Festo 152962 User manual

Festo Didactic
369805 en/de/es/fr
10/2020
152962
, 8065049
Hydraulic
Power Packs with 5 l Tank
Fluid Power
– Hydraulics
Operating Instructions
Betriebsanleitung
Instrucciones de
u
tilización
Notice d'utilisatio
n

Order number: 369805
Revision level: 10/2020
Author: Ulrich Schedel
Graphics: Doris Schwarzenberger
Layout: Festo Didactic
© Festo Didactic SE, Rechbergstraße 3, 73770 Denkendorf, Germany, 2021
[phone] www.festo-didactic.com
[phone] [email protected]
Original operating instructions
© 2021 all rights reserved to Festo Didactic SE
Originalbetriebsanleitung
© 2021 alle Rechte sind der Festo Didactic SE vorbehalten
Instrucciones de utilización original
© 2021 Festo Didactic SE se reserva todos los derechos
Notice d'utilisation originale
© 2021 Tous droits réservés à la Festo Didactic SE
English: Hydraulic power packs with 5 l tank __________________________________________________ 5
Deutsch: Hydraulikaggregate mit 5 l Tank ___________________________________________________ 25
Español: Grupos hidráulicos con depósito de 5 l ______________________________________________ 45
Français : Groupes hydrauliques à réservoir de 5 l_____________________________________________ 65

© Festo Didactic 369805 3
For the sake of readability
throughout these operating instructions, all gender-specific
terms are to be considered to refer to both the femi
nine and the masculine form,
e
xcept when referring to a particular person.
CAUTION
These operating instructions must always be available to the user.
The operating instructions must be read before commissioning.
The safety instructions must be observed
Non-observance may result in severe personal injury or damage to property.
Soweit in diese
r Betriebsanleitung nur von Lehrer, Schüler etc. die Rede ist, sind
selbstverständlich auch Lehrerinnen, Schülerinnen etc. gemeint.
Die Verwendung nur
einer Geschlechtsform soll keine geschlechtsspezifische Benachteiligung sein, sondern
dient nur der besseren Lesbarkeit und dem besseren Verständnis der Formulierungen.
VORSICHT
Diese Betriebsanleitung muss dem Anwender ständig zur Verfügung stehen.
Vor Inbetriebnahme muss die Betriebsanleitung gelesen werden.
Die Sicherheitshinweise müssen beachtet werden.
Bei Missachten kann es zu schweren Personen- oder Sachschäden kommen.

4© Festo Didactic 369805
Se sobreentiende que el uso de términos en género masculino incluye también los
correspondientes términos de género femenino. El uso de una sola forma de género no
supone ninguna
discriminación específica, sino que sirve para mejorar la lectura y la
compresión de los textos.
ATENCIÓN
Estas instrucciones de utilización deben estar a disposición del usuario en todo
momento.
Deben leerse estas instrucciones antes de la puesta en funcionamiento.
Deben respetarse las instrucciones de seguridad.
De no hacerlo, pueden producirse graves daños físicos y materiales.
Les termes enseignant, étudiant, etc. employés dans les présentes instructions de
service désignent aussi, bien entendu, les enseignantes, étudia
ntes,
etc. L'emploi d'un
seul genre ne saurait constituer une discrimination sexuelle, mais a simplem
ent pour
but de faciliter la lecture et la compréhension de ce qui est dit.
ATTENTION
Ces notices d'utilisation doivent être constamment à la disposition de l'utilisateur.
Les instructions de service doivent avoir été lues avant la mise en service.
Se conformer aux consignes de sécurité.
Le non-respect peut entraîner de graves dommages corporels ou matériels.

