Interface Devices P-Series Manual de instrucciones

P-Series INTENSIFIER PUMP

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

INTERFACE DEVICES, INC. 230 Depot Road, Milford, CT 06460

Ph: (203) 878-4648, Fx: (203) 882-0885, E-mail: [email protected]

www.interfacedevices.com

IMPORTANT! FILE THIS MANUAL IN A SAFE PLACE FOR FUTURE SERVICE & PARTS NEEDS

ALWAYS REFERENCE THE SERIAL NUMBER FOR SERVICE & PARTS REQUESTS

Pump Serial Number: Generic

Pump Model Code: None

Sold to: None

Purchase Order:

End User: None

Order Date:

STATEMENT OF WARRANTY

INTERFACE DEVICES, INC. (hereafter, the factory) warrants it’s products to be free from defects

in material and workmanship under normal use and service for a period of one (1) year from date

of shipment from the factory. Any defect discovered after the warranty period has expired will be

deemed to be outside the above coverage. No goods claimed to be under warranty shall be

accepted for return unless authorized by the factory beforehand.

Upon discovery of a defect (other than freight damage) or a shortage of an item received in the

original factory container, the purchaser shall, within (10) calendar days, deliver notice of the

defect or shortage. Damaged freight claims must be placed with the freight carrier and will not be

honored by the factory. If after due investigation of a claim of defect or shortage is found valid,

the factory, at it’s sole discretion, may discharge it’s entire obligations to the purchaser by either

repair or replacement of the defective product or component and for shortages by furnishing a

replacement of the missing quantity (FOB, factory).

This express warrantee supersedes and is in lieu of all other remedies and warranties, including

the implied warranties of merchantability and fitness for a particular purpose, and liability for

negligence. IN NO EVENT SHALL THE FACTORY BE LIABLE FOR INCIDENTAL OR

CONSEQUENTIAL LOSSES, EXPENSES OR DAMAGES INCLUDING DAMAGES FOR

PERSONAL INJURY OR COMMERCIAL LOSS.

1.0 INTRODUCTION PAGE

1.1 Description.................................................................................................1

1.2 The P-Series Pump.........................................................................1

2.0 INSTALLATION AND OPERATION

2.1 Prior to Operation ......................................................................................1

2.2 Check List ................................................................................................2

2.3 Reservoir Filling and Draining ..................................................................2

2.3.1 One, Two, and Five Gallon.........................................................2

2.3.2 Self-Contained Vented................................................................2

2.3.3 Self-Contained Bellows ..............................................................3

2.4 Bleeding the Unit .......................................................................................4

3.0 MAINTENANCE AND SERVICE

3.1 General ................................................................................................3

*3.1.1 Air Spool Lubrication..............................................................3

3.2 Hydraulic Valve Adjustment .....................................................................4

3.2.1 Pressure Relief Valve (RV) ........................................................4

3.2.2 Kick Down Relief Valve (RV1)

and Sequence Valve (SQV1);

Calculation of setpoints ...............................................................4

3.2.3 Hydraulic Dump Valve...............................................................5

3.3 Trouble Shooting Guide.......................................................................................6

4.0 GENERAL ASSEMBLY

4.1 Mounting the Ratio Plate ...........................................................................7

4.2 Mounting the Air Body..............................................................................7

4.3 Mounting the Air Cap ................................................................................7

4.3.1 Pump Final Assembly.................................................................8

4.4 Drawings & Bills-of-Material....................................................................9

5.0 RECOMMENDED SPARE PARTS

*This is the only preventative maintenance task required. Please read carefully

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SECTION 1.0 INTRODUCTION

1.1 DESCRIPTION

IDI Air/Oil Intensifier Systems are the latest concept in hydraulic power units. These

units need no external electrics or plumbing to operate. Just plug in shop air and the unit

is ready to go. The manifold design yields an inherently small package that can include

air and hydraulic gauges, air regulator, exhaust mufflers, and all necessary pneumatic and

hydraulic valving. Thus, the end user enjoys rapid service and little maintenance.

