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Bulletin HY30-3250-INST/UK

Installation and start-up information PV series


Design series 40, PVplus
Effective: November 15, 2006

Variable displacement axial piston pump

Bulletin HY30-3250-INST/UK

Installation Manual
Contnets 1 2 3 4. 5. 6. 7. 8. 9. Installation and start-up Displacement adjustment Standard pressure compensator, code ...F*S Remote pressure compensator, code FRC

Axial Piston Pump Series PV, series 40


Page 3 6 6 7 8 9 10 11 12 13 13 13 14 15 16 16 17 18

Remote pressure compensator, codes FR1, FRZ Load sensing compensator, code FFC Load sensing compensator, codes FF1, FRZ Two-spool load sensing compensator, codes FT1, FTZ Horse power compensator, codes *L*, *C*

9.1 Horse power compensator, ordering codes *LA resp. *CA 9.2 Horse power compensator, ordering codes *LB resp. *CB

9.3 Horse power compensator, ordering codes *LC resp. *CC 10. Proportional displacement control, code FPV 11. Electrohydraulic p/Q control, codes FPR, FPZ 12. Compensator accessories 12.1 Pressure relief pilot valve, code PVAC1P* 12.2 Multiple pressure pilots PVAC1E*, PVAC2P*, PVAC2E* aund PVAC2M* 13. Trouble shooting guide

Note:  The compensator ordering code is represented by the last three digits of the pump ordering code (digit 13 to 15).

Note This document and other information from Parker Hannin GmbH, its subsidiaries, sales ofces and authorized distributors provide product or system options for further investigation by users having technical expertise. Before you select or use any product or system it is important that you analyse all aspects of your application and review the information concerning the product or system in the current product catalogue. Due to the variety of operating conditions and applications for these products or systems, the user, through his own analysis and testing, is solely responsible for making the nal selection of the products and systems and assuring that all performance and safety requirements of the application are met. The products are subject to change by Parker Hannin GmbH at any time without notice.

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
1. Installation and start-up For a safe and disruption free operation of any machine or system a careful installation and start up following the manufacturers instruction is mandatory.

Axial Piston Pump Series PV, series 40

inlet as far as possible away from return line and drain line. Make sure that the uid circulation in the reservoir does keep return ow from suction pipe inlet. In case of positive head use shut off valve in the inlet, monitored with proximity switch or equivalent to avoid start up of motor Hydraulic systems can be designed for many totally difwhen valve is closed. When installed into the reservoir use ferent functions and they require consequently different short suction pipe with pipe end cut under 45. start up procedures. The hydraulic pump is in this respect only one, but nevertheless very important component of the whole system. Pressure port A general start up instruction therefore can give many Select correct pressure rating for pipe, hose and connechelpful hints but it needs to be completed by specic ad- tors. Take pressure peaks into account. Dimension the ditions depending of the individual nature of the system piping according to the port size. Prevent excitation of the or power unit. system by using exible port connections. During installation and start up the following steps need to be carried out carefully: Drain port Always use highest possible drain port of the pump. Drain port must be higher than pump centerline or install adMake sure that all components of the shipment are com- ditional air bleed line. Never combine pump drain line with plete, free of any damage, free of outside contamination other return lines and/or drain lines. Pump shall not be and properly protected against ingression of contamina- able to run empty. Max. allowable case pressure 0.5bar (2bar peak), also during compensation. tion. Visual inspection Cleanliness Use low pressure pipe/hose, as short as possible and full cross section according to port dimension. Do not use elbows or sharp corners. When drain port is on the side of the pump drain line should have bridge higher than pump top (also when installed in reservoir). Drain pipe must end at least 200 mm below uid level even at lowest lling level. Never let drain ow go direct into suction area of reservoir (temperature, air bubbles). Max. length 2m, otherwise use larger pipe diameter than port size.

Contamination of any kind is the enemy of any hydraulic component. It is still the number 1 cause for component failure. Therefor maximum care and cleanliness are required during all handling and managing of parts that come in contact with the hydraulic uid. All ports of the pumps and other components must be covered until pipes or hoses are mounted to them. Perform assembly preferNote: During operation of PV pumps of all sizes under the ably in a dry and dust free room. Use only suitable tools. following conditions: Installation Q ~ Qmax

pinlet < 2 bar absolute Installation horizontal or vertical, avoid rigid connection Poutlet < 25 bar from pump to reservoir cover or frame and to inlet and outlet piping to prevent excitation of the whole system (e. g. low pressure circulation) the drain ow can change direction. Fluid is taken from the case into the piston mainly due to pump vibrations. through the decompression orice and across the slipper. There is a danger that the pump case runs dry, the pump Suction port overheats and the bearings lack of lubrication when the Position to the side or to the bottom, max. uid velocity uid is removed from the pump case. approx. v = 0.5m/sec, cut suction pipe inlet under 45. Therefore the drain pipe must be able to take uid from Minimum distance from bottom 2 - 3 times diameter and, the reservoir. That means: The drain line must end below even at lowest uid level, approx. 200mm below uid level. uid level, and a check valve in the drain line is not perInlet pressure, even during compensation, never should missible. If it has to be installed for whatever reason the drop below 0.8bar (absolute). case needs to be ushed with a ow of 10 - 15% of the Absolute gas tight connection (risk of cavitation, noise). nominal pump ow. Air bubbles due to vacuum in the inlet can destroy pumps within a short time due to cavitation erosion. Suction pipe should be as short as possible. Use only clean, low pressure pipe, avoid sharp elbows and any restriction of cross section. The suction pipe must have access to clean, cooled and ltered uid, free of air bubbles. No turbulences or high ow velocities should occur at the tube inlet. Therefore position 3
Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

