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The content of this publication are presented for information purposes only, and while effort has been made to ensure their accuracy, they are not to be construed
as warranties or guarantees, expressed or implied, regarding the products or services described herein or their use or applicability. All sales are governed by our
terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of our products at any time with-
out notice. Damcos A/S accepts no responsibility for any errors that may appear in this publication.
As each system may be configured for each delivery, the content and illustrations in this manual may differ from your system.

Copyright © Damcos A/S, 2017
Service Manual for LPU in English

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Summary of Contents for Damcos

Page 1: ...Service Manual Version SM 8000 1000 01 Ed 04 Release February 2017 Damcos Local Power Unit Service Manual ...

Page 2: ...licability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of our products at any time with out notice Damcos A S accepts no responsibility for any errors that may appear in this publication As each system may be configured for each delivery the content and illustrations in this manual may d...

Page 3: ... 27 Overview LPU S Ex ia 28 LPU D Overview 31 Overview LPU D 32 LPU D Ex Overview 35 Overview LPU D Ex 36 LPU D Ex ia Overview 39 Overview LPU D Ex ia 40 Troubleshooting Guide LPU 43 Fault Finding List LPU 45 LPU S frequently restarting in open position 47 Motor not running and is hot 49 Motor not running and is Cold 49 Motor not stopping 50 Pump rendering too low or no pressure in one or both dir...

Page 4: ...ing too slowly 61 Motor running for a short time and stops High pressure on the port to which oil is led 62 Motor running for a short time and stops 62 Motor diving in RPM in end position 63 Motor diving in RPM as spring actuator opens 63 Oil spillage generally 64 Oil in electronic connection box 64 Oil spillage from breather valve 64 Unit drawing too much current 65 Too little tank volume for ope...

Page 5: ... Solenoid Valve in LPU D 107 Replace pressure switch 109 LPU Technical Data 111 Technical Data 113 LPU Power Control System 119 LPU Power Control Description 121 Operation LPU S 123 Operating LPU D 124 LPU with LED Position Indicator 125 LPU P NET System 129 LPU P Net Description 131 PCB Diagram for Local Control 132 PCB Diagram for Stand Alone Unit 133 Hydraulic Hand Pump 135 Technical Data 137 H...

Page 6: ...Service Manual Damcos LPU Table of Contents SM 8000 100 01 Ed 04 February 2017 6 ...

Page 7: ...lot Operated Check Valve HP Hand Pump ISC Integrated Ship Control LPU Local Power Unit LPU D LPU for double acting actuator LPU S LPU for single acting spring operated actuator LPU Ex LPU approved for mounting in hazardous area PLC Programmable Logic Controller BB VPI Bulkhead mounted Valve Position Indicator VPI Valve Position Indicator ...

Page 8: ...Service Manual Damcos LPU Abbreviation and Denomination SM 8000 100 01 Ed 04 February 2017 8 ...

Page 9: ...Damcos LPU Safety Service Manual February 2017 SM 8000 100 01 Ed 04 9 Safety A description of issues concerning personal safety when handling Damcos TM VRC ...

Page 10: ...icates a potentially hazardous situation which if not avoided could result in death or serious injury Caution Indicates a potentially hazardous situation which if not avoided may result in prop erty damage Note Indicates important information regarding the product Warnings All personnel that handles Damcos LPU shall take part of and understand the following information prior to handling the system...

Page 11: ...Damcos LPU Safety Service Manual February 2017 SM 8000 100 01 Ed 04 11 ...

Page 12: ...Service Manual Damcos LPU Safety SM 8000 100 01 Ed 04 February 2017 12 ...

Page 13: ...eneral Service Instructions for LPU Service Manual February 2017 SM 8000 100 01 Ed 04 13 General Service Instructions for LPU This Chapter Describes the General Requirements and Service Recommendations for the LPU ...

Page 14: ...ersonnel Note Read Safety chapter before handling any equipment Bleeder valve positions on LPU It is extremely important that bleeder valve position is correctly chosen when mounting LPU with actuator on pipe Other positions are plugged when not used This is normally done at installation Note The choice of bleeder valve position is always selected at the highest point on LPU or actu ator tank For ...

Page 15: ...Damcos LPU General Service Instructions for LPU Service Manual February 2017 SM 8000 100 01 Ed 04 15 LPU D and LPU S on KF KFR Bleed valve positions LPU S on BRCF Bleed valve positions ...

Page 16: ...ned to be controlled by two electrically different types of controls Power controlled P NET bus controlled The LPU can also be used as a stand alone system LPU with an LED Position Indicator LPU except the Ex version with an IP 68 LED indicator showing clear RED or GREEN light when the valve is CLOSED respectively OPEN is available in Power controlled and P NET controlled LPU systems This may espe...

Page 17: ...bulk head mounted LPU Note If bulk head mounted Oil level must be checked before starting up the LPU LPU must be placed with motor pointing down and breather valve on top short suction pipe recommend The LPU may be emergency operated as if mounted direct on actuator Properly de airing via quick connections on the LPU ...

Page 18: ...Service Manual Damcos LPU General Service Instructions for LPU SM 8000 100 01 Ed 04 February 2017 18 ...

Page 19: ...Damcos LPU LPU S Overview Service Manual February 2017 SM 8000 100 01 Ed 04 19 LPU S Overview This Chapter Describes the LPU S with Overview and Handling Instructions ...

