Components,

Systems and Service

for Drill Rigs

E 10.152.0/02.15
 Your expert partner for
system solutions in specialised
Energy efficient,
foundation engineering and drill rigs. safe,
comfortable.
HYDAC Demands of modern drill rigs
Your expert partner The development of modern machinery is characterised by shared requirements across the various
for drill rigs and drilling machine classes. Increasingly complex control and regulation processes go hand-in-hand
with greater productivity and efficiency of the machines. The machine operators are aided by modern
specialised electronic assistance and visualisation systems and the work process is optimised.

foundation machines. Changes to the regulatory framework result in increased investment in the functional safety of the
machines and to a further development of the drive and control systems of the drill rigs.
As is also the case with the EU & US exhaust emissions regulations, the emerging markets in the rest
of the world are taking up these standards and are introducing new standards at the same time.
HYDAC has been one of the
leading suppliers of fluid technology,
hydraulics, electronics and cooling HYDAC's contribution
equipment for more than 50 years HYDAC offers a variety of components and systems that meet these requirements and fulfil your
and has over 7,500 members of staff demands. In addition to standard components, HYDAC offers a comprehensive modular system
worldwide. designed for drilling machine applications. HYDAC will also work with you to develop an individual
solution for your machine.
With our wide range of products, and
with our acknowledged expertise in HYDAC's key issues
development, manufacturing, sales Our development team and application engineers are working continuously to further develop our
and service we provide solutions for products. The focus of these developments is on the following key topics:
the wide range of requirements in the
machine tool industry.
Our technology Your benefits
In addition to the standard products,
z Increases in: z Energy efficiency
HYDAC offers a multitude of industry-
Ö Drilling performance Ö Reduced fuel consumption
specific components developed The use of energy-efficient pumps and Ö Lower hydraulic losses
from hydraulics, cooling, electronics valve technology, optimal positioning of Ö Energy saving and recovery
and systems technology for use in the drill mast in working position with Ö Precise cooling
drill rigs and specialised foundation sensitive controls, accurate repeatability requirement temperature control
for automatic and control functions
engineering machines. Intelligent Ö Reduced electrical power requirement
Ö Corrosion resistance owing to surface
integration of products also creates coating and special materials
innovative and technologically z Safety
z Reduction in:
advanced subsystems and Ö Certified software modules
Ö Piping and installation expenditure due
complete systems for the increased to combined hydraulic function units Ö Systems for functional safety
requirements of specialist machinery. Ö Noise emissions and power consumption Ö Service life increased
through regulated fan speeds by protecting materials
Ö Driver's exposure to dust due to z Noise reduction
cabin ventilation systems
Ö Lower noise level in
Customer benefits: Ö Hydraulic oil tank sizes by optimizing partial-load range of fan control
air separation in hydraulic oil, proven
z Cost-optimisation achieved by through simulation and testing
customised system solutions which Ö Installation space, component weight z Health & safety
use standard components and electrical power requirement by Ö Reduced exposure to dust for the driver
reducing solenoid valve sizes Ö Reduced aerosol exposure for the driver
z Reduction in number of models
through standardisation and modular Ö Learning curve of the drivers through
intelligent control and visualisation
construction systems z Installation space reduction
z On hand everywhere: more than z Extension of: Ö Combined functional units
45 foreign companies and more than Ö Maintenance intervals by monitoring Ö Integrated tank and
500 Sales and Service Partners the hydraulic oil quality filter systems

z Fluid engineering and service: z Reduction in:

Support in technical design for Ö Software development time by using
tested and certified software libraries z Function integration
commissioning, maintenance, Ö Reduced number of components
Ö Development times by means of HYDAC
training and in the event of claims. modular systems and industry know-how Ö Reduced weight
Ö Reduced joints and leakage points
z Customized solutions: Designs can Ö Assembly times through control
be tailored to individual customer technology tailored to customer
specifications z Comfort
requirements, made-to-order
solutions for your machines. Ö Improved working
environment for the driver
z Advice on and implementation of the Ö Sustained driver performance on
safety requirements in accordance longer jobs
E 10.152.0/02.15
E 10.152.0/02.15

