HANMI POWER VTU-2100 RT-flex96C MANUAL NO. : VTU-2100-1,9(2006.08) 180 9001 INSTRUCTION MANUAL FUEL VALVE TEST DEVICE MODEL : VTU-2100 HANMI HYDRAULIC MACHINERY CO., LTD E-mail : hm1a1@kornet.net | Hm132@kornet.netHANMI POWER 180 9001 CONTENTS A. SPECIFICATIONS B, OPERATION INSTRUCTIONS 4, PREPARATION 2. OPERATING THE PUMP UNIT 3, TEST PROCEDURE OF FUEL VALVE 4, TEST OF THE OTHER VALVE 5, CLEANING OF OIL FILTERS 6. LUBRICATION INSTRUCTION ©. OUTLINE OF THE VTU-2100 APPENDIX ~ GENERAL ASSEMBLY (DWG NO. M12-8000-1.0) = DIMENSION OF OUTLINE (OWG NO, M12-5000-1.0), = JIG & SPANNER (OWG NO, M12-5012-1.0) ~ ASSEMBLY OF BOOSTER (DWG NO, M10-3200-0.0) - TOOLS (OWG NO. M12-5014-0.3) = SPARE PART (DWG NO. M12-5015-0.1) CONTROL BOX (OWG NO. M12~5503-0.2) = JIG & ACCESSORY (DWG NO. M12-5117-1.0) PAGE : 1 VTU-2100_RT-flex96C MANUAL NO, : VTU-2100-1,9(2006.08) PAGE 2 PAGE 4 PAGE 4 PAGE 4 PAGE 5 PAGE 8 PAGE 8 PAGE 8 PAGE 9HANMI POWER A. SPECIFICATION 1. Model No. 2. Voltage | Frequency 3, Electric PUMP Delivery flow Stroke volume Electric motor il tank capacity Pressure setting 4, Air booster pump Outlet pressure Max. flow at no pressure Pumping speed Displacement per cycle Oil tank capacity 5. Electric motor 6 Weight PAGE : 2 VTU-2100_RT-flex96C MANUAL NO, : VTU-2100-1,9(2006.08) + VTU-2100 3ph x 440V x 6OHZ 44Lmin at 1720 rpm 2 2620 / rev, 3.0kw x 440V x 60HZ + 20 Liter Pressure relief valve. Pre ~ set 400bar Cartridge valve M22 x 1.5 +: 1800bar at 7bar air input OStiter 7 min = APPROX. 417 cyclelmin. at 7bar air input 1.208 Approx. 6Liter BIA flange. 3-Phase Squirrel cage induction motor. IP55 Enclosure according to IEC 34-6. Insulation class F. Approx. 200kgPAGE : 3 HANMI| POWER VTU-2100_ BT-flex96C 509001 MANUAL NO. : VTU-2100-1.9(2008.08) : (Figure 1. Unit Layout ) @ Hydraulic Control Valve @ Pressure Gauge (0-1000bar / 100Mpa) ® Pressure Gauge (0-1600bar/160Mpa) © Relief Valve (325bar) @ Pressure Release valve QD Torque Cylinder ® Pressure Release Valve for Booster Pump ® Pressure Control Valve ® Air Pressure Gauge (0-10bar/1.0Mpa) G Hydr, Hose for Fuel Valve Gti Hydr. Hose for Torque CyldIF.0 Relief Valve | Cyd cover Safety ValvePAGE : 4 HANMI POWER VTU-2100 RT-flex96C MANUAL NO. : VTU-2100-1,9(2006.08) 180 9001 B. OPERATING INSTRUCTION ‘The VTU-2100 ensures the correct testing of SULZER Diesel RT-flex fuel valve. ‘All numbers in the test refer to the numbers found on the VTU-2100 front panel (see the figure 1, Unit Layout illustrated overleaf.) 1. PREPARATION Before connect the air line to the unit, check the oil tank is filled with clean hydraulic oil (viscosity 7-10 Cst at 50° c) Place the lever of the hydraulic control valve (3) is “NEUTRAL" position. ‘Turn the Pressure control valve (5) anti-clockwise until the handle of the regulator is smooth. 