Sonny's Hydraulic Power Pack Owner's Manual

Table of Contents

• WARNING: Safety Requirements
• Installation
• General Operation
• Preventive Maintenance
• Warranty
• Customer Service

WARNING: Safety Requirements

1. All employees must be thoroughly trained in safe operation and standard maintenance practices. Review this manual monthly.
2. Do not enter the wash tunnel when equipment is operating. Risk of death or dismemberment.
3. Avoid loose clothing or jewelry around moving equipment. Keep body parts and objects away from moving equipment to prevent entanglement, which can cause death or dismemberment.
4. Do not leave ladders, hoses, or tools in the wash tunnel while equipment is running. This can cause vehicle damage and injury, including death.
5. Exercise caution when walking in the wash tunnel due to potentially slippery conditions. Avoid bumping into or tripping over equipment.
6. Only trained and instructed employees are permitted to enter the wash tunnel for inspections or maintenance. At least two qualified maintenance personnel must be present for repairs or preventive maintenance.
7. Perform LockOut Safety Precautions before any maintenance or work on equipment. All electrically powered equipment must have manually operated disconnects capable of being locked in the "OFF" position. Only the person who performed the lockout can restart the equipment.
8. Use a fiberglass ladder in good condition when working on equipment higher than your shoulders.
9. Do not attempt to repair or adjust pressurized liquid or pneumatic parts, hoses, pipes, or fittings while equipment is in operation.
10. Electrical connections and repairs must be performed by a Licensed Electrician. Emergency "STOP" buttons must be clearly marked and their use reviewed with all personnel. Any activated "STOP" button must be reset only by the person who activated it. Clear the wash tunnel of all personnel and items before restarting. An audible device must sound to warn of equipment startup.
11. Do not operate equipment with safety covers removed or improperly installed. Do not operate equipment if any component is suspected to be defective or malfunctioning.
12. Store cleaning solutions and oils in a well-ventilated area. Clean up spills immediately. Follow SDS Sheets for chemical product safety procedures.
13. Check and set torque relief or overload on hydraulic and electric systems to the minimum amount for proper functionality under normal washing conditions.
14. No unauthorized personnel should be permitted in the wash tunnel or near the equipment.

CAUTION: If equipment must be in operation during inspection or maintenance, one qualified technician must remain at the power disconnect switch while another performs the inspection or maintenance.

Introduction

This manual contains vital information for the successful installation, operation, and maintenance of Sonny's vehicle washing equipment. Please read and understand the full contents before installation and operation. Keep this booklet for ongoing reference.

For questions regarding operation or servicing, contact:

TECHNICAL SERVICES DEPT.
SONNY'S ENTERPRISES INC.
5605 Hiatus Road
TAMARAC, FLORIDA 33321
TELEPHONE: 800-327-8723
FAX: 800-495-4049

Thank you for your confidence in SONNY'S!

Product Specifications

Sonny's Power Packs with Vickers Vane Pumps come complete with:

• Sight glass & temperature gauge
• Return line filter
• Filter breather
• Clean-out cover(s)
• Suction strainer
• System relief
• Pressure-compensated flow control
• Pressure gauge
• Low level switch
• Vickers Vane pump on 5HP through 20HP packs
• Vickers Gear pump on 3HP packs

Installation

Utilities Requirements

Utilities interconnection and materials for interconnection to Sonny's equipment are the customer's responsibility. All trades work must comply with applicable local and national codes.

Hydraulic

The installer must provide and install pressure and return lines to and from the hydraulic power pack flow control valves and the equipment. Lines should be Schedule 80 BIP or hose rated at least 2200PSI. A minimum 18-inch flexible hose should be used at each termination. It is recommended that the return line from the last hydraulic motor in a circuit to the power pack return filter be one size larger than the pressure line (e.g., pressure line is 1½ inch, return line should be ½ inch) to extend hydraulic motor and pump life by reducing line friction and oil temperature.

Electrical

• The customer's electrician must provide and install 208VAC, 230VAC, or 460VAC, 3-phase, 60Hz power to the electric motor on the hydraulic power pack, using a properly sized three-pole circuit breaker and motor starter with three thermal overloads.
• The customer's electrician must provide and install single-phase power (24VAC or 110VAC) from the customer-supplied start/stop system through the low oil level switch on the hydraulic power pack to the motor starter coil for the hydraulic power pack.

For questions, call the Technical Services Department.

Hydraulic Power Pack Capabilities

Hydraulic Motor Chart

Example Applications:

One 5HP Power Pack with 7.5GPM pump can operate:

• One pair of tire brushes plumbed in series, running at 300RPM with 4.5 cu in/rev motors (5.9GPM fluid requirement).
• OR Four side washers plumbed in parallel with separate speed control valves running at 80RPM, each using 5.9 cu in/rev motors (6.13GPM total fluid requirement).

