Internal Gear Pumps Installation Manual
Contents
1. C N INTERNATIONAL Internal Gear Pumps Installation Manual MEDIUM HEAVY DUTY SERIES SIZE 2 PGI100 PGI100 2 005 PGI100 2 006 PGI100 2 008 PGI100 2 011 PGI100 2 013 PGI100 2 016 PGI100 2 019 PGI100 2 022 PGI100 2 025 MEDIUM HEAVY DUTY SERIES SIZE 3 6 PGI101 PGI101 3 020 PGI101 6 125 PGI101 3 025 PGI101 6 160 PGI101 3 032 PGI101 6 200 PGI101 3 040 PGI101 6 250 PGI101 3 050 PGI101 3 064 HEAVY DUTY SERIES SIZE 2 3 6 PGI102 PGI102 2 004 PGI102 3 014 PGI102 6 040 PGI102 2 005 PGI102 3 016 PGI102 6 050 PGI102 2 006 PGI102 3 020 PGI102 6 064 PGI102 2 008 PGI102 3 025 PGI102 6 080 PGI102 2 011 PGI102 3 032 PGI102 6 100 PGI102 2 013 PGI102 3 040 PGI102 6 125 PGI102 2 016 PGI102 3 050 PGI102 6 160 PGI102 2 019 PGI102 3 064 PGI102 6 200 PGI102 2 022 PGI102 6 250 PGI102 2 025 MEDIUM HEAVY DUTY SERIES SIZE 5 6 PGI103 PGI103 5 064 PGI103 6 125 PGI103 5 080 PGI103 6 160 PGI103 5 100 PGI103 6 200 PGI103 6 250 HYDAC E 2 905 M 0 02 14 oe Q 0 E 2 905 M 0 02 14 Q9 oO gt To prevent serious accidents equipment damage and other property damage please observe the following precautions as well as all related regulations regarding safety Before using the product make sure you read and understand all the instructions in the Operator s Manual entirely In this catalogue safety precautions are classified under three headings DANGER WARNING and CAUTION These words are defined as follow2. Size 3 Series PGI101 3 020 PGI101 3 025 PGI101 3 032 PGI101 3 040 PGI101 3 050 PGI101 3 064 Geometric displace ment cm rev Operating pressure Intermittent bar PGI101 Maximum drive speed rpm 3600 3200 3000 2500 1800 Heavy Duty Series Size 2 3 6 Series PGI102 2 004 PGI102 2 005 PGI102 2 006 PGI102 2 008 PGI102 2 011 PGI102 2 013 PGI102 2 016 PGI102 2 019 PGI102 2 022 PGI102 2 025 PGI102 3 014 PGI102 3 016 PGI102 3 020 PGI102 3 025 PGI102 3 032 PGI102 3 040 PGI102 3 050 PGI102 3 064 PGI102 6 040 PGI102 6 050 PGI102 6 064 PGI102 6 080 PGI102 6 100 PGI102 6 125 PGI102 6 160 PGI102 6 200 PGI102 6 250 Series PGI103 5 064 PGI103 5 080 PGI103 5 100 PGI103 6 125 PGI103 6 160 PGI103 6 200 PGI103 6 250 Geometric displace ment cm rev Geometric displace ment cm rev Q DD O N 00 O Operating pressure 350 400 300 325 280 300 350 400 0 oO O DD N O1 300 325 340 350 330 340 300 320 PGI102 Maximum drive speed rpm 4200 4000 3600 4000 3000 2500 1800 2400 2200 2000 PGI103 Maximum drive speed rpm 3000 2500 2200 2000 2200 Documentation Check the product s model code and compare it with your paper work HYDAC HYD Postfach 1261 D 66273 Sulzbach Saar Indi SYSTEM rstellererkl rung im Sinne der EG Richtlinie Maschinen Hiesmit erkl r
3. reservoir until the system has been completely vented Under no circumstances must the oil fall below the minimum level e After venting the pump it should be loaded to the required pressure and the pressure relief valve should be protected from unauthorised adjustment e Prior to switching off the pump the system should be unloaded e After operating for some time check the filter and oil temperature HYDAC
4. 8063 Gusch fsfutrer Barkvectisdsrgen h Senrtrdehen Landesbank Sear Dresdner Bank AG Otmar P Sch n toit Nr 20015178 BLZ 530 500 CO Nr 3068659 BLZ 580400 50 Site dor Gesell ers Biz BIC SALADESSIOK BIO DRESGErTERE ie 65290 SuthachtSaa fidi IBAN D28 005 0000 0029 0151 i 5583 Ragiasargarichi Saartulcikan IBAN DEB4 5997 0000 73800 HRB 12364 I Delivery note and or sales acknowledgement HYDAC E 2 905 M 0 02 14 N E 2 905 M 0 02 14 Q Qo 00 INSTALLING THE PUMP Installation position The pumps can be installed vertically shaft at the top or horizontally Note Internal gear pumps are self priming They can be installed both above and below the tank level The permitted pressure values on the suction side of the pump must not be exceeded see Technical Specifications Installation instructions Important Prior to installing and commissioning the pump it must be filled with oil from the suction side When installing the pump ensure that e the direction of rotation of the drive and pump marked by an arrow on the case or nameplate correspond to each other For example a drive running anti clockwise requires a pump which runs clockwise e the pump and motor shaft are aligned e compensating couplings flexible drive or curved gear couplings are used e the pump is driven free of axial and lateral forces A drive using gear wheels belts or chains without an adapter bearing i
