HAWE Hydraulik A 100 User manual

Mini hydraulic power pack type A 100 and A
065
Original assembly instructions
B 6025
12-2021-1.1en
Operating pressure pmax:
Usable volume Vuse:
210bar
0.2 to 0.8 l

© by HAWE Hydraulik SE.
The reproduction and distribution of this document as well as the use and communication of its contents to others without explicit
authorization is prohibited.
Offenders will be held liable for the payment of damages.
All rights reserved in the event of patent or utility model applications.
Brand names, product names and trademarks are not specifically indicated. In particular with regard to registered and protected names
and trademarks, usage is subject to legal provisions.
HAWE Hydraulik respects these legal provisions in all cases.
HAWE Hydraulik cannot provide individual guarantees that the stated circuits or procedures (including in part) are not subject to the
intellectual property rights of third parties.
Printing date / document generated on: 20.12.2021
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Table of Contents
1 About these instructions.................................................................................................................................. 4
1.1 Target audience................................................................................................................................................. 4
1.2 Safety instructions and symbols...........................................................................................................................4
1.3 Applicable documents......................................................................................................................................... 5
2 For your safety................................................................................................................................................ 6
2.1 Intended use.....................................................................................................................................................6
2.2 Misuse.............................................................................................................................................................. 6
2.3 Residual risks.................................................................................................................................................... 6
2.4 Duties of the operator........................................................................................................................................7
2.5 Qualification of the personnel............................................................................................................................. 8
2.6 Personal protective equipment.............................................................................................................................8
3 About this product........................................................................................................................................... 9
3.1 Markings........................................................................................................................................................... 9
3.2 Structure......................................................................................................................................................... 10
3.3 Functions........................................................................................................................................................ 11
3.4 Control............................................................................................................................................................12
4 Transport and storage..................................................................................................................................... 13
4.1 Transport equipment......................................................................................................................................... 13
4.2 Scope of delivery............................................................................................................................................. 13
4.3 Checking the delivery........................................................................................................................................14
4.4 Storage........................................................................................................................................................... 14
5 Assembly and installation...............................................................................................................................15
5.1 Hydraulic connection........................................................................................................................................ 15
5.2 Electrical connection........................................................................................................................................ 16
6 Start-up......................................................................................................................................................... 18
7 Operation....................................................................................................................................................... 19
7.1 Switching the hydraulic system on/off................................................................................................................ 19
8 Maintenance...................................................................................................................................................20
8.1 Maintenance plan............................................................................................................................................. 22
8.2 Service............................................................................................................................................................22
8.2.1 Checking for leakage in the hydraulic system....................................................................................................... 22
8.2.2 Venting the hydraulic system............................................................................................................................. 23
8.2.3 Checking the hydraulic uid level and replacing it................................................................................................23
8.2.4 Replacing 2/2-directional seated valve SP3......................................................................................................... 24
9 Disassembly and disposal................................................................................................................................25
10 Troubleshooting..............................................................................................................................................26
11 Appendix........................................................................................................................................................27
11.1 Technical data..................................................................................................................................................27
11.1.1 Operating conditions.........................................................................................................................................27
11.1.2 Weights and measures.......................................................................................................................................28
11.1.3 Electrical data..................................................................................................................................................28
11.2 Circuit diagram................................................................................................................................................ 33
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1About these instructions
This manual is part of the product and describes the safe and proper use in all operating phases.
All photos and drawings in this manual show an available product variant. For precise details concerning
the variant you have purchased, please refer to the type plate attached to the product.
Read instructions before use.
Make the manual accessible to operating and maintenance personnel at all times.
Keep this manual for the lifetime of the product.
Only pass on the product to third parties together with this manual.
1.1 Target audience
The target audience of this manual is trained and qualied personnel who are familiar with the installa-
tion, operation and maintenance of machines.
The manual provides relevant information for the machine manufacturer and machine operator as well as
for training courses.
To request further information about the product, contact HAWE Micro Fluid GmbH.
