Flo-tech USB Hydraulic System Analyzer manual PDF
Contents
1. csv file when in Record mode Form ZFLIT 560 09 10 Page 13 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Changing Alarm Settings 1 Ifin the Run or Record modes press the Stop button 2 Select View Alarm Settings from the main menu Pressure Temp Alarm High Alarm High 5500 160 Psi zl Alarm Low Alarm Low 0 alf 0 Psi Sed csse Flow Alarm High iP 120 v GPM Alarm Low ajf 0 v GPM Exit FIGURE 4 Alarm Settings Screenshot 3 Use the Up Down arrows to adjust the level of each alarm to the desired position 4 Press the Exit button when finished The alarm level for each measurement is indicated on the strip chart by the highlighted area shown on its associated scale Any measurement taken inside the highlighted area will trigger the alarm Resetting the Alarms Press the Reset Alarms button Alarms will be reset if the alarm condition is false Page 14 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Flo tech Installation amp Programming Instructions Viewing Alarm History 1 Ifin the Run or Record modes press the Stop button 2 Select View Alarm History from the main menu Alarm History Alarm Count 4 Clear History Alarm Count 0 Clear History Alarm Count 0 FIGURE 5 Alarm History Screenshot The alarm events are shown for each measurement Press the Clear History button at the bottom2. Form FLIT 560 09 10 i tec h TM 8635 Washington Avenue Racine WI 53406 3738 Tel 800 433 5263 or 262 639 6770 Fax 800 245 3569 or 262 639 2267 E Mail flo techsales racinefed com flo tech com Materials and specifications subject to change without notice RFD Racine Flow Meter Group EMEA DYNASONICS Flo tech PRESO racine HEDLAND and FLO CHECK are registered trademarks of Racine Federated Inc Flo tech is a trademark of Racine Federated Inc WINDOWS WINDOWS VISTA and EXCEL are registered trademarks of Microsoft Corp 2010 Racine Federated Inc VITON is a registered trademark of DuPont Dow Elastomers All rights reserved COREL and QIATRO PRO are registered trademarks of Corel Corporation Printed in USA UL is a registered trademark of Underswriters Laboratories Form FLIT 560 09 10
3. and select the desired unit The digital display and strip chart legends will change to the selected unit Pressure Digital Display Only TABLE 2 Available Measurement Units Page 12 Form ZFLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech Using the Graph The graph on the main screen consists of a strip chart When the software is in Run or Record mode the strip chart scrolls from right to left at a rate of 1 group of plots per second The complete graph displays the last 60 plots or 60 seconds of data Previous data points that scroll off the graph are saved in memory and can be viewed at any time until the graph is cleared or the application is closed Viewing Graph History If the strip chart contains more than 60 points of data select the View History checkbox located on top of the upper left hand corner of the graph A horizontal scroll bar will appear below the graph allowing the operator to scroll through the data The current incoming data will not be lost while viewing history data so it can be done while the Hydraulic Analyzer is in Run or Record mode When finished viewing the history data un check the View History checkbox and the graph will return to displaying the current real time data Displaying and Hiding Individual Graph Plots The top of the graph contains a color coded legend for each plot Next to each legend label is a checkbox that cont
4. eR A ERA EERE eene nnne nennen nenne rennen nennen nennen 16 To Save a Software Configuration osoa na a A EAE eene en nennen nennen en nnne nennen nnns 16 To Eoad a Software Conflg tatlon 1 toa ttbi ete REDITU Pr Ee EEEE texte dieta t d D b riae tides 16 Calibration sene ete titan nia tettante tt tette eden tet tede 17 To Reset Zero for the Pressure Transducer sssssssssssssseseseeeeeenen nennen nennen enne nennen nennen nnne nnns 17 To Reset Factory Calibration Defaults niece tenent entrent td ee nena o MERE La Ee EX a a RE REA East Ea 17 Test Proceduro on tni petet ntt nt et itin eden werden 18 Standard Test Conditions 3 uid ee D RR Rebel ME 18 NIr rcu 18 Inline Systema on o tee tetti do iadertitte tede D ee E DE dte rope ete Habet er de 20 Control Valve and Bi directional Hydraulic Motor Test eene memes 21 Bi directional Gylinder Test 5 iet eite Denia Um ee EE Ue EO aide En eR ES 23 Hydrostatic Transmission Diagnostics cedna ia E EAA emen mener nnne nn nennen nnns 24 Other Test Procedures eoi ood Rap inm trei n Hasfpe inter oleis 25 Maintenance Troubleshooting 2 m c t eee e eet t e deae aee hl ape d oet oe e ua eee eta ee geo ede iud 26 LOA Valve mr 26 do Nu 26 Burst DISCS itin A mcm t iL Ei Mn n M DM MM UMEN cated 26 Flow vs Pressure Drop Charts 4 eerte Rete inne te rra etate Eod Eau ued eT dened
5. name Test 3l My Network Save as type CSV Comma Delimited csv Places FIGURE 3 Record Data File to Screenshot Note The default location for saving a log file for Windows XP and Windows 2000 is C Documents and Settings lt user name gt My Documents Flo tech Hydraulic Analyzer Datalog The default location for saving a log file for Windows Vista is C Users lt user name gt Documents Flo tech Hydraulic Analyzer Datalog Note If you wish to record over an existing file double click on the file from the list Data will be displayed on the digital displays and the strip chart will be updated once per second The message Recording is also displayed under the Run button to indicate the software is in Record mode rather than run mode It s important to note that data is not recorded if the file is already open by another application such as Excel 5 Press the Stop button when finished to halt the collection of data Page 10 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech To Start Recording a File while in Run Mode 1 Qu seruos Connect the USB cable from the Hydraulic Analyzer to the computer Note This is required before starting the software This allows the software application to detect a connected unit Start the software application by double clicking on the Flo tech Hydraulic Analyzer icon on your desktop In the men