5. NG FLUID Hydraulic mineral oils Selection e Branded hydraulic oil to DIN 51524 Part 2 must always be used e Blending several types of oil or oil of different manufacturers must be avoided because it can have a detrimental effect on the hydraulic characteristics of the fluid Operating temperature e The optimum operating temperature is from 40 C to 60 C a short term maximum temperature from 80 C to 100 C is permitted Viscosity Minimum operating viscosity 10 mm s cSt Optimum operating viscosity 25 100 mm s cSt Maximum starting viscosity 2000 mm s cSt When selecting the operating medium s viscosity consideration must be given to the average operating temperatures whilst maintaining the permitted viscosity values FIRE RESISTANT FLUIDS AND OTHER FLUIDS Please contact HYDAC E 2 905 M 0 02 14 HYDAC Q DD co E 2 905 M 0 02 14 Q gt O FILTRATION Careful filtration of the pressure fluid is essential for a long service life and trouble free operation of the hydraulic system Cleanliness level e Cleanliness class of the operating fluid Code 20 18 15 to ISO 4406 1999 or NAS 1638 Class 9 or cleaner e In order to ensure a longer service life we recommend to ISO 4406 Code18 16 13 or cleaner or NAS 1638 Class 7 or cleaner We recommend using a filter with a minimum retention rate of B gt 100 e The filter or filter elements must be maintained regularly and replaced if nec
6. en wir da die auf diesem Lieferscheln aufgef hrten Produkte in der von uns gelieferten Ausf hrung zum eine Maschine bestimmt sind und da ihre Inbetriebnahme so lange untersagt ist bis festgestellt wurde da chine in die unsere Produkte eingebaut werden sollen den Bestimmungen der EG Richtinie Maschinen rkl rung wurde maschinell erstellt und ist ohne Unterschrift g ltig rstellerzertifikat O nac 18 igen Ihnen hiermit dass der folgende Lieferumfang bestelkonform und nach den zum Zeitpunkt des imaligen Inverkehrbringens allgemeinen anerkannten Regeln der Technik beschaffen ist rsteller eauflragte nsport Detall ersandart KW ieur SV iafarbodingui IP KAI SLAUTERN KT 68 teriai Menge ezelchnui Gest tsl hrer Bankvarbindungen I Svarbrieks Landestans Saar Grosch an Druso a5 Man ai ici niz momo pronti AI i i IBAN DE2B 5506 0009 0020 015178 BAN DET S808 0980 0906 53 c0 Regfeierparicht Saarbr cken IOAN DEA 3907 0050 RB 1704 HYDAC System GMBH Postfach 1251 D 66273 Sulzbach Soar Industriogebist D 66280 Sulzbach Telefon 106897 509 01 Telefax 106897 509 454 www bydao c fersandans Bales Nr Datum EBR PFE 81042917 09 200 D 67655 KAISERSLAUTERN Pos Material jens Bezeichnung Beipack zu 6104291 0001 620365 A2FO 45 61R PPBOS AXIALKOLBENPUMPE A2FO 48 61R PPB05 Kundenartkehummer 59803228 Bestelinumi 1 55557 891 08 Peeilion Nr 000001 unssres Auftrages Nr 828200
7. essary e To check if the filters are operating correctly they must be fitted with a visual or preferably an electrical clogging indicator PRESSURE LIMITING e To avoid excessively high pressures in the pump the pressure relief valve should be positioned as close to the pump outlet as possible and definitely between the pump and the hydraulic system downstream e Select an appropriate setting to ensure that the pump s maximum pressure setting will not be exceeded see Technical Specifications FUNCTIONAL TEST AND COMMISSIONING Direction of rotation Internal gear pumps can be supplied in clockwise