Port positions for PV (shown for clockwise rotation, for ccw rotation ports are mirrored)

Alternative drain port Drain port Interface for compensator

Gage port Suction port (inlet) Flushing port, covered below pump Pressure port (outlet)

Flushing port The PV pumps of design series 40 (PVplus) are equipped with a ushing port. This port is smaller in diameter than the drain port(s) and is located opposite to these ports in the bottom of the pump case. The ushing ow can depending on the actual working conditions - be used to keep the pump case lled, to warm up the pump (during cold temperature operation) or for a better heat dissipation. Permanent dead head operation (>15min) either for pumps of frame size 3 and larger (PV063 and higher) or at high input speeds above 1,800rpm as well as high environmetntal temperatures ushing are recommended. Also dead head operation with HFC uids (water glycole) requires ushing of the pump case, to avoid high uid temperatures. The ushing ow depends on the frame size of the pump:
Frame size 1 Frame size 2 Frame size 3 Frame size 4 Frame size 5 4 to 6 l/min 5 to 8 l/min 7 to 10 l/min 9 to 12 l/min 13 to 17 l/min

Drive input For direct drive use elastic coupling free of axial and radial reaction forces. Please follow strictly the instructions of the coupling supplier regarding axial clearance, axial displacement and angular tolerances. Couplings never shall be mounted using a hammer. Threads in the shaft end allow smooth mounting of the coupling. The drive shaft should only carry true torque. Contact Parker for allowable side loads or axial forces. PV pumps are normally for one direction of rotation only. Therefore check rotation of drive motor prior to installation.

The ushing ow should be taken from the return ow of the separate cooling and lter circuit. Pre load at 1 to 2 bar, consider orice cor responding to preload pressure and recommended ushing ow. 4
Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

Suction lter should be avoided. Suction conditions will be Electrical interface Check voltage, current, phase and connection properties. affected. Filter can be blocked and cause cavitation and severe pump damage. When used, a vacuum sensor with Verify direction of motor rotation. shut off function is mandatory. Properly dimensioned breather rating 10m should be Fluid reservoir The reservoir needs to meet all system requirements used. Observe min. and max. uid level; consider exconcerning design, size, location and porting. Beside change volume with cylinders in the system. beeing reservoir for the hydraulic uid, the tank also supports heat dissipation, air removal, water removal and Filling of pump case contamination sedimentation. Often the reservoir also is Pump case must be lled via the drain port, to ensure the fundament for the motor pump unit. In this case the lubrication, sealing and smooth start up. separation of pump and remaining structure by elastic means is mandatory to avoid noise and vibration being Start up induced into the frame work. The reservoir needs to be carefully sealed against ingression of contamination and Check if all ports are properly connected according to the water. A level indicator and thermometer should be placed specication, all connectors are tightened and all adjustments are made. in an easily accessible location. Open suction valve! Fluid content (general rule): stationary systems 3 to 4 Switch system to free circulation or to lowest pressure. times pump nominal ow, 1 times or even smaller in Allow air bleeding for quick priming. Start pump in tip mobile systems. mode operation until pump and all pipes are lled and free from air bubbles. Filling of the system If pump does not build up pressure double check the Use only high quality mineral oil based uids, like HLP installation. oils according to DIN 51524 part 2. For other uids (HFC, Raise pressure setting only when all air is removed. HFD, bio degradable or synthetic uids) please contact Parker and review the Hydraulic Fluids Information in Let the pump work at reduced pressure for 5 - 10 min, check if all pipes and connections are leak free and Catalogue 2500/UK. tight. Operation viscosity should be 16 to 100mm/s, optimum viscosity range is in the 20 to 40mm/s, max. viscosity for Observe reservoir: uid level, built up of foam, uid temperature. When system is warmed up rst functional tests short time up to 320mm/s. Because of the possibly uncompatible ingredients uids can be performed. should not be mixed (separation of uid, reduction or loss Note of uid properties). All pumps are tested and adjusted after assembly in our factory. Pay highest attention on cleanliness! Fill system only via a ltration device. Use ltration unit, If no specic pre-setting is required on the order only the when basic contamination of the rell uid exceeds class compensating pressure needs to be adjusted. Depending 10 according NAS 1638 (contamination level 18/16/13 on the compensator option this might be done on a pilot according to ISO 4406). Hydraulic uid supplied in barrels valve only. In this case no adjustments on the compensatypically exceeds these contamination levels. tor or the pump is required. Only after service or repair a basic adjustment needs to be performed. Filtration Filtration is the most important factor to the opera-tional life of the hydraulic system. Statistical analy-ses indicate, that contamination is by far the most important reason for system or component failure. Use return line, pressure and/or bypass ltration. Bypass ltration usually is most efcient. For general purpose hydraulic systems with limited requirements for operational life contamination level 20/18/15 according to ISO 4406 should be desired; corresponding lter rating: x = 25m ( b2575 ) according to ISO 4572. Cleanliness level for systems with higher re-quirements for operational life and functional safety should be 18/16/13 according to ISO 4406; corresponding lter rating x = 10m ( b1075 ) according to ISO 4572. Use lter with indicator or electrical signal when capacity limit is approached.

