HydraSmart Operations Manual Models: HS-11-1400; HS-20-2600 … · 2018-03-15 · Idle Delay: The Idle Delay is an optional timer that sets the time delay before the system goes into

HydraSmart Operations Manual

Models: HS-11-1400; HS-20-2600

Including the MultiSet Feature

and Optional Valve Kits Revision 5.3

HydraSmart Power Unit Page 2

HydraSmart Operations Manual

Models: HS-11-1400; HS-20-2600 Revision 5.1

Table of Contents Safety Precautions…………….……………………………………………3 Startup Procedure…….…………………..………………….……………3

Touch Screen Pendant Operation..…….…………………………..4 STATUS page.....………………………………………………….…....5 SETUP page…..………………………………………………………..…6 Changing Pressure and Flow...…………………………………6 Idle Speed …………………………………………………………..….7 Help Screens……………………………………………………………7 Timer Help..……………………………………..….……….7 Zero Speed Help………………………………….………..7

Multiset Help……….………………………….…………….……….8 MULTISET page.……………………………….……………………….9 RECIPE page................................................................10 Using Recipes...........................................................11 MAINTENANCE page..................................................13

Machine Maintenance and Troubleshooting………..………15 Filter Replacement…………………………………………..……..15 Quick Troubleshooting Guide.....................................16 Motor Drive troubleshooting Tips..............................17 Reset Drive Fault….……………………………………………….17 Useful Motor Drive Parameters………………….…………..18 Fault History……………………………………………….………..18 Fault Codes………………………………………………….……….19 Motor Drive Fault Codes Table......………………….…...19 PLC Troubleshooting Tips…………………………….………….20

Recommended Spare Parts ……………………………….………..21

Specifications……………………………………………………………….22

OPTIONS: ADDENDUMS:

A. Manual Flow and Pressure Adjustments……..………….…23 B. Multi-Valve Add-On Kit..…………...………….…….………….…25


Safety

1- Do not connect main electrical plug until all hydraulic connections have been made. Pump will start

when power is applied.

2- Be aware that the heat exchanger at the top of the unit, the solenoids on the valves and the motor

will reach temperatures that may exceed 120 degrees Fahrenheit.

3 -Inspect all hydraulic hoses in your entire system at least once per month. Look for cracks in the hose

coverings and leaks in tubing joints.

CAUTION: Be aware that even though the unit may not be running, under some operating conditions

it may start unexpectedly.

CAUTION: Be aware that though the unit may not be running, the system may be pressurized up to

2600 psi and that the parts of the machine may reach temperatures exceeding 120 °F.

Startup Procedure

1 – Through the filler port, fill the unit with 5 gallons of hydraulic oil for HS-10-1300 or 7 gallons for HS-

20-2600, any standard mineral oil grade VG 24 or 32 can be used. It is normal to require added oil

once the system has been run and the lines are filled. The pump will stop and a notice on the Status

HMI screen will indicate a low oil condition. Add more clean oil and the pump will restart when the

proper oil level is reached.

Breather/Filler Cap

Figure 1 FILLER / BREATHER LOCATION


Start Up (Continued)

2 – Connect hoses to the A, and B ports. On HS10-1300 and the HS15-2000 units, the port size is SAE8

and on the larger HS20-2600 units, the port size is

SAE12. (Note: In the case of a core pull unit, the rod

end cylinder connection will go the A port and the cap

end cylinder connection will go to the B port)

3 – Plug the electrical power and interface plugs directly

into their respective receptacles. The standard

machine voltage is 208v, three phase. Be sure the

voltage to the unit is the same as the sticker on the

door of the unit as the machine is available in several voltages for different installations.

4 – Turn on the power to the HPU. The unit is ready to operate as soon as the Status screen appears on

the operator station.

5 – Enter Pressure and Flow if the default settings are not desired (via “SETUP” page on HMI – See Touch

Screen Pendant Operation section below)

Touch Screen Pendant Operation

The operator station has five primary pages which the operator

needs to control the machine. The Status page (appears at

start up), Set Up page, Multiset page, Recipe page and the

Maintenance page. Each page has displayed information,

like pressure values and timer settings and control buttons

for turning thing off and on.

