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Compact hydraulic power pack type INKA 1
Assembly instructions
Oil immersed compact hydraulic power pack with built-in
electric motor (AC or 3-phase version) and single-circuit
pump.
For short period operation S2 and periodic intermittent
operation S3.
(Translation of the original instructions)
B 8132-1
02-2023 -1.3 en
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Table of Contents
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Summary of Contents for HAWE Hydraulik INKA 1
- Page 1 Compact hydraulic power pack type INKA 1 Assembly instructions Oil immersed compact hydraulic power pack with built-in electric motor (AC or 3-phase version) and single-circuit pump. For short period operation S2 and periodic intermittent operation S3. (Translation of the original instructions) B 8132-1 02-2023 ...
- Page 2 HAWE Hydraulik respects these legal provisions in all cases. HAWE Hydraulik cannot provide individual guarantees that the stated circuits or procedures (including in part) are not subject to the intellectual property rights of third parties.
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Page 3: Table Of Contents
Checking and replacing the pressure and return line lters..................33 7.2.5 Checking the valves............................34 7.2.6 Checking accumulator systems........................... 34 7.2.7 Checking the motor............................34 7.2.8 Replacing an external fan..........................35 Disassembly and disposal..........................37 Troubleshooting..............................38 HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 3/55... - Page 4 Current consumption characteristic lines......................48 10.1.8 Additional options............................49 10.1.8.1 Additional option: sensor system........................49 10.1.8.2 External fan..............................49 10.1.9 Sensor characteristics............................49 10.2 Documents...............................51 10.2.1 Declaration of incorporation..........................51 10.2.2 Declaration of conformity..........................53 4/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 5: About These Instructions
The manual provides relevant information for the machine manufacturer and machine operator as well as for training courses. You can request further information on the product at: HAWE Hydraulik SE, Einsteinring 17, 85609 Aschheim/Munich, Germany. 1.2 Safety instructions and symbols... - Page 6 Wear safety goggles to protect your eyes against chemical and mechanical hazards. Protective clothing Wear tted clothing without protruding parts. Follow the safety data sheet of the hydraulic uid. 6/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 7: Applicable Documents
1.3 Applicable documents Documents D 5488/1 Oil recommendations D 8132-1 Data sheet for compact hydraulic power pack type INKA 1 B 5488 General operating manual for the assembly, initial operation and maintenance of hydraulic components and systems Declaration of incorporation "Declaration of incorporation (EU)"... -
Page 8: For Your Safety
Only use the product for the stipulated purposes. Use in other operating modes than specied in the intended use ■ Using the product beyond the specied performance limits ■ 8/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 9: Residual Risks
The operating company must ensure the operating conditions (see the technical data) are within the limits for use of the product. Keep all instructions/signs on the product in legible condition and observe them. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 9/55... -
Page 10: Qualification Of The Personnel
In the instructions, safety instructions with mandatory symbols indicate the wearing of special protective equipment for special activities. The supply of PPE, and instruction in its proper use, is carried out by the operator. 10/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 11: About This Product
The external fan is mounted on the side on the intermediate ange. External fan (optional) External fan start can be programmed for an oil temperature between 40°C and 70°C (any 10°C increment selectable). Programmed switching hysteresis is 10°C. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 11/55... -
Page 12: Control
■ Function Sensors with IO-Link Sensors with switch output ✓ IO-Link ✓ 3 switch outputs ✓ ✓ Visualisation ✓ ✓ External fan control ✓ Parametrisation interface Parametrisation via IO-Link 12/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 13: Parametrisation
1 s, a speed at least 10% above idle speed (which is at least 1650 rpm in 4-pole motors), the parametrised power frequency is automatically raised to 60 Hz. Automatic parametrisation will not occur in the reverse direction. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 13/55... -
Page 14: Values Measured By The Sensors
The measured speed and the geometric pump output volume congured ex-works are used to continuous- Theoretical ow rate ly calculate the (theoretical) ow rate. This value is equivalent to the ow rate under ideal conditions, i.e. without taking into account internal leaking etc. 14/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... - Page 15 LEDs are off, the external fan is running and the switch outputs are at GND potential. If the rmware is invalid (e.g. because the update was interrupted), the sensors remain in this operating mode. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 15/55...