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
2. Displacement adjustment All axial piston pumps of the PV series are equipped with an adjustable displacement limiter. The servo piston stroke is limited at full displacement by a screw, guided in the end cover plug of the servo piston bore. The screw is protected against unintentional adjustment by a self-sealing lock nut. The factory setting of the displacement is according to the nominal displacement of the pump. An adjustment may only be made to a lower displacement (turning screw in). An adjustment to a higher than the nominal displacement can destroy the pump. Adjustment should only be made with the pump working at full displacement (not compensated) and at a low output. At full displacement the piston area of the servo piston is under case pressure. Opening the self-sealing nut will only cause a negligible leakage under these conditions.

Axial Piston Pump Series PV, series 40


Displacement change per mm (approx. cm/U) 1.5 1.5 1.5 2.2 2.2 2.2 3.4 3.4 3.4 5.6 5.6 6.8 Displacement change per turn (approx. cm/U) 1.5 1.5 1.5 2.2 2.2 2.2 3.4 3.4 3.4 8.4 8.4 10.2 Minimum adjustable displacement (approx. cm/U) 9 13 16 17 25 30 35 50 65 20 60 120

Size PV016 PV020 PV023 PV032 PV040 PV046 PV063 PV080 PV092 PV140 PV180

Adjustment screw Lock nut

PV270

3. Standard pressure compensator, code ...F*S The adjustment of the compensating pressure is performed for the standard pressure com pen sa tor directly at the compensator. To adjust the pressure, the lock nut (SW 19) is to be loosened and the adjustment spindle is to be turned. Turning clockwise will increase the com-pensating pressure, turning counter-clockwise will decrease the compensating pressure. The adjustment spindle has a thread pitch of 1mm (thread M 12 x 1). The following limits exist for the three spring options: Pressure range Nominal pressure bar Minimum pressure setting bar 8 - 10 8 - 10 8 - 10 Pressure variation per turn / per mm bar 20 40 60 Note! Maximum possible adjustment bar 170 350 450

D H W

140 210 350

Turning the adjustment screw clockwise will reduce the Note! Danger of spring overload at maximum possible pumps displacement. For the sizes PV016 PV092 the adjustment pressure! thread pitch is 1mm, for sizes PV140 PV270 the thread pitch is 1.5mm. The following table shows the displacement change per mm resp. per turn and the minimum adjustable displacement:

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40


Snap ring Adjustment spindle Lock nut

Although for all three springs the min. adjustable pressure is approx. 8 - 10bar (min. compensating pressure of a PV pump), for the spring code H a min. pressure adjustment of 40 bar and for the spring code W a min. pressure adjustment of 70bar is recommended. Adjusting lower pressures with these springs can lead to an extremely slow compensator response. 4. Remote pressure compensator, code FRC

The max. possible pressure adjustment is reached, when the spindle is completely turned in (snap ring touches the lock nut). In this situation there is a danger of spring overload depending of manufacturing tolerances. If such a high adjustment should be prohibited, washers can be placed between lock nut and snap ring.

Snap ring Adjustment spindle Lock nut Remote port

For the remote pressure compensator the pressure adjustment is done at a pressure pilot valve (not included in the shipment of the pump). The pilot valve is connected to the remote port. The pressure pilot valve must be capable of hand ling securely a pilot ow of approx. 1.2l/min.Therefore a nominal ow of 3 - 6l/min is re com mended for the pilot valve. Selection of a pilot valve too small or too large can result in compensator instability. The pilot port thread can be determined from the ordering code of the pump (threads and port code):

The pilot valve can be mounted as far as 15m away from the pump. Please note for a distance above 5m, that low temperatures and a high uid viscosity can signicantly increase the compensating pressure. The pilot connection should be dimensioned to avoid any considerable pressure drop in this line. The pressure adjustment and the max. pressure setting are given by type and setting of the pilot valve. The min. compensating pressure can be calculated from the min. adjustable pressure of the pilot valve plus the differential pressure setting at the compensator. Factory setting for the compensator differential pressure is 15 1bar. This adjustment should only be modied, if specically required. To change the adjustment the lock nut is to be loosened and the adjustment spindle to be turned. Clockwise turning will increase the differential pressure setting.

Threads and port code 1 3 7 8

Port dimensions G 1/4 BSPP 7/16-20 UNF M12 x 1.5 ISO 6149-1 M12 x 1.5 ISO 6149-1

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
The adjustment range reaches from approx. 8bar to approx. 80bar. The actual compensating pressure is given by the pressure setting of the pilot valve at nominal pilot ow (approx. 1.2l/min) plus the compensator differential pressure.

Axial Piston Pump Series PV, series 40


For differential pressure adjustment the true differential pressure should be measured (pump outlet pressure minus pilot pressure). An adjustment only measuring pump outlet pressure requires an absolutely pressure free remote port.

At factory setting and fully unloaded remote port the min. Functional descriptions and circuit diagrams of all comcompensating pressure is 15bar. pensators see Catalogue HY11-2500/UK, chapter 1.

