Open Circuit RAP Training

Spring, 2002
Circuit Recommendations
Transmission Circuit Recommendations

BULLETIN PURPOSE

Suggest circuit
design to help
assure
performance and
expected life

BLN-9886
Technical Data

BULLETIN PURPOSE

Technical
Information
Series 45 Open
Circuit Axial
Piston Pumps

Transmission Circuit
Recommendations
BLN-10128
Transmission Design Elements
SAUER-
SUNDSTRAND
HYDRAULIC
FLUID UNIT DESIGN
PRESSURE
QUALITY
AND SPEED
REQUIREMENTS
RATINGS

CIRCUIT COMPONENT
DESIGN SIZING
CUSTOMER
TRANSMISSION
DESIGN
Circuit Design Significantly Impacts

• System performance
• Expected life
• Serviceability
• Cost
Circuit Elements Function to

• Control Flow
• Control pressure
• Control fluid quality
• Control fluid transfer between components
Circuit Elements Include

• Reservoir
• Fluid lines
• Filter
• Pressure control valves
• Flow control valves
• Heat exchanger
• Accumulator

* Indicates optional circuit features

Objective: A Successful installation!

First choices include “functional” devices to

fulfill system requirements:

• Pump(s),
• Valves
• Actuators and Motors,
Next

After basic sizing and an estimate of static

system performance are established, “other”
considerations are made:

• Line sizes
• Reservoir design
• Heat generation and cooling
• Filtration
• Oil
Finally

Other considerations may include:

• Component life
• Pressure shock
• System stability
• Noise
Each Circuit Is Unique

TO BE SUCCESSFUL,
CIRCUITS MUST BE
VERIFIED BY TEST !
Open Circuit System
Operator Control

Load Sense

Directional Flow Ctrl

Engine Pump Control Valve Valve
Motor

Cylinders
Holding
Valves
Enemies of the System

• Contamination (wear)
• High temperature (low oil viscosity)
• High temperature (seals and other elements)
• High inlet vacuum (cavitation/incomplete filling)
• High oil velocities in conduits (power loss)
• High case pressure (HST, destroyed units)
• Entrained air in fluid (cavitation, noise, controls
instability)
“Circuit recommendations” address these issues
Reservoir Functions

• Provide fluid for pumping elements

• Allow dwell time for air removal
• Allow fluid volume change due to expansion
• Help in heat rejection
Reservoir design Considerations

• Fluid capacity and content

• Atmospheric or pressurized
• Contamination ingression
• Flow paths
• Conduit sizes
• Location
• Maintenance
 RESERVOIR DESIGN
Water-Tight Sealed
Construction Filler Cap
Return Pressure Valve, Suction
Flow Breaker, Breather Filter

Diffuser Total Volume:

~~~~~~~~~~~~~~~~~~~~~~~ 1 to 3 X pump flow
for Open circuit

Fluid Content
50-70% of
Baffle
3 total Volume
2
1
X
TOP VIEW To Drain SIDE VIEW
Pumps
Piping and Line sizing

Proper line sizing is a function of pressure drop.

Must consider unit limits and total line losses.

Fluid velocities can be used as general indicator:

• System lines: 20 to 30 ft/sec.

• Suction line: 4 to 6 ft/sec.

• Case drain lines: 10-15 ft/sec.

 Piping and Line sizing

Line velocity is calculated as:

V = Q/A = 0.321 * gpm  in**2 (ft/sec)

Bottom line is that pump inlet vacuum

requirements must be met and line losses
must not be excessive.

For HST pumps, vacuum at the pump inlet

must be limited to 0.8 bar absolute minimum
(0.2 bar vacuum or 6 in. hg vacuum) for
continuous operation.
Inlet Pressure Limits
Inlet Pressure Limits
Piping and Line Design

JOINTS AND CONNECTIONS:

• Keep number of joints to a minimum.

• Avoid or minimize sharp bends.
• Provide adequate flow capacity
Piping and Line Design

JOINTS AND CONNECTIONS:

• Pressure lines: O-Ring, Face Seal, or

JIC flared
• Suction lines: O-Ring, Face Seal, or
JIC flared

Avoid Pipe Threads Everywhere!

Use type of connector that doesn’t leak!
Heat Exchanger

• Size for worst continuous operating condition at

highest ambient.
• Meet continuous temperature limits
• Hottest location (usually case drain)
• Bypass suggested
• Limit pressure drop and check its effect on
upstream components
• Verify design by test!
Fluid Temperature limits

What are oil temperature limits for OC Systems?

• Hydrostatic Pumps
Intermittent, cold start -40C (-40F)
Continuous 82C (180F)
Maximum (at hottest point) 104C (220F)

“Hydraulic fluid viscosity must be maintained

within prescribed limits”
Viscosity limits

Open Circuit Hydrostatic Pumps

• Minimum continuous 9 cSt

• Minimum intermittent 6.4 cSt
• Maximum continuous 110 cSt
• Maximum cold start 1000 cSt
Fluid Temperature limits

What are oil temperature limits for OC Systems?

• Gear product
Intermittent, cold start -20C (-4F)
Continuous 80C (176F)
Maximum (at hottest point) 90C (194F)

“Hydraulic fluid viscosity must be maintained

within prescribed limits”
Viscosity limits

Open Circuit Gear Components

• Minimum 10 cSt
• Recommended range 12 to 60 cSt
• Maximum cold start 1600 cSt
Heat

Pressure drop without useful work is power

loss!

Inspect your circuit for pressure drops that cause

losses.

HP(LOSS) = Q*P/1714.
Open Circuit System
Operator Control

Load Sense

Directional Flow Ctrl

Engine Pump Control Valve Valve
Motor

Cylinders
Holding
Valves
Filtration

• Is covered in a later session

• Fluid Cleanliness required is ISO 4406 18/13
or better
• Suction (inlet) screen 100-125 micro-meter
(150 mesh) required
• Full flow filter in return lines
CASE DRAIN REQUIREMENTS

For HST Variable Displacement Open Circuit Pumps:

• Case drain flow should NOT to be directed
through cooler or return line filter
• Case drain flow should be returned directly to
reservoir with minimum restriction
CASE DRAIN REQUIREMENTS

PRESSURE CONSIDERATIONS:

• Case pressure limited to 0.5 bar above inlet

pressure
Circuit Design

Without proper control of

• Fluid temperature and quality

• System and unit pressures
• Unit speeds

the most thought-out and carefully

selected circuit is doomed to failure as a
direct result of improper CIRCUIT DESIGN!
CIRCUIT DESIGN

Each Circuit is Unique

SUCCESSFUL CIRCUITS MUST BE
VERIFIED BY TEST!
Circuit Recommendations