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Page 16: Transport And Storage
■ Cable tting M20x1.5 for version with communication box or M16x1.5 for connecting motor in ■ communication box (not required for version with HARTING plug [P1-P3]) Hydraulic uid ■ 16/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 17: Checking The Delivery
Document transport damage with photos and report to the manufacturer. 3. Properly dispose of the product packaging in accordance with local regulations. NOTICE For any defect found, le a complaint immediately with: HAWE Hydraulik SE Einsteinring 17 85609 Aschheim near Munich, Germany Tel.: +49 89 379100-1491 service@hawe.de... -
Page 18: Assembly And Installation
Property damage from incorrectly installed hydraulic system Assembly by trained specialists only. Ensure all labels and markings of the hydraulic system are easily visible and legible after assembly. Check installation space/connection points for damage. 18/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... - Page 19 7. Connecting hydraulic lines: To connection block or valve section ■ Or to your own connection block ■ 8. After a week of operating time at the latest, check the ttings. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 19/55...
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Page 20: Hydraulic Connection
2. Filter fresh hydraulic uid. Recommended lter: 10 μm, see "Technical data", page 40 3. Pour the ltered hydraulic uid into the tank. 4. Close the tank opening with the breather lter. 20/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 21: Electrical Connection
Route control cables and power cables separately. Leave a 10 to 20 cm gap between the control cables and power cables. Provide separate shields for analogue and digital control lines. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 21/55... -
Page 22: Connecting The Motor
The product type can optionally connect the motor to the communication box (order coding in to communication box 8132-1D 8132-1). (Coding P0) Remove communication box’s cover 3-phase power Alternating current U1/Z2 U1/W2 V1/U2 W1/V2 22/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 23: Connecting An External Fan
The unit is secured against being switched on unintentionally. Motor is connected. Check external fan’s wiring to communication box. Plug connector (Coding P1 The unit is secured against being switched on unintentionally. to P3) Motor is connected. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 23/55... -
Page 24: Connecting To Parametrisation Interface
✓ Scope of information is equivalent to IO-Link variant. 5. Remove the programming cable. 6. Place the communication box’s cover back in position and tighten the screws to a torque of 1 + 0.3 Nm. 24/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 25: Connecting The Sensors
Sensors with switch output (coding E2): Position X2, permitted cable length 20 m (M12 for ■ interface’s switch output) NOTICE When not using the plug, protect it with an IP67-rated protective cover. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 25/55... -
Page 26: Connecting The Operating Capacitor
3. Wire the operating capacitor to the machine controls in accordance with the circuit diagram. 4. Connect the hydraulic power pack to the electrical power supply. 5. Check the electrical connections after a week’s operating time. 26/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 27: Start-Up
3. Electrical: Wiring, power supply, control Set motor protection circuit 1. The electric motor must be protected with a motor protection circuit, see Chapter 5.3.1, "Connecting the motor", page 22 HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 27/55... - Page 28 The operating states of the external fan, LEDs and switch outputs (optional) match their parametri- ■ sation. Check LEDs’ status ■ Compare switch outputs’ status with expected values ■ 28/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 29: Switching The Hydraulic System On/Off
The hydraulic system is switched on and off via the system controller. Initial start-up of the system must have been performed properly. When using with an external fan, it must be ensured that fresh air can be aspirated and that the hot air can be vented. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 29/55... -
Page 30: Maintenance
NOTICE Disconnecting electrical power sources Plug connection on compact hydraulic power pack (various types of plug optionally available) or Power supply unit in overall machinery (see owner’s operating instructions) 30/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 31: Maintenance Plan
– Insert the other end into the tank ller opening (unscrew the breather lter). ✓ When the hydraulic uid ow is free of bubbles, the pump has been bled. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 31/55... -
Page 32: Check The Hydraulic Uid Level
10 to 20 to 40 to 60 to 70 to 80 to > 98% 20 % 40 % 60 % 80 % 80 % 98 % measured LED 6 LED 5 LED 4 32/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 33: Replacing The Hydraulic Uid
2. If external leakages are found, shut down and repair the system. Replacing The hydraulic system is switched off and secured against unintentional restart. The system is pressureless. The work environment is clean. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 33/55... -
Page 34: Checking The Valves
Checking and lling NOTICE Refer to the following additionally applicable documents concerning checking and lling of accumulator systems: D 7969 D 7571 7.2.7 Checking the motor Once a year. Maintenance interval 34/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 35: Replacing An External Fan
Electrical and electronic components must only be replaced and connected by trained specialist personnel. Obey all applicable electrical safety rules. Only connect electric lines to the hydraulic system while the system is de-energized. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 35/55... - Page 36 3. Undo the ange connection between tank and external fan. 4. New external fan: Connect mechanically. Wire to communication box or connect using the plug connector. 5. Connect the electric power supply. 36/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 37: Disassembly And Disposal
uid according to the regional waste disposal requirements. Dispose of the electronic components at approved collection points or with approved disposal companies according to local regulations. Dispose of metal with approved specialist disposal companies. HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 37/55... -
Page 38: Troubleshooting
6156 [0x180C] Warning Temperature unknown – the temperature cannot be measured or the measured value is potential- ly invalid (e.g. if the uid level is too low) 38/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... - Page 39 35904 [0x8C40] Info Cleaning message 35905 [0x8C41] Info Rell message 35906 [0x8C42] Info Replacement message 36350 [0x8DFE] Error Test parameter event A 36351 [0x8DFF] Error Test parameter event B HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 39/55...