5. Remote pressure compensator, codes FR1, FRZ

Mounting interface NG6, DIN 24 340 for pressure pilot valve Snap ring Adjustment spindle Lock nut

For the remote pressure compensator the pressure adjustment is done at a pressure pilot valve (not included in the shipment of the pump). This pilot valve is mounted to the NG6 interface on top of the compensator valve. Parker offers a wide variety of compensator accessories (pilot valves) under ordering code PVAC* . The pressure pilot valve must be capable of hand ling securely a pilot ow of approx. 1.2l/min.Therefore a nominal ow of 3 - 6l/min is re com mended for the pilot valve. Selection of a pilot valve too small or too large can result in compensator instability.

The min. compensating pressure can be calculated from the min. adjustable pressure of the pilot valve plus the compensating differential pressure adjusted at the compensator. Factory setting for the compensator differential pressure is 15 1bar. This adjustment should only be modied if necessary. To change the adjustment the lock nut is to be loosened and the adjustment spindle to be turned. The adjustment range reaches from approx. 8bar to approx. 80 bar. The actual compensating pressure is given by the pressure setting of the pilot valve at nominal pilot ow (approx. 1.2l/min) plus the compensator differential pressure.

The pilot valve is mounted directly on top of the compensator valve (mounting interface NG6, DIN 24340 on compensator topside). The mounting threads for the pilot At factory setting and fully unloaded remote chamber valve are M5 for threads and port code 1 and 8 or #10 - 24 (compensator spring chamber) the min. compensating UNC for threads and port code 3 and 7. pressure is 15bar. Beside a manual operated pilot valve (e. g. code PVAC1P*) also a proportional pressure valve (e. g. DSAE* or RE*) or a multiple pressure pilot circuit (e.g. PVAC2P*) can be installed. For differential pressure adjustment the true differential pressure should be measured (pump outlet pressure minus pilot pressure). An adjustment when only measuring the pump outlet pressure requires an absolutely pressure Compensator accessories see Catalogue HY11-2500/ free compensator spring chamber. UK, chapter 1. Functional descriptions and circuit diagrams of all comProportional pressure pilot valves and driver electronics pensators see Catalogue HY11-2500/UK, chapter 1. to operate these valves see Catalogue HY11-2500/UK, chapters 4 and 10.

The pressure adjustment, and the max. pressure are dened by type and nature of the pressure pilot valve.

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
6. Load sensing compensator, code FFC

Axial Piston Pump Series PV, series 40

Snap ring Adjustment spindle Lock nut Load sensing port

The load sensing or ow compensator primarily controls the pump output ow. To achieve this the load pressure after a main stream throttle valve (load sensing valve, not included in the shipment of the pump) is connected to the load sensing port of the compensator. The compensator control strategy is, to keep the pressure drop constant across this main stream throttle valve. To add pressure compensation to the load sensing function, an orice ( 0.8mm) is to be added into the load sensing line and a pressure-pilot valve must be connected between orice and compensator valve (see circuit diagram).

The pressure pilot valve must be capable of hand ling securely a pilot ow of approx. 1.2l/min.Therefore a nominal ow of 3 - 6l/min is re com mended for the pilot valve. Selection of a pilot valve too small or too large can result in compensator instability. The pressure adjustment and the max. pressure are dened by type and nature of the pressure pilot valve. The minimum compensating pressure can be calculated from the min. adjustable pressure of the pilot valve plus the compensating differential pressure adjusted at the compensator.

Circuit diagram of a load sensing compensator with external pressure pilot valve

Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

The connecting thread at the load sensing port is dened The actual compensating pressure is given by the presby the threads and port option of the pump ordering sure setting of the pilot valve at nominal pilot ow (approx. code: 1.2l/min) plus the compensator differential pressure. Threads and port code 1 3 7 8 Port dimensions G 1/4 BSPP 7/16-20 UNF M12 x 1.5 ISO 6149-1 M12 x 1.5 ISO 6149-1 At factory setting and fully unloaded remote chamber (compensator spring chamber) the minimum compensating pressure is 10bar. For differential pressure adjustment the true differential pressure should be measured (pump outlet pressure minus pilot pressure). An adjustment only measuring pump outlet pressure requires an absolutely pressure free compensator spring chamber. The pressure adjustment also inuences the effective output ow of the pump. The higher the differential pressure setting, the higher the ow at a given setting of the load sensing valve.

Factory setting for the compensator differential pressure is 10 1bar. This adjustment should only be modied if necessary. To change the adjustment the lock nut is to be loosened and the adjustment spindle to be turned.

The adjustment range reaches from approx. 8bar to ap- Functional descriptions and circuit diagrams of all comprox. 80bar. Note, that a higher adjustment means higher pensators see Catalogue HY11-2500/UK, chapter 1. power losses at the load sensing valve.

7. Load sensing compensator, codes FF1, FRZ

Mounting interface NG6, DIN 24 340 for pressure pilot valve Snap ring Adjustment spindle Lock nut Load sensing port

The load sensing or ow compensator primarily controls the pump output ow. To achieve this the load pressure after a main stream throttle valve (load sensing valve, not included in the shipment of the pump) is connected to the load sensing port of the compensator. The compensator control stra tegy is, to keep the pressure drop across this main stream throttle valve constant. In addition the compensator with the code FF1 comes with a top side mounting interface NG6 DIN 24340 and a pilot orice 0.8mm in the load sensing port. Directly on the mounting interface a pressure pilot valve can be mounted. The mounting threads for the pilot valve are M5 for threads and port code 1 and 8 or #10 - 24 UNC for threads and port code 3 and 7.

