Hydraulic Power Supply (Sep 2015) PDF

purposes only
For training
Hydraulic Power Supply
MAN Diesel & Turbo Author Current topic  00.00.2012 < 1 >
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps
4) Engine Driven Pumps

 Pump design
 Driven mechanism
 Control principle
 Sensors
5) El - Driven Pumps
6) Valve Block
MAN Diesel & Turbo AAA-CPH Hydraulic Power Supply 22.05.2015 < 2 >
purposes only
For training
Lubricating and Cooling Oil System
50 μ filter
Connection to
hydraulic system
purposes only
For training
Hydraulic Power Supply - HPS
 Contamination of
hydraulic oil must
not exceed:
 ISO 4406: 16/13
 NAS Code: 7 or 8
In 100 ml oil sample
the number of particles
with the size should be
within the range.
Bearings and piston cooling
16: 32,000 ≤ 6µm ≤ 64,000

13: 4,000 ≤ 14 µm ≤ 8,000
25 μ 6μ
Supply line from cooler and 50 μ filter
purposes only
For training
Separate Hydraulic System
purposes only
For training
Engine driven HPS vs Electric driven HPS
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
Filter Unit, Schematic
6 µm
25 µ
purposes only
For training
HPS Components
Filter and pumps
Filter unit
Start-up pumps
High pressure
pumps
Drain pipe
System oil
High pressure
pipes
purposes only
For training
Filter unit
Boll & Kirch ver. 6.64
Single filter cartridge
purposes only
For training
Filter Cartridges
Mesh filter vs Sintered filter
10 µm filter cartridge: 6 µm filter cartridge:

08/06 = production month/year 09/06 = production month/year
1340006 = filter cartridge ID 1341446 = filter cartridge ID
25 = manufacturer's filter mesh code Sintered filter material
purposes only
For training
Automatic Filter, Type 6.64
Filtering process Back flushing process

purposes only
For training
Automatic Filter, Type 6.64
30 - 120 minutes.
Back flushing process

purposes only
For training
Backflushing Line to Lube Oil Tank
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
Start up pumps
Inlet
Electric motor
Pressure relief
valve set point
175 / 225 bar
Pump
Outlet
Valve
Pump drain
purposes only
For training
Start up pumps
Safety valve setting

Automatic mode: 175 / 225 bar
 Stopped at Finish With Engine.
 Master pump running at engine standby.
(both pumps are running during
pressure build up).
 Stopped via a timer at a specified
engine RPM (default 15 % MCR)
Manual mode:
 Controlled by the operator via the Main
Operating Panel
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
Engine Driven Pumps
purposes only
For training
Axial Piston Pump

Bosch Rexroth
Axial Piston Pump – A4VSO xxx HS3xxx…. (Bosch-Rexroth)
Inlet, 2 Bar
Outlet, 300 Bar
Control pressure
Case drain
purposes only
For training
Swash Plate Principle
Ahead Astern
purposes only
For training
Axial Piston Pump

Pump sizes
Pump sizes:
• 125 ccm/rev - 3 pumps

• 500 ccm/rev - 3 to 5 pumps
• (750 ccm/rev - 3 to 5 pumps)
purposes only
For training
Design features
200 bar system VS 300 bar system
210 Bar  300 Bar
Working pressure increased from 210 bar to 300 bar resulting in:
HPS:
 Necessary pump size reduced from 355 cc to 250 cc.
 Only 3 pumps needed.
 Same pipe and hose dimensions.
This is because of the relation between Q’ (flow) and pressure (p) shown by the equation:
P=Q’x p, where P is the power generated by the pump, the power consumption is the
same; therefore a higher pressure will result in a lower flow
purposes only
For training
Engine Driven Pumps

200 bar system
purposes only
For training Engine Driven Pumps
300 bar system
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Drive mechanisme
 Sensors
6) Valve Block
purposes only
For training
7S50ME-C
Accumulator
Safety and
accumulator
block
Three engine driven
axial piston pumps
with flow controlled
by ECS
Generates hydraulic
oil pressure up to
250 bar
Redundancy:
The engine can
operate on two
pumps
Gear Box
purposes only
For training
Gear Driven HPS

