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D860MGB rev04

OPERATING INSTRUCTIONS

for

HI PUMP UNIT

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Summary of Contents for HI

Page 1: ...D860MGB rev04 OPERATING INSTRUCTIONS for HI PUMP UNIT ...

Page 2: ... PHASE MOTOR 10 4 4 MOTOR PROTECTION WITH THERMISTORS 11 4 5 ELECTRICAL CONNECTION OF THE VALVE GROUP 11 4 6 POSITIONING OF THE SHAFT SWITCHES FOR THE DECELERATION DISTANCE 12 4 7 ELECTRICAL GROUP INVERTER 12 INTRODUCTION 12 WARNING 12 5 OIL FOR LIFTS CIRCUIT FILLING AND AIR PURGING 13 5 1 CHARACTERISTICS 13 5 2 CHOICE OF THE OIL 13 5 3 CIRCUIT FILLING AND AIR PURGING 14 6 CONTROLS AND TEST 16 6 1...

Page 3: ...SISTANCE optional 23 9 2 OIL COOLING optional 23 GENERAL INFORMATION 23 COOLING SYSTEM WITH AIR 24 COOLING SYSTEM WITH WATER 24 10 MAINTENANCE 25 10 1 GENERAL INFORMATION 25 10 2 OIL LOSSES AND CAR LOWERING 25 LOSSES ALONG THE PIPES 25 CYLINDER LOSSES 25 LOSSES INSIDE THE VALVE GROUP 25 10 3 AIR PRESENCE IN THE OIL 29 10 4 FILTER CLEANING INSIDE VALVE GROUP 29 10 5 MINERAL OIL DETERIORATION 29 10 ...

Page 4: ...tent staff or any possible non competent persons or objects from damages or accidents These operating instructions report some symbols which correspond to important safety measures Danger This symbol draws attention to high risk of injury of persons It must always be obeyed Warning This symbol draws attention to information which if it is not observed can lead to injury to persons or extensive dam...

Page 5: ...the safety measures in force and according to the pressure of the installation Note that the only use of the hard pipe to connect the pump unit to the cylinder can transmit and increase the noise Install the flexible hoses with the right bending radius suggested by the manufacturers and avoid the use of hoses which are longer than necessary MAINTENANCE During the periodical works of maintenance be...

Page 6: ...ways have to be followed When loads have to be lifted only use proper hoists and respect their max capacity Never walk or stop under the hanging loads Avoid hydraulic components from shocks If the hydraulic components have to be stored first control that packaging and protections are in a perfect state if necessary repair or replace them with other more suitable ones Store the hydraulic components...

Page 7: ...of the pump unit is reported on the plate on the tank cover All the pump units and the shut off valves are tested and adjusted before the delivery For this reason they can work immediately without any further adjusting When the installation has been finished the oil filled and the air purged it will be possible to readjust the low speed and the deceleration to optimize the installation working see...

Page 8: ...of the fitting Warning some countries do not allow the use of a joint with a cutting ring In these cases it is necessary to use a type of fitting called WALFORM for the connection see Figure 2 or fittings to be welded When a flexible hose is used please note that The flexible hose has not to be subject to tension torsion and the bends have to be as wide as possible The minimum bending radius given...

Page 9: ...trong heating The grounding cable has to be always connected to the bolt marked with the proper symbol 4 2 CONNECTION BOX The connection box is on the pump unit cover near the valve block The box of the standard pump unit includes see Figure 5 a Terminal block of the electrical motor b Grounding bolt c Thermostat for oil temperature 70 C d Motor thermistors 110 C The pump unit box cabled optional ...

Page 10: ...se of a direct start of the motor frequency and one tension of the motor have to correspond to the frequency and tension of the electrical power network The connection bands on the terminal block have to respect the diagram appearing on the motor plate or the directions of the table see Figure 7 Figure 6 Connection box for wired pump unit DISPOSITION OF TERMINAL CONNECTION BANDS FOR THREE PHASE MO...

