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    52 views49 pages

    Vickers V20 Vane Pumps I-3143-S

    Uploaded by

    arun kumar

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    of 49
    ite Overhaul mee Manual Vane V10, V20, V10F, V10P, Pumps V20F, V20P Series Vickers, Incorporated bord tate Revised 12-1-87 1-3143-S Section wv vi TABLE OF CONTENTS INTRODUCTION ‘A. Purpose of Manual. 6.2 eee ee eee eee eee B. General Information 6222222022022 2002 DESCRIPTION As General. oe eer ee eee eee eaeeeee tite B. Assembly and Construction 222... tite C. Flow Control and Relief Valve. 2... 2! eae D. Priority Valve... eee eects terete : E. Application. . 12.1 PRINCIPLES OF OPERATION ‘A. Pumping Cartridge... . B. Hydraulic Balance»... 2. 2.2 C. Pressure Plate. 022221011 D. Flow Control and Relief Valve. | << E. Priority Valve Operation INSTALLATION AND OPERATING INSTRUCTIONS ‘4. Installation Drawings. B. Drive Connections . CL Shalt Rotation, D. Piping and Tubing « E, Hydraulic Fluid Recommendations. | | | F. Overload Protection... 2... 0000 G. Port Positions . . HL Start-Up... SERVICE INSPECTION AND MAINTENANCE A. Service Tools. ..... 2+. - B. Inspection. . - eee tee .Aading Fluid To The System. -- D. Adjustments . a E. Lubrication. 2222222022 F. Replacement Parts G__ Trouble-Shooting . OVERHAUL ‘A. General... B, Disassembly |... 1. C. Inspection and Repair * D. Assembly. TESTING... 2.2... eee Page Section I - INTRODUCTION A. PURPOSE OF MANUAL ‘This manualhas been prepared to assist the users of Vickers balanced vane type hydraulic single pumps inproperly installing, maintaining and repairing their units. In the sections which follow, the single pumps are deseribed in detail, their theory of operation is discussed and instructions are given for their proper installation, maintenance and overhaul, ‘The general series of models coveredare V10, 20, ‘VI0F, VIOP, V20F, and V20P. ‘The information ‘given applies to the latest design configurations listed in Table 1, Earlier designs are covered only insofar as they are similar to the present equipment. B, GENERAL INFORMATION 1, Related Publications ~ Service parts informa- tion and installation dimensions are not contained in thie manual. The parts catalogs and installation draw- {ings listed in Table 1 are available from any Vickers OUTLET PORT Application Engineering office, or from: Vickers, Incorporated 1401 Crooks Road Troy, MI 48084 2. Model Codes ~ There are many variations within each basic model series, which are covered by vari~ ables in the model code.” Table 2 is acompletebreak- down of the code covering these units. Service in- quiries should always include the complete unit model number, which is stamped on the pump cover. TABLE 1. PARTS CATALOGS AND INSTALLATION DRAWINGS MODEL] PARTS [INSTALLATION SERIES | DRAWING| DRAWING ‘VIO Vi0F] M-2005-s| MB-53, ViOP- V20. V20F | M-2004-s| MB-53, “y20P- 'YDRAULIC OI] INDUs ‘MOBIL! RECOMMEN- |APPLICATIONS| APPLICATION: DATIONS |_ PUMPING ‘CARTRIDGE . Figure 1 MODEL CODE BREAKDOWN vi0-P) vane puxpp_————] SERIES 10 OR 20 F - FLOW CONTROL COVER P - PRIORITY VALVE COVER OMITTED - STD. COVER MOUNTING 1-2 BOLIT FLANGE (SAE "A" SIZE) 2-FOOT BRACKET AT 12 O'CLOCK (VIEWED FROM THE SHAFT END)| 23-FOOT BRACKET AT 3 O'CLOCK 26-FOOT BRACKET AT 6 O'CLOCK 29-FOOT BRACKET AT 9 O'CLOCK’ TNEET PORT (CODETMODEL| SIZE, y20 “2 BOLT FLG, i, 150"Dia, -2 BOLT FLG, 1 0.D. TUBE CONN. 1, 3125" 12 UN2B THD. TN POT, F, 125" NPT "NP. TF, 13125" =13 STR, THD, 2 UN25 THD. P=12 STR THD. S| vio v20 V0, v20, vio fa} co Joo} om foals RING CAPACITY -1200 RPM-100PSI Fete 8s OG) 20-78 tL [| FOR LEFT HAND ROTATION VIEWED FROM SHAFT END L_4 speciaL FEATURE SUFFIX DESIGN & MODIFICATION vi0-10V20(E)-11 Ivi0(F)-20 v20P-11/12 PRESSURE SETTING ‘4-250 PSI 'B-500 PSL (€-750 PST 1000 PSt E-1250 PS F-1500 PSI G-1750 PSI H-2000 PSI 53-2250 PST K-2500 PSI FLOW RATE THROUGH ORIFICE IN COVER 2-2 GPM 3-3 GPM (V10F ONLY) 4-4 GPM 5-5 GPM (VIOF ONLY) 6-6 GPM 7-1 GPM (V10F ONLY) 8-8 GPM (V20F ONLY) PRESSURE PORT POSITIONS VIEW FROM COVER END A-OPPOSITE INLET ‘CONNECTION. (v0) (v20) B- 90° COUNTERCLOCKWISE 1-1USGPM 6-6 uscpM FROM INLET CONNECTION 2-2UsGrM 7-7 USGeM (C-INTINE WITH INLET 3-3 UscPM 8-8 USGPM D-90° CLOCKWISE FROM INLET 4:4 USGPM 9-9 USGPM CONNECTION 55 USGPM 11-11 USGPM. 6-6 USGPM 12-12 USGPM T.TUSGPM 13-13 USGPM SHAFTS 1-S7R. KEYED ‘OUTLET PORT CONNECTIONS S-THD. [FLOW CONTROL COVER! ‘PRIORITY VALVE COVER -THD. ISTANDARD PRIMARY|SECONDARY 6-STR. STUB-KEYED cope)” COVER pressure} tank | ourner| ouruer | rank 11-SPLINE-9TOOTH i818 | 378-16 —] 0/1618 12-SPLINE-13 TOOTH ees esas st. THD) st. THp, |st. THD) —|15-sPLINE-13 TOOTH {V10P) {V10P) (v10P) 27-TANG TEN, | 718 | 7 34TH, NPT THD, ST. THD, [NPT THD. | —— — 38-SPLINE-11 TOOTH P [wioonzy} S/TIK. |V10F AND|VIOF AND npr Tip| vaor | v20r eerie | eeeeeeee jeer 20ONLY) TA-16- st, THD. s fiife-i2 [316 [ria st. TaD, |st, tuo, |sr, tap. | —— | —— | —— (V20ONLY}| (V20F) (V20F) 374-16 374-16 S7a-16 TE=-1t BA-TS_| t | __ |sr. tun, |sr. rap, Jet. THp.| sr, TH, | st. THD] Gor) | wior) | (vz0r) | —v20r) | iv2or) Section Il - DESCRIPTION A. GENERAL. Pumps in this series areusedto develop hydraulic fluld low for the operation of Mobile and Industrial equipment. ‘The positive displacement pumping car= ‘trldges are the rotary vane type with shaft side loads hydraulically balanced. The flow rate depends on the pump size and the speed at which it is driven. ‘AU units are designed s0 that the direction of rolation, pumping capacity and port positions can be readily changed to suit particular applications. B, ASSEMBLY AND CONSTRUCTION ‘The V10 series pump illustrated in the cut-a-way of Figure 1 is representative of all single pumps in this series, ‘The unit consists principally of a ported body, a ported cover and a pumping cartridge. Components fof the pumping cartridge are an elliptical cam ring, a slotted rotor splined to fit the drive shaft and twelve ‘vanes fitted to the rotor slots. "The pumping cartridge cam ring