Operating en

Instructions
Pneumohydraulic controller
HP 036./HP 037.
1. Safey 2
2. Function 3
3. Variants 5
4. Mounting 7
5. Installation 9
6. Commissioning 10
7. Maintenance 14
8. Spare Parts 15
9. Technical Data 16

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 Pneumohydraulic controller HP 036./HP 037.

1. Safey
1.1 Approved applications The E+L controller HP 03.. must only be used to operate a hydraulic
positioning device.
Only use the controller
- if it is in perfect condition technically
- in accordance with its intended usage
- with an awareness of safety and risk factors and in compliance
with the operating instructions.
Any jobs regarding controller operation, gearing to production re-
quirements, conversion, setting, its safety-related mechanisms, servi-
cing, maintenance and repair must be performed by qualified person-
nel only. Please observe the switching on/off procedure laid out in the
operating instructions.

1.2 Operating instructions Look after these operating instructions carefully and make sure they
are available to personnel at all times.
The operating instructions are part of the package and should be
read carefully prior to mounting, operation and maintenance work.

1.3 Mounting Please observe the locally applicable and customary safety and acci-
dent prevention regulations.
Hydraulic and pneumatic lines should be installed so that they do not
present any risk. There should be no bending (minimum bending ra-
dius 50 mm for lines supplied by E+L).
Operating elements that are a potential risk when pressure is redu-
ced, e.g. bursting of the hose or motor standstill, should be appropri-
ately safeguarded by the user.

1.4 Installation Please ensure that:

L 1 - electrical components without enclosures such as switch panels
or operating devices are protected according to the locally appli-
cable safety regulations, e.g. VDE 0100
Main switch on - when laying electrical leads the customer shall ensure that the in-
your machine sulation is not damaged and that leads are correctly secured and
screened
- controller power is switched on along with the main machine sys-
Controller tem switch
HP 03.. electric
control - the controller is integrated into the machine control in such a way
as to prevent it starting up independently after a machine standstill
1-pole illustration or an emergency OFF device reset.

1.5 Operation The controller should be operated by qualified persons or suitably in-
structed personnel only.

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 Pneumohydraulic controller HP 036./HP 037.

2. Function
2.1 Purpose The HP 03.. controller is used to position actuators in web guiding
systems or in unwinding/rewinding stations. The controller is desig-
ned for systems guiding by the web edge with a pneumatic sensor
FL2.. .
2.2 Design

Air intake filter Three-phase a.c. motor

Pressure gauge
Side channel compressor

Pressure relief valve

Fluid tank

Servo-valve

HP 03.. controller
The HP 03.. controller is made up of the following components:
- three-phase a.c. motor
- side channel compressor
- air intake filter
- servo-valve
- pressure relief valve
- pressure gauge
- fluid tank

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 Pneumohydraulic controller HP 036./HP 037.

Fuses

Motor protec-
tion switch

Contactor Connection terminals

Switch panel SE 12521

The HP 03.. controller is available in three different electrical versi-

ons.
- Switch panel SE 12521 with motor protection switch, three-phase
a.c. motor contactor and connection terminals for the valve wiring.
- Terminal box SZ 0921 with connecting terminals only for the three-
phase a.c. motor and valve wiring.
- No electrical wiring.

2.3 Mode of operation To generate the air required for sensing, ambient air is drawn into the
side channel compressor and fed to connection S 1 of the pneumatic
sensor. The level of the probing air pressure and thus the control
sensitivity for adjustment to different situations is set via a restrictor.
Some of the compressed air is sent to diaphragm D 1 (see pneu-
matic system plan on opposite page, at top). A pressure spring works
in the opposite direction to the dia­grapm. If the sensor is covered ap-
propriately, the diaphragm is maintained in the center and the system
in a zero position.
If the web moves away from the zero position, it changes the air cur-
rent which, in turn, influences the diaphragm. The change to the dia-
phragm directly affects the servo-valve controlling the fluid flow. The
fluid flow changes the location of the positioning cylinder until the
web returns to its zero position.

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 Pneumohydraulic controller HP 036./HP 037.

3. Variants
3.1 Basic model, system 1 On the basic model HP 03.. without valve assembly, guiding by the
web edge only (automatic) is possible.

FL = pneumatic sensor
HZ = positioning device - HZ

:S 2
- FL
:S 1

:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B

AIR
D 1

OIL
P P A

T B
HP 0360 20 bar
HP 0370 30 bar
T

3.2 Valve assembly 02, Valve assembly 02 permits guiding by the web edge (automatic) or
system 2a servo center. Reversing is effected via a manually-actuated valve.