Page 11: ...ic relay susceptible to the resistance variation Warning The thermistors have not to be submitted to tensions higher than 2 5 V When the thermistors are properly connected they protect the motor against the overheating of the windings Overheating could be caused by lack of a phase in the feeding too frequent activation excessive tension variations excessive oil temperature 4 5 ELECTRICAL CONNECTIO...

Page 12: ...able Car Speed EVD de energizing Upward distance Downward distance 0 40 m s 0 50 m 0 60 m 0 60 m s 0 70 m 0 80 m 0 80 m s 0 90 m 1 m 4 7 ELECTRICAL GROUP INVERTER INTRODUCTION OmarLift uses an inverter which operates in open loop condition with a special software for hydraulic lifts It controls both the upward run and the downward run You can achieve the following benefits No starting current peak...

Page 13: ...d conserves the metallic components Anti emulsion It makes the spontaneous separation of water from oil easy 5 2 CHOICE OF THE OIL The oil has to be chosen focusing on the installation characteristics temperature and ventilation of the machine room installation traffic as well as on the temperature viscosity characteristics of the oil In particular it should be noted that the names of the hydrauli...

Page 14: ...APILUBE HS 68 150 CASTROL HYSPIN M46 160 HYSPIN M68 190 ESSO INVAROL EP 46 160 INVAROL EP 68 180 FINA HYDRAN HV 68 151 I P HYDRUS HI 46 HYDRUS HX 68 175 OLEOTECNICA MOVO M 46 68 154 MOVO HVI 46 68 182 ROLOIL LI 46 HIV 160 LI 688 HIV 175 SHELL TELLUS T 46 153 TELLUS T 68 193 SHELL ELEVOIL 68 183 TOTAL EQUIVIS HZS 46 68 160 EQUIVIS HZS 68 Tab 1 Some oil alternatives No responsibility is taken for di...

Page 15: ...n of rotation is wrong a pump cavitation noise will be heard It shall then be necessary to exchange two phases on the motor connection 5 Keep the motor activated for 10 15 seconds and stop it for 20 30 seconds to allow the air to go out Repeat this operation several times until only oil without air comes out from the purge screw 6 Close the purge screw of the cylinder and adjust the rupture valve ...

Page 16: ...correspond to 1 4 times the max static pressure with full load 6 3 CHECK OF THE START IN UPWARD DIRECTION In order to get a smooth start of the motor in upward direction without load be sure that When the shut off valve is closed discharge pressure using the emergency button and start up the motor again check that the pressure rises slowly from its minimum to its maximum value If necessary adjusti...

Page 17: ...ake back the pressure to the value of the static pressure activating the emergency button manually and control visually the integrity of the hydraulic system 6 7 CHECK OF THE ROD COUNTER PRESSURE AND HAND WORKING For indirect acting installations 2 1 check that when the car is blocked on the proper parachutes or lays on its dampers by activating the red emergency button the rod does not go down ma...

Page 18: ...justing a valve means limiting the passage to a minimum value which lets an oil quantity lower than the adjusting value run free and blocks the oil flow when the adjusting value is reached For the calibration procedure the appropriate manufacturer s manual 7 2 TEST AND WORKING OF THE RUPTURE VALVE a Get the travel shaft free and be sure that the whole lift equipment is perfectly working b Load the...

Page 19: ... and all identification data Before any regulation of the valve or the inverter verify all the electrical connections have been carried out correctly the oil in the tank is the advised one and it temperature is between 20 and 30 C Figure 10 Upward and downward speed diagram Figure 11 Identification plate 8 2 HYDRAULIC SCHEME Figure 12 OmarLift HI valve hydraulic circuit without A3 device ...

Page 20: ... project phase The max pressure is reached only when the piston is in upper end position or when the main line valve is closed Close the shut off valve of the main line and open the manometer valve Screw the screw n 1 and discharge the possible pressure with the red manual emergency button Start the motor in up direction Screw the screw n 1 until the max wanted pressure value is reached and stop t...

