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HAWE Hydraulik KA 2 Assembly Instructions Manual

Compact hydraulic power pack
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Compact hydraulic power pack type KA 2
and KAW 2
Assembly instructions
Oil immersed compact hydraulic power pack built-in electric
motor (single or 3-phase VAC versions) and single-circuit or
dual-circuit pump.
For short period and intermittent operation (S2, S3).
(Translation of the original instructions)
B 8010-2
07-2022    -1.1 en

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Summary of Contents for HAWE Hydraulik KA 2

  • Page 1 Compact hydraulic power pack type KA 2 and KAW 2 Assembly instructions Oil immersed compact hydraulic power pack built-in electric motor (single or 3-phase VAC versions) and single-circuit or dual-circuit pump. For short period and intermittent operation (S2, S3). (Translation of the original instructions) B 8010-2 07-2022  ...
  • 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.

  • Page 3: Table Of Contents

    Checking the uid level............................ 44 7.2.6 Replacing the hydraulic uid..........................45 7.2.7 Checking and replacing the silica gel lter......................46 7.2.8 Checking electrical equipment..........................47 7.2.9 Checking accumulator systems........................... 47 Repairs................................47 Disassembly and disposal..........................49 Troubleshooting..............................50 HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  3/70...
  • Page 4 Weight................................52 10.1.3 Characteristic lines............................53 10.1.4 Hydraulic data..............................54 10.1.5 Electrical data..............................55 10.1.6 Motor data..............................59 10.2 Declaration of incorporation..........................65 10.3 Declaration of conformity..........................66 10.4 UKCA certificates..............................67 Contact details............................... 69 4/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • 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. HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en ...

  • Page 6: Safety Instructions And Symbols

    Dragging hazard from moving parts Harmful substances Tripping and falling hazard Fire accelerants Falling loads Burn hazard Crushing hazard Electrical voltage Suspended loads No access to persons with pacemakers and defibrillators 6/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 7: Applicable Documents

    Document required to install hydraulic power pack correctly in entire machine Optional add-ons to hydraulic power pack from other manufacturers Manufacturer’s operating instructions e.g. hydraulic accumulator, lter etc. Explanations "Declaration of incorporation", page 65 "Declaration of conformity", page 66 HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  7/70...

  • Page 8: For Your Safety

    ■ Improperly installed, outdated, un-secured or damaged pipes and hose lines ■ Use in atmospheres at risk of explosion ■ Structural changes, especially if function and safety are compromised ■ 8/70 B 8010-2 - 07-2022 - 1.1en  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 8010-2 - 07-2022 - 1.1en  9/70...

  • 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. 10/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 11: About This Product

    About this product 3.1 Markings Example order coding KA 2 KA 24 H 1,81 - AB1K/C180 - FSR-24V - 3x400 V 50 Hz KA 28 HZ 0,59/8,8 - ... - 3x400 V 50 Hz /24 V DC - G 1/2 x 300...
  • Page 12 Protection class EN standard Operating mode max. temperature Pump connection: P1: Single circuit: P1 and P3: Dual circuit Geometric output volume V /rev) Pump’s max. permissible operating pressure DataMatrix code 12/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 13: Structure

    The compact hydraulic power pack’s uncompromisingly module design will enable you to quickly and easily set up a variety of Compact hydraulic power pack type KA 2 usage volumes and sizes. Compatible, ready-for-connection, and KAW 2 complete solutions can be assembled easily using a wide range of connection blocks and the valve banks that can be combined with them.
  • Page 14 Connection block and valve bank Electrical connection of valves and monitoring components, e.g. pressure switches Hydraulic connections to consumers Level gauge External fan (optional) Filler port (hydraulic uid) and breather lter Type plate 14/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 15: Control

    The motor’s duty cycle should be monitored by the device control. An increase in the duty cycle is an ■ indicator of abnormal internal leakage. The following must be integrated in the machine controls: The technical data specifications in the data sheets must be complied with. ■ HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  15/70...

