9886A Circuit Recommendataions
9886A Circuit Recommendataions
9886A Circuit Recommendataions
Applications Manual
Section 4
Transmission Circuit
Recommendations
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Applications Manual
Section 4
Circuit Recommendations
Table of Contents
4.1
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.1.6
4.1.7
4.1.8
4.1.9
4.1.10
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.2.5
4.3
Introduction ....................................................................................................................................25
Circuit Recommendations .............................................................................................................. 25
4.10.1
4.10.2
4.10.3
4.10.4
4.10.5
4.10.6
4.10.7
4.10.8
Description .....................................................................................................................................23
4.5.1
4.5.2
4.6
4.7
4.8
4.9
4.10
Introduction ....................................................................................................................................18
Circuit .............................................................................................................................................18
Component and Circuit Performance ............................................................................................ 20
Applications ...................................................................................................................................22
4.4.1
4.5
4.3.1
4.3.2
4.3.3
4.3.4
4.4
Introduction ...................................................................................................................................... 3
Charge Pump ................................................................................................................................... 4
Controls ........................................................................................................................................... 5
Reservoir ......................................................................................................................................... 6
Conduit Sizing .................................................................................................................................. 7
Case Drain Requirements ............................................................................................................... 8
Heat Exchangers ............................................................................................................................. 8
Filters ...............................................................................................................................................9
Loop Flushing Shuttle .................................................................................................................... 12
Pressure Controls ..........................................................................................................................13
Introduction ....................................................................................................................................31
Heat Generation ............................................................................................................................ 31
Design Flow Range .......................................................................................................................31
Loop Flushing ................................................................................................................................ 32
Motor Life Reduction ...................................................................................................................... 32
Differential Flow for Steering ......................................................................................................... 33
Motor Speed Synchronization (Non-Propel) .................................................................................. 33
Recommendations for Trouble-Free Circuit ................................................................................... 33
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Applications Manual
Section 4
4.1
4.1.1
Introduction
Circuit Recommendations
Circuit elements must be present to remove undesirable heat and contamination and to control the passage of cool, clean fluid into the main power loop.
Other circuit elements are present to control pressure
and, sometimes, to control flow.
The purpose of this article is to advise SauerSundstrand users on generally accepted circuit arrangements, but it does not, and cannot, describe all
possible circuits which may be appropriate for various applications. Transmission circuits are unique
designs and must be developed and tested to ensure
required performance and life.
SERVO
HYDROSTATIC
PUMP
CHARGE
RELIEF
CHECK
RELIEF
CHARGE
RELIEF
HYDROSTATIC
MOTOR
HIGH
PRESSURE
RELIEF
CHARGE
PUMP
LOOP
FLUSHING
SHUTTLE
CONTROL
VALVE
HEAT
EXCHANGER
FILTER
Figure 4-1
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Applications Manual
4.1.2
Section 4
Circuit Recommendations
Charge Pump
The charge pump functions associated with its volume flow rate are:
replenish loop fluid lost through volumetric inefficiency of the pump and motor(s).
control loop flushing flow by the differential pressure between the charge relief valve and the loop
flushing relief valve.
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Applications Manual
4.1.3
Section 4
Circuit Recommendations
Controls
Servo controls are an interface between the operator and the swashplate. The operator input is a low
force device which ports charge pressure to the servo
piston which moves the swashplate. Thus, the operator input is not dependent on system pressure. Servo
controls have a neutral deadband. Standard servo
controls also have a mechanical feedback mechanism which ensures that the swashplate position
stays where commanded. Several Sauer-Sundstrand
products are available with non-feedback servo
controls which are appropriate for certain applications. The three types of operator inputs for servo
controls are manual, electric, and hydraulic.
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Applications Manual
4.1.4
Section 4
Circuit Recommendations
Reservoir
Water contamination is harmful to transmission components, and reservoirs must be designed to prevent
the entrance of water into the reservoir. Since many
machines must withstand high pressure washing,
covers and other openings must be designed to
always seal tightly, especially after maintenance operations are performed.