One 7.5HP Power Pack with 10.5GPM pump can operate:

• A surface mount or over-under conveyor 100 ft. long or shorter at 120CPH (assumes 15RPM drive sprocket with 5.2:1 speed reducer) using a high torque / low speed hydraulic motor 24.0 cu in/rev (8.1GPM fluid requirement).
• OR One pair of wraps or high side washers plumbed in parallel with separate speed control valves running at 80RPM, each using 9.7 cu in/rev motors (6.72GPM total fluid requirement).
• OR One pair of low side washers plumbed in series running at 80RPM with 5.9 cu in/rev motors, one pair of high side washers plumbed in series running at 80RPM with 11.3 cu in/rev motors, and one pair of tire washers plumbed in series running at 200RPM with 4.5 cu in/rev motors using a flow divider and 3 speed control valves (total fluid requirement of 8.37GPM).

One 10HP Power Pack with 12.3GPM pump can operate:

• A surface mount or over-under conveyor longer than 100 ft. at 150CPH (assumes 15RPM drive sprocket with 5.2:1 speed reducer) using a high torque / low speed hydraulic motor 24 cu in/rev (10.12GPM fluid requirement).
• OR A surface mount or over-under conveyor longer than 100 ft. at 150CPH (assumes 15RPM drive sprocket with 5.2:1 speed reducer) using a medium torque / medium speed hydraulic motor 14.9 cu in/rev (6.3GPM fluid requirement).
• OR One pair of low side washers plumbed in series running at 80RPM with 5.9 cu in/rev motors, one pair of wraparound washers plumbed in parallel running at 80RPM with 11.3 cu in/rev motors, and one pair of high side washers plumbed in series running at 80RPM with 11.3 cu in/rev motors using 4 speed control valves (total fluid requirement of 10.35GPM).

NOTE:

• Recommended shaft speed for Tire Brushes with plastic bristles is 300-400RPM.
• Recommended shaft speed for Washers with cloth is 60-70RPM.
• Recommended shaft speed for Washers with NeoGlide is 80-90RPM.

Hydraulic Power Pack Selection

Selecting the correct power pack is crucial for long-term reliability and cost-effective maintenance. Sizing the hydraulic power pack so its full running load is approximately 80% of the pump's maximum delivery (GPM) contributes to reliability and reduced maintenance. Consider an operating backup power pack for critical equipment to mitigate unexpected breakdowns. For example, if your conveyor power pack is a 7.5HP, 10.5GPM unit, selecting the same size for your tire brush equipment allows for easy line switching in case of conveyor failure, ensuring continued operation of other systems.

Sizing a hydraulic power pack is straightforward. The following formula helps calculate hydraulic motor loads:

Formula for determining hydraulic motor demand (GPM):

(equipment shaft rotation rpm X cu in/rev rating of the hydraulic motor) / 231 = required GPM of pumped hydraulic fluid

SPECIAL NOTE: Consider series or parallel plumbing of hydraulic drive motors when sizing a power pack. Series plumbed motors with the same cu in/rev displacement can be calculated as one motor. Parallel plumbed motors must be calculated as separate fluid loads, and their total usage in GPM added for the total requirement.

Examples:

• Example #1: A pair of cloth-equipped wraparound washers using 11.3 cu in/rev motors plumbed in parallel requires a new power pack. Calculation: (90 rpm X 11.3 cu in/rev) / 231 = 4.40 GPM per motor. Total for two motors in parallel = 8.80 GPM. A 7.5HP power pack with a 10.5GPM pump and two pressure-compensated speed control valves will meet this demand.
• Example #2: Running a pair of low side washers (5.9 cu in/rev motors in series), a pair of van side washers (11.3 cu in/rev motors in series), and a pair of tire brushes (4.5 cu in/rev motors in series) on one power pack: Side Washers: (80 RPM X 5.9 cu in/rev) / 231 = 2.04 GPM. Van Washers: (80 RPM X 11.3 cu in/rev) / 231 = 3.91 GPM. Tire Washers: (350 RPM X 4.5 cu in/rev) / 231 = 6.82 GPM. Total GPM required = 12.77 GPM. A 15HP power pack with a 19.5GPM pump and three pressure-compensated speed control valves is needed.
• Example #3: A power pack for a 100 ft. over-and-under conveyor running at 120CPH, using a 14.9 cu. in./rev. motor coupled to a 5.2:1 speed reducer. With 32 inches of conveyor chain travel per drive sprocket revolution, and 120 cars per hour equating to approximately 40 ft. per minute pusher roller travel: (480 inches pusher roller travel per minute / 32 in. conveyor chain travel per drive sprocket revolution) = 15 RPM for drive sprocket. 15 RPM X 5.2 speed reduction = 78 RPM of hydraulic drive motor shaft. (78 RPM X 14.9 cu in/rev) / 231 = 5.03 GPM hydraulic fluid required for 120 CPH. For conveyor chain speed increases above 120CPH for this 100 ft. conveyor, a 7.5HP, 10.5GPM hydraulic power pack would be chosen.