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Table of contents
1 General prerequisites for operating the devices _________________________________________ 7
2 Pictograms _______________________________________________________________________ 8
3 Use for intended purpose ___________________________________________________________ 9
4For your safety ___________________________________________________________________ 10
4.1 Important information _____________________________________________________________ 10
4.2 Obligations of the operating company_________________________________________________ 10
4.3 Obligations of the trainees __________________________________________________________ 10
5 Work and safety instructions________________________________________________________ 11
5.1 General safety ____________________________________________________________________ 11
5.2 Mechanical safety _________________________________________________________________ 11
5.3 Electrical safety___________________________________________________________________ 12
5.4 Hydraulic safety __________________________________________________________________ 13
6 Technical data ___________________________________________________________________ 15
6.1 General specifications _____________________________________________________________ 15
6.2 Electrical specifications ____________________________________________________________ 15
6.3 Hydraulic specifications ____________________________________________________________ 16
7 Transport, unpacking, scope of delivery ______________________________________________ 17
7.1 Transport________________________________________________________________________ 17
7.2 Unpacking _______________________________________________________________________ 17
7.3 Scope of delivery__________________________________________________________________ 17
8 Design and function _______________________________________________________________ 18
8.1 Design __________________________________________________________________________ 18
8.2 Function_________________________________________________________________________ 19
9 Commissioning___________________________________________________________________ 20
9.1 Installation ______________________________________________________________________ 20
9.2 Filling with hydraulic oil ____________________________________________________________ 21
9.3 Electrical connection_______________________________________________________________ 21

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10 Maintenance_____________________________________________________________________ 22
10.1 Hydraulic oil _____________________________________________________________________ 22
10.2 Regular checks ___________________________________________________________________ 22
10.3 Oil change _______________________________________________________________________ 22
11 Declaration of conformity according to 2006/42/EC and 2011/65/EU ______________________ 23

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1General prerequisites for operating the devices
General requirements for safe operation of the devices:
•National regulations for operating electrical systems and equipment must be observed in commercial
facilities.
•The laboratory or classroom must be overseen by a supervisor.
–A supervisor is a qualified electrician or a person who has been trained in electrical engineering,
knows the respective safety requirements and safety regulations and whose training has been
documented accordingly.
The laboratory or the classroom must be equipped with the following devices:
•An emergency-off device must be provided.
–At least one emergency-off device must be located within, and one outside of the laboratory or the
classroom.
•The laboratory or classroom must be secured so that operating voltage and compressed air supply
cannot be activated by any unauthorized persons, for example with:
–A key switch
–Lockable on-off valves
•The laboratory or classroom must be protected by residual current devices (RCDs).
–Electrical devices (e.g. power supply units, compressors and hydraulic power units) may only be
operated in training rooms which are equipped with residual current devices.
–Type B residual current circuit breakers with a residual current of ≤ 30 mA must be used.
•The laboratory or classroom must be protected by overcurrent protection devices.
–Fuses or circuit breakers
•No damaged or defective devices may be used.
–Damaged devices must be banned from further use and removed from the laboratory or classroom.
–Damaged connecting cables, pneumatic tubing and hydraulic hoses represent a safety risk and
must be removed from the laboratory or classroom.

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8© Festo Didactic 369805
2Pictograms
This document and the hardware described herein include warnings about possible hazards which may arise
if the system is used incorrectly. The following pictograms are used:
WARNING
… indicates a possibly hazardous situation which may result in death or severe personal
injury if not avoided.
CAUTION
... indicates a possibly hazardous situation which may result in moderate or slight
personal injury or severe property damage if not avoided.
NOTICE
... indicates a potentially hazardous situation that may result in property damage or loss of function
if not avoided.

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3Use for intended purpose
Festo Didactic components and systems may only be used:
•For its intended use in teaching and training applications
•When its safety functions are in perfect condition
The components and systems are designed in accordance with the latest technology and recognized safety
rules. Nevertheless, incorrect use can lead to risk of severe or fatal injury for the user and third parties and
damage to the components.
The learning system from Festo Didactic has been developed and produced exclusively for education and
training in the field of automation technology. The training company and/or trainers must ensure that all
apprentices observe the safety precautions described in these operating instructions.
Festo Didactic hereby excludes any and all liability for damages suffered by trainees, the training company
and/or any third parties, which occur during use of the device in situations which serve any purpose other
than training and/or vocational education, unless such damages have been caused by Festo Didactic due to
malicious intent or gross negligence.