with DIN ISO 13849 and DIN

EN 16228 for all types of drilling
z NoX
applications Ö Compliance with the Emissions Directive
Ö Reduced nitrogen oxide and
2 5 CO2 emissions
 Solutions
for different
machine types
We offer you different solutions for the various primary and auxiliary
functions of your drill rigs and are your partner for complete drive and control
technology.
We have the correct solution for your machine in our product range.
Pile driving rigs / leaders / trench cutters
z Work functions:
Rotary drive in open circuit, crowd
system, crawler track
z Kinematic and cylinder functions: Mast
kinematics, telescopic chassis
z Feed function on the trackball
z Pilot oil supply and electro-hydraulic pilot
control of the directional valves
z Cooling system:
Oil-air cooler, combination cooler, diesel
engine cooling
z Accessories:
Mounting technology for exhaust gas
system
and accumulators, fluid level gauges and
ball valves
Underground drilling machines, drilling jumbos
z Main functions:
Rock drills for turning and hammering,
crowd, boom kinematics and cylinder
functions, outrigger
z Hydrostatic steering
z Pilot oil supply and electro-hydraulic pilot
control of the directional valves
z Cooling system:
Oil-air cooler, combination cooler, diesel
engine cooling
z Filtration:
Suction filter, pressure filter, return line
filter, diesel filter
z Tank systems
Horizontal directional drill rigs (HDD)
z Main functions:
Travel drive, rotary drive, crowd drive,
break-out tool, outrigger, mast
z Hydraulic supply to the primary crusher,
turning mechanism and clamping jaws
z Torque limitation for rotary drives
z Feed function on the rotary drive
z Customer-specific control blocks for rod
magazines and delivery systems
z Pilot oil supply and electro-hydraulic pilot
control of the directional valves
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z Cooling system:
Oil-air cooler, combination cooler, diesel
engine cooling
3 4
z Control blocks for winch control, trackball
drive, hydraulic hammer, locking functions
z Filtration:
Suction filter, pressure filter, return line
filter, diesel filter
z Control technology:
Mobile controller, I/O modules and sensors
for pressure, length measurement and
temperature with enhanced functional
safety
z Control technology:
Mobile controller, I/O modules and sensors
for pressure, length measurement and
temperature with enhanced functional
safety
z Accessories:
Mounting technology for exhaust gas
system
and accumulators, fluid level gauges and
ball valves
z Filtration:
Suction filter, pressure filter, return line
filter, diesel filter
z Tank systems
z Control technology:
Mobile controller, I/O modules and sensors
for pressure, length measurement and
temperature with enhanced functional
safety
z Accessories:
Ball valves, hose and cylinder clamps and
fluid level gauges
Universal drill rigs
z Main functions:
Rotary drive in open circuit, crowd system,
feed function on the trackball, switching of
the trackball motors
z Kinematics and cylinder functions:
Outrigger; mast kinematics; tilting, pivoting/
moving and locking powerhead, catching
device
z Pilot oil supply and electro-hydraulic pilot
control of the directional valves
z Cooling system:
Oil-air cooler, combination cooler, diesel
engine cooling
z Complete tank systems
z Accumulator systems for the crusher
clamps
Anchor / blast-hole drill rigs
z Main functions:
Crowd, rotary drive, dual-head drive,
crawler chassis
z Kinematic and mast positioning functions,
break-out tool and bracing device,
outrigger
z Control hydraulics for sonic trackballs
z Torque limitation for rotary drives
z Customer-specific control blocks for rod
magazines and delivery systems
z Accumulator systems for the crusher
clamps
z Complete diesel power units
z Pilot oil supply and electro-hydraulic pilot
control of the directional valves
Excavator attachments
z Central control block for rotary and z Kinematic and positioning functions,
crowd drive
z Control blocks for crusher and clamping
device z Accessories:
z Control technology:
z Control blocks for winch control,
trackball drive, switching and locking
functions, length compensation and
load compensation, superimposed load
regulation and torque limitation
z Filtration:
Suction filter, pressure filter, return line
filter, diesel filter
z Control technology:
Mobile controller, I/O modules
and sensors for pressure, length
measurement and temperature with
enhanced functional safety
z Accessories:
Ball valves, fluid level gauges, pipeline
and hose clamps
z Cooling system:
Oil-air cooler, combination cooler, diesel
engine cooling
z Filtration:
Suction filter, pressure filter, return line
filter, diesel filter
z Accessories:
Mounting technology for exhaust gas
system, cylinder and hose clamps and
ball valves
z Control technology:
Mobile controller, I/O modules
and sensors for pressure, length
measurement and temperature with
enhanced functional safety
telescopic outrigger, tilting the drill mast,
vibration drive,
Coupling technology and clamps
Mobile control and I/O modules for a
modular control system, sensors for
pressure and speed, for example, with
enhanced functional safety
E 10.152.0/02.15
 


 

 



System intelligence 


 


 


  
  
 
Electro-hydraulic system

  
  
      
   
 

solutions as the interface between


    
 

 

  

    
  

actuators and sensors.   

     
  
 
  
 
  
    
   
 
 
 
 

The demands of modern drill rigs are leading to ever-increasing complexity In addition, the introduction
of the new drilling machine

of control systems. Modern machines require a variety of assistance and safety standard DIN EN 16228 calls for increased safety
control systems wherever simpler operating concepts and a better overview requirements for new drill rigs:
and controllability of the machine functions become necessary.

