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This 'Original instructions' document assumes that the operator carrying out any operation with this
product is trained and competent to do so. This manual does not attempt to cover all details or variations
in the equipment. Nor does this manual claim to provide for every possible contingency met in connection
with the installation, operation, or maintenance thereof. Should further information be desired, or should
a particular problem arise which is not covered in sufficient detail, the matter should be referred to
Hi-Force.
OPERATING INSTRUCTION MANUAL
SLV SERIES | SYNCHRONOUS LIFTING SYSTEM
The Hi-Force SLV Synchronous Lifting System with Variable Speed Drive is designed for precise lifting and
lowering of heavy loads, using multiple synchronised hydraulic cylinders. The system can maintain a
tolerance across all cylinders of as low as 1mm. Available as standard with up to 32 outlet ports for
single-acting or double-acting cylinders and a variable speed motor for better operational speed control. In
high-pressure mode, the pump delivers 4.8 lpm of hydraulic oil at a maximum operating pressure of
700 bar (10,000 psi). This manual applies to the Hi-Force SLV Synchronous Lifting System with Variable
Speed Drive. It contains the latest product information available at the time of publication and approval. For
information relating to the servicing of a synchronous lifting system pump, see the servicing instructions,
which are available on the Hi-Force website. Hi-Force reserves the right to make changes to this document
at any time without notice.
Operating Instruction Manual:
OM-SLV-01
- VARIABLE SPEED DRIVE
1
Serial Numbers:
All
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Summary of Contents for Hi-Force OM-SLV-01 Series
- Page 1 Speed Drive. It contains the latest product information available at the time of publication and approval. For information relating to the servicing of a synchronous lifting system pump, see the servicing instructions, which are available on the Hi-Force website. Hi-Force reserves the right to make changes to this document at any time without notice.
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Page 2: Table Of Contents
Operating Instruction Manual: Serial Numbers: OM-SLV-01 Table of Contents 1.0 Inspection upon Receipt ................4 2.0 Safety Precautions ..................4 2.1 Introduction ............................4 2.2 Work Area Safety ..........................4 2.3 Electrical Safety Precautions ......................4 2.4 General Hydraulic System Safety Precautions ................5 2.5 Synchronous Lifting System Specific Safety Precautions ............ - Page 3 Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.9 Automatic Lifting ..........................28 6.10 Automatic Lowering ........................29 6.11 Releasing Hydraulic Pressure from the System ................. 30 6.12 Throttle Flow Control Valves ......................31 6.13 Centre of Gravity ........................... 32 6.14 Data Logging ..........................34 7.0 Error Reporting .....................
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Page 4: Inspection Upon Receipt
If in doubt on the correct use of any Hi-Force equipment, contact your nearest Hi-Force office or distributor. Only qualified personnel should be allowed to operate hydraulic equipment. If an operator has not been trained on high-pressure hydraulic equipment and its safe usage, consult your local Hi-Force sales office or distributor who can offer training courses for operators. -
Page 5: General Hydraulic System Safety Precautions
Operating Instruction Manual: Serial Numbers: OM-SLV-01 2.4 General Hydraulic System Safety Precautions Failure to observe and obey the following safety precautions could result in property damage, significant personal injury or death; • When operating any hydraulic equipment, all operators should ensure that all necessary personal protective equipment (PPE) is worn, as specified by their employer. - Page 6 NEVER attempt to solve, or clean-up leaks in the system while the system is pressurised. • Immediately replace any worn or damaged parts using genuine Hi-Force parts only. • DO NOT use any hydraulic equipment if you are under the influence of alcohol, drugs or medication.
