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High PressurePower Unit HP

up to 500 barup to 5.25 l/min

suitable for:short--term operation S 2intermittent operation S 3

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1. DESCRIPTION1.1. GENERAL

HYDAC high pressure powerunits, type HP, are highperformance hydraulic units ofcompact construction.They are used to supply oil tohydraulic systems. The flow ofthe operating fluid is controlled byan extensive range of build--oncontrols.The special design and the use ofa noise--damping cast--ironhousing result in a particularly lownoise level.

1.2. FUNCTIONThree valve--controlled radialpiston pump elements areoperated, independent of thedirection of rotation, by a cam,which is driven by anoil--immersed motor.The HP power unit owes itsspecial stability to the steel oiltank.The four fixing holes in the footbracket make for cost--saving,simple installation. The terminalbox in the cover plate (HP 1 andHP 2) simplifies the electricalinstallation.HP type units must only be usedfor short--term or intermittentoperation because of theircompact design, and the highspecific performance due to thethermal load.The switch--on time, dependenton the output and the operatingand ambient conditions, must beselected to ensure that the max.permissible operatingtemperature (oil temperature inthe unit) of 80 5C is notexceeded.A temperature switch can besupplied for independentmonitoring of the operatingtemperature.

1.3. APPLICATIONSHP type units are particularlysuitable for:

• tensioning, clamping, releasing,indexing on machine tools,presses and jigs

• operating lifting and swiveldevices

• dock levellers and vehicle lifts• auxiliary and off--line drives• hydraulic tools as a drive unit• pressure controls• industrial and mobile brakingsystems

• cutting and shearing operations• weight compensation• valve drivesNot suitable for long--termoperation!

Note!�� do not use unit in applications forwhich it is not intended

�� unit produces high pressure�� do not exceed max. permissiblepressure

�� tank can become hot duringoperation -- risk of injury

2. TECHNICALSPECIFICATIONS

2.1. GENERAL2.1.1. Designation and symbol

Electro--hydraulic power unit

2.1.2. Type of constructionValve--controlled hydraulic pump,radial piston type, with a constantdisplacement volume, driven byan oil--immersed electric motor.

2.1.3. Type of mountingMounting holes on the footbracket for 4 screwsM 6 ... HP 0M 8 ... HP 1, HP 2

or use flexible mounting elements.Also see point 2.1.15.

Required surface finishof the mounting area:

2.1.4. Weights (dry units)HP 0 7.2 kg. . . .HP 1 . 16.5 kg. . .HP 1 H 18.3 kg. . . .HP 2 21.5 kg. . . .HP 2 H. 25.7 kg. . .

2.1.5. Ambient temperature-- 20 °C to + 40 °C

2.1.6. Direction of rotation (motor)Optional

2.1.7. Mounting positionVertical, air breather and terminalbox on the top.

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CONSTRUCTION OF THE HP POWER UNIT

Connection flangefor build--on controls

Pump bearingfriction bearinglow--noise

Unit flangespherical cast ironinherently stablenoise--dampingthrough bores for simple mounting

Triple cylinder radial piston pumpvalve--controlledindependent of direction of rotationfor high pressurenarrow flow rate gradation

Oil--immersedmotorsquirrel--cage motorlow--noiseoil--cooled

Tankinherently stablevarious tank sizessteel

Air breatherwith dipstickoptionally BF 4 --10 μm

HP 0with approx. 3 mflying leads, incl.tension--free PGgland

HP 1, HP 2built--in terminal boxwith terminal stripfor motor andtemperature switch

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Build--on control Suppl.details

High pressure power unit

SizeFor selection criteria see point 2.1.9. and 2.1.11.012

Tank sizeno details ... standard tankH ... tall tankfor usable volume see point 2.1.11.

Fluid level gaugeno details ... no fluid level gaugeF ... FSA0 ... FSK, N/C contact00 ... FSK, 2 off, at different heights

(HP 1, HP 2)(see point 2.1.11. and 2.1.12.)

Electrical connection for FSKno details ... small connector (standard)Z5L ... large connector with light

Flow rate codesee point 2.1.9.

Motor codesee point 2.1.10.

Modification number

Air breatherno details ... standard air breather1 ... BF4, filtration rating 10 μm (see point 2.1.13.)

Temperature switchno details ... no temperature switchTS ... temperature switch, actuating temperature

80 °C ±2.5 K (see point 2.1.14.)

Carrying handleno details ... no carrying handleT ... carrying handle (see point 4.)

Additional units(see point 3.1.)no details ... no additional units

Build--on control(see point 5.)

