Powapak Air Ultra Operating Manual
Powapak Air Ultra Operating Manual
Powapak Air Ultra Operating Manual
Page 1 of 45 T-ENG0071-AE
SECTION: DESCRIPTION:
1 INTRODUCTION Page 3
2 SAFETY Page 4
3 SPECIFICATION Page 7
5 OPERATION Page 13
9 APPENDICES Page 20
10 CONTACTS Page 36
Page 2 of 45 T-ENG0071-AE
SECTION 1
INTRODUCTION
1.1 Product:
This pneumatic – hydraulic pump system is designed for use with Hydratight
hydraulic torque equipment; the pump system has been optimised to torque
tighten or break loose any application within a minimal time frame while still
maintaining a safe and reliable product.
1.2 Components:
Listed below are some of the key components and assemblies used in this
system.
1.4 Training:
Anyone who uses and operates this system must be suitably competent, if in
doubt contact Hydratight for training information and schedules.
1.5 Safety:
Although the pump system has been designed with operator safety in mind,
the system itself still requires the operator to be vigilant upon use, therefore
ensure that all the following safety instructions (See Section2) have been read
and understood! Contact Hydratight if in doubt.
SECTION 2
Page 3 of 45 T-ENG0071-AE
SAFETY
Read all instruction, warnings, and cautions carefully. Follow all
safety precautions to avoid personal injury or property damage
during system operation. Hydratight Limited cannot be held
responsible for damage or injury resulting from unsafe use, lack of
maintenance or incorrect product and/or system operation. Contact Hydratight
Limited if in doubt as to the safety precautions and operations. Failure to
comply with the following cautions and warnings could result in equipment
damage and personal injury.
Page 4 of 45 T-ENG0071-AE
SECTION 2
SAFETY
Do not exceed the maximum working pressure of system.
Avoid sharp bends and kinks when routing the hydraulic hoses.
Only use hydraulic hoses and fittings pressure rated to this system.
Page 5 of 45 T-ENG0071-AE
SECTION 2
SAFETY
Ensure that the pump motor is not kept under load for excessive
periods of time, as this will generate excess heat. Monitor the tank
reservoir temperature and do not let the oil temperature exceed 80
degrees “C”.
Ensure the pneumatic source is adequate for the pump system. SEE
SECTION 3 “Specification” for pneumatic source requirements.
Care should be taken when adjusting the main pressure valve after the
pump system has been running for a long period of time as the
directional control manifold block and surrounding areas can become
hot “dependant on duty cycle”. Gloves should always be worn when
operating this equipment.
Page 6 of 45 T-ENG0071-AE
SECTION 3
SPECIFICATION
Air Motor 3.0kW (4hp)
Hydraulic Pump Output (Stage1) 7.5lpm (1.6gpm) > 80bar (1160psi)
(Stage2) 3.8lpm (0.8gpm) > 290bar (4205psi)
(Stage3) 1.0lpm (0.2gpm) > 690bar (10000psi)
Max Pressure Output “Port A” 690bar (10000psi)
Max Pressure Output “Port B” 110bar (1595psi)
Pneumatic Source Input Requirements 5bar (72psi) @ 1700lpm (374gpm)
ISO VG15 to 68 & Biodegradable “SEE
Hydraulic Oil Classification
SECTIONS 6 & 9.1” Pressure Fluids
Ambient Start-up Temperature -20C (-4F) to 40C (104F)
Max Ambient Temperature 64 C (147 F)
Maximum Oil Reservoir Capacity 10.0 Litres (2.2Gallons UK)
Oil Reservoir Minimum Fill Capacity 7.0 Litres (1.5Gallons UK)
Overall Height 466.0MM (18.34In)
Diameter Ø375.0MM (Ø14.76In)
Complete Pump System Weight 37KG (81.5 lbs) (aluminium system without
oil)
44KG (97.0 lbs) (aluminium system with oil)
39KG (86.0 Ibs) (stainless system without oil)
46KG (101.4 lbs) (stainless system with oil)
Hand Held Control Pendent Length 6.0M (19.6ft)
“Standard” (Other Lengths Available)
Noise Level 82db – 86db (standard cycle) operator
protection levels should be calculated using
this and background noise levels. Operator
exposure times calculated accordingly.
Page 7 of 45 T-ENG0071-AE
SECTION 4
PRE START-UP CHECKS
4.1 Oil Reservoir:
Check oil level in reservoir. If required,
fill the oil reservoir via the filler point
until oil is seen in the sight “bubble”
glass. Do not remove the oil filler
catcher when filling. Fill the reservoir
with clean mineral oil or appropriate
equivalent oil; see “SECTIONS 6 & 9.1
PRESSURE FLUIDS” for suitable oils.
Replace the filler cap when completed.
In operation do not let the oil level
fall below the sight “bubble” glass
level.
