Series 505 Silentflo Hydraulic Power Unit Product Information

Series 505 SilentFlo Hydraulic Power Unit
Product Information
l
Model 505.60
Model 505.90
Model 505.120
Model 505.150
Model 505.180
100-006-453 D
Copyright information © 1999-2001 MTS Systems Corporation. All rights reserved.
Trademark information MTS is a registered trademark of MTS Systems Corporation.
DTE is a registered trademark of Mobil Corporation.
Tellus is a registered trademark of Shell Oil Corporation.
Molykote is a registered trademark of Dow Chemical Corporation.
Synasol is a registered trademark of Union Carbide Corporation.
Contact information MTS Systems Corporation

14000 Technology Drive
Eden Prairie, Minnesota 55344-2290 USA
Toll Free Phone: 800-328-2255 (within the U.S. or Canada)
Phone: 952-937-4000 (outside the U.S. or Canada)
Fax: 952-937-4515
E-mail: info@mts.com
www.mts.com
ISO 9001 Certified
Publication information MANUAL PART NUMBER PUBLICATION DATE
100-006-453 A October 1999
100-006-453 B January 2000
100-006-453 C September 2000
100-006-453 D January 2001

Contents
Introduction 5
Component Identification 6
Functional Description 8
Specifications 11
Model 505.60 Specifications 12
Installation 17
Operation 23
Controls 24
Using the Operator Interface 26
Operation 29
Recovering from an Interlock 30
Changing the Water Flow 31
Resetting the Thermal Overloads 32
Setting Up the Run-On-Demand Parameters 33
Maintenance 35
Replacing the Filter 36

Sampling the Hydraulic Fluid 38
Replacing the Hydraulic Fluid 40
Service 43
Replacing the Low Level/Temperature Fixture 44

Replacing a Pump Assembly 45
Series 505 Hydraulic Power Unit Contents 3

Appendix 47
Model 505.90 Hydraulic Schematic 48

Model 505.90 Electrical Schematic 50
4 Series 505 Hydraulic Power Unit

Introduction
The Model 505.60/.90/.120/.150/.180 Hydraulic Power Units (HPU, also
called a hydraulic power supply or HPS) produce the high-pressure
hydraulic fluid for test system operation. The various models represent
different flow ratings based on the number of pumps in each model.
Contents Component Identification 6

Functional Description 8
Specifications 11
Models 505.60/.90 HPU
Models 505.120/.150/.180 HPU
Series 505 Hydraulic Power Unit Introduction 5

Component Identification
Heat Exchanger and

Manifold Enclosure
Electrical
Enclosure
Operator Filter Assembly

Interface
Hour Meters
Pump
Emergency Assemblies
Stop Switch
Power
Disconnect
Switch
Level/ Temperature
Switch
Level/ Temperature
Transducer
Oil Level
Dial Gage
Filler Cap
Reservoir
Commoning
Expansion Plate
Component Identification
6 Introduction Series 505 Hydraulic Power Unit

Component Descriptions
COMPONENT DESCRIPTION
Electrical enclosure Houses the electrical control components. The wye-delta starters for the
Model 505.60/.90 HPUs are located in the electrical enclosure. The wye-
delta starters for the Model 505.120/.150/.180 HPUs are located in the
pump assemblies. Main service power lines enter the electrical enclosure
at its top.
Operator interface Configures the hydraulic power unit and it is used to enter control
commands. It displays the current status of several sensors. For a
description of each control and indicator, see “Controls” on page 24.
Hour meters Individual meters display the number hours each motor has been
running.
Power disconnect switch Disconnects the incoming power from the HPU. The switch is a lockable,
mechanical latch. The switch is a lockable mechanical latching
mechanism. Power is removed whenever the door to the electrical
enclosure is open. The switch will not allow the door to be opened
when in the ON (|) position. Incoming power lines to the switch are live
unless power is removed externally.
Level/temperature switch Senses the hydraulic fluid level and temperature. Control interlocks
automatically shut the HPU down if the fluid level drops too low or the
hydraulic fluid temperature rises above the temperature setting. For more
information see “Replacing the Low Level/Temperature Fixture” on page
44.
Level/temperature Senses the hydraulic fluid temperature and produces an analog signal for
transducer control purposes.
Oil level dial gage Indicates the reservoirs hydraulic fluid level.
Filler cap Vents the hydraulic fluid reservoir. This is where you add hydraulic fluid.
Reservoir Holds the hydraulic fluid and houses the pump and motor.
Commoning expansion Allows the HPU to be commoned with another HPU.
plate
Pump assemblies Produces the pressurized hydraulic fluid for system use. Each pump
assembly includes a motor, pump, and electrical enclosure for
connecting with the main starter.
Filter assembly Filters, to 3 micron absolute, particles out of the hydraulic fluid as it is
returned to the HPU. For more information, see “Replacing the Filter” on
page 36.
Heat Exchanger Regulates the temperature of the hydraulic fluid using a highly efficient,
stainless steel oil-to-water heat exchanger. It is engineered to remove the
heat generated by the HPU. For more information, see “Changing the
Water Flow” on page 31.
Manifold Combines the output of the separate pumps to deliver the full output of
the HPU through a single port. The manifold provides solenoid control
of the high/low pressure output from the individual pumps. It also
contains relief valves for each pump circuit and a bypass circuit to
maintain the hydraulic temperature during low flow conditions.

Functional Description
The Series 505.60/.90 and 505.120,/.150/.180 HPU platforms are a modular
design that can be configured with up to six pump assemblies.
Note The hydraulic schematics and the electrical schematics for the Model
505.60/.90 and Model 505.120-180 are located in the “Appendix” on
page 47. The difference between the models is the number of pump
assemblies.
Pump assemblies One to six pump assemblies draw hydraulic fluid from the reservoir and
pressurize it to a maximum of 21 MPa (3000 psi). Each pump assembly
contains a variable volume pump, a motor, and an electrical enclosure.
Each pump assembly has a flow capacity of 113 L/min (30 gpm) and
contributes to the hydraulic flow capacity of the HPU.
Manifold The manifold combines the pressurized hydraulic output of the discrete
pump assemblies, and provides the hydraulic connection to your hydraulic
system. The manifold contains the high/low pressure solenoid valve and a
nonadjustable relief valve set at 22.4 MPa (3250 psi). Check valves are
located within the manifold to prevent pressurized hydraulic fluid from
being forced back through the pumps.
The hydraulic power unit uses solenoid-operated valves to control when

high-pressure is available to the hydraulic circuit. Start/low/high control
settings are selected at the operator interface on the electrical enclosure’s
front panel.
The HPU is designed to start in low pressure which reduces the amperage
needed for starting and extends the life of the pump and motor. When
operating at this setting, low-pressure hydraulic fluid circulates back to
reservoir through the manifold. The direct fluid path back to the reservoir
limits pressure and flow available out to the external hydraulic circuit.
When high pressure is selected, the unit forces pressurized hydraulic fluid
out to the hydraulic circuit.
Accumulator option Accumulators can be added to the hydraulic output lines to damp pressure
line fluctuations. This option accommodates one pressure line accumulator.
Filtering Hydraulic fluid returning to the reservoir is filtered by a full flow 3-micron
element. This ensures the filtering of all hydraulic fluid whether it travels
out through the circuit or returns by way of the unit’s manifold under low
pressure. Filter element loading is monitored automatically. A warning
registered on the unit’s operator interface signals when the filter needs an
element change.