6. of the form to erase captured alarms 3 Press the red X in the upper right hand corner to exit the form Note Alarm events are also recorded to the csv file when in Record mode Form FLIT 560 09 10 Page 15 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Saving Loading Software Configurations The current software application s settings can be saved to a configuration file that can be recalled at a later time This feature is useful if the operator has different tests that use different measuring units and alarm settings Rather than resetting each parameter all test parameters can be recalled from a file To Save a Software Configuration If in the Run or Record modes press the Stop button Set all software parameters to desired settings Select File Save Setup Configuration from the main menu Esp qc A Save Data File as dialog box will be displayed asking you to name the configuration file and where to save it Type a name in the File Name textbox and press the Save button Note The default location for saving a configuration file for Windows XP and Windows 2000 is C Documents and Settings lt user name gt My Documents Flo tech Hydraulic Analyzer Configurations The default location for saving a configuration file for Windows Vista is C Users lt user name gt Documents Flo tech Hydraulic Analyzer Configurations To Load a Software Configuration If in t
7. pied eere d ra ea 28 Retu Goods Authorization oc tr et OO t d o Pt Ee OR eee 29 Waste Electrical and Electronic Equipment WEEE Directive emen 29 l EWuChEEIE M 30 Form ZFLIT 560 09 10 Page 3 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech Overview The Flo Check USB Hydraulic System Analyzer can be used as a stationary or portable tester for both industrial and mobile hydraulic system diagnostics and analysis of the prognostic health of a hydraulic system It features flow pressure and temperature sensors that are monitored by a data acquisition module This module records the operating parameters of the system and transfers them to the user s laptop via the USB port The custom software utility is a Windows based application which is compatible with Windows Vista Windows XP and Windows 2000 This intuitive software configures the displayed information into user selected engineering units and provides real time graphics with instantaneous readings and trends for all three measurement parameters The software also permits the data to be saved for export into a spreadsheet program The Hydraulic System Analyzer is powered through the USB port of a PC making it easy to setup and ideal for portable applications Interfaced to the PC application the Hydraulic Analyzer offers a straightforward method of monitoring System pa
8. pressure Pressure will increase until the relief valve opens Record the pressure at this point Repeat to check the relief valve adjustment C Relief Valve in Separate Housings 1 Install the Flo Check in the Tee Test configuration and plug the line to the control valve 2 Select Run and or Record on the PC see Recording Measurements to a File on page 8 Form FLIT 560 09 10 Page 19 Flo Check USB Hydraulic System Analyzer Flo tech i Installation amp Programming Instructions 3 Close the Flo Check loading valve while recording or viewing the pressure and flow Pressure will increase until the relief valve opens You can reference this point on the Flo Check software Repeat to check the relief valve adjustment D Relief Valves Often relief valves will start to open before they reach their full pressure flow settings This can be noted by comparing the pressure and flow rate readings made in pump test Any great decrease in flow rate from tests made in pump test indicates a faulty relief valve ll Inline System Test Virtually all system components can be unidirectionally tested or set in this configuration FIGURE 8 Inline System Test Begin by installing the Flo Check between the pump and the control valves A Pump Test 1 Ifthe directional control valve s DCV s center does not allow an unrestricted flow path back to tank see Pump Test in the Tee Test installation on page 19 Open the Flo Che
9. CV Test 1 Isolate the motor from the circuit and connect the Flo Check s output to the DCV s B port Select Run and or Record on the PC see Recording Measurements to a File on page 8 Slowly close the Flo Check loading valve to achieve the rated pump pressure Repeat for all operating positions of all DCV s a Ifall components are in good operating condition pressure and flow measurements should be the same as in the Pump Test b Ifa decrease in flow in any DCV position is noted leakage is indicated c Ifthe decrease in flow is the same with the control valve in all positions it indicates the relief valve is at fault Note This can also indicate some other leak is present in the control valve such as a defective casting damaged seals or worn valve position detents but always check the relief valve FIRST d If the flow readings are now higher and comparable to the other control valves then a faulty cylinder or motor is indicated IV Bi directional Cylinder Test This setup allows you to calculate extension times and verify force FIGURE 10 Bi directional Cylinder Test 1 Install the Flo Check on the rod or cap side of the cylinders Form ZFLIT 560 09 10 Page 23 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Select Run and or Record on the PC see Recording Measurements to a File on page 8 With the load valve fully open the extension or retraction
10. Check FIGURE 9 Control Valve and Bi directional Hydraulic Motor Test A Motor Test No Load Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put one control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time Using a tachometer run the motor with no load The flow and RPM should match the manufacturer s specification A decrease in RPM from the manufacturer s specifications indicates a loss of the motor s efficiency Note This test can be repeated for the reverse direction B Motor Test Loaded Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put one control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time Using a tachometer run the motor while providing a load on the motor The flow and RPM can now be checked against the motor manufacturer s specifications A decrease in RPM from the manufacturer s specifications or the unloaded motor test indicates a loss of the motor s efficiency Note This test can be repeated for the reverse direction C Motor Test Simulated Load Page 22 Reverse the pump fl