2. OPERATING THE PUMP UNIT ™ Connect the electric power source of 3x440Vx60Hz to the control box. ™ Connect the compressed air pressure of 5-8 bar to the unit marked “AIR INLET ™ To avoid contamination of the pump, it is essential that an effective air filter and water separator is inserted in the air line. A lubro unit should however be avoided. See lubrication instruction. WHEN OPERATING THE ELECTRIC PUMP © Place the lever of the hydraulic control valve @) to "NEUTRAL" position, © Pump start switch “ON, and then electric pump will be operated. © To vent the air in pump and the high pressure pipe lines, maintain this pumping during 1-2 minutes. © Pressure gauge @) indicates 0 bar. ‘© Pump stop switch “ON”, and then electric pump will be OFF. WHEN OPERATING THE AIR BOOSTER PUMP Open the pressure release valve (13) 2-3 turns anti-clockwise. Increase the air pressure to 3-4 bar by turning the Pressure control valve (5) clockwise. The pump will be operated. Maintain this pumping during 1-2 minutes to vent the air in the high pressure pipe lines, Decrease the air pressure by turning the Pressure control valve (5) anti-clockwise until the air pressure gauge @ indicates 0 bar. ‘© Now every preparation for test of each valve and operating torque cylinder has finished.PAGE : 5 HANMI POWER VTU-2100 RT-flex96C La MANUAL NO. : VTU-2100-1,9(2006.08) 3. TEST PROCEDURE OF FUEL VALVE "install the Holder to the mounting stand by two bolts. ‘install the fuel valve to the mounting by two bolts. "After assembling, 4-7mm gap to be performed between stand upper side and fuel valve flange lower side. (Refer to Figure 2.) "Connect the hydraulic hose Gi to the valve. (i itis difficult to connect hydraulic hose owing to remaining pressure in the hose, remove the pressure by turning pressure release valve @) 2-3 tum anti-clockwise) (Figure 2. Install the fuel valve) OPENING PRESSURE © Close the pressure release valve (8) firmly by turning clockwise © Pump start switch “ON", and then electric pump will be operated. © Move the handle of the hydraulic control valve (3) to “OPENING TEST" (3A) position. © At that time check the opening pressure which is read on pressure gauge @ is correct. © Move the handle of the hydraulic contro! valve @) to NEUTRAL" position ‘© Pump stop switch "ON", and then electric pump will be OFF. LEAKAGE OF THE FUEL VALVE © Close the pressure release valve @®) firmly by turning clockwise. © Pump start switch “ON, and then electric pump will be operated. © Move the handle of the hydraulic control valve @) to “LEAK TEST" (38) position. © The pressure gauge @ will indicator approx. 325bar by pressure relief valve control Check that there is no leak at the atomizes. © Confirm the lever of the hydraulic control valve @) to "NEUTRAL" position, ‘© Pump stop switch “ON", and then electric pump will be OFFPAGE : 6 HANMI POWER VTU-2100 RT-flex96C MANUAL NO. : VTU-2100-1,9(2006.08) 180 9001 DISMANTLING OF CAP NUT © Separate the holder from mounting stand. © Rotate the mounting stand horizontally which the fuel valve is installed, And fix it by the fixing pin © After assembling, Omm gap to be performed between stand upper side and fuel valve flange lower side. (Refer to Figure 3) © Insert the spanner to the fuel valve as shown fig. 4, (Figure 3. Install the fuel valve) (Figure 4. Dismantling) © Push the spanner by the torque cylinder as follows. a) Close the pressure release valve 1 firmly by turning clockwise. b) Confirm the pressure