1.2 Safety instructions and symbols
Safety indication In these instructions, the following warning and safety notes are used:
Symbol Meaning
DANGER
Draws your attention to a hazardous situation that can lead directly to serious injury
or death if not avoided.
WARNING
Draws your attention to a hazardous situation that can indirectly lead to serious
injury or death if not avoided.
CAUTION
Draws your attention to a hazardous situation that can indirectly lead to light to
moderate injury if not avoided.
Notice to prevent environmental and material damage.
Information to ensure the correct use of the product.
Safety symbols General safety symbol
Draws your attention to additional safety information.
Slipping hazard Dragging hazard from moving parts
Harmful substances Tripping and falling hazard
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Fire accelerants Falling loads
Burn hazard Crushing hazard
Electrical voltage Suspended loads
No access to persons with pacemakers
and defibrillators
Mandatory signs Protective equipment
Safety boots
Wear appropriate safety boots to protect your feet against mechanical hazards
Work gloves
Wear suitable work gloves to protect your hands against chemical and mechanical
hazards.
Safety goggles
Wear safety goggles to protect your eyes against chemical and mechanical hazards.
Protective clothing
Wear tted clothing without protruding parts.
Follow the safety data sheet of the hydraulic uid.
1.3 Applicable documents
Standard Designation
2006/42/EC
DIN EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1
ISO 4413
DIN EN ISO 12100
DIN 51524 Pressure uids - Hydraulic oils - Part 1: HL hydraulic oils, Minimum
requirements
ISO 4406
D 6025 Mini hydraulic power pack type A 100 and A 065 data sheet
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2For your safety
The product is built according to the state of the art and recognized safety regulations.
Nevertheless, there is a risk of personal injury and damage to property if this chapter and the safety
instructions in this manual are not observed.
2.1 Intended use
■The product is a technical work tool and intended for commercial and industrial use only.
■The product may only be operated in accordance with the technical data, operating conditions and
performance limits specied in this manual.
■Only use original accessories and original spare parts approved by the manufacturer.
■The product may only be used indoors.
■The product is primarily used to raise and lower operating tables/robots, window lifters and test
benches.
Partly completed machinery
The product is a partly completed machine according to the EC Machinery Directive 2006/42/
EC and is intended exclusively for installation in a machine or system. The product is
controlled via the manufacturer's machine / plant control.
Follow the manufacturer's operating instructions.
2.2 Misuse
■Use in other operating modes than specied in the intended use
■Using the product beyond the specied performance limits
■Do not use the product in potentially explosive areas.
■Do not paint over elastic seals, the bearings of moving parts or hose lines.
2.3 Residual risks
When handling hydraulic uid, comply with the safety data sheet of the manufacturer of the
hydraulic uid.
DANGER
Hazard from explosive combustion
Hydraulic uid as well as the mist and vapor of hydraulic uid are re accelerants. Contact with ignition
sources leads to explosive combustion. Serious injury or death.
Avoid re, open ames and smoking in the vicinity of the product.
Immediately dispose of combustible materials wetted with hydraulic uid as special waste.
Do not use ammable or corrosive cleaning uids.
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WARNING
Electrical and magnetic elds
Electrical and magnetic elds impair the functionality of cardiac pacemakers and implanted defibrilla-
tors.
People with pacemakers or implanted defibrillators must maintain a sufcient distance from
magnets.
Advise people with pacemakers or implanted defibrillators against approaching magnets.
Cordon off the area around the drive system and afx suitable warning signs to the barriers.
WARNING
Risk of injury from crushing and shearing
Parts of the body may be crushed or severed between the machine frame and hydraulic system due
to lack of caution during transport, assembly and disassembly.
Never reach between the hydraulic system and the machine frame.
Ensure that third parties cannot enter the hazardous area.
Wear work gloves and work boots.
2.4 Duties of the operator
Observe and comply with regulations:
Do not put the product into operation until the complete machine or system complies with the
country-specic regulations, safety regulations and standards of the application.
