Enerpac SLCV-24 User manual

Hydraulic Technology Worldwid
e
Instruction Sheet
8-Point Synchronous Lift Controller
L2583 Rev. E 04/08
Table of Contents Page
Important Receiving Instructions.........................................................2
Safty First - Safety Issues ...................................................................2
General Description /Glossary Of Terms Used ...................................3
Components Used ..............................................................................3
Electrical Specifications ......................................................................3
Selection Of Hydraulic Components ..................................................4
System Lifting/Lowering Speed ..........................................................4
Control Panel Switch Functions ..........................................................5
System Requirements .........................................................................5
Hydraulic Component Assembly.........................................................6
Basic 4 Point System Schematic ........................................................6
Electrical Component Assembly .........................................................7
System Power Up And Control Verification...........................................7
A. Language................................................................................7
B. System Setup.........................................................................8
C. Lift Type..................................................................................8
D. Cylinder Control Check..........................................................9
E. Cylinder/Sensor Interface Check .........................................10
F. System Flow Control Valve Setting......................................10
Lifting Sequence..............................................................................10
System Error Messages ..................................................................11
Trouble Shooting Guide...................................................................11
Lowering the Load...........................................................................12
Index:
English: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Español: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NA
Portuguese: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NA

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Repair Parts Sheets for this product are available from the
Enerpac web site at www.enerpac.com, or from your nearest
Authorized Enerpac Service Center or Enerpac Sales office.
1.0 IMPORTANT RECEIVING INSTRUCTIONS
Visually inspect all components for shipping damage. Shipping
damage is not covered by warranty. If shipping damage is found,
notify carrier at once. The carrier is responsible for all repair and
replacement costs resulting from damage in shipment.
SAFETY FIRST
2.0 SAFETY ISSUES
Read all instructions, warnings and cautions
carefully. Follow all safety precautions to avoid
personal injury or property damage during system
operation. Enerpac cannot be responsible for damage or injury
resulting from unsafe product use, lack of maintenance or
incorrect product and/or system operation. Contact Enerpac
when in doubt as to the safety precautions and operations. If you
have never been trained on high-pressure hydraulic safety,
consult your distribution or service center for a free Enerpac
Hydraulic safety course.
Failure to comply with the following cautions and warnings could
cause equipment damage and personal injury.
A CAUTION is used to indicate correct operating or maintenance
procedures and practices to prevent damage to, or destruction of
equipment or other property.
A WARNING indicates a potential danger that requires correct
procedures or practices to avoid personal injury.
A DANGER is only used when your action or lack of action may
cause serious injury or even death.
WARNING: Wear proper personal protective gear when
operating hydraulic equipment.
WARNING: Stay clear of loads supported by
hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device.
After the load has been raised or lowered, it must always be
blocked mechanically.
WARNING: USE ONLY RIGID PIECES TO HOLD
LOADS. Carefully select steel or wood blocks that are
capable of supporting the load. Never use a hydraulic
cylinder as a shim or spacer in any lifting or pressing
application.
DANGER: To avoid personal injury keep hands
and feet away from cylinder and workpiece during
operation.
WARNING: Do not exceed equipment ratings. Never
attempt to lift a load weighing more than the capacity
of the cylinder. Overloading causes equipment failure
and possible personal injury. The cylinders are designed for a
max. pressure of 700 bar [10,000 psi]. Do not connect a jack or
cylinder to a pump with a higher pressure rating.
Never set the relief valve to a higher pressure than the
maximum rated pressure of the pump. Higher settings
may result in equipment damage and/or personal injury.
WARNING: The system operating pressure must not
exceed the pressure rating of the lowest rated
component in the system. Install pressure gauges in the
system to monitor operating pressure. It is your window to what
is happening in the system.
CAUTION: Avoid damaging hydraulic hose. Avoid sharp
bends and kinks when routing hydraulic hoses. Using a
bent or kinked hose will cause severe back-pressure.
Sharp bends and kinks will internally damage the hose leading
to premature hose failure.
Do not drop heavy objects on hose. A sharp impact
may cause internal damage to hose wire strands.
Applying pressure to a damaged hose may cause it
to rupture.
IMPORTANT: Do not lift hydraulic equipment by the
hoses or swivel couplers. Use the carrying handle or
other means of safe transport.
CAUTION: Keep hydraulic equipment away from
flames and heat. Excessive heat will soften packings
and seals, resulting in fluid leaks. Heat also weakens
hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C [150°F] or higher.
Protect hoses and cylinders from weld spatter.
DANGER: Do not handle pressurized hoses. Escaping
oil under pressure can penetrate the skin, causing
serious injury. If oil is injected under the skin, see a
doctor immediately.
WARNING: Only use hydraulic cylinders in a coupled
system. Never use a cylinder with unconnected
couplers. If the cylinder becomes extremely
overloaded, components can fail catastrophically causing
severe personal injury.
WARNING: BE SURE SETUP IS STABLE BEFORE
LIFTING LOAD. Cylinders should be placed on a flat
surface that can support the load. Where applicable, use
a cylinder base for added stability. Do not weld or
otherwise modify the cylinder to attach a base or other support.
Avoid situations where loads are not directly centered
on the cylinder plunger. Off-center loads produce
considerable strain on cylinders and plungers. In
addition, the load may slip or fall, causing potentially dangerous
results.
Distribute the load evenly across the entire saddle
surface. Always use a saddle to protect the plunger.