Page 20: ... Overview LPU S LPU S Front View Emergency Operation See Emergency Operation of LPU V 2 on page 77 How to Operate the LPU S See Operating LPU S 2 on page 73 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 ...

Page 21: ...Damcos LPU LPU S Overview Service Manual February 2017 SM 8000 100 01 Ed 04 21 LPU S Top View with top cover made partly transparent LPU S Bottom View ...

Page 22: ...Service Manual Damcos LPU LPU S Overview SM 8000 100 01 Ed 04 February 2017 22 ...

Page 23: ...Damcos LPU LPU S Ex Overview Service Manual February 2017 SM 8000 100 01 Ed 04 23 LPU S Ex Overview This Chapter Describes the LPU S Ex with Overview and Handling Instructions ...

Page 24: ...mergency Operation See Emergency Operation of LPU V 2 on page 77 How to Operate the LPU S Ex See Operating LPU S 2 on page 73 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 Cable Glands See Cable Gland on page 116 Cable See Cables on page 116 ...

Page 25: ...Damcos LPU LPU S Ex Overview Service Manual February 2017 SM 8000 100 01 Ed 04 25 LPU S Top View with top cover made partly transparent LPU S Bottom View ...

Page 26: ...Service Manual Damcos LPU LPU S Ex Overview SM 8000 100 01 Ed 04 February 2017 26 ...

Page 27: ...Damcos LPU LPU S Ex ia Overview Service Manual February 2017 SM 8000 100 01 Ed 04 27 LPU S Ex ia Overview This Chapter Describes the LPU S Ex ia with Overview and Handling Instructions ...

Page 28: ... See Emergency Operation of LPU V 2 on page 77 How to Operate the LPU S See Operating LPU S 2 on page 73 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 Cable Glands See Cable gland LPU Ex and LPU Ex ia on page 116 Zener barrier See Zener barrier LPU Ex ia on page 117 ...

Page 29: ...Damcos LPU LPU S Ex ia Overview Service Manual February 2017 SM 8000 100 01 Ed 04 29 LPU S Ex ia Top View with top cover made partly transparent LPU S Bottom View ...

Page 30: ...Service Manual Damcos LPU LPU S Ex ia Overview SM 8000 100 01 Ed 04 February 2017 30 ...

Page 31: ...Damcos LPU LPU D Overview Service Manual February 2017 SM 8000 100 01 Ed 04 31 LPU D Overview This Chapter Describes the LPU D with Overview and Handling Instructions ...

Page 32: ...Overview LPU D LPU D Front View Emergency Operation See Emergency Operation of LPU V 2 on page 77 How to Operate the LPU D See Operating LPU D 2a on page 75 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 ...

Page 33: ...mcos LPU LPU D Overview Service Manual February 2017 SM 8000 100 01 Ed 04 33 LPU D Top View with top cover made partly transparent Pressure switch is not present in all versions of LPU D LPU D Bottom View ...

Page 34: ...Service Manual Damcos LPU LPU D Overview SM 8000 100 01 Ed 04 February 2017 34 ...

Page 35: ...Damcos LPU LPU D Ex Overview Service Manual February 2017 SM 8000 100 01 Ed 04 35 LPU D Ex Overview This Chapter Describes the LPU D EX with Overview and Handling Instructions ...

Page 36: ...Emergency Operation See Emergency Operation of LPU V 2 on page 77 How to Operate the LPU D See Operating LPU D 2a on page 75 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 Cable Glands See Cable Gland on page 116 Cable See Cables on page 116 ...

Page 37: ...Damcos LPU LPU D Ex Overview Service Manual February 2017 SM 8000 100 01 Ed 04 37 LPU D Top View with top cover made partly transparent LPU D Bottom View ...

Page 38: ...Service Manual Damcos LPU LPU D Ex Overview SM 8000 100 01 Ed 04 February 2017 38 ...

Page 39: ...Damcos LPU LPU D Ex ia Overview Service Manual February 2017 SM 8000 100 01 Ed 04 39 LPU D Ex ia Overview This Chapter Describes the LPU D Ex ia with Overview and Handling Instructions ...

Page 40: ...Emergency Operation of LPU V 2 on page 77 How to Operate the LPU D See Operating LPU D 2a on page 75 Fault Finding See Troubleshooting Guide LPU on page 43 Technical Data For technical data see LPU Technical Data on page 111 Cable Glands See Cable Gland on page 116 Cable See Cables on page 116 Zener barrier See Zener barrier LPU Ex ia on page 117 ...

Page 41: ...Damcos LPU LPU D Ex ia Overview Service Manual February 2017 SM 8000 100 01 Ed 04 41 LPU D Top View with top cover made partly transparent LPU D Bottom View ...

Page 42: ...Service Manual Damcos LPU LPU D Ex ia Overview SM 8000 100 01 Ed 04 February 2017 42 ...

Page 43: ...Damcos LPU Troubleshooting Guide LPU Service Manual February 2017 SM 8000 100 01 Ed 04 43 Troubleshooting Guide LPU This Chapter Describes how to Identify and Correct minor Problems for LPU ...

Page 44: ...Service Manual Damcos LPU Troubleshooting Guide LPU SM 8000 100 01 Ed 04 February 2017 44 ...

