Pascal Wall Mount Unit

211061

Manufacturers of Custom Fluid Systems

Pascal Portable Unit O&M Manual

PASCAL SYSTEMS

Operation and Maintenance Manual

Pascal Systems 2350 Del Monte Street Phone (916)-372-5411 Fax (916)-373-0952

PASCAL SYSTEMS HAS USED ITS BEST EFFORTS TO MANUFACTURER A SAFE RELIABLE FLUID SYSTEM. PASCAL SYSTEMS RECOMMENDS THE CUSTOMER READ AND PRACTICE THE TECHNIQUES INCLUDED IN THIS OPERATING AND MAINTENANCE MANUAL. THE INFORMATION CONTAINED IN THIS DOCUMENT IS, TO THE BEST OF OUR KNOWLEDGE, ACCURATE AND IS DESIGNED TO AUGMENT THE CUSTOMERS EXISTING SAFETY AND OPERATING AND MAINTENANCE PROCEDURES. THE INFORMATION CONTAINED HEREIN IS LIMITED TO THE EQUIPMENT SUPPLIED BY PASCAL SYSTEMS AND PASCAL SYSTEMS ASSUMES NO LIABILITY FOR THE RESULTANT USE OF THE INFORMATION CONTAINED IN THIS DOCUMENT.

O & M

M A N U A L

Section

1
Safety Precautions
Safety is of the utmost concern to all persons involved with this system. Careful review of this section is highly recommended.

he safety of personnel and preservation of equipment is the prime concern during installation, testing, operation and maintenance of this equipment. This safety section is as an addition to established safety procedures and practices in place at this equipments final destination. These safety precautions are meant as suggestions only. Pascal Systems is not responsible or liable for personnel safety or the safe operation of the equipment provided. Pascal Systems assumes no liability for the resultant use of this document. Listed below are caution statements and symbols. Next to each symbol is a brief description of the symbols meaning. These symbols will be used throughout this manual. Please refer to these symbols and descriptions.

This hydraulic system has operating pressures in excess of 2000 psi working on movable surfaces. These surfaces can generate Movable Surfaces large forces, which is a potential hazard for personnel. Care should be taken while operating or maintaining the system to monitor the resulting motion to prevent injury.
C A U T I O N S

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M A N U A L

Normal operations of hydraulic systems are at temperatures at and below levels to cause discomfort on unprotected skin. High Temperature There are conditions at which the fluid and surfaces will be above 138F that will cause burns to unprotected skin. Extreme caution and safety clothing should be used while in contact with these surfaces.
C A U T I O N S

The majority of hydraulic systems use an electric motor as the prime mover. This system may also include switches, solenoids Electrical Shock and/or motor starters running at high voltages. These high voltages are at lethal levels. All electrical power must be disconnected anytime maintenance is performed on this unit. Only qualified electricians should maintain the electrical system of this unit.
C A U T I O N S

This unit must not be exposed to an explosive atmosphere.

C A U T I O N S

Explosion Area

C A U T I O N S

No Smoking, Flammable Area

Hydraulic fluid is flammable. Other debris in this area may be flammable as well. There should be no smoking or other forms of ignition in and around the location of this unit.

Hydraulic systems operate with high pressure in the system. These pressures are present anytime the unit is in operation. Pressurized Fluid This unit may allow high fluid pressures to remain in the system when the system is not operating. Ensure the fluid is depressurized anytime maintenance is performed on the unit.
C A U T I O N S

G E N E R A L P R A C T I C E S

Eye Protection

Eye protection should be worn at all times in an industrial environment. Fluid power systems have pressures that if become un-contained can pose serious potential for eye injury. Hydraulic systems can operate at elevated temperature and with fluids that may cause tissue damage. Protective clothing is recommended when a hydraulic system is being serviced or maintained. Hardhats may be required in certain areas and/or situations.

G E N E R A L P R A C T I C E S

Protective Clothing

Section

2
Operation
Since these units are used in diverse environments, this section provides helpful tips for the operation of this unit. This is not a comprehensive operation procedure.

ualified personnel are required for the proper installation and operation of this unit and associated systems. This section is not meant to be a step-bystep procedure to guide unqualified personnel through this process. If in doubt, qualified electrical and mechanical personnel should be utilized for these requirements.