1
10:5
z Field of vision monitoring

0-02
z Safety of the controls in accordance with DIN ISO

014-1
13849 with defined performance levels for selected

001-2

 safety functions


2674



78
  z New standardised procedure for determining stability

fNr.6
  
  

656-L
   zProtection from moving parts through the

  

required
 use
of separating safety

116
 

dNr.
 
devices 

bH-K
 
 
z Introduction of the limited operation
Gm
  
ung  
mode  

rwalt

(ROM – restricted operation mode) 

C Ve
YDA
th-H
-Beu

Electro-hydraulic
load
own

control technology

en-D

 
  

Norm

 
 
 
   
   
  
From the component to    

USER LEVEL
   
   
intelligent drive solution. 


 

 
  
  
  

  
HYDAC offers a comprehensive Displays for the highest visual requirements





selection of hydraulic and 


electronic components to Peripherals, e.g.,
 joysticks

 


subsystems, right through to

 

 
finished functional solutions



that can also include the
corresponding application
software.
See Product Catalogue 18.500
- Control Technology for Mobile
Machines CONTROL LEVEL
Functional Safety
PL d
SIL 2 Controllers in various classes
I/O expansion modules
Standard version and versions with increased functional safety are available

SENSOR LEVEL
Functional Safety
PL d
SIL 2 Pressure and temperature
Distance, position, angle, inclination and level
Speed
Flow and oil level
Standard version and versions with diagnostics
and increased functional safety available

ACTUATOR LEVEL
Pilot-controlled and direct-acting valves
Control blocks (monoblock/sandwich)
E 10.152.0/02.15

E 10.152.0/02.15
Pilot and primary control systems
Intelligent axles
Cylinders and motors
6 7
System development "MATCH" development environment

Joysticks Display Additional input devices

Trackball Keypad Joystick
Mobile Application Tool Chain
Development environment for mobile working machines
System Definition Software Development Commissioning & Test

Application Programming Vehicle Level

"Main Machine Control BUS" CAN0 (CANopen or J1939) Application
(ECU w/ *.hex)

Download hex File

Config
Adjust
“Standard” IDE
Controller PIN definition (I/O´s) Software Frame
Auto Code Builder Standard
IDE
Machine error definitions Emb.Core & Lib´s Service Tool
PLc PLd PLd Parameterization,

Test
Diagnostics,
Communication protocol
Commissioning
Complete System Definition
Parameters & Configurations

Test
I/O modules Additional Machine Drivers (sensors, valves, …)
Test & Simulation Environment
control Service & Test Frame
Remote Control Test Bench, SIL, Integration
control device Software architecture & frame Config, Labels, …

diagnostics and Unit Tests, (Automated) Test Scripts

Docu

Docu

Docu
tool
Documentation
"Chassis & Engine BUS" CAN1 (J1939)

Mobile Application Tool Chain

PLc
With the "MATCH" (Mobile Application Tool Chain) development environment, HYDAC offers a
tool chain for system-level software development by the customer that is specially suited to the
Pedals Sensors Suspension EEC requirements of mobile machinery. "MATCH" supports development from defining the system at the
Diesel engine
vehicle level, to creating the application software, to start-up, testing, and documentation.
Example of control architecture
"MATCH" offers modules for:
z Defining the system at the vehicle level
Based on the customer's requirements, HYDAC offers support across the spectrum with developing electro- z Starting up and servicing the machine
hydraulic control systems for mobile machinery. The scope of development is determined together with the z The software test
customer according to the task.
z The documentation
Services include: Furthermore, an "embedded Middle Ware" is offered which permits a hardware-independent
z Creating customer-specific application software (according to specification) programming of the application and which contains a multitude of basic functions. A comprehensive
z Integrating intelligent subsystems into the customer's machine selection of library modules (e.g. for sensor and valve drives) is also available for an efficient
(e.g., suspension systems, secondary steering systems, fan controls) development of the application software.
z Complete control solutions for mobile machinery Functional safety
(safety functions, electrical/electronic control architecture, application software)
"MATCH" can also write application software with increased functional safety according to the
following safety standards:
z "SIL 2" to IEC 61508
Software development z "PL d" to EN ISO 13849

Depending on the hardware, the following

programming languages can be used to program the
application software:
z CoDeSys 2.3 / 3.5 / 3.5 SIL2
zC
z MATLAB/SIMULINK Programming languages Software library

System development support

Severity of injury
S1 Minor, reversible injury
Starting point for risk assessment S2 Severe, irreversible injury
including death

Frequency/duration of exposure

System intelligence
to hazard
F1 Seldom or short Selection of library modules
exposure to hazard
F2 Frequent to continuous
In order to make software development significantly easier for the customer, HYDAC offers software
exposure to hazard
libraries with ready-made modules as part of its "MATCH" development environment. The library
modules can be configured and parameterised as desired.
Possibility of avoiding the ha-
zard or limiting the damage
P1 Possible under certain
Examples of library modules include:
circumstances z Sensors
P2 Practically impossible
z Switches
z Proportional and switching valves
z Relays, LEDs
E 10.152.0/02.15
E 10.152.0/02.15

HYDAC offers extensive consultation and support for customer projects with regard to: z Transfer functions/signal elements
z Hazard and risk (H&R) analysis Special error modules can also be used to detect system errors.
z Definition and description of safety functions
z Drafting safe system architectures and user interfaces (HMI)
8 9
 Sensors, system electronics
and control systems.
Solutions perfectly tailored to the
application – All from a single source.

