catalogue technique mg05 - poclain hydraulics€¦ · cleanstart system / hydraulic starter poclain...

T E C H N I C A L C A T A L O G

C LE A N S TA R T S Y S TE MH Y D R A U LIC S TA R TE R

2 25/10/2017

CleanStart system / Hydraulic starter POCLAIN HYDRAULICS

Methodology :This document is intended for manufacturers of machines that incorporate Poclain Hydraulics products. It describes the technical characteristics of Poclain Hydraulics products and specifies installation conditions that will ensure optimum operation. This document includes important comments concerning safety. They are indicated in the following way:

This document also includes essential operating instructions for the product and general information. These are indicated in the following way:

The views in this document are created using metric standards. The dimensional data is given in mm and in inches (inches are between brackets and italic)

Safety comment.

Essential instructions.

General information .

Information on the model number.Information on the mo-del code.

Weight of component without oil.

Volume of oil.

Units.

Tightening torque.

Screws.

Information intended for Poclain-Hydraulics personnel.

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CONTENT

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HES

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POCLAIN HYDRAULICS CleanStart system / Hydraulic starter

DESCRIPTION 4

HES STARTER 7

Characteristics 7Main dimensions 8Model code 9

VHES VALVE 11

Characteristics 11Main Dimensions 12Model code 13ACCUMULATOR 14

SD-CT-PWE 15

PWe ECU 15SmartDrive CT PWe electronic overview 16General chart 17PHASES™ CT 18

INTEGRATION 19

Auxiliaries 19Hydraulic scheme 21Wiring 21

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DDESCRIP

Mark Designation Quantity1 Hydraulic Starter 12 Hydraulic Pump 1

3Sequence Valve 1

Electronic Control Unit 14 Tank 15 Accumulator 1

9

2

3

54

Pressurizes the accumulatorfor the next restart.

Stores the oil.

Hydraulic Pump

AccumulatorStores the energy required fora start-up.

Tank

Sequence valveFills and empties the accumulator.

Electronic Control UnitOptimizes the start-up sequence.

+

DESCRIPTION

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VHES

val

ve

SD-C

T-PW

E In

tegr

atio

n D

escr

iptio

n H

ES s

tart

er

1

TTION

Installed in the main pulley of the internalengine.

Hydraulic Starter

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HHES STARTERCharacteristics

• Compact• Powerful• Installed on the crankshaft

Operation Hydraulic symbol

Hydraulic starter compatible with 3 to 12 litres displacement engines dedicated to heavy duty application.

Features

Displacement cm3/rev. [in.cu/rev.] 127,5 [7.78]Max. pressure * bar [PSI] 280 [4000]

Max. speed (start/freewheel mode) RPM 800 / 3000

Max. torque N.m [in.lbf] 550 [4800]

Total oil capacity L [cu.in] 0,4 [24.41]Rotating inertia kg.m2 [lb.ft2] 0.025 [0.59]Mass kg [lb] 13,421 [29.58]

T2

T

P

* Operating phase

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Main dimensions

Hydraulic connections

Port FunctionHES2-X-118-X HES2-X-113-X Max pressure

bar [PSI]Connection Standard Connection StandardP HP connection M22x1.5 ISO 6149-1 G 1/2 ISO 1179-1 280 [4061]T Tank connection M27x2 ISO 6149-1 G3/4 ISO 1179-1 10 [145]

T2 Tank connection M16x1.5 ISO 9974-1 M16x1.5 ISO 9974-1 10 [145]

Any contact with petroleum fluid or brake fluid should be avoided. Sensible parts are protected but in case of long term contact, sealing could be damaged.

