SPX Power Team MCS Series Operating Instructions Manual
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SPX Power Team MCS Series Operating Instructions Manual

SPX Power Team MCS Series Operating Instructions Manual

Motion control system
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SPX Hydraulic Technologies
5885 11th Street
Rockford, IL 61109-3699 USA
powerteam.com
MOTION CONTROL SYSTEM
WARNING
These operating instructions must be read and thoroughly understood for the
safe commissioning, operation, and maintenance of the Motion control system. The
following procedures must be performed by qualified, trained personnel who are
familiar with this equipment. While every attempt has been made to ensure clarity, the
intent of this document is to provide basic guidance and it is the responsibility of the
end user to review each application thoroughly for suitable usage. Users should utilize
sound engineering judgment prior to, and during, product operation. Failure to comply
may result in damage, injury, or death.
© 2014 SPX CORPORATION
Tech Services: +1 800 477 8326
Fax: +1 800 765 8326
Order Entry: +1 800 541 1418
Fax: +1 800 288 7031
1
Operating Instructions for:
Rev. 0 August 12, 2014
MCS Series
Form No. 1000773

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Summary of Contents for SPX Power Team MCS Series

  • Page 1 Users should utilize sound engineering judgment prior to, and during, product operation. Failure to comply may result in damage, injury, or death. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 2: Table Of Contents

    SETUP AND STARTUP ALARMS AND HOW TO RESET GENERAL MAINTENANCE 1. System Evaluation 2. Inspection 3. Periodic Cleaning 4. Hydraulic Fluid Level 5. Hose Connections 6. Storage TROUBLESHOOTING GUIDE SCHEMATICS Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 3: Declaration Of Conformity

    TABLE OF CONTENTS COMPONENT SPECIFIC DATA SHEETS ANNEX 1. SPX cylinder size and square centimeter (aera) table 2. Motion Control System Checklist 3. Declaration of Conformity POWER TEAM FACILITIES Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 4: Glossary

    Any type of movement or translocation of a heavy load by means of forces generated by hydraulic cylinders operated by and under the control of a PLC-based control system Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 5 Displacement sensor. Target Total movement of the load that shall be achieved simultaneously at lifting points under the control of the PLC unit. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 6: Description

    SPX® Power Team® Motion Control System. The PLC-controlled system includes a combination of digital actuation and digital control that provides significant advantages including time savings, repeatability, and extremely low inter- nal stress in the object being moved.
  • Page 7 • Controlled cylinder movement in both directions: advance and retract • Complete Motion Control System package consists of the following modules Controller Measuring System Pump Unit Valve System Electrics/Electronics Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 8: Safety Symbols And Definitions

    ISO 31000 and ISO/IEC 31010 in their ac- tual current version. Create a lifting log documenting the lifting job as per annex XX of this manual. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 9 IMPORTANT: All movements to be performed by the Motion Control System must be ordered and approved by the person responsible at the job site. SPX Power Team will assist in operating the Motion Control System, but cannot be responsible for static or strength calcula- tions of the structure or load to be moved.

  • Page 10: Pump

    Connections should be only secure and leak-free. Over-tightening can cause premature thread failure or high pressure fittings to split at pressures lower than their rated maximum operating pressure. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 11: Cylinder

    Do not use the locking collar on a threaded piston as a stop. The threads may shear resulting in loss of the load, Dammage to equipment and personal injury. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 12: Electric Control Unit

    Always use an anti-static wrist band connected to the ground-earth bar inside the electrical Control unit before performing any maintenance or repair work on those electronic components. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 13: General Overview

    NOTE: For the first test of lifting the platform, set the set point target at 25 mm. Before performing lift, manually measure the platform height at each active cylinder. Record the data for each cylinder. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 14 You will establish these through drop down menus as described before. • Touch the auto button on the home screen. The pump will turn on. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 15 1 or 2 inches at a time until it gently touches the load to be lifted. (SEE NOTES ON NEXT PAGE) Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 16: Cylinder Approach To Load

    • Reattach the cable and touch re-set button on home page to continue testing. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 17: Transportation

    Confirm that the covers are in place and should remain in place until unit is ready to use. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 18 Check and confirm that the following items are undamaged and in good condition: A. Pressure Gauges B. Electrical Plug Outlet C. HMI (Tough Screen) D. External Cabinet Vents E. Door Switch F. Displacement Sensor Connectors G. Hose Connection Quick Couplers Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 19: Operating Instructions

    MCS face plate. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 20: Cylinders

    As a general rule always protect the electrical control unit from environmental influences such as rain, dust, vibration , heat, the physical damage ,etc. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 21: Hydraulic Connections

    NOTE: After installing cylinders, hoses, sensors, and cables; have a second individual verify each hose and sensor cable connection for - 1) correct lift point and - 2) confirm connections are tight. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 22: Setup And Startup