Heat exchanger Hydraulic fluid temperature is maintained with a high efficiency stainless
steel heat exchanger that cools the fluid. A regulating valve monitors the
temperature of the hydraulic fluid and adjusts the flow of water through
the plates.
• The normal operating temperature range of the hydraulic fluid is

16–49°C (60–120°F).
• If the hydraulic fluid temperature exceeds 55ºC (131ºF), a switch

opens and shuts down the HPU.
• When the HPU is shut off, the flow of water is automatically stopped
by a shutoff solenoid valve.
Electrical control The HPU can be controlled locally using the operator interface, or remotely
through a controller via the J1 connector. A PLC (programmable logic
controller) manages the electrical systems within the HPU. The electrical
system includes the following:
• An operator interface that contains a keypad to program preferences

and operational settings. The operator interface also provides displays
of the unit’s condition, including motors status, hydraulic fluid level
and temperature conditions, and filter condition.
• Wye-delta starting reduces the initial current rush when the motor
starters are engaged.
• Thermal overloads protect the individual HPU motors from excessive

current draw.
• A latchable Emergency Stop button prevents inadvertent starts.
• Interlocks protect the HPU against low hydraulic fluid level,

overtemperature, and dirty filters.
• A reset button brings the unit back into operation after a fault has
been detected and corrected.
• A dirty filter signal will not shut the unit down, but will prevent the
unit from starting.
• Hour meters provided for each pump/motor assembly help you

determine maintenance intervals.
• A power disconnect switch located on the electrical enclosure’s door
ensures power is removed whenever the door is opened. This device
is both an ETL and TÜV certified lockable, main-disconnect switch.
Note The electrical schematics for the Model 505.60/.90 and Model 505.120-
180 are located in the “Appendix” on page 47. The difference between
the models is the number of pump assemblies.

Run-on-demand The run-on-demand (R-O-D) option will turn individual pumps on and off
option as needed to accommodate the systems demand for hydraulic fluid. A PLC
monitors the fluid flow, when flow changes beyond preset limits, a pump
will be turned on or off as needed.
For example, if 5 pumps are enabled, a total capacity of about 550 L/m is
available. Suppose the fluid flow is 400 L/m. The auto demand feature will
run four pumps. When the fluid flow increases to a user defined trigger
point, the fifth pump automatically starts to meet the increased fluid
demand.
In addition to the front panel hour meters, the PLC also monitors the
running time (hours) of each pump. When hydraulic power is applied, the
HPU checks the running time of the enabled pumps and starts pumps with
the lowest running time.

Specifications
The following table lists the specifications that are common to all models.
General Specifications
PARAMETER S PECIFICATION
Environmental For use in a controlled environment.
Operating temperature 5–40°C (40–104°F)
Humidity 0–85% noncondensing
Heat load < 630 kcal/hr (2500 Btu/hr)
Noise rating at 1 m 70 dB (A) fully compensated*
Hydraulic fluid Mobil DTE 25 or Shell Tellus 46 AW
Nominal temperature 16–55°C (60–130°F)
Filtration (microns) 3 µ nominal
Output Pressure 21 MPa (3000 psi)
Heat exchanger Water-cooled
Flow requirements 13 L/m at 21°C (12 gpm at 70°F)
Water pressure 0.2–0.3 MPa (35–45 psi)
Maximum pressure 0.8 MPa (120 psi)
Cooling 38,520 kcal/hr (153,000 Btu/hr)
Water hose 38 mm (1.5 in) NPT standard
Hydraulic connections
Pressure 2 inch SAE
Return 2 inch SAE
Drain -16 JIC
Electrical Power
Line voltage 380–575 V AC
Control voltage 24 V DC
* Can vary due to ambient conditions.

Model 505.60 Specifications
See “General Specifications” on page 11 for specifications that are common
to all of the HPU models.
PARAMETER S PECIFICATION
Pump/Motor Wye-Delta starter configuration
Number of pump/motors 2
Flow capacity 200 L/m (53.2 gpm) at 50 Hz

at 21 MPa (3000 psi) 227 L/m (60 gpm) at 60 Hz
Motor rating* 45 kW (60 hp) at 50/60 Hz
156 A continuous at 460 V AC 60 Hz

Current draw†
Reservoir capacity 950 L (250 gal) maximum

605 L (160 gal) minimum
Water flow rating

(input temperature)
15.5°C (60°F) 41.6 L/m (11 gpm)
21.1°C (70°F) 56.8 L/m (15 gpm)
26.7°C (80°F) 83.3 L/m (22 gpm)
32.2°C (90°F) 177.9 L/m (47 gpm)
Heat load (maximum) 89.6 kW/hr (306,000 Btu/hr)
Dimensions
Length 2870 mm (113 in)
Height 2006 mm (79 in)
Width 990 mm (39 in)
Weight
Empty 1044 kg (2300 lb)
With hydraulic oil 1589 kg (3500 lb) minimum oil

1907 kg (4200 lb) maximum oil
* For one motor

† For all motors

P ARAMETER SPECIFICATION
Flow capacity 300 L/m (80 gpm) at 50 Hz


Current draw†

Water flow rating

(input temperature)
15.5°C (60°F) 64 L/m (17 gpm)
21.1°C (70°F) 83 L/m (22 gpm)
26.7°C (80°F) 129 L/m (34 gpm)
32.2°C (90°F) 269 L/m (71 gpm)
Heat load (maximum) 134.4 kW/hr (459,000 Btu/hr)
Dimensions
Weight
Empty 1271 kg (2800 lb)
With hydraulic oil 2134 kg (4000 lb) maximum oil

1816 kg (4700 lb) minimum oil
* For one motor

† For all motors

PARAMETER SPECIFICATION
Flow capacity 400 L/m (106.4 gpm) at 50 Hz


Current draw†

Water flow rating

(input temperature)
15.5°C (60°F) 72 L/m (19 gpm)
21.1°C (70°F) 91 L/m (24 gpm)
26.7°C (80°F) 114 L/m (30 gpm)
32.2°C (90°F) 174 L/m (46 gpm)
Heat load (maximum) 296 kW/hr (612,000 Btu/hr)
Dimensions
Weight
Empty 1476 kg (3250 lb)