60 [2.36]

39[1.53]10 [0.39]

226

[8.9

0]

115

[4.5

3]11

5 [4

.53]

96 [3

.78]

96 [3

.78]

4x Ø13 [4 x dia.0.51]

56,3 [2.22]20 [0.79]

100

[3.9

4]99

[3.9

0]

22 [0.87]

P

T

55 [2.17]54 [2.13]15,5

[0.61]

12,5

°12

,5°

4x2 M10x80

Ø141 [dia.5.55]

17 [0.67] 71,1 [2.80] 15,5 [0.61]

162,

5 m

ax. [

max

.6.4

0]

Ø12

6

[dia

. 4.9

6

]

0 -0,2

0 -0,0

08

7,5 [0.29] 73 [2.87]

100,1 [3.94]

T2

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Model code

C1Cam ring type

cm3/tr [cu.in/rev.]

HES2 127 [4.99] 2

D1Valving typeClockwise RCounterclockwise 1

D2CoverSymmetrical fixation on cover(with screwed ports) 1

D3Connection typeISO 1179-1 (BSPP + spot face) ports 3ISO 9974-1 (metric + spot face) ports 4ISO 6149-1 (metric + cone) ports 8ISO 11926-1 (SAE J514 with O-ring seal) A

S3-6Options

D Special paint or no paintF Special mountingsP Number plate specific to the customer

S1Standard

4 Mechanical free-wheeling

S2Standard

H High efficiency-torque at low speed very regular(piston with special ring)

P1Turning fixationFixation by came screws 8xM10 on Ø141(centering diameter=126) 1

P2Bearing support

A HES standard bearing support (in 2 parts)

H S 2 1 0 0 0 1 A 0 0 4 HE1

C

1 2

D

3 1 2

F

3 1 2

P

3 4 1 2

S

3 4 5 6

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VVHES VALVECharacteristics

• Only one component to manage CleanStart system

OperationManage the operating phases of the CleanStart system : accumulating, waiting and starting.

FeaturesMax. pressure (cracking pressure) bar [PSI] 330 bar [4700] *Oil max. temperature °C [°F] 90 [194]

Ambient max. temperature °C [°F] 100 [212]

Mass kg [lbs] 7.5 [16.53]

* Accumulator Relief Valve Protection

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Main Dimensions

Hydraulic connections

Port Function Connection StandardMax pressure

bar [PSI]

A Connection to accumulator G1/2 ISO 1179-1350 [5000]M Output for starter supply G3/4 ISO 1179-1

P Inlet from pump G3/8 ISO 1179-1T Output to tank G3/8 ISO 1179-1 1 [14]

Pressure sensorPressure 600 bar [8702 PSI]Power supply 5±0,5 VOutput signal 0,5 - 4,5 VElectrical connection DIN72585 4 pins coding 1

SolenoidsPort Type of connector Voltage

VS1/VS2DEUTSCH DT04-2P

12/24VPACKARD (METRI-PACK)

DIN-EN 175301-803 (HIRSCHMANN)

55[2

.165

]

55[2.165]

22[0.866]

10[0.394]

46,458

,8

9[0

.354

]

[1.8

26]

[2.3

15]

25[0

.984

]61

,5[2

.421

]

[0.787]20

[0.7

87]

20

58,2

[2.2

91]

85[3.346]

20[0.787]

137 [5.394]

51 [2

.008

]

25[0.984]

28,5

[1.1

22]84

,5 [3

.327

]

105

[4.1

34]

59 [2

.323

]

194

[7.6

38]

23[0.906]

105 [4.134]

175 [6.889]

140

[5.5

12]

75 [2

.953

]48

[1.8

89]

65 [2

.559

]

47,5

[1.8

7]14

[0.5

5]

M

P

T

A

VS2VS1

MA

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Model code

SequencesVS1 VS2

Accumulator charging On OffP to AP max = 300 bar [4300 PSI]M to T

Accumulator charged pump in by-pass mode Off Off

P to TA max = 300 bar [4300 PSI]M to T

Motor starting Off On P to TA to M

Manual accumulator discharging ( A to T) : unscrew by-pass screw one revolutionAccumulator protection by relief valve (cracking pressure) : 330 bar [4700 PSI]

