test procedure to evaluate fluids in open loop axial...

Test Procedure to Evaluate Fluids inOpen Loop Axial Piston PumpsTechnical Data V-PUPI-TS022-E Pump Model

PVH57C-RF-2S-11-C25V-31

This test procedure is to evaluate fluids for use inopen loop axial piston pumps. It consists of 250 hoursof actual test time (not including break-in or per-formance running).The operation temperature isdependent upon the capability of the test fluid asspecified by the fluid manufacturer or the ratedtemperature specified for the pump, whichever islower. Inlet fluid temperature must be maintained perfluid/pump rating throughout the complete test.

The pump to be used is a PVH57 with a pressurecompensator and load sensing control, model codePVH57C-RF-2S-11-C25V-31.

Table of Contents

Fluid Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Pump Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pump Performance Check Procedure . . . . . . . . . . . . . . . . . . . . . . . 3

Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Test Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Fifty-Hour Pressure Cutoff Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Two Hundred-Hour Cyclic Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Final Fluid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fluid Pass/Fail Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Appendix A - Efficiency Formulas. . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Appendix B - Control Pressure Hysteresis Test . . . . . . . . . . . . . . . . 10

Pump Performance Check Record . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fluid Properties Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Piston/Bore Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

™™

2EATON CORPORATION Fluid Power Test Procedure to Evaluate Fluids in Piston Pumps Technical Data V-PUPI-TS022-E March 2009

Installation

Fluid Ratings For standard anti-wearpetroleum base fluids, thePVH57 pump has the followingratings:• Rated Speed: 2400 rpm• Rated Pressure: 250 bar (3625

psig)• Rated Temperature: 95°C

(203°F)• Inlet Pressure: Atmospheric

Pressure 1 bar absolute (0psig)

For performance testing, thePVH57 is to be tested at theratings listed in Table 1.

Install pump into test circuit perFigure 1. Fill the pump case withpre-filtered anti-wear petroleum-based hydraulic fluid.

Table 1 – PerformanceTesting RatingsRATED SPEED RATED PRESSURE RATEDTEMP

FLUID MAX RPM MAX BAR (PSIG) MAX °C (°F)

Water Glycol 1800 170 (2465) 50 (122)Invert Emulsion 1500 155 (2247) 50 (122)90-10 HWBF 1500 155 (2247) 50 (122)Polyolester 1800 230 (3335) 65 (149)Phosphate Ester 1800 230 (3335) 65 (149)EnvironmentallyFriendlyVegetable Base 1800 250 (3625) 65 (149)EnvironmentallyFriendlySynthetic Base 2400 250 (3625) 95 (203)

Figure 1

Component #1 Vented reservoir (approx 102 gallons)2 Heater3 Strainer (optional)4 Thermometer5 2" gate valve6 Thermometer7 Inlet pressure transducer 100 psia8 PVH57C-RF-2S-1*-C25V-31 Pump9 Variable speed drive

10 Cooler11 Flow meter12 Return filter - 3 micron absolute full flow.

Typical model: filter #OFR60SM11, element#V4051B3C05 (use 10µm absolute for invertemulsion)

13 Outlet pressure transducer 5000 psig14 Pilot operated relief valve15 Typical model: DG4V-3S-22A-M-FW-B5-60 (02-

109636)16 Typical model: DG4V-3S-2B-M-FW-B5-60 (02-

109572)17 Remote relief valve18 Case pressure transducer 500 psig19 Flow meter20 Torque transducer21 Load sensing line transducer 5000 psig22 Variable orifice throttle valve (in parallel with

relief valve 14)Note: Case line should be a separate line with theshortest route to the return side of the reservoirand return below the oil level.

Orifice (preferably in DG Valve 15 Body) tolimit L.S. decay rate of 6.9 to 10.3 kbar/sec(100,000 to 150,000 psi/sec)


Pump Break-In

Pump PerformanceCheck

Table 2 – Pump Break-In ProcedureOUTLET PRESS

DURATION SPEED BAR (PSIG) INLET OILTEMPSTEP MIN RPM ±20 ±5 (72.5) °C ±5 (°F ±9)

1 5 600 50 (725) Ambient increase2 5 1200 50 (725) to3 10 1200 100 (1450)4 10 1200 150 (2175)5 10 1800 150 (2175)6 10 1800 200 (2900)7 10 2400 220 (3190) 95 (203)

Pump Break-In

Break in the pump using anti-wear petroleum base hydraulicfluid that complies with VickersOil Recommendation Data SheetM-2950-S. Run the break-inprocedure step-by-step as listedin Table 2. Inlet is to be atatmospheric. No external leak-age is allowed during the entiretest.