IMPORTANT: Hydraulic equipment must only be
serviced by a qualified hydraulic technician. For repair
service, contact the Authorized ENERPAC Service
Center in your area. To protect your warranty, use only
ENERPAC oil.
WARNING: Immediately replace worn or damaged
parts by genuine ENERPAC parts. Standard grade parts
will break causing personal injury and property
damage. ENERPAC parts are designed to fit properly and
withstand high loads.
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3.0 GENERAL DESCRIPTION/GLOSSARY OF TERMS
The Enerpac Synchronous Lift System is a package that provides
precise positional control of the lifting and lowering of high
tonnage objects. The microprocessor-based
controller receives electronic signals from
load position sensors attached to the load in
the vicinity of each cylinder. The controller
processes this information and sends signals
to the valves controlling each cylinder,
opening and/or closing the valves as required
to raise or lower a load evenly and within the
accuracy parameters defined by the operator.
The Enerpac Synchronous Lift System
consists of the basic components shown
below. Refer to Figure 3 for the layout of a
typical four point lift system.
3.1 Standard Components
(refer to Fig. 1)
CONTROLLER, SLCG-8
The CONTROLLER is where the operator
selects the lift parameters and controls
up to eight lift points. The CONTROLLER
distributes signals to the appropriate CYLINDER CONTROL
VALVES, causing them to open or close, as necessary, to
control the lifting or lowering functions.
CYLINDER CONTROL VALVES, SLCV-24 (24 volt coils)
The CYLINDER CONTROL VALVES receive on/off commands
from the controller. These valves open and close, controlling
flow into the cylinders as they advance, or controlling flow out
of the cylinders as they retract, keeping the load moving in a
controlled synchronous motion while maintaining the
accuracy desired by the operator.
PUMP DIRECTIONAL CONTROL VALVE CABLE, SLPVC-1
Connects PUMP DIRECTIONAL CONTROL VALVE to the
SLGG-8 controller.
STROKE SENSOR, SLSS-500, 1000, 2000
Contains the electronics to detect load movement.
SENSOR CABLE (SLSC-15)
The SLSC15 (15 meters) SENSOR CABLE transmits sensor
feedback to the CONTROLLER. Optional cable extensions
(SLEC 15 & SLEC 50-meter lengths) are available to permit
sensor placement farther than 50 feet.
CHECK VALVE PACKAGE (SCK-1) (not shown)
The PILOT-OPERATED CHECK VALVE
provides additional safety margin for load
holding in the event of a leaking or ruptured
hose. Useable on both double- and single-
acting cylinders. VELOCITY FUSE locks and
holds the cylinder position in the event of a
catastrophic hose failure. Useable on single-
and double-acting cylinders. The VELOCITY
FUSE can be used in lieu of the CHECK VALVE
PACKAGE in some cases. Consult Enerpac on
specific recommendations.
HYDRAULIC PUMP
The HYDRAULIC PUMP provides flow to the
HYDRAULIC CYLINDERS allowing them to
advance or retract. The CONTROLLER
operates the pump-mounted DIRECTIONAL
CONTROL VALVE.
HYDRAULIC CYLINDER (single- or
double-acting)
The HYDRAULIC CYLINDER lifts or lowers
the load.
CYLINDER CONTROL VALVE CABLE, SLCVC
Connects CYLINDER CONTROL VALVE to SLCG 8 Controller.
PRESSURE GAUGES (Optional, not shown)
PRESSURE GAUGES allow the operator to monitor system
pressures.
DIRECTIONAL CONTROL VALVE
The pump-mounted or remote-mounted DIRECTIONAL
CONTROL VALVE controls the advance and retract flows of
hydraulic fluid and is managed by the CONTROLLER.
CYLINDER CONTROL VALVE
Model No. Power Pressure Rating
SLCV-24 24 Volts (35 watts) 10,000 psi (700 bar)
IMPORTANT: The ENERPAC
PLC BASED SYNCHRONOUS
LIFT SYSTEM is a precision
position control system,
which can be used in a wide
variety of applications. Make
certain that user supplied
components are compatible.
All operators should read and
thoroughly understand this
operating manual before
using the equipment.
SLCG-8
Operating Temperature Range: 32 °F to 115 °F (0 °C to 46 °C)
Storage Temperature Range: 32 °F to 140 °F (0 °C to 60 °C)
Enclosure Rating – Closed NEMA 4 (IP60)
Enclosure Rating – Open NEMA 1 (IP20)
Power: 115/230 VAC, 50/60 Hz, 15-amp maximum
Physical Dimensions: 24 in x 20 in x 8 in (61 cm x 50.8 cm x 20.3 cm)
CAUTION: The CONTROLLER is designed to be water-resistant
when closed but not waterproof. Avoid working in direct sunlight, while
not causing damage, the display can be difficult to properly view. When
storing unit, always make sure that the cover is closed and stored out
of the weather. The CONTOLLER is a sensitive piece of electronic
equipment and should not be subjected to shock, rain, snow, sand or
very dusty conditions.
SENSOR: SLSS-500, 1000, or 2000
Measuring Range:
SLSS-500 – 0-19.7 in (500 mm) of cord extension
SLSS-1000 – 0-39.4 in (1000 mm) of cord extension
SLSS-1000 – 0-78.7 in (2000 mm) of cord extension
Operating Temperature Range: -4 °F to 176 °F (-20 °C to 80 °C)
Storage Temperature Range: -40 °F to 176 °F (-40 °C to 80 °C)
Stainless steel eyelet and magnets for securing to load
CAUTION: The SENSOR is also designed to be water
resistant, but not waterproof. Do not immerse in liquid. The
SENSOR is also a sensitive piece of electronic equipment and
should not be subjected to severe shock, rain, snow, sand or very
dusty conditions.
