Bieri BKA Series Manuale utente
Installation and
Operating Instructions
High-Pressure Compact Power Unit of BKA Series
(Translation of the original operating instructions)
BA_BKA_000-00-Montageanleitung EN.doc 2
Contents
1Hazard classes ............................................................................................. 4
2Product Safety.............................................................................................. 5
3Intended use................................................................................................. 7
4Description of Functions............................................................................. 8
4.1 General................................................................................................................... 8
4.2 Pump ...................................................................................................................... 8
4.3 Pressure change-over valve (optional)................................................................ 9
4.4 Electric motor........................................................................................................9
4.5 Control valves .......................................................................................................9
4.6 Oil tank................................................................................................................... 9
4.7 Connections ..........................................................................................................10
5Installation and Connection...................................................................... 10
5.1 Installation preparation ........................................................................................ 11
5.2 Mechanical installation ........................................................................................ 11
5.3 Electrical connection............................................................................................ 16
5.3.1 Electrical connection for single-phase motor ..........................................16
5.3.2 Electrical connection for three-phase motor............................................ 18
5.3.3 Electrical connection of valves and control elements ............................. 19
5.4 Hydraulic Connection........................................................................................... 21
6Start-up ....................................................................................................... 23
6.1 Filling with hydraulic fluid ................................................................................... 23
6.2 Venting................................................................................................................... 24
6.3 Starting the power unit......................................................................................... 25
7Operation.................................................................................................... 25
8Maintenance and Servicing....................................................................... 26
8.1 Recommended hydraulic fluids ..........................................................................27
8.2 Operating and storage temperature range......................................................... 28
8.3 Changing the hydraulic fluid ............................................................................... 28
8.4 Cleaning and changing of suction filter ............................................................. 29
9Repairs........................................................................................................ 31
10 Troubleshooting......................................................................................... 32
11 Shutdown and Disposal ............................................................................ 32
ITechnical Data............................................................................................ 33
II Hydraulic Plan ............................................................................................ 34
III Shortlist of Recommended Running and Starting Capacitors............... 35
IV List of associated documents................................................................... 37
BA_BKA_000-00-Montageanleitung EN.doc 3
BA_BKA_000-00-Montageanleitung EN.doc 4
1 Hazard classes
There are two different categories of safety information. The table below shows the symbols
(pictograms) and signal words relating to concrete hazards and possible consequences.
Pictogram
Danger to
Signal
words
Definition
Consequences
persons
DANGER!
Imminent danger
Death or severe
injuries
WARNING!
Potentially
hazardous
situation
May cause death or
injuries
material CAUTION!
Risk of material
and ecological
damage
Damage of device,
environmental
damage, material
damage in the
vicinity
- NOTE
Tips and other
important useful
information and
advice
No damage to
persons,
environment
and device.
Wear helmet and face shield!
Wear protective gloves!
Wear safety boots!
Recycle properly!
Observe environmental protection!
Read and observe the operating instructions!
BA_BKA_000-00-Montageanleitung EN.doc 5
2 Product Safety
BIERI products are designed and made to ensure best performance and quality for the
LQWHQGHGXVH2SHUDWRU¶VVDIHW\LVSULPDU\ZKHQ it comes to product design. These
instructions shall also help to safely integrate and use BIERI products in systems. In addition
to these instructions observe and follow all general, statutory and other binding accident
prevention regulations. Installation and operation of the unit shall be reserved to personnel
adequately trained and familiar with safety issues. Otherwise there would be the risk of
injury. We strongly recommend studying these instructions prior to installation and use and
fully observe the same. We also recommend getting instructions in how to use the product by
a qualified instructor.
The safety information below should be included in the operating instructions of the
"complete machine":
All safety and hazards notes on
the device shall be kept
complete and legible.
Observe all safety and hazard
notes on the device and in these
instructions.
Immediately stop and secure the
device in the event of fault.
Eliminate the fault or have it
eliminated as quickly as
possible.
