Et HP 036. User manual

Operating
Instructions
Pneumohydraulic controller
HP 036./HP 037.
en
BEA--206006-EN-04
1. Safey 2
2. Function 3
3. Variants 5
4. Mounting 7
5. Installation 9
6. Commissioning 10
7. Maintenance 14
8. Spare Parts 15
9. Technical Data 16

Pneumohydraulic controller HP 036./HP 037.
Page 2/16 BEA--206006-EN-04
1. Safey
1.1 Approved applications
1.2 Operating instructions
1.3 Mounting
The E+L controller HP 03.. must only be used to operate a hydraulic
positioning device.
Only use the controller
- if it is in perfect condition technically
- in accordance with its intended usage
- with an awareness of safety and risk factors and in compliance
with the operating instructions.
Any jobs regarding controller operation, gearing to production re-
quirements, conversion, setting, its safety-related mechanisms, servi-
cing, maintenance and repair must be performed by qualied person-
nel only. Please observe the switching on/o󰀨 procedure laid out in the
operating instructions.
Look after these operating instructions carefully and make sure they
are available to personnel at all times.
The operating instructions are part of the package and should be
read carefully prior to mounting, operation and maintenance work.
Please observe the locally applicable and customary safety and acci-
dent prevention regulations.
Hydraulic and pneumatic lines should be installed so that they do not
present any risk. There should be no bending (minimum bending ra-
dius 50 mm for lines supplied by E+L).
Operating elements that are a potential risk when pressure is redu-
ced, e.g. bursting of the hose or motor standstill, should be appropri-
ately safeguarded by the user.
Please ensure that:
- electrical components without enclosures such as switch panels
or operating devices are protected according to the locally appli-
cable safety regulations, e.g. VDE 0100
- when laying electrical leads the customer shall ensure that the in-
sulation is not damaged and that leads are correctly secured and
screened
- controller power is switched on along with the main machine sys-
tem switch
- the controller is integrated into the machine control in such a way
as to prevent it starting up independently after a machine standstill
or an emergency OFF device reset.
The controller should be operated by qualied persons or suitably in-
structed personnel only.
1.5 Operation
Main switch on
your machine
L 1
1-pole illustration
Controller
HP 03.. electric
control
1.4 Installation

BEA--206006-EN-04 Page 3/16
Pneumohydraulic controller HP 036./HP 037.
The HP 03.. controller is used to position actuators in web guiding
systems or in unwinding/rewinding stations. The controller is desig-
ned for systems guiding by the web edge with a pneumatic sensor
FL2.. .
2. Function
2.1 Purpose
HP 03.. controller
2.2 Design
Side channel compressor
Air intake lter
Servo-valve
Pressure gauge
Fluid tank
Pressure relief valve
Three-phase a.c. motor
The HP 03.. controller is made up of the following components:
- three-phase a.c. motor
- side channel compressor
- air intake lter
- servo-valve
- pressure relief valve
- pressure gauge
- uid tank

Pneumohydraulic controller HP 036./HP 037.
Page 4/16 BEA--206006-EN-04
2.3 Mode of operation
Motor protec-
tion switch
Contactor
Fuses
Switch panel SE 12521
Connection terminals
The HP 03.. controller is available in three di󰀨erent electrical versi-
ons.
- Switch panel SE 12521 with motor protection switch, three-phase
a.c. motor contactor and connection terminals for the valve wiring.
- Terminal box SZ 0921 with connecting terminals only for the three-
phase a.c. motor and valve wiring.
- No electrical wiring.
To generate the air required for sensing, ambient air is drawn into the
side channel compressor and fed to connection S 1 of the pneumatic
sensor. The level of the probing air pressure and thus the control
sensitivity for adjustment to di󰀨erent situations is set via a restrictor.
Some of the compressed air is sent to diaphragm D 1 (see pneu-
matic system plan on opposite page, at top). A pressure spring works
in the opposite direction to the diagrapm. If the sensor is covered ap-
propriately, the diaphragm is maintained in the center and the system
in a zero position.
If the web moves away from the zero position, it changes the air cur-
rent which, in turn, inuences the diaphragm. The change to the dia-
phragm directly a󰀨ects the servo-valve controlling the uid ow. The
uid ow changes the location of the positioning cylinder until the
web returns to its zero position.

