Product Information

• General Information
  • Safety Signal Words
  • Warranty
  • Website
  • ServAid
  • Safety Data Sheets MSDS/SDS
  • Country of Origin
  • Dimensional Drawings
• Overview
  • Unpacking and Storage
  • Product Description
  • Operating Conditions
  • Product data
  • Technical Product Data
• Service Overview
  • Hydraulic Fluid

General Information

WARNING

Risk of Property Damage or Severe Injury

Ensure that you read, understand and follow all instructions before operating the tool. Failure to follow all the instructions may result in electric shock, fire, property damage and/or severe bodily injury.

• Read all Safety Information delivered together with the different parts of the system.

• Read all Product Instructions for installation, operation and maintenance of the different parts of the system.

• Read all locally legislated safety regulations regarding the system and parts thereof.

• Save all Safety Information and instructions for future reference.

Safety Signal Words

Warranty

• Product warranty will expire 12+1 months after dispatch from Atlas Copco's Distribution Center.

• Normal wear and tear on parts is not included within the warranty.

  • Normal wear and tear is that which requires a part change or other adjustment/overhaul during standard tools maintenance typical for that period (expressed in time, operation hours or otherwise).

• The product warranty relies on the correct use, maintenance, and repair of the tool and its component parts.

• Damage to parts that occurs as a result of inadequate maintenance or performed by parties other than Atlas Copco or their Certified Service Partners during the warranty period is not covered by the warranty.

• To avoid damage or destruction of tool parts, service the tool according to the recommended maintenance schedules and follow the correct instructions.

• Warranty repairs are only performed in Atlas Copco workshops or by Certified Service Partners.

Atlas Copco offers extended warranty and state of the art preventive maintenance through its ToolCover contracts. For further information contact your local Service representative.

For electrical motors:

• Warranty will only apply when the electric motor has not been opened.

Website

Information concerning our Products, Accessories, Spare Parts and Published Matters can be found on the Atlas Copco website.

Please visit: www.atlascopco.com.

ServAid

ServAid is a portal that is continuously updated and contains Technical Information, such as:

• Regulatory and Safety Information

• Technical Data

• Installation, Operation and Service Instructions

• Spare Parts Lists

• Accessories

• Dimensional Drawings

Please visit: https://servaid.atlascopco.com.

For further Technical Information, please contact your local Atlas Copco representative.

Safety Data Sheets MSDS/SDS

The Safety Data Sheets describe the chemical products sold by Atlas Copco.

Please consult the Atlas Copco website for more information www.atlascopco.com/sds.

Country of Origin

For the Country of Origin, please refer to the information on the product label.

Dimensional Drawings

Dimensional Drawings can be found either in the Dimensional Drawings Archive, or on ServAid.

Please visit: http://webbox.atlascopco.com/webbox/dimdrw or https://servaid.atlascopco.com.

Overview

• Unpacking and Storage
• Product Description
• Operating Conditions
• Product data
• Technical Product Data

Unpacking and Storage

Open the package carefully to avoid damaging fixed accessories, for example, the gauge and the hydraulic connection. Check the contents of the package for obvious damage upon receiving. Check the contents against the delivery note. During transport, the oil filling tube will be plugged with a black cap. After unpacking and setting up the pump for use, replace the black cap with the orange cap.

• Storage for less than two months:

  Preferably in its original packaging and protected from the elements. If the original package is not available, store it covered with a plastic cover.

• Storage for longer than two months:

  Preferably in its original packaging, protected from the elements, with a heat sealed plastic cover.

Before storage, if there is any hydraulic oil in the tank, either empty the tank or add a label on the pump showing that it contains oil.

Product Description

The SP1500 is a portable and automatic hydraulic pump which has been designed for tightening bolts by tensioning process in an industrial environment. It can quickly reach high pressures, significantly saving time in assembly operations. The SP1500 must only be used for the purpose for which it is intended and not for any other purposes not listed in this manual.

One of the features of the SP1500 hydraulic pump is that it can be totally remote-operated using the remote control.. The processes of switching on-off, raising pressure, circuit relief and maintaining the work pressure are always carried out using the remote control. This means that the same operator who inspects the tightening operation can also operate on the pump according to the needs of the tightening process being carried out.