Functional Safety
PL d
SIL 2

Linear position and distance Inclination and angle sensors

sensors

Functional Safety Functional Safety

Functional Safety PL d PL c
PL d
SIL 2 SIL 2

Pressure transducers/ Sensors for increased safety Controller for mobile applications HY-TTC 500 HY-TTC 30X Displays with integrated HY-eVision² controller
pressure measurement switches requirements (e.g. PL d, SIL 2)

Sensors Mobile controller I/O Expansion Module Mobile display

HY-TTC 500 HY-TTC 30X / 30XS HY-TTC eVision²
Function Function Function Function

Sensors, system electronics & control systems

The range of sensors includes products for The HY-TTC 500 controller series is based on a 32-bit The new HY-TTC 30X series of I/O expansion The compact background-lit TFT colour displays
measuring pressure, temperature, distance, processor with a modern micro-controller platform. modules provides an outstanding power balance with integrated high-end display controller are
position, level, flow rate, speed, inclination The controller is notable for its impressive 96 inputs combined with extremely compact design. characterised by a very high image quality, low
and angle as well as contamination and oil and outputs and for its high performance capability. The HY-TTC 30X series extension modules are reflections and high colour saturation as well
condition. In addition to products for standard This new HY-TTC 500 controller series is therefore integrated very easily. as optimal readability, even under the most
applications, the product portfolio also covers especially suitable for complex unfavourable light conditions.
special applications such as potentially explosive They provide a simple extension of on-board
control tasks in centralised and decentralised control electronics. The displays are protected by a robust aluminium or
atmospheres or applications with increased architectures. plastic housing and can either be built directly into
functional safety. The communication and integration of the extension the instrument panel or surface-mounted in the field
The controller has three alternative PWM shut-off modules takes place via CANopen according to
Electronic sensors and controls to complement the groups for differentiated safety functions. of vision of the driver/operator using a RAM Mount®
system electronics. CiA DSP 401. It enables inputs and outputs to system in the cockpit.
be configured and parameterized via the control
z Max. load regulation configuration of the available control device in a Ten programmable illuminated control keys, together
Features with the optional touchscreen feature, provide an
z Electro-hydraulic load sensing simple and uncomplicated way.
z SIL 2 / PL d easy-to-use human-machine interface.
z Working hydraulics The different I/O modules provide a large number of
z Three alternative PWM shut-off groups high performance switching outputs or diverse PWM Up to two external cameras can be connected to the
z Positioning display via the two integrated composite video ports,
z Up to 36 PWM power outputs with current outputs with internal current measurement as well as
z Controls of special equipment measurement configurable analogue and flexible digital inputs. and controlled via software.
z Switch-off devices z Numerous and highly flexible IO groups Our product range includes two additional safety-
z Safety systems z Excellent processor performance oriented versions for the implementation of Features
distributed applications with enhanced functional z User-friendly, self-explanatory and time-saving
z Large number of interfaces, communication and safety (Safety PL c, EN ISO 13849).
Features information interfaces graphical design and user interface
z The sensors are available with a variety of z Four to seven CAN-bus interfaces z Good portability via CoDeSys platform
output signals, connectors and fluid port Features z High image brilliance
z Ethernet interface for extremely fast software
connection options download and debugging z PL c z High refresh rate
z Robust design z Freely configurable Node-ID via pin z Fast boot-up times
z ECE type authorisation z 30 E / A, with up to 8 PWM outputs, z Impressive display options such as 3D,
z Approved for potentially explosive atmospheres 6 of these with integrated current measurement picture-in-picture, overlapping effects, etc.
z Separate product portfolio, especially for z Robust, very compact housing z Two pictures can be displayed simultaneously
applications with increased functional safety z Up to 4 CAN, USB and Ethernet interfaces
(SIL 2,3 / PL c,d)
z Robust housing with appealing design, suited for
mobile applications
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10 See Product Catalogue 18.500 - Control Technology for Mobile Machinery See Product Catalogue 18.500 - Control Technology for Mobile Machinery 11
 Hydraulic systems
The optimal working hydraulics
for fast, accurate and efficient control.

