Hytorc HY-Ex Quick guide

Hydraulic unit
HY-Ex
English translation of the original German operating
instructions
for qualified and authorized operating personnel
Status 11/2017
Always store these operating instructions together at the hydraulic unit. Ensure that the operating instructions
are available for the qualified and authorized operating personnel. Read and comply with the operating
instructions.
Non-observance can lead to injury and possibly death.

Publisher
HYTORC Technologies GmbH
Kleinbeckstr. 3–17
45549 Sprockhövel, Germany
Tel.: [phone]
Fax: [phone]
[e-mail]
www.hytorctech.com
Document no.
BA-0038-EN00
Revision no.
0
Document type
Operating instructions
Issue date
11/10/2017
Copyright
© 2017, HYTORC Technologies GmbH
All rights, including those of reprinting and reproduction of any parts of
this document and its translation, are reserved by the publisher.
No part of this document may be reproduced in any form or copied
using electronic reproduction systems without the written consent of
the publisher.
We reserve the right to make technical changes in the course of further
development.

Table of contents
Notes concerning this manual and the manufacturer ............................................6
Keep the manual available .............................................................................................6
Design features of this manual.......................................................................................6
Referenced documents...................................................................................................7
Manufacturer's address ..................................................................................................7
Person responsible for documentation...........................................................................7
Warranty and liability ......................................................................................................8
Safety........................................................................................................................9
ATEX marking.................................................................................................................9
Equipment group (1).............................................................................................9
Equipment category (2)......................................................................................10
Ignition protection type (3)..................................................................................10
Explosion group (4) ............................................................................................10
Temperature class (5) ........................................................................................10
Equipment protection level (6)............................................................................11
ATEX marking of the unit....................................................................................11
Responsibilities of the operating company...................................................................12
Persons at particular risk..............................................................................................12
Qualification of personnel.............................................................................................13
Power supply connection ...................................................................................13
Tool connection ..................................................................................................13
Setting pressure/torque......................................................................................13
Assessing the state of the unit ...........................................................................14
Ban of unauthorized conversions .................................................................................14
Personal protective equipment.....................................................................................15
Basic safety information................................................................................................15
Preventing serious injury or death......................................................................15
Preventing explosion hazards ............................................................................15
Preventing electric shock....................................................................................16
Preventing burns from fire..................................................................................16
Preventing burns from oil and hot surfaces........................................................16
Preventing poisoning..........................................................................................17
Preventing bone fractures and crushing.............................................................17
Preventing eye damage......................................................................................17
Preventing skin irritation.....................................................................................18
Preventing material damage ..............................................................................18
Intended use.................................................................................................................18
Ambient conditions .......................................................................................................18

Design characteristics of warning information..............................................................19
Design of information about property damage .............................................................20
Warning and information signs.....................................................................................21
Description............................................................................................................. 23
Directional data.............................................................................................................23
Overview front right.......................................................................................................24
Overview rear right .......................................................................................................25
Overview of the hydraulic unit with one tool connection...............................................26
Layout...........................................................................................................................26
Display and operating elements ...................................................................................27
Pressure gage....................................................................................................27
Couplings............................................................................................................27
Remote control...................................................................................................28
Torque valve.......................................................................................................29
Type plate.....................................................................................................................29
Available accessories...................................................................................................30
Workspaces and positions............................................................................................30
Purpose and function....................................................................................................31
Unpacking and checking the delivery................................................................... 32
Unpacking.....................................................................................................................32
Checking package and condition..................................................................................32
Storing the unit ...................................................................................................... 33
Moving the unit ...................................................................................................... 34
Commissioning the unit ........................................................................................ 35
Initial commissioning.....................................................................................................35
Daily commissioning.....................................................................................................37
Tool connection..................................................................................................37
Connect mains plug............................................................................................39
Bleeding the screw system (generator, hose, tools) ..........................................40
Check oil level ....................................................................................................40
Checking functioning of the manometer.............................................................41
Performing a test run....................................................................................................41
Operating the unit.................................................................................................. 42
Changing tools..............................................................................................................42
Setting the pressure......................................................................................................46
Performing a screwing process ....................................................................................48
Checking the pressure during operation.......................................................................48