7S50ME-C
Output wheel ………………
Intermediate wheel……………….
Connections wheel……………
Gearwheel on crankshaft…
 Two rows of gears,

one is spare.
Spacer………..
Gear ratio - 12:1
purposes only
For training
Pump Drive and Moment Compensator
purposes only
For training
Pump Drive
purposes only
For training
Pump Drive
purposes only
For training
Chain Driven HPS
Hydraulic Pump
Step Up Gear
Chain wheel for

4” Duplex chain
purposes only
For training
Pump Shaft Principle
Gear end
High friction disc

Pump end
purposes only
For training

7S60ME-C8.2 Tier II
Comfortable platform
height around HPS
Easy access to Chain Tightener
purposes only
For training
Easy access to Hydraulic Power Supply
purposes only
For training
purposes only
For training Hydraulic Power Supply
purposes only
For training

HPS in the middle of engine
purposes only
For training
12K98ME
Engine Driven Hydraulic Power Supply
purposes only
For training
12K98ME
Different Mark Versions
ME-Mark 1 ME-Mark 2 ME-Mark 3 ME-Mark 4
purposes only
For training
12K98ME, Mark 4
Complete HPS with Accumulator Blocks
 Gearbox unchanged
 Hoses from pumps to accumulator
blocks
 Pumps turned for easy piping and
mounting of low pressure pipe
 Improved access of valves
 Common drain pipe on both sides of
HPS
 Drain valve on low pressure pipes
purposes only
For training
12K98ME, Mark 4
Galleries and Shielding
purposes only
For training
12K98ME, Mark 4
Complete HPS
HPS unit ready

for installation
on the engine.
purposes only
For training
12K98ME-C7
HPS Design
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
Engine Driven Pumps
P2
P1
1204
Sensors for suction pressure.
Low pressure = shut down
purposes only
For training
Engine Driven Pumps
Automatic mode:
 The pressure set point is depending on the engine load.
 The pumps have two running modes, 1 in pressure control mode [Ctrl]
(selected via the MOP screen), 2 in follow mode [Folw].
 The [Ctrl] pump is running 50% and compensates immediately for deviations
between actual pressure and set point. Over time the [Folw] pumps will take
over the compensation while the [Ctrl] pump goes back to 50 %.
 In case the pressure controlling pump faces a failure, one of the other pumps
will take over pressure control.
Manual mode:
 The pressure set point is set by the operator
purposes only
For training
Engine Driven Pumps

Summary
In case of control failure of a pump, the swash plate will be forced to maximum
capacity in AHEAD direction.
Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.
Pump Nos. 1, 2, and 3 have their own sensor for system pressure, connected to
their controlling ACU
Pump Nos. 4 and 5 are controlled by a binary signal, either max capacity AHEAD
or ASTERN. No. 4 is controlled from ECU A, and No. 5 from ECU B.
All pumps have sensors for suction pressure. If the pressure is to low, or all sensors
are failing, a SHUT DOWN will be activated.
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
Leak Detection
Shut down level
Alarm level
purposes only
For training
Leak Detection
Hydraulic Power Suply
Drain pipe
Sensors
”vibrating fork” type.
LS 1235 = Alarm
LS 1236 = Cancelable Shut Down
purposes only
For training
Pump Drive with Accumulator Block
Located on aft end

of the engine
(7S50ME-C).
7S50ME-C
purposes only
For training
HPS Pump Inlet Pressure Sensors
purposes only
For training
Engine Driven Pumps,

Nordic Brasilia, 6S70ME-C
Feed back, swash plate
Feed back, pilot valve
Pilot valve for swash

plate control
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training
EL HPS
purposes only
For training
EL HPS
Mounting and assembling
Unit for easy Assembling
purposes only
For training
EL HPS
Overhaul and maintenance
Easy disassembly for main components
purposes only
For training
El HPS
 As an example, if there are 4 electric driven pumps installed on the engine.