Open center primary control valves

HYDAC's open centre primary control valves offer you a modular
system with which to design robust, energy efficient and cost-effective
open centre controls for mechanical, pneumatic, hydraulic and electro-
hydraulic controls.
RS 160
Features: Open centre primary control valve
z Structural design as monoblock, multi-section and slice construction
z Key data: Qmax ≤ 180 l/min; pmax = 350/420 bar
z Energy-saving Q-inlet option
z Robust, high quality and maximum controllability
z Low internal leakage
z Inlet track switching for safe volume flow distribution
z Electrical pump volume current cut-off
z Main consumer in parallel, series and tandem switching RS 220
Open centre primary control valve
z Simple integration of secondary safeguards
z Optional switch position monitoring of the main control spool
z Optionally also for the actuation of LS variable pumps

Overview of HYDAC Compact Hydraulics – Components, Modules, Compact control block with cartridge valves
Subsystems as solution according to customer preference

Key data for open centre primary control valves (see photos on right):
Solutions for load Compact control block for
z RS 160 primary control valve Ö Qmax= 60 l/min; pmax= 250 bar
RS -6 compensation actuation of a clamping
Ö Qmax= 80 l/min; pmax= 300 bar
in form of crowd system and break-out tool on a
z RS 220 primary control valve Open centre primary control valve
z DX-6 primary control valve Ö Qmax= 140 l/min; pmax= 350 bar
horizontal drill
The load of the drill string weight is compensated for by a
variable hydraulic back pressure as decided by the driller.
The skid can be tared out as a result and automatic drilling
Load-sensing primary control valves progress can be achieved using an adjustable weight on bit
(WOB). Customised control block, developed and designed
from the proven modular system of HYDAC compact
HYDAC offers a variety of solutions for this:
HYDAC's load sensing primary control valves offer you a modular valves
system with which to design load-compensated, energy efficient load- z Load compensation in the main flow for rigs with
z For integration in a load-sensing system
sensing controls for mechanical, pneumatic, hydraulic and electro- mechanical length compensation with threaded
hydraulic controls. connection (floating spindle) z 2/2-way switching valves
z Load compensation in the bypass flow, can be extended z Flow rate: 20 l/min
Features: LX-6 to include hydraulic length compensation z Load pressure: 350 bar
Load-sensing primary control valve
z Structural design as monoblock, multi-section and section z Can be used on hydraulic motors with chain or cable z Leak-free closing of the clamping cylinders
construction feed as well as with rack and pinion drives and on crowd
z Second switch-off path for fulfilling the enhanced
cylinders.
z Key data: Qmax ≤ 180 l/min; pmax = 350/420 bar functional safety, e.g. PL c for inadvertent opening of
z Possible integration of additional functions, e.g. release the clamping functions
z Extra-large 10 mm piston stroke for optimal high-precision control
of holding brake, control of the motor setting, chain
z Load-independent parallel actuation without reciprocal influencing z Consumers in interaction with the electronic control
tensioning cylinders, rapid traverse-control for crowd
possible cylinders or free-running of the crowd system z Upper clamping jaws
z Simple integration of primary/secondary safeguards z RSM counterbalance valves for the safe operation of the z Lower clamping jaws

Hydraulic systems
z Inlet track switching for safe volume flow distribution crowd skid z Optional third clamping jaw
z Electrical pump volume current cut-off z Robust 2-way switching valves and proportional pressure z Thread of break-out
HX-1
valve technology z Lubrication of rods
z Optional switch position monitoring of the main control spool Load-sensing
primary control valve
z Optional switch-off of individual sections with complete functionality of
the remaining sections
Load compensation Optional extensions
1

Clamp 3 Clamp 2 Clamp 1 Crushing Lubrication

2
3

1 2
1

2 2 2
E 10.152.0/02.15

E 10.152.0/02.15

Key data for load-sensing primary controlvalves (see photos on right):

1
2
P
1 3 1 3 1 3
LS
T

z HX-1 load-sensing primary control valve Ö Qmax= 120/35 (prop) l/min; pmax= 250 bar LX-6 + HX-1
z LX-6 load-sensing primary control valve Ö Qmax= 160 l/min; pmax= 350 bar Primary control valve combination solution
Lower Lift Switching function 1 Switching function 2 Switching function 3
e.g. brake e.g. gear switching See Product Catalogue 53.000 - Hydraulics