Observe and apply regulations for accident prevention and environmental protection.
Operate product safely:
Despite safety devices, the product still poses residual risks. Observe the safety instructions in this
manual to reduce health hazards and avoid dangerous situations.
The operator must ensure that the operating conditions (see general, hydraulic and electrical data) are
within the operating limits of the product.
Keep all instructions / signs on the product in legible condition and observe them.
Instruct personnel:
Regularly train the personnel in all points of these instructions and ensure that they are observed.
Ensure the terms of the industrial safety and operating instructions are observed.
Only use qualied personnel. Due to their training and experience, the qualied personnel must be
able to recognize risks and avoid possible hazards.
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2.5 Qualification of the personnel
The activities described in these instructions require basic knowledge of mechanics, hydraulics and
electrics.
For the transport and handling of heavy loads, additional knowledge in handling hoists and slings is
required.
The activities may only be carried out by an appropriate specialist or an instructed person under the
supervision of a specialist.
Activities other than those described in these instructions may only be performed by HAWE or
authorized specialist companies.
The personnel must have read and understood these instructions.
Trained personnel Personnel instructed comprehensively, by skilled staff on behalf of the owner, in how to perform its
appointed tasks and in how to use the product safely.
Specialist personnel Due to their technical training, knowledge and experience, specialists are able to assess and carry out the
assigned work and can independently recognize possible dangers.
Qualied electrician A person with appropriate professional training, knowledge and experience, so that he/she can recognize
and avoid dangers that can be caused by electricity.
Auditor Persons of a technical inspection body who are authorized to perform testing and monitoring tasks for
pressure equipment and electrical systems.
2.6 Personal protective equipment
Personal protective equipment is designed to prevent and reduce hazards.
In the instructions, safety instructions with mandatory symbols indicate the wearing of special
protective equipment for special activities.
Instruction and supply is carried out by the operator.
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3About this product
3.1 Markings
(1) Type plate
The type plate can be found on the equipment rack with the following information:
■Material number (6XX-XXXX-X)
■Serial number
■Production date (week, year)
(2) Hydraulic uid inlet (oil)
(3) Engravings for hydraulic connections (P / T)
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3.2 Structure
This hydraulic power pack is a hydraulically driven motor-pump unit with electric drive. It can be
connected to different consumers via the hydraulic interfaces P and T.
The hydraulic power pack is mainly used to generate pressure in a small installation space, such as for
actuating (operating) tables/robots, mobile working platforms or window lifters.
It is designed in the versions Q (one ow direction), and H (the lifting version), and it provides a ow
rate and pressure in accordance with the technical data. Here, the size of the tank, pump and motor can
be varied, along with the motor type.
A 065
1Hydraulic uid ller plug (M 14x1.5)
2Tank
3Equipment rack with pump and pressure-limiting valve
4Motor
A 100 H
1Hydraulic uid ller plug (M 14x1.5)
2Tank
3Equipment rack with
•pump
•pressure limiter P3B
•seated valve SP3 and
•throttle NG3
4Motor
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A 100 Q
1Hydraulic uid ller plug (M14 x 1.5)
2Tank
3Equipment rack with
•pump
•check and pressure-limiting valve
4Motor
The external gear pump is directly ange-mounted via specic equipment rack/Q or H on the motor. The
condition and quality of the hydraulic uid can be easily checked via the plastic cover on the hydraulic
tank.
Depending on the version of the mini hydraulic power pack, the 2/2-directional seated valve SP3
(lowering valve) and throttle are integrated in the equipment rack.
3.3 Functions
Version Q Motor (M)
Pressure at connection P:
Energize the electric drive so there is pressure at connecting line
P. The hydraulic uid ows with a constant ow rate from the
hydraulic tank via the consumer port/hydraulic connection P to T.
ON
Releasing pressure:
The electric drive is not energized. The hydraulic uid is not
conveyed from the tank.