* For one motor

† For all motors



Current draw†

Water flow rating

(input temperature)
15.5°C (60°F) 95 L/m (25 gpm)
21.1°C (70°F) 121 L/m (32 gpm)
26.7°C (80°F) 159 L/m (42 gpm)
32.2°C (90°F) 265 L/m (70 gpm)
Dimensions
Weight
Empty 1679 kg (3700 lb)

* For one motor

† For all motors



Current draw†

Water flow rating

(input temperature)
15.5°C (60°F) 128.7 L/m (34 gpm)
21.1°C (70°F) 166.5 L/m (44 gpm)
26.7°C (80°F) 257.4 L/m (68 gpm)
32.2°C (90°F) 537.5 L/m (142 gpm)
Dimensions
Weight
Empty 1271 kg (2800 lb)

* For one motor

† For all motors

Installation
This section describes how to install the Series 505.60–.180 Hydraulic
Power Unit (HPU).
Note These HPUs are designed for indoor use and should be installed
accordingly.
1. Position the hydraulic power unit.
You should determine where to put the HPU. Because it is connected

to the other hydraulic equipment through hydraulic lines, the HPU can
be located anywhere. Consider the following:
• The HPU can fit through a standard 1.04-m or 41-in door.
• The HPU can be moved by a fork lift, pallet jack, or over head
crane.
• Placement considerations should include proximity to the facility

electric power and the hydraulic components. (Positioning the
HPU close to the hydraulic components can reduce the cost of
hydraulic distribution.)
• The HPU produces less than 70 dB (A) of noise under free field
conditions and fully compensated. Readings can vary with the
acoustic environment.
When moving the HPU with an

overhead lift, use a spreader bar
to help balance the weight.
When moving the HPU with

a fork lift or pallet jack, lift
the HPU from both ends.
Series 505 Hydraulic Power Unit Installation 17

2. Connect the electrical service to the HPU.
Note Local electrical codes supersede any information found here.
Electrical connections must be made by qualified personnel and

conform to local codes and regulations.
The electrical box has a power disconnect switch that must be off (O)
in order to open the electrical box. An electrical service panel to
provide the electrical power feed (line voltage) to the HPU is not
necessary, but can be required by local electrical codes.
Electrical Power Feed Wires

(L1–L3 connections)
Common Ground
FU4
FU5
FU6
XFMR1
Connect the three (or six if parallel phase conductors are used)
electrical power feed wires to the lugs labeled L1, L2, and L3.
Connect the grounding wire to the lug labeled PE (protective earth

ground).
18 Installation Series 505 Hydraulic Power Unit

3. Connect the hydraulic and water lines.
Each port is labeled on the manifold. Take care to identify and

correctly make these connections. Failure to make proper connection
could lead to water in the hydraulic fluid, hydraulic fluid in the
cooling water, or pressurization of low pressure lines.
The HPU requires connection to a suitable water supply to cool the

hydraulic fluid. The differential pressure required between the HPU
water inlet and outlet connections is 0.2 to 0.3 MPa (30 to 45 psi). The
maximum allowable water inlet pressure is 0.8 MPa (120 psi).
1 1/2 inch NPT

Water Input
2 inch 2 inch
Hydraulic Hydraulic
Return Pressure
-16 Drain
1 1/2 inch NPT
Water Output
A. Connect the hydraulic pressure and drain lines to the hydraulic

fluid distribution system or directly to a hydraulic device. Use
hydraulic line or hose that is rated to handle the maximum
hydraulic pressure of the HPU.
B. An appropriate shutoff valve should be installed between the

water source and HPU.
C. Connect the water supply to the HPU Water In port. Connect the
Water Out port to your drain line.
D. A regulating valve must be adjusted according to your waters

temperature. For a description of how to set the water regulating
valve “Changing the Water Flow” on page 31.
The water supply must also be capable of maintaining water flow at a

rate listed in the following table.
Water Flow Ratings
W ATER MODEL NUMBER

TEMPERATURE
505.60 505.90 505.120 505.150 505.180
15.5°C (60°F) 42 L/m 64 L/m 72 L/m 95 L/m 128 L/m

(11 gpm) (17 gpm) (19 gpm) (25 gpm) (34 gpm)
21.1°C (70°F) 57 L/m 83 L/m 91 L/m 121 L/m 166 L/m

(15 gpm (22 gpm) (24 gpm) (32 gpm) (44 gpm)
26.7°C (80°F) 83 L/m 128 L/m 114 L/m 159 L/m 257 L/m
(22 gpm) (34 gpm) (30 gpm) (42 gpm) (68 gpm
32.2°C (90°F) 178 L/m 268 L/m 174 L/m 265 L/m 537 L/m
(47 gpm) (71 gpm) (46 gpm) (70 gpm) (142 gpm)

4. Add hydraulic fluid to the reservoir.
The unit is shipped with a plug in the filler cap. Remove the red filler
cap plug and install the screen in the fill port on the top of the
reservoir. The screen is shipped in the electrical enclosure.
Pump hydraulic fluid (filtered to 10 microns) into the reservoir. Stop

when the fluid level reaches the maximum fluid level as indicated by
the oil level dial gage.
5. Test the HPU.
A. Rotate the power disconnect switch to the on (|) position.
B. Enable a pump on the keypad located on the operator interface.
C. Momentarily start a motor by pressing the Run key. Check for the
proper rotation of each pump by verifying a pressure of 50 psi
registered on the operator interface. Each enabled pump will
sequence on and start running in low pressure.
D. Check for unusual noises or leaks. If a problem is found, press

the Stop key. You must correct the problem before you continue.
E. Press the Pressure key to change the HPU output to 21 MPa

(3000 psi).
F. Check that the output pressure gage is registering pressure. The

output pressure is preset at the factory for optimal performance. If
the pressure requires adjustment make corrections using the
individual pump’s pressure compensators.
G. Check for unusual noises or leaks. If a problem is found, press

the Stop. You must correct the problem before you continue.
H. Press the Stop key to shutdown the unit.
I. Repeat Steps C–H for each pump.
J. Press the Run key. Run the HPU at low pressure for about three
hours to filter the new hydraulic fluid.
K. Press the Stop key.

6. Set up the operator interface (if necessary).
The operator interface is programmed when manufactured. This step

describes how to set up the unit in the event the program has been
cleared or replaced.
SilentFlo HPU TM
SilentFlo HPU TM
Pump Motor Master Unit Control

Enable Disable Stop Run
Pump Motor Master Unit Control 1
Enable Disable Stop Run Del 7 8 9

Del 7 8 9
Pressure
1 2
Home Syst
Menu 4 5 6
4 5 6
Esc +1 Auto
Remote Pressure
2 3 Home Syst
Demand
1 2 3 Esc +1 Menu 1 2 3
Mod
Display Reset
3 4
Alarm
Enter +/- Mod +/- 0 .

