(Series 3/GTC) PUMP005/7/8/8A/9/9A Hydraulic Oil Temperature Does Not Indicate As Expected - Troubleshooting

(Series 3/GTC) PUMP005/7/8/8A/9/9A Hydraulic Oil Temperature Does Not Indicate As Expected - Troubleshooting

(Series 3/GTC) PUMP005/7/8/8A/9/9A Hydraulic Oil Temperature Does Not Indicate As Expected - Troubleshooting



Article Type:
 Applicable Equipment:
Troubleshooting
 PUMP005: 20 HP RWE Hydraulic Pump

PUMP007: 20 HP RWE Hydraulic Pump

PUMP008: 20 HP RWE Hydraulic Pump Filtered

PUMP008A: 20 HP RWE Hydraulic Pump Filtered (GTC)

PUMP009: 20 HP RWE Hydraulic Pump OilGear Main Pump

PUMP009A: 20 HP RWE Hydraulic Pump OilGear Main Pump (GTC)

Error Description:

The oil temperature on the console display does not indicate as expected. The oil temperature can be higher or lower than expected; or the oil temperature can be inaccurate.

Possible Error Causes:

There are many reasons for variations in oil temperature including ambient temperature of the hydraulic pump, coolant supply to hydraulic pump, abnormal operation of the Gleeble System, disconnected communication wiring, and or faulty components.

Warning and Cautionary Statements:

Read and understand all warning statements before proceeding:

Warning: The following may involve exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  
Warning: Some sections of this manual may require the Load Unit and Hydraulic Pump be de-energized and locked out and tagged out according to all local and facility regulations. Failure to do so could lead to serious injury or death
Warning:  Body parts must never be within the boundary of any moving components with the hydraulic or pneumatic (air ram) system energized. Failure to obey this instruction can result in serious injury or death.    
Warning: Hot surfaces may be present which could result in severe burns.  Wear suitable Personal Protective Equipment to avoid injury from accidental contact with hot surfaces.  
Warning: The Gleeble is capable of generating strong electromagnetic fields. Individuals with pacemakers or other medical equipment should not use or work on the Gleeble. Failure to obey can result in serious injury or death.
Caution: Improper measurements or mishandling of measurement equipment could result in damage to equipment. This work must be performed by experienced, qualified personnel.
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump 
Caution:  Observing test samples at elevated temperature could lead to vision damage. Proper vision protection must be used when observing samples at high temperature.
Caution: The reader should fully understand all instructions listed in this article. If any points are unclear or the reader is uncomfortable performing any listed steps they should contact DSI before proceeding with any of the listed actions. 

Tools Required for Troubleshooting:

  • Multimeter (DC Voltage, Ohms)

Troubleshooting Flow Chart:



Troubleshooting Steps:


Compare Displayed Temperature To Thermometer on Hydraulic Pump:

The temperature reading found on the Gleeble console can be compared to the thermometer located on the hydraulic pump in order to determine if the console reading is accurate.
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump

  1. Power on Gleeble System.


  2. Select "Accept Configuration" from configuration screen (This step is for GTC equipped systems only).


  3. Reset panic safety by pressing the blue reset button.

  1. Reset the hydraulic pump E-Stop with supplied key.


  1. Ensure the hydraulic oil is filled half way up the upper sight glass.
    1. Fill as needed.


  1. Compare the temperature displayed on the console with the thermometer on the hydraulic pump sight glass.
     

 
If the console and hydraulic pump thermometer match and read as expected then troubleshooting is complete.
If the console and hydraulic pump thermometer display the same temperature, but the temperature is not as expected proceed to Oil Over Temp Error or Oil Is Hotter Than Expected or Oil Is Colder Than Expected 
If the console and hydraulic pump thermometer display very different temperatures proceed to Investigate Electrical Connections.


Oil Is Colder Than Expected

If the hydraulic oil temperature is below the expected value (~30°C), the hydraulic oil most likely just needs to be circulated through the pump in order to let it warm up. It is recommended that tests be run when the hydraulic oil is about 30°C.
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump
The ambient atmosphere surrounding the hydraulic pump can impact the hydraulic oil temperature. Ambient temperature should be between 21 °C and 27 °C, climate controlled and non-condensing.
  1. If using a GTC equipped system, place the Gleeble in run mode. If using a series 3 system, simply turn the Gleeble on.
  2. Disengage the panic safety system.
  3. The circulating pump will circulate the hydraulic oil to achieve and maintain an oil temperature of 30°C.
Troubleshooting is complete if the circulator pump heats the oil to the desired temperature.
If the circulator pump is unable to heat the oil to the desired temperature, contact DSI for further assistance.