Each is explained as follows;

Figure 2 HOSE CONNECTIONS

Figure 3 HMI Pendant Box


Touch Screen Pendant Operation (Continued)

STATUS Page

This is the page that appears on startup of the machine. It displays current operating conditions.

Figure 4 STATUS PAGE AT STARTUP

Display Information

STATUS: HPU system status provides general operation status and any active system faults:

“SYSTEM OFF” – Pump is not operating

“SYSTEM RUNNING” – Pump is operating at displayed pressure and flow set points.

“DRIVE FAULT” – Pump Drive fault has occurred. Note error code on drive before resetting power.

“LOW LEVEL FAULT” – Oil level low level fault has occurred.

“HIGH TEMP FAULT” – Oil over-temperature fault has occurred.

“CHANGE FILTER” – Appears after 3000 hours of pump operation (pump running time only)

PRESSURE: Displays the active HPU operational pressure set point

FLOW: Displays the active HPU operational flow set point

MULTISET: This special status indicator appears and flashes to indicate that the multiset feature

is activated. Refer to MULTISET page instructions for using the Multiset feature.

STATUS Page Buttons

SETUP: This button takes you to the setup screen which allows pressure and flow set point to be

changed.

MAINTENANCE: This button takes you to the maintenance screen.

Figure 5 STATUS PAGE WITH MULTISET ON


SETUP Page

This is the page that allows the operator to change machine conditions for normal operation.

Figure 6 SETUP PAGE

Displayed Information

Pressure: Displays the currently selected pressure set point, this is also an input

Adjustment: If you touch the displayed number, the numerical keypad will appear allowing user

input of pressure (300-1,400 PSI for HS-11-1400, or 300-2,600 PSI for HS-20-2600).

Note: See page 22 for pressure (P) and flow (Q) characteristics.

Flow: Displays the currently selected flow set point.

Adjustment: This is also an input. If you touch the displayed number, the numerical keypad will

appear allowing user input of flow (3.0-11.0 GPM for HS-11-1400 or 3.0-20.0 GPM for HS-20-2600).


Idle Delay: The Idle Delay is an optional timer that sets the time delay before the system goes into idle

mode after receiving a SET input. When setting this timer, allow time for complete cylinder

movement plus a small amount for insuring proper seating of the moving device.

Molding time: The Molding Time is an optional timer that defines the duration of the idle mode in a SET

condition. At the end of the Molding Time, the HPU exits idle mode.

*Note: If Idle Delay and Molding time are both set to zero, idle mode will be disabled and the cycle will

depend solely on the inputs to the machine


Setup (Continued)

Setup Page Buttons

IDLE SPEED: This button controls the additional power saving option. In cases where the machines duty

cycle is greater than 15 seconds, you may choose to allow the motor to stop completely during the

set phase of the cycle. In this case, press this button and it will change to “ZERO SPEED” and the

motor will stop completely. It will restart after the time set in “MOLD TIME.” So, if the machine’s

mold time is thirty seconds, for instance, set “MOLD TIME” to twenty eight seconds and the motor

will be up to speed when needed. This is not always necessary, as the motor will automatically

speed up when the machine calls for a valve to open.

BACK: This button will take you back to the Status page.

HELP: This button will take you to a series of HELP screens. The first is the Idle DELAY/MOLDING TIME

HELP timing diagram which helps you understand the functioning of the two timers. The BACK

button on this page returns to the OPERATOR SETUP page.

IDLE SPEED HELP: This button will take you to a screen that explains the difference between the low

speed idle and the zero speed idle. The BACK button on this page returns to the OPERATOR SETUP

page.

Figure 8 ZERO SPEED HELP PAGE

Figure 7 TIMER HELP PAGE


Setup Page Buttons – HELP (Continued)

MULTISPEED HELP: This button will take you to the instructions for using the Multiset feature. The BACK

button on this page returns to the OPERATOR SETUP page.

Figure 9 MULTISPEED HELP PAGE


MULTISET Page

This page allows individual pressure and flow setting for each direction of each valve. This gives the operator the flexibility to compensate for differences in force and speed caused by rod end vs. cylinder end conditions.

