is normally shipped loose, and must be mounted and wired per the project CD drawing.

7.2.4 An emergency stop circuit must be wired per the CD drawing and verified operational.

7.2.5 All customer inputs and outputs must be wired per the CD drawing. A bus communication card may be used as specified on the CD drawing.

7.2.6 All power unit devices to be make/break checked back to customer control system to verify correct operation.

7.2.7 The power unit frame shall be grounded, using the lug provided.

7.2.8 The electric motor(s) are to be wired and grounded as per the technical documentation.

7.2.9 Electric motor bearing RTD’s (if so equipped) shall be wired according to the technical documentation.

7.2.10 Electric motor anti-condensation heaters (if equipped) shall be wired according to the technical documentation. It is recommended that anti-condensation heaters remain wired and powered when the electric motor(s) are idle for any extended period of time, including storage, in accordance with the manufacturer’s specification.

7.2.11 Verify that the water valve solenoid (if water cooled) is wired according to the technical

7.2.12 Verify that the air cooler electric motor (if air cooled) is wired according to the technical documentation including a “bump” start to verify correct direction of rotation. (See section 8.1.5)

7.2.13 Verify that any separate charge or flushing pump e-motors are wired according to the technical documentation including a “bump” start to verify correct direction of rotation. (See section 7.1.5).

7.2.14 Verify that reservoir oil heater(s) are wired correctly.

7.2.15 Verify the power unit space heater (if equipped) is wired according to the technical

7.2.16 List any supplied items not used and attach it to the Startup Checklist.

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8 Hydraulics and Controls

8.1 Pump Start up and check out

8.1.1 Verify that the hydraulic fluid to be used is per the project specifications; usually document PS-job number in the technical documentation. Any discrepancy must be approved by Bosch Rexroth’s engineering department. Record the oil type and ISO viscosity weight rating on the startup checklist.

Note: Do not mix different types of oils without first checking with the manufacturer. Insure that hydraulic oil containers are not contaminated with water or other substances.

Caution: New hydraulic fluid, even from sealed containers, is normally not filtered and will introduce dirt into the system. Therefore, fluid must always be added through a filter with a filter rating of 10 microns or better. Using the quick disconnect on the Bosch Rexroth power unit will provide the needed filtration. Never pour hydraulic fluid into the reservoir through the breather cap. Doing so may cause system damage and void the equipment warranty.

8.1.2 Fill and bleed the pump suction lines. Open the suction valve to allow oil into the charge pump. The suction line must be bled of air before continuing. For Goldcup pumps loosen the split flange suction line connection at the pump, allow air/oil to flow freely and then re-tighten, being careful not to dislodge o-ring. On Goldcup pumps size P6s-P14s, also loosen the “C” port suction connection where the hose joins the pump, bleed and re-tighten. On SP pumps, remove the plug on the Ms port and allow to bleed until oil flows freely without air bubbles and re-tighten.

8.1.3 The pump case(s) must be completely filled before starting. On Goldcup pumps vertically mounted, fill up to or bleed from the air bleed port, a SAE-4 plugged port near the shaft end of the pump. On SP pumps vertically mounted, fill up to the T port and bleed from the U port. For horizontally mounted pumps, fill up to the highest case drain port on the pump. For Goldcup pumps this is usually the D₁ or D₂ port. On SP pumps this is usually the T or R L port.

Use a transfer cart or hand fill as required (always using filtered oil) until the pump case is full up to the U port on SP pumps and the air bleed port on a Goldcup pump.

Caution: A transfer cart if used should first always be checked to verify a clean un-damaged filter element is present. The output hose should always be run into a waste bucket or barrel at first startup, to insure water or other contaminants are not pumped into the system.

Note: If the system is so equipped, it is always desirable to use the separate pre-charge/flushing pump to pre-fill the pump/motor cases. Remember first to bleed the suction line feeding the pre-charge/flushing pump. For vertically mounted units, you can completely fill and bleed the pump cases by loosening the U port plug on a SP pump, or the air bleed port (beside the upper eductor tube connection) on a Goldcup pump.