Nominal voltage for actuating solenoid(only for build--on control)G 24 ... 24 V DCW 230 ... 230 V 50/60 Hz ACother voltages on request

Electrical connection for actuating solenoidno details ... socket to DIN 43650 without connectorZ4 ... connector to DIN 43650--AF2--PG11Z5L ... large connector with lightFor AC voltage the connector is supplied with a bridge rectifier insert.

Emergency manual override on directional seat valves(see point 6.2.)no details ... no emergency manual overrideN ... pin type operationNG ... thumb pressure operation

for symbols V, W, Y, YR, only

Supplementary detailsPlease quote supplementary details in full

2.1.8. Model code(also order example)

HP 1 H F Z5L -- 0.82 -- 05 -- X 1 TS T + . . . . . . + . . . . +G24 -- Z4 --N + . . . . . . .

Power unit Addit.units

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2.1.9. Flow rate code table

Three phase (3~) motor Single phase motor (1~)Flow ratecode

Nom.press.

Motor outputP (kW)

Nom.press.

Motor outputP (kW)

50 Hz 60 Hz (bar) 50 Hz 60 Hz (bar) 50 Hz 60 Hz0.30 0.36 500 0.28 0.33 500 0.24 0.280.52 0.62 390 0.28 0.33 330 0.24 0.280.82 0.95 240 0.28 0.33 210 0.24 0.281.05 -- 230 0.33 -- 200 0.28 --

HP 0 1.25 1.50 160 0.28 0.33 135 0.24 0.28HP 01.65 -- 150 0.33 -- 125 0.28 --1.70 1.95 120 0.28 0.33 100 0.24 0.282.50 -- 100 0.33 -- 80 0.28 --3.35 -- 75 0.33 -- 60 0.28 --0.49 0.60 500 0.7 0.8 500 0.6 0.70.82 1.00 500 0.7 0.8 450 0.6 0.71.00 1.20 500 1.05 1.2 500 0.9 1.051.25 1.50 380 0.7 0.8 300 0.6 0.7

HP 11.70 -- 420 1.05 -- 350 0.9 --

HP 11.95 2.40 250 0.7 0.8 190 0.6 0.72.55 -- 270 1.05 -- 220 0.9 --2.60 3.15 180 0.7 0.8 130 0.6 0.74.00 -- 170 1.05 -- 140 0.9 --5.25 -- 120 1.05 -- 100 0.9 --0.49 0.60 500 0.95 1.1 500 0.95 1.10.82 1.00 500 0.95 1.1 500 0.95 1.11.00 1.20 500 1.60 1.85 500 1.40 1.61.25 1.50 450 0.95 1.1 450 0.95 1.1

HP 21.70 -- 500 1.60 -- 500 1.40 --

HP 21.95 2.40 350 0.95 1.1 300 0.95 1.12.55 -- 450 1.60 -- 340 1.40 --2.60 3.15 250 0.95 1.1 230 0.95 1.14.00 -- 300 1.60 -- 220 1.40 --5.25 -- 200 1.60 -- 150 1.40 --

2.1.10. Motor code table

HP 0 HP1/HP205...3--phase 400 V -- 50 Hz 230/400 V -- 50 Hz06...3--phase 415 V -- 50 Hz 240/415 V -- 50 Hz08...3--phase 500 V -- 50 Hz 290/500 V -- 50 Hz09...3--phase 660 V -- 50 Hz 380/660 V -- 50 Hz34...3--phase 400 V -- 60 Hz 230/400 V -- 60 Hz36...3--phase 460 V -- 60 Hz 266/460 V -- 60 Hz

HP 0 / HP 1 / HP 261...single phase 230 V -- 50 Hz62...single phase 240 V -- 50 Hz80...single phase 115 V -- 60 Hz

Filling Usable volume (l)volume (l) Vmax V1 V2

HP 0 1.1 0.7 -- --HP 1 2.4 1.6 1.15 1.3HP 1 H 4.0 3.2 2.75 2.9HP 2 4.0 2.8 2.0 2.2HP 2 H 7.0 5.8 4.6 4.7

Note! The nominal pressure of the build--on control must betaken into account.The flow rate code is approximately equivalent to the flowrate (l/min) at nominal rpm.At nominal pressure the flow rate is 0.8 to 0.92 x flow ratecode.Model recommended due to its particularly low noise level.

2.1.11. Oil volume (l)

Approximate values, component--relateddeviations are possible.