Displayed Information

Pressure: Displays the currently selected pressure set point for each individual solenoid. This is also an

input – if you touch the displayed number, the numerical keypad will appear allowing user input of

pressure (300-1,400 PSI for HS-11-1400, 300-2000 for HS15-2,000 and 300-2,600 PSI for HS-20-

2600).


Flow: Displays the currently selected flow set point. This is also an input – if you touch the displayed

number, the numerical keypad will appear allowing user input of flow (3.0-11.0 GPM for HS-11-

1400, 3.0-15 for the HS15-2000 and 3.0-20.0 GPM for HS-20-2600).


MULTISET Buttons

BACK: This button will take you back to the Status page.

MULTISET ON/OFF: Press the ON button to use the indicated pressures and flows on this page. The

legend above the buttons will flash and an indicator will appear on the STATUS page. Use the OFF

button to disable this feature and the machine will then use the values set on the OPERATORS

SETUP page.

Figure 11 MULTISET VALVES 3 AND 4 Figure 10 MULTISET VALVES 1 AND 2


RECIPE Page

The recipe page allows all of the set operating parameters of the machine to be stored under a name or number for later recall.

A total of 150 recipes can be saved. The pressure and flow settings for all solenoids, idle delay,

molding time, and recipe name are saved for each recipe. Each recipe has a recipe number 0-149

displayed to the left of the recipe name.

Displayed Information Pressure: Displays the currently selected pressure set point, this is also an input – if you touch the

displayed number, and the numerical keypad will appear allowing user input of pressure (300-1,400

PSI for HS-11-1400, 300-2000 for HS15-2,000 and 300-2,600 PSI for HS-20-2600).

Flow: Displays the currently selected flow set point. This is also an input – if you touch the displayed

number, the numerical keypad will appear allowing user input of flow (3.0-11.0 GPM for HS-11-

1400, 3.0-15 for the HS15-2000 and 3.0-20.0 GPM for HS-20-2600).

Idle Delay: The Idle Delay is an optional timer that sets the time delay before the system goes into idle

mode after receiving a SET input. When setting this timer, allow time for complete cylinder

movement plus a small amount for insuring proper seating of the moving device.

Molding time: The Molding Time is an optional timer that defines the duration of the idle mode in a SET

condition. At the end of the Molding Time, the HPU exits idle mode.

Figure 12 RECIPE PAGE


RECIPE (Continued)

RECIPE Page Buttons

SLOW IDLE: A power saving feature that chooses between a low RPM idle speed or a zero RPM speed.

MultiSet: Changes to the MultiSet page so that settings may be verified before saving.

SAVE AS: Saves settings as a new recipe.

SAVE: Saves settings to selected recipe.

LOAD: Loads selected recipe.

DELETE: Deletes selected recipe.

TOP: Brings user to the first recipe (recipe # 0)

BOTTOM: Brings user to the last recipe (recipe # 149)

UP ONE: Brings user to the next recipe number (selected recipe # +1)

DOWN ONE: Brings user to the previous recipe number (selected recipe # -1)

BACK: This button will take you back to the SETUP page.

STATUS: This button will take you back to the Status page.

Using the recipe page Save a new recipe

Whenever you want to save the machine settings, press the “save as” button and a keyboard will

appear. Enter a name or number (up to 80 characters) and press return. The following parameters

are saved:

1. The pressure and flow which is set on the “setup” screen

2. The mold and idle timer settings

3. The status of the “idle speed/zero speed” toggle button

4. All of the individual flow and pressure settings from the “Multiset” page

5. And, the status of the “Multiset” ON/OFF buttons.

IMPORTANT NOTE: When you load a saved recipe, all of the Multiset values are changed also, even if

you are not currently using this feature. Whenever you engage the multiset feature, be sure to check

that the values set on the “Multiset” screen are the values you want to use.


RECIPE (Continued)

Load a previously saved recipe

To load a previously saved recipe, use the top row of gray buttons to move up and down the list

of saved recipe names which will appear in the window below the “RECIPE NAME” window.

Press the “LOAD” button and the values from that recipe will appear at the top of the page and

the name will appear in the “RECIPE NAME” window.