Is sandwiched be~ tween the body and cover. A ball bearing and bushing located inthe body and pressure plate respectively sup~ port each end of the drive shaft and center the rotor ‘withinthe camring. Asthedrive shaft is driven by the prime mover, the rotor and vanes generate flow by car- rying fluid around the elliptical cam ring contour. Fluid centers the cartridge through the inlet port in the body and is discharged through the pressure plate into the outlet port of the cover. ©. FLOW CONTROL AND RELIEF VALVE 'V10 and V20 pumps are available with an integral Flow Control andRelief Valve in the pump cover. This Limits the fluid flow in the system to amaximum pre- seribed rate and prevents excessive pressure build~ wp. Fluid not required in the system is recirculated to tank. D. PRIORITY VALVE ‘V10 and V20 pumps are also available with a pri- ority valve located in the pump cover. The priority valve maintains nearly a constant flow toa primary ccireuit and diverts the remaining flow to a secondary circuit, Flow going to the secondary circuit is deter- ‘mined by pump delivery. Theprimary circuit is pro- tected by an integral relief valvebutan external relief valve must be provided for the secondary circult. E. APPLICATION ‘Pump ratings inGPMas shown in the model coding are at 1200 RPM and 100 PS}. For ratings at other speeds, methods of installation and other application information, Viekers Application Engineering person nel ahould be consulted, Section IH - PRINCIPLES of OPERATION A. PUMPING CARTRIDGE ‘As mentioned in Section Tl, fluid flow is developed by the pumping cartridge. ‘The action of the cartridge is illustrated in Figure 2. The rotor is driven within the cam ring by the driveshaft, which is coupledtoa power source. As the rotor turns, centrifugal force causes the vanes to follow the elliptical inner surface of the cam ring. Radial movement of the vanes and turning of the rotor eause the chamber volume between the vanesto increase as the vanes pass the inlet sections of the cam ring. This results in a low pressure condition which allows atmospheric pressure to force fluid into the chambers. (Fluid outside the inlet is at atmospher- ie pressure or higher.) ‘This flutd is trappedbetween the vanes and carried ourreT past the large diameter or dwell section of the cam ring. As the outlet section is approached, the cam ring diameter decreases and the fluid is forced out into the system, System pressure is fed under the vanes, assuring their sealing contact against the cam ring during normal operation. B, HYDRAULIC BALANCE ‘The pump cam ring is shaped go that the two pump- ing chambers are formed diametrically opposed. Thus, hydraulic forces which would impose side loads on the shaft are cancelled, C, PRESSURE PLATE ‘The pressure plate seals the pumping chamber as shown in Figure 3, A light spring holds the plate against the cartridge until pressure builds up in the system. Systempressure iseffective against the area at the back of the plate, which is larger than the area ‘exposed to the pumping cartridge, Thus, an unbal- anced force holds the plate against the cartridge, seal~ ing the cartridge and providing the proper running clearance for the rotor and vanes. D, FLOW CONTROL AND RELIEF VALVE 1, Maximum flow to the operating circuit and maximum system pressure are determined by the in~ tegral flow control and relief valve in a special outlet cover used.on some V10 and V20 pumps. This feature is Mustrated pictorially in Figure 4. An orifice in the cover limits maximum flow. A pilot-operated type relief valve shifts to divert excess fluid delivery to tank, thus limiting the system pressure to a pre- determined maximum. 2. Figure 4A shows the condition when the total pump delivery can be passed through the orifice. ‘This condition usually occurs only at low drive ‘speeds. The large spring chamber is connected to the pressure port through an orifice. Pressure plus spring load in this chamber slightly exceeds pressure atthe iscHARGE BACK PRESSURE 1m SysTea EFFECTIVE WERE PRESSURE IN Figure 3 other end of the relief valve spool and the spool re- mains elosed, Pump delivery isblocked from the tank port by the spool land. 3. When pump delivery is more than the flow rate determined by the orifice plug, pressure builds up across the orifice and forces the spool open against the light spring. Excess fluid is throttled past the ‘spool to the tank port as shown in Figure 4B. 4. LU pressure in the systembullds up to the relief valve setting (Figure 4C), the pilot poppet is forced off its seat. Fluid in the large spring chamber flows through the spool and out to tank. This flow through the small sensing orifice, causes a pressure drop and prevents pressure in the large spring area from in- creasing beyond the relief valve setting. As pressure against the right end of the spool starts to exceedthe relief valve setting, the pressure differential forces the spool to the left, against the light spring, porting the full pump flow to tank, “rave spain HOLDS RELIER siLoT Wate CLOsHD POPPED Wie PRESSURE Spo ENDS ‘TANK PORT OFF RELIRE vaLve ro TANK pa svsrem prifsSone pumpin SENSED IN ‘PRESSURE ccARTRIDOE SPRING CHAMBER PORT ORIFICE, [TuROWOH ONTFICE DETERMINES aq FLOWRATE, ‘LOW DRIVE . ena (1 pEsiGn) SEAT) PLUG S(-i2 DEsiGn) PISTON: SHIM SPRING: an mop O'RING) SPRING GUDE: %e- pve RING schEw TORQUE TO: ‘v10-85-45 LB. FT. y20-75-85 LB. FT. NOTE: Priority Cover Informati V10-10 early models and V20-I1 models use pipe threaded plugs, 'V10-10 eurront design and V20-12 models use straight threaded plugs and "Oring seals. Flow Control Cover Information: 10-20 early models and VZ0-I1 models ‘threaded plugs. 