Page 8 of 45 T-ENG0071-AE
SECTION 4
PRE START-UP CHECKS
4.4 Air Lubrication:
Check and fill if required the air lubrication bowl, note minimum and maximum
oil fill level markings on bowl. Use ISOVG10 – 32, set the drip frequency for a
minimum of two drips per minute. In cold conditions the drip rate should be
increased to help avoid the air motor freezing up.
Do not run the system without lubrication.
FILL POINT ADJUSTMENT
NOTE! The bowl will disperse its contents under pressure if emptied
while connected to air source.
Page 9 of 45 T-ENG0071-AE
SECTION 4
PRE START-UP CHECKS
4.6 Hydraulic Connection:
PARKER COUPLINGS
CEJN COUPLINGS
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4.7 Pendant Operation:
Before operation, ensure you have read and fully understand the function of
the hand held operator’s pendent.
NOTE! The pendant below supersedes and replaces earlier designs before
MAY 2008. Replacement pendant part No PAPKPAC06000
Pump Start (Air Motor ON), when switched to the “ON” position “as shown”
the pump system will be in the retract mode until the tool advance trigger is
pressed.
MOTOR ON / OFF
RED actuator is located against face (MOTOR OFF)
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Page 12 of 45 T-ENG0071-AE
ADVANCE / RETRACT
Push and hold down the valve direction button, this will direct the hydraulic
flow to the advance position.
Releasing the valve direction button will direct the hydraulic flow to the retract
position.
Push and hold down the valve actuation button until the main (hydraulic)
pressure gauge displays ZERO pressure, release once achieved.
Page 14 of 45 T-ENG0071-AE
SECTION 5
OPERATION
5.1 Setting Main Relief Valve:
To ensure the relief valve has been set correctly, the following procedure
should be carried out: NOTE! This should not be carried out while the
wrench is connected to fastener.
Switch the pump system on via the actuator on the operators’ pendant;
press and hold down the “ADVANCE” button on the operators’
pendant. With the button held down, slowly wind the main system relief
valve “clockwise” until the desired value is achieved on the high
pressure gauge; release the “ADVANCE” button.
Press and hold the “ADVANCE” button again to check the setting is
correct, adjust if required.
Wind the locking nut “clockwise” against washers to ensure the valve
does not move in operation. DO NOT OVER TIGHTEN!
Page 15 of 45 T-ENG0071-AE
5.2 Application:
Apply appropriate tooling to the application, by pressing and releasing the
“ADVANCE” button the application can be completed. See relevant operation
manual for correct usage of tooling. Upon the application being completed
switch the air motor “OFF” via the operator’s pendant then press the
“ADVANCE” button; this will release any hydraulic pressure in the system.
Page 16 of 45 T-ENG0071-AE
SECTION 6
PRESSURE FLUIDS
6.1 Pressure Fluids General Information:
It’s very important that the correct specification of pressure fluid has been
selected to suit the operational environment where the pump system is to be
operated.
6.2 Filtration:
Failure of a hydraulic system can be caused by contamination of fine wear
particles or larger. i.e.. swarf, ingress, etc. It is important that the cleanliness
of the hydraulic fluid is maintained, and continuously checked, as this has a
direct impact on the repeatable accuracy of the system, and correct operation
of the control valves.
It is important to be aware that fresh fluid from the “barrel” does not always
fulfil the standards of cleanliness.
Page 17 of 45 T-ENG0071-AE
6.4 Draining Of Pressure Fluids:
The hydraulic reservoir should be fully
drained when renewing oil, or for shipping
purposes. Remove the oil filler cap; ensure
you have suitable capacity oil capture
equipment; the minimum fill capacity is
7.0litres (1.5gallons UK). Remove the
reservoir draining plug and let oil drain, re-fit
draining plug. If draining for the purpose of
shipping, label unit with the comments
“SHIPPED WITH NO OIL”. If renewing the
oil, fill with appropriate hydraulic oil “SEE
SECTION 9.1: APPENDIX A Viscosity
Classification” re-fit filler oil cap. Also “SEE
SECTION 6.6 Change Of Pressure Fluids”
(ISO VG15) Systems intended for continuous operation (for use in the
open, operation in cool climate).
Min temperature during start up not lower than -20 C
(ISO VG22, VG32) General application (for use in the open, operation
in warm climate).
(ISOVG46, VG68) Systems in hot climate, at ambient temperature up
to 40 C or closed rooms
Max temperature during start up not higher than +50 C
Page 18 of 45 T-ENG0071-AE
SECTION 7
GENERAL MAINTENANCE
GUIDE
7.1 Hydraulic connections:
All hydraulic connections should be checked for leaks, damage, etc, any
connections found to be leaking or faulty are to be replaced immediately.
The system should be pressure tested prior to use.
Page 19 of 45 T-ENG0071-AE
SECTION 7
GENERAL MAINTENANCE
GUIDE
7.5 Storage:
The complete system should be stored in a dry “safe from damage”
environment.