The charge pump suction port must be near the
bottom of the reservoir, but not so near that settled
contaminants are sucked into the charge pump. The
return port should be located as far from the inlet port
as possible to provide maximum dwell time of the fluid
in the reservoir. The returning fluid must always
discharge below the fluid level, preferably through a
low velocity diffuser to prevent aeration. Reservoirs
should have a baffle(s) between the inlet and outlet
ports to ensure adequate dwell time and to prevent
surging and aeration of fluid.
A filler port should be provided which minimizes the
potential for contamination entering the system during servicing or operation. A drain port in the reservoir
is recommended to permit a complete change of
hydraulic fluid without disconnecting other hydraulic
fittings.
When designing a reservoir to serve multiple hydraulic systems, stagger the elevation of the fluid outlet
ports. If the fluid level becomes low during operation,
the system with the highest outlet port will malfunction first and provide a warning to the operator.
RETURN
FLOW
SEALED
FILLER CAP
DIFFUSER
WATER TIGHT
CONSTRUCTION
TOP
VIEW
FLUID CAPACITY
5/8 CHARGE FLOW MIN.
SIDE
VIEW
FLUID CONTENT
1/2 CHARGE FLOW MIN.
BAFFLE
DRAIN
TO CHARGE
PUMP
Figure 4-2
Reservoir Design
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Applications Manual
4.1.5
Section 4
Circuit Recommendations
Conduit Sizing
20-30
10-15
Suction lines:
4-6
Consult hydraulic hose and tube suppliers for recommendations on calculating pressure drop and for
applicable pressure ratings.
Undersized main system lines will result in heat
generation caused by high fluid velocity. Oversized
main system lines can contribute to charge pressure
droop by increasing the amount of fluid being compressed when system pressure rises.
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Applications Manual
4.1.6
Section 4
All Sauer-Sundstrand closed circuit pumps and motors require case drain lines to relieve internal leakage. Also, flow passing over charge relief valves and
loop flushing valves must be removed through the
case drain line.
The main criteria for case drain line routing are:
back pressure on the unit cases
fluid velocity / line sizing considerations
cooling requirements.
Case drain lines can be routed in series through
multiple hydraulic unit cases. For circuits with loop
flushing, the loop flushing manifold would be the
initiation point of case drain flow and the pump would
be the unit immediately before the heat exchanger
(see Figure 4-1). This allows flow through all unit
cases for lubrication, cooling, and contamination
removal. The pressure drop through the heat exchanger is additive to the unit case pressure. If this
approach results in excessive unit case pressures,
alternate routing must be considered. Article 4.6 of
this application manual provides variations for case
drain circuits.
For hydraulic units with lip seals, case pressure
limitations are seal structural limitations. Exceeding
these values, even for short pulses, could result in
premature wear out or blow-out of the seal.
4.1.7
Heat Exchangers
Circuit Recommendations
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Applications Manual
4.1.8
Section 4
Circuit Recommendations
Filters
To prevent premature wear of the hydraulic components, it is imperative that only clean fluid enter the
hydrostatic circuit. A filter capable of maintaining the
fluid cleanliness to ISO 18/13 or better is recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure filtration) side of the charge pump. All Sauer-Sundstrand
pumps can be used with suction filtration, and several
can be equipped with charge pressure filtration adapters.
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Applications Manual
Section 4
Circuit Recommendations
Suction Filtration
The suction filter is placed in the circuit between the
reservoir and the inlet to the charge pump as shown
in Figure 4-3. A non-bypass filter is recommended
with a filter contamination monitor. A vacuum gauge,
located nearest the charge pump inlet, is suggested.
