Durapac 30 Series User manual

ABSOLUTE EQUIPMENT PTY LTD –2/186 Granite Street, GEEBUNG QLD 4034 –Australia
[e-mail] –Phone: [phone] –Fax: [phone]
Maximum Operating Pressure –700 bar
Instruction Manual
30 Series Auto, 2 Speed Electric Power Unit
Model –PES3024

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 2 of 8
This is a safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid injury or death
1.0 Product Information
DURAPAC –30 Series Auto 2 Speed Power Units are engineered to meet Industrial Standards for
Performance and Safety. They feature a two speed pump delivering 10.5 Lpm up to 100 bar and 2.1
Lpm up to 700 bar pressure. The power unit has a 4 way solenoid valve and remote pendant to
actuate advance/hold/retract functions on double acting cylinders and tools. The power unit is driven
by a 3.0 kW 415 Volt/50 Hz 3 phase electric motor and is ideal for operating medium to large
tonnage cylinders and systems.
Special skill, knowledge and training may be required for a specific task and the product may not be
suitable for all jobs. The user must ultimately make the decision regarding suitability of the product
for any given task and assume the responsibility of safety for all in the work area. Contact a Durapac
representative if you are unsure of your power unit’s suitability for a particular application.
2.0 Receiving Instructions
It is recommended prior to use that an inspection be done by qualified personnel and that any
missing or damaged parts, decals, warning/safety labels or signs are replaced with Durapac
authorised replacement parts only. Any power unit that appears to be damaged in any way, is worn,
leaking or operates abnormally should be removed from service immediately until such time as
repairs can be made. Any power unit that has been or suspected to have been subject to a shock
load should be removed from service immediately until inspected by a Durapac authorised service
centre. Owners and operators of this equipment should be aware that the use and subsequent
repair of this equipment may require specialised training and knowledge.
3.0 Safety
Save these instructions. For your safety, read and understand the information contained within. The
owner and operator should have an understanding of this product and safe operating procedures
before attempting to use this product. Instructions and safety information should be conveyed in the
operator's native language before use of this product is authorised. Make certain that the operator
thoroughly understands the inherent dangers associated with the use and misuse of the product. If
any doubt exists as to the safe and proper use of this product as outlined in this factory authorised
manual, remove from service immediately.
DANGER:
To avoid personal injury keep hands and feet away from work area during operation
Do NOT handle pressurised hoses. Escaping oil under pressure can penetrate the skin
causing serious injury. If oil is injected under the skin, see a doctor immediately
Stay clear of loads supported by hydraulics. A cylinder, when used as a load lifting
device, should never be used as a load holding device. After the load has been raised
or lowered, it must always be blocked mechanically

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 3 of 8
WARNING:
The system operating pressure must not exceed the pressure rating of the lowest
rated component in the system. Install pressure gauges in the system to monitor
operating pressure. It is your window to what is happening in the system
Always wear protective gear when operating hydraulic equipment. The operator must
take precaution against injury due to failure of the tool or work piece(s)
Do NOT hold or stand directly in line with any hydraulic connections while pressurising
Do NOT attempt to disconnect hydraulic connections under pressure. Release all line
pressure before disconnecting hoses
All personnel must be clear before lowering load or depressurising the system
Do NOT attempt to lift a load weighing more than the capacity of the cylinder
IMPORTANT:
If at any stage, the safety related decals become hard to read, these must be replaced
Minimum age of the operator must be 18 years. The operator must have read and
understood all instructions, safety issues, cautions and warnings before starting to
operate the equipment. The operator is responsible for this activity towards other
persons
Do NOT lift hydraulic equipment by the hoses or couplers. Use the carrying handle or
other means of safe transport
Hydraulic equipment must only be serviced by a qualified hydraulic technician. For
repair service, contact the Durapac authorised service centre in your area. To protect
your warranty, use only high quality hydraulic oil
CAUTION:
KEEP HYDRAULIC EQUIPMENT AWAY FROM FLAMES AND HEAT. Hydraulic fluid can
ignite and burn. Excessive heat will soften packings and seals, resulting in fluid leaks.
Heat also weakens hose materials and packings. For optimum performance do not
expose equipment to temperatures of 65°C (150°F) or higher. Protect all equipment
from weld spatter
No alteration should be made to this device
3.1 Hydraulic Power Units
Do use a gauge or other load measuring instrument to verify load
Do NOT exceed the rated capacity of the power unit or any equipment in the system.
Burst hazard exists if connection pressure exceeds rated pressure
Do NOT operate the system with bent or damaged couplers or damaged threads
Do NOT subject the power unit and its components to shock loads
Use only Durapac approved accessories and components
Do NOT connect to an application which can return more oil to the reservoir than the
power unit reservoir can hold