'V10-20current design uses straight threaded plugs with “O"'rings. The V20-11 is the current design and still uses pipe threaded plugs. Pipe SCREW FLOW CONTROL VALVE COVER eis a Peace rata SNAP RING PLUG PRESSURE PORT. Z (use this port to determine orninc PLUG ‘cover position) SECTIONAL VIEW Figure & n ing. Align square and press into place. Use ashort length of brass rod as a pressing tool, to prevent seat damage, Clean the relief valve bore to remove chips and filings. Insert the poppet into the bore, align Square and lightly tap the stem of the poppet tomate ‘the poppet and seat. Install the spring, shims, and plug into the cover. (ater design uses a spring guide and straight thread plug with "O"'rings) Be sure to chockthe pressure setting ofthe relief valve against the model code. Ifthe setting is out of tolerance, readjust by removing or adding shims. (Removing shimsreduces pressure while adding shims increases pressure. ) Priority Valve = Install the snap ring within the priority valve cover bore, (early V20.series only);make ‘sure the snap ring is seated within its groove, Insert ‘the priority valve spool, small land first, into the bore, Installplugs at each endof the bore and secure, Refer to Figure 8 for spool orientation, 3. Assembly of Pump - See Figure 8, Bogin as- sembly by pressing the shaft into the front bearing while supporting the bearing inner race. Install the small snap ring on the shaft. NOTE Before assembling the shaft seal, determine the cor- rrect position ofthe sealing lip. (See Figure 9.) Seals are assembledwith the garter spring toward the pump~ ing cartridge. Press the seal firmly in place and Iu— bricate the lip with petroleum jelly or other grease compatible with the system fluld, Slide the drive shaft into the body until the bearing is seated. Tap lightly on the end of the shaft if necessary. Install the snap ring, Install new "O" rings in the body and cover. In- srt the ring locating pins in the body and assemble ‘the ring so that the arrow on the perimeter points in the direction of rotation. Check the assembly against Figure 10, Install the rotor on the shaft and insert ‘the vanes in the rotor slots. Be certain the radius ‘edges of the vanes are toward the cam ring. Place the pressure plate on the locating pins and flat against the ring. Place the spring overthe pres ~ sure plate, and then install the cover with the outlet pportinthe correct position. Tighten the cover screws to the torque shown in Figure 8. Rotate the shaft by hand to insure that there is no internal binding, In- stall the shaft key. If a foot mounting is used, assemble the pump to its foot mounting. If a gasket is used, be certain itis flat to avoid misalignment of the shaft. Section VII - TESTING Afatest stand is available, the pump should be tested atthe recommended speeds and pressures shown on the installation drawing,» (See Table 1). GARTER SPRING ‘VIEW FROM COVER END SHAFT SEAL (Assemble with apring toward cover end of pump) RIGHT HAND ROTATION LEFT HAND ROTATION] Figure 9 Figure 10 2 ILKERS Stop Leaks Introduction Hydraulics And Industry Viekers is committed to drying up , leaks because leakage has been 4 stumbling block to complete acceptance of hydraulics by industry. We have launched a three-pronged attack on leakage. First, we are busy improving the leakage resistance of our products. ‘Second, we are expanding our knowledge of sealing technology through research Third, we are working to assist you in reducing leakage trom your plant hydraulic system. Contents Hydraulics And You This booklet, a part of our third approach, is for people whe build, install, or maintain hydraulic machinery. Right now. you can do more to stop leakage than anyone else in the industry. Nonew technology is needed. Leakage comes from many individual points, usually where some small detail has ‘been overlooked. Uniess the sealing technology at each point is understood, itis hard to correct Seating Lip Figure 22. Simple Lip Seal Seal Dynamics Sealing is normally a result of an Interference ft between the flexible sealing ip and a shat. However, as. ‘seals age and temperatures change, the interference ft oF lip pressure falls off To maintain a more constant load on the ‘shaft a garter oF finger spring is used, Figure 23. This permits operation at higher speeds and moderate pressures. It should be noted, the seal lip does NOT act lke a squeegee to wipe the shatt cry “The lip must ride on a tin fin of Jubricant to be suecesstul If tho fim gets too thick, the seal leaks. Hit gets too thin, the seal lp wears and gets hard. The harder the seal, the more diicuiy the lip has in following the shat movement. Low Pressure 1 Garner Spring Motal Rotainer Housing Pane High Pressure Figure 23. Lip Seal with Garter Spring Surface Finish ‘Tests have shown maximum seal fle is obtained when the shatt sealing surtace is 8 to 20 mieroinches. I the shaft is too ‘smooth, it won't support a film, Ift00 rough, it wears the seal lip. In ether ‘case, premature geal failure may occur. Finish marks should be circumferential rather than axial to retain the fluid. A spiral tool mark wil pump oil out or ai in past a seal, depending on shatt rotation, Lip Seal Installation 1. Lip seals must be installed correctly to operate successtully, But you must star with a good product. Examine the seal to be sure it's the ‘correct part. has not been damages, or lost its spring, 2. Apress should be usod for instaing ‘the ol seal into the bore. The press ram oF driving oo! should not be ‘more than 010" smaller in 0.0. than the bore diameter and should have a flat face to contact the back ofthe ‘metal case on the seal. I installing the seal in a reverse postion, be sure that ram pressure is applied nly to the rolover bead around the ‘outer diameter of the seal face and ot to the inside face or filer ing inside the metal outer case. Figure 24. Optimum Seal Bore imensioning 3, Polish shat to remove burrs, sharp or rough edges that touch seal lip during assembly, Use mounting thimble or a sheet of shim stock as in Figure 25, to protect the seal. The thimbe wall should be as thin as possible (012 in. 3mm max.) to avoid seal lp distortion during assembly, We recommend lubricating the shaft and oll seal lip bofore mounting the seal over shat 1 £ Thimbie 1 4 ‘ ‘ + 4 Figure 25, Shatt in Place 2 4. fa press cannot be used, the seal may be seated wit a deving plug or tool, Figure 26. This too! i placed into postion and tapped with a mallet. When large seals are being ‘seated, or in an emergency, a block ‘of wood resting squarely on the seal ‘may bo used instoad of a driving tool. Never hit the seal direetiy! 