After use .................................................................................................................49
Decommissioning the unit.....................................................................................51
Servicing the unit ...................................................................................................52
Maintenance schedule..................................................................................................52
Changing the hydraulic oil ............................................................................................53
Cleaning the unit ....................................................................................................57
Remedying faults or malfunctions ........................................................................58
Table of faults ...............................................................................................................58
Replacing fuses ............................................................................................................62
Prepare for fuse replacement.............................................................................62
Replace 115 V/230 V fuse..................................................................................63
Replace 400 V fuse............................................................................................64
Disposal..................................................................................................................65
In the USA.....................................................................................................................65
In Europe ......................................................................................................................66
Technical specifications ........................................................................................67

Notes concerning this manual and the
manufacturer
6
Notes concerning this manual and the
manufacturer
These instructions help using the HY-Ex hydraulic unit safely.
The HY-Ex hydraulic unit is hereinafter referred to as "unit".
Keep the manual available
These operating instructions are a part of the unit. Make sure that the
operating instructions are always accessible for the user at the site and are in
legible condition. Enclose the operating instructions when you sell the unit or
transfer it in any other way.
Design features of this manual
Various elements of these operation manual have fixed design characteristics.
These allow you to easily distinguish the following elements:
Normal text
Lists
Action steps
References to headers are set in quotation marks.
‘Labels’ of switches or other elements are set in inverted commas.
Table titles are set in bold.
Tips. Contains additional information.

Notes concerning this manual and the
manufacturer
7
Referenced documents
WARNING
Risk of injury from non-compliance with the applicable
documentation.
Prior to working with the unit, read all applicable
documents and comply with them.
These can be found in the documentation folder of the unit.
More information, instructions and details about the unit components can be
found in the documentation from the respective manufacturers. These
documents are regarded as a part of these instructions. Store these
documents together with this manual. Hand over these documents when
selling the unit or passing it on in other ways.
Applicable documents are especially the following document types:
Operating instructions
Assembly instructions
Maintenance and repair manuals
Circuit diagrams
Terminal layouts
Hydraulic layouts
Safety data sheets
Drawings
Spare parts lists
Declarations of conformity or declarations of incorporation
Please heed and comply with the information from the applicable
documents.
These can be found in the documentation folder of the unit.
Manufacturer's address
HYTORC Technologies
Kleinbeckstr 3–17
45549 Sprockhövel
Germany
Telephone: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.hytorctech.com
Person responsible for documentation
HYTORC Technologies
Michael Westermann
Kleinbeckstr 3–17
D-45549 Sprockhövel
Germany

Notes concerning this manual and the
manufacturer
8
Warranty and liability
In general our General Terms and Conditions apply. Warranty and liability
claims for personal injury or property damage are always excluded if they are
due to one or more of the following causes:
Improper use of the unit
Improper transport, installation, commissioning, operation and maintenance
of the unit
Ignoring the instructions in this manual
Ignoring the hazard notices on the unit
Unauthorized modifications of the unit
Inadequate monitoring of components which are subject to wear.
Incorrectly executed repairs
Disasters caused by outside intervention or an act of God.

Safety
9
Safety
WARNING
Severe injuries or death caused by accidents due to
disregard of the instructions in this guide.
In particular the failure to observe the instructions in the
Chapter on Safety, can lead to accidents.
Read and follow all instructions in this manual before you
begin working with or on the unit.
In addition to the notes in these operating instructions, also follow, in any
case, the statutory and other regulations, e.g.:
Accident prevention regulations
Regulations for safe and professional work
The applicable on-site regulations for explosion protection and fire protection
ATEX marking
The ATEX marking contains notes on the permissible use of the unit in
potentially explosive atmospheres. The following information is displayed:
Equipment group (1)
Equipment category (2)
Ignition protection type (3)
Explosion group according to DIN EN ISO 80079-36: 2016, DIN EN ISO
80079-37: 2016 (4)
Temperature class (5)
Equipment protection level (EPL) (6)
Equipment group (1)
Equipment that is intended for operation in a potentially explosive atmosphere
is classified into two groups. Group I includes equipment that is used in mines
susceptible to firedamp, e.g. in coal mines. The unit belongs to equipment
group II and can therefore be used in all potentially explosive areas except for
mining.