OFF
Lifting version H Motor (M) Valve (QM)
Pressure at connection P:
Energize the electric drive so there is pressure at connecting
line A. The hydraulic uid ows with a constant ow rate from
the hydraulic tank via the pump to the consumer port/hydraulic
connection P.
ON CLOSED
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Motor (M) Valve (QM)
Releasing pressure:
The electric drive is not energized. The hydraulic uid is not
conveyed from the tank. If the 2/2-directional seated valve SP3
(QM) is open simultaneously, the hydraulic uid ows back into
the tank.
OFF OPEN
Maintaining pressure:
The electric drive is not energized. Closed seated valve (QM)
ensures that the pressure is maintained.
OFF CLOSED
3.4 Control
The product is preassembled and tested for installation in the higher-level machine. Hydraulic uid
is not included in the scope of delivery.
All of the necessary safety equipment, safety functions and the safety controller should be provided
by the machine manufacturer.
Ensure the following at the
machine.
■Faults on the hydraulic power pack cannot trigger any hazard and can be safely rectied.
■There is no hazard from failure of the electric power supply to the hydraulic power pack.
■People cannot reach into the hazard zone of the hydraulic power pack.
■People cannot burn themselves on the hot surfaces. After installing the hydraulic power pack in the
machine, label any hot surfaces that could pose a danger to people.
■Choose a suitable hydraulic uid (mineral oil according to DIN51524) and document this on the type
plate.
Operating modes and
vibration measurement
■Operating modes & vibration measurement
■The machine manufacturer must determine the operating modes for safe operation of the hydraulic
locking unit in the system.
Central control system and
software
■A main switch and emergency stop function are integrated in the machine/higher-level control.
■The pressure-limiting valve (P3B) is factory-set and safeguards the hydraulic system against excessive
pressure.
■The motor’s duty cycle should be monitored by the device control. An increase in the duty cycle is an
indicator of abnormal internal leakage.
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4Transport and storage
Observe the following safety instructions additionally to the safety instructions in chapter For your
safety.
CAUTION
Personal injury from tipping and falling loads
The pallet or skeleton container may tip and/or fall during transport. Hands and feet can be crushed.
Adhere to the symbols on the packaging.
Carefully transport the pallets or skeleton containers as near as possible to the installation location
using approved transport equipment.
Select transport equipment that has the capacity to transport the maximum load safely.
Wear protective clothing.
4.1 Transport equipment
Only tested and approved aids are permitted for use.
DAMAGE
Preventing damage in transit
Do not subject valves or other assembled components to any loads.
Do not kink hoses.
4.2 Scope of delivery
Delivery of the completely assembled units includes:
■assembled hydraulic power pack with motor (connections P and T sealed with plastic screw plugs).
Scope of delivery does not include:
■bolts, screws and sleeves for attachment
■electrical connecting lines (if to be attached separately on the motor)
■hydraulic uid
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4.3 Checking the delivery
Unpacking 1. Take out the product.
2. Check that the product is complete and check for transport damage.
Note all transport damage on the transport documents or the carrier's delivery note.
Take photos of any transport damage and submit a claim to the manufacturer.
3. Dispose of the product packaging correctly in accordance with local regulations.
DAMAGE
For any defect found, le a complaint immediately with:
HAWE Micro Fluid GmbH
Borsigstraße 11
93092 Barbing, Germany
Tel.: [phone]
Claims for damages can only be addressed within the applicable complaint periods. HAWE does not
accept any liability for subsequent complaints.
4.4 Storage
DAMAGE
Property damage from incorrect storage
Incorrect storage can lead to damage. Refer to the technical data.
Store the product and its separate components as follows:
■Do not store outdoors.
■Store dry and free of dust.
■Protect the equipment against sunlight (UV radiation).
■optimum storage temperature: 15 - 20 °C
■Do not store close to ignition and heat sources, aggressive media (e.g. acids, fuel, lubricants), and
ozone-emitting illuminants (e.g. fluorescent light sources, mercury vapor lamps).