Modify a recipe

If you want to make a permanent modification to a recipe, change the value of one or more

parameters (i.e. pressure, SLOW/ZERO IDLE or mold time) and then press “SAVE.” The new

value will be stored along with the unchanged parameters.

Delete a recipe

To delete a recipe, use the top row of grey buttons to scroll to the desired recipe and then press

the “DELETE” button.


MAINTENANCE Page On this page are controls for manually operating the valves, and also, various warnings that may aid in diagnosing machine problems. Machines shipped after May of 2017 will have the HPU ON/OFF buttons and the valve control buttons password protected to prevent the inadvertent operation of valves that may cause damage to the connected load. Only authorized supervisors and maintenance personnel should use the LOGIN feature to enable these controls. After testing is complete, press the LOGIN button again and, on the screen that appears, press the LOGOUT button to disable the controls.

DISPLAYED INFORMATION

FILTER STATUS: When the pump has been running for approximately 3000 hours, the status will change

to “DIRTY.” A status warning will flash red on the Status screen on the status page, and a text

message with a new button will appear below the FILTER STATUS button on this page. As soon as

possible, replace the oil filter, then press the “RESET FILTER” button and hold it for three seconds.

The status will change back to OK and the reset button will disappear.

OIL LEVEL: If the Fluid level is ok, the status will read “OK.” If the fluid level is low, the status will read

“LOW.” If the level is low fill the reservoir through the filler, port until the level reaches to the

bottom of the filler port.

TEMPERATURE: If the temperature is ok, the status will read “OK.” If an over-temperature occurs, the

status will read “HI.” If an over-temperature occurs, contact CMA/Flodyne/Hydradyne Service at

(630) 563-3600.

DRIVE FAULT: If the pump drive is ok, the status will read “OK.” If the pump drive is in a faulted state,

the status will display “FAULT.” If a drive fault occurs, please note the error message and then

contact CMA/Flodyne/Hydradyne Service at (630) 563-3600. You may try to reset the fault by

turning the power off for twenty seconds and then turning it on again.

Figure 14 MAINTENANCE PAGE WITH OIL FILTER ALERT Figure 13 MAINTENANCE PAGE


Maintenance (Continued)

MAINTENANCE Page Buttons

RESET FILTER button appears only after 3000 hours of the pump motor being turned on. After changing

the filter, press and hold this button for 3 seconds and it will reset the timer and then disappear.

LOGIN: This button is used to grant access to the HPU power ON/OFF buttons and the manual override

buttons for the valves. Only authorized supervisors and maintenance personnel should use the

LOGIN feature to enable these controls. After testing is complete, press the LOGIN button again and,

on the screen that appears, press the LOGOUT button to disable the controls. Contact CMAFH for

the password and further instructions.

OEM – This is a special set up and test screen that is also protected and accessed by using the LOGIN

button to enter a password. It contains a continuous running “Demo” mode which is useful for

testing.

HPU OFF: Turns HPU OFF when enabled by a password fur use during testing.

HPU ON: Turns HPU ON when enabled by a password fur use during testing.

C1-SET: Allows manual triggering of the core 1 set signal (for testing purposes).

C2-SET: Allows manual triggering of the core 2 set signal (for testing purposes).

C1-PULL: Allows manual triggering of the core 1 pull signal (for testing purposes).

C2-PULL: Allows manual triggering of the core 2 pull signal (for testing purposes).

NOTE: If your unit uses the optional remote manifold, more SET and PULL buttons may be included.

DEMO OFF: This button is used to stop the DEMO mode when it has been activated on the OEM screen.


Machine Maintenance and Troubleshooting

Many features have been incorporated on the HydraSmart HPU to make maintenance as fast and easy

as possible. Here are a few of them:

1. Easy to access oil filter with a reminder based on actual running time that appears on the HMI to tell

you when to change it.

2. Lighted solenoid caps to indicate visually when they are energized. Valves include manual override.

3. Faults are annunciated on the Status screen as well as the Maintenance screen.

4. Manual control of the solenoids is provided on the maintenance screen for “test firing” all valves.

5. A continuous cycling of valves SV1 and SV2 with variable timing is available on the OEM page. CAUTION: Be aware that even though the unit may not be running, under some operating conditions

it may start unexpectedly.