11. Flo tech Flo heck 5 Hydraulic System Analyzer Installation amp Programming Instructions Hydraulic fo grietecn i Flo Uheckh 7 ulic System Analuzer mearecporner L o 8635 Washington Avenue a Racine WI 53406 Tel 800 433 5263 or 262 639 6770 Fax 800 245 3569 or 262 639 2267 E Mail flo techsales racinefed com www flo tech com ow M08 EDERA SS Q oe Ej BON 395 P i E om iS Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech Table of Contents OVEIMIOW n 4 SPECIICALONS uL E A E ahinge seit ae hete nlanel deca abdeal Mabeatey lanenes acca nace 4 Materlal 2 eurer bene heec tpe AT O E OEA EE date per ena nes 4 POWOI tcs diete m hl E ce e Al e pev TUER Eee et Bel e E vn cebat re E CC TED eo Ie ce e eT 5 Environmental nre tte dtp estt n de eade eee eade tme cba 5 Performarnce fice Letti tee eec la he ae descente Rege aed eee bed ep pe LR 5 Gallbratlonzzosmic m d SRM EORR e Hin dot be tette un tnde 5 Model Number Designations eer e ete eee e Ee t eg e ht ee Pe oe de Paseo de AA v bod e Ud 6 General IMfOrrmMation eere E 6 Installing the SoftWale itn rt ED t reb ttu d ee etn teni feste es 7 Connecting the Hydraulic Analyzer to Your Computer for the First Time sssssse em 7 Software OVervlowW x tst nett edet ento ime pta tete ER Pec S
12. a new burst disc housing 7 Set the torque wrench to 40 foot pounds 50 8 N m 8 Torque the burst disc housing into the block Torque to 40 foot pounds 50 8 N m A CAUTION Do not over torque the burst disc housing Applying too much torque will damage the burst disc and cause the disc to rupture prematurely Form FLIT 560 09 10 Page 27 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Dimensions DIMENSIONS L x D x H WEIGHT SERIES INCHES mm LBS KG F7164 11 41 x 5 70 x 7 93 289 81 x 144 78 x 201 42 17 7 71 F7160 11 41 x 5 70 x 7 93 289 81 x 144 78 x 201 42 17 7 71 307 34 x 157 48 201 42 20 907 28981 x 144 78 x 20142 7 771 289 81 x 144 78 x 201 42 7 T70 307 34 x 157 48 x 20142 20 907 Ce Flo tech co FI Check USB J d DO Hydraulic System Analyzer Bi directional Flow vs Pressure Drop Charts AP Captured Using Loading Valves F7160 F7162 F7161 F7163 7 a n fe x 2 I 2 7 n Ww 2 a 4 FORWARD 4 FORWARD 4 REVERSE REVERSE 10 5 0 0 0 10 20 30 40 50 60 70 80 90 100 0 20 40 60 80 100 120 140 160 180 200 220 NOTE For Flow vs Pressure Drop information on the F7164 and F7165 models please contact the factory Page 28 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Flo tech E Installation amp Programming Instruct
13. bligation under this warranty is limited to the repair or replacement of a defective product at no charge to the end purchaser if the product is inspected by Flo tech and found to be defective Repair or replacement is at Flo tech s discretion A returned goods authorization RGA number must be obtained from Flo tech before any product may be returned for warranty repair or replacement The product must be thoroughly cleaned and any process chemicals removed before it will be accepted for return The purchaser must determine the applicability of the product for its desired use and assumes all risks in connection therewith Flo tech assumes no responsibility or liability for any omissions or errors in connection with the use of its products Flo tech will under no circumstances be liable for any incidental consequential contingent or special damages or loss to any person or property arising out of the failure of any product component or accessory All expressed or implied warranties including the implied warranty of merchantability and the implied warranty of fitness for a particular purpose or application are expressly disclaimed and shall not apply to any products sold or services rendered by Flo tech The above warranty supersedes and is in lieu of all other warranties either expressed or implied and all other obligations or liabilities No agent or representative has any authority to alter the terms of this warranty in any way Page 30
14. ck loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 then close the loading valve to increase pressure from zero pressure to rated or maximum pump pressure to determine pump condition 4 The pump flow at rated pressure can now be checked against the pump manufacturer s specifications A decrease in flow from zero pressure to maximum pressure indicates the pump condition A pump that delivers a constant low flow at zero pressure and at maximum pressure suggests suction problems Page 20 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech B Relief Valve in Separate Housings 1 If the DCV s center does not allow an unrestricted flow path back to tank see Pump Test in the Tee Test installation on page 19 Select Run and or Record on the PC see Recording Measurements to a File on page 8 Close the Flo Check loading valve while viewing or recording the pressure and flow Pressure will increase until relief valve opens You can reference this point on the Flo Check software Repeat to check the relief valve adjustment C Relief Valves Often relief valves will start to open before they reach their full pressure flow settings This can be noted by comparing the pressure and flow rate readings made in Pump Test Any great decrease in flow rate from tests made in Pump Tes
15. control can result in excessive increases in flow and or pressure Such uncontrolled changes may cause a failure in the system and result in component damage or personal injury 1 For complete information visit www hedland com and select Petroleum Fluids under Products Variable Area High Pressure Flow Meters MAINTENANCE TROUBLESHOOTING The Flo Check Hydraulic Analyzer is designed to give years of trouble free service However if trouble is suspected a few simple checks can be made Load Valve If the valve fails to load the system remove the valve body and check for foreign material worn parts or seals Flow The absence of any flow reading may indicate a blockage of the turbine Remove the retaining ring from the inlet port and carefully remove the turbine assembly Remove any material that may be preventing easy rotation of the rotor Reassemble and attempt a flow reading again If the tester still fails to indicate flow it is recommended to return the tester to the factory For return procedures see the Return Goods Authorization section of the manual on page 29 Burst Discs The burst discs are designed to rupture at a specified pressure Testers provide protection from excessive pressure in either direction 7500 PSI differential with two internal burst discs that when ruptured by pass flow around the loading valve If rupture occurs the burst discs must be replaced A WARNING If you do not have the proper tools to acco