12 See brochure no. 5.254 - Mobile Valves 15

z Crowd OK-ELH
The high traverse speed of the 6 Oil-air cooler for mobile

Various control and switching functions

drilling head when moving up and machines
down requires a high oil volume These coolers use a
9
flow. At the same time, the very combination of high-
low speeds when drilling into 2 2

performance cooling elements

hard bedrocks necessitate high-
1 3 1 3

and hydraulic drive motors in

precision control valves, also with
minimal oil flows.
In order to control the weight on
bit, the directional valves have an
integrated, adjustable pressure
reduction feature with which the
maximum weight on bit can be
set precisely.
z Rotary drive
order to ensure a long, trouble-
free operation of hydraulic
Shut-off and safety Shut-off and safety systems in the mobile sector.
Load holding &
load compensation
Load holding &
brake control
Braking and
holding valves
Braking and holding block block
Load holder The compact design ensures
valves
simple installation in hydraulic
systems and excellent cooling
MY A B MY A B MY A B MY A B MY A B PC MY A B MY A B MY A B MY A B MY A B MY A B PC
capacity while at the same time
7 Z Z
LS
taking up very little space.
Z Z
C

C C

The rotary drive requires very

LS
A A A A A A A A A

L1 C

sensitive actuation via high-

B B B B B B B B B
P

CX
CX
LX
Z

resolution control spools when P

screwing on the pipe connectors. T

When drilling in difficult terrain,

A A A
A A A A A A

the machine requires a powerful

B B B B B B B B B

LS LS

drive that exhibits stable, highly

LX

P P

MP T
MP T

dynamic control behaviour, even

Z LA LB LR LS Z LA LB LR LS Z LA LB LR LS Z LA LB LR LS Z LA LB LR LS Z LA LB LR LS

P T LS P T LS

under extremely variable loads.

z Functional safety A modular Rotate trackball Fast crowd Main winch Chassis Trackball Water pump Drilling crowd Chassis Upper Lower Auxiliary winch
speed kinematics
system comprised of proven clamping jaw clamping jaw
components is used to
guarantee the safety technology
requirements specified by 7 LX6 Load-sensing directional spool valve
EN 13849 and EN 16228. LX-6 is a load-compensated LS valve with upstream pressure
Includes integrated solutions for compensator for systems with fixed and/or variable displacement
switching-off individual functions 8
pumps. Up to ten functions can be controlled independently of one
intelligently, thus reducing the another. The LX-6 was developed with a focus on high precision,
6
PP L P T3 P2
G3/4 G3/8

number of required components sensitive control and energy efficiency. The valve is suitable for
A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 T2
T T T T T G ½’’
1 PL PL PL PL PL

and minimising the sources of 1 2

1
2
controlling the main function of modern drill rigs. Special drilling
error. Thus the HYDAC-Load-
PM

functions, e.g. weight on bit adjustment, torque limitation or

G1/4 180 bar
Q 2 1

Sensing LX valve has a variety P S DR

2
P1
G1/2 P P P P P P
T1
G ½“

clamping force limitation can be integrated just as easily as safety

of safety features, e.g. integrated cut-outs.
control pressure switch-off, PP L P 99 9 9 9 9

switch-off of certain flow R1 R2

U01A

directions, sections and function S1

T T T T T T

8 RS 160 directional control

groups or the entire directional Q
3 4 5 S2 Striking
mechanism
Lock
mast crown
Extend
mast extension
Swivel
boom
Telescoping folding mast /
crown of mast
valve
valve. P S DR T The RS 160 valve is ideally
z Energy efficiency suited to controlling various
Energy-efficient multi-circuit auxiliary functions on a drill
hydraulics systems with pump rig thanks to its modular and
sectional construction. The
flows adjusted according to 1 PPV100S 3 RKM Return Line &
requirement have become the Medium Heavy Duty Pump Suction Boost Filter valve is very robust and well-
standard for modern drill rigs. z Variable displacement pump The RKM return line &
T3
G3/
4
P2
G3/
8
A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 A G3/8 B G3/8 T2
equipped for sophisticated
mobile applications.
T T T A G3/8 B G3/8 A G3/8 B G3/8
T T T T G ½’’
PL

Load-sensing systems which are

PL PL PL PL PL PL

for load-sensing circuits with a suction boost filters are

supplied by variable displacement
pumps are the primary choice.
maximum displacment volume ideally suited for use in PM
G1/4 180 bar Examples of applications
of 180 cm³/rev and pressure of equipment with two or more P1
P P P P P
T1
G ½“
include the outrigger and mast
kinematics of the drill rig or the
G1/2 P P P