Shift -1 0 . Remote
5 Alarm
Shift -1 Enter
Display Reset
6
Models 505.60/.90 Models 505.120/.150/.180
A. Press and hold Display on the keypad until the setup screen is
displayed (about 10 seconds).
Note The following figure shows the active display area of the control terminal
as gray boxes. Two types of control terminals are available.
The Model 505.60/90 Setup-Use Arrow Keys

display shows two lines To Scroll And Toggle
of information. Motor #1: Present
Motor #1: Present
Motor #1: Present
Temp Units: oC
Press Units: MPa
Pr Filt FB?: Yes
Rem Logic: Normal
Setup-Use arrow keys to scroll up/down.

The Model 505.120/150/180 Use MOD,arrow,and ENTER keys to modify.
display shows four lines of
information. PUMP#1:YES PUMP#4:YES PUMP#4:YES
PUMP#2:YES PUMP#5:YES PUMP#2:YES
Temp Units: oC Press Units: MPa
Rem Logic: NORM Pr Filt FB?: YES
Flow Meter: YES Flow Units: GPM
Use the arrow keys to scroll between the different lines of information.
Press the Mod key to select an item to edit (the Mod key also steps
between edit fields). Use the arrow keys to edit a selected field.
B. Identify each motor and pressure filter installed.
Press the up arrow if the selected item is not present.

Press the down arrow if the selected item is present.
C. Select your preference for temperature scales.
Press the up arrow to display the temperature in Fahrenheit.

Press the down arrow to display the temperature in Celsius.
D. Select your preference for the hydraulic pressure units.
Press the up arrow to display the pressure in pounds per square

inch (psi). Press the down arrow to display the pressure in
pascals (MPa).

E. Identify if a pressure filter is installed.
Press the up arrow to display yes.

Press the down arrow to display no.
F. If you have an external device (such as a controller) connected to

the emergency stop circuitry, select the type of logic circuit of the
external device.
Press the up arrow to select normal (active high).

Press the down arrow to display reverse (active low).
7. Connect the controller cable (if used).
The controller cable provides a means to connect a remote controller

to the HPU. When connected, your controller can remotely start and
stop the unit and switch between the low and high pressure
selections. The cable also permits the controller to monitor the low
level, over temperature, and dirty filter status. For information about
the connection, see the schematics in the “Appendix” on page 47.
Remote Control Connector
Note If a controller is not used, the installed jumper plug must be used or the
unit will not start.
8. Set up the optional R-O-D parameters.
The run-on-demand (R-O-D) option does not apply to the Model

505.60/90 HPU. If you have the run-on-demand option, go to “Setting
Up the Run-On-Demand Parameters” on page 33 and complete the
procedure.
This completes the HPU installation.

Operation
This section describes the controls and indicators on the front panel, and
provides operating instructions for the Series 505 Hydraulic Power Unit
(HPU).
Contents Controls 24
Using the Operator Interface 26
Operation 29
Recovering from an Interlock 30
Changing the Water Flow 31
Resetting the Thermal Overloads 32
Setting Up the Run-On-Demand Parameters 33
Series 505 Hydraulic Power Unit Operation 23

Controls
The Series 505.60/.90 and 505.120–.180 HPUs have different operator
interfaces on the front panel. The primary difference is how much
information can be displayed and how many pumps can be controlled.
The controls shown in the following figure are described on the following
page.
SilentFlo HPU TM

Del 7 8 9
1
Home Syst
Esc +1 Menu 4 5 6
Remote Pressure
2
Mod 1 2 3
Display Reset
3
Alarm
Shift -1 Enter +/- 0 .
SilentFlo HPU TM

Del 7 8 9
Pressure
2
4 5 6
Auto
3 Home Syst
Demand
Esc +1 Menu 1 2 3
Mod +/- 0 .
Remote
5 Alarm
Shift -1 Enter
Display Reset
6
Front Panel Controls
24 Operation Series 505 Hydraulic Power Unit

CONTROL /INDICATOR FUNCTION
Display Displays two lines (505.60/.90) or four lines (505.120–.180) of

information.
Master Unit Control Starts and stops the HPU.
• Pressing the Run key once starts the enabled pumps in sequence.
Pumps are started in sequence to prevent an electrical overload.
Pump numerical order is keyed to their relative position to the
electrical enclosure (pump one is nearest the electrical enclosure).
The pumps start in low hydraulic pressure.
• Pressing the Stop key turns the HPU off.

Pressure Toggles between low and high pressure for each pump that is running.
Run on demand Automatically controls pump operation as system demand changes. See
(optional) “Setting Up the Run-On-Demand Parameters” on page 33 for more
information.
Remote Enables the interface with your controller. Your controller can remotely
start and stop the HPU. It can select high or low pressure. It can also
monitor the low level, high temperature, and dirty filter signals.
Display Steps through the screens of information in the display. Two screens are
available for normal operation (see “Main status” on page 26 and “Fault
status” on page 28). Pressing and holding the button for 10 seconds
enters the setup mode (see “Set up the optional R-O-D parameters.” on
page 22).
Reset Clears any interlocks caused by the HPU (provided the reason has been
corrected). This switch operates independently from any other reset
functions in your control system. See “Recovering from an Interlock” on
page 30 for more information.
Pumps Enables or disables each pump in the HPU. Disabling a pump completely
prohibits its use.
Hour meters Records how long each pump has been running. Use the hour meter to
schedule maintenance.
Emergency Stop Turns all HPU power off. The Emergency Stop button is a latching
switch. Once it is pressed, it remains in the off position until it is twisted
which resets the Emergency Stop button.
Main disconnect switch Allows access the electrical enclosure to perform maintenance. The main
disconnect switch is located on the upper right corner of the electrical
enclosure’s door. The switch has two functions:
• Disconnects electrical power from the electrical enclosure when the
switch is off (O).
• Contains a mechanical release so the door of the electrical enclosure

cannot be opened when the switch is on (|).
Turn the switch counterclockwise to disconnect electrical power and

release the front panel (additional screws help secure the front panel).

Using the Operator Interface
The display can show different screens of information. The screens are:
• Main status display
• Fault status display
Main status Displays the current status of each pump. The following figures show the
main status displays for both the 505.60/.90 and 505.120–.180 operator
interfaces. The gray area represents what can be seen in the display on
each operator interface.
#1:ENABLED #3:ENABLED
#2:ENABLED NORMAL Model 505.60/.90 display
Press the Display key to step
108 oF 3000 PSI between the displays.
Lev:7/8 Unit: OFF
Model 505.120–180 display

#1 ON-HIGH #4 ON-HIGH Level: 7/8
#2 ON-HIGH #5 ON-HIGH Temp: 42 oC
#3 ON-HIGH #6 ON-HIGH Press: 21 MPa
Unit: RUN-HIGH NORMAL FLOW: 652 LPM
If a problem is detected the unit status will change from NORMAL and flash
one of the possible faults (see “Fault status” on page 28).
Pump status Each pump can be enabled or disabled using the Pump Motor Enable
and Disable keys.
Pump Status
DISPLAY DESCRIPTION
OFFLINE The pump is disabled.