NOTE: Hydraulic fluid requirements vary with conveyor hydraulic drive motor size and conveyor chain speed. Always calculate requirements using the highest conveyor chain speed and the largest (cu in/rev) hydraulic drive motor. Refer to the Motor Chart for motor speed and torque notes related to high/low speed and high/low torque needs. High speed, low torque motors may stall at very slow speeds. Low speed, high torque motors may not achieve sufficient chain speeds for high production. To accommodate seasonal variations in conveyor speed (off-season slow, peak season fast), consider having both high torque/low speed and low torque/high speed hydraulic motors available.

Equipment Installation

Hydraulic Power Pack Installation

Tools Required:

1. Safety Glasses
2. ½" Drive Ratchet Set
3. Standard Combo Wrenches
4. Standard Screwdriver
5. 1" Hammer Drill
6. Sledge Hammer
7. Tape Measure

Consumables:

1. Stainless Shims
2. Standard Combo

Work Force: Two (2) persons, 1.00 - 2.00 hours (assuming no problems)

Installation Steps:

1. Determine the installation location for the Power Packs.
2. Sweep any debris from the installation area.
3. Bring the Power Pack into the building and set it in place.
4. Lag the Power Pack down, using shims as needed.
5. If a second Power Pack is to be mounted above the first, install the 4 stacking legs to the lower pack, lift the second pack into place, and bolt it to the stacking legs.
6. Thread the 90-degree fitting into the output port of the flow control valve of the top pack and tighten.
7. Thread the 90-degree fitting into the input on the return filter and tighten.
8. Repeat steps 6 & 7 on the top pack if present.
9. Install the gauges on both Power Packs.
10. Fill the reservoirs with oil.
11. Connect feed and return lines before operation.

Adjustments and Testing

Initial Start-Up: After washing the first 200 cars with a new hydraulic system, change the return line filter. Subsequently, change the return line filter every 6 months.

1. Check all fittings for tightness.
2. Fill the hydraulic system with non-detergent, non-foaming, ISO 32 10W grade hydraulic fluid. With power on, fill until the low level switch activates, then add a small amount more.
3. Adjust Relief Pressure on Flow Control Valves (FCV):
   1. Install caps on the output of each FCV.
   2. Ensure pressure is equal on each FCV. Turn all FCVs to zero flow (off) to achieve this.
   3. Advance the adjustment handle on the FCV closest to the pump to the full flow position. This FCV should have the highest GPM placed on it, and proceed accordingly.
   4. Adjust the set screw under the hex cap on this FCV to the minimum relief setting required for each piece of equipment's operation.
   5. Turn this first FCV to zero flow.
   6. Repeat steps b-d for each FCV in order. Ensure all FCVs are off except the one being adjusted for pressure relief.
4. Check that rotation is correct for each hydraulic motor in each circuit. Reverse hydraulic lines at the motors to reverse rotation if necessary.
5. Adjust hydraulic motor speeds using the appropriate flow control valves on the hydraulic power pack.
6. Repair any hydraulic fluid leaks.

Speed and Torque Adjustment (where applicable)

1. Hydraulic:
   1. Speed is adjusted on the flow control for the power pack.
   2. To increase speed, move the handle closer to the number 10.
   3. To decrease speed, move the handle closer to the number 1.
   4. Torque must be set before operation, between 600 and 900 PSI. Refer to the Hydraulic Power Pack Manual for detailed torque setting instructions.
2. Electric:
   1. Speed is adjusted on the Variable Frequency Drive (VFD).
   2. To increase speed, adjust the Hertz on the VFD to a higher number.
   3. To decrease speed, adjust the Hertz on the VFD to a lower number.
   4. The Overload on the Motor Starter protector(s) must be set at the lowest level for operation. Adjust amps according to the motor's nameplate.

General Operation

Power Pack Operation: Starting and stopping of the electric motor is controlled by the motor starter coil for the designated function of the power pack. The speed of the driven motor(s) can be adjusted by the flow control valve on the hydraulic power pack (refer to Adjustments and Testing Section). Flow dividers are used to distribute hydraulic fluid from a power pack among several pieces of tunnel equipment, reducing the number of power packs required for a given tunnel layout.

