No.

1400-0267-4
Framo Date/sign.: 28Aug2000/TS
Rev. C: 10Dec2001
Pressure Control System

Adjustment Procedure A4V DP

CONTENTS
A. Application / General

B. Basic adjustment of pumps

C. System adjustment at Framo test stand

D. Commissioning

E. Adjustment and testing after service /

Replacement of pump
 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 2 of 8
Rev. C: 10Dec2001/TS

A. APPLICATION / GENERAL.

This procedure is valid for testing and adjustment of all A4V powerpacks with pressure
control block acc. to dwg 0125-0609-3, or 0125-0677-3.

For basic pump adjustment of pumps (min. and max. displacement, min. pressure), refer
to part B. Brueninghaus Hydromatic normally do this adjustment.

For adjustment at Framo test stand (system pressure, relief valve setting, parallelism),
refer to part C.

For system commissioning (no adjustment, only system check), refer to part D.

For adjustment after service or replacement of pump, refer to part E.

All adjustments to be done at oil temperature 40-50C, (Viscosity 30-60 cSt).

Most systems are delivered with a system pressure regulator. Based on feedback from
system pressure transmitter, system pressure is regulated by the PLC, according to a
given command signal, and is independent from pump angle. All adjustments must be
done with system in override mode 1 (system pressure regulator overridden).

B. BASIC ADJUSTMENT OF PUMPS.

B1 Adjust minimum displacement until minimum pressure is 35 +/-5 bar. Adjustment to be

done with pump outlet closed. If pump is adjusted after installation in Framo powerpack,
keep outlet closed by running another pump at system pressure 100 bar, and open
unloading valve for the pump to be adjusted.

B2 Adjust minimum pressure with pressure balance valve, to 55 +/-1 bar. Adjustment of
minimum pressure to be done with 0.8 orifice in pilot line, according standard Framo
system.

B3 Adjust maximum displacement/flow at specified differential pressure according pump

specification for actual pump (0 - +1%). If flow is too low for one or more pumps in a
series of pumps for one order, total flow Q1+Q2 must not be below n x QSPECIFIED.

B4 Adjust pump ramp by DP valve (change in PP from min. to max. displacement), to 7 +/-1
bars.

B5 Min flow to max flow speed adjustment:

5.1 Run one power pack and set the system pressure (Ps) to 100 bar and swivel angle to
approx. 5.

5.2 Turn swash plate speed adjustment screw CW until pump swivels back to min. flow and
then carefully turn the adjustment screw CCW until the pump swivels back to 5 swivel
angle.

5.3 Now adjustment screw to be turned CCW turn. Pump swivelling time from min to max
should be between 0.5 and 1 second. If swash plate speed becomes too high, turn
carefully CW, maximum 1/8 turn. Check maximum capacity. If maximum capacity has
been reduced, turn carefully CCW, maximum 1/8 turn.
 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 3 of 8
Rev. C: 10Dec2001/TS

5.4 After adjustment, lock with the counter nut.

Figure 1:Details for swash plate speed adjustment

C. SYSTEM ADJUSTMENT AT FRAMO TEST STAND.

C1 Start power packs according standard Framo powerpack test procedure, 0074-0067-4.

C2 Back-up relief valve setting:

2.1 Open system pressure relief valve, and close system pressure control valve and back-up
valve (isolating valve always open, and manual pressure control valve always to be
closed)

2.2 Adjust system pressure relief valve to Ps + 25 bar. Ref. fig. 5. Then adjust back-up valve
until valve opens. The valve opens when drain flow increases. Drain flow is checked by
open 3-way valve in drain line from the valve. (Closed valve 0-0,5 l/min., open valve
approx. 3 l/min.).

C3 System pressure relief valve setting:

With no consumers running, set system pressure relief valve to system pressure + 20
bar.

Figur 2:Pump adjustments. Shown for pump with CW rotation.

 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 4 of 8
Rev. C: 10Dec2001/TS

Figure 3: Principle system hydraulic diagram.

 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 5 of 8
Rev. C: 10Dec2001/TS

Figure 4: System pressure control block (Shown for block acc. to dwg. 0125-0677-3).

C4 System pressure control valve setting and parallelism adjustment. Ref. fig. 5:

4.1 Run the powerpack with shortest HP piping.

4.2 Turn potmeter to minimum and adjust minimum current for the system pressure control
valve according to pt. 5.3.

4.3 Turn potmeter to maximum and start consumers until Q is 93-97% of Qmax. Adjust
maximum current until system pressure (Ps) equals specified Ps +4 bar. Increase
consumers until Q equals specified QMAX. If PS is lower than specified PS at this point,
increase maximum current.