ENABLED The pump is enabled.
STANDBY The pump is waiting its turn to start.
ON-LOW The pump has started and is producing low pressure.
ON-HIGH The pump is producing high pressure.
Unit status The HPU status can be:
• OFF
• RUN-Low
• RUN-Hi
The pumps always start in low pressure. Press the Pressure key to switch
between low and high pressure.

Unit faults The unit fault can flash the name of several faults that are monitored. Press
the Display key to show the fault status display (see “Fault status” on page
28).
Level status The level status ranges from NUL to MAX in 1/8 increments. The level of
the hydraulic fluid in the reservoir is detected with a sensor. The sensor
only measures the top portion of the reservoir. The level status represents
the minimum fluid level (NUL) and the full fluid level (MAX).
A low fluid level will cause an interlock and turn the HPU off. The
interlock signal can be monitored by your system controller. After adding
hydraulic fluid to the reservoir, press the Reset key to clear the interlock.
Temperature status The temperature status displays the temperature of the hydraulic fluid in
degrees Celsius or Fahrenheit (depending on the setup settings).
If the temperature of the hydraulic fluid exceeds 54°C (130°F) an over-
temperature condition will cause an interlock and turn the HPU off.
For more information see “Changing the Water Flow” on page 31. After
reducing the temperature of the hydraulic fluid, press the Reset key to
clear the interlock and turn the indicator off.
Pressure status The pressure status displays the hydraulic pressure being produced by the
HPU. Press the Pressure key to change between high and low pressure. If
remote is enabled, Run and Pressure are disabled.
Flow status The flow status is the amount of hydraulic fluid being output from the
HPU. The flow rate is displayed in liters or gallons per minute (L/m or gpm
is selected at setup). Each pump can produce about 110 L/m (30 gpm).
Enable or disable pumps to provide an appropriate flow to meet demand.
Note Minimizing pump hours conserves energy and reduces wear which
produces lower operating costs.

Fault status The fault status display flashes the fault name and the condition. Press the
Display key to view the fault status display. Each status field can display
NORMAL or FAULT. The gray area represents what can be seen in the
display on each control module.
Faults & Warnings Model 505.60/.90 display

Up/down keys to veiw
Press á and â on the
#1: NORMAL
#2: NORMAL keypad to scroll through
#3: NORMAL the fault status.
Overtemp:NORMAL
Low Lev: NORMAL
Ret Filt:NORMAL
PR FILT:NORMAL
Model 505.120–180 display
#1: NORMAL #4: NORMAL OVERTEMP:NORMAL
#2: NORMAL #5: NORMAL LOW LEV: NORMAL
#3: NORMAL #6: NORMAL RET FILT:NORMAL
PR FILT:NORMAL
Fault Codes
DISPLAY DESCRIPTION
ESTOP Indicates the HPU had been stopped through the

Emergency Stop circuitry
FAULTED Displays any faults that are detected. The field displays
FAULTED, the name of a fault, FAULTED, and the name
of the next fault (or the first fault again).
OVR TEMP Indicates when the temperature of the hydraulic fluid
exceeds 54°C (130°F).
OIL LEV Indicates the hydraulic fluid is below a preset level.
MTR OL Indicates when a thermal overload has been detected in
one of the pump motors. See “Fault status” on page 28
display to determine which pump is at fault. Then see
“Resetting the Thermal Overloads” on page 32 to correct
the fault.
WARNING Indicates when the dirty filter detector becomes active.
This does not stop the pump, but it will prevent it from
starting.
FILTER Indicates when the filter needs replacement. A dirty
filter condition will prevent the HPU from being started,
but it will not stop the HPU while it is running. The
signal can be monitored by your system controller.
For more information see “Replacing the Filter” on page
36. After replacing the filter, press the Reset key to clear
the signal and turn the indicator off
NORMAL Indicates that the HPU is operating properly.
To correct any of these faults, go to “Recovering from an Interlock” on

page 30.

Operation
The hydraulic power unit (HPU) can be operated locally using the controls
on the operator interface or remotely using an industrial or test system
controller.
Local operation 1. Make a general inspection of the HPU. Ensure that all cooling water
valves are open. Ensure the Emergency Stop button is released.
2. Press the Run key to start the pumps. The pumps start sequentially to
prevent an electrical overload. Each pump is in standby until its turn
to start. When first started the HPU produces low hydraulic pressure.
3. Check the HPU for leaks and unusual sounds. Stop the HPU
immediately if leaks or unusual sounds are noted. Determine the
cause and fix the problem before restarting the HPU.
4. Press the Pressure key to turn on high hydraulic pressure.

Note If the HPU generates an interlock during operation (low fluid level or high
temperature), the HPU will stop. Once the cause has been corrected,
press the Reset key before restarting.
Note Run the HPU for about 30 minutes or until the hydraulic fluid is up to
operating temperature before using your test system.
5. To stop the HPU, press the Stop key.
Remote operation Remote operation can occur at a remote control panel or from your
controller. The controller must be connected to the HPU (see Step 7 on
page 22).
1. Make a general inspection of the HPU. Ensure that all cooling water
valves are open. Ensure the Emergency Stop button is released.
2. Start the HPU at your controller. If the HPU does not start, you might
need to press the Remote key of the operator interface.
3. Check the HPU for leaks and unusual sounds. Stop the HPU
immediately if leaks or unusual sounds are noted. Determine the
cause and fix the problem before restarting the HPU.
4. Select high pressure at your system controller.

Note If the HPU generates an interlock during operation (low fluid level or high
temperature), the HPU will be stopped. Once the cause has been
corrected, press the Reset key before restarting.
Note Run the HPU for about 30 minutes or until the hydraulic fluid is up to
operating temperature before using your test system.
5. Stop the HPU with the controller.

Recovering from an Interlock
This section describes how to reset each type of HPU interlock. If a fault
occurs (Low Level, Overtemperature, Dirty Filter), the HPU will not start.
The source of the interlock must be corrected before using the HPU.
Low level The operator interface displays OIL LEV when the hydraulic fluid falls
below the setting of the low level/overtemperature sensor which is
mounted to the top of the reservoir. Perform the following to correct a low
level interlock:
1. Determine the cause for the low fluid level and correct it.
2. Add hydraulic fluid to the reservoir (see “Hydraulic fluid” on page 11)
for the recommended fluids).
3. Press the Reset key to clear the interlock and change the unit status
back to NORMAL.
Overtemperature The operator interface displays OVRTEMP when the temperature exceeds
54°C (130°F). The temperature is detected by the low level/
overtemperature sensor mounted on the reservoir. The HPU cannot be
restarted until the fluid has cooled. Perform the following to correct an
overtemperature interlock:
1. Check the temperature of the hydraulic fluid. You can monitor the
temperature in the operator interface display.
2. Determine if the hydraulic fluid is receiving adequate cooling.
• The cooling water inlet temperature affects the efficiency of

cooling the hydraulic fluid. See “Changing the Water Flow” on
page 31.
• Check the cooling water inlet-to-outlet pressure differential. It

should be between 0.24–0.31 MPa (35–45 psi). Adjust the water
pressure at its source.
3. If necessary, cool the hydraulic fluid. You can circulate hydraulic fluid
through the heat exchanger to cool the fluid.
4. Press the Reset key to clear the interlock and turn the indicator off.
Dirty filter The operator interface displays FILTER when the filter capacity has
reached a critical level. A dirty filter condition will prevent the HPU from
being started, but it will not stop the HPU while it is running.
1. Replace the hydraulic fluid filter. See “Replacing the Filter” on page 36.
2. Press the Reset key to clear the interlock and turn the indicator off.