 2 pumps are running at stand-by
 When engine load increased, next pumps are started automatically with time
delay of approx. 2.5 sec. at above 90% of each elec. driven pump and share the
total swash plate %.
Example) 2 pumps running 90% 90% Stop Stop
3 pumps running 60% 60% 60% Stop
 One pump is stopped automatically with time delay of approx. 15 sec. at below
50% of each elec. driven pump.
 No.4 pump is fixed
Example) 4 pumps running 50% 50% 50% 85% displacement pump
 Max 85% due to mech.
stopper
3 pumps running 81% 81% 81% Stop

 Start/stop percentage can be changed without notice.
purposes only
For training
1) System
2) Filter Unit
3) Startup Pumps

 Pump design
 Sensors
6) Valve Block
purposes only
For training Hydraulic Power Supply
Valve Block
Valve Block Safety and Shutdown

Valve 310 and 311
purposes only
For training
Valve Block
1233 1201-1,2,3 Oil Sample Point, 340
P2 pressure
To hydraulic
from pumps
cylinder unit (HCU)
230 / 310 bar

311 Safety valve.
(9 - 12 cyl. 90~98 bore
have 2 valves, one on
each valve block)
250 / 315 bar
Safety system for leaking

high pressure inner pipe
LPS From filter unit

315 311 310
purposes only
For training
Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially
not guaranteed in any way. Depending on the subsequent
specific individual projects, the relevant data may be subject
to changes and will be assessed and determined individually
for each project. This will depend on the particular
characteristics of each individual project, especially specific
site and operational conditions.

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purposes only

Hydraulic Power Supply

Hydraulic Power Supply

4) Engine Driven Pumps

Lubricating and Cooling Oil System

Hydraulic Power Supply - HPS

 ISO 4406: 16/13

16: 32,000 ≤ 6µm ≤ 64,000

Supply line from cooler and 50 μ filter

Separate Hydraulic System

Engine driven HPS vs Electric driven HPS

4) Engine Driven Pumps

Filter Unit, Schematic

Single filter cartridge

10 µm filter cartridge: 6 µm filter cartridge:

Automatic Filter, Type 6.64

Filtering process Back flushing process

Automatic Filter, Type 6.64

Back flushing process

Backflushing Line to Lube Oil Tank

4) Engine Driven Pumps

Safety valve setting

Hydraulic Power Supply

4) Engine Driven Pumps

Engine Driven Pumps

Axial Piston Pump

Axial Piston Pump – A4VSO xxx HS3xxx…. (Bosch-Rexroth)

Swash Plate Principle

Axial Piston Pump

• 125 ccm/rev - 3 pumps

210 Bar  300 Bar

 Necessary pump size reduced from 355 cc to 250 cc.

 Only 3 pumps needed.

 Same pipe and hose dimensions.

Engine Driven Pumps

Hydraulic Power Supply

4) Engine Driven Pumps

Gear Driven HPS

Output wheel ………………

 Two rows of gears,

Gear ratio - 12:1

Pump Drive and Moment Compensator

Chain Driven HPS

Chain wheel for

Pump Shaft Principle

High friction disc

Hydraulic Power Supply

Easy access to Chain Tightener

Easy access to Hydraulic Power Supply

Hydraulic Power Supply

Hydraulic Power Supply

ME-Mark 1 ME-Mark 2 ME-Mark 3 ME-Mark 4

HPS unit ready

4) Engine Driven Pumps

Engine Driven Pumps

Engine Driven Pumps

Engine Driven Pumps

Pump No. 1 is controlled by ACU 1, pump 2 by ACU 2, and pump 3 by ACU 3.

4) Engine Driven Pumps

Shut down level

Hydraulic Power Suply

Pump Drive with Accumulator Block

Located on aft end