BEA--206006-EN-04 Page 5/16
Pneumohydraulic controller HP 036./HP 037.
On the basic model HP 03.. without valve assembly, guiding by the
web edge only (automatic) is possible.
:S 1.1 :S 1.2 :S 2.1 :S 2.2
- HZ
:S 1
- FL
AIR
T
AP
T
P
OIL
HP 0360 20 bar
HP 0370 30 bar
B
:A :B
D 1
:S 2
FL = pneumatic sensor
HZ = positioning device
P
D 1
- FL
AIR
:S 2.2
OIL
- SC
T
:S 1
:S 2
:S 1.1 :S 1.2 :S 2.1
PA
B
T
HP 0360 20 bar
HP 0370 30 bar
:A :B
- HZ
- V 1
FL = pneumatic sensor
HZ = positioning device
SC = servo center actuator
V 1 = manually-actuated valve
Valve assembly 02 permits guiding by the web edge (automatic) or
servo center. Reversing is e󰀨ected via a manually-actuated valve.
3. Variants
3.1 Basic model, system 1
3.2 Valve assembly 02,
system 2a

Pneumohydraulic controller HP 036./HP 037.
Page 6/16 BEA--206006-EN-04
Valve assembly 03 permits guiding by the web edge (automatic) or
servo center. Reversing is e󰀨ected via solenoid valves.
Valve assembly 05 permits guiding by the web edge (automatic). The
positioning cylinder can be set via pushbuttons. A P/T connection is
possible with this valve assembly (please quote it however when or-
dering controller HP 03..).
T
T
P
HP 0360 20 bar
HP 0370 30 bar
:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B
:S 1
- FL
:S 2
- SC
- Y 2
- Y 3 - HZ
B
A
D 1
OIL
P
AIR
FL = pneumatic sensor
HZ = positioning device
SC = servo center actuator
Y 2/Y 3 = solenoid valves
:S 1
- FL
HP 0360 20 bar
HP 0370 30 bar
T
P:P
:T
:S 1.1 :S 1.2 :S 2.1
Y 10 Y 11
- HZ
:S 2
- Y 2
:A :B
:A :B
T
P
B
A
OIL
D 1
AIR
:S 2.2
FL = pneumatic sensor
HZ = positioning device
Y 2/Y 10 = solenoid valves
3.3 Valve assembly 03,
system 2a
3.4 Valve assembly 05,
system 2b

BEA--206006-EN-04 Page 7/16
Pneumohydraulic controller HP 036./HP 037.
Web guiding is by the web edge (automatic) or servo center. The
positioning cylinder can be set via pushbuttons. A P/T connection is
possible with this valve assembly (please quote it however when or-
dering controller HP 03..).
HP 0360 20 bar
HP 0370 30 bar
- HZ
- FL
AIR
:S 2.1 :S 2.2
:S 1.1 :S 1.2
- SC
:S 1
:S 2
- Y 3
- Y 2
:A :B
:A :B
Y 10 Y 11
T B
PA
P
P
T
T
OIL
D 1
4. Mounting
Controller HP 03.. should be mounted so that the air hoses and hy-
draulic lines to the sensor, return-to-center switch and positioning
cylinder are kept as short and straight as possible and are laid accor-
ding to the connection diagrams. The minimum bending radius is 50
mm (for air and hydraulic lines). Please ensure easy access to the
controller for operating and maintenance purposes.
Controller HP 03.. must be mounted a little higher than the positio-
ning cylinder to ensure the self-venting of the system.
 Donotdrilltheuidtank
3.5 Valve assembly 06,
system 2ab
4.1 Controller HP 03..
FL = air sensor
HZ = positioning device
SC = servo center actuato-
rY 2/Y 3 = solenoid valves
Y 10

Pneumohydraulic controller HP 036./HP 037.
Page 8/16 BEA--206006-EN-04
The switch panel or terminal box can be mounted in three positions
(see g. below).
When the web passes through the air sensor on the horizontal, sen-
sor connection S 1 should be located underneath the web (see g.
on left). This protects the air sensor from soiling.
The pneumatic sensor should be connected as follows.
Connect S 1.1 on controller to sensor via S 1.
Connect S 2.1 on controller to sensor via S 2.
The air lines to the sensor must be of the same length and not ex-
ceed 3 m. The line to the pneumatic return-to-center switch must not
exceed 6 m. Narrowing of cross- sections and narrow hose elbows
are not permissible due to the danger of rupture. For temperatures
over 70 °C, silicon hoses should be used for the air lines and copper
pipes for the hydraulic lines.
The plastic tubes supplied (6 mm inner diameter, 10 mm outer dia-
meter) should be used for the hydraulic lines. When using steel pipes
(10 mm x 1 mm) these must be cut to size using a pipe cutter. The
pipes must be cleaned prior to installation. The hydraulic lines must
securely xed.
Mounting options
Standard
A
B
C
Air sensor
Web S 1
S 2
Pneumatic sensor FL 2..
4.2 Switch panel
4.3 Pneumatic sensor