Page 21: ...to be verified Increase the pressure in the circuit with the hand pump Discharge the pressure with the hand button and read the remaining pressure If necessary repeat the previous operations until the wanted counter pressure is reached Figure 13 Adjusting of the rod counterpressure CALIBRATION OF THE HAND PUMP PRESSURE SCREW N 9 The hand pump has a safety valve which has to be adjusted at 2 3 time...

Page 22: ...ee types of pressure switches and two types of contacts The regulation of the intervention pressure is obtained through single slot screw which lays in the center of the pressure switch see Figure 14 Turn clockwise the intervention pressure increases turn anti clockwise it decreases The pressure switch is assembled on the valve block and lays directly on the pressure line which gets to the cylinde...

Page 23: ...th high traffic or for workplaces particularly critical According to the different situations it is suggested to use an oil cooling system in installations with more than 50 70 travels per hour The oil cooling system can be with air or with water and is available in two sizes from 6kW to 21kW The main parts of an oil cooling system are An electro pump for the forced oil running An heat exchanger o...

Page 24: ... operating instructions COOLING SYSTEM WITH WATER The cooling systems with water are generally connected directly to the tank when the pump unit is being built see Figure 18 If the cooling system with water is supplied alone without pump unit the customer will have to connect it to the pump unit The holes for the oil suction have to be as far as possible from the holes for fresh oil return to the ...

Page 25: ... the joints of the rigid pipes or along the flexible hoses These losses can be visually detected They can be eliminated tightening the fitting nuts joining the pipes correctly or replacing the flexible hoses CYLINDER LOSSES Big cylinder losses are due to wear or to damaged seals which are located in the head of the cylinder itself The oil coming out from the cylinder is collected in a proper room ...

Page 26: ...also assured by a ball whose working can be jeopardized by dirt laying between seat and ball Carry out a first check by removing the moving half cover of the tank and look under the valve Every time the emergency button is activated an oil outflow will be noted This outflow has to stop when the button is left In case this does not happen there can be losses from the emergency valves or losses from...

Page 27: ...reasons why the downward travel valve may not work properly are the following Small metal particles or dirt have got inside the coil between the tube and the cursor delaying or preventing the return movement of the coil cursor It is necessary to remove the coil unscrew the mechanical part of the EVD and shake it backwards and forwards with the hand to insure that the inside piston is free If not r...

Page 28: ...mpose its piston This seal wears with the passing of the time and can be damaged by metal particles which engrave it and hinder its sealing because they come between seat and seal The closing can also be slowed by the bad running of the VBP piston because of dirt and hindered by the faulty closing of the electrovalve EVD Operate as follows to get rid from VBP losses Close the main line shut off va...

Page 29: ...vent screw and leave everything rest for about 8 10 hours In this way the air in the oil will go up and the air in the tank will be automatically released Now purge the air from the cylinder see paragraph 5 3 10 4 FILTER CLEANING INSIDE VALVE GROUP With a general overhaul or when operation faults occur clean all filters located on the electro valves and indicated in the Figure 22 To clean or repla...

Page 30: ...smooth operation of the drive carry out the following checks at regular intervals Always isolate the drive from the power supply and make certain the keypad is off before proceeding Remove the dust that collects on the cooling fans and on the control circuit board preferably by means of compressed air or using a vacuum cleaner Check that there are no screws loose at the power or control terminals ...

Page 31: ... 9 10 9 CHECK OF THE ELECTRICAL INVERTER CONNECTION 10 9 11 DIMENSIONS AND WEIGHTS 11 1 DIMENSIONS AND WEIGHTS OF THE PUMP UNITS The weights of the pump units with shut off valve are divided per kind of tank and do not consider the weight differences of pumps and motors of different size Consequently there is a are approx calculated with a 5 tolerance TANK TYPE TANK BASE HANDLES INCLUDED MM HEIGHT...

Page 32: ...OMARLIFT s r l Via F lli Kennedy 22 D 24060 Bagnatica BG ITALY Phone 39 035 689611 Fax 39 035 689671 Email info omarlift eu Web http www omarlift eu ...

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