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 4 of 8
Do NOT connect power unit to a hydraulic system that is powered by another pump
3.2 Hydraulic Hoses & Fluid Transmission Lines
Avoid short runs of straight line tubing. Straight line runs do not provide for expansion
and contraction due to pressure and/or temperature changes
Reduce stress in tube lines. Long tubing runs should be supported by brackets or clips.
Before operating the power unit, connections should be tightened securely and leak-
free. Over tightening can cause premature thread failure or high pressure fittings to
burst
Should a hydraulic hose ever rupture, burst or need to be disconnected, immediately
shut off the power unit and release all pressure. Never attempt to grasp a leaking
pressurised hose with your hands. The force of escaping hydraulic fluid can inflict
injury
Do NOT subject the hose to potential hazard such as fire, sharp objects, extreme heat
or cold or heavy impact
Do NOT allow the hose to kink, twist, curl, crush, cut or bend so tightly that the fluid
flow within the hose is blocked or reduced. Periodically inspect the hose for wear
Hose material and coupler seals must be compatible with the hydraulic fluid used.
Hoses also must not come in contact with corrosive materials such as battery acid,
creosote-impregnated objects and wet paint. Never paint a coupler or hose
FAILURE TO HEED THESE WARNINGS MAY RESULT IN PERSONAL INJURY AS WELL AS PROPERTY DAMAGE.
4.0 Installation
IMPORTANT: Always secure threaded port connections with high grade, non-hardening pipe
thread sealant. Teflon tape can be used if only one layer of tape is used and it is applied
carefully, two threads back, to prevent the tape from being introduced into hydraulic system,
which could cause jamming of precision-fit parts
4.1 Familiarise yourself with the specifications and illustrations in this owner’s manual. Know
your power unit, its limitations and how it operates before attempting to use. Refer to
the specification chart below or if in doubt, contact a Durapac representative.
4.2 Remove the manifold plug and then connect oil output port to suitable fittings and
application/cylinder. Check all system fittings and connections to be sure they are tight
and leak free.
4.3 Check oil level in reservoir before operating the power unit.
4.4 Ensure a clockwise motor rotation when motor is viewed from the fan end.
100 bar 700 bar
PES3024 3.0 415 50 6.3 20 700 10.5 2.1 Solenoid Adv/Hold/Retract D/A 77
Maximum
Pressure
Rating
(bar)
Flow Rate
(Lpm)
Remote Pendant Function
4 mtr
Used
with
Cylinder
Weight
(kg)
Model
Number
kW
Voltage
(3 Phase)
Hz
Amps
Usable Oil
Capacity
(L)

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 5 of 8
4.5 Remove air from the system –Position the cylinder/nut splitter/spreader so that the
piston rod is pointed down and the cylinder is lower than the power unit. Advance and
retract the cylinder several times, avoiding pressure build-up. Air removal is complete
when the cylinder motion is smooth.
5.0 Operation
IMPORTANT:
Always monitor pressure, load or position using suitable equipment. Pressure may be
monitored by means of an optional manifold and gauge. Correct application position
can only be determined by the operator of the equipment
Do NOT operate a power unit that is disconnected from the application. If operated in
this condition, the hose and connections will become pressurised. This increases the
chance of a burst hazard. Damage may also occur to the power unit and its
components
5.1 Starting the Power unit
5.1.1 Turn the motor power ON/OFF button to the ON position.
5.1.2 Switch the RUN/STOP switch to the RUN position to start the electric motor.
5.2 Lifting
5.2.1 To advance the cylinder, press the ↑arrow on the remote pendant. Fluid will
flow from the “A” port of the subplate.
5.2.2 To stop advancing the cylinder, release the ↑arrow on the remote pendant.
5.3 Lowering
To retract the cylinder, press the ↓arrow on the remote pendant. Fluid will flow from
“B” port of the subplate.
5.4 Pressure Adjustment
The directional control valve subplate is fitted with an adjustable pressure relief valve.
The operator can dial in the maximum desired pressure required for the application at
hand. The pressure adjusting range is from 0-700 bar.
6.0 Maintenance
IMPORTANT:
Check oil level regularly
Use only good quality hydraulic fluid. Do NOT use brake fluid, transmission fluid,
turbine oil, motor oil, alcohol, glycerine etc. Use of anything other than good quality
hydraulic oil will void warranty and damage the power unit, hose, and application. We
recommend Durapac Hydraulic Oil or equivalent
Equipment must only be serviced by a qualified hydraulic technician. For repair service,
contact your local Durapac authorised service centre