Changing the Water Flow
Water is used to maintain hydraulic fluid temperature. The water regulating
valve, located on the water inlet line of the HPU senses the hydraulic fluid
temperature and automatically controls water flow to the heat exchanger.
Note When the HPU is turned off, a solenoid valve also shuts off the flow of
water to the heat exchanger.
The valve is adjusted at MTS Systems Corporation to maintain the hydraulic

fluid temperature at 43°C (110°F). However, the temperature of your water
might require you to readjust the regulator.
Water Inlet Water Regulating Valve Solenoid Valve Filter Assembly
Perform the following steps to set the operating temperature of the

hydraulic fluid.
1. Start the HPU and switch to the high-pressure mode.
2. Observe the temperature on the display of the operator interface as

the hydraulic fluid temperature rises. Note the temperature where the
hydraulic fluid stabilizes.
3. Adjust the water-regulating valve. One full turn (360°) of the adjusting
screw produces a change in hydraulic fluid temperature a few
degrees.
• Adjust the screw clockwise to decrease the operating

temperature.
• Adjust counterclockwise to increase the operating temperature.
4. Note the effect after 15 minutes.
5. Repeat Step 3 and Step 4 until the hydraulic fluid temperature

stabilizes between 41°C–43°C (105°F–110°F).

Resetting the Thermal Overloads
Each incoming electrical power feed line has a thermal overload switch. If
any line becomes too hot, its thermal switch trips and disconnects the
hydraulic power unit (HPU) from the electrical power feed.
Additional protection is provided by line fuses (FU1–FU3 for the Model

505.60/.90 and FU1-FU18 for the Model 505.120–.180) and transformer
fuses (FU19–FU21). These cartridge-type fuses must be replaced with fuses
of the same size, type, and rating which vary according to the voltage
configuration.
A tripped thermal overload or a blown fuse indicates a potential short

circuit, too much heat in the electrical box, or a component failure
(mechanical or electrical).
Transformer Fuses
FU19–FU21
Line Fuses
FU1–FU9
or
FU1–FU18
Thermal Overloads
Reset the thermal overload switches or replace the fuses as follows:
1. On the front panel, turn the main disconnect switch counterclockwise

to remove power from the electrical control box.
2. Loosen the two bolts securing the door of the electrical enclosure and
open the door.
3. Locate the thermal overload switch. Press the Reset key to clear the
switch. If thermal overload switch trips again, wait until the switch
cools.

Setting Up the Run-On-Demand Parameters
The run-on-demand (R-O-D) option automatically starts or stops pumps to
meet the hydraulic flow demand from the system. The PLC monitors the
hydraulic fluid flow; when the flow changes beyond a trigger point for a
set period of time, one of the pumps is turned on or off.
From the main display screen, press the Display key for about ten
seconds. When the display shows the setup screen, press the right arrow
key to show the auto demand screen.
Auto Demand Setup Parameters

MINIMUM NUMBER RUNNING: 1 PUMP(S)
STAGE NEXT PUMP ON-DELAY: 10 SECONDS
MIN AVAILABLE FLOW TRIGGER:100 LPM
STAGE NEXT PUMP OFF-DELAY: 10 MINUTES
RATED FULL FLOW PER PUMP: 30 GPM
CURRENT RUNNING HOURS
PUMP #1 000000 Hrs PUMP #4 000000 Hrs
PUMP #2 000000 Hrs PUMP #5 000000 Hrs
PUMP #3 000000 Hrs PUMP #5 000000 Hrs
Use the arrow keys to navigate the parameters. When a parameter is

selected, enter a new value on the keypad to change it.
PARAMETER DESCRIPTION
Minimum Number Running Specifies the minimum number of

pumps that can be running when the
auto demand feature is enabled.
Stage Next Pump On-Delay Sets the amount of time the fluid flow
must be maintained (without tripping
the flow trigger) before starting one
pump. The time starts after the flow
trigger is tripped.
Min Available Flow Trigger Specifies the amount of change in the
hydraulic fluid flow that is required to
trip the flow trigger.
Stage Next Pump Off-Delay Sets the amount of time the fluid flow
must be maintained (without tripping
the flow trigger) before stopping one
pump. The time starts after the flow
trigger is tripped.
Rated Full Flow Per Pump Displays the rated flow of the pumps.
The flow is based on the hydraulic
pressure produced by the pumps.
After you have defined the run on demand parameters press the Display
key to return to the main status screen. Then press the Auto Demand key
to enable the feature.

Maintenance
This section describes the maintenance requirements for the Model 505.60–
.180 Hydraulic Power Unit (HPU).
Contents Replacing the Filter 36

Sampling the Hydraulic Fluid 38
Replacing the Hydraulic Fluid 40
Maintenance The following table lists the recommended interval for each of these
schedule procedures.
W HAT TO DO WHEN TO DO IT * H OW TO DO IT
Making daily inspections Before the start of each day’s Check fluid level in the control module
testing. display and replenish as required.
Check fluid quality and Every 1000 hours or six months. Compare the condition of the fluid to
condition that of your reference sample. Perform
“Sampling the Hydraulic Fluid” on page
38.
Replace fluid filter Every 1000 hours, six months, Perform “Replacing the Filter” on page
or when dirty-filter indicator 36.
lights.
Conduct a hydraulic fluid Yearly or sooner if duty is Perform “Sampling the Hydraulic Fluid”
analysis severe† on page 38 and submit the sample for
analysis. Most oil companies can analyze
hydraulic fluid or consult MTS Systems
Corporation.
Replace hydraulic Yearly or sooner if fluid analysis Perform “Replacing the Hydraulic Fluid”
fluid† is not to specifications. on page 40.
Clean pump inlet strainer Whenever replacing fluid. It is part of the procedure “Replacing the
Hydraulic Fluid” on page 40.
* The interval is based on an 8 hour a day, 5 days a week operation schedule. Dusty or dirty environments
require more frequent maintenance..
† See the MTS Fluid Care Guide (part number 050-000-536)
Spare parts Parts that are specified in the maintenance procedures of this section can
be obtained from MTS Systems Corporation. See ““Contact information” on
page 2” to order spare parts.
Lockout/tagout For your safety, follow all appropriate lockout/tagout procedures while
performing HPU maintenance.
Series 505 Hydraulic Power Unit Maintenance 35

Replacing the Filter
The filter element of the hydraulic power unit (HPU) should be replaced
for the following reasons:
• When the dirty-filter detector trips
• Whenever the hydraulic fluid is changed
• The filter manufacturer’s recommended maximum interval

(1000 hours or 6 months)
Required equipment You will need a filter element (MTS part number 100-015-519).
Procedure Perform the following procedure to change the filter element.
“T” Handle
Clamp
Cover Seal
Seal Bypass Valve

Assembly
Head Assembly
Filter Cartridge
Gasket
Filter Tube Cartridge Rod
Filter Components
36 Maintenance Series 505 Hydraulic Power Unit

1. Turn off the HPU. Ensure that the hydraulic pressure is at zero before
proceeding.
2. Unlock and open the cover next to the electrical enclosure to access
the filter.
3. Release the clamp securing the cover to the head assembly.