8.1.4 The motor case(s) should now be filled to the level of the highest drain port, even if the motor elevation is above the power unit and the main lines are empty. Use a transfer cart or hand fill with filtered oil as necessary, or use the system pre-charge flushing pump (if equipped).

Insure any main line ball valves are open for this step.

8.1.5 Bump start each electric motor/pump assembly (energize and then immediately de-energize) while carefully observing pump/motor coupling assembly to confirm correct rotation.

Direction is normally clockwise when viewing end of pump shaft, but should be confirmed to match rotation direction arrow on pump tag. Have qualified personnel correct and re-confirm as needed. Also verify direction of air cooler electric motor (if equipped).

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8.1.6 With rotation correct, and pumps completely unloaded, continue to bump in 5 second intervals until main loop lines are filled and charge pressure is steady on pressure gauge.

Caution: Some customer control systems, particularly with larger HP electric motors, limit the permissible number of electric motor starts per hour. Consult the technical documentation for the electric motor/motor starter to insure limit is not exceeded.

8.1.7 With unit running, notice change pressure will be approximately 200 PSI or higher, and servo/control pressure should be 400 PSI or higher.

8.1.8 Turn on water to heat exchanger (if equipped). Allow unit to warm up to operating temperature. While unit is warming up, proceed to check for oil leaks on application (leaks are not allowed).

8.1.9 At normal operating temperature, typically 104° F (40° C) the water valve or air cooler e-motor should cycle on to maintain temperature setting of approximately 95° - 110° F in tank.

8.1.10 With unit at operating temperature proceed to adjust the compensator and charge relief pressures to technical documentation. On SP pumps the crossover valve settings should also be checked and adjusted as needed. Shut off valves on the main loops must be closed and 50% command given in order to adjust the compensator. If no shut off valves are on the system then the main ports of (A & B) pump need to be blanked off. (Refer to the manual for the location of the compensator and charge relief on the hydraulic pump.)

8.2 Controls

8.2.1 Proceed to check out the interlocks to the technical documentation.

Typically the following should be a shutdown of the electric motor:

• Suction line switch

• Charge pressure switch

• Low low level switch

• High high temperature switch

• Emergency stop

Typically the following indicators are usually a warning:

• Filters impending bypass (case motors and case pump)

• High oil temperature

• Low level switch

• High pressure (system)

Note: Applications vary on how interlocks are applied and wiring mistakes are made due to construction electricians. All interlocks must be completely verified (i.e. each alarm causes drive to actually shut down) to protect the system.

8.2.2 Open the ball valves start the hydraulic motor and turn slowly until the air is purged.

(Remember to consult with the operator/customer representative prior to issuing any drive command).

8.2.3 Adjust gain for linearity and check the speeds if encoders are used. Once all adjustments are made, production can start.

Note: Systems set up unloaded normally require some re-adjustment when under load.

Always check and re-adjust as needed with actual production loads when possible.

8.2.4 Review any concerns or questions with operators/customer representatives before site departure.

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8.2.5 Be sure to note any needed follow up actions by Engineering or Service, and prepare clear markups of all changes made to technical documentation so that accurate as-built revisions can be made.

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9 Supporting documents If no supporting documents are quoted, this section does not apply.

Column “Note”: - = please consider document worked in = document as regards content is worked in

Sect. x.x = please consider relevant section

Publication Edition Title Note

Forms and Templates

FR 38215-001 2012-10-15 Project Bill of Material worked in

FR 38225-004 2012-10 Start-Up Checklist worked in Central Standards ZN 01315 2008-04-15 BOM Item Category worked in Process Instructions

VA 38215-000 2013-05-09 Design Control Procedure -

VA 38236-000 2014-01-18 Power Unit Test Procedure – PAC-PBS-PHS-TADS -

VA 38236-001 2013-08-16 Spider Test Procedure -

VA 38236-002 2013-09-19 Jupiter 500 Driver Test Procedure - Work Instructions AA 38236-000 2014-01-20 Power Unit Test Procedure – PAC-PBC-PHS-TADS - Specifications AB 38230-020 2014-04-01 Hägglunds Low Speed, High Torque Hydraulic Drive