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4For your safety
4.1 Important information
Knowledge of the basic safety instructions and safety regulations is a fundamental prerequisite for safe
handling and trouble-free operation of Festo Didactic components and systems.
These operating instructions include the most important instructions for safe use of the components and
systems. In particular, the safety instructions must be adhered to by all persons who work with these
components and systems. Furthermore, all pertinent accident prevention rules and regulations which are
applicable at the respective place of use must be adhered to.
WARNING
Malfunctions which could impair safety must be eliminated immediately!
CAUTION
Improper repairs or modifications may result in unforeseeable operating states. Do not
carry out any repairs or changes to the components and systems that are not described
in these operating instructions.
4.2 Obligations of the operating company
The operating company undertakes to allow only those persons to work with the components and systems
who:
•Are familiar with the basic regulations regarding work safety and accident prevention and have been
instructed in the use of the components and systems.
•Have read and understood the safety chapter and warnings in these operating instructions.
Personnel should be tested at regular intervals for safety-conscious work habits.
4.3 Obligations of the trainees
All persons who have been entrusted to work with the components and systems undertake to complete the
following steps before beginning work:
•Read the chapter concerning safety and the warnings in these operating instructions.
•Familiarize themselves with the basic regulations regarding work safety and accident prevention.

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5Work and safety instructions
5.1 General safety
CAUTION
•Trainees should only work with the circuits under the supervision of an instructor.
•Observe the specifications included in the technical data for the individual
components, and in particular all safety instructions!
•Wear personal safety equipment (safety glasses, safety shoes) when working on
circuits.
5.2 Mechanical safety
WARNING
•Switch off the power supply!
–Switch off working and control power before working on the circuit.
–Only reach into the setup when it’s at a complete standstill.
–Be aware of potential overtravel times for the drives.
•Always assemble the cylinders with the corresponding cover.
CAUTION
•Set all components up so that it’s easy to activate the switches and interrupters.
•Mount all of the components securely on the profile plate.
•Follow the instructions about positioning the components.
•Make sure that limit valves are not actuated from the front.
•Risk of injury during troubleshooting!
Use a tool such as a screwdriver to actuate limit switches.

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5.3 Electrical safety
WARNING
•Disconnect from all sources of electrical power!
–Switch off the power supply before working on the circuit.
–Please note that electrical energy may be stored in individual components.
Further information on this issue is available in the data sheets and operating
instructions included with the components.
–Caution!
Capacitors inside the device may still be charged even after being disconnected
from all sources of voltage.
•Risk of death in case of interrupted protective conductor!
–The protective conductor (yellow-green) must not be interrupted,
either inside or outside of the hydraulic power pack.
–The insulation of the protective conductor must never be damaged
or removed.
•Hazard-free operation of the device is no longer possible in the case of
–Visible damage
–Malfunction
–Incorrect storage
–Incorrect transport.
–Immediately remove the mains plug from the electric outlet.
–Protect the device against inadvertent restart.
CAUTION
•The hydraulic power pack must be switched off and its mains plug must be removed
from the electric outlet before installation, repair, maintenance and cleaning work.
•The electric motor’s ventilation slots must not be covered!
•Set the hydraulic power pack up so that switches and interrupters are easy to
activate.