CAUTION: Be aware that though the unit may not be running, the system may be pressurized up to

2600 psi and that the parts of the machine may reach temperatures exceeding 120 °F.

Filter replacement: The recommended time interval for replacing the filter element is 3000 hours.

Follow the below steps to replace the filter element:

1 – Turn the Hydraulic Power Unit OFF via the core pull button on the main molding machine HMI or by

pulling the power plug of the HPU.

3 – Place a drain pan under the filter and remove the filter element by turning the filter canister counter

clockwise.

4 – Refer to the parts list for your machine to ensure that you use the recommended filter unit. It is a 5

micron hydraulic system filter. Lubricate the seal on the replacement element and install the new

filter by turning the filter canister clockwise. Screw in by hand until the element contacts the sealing

surface, then tighten by hand ¾ turn more. Visually inspect to insure that the seal ring is not

protruding from one side of the seal. Top off the oil reservoir, if necessary, and then put the

machine back into service and observe the filter for a few minutes to insure there are no leaks.

Filter Canister

Figure 15 FILTER LOCATION


Machine Maintenance and Troubleshooting (Continued)

Fluid Level: Check maintenance screen for status. If the Fluid level is low, the OIL LEVEL indicator will

read “LOW.” If the level is low, fill the reservoir through the filler port until the level reaches to the

middle of the filler port. The motor will not run if the level is low and will start again when the

proper oil level is restored.

Fluid Temp: Check maintenance screen for status. If the temperature is too high, the TEMPERATURE

indicator will read “HIGH.”

Quick Trouble Shooting Guide

TABLE 1 TROUBLE SHOOTING SOLUTIONS

Problem Things to Check Possible Solutions

HMI indicates “LOW OIL” Oil level Float sensor

Fill with oil Replace sensor

HMI indicates “HIGH TEMP” Is the fan running? Check 24 volt, 10 amp fan supply Temperature switch is closed?

Reset circuit breaker Power supply output is shorted, check wiring Fan is broke

HMI indicates “DRIVE FAULT” Look at drive display See Drive Trouble Shooting Tips

A valve does not turn on Valve light in connector should be on CR relay light should be on

See PLC Trouble Shooting Tips Faulty valve coil Call for service

Motor does not run Drive display See Drive Trouble Shooting Tips

Motor drive is not on Drive circuit breaker is tripped PLC output Y0 must be on

Reset circuit breaker Call for service

HMI is not on Cable from machine to HMI damaged, 24 volt power supply.

Repair cable Reset power supply circuit breaker Call for service

Nothing happens when buttons on the HMI are pressed

Make sure connector is tight on HMI cable to box Cable from machine to HMI damaged, PLC not working

Cycle machine power Repair cable See PLC trouble shooting tips

Drive repeatedly trips due to F_PF or Fan is running but oil still overheats

Motor is over loaded Leaking directional valve Leaking pressure relief valve

Lower flow or pressure setting Test valve Remove and clean or replace relief valve

Unit does not develop pressure

Faulty or clogged pressure relief valve Remove and clean or swap out valve

Unit does not develop pressure or pressure cannot be varied

Faulty or clogged proportional relief valve

Remove and clean or swap out valve Swap amplifier coil


Machine Maintenance and Troubleshooting (Continued)

Motor Drive Trouble Shooting Tips

Using the display

The motor on the HydraSmart units are powered by an A.C. vector drive. The drive contains a red LED

display that displays many types of useful information. The default display is the speed of the motor

in set frequency which is in Hertz. The base speed of the motor which is around 1750 RPM is

achieved at 60 Hz. The maximum motor speed is 3000 rpm or 100 Hz. The higher the desired flow is

set on the operator HMI, the faster the motor will run. Maximum flows are achieved between 70

and 95 Hz depending on which HydraSmart unit is being used.

Other useful drive information is available by using the up and down arrow keys on the drive to change

the address of the information to be displayed. Press the key marked with an “M” (mode) and the

display will change to a “Pnnn” with nnn indicating the parameter number. Use the up and the

down arrow keys to increase and decrease the parameter number. Press the M button again and

the display will show the value for that parameter.