System

AB 38230-024 2014-05-30 Stainless Steel Tubing Specification -http://intranet.boschrexroth.com/redirect?coid=25235 http://intranet.boschrexroth.com/redirect?coid=25235

DC-HD/SAL3-NA Process instruction DCPD 38280-001

Power Unit Test Procedure – PAC-PBC-PHS-TADS Edition: 2019-08-13 Editor: DC-HD/SAL3-NA Reference: -

Testing Ref.-Edition: -

Order Processing, Standard Replacement for

DCPD 38236-000; 2018-04-19

Target language: en Translation: en en Dept.: DC-HD/SAL3-NA 1234567890 Source language: En Date: 2018-04-30 Name: Caleb Barnhart In case of doubt the original language edition of this instruction applies. 12345678901212

Bosch Rexroth Corporation created checked approved

3940 Gantz Road, Suite F Dept.: DC-HD/SAL3-NA DC-HD/SAL3-NA DC-HD/SAL3-NA Grove City, OH 43123 Name: Rick Waller Scott Reynolds Harvey Richardson

USA BWN: US13 US13 US13

Uncontrolled copy if printed; it is the user’s responsibility to verify that this document reflects the latest revision. Page 1 / 12

Table of contents Page Amendments 1 Aim 2 Scope 3 Terminology and abbreviations 4 Responsibilities 5 Retention 6 Description

6.1 General

7 Procedure

7.1 Pre-Test Verification-General

7.2 Pre-Test Verification-Hydraulic

7.3 Pre-Test Verification-Electrical

7.4 Operational Performance Test

7.5 Disconnect and Clean Up

7.6 Final Inspection

8 Supporting documents

Compared to Hagglunds 10208: 2011-05-09 the following essential modifications were carried out:

a) Amendment 1: Transferred to current format; 2013-05-09

b) Amendment 2: Added additional information; 2014-01-08

c) Amendment 3: Changed the address and acronym of the facility. Changed the acronym of the department.; 2016-05-25

d) Amendment 4: Updated department acronyms and document titles; 2018-04-30.

e) Amendment 5: Updated document number to comply with new Gvc Process Structure. 209-08-13

Power Unit Test Procedure – PAC-PBC-PHS-TADS Page 2 / 12 Testing DCPD 38280-001 : 2019-08-13

1 Aim

This process instruction will provide a process for verifying Power Unit construction and operation to meet the customer’s requirements for our PAC/PBC/PHS power unit with Parker Goldcup or Rexroth SP closed loop hydrostatic transmission pumps

This process instruction is valid for DC-HD/SAL3-NA

VA = Process instruction of DC PAC = Power Unit American Revision C PBC = Power Unit American Revision C without panels PHS = Power Unit Hydraulic Skid TADS = Torque Arm Drive System GA = General Arrangement Drawing HS = Hydraulic Schematic S/N = Serial Number RPM = Revolutions per minute PSI = Pounds per square inch No. = Number

DC organizational units DC = Drive and Control Technology DC-HD = Large Hydraulic Drives Business Unit Gvc = Grove City facility SAL3-NA = Engineering ADM = Administration

DC-HD/SAL3-NA is responsible for the preparation and care of the process instruction.

5 Retention As per Corporate Policy No. 112, this process instruction is to be retained until it is either outdated or superseded.

6 Description

6.1 General

Delivery testing of the unit must be carried out by qualified personnel and be documented in Power Unit Test report (DCFR 38236-000). The report produced for each unit contains information on the settings and markings which show each step or check has been carried out and the results are satisfactory.

Delivery testing is carried out in accordance with the delivery information provided by the relevant engineer and based on a confirmed Project Specification from the customer. The delivery information contains information about set values, pressure settings, flow rates, etc., which must be verified or transferred to the unit, drawings, etc.