gauge (® indicates 0 bar, If not, turn the Pressure control valve 1) anti-clockwise ©) Confirming the top of the torque cylinder is correct position of the spanner, increase the pressure slowly by turning the Pressure control valve (6) clockwise until the pressure gauge ©) indicates max. 450 bar. 4) Open the pressure release valve firmly by turning anti-clockwise. e) Decrease the air pressure by turning the Pressure control valve () anti-clockwise until the pressure gauge @ indicates 0 bar.PAGE : 7 HANMI POWER VTU-2100 RT-flex96C La MANUAL NO. : VTU-2100-1,9(2006.08) ASSEMBLY OF CAP NUT Insert the spanner to the fuel valve as shown figure 5. © Push the spanner by the torque cylinder as follows. a) Close the pressure release valve (2 firmly by turning clockwise. b) Confirm the pressure gauge @ indicates 0 bar. If not, turn the Pressure control valve ) anti-clockwise. ©) Confirming the top of the torque cylinder is correct] position of the spanner, increase the pressure slowly by turning the Pressure control; valve Figure 5. Assembly) ® clockwise until the pressure gauge () indicates 420 bar. (Tightening - Nut : SW-70) (Be careful in order not to add than 420 bar. (SW-70) If not the fuel valve may be damaged) @) Open the pressure release valve 1) firmly by turning anti-clockwise. e) Decrease the air pressure by turning the Pressure control valve “) anti-clockwise until the pressure gauge @ indicates 0 bar. f) After every test of the fuel valve, separate it from the mounting stand. 4. TEST OF THE OTHER VALVES. y BOLT CYL’ COVER SAFETY VALVE © Install the Test block to the mounting stand by two bolts. JOUNING © Install the safety valve to the mounting test block. STAND (Refer to, Figure 6) a) Connect the high pressure hose(2i-1: to the test block. b) Close the pressure release valve ‘1d) firmly by turning clockwis TEST BLOCK c) Confirm the pressure gauge © indicator Obar. If not, turn the pressure control valve 15) anti-clockwise. d) Increase the air pressure slowly by turning the pressure control valve (8) clockwise watching the pressure (Figure 6. cyl’ cover safety valve) gauge (5) and the valve. ©) When the valve opens and hydraulic oil comes out from it, read the pressure. f) Open the pressure release valve 3) firmly by turning anti-clockwise. g) Decrease the air pressure by turning the pressure control valve (8) anti-clockwise until the pressure gauge © indicator Obar h) After every test of the valve, separate it from the mounting stand.PAGE : 8 HANMI| POWER VTU-2100_RT-flex96C Sra001 MANUAL NO, : VTU-2100-1,9(2006.08) F.0 RELIEF VALVE sb © install the F.0 relief valve to the mounting test block. t TEST LOCK ‘© Install the spacer ring to the mounting stand by two bolts, i ACER. RING © Install the Test block to the mounting stand by two bolts. (Refer to. Figure 7) A fh MOUNTING a) Connect the high pressure hose to the test block. 