Emerson Damcos Service Manual
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Emerson Damcos Service Manual

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Service Manual
Version: SM 8000-1000-01 Ed 04
Release: February, 2017
Damcos
Local Power Unit
™
Service Manual

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Summary of Contents for Emerson Damcos

  • Page 1 Service Manual Version: SM 8000-1000-01 Ed 04 Release: February, 2017 Damcos Local Power Unit ™ Service Manual...
  • Page 2 We reserve the right to modify or improve the designs or specifications of our products at any time with- out notice. Damcos A/S accepts no responsibility for any errors that may appear in this publication.

  • Page 3: Table Of Contents

    Damcos LPU: Table of Contents Service Manual February 2017 SM 8000-100-01 Ed 04 Table of Contents Abbreviation and Denomination ....... . . 7 Safety .

  • Page 4: February 2017 Sm 8000-100-01 Ed

    Service Manual Damcos LPU: Table of Contents SM 8000-100-01 Ed 04 February 2017 Noise from pump, but only at high pressure ......55 Noise from pump at both high and low pressure.
  • Page 5 Damcos LPU: Table of Contents Service Manual February 2017 SM 8000-100-01 Ed 04 Refill of Oil in LPU ..........87 Replace Pump in LPU .

  • Page 6: Table Of Contents

    Service Manual Damcos LPU: Table of Contents SM 8000-100-01 Ed 04 February 2017...

  • Page 7: Abbreviation And Denomination

    Damcos LPU: Abbreviation and Denomination Service Manual February 2017 SM 8000-100-01 Ed 04 Abbreviation and Denomination DPCV Double Pilot Operated Check Valve Hand Pump Integrated Ship Control Local Power Unit LPU-D LPU for double-acting actuator LPU-S LPU for single-acting spring operated actuator...
  • Page 8 Service Manual Damcos LPU: Abbreviation and Denomination SM 8000-100-01 Ed 04 February 2017...

  • Page 9: Safety

    Damcos LPU: Safety Service Manual February 2017 SM 8000-100-01 Ed 04 Safety A description of issues concerning personal safety when handling Damcos...

  • Page 10: Warning Levels Used In Manuals

    SM 8000-100-01 Ed 04 February 2017 Warning Levels Used in Manuals The following warning levels are used in the documentation of Damcos A/S for the safety of people and equipment. Warning! Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
  • Page 11 Damcos LPU: Safety Service Manual February 2017 SM 8000-100-01 Ed 04...
  • Page 12 Service Manual Damcos LPU: Safety SM 8000-100-01 Ed 04 February 2017...

  • Page 13: General Service Instructions For Lpu

    Damcos LPU: General Service Instructions for LPU Service Manual February 2017 SM 8000-100-01 Ed 04 General Service Instructions for LPU This Chapter Describes the General Requirements and Service Recommendations for the LPU...

  • Page 14: General Considerations

    Service Manual Damcos LPU: General Service Instructions for LPU SM 8000-100-01 Ed 04 February 2017 General Considerations Important notes on LPU equipment and systems: • use original spare parts and tools • use lifting facilities and transport equipment • use handling instructions •...
  • Page 15 Damcos LPU: General Service Instructions for LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D and LPU-S on KF/KFR - Bleed valve positions LPU-S on BRCF - Bleed valve positions...

  • Page 16: Lpu And Optional Equipment

    Always check your specific system drawings and documents for correct information. This manual is a guide on how to perform the service parts of your system. For further information please contact Emerson service engineer or appointed agent. Description The LPU offers installation in both safe and hazardous area in two basic versions: •...
  • Page 17 Damcos LPU: General Service Instructions for LPU Service Manual February 2017 SM 8000-100-01 Ed 04 B-VPI Block for bulk-head mounted LPU. Note! If bulk-head mounted: Oil level must be checked before starting up the LPU. LPU must be placed with motor pointing down and breather valve on top, short suction pipe recommend.
  • Page 18 Service Manual Damcos LPU: General Service Instructions for LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 19: Lpu-S Overview

    Damcos LPU: LPU-S Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S Overview This Chapter Describes the LPU-S with Overview and Handling Instructions...