Hydraulic units are equipped with different types of equipment depending on the application and requirements. For this reason the scope of delivery testing may vary and some of the points listed below may not apply. These points must be indicated by an N/A (not applicable) indication. Additional points must be noted in the comments field at the end of the report, or in a separate document that is enclosed with the report.

Power Unit Test Procedure – PAC-PBC-PHS-TADS Page 3 / 12

Checks and adjustments which involve pressures, voltages or currents, etc., must be carried out using calibrated measuring equipment.

Delivery testing must be carried out at room temperature, using Shell Tellus ISO 68 with 5% Rust Veto 4225 at a temperature of 104±18°F (40±10 °C) unless otherwise specified.

7 Procedure

7.1 Pre-Test Verification-General

6.1.1 Tester to check and make sure that the basic data (Job Number, E-motor Horse Power, Pump, Design Info, etc.) in the Project Specification (DCFR 38205-001 and DCFR 38205-002) matches to the supplied project specific drawings and Bill of Material (DCFR 38215-001) as well as the Serial Number Plate data. The tester must have a set of documentation that has been signed off and is marked “For Construction” and “Working Copy”. All of the documentation used during the test should be listed on the test report including any revisions.

6.1.2 Check GA print specs to as built unit. Identify any discrepancies and if necessary contact the Project Engineer to verify changes are acceptable.

6.1.3 Confirm that the plumbing is correct to the HS print. It is also necessary to verify all check valves are positioned properly for flow direction and are the proper value of check valve stated on the HS print. Confirm the proper hose and tube size matches the Hydraulic Schematic print. Check all the filters are pointed in the correct direction in relation to flow.

6.1.4 Check and verify that the main components (pump, electronics, filters, etc.) that pertain to the HS and ES of a power unit correspond to the Bill of Material. Report any discrepancies immediately to the Project Engineer.

7.2 Pre-Test Verification-Hydraulic

7.2.1 Review the Power Unit Build Report (FR 38230-000) for the power unit being tested and verify that the tank was inspected during assembly. If not, the tank will need to be inspected by assembly and cleaned.

7.2.2 Check the filters on the unit and verify that they match the size and type (Single/Duplex) specified on the Bill of Material.

7.2.3 Prior to filling the unit with oil, verify that assembly has installed elements in the filter bowls by observing assebmly’s indication marking on the filter bowl. If there is no marking indicating the presence of a filter element, notify assembly to correct the issue.

7.2.4 Connect test stand to power unit by attaching the high pressure hoses to the pump ports. Ensure that the A port will be the main working pressure port. If port B is used as the main working pressure port, this will need to be noted in the test report.

7.2.5 Connect the test motor’s drain hose to the “D” port on the power unit. If flushing is needed, connect the test motor’s flushing hose to the “F” port on the power unit.

7.2.6 Fill the reservoir through the quick disconnect coupling with oil specified in the project specifications or hydraulic schematic, through the designated oil transfer cart using 5-10 micron filter elements. Ensure that the filter elements in the transfer cart have been changed prior to using the transfer cart. Fill the reservoir to the top of the sight level gauge.

7.2.7 Verify that the suction lines are free of air.

All Goldcup Pumps and SP-40 to 180: Bleed air out the hose near the pump suction port.

SP-250 to 750: Bleed air out the hose near the pump suction port or use the MS port.

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7.2.8 Verify that the pump case is full of oil.

On Goldcup pumps, install a quick disconnect in the “D2” port and open the air bleed plug. Use the oil transfer cart on the quick disconnect and transfer oil into the case until oil emerges from the air bleed port.

Close the air bleed port and remove the transfer cart from the quick disconnect. The quick disconnect will be removed at the end of testing.

On SP pumps, open the “U” port and allow tank pressure to fill the pump case. If isolation check valves are installed on the pumps, then the isoloation check valves will need to be bypassed through the “T” port.

Alternatively, if case flushing is provided by an auxiliary pump, open the “air bleed plug” or “U” port and allow flushing to fill the pump case.

