When Power is Critical Product Datasheet

HYDRAULIC STARTERS

HYDRAULIC STARTING SYSTEMS

For diesel engines up to 80 litres

IPU’s hydraulic starting systems provide guaranteed

reliability no matter how challenging or

unpredictable the environment. This independent,

dead-ship or black-start capability is ideal as your

primary method of starting fire pumps, emergency

generators and compressors.

IPU’s ATEX-approved starter motors provide safe

starting on offshore platforms, in mines and at

other hazardous locations.

Manufactured from cast iron, IPU’s hydraulic starter

motors combine quick acceleration with high

torque output for guaranteed starting in extreme

temperatures, after long shut down periods and in

damp and hostile conditions.

Reliable

IPU’s hydraulic starting systems do not depend on

electrical power. They can act as the primary start

system for emergency systems or a secondary start

system in case electrical starting fails.

Convenient

IPU’s hydraulic starting systems are self-contained and

sealed making them ideal for use in underground and

dusty environments.

ATEX-Approved

To meet ATEX’s stringent standards, IPU’s hydraulic

starting systems are manufactured with a cast-iron

casing. A pre-engaged pinion option prevents

sparking in explosive environments.

Reliable and powerful starting for diesel engines and generators

EN-1834-1

EN-1834-2

How hydraulic starting systems work

Energy is stored in the form of hydraulic oil under pressure inside the accumulator. The oil is released using

a foot switch, solenoid or manually-operated start valve. Once released, the oil travels to the starter motor

which engages with the engine ring gear and cranks the engine. Once the engine has reached firing speed

the pinion is automatically kicked back by the ring gear.

The system can be recharged manually using a hand-operated pump, electrically using a hydraulic pump or

even through the host machine's on-board hydraulics.

Installation

IPU provides a total solution not just a system. We can design to your exact specifications, build, test, install

and commission your system. If space is a problem, items can be supplied loose and mounted on the

engine skid.

Product Datasheet

HYDRAULIC STARTERS

Starter Motor

Level Sight Glass

Foot Valve

Safety Relief Valve High Pressure Filter

Accumulator

Hand Pump

Pressure Gauge

Oil Reservoir

Filler Breather

Customer Benefits

• Guaranteed start: The energy can be stored indefinitely providing the system is installed and

maintained to IPU specifications. It can be quickly and easily recharged via a hand pump.

• Performance in all conditions: Performance is unaffected by hot or cold conditions provided

the correct oil is used. Starters operate efficiently following extensive periods of shut down.

• Low maintenance: Hydraulic starting systems last as long as your engine. The system is

totally enclosed with all internal components immersed in oil, protecting them from the

adverse environmental conditions that damage electric or vane starters.

• Safe in hazardous areas: IPU’s pre-engaged hydraulic starters meet ATEX regulations for

both gas and dust environments such as offshore, marine and mining.

Product Datasheet

HYDRAULIC STARTERS

ATEX-Approved

ATEX regulations ensure that equipment being used in hazardous or explosive environments is safe to use.

IPU’s pre-engaged hydraulic starters are ATEX-approved. They offer two key technical advantages:

• Cast-iron casings: IPU avoids the aluminium casings used by other starter motors. Aluminium is not

safe for hazardous environments due to the risk of a thermite reaction. When aluminium and iron

oxide (i.e. rust) are ignited by a spark the reaction produces temperatures up to 3000°C. That would

be a disaster in any explosive atmosphere.

• Pre-engaged mechanism: to avoid sparks, a pre-engaged starter motor waits until the pinion has

engaged with the ring-gear before cranking the engine. By contrast, inertia starters move a spinning

pinion onto the ring-gear. The inevitable sparks are a danger in hazardous environments. IPU’s pre-

engaged starter motors conform to ATEX EN1834-1 and 2. They are safe to use in flammable gas

atmospheres and underground environments vulnerable to combustible dust.

PED Certified

The Pressure Equipment Directive 97/23/EC (or PED) sets out standards for the design and manufacture of

pressure equipment. It covers the sale and use of equipment that contains pressures above 0.5 bar.

IPU’s hydraulic and air starting systems comply with the Pressure Equipment Directive. Our systems are

approved by an independent Notified Body.

We offer maintenance and servicing of your equipment to ensure it remains compliant. We can provide

training on basic maintenance tasks that can be performed regularly by owners and operators.

Certified offshore maintenance service

Although our starters are rugged and designed to withstand the harshest environments, extreme conditions

always take their toll. Regular inspection and servicing is essential to ensure that your starter works if

disaster strikes.