Page 45: ... by hand pump not possible on page 60 Spring actuator do not close by emergency hand pump operation on page 69 LPU D LPU D not maintaining pressure on actuator on page 57 LPU Ex LPU Ex motor do not run on page 70 LPU Ex has to be bulkhead mounted because of too little space or zone 0 at actuator on page 71 LPU S LPU S frequently restarting in open position on page 47 MOTOR LPU Ex motor do not run ...

Page 46: ...e 55 Noise from pump at both high and low pressure on page 55 Pump not rendering sufficient oil at high pressure valve running too slowly on page 61 Pump not rendering sufficient oil at low pressure valve running too slowly on page 61 PRESSURE Pump rendering too low or no pressure in one or both directions on page 51 LPU D not maintaining pressure on actuator on page 57 LPU cannot raise pressure a...

Page 47: ...check valve in valve block Check for leakage in solenoid valve Check valve in valve block for external leakage e g at pressure switch or closing speed adjust ment Check for external leakage and if no leakage is found replace solenoid valve or check valve Pressure drops Leakage in bypass valve at actuator release valve shuttle valve emergency valve or actuator Check o rings on emergency slide and s...

Page 48: ...t Leakage in solenoid valve quick connection B or external leakage e g at pressure switch Possi bly too low adjusted pressure at pump relief valve pump safety valve Check for external leakage if no leakage adjust pump pressure see Pump pressure adjust ment for LPU on page 85 If this cannot be adjusted any higher check internal sealings and flow reducing valve opening speed adjustment Replace solen...

Page 49: ...ive pump should be found e g insufficient quantity of oil no stop of motor impurities in oil etc Note For LPU Ex the temperature cut off box might have interrupted power to motor due to too high motor temperature If this is the case the motor needs time to cool down then 24 V to LPU Ex is interrupted for 10 seconds and LPU Ex should be ready to run again Motor not running and is Cold Action Check ...

Page 50: ... between 95 to 105 bar Adjust and if necessary replace pressure switches see Replace pressure switch on page 109 LPU D P Net If motor does not stop at all the printed circuit board must be replaced see Replace Printed Circuit Board on page 105 If the motor runs longer than normal but then stops the fault should be found in the position indica tor the calibration of the analogue indicator or setup ...

Page 51: ...at by pass for tank filling in front of LPU is closed LPU Power Check that power supply is connected to terminal open and that terminal close is not connected If pressure remains constantly low At too low pressure in one direction LPU S or both directions LPU D the safety valve is adjusted according to instruction see Pump pressure adjustment for LPU on page 85 If higher pressure cannot be obtaine...

Page 52: ... solenoid valve does not work the resistance of the coil is measured LPU D The coil must have a resistance of approximate 520 for LPU D Due to a diode bridge resis tance cannot be measured for LPU S coil Another way to check the coil is to loosen it and try to lift the coil when energized If coil does not work it is replaced If coil works the valve is to be replaced See Replace Solenoid Valve in L...

Page 53: ...is pow ered and working and that free travel of solenoid valve slide is OK LPU S If actuator can close but not open see Pump rendering too low or no pressure in one or both direc tions on page 51 If actuator can open but not close see Spring actuator only partly closing or not starting to close on page 58 Note BRCF and KF can always be closed by opening bypass valve at actuator KFR can be closed o...

Page 54: ...hand Then if Sound disappears Too low compression of O ring on motor shaft so that rotor is vibrating on coupling Replace O ring Sound is unchanged A pump piston is operating too tightly and does not follow the ball bearing curve during move ment At relatively high pressure it is pressed out hydraulically The sound can disappear at start ing up Otherwise pump is dismounted and pistons and rotor ar...

Page 55: ...e sound can disappear at start ing up Otherwise pump is dismounted and pistons and rotor are checked for coverings or burrs Note If pump rotor has to be replaced the stator version has to be checked check placement and number of expanding plugs If stator versions are different both rotor and stator must be exchanged complete pump set see Replace Pump in LPU on page 93 Noise from pump at both high ...

Page 56: ...he required voltage the voltage must be modified Measure the resistance over the motor windings on the terminal easiest with disconnected capacitor There must be approximately 15 between N and OPEN and CLOSE respec tively If this resistance is not observed the motor is to be replaced The mechanical resistance of the motor can be too high If it cannot be turned easily with the fingers it is to be r...

Page 57: ...age in check valves for DPCV or release valve Change check valves for DPCV A leakage in actuator might give pressure drop on only one port Replace the seal set in actuator with a new one Pressure drops on both ports Leakage in bypass valve actuator or actuator Check bypass valve possibly replace release valve see Replace release valve in LPU on page 99 Check actuator ...

Page 58: ...at opening and closing command by remote operation for LPU If closing does not function check that the power for the solenoid valve is turned off If not check relay in control cabinet power controlled with separately connected solenoid valve or on printed circuit board P Net Else remove coil from solenoid valve Check filter below pressure switch valve must be closed Adjust closing speed valve to f...

Page 59: ...by key not possible hydraulically locked Reason Bypass not active or bypass valve is blocked Action Open bypass valve and keep it opened during emergency operation If emergency operation is still locked bypass valve is to be dismounted and checked If bore contains dirt it has to be removed Emergency operation by hand pump giving oil spillage through breather valve Reason Tank pressure in LPU is to...