ELECTRICAL COMPONENT SPECIFICATIONS

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MANIFOLDS (Not shown)
The MANIFOLDS channel advance and retract flows to and
from the hydraulic cylinders.
Note: These are the major system components required to
operate a four-point lifting system. Additional components
will be required for additional lift points. Contact Enerpac for
assistance in selecting additional components.
VELOCITY FUSE (VF-1) (Not shown)
The VELOCITY FUSE provides an additional safety margin for
load holding in the event of a ruptured hose or a power
failure. The VELOCITY FUSE is designed to be used with
single-acting or double-acting HYDRAULIC CYLINDERS.
SUCTION VALVE (VUV-5) (Not shown)
The SUCTION VALVE is used to help assist the return of
hydraulic fluid back from the HYDRAULIC CYLINDER into the
reservoir of the HYDRAULIC PUMP.
4.0 SELECTION OF HYDRAULIC COMPONENTS
4.1 Recommended Lifting/Lowering Speed
When selecting hydraulic components (pumps and cylinders), it is
important to know that a trade-off exists between cylinder speed
and lifting accuracy. The faster the cylinders move the harder it
becomes to maintain programmed accuracy. Ideally, pump and
cylinders should be selected such that the maximum lifting speed
does not exceed 3-in./min. (7.5 cm./min.) with all cylinders activated.
Obviously, slower speeds yield HIGHER degrees of accuracy.
4.2 Calculating Lifting Speed
A rule of thumb is to use the total effective area of all the cylinders
in your lift system. Divide the flow rate of your pump under load
by the total effective area of your lift cylinders. This equals the
theoretical lift speed (distance/time).
Flow Rate ÷ Total Effective Area = Lift Speed
Example 1: 4 cylinders, RR-506, and a 11/2 HP Z-Class Pump.
The area per cylinder is 11 in2X 4 cylinders = 44 in2. The pump
flow rate is 60 in3/minute. 60 in3/min ÷ 44 in2= 1.4 in/min.
Example 2: 4 cylinders, RR-506, and a 1.1kw Z-Class Pump.
The area per cylinder is 71.2 cm2X 4 cylinders = 284.8 cm2.
The pump flow rate is 0.82 liters/minute (@50 hertz) and 1.02
liters/minute (@60 hertz). 820 cm3and 1020 cm3/minute
respectively. 820 cm3/min ÷ 284.8 cm2= 2.88 cm/min (@50
hertz) and 1020 cm3/min ÷ 284.8 cm2= 3.58 cm/min lift rate
(@60 hertz).
CAUTION: Due to heavy flow restriction requirements,
oil temperatures could potentially rise above
acceptable levels. Coolers and/or larger pump
reservoirs should be considered for lifts of long duration. Oil
temperatures should not exceed 150 °F (65 °C.). By the same
token, if the ambient temperature is below 32 °F (0 °C) the pump
should be run and warmed to the touch before any lifting takes
place. For very cold conditions, consult Enerpac on reservoir
heaters and the use of synthetic oil.
The ENERPAC SYNCHRONOUS LIFT SYSTEM was designed to
be modular in order to minimize expense to the customer who
may already have some of the hydraulics required for lifting.
When selecting components, it is important to keep in mind that
the system is designed for 10,000 psi (700 bar) maximum
operating pressure. Cylinders should be selected to lift the load at
a maximum working pressure of 9000 psi (628 bar) allowing for
reserve pressure to handle potential load shifts from one cylinder
to another.
WARNING: All double-acting cylinders must be
equipped with a load holding SCK-1 CHECK VALVE
PACKAGE. All single-acting cylinders must be
equipped with either the SCK-1 CHECK VALVE PACKAGE (see
Fig. 4) or the VF-1 VELOCITY FUSE (see Fig. 5). The VELOCITY
FUSE gives the advantage of single hose operation, whereas
the SCK-1 requires two hoses even on a single-acting system.
SLCV-24 CYLINDER CONTROL VALVE is required for safety and
SENSOR 1
X 41
SENSOR 2
X 42
SENSOR 3
X 43
SENSOR 4
X 44
SENSOR 5
X 45
SENSOR 6
X 46
SENSOR 7
X 47
SENSOR 8
X 48
VALVE1
X 11
SENSOR 1
X 10
VALVE2
X 12
VALVE3
X 13
VALVE4
X 14
VALVE5
X 15
VALVE6
X 16
VALVE7
X 17
VALVE8
X 18
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Figure 1, General Layout
Hose

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lift/lower control for each cylinder. The SCK-1 check valve is
designed to block the flow of hydraulic fluid out of the cylinder,
holding the load in the event of a hose failure or loss of electrical
power. Failure to install a CHECK VALVE or VELOCITY FUSE
could result in personal injury and/or property damage.
IMPORTANT: One of the key components of the lifting
system is the CYLINDER CONTROL VALVE assembly. One
valve assembly is required to control each lift point. Any Enerpac
pump equipped with a VE-43 solenoid activated DIRECTIONAL
CONTROL VALVE can be used with this system and double-
acting cylinders. A VE-33 valve can be used to control single-
acting cylinders.The DIRECTIONAL CONTROL VALVE selects the
cylinder extend/retract function and is under system control. The
pump on/off is controlled manually.