4.4 Check required power at specified Q / PS.

4.5 Run another powerpack separately. Turn potmeter to maximum and start consumers
until Q is 93-97% of Qmax. If necessary, adjust pressure balance valve until Ps equals
specified Ps+4 bar. . Increase consumers until Q equals specified QMAX. If PS is lower
than specified PS at this point, increase pressure at pressure balance valve.

4.6 Check power according 4.4.

4.6 Repeat 4.5 and 4.6 for all powerpacks.

Figur 5:Pressure-flow diagram.

 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 6 of 8
Rev. C: 10Dec2001/TS

C5 System pressure control valve, electrical adjustment:

5.1 When adjusting the valve driver, take the following into account:

- Adjustment to be done with one power unit running.

- Adjustment to be done with working temperature (40-50C).
- When altering I maximum setting, I minimum will be affected, and vice versa.
- Amplifier card frequency shall be set to 85 Hz (see fig 9).

5.2 Connect an ampere-meter in series with the system pressure control valve, and a
voltmeter across output terminals to pressure control valve.

5.3 Supply 0% request (pressure set potmeter in minimum position) to the valve driver. With
no consumers running, adjust minimum current until Ps is 70 bar. Note: After parallelism
adjustment acc. pt 4, minimum system pressure may vary, depending on which pump is
running. Note also that minimum pressure will increase when running more than one
pump at minimum pressure.

5.4 Adjust maximum pressure (PS) by adjusting maximum current.

5.5 Adjust the ramp times up/down to 20 seconds. Ramp up = time delay between a sudden
change from 0% - 100% request and achievement of max. pressure. Ramp down = time
delay between a sudden change from 100% - 0% request and achievement of the
minimum system pressure (governed by pump regulator). Ramp time is for closed loop
systems controlled by the PLC. If so, ramp time on control card functions only as a back
up ram if the PLC fails, and shall be adjusted to 15 s.

Figure 6: Typical electrical

connection. Ref. Framo wiring
diagram.

Figur 7:Typical current / pressure

relation for proportional valve.
Values for guidance only.
 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 7 of 8
Rev. C: 10Dec2001/TS

Figur 8:Fluid Team driver card, type ESC2000 (old type).

Ramp

Imin

Imax

Figur 9: Fluid Team control card ESC704 (new type)

Ramp

Switch to choose amplifier

card frequency

Imin

Imax

5.6 Sealing of adjustment pot-meters: After system is completely adjusted, pot-meters on

driver card shall be sealed.

C6 Checking system capacity and stability

6.1 Run two powerpacks together. Adjust the system pressure by means of the potmeter
from minimum to maximum and from maximum to minimum and check the stability of the
system.

6.2 Adjust the system pressure to maximum and start and stop consumers. Check the
stability of the system. Check and note system pressure at maximum oil flow.

6.3 Backup valve might be leaking even with very small drain oil (ref. pt. 5.2). At maximum
system pressure, check that back up valve is closed, by checking temperature on back
up valve return line.

D COMMISSIONING.

All necessary adjustment has been done at Brueninghaus and Framo test stand. The
only necessary adjustment is readjusting back-up relief valve after flushing / first system
start-up.

D1 Adjustment of back-up relief valve.

1.1 Start one powerpack and close back-up relief valve completely. Set system pressure
command to maximum, and then close isolating valve. Increase system pressure to Ps +
25 bar by using system pressure relief valve. Adjust back-up relief valve according pt. C
2, and then adjust system pressure relief valve according to pt. C 3.

1.2 Open isolating valve and check system according to C 6.

 No. 1400-0267-4
ADJUSTMENT PROCEDURE FOR A4V DP Date/sign.: 28.08.00/TS
PRESSURE CONTROL SYSTEM Distr.: External
Page: 8 of 8
Rev. C: 10Dec2001/TS

D2 Check system pressure at minimum displacement, maximum command, for each pump.
Should normally be PS + 15 bar, but may vary +/-3 bar because of parallelism adjustment.
This check must be done with system in override mode 1 (system pressure regulator
overridden).

D3 Parallelism adjustment: No adjustment is normally necessary. Pumps are adjusted to

run parallel at 95% capacity. Because of individual differences in pressure/displacement
characteristic, pumps will have a difference in pump angle even though correctly adjusted
(optimised at maximum capacity).

Figur 10: Pump parallelism.

A difference in pump angle as shown above is possible and acceptable as long as all
pumps give maximum capacity at specified system pressure.

E Adjustment and testing after service/replacement of pump.

E1 Check / adjust minimum displacement for this pump according to pt. B 1.

E2 Check / adjust minimum pressure for this pump according to pt. B 2.

E3 Run serviced pump together with another pump, and start consumers until both pumps
are running between 10 and 15. Adjust pressure balance valve on serviced pump, until
pumps are running at the same angle.