and anti clockwise versions The pump s direction of rotation is determined when viewing the drive shaft and is marked by an arrow on the pump case or the name plate Prior to commissioning the pump check that the direction of rotation of the drive and pump correspond Drive speed The permitted range of drive speeds is given in the brochures CAUTION When operating a combination of pumps especially when different pump series or sizes are combined the drive speed must not exceed that permitted for the pump with the lowest speed Commissioning e It must be possible for the pump to be started without load that is with a consumer that is unloaded e During the initial commissioning the pressure line must be vented e Vent the system until all cracking noises and foaming have stopped At the same time check the fluid level in the
8. ion removal maintenance piping or wiring work the following procedures must be carried out Failure to do so may cause the equipment to move suddenly or oil to spill during the work which may result in serious accidents Shut off the power supply to the equipment and make sure that all the electrical motors or machines cannot re start unintentionally e Secure the cylinder rods before installing removing the cylinder e Reduce the pressure in the pipes and cylinders in the hydraulic system to zero pressure WARNING 3 Before working on any electrical wiring be sure to shut off the power supply Failure to do this may cause an electric shock CAUTION 4 Keep all installation holes and surfaces clean Failure to do this may cause insufficient tightening of the bolts which may lead to a fire due to oil leakage CAUTION 5 Before commissioning the device make sure that all bolts are tightened with the specified torque Failure to comply with the specifications may cause incorrect operation damage oil leakage etc gt gt gt gt gt gt B B gt PRECAUTIONS FOR OPERATION DANGER 1 Never operate any device in an environment where there is danger of explosion or fire unless the device is fully protected This may lead to major and serious accidents including explosion or fire WARNING 2 Do not approach the pumps or motors when in operation Hands or clothes can be caught up and wou
9. nd into the pumps and motors which can lead to serious injury WARNING 3 In event of abnormal operation unusual sounds oil leakage smoke etc immediately stop operation and take appropriate corrective measures WARNING 4 Completely discharge air from the cylinder at low pressure Failure to do so may result in unexpected movement of the cylinder which in turn may cause injury WARNING 5 To adjust the damping gradually increase the cylinder speed from a low speed 50 mm s or less Rapidly accelerating the cylinder may produce an abnormal pressure surge resulting in damage to the cylinder or the machinery and causing a serious accident WARNING 6 Before operating this device for the first time check that hydraulic and electrical circuits are properly connected and that adjoining surfaces are tightly aligned WARNING 7 Do not use the product outside of the specifications described in the catalogue related data sheets drawings etc Failure to adhere to them may cause incorrect operation damage or injury WARNING 8 During operation high temperatures in the hydraulic system or solenoid valves may occur Wear protective equipment on hands and body when in the vicinity of these devices WARNING 9 Always operate the device with clean oil and within established ranges for temperature viscosity and cleanliness Failure to adhere to the specified limits may result in incorrect operation or fire due t