  • Page 20: Overview Lpu-S

    Service Manual Damcos LPU: LPU-S Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-S LPU-S Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-S 2” on page 73. How to Operate the LPU-S See “Troubleshooting Guide LPU”...
  • Page 21 Damcos LPU: LPU-S Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S Top View with top cover made partly transparent. LPU-S Bottom View...
  • Page 22 Service Manual Damcos LPU: LPU-S Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 23: Lpu-S-Ex Overview

    Damcos LPU: LPU-S-Ex Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S-Ex Overview This Chapter Describes the LPU-S-Ex with Overview and Handling Instructions...

  • Page 24: Overview Lpu-S-Ex

    Service Manual Damcos LPU: LPU-S-Ex Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-S-Ex LPU-S Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-S 2” on page 73. How to Operate the LPU-S-Ex See “Troubleshooting Guide LPU”...
  • Page 25 Damcos LPU: LPU-S-Ex Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S Top View with top cover made partly transparent. LPU-S Bottom View...
  • Page 26 Service Manual Damcos LPU: LPU-S-Ex Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 27: Lpu-S-Ex-Ia Overview

    Damcos LPU: LPU-S-Ex-ia Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S-Ex-ia Overview This Chapter Describes the LPU-S-Ex-ia with Overview and Handling Instructions...

  • Page 28: Overview Lpu-S-Ex-Ia

    Service Manual Damcos LPU: LPU-S-Ex-ia Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-S-Ex-ia LPU-S Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-S 2” on page 73. How to Operate the LPU-S See “Troubleshooting Guide LPU”...
  • Page 29 Damcos LPU: LPU-S-Ex-ia Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S-Ex-ia Top View with top cover made partly transparent. LPU-S Bottom View...
  • Page 30 Service Manual Damcos LPU: LPU-S-Ex-ia Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 31: Lpu-D Overview

    Damcos LPU: LPU-D Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Overview This Chapter Describes the LPU-D with Overview and Handling Instructions...

  • Page 32: Overview Lpu-D

    Service Manual Damcos LPU: LPU-D Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-D LPU-D Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-D 2a” on page 75. How to Operate the LPU-D See “Troubleshooting Guide LPU”...
  • Page 33 Damcos LPU: LPU-D Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Top View with top cover made partly transparent. *)Pressure switch is not present in all versions of LPU-D! LPU-D Bottom View...
  • Page 34 Service Manual Damcos LPU: LPU-D Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 35: Lpu-D-Ex Overview

    Damcos LPU: LPU-D-Ex Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D-Ex Overview This Chapter Describes the LPU-D-EX with Overview and Handling Instructions...

  • Page 36: Overview Lpu-D-Ex

    Service Manual Damcos LPU: LPU-D-Ex Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-D-Ex LPU-D Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-D 2a” on page 75. How to Operate the LPU-D See “Troubleshooting Guide LPU”...
  • Page 37 Damcos LPU: LPU-D-Ex Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Top View with top cover made partly transparent. LPU-D Bottom View...
  • Page 38 Service Manual Damcos LPU: LPU-D-Ex Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 39: Lpu-D-Ex-Ia Overview

    Damcos LPU: LPU-D-Ex-ia Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D-Ex-ia Overview This Chapter Describes the LPU-D-Ex-ia with Overview and Handling Instructions...

  • Page 40: Overview Lpu-D-Ex-Ia

    Service Manual Damcos LPU: LPU-D-Ex-ia Overview SM 8000-100-01 Ed 04 February 2017 Overview LPU-D-Ex-ia LPU-D Front View See “Emergency Operation of LPU V.2” on page 77. Emergency Operation See “Operating LPU-D 2a” on page 75. How to Operate the LPU-D See “Troubleshooting Guide LPU”...
  • Page 41 Damcos LPU: LPU-D-Ex-ia Overview Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Top View with top cover made partly transparent. LPU-D Bottom View...
  • Page 42 Service Manual Damcos LPU: LPU-D-Ex-ia Overview SM 8000-100-01 Ed 04 February 2017...

  • Page 43: Troubleshooting Guide Lpu

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Troubleshooting Guide LPU This Chapter Describes how to Identify and Correct minor Problems for LPU...
  • Page 44 Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 45: Fault Finding List Lpu

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Fault Finding List LPU ACTUATOR CONNECTED PROBLEM “Actuator only running in one direction (the unit can either only open or only close)” on page 53 “LPU-D not maintaining pressure on actuator” on page 57 “Spring actuator only partly closing or not starting to close”...
  • Page 46 Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 POSITION INDICATOR “Position indicator errors” on page 72 PUMP “Pump rendering too low (or no) pressure in one or both directions” on page 51 “Noise from pump, but only at low pressure” on page 54 “Noise from pump, but only at high pressure”...