The SP1500 pump is designed to work "continuously" so that once the operator selects the pressure of work and this pressure is achieved by the pump, the machine compensates the possible pressure drops in the circuit due to dilatations or small leaks, therefore maintaining the initially selected pressure.

The SP1500 portable hydraulic pump is a tool designed to work in adverse environmental conditions. To ensure its durability, the tool has an IP-54 degree of protection.

In addition, it is equipped with an oil gauge, temperature control, and light signals in the control box of the hydraulic pump to guarantee a correct and safe use.

The hydraulic pressure pump is a compact electro-mechanical kit, developed to facilitate its use in different sites. It consists of the following parts:

• Submerged electrical motor

• Gear pump

• Directional solenoid valve

• Manifold and secondary solenoid valve

• Pressure gauge

• Remote control handgrip

• Control box

• Protective steel frame

• Hydraulic oil tank

• Pressure regulating manual valve

A logic module manages the control of the whole system. It is installed inside the control box.

Operating Conditions

Reading the present manual is highly recommended to carry out correctly the transport, installation, commissioning, use, regulation, assembly, disassembly and maintenance of the hydraulic pump.

This manual is an integral part of the supplied product; the buyer is responsible for enforcing its careful reading to all the personnel involved with the equipment and those, for any reason, who have to use it or intervene on it. The hydraulic pressure pump is a piece of equipment suitable for its industrial use, in association with bolt tensioners. The hydraulic pressure pumps described in this manual are not suitable for domestic use or similar use; therefore they must not be within reach of children or, in general, of people without expertise in installation, operation and maintenance.

The contents of this manual correspond to the “Commercial Type” pump application. Other similar pumps supplied by order can have variations with regards to the instructions contained on this manual. The manufacturer does not assume any responsibility for possible injuries to people, animals or damages to goods, caused by not strictly following all the recommendations contained in this manual. For safety reasons and to ensure the conditions of the warranty, it is absolutely prohibited to use it in case of a breakdown or variations in the performance of the pressure pump. To obtain subsequent information, contact Atlas Copco local service or sales representative.

The standard pressure pump has NOT been manufactured to be used in explosive environments or to be installed in areas classified as with explosion risk. To work in classified areas, the manufacturer or the dealer must be contacted and there must be equipment available with flame proof characteristics, codified in the pressure pump plate that satisfy the classification demands of the installation zone.

Product data

*Oil flow below 1/10 of the set pressure.

**Oil flow above 1/10 of the set pressure.

The hydraulic pump has a submerged electrical motor, so the hydraulic oil achieves the optimal operating temperature about 10 to 15 minutes after the motor starts working. It is always recommended to start the hydraulic pump and leave it working without pressure for 10 to 15 minutes to improve its performance.

It is necessary to use special hydraulic oil to facilitate cold start. See also Hydraulic fluids, when working at temperatures lower than -20ºC (down to -30ºC).

The display of the logic module is not able to show any text when it is working at very low temperatures, but both the logic module and the hydraulic pump continue operating as usual. The movement of the pressure gauge needle can be slower due to the higher viscosity of fluid.

Technical Product Data

Technical Product Data can be found on either ServAid, or the Atlas Copco website.

Please visit: https://servaid.atlascopco.com or www.atlascopco.com.

Service Overview

• Hydraulic Fluid

Hydraulic Fluid

The behaviour “In-service” of hydraulic equipment heavily depends on the quality and characteristics of the hydraulic fluid selected. The choice of the specification and viscosity of the hydraulic fluid should be based on the conditions of use, taking into account several factors as follows:

• The range of environmental temperature.

• The range of oil viscosity defined for the equipment.

• The application (range of pressures, sources of contamination of the hydraulic fluid, the type of pump…)

• The ease of getting a proper replacement or equivalent hydraulic fluid.

In general, hydraulic fluids recommended for this kind of portable hydraulic equipment should be manufactured under these specifications:

• AFNOR NF E 48-603 HV

• ISO 6743/4 HV

• DIN 51524/ P3 HVLP

It is always recommended to use fluids with a high viscosity index fluid (V.I. > 140) to ensure a good stability under a wide range of temperatures. The user could cover a wide range of temperatures using the high V.I. TOTAL Equivis ZS or, Maximizer fluids. Refer below given chart for the hydraulic oil selection

For Artic Climates, we recommend a fluid such as the TOTAL XLT 22, which allows for a good start-up below -20ºC. For applications with critical conditions of service, environmental restrictions, or similar, please contact Atlas Copco to select the appropriate hydraulic fluid for each service.