  • Page 16: Transport And Storage

    Only tested and approved aids are permitted for use. Transporting the product Make sure the eye-bolts are rmly attached, there are enough of them, and they are in the correct positions on the hydraulic power pack. 16/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 17 Use suitable lifting gear and pallet trucks. Attachment points for The eye-bolts are included with the product. transport eye-bolts Vertical version Pump with fan Eye-bolt screw-in points Eye-bolt screw-in points Horizontal version Eye-bolt screw-in points HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  17/70...
  • Page 18 18/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 19: Scope Of 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 20: Storage

    If stored for more than 2 years, protect the valves and valve controls against resinification of the ■ hydraulic uid. Please contact the hydraulic uid manufacturer in this regard. Avoid electric drives and electronic components being subjected to mechanical shocks. ■ 20/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 21: Assembly And Installation

    This impairs the performance of the hydraulic system. All lines are as short as possible and not kinked. No bend radii are smaller than the smallest bend HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  21/70...
  • Page 22 For detailed hydraulic data, see the type plate. Horizontal version coding L Vertical version coding S Mounting hole pattern Coding tank size Coding tank size Without coding 1, 01 2, 02 22/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 23 Centring pin #4 mm Centring pin #4 mm a = 121.5 Hole for self-made connection block Sealing of the connections: P, P1, P3 = 8x2 NBR 90 Sh R = 10.5x1.4x1.9 NBR (Kantseal) HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  23/70...

  • Page 24: Pump Dimensions

    5.1.1 Pump dimensions Vertical version Basic type KA 2/KAW 2 87.5 121.5 Coding tank size Without coding 1, 01 2, 02* Tank sizes 02, 22 only appropriate for horizontal version 24/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 25 Horizontal version Basic type KA 2/KAW 2 87.5 121.5 Coding tank size Without coding 1, 01 2, 02* Tank sizes 02, 22 only appropriate for horizontal version HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  25/70...

  • Page 26: Additional Components' Dimensions

    Suppressor coding E Coding G Silica gel lter Terminal box: M12 connections for temperature and/or level switch Temperature and/or level switch Coding M, PM Coding M1 and PM1 Coding M2 and PM2 26/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 27 Electrical connection to fan Coding FSL, FSR, FSLR, FSH Fan (on side) Coding FSL, FSR, FSLR, FSH Filler reduction Coding B Coding B Coding B1 Horizontal version Vertical version Horizontal version HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  27/70...
  • Page 28 28/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 29 Oil drain hose G 1/2 x L G 1/2 W x L Coding Coding L = 300 mm/500 mm L = 300 mm/500 mm with ball valve with ball valve and elbow HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  29/70...

  • Page 30: Hydraulic Connection

    2. Screw in the silica gel lter by hand. Caution: risk of breakage! NOTICE Remove the silica gel lter's caps before commissioning There is a risk of damaging the hydraulic power pack during operation. 30/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 31: Electrical Connection

    After switching off the electrical power supply, wait at least 15 minutes for the energy stored in the capacitors to dissipate. Do not expose components to moisture or an aggressive environment. To avoid overheating, always keep ventilation openings (if any) open to allow sufcient air circula- tion. HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  31/70...
  • Page 32 Induction motor acc. to EN 60034-1 section 12.1.2.1 e.g. power supply acc. to EN 60034-1 section 6 EN 60034-1 section 19 Type 23140, 3x400 V AC 4 kW 50-60 Hz by Murr-Elektronik, D-71570 Oppenweiler or from HAWE. 32/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 33: Connecting The Motor

    AC motor Flat plug 4x cable ttings M20x1.5 Flat plug For vertical version (only D2/T2-T1) 4x cable ttings M20x1.5 Earth For vertical version (only D2/T2-T1) Earth - operating capacitor (not included) HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  33/70...