Page 60: ... so that change over to emergency operation cannot take place LPU S Outlet from actuator blocked so that return oil cannot pass Fault on quick connections so that check valve in hand pump quick connection is not open ing Hand pump is pumping oil but cannot build up pressure Leakage in DPCV LPU D bypass valve release valve emergency valve LPU S or actuator After a few strokes hand pump is not pumpi...

Page 61: ...speed adjustment is loosened by a 19 mm wrench must be turned maximum 3 turns as there is full pump pressure below housing until airless oil is running from it Then valve housing is tightened and pump flow is checked again If pump flow is still not OK dismount adjusting screw for speed control check with a screw driver that the ball bearing behind this can be moved back and forth by press ing it C...

Page 62: ...tor is not moving or is hardly moving Operating pressure for actuator too high due to blocking in return could be dirt in holes near the port surface or in actuator Fault in actuator valve requires a too high torque or more than 7 seconds before breaking away from the seat or choice of actuator for the valve in question Motor running for a short time and stops Reason Pressure switch does not break...

Page 63: ...the fault is to be found here Take corrective measures LPU can operate down to 185V at 60 Hz but such a low voltage is an indication of something being wrong Check connection of motor Check connection of capacitor Check the maximum pressure connect a pressure gauge to the quick connection pressurised Possibly adjust relief valve to 150 bar Dismount adjusting screw for speed control check with a sc...

Page 64: ...llage from breather valve Oil spillage at emergency operation see Emergency operation by key giving oil spillage through breather valve on page 59 or Emergency operation by hand pump giving oil spillage through breather valve on page 59 Oil spillage during operation when motor is changing direction Compressed air in actuator Actuator is to be de aired Especially linear actuators KC KF and KFR may ...

Page 65: ...awing too much current Reason Mechanical resistance in motor Mechanical resistance in pump Too small winding resistance in motor meaning a 110 V motor has been used instead of 230 V motor Too high or too low supply voltage Too low frequency Faulty electrical connection of motor Defective capacitor ...

Page 66: ...n expansion tank at LPU Expansion tank at hand pump is not allowed as it gives risk of oil spillage at breather valve LPU S No connection from LPU tank and hand pump tank to actuator tank spring chamber Hand pump tank and LPU tank need tank connection to actuator to maintain constant oil volume in system for mix of emergency and remote operation For large actuators Oil compression by pressurizing ...

Page 67: ...eason Leakage from LPU to hand pump Portable hand pump must be disconnected Make sure that by pass at possible bulkhead hand pump is closed Try to operate valve in the selected direction by hand pump first then by LPU If LPU can raise pressure now the DPCV valve slide has too high friction If problem is not solved DPCV is leak ing due to defect non return valve or slide is sticking ...

Page 68: ... free T flow is essential for function of hand pump For LPU D At remote operating LPU is compressing oil in piping for hand pump or when bulkhead mounted LPU for actuator The oil volume needed for compressing this oil is depending on oil volume in pipes and proper de airing This oil volume will be taken from hand pump tank and cannot be returned because of DPCV in hand pump If de airing of piping ...

Page 69: ...by changing bulkhead hand pump to close as there will be no pressure rise to open the DPCV Close actuator through by pass valve at hand pump or actuator instead Close by pass valve when the actuator is fully closed For KFR If KFR is emergency opened at the actuator an opening operation followed by closing the actuator is necessary Opening operation can be made by hand pump or remote control ...

Page 70: ...n Reason LPU Ex motors contain temperature sensors that have to be reset manually After motor cut off by temperature sensors they have to be reset by turning off 24 V power for at least 10 sec If this don t solve the problem see Motor not running and is hot on page 49 and Motor not run ning and is Cold on page 49 ...

Page 71: ...by means of BB block or BB VPI but then needs an intrinsically safe position indicator All LPU Ex can be delivered with integrated intrinsically safe outlet for position indicator ia to solve the problem Note For LPU Ex with ia outlet the hole for DPI in LPU must contain a special plug to ensure that flameproof enclosure of LPU Ex is maintained This plug is delivered with ia parts and must always ...

Page 72: ...o the relevant instruction Analogue position indicator not functioning correctly For power controlled LPU Check supply voltage at 4 20 mA transmitter which has to be 15 27 VDC Disconnect the wires from the position indicator Check the adjustment of the potentiometer and possibly re adjust the indicator according to the relevant instruction Check the function of the potentiometer measured on the in...

Page 73: ...l not cause any problems because of the safety valve 6 which will open at approximately 225 bar To stop valve in intermediate position The valve can be stopped and hydraulically locked in any intermediate position simply by de ener gizing the motor If the pressure drops while valve is fully open due to a minor leakage in the solenoid valve or due to temperature variations the pressure switch 12 wi...

Page 74: ...ing the open posi tion This may take place automatically Close valve To move the valve towards closed the solenoid valve is de energized The springs then move the actuator pressing the oil back from the actuator B port through the throttle valve 11 and the sole noid valve 14 to the LPU tank Note For power controlled LPU please see also Operation LPU S on page 123 ...