10. o oil leakage GENERAL PRECAUTIONS WARNING 1 Never modify the device If any alterations are made unexpected machine movement may cause injury CAUTION 2 Do not disassemble the products without prior consent of the manufacturer Failure to adhere to this can cause the products to operate incorrectly which can lead to accidents or damage CAUTION 3 For transportation storage of the product pay attention to environmental conditions such as ambient temperature and humidity and implement anti dust anti corrosion measures CAUTION 4 The seals may need to be replaced if the product is used after long term storage CAUTION 5 Read the manual thoroughly and ensure that the seals are replaced properly RELATED REGULATIONS CAUTION To ensure that this product is used in a safe manner it is essential to observe the above precautions as well as all related regulations regarding safety E 2 905 M 0 02 14 HYDAC Q Q O1 E 2 905 M 0 02 14 0 09 O HYDAC INTERNAL GEAR PUMPS Technical specifications Medium Heavy Duty Series Size 2 Series PGI100 2 005 PGI100 2 006 PGI100 2 008 PGI100 2 011 PGI100 2 013 PGI100 2 016 PGI100 2 019 PGI100 2 022 PGI100 2 025 Geometric displace ment cm rev 4 4 9 Operating pressure Intermittent bar 320 350 250 PGI100 Maximum drive speed rpm 4200 4000 300 325 3600 Medium Heavy Duty Series
11. s DANGER Indicates an imminent danger that is very likely to cause death or severe injury unless the situation is avoided WARNING Indicates a potential danger that may cause death or severe injury unless the situation is avoided CAUTION Indicates a potential danger that may cause a minor or moderate injury or that may result in property damage INFORMATION Indicates useful hints and system tips They are necessary for correct installation and safe use of the product HYDAC gt B gt PRECAUTIONS FOR USE CAUTION 1 To avoid possible injury when handling the products wear protective safety equipment in accordance with the instructions in the Operator s Manual CAUTION 2 Failure to support the weight of the product or lifting the product with incorrect posture may result in injury to the hands or back Be sure to follow the instructions in the Operator s Manual CAUTION 3 Do not climb on strike drop or exert unnecessary force on the product This may lead to injury or fire due to incorrect operation damage or oil leakage CAUTION 4 Oil on the product or floor must be cleaned up thoroughly Oil could cause you to drop the product or slip on the floor PRECAUTIONS FOR INSTALLATION REMOVAL AND MAINTENANCE WARNING 1 All installation removal maintenance piping or wiring work should be carried out by properly trained personnel WARNING 2 Before beginning any installat
12. s possible only to a limited extent and always requires approval from HYDAC e no stresses are caused to the pump by uneven pump support e no distortion is caused by incorrectly mounted pipes x e coupling parts are installed without using force When installing a HYDAC pump always ensure that the fluid remains in the pump during stoppages Sealing faces must not be damaged Permitted torques for mounting screws at the pump and pipe connections must be adhered to When mounting pumps with an O ring at the drive shaft make sure the O ring has been greased and that there is a lead in chamfer on the mating part to avoid damage to the O ring HYDAC OIL RESERVOIR e The amount of oil required in the reservoir depends on the particular operating conditions It should be at least twice for intermittent operation and correspondingly long cooling phases to five times the amount of the pump delivery rate per minute If the reservoir is too small cooling of the oil may be required The reservoir must be provided with an air breather filter and a strainer in the filling port Prior to filling the reservoir with oil it must be thoroughly cleaned Oil resistant paint must be used to paint the reservoir Use baffles to ensure sufficient distance between the suction and return lines and to enable complete deaeration of the oil Recommended suction velocity 0 5 1 5 m s Maximum return flow velocity 2 0 3 0 m s Min 50 mm OPERATI
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