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Page 7: Synchronous Lifting System Specific Safety Precautions
700 BAR (10,000 PSI). Overloading hydraulic pumps can result in component failure and possible serious personal injury. • DO NOT connect hydraulic equipment with a lower pressure capacity rating to any Hi-Force Pump of this model series. •... -
Page 8: Declaration Of Incorporation / Conformity
3.0 Declaration of Incorporation / Conformity Hi-Force declares that this product has been tested and complies with the standards set out in the relevant EU directives. The EU Declaration of Incorporation / Conformity is included as Annex A to this... -
Page 9: Component Identification
Operating Instruction Manual: Serial Numbers: OM-SLV-01 4.0 Component Identification 4.1 SLV Pump Unit Hydraulic Oil Drain Plug Hydraulic Oil Level Gauge Hydraulic Control Manifold Electrical Control Box Motor Hydraulic Outlet Couplings Oil Filler Breather Cap Pressure Relief Valve ‘Return Line Filter’ Pressure Gauge Oil Reservoir Can be configured for single-acting or double-acting cylinders. -
Page 10: Control Unit
Operating Instruction Manual: Serial Numbers: OM-SLV-01 4.2 Control Unit Control Unit Control / Settings Screen Emergency Stop Jack / Cylinder Screens Data Logging “Upload” Port Motor ‘Start’ Operate ‘Start’ Motor ‘Stop’ Operate ‘Stop’ Motor Variable Speed Control Quantity and Layout dependant on no. of outlet ports. Figure 4.2: Component Identification - Control Unit... -
Page 11: Cylinder And Displacement Sensor
Operating Instruction Manual: Serial Numbers: OM-SLV-01 4.3 Cylinder and Displacement Sensor Cylinder Body Mounting Kit - Base Plate Female Coupler Displacement Sensor Lifting Eye Over-Stroke Port Mounting Kit - Cylinder Saddle Advance Coupler Mounting Kit - Cylinder Saddle Bar Retract Coupler Mounting Kit - Band Pressure Relief Valve NOTE: For cylinder specific component identification, see cylinder’s instructions manual. -
Page 12: Installation / Setup
Operating Instruction Manual: Serial Numbers: OM-SLV-01 5.0 Installation / Setup IMPORTANT: Images used through-out this manual are for illustrative purposes ONLY. Images may display a different system configuration and different tools or accessories to those being used. Additionally, some details may have been removed for clarity purposes. 5.1 Before First Use 1. -
Page 13: Hydraulic Connections
1. Fit the correct, complete (SLMK - * ) sensor mounting kit to each cylinder in the system. A detailed table of cylinders and their applicable sensor mounting kits can be found on the Hi-Force website or in the latest Hi-Force Catalogue. - Page 14 Figure 5.3: Mounting Kit Saddle Bar Installation & approx. Base Plate Position 2. With cylinders setup in their correct operating positions, use Hi-Force HC*C type hoses to make hydraulic connections between the cylinders and the pump (See section 5.3). The SLV outlet ports are labelled V1 → V#. The outlet port number is important, as it is how each cylinder will be identified by the control unit (E.g.
- Page 15 Operating Instruction Manual: Serial Numbers: OM-SLV-01 4. Use sensor signal cables to connect each displacement sensor to the corresponding port on the electrical control box. (See figure 5.4) To connect each cable, line up the keyways on the male and female connector/s for correct orientation and press together.
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Page 16: Electrical Connection
415V 32A cable ‘end socket’ provided. (See figure 5.7) NOTE: Supply voltages vary from country to country. Hi-Force pumps will operate within the normal voltage tolerance ranges. But in extreme cases where they are operated for long periods at high pressures and in low voltage conditions, the motor may overheat and shut down. -
Page 17: Bleeding Trapped Air From The System
Operating Instruction Manual: Serial Numbers: OM-SLV-01 5.6 Bleeding Trapped Air from the System Hydraulic cylinders and hoses are not always completely filled with oil when new. For safe and efficient operation, the air must be removed (bled) from the system. Single-Acting Cylinders It is not usually necessary to bleed air from single-acting cylinders. -
Page 18: Operation
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.0 Operation 6.1 Control Unit - Screen Layouts and Button / Panel Functions 6.1.1 Settings Screen... - Page 19 Operating Instruction Manual: Serial Numbers: OM-SLV-01 Settings Screen - Button / Pane Functions Image Description Applicable to: Type Range Jack Name Individual Jack 9 Character Button (Press to change) Setting input Press to set the Individual Jack 0 - 99999mm X-coordinate of the jack.