The pressure pilot valve must be capable of hand ling securely a pilot ow of approx. 1.2l/min.Therefore a nominal ow of 3 - 6l/min is re com mended for the pilot valve. Selection of a pilot valve too small or too large can result in compensator instability. The thread at the load sensing port is given by the threads and port option of the pump ordering code:

Threads and port code 1 3 7 8

Port dimensions G 1/4 BSPP 7/16-20 UNF M12 x 1.5 ISO 6149-1 M12 x 1.5 ISO 6149-1
Parker Hannin Pump ands Motor Division Chemnitz, Germany

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Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

The pressure adjustment and the max. pressure are de- At factory setting and fully unloaded remote cham-ber ned by type and nature of the pressure pilot valve. (compensator spring chamber) the min. com-pensating The min. compensating pressure can be calculated from pressure is 10bar.

the min. adjustable pressure of the pilot valve plus the For differential pressure adjustment the true differential compensating differential pressure adjusted at the com- pressure should be measured (pump outlet pressure pensator. minus pilot pressure). An adjustment only measuring Factory setting for the compensator differential pressure pump outlet pressure requires an absolu-tely pressure is 10 1bar. This adjustment should only be modied if free compensator spring chamber. necessary. To change the adjustment the lock nut is to be loosened and the adjustment spindle to be turned. The adjustment range is from approx. 8bar to approx. 80bar. The actual compensating pressure is given by the pressure setting of the pilot valve at nominal pilot ow (approx. 1.2l/min) plus the compensator differential pressure. The pressure adjustment also inuences the effective output ow of the pump. The higher the differential pressure setting is, the higher the ow is going to be at a given setting of the load sensing valve.

Functional descriptions and circuit diagrams of all compensators see Catalogue HY11-2500/UK, chapter 1.

8. Two-spool load sensing compensator, codes FT1, FTZ Mounting interface NG6, DIN 24 340 for pressure pilot valve Snap ring Adjustment spindle Lock nut

ssure remote pre tor compensa ing c load sens sator ompen-

Snap ring Adjustment spindle Lock nut Load sensing port

The two spool compensator, code FT1 has two separate To change the adjustment the lock nut is to be loosened compensator valves for ow and pressure. and the adjustment spindle to be turned. The adjustment The ow compensation is done with the lower valve. It range reaches from approx. 8 bar to approx. 80bar. The is connected to the load sensing port of the hydraulic actual compensating pressure is given by the pressure setting of the pilot valve at nominal pilot ow (approx. 1.2l/ circuit. min) plus the compensator differential pressure. The remote pressure compensator is mounted on top of the ow compensator and it overrides the ow compensa- At factory setting and fully unloaded remote chamber tion, when pressure setting is reached. On the mounting (compensator spring chamber) the min. compensating interface NG6, DIN 24340 on top of the pressure compen- pressure is 10bar. sator stage as described for the remote pressure com- For differential pressure adjustment the true differential pensator FR1 any pressure pilot valve can be mounted, pressure should be measured (pump outlet pressure as long as is fullls the requirements described there. minus pilot pressure). An adjustment only measuring Mounting interface, threads and port dimensions see pump outlet pressure requires an absolutely pressure free compensator spring chamber. Catalogue HY11-2500/UK, chapter 5. The factory setting of the ow compensator is 10 1bar, the adjustment for the pressure compensator is 15 1bar. These adjustments should only be modied, when necessary. 11
Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

9. Horse power compensator, codes *L*, *C* Section of a horse power compensated pump Depending on its type, the horse power compensator consists of a modied remote pressure com pen sator or a modied load sensing compensator in combination with the horse power pilot cartridge. The opening pressure of this pilot cartridge depends on the actual displacement of the pump. At large displacements the opening pressure is low. As the displacement is reduced the opening pressure is increased according to the form of the contour sleeve in the pump. That leads to the desired control characteristic (constant input horse power). That is achieved by having the pilot cartridge seat being guided by the contour sleeve. This contour sleeve is rmly connected to the servo piston. The contour represents the desired input horse power. The horse power pilot cartridge is internally con-nected to the compensator valve. Compensator valves for horse power compensated pumps differ from standard compensator valves only in this additional port in the mounting interface. Horse power pilot cartridge For a standard horse power compensator with ordering code *L* a modied remote pressure compensator is used. Set screw For a horse power compen-sator with load sensing, code *C* a modied load sensing compensator is used. Lock nut Constant horse power curve with adjustment

At the adjustment screw of the horse power pilot valve a basic adjustment of the horse power compensator can be made. Attention: 0.1 mm equals approx. 20 bar! After loosening the lock nut (self-sealing nut) the compensator control curve can be moved by turning the adjustment screw (adjustment A in the diagram left). This adjustment, done to meet the required constant input horse power curve, is already made during the factory test and should be modied only in exceptional cases. To adjust the correct constant horse power curve a measuring device is required. An output power measurement requires pressure and ow metering. An input power measurement requires torque and speed measurement or a measurement of the electric motor current. Adjustment A Tolerance compensation for optimized performance; done at pilot cartridge. Adjustment B Max.pressure setting; done at pressure pilot valve.