7.5 Serial No :
Each pump system has a unique serial number; the number is located on the
tank lid. Please use this number if contacting Hydratight.
7.6 General:
The complete system should be cleaned down to remove any debris and oil
contaminates which accumulate upon use. This can be carried out with dry
wipers. Any parts found to be missing or damaged should be reported
immediately.
7.7 Shipping:
If the unit is to be shipped, the oil should be drained from the reservoir, the
system should be despatched in an upright position, and maintained in this
position throughout its journey.
7.8 Fluids & Components Disposal: Ensure all fluids and components
are disposed of in accordance with local environmental health and safety
practices, if in doubt contact your local authority for guidance.
Page 20 of 45 T-ENG0071-AE
SECTION 8
FAULT FINDING
Problem Possible Cause Solution
Page 21 of 45 T-ENG0071-AE
SECTION 9
APPENDICES
9.1 Temperature / Viscosity Curve:
Page 22 of 45 T-ENG0071-AE
SECTION 9
APPENDICES
9.2 Hydraulic – Pneumatic Schematic (Standard Pump)
Page 23 of 45 T-ENG0071-AE
SECTION 9
APPENDICES
9.3 Sub-Sea Conversion
This section covers a sub-sea conversion of a standard “topside” configured
pump. This will enable the pump to operate in conjunction with a remotely
operated three port hydraulic valve. This conversion is based on modifying the
pneumatic circuit of the pump via the pendant, additional pneumatic
components are required and the kit can be supplied as described below
under part number PAPKSSCK.
Once fitted, this conversion enables the pump operator to select between
“topside” or “sub-sea” functionality via a switch position air valve.
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This conversion is based on the pendant design (POST MAY 2008) shown
below with the pneumatic layout.
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Conversion Procedure
Drill frame cross support and
fit “OR” valve with M4 x
25mm screws & nyloc nuts
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Fit “push in” OR” valve into
banjo as shown
“OR” VALVE
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Completed Conversion
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Operation Modes
Topside: -
In this mode the operation of the pump is that of a standard hydraulic wrench
operation as stipulated in SECTION 4.7 “Pendant Operation”
Sub Sea: -
In this mode the air motor ON – OFF via the actuator on the pendant functions
as the standard operation, however when the advance button is pressed it
actuates the pneumatic “OR” valve which in turn locks the hydraulic system
onto the advance line; producing constant flow to the three position sub sea
valve. From here the hydraulic flow will be controlled via the diver “sub sea”.
Mode Selector
Use the “finger” valve selector to change the mode from “topside” to “sub sea”
operation. (Shown above in “topside” mode)
Page 29 of 45 T-ENG0071-AE
SECTION 9
APPENDICES
9.4 Hydraulic – Pneumatic Schematic (Sub-Sea Conversion)
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Page 31 of 45
SECTION 9
APPENDICES
9.5 General Assembly (Parker – Pioneer coupling system)
T-ENG0071-AE
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SECTION 9
T-ENG0071-AE
SECTION 9
APPENDICES
9.7 Air Filter – Regulator – Lubrication Assembly
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SECTION 9
APPENDICES
9.8 Tool Valve Assembly
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SECTION 9
APPENDICES
9.10 Gauge Pipe Set Assembly
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SECTION 9
APPENDICES
9.11 Drive Shaft Assembly
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SECTION 9
APPENDICES
9.12 Pipe Set 1
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SECTION 9
APPENDICES
9.13 Pipe Set 2
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SECTION 9
APPENDICES
9.14 Pipe Set 3
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SECTION 9
APPENDICES
9.15 Parker – Pioneer Coupling System Assembly
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SECTION 9
APPENDICES
9.16 CEJN Coupling System Assembly
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SECTION 9
APPENDICES
9.17 Service Kits
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SECTION 9
APPENDICES
9.18 Warranty:
Any action for breach of this warranty, regardless of the legal theory of the
action, must be brought within one year after the date breach.
Documentation of the date of delivery to the original purchaser and serial
number is required with all requests for warranty. Contact Customer Service
for a “Return Refurb” form and shipping instructions. Product returned without
this will not be accepted.
Page 43 of 45 T-ENG0071-AE
SECTION 9
APPENDICES
9.19 Declaration Of Conformity
DECLARATION OF CONFORMITY
MANUFACTURER: Hydratight Operations Limited
5 Coopies Field,
Morpeth,
Northumberland,
NE61 6JT
England.
The pump covered by this certification has been assessed and tested in
accordance with Hydratight Operations Limited ISO 9001: 2000 quality
management system.
This equipment must not be put into use until the machinery into which it is to
be incorporated has been declared in conformity with the necessary
directives.
Page 44 of 45 T-ENG0071-AE
SECTION 10
CONTACTS
Page 45 of 45 T-ENG0071-AE