  • Page 47: Lpu-S Frequently Restarting In Open Position

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S frequently restarting in open position Action: Place pressure gauge on quick connection B. Read maximum pressure and observe if pressure drops when motor stops. Then if: Pressure is raised to approx.
  • Page 48 Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 – Pressure switch is adjusted, so that pressure switch breaks by falling pressure at 100 ±5 bar. Pressure switch must close below 125 bar by rising pressure.

  • Page 49: Motor Not Running And Is Hot

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Motor not running and is hot Action: Check that electrical connections to motor and capacitor are OK! Open bypass to release possible pressure on pump and try to run the motor with opened bypass.

  • Page 50: Motor Not Stopping

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Motor not stopping Action: • The pressure on B-port is measured. If the pressure is below 120 bar, while motor is running, see “Pump rendering too low (or no) pressure in one or both directions”...

  • Page 51: Pump Rendering Too Low (Or No) Pressure In One Or Both Directions

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Pump rendering too low (or no) pressure in one or both directions Action: • Check that solenoid valve is clicking at connection. If not see “Solenoid valve not working” on page 52.

  • Page 52: Solenoid Valve Not Working

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Solenoid valve not working Action: • Check that solenoid valve is energized (230 V on terminals “N” and “SV”). • If coil is energized, but solenoid valve does not work, the resistance of the coil is measured (LPU- ...

  • Page 53: Actuator Only Running In One Direction

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Actuator only running in one direction (the unit can either only open or only close) LPU-D If LPU-D can close, but not open check by-pass valve for oil filling. Check that solenoid valve is pow- ered and working and that free travel of solenoid valve slide is OK.

  • Page 54: Noise From Pump, But Only At Low Pressure

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Noise from pump, but only at low pressure Action: Adjust speed from maximum to minimum (see “Speed adjustment for Actuator on LPU (v.2)” on page 83). If possible, place key on emergency operation shaft of the actuator and hold against rotat- ing direction (i.e.

  • Page 55: Noise From Pump, But Only At High Pressure

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Noise from pump, but only at high pressure Reason: • Air in the pump if actuator has not been properly de-aired. Check oil level in tank. •...

  • Page 56: Motor Running Hot, Lpu Is Operating Normally

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Motor running hot, LPU is operating normally Caution! Motor is designed for 25% duty cycle only. Action: • LPU-S Observe that LPU does not restart. If it is restarting frequently, the motor is running hot. See“LPU-S frequently restarting in open position”...

  • Page 57: Lpu-D Not Maintaining Pressure On Actuator

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D not maintaining pressure on actuator Pressure drops only on 1 port • Leakage in check valves for DPCV or release valve. Change check valves for DPCV.

  • Page 58: Spring Actuator Only Partly Closing Or Not Starting To Close

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Spring actuator only partly closing or not starting to close Action: Check that throttle valve for adjustment of closing speed is not blocked. Open bypass while motor is not operated.

  • Page 59: Emergency Operation By Key Giving Oil Spillage Through Breather Valve

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Emergency operation by key giving oil spillage through breather valve Reason: When valve is emergency operated by key, oil is pumped from actuator to LPU tank and further on to the actuator.

  • Page 60: Emergency Operation By Hand Pump Not Possible

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Emergency operation by hand pump not possible Reason: • Hand pump is building up pressure, but actuator is not moving – Slide for shuttle valve is sticking, so that change over to emergency operation cannot take place (LPU-S).

  • Page 61: Pump Not Rendering Sufficient Oil At High Pressure ("Valve Running Too Slowly")

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Pump not rendering sufficient oil at high pressure (“valve running too slowly”) Reason: LPU is built up, so that oil quantity from pump, independent of adjusted speed, is reduced to approx- imate 240 cm /min from pressure exceeding 75 bar.

  • Page 62: Motor Running For A Short Time And Stops

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Motor running for a short time and stops High pressure on the port to which oil is led Action: Mount pressure gauge on quick connection on return oil from actuator (LPU-D). At the same time check that actuator is moving.

  • Page 63: Motor "Diving" In Rpm In End Position

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Motor ”diving” in RPM in end position Reason: Voltage too low, pump relief valve misadjusted, defective flow reducing valve (the displacement of the pump is not reduced at high pressure), fault in motor, or faulty connection of motor. Possibly fault in capacitor/connection.