Check the device prior and after
use for any obvious defect or
damage.
Make no changes (add-ons or
conversions) of the "incomplete
machine"ZLWKRXW%,(5,¶V
approval.
Immediately report any change
(incl. operating characteristics)
to the responsible person. If
necessary, shut down and
secure the device immediately.
Make sure all coverings are in
place and proper condition.
Make sure no parts of the body
or items of clothing are caught
by movable parts of the device.
WARNING / CAUTION!
This unit is legally deemed an "incomplete machine". Prior to use it
needs to be complemented to become a "complete machine"or
incorporated in a "complete machine". All general, statutory, legal and
other binding accident prevention regulations and environmental
requirements shall be observed.
The responsibility for the machine will be passed on to those placing the
"complete machine"on the market.
Make sure that all mechanical, hydraulic and electrical components to be
connected are selected so that they fit the operating data of the high-
pressure unit.
BA_BKA_000-00-Montageanleitung EN.doc 6
Never make safety devices
inoperative.
Avoid anything that affects the
safety and/or stability of the
device.
Prior to connection/putting into
operation and during operation
make sure that no-one is put at
risk by the operation of the
device.
The maximum admissible
operating pressure set shall not
be changed.
When working in the vicinity of
live components and lines, take
suitable precautions to avoid
current transfers or high-voltage
flashovers to the device.
Maintain all intervals for
recurring tests and/or
inspections that are prescribed
or given in these instructions.
Take measures to prevent any
electrostatic charge and
potential sparking when using
this device.
Use no other than original BIERI
accessories and spare parts for
repairs.
Replace or have replaced all
defective electrical components
(e.g. charred cables) as quickly
as possible.
Defects of electrical components
may only be eliminated by a
trained electrician observing all
applicable national and
international safety directives
and regulations.
During operation, handling and
storage of the device it must be
made sure that the functions
and safety of it are not affected
by exposure to extreme external
temperatures or the device is
damaged. Keep in mind that the
device may heat up if in
constant use over a longer
period of time.
The device is filled with hydraulic
fluid. It may affect health if
swallowed or vapours are
inhaled. Avoid direct skin contact
for the same reason. Also keep
in mind that hydraulic fluid keep
may affect biological systems.
Provide for sufficient lighting
during operation.
Before you transport the device
make sure that the accessories
are safely accommodated to
avoid accidents.
BA_BKA_000-00-Montageanleitung EN.doc 7
Always keep the instructions on
hand at the place of work.
Provide for a proper disposal of
all parts removed, hydraulic fluid
residues and packing material.
In addition to this safety information observe and follow all general, statutory and other
binding national and international accident prevention regulations.
WARNING / CAUTION!
The device shall be used for no other than the purpose described in these instructions (see
chapter "Intended use"). Any other use or use beyond it shall not be considered intended
use. No liability will be accepted by the manufacturer/supplier for any resulting damage. The
risk shall be solely borne by the user. Intended use shall also include the observance of
these instructions and the compliance with the inspection and maintenance requirements.
3 Intended use
High-pressure compact power units by BIERI are specifically designed for equipment
operating on the principle of hydraulic cylinders. The allowable working pressure of the
equipment has to be adjusted to that of the high-pressure compact power unit. The latter
comes as an "incomplete machine" to be complemented to become a "complete machine" or
incorporated into such.
Accessories and spare parts are available from your authorised dealer.
WARNING / CAUTION!
Always observe the safety information of these instructions and the place of
installation and type of installation resp. Keep in mind that the devices may
not be operated in every atmosphere because of the potential risk of
explosion.