16. der the File Record To menu selection Log Interval The Log Interval is used to stop the Hydraulic Analyzer and software from running or recording data after a set period of time It can be adjusted using the up down controls next to the log time hours and minutes found on the main screen Next to the Log Interval setting is the Time Period in seconds Since the strip chart increments once every second the elapsed time can be compared to the log interval in seconds For convenience the elapsed time is also displayed in hours and minutes on the lower right hand side of the software application The default Log Interval setting is 4 hours when launching the application This is sufficient for most tests and also allows using the software without having to adjust the Log Interval first If the operator doesn t need to setup a test period and each test is less than 4 hours then the Log Interval setting does not need to be adjusted and can be ignored Note Pressing the Clear Graph button clears the graph and also resets the number of measurements that s compared to the log period Therefore if the Log Interval is set to 4 hours and the Clear Graph button is pressed another 4 hour test can run before timing out Changing Measurement Units Changing measurement units must be done before entering the Run or Record modes To Change Measurement Units 1 Select the menu item Options 2 Select Pressure Temperature Flow or Power Units
17. driver is installed with Windows operating systems that support USB gt The first time you connect the device to your PC your computer automatically detects it and configures the necessary drivers No third party device drivers need to be installed gt The Hydraulic Analyzer interface is plug and play You can connect it to the computer before or after you install the software and without shutting the computer off Note Before connecting the Hydraulic Analyzer to the computer download and install the latest Microsoft Windows updates For Windows XB there is a Hotfix KB822603 that is installed to address a serious error within Windows XP and the use of USB devices To connect the Hydraulic Analyzer to your computer 1 Connect the USB cable to the Hydraulic Analyzer and then plug the other end into a USB port on the computer 2 The first time the Hydraulic Analyzer is connected to the computer several Found New Hardware balloons or dialogs pop up This is normal 3 Once the Hardware has been found and installed the last balloon or dialog states Your new hardware is installed and ready to use At this point the Hydraulic Analyzer interface has been successfully installed and can be used with the software application Form ZFLIT 560 09 10 Page 7 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Software Overview The software provides a real time graphical and digital int
18. e in RPM in the manufacturer s specifications or the unloaded motor test indicates a loss of the motor s efficiency D Motor Test Simulated Load 1 Reverse the pump flow 2 Open the Flo Check loading valve fully to read maximum pump flow at zero pressure 3 Install one or both of the following instruments on the hydraulic motor a Place a Hedland variable area meter on the case drain and manually record the flow as you increase the load on the tester Then compare it to the manufacturer s specifications b Place a tachometer on the motor s shaft Select Run and or Record on the PC see Recording Measurements to a File on page 8 5 Increase the load on the Flo Check tester to produce back pressure on the hydraulic motor A WARNING See manufacturer s specifications for maximum allowable back pressure If the motor does not have an external drain it can not have a back pressure load Failure to follow the manufacturer s specifications can result in injury to personnel and or damage to the equipment 6 The flow at rated RPM can now be checked against the motor manufacturer s specifications A decrease in RPM and an increase of case flow with increased load indicates a loss of the motor s efficiency Note If the motor does not have a case drain it cannot be loaded on the discharge side Vl Other Test Procedures A Case Drain Case drain flow can be checked concurrently with any of these setups using a second Hedland Variable A
19. ede GEA Re ibi bae aere da 8 Running the Software and Viewing Real Time Data ssssssssessssseeeneeneneemeeenen eee 9 Recording Measurements to a File eee e Ate need header ete odere d duae od odo eed ui dede e d e p 9 Io Record a Flle eR be ret oben dt teu 10 To Start Recording a File while in Run Mode sssssseeeneeeeene eene rnnen ennt nennen nennen ns 11 When Entering Rum or Record Mode diede edocti ieee dant re iet epe eru ee a tee uad Re R Ri ane 11 Recording Modes EM E 11 Log Interval i c EUN 12 Changing Measurement Units ariennir inenen a ad ee LL eee 12 Using the Graphi vic sai eels D toe Meee aS ete es edt ee Me en ee ee 13 Miewing Graph HIStory site Ree n to ee nae tuo e See ie ath en aed ex eee etta A a ut kei Ga 13 Displaying and Hiding Individual Graph Plots sssesssesseeeenn eene mm eren en nennen 13 Adjusting the Graph Scales 3 5 intentado 13 Displaying Graph Gridlin s oo 1 vene ee aeter redi oet Pee ante ote det e ae uad ba aee o Eu oec ae 13 Clearing tlie Grap i coorta AE A as sene ey es daas ete a eee 13 Using ther Alarms MP EE E denatuleauseaniees 13 Changing Alarm Settings 25 1 ten er RR et tme 14 Resetting the Alarms eun RIRIREREDEMeIpiea sepe tun AOT 14 Miewing Alarm HIStODy e ied o oH p Hm DRE UL D E Pd LE PEE PR UE te bp cere cette 15 Saving Loading Software Configurations seeen r akne
20. erface for monitoring and or recording pressure temperature and flow rate parameters from the Hydraulic Analyzer In addition to the graphical and digital displays the main screen also consists of a menu bar buttons with common functions and alarm indicators Flo tech Hydraulic Analyzer v2 01 File View Options Tools About E Log Interval Test Periad i a Seconds Run Clear Graph Record Reset Alarms ud 4 Hours um 0 Minutes 14400 Pressure Alarms Temp Alarms Alarms High Low High Low High Low EEA O View History Pressure Avg 10000 PSI 9000 PSI 8000 PSI 7000 PSI 6000 PSI 5000 PSI 4000 PSI 3000 PSI 2000 PSI 1000 PSI 0 PSI PAA a oA A AS Ae AA E 0 0s gt Scale Adjustments Device ID Elapsed Time 00 00 00 FIGURE 1 Flo Check USB Hydraulic Analyzer Screenshot Measurement Color Alarm Digital Graphical Record to over a 1 second time period Indication Indication Indication Display Average Pressure Green Minimum Pressure Dark Green Maximum Pressure Dark Green Average Temperature Blue Average Flow Rate Yellow TABLE 1 Measurement Display and Record Features Page 8 Form ZFLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Running the Software and Viewing Real Time Data 1 Connect the USB cable from the Hydraulic Analyzer to the computer Flo tech Note This is required before sta