IPU has a dedicated service team for starting systems. We can simplify your maintenance and inspection

processes. IPU’s service team are offshore-certified engineers who are able to monitor, repair and maintain

critical starting systems on platforms and rigs.

Our experienced engineers will perform various tests on functionality and performance including pressure

testing of your accumulators, oil condition testing and calibration of gauges. We can also monitor the

integrity of your system and have full access to any parts your application may require.

Additional Information

Product Datasheet

HYDRAULIC STARTERS

Components

Components of a hydraulic starting system

Hydraulic starter

motor Accumulators Hand pump Foot start valve

Starter motors are available

for engines up to 80 litres.

Manufactured from cast iron,

the unique design of the

starter motors allows

displacement to be easily

increased. This gives greater

torque and power to start

larger engines or

compensates for greater

torque requirements in

extreme environments.

Accumulators range from 1 to

16 litres. Bladder

accumulators are available in

sizes up to 54 litres.

Hand pumps can manually

recharge accumulators if no

hydraulic pressure system is

available.

The foot start valve has a

simple, rugged design with a

wiper seal for self cleaning.

Engine pump Motor driven Combined Pneumatic recharge

Suitable where there is no

other source of power. The

engine is used to recharge

the accumulators to starting

pressure. Engine driven

pumps can be belt or power

take off driven (PTO).

Suitable where an electrical

supply is present. It has the

advantage of not relying on an

engine to Recharge; it does so

automatically when it senses a

drop in pressure. Motors are

available in most voltages and

certifications. ATEX (hazardous

area) motors are also available.

Combining both systems offers

a higher level of security. It can

be a specific project

requirement.

Pneumatic recharge systems

rely on an external source of

compressed air to drive a

hydro-pneumatic pump. The

pump works on a ratio of 60:1.

A pneumatic input pressure of

50 psi (3.5 bar) drives the pump

to pressurise the accumulator to

3000 psi (207 bar).

Product Datasheet

HYDRAULIC STARTERS

Component Technical Specifications

Hydraulic cranking motor Accumulator

Maximum working

pressure 2 MPa (3000 psi)

Piston Type Bladder type

Torque range From 30 Nm to 216 Nm (22

lbf.ft. to 160 lbf.ft.)

Construction Certified seamless tube Forged certified steel

Displacements in cc/

rev 10, 16, 22, 28, 38, 66

Max working pressure 21 MPa (3000 psi) 21 MPa (3000 psi)

Displacements in

cu.iv/rev 0.6, 0.95, 1.35, 1.71, 2.32, 4.0

Test Pressure 35 MPa (5000 psi) 35 MPa (5000 psi)

Minimum efficiency 95%

Average burst pressure 120 MPa (20000 psi) 120 MPa (20000 psi)

Seals Nitrile (standard), Viton

(optional)

Safety factor In excess of 4:1 In excess of 4:1

Seals

Nitrile (standard), Viton

(optional)

Nitrile (standard), Viton

(optional)

Foot start valve

Nominal volumes in litres 1.0, 2.5, 4.0, 5.5, 7.5, 10.0,

12.0, 16.0 10, 20, 37, 54

Maximum working

pressure 21 MPa (3000 psi)

Nominal volumes in usg

0.25, 0.66, 1.06, 1.50,

1.88, 2.60, 3.20, 4.20 3.0, 5.5, 10, 15

Flow rate (3/8” NPT

port) 75 l/min (20 usgpm)

Flow rate (1/2” NPT

port) 100 l/min (26 usgpm)

Part number VF (3/8” NPT port)

VF8 (1/22 NPT port)

Hand pump

Maximum working

pressure 21 MPa (3000 psi)

Suction pressure 75 kPa (11 psi)

Displacement 20cc/cycle (1.22 cu.in.)

Part number PH20

Product Datasheet

HYDRAULIC STARTERS

M10 Hydraulic Starter

The M10 hydraulic starter motor is the smallest starter motor in our range.

Suitable for engines with up to 3 litres capacity, it can produce a maximum

torque of 30Nm at 3000 psi (207bar). The M10 is cast iron (including the

flange and pinion housing) making it suitable for all environments.

The M10 is fitted with a heavy-duty inertia bendix and pinions which are

machined from one cast block. This eliminates the process of pressing the

pinion onto the bendix cup, a common source of system failure.

The M10’s optional beryllium-copper pinion reduces the risk of sparks in

hazardous environments.

M16 Hydraulic Starter

The M16 hydraulic starter motor produces a maximum torque of 48Nm at

3000 psi (207bar). The M16 is cast iron (including the flange and pinion

housing) making it suitable for all environments and resistant to damage.

The M16 is fitted with a heavy-duty inertia bendix and pinions which are

machined from one cast block. This eliminates the process of pressing the

pinion onto the bendix cup, a common source of system failure.