Inlet vacuums up to 6 in Hg (0.8 bar absolute) are
acceptable during normal system operation. An indicator set at 10 in Hg (0.7 bar absolute) is recommended for a filter change. Vacuums on the order of
20 in Hg (0.3 bar absolute) are acceptable during cold
start or intermittent conditions. Exceeding these values may result in charge pump cavitation, aerated
fluid, and life reduction of the hydraulic components.
There are two basic types of charge pressure filtration; full flow and partial flow. In either case, the
pressure filter is located downstream of the charge
pump. Charge pressure filtration is often used in
systems where the inlet vacuum recommendations
would be exceeded if using a suction filter. Cold
weather applications and systems with a long inlet
lines are prime candidates for charge pressure filtration. Charge pressure filtration generally provides
greater filtering efficiency than suction filtration.
Charge pressure filters must be rated for at least the
maximum expected charge pressure per the application. Generally, filters rated at 35 bar (500 psi) minimum collapse pressure are acceptable. A 100m to
125m strainer located in the reservoir or in the
charge pump inlet line is recommended to protect the
charge pump from coarse contaminants.
10
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Applications Manual
Section 4
Circuit Recommendations
CHARGE
RELIEF
CHARGE
RELIEF
FILTER
CHARGE
PUMP
LOOP
FLUSHING
SHUTTLE
SCREEN
TO CONTROL
Figure 4-3
CHARGE
RELIEF
FILTER
BY-PASS
FILTER
SCREEN
TO CONTROL
Figure 4-4
11
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Applications Manual
4.1.9
Section 4
Circuit Recommendations
12
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Applications Manual
Section 4
Circuit Recommendations
PRESSURE
LIMITER
VALVE
SERVO
CHECK
VALVE
CONTROL
VALVE
Figure 4-5
13
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Applications Manual
Section 4
Circuit Recommendations
pressure limiter or pressure override will act to increase vehicle speed if the pressure setting is reached.
This may decrease the amount of braking power
available from the transmission at high vehicle speed
as compared with a relief valve pressure control
system. Because the pressure limiter and pressure
override valves are nondissipative by design, the
engine absorptive power limits the amount of high
speed braking effort. With relief valves, some of the
power required for high speed, steep slope braking
can be dissipated over the reliefs by destroking the
pump.
Continued braking over relief valves will heat the
hydraulic fluid and may damage the transmission, so
only emergency situations should be considered for
use of reliefs. Since vehicles must also be equipped
with mechanical brakes which are suitable for emergency stops, emergency relief valve braking is usually redundant. In other words, a braking system
which is independent of the hydrostatic transmission must be provided which is adequate to
stop and hold the vehicle should the condition
develop.
Machines with dual path transmissions which depend on differential output speed to steer must verify
that the pressure control device does not prohibit
adequate steering control. This applies for both driving and braking.
DISPLACEMENT
CONTROL
PRESSURE
OVERRIDE
Figure 4-6
14
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Applications Manual
4.2
Section 4
Circuit Recommendations
Some applications may require additional circuit components in order to perform specific functions. A few of the
frequently used components are discussed in this article which includes suggestions and precautions on their use.
4.2.1
4.2.2
Flow Limiters
15
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Applications Manual
4.2.3
Section 4
Counterbalance Valves
4.2.4
Accumulators
16
Circuit Recommendations
modulus effect. Systems with long lines or applications which experience load induced pressure spikes
are vulnerable to fluid compressibility and normally
require supplemental low loop make-up fluid for a
short time duration. However, the accumulator volume adds to the total volume of the system which is
subject to the fluid compressibility during a load
induced pressure spike.
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Applications Manual
4.2.5
Section 4
Circuit Recommendations
Cylinders
17
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Applications Manual
Section 4
4.3
4.3.1
Introduction
Circuit Recommendations
4.3.2
SERVO CYLINDER
PRESSURE
GAGE PORT M5
Figure 4-7
Circuit
The external RVPL valve becomes a second pressure limiter valve which is connected in parallel with
the internal pressure limiter valve. Of these two
valves, the one which is set at a lower pressure will
limit system pressure. The internal pressure limiter
should be set at a maximum desired system pressure, and it will limit maximum system pressure, even
if the external RVPL valve is adjusted to a higher
setting. Lower system pressures are maintained by
adjusting the external RVPL valve to settings lower
than the internal pressure limiter.