  • Page 64: Oil Spillage, Generally

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Oil spillage, generally Avoid starting motor until the correct level in tank has been ensured. After elimination of faults, replenish tank with the correct oil for the specific system.

  • Page 65: Unit Drawing Too Much Current

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Unit drawing too much current Reason: • Mechanical resistance in motor • Mechanical resistance in pump • Too small winding resistance in motor meaning a 110 V motor has been used instead of 230 V motor •...

  • Page 66: Too Little Tank Volume For Operating Actuator

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Too little tank volume for operating actuator • Incorrect oil filling and de-airing of actuator. Check oil filling. • Too high compressibility of oil in pipes between hand pump and LPU or between LPU and actua- tor.

  • Page 67: Lpu Cannot Raise Pressure After Hand Pump Operation (But No Problems After Remote Operation)

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU cannot raise pressure after hand pump operation (but no problems after remote operation) Reason: • Leakage from LPU to hand pump. – Portable hand pump must be disconnected.

  • Page 68: Lpu Leaking From Bleeder Valve When Hand Pump Is Mounted

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 LPU leaking from bleeder valve when hand pump is mounted For LPU-S Reason: • Bad T-connection from LPU to hand pump: – Check piping and connections. –...

  • Page 69: Spring Actuator Do Not Close By Emergency Hand Pump Operation

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Spring actuator do not close by emergency hand pump operation Reason: • Spring actuators will not close by changing bulkhead hand pump to close, as there will be no pressure rise to open the DPCV.

  • Page 70: Lpu-Ex Motor Do Not Run

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 LPU-Ex motor do not run Reason: LPU-Ex-motors contain temperature sensors that have to be reset manually. After motor cut-off by temperature sensors they have to be reset by turning off 24 V power for at least 10 sec.

  • Page 71: Tuator

    Damcos LPU: Troubleshooting Guide LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-Ex has to be bulkhead mounted because of too little space or zone 0 at actuator Like other LPU’s LPU-Ex can be bulkhead mounted by means of BB-block or BB-VPI, but then needs an intrinsically safe position indicator.

  • Page 72: Position Indicator Errors

    Service Manual Damcos LPU: Troubleshooting Guide LPU SM 8000-100-01 Ed 04 February 2017 Position indicator errors Fault: • ON/OFF position indicator is not functioning correctly: – Check the control cable connections. – Check the function of the position indicator, measured on the position indicator wire connec- tion.

  • Page 73: Operating Lpu-S 2

    Damcos LPU: Operating LPU-S 2 Service Manual February 2017 SM 8000-100-01 Ed 04 Operating LPU-S 2 Tank for hydraulic oil Suction filter Electrical motor Pressure controlled flow adjustment Pump safety valve Actuator relief valve Quick connection for hand pump suction...
  • Page 74 Service Manual Damcos LPU: Operating LPU-S 2 SM 8000-100-01 Ed 04 February 2017 for some seconds in order to keep up the pressure, and prevent the valve from leaving the open posi- tion. - This may take place automatically. Close valve To move the valve towards closed, the solenoid valve is de-energized.

  • Page 75: Operating Lpu-D 2A

    Damcos LPU: Operating LPU-D 2a Service Manual February 2017 SM 8000-100-01 Ed 04 Operating LPU-D 2a Tank for hydraulic oil Suction filter Electrical motor Pressure switch Double pilot operated check valve, closing side Actuator relief valve, closing side Quick connection for hand pump,...
  • Page 76 Service Manual Damcos LPU: Operating LPU-D 2a SM 8000-100-01 Ed 04 February 2017 Close valve Closing the valve follows exact the same procedure, except that the solenoid valve is not activated which causes the ports A and B to be reversed.