21. he Run or Record modes press the Stop button Select File Open Setup Configuration from the main menu 3 A Select Data File to Open dialog box will be displayed asking you to select the desired configuration file Select a configuration file and press the Open button Note The default location of this dialog box shows files in the following folder for Windows XP and Windows 2000 C Documents and Settings lt user name gt My Documents Flo tech Hydraulic Analyzer Configurations The default location of this dialog box shows files in the following folder for Windows Vista is C Users lt user name gt Documents Flo tech Hydraulic Analyzer Configurations Page 16 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech Calibration The Hydraulic Analyzer comes calibrated from the factory but it may be necessary for the operator to reset zero for the pressure and flow rate sensors occasionally Calibration parameters are stored within the electronic interface and not the PC software The software application automatically reads the calibration parameters from the device when it s launched Therefore owners of multiple units can use the same PC without worrying about calibration files To Reset Zero for the Pressure Transducer 1 Select Tools Calibration from the main menu Calibration Pressure C Temperature C Flow Factory Serial No 12345578 Factory Mode
22. information General Information The power measurements are derived from the product of flow and pressure H P GPM x PSI H P liters min x kg cm 1714 456 2 H P liters min x Bar H P liters min x MPa 447 40 44 74 kW liters min x kg cm kW liters min x Bar 611 600 kW liters min x MPa 60 1 Make all tests at the same operating temperature to ensure consistency of results A typical operating temperature for mobile machinery is 150 F 66 C 2 Testing will be easier and faster if quick disconnect couplers are used to install the Flo Check USB Hydraulic System Analyzer 3 Complete descriptions of the following basic hydraulic tests using the Flo Check USB Hydraulic System Analyzer can be found starting on page 18 a Tee Test b Inline System Test c Control Valve and Bi directional Hydraulic Motor Test d Bi Directional Cylinder Test e Hydrostatic Transmission Diagnostics A CAUTION The information in this manual is for general application only Any information furnished by the manufacturer of the machine s hydraulic components should be followed Specific systems may require specific test procedures 4 Apreliminary check of the hydraulic system s oil supply pump speed oil lines and cylinder rods as well as an external leak check should be made prior to installing the Flo Check Page 6 Form ZFLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instruct
23. ions Flo tech Installing the Software To install the software package on your computer perform the following steps Close all applications you have running 2 Insert the Flo Check USB Hydraulic System Analyzer CD into your CD drive If you have the auto run feature enabled on your computer the installation prompts will automatically be displayed Note If auto run is not enabled use Windows Explorer to navigate to the root directory on the CD Double click on the setup exe file to begin the installation 3 Follow the installation prompts to complete the installation After a successful installation a dialog will be displayed asking to restart the computer Select Yes Note If you wish to wait to reboot the computer select No However you will need to reboot before initial use for proper operation 5 The installation creates two shortcuts on the computer one on the desktop and the second in the START PROGRAMS FLO TECH Windows menu Connecting the Hydraulic Analyzer to Your Computer for the First Time The Flo Check USB Hydraulic System Analyzer connects to your computer through a USB port A cable is shipped with the unit but any standard USB A Male to USB B Male cable can be used The initial connection is easy and uses standard drivers within Windows that do not require special driver installation by the operator gt The Hydraulic Analyzer interface uses the Microsoft Human Interface Driver HID This
24. ions Return Goods Authorization When returning equipment for service a Returned Goods Authorization RGA number must be obtained from our Customer Service Department Please contact them by phone at 800 433 5263 or 262 639 6770 or by e mail to flo techtechhelp racinefed com All returns go to the following address and must include the RGA number on the outside of the box Flo tech Division of Racine Federated Inc 8635 Washington Avenue Racine WI 53406 3738 USA Attn RGA xxx xxxx Waste Electrical and Electronic Equipment WEEE Directive In the European Union this label indicates that this product should not be disposed of with household waste It should be deposited at an appropriate facility to enable recovery and recycling For information on how to recycle this product responsibly in your country please visit www racinefed com recycle Form FLIT 560 09 10 Page 29 Flo Check USB Hydraulic System Analyzer Flo tech Installation amp Programming Instructions Flo tech Division of Racine Federated Inc Limited Warranty and Disclaimer Flo tech Division of Racine Federated Inc warrants to the end purchaser for a period of one year from the date of shipment from the factory that all flow meters manufactured by it are free from defects in materials and workmanship This warranty does not cover products that have been damaged due to misapplication abuse lack of maintenance or improper installation Flo tech s o
25. l No USB Analyzer Customer Tag ID Test Stand 4 Volts Units psi Full Scale with Gain 4 1000 Min Scale with Gain 004 oF Low Pressure Cutoff e O Voltage Reading 1857364 Scale Factor 2501501 Calibrated Value 167124V 4180 61 psi Set Zero Set Full Scale Save to File Save to Device Restore Factory Settings Load from File Load from Device FIGURE 6 Calibration Screenshot Select the Pressure or Flow radio button at the top of the calibration screen Make sure the pressure flow of the Hydraulic Analyzer is at zero and press the Read button If the Calibrated Value reading under the Units column is not around zero press the Set Zero button This will recalibrate the sensor s zero output and write the value to the Hydraulic Analyzer To Reset Factory Calibration Defaults Press the Restore Factory Settings button Form FLIT 560 09 10 Page 17 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Test Procedures A WARNING All testers are shipped with the loading valve in the closed position The loading valve must be opened fully before initiating flow and testing of the hydraulic circuit Turn the loading valve handle counterclockwise to the fully open position Failure to open the loading valve fully can result in injury to personnel and or damage to the equipment A CAUTION These units are not designed for high pressure deadhead loadi