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Page 40: Appendix
+70°C. Start temperature: down to -40 °C is permissible (take account of the start viscosities!), as long as the steady-state temperature is at least 20 K higher during subsequent operation. 40/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 41: Pressure And Volumetric Ow
Tank Tank size + 0 kg + 0.3 kg + 0.7 kg Motor 3 ~ 0.25 kW + 0.3 kg 3 ~ 0.55 kW + 2.2 kg 1 ~ 0.37 kW + 1.2 kg HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 41/55... -
Page 42: Tank Size
0.65 2.10 1.05 2.05 0.85 2.75 1.65 2.60 1.10 NOTICE Tank size 1 only available with 3-phase motor 0.25 kW 10.1.5 Characteristic lines 10.1.5.1 Build-up of heat 0.25 kW 42/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... - Page 43 ); ST steady-state excess temperature (K) Duty cycle = Relative duty cycle 0.37 kW hydraulic work value (bar cm ); ST steady-state excess temperature (K) Duty cycle = Relative duty cycle 0.55 kW HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 43/55...
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Page 44: Running Noise
Measured in acoustic measurement chamber acc. to DIN EN ISO 3744, distance sound sensor to pump (d) Running noise H pump = 1 m 0.25 kW hydraulic work value(bar cm ); noise level dB(A) 0.37 kW hydraulic work value(bar cm ); noise level dB(A) 44/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 45: Electrical Data
Operating voltage: 3x 575 V AC ■ Frequency: 10 to 400 Hz ■ max. motor power: 7.5 kW ■ Capacitor Capacitor is not included in the scope of delivery HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 45/55... - Page 46 46/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 47: Motor Data
(kW) (rpm) cos 9 (bar cm capacitor (V), f (Hz) (μF) Pump INKA 14 1~230 V 50 Hz 0.37 1380 2.69 0.95 135 121,5 128,25 12 ..-0.37 kW HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 47/55... -
Page 48: Current Consumption Characteristic Lines
); I current consumption (A) 0.37 kW hydraulic work value (bar cm ); I current consumption (A) 0.55 kW hydraulic work value (bar cm ); I current consumption (A) 48/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE... -
Page 49: Additional Options
VDE, CSA, UL, CE VDE, CSA, UL, CE VDE, CSA, UL, CE 10.1.9 Sensor characteristics Designation Power Unit Sensor Speed measuring range 120 to 5000 rpm Fluid level measurement ±5% accuracy HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 49/55... - Page 50 -15 to 15 V (PELV electrical circuit recommended) Activation/visualisation 1000 ms delay At ambient temperatures above 50°C, the total current for the external fan and switch outputs must not exceed 3000 mA. 50/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 51: Documents
10.2 Documents 10.2.1 Declaration of incorporation HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 51/55... - Page 52 52/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
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Page 53: Declaration Of Conformity
10.2.2 Declaration of conformity HAWE Hydraulik SE B 8132-1 - 02-2023 - 1.3 en 53/55... - Page 54 54/55 B 8132-1 - 02-2023 - 1.3 en HAWE Hydraulik SE...
- Page 55 Further information HAWE Hydraulik SE is a responsible development partner with application expertise and experience in more than 70 areas of mechanical and plant engineering. The product range includes hydraulic power packs, constant and variable pumps, valves, sensors and accessories.
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