BA_BKA_000-00-Montageanleitung EN.doc 8
4 Description of Functions
4.1 General
Main componets (see example) of a BIERI high-pressure compact power unit:
Item
Component
Item
Component
1
Pump
10
Optional: oil tank fastening device
2
Pump flange
11
Suction unit
3
Pump lid
12
Return unit
4
Pressure-limiting valve
13
Filler neck
5
Optional: pressure change-over
valve (not upgradable)
14
Device connection
6
Electric motor
15
Test port
7
Control valve(s)
16
Oil drain and vent
8
Adapter plate (valve bank)
17
Optional: low pressure port
9
Oil tank
4.2 Pump
Every high-pressure compact power unit comes with a radial piston pump featuring one
or (optionally) two pressure stages. The hydraulic fluid is sucked by the pump straight
from the hydraulic oil tank and delivered to the discharge end of the pump. The
discharge rate remains largely constant over the entire range of working pressure.
The maximum pump pressure is limited by a pressure-limiting valve.
BA_BKA_000-00-Montageanleitung EN.doc 9
4.3 Pressure change-over valve (optional)
If specified and ordered, high-pressure compact power units are supplied with a two-
stage radial piston pump. The pressure change-over valve installed in such case only
switches, depending on the factory setting, automatically between the higher low-
pressure discharge rate and the lower high-pressure discharge rate when the current
effective working pressure exceeds or falls below the preset switching threshold.
Pumps orginally built for one pressure stage only cannot be retroffited with a pressure
change-over valve.
4.4 Electric motor
Depending on the specification or purchase order the high-pressure compact power
units are provided with motors of different design, supply voltage and/or frequency.
When it comes to the type of electrical connection, operating voltage supply and the
required amperage, also observe the the "Technical data" chapter, any separate order
specifications and additional information being part of the scope of supply (e.g. motor
datasheet or name plate). Make sure that no voltage fluctuations or drops occur during
operation because it would impact the output, operating characteristics and stability of
the high-pressure compact power unit. The direction of rotation is a function of the
electrical connection. As to that refer to chapter 5.3.
4.5 Control valves
One or multiple control valves can be installed via an interface at the pump flange. A
single control valve may be screwed onto the pump flange directly. Banks consisting of
multiple linked control valves can be mounted onto the pump flange by use of an
adapter plate.
4.6 Oil tank
The oil tank is of translucent plastic material as standard. Under normal visibility
conditions the oil level can thus be determined by visual inspection. The oil tank is
connected with the pump via a plug-in nipple at the suction opening. The hydraulic oil
flows back into the tank through a short hose. Pump and oil tank are mechanically
connected with each other by the oil tank fastening device.
DANGER / WARNING / CAUTION!
The pressures set at the pressure-limiting and pressure change-over
valves must not be changed (without express approval by BIERI) for
safety reasons.
BA_BKA_000-00-Montageanleitung EN.doc 10
4.7 Connections
Every high-pressure compact power unit is provided with a device connection and an
additional pressure measuring connector. For more details see chapter 5.4 and
Attachment I.
5 Installation and Connection
Make sure that components and the workplace are neat and clean before and during
installation because any contamination may damage the equipment.
WARNING / CAUTION!
Make sure that the power unit is protected from accidental restart
before and during installation.
Otherwise there would be a high risk of injury.
WARNING / CAUTION!
Prior to installation of the power unit make sure that all other operatively
interacting components are designed and built in accordance with the
max. performance data of the device (e.g. hydraulic pressure, forces
and speeds).
CAUTION!
Neither the pump lid nor the oil tank fastening device is designed for
vibration damping, constraining force absorption or correction of angle
errors. Such may occur under adverse installation conditions or
impact loads between the pump and the oil tank or on one of the two
components.
This fact must be taken into account when it comes to the set-up and
installation of the power unit into the receiving unit by suitable design
measures. Failing to do so may cause severe wear or damage to the
power unit.
WARNING / CAUTION!
It may be installed by persons adequately trained in safety equipment
under consideration of all applicable norms, regulations and laws.
Additional hazardous areas may occur by the installation. Provide for
adequate safety distances or coverings when installed. The installer is
responsible for proper installation and connection of the device. No
responsibility will be assumed by BIERI for any improper installation or
connection.
Indice