S1: early warning point(on model 00 = 2 x FSK)

S2: min. switching point

max. filling heightfor given filling volume

switching

point

switching

point

Fluid level gauge F/0/00

Fluid level gauge 00

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2.1.12. Fluid level gaugeFSA ...visual fluid level gaugeFSK ...visual fluid level gaugewith additional electrical contactbefore the minimum fluid level isreached

Electrical function FSK

0 = N/C contact

Contact load: max. 8 WSwitching voltage:max. 50 V AC/DCSwitching current: max. 0.2 ATerminal 3 not connectedElectrical connection:small connector (standard)Z5L ... large connector with light(24--50 V AC/DC)

2.1.13.Air breather BF4Filtration rating 10 μm,without dipstick,for use in highly contaminatedenvironments.

2.1.14.Temperature switch TSTo protect the unit fromoverheating.Actuating temperature:80 °C ±2.5 KSwitch--back hysteresis:approx. 10 K -- 30 KNominal voltage:AC max. 250 VDC max. 60 VCurrent capacity with AC:1.6 A at cos ϕ = 0.62.5 A at cos ϕ = 1.0DC:60 V = 1.0 A42 V = 1.2 A6/12/24 V = 1.5 AType of contact: N/CConnection: terminal in terminalbox (HP1 and HP2), flying leads,approx. 400 mm long (HP0)

2.1.15.Noise generationDue to their design, HP powerunits are extremely quiet. Thenoise generation is determinedmainly by the installation site andthe type of mounting. Werecommend that the unit ismounted on vibration mounts andthat pressure hoses are used.Noise levels:44--70 dBA for those units in table2.1.9. which are designated asbeing especially low--noise.Max. 80 dBA for all other units.

2.2. HYDRAULIC DETAILS2.2.1. Nominal pressure

pN = 500 bar max.see point 2.1.9.When using build--on controls,the nominal pressure of theseunits must be taken into account.

2.2.2. Flow rateQ = 0.30 to 5.25 l/minsee point 2.1.9.

2.2.3. Operating fluidHydraulic oil to DIN 51524 part 2

2.2.4. Fluid temperature rangeMin. -- 20 °CMax. + 80 °C

2.2.5. Viscosity rangeMin. 10 mm2/sMax. 380 mm2/sOptimum viscosity range 12 to200 mm2/s.Max. initial viscosity 800 mm2/s

2.2.6. FiltrationMax. permissible contaminationlevel of the operating fluid

�� At operating pressure up to350 barto NAS 1638, class 10.We recommend a filter with aminimum retention rate ofb20 ≥100.

�� At operating pressure up to500 barto NAS 1638, class 9.We recommend a filter with aminimum retention rate ofb10 ≥100.The fitting of filters and regularreplacement of elementsguarantees correct functioning,reduces wear and tear andincreases the service life.Only filtered oil must be used!Filtration and filling can be carriedout simply and quickly in oneoperation using a filtration unit,the OF type for example. If theunit is used in a highlycontaminated environment, theuse of an air breather, type BF 4,is recommended.

2.3. ELECTRICAL DETAILS2.3.1. Type of construction

Three--phase squirrel--cage motoror single phase motor (suppliedwith continuous operationcondenser), oil--cooled.

2.3.2. Nominal voltage3 � 230 / 400 V -- 50 HzStandard modelother voltages available onrequest (see point 2.1.10.)

2.3.3. Type of operationShort--term operation S 2Intermittent operation S 3to VDE 0530The switch--on time, dependenton the output, the operating andambient conditions, must beselected to ensure that themaximum permissible operatingtemperature (that of the oil in theunit) of 80 °C is not exceeded.If necessary, fit a temperatureswitch (see point 2.1.14.)

2.3.4. Safety typeDIN 40050 -- IP 54 for acompletely assembled unit withcorrect electrical connection.

2.3.5. Type of connectionHP 1 / HP 2 ...Terminal box with terminal stripHP 0 ...approx. 3 m long flying leads

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3. ADDITIONAL UNITS3.1. RETURN LINE FILTER MODULE

HP power unit

filter module

clogging indicator

reference axis ”Z”build--on control

build--oncontrol

Return line filter module betweenHP power unit and build--oncontrol including check valve(prevents the tank from emptyingwhen the filter element ischanged).