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

9.1 Horse power compensator, ordering codes *LA resp. *CA Mounting interface NG6, DIN 24 340 for pressure pilot valve Snap ring Adjustment spindle Lock nut Load sensing port, for code *LA plugged

A horse power compensator with ordering codes *LA mounted when it fullls the requirements. Valve selection, resp. *CA has a compensator valve with a topside mount- requirements and mounting dimensions see Catalogue ing interface NG6, DIN 24340. Any pilot valve can be HY11-2500/UK, chapter 4. 9.2 Horse power compensator, ordering codes *LB resp. *CB Snap ring Adjustment spindle Lock nut Remote resp. load sensing port

For horse power compensators with ordering codes *LB resp. *CB the compensator valve has a pilot port on its side. If no pilot valve pilot valve for adjustable pressure compensation is connected, the compensating pressure is dened by the design of the contour sleeve and can be in the range of 370 20bar, depending on the adjustment of the horse power pilot valve.

If another compensating pressure or a closer tolerance is required, an external pilot valve can be connected. External pilot valve, requirements and adjustment procedures see Catalogue HY11-2500/UK, chapter 3. Functional descriptions and circuit diagrams of all compensators see Catalogue HY11-2500/UK, chapter 1.

9.3 Horse power compensator, ordering codes *LC resp. *CC Lock nut Set screw With horse power compensator ordering code *LC resp. *CC an adjustable pressure pilot valve is included in the shipment. The valve is mounted on top of the compensator valve. After loosening the lock nut, turning of the adjustment screw allows a setting of the compensating pressure between approx. 20bar and 350bar (adjustment B in gure on previous page).

pilot valve pressure MNS PVAC1PC . ssure resp remote pre nsator ing compe load sens
Load sensing port, for code *LC plugged

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
10. Proportional displacement control, code FPV Cap nut

Axial Piston Pump Series PV, series 40

Lock nut The electrohydraulic proportional displacement control consists of the proportional displacement control valve shown above and the inductive position transducer (LVDT) used for the displacement feedback.

Electrical connection After that the zero setting of the LVDT must be controlled. The LVDT must be connected to terminals 23, 24 and 25 of the electronic control module and the solenoid to terminals 14 and 15.

Setting dimension for LVDT armature

Inductive position transducer (LVDT) Plug with O-ring sealing

Zero adjustment (secured) Series 40 Do not adjust! Electrical connection

Series 41

Series 42

LVDT and proportional displacement control valve are When the pump is running the input command for the disfactory set and the adjustment is secured. Any new or placement is to be set to 0 and the pressure relief valve of re-adjustment is only necessary after repair or service. the system / test rig should be set to a pressure > 25bar. Prior to an adjustment rst the setting dimension of the All other valves of the system must be closed. LVDT probe is to be checked (see gure and table above). The pump then will compensate at the min. compensating The adjustment is secured with an adhesive. pressure (10 2bar) to its min. displacement. By adjusting Any new adjustment must be secured with an adhesive, the zero adjustment potentiometer at the LVDT the voltage at the diagnosis output must be adjusted to 0V, because to avoid unintentional variation of the adjustment. this situation represents the absolute minimum working displacement of the pump.

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
Then the set command for the displacement must be raised, until the max. swash plate angle is reached. This can either be checked by monitoring the diagnosis output or by using a ow meter. The swash plate angle has reached its maximum, when the displacement does not grow further, even when the input command is increased. If the input command reaches 10V (or 20mA for electronic modules with current input = max. input command) before the max. displacement is reached, the displacement can be increased further by using the MAX potentiometer on the module.

Axial Piston Pump Series PV, series 40


If the max. displacement is reached at an input command considerably below 10V, a correction can also be achieved by setting the MAX potentiometer accordingly. To perform a basic adjustment of the proportional displacement compensator valve, rst the cap nut, the lock nut and the O rings and washers must be removed. Then a medium input command is to be adjusted (e. g.: 50% displacement).

Set screw (basic compensator valve adjustment)

In this control situation the proportional solenoid should draw approx. 60% of its nominal current (nominal current 1.3A; current in control situation 750mA). Under this condition the solenoid works at half its nominal force in control position and a similar control response speed is achieved for upstroking and downstroking. Turning the set screw varies the solenoid current. Clockwise turning increases the solenoid current. After that the set screw is to be secured with the lock nut and the adjustment screw to be covered by the cap nut. See Catalogue HY11-2500/UK, chapter 10.

Note The proportional displacement control code FPV does not include pressure compensation. Therefore the hydraulic circuit must be equipped with a pressure relief valve capable of the full pump output ow.

11. Electrohydraulic p/Q control, codes FPR, FPZ The electrohydraulic p/Q control, code FPR is equipped with an additional remote pressure compensator valve on top of the proportional displacement control valve. This valve overrides the displacement control, when the max. pressure setting of the pilot valve is reached (see gure on following page). For an electronic pressure adjustment the use of a proportional pressure pilot valve with NG6 mounting in terface is recommended, e. g.: the series DSAE* or RE* on top of the remote pressure com pen sator stage. These valves are optimally adjus ted for use with pump compensator and can be powered by the electronic control modules This remote pressure compensator is equivalent to the PQ0*-P00 or PQ0*-Q00. The solenoid of the pressure valve used for pressure compensation in the two spool- valve is to be connected to terminals 16 and 17 of the compensator code FT1, described in Catalogue 2500/ control module. UK, chapter 8. There also the adjustment is described. As Please note: The proportional control only can work, when noted there the compensating differential pressure is fac- the pump output pressure is above 10 - 15bar. Below that tory set to 12 1bar, leading to a minimum compensating the servo spring of the pump cannot be compressed and pressure of also 12bar. the pump will not compensate.