Safety
10
Equipment category (2)
Equipment category II comprises equipment that was designed in such a way
that ensures a high level of safety if the equipment is used as intended with
the prescribed parameters. Equipment of this category can be used in areas
where a potentially explosive atmosphere of gases, vapors, mists or dust/air
mixtures occurs occasionally. This is indicated with the letter G. Equipment of
category III is also included if it is likely that a potentially explosive atmosphere
will only occur rarely or for a short period of time. The unit falls under
equipment category II. Equipment of this category may only be used in zones
1 and 2 and/or zones 21 and 22.
Ignition protection type (3)
The ignition protection type represents the design principle followed in the
unit’s development with regard to explosion protection. The ignition protection
type “h” stands for “constructional safety” of non-electrical equipment.
Constructional safety means that constructional measures have been taken to
reduce hazards caused by ignitable temperatures or sparks to a very low level.
Explosion group (4)
Equipment of group II can also be classified according to the type of
potentially explosive atmosphere where the equipment may be used. The
subgroups IIA, IIB and IIC are used for this purpose. This classification is
based on the maximum experimental safe gap (MESG) and the minimum
ignition current ratio (MICR) of the gas mixture.
Temperature class (5)
Flammable gases and vapors are split into different temperature classes
according to their level of flammability (see table). The maximum surface
temperature of a piece of electrical equipment must always be below the
ignition temperature of the gas, vapor or air mixture where it is used.
Equipment that meets the requirements of a higher temperature class (e. g.
T5) is naturally also permitted for applications that require a lower temperature
class (e. g. T2 or T3).
Temperature -
class
Ignition temperature of gases
and vapors in °C
Maximum surface temperature
of equipment in °C
T1
> 450
450
T2
> 300 to 450
300
T3
> 200 to 300
200
T4
> 135 to 200
135
T5
> 100 to 135
100
T6
> 85 to 100
85

Safety
11
Equipment protection level (6)
The abbreviation “EPL” stands for “equipment protection level”. According to
the 2007 issue of IEC 60079-0, equipment for potentially explosive areas is
classified into three different protection levels:
EPL Ga or Da:
Equipment with a “very high” protection level for use in potentially explosive
areas which do not represent an ignition hazard in normal operation or in the
event of foreseeable or rare faults / malfunctions.
EPL Gb or Db:
Equipment with a “high” protection level for use in potentially explosive areas
which do not represent an ignition hazard in normal operation or in the event
of foreseeable faults / malfunctions.
EPL Gc or Dc:
Equipment with an “increased” protection level for use in potentially
explosive areas which do not represent an ignition hazard in normal
operation and which are provided with several additional protective
measures to prevent the risk of ignition in the event of commonly
foreseeable faults in the equipment.
ATEX marking of the unit
According to DIN EN ISO 80079-36. 2016, Section 11:
EX II 2 G Ex h IIB T3 Gb
This ATEX marking is valid for the following HY-Ex unit types:
115 V:1PH100–115/50 Hz
115 V:1PH100–115/60 Hz
230 V:1PH200–230/50 Hz
230 V:1PH200–230/60 Hz
400 V:3PH380–460/50 Hz
400 V:3PH380–460/60 Hz

Safety
12
Responsibilities of the operating company
The operator must ensure that all accident prevention regulations are
complied with.
The operator must ensure that only qualified and authorized operating
personnel performs work on and with the unit.
Persons at particular risk
The following groups of persons must not be granted access to the unit as
they might sustain serious or lethal injuries:
children
persons with physical or mental limitations
persons under the influence of drugs and medication
persons under the influence of alcohol
unauthorized persons, e. g. pedestrians
People without the qualifications specified in the following section.