  • Page 77: Emergency Operation Of Lpu V.2

    Damcos LPU: Emergency Operation of LPU V.2 Service Manual February 2017 SM 8000-100-01 Ed 04 Emergency Operation of LPU V.2 For all operations: When the hand pump is disconnected and the by-pass valve is closed, the remote control is allowed to operate the system again.
  • Page 78 Service Manual Damcos LPU: Emergency Operation of LPU V.2 SM 8000-100-01 Ed 04 February 2017 Firmly mounted hand pump With a firmly mounted hand pump the following applies: Emergency open a fail-open LPU Open by-pass at the actuator or at the firmly mounted hand pump until the valve has reached the desired position.
  • Page 79 Damcos LPU: Emergency Operation of LPU V.2 Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Emergency operation of double acting actuator with key Actuators that can be opened by emergency operation actuator: BRC 125 - BRC 500 Open the crossover valve by turning counter clockwise.
  • Page 80 Service Manual Damcos LPU: Emergency Operation of LPU V.2 SM 8000-100-01 Ed 04 February 2017 Emergency opening of double acting actuator with hand pump Connect hand pump P-line with B-line quick connection at the LPU. Connect hand pump T-line with A-line quick connection at the LPU.
  • Page 81 Damcos LPU: Emergency Operation of LPU V.2 Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-S Emergency opening of single acting actuator with hand pump Connect hand pump P-line with B-line quick connection at the LPU. Connect hand pump T-line with T-line quick connection at the LPU.
  • Page 82 Service Manual Damcos LPU: Emergency Operation of LPU V.2 SM 8000-100-01 Ed 04 February 2017...

  • Page 83: Speed Adjustment For Actuator On Lpu (V.2)

    Damcos LPU: Speed adjustment for Actuator on LPU (v.2) Service Manual February 2017 SM 8000-100-01 Ed 04 Speed adjustment for Actuator on LPU (v.2) Speed adjustment for double acting actuators Speed will be adjusted by means of a 3 mm Allen key, see picture below where to adjust. By turning the screw clockwise (fasten screw), the actuator will run slower, turning the screw counterclockwise it runs faster.
  • Page 84 Service Manual Damcos LPU: Speed adjustment for Actuator on LPU (v.2) SM 8000-100-01 Ed 04 February 2017...

  • Page 85: Pump Pressure Adjustment For Lpu

    Damcos LPU: Pump pressure adjustment for LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Pump pressure adjustment for LPU Warning! Parts inside housing of LPU are connected to 230 Volts, please do not touch these parts without power supply securely OFF.
  • Page 86 Service Manual Damcos LPU: Pump pressure adjustment for LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 87: Refill Of Oil In Lpu

    Damcos LPU: Refill of Oil in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Refill of Oil in LPU Refilling of oil is normally done when needed. Refill of oil should also be done when parts are changed in LPU or if LPU starts to make special noises at operation.
  • Page 88 Service Manual Damcos LPU: Refill of Oil in LPU SM 8000-100-01 Ed 04 February 2017 Procedures LPU without pressurised reservoir using direct level control Remove the breather valve, placed on top or bottom of the LPU or end of oil tank, depending on the LPU mounting direction, see picture on page 87.
  • Page 89 Damcos LPU: Refill of Oil in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU with permanently mounted hand pump If the LPU is mounted with a permanently mounted hand pump, the oil level control has to be done in...
  • Page 90 Service Manual Damcos LPU: Refill of Oil in LPU SM 8000-100-01 Ed 04 February 2017 LPU-S mounted on BRCF oil filling with hand pump breather valve quick connection B (OPEN) by-pass valve quick connection T Connect hand pump pressure hose to quick connection T.
  • Page 91 Damcos LPU: Refill of Oil in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 LPU-D Oil Filling Instruction with hand pump breather valve breather valve quick connection B quick connection B tank filling valve tank filling valve (OPEN) (OPEN) Close the actuator fully.
  • Page 92 Service Manual Damcos LPU: Refill of Oil in LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 93: Replace Pump In Lpu

    Damcos LPU: Replace Pump in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Replace Pump in LPU Note! If permanently mounted hand pump is connected, close stop valves for hand pump if mounted in system. Replace Pump in LPU Oil tank is emptied by removing plug at bottom of Remove 4 pcs M8-screw and remove the tank.
  • Page 94 Service Manual Damcos LPU: Replace Pump in LPU SM 8000-100-01 Ed 04 February 2017 Replace Pump in LPU Oil the new stator and place it with slot for pin in Turn in the stator. When stator is turned to correct...
  • Page 95 Damcos LPU: Replace Pump in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Replace Pump in LPU 12.Check O-rings and exchange them if necessary. 13.Mount the disc on stator. 14.All pistons are kept in place in rotor while valve 15.Fasten suction pipe.
  • Page 96 Service Manual Damcos LPU: Replace Pump in LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 97: Replace Dpcv In Lpu

    Damcos LPU: Replace DPCV in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Replace DPCV in LPU Replace DPCV in LPU Remove plug. Use the correct tool or an M2 screw. Dismount NRV front. Dismount NRV back. Remove slide and spring.
  • Page 98 Service Manual Damcos LPU: Replace DPCV in LPU SM 8000-100-01 Ed 04 February 2017 Replace DPCV in LPU Mount NRV back. Mount plug at back. 10.Mount NRV in front. 11.Mount plug in front.