0- B000SH -EV -

C1-3Volume of tankWithout tank 0002 liter 020

D4Pressure wensor/switch Without 0Sensor 1Switch 2

D5-6Relief valve setting (bar [PSI])250 [3600] 25290 [4200] 29330 [4800] 33

P1Voltage12 V 124 V 2

P2Sensor/Switch connectorWithout 0Bare wire 1Packard (Metri pack connectorseries 150 P2S = 003241171M = IP67)(Metri pack 280 = sensor)

2

Deutch DT04-2P 3Baynet connector DIN 72 5854 pin A53472W = IP69K 4AMP (Superseal 1,5 = IP67) 5

P3Electrovalve S1 connectorDeutsch DT04-2P 3Packard (Metri-Pack) 2DIN EN 175301-803 (Hirschmann) 4

P4Electrovalve S2 connectorPackard (Metri-Pack) 2Deutsch DT04-2P 3DIN EN 175301-803 (Hirschmann) 4

P5Hydraulic connectionsISO 1179-1 (BSPP) 3Metric 4SAE A

-

S1SD-CT-PWEWithout 0SD-CT-PWE integration 1

S2SD-CT-PWE orientationHorizontal HVertical V

1 2

C

3 1 2

D

3 4 5 6 1 2

P

3 4 5 1 2

S

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AACCUMULATOR

Characteristics

• The accumulator stores and restitutes the hydraulic energy needed for next engine start.

Operation

FeaturesMass kg [lbs] 11,6 [25.57]Accumulator volume L [cu.in] 1,5 [91.53]

Design pressure bar [PSI] 300 [4 350]

Test pressure bar [PSI] 450 [6 500]Minimal body design temperature -15°C [5° F]Maximal body design temperature 80°C [176 °F]Thread for GAS filling G5/8

Main dimensions

406 [15.98]

Ø20

[dia

. 0.7

9]

100

[dia

. 3.9

4]G3/

4

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SSD-CT-PWEPWe ECU

Integrated ECU manages operation CleanStart phases:• Accumulator pressurization• Waiting phase• Engine restart

SmartDrive CT PWE characteristicsCommercial name SD-CT-PWEPart number B03822DOperating voltage 8 V to 32 VOperating temperature -40°C to 100°C [-40 °F to 212°F]Material PA66 30% GF; Silicon (potting)Mass 0,225 kg ±10% [0,496 lb] ±10%Ingress protection (with mating connectors mounted) IP6K9K (ISO20653)12V system max current 17 A24V system max current 8,5 APerformance level Capacity to reach PL d level according to ISO13849:2006 standardMean Time To Failure (MTTF) 162 years (duty cycle is 229 days of 8 hours)Mean Time To Dangerous Failure (MTTFd) 324 yearsDiagnostic Coverage (DC) 95.4 %Category 2Electrical protection Over-voltage, reverse polarity (with fuse), ground and battery short circuitMicrocontroller 16 bits microcontrollerDigital inputs 5Analog inputs (AN) 7Universal inputs 2HSD PWM outputs 4HSD DIG 2,6A outputs 2HSD DIG 0,5A outputs 2Sensor supply 5V 1

Certification E-Marking (2004/104/EC) – Automotive EMC directive

EC-Marking (2004/108/EC) – Agricultural, forestry, construction and forklifts machines

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SmartDrive CT PWe electronic overview

Charging request digital input

Start request digital input

Pressure analog input

T1 Temperature analog input

Engine speed frequency input

CAN Engine speed / EEC1

Charging request CAN input

Start request CAN input

VS1 coil PWM+ output



Low error feedback digital output

Critical error feedback digital input

Early start request digital output

System ready digital output

Low error feedback state

Critical error feedback state

Early start request state (CAN)

System ready state (CAN)

Low error feedback state (CAN)

Critical error feedback state (CAN)

Early start request state (CAN)

System ready state (CAN)

Charging request CAN input

Piloting request CAN input

Low error feedback digital output

Critical error feedback digital output

Early start request digital output

System ready digital output

Charging request digital input

Piloting request digital input

SD-CT-PWE-ECU

Vehicle ECU

CAN Bus

by CAN

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General chart

Engine ON

Clean Start ON

Accumulator charging (until P accu < P needed)

Hydraulics OKHydraulic motordisengagement

Clean Startready

Engine OFF

Low pressure level?(if P accu < P min)

Early Startrequest

Electric start Engine ON

Clean Start OFF

Hydraulic start OK?