■Protect the valves and valve controllers against gumming of the hydraulic uid if stored more than 2
years. To do so, contact the manufacturer of the hydraulic uid.
■Avoid mechanical jolts.
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5Assembly and installation
Observe the following safety instructions additionally to the safety instructions in chapter For your
safety.
WARNING
Risk of fatal injury / malfunction due to incorrectly installed hydraulic system
Incorrectly installed hydraulic systems or use of unsuitable line cross sections and connectors can cause
malfunctions, accidents, and irreversible or even fatal injuries.
1. Wear protective clothing.
2. Note the specied installation method and position of the hydraulic system.
CAUTION
Risk of tripping and falling
Insufficient space for performing the necessary jobs on the hydraulic system increases the risk of
accidents due to tripping or falling.
Provide a ladder or access platform to make sure the workspace can be reached safely.
Ensure there is sufcient space to perform all assembly and installation work.
Do not climb onto the hydraulic system.
CAUTION
Risk of falling from leaking hydraulic uid
Spilled or leaked hydraulic uid can form a slippery lm on the oor.
Use suitable aids when lling or bleeding.
Check all connecting elements that convey oil for leaks before switching on the motor in the parent
system.
Wipe up leaked hydraulic uid with suitable aids.
5.1 Hydraulic connection
DAMAGE
Property damage from incorrectly installed hydraulic system
Assembly by trained specialists only.
Ensure all labels and markings of the hydraulic system are easily visible and legible after assembly.
Check installation space/connection points for damage.
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DAMAGE
Damage from connecting soiled components
Connecting soiled components may cause system failure and irreparable damage.
Clean the workspace before connecting the hydraulic system.
Clean hydraulic components before connecting the hydraulic system.
Only use hydraulic uid of sufcient grade.
Add components which are not in the scope of delivery (e.g. bolts, screws and sleeves for attachment,
hydraulic uid). Use ltered hydraulic uid.
1. Space required for assembly, installation and commissioning: 500x500x500 mm (WxHxD).
2. Place the hydraulic power pack in position in the higher-level machine.
3. Ensure all the fastening bores and hydraulic connections align correctly. Installation space:
400x150x200 mm (WxHxD)
4. Fasten the hydraulic power pack via the 2x M6 fastening bores on the equipment rack.
5. Connect the hydraulics:
Exact connection designation and dimensions in D 6025
Version Q: via the 2x M10x1 threaded connections on the equipment rack
Version H: via the 1xM14x1.5 threaded connection on the equipment rack
6. After a week of operating time at the latest, check the ttings.
5.2 Electrical connection
DANGER
Risk of fatal injury from electric shock
Touching live components directly or indirectly causes injury or death.
Only trained specialist personnel are permitted to replace or connect electronic components.
Obey all applicable electrical safety rules.
Only connect electric lines to the hydraulic system while the system is de-energized.
WARNING
Electrical and magnetic elds
Electrical and magnetic elds impair the functionality of cardiac pacemakers and implanted defibrilla-
tors.
People with pacemakers or implanted defibrillators must maintain a sufcient distance from
magnets.
Advise people with pacemakers or implanted defibrillators against approaching magnets.
Cordon off the area around the drive system and afx suitable warning signs to the barriers.
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DAMAGE
Hazard for electronic components – property damage
Electromagnetic waves lead to malfunctions of electrical or electronic equipment.
To prevent electrostatic discharge, do not touch electronic components and contacts.
After switching off the electrical power supply, wait at least 15 minutes for the energy stored in the
capacitors to dissipate.
Do not expose components to moisture and an aggressive environment.
To avoid overheating, always keep ventilation openings (if any) open and allow sufcient air
circulation.
1. Secure the unit against being switched on unintentionally.
2. Connect the electromagnetic valve(s) to the control system:
■The coil has a socket for 2-pin plugs.
■Use a cable with the matching plug (AMP Superseal 1.5 series).
