Enerpac PC-115 User manual

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.
ACAUTION is used to indicate correct operating or
maintenance procedures and practices to prevent damage
to, or destruction of equipment or other property.
AWARNING indicates a potential danger that requires
correct procedures or practices to avoid personal injury.
ADANGER 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 packing
and seals, resulting in fluid leaks. Heat also
weakens hose materials and packing. 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.
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Instruction Sheet
PC-115, PC-230, PC-460, PC-575
L1645 Rev. B 11/99
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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.
3.0 ELECTRICAL ENCLOSURE/ELECTRICAL BRACKET
Before installing an electric solenoid valve (VS3-24, VS4-
24) on the new 30,000, 40,000 or 50,000 series pumps
that currently have a manual valve, it is also necessary to
obtain an electrical enclosure (PC-115, PC-230, PC-460 or
PC-575) and an electrical bracket (EB-200 for 2 Gal., EB-
510 for 5 & 10 Gal.). The PC-115 is to be used on 110 &
220 V., 1 phase models; the PC-230 on 230 V., 3 phase
models; the PC-460 on 460 V., 3 phase models; and the
PC-575 on 575 V., 3 phase models. The electrical
enclosure contains electrical components necessary to
operate the electric solenoid valves. Diagrams are shown
on the following pages for the various voltages. The
electrical box comes from the factory wired, except for
connecting the electric valve leads.
4.0 INSTALLATION INSTRUCTIONS
Caution: All electrical wiring must be performed by a
qualified electrician and should be made in
accordance with local electrical code. Electrical
installation, performance checks or other services also require
a qualified electrician.
1. Before beginning installation be certain all power to
system is off.
2. Remove power cord and on/off switch from motor
terminal box.
3. Mount electrical enclosure to pump using the bracket.
4. Wire motor cord to terminal box on motor according to
corresponding diagrams on following pages.
5. On single phase models, the electrical enclosure is
supplied with the power cord already wired. On three
phase models, install user supplied power cord through
strain relief and connect wires to corresponding motor
leads with wire nut. Also connect leads coming off of
transformer primary terminals to L1 and L2 with wire
nuts. Motor lead hookup may have to be changed to
achieve correct rotation (clockwise).
IMPORTANT: Note that the PC-115 comes wired for
use at 110V, 1 Phase. For use at 220V, 1 Phase, use the
short jumper wire included to make the following
change: Remove connectors from transformer terminals P2
and P3 and snip off at the opposite end (where they enter
splice connector). Install jumper wire (supplied in kit) between
P2 and P3. Note also that for 230V, 1 Phase operation, the
motor leads must be changed per the instructions on the
inside surface of the motor terminal box cover.
6. Install valve cord through small strain relief. For use with
VS4-24, connect wires directly to R1and R2.
Power Motor Value / Press.
Switch
Electrical Enclosure, 110/220 V., 1 Phase

3
Power Motor Value / Press.
Switch
Electrical Enclosure, 230/460 V., 3 Phase
Motor Terminal Box Wiring for Electric Valve Box
110V / 1-Phase
Motor Terminal Box Wiring for Electric Valve Box
220V / 1-Phase
Ground Ground

Motor Terminal Box Wiring for Electric Valve Box
230V / 3-Phase
Motor Terminal Box Wiring for Electric Valve Box
460V / 3-Phase
Ground Ground