Installation

• Main Supply Requirements
• Electrical Installation
• Hydraulic Installation

Main Supply Requirements

The SP1500 hydraulic pump has a single phase motor with a power of 1.8 kW. It generally requires the use of autonomous generators because the applications of this machine are usually in the field, with no connection to the mains supply.

Because of the peak in power consumption that occurs during the starting up process, a minimum power of 16 kVA is required; 20-30 kVA generators, that provide a more stable service, are usually used for this kind of applications.

Bear in mind that the length of cable used to connect the pump is a determining factor in applications for the wind power sector, as it normally exceeds 80 meters from the power supply to the pump. The voltage drop must be limited, as it can cause malfunction of the pump. Check the following table for advice on the section of power cable recommended for keeping the voltage drop below 5%:

Electrical Installation

Before connecting the equipment:

• Check the cables for damage. Cables must be free from erosions or scrapings.

• All the connections must be carried out with elements standardized for this purpose, marked with their electrical characteristics which must agree with the characteristics of the power supply and the pressure equipment.

• Check that the voltage indicated on the pump ID plate matches the power lead voltage.

• If it is necessary to replace the power cable, make sure to assemble correctly and carefully.

  • Before assembling, replace its insulating sheath.

  • Adjust the relevant screws, equally if the plug is replaced.

  • Check that the union is perfectly insulated and protected from humidity.

Any improper or unauthorized handling of the control box and its internal components can lead to the loss of the warranty and the manufacturer’s responsibility. For this reason, it is recommended to send the equipment to the distributer or contact Atlas Copco Service centers.

Hydraulic Installation

Wear protective gloves, eliminate any spillage immediately and clean the surfaces with degreaser.

Operation

• Ergonomic Guidelines
• Operating Instructions
  • Operating Instructions

Ergonomic Guidelines

Consider your workstation as you read through this list of general ergonomic guidelines to identify areas for improvement in posture, component placement, or work environment.

• Take frequent breaks and change work positions frequently.

• Adapt the workstation area to your needs and the work task.

  • Adjust for a convenient reach range by determining where parts and tools need to be located to avoid static load.

  • Use workstation equipment such as tables and chairs appropriate for the work task.

• Avoid work positions above shoulder level or with static holding during assembly operations.

  • When working above shoulder level, reduce the load on the static muscles by lowering the weight of the tool, using for example torque arms, hose reels or weight balancers. You can also reduce the load on the static muscles by holding the tool close to the body.

  • Take frequent breaks.

  • Avoid extreme arm or wrist postures, particularly during operations requiring a degree of force.

• Adjust for a convenient field of vision that requires minimal eye and head movements.

• Use appropriate lighting for the work task.

• Select the appropriate tool for the work task.

• In noisy environments, use ear protection equipment.

• Use high-quality inserted tools and consumables to minimize exposure to excessive levels of vibration.

Operating Instructions

• Operating Instructions

Operating Instructions

The SP1500 pump is designed to work with hydraulic tensioners. Before operating the pump, verify the maximum pressure of the tensioner and the hose, as well as compatibility between the connectors.

Service

• Maintenance Instructions
  • General concept
  • Oil change intervals
  • Maintenance and Conservation Program
  • Service Recommendations

Maintenance Instructions

• General concept
• Oil change intervals
• Maintenance and Conservation Program
• Service Recommendations

General concept

Before any intervention, unplug the pump from the main and make sure that the equipment cannot be switched on accidentally. Depressurize the whole hydraulic system prior to any disassembly.

Oil change intervals

Portable hydraulic equipment are susceptible to contamination due to the extreme conditions in which they work. Although selected fluids are designed to suffer less degradation than another product, we recommend an oil change and filter at least every 750 hours of use, or once a year, whichever occurs first.

It is recommended to periodically check the color of the oil and level seeking extreme contamination or loss of oil level that will require to refill the tank.

For oil changes or refilling, it is always recommended to use the same oil in the pump.

In case of an emergency and having to refill the tank and mix different types of fluids, it is preferred to use fluids with no additives as the HL or HLP fluids. After that, and always before a period of 2-4 working days, replace the oil with recommended oils.