Oil Over Temp Error or Oil Is Hotter Than Expected

If the oil temperature is higher than expected its possible that the valve that controls the water flow needs to be adjusted or that the chiller has simply been turned off. 

Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump
The ambient atmosphere surrounding the hydraulic pump can impact the hydraulic oil temperature. Ambient temperature should be between 21 °C and 27 °C, climate controlled and non- condensing.
The Gleeble software has a hydraulic oil limit of 50°C. if the hydraulic oil is above this temperature the oil needs to be cooled down prior to proceeding with troubleshooting.
    1. Ensure the chiller is turned on and circulating coolant properly.
    2. Ensure that all valves between the chiller and the hydraulic pump heat exchanger are open. 
    3. Adjust the coolant needle valve as needed to cool the hydraulic oil. Note that the water flow is increasing as more colored bands are revealed at the base of the valve knob.

  1. Allow 20 minutes for the oil temperature to equalize.
The default setting for hydraulic pump coolant needle valve is the gold ring.
If adjusting the hydraulic pump coolant needle valve is successful, no further troubleshooting is needed.
If the hydraulic oil still does not cool to a reasonable temperature, contact DSI for further assistance.


Investigate Electrical Connections.

It is possible that one of the necessary electrical connections that allows communication between the Gleeble and hydraulic pump temperature sensor has come loose. If this happens the oil temperature will typically display a constant value of 0C. The following connections should be investigated:
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump

  1. Re-seat the hydraulic pump CANBus cable to ensure a proper connection:
    1. Turn off power to the Gleeble
    2. Locate the hydraulic pump CANBus cable found on the side of the Gleeble load unit.

    1. Unplug and re-plug the CANBus cable. Ensure that the cable is firmly seated in its connector. Note that all four CANbus jacks are interchangeable. 
  1. Check to ensure that hydraulic pump oil temperature sensor cable is properly secured to the oil temperature sensor.
    1. Turn off all power to the Gleeble
    2. Locate the hydraulic oil temperature sensor and cable

    1. Ensure that the oil temperature sensor cable is firmly attached to its plug. Remove and re-seat as needed.

If re-seating one of the connectors has resolved the issue, no further action is needed.
If the oil temperature is still incorrect, please proceed to Check The Hydraulic Oil Thermometer.

Check The Hydraulic Oil Thermometer.

The presence of the voltage used to power the oil temperature sensor and the output signal from the temperature should be confirmed to be present and correct. 
Warning: The following may involve exposure to high voltages and could result in serious injury or death.  All high voltage measurements and troubleshooting must be performed by experienced, qualified personnel using the appropriate Personal Protective Equipment and following all local codes and facility regulations.  
Caution:  Adequate hearing protection must be worn at all times when working near the active hydraulic pump
  1. Confirm the presence of the oil temperature sensor power voltage:
    1. Locate the 3016 I/O board found in the Gleeble hydraulic pump

    1. Locate connector P4 on the 3016 I/O board. P4 is the 4 pin top most green combicon connector on the 3016 board. Use a multimeter set to measure DC voltage to measure across pins 3 and 4 of P4. Please use electrical drawing number 3000WHY05 as a reference and to confirm the measurement location on your machines specific wiring revision.


    1. If things are working properly, 5Vdc should be measured at this location. If this voltage is not present, its possible that the 3016 board is damaged. In this case contact DSI with your findings for further assistance. If 5Vdc is measured, proceed on to the next step.
  1. Confirm presence of output signal voltage from oil temperature sensor:
    1. Locate the 3016 I/O board found in the Gleeble hydraulic pump
    2. Using a multimeter set to measure DC voltage, measure across pins 24 and 25 of the green combicon connector found on the 3016. Please use electrical drawing number 3000WHY05 as a reference and to confirm the measurement location on your machines specific wiring revision.

    1. If working correctly, the measurement at this location should be the oil temperature divided by 100. For instance if the oil temperature was 20C, the voltage reading would be 0.20V. If the reading here seems incorrect, use electrical drawing 3000HY05 to confirm the wiring between this location and the oil temperature sensor. If the wiring looks correct, the oil temperature sensor itself could be bad.
If investigating the oil temperature sensor has resolved the problem, no further action is needed.
If investigating the oil temperature sensor has failed or faulty parts were identified, please contact DSI for further assistance.