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
Mounting interface NG6, DIN 24 340 for pressure pilot valve

Axial Piston Pump Series PV, series 40

Basic compensator setting

Electrical connection

Basic adjustment of the proportional displacement con- See also installation manuals for electronic modules trol valve (lower valve) see Catalogue HY11-2500/UK, PQ0*-P00, Bulletin 3241-M1/UK and PQ0*-Q00, Bulletin chapter 10. 3242-M1UK. For adjustment of the remote pressure compensator Functional descriptions and circuit diagrams of all comstage, see remote pressure compensator FR1 in Cata- pensators see Catalogue HY11-2500/UK, chapter 1. logue HY11-2500/UK, chapter 4.

12. Compensator accessories 12.1 Pressure relief pilot valve, code PVAC1P* The pressure relief pilot valve code PVAC1P* is optimally tuned for the requirements of the compensator valves of the series PV. It has a mounting interface NG6 according to DIN 24340 and can be mounted directly on top of all compensator valves with the topside mounting interface. After loosening the lock nut SW13 an adjustment of the compensating pressure for the pump is possible in a range of approx. 20bar up to 350bar. The pressure pilot valve is also available with a DIN lock.

Lock nut Set screw

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual

Axial Piston Pump Series PV, series 40

12.2 Multiple pressure pilots PVAC1E*, PVAC2P*, PVAC2E* aund PVAC2M* For multiple pressure pilots, codes PVAC2P*, PVAC2E* and PVAC2M* a sandwich valve with two direct-action pressure cartridge valves is used to pilot the pump. Mounting interface for DCV series D1VW (directional control valve included in shipment) Set screw Lock nut

For code PVAC2P* a single-solenoid directional control valve is included for pressure selection. The valve switches between low pressure setting and high pressure setting. During low pressure both pilot cartridges are connected to the compensator, in the high pressure situation (solenoid energized) only the A-side cartridge is connected. Therefore the B-side pilot needs to be set for low pressure. The directional control valve series D1VW has spool code 6.

When energizing solenoid A (B-side) the spring chamber is connected to the A-side pilot cartridge; the pressure adjusted here controls the pump.

When solenoid B is energized the spring chamber of the compensator is connected to pilot cartridge B; then the pressure adjusted on this cartridge denes the pump compensating pressure. With this version the pressure settings can be adjusted independently; no high / low For code PVAC2E* for pressure selection a two- sole- preference is to be observed. The DCV of the series D1VW noid directional control valve is included, which switches has spool code 2. between low pressure setting, high pressure setting and This version should be used, when between high and low standby pressure. In neutral position both cartridges are pressure selection the standby operation is used in the connected to the compensator valve. The lower pressure machine cycle. denes the compensating pressure of the pump. When the A solenoid (B-side) of the DCV is energized only the Code PVAC1E* is similar to code PVAC2P*, with the exA-side cartridge is connected; the (higher) pressure ad- ception, that only one pilot cartridge is installed. In neutral position of the D1VW the standby pressure is selected. justed there denes the compensating pressure. When solenoid B is energized the valve spool con-nects Please consult our main Catalogue HY11-2500/UK for all all four ports. Then the spring chamber of the compensator further information and functional descriptions. valve is directly connected to the case drain of the pump, the pump compensates works at minimum compensating pressure (standby). The directional control valve series D1VW has spool code 55. This spool code is used to avoid a blocked spool position during transient. This version is recommended, when during a machine cycle the pressure is to be switched between high and low. For code PVAC2M* also a dual solenoid valve is used. In neutral position all four ports are connected. The compensator spring chamber is connected to the case drain, For more information, spare parts or service please the pump is compensating at min. compensating pressure contact: (standby). Parker Hannin GmbH
Hydraulic Controls Division Business Unit Pumps and Motors Gutenbergstr. 38 41564 Kaarst, Germany Phone: +49-181-99 44 43 0 Fax: +49-2131 / 513-285

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
13. Trouble shooting guide Pump delivers no output ow. Drive motor does not turn. Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution

Axial Piston Pump Series PV, series 40

Motor is not connected correctly or one of the three phases has failed. Motor does not turn smoothly when pump is disconnected from pump. Check motor connections, check electrical power supply. Pump mechanically blocked. Motor turns smoothly when disconnected from pump. Send pump to factory for service. Motor is not selected properly. In star circuit not enough torque. Start pump at unloaded system. Use motor with more horse power. Pump is hydraulically blocked. No function of compensator, no pressure relief valve. Pump stops after e few turns. Check function of pump compensator (see below). Start pump at unloaded system. Coupling is not or not correctly mounted. Check coupling assembly and correct it. Wrong direction of rotation. Change direction of motor rotation. Fluid reservoir empty or not lled to level, suction line ends above uid level. Fill reservoir to required level, if necessary increase suction pipe length. Suction line is blocked. E. g. by plugs, cleaning tissues, plastic-plugs. Ball valve in the suction line closed. Suction lter blocked. Check suction line for free ow. Open valves in suction line. Valves should be equipped with electrical indicator. Check suction lter. Suction line not gas tight, pump gets air into suction port. Seal suction line against air ingression. Pressure line / system is not able to bleed air out. Unload pressure port, unload system before start, bleed air from pressure line. Standard pressure compensator is set to minimum pressure. Adjust compensator setting to desired pressure. Orice in remote pressure compensator blocked. Make sure orice 0.8 mm in control spool is free and open. No pressure pilot valve connected to port PR. Install suitable pressure pilot valve and adjust it to the desired setting. Multiple pressure pilot selector valve is not energized. Pump works in stand-by. Energize selector valve solenoid. No load sensing line connected. Connect system load sensing port to compensator. Load sensing valve is closed or too small. Open load sensing valve, use larger valve size.

Drive motor only turns at slow speed.

Drive motor turns, pump does not turn.

Drive motor turns and pump turns.

Pump does not build up pressure, but delivers full ow at low pressure.

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Installation Manual
Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution

Axial Piston Pump Series PV, series 40

Too much pressure drop between pump and load sensing valve. Make sure connection is wide enough and has not too much pressure drop. Differential pressure at compensator is adjusted improperly (too low). Check differential pressure adjustment and correct it as described above. Horse power compensator setting changed. Check setting of horse power compensator and correct it, if required. Proportional displacement control is not connected as required. Check wiring; connect according to installation manual for electronic module. Displacement transducer (LVDT) adjustement changed. Correct zero setting at displacement transducer. Electronic module has no supply power. Make sure module is powered with 22 - 36 V DC. Plug instead of orice 0.8 mm in the load sensing line to pump. Install orice as required. Cylinder block lifts from valve plate due to excessive wear. Send pump to factory for service. No orice is in load sensing line to compensator code FFC. Install orice 0.8 mm as shown in circuit diagram (page 9). No pressure pilot valve connected to compensator or valve is blocked. Connect pressure pilot valve to compensator, make sure valve opens as required. Load sensing line connected incorrectly (e. g. upstream of load sensing valve) Connect load sensing line downstream (actuator side) of load sensing valve.. No or too low pressure at pump outlet port. Pump outlet pressure must be at least 15 bar, because otherwise the bias spring in the pump cannot be compressed. Compensator is blocked due to contamination. Clean hydraulic uid, clean compensator valve. Cable to LVDT or proportional solenoid is interrupted. Check wiring and make sure cable is ok. Replace if necessary. Compensator spool sticks, due to contamination of hydraulic uid. Clean hydraulic system, clean compensator valve. Compensator differential pressure changed (too low or too high). Adjust compensator differential pressure to required setting. Wrong pilot orice or pressure pilot valve improperly selected. Select pilot orice and pressure pilot valve as recommended. Dynamic critical system, e. g.: pressure compensator combined with pressure reducing valve, load sensing (ow) compensator combined with ow control valve. Use remote pressure compensator instead of standard pressure compensator, install orice in load sensing line remote from compensator (as close as possible to load sensing valve).

Pump does not compensate.

Pump does not upstroke, sticks at zero displacement. Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution Reason Solution

Compensator is unstable.

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Parker Hannin Pump ands Motor Division Chemnitz, Germany

Bulletin HY30-3250-INST/UK

Axial Piston Pump Series PV, series 40

DECLARATION BY THE MANUFACTURER


(Directive 98/37/EG, Art. 4.2 and Annex II, sub B) PROHIBITION TO PUT INTO SERVICE

Parker Hannin AB Trollhttan declare with this declaration that our products: Are intended to be incorporated into machinery or to be assembled with other machinery to constitute machinery covered by Directive 98/37/EG. Are in accordance with technical specication stated in our product catalogue. And furthermore declares that is not allowed to put the machinery into service until the machinery into which it is to be incorporated or of which it is to be a component has been found and declared to be in conformity with the provisions of Directive 98/37/EG and with national implementing legislation, i.e. as a whole, including the machinery referred to in this declaration. Parker Hannin AB Hydraulics Group Pump and Motor Division, Trollhttan

Lars Eliasson Business Unit Manager

! WARNING
FAILURE OR IMPROPER SELECTION OR IMPROPER USE OF THE PRODUCTS AND/OR SYSTEMS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH, PERSONAL INJURY AND PROPERTY DAMAGE. This document and other information from Parker Hannin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application, including consequences of any failure, and review the information concerning the product or system in the current product catalogue. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the nal selection of the products and systems and assuring that all performance, safety and warning requirements of the application are met. The products described herein, including without limitation, product features, specications, designs, availability and pricing, are subject to change by Parker Hannin Corporation and its subsidiaries at any time without notice.

Please contact your Parker representation for a detailed Offer of Sale.

Offer of Sale

Parker Hannin GmbH & Co KG Pump and Motor Division Neefestr. 96 D 09116 Chemnitz Tel.: +49-(0)371-3937-0 Fax: +49-(0)371-3937-170 www.parker.com Copyright 2006 by Parker Hannin GmbH & Co KG

HY30-3250-INST/UK Art. No xxxxxxx