1 Isiallation Tool \ Figure 26, No Shatt 5. Check shaftto-bore misalignment and dynamic runout. Misalignment isthe distance that the shattis off Conter with respect tothe bore, Figure 27. Runout is the amount by which the shatt, atthe sealing surface, does not rotate around is true contr, Figure 28 wn Ste 2-Y" = Dynamic runout (TIR) Figure 27. Shalt-To-Bore Misalignment Conter of oa rotation Shan € oor Bore & Figure 28. Dynamic Runout Misalignment plus runout is called 4 Rahesive or Crean wih crocus seccontely. Fora gven eecenticly. the paintan’ eth Mask shaft brobablty of shat seal leakage Sealing during seal Increases a8 shalt speed increases, The surlact———_—assembly into recommended maximum eccortcy bore or panting of whieh should exist inthe stance ip nit Seal application is shown in Figure £9, “5. Seal coced Use proper ari snore ing tool instal iat ight angle nce Trad ube Ieshalt toce 46 (018) ea te Seo 1S Searap Check stock seal 41 (016) Leaking ‘everest lip belo soo YIN TT Dy ‘epacement eater Se teas double we, One, 25.010) + faces wart 20 000} | Ne No Spine tacos ouwara to 15.006} aa ude di ing 7. Sealip oat Replace seal tees fecal TS otto Lubricate seal 05 (002) Shaft Use thimble © 1000 2000 3000 4000 ‘ocary ip over toyways, spines Figure 28. Shalt Speed (RPM) Raebiss no stretched over “To oduce misalgnment tis nocossary to 035 in. (9 mm). remove te cause af bearings, ouseg, ‘Check for hata or shah side fad. To tower runout, epic?” Glazed. on highease pres: the shalt Table Vofers some suggestons —ardened, in raveng to tea leakage shahOK —— Seal'size. le seal hans | Iban good? ce Suggest 3 Seal spring Replace seal ise WesPASIserneaea eee! damaged avoiding exces- Worn shatt Check ah ‘Sve spreading of sealing surtace Sealing lip and haranese- Spring” Check for Rockwell 30 ‘roper storage minimum fd handling ot nocenay Seale place sea 70 Excesswe” Align shal. eet eees ‘eccentricity eliminate shaft on shat aval crmsalgn- Sido oa6,or use able, Otherwise ment-sedl ip abeterfexble replace shat. can't follow coupling. Woncate pars a 3 Rough finish Frish shaft sur ‘movement onshatt"facet08-20u ih. “T1-"Buitin" seal” Faplace seal 3. Damaged Replace shaft flaw such as Sheth Protec seaing contamination surfaces during peor ber handing and Bong to metal ry eflash on a seallp Table V. Lip Seal Leakage Analysis Face Seals ‘The mechanical face seal is one of the ‘most effective devices in preventing leakage along a rotating shaft which [passes in or out of an area of pressur- {zed ol, Two ultra‘at sealing tacos aro ‘mounted perpencicular fo the shaft. The ‘seal seat is allached to and rotates with the shaft, while the spring loaded seal head is stationary, Figure 30, ‘Bote Research Figure 90. Face Seal With Stationary Head And Rotating Seat ‘The usual seal face materials in hydraulic applications are bronze or hard carbon for the seal head, and steel ‘or cast iron for the seal seat. The two are separated by an oi film. With an ‘excellent matching of sealing forces and ‘seal flatness, ol suriace tension can ‘complete the seal and there is no leakage. Elevated pressures can induce seal wear, but wih proper balancing, pressure induced sealing forces can be kept low. Repair Of Worn Parts Only a properiy trained person should attemp! to repair the sealing suriaces of face seals. The condition ol the seal surfaces isso critical that one company provides 40 hours of training to its personnel on face seal operation, repair and installation. Handle With Care ‘With the new, correct ceplacement parts, {don't touch the sealing surfaces with fingers or an old wiping rag. Make sure ‘the seal seat is perpendicular to the shaft within .001 inch (.025 mm) TIR, Figure 31. Lubricate the sealing surfaces wall with the fd to be sealed before instalation, ‘TiRis the total change in Indicator Reading during one complete rotation of the sha. ¥ = Figure 31. Dial Indicator Mounted On “The Shalt Makes Alignment (OF The Stationary Seal Seat To 0,001 Inch TIR, Easy Troubleshoot Examine the old parts for teltale signs. ‘Abrasive wear of the sealing faces ‘means contarninated oil. Burned faces Indicate dry running of the seal. Heavy wear may mean either excessive ‘operating pressure or a hung-up spring. ‘cracked carbon ring leaks badly, Worn bearings should be replaced i end play ‘exceeds .002 inch (.05 mm) or radial looseness is greater than .004 inch (.10 mm). Replace the shaft with a new one ifrunaut exceeds .002 inch {.05 mm) ‘TIR. Polish the new shatt to remove burrs or scratches that might damage static seal, Test Assembly To insure against goots, test the ‘mechanical seal assembly with low pressure filtered ait (5 t0 20 psi, 1.4 bar) before installing the component ‘on a machine. For example, an externally drained piston pump housing is easily pressurized through the drain port connection. Packings A packing is a material, deformed 50 as 10 throtle leakage between a moving or ‘otatng par and a stalonary one. With rapid moton, there must be enough leakage 1 hibreate and cool the packing (On some large applications using ‘compressed packings, the desred leakage rate may be as high as 10 drops per minute. On sore small Oring applications wh rapad motion, the lekage rate may be {a fow as one crop per every cther hour Where there is relatively Ele motion, packings can seal without fi leakage, “Thveo basic types are: compression, lia ‘and squeeze packings Compression Packing Compression packing used in chemical processing is rarely found in industrial hrydrauic series. The packing is made twisted, woven, or braided cotton, ax oF asbestos fiber Metal flor wires sometimes added for reinforcoment alorg wth solid lubricants such as graphite, mica or