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5.4 Hydraulic safety
WARNING
•Depressurize the system!
–Switch off the hydraulic power pack before working on the circuit.
–Check the system using pressure gauges to make sure that the entire circuit is
fully depressurized.
–Please note that energy may be stored in reservoirs, cylinders with spring load
and cylinders with weight load. Further information on this issue is available in
the data sheets and operating instructions included with the components.
–Only reach into the setup when it’s at a complete standstill.
–Be aware of potential overtravel times for the drives.
•Risk of injury due to oil temperatures greater than 50° C!
Hydraulic oil with a temperature greater than 50° C may result in burns or scalding.
•Risk of injury when switching the hydraulic power pack on!
Cylinders may advance and retract automatically.
•Always assemble the cylinders with the corresponding cover.
•Maximum permissible pressure for all devices included in the training package is
12 MPa (120 bar). In the case of double-acting cylinders, pressure could be
increased relative to the surface area ratio due to pressure boosting. With a surface
area ratio of 1:1.7 and a system pressure of 6 MPa (60 bar), it may amount to more
than 10 MPa (100 bar).
CAUTION
•When filled with oil, the hydraulic power pack must always be positioned such that
the oil-filler plug with vent filter (red) is above the oil fill-level.
•The hydraulic power pack must be operated with the oil-filler plug with vent filter
(red).
Caution
The tank may burst if operated without the oil-filler plug with vent filter (red).
•Check the oil level at regular intervals. Unlubricated operation of the pump is not
permitted!
•When devices are started up initially, the oil level in the tank drops because the
devices and hoses are filled. If oil is no longer visible in the sight glass, hydraulic oil
must be added until the fill-level can once again be seen in the sight glass (7).

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CAUTION
•If the electric motor’s motor protection switch is tripped, the cause must be
determined and eliminated. The motor can be started back up again after allowing it
to cool down.
•If no discharge measuring container is connected to the corresponding connection
(15), it must be ensured that the connection is sealed with the protective sheath (as
is also the case upon delivery).
•The oil level drops considerably when measurements are performed with the
discharge measuring container and when the pressure accumulator is filled. The oil
level must therefore only be checked when the discharge measuring container and
the pressure accumulator are empty.
•If the power unit is moved, carried or pushed onto a trolley, the oil sloshes around in
the tank. As a result, a small amount of oil can escape via the vent filter in a time-
delayed fashion.
•Connecting more than one hydraulic power pack in order to increase the delivery
rate is not possible because the varying fill-levels in the tanks cannot equalize
themselves.
•The tank is emptied via the oil drain plug on the back of the oil tank. When the plug
is opened, the reducer fitting must be prevented from turning. Catch and dispose of
the oil.
•Limit system pressure to 6 MPa (60 bar).
•Connecting the hoses
–Never connect or disconnect the hoses when the hydraulic unit is running, or
while under pressure! Couplings must be connected when unpressurized.
–Place the coupling socket vertically onto the coupling nipple.
The coupling socket and the coupling nipple must not be fitted askew.
–After each disconnection, make sure that the couplings have closed themselves!
•Before commissioning, make sure that all tank lines have been connected and that
all couplings have been fitted securely.

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6Technical data
6.1 General specifications
Parameter Value
Dimensions Length 580 mm
Width 300 mm
Height 180 mm
Weight Empty approx. 19 kg
Filled with oil approx. 24 kg
Operating temperature 5 ... 40° C
Subject to change
6.2 Electrical specifications
Parameter Value
Order no. 152962 8065049
Nominal power 650 W 450 W
Nominal voltage 230 V 120 V
Nominal current 3.1 A 7.2 A
Frequency 50 Hz 60 Hz
Nominal speed 1320 rpm 1650 rpm
Protection IP 20
Actuation Manual with on/off switch
Connection Earthing contact plug CEE-7 Mains plug per NEMA 5-15P
Protection class 1, operation only permissible with protective earthing
CE marking EC Machinery Directive
EMC directive
Subject to change