CAUTION: Important drive parameters can be changed in this same way. Operation will be negatively

affected and in some cases damage to the motor may result. Only the parameters suggested here

are to be used to view conditions in the drive. Do not make any changes to the values you see in

any parameter. If you accidently enter undesired information, DO NOTHING, and the parameter will

change back to the original value in about 15 seconds.

Resetting Faults.

When faults occur, the drive will protect itself when possible by taking itself out of service or “tripping.”

Try to clear the cause of the fault before proceeding. There are several different ways to return the

drive to operation depending on the fault. First try pressing the red button on the drive control

panel. If this doesn’t restore operation, go to the MAINTENANCE screen on the HMI and press HPU

OFF, then press the red button on the drive. If this fails, remove power from the machine and wait

15 seconds or until the fan on the drive stops then re-apply power.


Motor Drive Trouble Shooting Tips (Continued)

Useful Motor Drive Parameters

There are many drive parameters, below are the most likely to be useful in troubleshooting the unit.

P508 Motor Current. When the pump is idling, this value will be less than half of the current on the

nameplate of the motor. When a valve first opens, motor current will ramp up to several times the

rated current. This is normal.

Use: watch this parameter for higher than normal idle current which may indicate valve leakage or

incorrect adjustment of pressure relief valve.

P521 Analog input value. This will indicate the motor speed being requested by the setting of oil flow

on the HMI. An indication of around 4 (milliamps) indicates minimum motor speed and flow.

Indications of around 17 ma (depending on the size of the HydraSmart unit) indicates maximum

motor speed and oil flow.

Use: From the operator input screen select “zero speed” operation. P521 should read 4 ma or slightly

less and motor speed should be zero. Now turn on any valve. P521 should read a higher value at 3

GPM and should increase depending on the flow set on the HMI. If this does not happen, check the

wiring from the drive to the PLC, the connectors on the PLC for proper installation and look for a

fault light on the PLC.

P540 Total Run Time. Indicates total hours the drive was enabled (ready to run.)

P541 Total Power-On Time. Indicates total hours the power was applied to the drive.

Use: Use in conjunction with the next three parameters to analyze the fault history.

FAULT HISTORY: Using the parameters P550, P551 and P552 it is possible to see how many faults have

occurred and at approximately what time. The fault logs are designed to avoid “overflow” resulting

from repetitive faults such as low buss faults caused by normal power down cycles. Refer to table 1

for interpretation of fault codes.

P550 Fault History. Shows the last eight unique faults. Press the up and down arrow keys to scroll

through the list of faults.

Format is n.xxx where n=fault number (1…8) with 1 indicating the newest fault. xxx= the three letter

fault code from table 1

P551 Fault History Time. Format is n.hhhh, mm, ss = fault number, hours, minutes, seconds

P552 Fault History Counter. This parameter indicates the sequential occurrences of a fault.

For example: The line voltage dips below minimum which will cause the drive to trip off line due to a

low bus voltage.


Motor Drive Trouble Shooting Tips (Continued)

If this happens three times over a period when there are no other faults, P552 will indicate 3, P550 will

indicate the fault “LF” and P551 will indicate the time counted from the first time power was

applied. Note that only the time of the first occurrence is displayed. The time of faults two and

three are not known unless another fault occurs, then you will know that the 2nd and 3rd occurrences

were between the time of the first fault and the next new fault displayed in P550.

FAULTS CODES: The drive is capable of displaying over 25 fault codes. Only the most likely or those that

you may be able to clear are listed here. If you see any other code, write it down and call for service.

TABLE 2 - FAULT CODES

F_AF HIGH TEMPERATURE Ambient temperature is above 95F. Fan filter is dirty.

F_EF EXTERNAL FAULT There may be a problem with the external wiring or braking resistor unit (on HS20 units only)

F_dbF DYNAMIC BRAKE UNIT FAULT (on HS20 units only) Check for high line voltage, Replace unit. Call for service.

F_LF LOW BUS VOLTAGE Check for low line voltage.

F_HF HIGH BUS VOLTAGE Check for high line voltage.