PTFE. Characteristics ‘The packing is sufficiently pliable when axially compressed to provide racial sealing for a moving shatt or rod twill not scratch of corrode the moving shat or rod. requires trequent adjustment to ‘compensate for packing wear 6 x ‘Compression T-Ring S URing X-Ring A AX. _| yt Figure 32. Flod Application With Ve-Ring And O-Ring Molded Lip Type Packing Lip type packing is mokied from rubberized fabric, Nile, poyurethane, oc PTFE, Two common shapes are Using and Ving Characteristics Distortion of the packing lips from an Interference fiton assembly creates a counter sealing force adequate for low pressure, With packing lips facing fuid pressure, any rise in pressure flattens the ips against wall surfaces and raises the sealing force, Up type packing has lower leakage, less friction, and longer ite than compressed packing, ‘The U-ting is an effective seal when Used singly. A ring support or pedestal with eross dried holes assures equal pressure loading on both sea! ips. ‘The Ving needs a stack of three rings. along with male and female adapters to Contain low pressure fluid, Five or more rings are needed in the stack for high pressure. Molded Squeeze Packing ‘Squeeze packing is molded from ‘synthetic rubber, polyurethane or PTFE. ‘Common shapes are the O-ring, T-ring and Xering, Characteristics Distortion of the squeeze packing from an interference fit on assembly generates ‘an internal seating force within the ‘packing to contain iow pressure. High pressure puts an addtional ‘squeeze on the packing, raising the internal sealing force to counter tho pressure force. This action tends to ‘extrude the packing through any clearance gap. Ant-extrusion rings are shown with the T-ring in Figure 32 ‘Squeeze packings have less tition than either compression oF lip ype packing and also seal in both directions. ‘On assembly the O-ring should be ‘squeezed about 10 percent, the T-ring ‘about § percont and the X-ring as low as 1 percent. Probable Source Suggested Remedy of Failure 7, Shaft orred Replace shat. worn ‘uid, change fier. For diay ‘mosphere, install protective shield or boot (Check shaft hardness: Rockwell C 30, in 2: Sealng surtaces Use proper are scratched. assombly and dis ‘Seals camaged assembly tools on overnaul. Repiace damaged parts. 3. Dynamic runout Inspect bearings, of shaft or replace if 100 ‘eccenitc motion loose. Check side Isexcessive loads on shaft or rod. Seals are not to be used as bearings. “F. Rapid wear out Seal compressed of seal too much. Loosen iWadjustment is available Other- wise check to be certain of correct seal size. Glazed or Check for high ol hardened temperature, Correct if saat |Ubrication ts inadequate, . Seal edges are Check parts for extruded too much clearance, Replace faulty parts. Use ant-oxtrusion rings on low pressure side of seal Table VI. Packing Failures Static Seals Installation Activated Seals Static seals prevent leakage between Stationary surfaces. To contain pressure, the seal and its mating parts must be in ‘contact at a pressute level higher than the pressure to be sealed. This pressure level may be obtained by parts installation alone, as withthe crush ‘washer, or jam packing, Figure 33. Jam Packing Figure 33. Pressure Activated Seals In other applications, such as with the Orting, V-ring, and X-ring, Figure 34, the initial Sealing pressure from installation alone is sufficient 10 contain only low pressure ol. High pressure deforms or ‘changes the seal shape and increases the sealing pressure level to complete the seal, Pr aoe ad le Figure 34, V-Ring and X-Ring Gaskets ‘A gasket isan installation activated seal made of relatively sot mater. must be detormed or compressed to fil surlace regulates and cose the gasket structure to fuid leakage. ‘The O-ring is replacing the gasket in many of the new hydraulic designs because ofits greater raabilty ang ‘ease of application. Ingeneral, the more compressible (softer) materials are used for low pressure gasket applications. Common materials are asbestos, cork, paper, plastic, rubber or a combination of these materials. ‘The majority of gasket applications can bbe represented by two basic flange designs: the flat face, Figure 35, and the (grooves face, Figure 96. Figure 34, V-Ring and X-Ring For a glvon gasket oress section, each ‘material has a minimum clamping foad necessary 1o close its structure to fuid leakage and fil surface inegulartes to a maximum of 250jtn, Higher internal pressures require higher clamping loads. The foroas acting on a gasketed joint are shown in Figure 37 Hydrostatic End Force Bott Load. on Blowout Pressure Gasket q Figure 98. How Internal Pressure ‘Acts On A Gasket Joint Most gasket materials relax and creep after being clamped. Aloss in loading occurs, most at it within 18 hours. For critical applications, wait a day after ini assembly and rotighten to the origina loading, preferably at system ‘operating temperature but with no internal pressure. [As pressures rise and operating conditions become more severe, metal ‘or metal-with-sot-core gaskets are ‘necessary. The required clamping force and surface finish to obtain a good seal vary widely, depending on the type of gasket. Foiow the manufacturer's recommendations O-Ring Static Seals (One of the most common static seals in the O-ring. Ithas found increasing use 138 a hich pressure seal. Recommended ‘surface roughness Is 32 to 63 microinch, With high pressure, the sealing surfaces may either side or separate. Siding causes seal weer. The rougher the surface, the greater the rate of seal wear lt siding can’ be prevented, suriace rouganess of 16 microinch may be necessary 0 obtain satisfactory seal le. ” Separation of the sealing surfaces due ta manufacturing tolerances or pressure loading permits the O-ring seal to be ‘extruded into the clearance gap, Figure 38a, With pressure pulsations, the ‘extruded edges will be nibbled away. Eventually, the seal wil leak Seal Extrusion thas been found that as O-ring hardress (called