Note You will need a minimum clearance of 712 mm (28 in) above the filter
housing to remove the filter. You will also need a container to catch oil
dripping off the filter assembly.
4. Use the “T” handle to pull the filter cartridge assembly out of the filter
tube. Be careful not to spill any hydraulic fluid.
5. Replace the O-ring(s) seals in the bypass valve assembly and under
the cover.
6. Unscrew the “T” handle from the cartridge rod and remove the filter
cartridge.
7. Install a new filter on the cartridge rod and secure it with the “T”
handle.
8. Install the filter cartridge assembly into the head assembly and into the
filter tube.
9. Replace the cover and clamp it to the head assembly.
10. Turn on the HPU and switch to high-pressure mode. Inspect the seal
between the housing, filter, and cover for any signs of leakage. If
leakage occurs, repeat this procedure (without replacing the filter
element). If leakage persists, contact MTS Systems Corporation (see
“Contact information” on page 2).

Sampling the Hydraulic Fluid
This section describes how to check the quality of the hydraulic fluid.
Review the following
• Avoid contamination.
– Keep the sample bottle in the storage box of the hydraulic fluid
sampling kit until it is needed.
– Do not remove the cap from the bottle until immediately before
taking the sample.
– Do not set the set the cap down on a dirty surface or in an area
where airborne dust can settle.
• For additional information on hydraulic fluid care, see the Hydraulic

Fluid Care Guide (part number 050-000-536) found in the
documentation package inside the electrical control box.
• Hold the hose valve assembly still when taking a sample.
• Do not let the sample line in the bottle or let it touch the mouth of the
bottle.
Prerequisite You will need a hydraulic fluid sampling kit (MTS part number
055-589-601).
Procedure Refer to the following drawing during the procedure:
Hose Valve Assembly
Sample Port
Control Manifold

1. Operate the HPU until the hydraulic fluid is at operating temperature
(about 30 minutes).
2. Connect the hose valve assembly (to the sample port located on the
hydraulic manifold on top of the HPU.
3. Flush 1 liter (1 quart) of hydraulic fluid though the sampling assembly.

This fluid can directed to a waste container or back into the HPU
reservoir.
Open the valve on the hose valve assembly to begin flushing.
4. Obtain a sample of the hydraulic fluid after flushing the valve hose
assembly.
Without closing the valve, quickly place the sample bottle into the
fluid stream (keep the sample bottle sealed until the sample is to be
taken).
5. Fill the sample bottle (175 mL/6 oz) with fluid. Close the valve on the
hose valve assembly and cap the sample bottle.
6. Check the fluid qualities. It is a good idea to keep a small jar of clean
hydraulic fluid for comparison purposes. Review the following:
• Considerable darkness, burnt odor, or an opaque quality of the

fluid indicates chemical breakdown. Replace the fluid.
Considerable darkness also may indicate that the fluid has been
allowed to rise above the maximum recommended temperature
(severe overheating). If this is the case, replace the fluid and flush
the entire system to remove varnish or residue.
• A milky appearance indicates water is present in the fluid. Correct

the source of the water leakage and replace the fluid.
• After allowing the sample to stand overnight, sediment at the

bottom of the sample container indicates collapsed, ruptured, or
clogged filter(s) in the system. Replace the fluid and all filter
elements.
7. If there still is any uncertainty regarding fluid quality, obtain another

sample of the fluid and have it analyzed. The fluid tests should include
chemical analysis, particle count, and viscosity checks. Most oil
companies have facilities for performing these tests or consult MTS
Systems Corporation.
8. Remove the hose and valve assembly.

Replacing the Hydraulic Fluid
The following procedure describes how to replace the hydraulic fluid in
the reservoir.
Note For additional information on hydraulic fluid care, see the Maintenance
manual found in your system manual set or the Hydraulic Fluid Care
Guide (part number 115681-01) found in the documentation package
inside the electrical control box.
Recommended • A transfer pump with a 10 micron filter (such as the Model 590.01
equipment Fluid Transfer Pump)
• Synasol® or a similar cleaning solvent
• Lint-free cloths or manufactured rags
• A container for the used hydraulic oil and a small drain pan that will fit
underneath the drain plug
• A hydraulic fluid sampling kit (MTS part number 055-589-601).
Procedure See “Component Identification” on page 6 to identify the components

called out in the following procedure.
1. Prepare the HPU.
A. Press the Stop key to turn off the HPU. Remove the electrical
power to the HPU via a circuit breaker at the power source.
B. Open the top cover of the HPU.
C. Remove the filler cap.
D. Remove the reservoir cover.
2. Remove the hydraulic fluid.
Use the transfer pump to remove the old hydraulic fluid out of the
reservoir and into an appropriate container.
3. Clean the reservoir.
A. Clean the inside of the reservoir using clean cloths dampened

with Synasol. Clean the pump, motor, and bottom of the cover
plate as well.
B. Install the reservoir cover.

CAUTION Mixing different brands of hydraulic fluid can contaminate your system.
Contaminated hydraulic fluid can cause premature wear of the hydraulic

components in your system.
Do not mix different brands of hydraulic fluid. MTS Systems Corporation

recommends using Mobil DTE-25 or Shell Tellus 46 AW hydraulic fluid.
4. Add new hydraulic fluid to the reservoir.
A. Pump hydraulic fluid (filtered to 10 microns) into the reservoir.

Stop when the fluid level gets close to the full mark on the sight
glass.
B. Reinstall the filter cap’s strainer assembly.
C. Change the filter (see “Replacing the Filter” on page 36).
5. Run the HPU.
A. Press the Run key.
B. Run the HPU at low pressure for about three hours to filter the
new hydraulic fluid.
C. Press the Stop key.
6. Sample the hydraulic fluid.
Do not run the system until the desired level of cleanliness is

achieved. See “Sampling the Hydraulic Fluid” on page 38.