5.0 CONTROL PANEL FUNCTIONS
Figure 2, Control Panel (CONTROLLER)
1Power Connection
2Pump Control Valve Connection
3Emergency Stop Button
4Displacement Connection
5Control Valve Connection
6Operator Touch Screen
7Start/Stop Push Buttons
5.1 Lifting Nomenclature
ABSOLUTE POSITION - When the stroke sensor is attached to
the load and the sensor cable is pulled out of the sensor body to
attach to the load you have the absolute position of that stroke
sensor. See Relative Position.
ACCURACY - Allows the system operator to define the maximum
allowable positional difference between the leading and lagging
lift points (AUTO mode only). The actual difference in position
between the leading and lagging cylinders is called the range.
Once accuracy is entered, the system will not allow a lift point to
vary from the mean any more than the programmed accuracy.
Example: An accuracy input of 0.08" will result in a system
accuracy of 0.04", approximately the mean. The input value of
accuracy is the maximum allowable variation from the highest to
lowest lift point. (AUTOMATIC Mode only).
Note: the controller will permit a best possible programmed
accuracy as follows:
0.040" (1mm) for the 500 mm stroke sensor
0.080" (2mm) for the 1000 mm stroke sensor
0.16" (4mm) for the 2000 mm stroke sensor
C1-C8 – Shows which cylinders are active at any given time.
Permits operating any and all of the cylinders in your lift system.
AUTO DOWN – Causes the cylinders to lower the load in a
synchronized mode.
AUTO UP – Causes the cylinders to raise in a synchronized mode.
CANCEL - stops the current function from occurring.
ENTER (Return Key)- Completes data entry sequence and exits
data entry mode
EXTEND/RETRACT - Selects extend or retract mode of cylinder.
MANUAL/AUTOMATIC - AUTOMATIC provides synchronous
motion of all active cylinders. MANUAL provides non-
synchronous control of active cylinders. When in MANUAL mode,
the cylinders can be jogged up or down by selecting the
appropriate cylinders and the EXTEND/RETRACT function and
depressing the controller "START" button.
CAUTION: When operating in the MANUAL mode, the
operator has only on/off control of active cylinders. The
MANUAL mode does not provide synchronization of the
cylinders. Note: only cylinders equipped with a stroke sensor
connected can be operated in the either the manual or
automatic mode.
EMERGENCY STOP (E-Stop Mushroom Button) - Cuts
power to valves to stop all motion. The load will hold temporarily.
ON/OFF - Enables or disables all electrical power to controller.
RELATIVE CYLINDER POSITION - Once the stroke sensors have
been attached to the load, the controller is "Reset" so that all the
lift positions read as "0". This permits equal lifting even though
stroke sensors cables may be extended varying amounts.
RESET - Zeros the value of the current load position of the
sensors on the display.
SET-UP - Allows the operator to select Imperial or Metric mode of
operation, change the type of sensors being used (500,1000 or
2000 mm stroke) and the type of lift (manual or automatic)
START - Starts the lifting or lowering cycle.
STOP - Stops the lifting or lowering cycle.
STROKE LIMIT - User defined limit which specifies the distance
the load will be raised or lowered (AUTOMATIC Mode only). Stroke
limit is an absolute numerical value relative to the starting position
of the load.
TOLERANCE - See Accuracy
6.0 SYSTEM REOUIREMENTS
Prior to system set-up all cylinders must be equipped with an
SCK-1 CHECK VALVE PACKAGE or VF-1 VELOCITY FUSE. All
necessary hardware is included. A 12" long hose with two female
1/4" tube swivel ends is included to connect the “Retract Side
Port” on a double-acting cylinder to the “Pilot Port” on the V-44
pilot operated check valve. For longer stroke cylinders, longer
length hoses are available: HLS-524: 24" (610mm) length, HLS-
536: 36" length (914mm). Other lengths also available. Contact
Enerpac customer service to determine the proper hose.
SENSOR 1
X 41
SENSOR 2
X 42
SENSOR 3
X 43
SENSOR 4
X 44
SENSOR 5
X 45
SENSOR 6
X 46
SENSOR 7
X 47
SENSOR 8
X 48
VALVE 1
X 11
SENSOR 1
X 10
VALVE 2
X 12
VALVE 3
X 13
VALVE 4
X 14
VALVE 5
X 15
VALVE 6
X 16
VALVE 7
X 17
VALVE 8
X 18
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Double-acting cylinder and pump systems should be equipped
with a 4-way directional control valve (VE-43) must have one
remotely installed. The advance port pressure should be set to a
maximum of 8800-9200 psi (606-634 bar) to allow a margin of
safety to handle shifting loads.
Single-acting cylinders and pump systems should be equipped
with a 3-way directional control valve (VE-43) and (for load return
cylinders) a VUV-5 vac-u-valve
Advance pressure should be set at a maximum of 8800-9200 psi
(606-634 bar). This should be done to allow for shifting loads.
Pressure in excess of 10,000 psi (700 bar) can cause system
failure and/or damage to components.
8.0 HYDRAULIC COMPONENT ASSEMBLY
CAUTION: It is very important to ensure the hydraulic
system remain free of contaminants. Make sure that all
hydraulic couplers and fittings are free of dirt before
assembly. A quality thread sealant such as Teflon paste or an
anaerobic hydraulic sealer should be used to seal the threads
on all hydraulic fittings. Contaminants in the hydraulic system
will cause poor system performance and/or system failure. Dirt
is the #1 cause of problems with this system.