Filter moduleFilter in the T lineBypass valve RVno details no bypass. . .R with bypass valve. .

po = 4.5 barFiltration rating20 20 mm (standard). . .10 10 mm. . .5 5 mm. . .Clogging indicatorB visual indicatorC electrical indicatorD 24 comb. vis./elec. indicatorD 24 ( 15 -- 30 V DC/AC)D 48 ( 30 -- 60 V DC/AC)D 110 (100 -- 130 V DC/AC)D 230 (150 -- 230 V DC/AC)For further details, see the CloggingIndicators for Filters brochure,no. E 7.050Modification number

Model codeF T R 20 B . X

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Type A B C D E F G H h

HP 1 164 125 85 40 107 115 143 315 281

HP 2 190 156 98 50 117 125 153 350 316

HP 1 H 164 125 85 40 107 115 143 424 390

HP 2 H 190 156 98 50 117 125 153 484 450

E...clearance for FSAF... clearance for FSK, small connectorG...clearance for FSK, Z5L -- large connector with lamp

All measurements in mm. For dimensions of build--on controls, see point 5.

2.1.8. Typenschlüssel(gleichzeitig Bestellbeispiel)

4. DIMENSIONSPower unitThe axes X, Y and Z are reference axes for calculating the installation dimensions when adding modulesas per point 5. (Build--on controls).

HP 0 HP 1/HP 2

referenceaxis”X”

referenceaxis”X”

reference axis ”Y”

reference axis ”Z” reference axis ”Z”

oil drain plug G 3/8

terminal boxwith terminal strip

reference axis ”Y”

interface for control block

oil drain plug G 1/4

FSA orFSK

air breather BF 4

carryinghandle

M20x1.5

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5. BUILD--ON CONTROLS5.1. OVERVIEW

Build--on controls and high pressure power units, type HP, combine to make a unit ready for installation.The build--on controls can be arranged to suit individual applications.Three types of build--on control systems are available.

Build--on modules

(see point 5.2.)

Build--on control moduleBuild--on modules are flangeddirectly onto the connectionflange of the HP unit. Theyconsist of various different typesof valves as well as allconnections necessary foroperation.

Modular valve stacking system(see brochure no. E5.304.)

Valve stacking system LModules with directional seatvalves, pressure and checkvalves as well as pressureswitches can be combined on abase module in any order,depending on the control task.It is always finished off with anend module.For model codes and dimensions,see brochure no. E5.304.”Valve stacking system L”.

Valve stacking modules forvalves with A6 interface toDIN 24340 (see point 5.3.)

Valve stacking modules CLUp to six horizontal stackingmodules can be mounted onto abase module. A vertical stackingsystem consisting of directionalvalves or sandwich plate valveswith A6 interface to DIN 24340 isfitted onto the valve stackingmodules. It is always finished offwith an end module.

Note:Build--on module controls and modules of control types L and CL cannot be combined.

Special controls:For control tasks which cannot be solved with standard controls, special control blocks can be fitted to the unitaccording to customers’ specifications.

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5.2. BUILD--ON MODULESPorts P, T, M, A...G 1/4

Designation and symbol Dimensions Model code

Connecting moduleInline mounting

Base module

Lift/lower module

Installation dimension Z: 25 max.

Installation dimension Z: 30 max.

Installation dimension Z: 43 max.

Type

PN = 500 bar

G 1/4

TypeGD no check valve RVGRD with check valve RV

Pressure relief valve DBPressure rangeand type of adjustmentsee point 6.4.

PN = 500 bar

GRD 350 M

Type

Directionalseat valve SVpossible symbolsV, W, Y, Zsee point 6.5.

Pressurerelief valve DBPressure rangeand type of adjustmentsee point 6.4.

see point 2.1.8.(build--on control)

PN = 350 bar

G...SW 3 Z 200 M + W...

Mountingside

HPunit

Mountingside

HPunit

Mountingside

HPunit

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Type

Directionalseat valve SVpossible symbolsV, W, Y, Zsee point 6.5.

Pressure switch DSsee point 6.3.

Pressure relief valve DBPressure range andtype of adjustmentsee point 6.4.

see point 2.1.8.(build--on control)

pN = 350 bar

Pressure control module

Build--on module for valves withA6 interface to DIN 24340Directional valve and sandwichplate valve construction possible

Installation dimension Z: 43 max.

Installation dimension Z: 53 max.

G...SB 3 Z --5 / 350 M + W...

Type

Check valve RVno details ... no RVR ... with RV

Pressurerelief valve DBD ... with DB

DB pressure range andtype of adjustmentsee point 6.4.

pN = 350 bar(or max. pressureof the built--on valves)

CE R D 350 M -- ...

Mountingside

HPunit

Mountingside

HPunit

A6 interface to DIN 24340

A6 interface to DIN 24340

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TypeNo. of valvestacking modules(max. 6)Check valve RVno details ... no RVR ... with RVPressure reliefvalve DBD ... with DBDB pressure range andtype of adjustmentsee point 6.4.Directional seat valve SVno details ... no SVpossible symbols V, W, Y, Zsee point 6.5.Directional valvesand sandwich plate valveswith standardised interface(see point 6.1.3.)