  • Page 34: Connecting Level Switch And Temperature Switch

    uid level rises above the monitoring level once again when the hydraulic uid ows back in at the end of the duty cycle. Terminal box NOTICE The operating capacitor (C ) is not included. 34/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 35 Coding S Coding D Coding DD Level switch Level switch Coding ST Coding DT Temperature switch Temperature switch Coding T Coding TT50 Coding P HARTING plug 3-phase motor AC motor HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  35/70...
  • Page 36 Coding T Coding T Temperature switch HARTING plug Coding TT50, TT60 Coding TT50, TT60 Coding M, M1, PM, PM1 Additional connection M12x1, 4-pin Pin assignment for level switch Coding D, S 36/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 37: Connecting The Fan

    3. Wire the fan with 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. HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  37/70...

  • Page 38: Start-Up

    Chapter 7.2.9, "Checking accumulator systems", page 47 1. Mechanical: attachment to the machine, the frame and the base 2. Hydraulic: piping, hoses, cylinders, motors 3. Electrical: Wiring, power supply, control 38/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 39 Chapter 7.2.4, "Bleed the hydraulic power pack", page 43 Coding Fill volume Usable volume vertical Usable volume horizontal ll usable usable 1.85 1.85 5.45 3.15 3.15 5.45 3.65 11.1 11.1 9.05 HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  39/70...
  • Page 40 – Radial piston pump = any – Gear pump = anticlockwise 3. For 3-phase version and Z-pump If there is no delivery ow, swap over two of the three main conductors. 40/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 41: Maintenance

    Modifications of any kind, especially mechanical, welding or soldering, are prohibited. 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) HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  41/70...

  • Page 42: Maintenance Plan

    ✓ "Visual check: Electrics (cables, connections, ✓ plugs)", page 43 and replace if necessary ✓ Electric drive: "Checking electrical equipment", page 47 ✓ "Checking and replacing hydraulic hoses", page 43 42/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 43: Service

    The directional valve is in the switching position in which the pump can idle (see manufacturer’s pack hydraulics schematic). 1. Slightly unscrew the bleeder screw. 2. Switch the pump on and off several times so that the pump cylinders bleed automatically. HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  43/70...

  • Page 44: Checking The Uid Level

    Use the visual level gauge to check the hydraulic uid level when the system is unpressurised. Top up the hydraulic uid at the latest when the uid level has reached its minimum. Visual level gauge 44/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 45: Replacing The Hydraulic Uid

    Directional valve is closed. 1. Undo the drain screw on the product. 2. Drain the expended hydraulic uid into a separate vessel. 3. Screw the drain screw back in (tightening torque: 9 Nm). HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  45/70...

  • Page 46: Checking And Replacing The Silica Gel Lter

    3. Screw in a new silica gel lter 4. Before commissioning, take the red sealing plug off the underside of the new silica gel lter ✓ The silica gel lter is ready for use 46/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 47: Checking Electrical Equipment

    D 7571 7.3 Repairs Spare and wearing parts Trained specialist personnel can perform repairs themselves. Order spare and wearing parts from the manufacturer by providing the commission number (see type plate). HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  47/70...
  • Page 48 The motor cannot be replaced as it is an integral part of the tank. NOTICE For safety reasons, only genuine spare parts and accessories may be used. HAWE Hydraulik SE disclaims any liability or warranty for damage caused by the use of non-genuine spare parts and accessories. 48/70 B 8010-2 - 07-2022 - 1.1en ...

  • Page 49: 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 8010-2 - 07-2022 - 1.1en  49/70...

  • Page 50: Troubleshooting

    ow rate, or the ow rate is too Excessive noise production Hydraulic uid level too low Filling hydraulic uid (foaming hydraulic uid) page 46 Hydraulic power pack Pump/motor faulty Shut down Repair or replace 50/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 51: Appendix

    Installation position Vertical (KA...S) or horizontal (KA...L) Line connection only via bolted-on connection blocks Basic pump: see mounting hole pattern Rotation direction Radial piston pump – any Gear pump – anticlockwise HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  51/70...