1. Install ADJUSTABLE RELIEF VALVES and GAUGES in the
advance and retract circuits of the hydraulic system. This can
be done at the pump-mounted or remote DIRECTIONAL
CONTROL VALVE.
2. Install FLOW CONTROL VALVE only on the advance side of
the PUMP DIRECTIONAL CONTROL VALVE. This valve can
be used to affect the rate of flow in the EXTEND AND
RETRACT directions. When opened, the FLOW CONTROL
VALVE allows more flow to pass through the CYLINDER
CONTROL VALVE to the cylinder. This valve may be opened
if the operator desires faster cylinder advance speeds and/or
when response becomes a problem. For best accuracy in the
lifting mode, start the flow control valve open about 1/4 turn.
IMPORTANT: Try to prefill all the hydraulic hoses by first
connecting them, one at a time, to the pump electric valve
and using the included pendant for the pump. Connect one end
of hose to the "A" port and the other end to the "B" port. Press
either the advance or retract button for a least a minute for
hoses less than 30 feet (9.1meters) long and at least 2 minutes
for hoses longer than 30 feet. Doing this small step will save
time and improve the safety of your actual lift. Failure to prefill
the hoses may result in dangerous cylinder movment, even if
the individual cylinder valves are not activated.
For Double-acting Cylinders
1. Install the pilot operated SCK-1 CHECK VALVE PACKAGE on
each lifting cylinder. The port marked CYL on the check valve
body connects to the advance port of the cylinder using the
fitting provided. The quick coupler in the cylinder advance
port is removed and used in the
“ PUMP” port of the check
valve body. NOTE: This coupler must be an Enerpac CR-400.
2. Install the “TEE” provided between the cylinder retract port
and the coupler.
3. Install the PILOT LINE between the “TEE” of the retract port
and the port marked “RET/PILOT” on the check valve body.
The pilot line must be the hydraulic hose included with the
SCK-1 kit or flared 1/4" tubing with a minimum wall thickness
of 0.049". (Refer to Fig. 4 for typical set-up, and the instruction
sheet that came with the V-44 pilot check valve in the SCK-1
kit.)
For Single-acting Cylinders
1. Remove the CR-400 coupler from the cylinder and install the
VELOCITY FUSE (VF-1 Kit) as shown in Figure 5.
2. Install the CR-400 coupler into the VELOCITY FUSE with
quality thread sealer, NOT TEFLON TAPE.
WARNING: Incorrect matching of hydraulic and
electronic components can cause unexpected lifting
behavior. Always test the control function of each
cylinder prior to positioning under the load.
3. Connect the hose from the CYLINDER CONTROL VALVE
(SLCV-24) to the CYLINDER CHECK VALVE. CYLINDER
CONTROL VALVES must have proper V-66 flow control valve
installed on the advance port of the power pump. (Refer to
Fig. 3, Basic 4-point Setup.)
IMPORTANT: Quick couplers should be used on the hose
assemblies, manifolds and valves, to facilitate system
assembly and disassembly of system components. All fittings
must be free of dirt or other contaminants when assembled.
Contaminants in the hydraulic system may result in poor system
performance and/or system failure.
Figure 3, Basic 4-Point System Hydraulic Diagram, Shown
Connected to Only One Cylinder for Illustrative Purposes
ADVANCE LINES
All cylinder advance lines are connected from a common
MANIFOLD to a port on the CYLINDER CONTROL VALVE (SLCV-
24) at each cylinder. The advance MANIFOLD is, in turn,
connected to the V-66 flow control and then to the port of the
DIRECTIONAL CONTROL VALVE (Refer to Figure 3, Basic 4-point
Setup.)
RETRACT LINES
All cylinder retract lines are connected from a common
MANIFOLD to the retract port of the hydraulic cylinders. The
retract MANIFOLD is, in turn, connected to the retract port on the
pump mounted electric valve. (Fig. 3, Basic 4 Point Setup.)
SENSOR1
X 41
SENSOR2
X 42
SENSOR3
X 43
SENSOR4
X 44
SENSOR5
X 45
SENSOR6
X 46
SENSOR7
X 47
SENSOR8
X 48
VALVE1
X 11
SENSOR1
X 10
VALVE 2
X 12
VALVE 3
X 13
VALVE4
X 14
VALVE5
X 15
VALVE6
X 16
VALVE7
X 17
VALVE 8
X 18
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1Stroke Sensor
2Cylinder Control
Valve
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4Controller
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IMPORTANT: The CYLINDER CONTROL VALVE (SLCV-24)
has a manual override capability. The valve is NORMALLY
CLOSED and can be manually opened by depressing the pin
located in the center of the valve coil. The valve will remain open
when the pin is depressed and will return to the closed position
when the pin is released. (Refer to Figure 4.)
9.0 ELECTRICAL COMPONENT ASSEMBLY
It is helpful to mark all cable connections and hose ends with
some sort of identifying feature for simple assembly and trouble-
shooting. Colored electrical tape is a good choice.
1. Swing open the cover from the SLCG-8 CONTROLLER and
make sure the power switch is in the OFF position.
2. Depress the EMERGENCY STOP button and rotate clockwise
to ensure that it is deactivated.
3. Connect the power cord to the CONTROLLER. The power
cord plugs into the three-pin plug on the face of the
CONTROLLER (Figure 2).
Note: The SLCG-8 CONTROLLER requires 115/230VAC
single-phase power to operate.