The M16’s optional beryllium-copper pinion reduces the risk of sparks in

hazardous environments.

M22 Hydraulic Starter

The M22 is a low maintenance start motor that’s well-suited to use in both

sub-zero and high temperature environments. It requires virtually no

attention other than replacing the filter element and periodically checking

the gas pre-charge and system pressure.

The M22 is designed as a modular system. Spacers and pinions are common

across IPU’s starter ranges, as are the flanges which mount to the engine.

This helps remote and offshore sites simplify stock-holding and improve

interchangeability.

The M22 can suit almost any engine configuration. The flange of the

standard model can be rotated to suit the engine. In special circumstances, a

custom flange can be installed for particularly difficult configurations.

The M22 starter motor is available as either an inertia and pre-engaged

model. Although the inertia version of the M22 is not ATEX-approved it can

be fitted with beryllium-copper pinions to reduce the risk of sparks.

Hydraulic Starter Motor Range

M22 Inertia Starter Motor

M22 Pre-engaged Starter

M28 Hydraulic Starter

Offering more power and torque than the M22, the M28 boasts a low-

maintenance design that is ideal for extreme conditions. Maintenance is

limited to replacing filters and checking gas pre-charge and system pressure.

The M28 can be oriented to fit almost any engine configuration. The flange

of the standard model can be rotated to suit the engine and ancillary

equipment. A custom flange can be installed for difficult configurations.

The M28 is a modular system. Spacers and pinions are common with IPU’s air

starter ranges, as are the flanges which mount to the engine. This makes for

simplified stock-holding and improved interchangeability.

The M28 is available in inertia and pre-engaged versions. The M28 inertia is

not approved for ATEX environments but can be fitted with beryllium-copper

pinions to lower the risk of sparks.

M38 Hydraulic Starter

The M38 hydraulic starter motor is capable of producing a maximum torque

of 124Nm at 3000 psi (207bar). The M38 is cast iron making it suitable for

hazardous and regular environments.

The M38 is fitted with a heavy-duty inertia bendix and pinions which are

machined from one cast block. This eliminates the process of pressing the

pinion onto the bendix cup, a common source of failure.

The M38 can be fitted with a steel or beryllium-copper pinion. The beryllium-

copper pinion reduces the risk of sparks in hazardous environments.

M66 Hydraulic Starter

The M66 hydraulic starter motor is capable of producing a maximum torque

of 216 Nm at 3000 psi (207 bar). The M66 is cast iron (including the flange

and pinion housing), making it suitable for all environments and resistant to

damage.

The M66 is fitted with a heavy duty inertia bendix and pinions which are

machined from one cast block. This eliminates the process of pressing the

pinion onto the bendix cup, a common technique on other starter motors

and a known fail-point in many applications.

Depending on your application, the M66 hydraulic starter motor can be

fitted with either a steel or beryllium-copper pinion. If the environment is

potentially hazardous the beryllium-copper pinion helps to reduce the risk of

Product Datasheet

HYDRAULIC STARTERS

Hydraulic Starter Motor Range

M28 Inertia Starter Motor

M28 Pre-engaged Starter

Product Datasheet

HYDRAULIC STARTERS

Technical Specifications

M10 M16 M22

Weight 9.5 kg (20.9 lbs) 9.5 kg (20.9 lbs) 11 kg (24.3 lbs)

Construction Cast iron (ductile iron) Cast iron (ductile iron) Cast iron (ductile iron)

Max. working pressure 21 MPa (3000 psi) 21 MPa (3000 psi) 21 MPa (3000 psi)

Design pressure 25 Mpa (3600 psi) 25 Mpa (3600 psi) 25 Mpa (3600 psi)

Fluid media Mineral oil Mineral oil Mineral oil

Viscosity range ISO 32 to 46

(SUS 140-230)

ISO 32 to 46

(SUS 140-230)

ISO 32 to 46

(SUS 140-230)

Temperature range -40°C to +100°C

(-40°F to +212°F)

-40°C to +100°C

(-40°F to +212°F)

-40°C to +100°C

(-40°F to +212°F)

Speed range 0-4000 rpm 0-4000 rpm 0-4000 rpm

Rotation CW - Standard

(CCW - Optional)

CW - Standard

(CCW - Optional)

CW - Standard

(CCW - Optional)

Duty cycle Intermittent Intermittent Intermittent

Volumetric efficiency 95% (minimum) 95% (minimum) 95% (minimum)

Displacement 9.98cc (0.6 cu.in.) 15.59cc (0.95 cu.in) 22.1 cc (1.35 cu.in.)