- Page 20 Operating Instruction Manual: Serial Numbers: OM-SLV-01 Settings Screen - Button / Pane Functions (continued…) Image Description Applicable to: Type Range Allows operator to select Global System Selector which units individual jack Setting Pane loads are displayed in. Allows operator to select Global Selector which units total system...
- Page 21 Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.1.2 Control Screen Control Screen - Button / Pane Functions Image Description Type Allows the operator to select how the displacement figures Selector are displayed on the jack screens. Pane Displays the extension pressure in the system. Display Displays the retraction pressure in the system.
- Page 22 Operating Instruction Manual: Serial Numbers: OM-SLV-01 Control Screen - Button/Pane Functions (continued…) Image Description Type Displays the remaining lifting / lowering distance. (Displayed above ‘Centre of Gravity X’, only when Display ‘Automatic Lift’ or ‘Automatic Lower’ mode selected) Displays the set preload target. (Displayed above ‘Centre of Gravity X’, only when Display ‘Automatic Preload’...
- Page 23 Automatic: May flick on and off as the solenoids work to maintain tolerance. Indicates a displacement sensor error. Jack Error (Red) (See sections 5.5 & 11.0 for trouble shooting) Indicates a pressure sensor error. Jack Error (Contact your local Hi-Force sales office or (Red) distributor for advice)
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Page 24: Jack Settings
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.2 Jack Settings There are 3 individual and 2 global jack settings / values that can be input / changed via the Settings Screen. The process for entering / changing each value is the same, and is as follows: 1. -
Page 25: Calculation Of The Jack Force At Max Pressure (Kn) & Max Jack Load Values
Load / Force (kN) = Maximum Ton of Cylinder x 8.90 To calculate a Hi-Force Cylinders load / force (kN) at Maximum Pressure (bar). Multiply the chosen cylinders maximum capacity in tonnes (I.e. at 700bar) by 9.81 (Round the result to the nearest whole number). -
Page 26: Displacement Sensors
The SLDS650 sensors supplied by Hi-Force have a full stroke length of 635mm. If a sensor with a different stroke length is used, the software will need to be updated to reflect this. Contact your local Hi-Force office / distributor for further details. -
Page 27: Automatic Preloading
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.8 Automatic Preloading This mode is selected in order to extend the jacks until they ‘just’ make contact with the object to be lifted / lowered. The preload value must be set in settings screen on the control panel unit before this operation is started. -
Page 28: Automatic Lifting
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.9 Automatic Lifting This mode is selected to lift a load, a specified distance in a synchronised fashion. The ‘Lift Target’ and synchronised ‘Tolerance’ must be set in the settings screen, and the displacement sensor/s should be zeroed before this operation is started. -
Page 29: Automatic Lowering
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.10 Automatic Lowering This mode is selected to lower a load, a specified distance in a synchronised fashion. The ‘Lower Target’ and synchronised ‘Tolerance’ must be set in the settings screen, and displacement sensor/s should be zeroed before the operation is started. -
Page 30: Releasing Hydraulic Pressure From The System
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.11 Releasing Hydraulic Pressure from the System After retracting the cylinders, there may be pressure trapped in the retract line of the system. This pressure is trapped behind the manifold/s and will be displayed under ‘Retract Pressure’ on the control screen. NOTE: This pressure does not extend past the manifold and will not inhibit hydraulic disconnections as long as the ‘Extend Pressure’... -
Page 31: Throttle Flow Control Valves
29.5 open 29.5 Hi-Force highly recommends that the flow control valves be left at their factory pre-set value. The factory setting has been optimised for use with the Hi-Force lifting cylinder ranges. Risk of injury due to unexpected operation movement speed in the system, due to incorrect flow settings! Be prepared for unexpected, fast movement, if flow settings are changed. -
Page 32: Centre Of Gravity
Operating Instruction Manual: Serial Numbers: OM-SLV-01 6.13 Centre of Gravity The centre of gravity function allows constant monitoring of the full load, performing calculations, measurements (in millimetres) and displaying the centre of gravity (COG) point in relation to the position of the jacks / cylinders. - Page 33 Operating Instruction Manual: Serial Numbers: OM-SLV-01 Jack /Cylinder 2 Jack /Cylinder 3 (0; 50,000) (50,000; 50,000) Centre of Gravity Position (25,000; 25,000) Jack /Cylinder 1 Jack /Cylinder 4 (0; 0) (50,000; 0) 1m = 1000mm Example of cylinder positioning with X and Y input measurements: X and Y Input values for each jack / cylinder: Jack / Cylinder 1 Input reading X = 0...