They are supplemented by simple 350 bar circuits. The return line flow
and cost-effective hydraulic z SAE version with splined shaft rate is supplied to the filter control of the mast head.
circuits for auxiliary functions and through drive element via one or several U01A

using fixed displacement pumps inlets. After the fluid has T T T T T T T T

and open center valves. passed through the filter

PGE gear pump for fixed element from outside to
2 ELF/BF
displacement systems inside (filtering the fluid), 9 Compact hydraulics control blocks
4 Breathers and filler breathers
z Size 2 up to a maximum of the back-pressure valve For the expansion of the directional valve technology, we offer
28 cm³/rev and a nominal creates a pressure inside Air filters are an essential component of customised valve block solutions. Our tried-and-tested compact
pressure of 250 bar the element, which ensures every hydraulic system. They guarantee valves extend the functionality of your machine – custom-fit,
that the filtered return line that the air drawn into the tank as a result of compact and cost-effective.
z Size 3 up to a maximum of 60 flow is available to support
cm³/rev and a nominal pressure fluctuations in the oil level is filtered reliably. In drill rigs we offer you various solutions, e.g. for load
the suction characteristics
of 250 bar of the connected pumps, compensation, brake control, gear shift and various switching and
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E 10.152.0/02.15
especially in cold start release functions.
conditions. The risk of Standard applications for control oil conditioning
Tank fittings and accessories and/or pilot circuit systems.
cavitation is significantly
5 such as fluid level gauges or
reduced.
tank cover plates

13 14
 Hydraulic supply
Optimal solutions from the
HYDAC technology platform.

RFM LF Optimicron® filter element

BDE RMTR Diesel

PreCare

Diesel PreCare filter Fuel pump for diesel fuel Plastic tanks

Diesel filtration Fuel pumps Hydraulic tanks Filtration

Features Features Function Function
z Suction-side pre-filter and water trap z Fuel pump for diesel or hydraulic oil Unlike welded steel tanks, customised plastic tanks are usually Our broad filter range offers inline filters (LF, MDF, DF)
z Manual or automatic water discharge z Flow rate used when installation space is extremely limited and very with various pressure ratings and materials in addition
lightweight construction is required. to filler/breathers (ELF) for the hydraulic tanks. We also
z Option: water sensor, fuel pre-heater, - Diesel: up to 80 l/min
have a broad range of in-tank return line filters (RF)
manual/electrical filling/booster pump - Mineral oil: up to 15 l/min and return line & suction boost filters (RKM). Specially
z Variants for diesel engines up to > 3000 kW Advantages designed in-tank return elements (RMTR) offer good
z Installation position optional
z Improved component cleanliness, since plastic tanks are distribution of oil flow in the tank, highly effective air
Function very clean following production. separation and thus a reduction in the size of the
Function hydraulic tank.
Guarantees the fuel purity required of modern common rail z Air from oil, special tank geometry allows quick and optimal
diesel engines to meet the requirements of the exhaust HYDAC fuel pumps are compact units with direct current
air separation (RMTR) The filters can also be used in explosion-hazard areas
emissions standards Euro6 and Tier4, and component drive for quick and simple tank-to-tank transfer of diesel fuel
z Improved use of existing installation space due to (ATEX).
protection of the fuel system through the use of the latest, or hydraulic oil.
optimised design (complex, curved designs available)
fully synthetic filter media and continuously reliable water
separation. z Inexpensive The costs depend on tank volume and not Advantages
Advantages
Reduction of the Life Cycle Cost (LCC) by extending the design complexity. High level of operating safety thanks to first class
z Possible to fill the fuel tank on the vehicle, away
service life and service intervals. z Clean tank surface, filtration
from stationary fuel stations
due to integral baffle designed to prevent fluid spill from the z Protection of system components
z Self-priming up to 2.5 m in height breather filter onto the tank
Advantages no initial filling prior to commissioning required z Element is easy to change and filter housing is
z Element does not block, easy to install
Protection of all of the components of the fuel system, e.g.: z Compact design due to dry air filter element and partial cleaning whenever
suction pump, common rail injection pump, diesel injectors saves on both space and weight air is expelled – dust is purged from the filter material z Low operating costs thanks to low pressure drops
by: across the filter and filter element
z DC motor with protection rating IP65
z Excellent water removal z Improvement in operating safety through the use
z Good efficiency, low current consumption
z Maximum contamination retention capacity of filter clogging indicators
z Suitable for dry running

Hydraulic Supply
z Very long service life z Brand labelling to protect the spare parts
Safe also for short run periods without fluid
business
z Very low pressure drop z Integrated temperature switch
z Tank-filter complete systems, optimized for
z Check valve completely sealed, leak-tight component protection, system cleanliness and
venting
z Ultra-modern laboratory and test rig technology
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E 10.152.0/02.15

Motor performance class [kW]

See Brochure 7.020 - Mobile Machinery Update See Fluid Filters brochure no. 70.000
See Brochure 7.125 - Diesel PreCare
16 19