FL = pneumatic sensor
HZ = positioning device - HZ
SC = servo center actuator
V 1 = manually-actuated valve
-V1

:S 2
- SC
- FL
:S 1

:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B

AIR
D 1

OIL
P P A

T B
HP 0360 20 bar
T HP 0370 30 bar

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 Pneumohydraulic controller HP 036./HP 037.

3.3 Valve assembly 03, Valve assembly 03 permits guiding by the web edge (automatic) or
system 2a servo center. Reversing is effected via solenoid valves.

FL = pneumatic sensor
HZ = positioning device
SC = servo center actuator
-Y3
Y 2/Y 3 = solenoid valves - HZ
- SC

-Y2
:S 2
- FL
:S 1

:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B

AIR
D 1

OIL
P P A

T B

HP 0360 20 bar
T HP 0370 30 bar

3.4 Valve assembly 05, Valve assembly 05 permits guiding by the web edge (automatic). The
system 2b positioning cylinder can be set via pushbuttons. A P/T connec­tion is
possible with this valve assembly (please quote it however when or-
dering controller HP 03..).

FL = pneumatic sensor
HZ = positioning device - HZ
Y 2/Y 10 = solenoid valves

-Y2
:S 2
- FL
:S 1 :A :B

Y 10 Y 11
:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B

AIR
D 1

:P P OIL
P A
:T
T B
HP 0360 20 bar
T HP 0370 30 bar

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 Pneumohydraulic controller HP 036./HP 037.

3.5 Valve assembly 06, Web guiding is by the web edge (automatic) or servo center. The
system 2ab positioning cylinder can be set via pushbuttons. A P/T connection is
possible with this valve assembly (please quote it however when or-
dering controller HP 03..).

FL = air sensor
HZ = positioning device
SC = servo center actuato- - HZ
rY 2/Y 3 = solenoid valves -Y3
Y 10 - SC

-Y2
:S 2
- FL
:S 1 :A :B

Y 10 Y 11
:S 1.1 :S 1.2 :S 2.1 :S 2.2 :A :B

AIR D 1

P OIL
P P A
T
T B

HP 0360 20 bar
T HP 0370 30 bar

4. Mounting
4.1 Controller HP 03.. Controller HP 03.. should be mounted so that the air hoses and hy-
draulic lines to the sensor, return-to-center switch and positioning
cylinder are kept as short and straight as possible and are laid accor-
ding to the connection diagrams. The minimum bending radius is 50
mm (for air and hydraulic lines). Please ensure easy access to the
controller for operating and maintenance purposes.
Controller HP 03.. must be mounted a little higher than the positio-
ning cylinder to ensure the self-venting of the system.
Do not drill the fluid tank

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 Pneumohydraulic controller HP 036./HP 037.

4.2 Switch panel The switch panel or terminal box can be mounted in three positions
(see fig. below).

A
Standard

Mounting options

4.3 Pneumatic sensor When the web passes through the air sensor on the horizontal, sen-
sor connection S 1 should be located underneath the web (see fig.
S2 on left). This protects the air sensor from soiling.
Air sensor
The pneumatic sensor should be connected as follows.
Connect S 1.1 on controller to sensor via S 1.
Connect S 2.1 on controller to sensor via S 2.
Web
S1 The air lines to the sensor must be of the same length and not ex-
ceed 3 m. The line to the pneumatic return-to-center switch must not
Pneumatic sensor FL 2.. exceed 6 m. Narrowing of cross- sections and narrow hose elbows
are not permissible due to the danger of rupture. For temperatures
over 70 °C, silicon hoses should be used for the air lines and copper
pipes for the hydraulic lines.
The plastic tubes supplied (6 mm inner diameter, 10 mm outer dia-
meter) should be used for the hydraulic lines. When using steel pipes
(10 mm x 1 mm) these must be cut to size using a pipe cutter. The
pipes must be cleaned prior to installation. The hydraulic lines must
securely fixed.

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 Pneumohydraulic controller HP 036./HP 037.

4.3 Positioning cylinder The positioning cylinder should be connected as follows.

When the FL 2.. pneumatic sensor is uncovered, the fluid flow is from
to A to B.
The positioning cylinder must be connected so that it moves towards
the pneumatic sensor (see fig. below)

Uncovered pneumatic sensor FL 2..