.3 The P-Series Pump

The P-Series pump offers all the same ratios and features of the E-SERIES pump but in a

smaller version. The stroke of the PI pump is one-half of the E-SERIES pump but

because of it’s speed, flow rate is reduced by just one-third. It’s output is rated 1.10

Hyd. Horsepower with maximum air consumption of 14 SCFM.

IDI Air Driven Pumps are available with self-contained reservoirs, sized from 20 to 120

cubic inches and including twin internal 40 micron suction filters. These reservoirs are

normally vented like the large tank style but can be furnished with bellows allowing the

pump to be operated at any attitude. Weighing just 15 pounds (30 CI reservoir, filled),

the units are ideally suited for portable “all-attitude” operation.

SECTION 2.0 INSTALLATION AND OPERATION

2.1 PRIOR TO OPERATION

IDI Air Driven Pumps come complete and ready to operate. The only customer

requirement is filling of the reservoir and connection of the appropriate air supply and

hydraulic system fittings. The air inlet is 3/8 NPT

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2.2 CHECK LIST

Before operating the unit, complete the following checklist to assure proper and safe

operation:

1. Make sure that all hydraulic components (fittings, hoses, valves, etc.) are

rated at or above the maximum operating pressure of the power unit.

2. Inlet air pressure must not exceed 150 psig (10 bar). Normal range of supply

air pressure shall be not less than 50 and not over 100 psig (4-7 bar).

3. All air supply fittings should be of non-corrosive materials and of pipe size

adequate for the pump.

4. Air supply must be free of contaminants and an air filter/separator installed as

close as possible to the pump.

5. Air lubrication should NOT be used.

6. The self-contained (or remote option) air regulator MUST be turned out

completely counter-clockwise (CCW) before the supply air source is turned

on.

2.3 RESERVOIR FILLING AND DRAINING

It is recommended that a light grade hydraulic oil be used. (Mobil DTE 24®, Shell Tellus

32®, or similar) Consult your distributor or the manufacturer if your application requires

other than light viscosity petroleum based fluids.

2.3.1 ONE, TWO AND FIVE GALLON RESERVOIRS

Remove filler cap and pour clean oil into the reservoir. View the fluid level in the sight

gauge on side of reservoir.

To drain, use the pump to evacuate the tank while operating at reduced air pressure until

the pump begins to cavitate (rapid cycle), then shut the pump down. One, two and five

gallon reservoirs are fitted with a drain plug at the bottom of the tank.

2.3.2 SELF-CONTAINED VENTED RESERVOIRS

Remove vent/filler cap. Pour clean oil through a strainer into reservoir until full.

Replace vent/filler cap. Top-off the reservoir after system is bled (Sec. 2.4).

To drain, use the pump as above, or invert the entire pump assembly to drain through the

fill port.

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2.3.3 SELF-CONTAINED BELLOWS RESERVOIRS

Remove seal/fill plug (-6 SAE plug on top of Hydraulic Body). Pour oil through a strainer

into fill port until bellows is full. Replace seal/fill plug. Bleed the system completely (Sec.

2.4). Top-off the reservoir and be sure seal/fill plug is tight. To drain, remove the seal/fill

plug and invert pump to drain. Do NOT use the pump to evacuate the bellows or it may be

damaged by excessive vacuum.

2.4 BLEEDING THE UNIT (HI/LO Pumps)

Once all the above requirements are met and the reservoir is full, make sure the air regulator is

completely turned out counterclockwise (CCW) before opening the air supply. Slowly turn in

the air regulator clockwise (CW) until the pump just begins to reciprocate. Crack open the

appropriate hydraulic bleed valve or fittings while at this minimal pressure until all air is bled.

Next, turn in (CW) the air pressure regulator until NO MORE THAN 500 psi hydraulic

pressure is reading on the system gauge. Cycle the hydraulic system several times. STOP.

Turn out (CCW) the air pressure regulator again and bleed the system again as above. Repeat

until no air is evident. Top off the reservoir as required.

