1. Introduction

The EHLT Hydraulic Power Pack is designed for double-acting and single-acting hydraulic actuators used in valve automation. This manual provides guidelines for installation, operation, and maintenance to ensure safe and efficient use.

2. System Configuration & Components

2.1 System Overview

• Provides hydraulic power for actuating valves.
• Supports both double-acting and single-acting actuators.
• Maximum valve pressure: 160 bar.
• Duty cycle: S2 15min (short-term operation).
• Noise level: Max 80 dB.

2.2 Key Components

• Hydraulic Pump: Provides the necessary hydraulic pressure.
• Oil Tank: Stores hydraulic oil; requires proper positioning.
• Oil Gauge & Vent Plug: Ensures correct oil levels and pressure regulation.
• Motor: Drives the hydraulic pump and requires temperature monitoring.

3. Installation & Commissioning

3.1 Handling & Storage

• Storage temperature: -10°C to +45°C (short-term up to +60°C).
• Protect from external shocks and moisture.
• For air transport, ensure the oil tank is empty.

3.2 Installation Guidelines

• Do not install with the oil tank facing upwards.
• Ensure the tank position is equal to or below the actuator axis.
• Vent plug must always be in the upper position.

3.3 Hydraulic Fluid Requirements

• Use only mineral oil meeting DIN 51524/51525 standards.

• Recommended oil types based on temperature:

  Temperature Range	Oil Type
  -5°C to +10°C	H-L-16 or H-LP16
  +10°C to +30°C	H-L-32 or H-LP32
  +30°C to +45°C	H-L-49 or H-LP49

• Always use a 20μ filter when filling the system.

4. Operation & Maintenance

4.1 Oil Filling & Checking

• Check oil level before operation.
• Ensure no contamination before refilling.
• Do not overfill the oil tank to avoid system failure.

4.2 Oil Change Procedure

1. Remove the oil plug.
2. Use a suction pump to remove old oil.
3. Refill with new hydraulic oil according to Section 3.3.
4. Ensure the oil level is below the filling hole before replacing the oil plug.

4.3 Replacing Components

4.3.1 Pump Replacement

1. Ensure power is disconnected.
2. Drain the oil tank.
3. Remove and replace the pump.
4. Reinstall the motor and check for proper sealing.

4.3.2 Oil Tank Plug Replacement

• Replace standard plugs with vent plugs for single-acting cylinders.

4.4 Periodic Inspection & Maintenance

• Check oil condition every 1,000 operations or every two years.
• Ensure oil remains transparent; replace if contaminated.
• Leaks must be avoided to prevent damage.

5. Troubleshooting Guide

• Continuous operation with low oil levels can lead to system damage.
• For other malfunctions, contact the supplier.