durometer) increases, Ag resistance to extrusion damage also increases. For example, nab tests of a {0d seal without back-up rings (Figure 38a) with 160°F (71°C) oil, 100,000 pressure pulses at 1500 psi (103 bar) caused significant O-ring extrusion damage when the diametral extrusion gap was greater than {a} 004 inches (.10 mm) with 70, durometer seals, (©) 008 inches (.20 mm) with 80 ‘durometer seals, (6) .014 inches (.36 mm) with 80 ‘durometer seats Caution: Don't jump at the first chance {o putin igh durometer O-rings! AS pressure level rise, they do resist ‘extrusion better than cotter seals, but they leak more readily against rougher surfaces. Back-up rings (Figure 38b) can minimize extrusion on rod seals and are required where pressures exceed 1800 psi (108 bar) Figure 38a, oyinear Figure 386. Remember: If two surfaces slide or ssoparate, seal woar will always be & problem. Troy holding the surfaces together. Use a higher class of bolt so bott torque may be increased. Coordinate this action with the parts ‘supplier to avoid product faire, such as sitipped threads. In all work with O-rings, they should be protected: (2) Lubricate with light grease or ‘uid to be sealed, () Avoid use of sharp tools during assembly or parts removal. (©) Use brass, paper or plastic cone {o pass O-ring over theads. SAE Split Flange Fitting (SAE J518) ‘The SAE spilt flange adapter fitting may bbe joined to ether pipe, tube, or hose. It ‘makes an excellent, easily removed, high pressure static seal, There are two pressure series: code 61, sometimes referred to as “Standard Series" (500 to {5000 psi) and code 62, the “High Pressure Series” (6000 psi). Special note is mage ofthis design because of | 175225 (20-5) | 175225 POPE) 3,983) | 2 | 250-350(@8-40) | 900-400 (4-45) 1254) “16 | 325-495 (87-48) | 500-600 (56-68) 1% (37.8) 20 __| 425-550 (48-62) | 750-800 (65-102) 172 Gat) | -24 | 850-700 (62-79) | 1400-1600 (758-181) 2608) 1850-800 (73-80) | 2400-2600 (277-254) Table Vil. SAE 4-Bolt Flange Torque ‘Static seal leakage problems and solutions are in Table VII. Possible Source) Suggested Ot Trouble Remedy 7" Seal as exraded or been | Replace seal and check te foROwing nibbled to death a. Sealing srtaces must be fat within 00S inches (013 mm), replace part if out ofits, ». Inia! bolt torque may nave been too low. Check ‘anal for proper torque. , Pressure pulses may be too high. Check for ‘proper roliet valve setting 4. Itnormat operating pressures exceed 1500 psi (103 bar), back-up rings are required. 2, Seals badly worn FRoplace seal and check the folowing: 2. Sealing surtace too rough, polish 1 16 yin it possible or replace part. 'b. Undertorqued bolts permit movement, Chock manual for correct setting «6. Seal material or durometer may be wrong. Check ‘manual tin doubt ‘3 Seal is hard or has taken | Replace seal and check the following: ‘excessive permanent seta, Determine what normal operating temperature is. ‘Check system temperature 'b. Check manual to determine thal correct seal material is being used. “4, Sealing surfaces are | Replace fault Krooedtamans | menatont f§CKERS 5. Seal has been pinche ‘Use petrolatum ig hold seal in place with bing Sreutsneesatu | sosonay Uae petacave sh sea estas over har ee fora deuce “ESearnas Wr apparel | Chak sat sre and pars Sia Gatco ——— 305 Corporate Dea See ee PO. Bon 802 7330 Vi Sate Soa Leake Anas Thay Mhigen USA soca Pineda USA ILCKERS Noise Control in Hydraulic Systems Released 8-91 ‘TABLE OF CONTENTS Section Title Page INTRODUCTION «2.2 ...eeceeeees Sect SYSTEM NOISE CONTROL, cecsteeeeee eee eee eee eat QUIET HYDRAULICS - A TEAM EFFORT NOISE TRANSMISSION AND GENERATION . . DESIGN FOR LOW NOISE eee oath NOISE FREQUENCIES 6.0002. 2.ecseeeeeseeeetsnenenee VIBRATION NOISE CONTROL, ISOLATION WITH HOSE FLUIDBORNE NOISE CONTROL «=... APPLICATION OF TECHNIQUES NOISE TERMINOLOGY... 22.0 0ee oe eet NOISE TERMS AND EQUATIONS sect HUMAN RESPONSE TO NOISE ~THE"A' SCALE... sssccssces ‘SOUND POWER RELATIONSHIP BETWEEN SOUND PRESSURE AND SOUND POWER EFFECT OF DISTANCE ON NOISE LEVELS «42.2.2. 2s2s20-005 NOISE ADDITION... NOISE MEASUREMENTS . ‘COMPONENT EVALUATION AND RATING . ‘SYSTEM NOISE EVALUATION eet rere i CORRECTION FOR BACKGROUND NOISE ........sssvssssseeseeveee : 10 2 13 INTRODUCTION ‘Athough a certain amount of noise Ccanitol is required in hydraulic systems, Just to conform to government regulations, @ conscientious noise ‘control program aciually provides a ‘competitive edge. The combination of & ‘quiet pump, well-engineered vibration ‘and pulsation cortrols, and good, ‘economical installation practices will result in 2 product with a distinct ‘advantage in the marketplace, ‘The Vickers publication "More Sound Advice,” Issued in the 1970's, ilvstrated ‘a variety of machine noise contro! methods, Because of the nearly infiite variety of hydraulic applications, it's not possiole here to discuss the inchvidual features of particular systems, There are, however, 2 numberof instalation techniques that can be applied to almost ail hydraulic systems. When Used correctly, these techniques can yield significant reductions in noise. This publication describes the tollowing: 1. Noise generation and noise controt techniques. 