F_OF OUTPUT FAULT Shorted output/Check motor wiring. Shorted output transistors/call for service

F_OFI GROUND FAULT Check motor leads for shorts to the chassis.

F_PF MOTOR OVERLOAD Extended period of high motor load. Check flow and pressure settings against max. permissible values

F_SF SINGLE PHASE FAULT Check line voltage for missing phase.


PLC Trouble Shooting Tips

The PLC is located in the lower part of the enclosure with the drive. It has green connectors on the front

along with a series of red or green LED lights. The connector on the upper left of the unit contains

the input wiring and the LED lights to the right of this connector represent the state of the adjacent

input. Inputs are designated by the letter “X.” If the light is on, the input is active (24 volt power is

applied).

The connector immediately below that one is the output connector and the lights indicate whether or

not the output is turned on. Outputs are indicated by the letter “Y.” The connector on the far right

module (HydraSmart units with add-on features such as extra valves may have a third module)

contains the analog outputs to the motor drive and to the pressure controlling servo valve on the

manifold. The analog current outputs are marked “I.”

By using the schematic for the unit and watching the lights on the PLC, important troubleshooting

information can be determined.

For Example: your machine is calling for solenoid SV1 to be on, then the lights on X4 and Y2 should be

on, as well as the light on CR1, which is located near the PLC.

Other Lights: Also, in the upper left corner of the PLC module are three more lights, Power, Run and

Error. When power is connected to the machine the POWER light should be on as well as the RUN

light. If neither is on, check the circuit breaker for the 24 volt power supply, CB3. If only the power

light is on, verify that the small slide switch below the lights, marked RUN is in the run position. If it

is, try cycling the power to the machine. Also, if the ERROR light is on, look at the two plugs on the

bottom of the PLC and be sure that both plugs are seated properly. Cycle the machine power. If the

error light remains on, call for service.


Recommended Spare Parts

Filter Canister

For HS11-1400: HS-FC01

For HS20-2600: HS-FC02

Electric Solenoid interchangeable for all directional valves on a system:

For HS11-4300: HS-DSO1

For HS20-2600: HS-DSO2

Exhaust Fan Filter

For HS11-1400: HS-FM01

For HS20-2600: HS-FM01

Proportional Relief Valve

For HS11-1400: PPR-1400

For HS20-2600: PPR-2600

Proportional Relief Amplifier Coil

For HS11-1400: PPRAC-1400

For HS20-2600: PPRAC-2600

Pressure Relief Valve

For HS11-1400: PR-1400-3K

For HS20-2600: PR-2600-3K


Specifications

Intermittent Pressure and Flow Characteristics


ADDENDUM A

Manual flow and pressure adjustment kit for HydraSmart – Instructions An option kit may be added to HydraSmart units to allow for manual adjustments which will override

the settings made from the operator’s touch screen. This kit consists of a flow control, which allows

individual control for each direction of cylinder motion, a pressure control for each valve set and

manual overrides for the check valve on each port which will relieve stored pressure.

PRESSURE FLOW

CONTROLS CONTROLS MANIFOLD VALVES FLOW CONTROLS CHECK VALVE MANUAL RELEASE

Figure 1A ADJUSTMENTS

Figure 2A MANIFOLD


Manual flow and pressure adjustment – Instructions (cont’d)

OPERATION:

1. On the operator station, enter the maximum pressure and flow that may be required for the

particular system connected to the manifold.

2. Control the actual pressure delivered to the cylinder with the pressure control valve for the circuit

desired. Use the gauges provided to determine actual pressure. NOTE: turning the adjustment screw

counter clockwise decreases pressure and clockwise increases pressure.