7 STAN b) Close the pressure release valve 113) firmly by turning clockwis y ©) Confirm the pressure gauge ( indicator Obar. If not, turn the pressure control valve (5) anti-clockwise. x | @) Increase the air pressure slowly by turning the pressure control valve (®) clockwise watching the pressure gauge ) and the valve, (Figure 7. F.0 relief valve) e) When the valve opens and hydraulic oll comes out from it, read the pressure. f) Open the pressure release valve (3) firmly by turning anti-clockwise. g) Decrease the air pressure by turning the pressure control valve (8) anti-clockwise until the pressure gauge ( indicator Obar h) After every test of the valve, separate it from the mounting stand. 5. CLEANING OF OIL FILTERS ‘The mesh filter which is found in the filler cap has to be removed and cleaned when the fuel oil has a tendency of slow flow. The oil filter @® which is found in the outlet from the oil vessel is of the “thraw-away type, which should be removed and substituted by a new filter, when the old one has clogged, and the filter should under all circumstances be changed at least once every six months. Please note that before removing this filter, the oil vessel should be empty completely, which Is easily done by operating the pump unit without a fuel valve. 6 LUBRICATION INSTRUCTION WARNING : AVOID AIRLINE LUBRICATION. The pump has been pre-lubricated and a lubro unit will decrease the efficiency of the pump. Air valves should be lubricated periodically. Remove exhaust fittings and valve spool and apply a thin coat of the supplied grease. If primary air drive section is dismantled, always apply a thin coat of the grease to entire inner surface of cylinder tube and plunger o-rings180 9001 HANMI POWER C. OUTLINE OF THE VTU-2100 Pos.t Pos2 Pos Pos Poss Pos Post Poss Pose Pos.10) Pos.tt PUMP START PUMP STOP. Bectric Pump Booster Pump (side VTU-2100unit) Hydraulic Control Vale for Working Pressure Gauge (0-100bar | 100Ma) Pressure Gauge (0-1600baI160VPa) Relief Valve (326ber'325MPa) Check Valve (nse VIU-2100 unt Pressure Release Valve Booster (0.7L) {side VTU-2100unit) Distributor (inside VIU-2t00uni Torque Cylinder (1e-s200-001 (1e-a200-001 (vvevTu-o3) (w-vTu-04) (vvevTu-o5) (w-vTu-08) ievTuor) (w-vTu-08) (12-4020) (wevTu=t0) (33-1000-00) Pos2t-1 Pos.t2 Pos.t3 Pos.td Pos.t5 Pos.t6 Post? Pos.18 Pos.t8 Pos.20 Pos2t PAGE : 9 VTU-2100 RT-flex96C MANUAL NO. : VTU-2100-1.9(2008.08) Ball Valve Pressute Release Vae for Booster Pump Ai iter inside VTU-2100 unit Pressure Control Valve A Pressure Gauge (-1Dai MPa) Oi Fier (inside Oil tank Oil tank (inside VTU-2100 unit) Oi Level Gavgeliside VTU-21004n9) Filer Cap with Strainer Hyd. Hose for Fuel Valve Hyd, Hose for Torque Oya Reet vale (huevTu-t2) (HMeVTU-13) cenevTU (HM-VTU-I8) (HMeVTU-18) (HMeVTU-I7) (12-8001-2.) (HM-VTU-I9) (HMeVTU-20) (HevTu-et) HM-VTU-2t-1)REASON FOR MODIFICATION |REV’D|CHK’D DETAIL OF AIR INLET COUPLING Gaintenance Space) \ eu START —+ <> - 4H AR INLET WN. S BAR Wax 10 848 POWER SUPPLY SAHOVAC soa Howes ter wi2 BOLT in. 700, [a win, 700, Mento (Waintenarce "ORT FUEL VALVE TEST DEVICE (VTU—2100) M.W.CHOI THE DIMENSION OF OUTLINE Hea _ PROJECTION D.H.KOO (0P-052-05(Rev 0} oso IANMI HYDRAULIC MACHINERY CO., LTD. S.Y.CHO! Sele DRAWING NO. M12-5000-1.0 "AA(210x297)(QP-052-05(Rev 0) SUPPORT ANGLE FOR INJECTION NOZZLE SUPPORTING STAND SPANNER FOR TIGHTENING AND LOOSENING PRED