Filling request

Startrequest

Safety controls(Temperature, pressure,...)

Thermal engine ormachine state/data

Safety controls(Temperature, pressure ...)

Clean Start/Hydraulic state

NoYes

Yes

No

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Set-upThe settings of the SmartDrive™ CT may need to be changed if there is a change in characteristics or operating conditions. The PHASES™ CT software manages 3 access levels to settings: • Service,• Manufacturer,• Expert.The last two levels are restricted to technicians with specific training (access restriced through password).

DownloadingUsing a PC and the PHASES™ CT software allows to :• Download the software to the SmartDrive™ CT;• Send and retrieve set-up files.

CalibrationThe PHASES™ CT software allows to calibrate the minimum, maximum and neutral positions of the sensors installed on the machine in order to optimize the system’s operation.

DiagnosticsThe PHASES™ CT software enables the user to download the system's operating data. The data collected is used to identify possible malfunctions.

Study of the systemOur sales engineers will analyze your specific needs to facilitate the integration of Poclain Hydraulics components into your system.

TrainingAvailable on request.

PWe pin-out:

PHASES™ CT

Any modification of the value of a setting must be carried out by a qualified engineer trained by the machine manufacturer. The Poclain Hydraulics technical support team can advise you in defining your settings. Modifications to the settings may require a new qualification of the machine. If in doubt, contact your Poclain Hydraulics sales engineer.

For further information, see PHASES™ CT user guide no. A48680N.

[1.1

8]

[2.95][2.95]

[2.3

6][1.2

9]

[1.4

7]

75 75

37,5

30

60

33

[0.21]

40° (2x)

Ø5,5 (3x)1 11 1 1110 20 10 20

12

Connector 1 Connector 2

Connector 3

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IINTEGRATIONAuxiliaries

CharacteristicsCommercial name KIT-CONNECT-PWE-DIAGPoclain Hydraulics part number B03983DFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.

Component Molex reference Quantity

Connector 33471-0201 x1

Pin 33012-3003 x2

Wire gauge 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]Insulation diameter 1,2 to 2,69 mm [0.047 to 0.105 in]Operating temperature -40°C to 125°C [-40°F to 257°F]

CharacteristicsCommercial name KIT-CONNECT-PWE-CUSTOMERPoclain Hydraulics part number B03982CFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.

Component Molex reference Quantity Wire gauge


Pin 33012-3001 x2 1,5 to 2 mm² [0.0023 to 0.0031 in²]

Pin 33012-3002 x4 0,75 to 1 mm² [0.0011 to 0.0015 in²]

Pin 33012-3003 x14 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]

Plug 34345-0001 x20

Insulation diameter 1,5 to 2,5 mm [0.05 to 0.098 in]Operating temperature -40°C to 125°C [-40°F to 257°F]

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Mounting tools for the connector

CharacteristicsCommercial name KIT-CONNECT-PWE-CUSTOMER-GREYPoclain Hydraulics part number B18082DFunction SmartDrive™ CT PWe controller's Counter-part connectors.Compatibility Electronic transmission management with SmartDrive™ CT PWe controller.