M4
M5
OPTIONAL
ORIFICE
A
M1
REMOTELY VARIABLE
PRESSURE LIMITER
M2
B
L1
L2
Figure 4-8
18
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Applications Manual
Section 4
Circuit Recommendations
M4
M5
OPTIONAL
ORIFICE
A
M1
REMOTELY VARIABLE
PRESSURE LIMITER
M2
B
L1
L2
Figure 4-9
The external RVPL valve will always be connected
to the system port in which it is desired to have the
RVPL function. However, the appropriate servo connection is dependent upon pump rotation shown in
Table 4-1.
WarningIf the servo gage port plumbing is reversed, the remote pressure limiter will not function.
If a two-level pressure limiter is desired without readjustment of the external RVPL valve, the external
valve can be switched in and out of the circuit with an
on/off valve (manually, hydraulically or solenoid operated) placed in series. This valve will switch pressure limiter operation between the internal and the
external valve settings. This logic can even be extended to more than two pressure limiter levels, using
additional external RVPL valves and on/off valves.
LH (CCW)
PORT
M1
M4
M2
M5
M1
M5
M2
M4
Table 4-1
19
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Applications Manual
4.3.3
Section 4
20
Circuit Recommendations
250 psi
500 psi
750 psi
1000 psi
42cc
0.21 sec
0.11 sec
0.07 sec
0.05 sec
55cc
0.35 sec
0.18 sec
0.12 sec
0.09 sec
75cc
0.45 sec
0.23 sec
0.15 sec
0.11 sec
100cc
0.65 sec
0.32 sec
0.22 sec
0.16 sec
Table 4-2
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Applications Manual
Section 4
Circuit Recommendations
800
600
400
200
0
1
-200
Steady State
Operating Point
-400
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Applications Manual
4.3.4
Section 4
Applications
As mentioned, the RVPL circuit is useful for applications requiring adjustable constant pressure control,
such as drill rig pulldowns and constant tension
winches. The circuit is normally used with a displacement control (manual, hydraulic or electrical). The
displacement control provides speed control when
the RVPL is set at a pressure higher than is required
to move the load. This allows precise load positioning
when the system is not in the constant pressure
mode. When operating at constant pressure, the
RVPL is adjusted to maintain a desired pressure
level, and the displacement control is set to limit the
maximum load speed. The RVPL is designed to
behave in a manner similar to the internal pressure
limiter to reduce pump displacement when the pressure reaches the RVPL setting.
In drilling applications, motor output torque is limited by limiting pressure with the RVPL. The RVPL
can be used to control drilling torque, with the internal
pressure limiter set at a higher pressure.
On a constant tension winch, the displacement
control is typically set to allow full pump displacement
to run full speed cable pay in, while constant cable
tension is maintained by means of the RVPL. The
ability of the RVPL to drive the pump swashplate over
center for a winch pay out condition makes it especially suitable for a mooring winch application. On a
mooring winch, the pumps displacement control is
set to pay in the cable at a certain speed. If the cable
tension increases to the point of the RVPL setting, the
pumps displacement will decrease to maintain the
pressure setting. If the tension is great enough, the
RVPL will drive the swashplate over center and the
pump will pay out cable. Consideration must be given
if the load can drive the swashplate to its maximum
displacement when paying out cable. Any flow generated by the load that the pump cannot take in will
either drive the pump faster or drive the pressure
higher. A relief valve can be used to limit the maximum pressure condition, but excessive heat will be
produced. In most cases the prime mover, acting in a
dynamic braking mode, will be the limiting factor. A
separate method of braking the load must be provided
to prevent engine or pump overspeed.