7.2.9 Ensure breather cap is installed into reservoir and is tight. Apply liquid thread lock on the threads where the breather cap screws into the reservoir, to be able to later verify that the breather cap has not been tampered with or removed in the field at the end of testing.

7.2.10 Ensure that the oil cooler is installed properly and is plumbed correctly. In the case of a water cooler, ensure that the water control valve (whether manual type or solenoid operated) is installed on the water inlet side of the cooler. In the case of an air cooler, ensure that the electric motor is the correct horsepower, voltage, and speed. If the motor was supplied with auxiliary components such as thermistors, space heaters, etc. verify that these are installed and wired according to the drawings if applicable. Record all auxiliary components onto the test report. In the case of either type cooler record all data from the cooler to the test report and in the case of an air cooler record the electric motor nameplate information into the test report.

7.2.11 In the case of an auxiliary circuit being supplied as an integral part of the main unit, a separate operational test must be performed for each auxiliary circuit. If an auxiliary circuit is provided then a separate specification, if necessary, should be provided with guidelines on the functions that need to be verified during the power unit test. The Project Engineer should write this document.

7.2.12 If the unit is fitted with an accumulator, the pre-charge pressure must be set according to the documentation and recorded in the test report. Verify that the accumulator is plumbed according to the hydraulic schematic and once it has been pre-charged it should be checked for gas leaks by using a soap solution on all of the gas fittings. Ensure that the warning tag with pre-charge value is installed on the accumulator after test is completed.

7.2.13 If a cooler vender does not flush and filter their coolers before arrival, connect a filter between the outlet of the cooler and the return to tank port on the power unit. Filtration is required to ensure any contaminants in the oil cooler do not enter the tank. Have the project engineer contact the cooler manufacture to see if the coolers are flushed before arrival.

7.3 Pre-Test Verification-Electrical

7.3.1 Conduct a point-to-point check of all wiring. Confirm terminal numbers correspond to those on the electrical schematics. Check that the correct gauge of wire was used.

7.3.2 If necessary, lubricate the electric motor drive end and non-drive end bearings with the grease/fluid recommended by the motor manufacturer to the appropriate level.

7.3.3 Connect the electric motor to the power source (motor starter switchgear) and check that the connection matches with what is required for the motor. If unsure about connection, check with Project Engineer prior to energizing the circuit. If the electric motor was supplied with auxiliary components such as thermistors, space heaters, etc. verify that these are installed and wired according to the drawings if applicable. Record all auxiliary components in the test report.

7.3.4 Confirm the electrical wiring in the unit is correct to the electrical drawings provided. Verify that they are properly installed and mounted to terminals, switches, plugs, etc. by pulling on each end. Check that all wires and terminals are marked and that marking corresponds to any special requirements in the Project Specification. Check that the correct gauge of wire was used.

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7.3.5 In the case of a Spider Control, Jupiter Control, or other type of control system being supplied as a loose item, this must be wired up to the unit to perform a full system check out.

7.3.6 If one of the above control systems is provided then it should have gone through a separate bench test prior to being connected to the power unit. In such case this does not eliminate the need to test and verify all functions of such control system. A separate specification, if necessary, should be provided with guidelines on the functions that need to be verified during the power unit test. The Project Engineer should write this document.

7.3.7 Check the oil level switches as the tank is being filled with oil. The switches should be wired Normally Open and close on rising oil level. The Min Oil Level switch should close first on rising level in the tank and the Low Oil Level switch after that.

7.3.8 Check and set the temperature switches according to the electrical drawings and project specification. The Oil Cooler Temperature switch is normally set at 105° F (40° C) and will close on rising temperature. The High Oil Temperature switch is normally set at 131° F (55° C) and will open on rising temperature. The Maximum Oil Temperature switch is normally set at 140° F (60° C) and will open on rising temperature. All switches contact status can be verified during the course of the test as the reservoir temperature rises. Once the Maximum Oil Temperature switch is verified the cooler should be turned on to allow the unit to cool back down to normal operating temperature (around 105° F).

7.3.9 Check the filter switch by making sure that the switch is normally closed at rest. Then remove the switch from the indicator and check function by inserting an activated pressure indicator in the switch to make sure the contact changes to an open condition.