Page 75: ...il flows back to tank The motor and the solenoid valve are then de energized The actuator is now hydraulically locked in position by the pilot operated check valves Safety Actuator relief valve In case of a major rise in temperature the pressure may rise This will not cause any problems because of the actuator relief valve 6 and 11 which will open at approx 225 bar 1 Tank for hydraulic oil 2 Sucti...

Page 76: ...follows exact the same procedure except that the solenoid valve is not activated which causes the ports A and B to be reversed When the motor is running the direction of oil flow is solely determined by the activation of the sole noid valve Note For power controlled LPU please see also Operating LPU D on page 124 ...

Page 77: ...stem again Note For LPUv 2 emergency operation with hydraulic hand pump a hand pump unit with reser voir can be used To avoid overfilling of the LPU both quick connections have to be mounted Note To close emergency opened actuator by remote open the actuator first to release shuttle valve and then close LPU with LED Position Indicator LPU except Ex version with IP 68 LED indicator will show clear ...

Page 78: ...and pump until the valve has reached the desired position Then close by pass valve again 2 If the actuator has been opened by remote control and power is still on the keep open func tion is activated and the LPU may start up trying to keep the actuator open You have to discon nect power or remove open command before manual operation is started The valve will now stay in position until operated wit...

Page 79: ...tuators that can be opened by emergency operation actuator BRC 125 BRC 500 1 Open the crossover valve by turning counter clockwise 2 Use the emergency operation key on the actuator 3 Open by pass valve at the actuator and turn the key counter clockwise to open valve and clockwise to close valve 4 After emergency operation by key the crossover valve is closed ...

Page 80: ...ion at the LPU 2 Connect hand pump T line with A line quick connection at the LPU 3 Operate hand pump and actuator will open 4 Disconnect hand pump Emergency closing of double acting actuator with hand pump 1 Connect hand pump P line with A line quick connection at the LPU 2 Connect hand pump T line with B line quick connection at the LPU 3 Operate hand pump and actuator will close 4 Disconnect ha...

Page 81: ...U With suction to T and pressure to B the shuttle valve will change over and prevents the oil from flowing to tank 3 Operate hand pump and actuator will open 4 Disconnect hand pump Emergency closing of single acting fail close actuator 1 Open cross over valve on actuator and let it stay open until the required position is reached 2 When the valve is fully closed the shuttle valve will be reset Eme...

Page 82: ...Service Manual Damcos LPU Emergency Operation of LPU V 2 SM 8000 100 01 Ed 04 February 2017 82 ...

Page 83: ...the screw counterclockwise it runs faster If the actuator has to run with maximum or minimum speed the adjustment screw shall only be tightened slightly max 1 5 Nm Speed adjustment for single acting actuators Opening and closing speed will be adjusted by means of a 3 mm Allen key see picture below where to adjust By turning the screw clockwise fasten screw the actuator will run slower turning the ...

Page 84: ...Service Manual Damcos LPU Speed adjustment for Actuator on LPU v 2 SM 8000 100 01 Ed 04 February 2017 84 ...

Page 85: ... at the actuator Tightening the screw will rise the pressure loosening the screw will lower the adjusted pressure 4 For Power controlled LPU To obtain a longer operating time of the motor than standard 7 sec onds the pressure switch cables to the specific pressure switch for B it is the pressure switch near the pressure adjustment can possibly be dismounted from the print These lines are from prin...

Page 86: ...Service Manual Damcos LPU Pump pressure adjustment for LPU SM 8000 100 01 Ed 04 February 2017 86 ...

Page 87: ... done when needed Refill of oil should also be done when parts are changed in LPU or if LPU starts to make special noises at operation The LPU seen from above and below Recommended refill oil Use an hydraulic oil as specified for the system The LPU is normally pre filled with Shell Tellus T S2 V 32 for deck mounting Shell Tellus S4 VX ...

Page 88: ...oil filling with hand pump on page 90 alt LPU D hand pump filling Open stop valve at front of LPU and apply pressure from hand pump directly to B quick connection Close stop valve after filling See LPU D Oil Filling Instruction with hand pump on page 91 5 Remount the breather valve LPU with pressurised reservoir 1 Oil level is controlled by measuring the distance from cap to piston with closed or ...

Page 89: ...bruary 2017 SM 8000 100 01 Ed 04 89 LPU with permanently mounted hand pump If the LPU is mounted with a permanently mounted hand pump the oil level control has to be done in the LPU and in the hand pump as malfunction is possible in an empty hand pump ...

Page 90: ... Apply oil to T port until oil is just about to pour out of BRCF spring chamber 7 Remount breather valve plug in BRCF 8 Disconnect hand pump 9 Open close actuator a few times by remote control Note For LPU S do not operate the directional slide of hand pump to release pressure The oil inside actuator will flow back to hand pump but oil will not flow from hand pump to tank line of actuator Thus oil...

Page 91: ... actuator fully 2 Connect the hand pump pressure hose B to quick connection B open 3 Open the tank filling valve 4 Pump the hand pump to fill the LPU reservoir and stop pumping when the oil is pouring out of the breather valve breather valve tank filling valve quick connection B OPEN breather valve tank filling valve quick connection B OPEN ...

Page 92: ...Service Manual Damcos LPU Refill of Oil in LPU SM 8000 100 01 Ed 04 February 2017 92 ...

