MAGISTER HPU-PR-12VDC-DA-SA Hydraulic Power Unit Instruction Manual

MAGISTER HPU-PR-12VDC-DA-SA Hydraulic Power Unit

Product Information

• Specifications
  • Manufacturer: MAGISTER HYDRAULICS
  • Address: 45 Montgomery St Belleville NJ 07109
  • Contact: Tel: 1 973-344-5313 | Fax: 1 973-344-5157
  • Email: info@magisterhyd.com.
  • Website: www.magisterhyd.com
• General Information
  • This manual is a complete guide designed for Hydraulic power units (HPUs) with specific models HPU-SR-12VDC-DA/SA and HPU-PR-12VDC-DA/SA.
  • It provides information on safety guidelines, assembly, maintenance, and more.
• Safety Guidelines
  • Trained or authorized experts should handle any task that involves removing or disassembling the unit or its electrical parts.
  • Alterations, modifications, or repairs not covered in the manual will void the warranty.
• Applications
  • The hydraulic power unit is suitable for integration into hydraulic systems of construction equipment, transportation machines, cars, and manual lifting tools.
  • It is used in systems that move in one or both directions, including tippers, car lifts, snowploughs, forklifts, and more.
• Operations Requirements
  • The unit has specific operational requirements that need to be followed for efficient and safe usage.
• Technical Characteristics
  • Detailed technical specifications such as motor power, pump displacement, and tank size can be found on the label located on the tank.

Product Usage Instructions

• Power Unit Assembly
  • Requirements of the Working Area: Ensure the working area is clean and free from obstructions.
  • Transportation of the Dump Trailer Power Unit: Use appropriate equipment to transport the power unit safely.
  • Power Unit Protection: Implement necessary protection measures to prevent damage.
  • Connecting Ports: Familiarize yourself with the different ports for connections.
  • Connection to Hydraulic System: Follow guidelines for proper connection to the hydraulic system.
  • Connection to Electrical System: Ensure correct connection to the electrical system.
• Maintenance of the Hydraulic Power Unit
  • Cleaning of the Power Unit: Regularly clean the power unit to prevent dirt buildup.
  • Pressure Adjustment: Adjust pressure settings as needed for optimal performance.
  • Problem Solving: Refer to the manual for troubleshooting common issues.

FAQs

• Q: What should I do if I encounter technical issues?
  • A: Contact our technical department at info@magisterhyd.com with specific information about the problem you’re facing.

General Data

• A1. Manufacture
  • MAGISTER HYDRAULICS
  • 45 Montgomery St Belleville NJ 07109
  • Fax: 1 973-344-5157
  • Tel: 1 973-344-5313
  • info@magisterhyd.com.
  • www.magisterhyd.com.
• A2. Introduction
  • This manual is a complete guide designed for Hydraulic power units (HPUs) with the specific models HPU-SR-12VDC-DA/SA and HPU-PR-12VDC-DA/SA.
  • In these pages, you’ll find lots of useful information about General
  • Information, Safety Guidelines, What HPUs Are and How They Work, Putting
  • Together the power unit, and Taking Care of the HPUs.
  • This manual assists you in installation, safety, maintenance, production, etc.
  • We strongly suggest reviewing Section B Safety Technics carefully. Trained or authorized experts should perform any job that requires the unit or its electrical parts to be removed or taken apart.
  • Please do not try to fix or change the unit or its parts if they are not discussed in this manual.
  • Any alterations, modifications, or repairs will void our 1-year warranty, which covers manufacturing defects only.
• A3. CORRESPONDENCE
  • If you encounter any technical issues, do not hesitate to contact our technical department at info@magisterhyd.com. Please include the following information so we can assist you effectively.
  • Power unit code (you’ll find it on the label)
  • The voltage and frequency of the current you’re using
  • The pressure at which the unit is working
  • Pump displacement
  • Production date
  • A detailed explanation of the problem you’re facing
  • Number of hours the unit has been in operation
  • Order Number
  • Video of unit operating demonstrating the issue
  • Photos of the equipment and connection
• A4. Label
  • The unit’s specifications, such as motor power, pump displacement, and tank size, can be found on the label located on the tank.
• A5. Applications
  • The hydraulic power unit is designed to fit into hydraulic systems in construction equipment, transportation machines, cars, and manual lifting tools.
  • It works for systems that move in one direction or both.
  • This includes things like tippers, car lifts, dock levellers, tailgates, wheelchair lifts, snowploughs, forklifts, and industrial automation setups.
• A6. OPERATIONS REQUIREMENTS
  • You can use the hydraulic power unit indoors or outdoors, where the temperature is between -13°F and 122°F.
  • It works well even when the air is a bit damp, with humidity up to 80%.

