Troubleshooting Italian ATOS piston pumps

Brand

ATOS/Italian Atos

Application Areas

Chemical, Petroleum, Mining, Road/Rail/Marine, Comprehensive

ATOS Relief Valve, ATOS Proportional Valve, ATOS Stack Valve, ATOS Solenoid Valve

ATOS piston pumps use a supplementary oil pump for oil supply. After 3000 hours of use, operators should check the piston pump 1-2 times daily to ensure the hydraulic pump's operating sound is normal. If a decrease in hydraulic cylinder speed or stalling is observed, the supplementary oil pump should be disassembled and inspected to check for scratches on the impeller edges and excessive clearance in the internal gear pump. For self-priming piston pumps, the hydraulic oil level in the tank must not be lower than the lower limit of the oil level gauge; a sufficient quantity of hydraulic oil must be maintained. Higher hydraulic oil cleanliness results in a longer service life for the hydraulic pump.

The most important component of the ATOS piston pump is the bearing. If the bearing has clearance, the normal clearance of the three pairs of friction surfaces inside the hydraulic pump cannot be guaranteed, and the hydrostatic support oil film thickness of each friction surface will also be damaged, reducing the service life of the piston pump bearing. According to data provided by hydraulic pump manufacturers, the average service life of bearings is 10,000 hours; exceeding this value necessitates replacement. Without specialized testing equipment, the clearance of disassembled bearings cannot be determined; visual inspection is required. If scratches or discoloration are found on the roller surface, replacement is necessary.

When replacing bearings, pay attention to the original bearing's lettering and model number. Piston pump bearings mostly use high-load-capacity bearings; it is best to purchase products from the original manufacturer and of the original specifications. If replacing with a different brand, consult an experienced bearing specialist to refer to a table for accurate replacement, ensuring the bearing's precision grade and load capacity are maintained.

The service life of ATOS piston pumps is related to routine maintenance, the quantity and quality of hydraulic oil, and oil cleanliness. Preventing particles in the oil from causing wear on the piston pump's friction pairs is also an effective way to extend the pump's lifespan. When replacing parts during maintenance, original manufacturer parts should be used whenever possible. These parts are sometimes more expensive than imitations, but their quality and stability are superior. While purchasing cheaper imitations may seem cost-effective in the short term, it introduces hidden dangers and could potentially cause greater damage to the piston pump.

Distributor plates come in two forms: planar and spherical. For spherical distribution plates, shallow scratches on the cylinder block's distribution surface can be repaired by grinding. For deeper grooves on the cylinder block's distribution surface, surface engineering techniques should be used to fill the grooves before grinding. Blind grinding should be avoided to prevent thinning of the copper layer or oil leakage through the steel base.

ATOS piston pumps can also save energy using frequency converters. Engineers at Shanghai Zhengyi point out that in actual production, piston pumps typically operate by regulating their working state based on pressure or flow rate. When the actual pressure exceeds the required pressure, an overflow valve is used to adjust and stabilize the working pressure, allowing the overflow valve to release the excess. Meanwhile, the motor runs at full speed repeatedly, resulting in constant power consumption. When overflow is used to regulate pressure and flow, some excess flow overflows back into the original system, resulting in wasted power and low efficiency in the piston pump. Using a Chuangjie energy-saving frequency converter allows the overflow valve to be closed, automatically adjusting the working pressure through the frequency converter itself to maintain stability and automatically track the equipment pressure. This achieves automated control and saves energy. The advantage of this regulation method is that it reduces the operating energy consumption of the piston pump, achieving energy savings of over 30%.

ATOS Hydraulic Pump Flow Problems

(1) Insufficient suction. This is caused by excessive resistance in the suction line or insufficient replenishment. For example, excessive pump speed, low oil level in the tank, air leakage in the inlet pipe, or clogged oil filter.

(2) Excessive leakage. This is caused by excessive pump clearance and poor sealing. For example, the distributor plate is scratched by metal fragments or iron filings, causing end-face leakage; the one-way valve sealing surface in the variable mechanism is not properly fitted; or there are sand holes or scratches on the support surfaces of the pump body and distributor plate. The location of pump damage can be determined by inspecting the hydraulic oil inside the pump body for foreign matter.

(3) If the swashplate angle is too small, the pump's displacement is low. This requires adjusting the variable piston to increase the swashplate angle.

Discharge is not zero in the neutral position.

The neutral position of a variable axial piston pump is when the swashplate angle is zero. At this time, the pump's output flow should be zero. However, sometimes the neutral position deviates from the midpoint of the adjustment mechanism, and there is still flow output at the midpoint. This is because the controller is misaligned, loose, or damaged, requiring readjustment, tightening, or replacement. Insufficient pump angle holding force and wear of the swashplate trunnion can also cause this phenomenon.

ATOS piston pumps are a new type of high-efficiency pump with high technological content. With the continuous acceleration of domestic production, radial piston pumps will inevitably become an important part of the piston pump application field; for details, please refer to the radial piston pump encyclopedia. The following explanation only uses axial piston pumps as an example. ATOS plunger pump

ATOS plunger pump

PVPC-LZQZ-5073/1D/18

PVPC-C-3029/1D

PVPC-C-3029/1D 11 /WG

PVPC-C-4046/1D

PVPC-C-4046/1S

PVPC-C-5073/1D

PVPC-C-5073/1S 10

PVPC-CH-5073/1D-IX 24DC

PVPC-CZ-5073/1D 12

PVPC-LQZ-5073/1D 11

PVPC-LW-4046/1D 10

PVPC-LZQZ-3029/1D

PVPC-LZQZ-3029/1D/18 PVPC-LZQZ-4046/1D

PVPC-LZQZ-4046/1D/18

PVPC-LZQZ-5073/1D 11

PVPC-LZQZ-5073/1D/18

PVPC-R-3029/1D 11

PVPC-R-4046/1D 11

PVPC-SLE-3029/10 20

PVPC-SLE-4046/1D 20

PVPCX2E-C-3029/31036/1D 10

PVPCX2E-LW-3029/31036/1D 10

PVT-206/35

PVT-210

PVT-316

PVT-322

PFR-203

PFR-206 PFR-308

PFR-202

Our company mainly deals in European and American brands and can source brands from any European country. For example, our key German brands include: BURKERT, DEMAG, HAWE, AVENTICS, HYDAC, PILZ relays, FESTO, IFM door sensors, E+H, HEIDENHAIN, P+F sensors, SICK, TURCK, and HIRSCHMANN industrial switches. German brands: Hengstler, Murr, Schmersal, Samson, EPRO (Emerson Group)

American brands: MOOG, ASCO, MAC, NUMATICS, PARKER, VICKERS, ROSS

British brands: Norgren

Italian brands: OMAL, ATOS, CAMOZZI, UNIVER, Camozzi