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6.3 Hydraulic specifications
Parameter Value
Order no. 152962 8065049
Oil tank capacity Approx. 5 liters
Pump design External gear pump
Geometric delivery rate 1.6 cubic cm
Delivery rate at 6 MPa 2.2 l/min. 2.7 l/min.
Max. operating pressure 6 MPa (60 bar)
Return filter Degree of filtration: 90 µm
Pressure adjustment Manual
Pressure gauge indicating range 0 … 10 MPa (0 … 100 bar)
Pressure gauge quality class 1.6
Hydraulic oil Hydraulic oil HLP 22 to DIN 51524/2 HLP, ISO 6743/4 HM
Connections
One quick coupling socket each for P and T,
one coupling for the line to the storage tank (order no. 152859),
one connection for the discharge measuring receptacle (order no. 535816)
Subject to change

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7Transport, unpacking, scope of delivery
7.1 Transport
The hydraulic power packs are delivered in a crate. The packaging material is designed so that it can be
reused as long as it has not been damaged during transport. Please keep the original packaging and use it if
you need to transport the hydraulic power pack again.
The crate may only be transported with a suitable pallet jack or forklift. The crate must be secured against
tipping over and falling.
–Report transport damage without delay to the freight forwarder and Festo Didactic.
7.2 Unpacking
Inspect the hydraulic unit for possible damage after unpacking.
–Report any damage without delay to the freight forwarder and Festo Didactic.
7.3 Scope of delivery
Check delivered items against the delivery note and the purchase order.
–Report any discrepancies without delay to Festo Didactic.
The hydraulic
oil is not included in the scope of delivery of the hydraulic power pack.

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8Design and function
8.1 Design
The electric motor and the tank are mounted on a flange. Mounting on profile plate, profile column or other
device is done by means of profile connectors. The grooves are compatible with the ITEM profile system,
grid dimension 50 mm.
P T T
S
L
Hydraulic power pack – Symbol
(1) electric motor, (2) on-off switch, (3) operating capacitor, (4) tank connection (blue) for storage tank TS, (5) tank connection T,
(6) pressure-relief valve, (7) sight glass for fill-level indication, (8) temperature measuring tape, (9) tank, (10) oil drain plug,
(11) IEC power cable, (12) pressure gauge, (13) oil-filler plug with vent filter, (14) pressure supply port P, (15) tank connection L for
discharge measuring container, (16) profile connector for mounting the power unit, (17) flange, (18) quick fix rotary mounting system,
(19, 22) plug connector, motor to control console, (20) on switch, (21) off switch with “mushroom actuator”, (23) mains plug
(NEMA5-15)

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(1) electric motor, (10) oil drain plug, (17) flange, (24) suction line, (25) return filter, (26) gear pump
8.2 Function
The hydraulic power pack converts electric energy into hydraulic drive power. The electric motor (1) drives a
gear pump (26). Oil is delivered from the tank (9) to the pressure supply port (14) via the suction tube (24).
Pressure is indicated at the pressure gauge (12). The pump delivers oil at a nearly constant volumetric flow
rate.
The maximum pressure value is set at the pressure-relief valve (6). Oil is returned to the tank (9) via tank
port T (5) and the return filter (25). A blue coupling socket (4) is provided for return flow from the pressure
accumulator. The fill-level can be viewed at the sight glass (7). Oil is returned from the discharge measuring
container via the respective connection (15).

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9Commissioning
9.1 Installation
There are mounting holes on three sides of the flange (11), which allows the hydraulic power pack to be
installed in different positions. The hydraulic power pack is secured with 2 profile connectors. These are
built into the flange on the back at the factory.
If the hydraulic power pack will be installed to a different flange surface, the profile connectors must be
remounted to the corresponding surface. Refer to the respective mounting instructions with regard to
possible laboratory furniture mounting positions.
The hydraulic power pack can be installed in 3 different positions.
Mounting position Description
Vertical, electric motor at top
Horizontal, pressure gauge at top
Horizontal, pressure gauge at side with connection T at bottom
Attention
The fill-level cannot be viewed in the sight glass in this mounting position.