Location
This unit can be operated outside and it is recommended it is covered. The covering should be sufficient to repel direct rain on the unit. The unit will tolerate rain and lowpressure water wash-down. No harsh cleaning solvents or high-pressure water spray should be used on this unit. The unit must be kept free of snow and ice. The ambient temperature must remain between 32F and 130F (see fluid recommendations in section 4).

Working Fluid
The correct fluid is critical to the proper operation of any fluid power system. This unit is only compatible with standard mineral based hydraulic fluid. The fluid must also be compatible with the fluid in the main hydraulic system or the fluid in the hydraulic actuator on the Tyco Knife Gate Valve. Poor performance may be caused by improper fluid type. Below are some suggested fluid manufacturers: Ambient Temperature Range Manufacturers Examples Chevron Rykon 32 -20F* to 80F 32 Shell Tellus Premium 32 Mobil DTE 24 Chevron Rykon 46 10F to 100F 46 Shell Tellus Premium 46 Mobil DTE 25 Chevron Rykon 68 40F to 120F 68 Shell Tellus Premium 68 Mobil DTE 26 All these fluids are compatible with each other. Phosphate Ester or water glycol fluids are not acceptable for this power unit. Synthetic oils are acceptable as long as they are compatible with the above mentioned brands of oil. Fluid Level Fluid level is critical to the proper operation of the Pascal Wall Unit. As the valves are becoming larger, the reservoir capacity of the Hydra-Helper (obsolete) has been increased from 3 gallons to 5 gallons and then to 8 gallons. Any Hydra-Helper (obsolete) purchased from 2003 to mid year 2006 will be 5 gallons, after mid-year 2006, all Hydra-Helper (obsolete) are 8 gallon capacity. In 2010, the Hydra-Helper was obsolete and the Pascal Portable Unit took its place. The Pascal Portable Unit uses a 12 gallon (nominal) reservoir. This is sufficient to stroke KGA valves up to 60. Even with the larger capacity reservoir, fluid level should be as follows: If opening a valve, the starting fluid level is to be at or near the bottom of the sight glass. If closing a valve, the fluid level must be at or near the top of the sight glass. See Illustration below: ISO Grade Hydraulic Fluid

Fluid Level to Close a Valve

Fluid Level to Open a Valve

Fill the Pascal Portable Unit though the filler-breather cap. Simply remove the cap by twisting and add fluid as needed.
Filler-Breather Cap

Operating the Pascal Wall Unit with Valve Control This Pascal Wall Unit is rated to run on 380/3/50 VAC power. This unit does not have a plug it is to be supplied by others. The unit must be wired to a suitable power supply. Specific requirements are shown in the electrical schematics in the last section of this manual. Only Valve Control Buttons Press valve 1 close button. The motor should automatically start. If the knife gate valves have limit switches, then the button can be released and the motor will run until the valve comes into position. As soon as the valve is in position the directional valve will de-energize and the motor will shut down. If the motor does not run or continues to run, then have a qualified electrical check all control circuits. Once Valve 1 is closed and the motor is shut down, then press Valve 1 open button. The motor should start and the valve will move to the open position. Once the valve is fully open, the directional valve will de-energize and the motor will shut-down. Open and close Valve 1 at least 2 or 3 times to purge all air from the system. Check the oil level when the valve is in the open position. Add oil as needed. Refer to Adding Fluid section. Repeat for all valves. Once all valves are stroked 2 or 3 times, and the reservoir is full as described in Adding fluid section, the power unit is ready for normal operation. Ensure the power unit motors are not running at the end of the initial start up operation.

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3
Schematics
The schematics provide a road map to the performance characteristics of this unit.

his section details in table and drawing form how this unit left the factory. This is an excellent section for referral back to original settings if settings of this unit get changed. This section includes hydraulic and electrical schematics (as applicable). The other useful document is a copy of the actual test report. This is the actual test data recorded on this unit prior to shipping.

Schematics & Bill of Materials

The schematics in this manual are electronic copies of as-built drawings. These drawings include the bill of materials of major components used in the manufacture of this unit. Major component cut sheets later in this manual are based on this bill of