  • Page 99: Replace Release Valve In Lpu

    Damcos LPU: Replace release valve in LPU Service Manual February 2017 SM 8000-100-01 Ed 04 Replace release valve in LPU Replace release valve in LPU Remove plug. Use the correct tool or an M2 screw. Remove release valve. Note that LPU-D has two Change the valve.
  • Page 100 Service Manual Damcos LPU: Replace release valve in LPU SM 8000-100-01 Ed 04 February 2017...

  • Page 101: Setup New P-Net Lpu Circuit Board

    Damcos LPU: Setup new P-net LPU circuit board Service Manual February 2017 SM 8000-100-01 Ed 04 Setup new P-net LPU circuit board Warning! Disconnect the power before changing the circuit board! Replace Circuit Board in LPU Replace the P-net LPU circuit board. See “Replace Go to the computer and switch to Project 3.10...
  • Page 102 Service Manual Damcos LPU: Setup new P-net LPU circuit board SM 8000-100-01 Ed 04 February 2017 Replace Circuit Board in LPU Password - Enter Password Enter password and press OK. Select from the menu. Select Tools - Work offline. This will set the system Select the LPU/valve where the P-net LPU circuit online.

  • Page 103: Setup New P-Net Lpu Circuit Board In View Ver. 3.16

    Damcos LPU: Setup new P-net LPU circuit board in VIEW ver. 3.16 Service Manual February 2017 SM 8000-100-01 Ed 04 Setup new P-net LPU circuit board in VIEW ver. 3.16 Warning! Disconnect the power before changing the circuit board! Setup New P-net LPU Circuit Board in VIEW ver. 3.16 Replace the P-net LPU circuit board.
  • Page 104 Service Manual Damcos LPU: Setup new P-net LPU circuit board in VIEW ver. 3.16 SM 8000-100-01 Ed 04 February 2017 Setup New P-net LPU Circuit Board in VIEW ver. 3.16 Right click on the module and select Change Node. Type in the serial number which is found on the The below dialog should appear.

  • Page 105: Replace Printed Circuit Board

    Damcos LPU: Replace Printed Circuit Board Service Manual February 2017 SM 8000-100-01 Ed 04 Replace Printed Circuit Board Warning! Disconnect the power before changing the circuit board! Replace Circuit Board in LPU Remove cover. Disconnect cable with wire. Remove screws.
  • Page 106 Service Manual Damcos LPU: Replace Printed Circuit Board SM 8000-100-01 Ed 04 February 2017...

  • Page 107: Replace Solenoid Valve In Lpu-D

    Damcos LPU: Replace Solenoid Valve in LPU-D Service Manual February 2017 SM 8000-100-01 Ed 04 Replace Solenoid Valve in LPU-D Warning! Disconnect the power before changing the solenoid valve! Replace Solenoid Valve in LPU-D Remove cover. Remove screw. Dismount coil.
  • Page 108 Service Manual Damcos LPU: Replace Solenoid Valve in LPU-D SM 8000-100-01 Ed 04 February 2017...

  • Page 109: Replace Pressure Switch

    Damcos LPU: Replace pressure switch Service Manual February 2017 SM 8000-100-01 Ed 04 Replace pressure switch Warning! Disconnect the power before changing the pressure switch! Replace Pressure Switch in LPU-S Remove cover. Disconnect wires. Loosen pressure switch with correct tool.
  • Page 110 Service Manual Damcos LPU: Replace pressure switch SM 8000-100-01 Ed 04 February 2017...

  • Page 111: Lpu Technical Data

    Damcos LPU: LPU Technical Data Service Manual February 2017 SM 8000-100-01 Ed 04 LPU Technical Data This Chapter Describes the Local Power Unit with Technical Data...
  • Page 112 Service Manual Damcos LPU: LPU Technical Data SM 8000-100-01 Ed 04 February 2017...