Service
This section describes service procedures that might need to be performed
on the Series 505 Hydraulic Power Units. If additional service is required,
contact your local MTS service representative.
Important This section describes service procedures that should be

performed by a person who has experience servicing MTS
servohydraulic equipment. The procedures in this section require
the HPU to be disassembled beyond what is needed for operation
or maintenance.
We assume you are familiar with all operating aspects of your

system controller (electronic and software controls) and you are
familiar with the hardware components of your system.
Contents Replacing the Low Level/Temperature Fixture 44

Replacing a Pump Assembly 45
Series 505 Hydraulic Power Unit Service 43

Replacing the Low Level/Temperature Fixture
The low level/temperature fixture monitors the level of hydraulic fluid in
the reservoir and the temperature of the hydraulic fluid.
The head of the low level assembly

is available in two configurations (as
shown here).
Perform the following to change the

fixture:
1. Note the distance between the

head assembly of the fixture
and the top of the reservoir.
2. Loosen the locknut on top of the reservoir that holds the assembly in
place.
3. Replace the low level/temperature fixture assembly. Ensure the

replacement fixture has the same length as the old fixture.
CAUTION Running the pump motors with hydraulic fluid below the top of the motors
can cause them to fail.
The low level position is factory set. The replacement fixture should be set to
the same level.
4. The distance between the head assembly of the fixture and the top of
the reservoir should be the same as noted in Step 1.
5. Tighten the locknut to hold the shaft in place.
Head Assembly
Cable
Locknut
Top of Reservoir
Shaft
44 Service Series 505 Hydraulic Power Unit

Replacing a Pump Assembly
The pump assembly includes a pump, motor, and electronic enclosure all
mounted to a cover plate which is installed into the HPU reservoir.
Electrical
Enclosure
Lifting Eyes
Pump Output
Motor
Cover Plate
Pump
Pump/Motor Assembly
WARNING High hydraulic pressure can be present at the pump output.
Removing the hydraulic connection to the pump output with high hydraulic
pressure present can cause injury to personnel.
Ensure system hydraulic pressure has been reduced to zero before proceeding.
before proceeding.
1. Ensure that system hydraulic pressure has been reduced to zero before
proceeding. To do this, turn off the hydraulic power unit and exercise
the actuator until it stops moving.
2. Disconnect the power to the HPU.
• Disconnect the electrical power to the HPU at an external circuit

breaker (if used).
• Otherwise, disconnect the electrical power in the main electrical

enclosure of the HPU (see “Connect the electrical service to the
HPU.” on page 18).
Series 505 Hydraulic Power Unit Service 45

3. Disconnect the electrical connections in the electrical enclosure.
Model 505.60/.90 HPU Model 505.120–.180 HPU
Electrical Enclosures
4. Disconnect the hydraulic connection to the pump output of the pump/

motor assembly.
5. Remove the eight 5/16–18 UNC bolts securing the pump/motor

assembly to the reservoir.
6. Lift the pump/motor assembly out of the reservoir.
Lifting eyes are mounted to the pump/motor assembly to allow it to

strapped or chained to a lifting device such as a fork lift or overhead
crane. When the assembly has cleared the hydraulic fluid, allow it to
drain hydraulic fluid back into the reservoir.
7. Move the pump/motor assembly to a place where it can be serviced.
Be prepared to collect hydraulic fluid dripping from the assembly

when you move it.
8. To install a pump/motor assembly, complete this procedure in reverse

order.
46 Service Series 505 Hydraulic Power Unit

Appendix
This section includes the schematics for the Series 505 Hydraulic Power
Units. The two sets of schematics represent the HPUs with two or three
pump assemblies (Model 505.90) and HPUs with four to six pump
assemblies (Model 505.180).
Contents Model 505.90 Hydraulic Schematic 48

Series 505 Hydraulic Power Unit Appendix 47

Model 505.90 Hydraulic Schematic
48 Appendix Series 505 Hydraulic Power Unit

Model 505.180 Hydraulic Schematic

Model 505.90 Electrical Schematic

Model 505.180 Electrical Schematic


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Series 505 SilentFlo Hydraulic Power Unit

Trademark information MTS is a registered trademark of MTS Systems Corporation.

DTE is a registered trademark of Mobil Corporation.

Tellus is a registered trademark of Shell Oil Corporation.

Molykote is a registered trademark of Dow Chemical Corporation.

Synasol is a registered trademark of Union Carbide Corporation.

Contact information MTS Systems Corporation

ISO 9001 Certified

Publication information MANUAL PART NUMBER PUBLICATION DATE

100-006-453 A October 1999

100-006-453 B January 2000

100-006-453 C September 2000

100-006-453 D January 2001

Replacing the Filter 36

Replacing the Low Level/Temperature Fixture 44

Series 505 Hydraulic Power Unit Contents 3

Model 505.90 Hydraulic Schematic 48

4 Series 505 Hydraulic Power Unit

Contents Component Identification 6

Models 505.60/.90 HPU

Models 505.120/.150/.180 HPU

Series 505 Hydraulic Power Unit Introduction 5

Heat Exchanger and

Operator Filter Assembly

6 Introduction Series 505 Hydraulic Power Unit

Series 505 Hydraulic Power Unit Introduction 7

The hydraulic power unit uses solenoid-operated valves to control when

8 Introduction Series 505 Hydraulic Power Unit

• The normal operating temperature range of the hydraulic fluid is

• If the hydraulic fluid temperature exceeds 55ºC (131ºF), a switch

• An operator interface that contains a keypad to program preferences

• Thermal overloads protect the individual HPU motors from excessive

• A latchable Emergency Stop button prevents inadvertent starts.

• Interlocks protect the HPU against low hydraulic fluid level,

• Hour meters provided for each pump/motor assembly help you

Series 505 Hydraulic Power Unit Introduction 9

10 Introduction Series 505 Hydraulic Power Unit

Environmental For use in a controlled environment.

Operating temperature 5–40°C (40–104°F)

Humidity 0–85% noncondensing

Heat load < 630 kcal/hr (2500 Btu/hr)

Noise rating at 1 m 70 dB (A) fully compensated*

Hydraulic fluid Mobil DTE 25 or Shell Tellus 46 AW

Nominal temperature 16–55°C (60–130°F)

Filtration (microns) 3 µ nominal

Output Pressure 21 MPa (3000 psi)

Heat exchanger Water-cooled

Flow requirements 13 L/m at 21°C (12 gpm at 70°F)

Water pressure 0.2–0.3 MPa (35–45 psi)

Maximum pressure 0.8 MPa (120 psi)

Cooling 38,520 kcal/hr (153,000 Btu/hr)

Water hose 38 mm (1.5 in) NPT standard

Pressure 2 inch SAE

Return 2 inch SAE

Drain -16 JIC

Line voltage 380–575 V AC

* Can vary due to ambient conditions.

Series 505 Hydraulic Power Unit Introduction 11

Model 505.60 Specifications