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Page 34: Data Logging
Type-B output connection in the top left corner. The control unit does not need to be connected to a power source to retrieve the collected data. Hi-Force ‘data translation’ software is included, on the provided Hi-Force memory stick. Data is converted from a text file into an Excel compatible CSV file, using the Hi-Force conversion software. -
Page 35: Error Reporting
Operating Instruction Manual: Serial Numbers: OM-SLV-01 7.0 Error Reporting Comms Lost Communication between the control unit and the electrical control box has been lost. • Check that the cable is connected properly at both ends, and check the cable for damage. Fault - System Stopped / Inoperable (Control Screen) A fault has occurred which requires attention before the system can be... -
Page 36: Maintenance And Storage
Operating Instruction Manual: Serial Numbers: OM-SLV-01 8.0 Maintenance and Storage IMPORTANT: Isolate the pump from the electrical supply when carrying out maintenance or adjustments. • Monitor the oil level in the oil reservoir and do not allow the oil level to fall below the minimum level marked by the lower indicator (item 6. - Page 37 Inspect the frame periodically for paint damage. Clean and touch up any exposed surfaces to prevent corrosion. • Have the pump serviced regularly by a Hi-Force authorised repair centre. • Inspect hoses regularly for damage and wear. DO NOT use hoses that are frayed, abraded or...
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Page 38: Specifications
Operating Instruction Manual: Serial Numbers: OM-SLV-01 9.0 Specifications Refer to the nameplate on the pump for model identification. Displacement Changeover Model Number of (litres per minute) Pressure Capacity Motor Voltage Number Outlets Low Pressure High Pressure (bar) (litres) SLV82 380 / 440V-3Ph 19.6 SLV122 380 / 440V-3Ph... -
Page 39: Accessories
Operating Instruction Manual: Serial Numbers: OM-SLV-01 10.0 Accessories (Refer to the Hi-force website or latest Hi-Force catalogue for further details) • HSS, HHS, HFL, HFG, HAS, HHA, HFA, HGG & HSG Single-Acting Cylinders. • HHR, HDA & HRA Double-Acting Cylinders •... -
Page 40: Troubleshooting
Operating Instruction Manual: Serial Numbers: OM-SLV-01 11.0 Troubleshooting Hi-Force SLV synchronous lifting system should be serviced and repaired only by authorised Hi-Force repair centres. The following table gives possible causes and solutions for common problems. TROUBLESHOOTING GUIDE Problem Possible Cause Solution 1. - Page 41 Operating Instruction Manual: Serial Numbers: OM-SLV-01 TROUBLESHOOTING GUIDE (continued…) Problem Possible Cause Solution 6. Displacement sensor a. Displacement sensor signal i. Check sensor signal cable/s for proper not being picked up by cable fault. connection. control unit. (under ii. Check signal cable for damage. Replace if range) required.
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Page 42: Contact Details
Operating Instruction Manual: Serial Numbers: OM-SLV-01 UK Head Office: Hi-Force Limited Prospect Way, Daventry, Northamptonshire NN11 8PL United Kingdom Tel: + 44 1327 301000 Fax: + 44 1327 706555 Email: daventry@hi-force.com... - Page 43 Baku Milano Azerbaijan Italy Tel: +994 124 474 100 Tel: +39 0257 607 174 Email: baku@hi-force.com Email: italy@hi-force.com Hi-Force Hydraulics (Asia) S.B. Hi-Force Nederland B.V. Selangor Numansdorp Malaysia Netherlands Tel: +603 5525 4203 Tel: +31 85 902 8111 Email: malaysia@hi-force.com Email: holland@hi-force.com...
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