Equipment FamiliarizationEquipment FamiliarizationExperiment 1-2Experiment 1-2

Amatrol 850 Basic Hydraulic Training SystemAmatrol 850 Basic Hydraulic Training System

Equipment FamiliarizationEquipment Familiarization

ObjectivesObjectives

1. Identify each of the components in the 850 basic hydraulics 1. Identify each of the components in the 850 basic hydraulics system.system.

2. Set up the 850 basic hydraulics system bench.2. Set up the 850 basic hydraulics system bench. (Satellite will not be (Satellite will not be used)used)3. Prepare the hydraulic power unit for use.3. Prepare the hydraulic power unit for use.

4. Operate a hydraulic power circuit.4. Operate a hydraulic power circuit.

5. Set up and operate a basic hydraulic circuit on the 850 trainer.5. Set up and operate a basic hydraulic circuit on the 850 trainer.

Equipment FamiliarizationEquipment Familiarization

The 850 system includes both Hydraulic as well as The 850 system includes both Hydraulic as well as Pneumatic training equipment with the majority of Pneumatic training equipment with the majority of focus given to the hydraulic trainer. The bench itself is focus given to the hydraulic trainer. The bench itself is mainly for storage, holding additional components, and mainly for storage, holding additional components, and to house the power unit. Earlier models located the to house the power unit. Earlier models located the power unit in a slightly different position. The modules power unit in a slightly different position. The modules may be moved where ever necessary and modules may may be moved where ever necessary and modules may even be used in pairs if needed. The benches roll but even be used in pairs if needed. The benches roll but have been locked in place for safety reasons.have been locked in place for safety reasons.

InventoryInventory

The loose components consist of Tee fittings, Male The loose components consist of Tee fittings, Male connectors, Friction shaft and Clamp, and a Load spring. connectors, Friction shaft and Clamp, and a Load spring. Although the loose components should be kept on the Although the loose components should be kept on the machines, they do tend to stray off and therefore may machines, they do tend to stray off and therefore may necessitate locating as they may be found in different necessitate locating as they may be found in different locations.locations.

Valve ModulesValve Modules

One of the most important features of the pneumatic valve module is One of the most important features of the pneumatic valve module is its transparent valve assemblies. Transparent components allow for its transparent valve assemblies. Transparent components allow for internal inspection without the need of disassembly. Another internal inspection without the need of disassembly. Another difference is that the pneumatic valve module includes the actuators difference is that the pneumatic valve module includes the actuators whereas the hydraulic module does not. The pneumatic module has whereas the hydraulic module does not. The pneumatic module has a directional control valve, 2 check valves, single acting cylinder, a a directional control valve, 2 check valves, single acting cylinder, a pair of cylinders, and a motor. The hydraulic module has one pair of cylinders, and a motor. The hydraulic module has one Directional Control Valve(DCV), a pair of check valves, a single Directional Control Valve(DCV), a pair of check valves, a single needle valve without a check, and a pair of pressure control valves.needle valve without a check, and a pair of pressure control valves.

Equipment FamiliarizationEquipment Familiarization

As can be seen from the illustration above, the primary As can be seen from the illustration above, the primary function of the bench is to serve as a storage facility for the function of the bench is to serve as a storage facility for the modules, provide a surface on which circuits may be modules, provide a surface on which circuits may be constructed, and to house the power unit.constructed, and to house the power unit.

Instrumentation ModulesInstrumentation Modules

The instrumentation modules are very similar but there exists some The instrumentation modules are very similar but there exists some differences worth noting. The pneumatic instrumentation module differences worth noting. The pneumatic instrumentation module has a pressure control valve whereas the hydraulic module does not. has a pressure control valve whereas the hydraulic module does not. Also, the pneumatic module has a second pressure measurement tool Also, the pneumatic module has a second pressure measurement tool used to observe very low pressures. Each of the modules uses a flow used to observe very low pressures. Each of the modules uses a flow meter, the pneumatic meter measure air flow in meter, the pneumatic meter measure air flow in standard cubic feet standard cubic feet of air per hourof air per hour(SCFH), and the hydraulic meter in (SCFH), and the hydraulic meter in gallons per gallons per minuteminute(GPM).(GPM).

Hydraulic Actuator ModuleHydraulic Actuator Module

The hydraulic actuator module has the same type of The hydraulic actuator module has the same type of cylinders as the pneumatic module does. It also has a pair of cylinders as the pneumatic module does. It also has a pair of flow control valves, with bypass checks, and a hydraulic flow control valves, with bypass checks, and a hydraulic motor which may or may not have a flywheel attached. Its motor which may or may not have a flywheel attached. Its important to remember that there may be some difficulty important to remember that there may be some difficulty encountered when attempting to install or remove the encountered when attempting to install or remove the flywheel. Under no circumstances should the flywheel be flywheel. Under no circumstances should the flywheel be forced on or off the shaft. Always consult the instructor if a forced on or off the shaft. Always consult the instructor if a problem is encountered.problem is encountered.

Loose ComponentsLoose Components

Each of the trainers was originally equipped with about eleven Each of the trainers was originally equipped with about eleven hoses, 3 Tee fittings, 2 Male connectors, a Flywheel for the motor, an hoses, 3 Tee fittings, 2 Male connectors, a Flywheel for the motor, an Extension piece for the friction shaft, a Friction shaft, a Clamping Extension piece for the friction shaft, a Friction shaft, a Clamping device for the friction shaft(not shown on page 7), and a Load device for the friction shaft(not shown on page 7), and a Load spring. There have been many additions to the loose components. If spring. There have been many additions to the loose components. If what you need is not located on your machine, check the drawers of what you need is not located on your machine, check the drawers of the other machines for the components.the other machines for the components.