26. mp Programming Instructions Performance Flow Accuracy 1196 of reading 32 cSt Repeatability 0 2 Pressure Accuracy lt 0 5 BFSL Stability lt 0 25 of full scale Zero Offset X296 of full scale TC Zero and TC Span lt 1 5 of full scale Response Time 0 2 milliseconds Temperature Absolute Error 2 7 F 41 5 C over range of 0 to 185 F Nonlinearity 0 7 F 40 4 C Repeatability 0 2 F 40 1 C Data Acquisition Sample Rate 10 kHz PC Screen Update Record Rate Flow 1 second average 10K samples Temperature 1 second average 10K samples Pressure 1 second min max average 10K samples Calibration Testers are calibrated with 0 876 specific gravity 150 SUS 32 cSt Mobil DTE 24 hydraulic oil Standard calibration is done using 5 points and is traceable to NIST ISO 9001 An optional 10 point calibration can be performed for increased accuracy Model Number Designations MODEL NOMINAL FLOW NUMBER PORT SIZE RATE F7164 SAE 12 2 30 GPM F7160 SAE 16 3 85 GPM F7161 SAE 24 7 199 9 GPM F7165 G 3 4 7 5 113 6 LPM F7162 G 1 15 321 LPM F7163 G 1 1 2 26 757 LPM Form FLIT 560 09 10 Page 5 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions A CAUTION Read instructions thoroughly before installing the tester If you have any questions regarding product installation or maintenance call your local supplier or the factory for more
27. mp and control valve and connected to the IN port of the Flo Check The OUT port of the Flo Check is connected to the tank Pumps and relief valves can be isolated from the system and checked with the Tee Test FIGURE 7 Tee Test A WARNING Increase pressure slowly The relief valve may now be isolated from the hydraulic circuit and system pressures higher than the relief valve setting can result in injury to personnel and or damage to the equipment A Pump Test 1 Plug the line to the control valve Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 then close the loading valve to increase pressure from zero pressure to rated or maximum pump pressure to determine pump condition The pump flow at rated pressure can now be checked against the pump manufacturer s specifications A decrease in flow from zero pressure to maximum pressure indicates the pump condition A pump that delivers a constant low flow at zero pressure and at maximum pressure suggests suction problems B Relief Valve Test 1 Put a control valve into a power output mode with the output flow blocked such as a cylinder at the end of its stroke or center a closed center valve Select Run and or Record on the PC see Recording Measurements to a File on page 8 Close the Flo Check loading valve while recording or viewing the
28. mplish this task it is highly recommended that you return the tester s to the factory for replacement of the burst disc housing and the burst discs Injury to personnel and or damage to equipment may result if the burst discs are installed improperly Page 26 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech The following tools and parts will be needed 5 8 open end box wrench e 0 50 or greater pound inch torque wrench Burst disc housing Housing F5144 1 each Ring support F6567 1 each O ring 2 015 F3137 015 1 each Backup O ring 2 015 F1015 015 1 each Burst discs F1614 7500 2 each Internal Burst Disc Procedure 1 Position the Flo Check to expose the internal burst disc housing as shown in Figure 12 Back up Ring 2 Sw A MS N Q yp Burst Disc 2 Burst Disc Ring Support O ring Burst Disc Housing FIGURE 12 Burst Disc Replacement 2 Remove the burst disc housing from the block using a 5 8 open end box wrench 3 Remove the ruptured burst discs from the burst disc housing 4 Insert one new burst disc F1614 7500 into the housing followed by the ring support and then the second burst disc 5 Ensure that the burst discs are seated Be careful not to scratch the surface of the discs 6 Insert the burst disc housing with the O ring and backup O ring into the port of the block and hand tighten If required use
29. nds PMin P Max P Avg P Alarm Temp T Alarm Flow FlowAlarm HP 12 11 52 50 2 2311 2467 2467 105 4 847 Low 121 9 13 11 52 51 11 3402 3510 3422 105 4 114 7 2522 14 11 52 52 12 3910 4002 3910 105 8 116 4 265 5 15 11 52 53 13 3978 4089 4001 105 9 120 6 281 5 16 11 52 54 14 4399 5020 4399 High 107 4 126 5 324 7 117 11 52 55 15 3971 4050 4025 108 8 120 8 283 7 18 11 52 56 16 4012 4012 4012 109 5 120 8 282 8 19 11 52 57 17 4003 4003 4003 109 9 120 7 281 9 20 11 52 58 18 3827 3881 3850 110 1 High 1162 261 0 21 11 52 59 19 3409 3409 3409 110 1 High 112 1 223 0 Form ZFLIT 560 09 10 FIGURE 2 Example File Page 9 Flo Check USB Hydraulic System Analyzer Flo tech Installation amp Programming Instructions To Record a File 1 Connect the USB cable from the Hydraulic Analyzer to the computer Note This is required before starting the software This allows the software application to detect a connected unit Start the software application by double clicking on the Flo tech Hydraulic Analyzer icon on your desktop Press the Record button A dialog box will be displayed asking you to name the file you wish to create and where to save it Type a name in the File Name textbox and press the Save button Record Data File to Save in c Datalog Y amp hjTest 1 csv Ee Bh Test2 csv My Rec amp hy Test Stand 4 csv Documents e Desktop ml My Documents 48 J My Computer File
30. ng valve fully closed applications in the reverse direction Usage under this condition could lead to lading valve failure Under such conditions maximum operating pressure is limited to 2000 PSI 138 Bar A CAUTION The information in this manual is for general application only Any information furnished by the manufacturer of the machine s hydraulic components should be followed Specific systems may require specific test procedures Standard Test Conditions 1 Install the Flo Check as described in one of the following test procedures a Tee Test b Inline System Test c Control Valve and Bi directional Hydraulic Motor Test d Bi directional Cylinder Test e Hydrostatic Transmission Diganostics Open the loading valve fully by turning the handle counterclockwise 3 Start the pump and adjust it to rated speed To raise the system temperature close the tester loading valve to develop a pressure somewhat below the relief valve pressure Maintain until the desired temperature is reached 5 Open the Hydraulic System Analyzer s loading valve fully and proceed with the required test procedure 6 The Flo Check will log flow pressure temperature and power readings concurrently See Recording Measurements to a File on page 8 Page 18 Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech l Tee Test A tee must be installed between the pu
