RE 57 020/05.

93

ARPT Hydraulic Power Units Type A

RE 57 020/05.93
Replaces: 09 309

Power units in the ARPT series are designed for the supply of servo-hydraulic systems. These systems make high demands on energy-transporting fluids in respect of cleanliness and high, constant and continuous operating pressures. The units can be used for a continuous operating pressure of up to 300 bar and supply a flow which is automatically adapted to the requirements of the system. They can be used as individual units or coupled for parallel operation. The abbreviated code for the units includes the nominal size of the fluid tank (for capacity see page 4), the model code and theoretical pump delivery. For effective flow see the following table.

The technical data and dimensions listed in this data sheet refer to the four standard power unit models. Different models (e.g. with a lower electrical drive capacity at reduced operating pressure) can be supplied on request.

Type

Flow L/min

Operating pressure max. bar 300 300 300 300

Drive power kW 37 55 90 132

ARPT 0400 A 060 ARPT 0630 A 100 ARPT 1250 A 160 ARPT 1500 A 250

55 95 160 230

Hydraulic power unit, model A

Characteristics
A 4 VSO Axial piston variable displacement pump
Axial piston variable displacement pumps in sizes 40 to 250 are used as hydraulic pumps for high pressure applications. The pumps are designed to incorporate swashplates mounted on plain bearings: this construction is characterised by its long service life together with low noise emission levels (for details see data sheet RE 92 050).

Filtration
The units are equipped with full flow filters in the feed and return lines. Filtration is suitable for servo systems. If a change of element is required the signal is given by opto-electrical contamination indicators.

Space requirement
Due to their compact construction the power units require a relatively small amount of floor space. When making arrangements for siting consideration should be given to the maximum height requirements.

Construction
In model A the motor/pump group is mounted vertically (construction type VI). All setting and operating equipment is arranged so that it is easily accessible. The tank and the control cabinet are mounted on a common base frame ( for a description of the electrics see page 7). The tanks are fitted with generously-sized DIN flange connections which, on single power units, are closed off with blind flanges. Where a number of power units are linked together the tanks can be coupled with one another by way of these connections. If required the power units can also be supplied with a fluid bath which has the same capacity as the main tank.

Operation
The units can be supplied wired together with their appropriate control cabinet. The control cabinet contains an operator panel with all necessary operating and display elements. It is possible to install the control cabinet so that it is separate. In this case the electric cabling inside the unit (with the exception of the electric motor) is laid to a terminal box.

Vibration damping
The unit base frame rests on vibration dampers (not illustrated) which should be anchored to the floor by the contractor. The mechanical isolation of the high pressure pump is carried out by means of a high pressure hose pipe and a damper ring .

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Characteristics
Installation
The units should be installed in areas that are frost-free, dry and free of dust. The air temperature should not exceed 40 C. If this value is exceeded sufficient cooling of the drive motors will no longer be possible. Care should be taken to ensure that the power units installed in a given area radiate heat and thus bring about an increase in the ambient temperature. It is the responsibility of the contractor to implement additional cooling measures in order to prevent any unauthorised heating of the area. The ambient temperature should not be less than 10 C by the hydraulic units at nominal capacity as a function of cooling water temperature. In order to prevent the risk associated with the precipitation of suspended matter (corrosion) during cooling operations using factory or cooling tower water, an open/shut control was selected on the coolant side. The cooling duty cycle is dependent both on the amount of heat to be dissipated (loading of the power unit) as well as the water inlet temperature. The mean water consumption is determined by the cooling duty cycle.

Fluid
This must conform to the requirements in respect of HLP hydraulic oil as set out in DIN 51 524, part 2.Viscosity class ISO VG 68 to DIN 51 519 is recommended. A filling filter or a suitable circulating pump unit must be used. For the flushing operation the use of additional filter elements is recommended e.g. type BN/HC. The operating filter elements are only installed once the flushing process is completed and evidence of the cleanliness of the hydraulic fluid has been achieved.

10

ARPT power unit

9 8

Cooling water flow QW in m3/h

7 6 5 4 3 2 1 0400 A 060 1250 A 160 1500 A 250

Cooling
The proportion of power in the installation which is converted into heat is dissipated through water/oil heat exchangers. The heat exchangers are located in the return line. Approx. 80% of the power in each power unit can be dissipated via the heat exchanger. The remainder is drawn off to the surroundings via the radiation surfaces of the hydraulic components. The preferred cooling medium is ammonia-free fresh water (e.g. cooling tower water); if spring, stream or brackish water is to be used a water analysis must first be carried out to determine the cooler materials. The following diagram shows the consumption of cooling water