3. Control the flow to the circuit by using the individual flow control valves and watching the speed of movement of the load while turning the adjustment screw. NOTE: Clockwise reduces the flow and counter clockwise increases the flow. EXAMPLE: a. A cylinder has been connected to ports A1 and B1. Maximum required pressure has been estimated at something less than 1500 psi and maximum flow as 13 GPM. b. As a rule of thumb, always set the system pressure more than 100 psi above the anticipated manual set point to avoid valve oscillation. Therefore, Set the system pressure on the HMI to 1600 psi or higher and the flow to 13 GPM or greater and start the pump. c. Cycle the cylinder and adjust the pressure to insure smooth travel of the cylinder in both directions. d. Now, adjust the speed of travel in each individual direction using the flow controls as required. e. If satisfactory operation cannot be attained, it will be necessary to go back to the operator panel and increase either the pressure or the flow. NOTE: always using maximum settings on the control screen will generate unnecessary heat and noise. PRESSURE RELIEF: For safety and convenience, when disconnecting hoses or for testing purposes, the pressure within the cylinders and hoses may be released and bled to zero by opening the check valves located on the manifold body. NOTE: Turning the adjustment screw counter clockwise will relieve the pressure in the hoses, but for the system to operate normally, the screws must be at the maximum clockwise position.


ADDENDUM B

Instruction For The Use Of The Hydrasmart Multi-Valve Add On Kit.

Introduction: The multi-valve add on kit provides multiple sources of hydraulic power in addition to the

normal bi-directional axes of power provided by the basic HydraSmart unit. The add-on valves are

powered by a 24 volt D.C. signal that is supplied by a separate source other than HydraSmart unit.

This auxiliary manifold may be mounted on the HydraSmart unit or located remotely. Illuminated

valve connectors are provided for easy troubleshooting. Variable pressure and flow controls are

provided for each port along with separate bleed valves, one for each output port, to relieve

trapped pressure.

Installation

If the auxiliary manifold is to be mounted separately, plug the multi-pin connector from the auxiliary

manifold into the junction box located on the rear of the power unit and plug in the extension feed

hoses to the quick disconnects provided on the power unit and the auxiliary manifold.

Operating Instructions (refer to “Controls Layout” section and Figure 1B on the next page)

On the HydraSmart operator control HMI, Set the pressure and flow as required for the bi-directional

valves on the HPU. The pressure and the flow must be equal to or greater than the pressure and

flow required at the auxiliary outputs. With the pump on, adjust the pressure reducing valve (PCn)

to set the desired pressure for each pair of outputs using the gauge provided. Now set the flow, as

required for each port, using the flow control valve for each port. Use the manual override on the

valve coils to open and close the valves to test.

To relieve the pressure in the output lines, turn the pump off and open the appropriate dump valve.

WARNING: Motor will be overloaded if any dump valves are open during operation!

Be sure to close (clockwise) all open valves again to return to normal operation. Note: when using the

“Multiset” feature on the main unit, it is possible to open any number of gate valves at the standby

pressure and flow settings, and then close the ports before the machine valve opens at the new

multiset level. The auxiliary pressure will then be maintained in each port by the check valve

located in the auxiliary manifold.


Instruction for the use of the HydraSmart multi-valve add on kit. (Continued)

Control Layout

For detailed hydraulic circuit information, refer to the hydraulics schematic provided in the customer

information packet that was included with the machine. A schematic for wiring is also provided.

ON/OFF VALVE (NOTE: THERE IS A MANUAL OVERIDE BUTTON IN CENTER OF THE BLACK KNOB)

PRESSURE REDUCING VALVE (TURN CCW TO REDUCE PRESSURE) PORT PRESSURE GAUGE

CHECK VALVES (NO ADJUSMENTS)

INTERNAL FLOW CONTROL VALVE METER OUT PORT A METER OUT PORT B

PORT A PRESSURE DUMP VALVE PORT B PRESSURE DUMP VALVE (TURN CCW TO RELEIVE, CW FOR OPERATION)

OUTPUT PORTS (8 SAE)

(LETTERS FOR A AND B PORTS ARE STAMPED ON THE MANIFOLD)

FIGURE 1B EIGHT GATE VALVE MANIFOLD


Contact us at:

CMA/Flodyne/Hydradyne

1000 Muirfield Drive

Hanover Park, IL 60133-5468

Website: www.CMAFH.com

Tel: 630.563.3600

http://www.cmafh.com/

Documents

HydraSmart Operations Manual Models: HS-11-1400; HS-20-2600 … · 2018-03-15 · Idle Delay: The Idle Delay is an optional timer that sets the time delay before the system goes into