31. o a csv file until the operator presses the Stop button Capture Points Manually setting allows the operator to enter Run mode and use the Record button to capture points at desired intervals To Capture Points Manually Select Options Record Mode Capture Points Manually from the main menu A Save Data File as dialog box will be displayed asking you to name the file you wish to create and where to save it Type a name in the File Name textbox and press the Save button Press the Run button to start viewing measurements Notice the Record button text has changed to Manual Capture When ready to capture points press the Manual Capture button The message Captured Point is displayed under the Run button for approximately one second to indicate the software has recorded one point to the csv file Form ZFLIT 560 09 10 Page 11 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions 5 Continue pressing the Manual Capture button to append desired points to the csv file 6 Press the Stop button when finished to halt the collection of data Note Unlike Record All Points mode pressing the Stop button does not erase the csv file name from memory This is due to the fact that data points are appended to the file on each button press Therefore there is no danger of overwriting a csv file Note If you wish to capture points to a new csv file you will need to enter a new file name un
32. ow Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Install one or both of the following instruments on the hydraulic motor a Place a Hedland Variable Area Flow Meter on the case drain and manually record the flow as you increase the load on the tester Then compare it to the manufacturer s specifications b Place a tachometer on the motor s shaft Form ZFLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech 4 Select Run and or Record on the PC see Recording Measurements to a File on page 8 5 Increase the load on the Flo Check tester to produce back pressure on the hydraulic motor A WARNING See manufacturer s specifications for maximum allowable back pressure If the motor does not have an external drain it can not have a back pressure load Failure to follow the manufacturer s specifications can result in injury to personnel and or damage to the equipment 6 The flow at rated RPM can now be checked against the motor manufacturer s specifications A decrease in RPM and an increase of case flow with increased load indicates a loss of the motors efficiency Note If the flow and RPM meet specifications it could indicate a relief valve problem or DCV problem 1 For complete information visit www hedland com and select Petroleum Fluids under Products Variable Area High Pressure Flow Meters D Directional Control Valve D
33. rameters complete with data acquisition Specifications Material Housing 6013 T351 Anodized aluminum Turbine Rotor T416 Stainless steel Rotor Supports 6061 T6 Aluminum Seals Viton standard EPR optional Ball Bearings 440 C Stainless steel Hub Cones 6061 T6 Aluminum alloy Temperature Probe Valve Spool Sleeve Straightening Sections Ports Magnetic Pick up Body Nut Electronic Case Power USB Power USB Voltage Tolerance Current Environmental Pressure Rating Operating Pressure Internal Valve By pass Pressure Drop Fluid Temperature Ambient Temperature Storage Temperature Humidity Page 4 T303 Stainless steel 12L14 Steel body with 303 SS seat 12L14 Steel 6061 T6 Aluminum SAE Straight thread O ring boss female J1926 1 BSPP ISO1179 12L14 Steel electroless nickel plate 12L14 Steel electroless nickel plate Cold rolled steel black zinc plate with clear seal 5 VDC supplied through USB port of a PC 4 6 VDC min 5 25 VDC max 100 mA typ 6000 PSI 414 Bar maximum with a 3 1 safety factor capable of 10 000 PSI 689 Bar transients 6000 PSI 414 Bar 41 4 MPa 420 kg cm capable of 10 000 PSI 689 Bar transients 7500 PSI DP See AP charts on page 28 4 to 300 F 20 to 150 C 32 to 185 F 0 to 85 C 40 to 185 F 40 to 85 C 0 90 non condensing Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Flo tech Installation a
34. re to determine pump condition The pump flow at rated pressure can now be checked against the pump manufacturer s specifications A decrease in flow from zero pressure to maximum pressure indicates a drop in volumetric efficiency B Motor Test No Load Page 24 Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put one control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time Form FLIT 560 09 10 Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Flo tech 4 Using a tachometer run the motor with no load The flow and RPM should match the manufacturer s specification A decrease in RPM from the manufacturer s specifications indicates a loss of the motor s efficiency C Motor Test Loaded 1 Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put one control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time 4 Usingatachometer run the motor while providing a load on the motor The flow and RPM can now be checked against the motor manufacturer s specifications A decreas
35. rea Flow Meter However the motor s case drain pump s case drain and charge pump are all connected in series This means that the charge pump flow must be factored into the case flow Any increase in case flow would indicate a pump or motor problem B Test Stand Calibration System The Flo Check USB Hydraulic Analyzer can be added to any existing test stand for diagnostics calibration certification and data logging of hydraulic components The Flo Check can be used for recording bi directional flow which makes it ideal for hydraulic motors and cylinders The meter can be installed either on the supply or the return line of the test bench However it is recommended to place the meter on the supply side in case any contamination is passed through the units under test Once the data is recorded it can be stored for future reference or printed and sent with the repaired unit Form FLIT 560 09 10 Page 25 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions C Servo Controlled Pumps Motors and Valves Special procedures for testing these components may be specified INSTRUCTIONS OF THE COMPONENT AND MACHINE MANUFACTURER MUST BE OBSERVED These components may have the capability of nearly instantaneous increases of flow and or pressure and should have a positive means of control An example of such a control is the push pull servo control for varying pump delivery Attempting to manually adjust this