■Insert the plug on the cable into the socket of the coil and connect the cable to the electric power
supply.
■Any pin assignment is allowed.
3. Connect the temperature sensor. (Temperature sensor only available with motor C2D.)
4. Wire motor M with the machine controls in accordance with the circuit diagram.
5. Connect the hydraulic power pack to the electrical power supply.
6. Check the electrical connection after a week’s operating time.
When connecting the temperature sensor and motor, observe the pin assignment from the
applicable technical data sheet (D 6025).
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6Start-up
WARNING
Danger of crushing/malfunction from unexpected startup
Body parts may be crushed or severed if the system starts up unexpectedly.
Keep the danger zone clear of people.
Wear protective clothing.
CAUTION
Burn hazard from hot surfaces and hydraulic uid
A burn hazard results from directly or indirectly coming into contact with hot hydraulic uid and hot
components of the hydraulic system.
Wear work gloves.
Arrange the access to the hydraulic system in such a way that hot surfaces are not accessible to the
user.
Wait until the hydraulic system has cooled down before servicing or disassembling it.
The pressure-limiting valve has been factory-set to the maximum permissible operating pressure of
the hydraulic power pack and marked with sealing wax. Do not adjust without consulting HAWE.
Only trained specialist personnel may perform commissioning.
Secure the unit against being switched on unintentionally.
1. Check the hydraulic power pack has been connected correctly:
✓hydraulically: fastened tight, no leakage
✓electrically: wiring, power supply, control
✓xed installation: attachment to the machine, in/on the base. Are all markings clearly visible?
2. Check the hydraulic uid level.
3. Switch on the power supply for the control system.
4. Vent the connecting hydraulic lines to the hydraulic power pack. During the venting process, it is not
permitted for anyone to be in the hazardous area. Please refer to the operating instructions of the
machine manufacturer/system operator for the measures and regulations for a safe venting process.
5. Check the hydraulic uid level again after several strokes or after the hydraulic system has been
vented.
6. Check the valve switching and function sequence.
7. After a week of operating time at the latest, check the ttings.
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7Operation
7.1 Switching the hydraulic system on/off
The product is switched on and off via the system control in accordance with the machine
manufacturer’s operating instructions. For this, the commissioning of the product must have been
performed properly.
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8Maintenance
Maintenance measures consist of inspection, service and repair. Maintenance measures are described here.
Maintenance work must only be carried out by qualied personnel.
Tasks not described in this chapter may only be carried out by HAWE Service.
If faults or damage occur, switch off the hydraulic system immediately.
Observe the information in the supplier documentation.
Document all activities in a maintenance log.
WARNING
Danger of accident and fatal injury due to lack of maintenance or careless maintenance
Omitted or negligently performed maintenance can cause the hydraulic system to malfunction.
Improperly performed maintenance or improperly conducted troubleshooting can pose a danger to
personnel.
Read and abide by all instructions provided in this section.
Observe the following safety instructions additionally to the safety instructions in chapter For your
safety.
DANGER
Risk of fatal injury from electric shock
Touching live components directly or indirectly causes injury or death.
Only trained specialist personnel are permitted to replace or connect electronic components.
Obey all applicable electrical safety rules.
Only connect electric lines to the hydraulic system while the system is de-energized.
DANGER
Danger to life from pressurized systems
When lines and components on pressurized systems are disconnected, hydraulic uid escapes at high
pressure and penetrates deep into the body via the skin and eyes. Severe injury or death.
Depressurize the hydraulic system including the pressure tank.
Secure the hydraulic system against unintentional restart.
Check components for correct assembly before pressure is applied.
Observe maximum pressure load for ttings and lines.
WARNING
Danger of accident and fatal injury due to lack of maintenance or careless maintenance
Omitted or negligently performed maintenance can cause the hydraulic system to malfunction.
Improperly performed maintenance or improperly conducted troubleshooting can pose a danger to
personnel.
Read and abide by all instructions provided in this section.
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