5.3. VALVE STACKING MODULESFor valves with A6 interface to DIN 24340 (pN = 350 bar), ports A, B, P, T ... G 3/8

Designation and symbol Dimensions Model codeBase module

Valve stacking module

Standard end module

Accumulator safetyend module

Installation dimension Z: 88 max.

Installation dimension Z: 50 max.

Installation dimension Z: 52 max.

Port M ... G 1/4

CL ... R D 350 M Z -- ... +

Typ+ PL

TypeDBpressure range(see point 6.4.)DBtype of adjustmentP ... can be lead--sealed,

on TÜV versionlead--sealed

Pre--set crackingpressure DBTÜV ... with TÜV approval for DBno details ... no TÜV approval for DBDetails for pressureaccumulator SPPlease quote in full(see point 6.1.2.)

+ PT 350 P 350 TÜV -- ...

Mountingside

HPunit

A6 interfaceto DIN 24340

A6 interface to DIN 24340

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6. DESIGNRECOMMENDATIONS

6.1. DOCUMENTATION6.1.1. Valves and units

DB -- Pressure relief valvesDB 4EBrochure No. E 5.161

-- Pressure relief valvesDB 4Epressure--set andlead--sealedBrochure No. E 5.163

DMV -- Pressure reducingvalvesBrochure No. E 5.162

DV -- Flow control valvesDV 5EBrochure No. E 5.113

RV -- Check valves RVEBrochure No. E 5.176

SV -- 2/2 directional seatvalves 2 SVEBrochure No. E 5.204

DS -- Pressure switchesSeries 5 -- 8Series 5 -- 8

6.2. EMERGENCY MANUALOVERRIDEFOR DIRECTIONAL SEATVALVES SVN ... pin type operationAvailable for symbols V, W, Y,YR,Mechanical operation is onlypossible with a pin.The opening has a diameter of5 mm. The pin is countersunk by2.5 mm. The operating stroke is1.5 mm.The valve is switched as pressureis applied to the actuatingmechanism by means of anappropriate pin.

6.1.2. Hydraulic accumulatorsThe following hydraulicaccumulators can be fitted (whenordering, please state type in full):Diaphragm accumulators, weld orscrew version, type: SBOBrochure No. E 3.100Bladder accumulators type: SBBrochure No. E 3.201

N ... pin type operationAvailable for symbols Z, ZRThe valve is switched as theactuating mechanism is pulledout using an appropriate tool.The operating stroke is 1.5 mm.

6.1.3. Valves with A6 interface toDIN 24340All directional valves with A6interface to DIN 24340 or CETOPR35H--42--4--03 can be fitted tothe CE build--on module and theCL horizontal stacking modules.For example: HYDAC directionalseat valves WSE 3 D as perbrochure No. E 5.203 ordirectional spool valves.Directional valves and sandwichplate valves can be supplied, ifrequired. Please give symbols infull or specify circuit diagram.

NG ... thumb pressure operation(rubber cap)Available for symbols V, W, Y,YR,Manual operation is possiblewithout tool (thumb pressure).

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6.3. PRESSURE SWITCH DS6.4. ORDER DETAILS FOR PRESSURE

RELIEF VALVE DB

Pressure range100 (... 100 bar)200 (... 200 bar)350 (... 350 bar)630 (... 630 bar)Type of adjustmentF ... fixed settingM ... adjustable, advise

pressure setting limit(standard)

SM ... scaled knob,advise pressure setting limit

P ... can be lead--sealedA ... lockable,

2H lockMax. pressure settingMust be specified for M and SMnot required for A, F and PPre--set cracking pressureMust be specified for FOptional for M, SM, A, P(no details: spring not set)

350 M 315 -- 300

Series 5 -- 8Order code Pressure range5 50 bar6 200 bar7 350 bar8 630 bar

�� with adjustment screw�� compact construction

If solenoid valves with Z4 connectors areordered, pressure switches with Z14connectors are supplied (standard).If solenoid valves with Z5L connectors areordered, pressure switches with Z15Lconnectors are supplied.

6.5. 2/2 DIRECTIONALSEAT VALVES SV

Symbols(For nominal voltage,electrical connection andemergency manual overrideof actuating solenoids,see point 2.1.8. Build--oncontrol)

F

P

M (standard)

SM

A

V

W

Y

Z

7. NOTEThe information in this brochure relatesto the operating conditions andapplications described.For applications or operating conditionsnot described, please contact therelevant technical department.Subject to technical modifications.

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