Preventive Maintenance

Daily

1. Opening Checks:
   1. Check for leaks around hoses and fittings; repair immediately.
   2. Check hydraulic fluid level in the power pack reservoir. Refill with non-detergent, non-foaming ISO 32 10W grade hydraulic fluid as necessary.
2. Operational Checks:
   1. Check fluid temperature on the tank sight gauge at mid-day. Oil temperature should not exceed 180 degrees Fahrenheit.
   2. Perform a general examination of operation, listening for unusual noises. Visually check each piece of equipment in each hydraulic circuit for proper operation.

Weekly

1. Clean the entire assembly thoroughly.

NOTE: For the first month of operation, check all fittings for tightness weekly. After the first month, perform inspections according to the schedule below.

Monthly

1. Inspect all hardware and fittings for tightness.

Semi-Annually

1. Measure and Record Full Load Amp Readings:
   1. Measure and record full load current readings from each of the three legs of each three-phase electric motor.
   2. If the differential of current load exceeds 10% between legs, or if the balanced load current of all three legs has increased over 10% since the most recent measurements, order a replacement motor.
   3. Record readings in the semi-annual log.
2. Change return line fiberglass filter.

Annually

1. Drain, flush, and refill the hydraulic power pack with new, non-foaming, non-detergent hydraulic fluid (ISO 32 10W).

Warranty Information

• Fill the hydraulic system with non-detergent, non-foaming, ISO 32 10W grade hydraulic fluid.
• For technical questions, contact Suncoast Hydraulics at 904-693-3318.
• Motors are manufactured by Baldor and are OEM. They can be purchased through Sonny's and will be Drop Shipped from Suncoast Hydraulics.
• All Power Pack Motors have an 18-month Baldor warranty and require evaluation at a local Baldor Service center. If a replacement motor is purchased before evaluation and the original is repaired under warranty, it will be returned at no charge. The customer is responsible for the cost of the new motor. If the motor fails under warranty, the customer will receive credit for the motor. Freight is not covered.
• All Pumps carry a 1-year warranty through Suncoast/Vickers and must be returned to Suncoast for evaluation. If a replacement pump is purchased before evaluation and the original is repaired under warranty, it will be returned at no charge. The customer is responsible for the cost of the new pump. The repaired pump becomes a spare. If the pump fails under warranty, the customer will receive credit for the pump. Freight is not covered.
• Warranty on other items, including low level switches, filters, and flow controls, is 1 year.
• Warranty is voided on all pumps when using water-based fluid.

SONNY'S ENTERPRISES, INC. FACTORY LIMITED LIFETIME WARRANTY

Equipment manufactured by SONNY'S ENTERPRISES, INC. is warranted to be free from defects in material and workmanship. Welded metal framework and other non-moving, non-wearable fabricated metal components manufactured by SONNY'S are warranted for the life of the equipment to the original purchaser. Fabricated metal wearable surfaces and moving components manufactured by SONNY'S are warranted for one (1) year to the original purchaser. Components assembled to SONNY'S equipment and manufactured by others are warranted by their respective manufacturers. Contact SONNY'S for specific warranty terms of other component manufacturers. All new cloth shipped with new SONNY'S equipment is warranted for one (1) year or 80,000 miles, whichever occurs first.

This warranty is not assignable or transferable. The warranty period begins the first day following installation or 30 days from the original invoice date, whichever occurs first. The Seller's liability is limited to repair or replacement of defective materials within the warranty period. The Purchaser must supply the Seller with immediate written notice of any defects. The Seller may require the return of defective material to validate the claim. Labor and transportation charges are not included. Transportation damage claims must be submitted to the carrier.

This warranty is based on the Purchaser's reasonable care and maintenance. It does not apply to misuse, neglect, accident, exposure to harsh chemicals (including organic acids, inorganic acids, oxidizing agents, and metals), or chemicals corrosive to aluminum alloys, carbon steel, or other metals. It also does not apply to equipment repaired or altered by unauthorized personnel, or equipment not properly installed with specified plumbing, electrical, and mechanical requirements. The warranty does not cover normal wear and tear or routine maintenance components.

EXCEPT AS EXPRESSLY STATED HEREIN, SONNY'S SHALL NOT BE LIABLE FOR DAMAGES OF ANY KIND IN CONNECTION WITH THE PURCHASE, MAINTENANCE, OR USE OF THIS EQUIPMENT, INCLUDING LOSS OF PROFITS AND ALL CLAIMS FOR CONSEQUENTIAL DAMAGES. THE LIMITED WARRANTY EXPRESSED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SONNY'S NEITHER ASSUMES NOR AUTHORIZES ANY PERSON TO ASSUME FOR IT ANY OTHER OBLIGATION OR LIABILITY IN CONNECTION HEREWITH.

Customer Service

For installation and/or operational questions regarding this equipment, please contact SONNY'S Equipment Department.

For replacement parts, refer to the Parts Catalog and contact SONNY'S Customer Service Order Entry Department.

Visit us online at www.SonnysDirect.com.