• A7. TECHNICAL CHARACTERISTICS
  UNIT

  Action:| Single Acting/Double Acting
  Max Flow:| 1.1 GPM
  Max Pressure:| 2600 PSI
  Max RPM:| 2500
  Pump Displacement:| 0.10 Cl/REV
  Reservoir Capacity:| 4/6/8/10/12 qts
  Tank Material:| Steel/Plastic
  Voltage:| 12 V
  Current:| Direct
  Motor power:| 1.6 kW
  Port Size:| SAE 8
  Mounting:| Horizontal
  Length:| 17/20/24/33/36 in
  Width:| 8/12/13 in
  Height:| 8/12/13 in
  Weight:| 31/32/34/35 lbs
  Country of Origin| Bulgaria, European Union

• A8. NOISE CHARACTERISTICS
  • The hydraulic power unit doesn’t make noise louder than 85 dB, following the EN 60034-9 standard.
• A9. WORKING FLUID
  • Use a new, clean mineral-based ISO 6743/4 fluid to fill the oil tank.
  • Choose hydraulic oil with a thickness between 15 and 68 CST at a temperature of 104°F.
  • Remember, the type of hydraulic fluid may need to change based on where you’re working. Don’t use motor oil, diesel oil, or water in the system.
  • Aim for a filtration class of -9 NAS 1638.
  • You should replace the hydraulic fluid every 6 months or 1 year, depending on how much you use it.
  • Also, make sure to clean the suction filter. If you notice the fluid level going down, just add more oil.

Safety

B1. RULES FOR TECHNICAL SAFETY

Only personnel who understand the rules for handling electrical and pressurized equipment should operate the power unit.

For safe operation of the hydraulic power unit, follow these guidelines:

• Don’t start the power unit if the motor’s terminal connecting box cap is changed or if connectors on solenoid valves differ from the ones the power unit comes with.
• An expert electrician should make the connections, ensuring the electric motor turns the right way (the arrow on the motor cover shows the correct rotation direction).
• Be careful with hydraulic connections. Letters on the main manifold indicate P for pump line (pressure) and T for tank line (return).
• Use pipes that match the system’s pressure and flow rate. Make sure tube connectors are secure and don’t leak. Use proper seals.
• Don’t replace the air breather with a plug.
• Don’t adjust the pressure relief valve to higher pressure.
• Secure the power unit to a stable base or frame.
• Don’t use the power unit in explosive or flammable environments.
• Keep enough oil to avoid damaging the hydraulic pump.
• Close the covers of both single-phase and three-phase AC motor terminal boxes.
• The AC motor’s right rotation is seen from the fan side. The hydraulic pump rotates clockwise from the shaft view.
• Use insulated cables for connections.
• Don’t assemble the power unit in a wet environment.
• Prevent the + and – poles of the DC motor from touching.
• Insulate DC motor cable ends.
• DC motor must always have a starter assembled.
• Don’t put blind plugs on the red-coloured breathers of oil tanks.
• Ensure hose diameters aren’t too small.

DESCRIPTION OF THE HYDRAULIC POWER UNIT

C1. MAIN COMPONENTS

The power unit is made up of these main parts:

• Electric motor
• Central manifold (made from a die-cast aluminium alloy)
• Hydraulic gear pump
• Oil tank
• Filter

When you turn on the electric motor, it makes the gear pump work. The pump pulls the working liquid from the tank and sends it to the valve block. Then it moves on to the parts of the power unit that do the work. The pressure relief valve, which is part of the main block, controls the pressure in the system. If needed, other hydraulic blocks can be added to the power unit.

C2. ELECTRICAL COMPONENTS

The hydraulic power unit is put together with these parts:

• Electric motor
• Starter (Only used for DC motors)
• Solenoid valves (Optional)

The electric motor can be three-phase or single-phase for AC power. For DC motors, the standard working voltages are 12 or 24 volts. The solenoid elements are of the cartridge type. Their coils can work with voltages of 12, 24, 110, or 220 volts. The connectors follow the DIN 43650 standard.