36. rols the visibility A checked box displays the plot and a un checked box hides the plot Adjusting the Graph Scales The scale of each plot Pressure Temperature and Flow Rate can be independently adjusted so the plot is displayed over most of the graph height The pressure scale is located on the left hand side of the graph while the temperature and flow rate scales are located on the right hand side Under each scale is a left and right arrow used for scale adjustment The left arrow decreases the scale and the right arrow increases the scale Scale adjustments can be made while in Run or Record modes Displaying Graph Gridlines The horizontal graph gridlines can be displayed by selecting View Show Graph Gridlines Clearing the Graph Press the Clear Graph button or select View Clear Graph from the menu Using the Alarms There are three sets of High Low alarm indicators on the main screen which monitor pressure temperature and flow rates The alarm indicators flash if the current system measurements exceed the alarm limits set by the operator The alarms continue to flash when the current system measurements return back to normal to alert the operator that an alarm condition occurred The operator must reset the alarms manually to acknowledge the alarm condition Upon exiting Run or Record mode the operator can view all alarm events time value alarm level in another form These alarm events are also recorded to the
37. rting the software This allows the software application to detect a connected unit Start the software application by double clicking on the Flo tech Hydraulic Analyzer icon on your desktop Press the Run button Data will be displayed on the digital displays and the strip chart will be updated once per second 4 Press the Stop button when finished to halt the collection of data Recording Measurements to a File All measurements can be saved to a comma separated value csv file This file type is a generic text file with the data separated by commas and can be read by many spreadsheet applications such as Excel and Corel Quattro Pro These spreadsheet programs can then re graph and manipulate the data All measurements taken as shown in Table 1 on page 8 are saved once per second to the file For example recording for 2 minutes would yield 120 points of data Even though data points are only recorded once per second pressure spikes and dips are captured by recording the maximum or minimum pressure during each measurement period Therefore the precise shape of the pressure spike is not recorded but its amplitude and the time it occurred are both recorded ER ER ET ES RR D E G H EA K 1 Device ID Test Stand 4 2 Serial No 12345678 3 Model No USB Tester 4 Date 11 1 2007 5 Time 11 52 50 AM 6 7 Pressure Units PSI 8 Temperature Units F 9 Flow Rate Units GPM 10 11 Time Seco
38. t indicates a faulty relief valve D Motor Test No Load 1 Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put the motor s control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time Using a tachometer run the motor with no load The flow and RPM should match the manufacturer s specification A decrease in RPM from the manufacturer s specifications indicates a loss of the motor s efficiency E Motor Test Loaded 1 Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 Put the motor s control valve in the forward operating position If there are multiple valves only one control valve should be in an operating position at any one time Using a tachometer run the motor while providing a load on the motor The flow and RPM can now be checked against the motor manufacturer s specifications A decrease in RPM from the manufacturer s specifications or the unloaded motor test indicates a loss of the motor s efficiency Form ZFLIT 560 09 10 Page 21 Flo tech Flo Check USB Hydraulic System Analyzer Installation amp Programming Instructions Ill Control Valve and Bi directional Hydraulic Motor Test Flo
39. times can be set verified and or logged in the circuit Inches per Minute 231 x GPM SQ IN Force can also be checked by checking the pressure when the cylinder is at the end of its stroke Force Pressure x Area a Ifall components are in good operating condition pressure and flow measurements should be the same as in the Pump Test b Ifa decrease in flow or pressure in any control valve position is noted leakage is indicated c If the decrease in flow is the same with the control valve s in all positions it indicates the relief valve is at fault Note This can also indicate some other leak is present in the control valve such as a defective casting damaged seals or worn valve position detents but always check the relief valve FIRST d Ifthe relief valve is operating normally see Directional Control valve DCV Test A decrease in pressure at the cylinders full stroke could indicate worn piston seals V Hydrostatic Transmission Diagnostics Install the Flo Check into the system between the pump discharge port and the inlet of the hydraulic motor Case Drain l Flow Bi directional Reservoir FIGURE 11 Hydrostatic Transmission Test A Pump Open the Flo Check loading valve fully to read maximum pump flow at zero pressure Select Run and or Record on the PC see Recording Measurements to a File on page 8 then close the loading valve to increase pressure from zero pressure to rated or maximum pump pressu
40. u select File Record To to open a Save As dialog form Enter the name you wish to save the file in the File Name textbox and press the Save button Press the Run button to start viewing measurements Notice the Record button is not grayed out This is because the software file name and location have been set up before entering Run mode When ready to start recording press the Record button The message Recording is displayed under the Run button to indicate the software has entered Record mode Press the Stop button when finished to halt the collection of data Note Once the Stop button is pressed the Record To file name is erased from memory This is to avoid accidental overwriting of files The user must enter this information before each session when trying to record while in Run mode When Entering Run or Record Mode The menu will disappear when entering Run or Record mode and return when pressing the Stop button This blocks changes from being made while the software is collecting measurements which can cause gaps in the collection process Entering the Run or Record mode also causes a blue indicator to flash in the Log Interval frame This indicates the Hydraulic Analyzer interface is running and collecting data Recording Modes There are two recording modes Record All Points and Capture Points Manually The default setting is set to Record All Points This setting records all points in one second intervals t
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