  • Page 113: Technical Data

    Damcos LPU: LPU Technical Data Service Manual February 2017 SM 8000-100-01 Ed 04 Technical Data Opening/Closing The LPU is fitted with a variable hydraulic pump enabling you to reduce the flow and thus the actua- tor speed. The pump flow and consequently the required motor power is automatically reduced whenever the pump pressure exceeds a certain point.
  • Page 114 Service Manual Damcos LPU: LPU Technical Data SM 8000-100-01 Ed 04 February 2017 Hydraulic Specification Actuator type Oil displacement Min. operating time (sec.) open/close for LPU-D 50 Hz 60 Hz BRC 125* BRC 250 BRC 500 BRC 1000 BRC 2000...
  • Page 115 Damcos LPU: LPU Technical Data Service Manual February 2017 SM 8000-100-01 Ed 04 Operating speed The operating duration can be calculated from the oil displacement of the actuator. The LPU can deliver a flow, smoothly manually adjusted from 250 to 1000 ml/min at 50 Hz.
  • Page 116 Service Manual Damcos LPU: LPU Technical Data SM 8000-100-01 Ed 04 February 2017 Materials Electrical housing and tank Cast iron Slides, etc. Steel Screws, sign plate, rivets and bracket Stainless steel Seals NBR/PTFE Cable glands Brass/nickel Hydraulic blocks Nodular cast iron Cable Gland Min.
  • Page 117 Damcos LPU: LPU Technical Data Service Manual February 2017 SM 8000-100-01 Ed 04 Zener barrier LPU-Ex-ia The internal zener-barrier is built-in in the top cover and holds an Ex-d cable gland. The 24 VDC power supply to the LPU must be connected 0 to ground.
  • Page 118 Service Manual Damcos LPU: LPU Technical Data SM 8000-100-01 Ed 04 February 2017...

  • Page 119: Lpu Power Control System

    Damcos LPU: LPU Power Control System Service Manual February 2017 SM 8000-100-01 Ed 04 LPU Power Control System This Chapter describes LPU Power Control System and Technical Data...
  • Page 120 Service Manual Damcos LPU: LPU Power Control System SM 8000-100-01 Ed 04 February 2017...

  • Page 121: Lpu Power Control Description

    Continuous: 4-20mA 24V DC 2 wire transmitter ON/OFF: Max 2.5 VA switches Cable: Continuous: Min. 5 x 1.5 mm? Damcos recommends standard cable, 7 x 1.5 mm² ON/OFF: Min. 6 x 1.5 mm? Cable diameter: ø 12.5 - 20.5 mm...
  • Page 122 Service Manual Damcos LPU: LPU Power Control System SM 8000-100-01 Ed 04 February 2017 Electrical Specification This unit has to be controlled directly with 115 V AC or 230V AC, 50 or 60 Hz. A cable e.g. 7 x 1,5 mm? containing motor control and position indicator signal is drawn from the...

  • Page 123: Operation Lpu-S

    Damcos LPU: LPU Power Control System Service Manual February 2017 SM 8000-100-01 Ed 04 Operation LPU-S Opening The LPU-S requires only 2 wires for ON/OFF-operation. When the LPU-S is energized, it opens the valve, runs for 7 sec. extra, and then the motor stops. The valve is kept open by a solenoid valve, pre- venting the oil from flowing back into the tank.

  • Page 124: Operating Lpu-D

    Service Manual Damcos LPU: LPU Power Control System SM 8000-100-01 Ed 04 February 2017 Operating LPU-D Opening / Closing LPU-D requires only 3 wires to operate the valve. When the motor is energized, it opens or closes the valve, dependent on the activation of the solenoid valve, runs for a further 7 sec., and then stops. The valve is locked in position by a double pilot operated check valve, preventing the oil from flowing back into the tank.

  • Page 125: Lpu With Led Position Indicator

    Damcos LPU: LPU Power Control System Service Manual February 2017 SM 8000-100-01 Ed 04 LPU with LED Position Indicator The LED position indicator in the top cover on the LPU can be powered by: • Directly via the ON/OFF position indicator (commonly DPI-E), if the signal back to the inputs may be 24VDC respectively 0V.
  • Page 126 Service Manual Damcos LPU: LPU Power Control System SM 8000-100-01 Ed 04 February 2017 Option 2 - External controlled power LPU with LED indicator &95&3/"- -16 $0/530- )JHI  7 -PX  7 7"$ .BY  N" )JHI 7%$ 07%$...
  • Page 127 Damcos LPU: LPU Power Control System Service Manual February 2017 SM 8000-100-01 Ed 04 Option 4 - External controlled power LPU with LED indicator &95&3/"- -16 $0/530-  N" $-04&%   7BMWF 1PT 7%$ 7"$  N"  7%$ 01&/  ...
  • Page 128 Service Manual Damcos LPU: LPU Power Control System SM 8000-100-01 Ed 04 February 2017...