Once the pump is bled as above, the internal HI pressure circuit must be bled. The pump will

abruptly change pressure when the factory preset ‘Kick Down’ pressure is reached and if air is

present, the pump will cycle rapidly. Once the low pressure bleed-off is complete, continue to

turn in (CW) the air pressure regulator until the ‘Kick-down’ occurs, normally 700-1000 psi.

If the pump suddenly cycles violently then quickly turn out (CCW) the air pressure regulator

until ALL system pressure is relieved (bleed-off if necessary). Repeat procedure until ‘Kick

Down’ is without stutter.

SECTION 3.0 MAINTENANCE AND SERVICE

3.1 GENERAL

The modular design of these units yield maximum service with minimal maintenance. Upon

receipt of the unit, inspect the assembly thoroughly. If physical damage is evident, do not

operate the unit. Consult your distributor or the manufacturer for replacement parts or

corrective action.

3.1.1 AIR SPOOL LUBRICATION

The only preventative maintenance task for the pump is to re-grease the air spool

assembly every 1000 hours of operation. A lithium based waterproof grease should be

used for this task.

To perform this task, first remove the left side Air Pilot Cap on the left side of the Air Cap as

viewed from the air inlet (Part No. 10298). Extract the Air Spool (Part No. 10659). Extract

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the Cages and Tee Seals (Part Nos. 10273 & 10629). Clean all the parts and internal cavity.

Apply lithium based, waterproof grease to each component and reassemble.

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3.2 HYDRAULIC VALVE ADJUSTMENT

The valves on IDI Air Driven Pumps are either cartridge or sub-plate mounted and are factory

preset to your specifications. In the unlikely event a valve needs to be replaced or reset, turn

off the pump, bleed off all system pressure and use the following instructions:

3.2.1 PRESSURE RELIEF VALVE (Marked ‘RV’ – Not supplied on all units)

This valve is incorporated in the system as a safety valve, and should NEVER be used to

adjust hydraulic system operating pressure. Setting of this valve should be done only under a

“no-flow” (ie: stalled) condition.

With the system under normal operating pressure, turn in (CW) the air pressure regulator until

the RV starts to weep fluid back to the reservoir (evidenced by screeching sound). Reduce air

pressure below this point before making any increase in setpoint and NEVER exceed system

component pressure ratings.

3.2.2 KICK DOWN RELIEF VALVE (RV1) AND SEQUENCE VALVE (SQV 1)

*** NOTE *** For 'Kick Down Relief Valve' (RV1) only, be sure an orifice disk is present

in the valve cavity faced radius side down before installing a replacement.

Figure 3.2.1

After the valve is installed in the appropriate cavity, loosen the lock nut on the adjustment

screw and turn the stem out (CCW) completely. Then, turn back in (CW) one turn.

Turn the pump on and slowly turn in (CW) the air pressure regulator until the 'kick down'

occurs. Make note of the pressure and de-pressurize the system completely before any more

adjustment is made. Turn the stem in (CW) in small steps to raise the 'kick down' pressure as

required. Please note that the system must be de-pressurized completely between setpoint

changes. Tighten lock-nut when complete. Top off reservoir as required.

3.2.1.1 CALCULATION OF 'KICK DOWN' PRESSURE FOR RV1 AND SQV1

VALVES (HI/LO PUMPS ONLY)

To calculate the 'kick down' pressure required to achieve proper HI/LO pump operation, first

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consult the model tag for the available ratio. For example, if the model number of the unit is

E060/10, then the HI ratio is 60 and the LO ratio is 10.

To obtain the 'kick down' pressure (KDP), multiply the final operating pressure (OP) times the

(LO) ratio number, divide the result by the (HI) ratio number, then multiply this result by the

fixed value of (0.9) to yield the (KDP).

In equation form: ((OP * LO) / HI) * (0.9) = (KDP)

Example

Determine the 'kick down' pressure for a pump model E060/10 operating a filter press

system in which the final desired ram pressure is 5000 psi.