2. Noise terms, definition and the use of tha decibel 3, Noise measurement procedures. ‘SYSTEM NOISE CONTROL, Quiet Hydraulics - A Team Effort ‘A successful noise control program requires a team effort by individuals in several areas of expense. & quiet hhycraulic pump Goes not guarantee a ‘uiet system, Tho choice of a quist [Bump should be only one part of 2 ‘multifaceted program that cals upon the talents ofthe system designe, ‘fabricator, installer, and maintenance technicians. And if any member of the team falls 10 do their job, it can mean failure of the entre noise control rogram, ‘The pump and eystam designers play a key role in achieving suocesstul noise control. Thay must evaluate every noise control technique available from the standpoints of both cost and practicality. Three ofthe basic ‘approaches used In quieting hydraulic power systems are: {A Interal and external pump pulsation control 1B) Pump and structure isolation ¢} Damping andior stifaning Noise Transmission and Generation Noise is defined as the unwanted by-product of fluctuating forces in a ‘component or eystem. Ina hydraulic ‘system, this noise can be transmittog in three ways: through the a, through the ‘uid, and through the system's physical structure. We generally think of nose as travelling only through the medium of the ar, oing direct from its source to some receiver (our ear. This s called airbome noise. That altborne noise, however, must have a source within some component ofthe hydraulic system. That component is normally the pump. Whather it's a piston, vane, ‘or gear pump, the internal pumping ‘and porting design can never be perfec, AS 2 result, unaven flow Ccharactoristics and pressure waves are created and transmitted through the fluid. This is known as fluidbome noise. “The pressure wave fluctuations of {luigome noise in turn create ‘corresponding force fluctuations. These resut in vibration, also known as. structureborne noise. This ‘sructuraborne noise is transmitted not ‘only through the pump body, but through attached structures 2s well ‘These structures then emit an audible ‘sound. ‘The surrounding stuctures and suriace arses in a hydraulic system tend tobe much larger than the pump itself, and therefore radiate noise more efficiently. For this reason, while the pump design ‘should minimize internal pulsations, i's also important to use proper isolation techniques to keep the remaining vibrations from reaching adjoining structures. Noise Control in Hydraulic Systems Design for Low Noise {a lntaligent program of noise contro} ‘should start al the scurce: the pump. A ‘quiet pump isthe responsibilty ofthe pump manufacturer. The problem for the Gesigner is that although a. hydraulic pump is required to perform ‘over a wide range of speeds and pressures, noise control can only be ‘optimized for & relatively narrow portion of that range. The most common strategy is 10 use poring design to limit the pressure pulsations at the pumps rated speed and pressure. The pulsations are reduced as much as possible without creating a large ‘amount of noise at lower speeds anc pressures, Pision, vane, and goar ‘bumps are similar in that their total ‘Output low is tho sum of the flows from the individual pumping elemenis or ‘chambers. Fluid fils the chambers at the pump inlet, is compressed mechanically and/or hysrauically through orifices, and is nen combined Into a single discharge flow. Each pumping elemant in a piston pump oliver Is fluid t0 he discharge port in a half-sine protil. The pump discharge Is tne total of ne equally spaced half-sines added in phase. The results {an inherent flow ripple, as shown in Figure 1 for a nine-piston pump. This ripple Is indopendent of any tid ‘compression. either through piston ‘motion 0° any type of internal hydraulic ‘metering. Vane pump flow ripple is ‘more controllable. Cam contours can 'be designed to reduce mechanical ‘compression eftecs. This is cone by making pressure transitions in tho dra section, where there is controlled ‘change in vane chamber volume. For {his reason, vane pumps will normally ‘generate less noise over a wider range of spaeds and pressures than piston pumps. Noise Control in Hydraulic Systems Lp hy py tee net |e rors i cE z L | Saat io gc eton Das Figure 1. Inherent Piston Pump Discharge Ripple Noise Frequencies Pump noise energies are generated in sovoral ways. Vierational energy Is Created by an Imoalance In the pump, Crive motor, or couplings. Itean also be produced by some undesired Interaction inthe assembly, but i's rare for any significant audible noise to be (gonerated by these interactions. Nonetheless, care should be takon to minimize its effects on pump or motor lite, Figure 2 shows the frequency frequency (900 Hz in Figure 2). Noise ‘spectrum of a ten-vane pump ‘energy is also produced at muitipes, or ‘operating at 1800 rpm with shaft rnarmonics, of this frequency. 600 Hz rotation frequency of 30 Hz. Any ‘and 900 Hare the second and thitd misalignments in the power train will harmonics seen in Figure 2. These Produce noise components at twice harmonics have enough ampiitude to ‘and four times this frequency. produce significant noise. This noise ‘comas nt only rom the pump its, ‘The strongest eneray components, bbut rom attached structures which are Sees eee eee toe offen more efficient at radiating the ‘Frequency equals the number of ‘noise transmitted from the pump. pumping chambers times the shaft A Ht L Cb t Uh ft POT TT Till uhh A a co Std “iio aan Frequency (Hz) Figure 2. Structureborne or Fiuldborne Spectrum Identifying Shaft and Pumping Frequency and Harmonics Vibration Noise Control Vioration contro is used to prevent pulsation energy from the pump from being transmitted to machine structures. Most pump and ctive motor ‘assembles are attached through a tlexible coupling and mounted on a ‘common base 0 maintain alignment ‘The common base is resiliently ‘mounted tothe support structure, as sean in Figure 3. An isolator should be higher the ratio between the forcing selected that has a natural frequency frequency and the natural frequency of approximately /p oF less the pump’s the Isolator gystem, the greater the rotational frequency. For example, an amount o Isolation (see Figure 4). isolator with a natural frequency of 10 typical commercial isolator {which Hz or lass would be appropriata fora costs about $18 in moderate quantities) [pump with rotational or forcing Can reduce transmitted vibration energy frequency of 20 Hz at 1200 ram, and by 10. dB at 1200 rpm and 15 dB at would work even better fora purnp with 1800 rpm (Figure 5), a frequency of 30 Hz at 1800 rpm. The Noise Cenwor Hr nyuraNG syste Figure 3. Pump and Motor on Subplate, Isolated from Stiff Foundation E | necionor No © [nandifon \ z ea q ay a neaidn'or \ : Beinn \ Yi x 4 = trig requ AATIO ot 122 nase neuer Figure 4. Typical Transmissibity Curve for an Isolated System iene Frcouevey Figur 5. Transmitted Vibration Energy Reduction Using Typical Commercial isolator Noise Control in Hydraulic Systems wwotmancisied year cod eitiat ete maphinewemnict pean hot he cae ecsemcmecooet, Sonnets Semeearee cena ence Soe estos cerns tan, Mesmeypectiooscanatoce SMa nnectacapmans ‘the amount of evenly distributed weight _US8d n power units with overhead. frequency of 9 x 20 rev/sec or 180 Hz. If ‘on each of the isolators can be reservoirs, Eight isolators can be 2.10 Hz isolator system were used, calculated. Isolators should be selected installed either under the reservoir feet there would be a very low level of ‘that will not be loaded above 60% to (Figure 6), oF under the upright leg vibration transmission, because the 70% of thelr capacity, This will alow a S*uCtUTes Supporting the reservok. The ratio between the two frequencies isolators shown would be very effective Would be 18-1. Figure 6. Reservolr Foot On Isolator The chat on the righ lists load ratings Max Static | Table 1 on the following page provides. ‘oftypical isolators with carrying toad | teotstor | toed Per two examples of proper isolator capacities of 60 10.4400 Ibs. per Series | Number | Ieolator (bs.) | selection isolator. ie vor fu | eo G 100 B 130 ivy 200 b 250 Mecim| Heavy ry 1500 xa | EH 1500 Heavy | EH2 — | 2000 Hs | 3000, FHA =| 4400 ‘ Noise Control in Hydraulic Systems 1A) Pump, motor, and subplate weight = 800s. Load on each of 6 isolators = 1380s, Maximum static load when loaded 10 6010 70% of capacity = 19010 222 Ios, Selection: # La (rom chart onpage 4) 1B) Reservoir weight = 580ibs Attached accessories weight = 1501s, +00 gallons oil weight (7 Tessa) = 7o0Its, TOTAL 1400 tos. ‘Lead on each of 4 isolators 350108 Maximum static load when loaded 10 6010 70% of capacity = 0010583 bs. Selection: #3 (rom chart on page 4) Table 1. Isolator Selection Isolation With Hose hose is probably the main cause of ‘of hose is that it acts as an efficient neice nary estos Factor regency range where Rubber hose must be used o meintin mest of ho energy is generaog: ho the vbraon solatonafrcac wren” AMPOUgHSUchxeborne rose can BE frst few harranies. Because oF these Tre pumpandmocoraesemy are TeSueed Byung ong length of Rese. yo aco, ong nes of hose ae ess mmoseted on soar. The solation Fresaure pulsations fom the PNP fia for rose reduction an the will use the hose to undergo cyclic ge nose at einer end of a solid line Se acer radial expansion. One of the drawbacks Faure 7). ‘amount of vibration energy entering the system. Unfortunately, improper use of au STEEL ALL FLEXIBLE HOSE. one FLEX HOSE ‘180° BEND SECTION est wo FLEX HOSE, SECTIONS Figure 8. Preferred Short Hydraulic Line Figure 7. Long Hydraulic Line Configurations Configurations ‘Two other shortcomings of hose are Both produce forces that act on eliminates problems caused by the that its length changes with pressure, connecting structures. The best way to Bourdon tube effect. Any change in the ‘and that when fs bent rough a radius maintain noise control wnile making _length of one hose is accommodated ‘tacts like a Bourdon tube, trying 10 bends with hose is to use a solid elbow by bending inthe other hose. Figure 8 Straighten out with increasing pressure. witha hase section on each end, This Noise Control in Hyaraulic Systems. Mustrtes the preferred configurations for 90° and 180° bends. Fluidborne Noise Control Fluldoore noise control begins with a ump's internal design. The ports should be configured so that the lowest practical pressure pulsations are (generated. Additional external controls can be added to prevent as much pulsation energy as possible from being communicated io the system, This is usually done by acing harmonics (where most ofthe pulsation ‘expansion volume at the outlet ofthe energy is generated). The flow-through ‘pump. These acoustic fters, as they _dviog, although generally larger and are called, car take many forms. The more expensive, has a distinct two most common are gas charged performance advantage: pulsations ‘side branch accumulators and {throughout the epectrum are recuced, ‘flow-through type pulsation fiers. Including thoes atthe most significant Each has its advantages and harmonics. The fters (shown in Figure disadvantages. The side branch type is 9} have optimum effectiveness when ‘cheaper, but limited 1o attenuating {92S charged to "the maximum pulsations in only a narrow range of operating pressure ofthe hycraulic frequencies. As a result it iso" totally system, ‘effective throughout the rst four pump VAWE ss & SIDE BRANCH ACCUMULATOR Gas CHARGING LOADING VALVE BLADDER —_PRECHARGED GAS CHAMBER nu | MANDREL” SLEEVE THROTTUNG ORIFICES PASS-THROUGH GAS CHARGED FILTER Figure 9. Acoustic Fiters Application of Techniques Experimental evaluations were made ona typical automotive application: a power unit witn 2 150 gallon overhead. reservoir supplying oil 10 @ piston ump. The pump delivered 40 gpm at Evaluation.) Four diferent noise: +1200 rpm ata pressure of 750 psi. The reduction techniques were apolied 10 ‘noise level, as received, was 88 CIA). the system, starting with those that (Standard accepted noise would have the greatest effect on noise measurement procedures are explained levels, The results are shown in Table 2 in the subsection entillec Syston Noise Noise Control in Hydraulic Systems pulsation Tem DESCRIPTION 1 (Changed raciused pressure hose ‘0 wo pleces, separated by right angle fiting 2 tem 1, plus structure isolators, ‘under reservoir and upright ‘supports (8 addtional 'solators), 3 tems 1 and 2, plus valve plate ‘designed for 1000 pl rather than 3600 psi. (Pulsatlons reduced ‘tor 200 psi to 140 pst} 4 toms 1, 2, and 3, plus flow-through ter. (Pulsations reduces from 140 psi to 88 psi) RESULTING CHANGE IN NOISE LEVEL NOISE LEVEL 63 081A) 79 0B(A) 76.0814) Te dBIA) -5

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