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Installation and Commisioning of Servo & Propotional Control Valves

The document provides installation and commissioning instructions for Star Hydraulics servo and proportional control valves. It discusses flushing the system to achieve the required cleanliness level before installing valves. Filters should be used to control particulate contamination, with recommended micron ratings provided. When installing valves, the area must be clean and locating pins or port alignment used to ensure correct orientation. Systems must be tested at low pressures before full operation.

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Idehen Kelvin
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91 views3 pages

Installation and Commisioning of Servo & Propotional Control Valves

The document provides installation and commissioning instructions for Star Hydraulics servo and proportional control valves. It discusses flushing the system to achieve the required cleanliness level before installing valves. Filters should be used to control particulate contamination, with recommended micron ratings provided. When installing valves, the area must be clean and locating pins or port alignment used to ensure correct orientation. Systems must be tested at low pressures before full operation.

Uploaded by

Idehen Kelvin
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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STAR

Installation and Commisioning


of Servo & Propotional Control Valves

Star Hydraulics Limited


Severn Drive
Tewkesbury Business Park
Tewkesbury
Gloucestershire
GL20 8SF
England (UK)

www.star-hydraulics.co.uk
ST-Install-2011.1-En
Always flush the system one class cleaner than the
General minimum requirement.

Installation / removal / commisioning of electro hydraulic


control valves should only be carried out by
experienced personnel that have completed appropriate
hydraulic, control and automation training courses.
Publications such as ISO 4413 provide general rules Filtration
and safety requirements for hydraulic fluid power
systems and components and significant hazards
associated with new installations and upgrades to such The main areas for filter location are pressure line
systems. The STAR product data sheets provide (pump outlet), return (tank) line, off-line (kidney loop),
essential technical details for each model. often used for filling circuit. Reservoirs should also be
fitted with filtered breathers to prevent external
All Star servo and proportional valves are calibrated in contaminants from entering the tank.
accordance with ISO 10770 standards for electrical
hydraulic control valve and fluid cleanliness monitored Ensure pressure and return filter element pressure drop
and controlled ISO 4406 : 1999 to class 12 /10 /8 or ratings are adequate for the full spectrum of operating
better and viscosity VG 32. temperatures/fluid viscosity ratings. Do not use fine
rated filters where dynamic changes occurr within the
All products supplied by STAR are fitted with protective system, they could fatigue. Do use filters without by-
shipping plates to prevent ingress of contaminaiton and pass and clogging indicators.
should not be removed until the very moment that the
valve is to be fitted to the system. Use good quality elements, low cost elements could
shed during use and therefore introduce more con-
taminants into the system.

The Beta ratio (x) is an indicator of how well a filter


Flushing & Fluid Cleanliness controls particulate. Therefore filters with higher ratio
values provide better system protection.

Contamination control in hydraulic systems is the most Recommended filter micron ratings:-
important aspect when preventing system failures, more
than 75% of all failures can be traced back to pump outlet 10 µm
contaminated oil. return line & tank breather 3 µm
off-line 2 µm
New oil is a source of contamination and is not supplied
to any cleanliness classification.

Effective flushing processes and monitoring must be


adopted to ensure fluid cleanliness has been achieved Valve Installation
and maintained prior to fitting a new or repaired servo
valve.

The system must be flushed without the servo valve When installating and removing valves ensure that the
fitted. Instead use a flushing plate that connects the immediate area is clean. Use only lint free cloth or
manifold pressure port back to tank. If the system special paper for cleaning.
allows the use of manual or low cost directional control
valves may also be used that can also allow flushing of Install the control valve only after completion of the
the control lines. flushing procedure. Ensure the manifold interface
surface finish and geomtry meet the product data sheet
The flushing time is goverened by the degree of specification.
contamination within a sample of fluid and can only be
determined by continuous monitoring with a particle Most valves have a locating pin to ensure correct port
counter or by sucessive bottle samples. Samples must orientation. Make sure the pin lines up with the mating
be taken from several points around the system. hole in the manifold interface. If there is no locating pin
make sure the valve P port is lined up with the system
Rapid removal of contamination from within the system pressure port and ensure all ports are aligned.
occurs when turbulent flow exists. System variables
such as flow rate, fluid viscosity and pipe bore Secure the valve to the manifold with the appropriate
diameters need to be assessed. Turbulent flow occurrs bolt torque values.
when the Reynolds value exceeds 4000.
All hydraulic functions must first be tested at low
There is no such thing as a 'x' micron rated system. pressures under fully controlled conditions.
Fluid clealiness standards relate to the amount of
particles by number in a given quantity of oil. The most
commonly used are:-

ISO 4406 : 1999


NAS 1638-01/1964
SAE AS 4059E
Warranty

1. STAR warrants that each item of its manufacture is


free from defects in material and workmanship at the
date of shipment. This warranty shall not apply to any
part or parts supplied to but not manufactured by STAR.
As to such parts, STAR agrees to purchase the same
from a reputable supplier and to assign to its customer
whatever rights STAR may have under warranties of
such suppliers.

2. Unless otherwise specified, STAR's obligation under


this warranty is limited to replacing or repairing any item
supplied as new, which within twelve (12) months from
date of shipment is proven by STAR inspection to have
been defective at the time of shipment. As a condition of
this warranty, the purchaser shall notify STAR in writing
of any claim(s) immediately upon discovery and shall
return the item to STAR for inspection. Unless
specifically approved in writing, STAR shall not provide
uncompensated field service under this warranty. No
allowance will be made for repairs or alterations unless
STAR has previously agreed in writing to such
allowance. STAR shall not be responsible for any work
carried out by any other party. STAR must in the first
instance carry out all warranty investigations on STAR
units, which must not have been tampered with before
being returned to STAR, In the event that disassembly
part or whole by anyone other than authorized STAR
personnel will immediately void the terms of this
warranty.

3. Unless STAR is specifically requested to provide


installation assistance under the terms of this quotation,
proper installation and checkout shall be the sole
responsibility of the customer.

4. STAR shall not be liable for improper use,


installation, operation or maintenance of items
manufactured by STAR, nor for any damage resulting
from improper use, installation, operation or
maintenance. In addition, STAR shall not be
responsible for any damages for loss of production or
profits, damage to product or economy of operation, or
any other consequential or incidental damages
occasioned by defects in, or failure of any goods
supplied by STAR or by defects in or failure of any
product in which a component manufactured by STAR
is incorporated.

5. STAR shall not be responsible for the performance of


any product, which incorporates component parts
manufactured by STAR unless such performance is
expressly designated as STAR's responsibility under
the terms of the written agreement between STAR and
the Customer.

6. The warranties contained herein are exclusive and


are given in lieu of all other warranties, express, implied
or statutory, including the implied warranty of
merchantability or fitness for a particular purpose and all
other obligations and liabilities.

7. Special and extended warranty periods are available


from STAR under approved conditions of contract.
These special conditions come into effect on a case-by-
case basis and the scope of these conditions is advised
under Addendum Clauses to these conditions
authorised only by a Board Director of STAR.

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