7.3.10 Check the suction line switch has a closed contact when the suction valve is open and when the suction valve is closed the switch contact should be open.

7.3.11 Set the charge pressure switch to 150 psi on falling pressure. The contact should be open below 150 psi and closed above 150 psi. This switch should be set using hand pump and the set value should be set to the specified value ±10 psi. The lines should be bled of air prior to making any adjustments to the switch setting.

Once this switch has been set and contact status has been verified the values should be recorded in the test report. Confirm switch contact status of N.O. or N.C. is correct to the electrical schematic prints. If you have questions about something on the print, contact the Project Engineer. Once the switch is set, liquid thread lock should be applied on the adjusting nut of the pressure switch at the end of testing, if applicable, to be able to later verify that the switch has not been tampered with in the field.

7.3.12 Set the high pressure switch to the value specified on the hydraulic circuit. This switch should be set on rising pressure. The contact should be closed below the set value and open above the set value. This switch should be set using a hand pump and the switch should be set to the specified value ±25 psi. The lines should be bled of air prior to making any adjustments to the switch setting. Once this switch has been set and contact status has been verified the values should be recorded in the test report. Once the switch is set liquid thread lock should be applied on the adjusting nut of the pressure switch at the end of testing, if applicable, to be able to later verify that the switch has not been tampered with in the field.

7.3.13 If the unit is equipped with a high pressure transmitter verify that its range matches the specified values in the documentation and confirm with a hand pump. The lines should be bled of air prior to making any adjustments to the transmitter setting. Also the output should be verified using a multi-meter. The signal should be proportional to the applied pressure and should be checked at 0%, 25%, 50%, 75%, and 100% of the specified range. Record model and serial numbers from the transmitters into the test report along with the values obtained from the test.

7.3.14 Confirm reservoir heater is wired correctly and set at approximately 65° F unless otherwise indicated on the drawings. Testing consists of turning thermostat full clockwise and measuring resistance. Use the following equation to calculate the approximate Ohms reading and then turn thermostat counter clockwise until thermostat clicks, which should indicate “O” Ohms on the meter.

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7.3.15 If the unit is equipped with a water valve ensure that operating voltage of the solenoid matches what is called for on the drawings. Also verify that the valve is operational and is activated by the Oil Cooler temperature switch during the performance test.

7.3.16 If the unit is equipped with an air-oil cooler the electric motor should be connected to a motor starter switchgear and capable to run during the performance test to verify cooler performance. Verify that the direction of rotation is indicated on the cooler and if not advise Project Engineer.

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7.4 Operational Performance Test

7.4.1 All of the above conditions must have been satisfied prior to beginning the operational test.

7.4.2 Reduce the compensator relief valve to its minimum setting prior to starting the electric motor.

7.4.3 Suction valve on the reservoir must be open.

7.4.4 Jog the electric motor to determine that the pump will have proper rotation. Rotation is clockwise viewed from the hydraulic pump shaft end.

7.4.5 Once you have proper rotation, continue to jog at 3-5 second intervals until charge and servo pressure (Goldcup pump), or flushing and control pressure (SP pump) are present on gauges. At the same time you are jogging the electric motor, check for leaks on power unit. If all is satisfactory, then start unit and allow it to run. Remember there are no interlocks connected to stop the unit in case there is an oil leak.

7.4.6 Allow the unit to warm up to 105°F cooler temperature setting. Once unit reaches 105°F setting then water valve can be checked to make sure heat exchanger is working properly. If an air-oil cooler is used the only way to check heat exchanger is to monitor the Oil Cooler temperature switch.

7.4.7 For units that will operate at 1500 RPM see following equation to calculate oil flow during test.

Proceed to 7.4.7.1 for Goldcup Pumps

Proceed to 7.4.7.2 for SP Pumps

7.4.7 Operational Performance Test: Goldcup Pumps

7.4.7.1 Close the high pressure ball valves on the test stand and stroke the pump in both directions and observe that the pressure gauges for A port and B port on the pump are equal when returned to a null (zero) position. If pressures are not equal then the mechanical centering on servo control (Goldcup pump) will need to be centered. Refer to the pump manual for the procedure on centering the pump. After attempting to center the pump and the pump still cannot center, contact Project Engineer and Denison.