Maintenance and Conservation Program

The checking and operations maintenance program depends on the equipment working conditions. The frequencies indicated here are only an orientation and it is for the user to adapt them to the conditions of use.

Total hours of use since the last pump maintenance can be checked as follows:

When re-placing the control box lid, be careful not to trap the earth wire.

Service Recommendations

Preventive maintenance is recommended at regular intervals. See the detailed information on preventive maintenance. If the product is not working properly, take it out of service and inspect it.

If no detailed information about preventive maintenance is included, follow these general guidelines:

• Clean appropriate parts accurately

• Replace any defective or worn parts

Troubleshooting

• Hydraulic Pump does not raise the pressure
• Changing the Oil Filter
• Changing the Hydraulic Oil
• Oil Level Alarm Turns On
• Update the Firmware with a Memory Card
• Temperature Alarm Turns On
• Alarms

Hydraulic Pump does not raise the pressure

• Check that the pump is properly connected to the main supply.

• Check that there is no sign of alarm in the control box.

• Check for leaks in the circuit.

• Check if right oil is used as per ambient temperature.

If the pump does not raise the pressure, contact local Atlas Copco sales representative.

Changing the Oil Filter

It is recommended to replace the oil filter at every oil change or at 1 year intervals along with the oil. If the oil is contaminated, change both oil and filter immediately.

Changing the Hydraulic Oil

It is recommended to change the hydraulic oil after 750 operation hours or after one year depending on what occurs first.

If the oil has a dark color, any traces of foam or particles, change both the oil and the filter immediately. Otherwise, the pump could be damaged.

Pay attention to the characteristics of the oil. In case of doubt, contact local Atlas Copco sales representative to avoid using the wrong oil.

Oil Level Alarm Turns On

Check that the hydraulic liquid level is in between the minimum and the maximum oil marking level.

Minimum level	Maximum level

Update the Firmware with a Memory Card

Updating the firmware of the logic module is quite easy. Only a specific memory card and the firmware file are needed.

Temperature Alarm Turns On

After a very intensive use, the pump may suffer an excessive increase in the hydraulic fluid temperature, accentuated if the drop of voltage in the current supply is above 5%. In that case (oil temperature > 85° C) turn off the pump and let it cool. Once the temperature of the pump falls, start working again as usual.

Alarms

The SP-1500 pump is equipped with a display which shows following alert messages and the machine status:

At the start

At the start-up of the pump, the main screen shows the following information:

• Pump model

• Atlas Copco web address

Working

When the pump is running, the screen could show different alarms described below:

• Temperature

  

The pump will automatically shut off and allow for the pump temperature to cool. The pump does not automatically restart, the message will carry on blinking in the screen until cool. At this point the pump can be restarted manually.

• Oil Level

  

Check the oil level and refill it if necessary. See the section Oil Level Alarm Turns On. The screen will return to normal once the adequate oil level required is reached.

• Oil and temperature Level

  

If the alarm is showed in the display, check the harting connection (A), because it could be disconnected. If this connection is correct and the message does not disappear, you must contact your local Atlas Copco Sales representative.

• Current supply fault

  

There is a safety switch which protects the control box and the motor. If there is a severe current supply fault, the switch turns off. In this case, you have to re-arm the breaker. If the cover of the control box is still removed, this can be done by flipping up the safety switch OFF, or by sliding the lever downwards on the side of the control without opening the control box.

If there are 5 current supply fault alarms in less than 5 minutes, the display shows the message during 5 minutes (see the picture below). Verify power of the generator and section cable recommended (see section Main Supply Requirements) and check voltage between terminal 6 (B) and input pin (A) of the circuit breaker before working. This voltage should be 230V or 110V according to the configuration of the pump. Otherwise, contact Atlas Copco Distributer or Sales representative.

• Emergency button

  

The emergency stop switch of the handgrip is pressed. Investigate the cause of the stop and take relevant actions. Release the emergency stop switch before operation.

• Oil Service

Every 750 operation hours from maintenance, a message in the blinking red screen appears when the pump is connected to main supply: "Oil Service". Change the oil and filter of the pump.

Recycling

• Environmental Regulations

Environmental Regulations

When a product has served its purpose it has to be recycled properly. Dismantle the product and recycle the components in accordance with local legislation.

Batteries shall be taken care of by your national battery recovery organization.