0630 A 100

10

15

20

25

30

Water inlet temperature tew in C

Description of function
Drive is by means of an electric motor. The drive motor starts in star configuration with the pressure relief valve open (11). The pump sucks up oil from the oil tank (1) and, in the starting phase, delivery is 'pressure-free'. Once the drive motor (3) has come up to nominal speed, the pressure relief valve switches into the blocked position which causes pressure to build up. The hydraulic fluid is conveyed to the system via pressure filters (12). The return hydraulic fluid is conveyed into the tank via filters (13) and the cooler (8) . The water shut-off valve (9) is operated according to the prevailing temperature (6). The power units are isolated leakage-free from the ring main on the pressure side by means of a solenoid-operated isolator valve (15) when the solenoid of this valve is de-energised (rest position). The pressure valve behind this valve is relieved to tank in the neutral position. In principle this also achieves pressure relief of the entire P ring line as long as there are no other isolating elements present in this. However, in larger systems, which usually also contain pressure accumulators, the provision of a separate means of pressure relief is recommended. In cases where there are several power units delivering in parallel into a common ring main, the instructions given under the heading 'Parallel Operation' should be followed.

Pressure control
The high pressure pump is fitted with a pressure control device for manual adjustment and, by request, for electrical remote adjustment. In the latter case the operating pressure can be set from the control cabinet on the power unit using a potentiometer or from a master control point using a selector switch (optional). The pump adjusts automatically to the flow required by the driven units once the set pressure has been achieved. The response characteristics of the pressure controller meet the demands made on a high quality pressurised fluid supply plant because of the former's dynamically fast control characteristics. If no pressurised oil is required by the driven units the pump will 'stall' back to the 'zero' poisition while still supplying sufficient oil to cover system leakage and to maintain the set pressure value.

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Basic circuit diagram

T L P

WA WE

1 2 3 4

Oil tank Pressure controlled axial piston pump 3-phase motor Level switch Warning L> / L<, Disconnect L>> / L<< Option: Level analogue sensor Temperature switch Warning T>, Disconnect T>> Option: Analogue sensor PT100 Contact thermometer Coolant valve ON/OFF Filling filter Heat exchanger (oil/water) Electrically operated water shut-off valve and optical flow indicator

10 Pressure relief valve Operating pressure setting 50 to 300 bar Option: Pressure relief valve for electrical proportional remote control 11 Pressure relief valve, with type approval, with damped unloading 12 Pressure filter (flange type) 13 Return line filter 14 Pressure switch Operating pressure / collapse of pressure Option: Pressure gauge 15 2/2-way isolating valve with pressure unloading to P port in rest position 16 Control cabinet

6 7 8 9

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Technical data (For applications outside these parameters please consult us)

Power unit Flow Control range Electric motor power Electric motor voltage / type of insulation Operating pressure (normal) Setting and control range Maximum pressure relief valve with type approval Circulating pressure with pressure relief valve open Filtration High and low pressure

ARPT L/min kW

0400 A 060 0 to 55 37

0630 A 100 0 to 95 55

1250 A 160 0 to 160 90

1500 A 250 0 to 230 132

3-phase 220 to 500 V 50 Hz / IP54 bar bar bar bar 280 50 to 300 330; fixed setting < 15

Recommended degree of cleanliness for servo systems Oil tank Fill volume to max. oil level Cooling Cooling water requirement at nominial capacity and cooling water inlet temperature 20C Cooling water outlet temperature Permissible water inlet pressure Differential pressure between water inlet and outlet Heat Heat to be dissipated to surrounding atmosphere Volume of air required for cooling electric motor at cooling air temperature max. 40C kW m3/s m3/h C bar bar dm3

Pore size 3 m, single use elements Filtration quotient 3 100 < Class 7 to NAS 1638

~ 350

~ 590

~ 950

~ 1400

1,3 approx. 40 max. 10 <2

1,9

3,2

4,3

4,5 0,45

6,5 0,55

8,5 0,7

12 1,0

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Unit dimensions

(in mm)

REXROTH

T WE P L WA
B

Power unit Length with control cabinet without control cabinet Width Height Max. height - motor / pump assy. Centre line parallel operation Ports: P T L WE , WA Connection for balance line

ARPT A A B C D

0400 A 060 1720 1270 1000 1520 ~ 2100 1200 1"BSP 1 1/4"BSP 3/4"BSP DN 20 (3/4"BSP) Nom.dia.100

0630 A 100 1920 1470 1000 1870 ~ 2500 1350 1 1/4"BSP 1 1/2" BSP 1"BSP DN 20 (3/4"BSP) Nom.dia. 125

1250 A 160 2050 1600 1100 2070 ~ 2700 1450 1 1/2"BSP 1 1/2"BSP 1 1/4" BSP DN 32 (1 1/4"BSP) Nom.dia. 150

1500 A 250 2450 2000 1200 2400 ~ 3300 1575 SAE 1 1/2", HD SAE 1 1/2" 1 1/2" BSP DN 32 (1 1/4"BSP) Nom.dia. 200

BSP pipe thread to ISO 228/1 NB: The dimensions given are approximate and for planning purposes only. When ordering please request certified drawings.