Hydraulic Power Unit InspectionHydraulic Power Unit Inspection

The power unit supplied with the trainers were designed for The power unit supplied with the trainers were designed for intermittent use only. Before startup, make sure that the stop intermittent use only. Before startup, make sure that the stop button is in the OFF position, the oil level is above the RED line, the button is in the OFF position, the oil level is above the RED line, the Pressure is at minimum setting, and the power cord is unplugged. Pressure is at minimum setting, and the power cord is unplugged. Also, the yellow valve should be in the DOWN position. If the unit Also, the yellow valve should be in the DOWN position. If the unit fails any of these checks, report it to the instructor immediately. fails any of these checks, report it to the instructor immediately.

Refer to Video OneRefer to Video One

Hydraulic Power Unit InspectionHydraulic Power Unit Inspection

Always be certain that the power unit will not start the Always be certain that the power unit will not start the moment you plug in the power cord.moment you plug in the power cord.

Make sure the power is off.Make sure the power is off. Plug in cord after checking the Plug in cord after checking the controller.controller.

Startup and Shutdown ProceduresStartup and Shutdown ProceduresStartupStartup

ShutdownShutdown

1.1. Perform Inspection of power unit.Perform Inspection of power unit.

2.2. Assemble circuit.Assemble circuit.

3.3. Start power unit and adjust pressure to specifications.Start power unit and adjust pressure to specifications.

4.4. Open yellow valve.Open yellow valve.

5.5. Operate circuit and record readings.Operate circuit and record readings.

1.1. Reduce pressure to minimum.Reduce pressure to minimum.

2.2. Shut off power unit.Shut off power unit.

3.3. Cycle any DCV in the circuit.Cycle any DCV in the circuit.

4.4. Close the yellow valve.Close the yellow valve.

5.5. Disassemble circuit.Disassemble circuit.

6.6. Clean up machine, modules, hoses, and area.Clean up machine, modules, hoses, and area.

Power Unit Start UpPower Unit Start Up

Notice that on start up, even before the pressure is Notice that on start up, even before the pressure is adjusted, that some pressure develops on the pressure adjusted, that some pressure develops on the pressure gauge.gauge.

Connecting CircuitsConnecting Circuits

Connecting circuits is easy and very fast thanks to the Connecting circuits is easy and very fast thanks to the quick connect feature of the hoses. Although this is not quick connect feature of the hoses. Although this is not the industry standard, it suits our purpose well because the industry standard, it suits our purpose well because breaking fittings loose is time consuming and would take breaking fittings loose is time consuming and would take away from the overall lab experience. Connections away from the overall lab experience. Connections should never be made while the machine is running and should never be made while the machine is running and this is consistent with OHSA lock out-tag out. If this is consistent with OHSA lock out-tag out. If difficulty is encountered while attempting to make a difficulty is encountered while attempting to make a connection, make sure that the machine is off and that connection, make sure that the machine is off and that the lines are not under pressure. Any oil spills should be the lines are not under pressure. Any oil spills should be cleaned up immediately. cleaned up immediately.

Connecting CircuitsConnecting Circuits

You will notice that a little oil leaks out of the You will notice that a little oil leaks out of the connectors every time they are disconnected and connectors every time they are disconnected and this is normal. This minor leakagethis is normal. This minor leakage

Basic Circuit DemonstrationBasic Circuit Demonstration

This video is a demonstration on the setup of a basic circuit This video is a demonstration on the setup of a basic circuit that uses a double acting cylinder.that uses a double acting cylinder.

General SafetyGeneral Safety

1.1. Observe all safety precautions.Observe all safety precautions.

2.2. Be conscience of where your hands are at all times.Be conscience of where your hands are at all times.

3.3. Always wear safety glasses in the lab.Always wear safety glasses in the lab.

4.4. Read all instructions before you attempt to work on the Read all instructions before you attempt to work on the equipment.equipment.

5.5. Respect pressurized fluids as you would any energy form.Respect pressurized fluids as you would any energy form.

6.6. Keep an eye on the people around you.Keep an eye on the people around you.

ReviewReview1. Which piece of the training equipment is for storage?1. Which piece of the training equipment is for storage?

2. What is the safe maximum operating pressure of the 850 trainer?2. What is the safe maximum operating pressure of the 850 trainer?

3. Explain the startup and shutdown procedures.3. Explain the startup and shutdown procedures.

4. What does it mean if a connection cannot be made?4. What does it mean if a connection cannot be made?5. How should you find the power cord prior to start up?5. How should you find the power cord prior to start up?

6. What must be done at the end of lab each day, immediately 6. What must be done at the end of lab each day, immediately following the last experiment?following the last experiment?7. Describe the setting of the pressure control valve on startup.7. Describe the setting of the pressure control valve on startup.8. Are the power units on the 850 trainer designed for continuous 8. Are the power units on the 850 trainer designed for continuous duty?duty?9. Why doesn’t oil pour out of the hoses when they are disconnected?9. Why doesn’t oil pour out of the hoses when they are disconnected?

10. How is pressure determined at the power unit?10. How is pressure determined at the power unit?