POWER UNIT ASSEMBLY

• D1. REQUIREMENT OF THE WORKING AREA
  • If there’s no mounting bracket, attach the power unit using M10 holes. Keep the area around the power unit clear, so you can easily reach the oil filler, valves, and unloading throttle. Make sure the power unit is in an open space so it doesn’t get too hot. Also, avoid putting it near vibrating or noisy parts.
  • The power unit’s job depends on the machine it’s connected to. When using the power unit, there shouldn’t be any leaks of the working fluid on the outside. The power unit turns on when the motor gets the right voltage. The control happens by correctly combining the motor and solenoid valves and switching them on.
• D2. TRANSPORTATION OF THE HYDRAULIC POWER UNIT
  • You can use any covered transport to move the power unit.
  • Follow the instructions on the box while transporting. If there’s oil in the tank, either replace the air breather with a blind plug or empty the oil before moving it.
• D3. POWER UNIT PROTECTION
  • Take the hydraulic power unit out of the box.
  • Remove the plastic wrap from it. Replace the safety plugs on the supply ports.
• D4. CONNECTING PORTS
  • On the main manifold, you’ll see two letters that stand for the pump (pressure) and tank lines.
  • P stands for the pump line, and T stands for the tank line. Both ports are 3/4 – 16UNF (SAE 8) or 9/16 – 18UNF (SAE 6) by default. The maximum tightness for fittings is 65 Nm.
• D5. CONNECTION TO HYDRAULIC SYSTEM
  • Connect the HYDRAULIC HOSE ASSEMBLIES from the power unit to the machine’s parts that make it work.
  • You can find the hydraulic circuit and technical details in the technical drawing.
  • Once you’ve finished setting up the power unit, add clean working liquid to the tank up to the marked level.
• D6. CONNECTION TO ELECTRICAL SYSTEM
  • Start by removing the cap from the motor’s terminal connecting box.
  • Unscrew the nuts from the terminals and attach the cable shoes to them. Once connected, securely tighten the nuts. Ensure the motor is not running.
  • Place the cap back on the terminal box. Connect the coils of the solenoid valves in a similar way.
  • Carefully check the motor’s rotation to make sure it’s correct.
  • When it comes to connecting the power unit to the electrical system, it’s best to have a certified electrician do it.
  • They’re familiar with safety rules for working with electrical equipment. Refer to the manufacturer’s instructions for the electrical layout.
  • For safe motor operation, use a current relay (100 mA), a thermic relay, and a main circuit cutoff switch.
  • After all the electrical connections are made, test the motor’s rotation by briefly giving short pulses of right rotation (from the fan side), each lasting no more than 1 second.

MAINTENANCE

MAINTENANCE OF THE HYDRAULIC POWER UNIT

• E1. CLEANING OF THE POWER UNIT

  • To clean the power unit, use a cloth made of fabric, without any cleaning liquids or chemicals. The cloth should not leave any threads on the surfaces you’re cleaning. Once a year, it’s important to change the oil in the tank and clean it.
  • Here’s how you do it:
  • Release the pressure in the system.
  • Turn off the power unit in the electric setup.
  • Take apart the pipes. Unscrew the screws holding the power unit to the base.
  • Stand the power unit upright on the tank. Unscrew the fixing screws and replace the tank brackets.
  • Move the electric motor, central manifold, and pump away. Empty out the old oil and clean the inside of the tank. Clean the suction filter too.
  • After cleaning, put the electric motor and central manifold back on the tank.
  • Screw in the fixing screws and brackets. Put the assembled power unit back in its usual spot.
  • Fill the tank with the working liquid up to the level indicated on the stick. Make sure to close the air breather tightly.
  • Put the pipes back together. Connect the power unit to the electrical system as needed for its use.
  • Remember, using dirty oil will shorten the life expectancy of the unit.

• E2. PRESSURE ADJUSTMENT

  • To adjust the pressure in the hydraulic power unit, you use a pressure relief valve found on the main manifold.
  • Here’s how you do it:
  • First, attach a pressure gauge at port “P.”
  • Unlock the nut of the adjusting screw.
  • Unscrew the adjusting screw until it’s out.
  • Turn on the hydraulic power. Now, turn the adjusting screw (turn it clockwise to increase, and counter-clockwise to decrease) until you reach the pressure you want. Once it’s right, lock the nut.
  • Important: Do not exceed the maximum working pressure shown on the technical drawing.

• E3. PROBLEM SOLVING
  PROBLEM| REASONS
  ---|---
  Not sufficient pressure|

  • No oil in the tank

  • The pressure relief valve is damaged

  • Solenoid- operated valve is damaged

  • The hydraulic pump is damaged

  • Incorrect filter pipe type

  • The filter blocks

  • Air in suction line |

  • Add oil

  • Adjust the relief valve again

  • Replace

  • Replace

  • Replace

  • Replace

  • Remove the air
     | Gear pump isn’t| Fix or replace
     | working right| Verify proper rotation
     | Electric motor| Inspect wiring
    No pressure| is turning the|
     | wrong way|
     | Electric wiring|
     | is incorrect|
    PROBLEM| REASONS
    ---|---
     | Broken| Replacement
     | solenoid valve| Replacement
     | Broken check| ****

Replacement

Non-| valve|
performance of|  | Replacement
the| Broken|
function| pressure relief|
 | valve|
 | Broken|
 | hydraulic pump|

• All power units are tested to 100% before delivery to the customer.

WARRANTY

• F. WARRANTY
  • The manufacturer ensures that the product meets the standard and technical specifications.
  • It should work properly when operated as explained in this manual.
  • Please don’t remove the product label from the oil tank while the warranty is valid.
  • The warranty lasts for 12 months from the Order date.

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