Solution (( 5000 * 10) / 60 ) * 0.9 = 749 psi KDP

Thus, set the 'Kick Down' valve as close as possible to 749 psi to supply maximum

output during LO pressure pumping before shifting to HI when the actual load is

compressed.

3.2.3 HYDRAULIC DUMP VALVE

This optional valve is configured either (NO) Normally Open (pump run. valve closed) or

(NC) Normally Closed (pump run, valve open) from the factory. A configuration

drawing at the back of this manual details possible field modifications.

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Pump Serial Number: «Serial_Number»

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3.3 TROUBLE SHOOTING GUIDE

If a problem arises with the unit, the following guide should help to make an accurate

diagnosis and a proper remedy:

SYMPTOM CORRECTIVE ACTION

Pump "stalls" after

extended no-flow

period.

• Check that supply air pressure exceeds 50 psi

• Check that Air Cap valve spool is not stuck in the null

position; if so, push the spool to the end of it’s stroke

manually.

• Perform spool lubrication task in 3.1.1

• Check for flow through the air pressure regulator.

Pump brings system

up to normal

operating pressure

but "chugs"

intermittently.

• Check all system components for leaks including valves that

may be bypassing internally.

• If symptom is coupled with evidence of fluid leakage from the

air cap muffler, then internal rod seals are worn excessively;

repair/replace without delay to prevent internal damage to the

pump.

SYMPTOM CORRECTIVE ACTION

Pump runs but does

not generate

pressure.

• Pump is airbound; check fluid reservoir level and bleed.

• Pump relief valve is set below operating pressure or leaking;

reduce air supply pressure; reset the RV setpoint; replace the

RV if faulty.

• Pump internal check valves are jammed with foreign material;

remove and clean; be sure that reservoir does not contain any

foreign material.

• Dump valve is leaking; check air supply to dump valve; check

for debris in valve seat (see diagram).

Pump Air Cap

leaking air

continuously.

• Leak from air regulator; replace diaphragm.

• Leak from muffler(s); spool valve seals worn or

contaminated; clean/replace seals.

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SECTION 4.0 GENERAL ASSEMBLY

This section is provided to give a general overview for all the service needs of your IDI

Air Driven Pump. An exploded view of all basic parts is included at the back of this

manual.

The general assembly of IDI Air Driven Pumps consists of four major sub-assemblies:

Air Cap, Air Body, Ratio Plate and Hydraulic Body. It is most efficient if each of these

four components is entirely sub-assembled prior to final assembly.

The Ratio Plate Assembly is normally received from the factory complete for

replacement. DO NOT disassemble as damage to the seals may occur and could void the

warranty.

4.1 MOUNTING RATIO PLATE TO HYDRAULIC BODY

Make sure that all components are clean and dry. Spread a thin film of waterproof grease

on the rod, hydraulic piston and bore. Place static seals (O-rings) in the appropriate

counterbores in the Hydraulic Body.

While holding the Ratio Plate sub-assembly by the air-end piston, align the actuator to

it’s counterbore and gently rock the hydraulic piston into the bore. Slide the Ratio plate

down the shaft until contact is made with the Body. Next, install the four mounting bolts

(1/4-20 x 1”) and lock-washers into the center pattern and snug to just compress the lock-

washers. If there are two more bolt holes along the bottom edge, install these bolts now,

without lock-washers, and snug.

Lastly, tighten all bolts in small increments using a cross-type pattern to a final torque of

approx. 15 ft/lb.

4.2 MOUNTING THE AIR BODY TO THE RATIO PLATE

Slip body gasket over the air-end piston and alien to the edges. Apply a thin film of waterproof

grease to the bore of the Air Body and lay atop the piston with chamfered bore edge down. Holding

the Air Body and piston with both hands, “squeeze” the body over the air piston seal and wiggle

down until contact is made with the Ratio Plate gasket.

Make sure that the serialized face of the Air Body is facing up. On later models, body pins assure

proper alignment.

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