Overall Efficiency Percentage

Continue running the pump atfull stroke displacement usingthe parameters in Table 2, Step7 to determine its overallefficiency.

The outlet flow must bebetween 121 lpm (32 gpm) and140 lpm (37 gpm).

If not, STOP THE TEST ANDCONTACT YOUR EATONREPRESENTATIVE.

Record the output flow, inputtorque, and case flow. Computethe overall efficiency using theformulas in Appendix A.

If the overall efficiency is lessthan 85%, continue running thepump (20 hours maximum)using the parameters in Table 2,Step 7 and re-check overallefficiency using the formulas inAppendix A.

If the overall efficiency is not85% or greater, DISCONTINUE

TESTING AND NOTIFY YOUREATON REPRESENTATIVE.

Performance Baseline Test

Continue using petroleum-basedfluid, but at the conditions listedin Table 1 for the test fluid. Setthe compensator at ratedpressure; adjust speed andtemperature per the ratings forthe test fluid.

Perform the pump performancecheck procedure.

Sequence of Operations1 Energize 15 while 16 is de-

energized. The pump is nowat full flow with pump outletpressure controlled by reliefvalve 14.

2 Vary pump outlet pressure byadjusting relief valve 14.

Performance Check Procedure

The pump performance checkmust be at 14 bar (203 psi)below the rated pressurespecified in Table 1.

Record the following parameterson the blank Pump PerformanceCheck Record (page 11).• Input torque• Output pressure• Output flow

• Case flow• Case temperature• Case pressure• Inlet temperature• Inlet pressureUse the results to compute theoverall efficiency per the formu-las in Appendix A.

Figure 2 shows an example oftest data obtained from thepump performance check.

Company: ___________________________________

Technician: ___________________________________

Test: ________________________________________

Pump Serial No. ______________________________

Date: ________________________________________

Pump Assembly: _____________________________

Pump Model: ________________________________

Pump Inlet Fluid Temperature: _________________

Baseline Performance Check with Petroleum-Based Fluid

Fluid: ________________________________________________________________________________________

Pressure: ___________________________________ Speed (rpm): __________________________________INPUT OUTPUT OUTPUT CASE CASE CASE INLETTORQUE PRESSURE FLOW FLOW TEMP PRESSURE TEMP EFFICIENCY

| | | | | | || | | | | | || | | | | | |

Figure 2

Petro Oil Company 19 January 1999

JoeTechnical 690825

Performance PVH57C-RF-2S-10-C25V-31

SC00002 120° F

Western AW Hydraulic Fluid

1750

1365 lb.in 2294 psig 25 gpm .5 gpm 149 F 7 psig 120 F 88%


Figure 3

Disassembly andInspection

Disassemble the pump perVickers Overhaul ManualM-2210-S, Figure 3. Identify thepistons and respective bores in

the cylinder barrel per Figure 4for re-assembly into the samelocation.

NOTE: In millimeters, measure cylinder barrelbores and piston OD to three decimal places(four decimal places if measuring in inches), anddimensions ‘A’ and ‘B’ to two decimal places(three decimal places if measuring in inches).

Record information on a blank Piston/BoreRecord (pages 14 and 15).

Figure 4


Figure 6Figure 5

Disassembly andInspection (continued)

Inspect its components asfollows:1 Valve plate running-face –

inspect surface finish visuallyand take a photograph.(Figure 5)

2 Cylinder barrel running face –inspect surface finish visually.(Figure 5)

3 Swashplate (yoke) runningface – inspect surface finishvisually. (Figure 5)

4 Swashplate (yoke) bearingjournals – inspect visually.(Figure 5)

5 Cradle (saddle) bearings –inspect visually. (Figure 5)

6 Bias and control piston/rod –inspect visually. (Figure 6)

7 Hold-down arms and shoeface – inspect visually.

8 Shaft and shaft bearings –inspect visually. (Figure 6)

9 Measure metering lands’diameters and widths onboth control spools (compen-sator). (Figure 6)

10 Measure shoe thickness (B),pocket depth (A), piston/shoe endplay (maximum

allowable end play 0.13mm[0.005”]), piston diameter attop, middle, and bottom ofpiston and cylinder barrelbores at top, middle, andbottom. Record results onthe blank Piston/Bore Record(page 14).

11 Shoe cage – inspect visually.12 Shaft seal and mating shaft

surface – inspect visually.13 Photograph visually worn

parts.