4. Connect the dual DIN plug electrical cable (SLPVC-1) from
the DIRECTIONAL CONTROL VALVE to the output plug on
face panel of the CONTROLLER (Refer to Figure 3, Basic 4-
Point Setup drawing.)
5. Connect the CYLINDER CONTROL VALVES to the controller
outputs marked VALVES. You only need to connect as many
valves as you plan to use. If you use four valves, connect
them to valve connection points 1-4 and so on.
6. Place an SLSS SENSOR at each lift point. Connect an SLSC-
15 SENSOR CABLE between the SENSOR and the
CONTROLLER. The SENSOR placed at lift point No. 1 must
be connected to sensor input plug No. 1 on the front panel of
the CONTROLLER; repeat this procedure for all remaining lift
points.
NOTE: SLEC-15 and SLVEC-15 EXTENSION CABLES can be
used to reach jack placement greater than 50 feet. Contact
Enerpac for more details.
WARNING: The matching of sensor and valve wiring is
essential to synchronous lifting. Failure to do so may
result in unexpected lift behavior. Always test the
control function of each cylinder individually prior to positioning
under the load.
Figure 4, Lift Point Configuration Showing Electric Valve,
Stroke Sensor, Cylinder and Pilot Operated Check Valve
Figure 5, Typical Velocity Fuse Installation
Figure 6, Alternative method of stroke sensor mounting to
prevent excessive amounts of water from running down the
sensor cable in raining or snowing conditions.
SYSTEM POWER UP AND CONTROL VERIFICATION
This set-up procedure should be completed in its entirety with
the PUMP TURNED OFF.
POWER CABLE
1. Plug power cable from the CONTROLLER into 115/230VAC.
2. Depress the EMERGENCY STOP button and rotate clockwise
to ensure that it is deactivated.
3. Turn CONTROLLER power switch on. The following screen
should appear showing Preferences and System Setup.
Figure 7
4. Select language by touching the appropriate bar.
Stroke
Sensor
Pilot Check
Valve
Cylinder
Electric Valve Overide

8
5. Touch "MEASUREMENT PREFERENCE" bar using the up
and down keys in this screen, select either inch or millimeter
to complete your selection.
6. Stroke Sensors – The software is compatible with Enerpac’s
500, 1000 and 2000 mm stroke sensors. Touch "System
Stroke Sensors" bar. Highlight the correct stroke sensor
length.
WARNING: SELECTING INCORRECT SENSOR
STROKE INFORMATION COULD LEAD TO A
DANGEROUS LIFTING SITUATION. NO DAMAGE
WILL BE DONE TO THE SYNCHRONOUS LIFT COMPONENTS
BUT THE ACCURACY AND DISTANCE LIFTED WILL BE
DIFFERENT THAN THE DISPLAY SCREEN VALUE!
7. After the stroke sensor has been selected, the Lift mode can
be selected. However, some basic system checkout should
be done before any actual lifting or lowering takes place.
Figure 8
8. Check the system for functionality. Go to the manual mode
screen by touching "MANUAL MODE". Press either Manual
Up or Manual Down with the lift system assembled but the
pump turned off. (See Fig. 8)
IMPORTANT: During this system check, your pump must
be turned off. Potentially dangerous cylinder movements
could take place during this test.
9. Choose the Active Cylinders by selecting C1-C8, the
cylinders turned on will display in yellow and cylinders turned
off will display in red.
SENSOR CHECK - The following check procedure should be
followed for all sensors to be used. A simple slow pull on the
spring loaded stroke sensor is all that is required to check sensor
functionality. Movement by the sensor cable will show as stroke
movement in the absolute and relative fields.
DO NOT LET THE SENSOR WIRE SNAP
BACK INTO THE HOUSING
Note: Sensors must be connected to the CONTROLLER in
order to check functionality.
VALVE CHECK - The following check procedure can be used to
check the function of the electric valves in the system.
Note: This should be done with your pump turned OFF for
safety reasons.
When you turn on the valves (Step 9 above) an LED on the DIN
plug should light up, you may also hear them click when shifted,
indicating a proper connection. You can also physically put your
hand on them and feel them shift. Also, the solenoid core
energized (operating) will magnetically attract any small metal
object such as a screwdriver.
CYLINDER CONTROL CHECK - Before the cylinders are placed
under the load, each cylinder should be activated individually and
control verified. Proceed through the following steps to verify
control of each lifting cylinder.
1. Start the hydraulic pump.
2. From the Set-up screen, select the MANUAL mode. (Fig. 7)
3. Select MANUAL UP (Fig. 8)
4. Activate the cylinder for lift point #1 only.
5. When the cylinder is moving, the display will show a numeric
value for that lift point. You saw the same thing when you
manually checked the sensor by pulling on the sensor cable.
Remember, this is the manual mode and no synchronization
will occur between the cylinders. If possible, run each
cylinder up and down a few times to help work the air out of
the cylinders. This air should be minimal if you pre-filled the
hoses before system setup. If you did not prefill the
hoses go back and do it now.
6. Press the START button. If no movement is observed at the
selected cylinder, check to see if movement has occurred at
another lifting cylinder. Movement of a cylinder other than the
one selected indicates incorrect electrical or hydraulic
plumbing. Check all electrical and hydraulic circuits and
make sure cables and hoses are plumbed correctly.
If the cylinder operation is opposite from the direction
selected, check for reversed hose plumbing from the
manifold to the cylinder and from the pump to the manifolds
and correct.
7. When proper cylinder control has been achieved, deactivate
the lift point. Continue the test for all lift points.