  • Page 129: Lpu P-Net System

    Damcos LPU: LPU P-NET System Service Manual February 2017 SM 8000-100-01 Ed 04 LPU P-NET System This chapter describes P-NET LPU system and Technical Data...
  • Page 130 Service Manual Damcos LPU: LPU P-NET System SM 8000-100-01 Ed 04 February 2017...

  • Page 131: Lpu P-Net Description

    Damcos LPU: LPU P-NET System Service Manual February 2017 SM 8000-100-01 Ed 04 LPU P-Net Description The P-NET controlled LPU can be used as a stand-alone unit without being connected to P-NET. In this case it is controlled from external inputs/outputs connected to simple push buttons, lamps or e.g.

  • Page 132: Pcb Diagram For Local Control

    Service Manual Damcos LPU: LPU P-NET System SM 8000-100-01 Ed 04 February 2017 PCB Diagram for Local Control Apart from being P-NET controlled, the LPU can simultaneously be controlled locally from e.g. an emergency control. From the connected controllers/workstations it is possible to check whether the LPU is locally operated either by internal or by the external push buttons.

  • Page 133: Pcb Diagram For Stand Alone Unit

    Damcos LPU: LPU P-NET System Service Manual February 2017 SM 8000-100-01 Ed 04 PCB Diagram for Stand Alone Unit Apart from being controlled by the P-NET the LPU can be used as a stand-alone unit without P-NET but controlled by hardwired inputs/outputs (24 VDC supply must be connected). 24 V DC I/O can be used directly i.e.
  • Page 134 Service Manual Damcos LPU: LPU P-NET System SM 8000-100-01 Ed 04 February 2017...

  • Page 135: Hydraulic Hand Pump

    Damcos LPU: Hydraulic Hand Pump Service Manual February 2017 SM 8000-100-01 Ed 04 Hydraulic Hand Pump This Chapter Describes the Hydraulic Hand Pump with Technical Data...
  • Page 136 Service Manual Damcos LPU: Hydraulic Hand Pump SM 8000-100-01 Ed 04 February 2017...

  • Page 137: Technical Data

    Damcos LPU: Hydraulic Hand Pump Service Manual February 2017 SM 8000-100-01 Ed 04 Technical Data Mounting Prepared for actuator and bulkhead block interface Maximum operation pressure 135 bar Test pressure 225 bar Maximum hand pump pressure 135 bar Weight without oil 4.3 kg BRC/F KF version...

  • Page 138: Hydraulic Diagram For Direct Mounted Lpu Handpump

    Service Manual Damcos LPU: Hydraulic Hand Pump SM 8000-100-01 Ed 04 February 2017 Hydraulic Diagram for Direct Mounted LPU Handpump...

  • Page 139: Hydraulic Diagram For Bulkhead Mounted Lpu Handpump

    Damcos LPU: Hydraulic Hand Pump Service Manual February 2017 SM 8000-100-01 Ed 04 Hydraulic Diagram for Bulkhead Mounted LPU Handpump...
  • Page 140 Service Manual Damcos LPU: Hydraulic Hand Pump SM 8000-100-01 Ed 04 February 2017...

  • Page 141: Index

    Damcos LPU: Index Service Manual February 2017 SM 8000-100-01 Ed 04 Index ..........116 Materials ..........16 Mounting ....53 Actuator only running in one direction ........115 Operating speed ....83 Actuator speed adjustment on LPU Technical data ........113 ......
  • Page 142 Service Manual Damcos LPU: Index SM 8000-100-01 Ed 04 February 2017 at emergency operation with key ....59 ........64 ......52 Oil spillage, generally Solenoid valve not working ........75 ....107 Operating LPU-D 2a Solenoid valve replacement in LPU-D .........
  • Page 144 Emerson Automation Solutions ©2017 Emerson. All rights reserved. Damcos A/S The Emerson logo is a trademark and service mark of Emerson Electric Co. Damcos and the Aaderupvej 41 Damcos logotype are trademarks of Damcos A/S, Rosemount and the Rosemount logotype DK-4700 Nadstved are registered trademarks of Rosemount Inc.

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