22
Circuit Recommendations
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Applications Manual
4.4
Wheel Assist
4.4.1
Description
Section 4
Circuit Recommendations
coefficients of traction
wheel diameter
23
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Applications Manual
Section 4
The wheel assist shown in Figure 4-11 is accomplished with two variable motors and wheel ends on
the steerable wheels. These variable motors are
typically capable of both zero and full displacement.
While in a mode of low torque requirements, the
variable motors are in zero displacement. When
more tractive force is required, the motors are shifted
to full displacement.
Circuit Recommendations
The wheel assist shown in Figure 4-12 can accomplish the additional tractive force required with a
separate designated pump for the assist function.
This system can produce a fixed or variable tractive
force by the use of a electronic pressure control. By
controlling pressure level from zero to maximum by
operator input, just the right amount of assist traction
is possible. At a zero pressure command, vehicle
coast is possible.
AXLE MOTOR
ENGINE PUMP
VARIABLE MOTORS
W/ WHEEL DRIVES
Figure 4-11
AXLE MOTOR
Figure 4-12
24
FIXED MOTORS
W/ WHEEL DRIVES
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Applications Manual
4.5
Ganged Pumps
4.5.1
Introduction
Section 4
4.5.2
Circuit Recommendations
Circuit Recommendations
is less than the RVPL setting. The remote pressure
limiter is a single side circuit. Two RVPL circuits are
necessary to control both sides of the loop.
RVPL VALVE
PORT "A"
LO
LO
EXTERNAL
HPRV
ED
ED
HI
HI
PORT "B"
Figure 4-13
25
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Applications Manual
Section 4
26
Circuit Recommendations
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Applications Manual
4.6
Section 4
Circuit Recommendations
MOTOR
HYDROSTATIC
PUMP
HEAT
EXCHANGER
Figure 4-14
MOTOR
HYDROSTATIC
PUMP
HEAT
EXCHANGER
Figure 4-15
MOTOR
HEAT
EXCHANGER
Figure 4-16
27
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Applications Manual
4.7
Section 4
Circuit Recommendations
PV
PV
CHARGE
INLET
CHARGE PUMP
GAGE PORT
MV
Figure 4-17
28
MV
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Applications Manual
4.8
Section 4
Circuit Recommendations
PV
CHARGE
INLET
PRESSURE
FILTER
IMPLEMENT
PUMP
LOAD
(CYLINDER, MOTOR, ECT.)
Figure 4-18
29
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Applications Manual
4.9
Section 4
Multiple Motors
30
Circuit Recommendations
HYDROSTATIC
PUMP
HYDROSTATIC
MOTOR
LOOP
FLUSHING
SHUTTLE
Figure 4-19
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Applications Manual
Section 4
Circuit Recommendations
31
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Applications Manual
Section 4
Circuit Recommendations
DIVIDING FLOW
CROSS-BLEED
ORIFICE
LOOP
FLUSHING
VALVE
MF
MF
COMBINING FLOW
Figure 4-20
32
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Applications Manual
Section 4
Circuit Recommendations
select the most appropriate valve for the application. Take into account flow and pressure ratings,
pressure and temperature compensation, differential flow capability, and volumetric effectiveness.
Test the vehicle extensively in all modes of operation to ensure correct functional performance as
well as correct circuit performance.
33
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Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND is a world leader in the design and
manufacture of Hydraulic Power Systems. Research and
development resources in both North America and Europe
enable SAUER-SUNDSTRAND to offer a wide range of
design solutions utilizing hydraulic power system
technology.
Cartridge Motors/
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Packages
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Original
Ersatzteile
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BLN-9886 July 1997 Rev. A
SAUER-SUNDSTRAND COMPANY
2800 East 13th Street
Ames IA 50010 U.S.A.
Phone: (515) 239-6000 FAX: (515) 239-6618