    Open fill tube cover by turning counter-clockwise and fill reservoir with 40 Gallons filtered Power Team oil (part numbers 9616, 9636, 9637 9638) Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 23 To install the position sensor electrical cables, press down on the connector cover retaining bracket to remove the connector cover. This will allow you to connect the sensor cable to the connector. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 24 This helps protect the connector assembly from becoming disengaged by vibration, or pulls on the cable during MCS operation. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 25 • This section of the front panel shows completed installation of hoses and electrical cables. Begin to install the hoses and cables as outlined in the following steps. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 26 • NOTE: Avoid releasing the the sensor retractable wire and letting it freely snap back to his neutral position. this can cause dammage to the calibration and functionality of the displacement sensor. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 27 • If you still see the word “OFF” visible on the plug, the plug is NOT LATCHED and the POWER IS NOT CONNECTED! Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 28 Pull the wire clasp forward and out from under the latch point. You will now be able to lift the cover. Slowly raise the cover to its full open position. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 29 OFF position. • Turn Power Switch 1/4 turn clockwise to turn on electrical console the electrical switch will now be in the vertical position. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 30 During the opening sequence, you will see a blank BLUE screen which is normal. This will change and the HMI will soon switch over to the SPX page. • At this point, the MCS controller is running through its diagnostics. This may take up to a minute or more.
  • Page 31 • Emergency stop button activated • Push the black Reset button on the right hand side of the console followed by the Reset button on the touchscreen to cancel both alarms out. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 32 ON time. In the example above it shows 110 msec. Press enter and the value is placed in the program. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 33 This will enable you to select 4 points, 5 points, 6 points etc., up to 8 points of lift/lowering. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 34 20 mAmps is 500 mm. The maximum load that is permissible would be entered in kiloNewtons and the maximum pressure the system should see would be 700 bar. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 35 (LIFT POINTS) have been turned OFF. • Here you can see that Cylinders 1, 2, 3 and 4 are ON, while Cylinders 5, 6, 7, and 8 are OFF. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 36: Alarms And How To Reset

    RESET button to erase the alarm. If the alarm still exists, review maximum load variable for correct data. • Overload Hydraulic Pump Alarm (cont.) - the overload relay/breaker inside the Electrical Control unit may have “tripped”. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 37 Confirm that there is no visible leakage. If leaking, replace the hose. If not leaking, press the blue RESET button on the HOME page. If alarm still exists, contact SPX Hydraulic Technologies for assis- tance.

  • Page 38: General Maintenance

    Check the fluid level in the reservoir after each 10 hours of use. The fluid level should be level with the bottom of the fill hole when all cylinders are retracted and the unit is in the upright (vertical) position. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 39: Hose Connections

    If the MCS unit has been stored for an extended period of time, it must be thoroughly inspected before it is used. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 40: Troubleshooting Guide

    3. Check line voltage. 4. Circuit breaker tripped be- 4. Use an alternate circuit cause total amperage draw too with sufficient power high for existing circuit. supply 1. Defective motor controls. 1. Disconnect unit from Electric motor will not power supply; contact a shut off. Power Team Service Center. Electric motor stalls, 1. Low voltage 1. Refer to electric pump surges, overheats, or will instruction sheet not start under load. 1. Wired incorrectly. 1. Disconnect unit from Electrical overload power source; have protector keeps tripping. qualified electrician re- view motor and circuit wiring. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 41 Maintenance section. 7. Vacuum in reservoir. 7. Clean plugged vent in filler plug. 1. Fluid leakage. 1. Look for external leaks. If Pump builds pressure no fluid leakage is visible, the but cannot maintain problem is internal. Seal leak- pressure. ing pipe fittings with PTSC. 2. Leaking pressure switch 2. Replace pressure switch. seal. 1. Faulty pressure gauge. 1. Replace pressure gauge. Pump does not build to 2. Check for external 2. Seal faulty pipe fittings with full pressure. leakage. pipe sealant. 3. Check external pressure 3. Refer to Adjusting the regulator. Check relief valve Pressure Regulating Valve. setting. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 42 TROUBLESHOOTING GUIDE CONTINUED PROBLEM CAUSE SOLUTION 1. Air in system. 1. Check for leaks. Refer to Erratic action bleeding procedure. 2. Internal leakage in 2. Refer to manufacturer's attached components. information for attached component 3. Attached component 3. Refer to manufacturer's sticking or binding. information for attached component. 4. Malfunctioning valve. 4. Verify connections. Contact authorized Power Team Service Center. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 43: Schematics

    SCHEMATICS Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 44: Component Specific Data Sheets

    OUTPUT......0.9 l/min @ 700 bar Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 45: Annex

    ANNEX 1. SPX CYLINDER SIZE AND SQUARE CENTIMETER (AERA) TABLE CYL TONS CYL BORE IN INCHES SQUARE CM 1.125 6.413 1.688 14.429 2.000 20.268 2.563 33.273 3.750 71.256 4.500 102.609 5.125 133.091 2. MOTION CONTROL SYSTEM CHECKLIST 1. Safety Information: a.
  • Page 46 Speed at which to lower c. If settling occurs d. May need to manually lower at “what” point? 8. Disconnecting a. Electrical power b. Sensors c. Hydraulics 9. Re-Crating a. Reusable crate Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...
  • Page 47 ANNEX CONTINUED 3. DECLORATION OF CONFORMITY Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

  • Page 48: Power Team Facilities

    POWER TEAM FACILITIES California Proposition 65 Warning This product contains or may contain chemical(s) known to the state of California to cause cancer or other reproductive effects. Form No. 1000773 © 2014 SPX CORPORATION Rev. 0 August 12, 2014...

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