M.W.CHOI on AE N/S. POET FUEL VALVE TEST DEVICE (VTU-2100) B.C.KIM me STAND & SPANNER: RT-flex96C PROJECTION Tes D.H.GU kar ‘ANMI HYDRAULIC MACHINERY CO., LTD. ) Bole DRAWING NO. M12-5012-1.0 "54(210x297)+ ASS'Y WEIGHT: ABT. 6 Kg [oammer ors Peewee ee aeeRP EEF ees i ay ra i z ip i a i a g a i § z : 5 i 5 iFUEL VALVE TEST DEVICE. E : VTU-2100 M12—5014-0.3, SUPPLY PER SHIP a MATERIAL DRAWING NO. | REMARK z= 2 SPARE & TOOLS TOOL BOX COMBINATION SPANNER SINGLE OPEN ENDED SPANNER + DRIVER MALE COUPLER COPPER MANUFACTURER'S. NAME HYDRAULIC MACHINERY CO., LTD. (QP-052-05(Rev 0} (FY Sere "Aa(210%297)ATE, (060330 FUEL VALVE TEST DEVICE MODEL : VIU-2100 DWG. NO. M12-5015-0.1_ (1/2) SUPPLY PER SHIP MATERIAL 2 DRAWING. NO. REMARK (WEIGHT) Kg PACKING SEAL UHMWPE 10-3217 -0.0 SPRING. ‘SUS304 O-RING MANUFACTURER'S NAME ‘QP-052-05(Rev 0) HYDRAUL aol eI C MACHINERY CO., LTD. ‘A4(210:287)ATE, 060330 FUEL VALVE TEST DEVICE MODEL : VIU-2100 M12—5015-0.1 (2/2) REMARK (WEIGHT) Kg MATERIAL DRAWING. NO. 10-3241 -sroa2- 0.0 014.38 — 10-3243 -0.0 10-3244 -0.0 MANUFACTURER'S. NAME HYDRAULIC MACHINERY CO., LTD. ‘QP-052-05(Rev 0) aol eI ‘A4(210:287)JIG & ACCES: SSORY FUEL VALVE TEST DEVICE VTU-2100 TYPE RT-flex96C M12—5117-1.0 SUPPLY. PER SHIP MATERIAL, REMARK ‘SPANNER FOR CAP NUT DISMANTLING & ASSEMBLY HOLDER FOR FUEL VALVE INJECTION TEST 3 -2-MI2210L a i TEST BLOCK FOR FUEL PUMP RELIEF VALVE 2-M12. STUD & NUT» Y Gen Be 2-12. BT TEST BLOCK FOR CYL’ COVER SAFETY VALVE. /-#160 t ay 2-Mi6x40 STUD BOLT FOR [ADJUSTING DEVICE M12 NUT & WASHER, CLAMPING TO USE CY'L COVER SAFETY V/V HEXAGON HEAD PLUG WITH FLANGE AND GASKET cael BE ADAPTER FOR HYDRAUUC HOSE FOR FUEL VALVE Zam 2980. TENSION WASHER CAGE wor Ps¢ a MANUFACTURER'S. NA (0P-052-05{Re" 0) (Fy Bae we | imap) LIC MACHINERY CO., LTD. "aa(z10%287)Project ...... CONTROL BOX FOR FUEL VALVE TEST DEVICE (VTU-2100) Supply ..... : 3Ph x 440V + 60Hz Drawing no. 12 — 5503 - 0.0 Ta z a SSS, a rE VOT Pg, om mc wanea [31% a Contents PAGE [DESCRIPTION REWSION 3__|Bectical cabinet layout 4 [Wein voltoge - Pump start 5_|Ports lst [Terminals Block list =, Ss = a OT woo | Bisa ‘CONTENTS $ nate rN . ae GaP mea mone, on. “ %OWER(CableTC—18) Aad PAL cow SWITCH sien075-4e) € =i z . waPlyet oe Te fs 2 Ce &e ts aS] POTN wt go FUEL VALE TEST DEWCE 2 — [DRAWING NO. 2 bal vsacnar woes cea | a 6 ww me ortT I La T I [ss TT 0 Parts list ‘SYMBOL| 'TY [NAME OF PARTS MODEL MAKER FAN NR. 2 [Cobinet Rittcl AE 1380 LX ttl x0 [20 [Terminals Terminals, Control voltage 4F2 1 [Thermal cireuit breaker [C60N/A Merlin Gerin 4«7_| + |Contoctor HiMC9/c220V coil HH 404 | 1 [Thermal circeuit breaker |HiTH22K_ 4-64 HHI 487.1 | 1 [Push botton switch [ZB5~AAS+ZB5~AZ102 elemecenique 487.2 | 1 [Push botton lamp switch | XB6AW33M5 /GREEN Telemeconiaue ame5 [1 [Control transformer 440/220V-SOVA [General = = “FROUESTION sos ya20 PARTS UST a A Koo DRAWING NO. ‘dy (R20) ean aan owe AER AGE] me Qa HAN HMI MACHER 0, TD, REVOKE | REASON FOR MODIFICATION [REVD/GHR'D APD) 22 [wow wr2-8506-04oa z I Tz 13 PUMP PANEL ° ' rena 10K rae : E =, Ss = a OT MMO TERMINAL BLOCK $ Soo DAE 8 lia) nmcrnaenncan |e Kp ot seu. wewer cm NE