BEA--206006-EN-04 Page 9/16
Pneumohydraulic controller HP 036./HP 037.
The positioning cylinder should be connected as follows.
When the FL 2.. pneumatic sensor is uncovered, the uid ow is from
to A to B.
The positioning cylinder must be connected so that it moves towards
the pneumatic sensor (see g. below)
Positioning cylinder stroke
Positioning cylinder
Positioning cylinder
A
B
Connec-
tion to
controller
Uncovered pneumatic sensor FL 2..
Positioning cylinder connection
The electrical connections should be carried out according to the at-
tached connection diagram.
Controller HP 03.. should be connected to the mains via an
electrical fuse.
5. Installation
4.3 Positioning cylinder
A
B
Connec-
tion to
controller

Pneumohydraulic controller HP 036./HP 037.
Page 10/16 BEA--206006-EN-04
Once the uid ller conver has been removed, the hydraulic uid
should be poured in using a funnel and lter paper. the uid leven
must not rise above the halfway mark on the uid inspection window.
The direction of rotation can be checked by briey applying voltage
to the three phase a.c. motor. The three phase a.c. motor must turn
to the right. An additional check is provided by the pressure gauge, if
the direction of rotation is wrong, no pressure will be built up. The di-
rection of rotation can be reversed by swapping over the two phases
in the connection lead.
6. Commissioning
Check the direction of the positioning cylinder travel when the three-
phase a.c. motor is switched on. To do so, select the guiding by web
edge mode (automatic).
The positioning cylinder or device must move the web away from the
sensor when the sensor jets are covered (see g. on opposite page).
When the air sensor is uncovered, the positioning cylinder should
move towards the air sensor. If the reverse is the case, hydraulic
connections A and B must be swapped.
The hydraulic lines may also be under pressure when the
systemisswitchedo󰀨.Whenthehydrauliclinesareopened,
power elements may be activated.
Fluid ller cover
Three-phase a.c. motor
direction of rotation
Fluid inspection window
Pressure gauge
HP 03.. controller
6.1 Checkingthepositioning
direction

BEA--206006-EN-04 Page 11/16
Pneumohydraulic controller HP 036./HP 037.
The hydraulic system is vented by advancing the positioning cy-linder
to its end positions several times. To this end, however, it is essential
that the hydraulic controller be mounted a little higher than the posi-
tioning cylinder. This process should be repeated until the positioning
cylinder operates without jerks and reacts immediately.
The uid level must be rechecked and topped up if required until it
reaches the halfway level on the uid inspection window.
On valve assemblies with a servo center mode, the servo center ac-
tuator must be set. The command device should be set to servo cen-
ter mode. The positioning cylinder moves until the pneumatic servo
center actuator is covered by a half (see g. on right).
If the positioning cylinder moves into an end position, the connection
on the servo center actuator must swapped from B to A.
The center position can be set by shifting the servo center actuator
or actuating element.
Positioning cylinder di-
rection of stroke
HP 03
Positioning
cylinder
Sensor jets
Web
Pneumatic
sensor
Positioning cylinder di-
rection of stroke
Positioning
cylinder
Sensor jets
Pneumatic
sensor
HP 03
Covered sensor jets Uncovered sensor jets
Actuating element
Servo center actuator
AB
6.2 Setting the pneumatic
servo center actuator
Web

Pneumohydraulic controller HP 036./HP 037.
Page 12/16 BEA--206006-EN-04
The basic setting when the pneumatic sensor is uncovered is
12 mbar (= 120 mm water column), measured at S 2. For sensitive
webs, the S 2 signal pressure can be reduced to approx. 9 mbar
(90 mm water column). The positioning speed is however also redu-
ced as the servo-valve is no longer actuated to its full extent. The air
ow setting is e󰀨ected via the AIR setscrew (see g. below).
The setscrew is covered by a protective cap. Once the nut is loose-
ned, the signal pressure can be set. Subsequently, the nut should be
retightened and the protective cap replaced.
On commissioning, however, check for synchronous operation. The
positioning cylinder speed must be identical in both directions. If this
is not the case, turn the set screw for synchronous operation (see
illustration above) up approximately one full turn left or right until syn-
chronous operation is attained.
Minimum air pressure
Maximum air pressure
Setscrew
Setscrew for synchro-
nous operation
Setscrew
Protective cap
Nut
6.3 Adjusting the pneumatic
system
6.4 Setting synchronous
operation