A A
B B
Connec- Connec-
tion to tion to
controller controller
Positioning cylinder Positioning cylinder

Positioning cylinder stroke

Positioning cylinder connection

5. Installation The electrical connections should be carried out according to the at-
tached connection diagram.
Controller HP 03.. should be connected to the mains via an
electrical fuse.

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 Pneumohydraulic controller HP 036./HP 037.

6. Commissioning Once the fluid filler conver has been removed, the hydraulic fluid
should be poured in using a funnel and filter paper. the fluid leven
must not rise above the halfway mark on the fluid inspection window.
The direction of rotation can be checked by briefly applying voltage
to the three phase a.c. motor. The three phase a.c. motor must turn
to the right. An additional check is provided by the pressure gauge, if
the direction of rotation is wrong, no pressure will be built up. The di-
rection of rotation can be revers­ed by swapping over the two phases
in the connection lead.

Pressure gauge Fluid filler cover

Three-phase a.c. motor

Fluid inspection window
direction of rotation
HP 03.. controller

6.1 Checking the positioning Check the direction of the positioning cylinder travel when the three-
direction phase a.c. motor is switched on. To do so, select the gui­ding by web
edge mode (automatic).
The positioning cylinder or device must move the web away from the
sensor when the sensor jets are covered (see fig. on opposite page).
When the air sensor is uncovered, the positioning cylinder should
move towards the air sensor. If the reverse is the case, hydraulic
connections A and B must be swapped.
The hydraulic lines may also be under pressure when the
system is switched off. When the hydraulic lines are opened,
power elements may be activated.

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Covered sensor jets Uncovered sensor jets

HP 03 HP 03

Pneumatic Pneumatic
Web Web
sensor sensor

Sensor jets Sensor jets

Positioning Positioning
cylinder cylinder
Positioning cylinder di- Positioning cylinder di-
rection of stroke rection of stroke

The hydraulic system is vented by advancing the positioning cy-linder

to its end positions several times. To this end, however, it is essential
that the hydraulic controller be mounted a little high­er than the posi-
tioning cylinder. This process should be repea­ted until the positioning
cylinder operates without jerks and reacts immediately.
The fluid level must be rechecked and topped up if required until it
reaches the halfway level on the fluid inspection window.

6.2 Setting the pneumatic
servo center actuator
Actuating element
On valve assemblies with a servo center mode, the servo center ac-
tuator must be set. The command device should be set to servo cen-
ter mode. The positioning cylinder moves until the pneumatic servo
center actuator is covered by a half (see fig. on right).
If the positioning cylinder moves into an end position, the connection
on the servo center actuator must swapped from B to A.
The center position can be set by shifting the servo center actuator
or actuating element.

Servo center actuator

A B

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 Pneumohydraulic controller HP 036./HP 037.

6.3 Adjusting the pneumatic The basic setting when the pneumatic sensor is uncovered is
system 12 mbar (= 120 mm water column), measured at S 2. For sensitive
webs, the S 2 signal pressure can be reduced to approx. 9 mbar
(90 mm water column). The positioning speed is however also redu-
ced as the servo-valve is no longer actuated to its full extent. The air
flow setting is effected via the AIR setscrew (see fig. below).
The setscrew is covered by a protective cap. Once the nut is loose-
ned, the signal pressure can be set. Subsequently, the nut should be
retightened and the protective cap replaced.

Minimum air pressure

Setscrew

Setscrew for synchro-

nous operation Maximum air pressure

Protective cap

Setscrew

Nut

6.4 Setting synchronous On commissioning, however, check for synchronous operation. The
operation positioning cylinder speed must be identical in both directions. If this
is not the case, turn the set screw for synchronous operation (see
illustration above) up approximately one full turn left or right until syn-
chronous operation is attained.

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6.5 Setting the positioning
speed
Pressure limiting valve
6.6 Setting maximum pressure
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Pneumohydraulic controller HP 036./HP 037.
The controller is factory preset to maximum speed. By turning the
fluid restrictor (see fig. below) by approx. 5 turns to the right, the po-
sitioning speed is reduced by approx. 50 %. If the system should dis-
play a tendency to hunt, we recommend you reduce the positioning
speed.
The fluid restrictor screw is also locked by a protective cap and nut.
Protective cap
Setscrew
Nut
Fluid restrictor
The pressure limiting valve on HP 036 is factory preset to ap­prox. 20
bar and to approx. 30 bar on HP 037. Once the protective cap has
been removed and the nut loosened, the set pressure can be adjus-
ted (see fig. above). By turning to the left, the pressure is reduced
and thus also the positioning force. Adjustments should be carried
out only when idling.
The pressure limiting valve should only be actuated when the
system is at a standstill or idling. It can only be turned with
difficulty when under pressure.
We recommend you reduce the fluid pressure if no great degree of
positioning force is required as the fluid doesn’t heat up so much.
The positioning force can be read off the pressure gauge when the
positioning device is in its end positions. Once set, the nut can be re-
tightened and the protective cap replaced.
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 Pneumohydraulic controller HP 036./HP 037.