  • Page 52: Weight

    + 0.22 kg (24 V DC) FSLR + 1.1 kg (1x110 V, 1x230 V) + 0.45 kg (24 V DC) The number of cylinders depends on the delivery ow coding. 52/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 53: Characteristic Lines

    10.1.3 Characteristic lines Radial piston pump Gear pump pressure ratio; dB noise level (A) pressure ratio; dB noise level (A) HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  53/70...

  • Page 54: Hydraulic Data

    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. Biologically degradable hydraulic uids: note manufacturer specifications. With consideration for the seal compatibility, not above +70°C. 54/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 55: Electrical Data

    Insulation material class Suppressor Type RC 3 R Coding E, PE Operating voltage: 3x 575 V AC ■ Frequency: 10 to 400 Hz ■ max. motor power: 4.0 kW ■ HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  55/70...
  • Page 56 50 V AC/DC Electrical connection Line connector acc. to 175301-803-B/ISO 6952 (industrial standard) M12x1, 5-pin (coding M, M1, M2, PM, PM1, PM2) Circuit symbol Coding KD Coding KS (N/C contact) (N/O contact) 56/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 57 1x110 V 60 Hz ( Motor data Rotation Protection speed class (rpm) 2800/3250 IP 44 1x230 V 50/60 Hz ( 1x110 V 60 Hz ( 3250 IP 44 24 V DC 3050 IP 20 HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  57/70...
  • Page 58 1x110 V 60 Hz ( Motor data Rotation Protection speed class (rpm) 2650/3100 IP 68 1x230 V 50/60 Hz ( 1x110 V 50/60 Hz ( 2650/3100 IP 68 24 V DC 2800 IP 68 58/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 59: Motor Data

    It can be operated at undervoltage. Notes on performance limitations: For pump version Z, HH or HZ the max working stroke (pV needs to be reduced by 10% . ■ HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  59/70...
  • Page 60 3x230 V 50 Hz 1380 0,76 3x200 V 50 Hz 1390 0.67 3x220 V 60 Hz* 1690 0,76 Motors for 200 V 50 Hz or 220 V 60 Hz networks (Japan) 60/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 61 3x200 V 50 Hz 1400 12.5 0.55 1225 3x220 V 60 Hz* 1,92 1680 10,8 0,55 1060 Motors for 200 V 50 Hz or 220 V 60 Hz networks (Japan) HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  61/70...
  • Page 62 (bar cm ); I motor current (A); Q delivery ow characteristic (trend) 1.0 1) For values at 230 V 50 Hz (265 V 60 Hz), values must be multiplied by V3. 62/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...
  • Page 63 3340 0.99 2750 15.0 0.96 1x115 V 50 Hz ( KAW 28 1x230 V 50 Hz ( 1370 0.94 1650 10.5 0.98 1x110 V 60 Hz ( Recommended operating capacitor HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  63/70...
  • Page 64 (A); Operating voltage 1x230 V 50 Hz/1x110 V 60 Hz Current consumption characteristic lines KAW 23, KAW 24, KAW 28 hydraulic work (bar cm ); I motor current (A); 64/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 65: Declaration Of Incorporation

    10.2 Declaration of incorporation HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  65/70...

  • Page 66: Declaration Of Conformity

    10.3 Declaration of conformity 66/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 67: Ukca Certificates

    10.4 UKCA certificates HAWE Hydraulik SE B 8010-2 - 07-2022 - 1.1en  67/70...
  • Page 68 68/70 B 8010-2 - 07-2022 - 1.1en  HAWE Hydraulik SE...

  • Page 69: Contact Details

    Contact details Headquarters HAWE Hydraulik SE Einsteinring 17 85605 Aschheim Germany e-mail: info@hawe.de www.hawe.com Phone: +49 (0) 89 / 37 91 00 - 1000 Contact to the Customer Service Phone (Head ofce) + 49 (0) 89 / 37 91 00 - 1000...
  • Page 70 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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