HYCON HPP18E FLEX User manual

Prior to Operation
We thank you for choosing a
HYCON powerpack.
Please note that the powerpack
is delivered without hydraulic
oil, and therefore it must e
filled up with hydraulic oil prior
to operation.
To ensure smooth operation
and long-lasting performance of
your new powerpack, we
recommend that you study this
operating manual carefully and
pay special attention to the
Safety and Service
Precautions
We hope you will e satisfied
with your new HYCON power-
pack.
Best regards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk
HPP18E FLEX
Hydraulic Powerpack
From serial No. 4708
Revised
13.04.2011

1
Contents
Page
Safety precautions ............................................................................................ 2
Filling up hydraulic oil ....................................................................................... 2
Technical data .................................................................................................. 3
Electrical Circuit Diagram .................................................................................. 4
Starting instructions ......................................................................................... 5
Service, maintenance and hydraulic settings ...................................................... 6
Oil types .......................................................................................................... 6
EC-Declaration of Conformity ............................................................................ 7
Warranty conditions ......................................................................................... 8
Spare parts list ................................................................................................. 9

2
Safety Precautions
1. Always use protective earplugs even though the powerpack has a low noise
level.
2. Always connect hoses efore starting.
3. Always keep electric ox, ca les and sockets clean.
4. In case of non-operation or performance of service, always turn off the motor.
5. Never start the motor without side covers.
6. Operation of the powerpack without tool connected and with lever at “ON” may
cause overheating of the system and damage to the powerpack.
7. When lifting the powerpack from a vehicle, we recommend the use of a crane.
8. The pressure relief valve is set at 160 ar from our plant. Never set it higher.
9. Always use filters with y-pass. The use of filters without y-pass may low the
hydraulic hoses and the filter cover.
10. Never perform service on the powerpack without disconnecting the power
supply.
Filling p Hydraulic Oil
•For påfyldning af hydraulikolie løsnes
filterlåget øverst på drivstationen
•Herefter tages filterindsatsen ud (se
foto) og der kan nu fyldes olie på.
Når der kan ses olie i unden af filter-
enheden, er der olie nok på.
•Filterindsatsen sættes i igen, låget
monteres, og drivstationen er nu klar
til rug.
Vær opmærksom på, at ved tilko ling af nye
forlængerslanger, vil der skulle påfyldes 2
liter olie mere. Derfor skal drivstationen
efterfyldes, hvis der tilko les nye slanger.
•To fill up with hydraulic oil, loosen the
filter cover on top of the powerpack.
•Remove the filter element (see photo),
and fill up with oil. When oil is showing
at the ottom of the filter unit, there is
enough oil on the powerpack.
•Insert the filter element again, mount
the cover and the powerpack is ready
for use.
Please note: When connecting new extension
hoses, it is necessary to fill up with extra 2 litres of
oil. Therefore always top up the powerpack when
connecting new extension hoses.

3
Technical data
The HYCON HPP18E FLEX open centre powerpack is an advanced hydraulic power
source, which regulates the revolutions of the motor and there y the oil flow
supplied y means of a uilt in frequency converter. The powerpack therefore covers
as much as three EHTMA-categories (C, D and E) with an output of 20, 30 and 40
l.p.m. respectively at 138 ar. The HYCON powerpack is fully compati le with and
sufficient for the common European tools.
The powerpack is mounted with a pressure relief valve to avoid a too high pressure.
Furthermore, the very efficient air cooling protects the powerpack against
overheating.
The frequency converter incorporates a phase inverter, which always ensures correct
motor rotation direction.
Oil flow 20, 30 or 40 l.p.m.
Working pressure nominal 120 ar
Pressure relief valve Set at 160 ar
Pump Gear pump
Oil temperature Max. 70° C
Tank capacity hydraulic oil Min. 8 litres/max. 11 litres
Hydraulic system complete Max. 12 litres
Filter system (filter element) 25 Micron with y-pass
Motor Electric motor
11 kW, 3x400 V
Motor rotation Counterclockwise
(from oil cooler fan side)
Fuse min. 35 Amp.
Protection class IP55
Guaranteed sound power level L
WA
98 dB
Sound pressure level 1 m L
PA
86 dB
Dimensions (LxWxH) 805x625x695 mm
Weight, without hydraulic oil 128 kg

4
Electrical Circuit Diagram
HPP18E FLEX (11 kW) Control Circuit Frequency Converter

5
Starting Instructions
Please o serve the starting instructions on the electric ox.
Start: •
••
• Check hydraulic oil level at sight glass
•Connect hoses and tool
•Press the green utton
•Move the lever to ”ON”
Stop: •
••
• Move the lever to “OFF“
•Press the ”STOP” utton
Oil Flow
Always set the oil flow correctly in accordance with the tool connected. Choose the oil
flow on the step cam switch:
1: 20 l.p.m.
2: 30 l.p.m.
3: 40 l.p.m.

6
Service, Maintenance and Hydraulic Settings
Service/Maintenance Daily Weekly Yearly
Hydraulic oil Check 1 x replacement
Hydraulic oil filter *) 1 x replacement
Check hoses (tighten up if needed)
*) use only filters with y-pass
Hydraulic Settings
Check the working pressure y means of test equipment. The test equipment must
comprise a pressure gauge, a flow meter and a valve for adjustment of pressure.
The pressure relief valve is placed on the valve lock on the right side.
1. Connect the test equipment, start the powerpack and move the lever to “ON”. Then
close the valve on the test equipment - the pressure gauge must show 160 ar.
Adjust the pressure relief valve y loosening the lock nut and turning the
adjustment screw in or out. “In” increases the pressure, and “out” decreases the
pressure.
Retighten the lock nut after adjustment.
2. When the pressure relief valve has een adjusted correctly, the working pressure
must e set at 100 ar y means of the valve on the test equipment. At 100 ar
check that the oil flow is correct according to the technical data.
Oil Types
The HYCON powerpacks use standard hydraulic oil, i.e. all types of mineral oil and
iodegrada le oil, which comply with the following values:
Recommended viscosity
20
-
40 cSt
Permitted viscosity
15
-
1000 cSt
Viscosity index
Min. 100
Temperature area
-
20° to +70° C
If correct pressure/oil flow cannot e achieved y following
the a ove
instructions, the powerpack must e re-adjusted. Is the pressure/oil
flow then still incorrect, the pump is defect and must e replaced.

7
EC-Declaration of Conformity
.
We here y declare that
HPP18E FLEX hydraulic powerpack – from serial No. 4708
(with 11 kW electric motor)
is manufactured in conformity with the EC directives:
2006/42/EC
2000/14/EC
2006/95/EC
Notified body 1585:
AkustikNet A/S
Frederikssundsvej 179 B
DK-2700 Brønshøj
Denmark
Guaranteed sound power level: 98 dB
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Henrik Steen
General Manager
08.03.2006
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www.hycon.dk

8
Warranty Conditions
We grant 12 months warranty from the first date of operation – however, not more
than 18 months from the date of delivery.
The warranty applies to faults that can e related to construction and production errors.
Faults caused y incorrect operation, incorrect handling, lack of maintenance or the like
will not e accepted as warranty.
The warranty covers the parts necessary for repair and the suggested average time
needed for repair.
For further warranty details, please contact your local dealer.