Page 93: ...top valves for hand pump if mounted in system Replace Pump in LPU 1 Oil tank is emptied by removing plug at bottom of tank or valve block 2 Remove 4 pcs M8 screw and remove the tank 3 Valve block with pump is removed from LPU 4 Remove suction pipe from valve block by means of Allen key 5 Press out the pump stator through suction pipe hole 6 Remove the rotor cont ...

Page 94: ...g tool 9 Check the height of stator Stator is pressed until extension above valve block surface is 19 mm This should correlate with the height of mounting tool as of point 8 10 Check suction pipe filter for contamination If nec essary clean the filter Mount the suction pipe 11 Rotor with pistons is placed on stator or in LPU block depending on mounting direction of LPU Rotor coupling must be place...

Page 95: ... mounted on LPU 15 Fasten suction pipe 16 Mount the filter on suction pipe 17 Mount tank Screws are cross tightened 18 Refill with clean oil See Refill of Oil in LPU on page 87 19 Open actuator by pass and start pump for 10 15 sec By passing the actuator ensures de airing of the pump 20 Control oil level if necessary replenish Close by pass valve and run a full open close cycle if possible Check o...

Page 96: ...Service Manual Damcos LPU Replace Pump in LPU SM 8000 100 01 Ed 04 February 2017 96 ...

Page 97: ...l February 2017 SM 8000 100 01 Ed 04 97 Replace DPCV in LPU Replace DPCV in LPU 1 Remove plug 2 Use the correct tool or an M2 screw 3 Dismount NRV front 4 Dismount NRV back 5 Remove slide and spring 6 Old DPCV New DPCV 7 Mount new DPCV cont 2 pcs ...

Page 98: ...Service Manual Damcos LPU Replace DPCV in LPU SM 8000 100 01 Ed 04 February 2017 98 8 Mount NRV back 9 Mount plug at back 10 Mount NRV in front 11 Mount plug in front Replace DPCV in LPU ...

Page 99: ... 01 Ed 04 99 Replace release valve in LPU Replace release valve in LPU 1 Remove plug 2 Use the correct tool or an M2 screw 3 Remove release valve Note that LPU D has two release valves check drawings for exact positions 4 Change the valve 5 Use tool to mount the valve 6 Mount plug ...

Page 100: ...Service Manual Damcos LPU Replace release valve in LPU SM 8000 100 01 Ed 04 February 2017 100 ...

Page 101: ...ower before changing the circuit board Replace Circuit Board in LPU 1 Replace the P net LPU circuit board See Replace Printed Circuit Board on page 105 Write down the S N of the new circuit board 2 Go to the computer and switch to Project 3 10 using the keyboard press ALT and TAB and then select Project 3 10 The window as of point 3 below should be opened 3 ...

Page 102: ...rk offline This will set the system online 7 Select the LPU valve where the P net LPU circuit board has been replaced 8 Double click on the Service Channel 9 Type in the S N from the new P net circuit board and the select Store and OK 10 Right click on the valve name and then select Store This will download the setting for the LPU 11 The LPU should now work again Replace Circuit Board in LPU ...

Page 103: ... Setup New P net LPU Circuit Board in VIEW ver 3 16 1 Replace the P net LPU circuit board See Replace Printed Circuit Board on page 105 Write down the S N of the new circuit board Go to the computer and select Status Note The following procedure should be carried out on one computer only 2 The following window should be opened 3 In the Node status window browse to the faulty module A fault will be...

Page 104: ...should appear 5 Type in the serial number which is found on the new spare P net LPU circuit board For the P net LPU circuit board the serial number must be fol lowed by PD The spare PNetNo is 0 6 Press OK and if the old module have been replaced then select Yes in the next dialog 7 Now the LPU should work again from the worksta tion Setup New P net LPU Circuit Board in VIEW ver 3 16 ...

Page 105: ...05 Replace Printed Circuit Board Warning Disconnect the power before changing the circuit board Replace Circuit Board in LPU 1 Remove cover 2 Disconnect cable with wire 3 Remove screws 4 Remove plug 5 Remove circuit board 6 Mount the new circuit board 7 Connect cable and wire 8 Mount the cover ...

Page 106: ...Service Manual Damcos LPU Replace Printed Circuit Board SM 8000 100 01 Ed 04 February 2017 106 ...

Page 107: ...lenoid Valve in LPU D Warning Disconnect the power before changing the solenoid valve Replace Solenoid Valve in LPU D 1 Remove cover 2 Remove screw 3 Dismount coil 4 Dismount cover 5 Mount new slide and bushing 6 Make sure that the slide can move easily up and down 7 Mount cover coil and screw 8 Mount cover ...

Page 108: ...Service Manual Damcos LPU Replace Solenoid Valve in LPU D SM 8000 100 01 Ed 04 February 2017 108 ...

Page 109: ... Warning Disconnect the power before changing the pressure switch Replace Pressure Switch in LPU S 1 Remove cover 2 Disconnect wires 3 Loosen pressure switch with correct tool 4 Remove the pressure switch 5 Mount the new pressure switch 6 Fasten pressure switch with correct tool 7 Mount the wire 8 Mount the cover ...

Page 110: ...Service Manual Damcos LPU Replace pressure switch SM 8000 100 01 Ed 04 February 2017 110 ...