Max. torque 30 Nm (22 lbf.ft.) 48 Nm (35 lbf.ft.) 66 Nm (49 lbf.ft.)

Starter motor length 293mm (11.5") 293mm (11.5") 328.5mm (12.9")

Starter motor diameter 89.5mm (3.5") 89.5mm (3.5") 101.5mm (4")

Inlet port 3/8" NPT 3/8" NPT 3/8" NPT

Outlet port 3/8" NPT 3/8" NPT 1/2" NPT

Product Datasheet

HYDRAULIC STARTERS

Technical Specifications

M28 M38 M66

Weight 11 kg (24.3 lbs) 21.5kg (47.4 lbs) 21.5kg (47.4 lbs)

Mounting Cast iron (ductile iron) Cast iron (ductile iron) Cast iron (ductile iron)

Max. working pressure 21 MPa (3000 psi) 21 MPa (3000 psi) 21 MPa (3000 psi)

Design pressure 25 Mpa (3600 psi) 25 Mpa (3600 psi) 25 Mpa (3600 psi)

Mineral oil Mineral oil Mineral oil Mineral oil

Viscosity range ISO 32 to 46

(SUS 140-230)

ISO 32 to 46

(SUS 140-230)

ISO 32 to 46

(SUS 140-230)

Temperature range -40°C to +100°C

(-40°F to +212°F)

-40°C to +100°C

(-40°F to +212°F)

-40°C to +100°C

(-40°F to +212°F)

Speed range 0-4000 rpm 0-3000 rpm 0-3000 rpm

Rotation CW - Standard

(CCW - Optional)

CW - Standard

(CCW - Optional)

CW - Standard

(CCW - Optional)

Duty cycle Intermittent Intermittent Intermittent

Volumetric efficiency 95% (minimum) 95% (minimum) 95% (minimum)

Displacement 28 cc (1.71 cu.in.) 38 cc (2.32 cu.in.) 66 cc (4 cu.in.)

Max. torque 84 Nm (62 lbf.ft.) 124 Nm (92 lbf.ft.) 216 Nm (160 lbf.ft.)

Starter motor length 328.5mm (12.9") 441mm (17.4") 441mm (17.4")

Starter motor diameter 101.5mm (4") 130mm (5.1") 130mm (5.1")

Inlet port 3/8" NPT SAE 12 SAE 12

Outlet port 1/2" NPT SAE 12 SAE 12

Product Datasheet

HYDRAULIC STARTERS

Hydraulic mini-packs

Hydraulic mini-packs are a convenient way to add reliable starting to a standard engine configuration. Each

mini-pack incorporates everything you need in a self-contained ‘bolt-on’ unit.

This includes:

• starter motor

• accumulator

• oil reservoir

• hand pump

• foot valve

• relief valve

• pressure gauge

• hoses and fittings

Mini-packs can be ordered with a variety of different starter motors and accumulators to suit different

engine sizes. They arrive fully assembled, piped and tested with all hoses and fittings needed to attach

them to the engine. All that is required is to fit the starter motor to the engine and fix the mini-pack to a

suitable surface.

Mini-packs sit comfortably between bare starter motors and custom packages in IPU’s range.

• Customers with the expertise to design and build their own starting system prefer to purchase bare

starter motors (and starter motor kits) such as the M22 and M28

• Customers who need a pre-configured starting system to fit precise spatial constraints or match

unusual starting specifications prefer custom packages

• Customers without particular spatial constraints and without the expertise (or time) to build their

own starting system prefer mini-packs

Product Datasheet

HYDRAULIC STARTERS

Custom Starting Packages

IPU’s enviable reputation in engine starting is built on the quality of its custom starting packages.

Few of the new oil platforms, drilling rigs or mining vehicles being designed today have a regular area of

free space available to house a starting system. The starting system has to fit into whatever free space is

left. That’s where IPU’s expertise and flexibility comes to the fore.

Our custom starting packages can fit into whatever space is available. A standard hydraulic starting

configuration would place the accumulators next to the starter motor and engine. When there’s no space

available, IPU will create a custom package that places the accumulators wherever there is some space.

Our design team works closely with your designers to ensure that the custom starting package integrates

perfectly into the proposed platform, rig or vehicle. It will fit the available space and meet any specialised

starting requirements you have: number of start attempts, cycle time, adverse environmental conditions,

etc.

Although every custom starting package is different, they all share one characteristic: they perfectly match

their application.

IPU Group Engine Starting Cygnus Way, West Bromwich, B70 0XB

Phone: +44 (0) 121 511 0460 Fax: +44 (0) 121 511 0401 Email: ipu@ipu.co.uk www.ipu.co.uk/starting

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