YZB-120PY-3液压动力站英文说明书.doc

YZB-120PY-3
HYDRAULIC POWER UNIT

OPERAIONAL MANUAL

YZB-120PY-3-SM

NANTONG JINNIU MANUFACTURE CO., LTD

Contents

1. Introduction
2. Technical performance
3. Structure and Work Principle
4. Operation and Maintenance
5. Trouble-shooting
6. Wearable Parts List

1. Introduction
YZB-120PY-3 hydraulic units are to supply hydraulic power for land translation forcing cylinder of oil field drilling derrick. The power unit contains electric motor, pump, oil filter, filter unit, valve block, and speed adjusting valve, hand-reversing valve, oil tank and pressure gauge. All the parts are explosion-proof, suitable for desert, and plateau work environment.
Only need to input AC 380V, 50Hz can start its running. Explosion-proof grade for electric parts is dIIBT6; protective grade is IP54, suitable for drilling environment with combustible gas.
The hydraulic power unit features compact structure, simple installation, good applicability.

2. Technical performance
1：Power unit
Max work flow： 120L/min (31.7gpm)
Available volume: 587L (129gal)
Max work pressure: 20Mpa (2900psi)
2：Explosion-proof motor
Model: YB2-225M-4-B35 Power: 37Kw (49.6hp)
Voltage: 380V Frequency: 50Hz Speed: 1500rpm
3：Plunger pump
Model: HY100S-LP Speed: 1500rpm
pressure: 31.5Mpa Flow: 120L/min
4：Connection description
Hydraulic pressure line joint： NPT3/4（6ea）(M30×1.5)
5：Overall dimensions：18330×1090×1255mm（72×43×49in）
6：Weight：1600kg（3527lb）

3. Structure and Work Principle
YZB-120PY-3 hydraulic power unit contains electric motor, pump, oil filter, filter unit, valve block, and speed adjusting valve, hand-reversing valve, oil tank and pressure gauge. The power unit is tank-on-the-side structure, to ensure enough intake of oil for electric motor-pump assembly.
Also there is an oil pool at the bottom of the power unit. The hydraulic oil will not flow to the ground when disassembling pipe line joint. And oil can be drained by unscrew releasing plugs.
Operation instructions:
1、 Synchronization regulation：Controlling three pushing cylinder by three adjusting valve（2FRM16-20/160L）. Keeping one-way synchronization of three cylinders by three adjusting valves.
2、 Pushing regulation：By adjusting spill valve (DBDSK20 /31.5).（increase in the clockwise direction；otherwise, decrease）.

4. Operation and Maintenance
Besides the above-mentioned structure and principle of YZB-120PY-3 hydraulic power unit, also needs to notice the following items:
1）Check if oil storage is within the range of liquid-meter. Normally, hydraulic oil is YB-N32 or YB-N46 anti-wear oil. When environmental temperature is below minus 25℃, YC-N32 or YC-N46 low setting oil also is a choice.
2）Choose a well ventilating place to set the power unit.
3）Electric source of the power unit should have a ground connection to secure safety of personnel and equipment.
Hanging for the unit
1) Shift the power unit near to drill platform. Hanging chain should fixed with ears of the power unit, avoiding impact and damaging.
2）The power unit is lifted with four ears to secure safe.
Operation：
1）Connect hoses between power unit and pushing cylinder.
2）Connect power source.
3）Turn on the main power switch and press start button. Check rotating direction of electric motor to secure it is correct. (Rotating direction should be identical to the tag pointed.)
4）Start electric motor to drive pump working. Check the pressure gauge reading to see if power unit running normally.
5）Check every connecting site to see if leaking.
6）When stop the power unit, do shut off main electric machine.
7）When do not use the power unit for a long time, do shut off electric source.
Maintenance：
It is important to perform maintenance for the power unit, and make sure that the unit can work normally, safely, and stably, and reliably.
Common maintenance:
1）Regular check the oil level in the tank, keep the oil within the indicating range of liquid-meter, or it will go against the normal work of hydraulic unit.
2）Check if any leakage at pipe connecting sites. If leakage occurs do stop the power unit and have a good repair. Do not perform connecting repair when power unit is running.
3）Check pressure gauge to see if ok. From the stability of reading and dial can judge fluctuation status of pressure and flow.
4）Check all the fastenings to see if loose.
5）Check if plunger pump is running normally, and return pressure if too high. Do stop the unit and replace the filter elements of oil taking filter when necessary.
6）Keep the unit clean. When the unit is working do shut off each door. Do not uninstall the doors and safeguard net. Do prevent water and impurities from entering into the oil pool at bottom.
7）Do not put articles on electrical motor screen, so as not to obstruct ventilating.
8）When replace wearable parts or other parts, do pull out the power plug.
Normally, hydraulic oil should be replaced once a year or after six months’ work. Clean oil tank and oil taking line; do prevent water and impurities entering into oil and line. If do not use the power unit for a long time, clear off oily dirt and dust on surface, and drain off remaining oil in the oil pool, protect with covering, and put the unit on a safe place.

5. Trouble-shooting
Item
Troubles
Reasons
Solutions
1
No oil goes from pump
1. Rotating direction of electric engine is wrong.
2. Too low of oil level in the tank.
3：Leaking of oil taking line.
4：Viscosity of oil is too high.
1：Change its rotating
Direction.
2：Add oil to liquid lever meter.
3：Repair oil taking line.
5：Replace with oil of low viscosity.
2
No pressure or pressure fails to go up.
1：Relief valve core is
Blocked.
2：Pressure is adjusted too lower through relief valve.
3：Leakage is too much.
4：Wear or damage inside the plunger pump.
1. Dismantle and repair relief valve or replace.
2. Adjust pressure higher.
3. Repair the system.
4.Repair or replace the plunger pump
3
Discharge decrease
1. Relief valve fails to lock well.
2. Much leakage for plunger pump or variable head is blocked dead.
1. Dismantle and clean relief valve or replace.
2. Repair or replace plunger pump.

4

Too much noise of plunger pump.
1. Oil level is too low.
2. Jammed oil taking filter.
3. Leaking of oil taking line.
4. Oil temperature is low.
5. Too high viscosity of oil or have much foam.
1. Add oil to liquid lever meter.
2. Replace filter element.
3. Repair oil taking line.
4. Start up electric heater.
5. Replace with low viscosity oil.
5
System is hot
1.Fail to unload when idle run or too little oil in external machine.
2. High viscosity of oil.
3. Return pressure is too high or return filter blocked.
4. Long time no use of the unit.
1. Should avoid such thing.
2. Lower its viscosity.

3. Repair return line or replace return filter element.
4. Stop and cool down.

6. Wearable Parts List

Item
Part No.
Description
Specification
Remarks
1
HX-250×20
Filter element

For ZU-H250×20F filter
2
JB/ZQ4224-97
O ring
30×3.1
Hand-reversing valve、speed-adjusting valve
3
JB/ZQ4224-97
O ring
48×3.5
Plunger pump valve block
4
JB/ZQ4224-97
O ring
60×3.5
Plunger pump oil absorbing flange
5
JB/ZQ4224-97
O ring
10×1.8
System pressure gauge pipe line connection
6
JB/ZQ4224-97
O ring
12×1.8
Hand-reversing valve
7
JB/ZQ4224-97
O ring
55×3.1
Oil-filter oil absorbing flange
8
JB982-77
Compound ring
22
Plunger pump oil releasing joint
9
JB982-77
Compound ring
27
Oil-releasing plug