The type of fluid being testedwill determine pressure, speed,and temperature. See Table 1.Run for 50 to 55 hours at ratedpressure (pressure compensatorcut-off), rated speed, and ratedtemperature.

Repeat the pump performancecheck and record the results on

the Pump Performance CheckRecord (page 11).

After completion of the 50-hourcut-off test, inspect valve plateand photograph the runningsurface.

Fail criteria is material transfer,or cavitation and/or erosion

damage. Slight cavitation/erosion may be observed at theoutput metering groove area ofthe valve plate (Figure 5).

Re-assemble the pump andrepeat the pump performancecheck. Record the results on thePump Performance CheckRecord (page 11).

Fifty-Hour PressureCutoffTest

Two Hundred-HourCyclicTest

Re-Assembly

Re-assemble the pump perVickers Overhaul Manual M-2210-S while lubricating all partswith the fluid to be tested.

Test Pump Re-Installation

Install the test pump back intothe test circuit per Figure 1 andfill the pump case with pre-filtered test fluid.

Follow NFPA T2.13.1 R3 - 1998procedure when changing fromone hydraulic fluid to another inthe test stand, or consult thefluid supplier for any otherspecific recommendations.

Test Fluid Filling

Measure the following on thetest fluid as received from thedrum. Record the results on theTest Fluid Record (page 13).• Viscosity cSt @ 40°C• Water content wt % (0.03%

max. – only for non-watercontaining hydraulic fluids)

• Cleanliness level ISO Code• Spectrographic analysis for at

least the following elements(ppm): P, Zn, Ca, K, Ba, B, Si,Fe, Cu, Pb, Sn

• Total Acid Number (TAN)mg/KOH (Report only forvegetable and syntheticenvironmentally acceptablehydraulic fluids, and poly-

olester fire resistant hydraulicfluids.)

After transferring the test fluidfrom the drum to the reservoirusing a filter cart to assure fluidcleanliness, report the following:• Water content wt %• Cleanliness level ISO Code

(maintain 18/16/14 or cleaner.)

Baseline Performance Check

The type of fluid being testedwill determine pressure, speed,and temperature. See Table 1.Repeat the pump performancecheck and record the results onthe Pump Performance CheckRecord (page 11).

Test Fluid

Sequence of Operations1 Energize 16 and 15 – puts

pump at full displacement andsome pressure set by 17.Time: 0.75 sec.

2 De-energize 16 – puts pumpinto P.C. cut-off. Relief valve14 is used to limit peak pres-sure. Time: 0.5 sec.

3 De-energize 15 – puts pumpat L.S. standby. Time: 0.5sec.

4 Repeat above sequence.

Cyclic Test Procedure

Continue running the cyclic testfor at least 200 hours. The pumpmust run for a minimum of 200hours (411,400 cycles) to amaximum of 210 hours (431,970cycles).

Perform the pump performancecheck once per day throughoutthe test. Record results on thePump Performance CheckRecord (pages 11 and 12).

Cycle/Pressure Parameters:• 0.75 sec full flow at 90%

rated pressure.• 0.5 sec @ cut-off (rated

pressure).• 0.5 sec @ load sense stand-

by.• Load sense pressure decay

rate of 6.9 to 10.3 kbar/sec(100,000 to 150,000 psi/sec)

Total cycle time of 1.75 seconds(2057 cycles/hr).

Figure 7 represents a typicalcycle plot.

Control PressureHysteresis Check

Perform a control pressurehysteresis check (Appendix B)before running the two hundred-hour cyclic test, at 100 hoursand after completion of the 200hours.

Pay special attention to the inletcondition. Inlet pressure mustbe maintained at 1 bar absolute(0 psig) at full flow.

Record actual hydraulic testingcycle plot.

If a 5% or greater flow loss isfound at rated conditions duringthe test, stop the test and disas-semble the pump for inspection.

Inspect valve plate and photo-graph the running surface. Failcriteria is material transfer, orcavitation and/or erosion dam-age. Slight cavitation/erosionmay be observed at the outputmetering groove area (Figure 5).

Re-assemble the pump if partsappear acceptable.

Pump Inspection

After completion of the 200-hourcyclic test, disassemble testpump and inspect as follows:• Valve plate running face –

inspect surface finish visuallyand photograph. (Figure 5)

• Cylinder barrel running face –inspect surface finish visually.(Figure 5)

• Swashplate running face –inspect surface finish visually.(Figure 5)

• Swashplate (yoke) bearingjournals – inspect visually.