8. If you encounter jerky cylinder movement at any of the lift
points you still have some air in the system. Using the
MANUAL-operating mode, bleed each cylinder by extending
and retracting the cylinder full stroke several times. If possible,
cylinders should be laying down with the couplers pointing
upward. The preferred method of bleeding is with the hydraulic
pump on a level higher than the cylinders, allowing the air to
rise to the pump reservoir. Avoid building pressure in the
cylinder during this procedure to prevent aeration of the oil.
9. After the system has been completely purged of air, set the
system relief valves.
Manually advance any cylinder to full stroke while adjusting
the desired pressure. Do not exceed the recommended limits.
(8800-9200 psi / 606-634 Bar.)
CAUTION: The system components are designed for
10,000 psi (700 Bar). Exceeding this pressure could cause
system failure and damage to system components.
Route cables and hoses in a safe manner. Do not step on
cables. Keep cables dry and protected from abrasion.
10. Position all cylinders under the load. Cylinders must be
placed on firm foundations and plunger saddles should make
full contact with the load. Using the manual mode, jog the
cylinders until they make firm contact with the load.
CYLINDER/SENSOR INTERFACE CHECK -
1. Sensors for each lift point should be placed as close as
possible to the cylinder for that lift point. This will ensure the
most precise measurement of load displacement.

9
2. Manually extend the sensor cord again to verify that the
sensor readout change corresponds to the lift point being
tested. The cylinder and sensor operation should correspond.
CAUTION: Inaccurate load displacement data may
result if SENSORS and CYLINDERS are not placed on
solid foundations and in close proximity. The display
may indicate that the sensors are seeing load movement, when
in fact, the load may not have moved because the cylinder base
has settled or compressed and the sensor position has
changed as a result.
FLOW CONTROL VALVE - Located on the advance side of the
PUMP DIRECTIONAL CONTROL VALVE. This valve can be used
to affect the rate of flow in the EXTEND AND RETRACT directions.
When opened, the FLOW CONTROL VALVE allows more flow to
pass through the CYLINDER CONTROL VALVE to the cylinder.
This valve may be opened if the operator desires faster cylinder
advance speeds and/or when response becomes a problem. For
best accuracy in the lifting mode, start the flow control valve open
about 1/4 turn.
LIFTING SEQUENCE
1. Using the MANUAL mode, individually extend each cylinder
until the load is contacted. This can be determined by
monitoring SENSOR readout. Raise the load a very small
amount with the manual mode. When readout begins
changing the load is contacted. Be sure to extend the
cylinders one at a time. Visually inspect each lift point to
ensure that each cylinder has made load contact.
2. After extending/inspecting each lift point select the AUTO UP
mode. Select the cylinders you want active. The STROKE
LIMIT and ACCURACY values shown on the display should
read zero unless the operator has entered these values
earlier. (Fig. 9.)
Figure 9
3. Set STROKE LIMIT. For the first run, set the stroke limit to a
small value, just enough to move the load. To do so, touch the
STROKE LIMIT box and enter the STROKE LIMIT. Do the
same for the desired TOLERANCE.
NOTE: The controller will hold as tight a tolerance as
possible. The value you enter will be the tolerance value that
will stop the lift and alert you to a possible problem.
Press RESET to zero the relative values of all lift point positions.
Resetting all the stroke values to zero establishes the plane of
reference for the lift. You can view the "Absolute" values on the
sensors above the releative values.
Check to make sure the mode reads AUTOMATIC UP. If so, press
START. When the cylinders stop, check the display to verify the
position of the lifting points. All lift points should have advanced.
If there is problem, the controller will stop the load and indicate
the problem.
Figure 10, Automatic Down
IMPORTANT: Before proceeding further with the lift, lower
the load to its original position by switching to AUTO
DOWN mode (Fig. 10). This should be done to verify that the
flow control setting at the pump is correct. A realistic lower
speed is 1 to 3 inches per minute. (25-75 mm per minute).
Faster speeds may not hold a high enough accuracy and slower
speeds may be too slow to be productive.
Choose ACTIVE CYLINDERS. Be sure to select the same
cylinders that you used to raise the load.
WARNING: This system is not intended as a load
holding device. When holding a lifted load, once the
desired stroke is completed, the system does not cycle
the valves on/off to make up for any leak-down which might
occur. Extended periods of load holding REQUIRE blocking
(cribbing) the load. Failure to do so could result in personal
injury and/or property damage. This problem can be corrected
by using Enerpac locknut cylinders that can mechanically lock
the load in place. Contact Enerpac for details.
WARNING: The stroke values you enter are
"Absolute" from the 0 (zero) position you started from.
This means if you set the stroke for 4 inches (100mm)
and stop the lift at 2 inches (50 mm) then restart the load, the
load will stop at the 4 inch (100 mm) point. However, to go
back to the 0 (zero) point you must enter a stroke value of 0
(zero) and set the controller to AUTO DOWN. If you were to
set the controller to 3 inches (75mm) in the AUTO DOWN
mode the load would retract down only 1 inch (25 mm) back
to the 3 inch (75 mm) "Absolute" position.
10.0 ERROR CODES
"ACCURACY ERROR"
CAUSES AND CURES:
Cylinder Speed Too Fast. If needed, go back and very slightly
close the flow control valve at the pump.
Mismatch Of SENSORS and Hydraulic Plumbing - Verify that the
hook-up of the SENSORS, valve wiring, and hydraulic plumbing is
correct (i.e. Valve wiring, sensor inputs and hydraulic circuits are
matched correctly.)