Safety
13
Qualification of personnel
These operating instructions are addressed to qualified and authorized
operating personnel.
The following sections list the necessary qualification for each activity on or
with the unit.
Power supply connection
The following skills and experience are required for the operating personnel:
have been taught and trained for the work
know that improper operation, maintenance and repairs can cause accidents
can asses hazards that arise from electrical voltage and power
can asses hazards that arise from noise and heat
can provide the unit's power connection using the provided power cable
can assess hazards that may arise from potentially explosive atmospheres.
Tool connection
The following skills and experience are required for the operating personnel:
have been taught and trained for the work
know that improper operation, maintenance and repairs can cause accidents
can assess risks and environmental damage that could be caused by
hydraulic oil
can assess risks that may arise from the high pressure components
can asses hazards that arise from noise and heat
can detect leaks
can handle screw couplings to connect tools to the unit
can assess hazards that may arise from potentially explosive atmospheres.
Setting pressure/torque
The following skills and experience are required for the operating personnel:
have been taught and trained for the work
know that improper operation, maintenance and repairs can cause accidents
can assess risks that may arise from the high pressure components
can asses hazards that arise from noise and heat
can set a predetermined pressure on the unit

Safety
14
Assessing the state of the unit
The following skills and experience are required for the operating personnel:
have been taught and trained for the work
know that improper operation, maintenance and repairs can cause accidents
can asses hazards that arise from electrical voltage and power
can assess risks and environmental damage that could be caused by
hydraulic oil
can assess risks that may arise from the high pressure components
can asses hazards that arise from noise and heat
can detect errors in the condition of the unit by performing a visual inspection
prior to commissioning
Leaks
Kinks in electric lines
Kinks in hydraulic hoses
External damage to electrical lines
External damage to hydraulic hoses
Incorrect fill level in the unit
Improperly closed cover on the pressure-resistant housing.
can assess hazards that may arise from potentially explosive atmospheres.
Ban of unauthorized conversions
Unauthorized conversions or changes on the unit may lead to serious or even
lethal injuries. This applies in particular to changing and altering safety
devices.
Never bypass or shunt any safety devices.

Safety
15
Personal protective equipment
Feet may be crushed when moving the unit.
Wear safety shoes with steel toe caps.
Slipping and thereby risk of fractures when performing hydraulic work is
possible!
Wear safety shoes with non-slip soles.
Skin irritation and eye damage when in contact with hydraulic oil and hydraulic
components is possible!
Wear oil resistant nitrile gloves and chemical-resistant goggles.
Burns on contact with hot fluids and components are possible!
Wear protective gloves against thermal risks.
Cuts and abrasions of the skin on sharp-edged components are possible!
Wear protective gloves against mechanical risks.
Hearing impairments while unit is running are possible!
In areas with high noise wear hearing protection.
Risk of poisoning possible in poorly ventilated rooms! The unit may overheat.
In this case, oil mist and oil vapors can form.
If this is the case, wear a respirator.
Basic safety information
Preventing serious injury or death
Avoid severe injury or death caused by failure of tools or hoses. Tools or
hoses that do not match the tool and hose specifications may fail.
Only use tools and hoses, which the manufacturer of the unit allows as an
accessory.
Preventing explosion hazards
Connecting tools to or changing tools at the unit in a potentially explosive
atmosphere can lead to serious injury or death.
Only connect tools to the unit in areas where there is no potentially
explosive atmosphere.
Only change tools at the unit in areas where there is no potentially explosive
atmosphere.
Maintaining the unit in a potentially explosive atmosphere can lead to serious
injury or death.
Maintain the unit only in areas where there is no potentially explosive
atmosphere.
Damaged electrical lines in a potentially explosive atmosphere can lead to
serious injury or death.
Use the unit only if all electrical lines are in perfect condition.

Safety
16
Preventing electric shock
Severe injury or death from electrical shock is possible!
Check the electrical supply line for damage.
Use the unit only with immaculate lead.
Immediately have a damaged electrical lead replaced by authorized
personnel.
Make sure that the ground wire connection (green yellow cable) on the unit
is properly designed and properly connected.
Connect the power plug of the unit only to a properly grounded electrical
outlet with the correct electrical voltage and frequency.
Unplug the power cord from the wall outlet before performing any electrical
work on the unit or cleaning the unit. For this, only hold the plug.
Only dry clean the unit. Do not clean the unit with a pressure washer, cold
cleaner or water.
Never immerse the unit in water or other liquids.
Preventing burns from fire
A short circuit could cause a fire and cause severe burns.
When not in use and before any maintenance work pull the mains plug from
the wall outlet. For this, only hold the plug.
Remove all unneeded and flammable materials from the work area.
Make sure that a fire extinguisher with powder or foam extinguishing agent
is available.
Preventing burns from oil and hot surfaces
During and after operation, burns on metallic surfaces or from hydraulic oil are
possible.
When working on or with the unit wear protective gloves against thermal
risks.