7. Maintenance
7.1 Controller HP 03.. The air intake filter should be renewed at regular intervals depending
on the amount of dust in the ambient air.
Check regulary that the hydraulic fluid and pipe connections are tight.
The level and purity of the hydraulic fluid must be checked regular-
ly. The purity of the hydraulic fluid can be checked by a simple test.
Using a clean screwdriver, sprinkle a little fluid onto a piece of white,
absorbent paper. If a deep brown coloured spot, metallic scuff or
other soiling appears in the center of the stain, the fluid should be
changed.
The fluid must be changed after approx. 6000 operating hours or at
least once a year. The fluid should only be changed at operating tem-
perature.
Once the controller is switched off, the hydraulic fluid is drained off by
opening the venting screw. To check the fluid intake filter and filter in-
sert, the whole controller assembly must be unscrewed from the fluid
tank. Once the 12 hexagon socket head screws have been removed
(see fig. below), the assembly can be removed.

Hexagon socket head screws

Air intake filter

Venting screw Hexagon socket head screws

Controller assembly

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The fluid intake filter is located on the gear pump. Once the nut­has
been removed (see fig. on right), the filter insert can be taken out. If
heavily soiled, the filters should be replaced. Depending on the de-
gree of soiling, the fluid tank should be clean­ed. Prior to reassembly,
the old silicon seal must be removed from the fluid tank and the valve
assembly and replaced by a new brush-on silicon sealant.

Nut Filter insert

Replacing the filter insert

7.2 Pneumatic sensor FL 2..
The air jets must be checked regularly for soiling and cleaned as
required. The hose lines on the pneumatic sensor must be remo­
ved for cleaning purposes as otherwise the compres­sed air
would destroy the diaphragm in the servo-valve. The air jets in
the pneumatic sensor should be flushed out with compressed air. In
the case of extreme soiling, the sensor should first be cleaned with
petroleum ether or paraffin. The hose lines may also have to be clea-
ned.
Do not clean the pneumohydraulic controller with com­
pressed air. Compressed air will destroy the controller.

8. Spare Parts We recommend you keep a stock of the following spare parts:

8.1 Mechanical Spare parts kit HP 036./HP 037. 205702

Plastic tube (dia. 10/6, please state length required) 008986
Support sleeves
(always order together with plastic tube) 023461
Hydraulic fluid 024870
Single air hose
(please state length required) 030917

The spare part kit contains replacements for all those filters
and seals subject to wear and tear.

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 Erhardt + Leimer GmbH
Postfach 10 15 40
D-86136 Augsburg
Phone (0821) 24 35-0
Telefax (0821) 24 35-6 66
Internet http://www.erhardt-leimer.com
E-mail info@erhardt-leimer.com

8.2 Electrical components The electrical spare parts are dependent on the on-site control volta-
ge.

(only in conjunction with a switch panel)

Miniature fuse (5x30) 10 AM (24 V) 070646
Miniature fuse (5x30) 4 AM (120 V) 012043
Miniature fuse (5x30) 2 AM (230 V) 005353

((only in conjunction with a terminal box)

Miniature fuse (5x30) 6,3 AM 012044

9. Technical Data Technical data HP 0360 HP 0370

3-phase motor see sticker motor rating
Operating pressure 20 bar 30 bar
Pressure on cylinder
when adjusted to maximum 14 bar 21 bar
Pump delivery 1,5 - 3 l/min 3 - 6 l/min
Fluid content 15 l 25 l
Fluid type H-LP 32 DIN 51524
ISO VG 32 DIN 51519
Temperature rise
above ambient 35 °C 45 °C
Maximum operating
temperature 80 °C
Sound level 64 dB
Sensor air pressure 5 - 30 mbar
Weight with fluid approx. 40 kg approx. 45 kg
Valve coil voltage 220-230 V, 50/60 HZ
110-120 V, 50/60 HZ
24 V =
2/2-way valve 31 VA / 15 W
4/3-way valve 80 VA / 30 W
Dimensions see attached dimensioned
drawing
Subject to technical modifications without notice

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