• Cradle (saddle) bearings –inspect visually. (Figure 5)

• Bias and control piston/rod –inspect visually. (Figure 6)

• Hold-down arms and shoeface – inspect visually.

• Shaft seal and mating shaftsurface – inspect visually.

• Measure land diameters andwidth on both control spoolsof the compensator. (Figure 6)

• Measure piston/shoe endplayand piston diameter and cylin-der barrel bores at top, middleand bottom of piston. Recordresults on the blank Piston/Bore Record (page 15).

• Shoe cage – inspect visually.• Shaft and shaft bearings –

inspect visually.• Photograph any worn parts.


Final FluidTesting

Fluid Pass/Fail Criteria

Measure the following on thetest fluid after completion oftesting. Record the results onthe Test Fluid Record (page 13).• Viscosity cSt @ 40°C• Water content wt % (0.03%

max. non-water based fluid)• Cleanliness level ISO Code

18/16/14 or better• Spectrographic analysis for at

least the following elements

(ppm): P, Zn, Ca, K, Ba, B, Si,Fe, Cu, Pb, Sn

• Total Acid Number (TAN)mg/KOH (Report only forvegetable and syntheticenvironmentally acceptablehydraulic fluids, and poly-olester fire resistant hydraulicfluids.)

The following are the criteria bywhich the fluid is judged to havepassed or failed the test:

• The overall efficiency of thepump is equal to or greaterthan 85%.

• The volumetric efficiency ofthe pump is not degraded by

more than 5% at the end ofthe 200-hour cyclic test.

• The control pressure hystere-sis is less than or equal to 45bar (652.5 psi) at the end ofthe 200-hour cyclic test.

Figue 7


Pressure CompensatorCut-off:

The pump is at maximumpressure without any outletflow. The control has de-strokedthe pump giving it the minimumdisplacement to maintain theoutlet pressure.

Load Sense Stand-by:

The pump is at minimumpressure without any outletflow. The control has de-strokedthe pump giving it the minimumdisplacement to maintain thede-stroked position. The loadsense signal line is at zeropressure.

Valve Plate:

The plate between the cylinderbarrel and end cover on whichthe cylinder barrel surface runs.

Cylinder Barrel (block):

The body in which the pistonsreciprocate producing flow.

Swashplate (yoke):

The surface on which the shoesof the piston/shoe assembliesrun. The swashplate also deter-mines the displacement of thepump. The control piston andbias piston provide the forces toposition the swashplate.

Cradle (saddle) Bearings:

The surface on which theswashplate rotates to determinethe displacement.

Glossary


Output Flow (gpm) X Output Pressure (psig)

Output Power = ——————————————————————- HP

1714

Input Torque (in-lb) X Speed (rpm)

Input Power = —————————————————————— HP

63025

Output HP

Overall Efficiency (%) = ———————————— X 100

Input HP

Output Flow (lpm) X Output Pressure (bar)

Output Power = ——————————————————————— kW

600

Input Torque (Nm) X Speed (rpm)

Input Power = ———————————————————————- kW

9550

Output Power kW

Overall Efficiency (%) = ———————————— X 100

Input Power kW

Appendix AEfficiencyFormulas

Inch

Metric


Sequence of Operations1 Energize 15 while 16 is de-

energized. Pump is now atcut-off (pressure compensa-tion mode, high pressure, noflow).

2 Open variable orifice valve 22to vary the pump outlet pres-sure to run a control pressurehysteresis check per AppendixB.

3 Once the control pressurehysteresis check has beencompleted, close the variableorifice valve 22 and resumetest.

Control Pressure HysteresisCheck Procedure

Control pressure hysteresis iscalculated using a plot of outletflow versus control pressure.To check control pressurehysteresis, plot outlet flow (onthe y-axis) versus control piston

pressure while varying outletpressure from 500 psi (at fullflow) to the compensator setting(high-pressure, no-flowcondition) and back to 500 psi(at full flow).

An adapter block needs to beassembled between the controland the end cover (valve block)to pick up control pistonpressure. Use a variable orificevalve to vary the pump’s outletpressure (refer to page 3 forpreparatory steps). It may take1.5 to 2.0 minutes to run asweep from full flow to pressurecompensation and back again.The majority of the sweep timeshould be while the pump isgoing into and out of thecompensator mode.

After generating a plot of outletflow vs. control piston pressure:• Determine the full flow value.

• Draw horizontal lines on theplot at 75%, 50% and 25% offull flow.