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 6 of 8
Damage to hydraulic hoses may not be detected during visual inspections. For this
reason, Durapac recommends that hydraulic hoses be replaced on a regular basis
Tighten connections as needed. Use non-hardening pipe thread compound when
servicing connections
Dirt, sand, etc. will quickly ruin any hydraulic system. Ensure that couplings are clean and
free of foreign matter. After each use, clean couplings and attach dust caps.
Maintenance is required when wear or leakage is noticed. Periodically inspect all
components to detect any problem that may require service and maintenance.
6.1 Adding Hydraulic Fluid
WARNING: Always add oil with cylinders fully retracted (or extended, if pull cylinders) or
the system will contain more oil than the reservoir can hold
6.1.1 Depressurise and disconnect hydraulic hose from application/cylinder.
6.1.2 With the power unit in its upright, horizontal position, remove the air vent
plug located on the top plate of the reservoir.
6.1.3 Use a small funnel to fill the reservoir to within 19mm (3/4") of the opening.
6.1.4 Bleed air from system if necessary.
6.1.5 Wipe up any spilled fluid and reinstall the air vent plug/reservoir cap.
6.2 Bleeding Air from the System
6.2.1 Repeat Steps 6.1.1 to 6.1.3 (above), if required.
6.2.2 Invert cylinder and place at a lower level than the power unit reservoir.
6.2.3 Extend and retract the cylinder several times without putting a load on the
system. Air will be released into the power unit reservoir.
6.2.4 Recheck oil level after removing air.
6.3 Changing Hydraulic Fluid
For best results, change fluid once a year or every 300 hours of use
6.3.1 Repeat Steps 6.1.1 to 6.1.2 (above).
6.3.2 Pour used fluid into a sealable container.
6.3.3 Repeat Steps 6.1.3 to 6.1.5 (above).
6.3.4 Dispose of fluid in accordance with local regulations.
6.4 Storage
6.4.1 When not in use, depressurise and disconnect the power unit from the
application.
6.4.2 Wipe clean thoroughly and store in a clean, dry environment. Avoid
temperature extremes.
6.4.3 For transportation or long storage, replace the air vent plug with shipping
plug.
6.4.4 Shield power unit with a protective cover.

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 7 of 8
7.0 Troubleshooting
Problem
Cause
Solution
Motor will not start
Inadequate or faulty electrical
supply
Check the condition of the
power unit’s power cord.
Check the condition of
extension cords
Check for tripped circuit
breaker. Be sure breaker is of
adequate size
Contact a qualified electrician
for any necessary repairs
Noisy operation
Air trapped in system
Check all points where air may
leak into the system
Refer to 6.2 –Bleeding Air from
the System
Power unit reservoir too full
Drain fluid to correct level
Low fluid level in power unit
reservoir
Refer to 6.1 –Adding Hydraulic
Fluid
Fill and bleed the system
Power unit oil is over-
heating
Oil viscosity is too high
Refer to 6.3 –Changing
Hydraulic Fluid
Refill with a good quality
hydraulic oil
Low fluid level in power unit
reservoir
Refer to 6.1 –Adding Hydraulic
Fluid
Fill and bleed the system
Power unit runs but will
not power unit oil
Power unit is not primed
Run power unit a few minutes
tipping from side to side
Externally adjustable relief valve
is not correctly set
Reset the relief valve to
appropriate level
Damaged o-ring
Send to a Durapac authorised
service centre for repair
Defective control valve
Send to a Durapac authorised
service centre for repair
Power unit does not
reach rated capacity
Low fluid level in reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Leaking system components
Repair or replace as necessary
Poor performance
Fluid level in power unit is low
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Application does not
extend, move or respond
to pressurised fluid
Overload condition
Remedy overload condition
Loose couplers
Tighten couplers
Faulty couplers
Replace couplers
Malfunctioning power unit
Contact a Durapac authorised
service centre for repair

Instruction Manual
PES3024 Electric Power Unit - V1.1 www.durapac.com Page 8 of 8
Problem
Cause
Solution
Application does not
fully extend (cylinder or
tools)
Reservoir overfilled
Secure load by other means.
Depressurise power unit and
hose, remove application, then
drain fluid to proper level
Low fluid level in power unit
reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Load above capacity of system
Use correct equipment
Application responds
slower than normal
Loose connection or coupler
Tighten couplers
Restricted hydraulic line or fitting
Clean and replace if damaged
Power unit not operating
correctly
Check power unit’s operating
instructions
Repair or replace as necessary
Low fluid level in power unit
reservoir
Secure load by other means.
Depressurise power unit and
hose, remove application, then
fill and bleed the system
Application responds to
pressurised fluid, but
system does not
maintain pressure
Leaky connection
Clean, reseal with thread
sealant, and tighten
connection
Leaking cylinder seals
Replace worn seals. Look for
excessive contamination or
wear. Replace contaminated
fluid
Power unit or valve not operating
correctly
Contact a Durapac authorised
service centre for repair
Overload condition
Remedy overload condition
Application does not
return fluid to power
unit (i.e. cylinder will not
retract)
Closed release valve
Secure load by other means.
Open release valve
Loose couplers
Secure load by other means.
Tighten couplers
Blocked hydraulic lines
Secure load by other means.
Clean and flush lines
Weak or broken retraction
springs
Secure load by other means.
Contact a Durapac authorised
service centre for repair
Internally damaged cylinder
Secure load by other means.
Contact a Durapac authorised
service centre for repair
Power unit reservoir too full
Secure load by other means.
Depressurise power unit and
hose, remove application, then
drain fluid to proper level