HYCON HPP18E FLEX User manual

Operating Manual
Prior to Operation
We thank you for choosing a
HYCON power pack.
Please note that the power
pack is delivered without hy-
draulic oil. Therefore it must be
filled with hydraulic oil prior to
operation.
To ensure smooth operation
and long-lasting performance of
your new power pack, we
recommend that you study this
operating manual carefully and
pay special attention to the
Safety and Service
Precautions
We hope you will be 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]
www.hycon.dk
HPP18E FLEX
Hydraulic Power pack
From serial No. 12924
Revised
08.11.2018

1
Contents
Contents .......................................................................................................................1
Safety Precautions .........................................................................................................2
Filling of Hydraulic Oil.....................................................................................................3
Technical data ............................................................................................................... 4
Electrical Circuit Diagram ................................................................................................5
Starting Instructions....................................................................................................... 6
Service, Maintenance and Hydraulic Settings ....................................................................7
Oil Types.......................................................................................................................7
EC-Declaration of Conformity.........................................................................................8
Warranty Terms............................................................................................................. 9

2
DANGER: The power pack must only be connected to an electrical power source
with the correct fuse and fault current protection.
If this is not observed, there is a risk of major personal injury or, in extreme
consequence, death due to electric shock.
IMPORTANT: All national laws and rules must be followed at any time
WARNING: The electrical motor is not approved by a US National Recognized
Test Laboratory.
Safety Precautions
1. Always use ear protection, though power pack has a low noise level.
2. Always connect hoses before starting.
3. Always keep electric box, cables and sockets clean.
4. Always turn of the motor and disconnect the power supply when the power pack not
used and before performing any service.
5. Never start the motor without side covers and the safety guard.
6. Operation of the power pack without tool connected and with lever at “ON” may cause
overheating of the system and damage to the power pack.
7. It is recommended to use a crane when lifting the power pack.
8. The pressure relief valve is set at 160 bar / 2320 psi from the HYCON plant. Never set it
higher.
9. Always use original HYCON filters with by-pass. The use of filters without by-pass may
blow the hydraulic hoses and the filter cover.
IMPORTANT: Read and follow this operating manual carefully to avoid personal
injury and damage to the power pack.

3
Filling of Hydraulic Oil
To fill up with hydraulic oil, loosen the filter
cover on top of the power pack.
Remove the filter element (see photo), and
fill up with oil. When oil is showing at the
bottom of the filter unit, there is enough oil
on the power pack.
Insert the filter element again, mount the
cover and the power pack is ready for use.
IMPORTANT: When connecting new extension hoses, it is necessary to fill up with
extra 2 liters / 0.53 gallons of oil. Therefore always top up the power pack when
connecting new extension hoses.

4
Technical data
The HYCON HPP18E FLEX open center power pack is an advanced hydraulic power source,
which regulates the revolutions of the motor and thereby the oil flow supplied by means of a
built in frequency converter.
The power pack covers four different flow outputs of 20, 30, 40 and 46 LPM / 5, 8, 10 and
12 GPM respectively at 120 bar / 1740 psi. This HYCON power pack is fully compatible with
and sufficient for the common European and North American tools.
A pressure relief valve are used to avoid a too high pressure of the power pack. The very
efficient air cooling protects the power pack against overheating.
HPP18E FLEX
Oil Flow
LPM / GPM
20, 30, 40, 46 / 5, 8, 10, 12
Oil Flow EU
LPM / GPM
20, 30, 40 / 5, 8, 10
Working Pressure nominal
bar / psi
120 / 1740
Pressure relief valve
bar / psi
160 / 2320
Pump
14cc gear pump
Oil temperature
°C / °F
Max. 70 /158
Tank capacity hydraulic oil
liters / gallons
Min. 8 / 2.1
Max. 11 / 2.9
Hydraulic system complete
liters / gallons
Max. 12 / 3.2
Filter system
25 micron with oil by-pass
Electrical Motor
11 kW, 3x400 V / 13.2 kW
3x480V
Motor rotation
CW, seen from rear end
Fuse min.
Amp.
See table below
Protection class
IP 55
Guaranteed sound power level LWA
dB
98
Sound pressure level 1m LPA
dB
86
Dimensions (LxWxH)
mm / inch
805x625x704 / 31.7x24.6x27.7
Dry weight
kg / lbs
135 / 300
Important: Power packs with 46 LPM / 12 GPM option are not CE approved.
Maximum power consumption of the power pack is given at the respective flow options of
the power pack at maximum pressure 160 bar / 2320 psi.
400V, 50Hz
Flow
20 LPM / 5 GPM
30 LPM / 8 GPM
40 LPM / 10 GPM
46 LPM / 12 GPM
Current
10 A
15 A
20 A
24 A
480V, 60Hz
Current
9 A
13 A
17 A
21 A

5
Electrical Circuit Diagram

6
Starting Instructions
WARNING: Before start up, ensure all conditions under Safety precautions are full
filled.
Please observe the starting instructions on the frequency converter box.
Start: Check hydraulic oil level at sight glass
Connect hoses and tool
Turn the “0 / 1”cam switch to “1”
Move the lever to “ON”
Stop: Move the lever to “OFF”
Turn the “0 / 1” cam switch to “0”
Oil Flow
Always set the oil flow correctly in accordance with the tool connected. Choose the oil flow on
the four step cam switch:
1: 20 LPM / 5 GPM
2: 30 LPM / 8 GPM
3: 40 LPM / 10 GPM
4: 46 LPM / 12 GPM (N/A for CE approved power packs)

7
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 if needed)
Hydraulic Settings
Check the working pressure by 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 block on the right side.
1. Connect the test equipment, start the power pack and move the lever to “ON”. Then
close the valve on the test equipment - the pressure gauge must show 160 bar / 2320
psi.
Adjust the pressure relief valve by 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 been adjusted correctly, the working pressure must
be set at 100 bar / 1450 psi by means of the valve on the test equipment. At 100 bar /
1450 psi check that the oil flow is correct according to the technical data.
IMPORTANT: If correct pressure/oil flow cannot be achieved by following the
instructions above, the power pack must be re-adjusted. Is the pressure/oil flow
then still incorrect, the pump might be defect and a replacement is necessary.
Oil Types
The HYCON power packs use standard hydraulic oil, i.e. all types of mineral oil and
biodegradable oil, which comply with the following values:
Ambient temperature range
Below 10°C
50°F
10 … 30°C
50 … 86°F
Above 30°C
86°F
Recommended oil viscosity grade
VG 32
VG 46
VG 68
Recommended oil cleanliness
ISO 4406 /19/16 / NAS 1638 10
Permitted viscosity
cSt
10 –600
Viscosity index
Minimum
100
Oil temperature area
°C /°F
-20 to 70 / -4 to 158

8
EC-Declaration of Conformity
We hereby declare that
HPP18E FLEX hydraulic power pack –from serial No. 12924
-with 11 kW electrical motor
is manufactured in conformity with the EC directives:
Machine Directive - 2006/42/EC
Noise Emission Directive - 2000/14/EC
Notified body 1585:
AkustikNet A/S
Frederikssundsvej 179 B
DK-2700 Brønshøj
Denmark
Guaranteed sound power level: LWA 98 dB
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Martin Møller
Managing Director
18.05.2018
) Note that only the HPP18E FLEX EU model with maximum 40 LPM / 10 GPM is embraced by this conformity.
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail: [email protected]
www.hycon.dk

9
Warranty Terms
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 be related to construction and production errors.
Faults caused by incorrect operation, incorrect handling, lack of maintenance or the like will not
be 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.