Safety
17
Preventing poisoning
The unit may overheat. In this case, oil mist and oil vapors can form.
Make sure there is sufficient ventilation.
In poorly ventilated areas and upon formation of oil mist and oil vapors,
wear a respirator.
Switch the unit off when it overheats.
Allow the unit to cool down.
With the help of a non-contact infrared thermometer, ensure that the unit is
cooled down to 25 °C (77 °F).
Check the unit for possible damage.
Have the unit repaired, if damaged, by qualified personnel before
recommissioning.
When fluids leak, proceed as follows:
Wear temperature- and media-resistant gloves.
Take up liquid spills immediately with a suitable binding agent and a rag.
Dispose of the binding agent and rag environmentally correct.
Preventing bone fractures and crushing
Bone fractures and crushing possible. An unstable set-up can lead to the unit
toppling over.
Risk of slipping on leaked liquids and therefore of bone fractures!
Never reach into moving parts.
Always set up the unit on a flat, solid and stable base.
Secure the unit and tools against falling.
Secure the unit against unintended movement on site by locking the rollers.
Wear safety shoes with steel toe caps when moving the unit.
Wear safety shoes with non-slip soles when working on hydraulics.
Clean up liquid spillages.
Preventing eye damage
At pressures of more than 700 bar (10,000 psi) and operating the unit outside
of the tool and tubing specifications can lead to bursting of the hydraulic hoses
and spraying of hydraulic oil.
Make sure that the permissible pressure defined by the manufacturer is not
exceeded.
Observe the tool and hose manufacturer's specifications.
Observe and follow the operating instructions of the tools and hose
specifications.
Wear chemical-resistant goggles.

Safety
18
Preventing skin irritation
Contact with hydraulic oil may cause skin irritation.
Always provide a strong and tight connection between the unit and hydraulic
tools.
Wear nitrile gloves at work where you might come in contact with hydraulic
oil.
Make sure that the permissible pressure defined by the manufacturer is not
exceeded.
Observe the tool and hose manufacturer's specifications.
Observe and follow the operating instructions for the hydraulic tool.
Preventing material damage
Avoid soiling the couplings by installing the protective caps and protective
plugs when the couplings are not in use.
Always set the hydraulic tool down safely.
Intended use
The unit is used exclusively for driving hydraulic assembly tools for screws and
nuts in the commercial sector. With the screwing assembly tool, screw
connections can be loosened or tightened with a predetermined torque.
Intended use also includes observing and following all instructions in this
manual, especially the safety instructions. Any other use is considered to be
improper and will void the warranty and liability claims.
The unit may be used with a connected screwing tool in potentially explosive
areas in accordance with its marking. The screwing tool and the hoses used
must be approved for use in potentially explosive areas by the manufacturer.
Ambient conditions
Make sure that the unit is used under the following environmental conditions:
Temperature range: –20 °C to +40 °C (–4 °F to 104 °F)
Humidity non-condensing
Make sure that the unit is stored and transported under the following
environmental conditions:
Temperature range: -30 °C to +60 °C (-22 °F to 140 °F)
Humidity non-condensing

Safety
19
Design characteristics of warning information
DANGER
Sections with the word DANGER warn of imminent
dangerous situations that lead to death or serious injury.
WARNING
Sections with the word WARNING warn of imminent
dangerous situations that may lead to death or serious injury.
CAUTION
Sections with the word CAUTION warn of dangerous
situations that may lead to minor or moderate injuries.
Special symbols may be used in the warnings, in addition to the general
danger signs. These symbols indicate the possible danger. The meanings of
the individual symbols are found in the following section.

Safety
20
Explanation of symbols
Hazard from electric shock
Slipping hazard from leaked media
Burning hazard, scalding hazard
Risk of explosion in potentially explosive areas
Risk of eye damage due to splashing liquid
Risk of explosion and explosive media discharge
Design of information about property damage
ATTENTION!
These notes warn of situations that can lead to property
damage and limited functionality.