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Parallel Operation

(in mm)

2450

WE W A L E

4350

The above figure is an example of three ARPT 1500 A 250 working in compound mode. The total delivery flow is 690 L/min at an operating pressure of 290 bar. The tanks are connected by means of 200 diameter flexible pipe unions. Each tank can be isolated separately by means of shutoff valves. Combination with power units in the next smallest size group is possible subject to adaptation of the compensation line and installation height. When planning a ring main system to which several power units are to be connected the following points must be observed: a) It must be possible to shut down each individual power unit e.g for servicing, without having to switch off the entire hydraulic system.

This is achieved by having the power units deliver into the ing main via a check valve. The various leak oil and return lines must also be capable of being isolated. For safety reasons and the valve position must be monitored and electrically interlocked with the switch-in function of the isolator valve. b) The unloading of the pressure line achieved when using single units can only be achieved up to the check valve with units used in parallel. It is necessary here to provide a separate circuit for pressure relief in the P ring main line. Locating this circuit at the end of the ring line gives the simultaneous advantage of being able to carry out flushing of the P-T ring line without any additional connection devices.

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Power Switching and Electronic Controls

The compact construction of the power units makes it possible to mount the control cabinet directly on the base frame. A star delta combination is used to start the motors. A thermistor and an overload relay unit are fitted to protect the motor. The control logic is based on a SIMATIC S5 - 100 U. programmable memory control. The power unit is operated via a control console with the switches and warning lights mounted in an anodised panel on the door of the control cabinet. Conventional warning lights indicate fault or status messages. The control cabinet is supplied with socket, ammeter, voltmeter, emergency off switch and elapsed time meter as standard. Text display for messages As an alternative to the conventional messages delivered by warning lights a 2-line text display can be supplied to indicate operator and fault messages. On this display it is possible, using a keypad, to quit a fault message which has been called up. The use of this text display is of particular advantage when the monitoring equipment in respect of pressurised fluid levels, fluid temperature or pressure is designed as analogue sensors on the power unit side. The command values for the limit value messages can then be programmed by way of the keypad. System pressure remote setting If the unit is to be operated on different system pressures pressure setting may be carried out using electrically proportional control of the pressure regulator. Remote operating console This option is used if the unit is to be started from a central point e.g. control station or test area. The fault messages are displayed as collective messages in the remote control console; the hydraulics are switched on and off using corresponding switches. The console consists of a 19" wide anodised panel with 3HE. The The panel is designed for installation in an existing control or electronics cabinet; a 2m-long multi-core cable labelled at the ends is provided for connecting to a terminal strip. For other possible connections or different housing designs for the remote operation console please enquire. Parallel operation When a number of power units are combined in a parallel operation coordination of the performance and control electrics or the individual control cabinets will be required. As a rule, the use of a separate control cabinet (centralised control) is necessary. The individual control cabinets will continue to be used but with the CPU of the PLC exchanged for a unit which can be connected to the control unit. Control and monitoring of additional equipment specific to the installation such as, for example, accumulator stations, isolating fittings etc. is also carried out from the central control station. This solution is quoted on request and is subject to specific project planning. Control cabinet stand If separate mounting is required, the control cabinet can also be fitted with a stand. The electrical equipment (with the exception of electric motors) is then wired to a terminal box on the unit. A 5m long cable set for connecting the terminal box as well as the electric motor is included in the supply for this model. Other cable lengths can be supplied on request at additional cost.

Power switching and electronic controls The documentation supplied with the equipment has been drawn up on EPLAN CAD and is in conformity with DIN 40 719, part 2. Options Listed below are some possible operational options as well as some general design options. In conjunction with this the appropriate hydraulic components in the unit will need to be modified or adapted with regard to the options mentioned.

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Notes

Mannesmann Rexroth GmbH D-97813 Lohr am Main Jahnstrae 3-5 D-97816 Lohr am Main Telefon 0 93 52 / 18-0 Telefax 0 93 52 / 18-10 40 Telex 6 89 418

G.L.Rexroth Ltd., Cromwell Road, St. Neots, Cambridgeshire, PE19 2ES. Tel: 0480 476041 Fax: 0480 219052 All rights reserved Subject to revision

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