7.4.7.2 When checking equal pressures on A and B, pay particular attention to the charge pressure gauge.

7.4.7.3 Goldcup pumps have an internal charge pressure relief valve and an external charge pressure relief valve. The internal charge pressure relief valve pressure setting should be verified to the appropriate Hydraulic Schematic setting. To verify the setting of the internal charge relief valve increase the setting of the external charge relief until the charge pressure will no longer rise. Factory setting is 480 PSI. The internal relief should now be in operation. To verify that it is, stroke the pump to 50% command and by watching the charge pressure gauge the charge pressure should stay at the designated internal charge relief pressure setting on the hydraulic schematic ± 25 psi and then stroke the pump back to zero flow and the charge pressure should be at the same value. If this is not correct then the external relief is not set high enough. If the internal relief setting is below the specified value then the pump should be stopped and the internal relief should be removed and adjusted. Now back down the setting of the external relief valve to 300-325 psi when the pump is in neutral. The charge pressure at zero flow should be 300-325 PSI on the charge pressure gauge, and when pump is on stroke (at least 50%), charge pressure will go down to a setting of 200-225 PSI. When pump is returned to zero flow, the charge pressure will return to original setting of 300-325 PSI. Note: Verify external charge pressure relief is adjusted to match the setting specified in the documentation if it does not match the setting called out above. For shredder applications, the charge pressure should be set to 290 psi.

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7.4.7.4 With the unit now connected to the test stand and the high pressure ball valves open it is time to set the flows on the pump.

7.4.7.5 If centering is acceptable then the next step required is to give a + command signal and verify that a plus signal strokes the pump on A port. Once this is confirmed then proceed to give a higher command until the pump just comes on stroke. With a 1% input the minimum control current (gain) should be set to just have the pump start outputting flow. Next the input should be set to 100% and the maximum control current (gain) setting should be set to the appropriate value to obtain the flow called out in the documentation. Once the maximum flow is set return to zero flow to ensure that the pump is still centered. Record the current at the start of flow (Imin) and the current at full flow setting (Imax) on the test report. This same procedure should be followed by applying a negative input command, and setting the flow for the B port on the pump to the settings called out in the documentation.

7.4.7.5.1 Next the mechanical volume stops should be set to match the flows called out in the documentation (see Project Specifications) for both the A and B ports. Once stops are set, re-check the pump flows at 0%, 50%, and 100% to verify that the flow is proportional to the input command value. Record these flow values and the control current in the test report.

7.4.7.5.2 Next the unit should be allowed to run up to the maximum oil temperature switch (140° F) setting to check the unit for any leaks. Once this is done and all leaks have been fixed the cooler should be turned on and the unit allowed to cool back down to normal operating temperature of 105° F. If the cooler does not bring the temperature down within 20 to 30 minutes of starting the cooler, contact Project Engineer.

7.4.7.5.3 Next the compensator needs to be set on the pump to the value specified in the documentation. First the high pressure ball valves should be closed and a positive command given to the pump of approx. +25%. Adjust the compensator (see Project Specifications) and verify the setting by reading the by A port pressure gauge. Return the command to 0% and ensure the pump pressure on A and B port are equal again. Now apply a negative command signal and verify the compensator setting is at the same value on the B port pressure gauge. Note: servo pressure on a Goldcup will be at 550-600 psi when pump is compensated.

7.4.7.5.4 Once unit is set for correct charge pressure. Compensator, and flows the following pressures should be recorded on test report.

7.4.7.5.5 Charge and servo @ center. Pressure should be 300-325 psi for charge and 425-550 psi for servo.

7.4.7.5.6 Charge and servo @ normal full flow. Charge pressure should be 200-225 psi and servo 375-425 psi.