HYCON HPP18E FLEX User manual

HPP18E
Hydraulic
Powerpack
30 l.p.m. from serial No. 4727
40 l.p.m. from serial No. 4676
Revised 13.04.2011
Prior to
Operation
We thank you for choosin a
HYCON powerpack.
Please note that the power-
pack is delivered without hy-
draulic oil, and therefore it
must be filled up with hydrau-
lic oil prior to operation.
To ensure smooth operation
and lon -lastin performance
of your new powerpack, we
recommend that you study
this operatin 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 re ards
HYCON A/S
HYCON A/S
Juelstrupparken 11
DK-9530 Støvring
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]k
www.hycon.dk

1
Contents
Page
Safety precautions ................................................................................................ 2
Fillin up hydraulic oil ........................................................................................... 2
Technical data ...................................................................................................... 3
Electrical circuit dia rams...................................................................................... 4
Startin instructions ............................................................................................. 6
Service, maintenance and hydraulic settin s .......................................................... 8
Oil types .............................................................................................................. 8
EC-Declaration of Conformity ................................................................................ 9
Warranty conditions ............................................................................................10
Spare parts list ....................................................................................................11

2
Safety Precautions
1. Always use protective earplu s. The powerpack complies with the EC noise limits,
but by daily lon -lastin operation there is a risk of hearin defects.
2. Always connect hoses before startin .
3. Always keep the electrical box, cables and sockets clean.
4. In case of non-operation or performance of service, always turn off the motor.
5. Never start the en ine without side covers.
6. Operation of the powerpack without tool connected and with lever at “ON” may
cause overheatin of the system and dama e to the powerpack.
7. When liftin the powerpack from a vehicle, we recommend the use of a crane.
8. The pressure relief valve is set at 160 bar from our plant. Never set it hi her.
9. Always use filters with by-pass. The use of filters without by-pass may blow the
hydraulic hoses and the filter cover.
Filling Up Hydraulic Oil
•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 showin
at the bottom of the filter unit, there is
enou h oil on the powerpack.
•Insert the filter element a ain, mount
the cover and the powerpack is ready
for use.
Please note: When connectin new extension
hoses, it is necessary to fill up with extra 2 litres of
oil. Therefore always top up the powerpack when
connectin new extension hoses.

3
Tec nical Data
Hydraulics
The HYCON HPP18E open centre hydraulic powerpack is desi ned in accordance with
the EHTMA cate ories D and E, which prescribe a performance of minimum 30 l.p.m.
or 40 l.p.m. at 138 bar. The HYCON powerpack is fully compatible with and sufficient
for the common European tools.
The powerpack is mounted with a pressure relief valve to avoid a too hi h pressure.
Furthermore, the very efficient air coolin protects the powerpack a ainst over-
heatin .
Oil flow 30 l.p.m. or 40 l.p.m.
Working pressure nominal 120 bar
Pressure relief valve Set at 160 bar
Pump Gear pump
Oil temperature Max. 70° C
Hydraulic oil tank capacity Min. 8 litres/max. 11 litres
Hydraulic system compl. Max. 12 litres
Filter system (filter element) 25 Micron with by-pass
Motor Electric motor
11 kW, 3x400 V, 50 Hz
2900 r.p.m.
Motor Rotation Counterclockwise
(from oil cooler fan side)
Fuse min. 25 Amp. at 30 l.p.m.
35 Amp. at 40 l.p.m.
Protection class IP55
Guaranteed sound power level L
WA
98 dB
Sound pressure level 1 m L
PA
86 dB
Dimensions (LxWxH) 805x625x695 mm
Weig t, wit out ydraulic oil 128 k

4
Electric Circuit Diagram - Components

5
Electric Circuit Diagram

6
Starting Instructions
Please observe the startin instructions on the electric box.
Start: •
••
• Check hydraulic oil level at si ht lass
•Connect hoses and tool
•Press the reen button
•If the powerpack does not start, invert the phases in the socket by
means of a screw driver
•Move the lever to “ON”
Stop: •
••
• Move the lever to “OFF“
•Press the “STOP” button
The powerpack is not equipped with a
phase inverter. If the motor does NOT start,
the phases must be inverted in the socket.
Also see above under “Start”.
Motor Rotation: Counterclockwise (from oil cooler fan side)

7
S ort Circuit
If the motor stops due to a short circuit (water), malfunctionin etc., the fuse in the
relay mi ht need to be reset.
1. Open the electrical box
2. Open the clear doors on the relays (Q34 and Q35)
3. Push the blue fuses to reset the relays (see picture)

8
Service, Maintenance and Hydraulic Settings
Service/Maintenance Daily Weekly Yearly
Hydraulic oil Check 1 x replacement
Hydraulic oil filter *) 1 x replacement
Check hoses (ti hten up if needed)
*) Use only filters with by-pass
Hydraulic Settings
Check the workin pressure by means of test equipment. The test equipment must
comprise a pressure au e, a flow meter and a valve for adjustment of pressure.
The pressure relief valve is placed on the valve block on the ri ht 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 au e must show 160
bar.
Adjust the pressure relief valve by loosenin the lock nut and turnin the
adjustment screw in or out. “In” increases the pressure, and “out” decreases the
pressure.
Reti hten the lock nut after adjustment.
2. When the pressure relief valve has been adjusted correctly, the workin pressure
must be set at 100 bar by means of the valve on the test equipment. At 100 bar
check that the oil flow is correct accordin to the technical data.
Oil Types
The HYCON powerpack uses standard hydraulic oil, i.e. all types of mineral oil and
biode radable oil, which comply with the followin values:
Recommended viscosity
20
-
40 cSt
Permitted viscosity
15
-
1000 cSt
Viscosity i
ndex
Min.
100
Temperatur
e area
-
20°
to
+70° C
If correct pressu
re/oil flow cannot be achieved by followin
the above
instructions, the powerpack must be re-adjusted. If the pressure/oil flow is
then still incorrect, the pump is defect and must be replaced.

9
EC-Declaration of Conformity
We hereby declare that
HPP18E ydraulic powerpack 30 l.p.m. from serial No. 4727
(with 11 kW electric motor) 40 l.p.m. from serial No. 4676
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 Støvrin
Denmark
Henrik Steen
General Mana er
15.05.2003
HYCON A/S
Juelstrupparken 11
DK-9530 Støvrin
Denmark
Tel: [phone]
Fax: [phone]
Mail [email protected]
www. ycon.dk

10
Warranty Conditions
We rant 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 handlin , lack of maintenance or the
like will not be accepted as warranty.
The warranty covers the parts necessary for repair and the su ested avera e time
needed for repair.
For further warranty details, please contact your local dealer.