NN.NNNNNN.NN 00.000000.00
DIFFERENCE (mm):
MODE: AUTOMATIC DOWN
AUTO
UP
MODE
MANUAL
MODE
SETUP
MODE
RELATIVE
RESET
RELATIVE (mm)
ABSOLUTE (mm)
C5 C6 C7 C8
RELATIVE (mm)
ABSOLUTE (mm)
C4C3C2C1
TOLERANCE (mm)STROKE LIMIT (mm)
00.00
OFF OFF OFF OFF
OFFOFFOFFOFF
STOPPED
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00
NN.NNNNNN.NN0000.00 00.00
DIFFERENCE (mm):
MODE: AUTOMATIC UP
SETUP
MODE
STROKE LIMIT (mm) TOLERANCE (mm)
MANUAL
MODE
AUTO
DOWN
MODE
RELATIVE
RESET
RELATIVE (mm)
ABSOLUTE (mm)
C5 C6 C7 C8
RELATIVE (mm)
ABSOLUTE (mm)
C4C3C2C1
00.00
OFF OFF OFF OFF
OFFOFFOFFOFF
STOPPED
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00
0000.00 0000.00 0000.00 0000.00

10
Advance And Retract Hoses Reversed - Check all cylinders
making sure the advance ports are connected to the advance
manifold and the retract ports of the cylinder to the retract
manifold.
Figure 11
RESETTING SYSTEM:
Refer to the "typical display" above. (Fig. 11)
Anytime an error occurs, the computer shuts down the system
and displays the above screen with a varying message depending
on the actual error that occurs. The above example is an error for
the accuracy for all the lift points. This indicates that one or more
than one lift point has varied by a value greater than your specified
maximum. This is the most common error, especially when lifting
the fist time. You may need to increase the tolerance or manually
adjust the lagging cylinders at least once.
THE FOLLOWING IS A LISTING OF PROGRAM ERROR
MESSAGES:
System has reached Stroke Limit
System Is Over Tolerance
Minimum Tolerance for Stroke Sensors/*X*/is Exceeded
Limit of Stroke Sensor #1 Reached
Limit of Stroke Sensor #2 Reached
Limit of Stroke Sensor #3 Reached
Limit of Stroke Sensor #4 Reached
Limit of Stroke Sensor #5 Reached
Limit of Stroke Sensor #6 Reached
Limit of Stroke Sensor #7 Reached
Limit of Stroke Sensor #8 Reached
Error Reading Active Stroke Sensor #1
Error Reading Active Stroke Sensor #2
Error Reading Active Stroke Sensor #3
Error Reading Active Stroke Sensor #4
Error Reading Active Stroke Sensor #5
Error Reading Active Stroke Sensor #6
Error Reading Active Stroke Sensor #7
Error Reading Active Stroke Sensor #8
Error: System Inactive
Error: Loss of Power at Pump Valve
Error: Loss of Power to Valves 1-4
Error: Loss of Power to Valves 5-8
Error: Loss of Power to Stroke Sensors
Emergency Stop Button is Pushed In
NOTE: Minimum tolerance will vary from sensor to sensor. See
page 5 for these limits.
NOTE: Cylinder valves cannot be operated from the controller
without a stroke sensor present for that cylinder. Only Enerpac
can override this because of safety reasons.
NOTE: System Inactive usually points to a load that is too heavy
and cannot be lifted by some or all the cylinders.
10.1 METHODS FOR CORRECTING CYLINDER TO
CYLINDER ACCURACY ERRORS
METHOD #1
The error may be corrected by bringing the high or low cylinder
back into the ACCURACY range.
a) Determine the cause of the fault and correct.
b) Adjust the cylinders back into position manually. Turnoff all
other cylinders, change from AUTO to MANUAL operation,
and select proper cylinder direction (UP or DOWN).
d) Momentarily depress the start and stop buttons to jog the
cylinder into position.
e) Return to the AUTO mode and reactivate all cylinders.
f) Confirm that the tolerance value is less than the programmed
tolerance. If not repeat cylinder adjustments above.
g) You may now proceed with Synchronized lifting or lowering.
METHOD #2
a) Determine the cause of the fault and correct.
b) If you feel the tolerance is too small and a larger tolerance is
acceptable, it can be changed to a value larger than the value
of the tolerance indicated.
c) Once the cylinders start to move the controller will try to bring
all the cylinders into as close a tolerance as possible.
d) Stop the lift (or lower) and reset the tolerance to a smaller
value and start the lift again.
CAUSES AND CURES FOR CYLINDER ACCURACY
ERRORS:
1) Hydraulic coupling that is not fully tightened will cause
blocked or restricted flow– check couplings and tighten.
2) Cylinder or sensor cord has reached its stroke limit -
You may need to crib the load and take an additional step in
lifting the load.
3) Flow control on advance line is permitting too much flow -
adjust FLOW CONTROL VALVE to slow down flow rate.
4) Load is obstructed from movement - remove obstruction.
5) Load too heavy to allow movement at system pressure -
increase system pressure, but do not exceed rated capacity
of system components. If system pressure is increased to
maximum and no movement occurs, larger capacity cylinders
may be required.
6) In retract mode, if pressure is too low, P.O. Check may not
release.
7) Sensor cable not connected to load. Connect sensor cable.
ALARM
ACKNOWLEDGE
MINIMUM TOLERANCE
FOR STROKE SENSORS
IS EXCEEDED