BEA--206006-EN-04 Page 13/16
Pneumohydraulic controller HP 036./HP 037.
The controller is factory preset to maximum speed. By turning the
uid restrictor (see g. below) by approx. 5 turns to the right, the po-
sitioning speed is reduced by approx. 50 %. If the system should dis-
play a tendency to hunt, we recommend you reduce the positioning
speed.
The uid restrictor screw is also locked by a protective cap and nut.
The pressure limiting valve on HP 036 is factory preset to approx. 20
bar and to approx. 30 bar on HP 037. Once the protective cap has
been removed and the nut loosened, the set pressure can be adjus-
ted (see g. above). By turning to the left, the pressure is reduced
and thus also the positioning force. Adjustments should be carried
out only when idling.
The pressure limiting valve should only be actuated when the
system is at a standstill or idling. It can only be turned with
di󰀩cultywhenunderpressure.
We recommend you reduce the uid pressure if no great degree of
positioning force is required as the uid doesn’t heat up so much.
The positioning force can be read o󰀨 the pressure gauge when the
positioning device is in its end positions. Once set, the nut can be re-
tightened and the protective cap replaced.
Pressure limiting valve Fluid restrictor
6.5 Setting the positioning
speed
6.6 Setting maximum pressure
Setscrew
Protective cap
Nut

Pneumohydraulic controller HP 036./HP 037.
Page 14/16 BEA--206006-EN-04
7. Maintenance
Venting screw
Air intake lter
Hexagon socket head screws
Hexagon socket head screws
Controller assembly
The air intake lter should be renewed at regular intervals depending
on the amount of dust in the ambient air.
Check regulary that the hydraulic uid and pipe connections are tight.
The level and purity of the hydraulic uid must be checked regular-
ly. The purity of the hydraulic uid can be checked by a simple test.
Using a clean screwdriver, sprinkle a little uid onto a piece of white,
absorbent paper. If a deep brown coloured spot, metallic scu󰀨 or
other soiling appears in the center of the stain, the uid should be
changed.
The uid must be changed after approx. 6000 operating hours or at
least once a year. The uid should only be changed at operating tem-
perature.
Once the controller is switched o󰀨, the hydraulic uid is drained o󰀨 by
opening the venting screw. To check the uid intake lter and lter in-
sert, the whole controller assembly must be unscrewed from the uid
tank. Once the 12 hexagon socket head screws have been removed
(see g. below), the assembly can be removed.
7.1 Controller HP 03..

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Pneumohydraulic controller HP 036./HP 037.
The uid intake lter is located on the gear pump. Once the nut has
been removed (see g. on right), the lter insert can be taken out. If
heavily soiled, the lters should be replaced. Depending on the de-
gree of soiling, the uid tank should be clean ed. Prior to reassembly,
the old silicon seal must be removed from the uid tank and the valve
assembly and replaced by a new brush-on silicon sealant.
The air jets must be checked regularly for soiling and cleaned as
required. The hose lines on the pneumatic sensor must be remo-
ved for cleaning purposes as otherwise the compressed air
would destroy the diaphragm in the servo-valve. The air jets in
the pneumatic sensor should be ushed out with compressed air. In
the case of extreme soiling, the sensor should rst be cleaned with
petroleum ether or para󰀩n. The hose lines may also have to be clea-
ned.
Do not clean the pneumohydraulic controller with com-
pressed air. Compressed air will destroy the controller.
We recommend you keep a stock of the following spare parts:
Spare parts kit HP 036./HP 037. 205702
Plastic tube (dia. 10/6, please state length required) 008986
Support sleeves
(always order together with plastic tube) 023461
Hydraulic uid 024870
Single air hose
(please state length required) 030917
 Thesparepartkitcontainsreplacementsforallthoselters
and seals subject to wear and tear.
Filter insert
Nut
Replacing the lter insert
8. Spare Parts
7.2 Pneumatic sensor FL 2..
8.1 Mechanical

Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Phone [phone]
Telefax (0821) 24 35-6 66
Internet http://www.erhardt-leimer.com
E-mail [e-mail]
The electrical spare parts are dependent on the on-site control volta-
ge.
(only in conjunction with a switch panel)
Miniature fuse (5x30) 10 AM (24 V) 070646
Miniature fuse (5x30) 4 AM (120 V) 012043
Miniature fuse (5x30) 2 AM (230 V) 005353
((only in conjunction with a terminal box)
Miniature fuse (5x30) 6,3 AM 012044
Technical data HP 0360 HP 0370
3-phase motor see sticker motor rating
Operating pressure 20 bar 30 bar
Pressure on cylinder
when adjusted to maximum 14 bar 21 bar
Pump delivery 1,5 - 3 l/min 3 - 6 l/min
Fluid content 15 l 25 l
Fluid type H-LP 32 DIN 51524
ISO VG 32 DIN 51519
Temperature rise
above ambient 35 °C 45 °C
Maximum operating
temperature 80 °C
Sound level 64 dB
Sensor air pressure 5 - 30 mbar
Weight with uid approx. 40 kg approx. 45 kg
Valve coil voltage 220-230 V, 50/60 HZ
110-120 V, 50/60 HZ
24 V =
2/2-way valve 31 VA / 15 W
4/3-way valve 80 VA / 30 W
Dimensions see attached dimensioned
drawing
Subjecttotechnicalmodicationswithoutnotice
9. Technical Data
8.2 Electrical components