Page 111: ...Damcos LPU LPU Technical Data Service Manual February 2017 SM 8000 100 01 Ed 04 111 LPU Technical Data This Chapter Describes the Local Power Unit with Technical Data ...

Page 112: ...Service Manual Damcos LPU LPU Technical Data SM 8000 100 01 Ed 04 February 2017 112 ...

Page 113: ... be built up until necessary running torque is obtained 25 bar Valve begins to open and only running torque is required from the LPU pressure is reduced to 25 bar Valve begins to touch the valve disc and more pressure torque is required LPU starts building up pressure to the reset torque 67 bar Pressure is 25 bar during running of the valve Pressure builds up to 67 bar and valve starts end closing...

Page 114: ...ould always be equipped with a Pressure tank Actuator type Oil displacement Min operating time sec open close for LPU D ml 50 Hz 60 Hz BRC 125 26 1 6 1 3 BRC 250 50 3 0 2 5 BRC 500 102 6 1 5 1 BRC 1000 209 13 10 BRC 2000 400 24 20 BRC 4000 800 48 40 BRC 8000 1600 96 80 BRC 16000 3100 186 154 KC 65 21 1 35 1 1 KC 125 82 4 9 4 1 KC 250 428 25 6 21 2 KC 325 793 48 40 KC 400 1700 102 85 Actuator type ...

Page 115: ...metal switch Working pressure 135 bar Relief valve cracking pressure 150 bar Safety valve pressure 210 40 bar Max running time Up to 10 minutes dependent on ambient temperature Enclosure rating IP 68 3 bar in 24 hours Test pressure 225 bar Ambient temperature 5 C to 70 C 25 C to 70 C on request Tank volume utility volume approx 300 ml 120 ml Weight 18 kg 230 V AC 110 V AC Power supply 230 V AC 50 ...

Page 116: ...PU Ex and LPU Ex ia Electrical housing and tank Cast iron Slides etc Steel Screws sign plate rivets and bracket Stainless steel Seals NBR PTFE Cable glands Brass nickel Hydraulic blocks Nodular cast iron Application Thread No Min cable ø Max cable ø Screen IP Note P Net Control 230 V M20x1 5 2 8 15 no 68 P NET M25x1 5 2 13 16 yes 68 Power Control 230 V M25x1 5 1 12 20 no 68 Alternative and additio...

Page 117: ...a Service Manual February 2017 SM 8000 100 01 Ed 04 117 Zener barrier LPU Ex ia The internal zener barrier is built in in the top cover and holds an Ex d cable gland The 24 VDC power supply to the LPU must be connected 0 to ground ...

Page 118: ...Service Manual Damcos LPU LPU Technical Data SM 8000 100 01 Ed 04 February 2017 118 ...

Page 119: ...Damcos LPU LPU Power Control System Service Manual February 2017 SM 8000 100 01 Ed 04 119 LPU Power Control System This Chapter describes LPU Power Control System and Technical Data ...

Page 120: ...Service Manual Damcos LPU LPU Power Control System SM 8000 100 01 Ed 04 February 2017 120 ...

Page 121: ...directly to the substation Position Indication Signals The position indicator is built into the pump block with internal wiring from position indicator to the circuit board mounted in the LPU electrical encapsulation Potentiometer for analogue position indication or 2 micro switches for end position indication are available For analogue position indication signals two wires are required For ON OFF...

Page 122: ...100 01 Ed 04 February 2017 122 Electrical Specification This unit has to be controlled directly with 115 V AC or 230V AC 50 or 60 Hz A cable e g 7 x 1 5 mm containing motor control and position indicator signal is drawn from the control cabinet to each LPU unit ...

Page 123: ... the spring closing actuator to close the valve This may be used as a fail safe function If the control system is built up so that the LPU open terminal is energized whenever the valve is to be open An interruption in the power supply will cause the LPU motor to restart as soon as the power is reconnected This will be avoided by defining the system so that only the solenoid valve is energized If t...

Page 124: ...t operated check valve preventing the oil from flowing back into the tank If you wish to obtain intermediate positions the motor and the solenoid valve are simply de ener gized when the required position has been reached Note To prevent automatic restart after blackout it is recommended to take away the power for 30 seconds after the valve has reached end position Electrical LPU D The motor pump s...

Page 125: ...C connected to the com mon anode of the LED From customer specified output Note Under all circumstances 24VDC power to the LED must be available in LPU Diagrams for Power Controlled LPU with LED Position Indicator Option 1 PD527 controlled power LPU with LED indicator 1 0 6 9999 7 7 0 999 9999 6 6 7 308 308 065 9999 7 065 7 04 01 4 04 04 N 04 01 01 01 3 0 0 0 139 9 7 Y NNÞ JHI PX JHI PX MPTFE 3FE ...

Page 126: ...MPTFE 3FE MJHIU 16 108 3 0 530 0 04 01 0 0503 7 7 7 7 3 56 503 03 6 06 5 3 3 16 6 5 16 07 3 JHI 7 PX 7 139 9 7 Y NNÞ 3 3 8 3 3 8 3 3 8 3 1 0QFO SFFO MJHIU 1 7BMWF 1PT 503 06 5 0 5 56 503 0 04 7 01 7 95 3 16 0 530 0 01 165 04 7 0 0 0 139 9 7 Y NNÞ JHI PX JHI PX 05 0 5 5 4 0 08 165 0 5 3 MPTFE 3FE MJHIU 16 108 3 0 530 0 04 01 0 0503 7 7 7 7 1 56 503 03 6 06 5 3 3 16 6 5 16 07 3 JHI 7 PX 7 139 9 7 Y ...