• Determine the pressurevalues at which these linesintersect the vertical sectionsof the plot. (Note: There willbe two intersection points foreach horizontal line.)

• Calculate the differencebetween each pair of pressurevalues (one ∆p for 75% flow,one ∆p for 50% flow, and one∆p for 25% flow).

• Take the average of thesethree ∆p values.

This is considered the averagecontrol pressure hysteresis. Thisvalue should not exceed 45 bar(652.5 psi).

A sample curve is shown inFigure 8.

Appendix BControl PressureHysteresisTest

Figure 8


Pump PerformanceCheck Record

Company: ___________________________________

Technician: ___________________________________

Test: ________________________________________

Pump Serial No. ______________________________

Date: ________________________________________

Pump Assembly: _____________________________

Pump Model: ________________________________

Pump Inlet Fluid Temperature: __________________

Baseline Performance Check with Petroleum-Based Fluid

Fluid: ________________________________________________________________________________________


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Baseline Performance Check withTest Fluid


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Performance Check After 50-HourTest


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Performance Check After Re-Assembly


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Performance Check During 200 HourTest (24 hours)


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Viscosity cSt @ 40°C ________

Water content wt %(0.03% max. non-waterbased fluid)

Cleanliness levelISO Code 18/16/14 or better

Spectrographic analysis(ppm):

P _______________________

Zn ______________________

Ca ______________________

K _______________________

Ba ______________________

B _______________________

Si ______________________

Fe ______________________

Cu ______________________

Pb ______________________

Sn ______________________

Total Acid Number(TAN) mg/KOH(Only for vegetable and syn-thetic environmentally accept-able hydraulic fluids, and poly-olester fire resistant hydraulicfluids)

Test Fluid Record

AtTest Fluid Filling

Viscosity cSt @ 40°C ________

Water content wt %(0.03% max. non-waterbased fluid)

Cleanliness levelISO Code 18/16/14 or better

Spectrographic analysis(ppm):

P _______________________

Zn ______________________

Ca ______________________

K _______________________

Ba ______________________

B _______________________

Si ______________________

Fe ______________________

Cu ______________________

Pb ______________________

Sn ______________________

Total Acid Number(TAN) mg/KOH(Only for vegetable and syn-thetic environmentally accept-able hydraulic fluids, and poly-olester fire resistant hydraulicfluids)

At Completion of200-Hour CyclicTest


Piston/BoreRecord

Cylinder Block Bores

NO. TOP MIDDLE BOTTOM

| | |1 | | |

| | || | |

2 | | || | || | |

3 | | || | || | |

4 | | || | || | |

5 | | || | || | |

6 | | || | || | |

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8 | | || | || | |

9 | | || | |

Piston OD Dimensions


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2 | | || | || | |

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9 | | || | |

MAX & MIN. PISTON PISTONTO SHOENO. TO BORE CLEARANCE END PLAY DIMENSION “A” DIMENSION “B”

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6 | | | || | | || | | |

7 | | | || | | || | | |

8 | | | || | | || | | |

9 | | | || | | |

AtTest Fluid Filling


Piston/BoreRecord

Cylinder Block Bores


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Piston OD Dimensions


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2 | | || | || | |

3 | | || | || | |

4 | | || | || | |

5 | | || | || | |

6 | | || | || | |

7 | | || | || | |

8 | | || | || | |

9 | | || | |

MAX & MIN. PISTON PISTONTO SHOENO. TO BORE CLEARANCE END PLAY DIMENSION “A” DIMENSION “B”

| | | |1 | | | |

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2 | | | || | | || | | |

3 | | | || | | || | | |

4 | | | || | | || | | |

5 | | | || | | || | | |

6 | | | || | | || | | |

7 | | | || | | || | | |

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9 | | | || | | |

At Completion of 200-Hour CyclicTest

© 2008 Eaton CorporationAll Rights ReservedPrinted in USADocument No. V-PUPI-TS022-ESupersedes 03-06-0002-EN-0601March 2009

EatonFluid Power GroupHydraulics Business USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722www.eaton.com/hydraulics

EatonFluid Power GroupHydraulics Business EuropeRoute de la Longeraie 71110 MorgesSwitzerlandTel: +41 (0) 21 811 4600Fax: +41 (0) 21 811 4601

EatonFluid Power GroupHydraulics Business Asia Pacific11th Floor Hong Kong New World Tower300 Huaihai Zhong RoadShanghai 200021ChinaTel: 86-21-6387-9988Fax: 86-21-6335-3912

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