Component Molex reference Quantity Wire gauge


Pin 33012-3002 x8 0,75 to 1 mm² [0.0011 to 0.0015 in²]

Pin 33012-3003 x12 0,35 to 0,5 mm² [0.0005 to 0.0007 in²]

Plug 34345-0001 x20

Insulation diameter 1,5 to 2,5 mm [0.05 to 0.098 in]Operating temperature -40°C to 125°C [-40°F to 257°F]

Description Molex reference Wire gauge

Crimping tool 63811-5900 1,5 mm2 to 2 mm2

Crimping tool 63811-6000 0,35 mm2 to 1 mm2

Pin extractor 63813-1500

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Hydraulic scheme

M

P M

MA

A

P

T

T

P

T2

A

B

P2

A

B

PU

T

TU

VS3

Name pin Wire gauge (mm2)DIG-IN 1 0,35 to 0,5DIG-IN 2 0,35 to 0,5ANA-IN 1 0,35 to 0,5ANA-IN 2 0,35 to 0,5+5V out 0,35 to 0,5AGND 0,35 to 0,5+VBAT 1,5 to 2-VBAT 1,5 to 2

PWM 1+ 0,75 to 1 PWM 2+ 0,75 to 1 PWM2- 0,75 to 1 PWM 3+ 0,75 to 1 PWM 3- 0,75 to 1

DIG-OUT 1 0,75 to 1 DIG-OUT 2 0,75 to 1 DIG-OUT 3 0,75 to 1 DIG-OUT 4 0,75 to 1

CAN2-H 0,35 to 0,5CAN2-L 0,35 to 0,5CAN1-H 0,35 to 0,5CAN1-L 0,35 to 0,5

Wiring

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1 2

2 P

IN

1 2

1 2

2 P

IN

1 2

1

2

1

2

1 2

2 P

IN

1 2

1 2 3

0.1

GND

GND

VBAT_P5 A

KEY SWITCH

IGN

ITIO

N

STA

RTE

R

CO

M

EMERGENCY SWITCH

15 A

15 A

5 A

20 A

Charging request

Piloting request

HPA pressure sensor

Temperature sensor

+5VS

GNDU

P

+ BATKL 30

STARTER

IGNITIONKL 15

GNDKL 31

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D

C

BA

J

HG

F

E

1 2

10 P

IN

3 4

1 2 3 45

56

67

78

89

91

01

0

GND

1 2

3 P

IN

3

1 2 3

VBAT_P

C2-6C2-8

SmartDrive CT-PWEPower outDigital input

C1-2

C1-12

C1-11

C1-1

C2-7C2-5

C2-1C2-2

C2-3

C2-4

C3-1C3-2C1-8C1-7

CAN2-HCAN2-LCAN1-HCAN1-L CAN_L

CAN_H

PWM 1+PWM 1-

PWM 2+PWM 2-

PWM 3+PWM 3-

PWM 4+PWM 4-

DIG-OUT 1

DIG-OUT 2

DIG-OUT 3

DIG-OUT 4

Digital output

CAN

C1-3C1-13*

C1-14C1-4C1-15

C2-13C2-14

C2-12C2-15C1-16C1-6C2-16

C2-11C1-17C1-18

C1-19C2-19C1-9C2-10C2-20C2-9

C1-20C1-10

+5V out+5V outAGNDAGND

Digital output

+VBAT SENSOR+VBAT SENSOR GND

DIG-IN 1DIG-IN 2DIG-IN 3DIG-IN 4DIG-IN 5

ANA-IN 1ANA-IN 2ANA-IN 3ANA-IN 4ANA-IN 5ANA-IN 6ANA-IN 7

UN-IN 1UN-IN 1UN-IN 2

Analog input

Universal input

VS2

VS1

VS3

Diagnostic connector(SAE J1939-13)

+ VBAT- VBAT

Power

Low failure

Critical failure

Engine manuallystart

System ready

* C1-13C1 Connector 113 Pin 13

www.poclain-hydraulics.com

25/10/2017

Poclain Hydraulics reserves the right to make any modifications it deems necessary to the products described in this document without prior notification.The information contained in this document must be confirmed by Poclain Hydraulics before any order is submitted.Illustrations are not binding.The Poclain Hydraulics brand is the property of Poclain Hydraulics S.A.

B19278D

catalogue technique mg05 - poclain hydraulics€¦ · cleanstart system / hydraulic starter poclain...

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