Page 127: ...n 4 External controlled power LPU with LED indicator 04 7 01 7 95 3 16 0 530 0 N N 0 7 0 139 9 7 Y NNÞ N N MPTFE 3FE MJHIU N 0 0503 7 7 7 108 3 0 530 0 16 56 503 03 6 06 5 3 3 16 6 5 16 07 3 04 7BMWF 1PT 01 7BMWF 1PT 139 9 7 Y NNÞ 04 8 1 3 01 0QFO SFFO MJHIU 1 3 3 08 7BMWF 1PT 503 06 5 0 5 56 503 ...

Page 128: ...Service Manual Damcos LPU LPU Power Control System SM 8000 100 01 Ed 04 February 2017 128 ...

Page 129: ...Damcos LPU LPU P NET System Service Manual February 2017 SM 8000 100 01 Ed 04 129 LPU P NET System This chapter describes P NET LPU system and Technical Data ...

Page 130: ...Service Manual Damcos LPU LPU P NET System SM 8000 100 01 Ed 04 February 2017 130 ...

Page 131: ...trol of the LPU which is never overloaded Position Indication Input Signals The position indicator is built into the pump block with internal wiring from position indicator to the circuit board mounted in the LPU electrical encapsulation except for KFR Potentiometer for ana logue position indication or 2 micro switches for end position indication are available The P NET LPU is to be configured eit...

Page 132: ...workstations it is possible to check whether the LPU is locally operated either by internal or by the external push buttons It is possible to have an alarm indication activated when the LPU is locally operated L L N N LPU 4 20mA Closed feed back Open feed back Common feed back Common command Close command Open command 230 V AC P NET B Gnd P NET A B 24 V DC Gnd A 24 V DC Close 7 1 2 5 3 4 6 13 8 10...

Page 133: ... 24 V DC I O can be used directly i e from PLC P NET is applied in connection with end testing for configuration and test only Control follows by means of voltage inputs Position feedback signal from relay outputs or a 4 20 mA transmitter N L L N LPU Gnd Open feed back Common feed back Closed feed back Common command Close command Open command 230 V AC 4 20mA P NET A P NET B 24 V DC B Gnd A 24 V D...

Page 134: ...Service Manual Damcos LPU LPU P NET System SM 8000 100 01 Ed 04 February 2017 134 ...

Page 135: ...Damcos LPU Hydraulic Hand Pump Service Manual February 2017 SM 8000 100 01 Ed 04 135 Hydraulic Hand Pump This Chapter Describes the Hydraulic Hand Pump with Technical Data ...

Page 136: ...Service Manual Damcos LPU Hydraulic Hand Pump SM 8000 100 01 Ed 04 February 2017 136 ...

Page 137: ...25 bar Maximum hand pump pressure 135 bar Weight without oil 4 3 kg BRC F KF version 5 kg KC version Oil displacement per double stroke 8 cm3 Oil viscosity range From 15 to 200 cSt Temperature range From 25o to 80o C Recommended oil filtration ISO Solid contaminant code 18 15 or NAS 160 10 Housing Cover Brass Spindle Piston Brass Valves Brass Screws Sign plate Rivet Stainless steel Sealings NBR Ac...

Page 138: ...Service Manual Damcos LPU Hydraulic Hand Pump SM 8000 100 01 Ed 04 February 2017 138 Hydraulic Diagram for Direct Mounted LPU Handpump ...

Page 139: ...Damcos LPU Hydraulic Hand Pump Service Manual February 2017 SM 8000 100 01 Ed 04 139 Hydraulic Diagram for Bulkhead Mounted LPU Handpump ...

Page 140: ...Service Manual Damcos LPU Hydraulic Hand Pump SM 8000 100 01 Ed 04 February 2017 140 ...

Page 141: ... Mounting 16 Operating speed 115 Technical data 113 LPU and Optional Equipment 16 LPU cannot raise pressure after hand pump operation 67 LPU leaking from bleeder valve 68 LPU Power Control Description 121 LPU D 32 Emergency operation 79 LPU D not maintaining pressure on actuator 57 LPU D Ex 36 LPU D Ex ia 40 LPU EEx has to be bulk mounted because of too little space or zone 0 at actuator 71 LPU Ex...

Page 142: ...ering no pressure 51 Pump rendering too low pressure 51 Pump replacement in LPU 93 R Recommended refill oil 87 Refill of Oil in LPU 87 Release valve replacement in LPU 99 Replace DPCV in LPU 97 Replace pressure switch in LPU 109 Replace Printed Circuit Board in LPU 105 Replace Pump in LPU 93 Replace release valve in LPU 99 Replace Solenoid Valve in LPU D 107 S Safety 9 Setup new P net LPU circuit ...

Page 143: ......

Page 144: ...ation purposes only and while effort has been made to ensure their accuracy they are not to be construed as warranties or guaran tees expressed or implied regarding the products or services described herein or their use or applicability Standard Terms and Conditions of Sale can be issued by contacting Damcos A S We reserve the right to modify or improve the designs and specifications of our produc...

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