OK-ELD with DC Motor OK-ELH / AC-LNH with hydraulic motor
Cooling
Hydraulic oil cooling
- Oil/air cooler with DC or hydraulic motor
- Electro-hydraulic fan controls
Features
z Robust aluminium plate construction
z Compact design for confined installation spaces
z High performance air fin with very good
anti-contamination properties
z Low-noise fan
Function
Air coolers with DC motors (OK-ELD) or
hydraulic motors (OK-ELH) are used to cool
hydraulic oil. They were specially designed for
mobile applications where high performance
and easy installation in the smallest space is
necessary. HYDAC offers electrically powered
and hydraulically powered fans. They regulate the
speed of the fan depending on the temperature of
the medium. As an option, these controls can also
be supplied with a reversing function, to "purge" the
cooler of dirt (e.g. dust and debris).
z Cooling capacity up to 34 kW (OK-ELD) and
140 kW (OK-ELH)
z DC motor with 12 V or 24 V
z Hydraulic motors from 6.3 to 22 cm³/rev
Advantages
z Compact design
z Efficient due to individually controllable cooling
circuits
z Low-noise fan
z ATEX version available for operation in explosive
gas and explosive dust atmospheres
See Cooling Systems brochure no. 5.700
Combination cooler CMS
Combination cooler
- CMS combination cooler for hydraulic oil,
transmission oil, charge air, coolant, diesel fuel
The following cooling circuits can be combined
together in various ways in a CMS mobile cooler:
z Charge air cooling (CAC)
z Coolant cooling (RAD)
z Oil circuits: transmission, hydraulics, fan drive
z Fuel cooling
With the aid of our cooling calculation software (KULI),
and on the basis of available data, it is simple to
adjust for pressure losses and heating of the cooling
air which will also occur as a result of installing a
condenser.
z Drive: direct, electrical or hydraulic
Fan control components and control blocks
Hydraulic and electro-hydraulic controls for regulating fan motor speed with
optional reversal of rotation direction for use with various types of pumps.
Valves specially developed for the application:
z Directional control valves
z Non-return anti-cavitation valves
z Manually adjustable pressure relief valves
z Inversely proportional pressure relief valves
Proportional Directional control valve
pressure relief valve
Example of fan control application
PGE100 PGI100
PVF100 PPV100S and PPV101
Drive technology
HYDAC offers a wide range of pumps for the working hydraulics
of lift-lower systems in open hydraulic circuits. The pump range
includes fixed and variable displacement pumps of various
designs from 0.25 ccm/rev to 560 ccm/rev and pressure ranges
Front-to-back layout of up to 400 bar.
HYDAC fixed displacement pumps for auxiliary circuits and
control oil supply:
z External gear pump PGE
from 0.25 ccm/rev – 60 ccm/rev, nominal pressure
up to 250 bar and maximum pressure up to 300 bar.
Also available in multiple pump combinations.
Side-by-side layout
z Internal gear pump PGI
Individual cooler requirements for from 3.8 ccm/rev – 250 ccm/rev, nominal pressure
combination cooler systems - oil, up to 330 bar and maximum pressure up to 400 bar.
water and charge air cooling
Also available in multiple pump combinations.
z Vane pump PVF
from 5.8 ccm/rev – 237 ccm/rev, nominal pressure
up to 210 bar.
Ideally suited to offline cooling and filtration circuits.
Also available in multiple pump combinations.
HYDAC variable displacement pumps for main functions:
z Axial piston pump PPV100S
from 16 ccm/rev – 180 ccm/rev, nominal pressure = 315 bar
and maximum pressure = 350 bar.
High speed reserves, finely graduated flow levels, control
range constantly being expanded.
Design standard in accordance with DIN ISO 3019-2 and SAE.
Also available in multiple pump combinations.
z Axial piston pump PPV101
from 45 ccm/rev – 200 ccm/rev, nominal pressure = 320 bar
and maximum pressure = 350 bar.
E 10.152.0/02.15
High speed reserves, versatile range of controls.
Design standard in accordance with DIN ISO 3019-2 and SAE.
Also available in multiple pump combinations.
See Pump Specifications brochure no. 2.900
17
Bladder, piston and diaphragm accumulators for mobile applications
Accumulators
HYDAC offers an exceptionally wide product portfolio
of accumulators and dampers for a very wide array of
hydraulic applications on drill rigs and their accessories.
This enhances working comfort and functionality of the
machines and thus minimises stress for both humans and
machines.
Typical accumulator tasks and benefits resulting from
them include:
z Providing energy to hydraulic hammers
 Increase in performance for comparable technical
conditions
z Pulsation damping on flushing pumps
 Increased service life of the built-on parts by
minimising vibrations
z Energy storage to compensate for leaks on clamping
and tensioning devices
z Emergency and safety tasks in the pilot circuit
 Increase in functionality
z Media separation for pressure measurement in the
flushing system
 Prevention for the purpose of avoiding down times
Advantages:
Our accumulator specialists have decades of experience
in the development and design of all the major types of
accumulator. This means that they can select the right
accumulator from the extensive product range to suit each
application and to size it in accordance with operating
conditions. The correct accumulator will always provide
the best performance for an application and country-
specific approvals mean that HYDAC accumulators can
be used world-wide.
E 10.152.0/02.15
See Catalogue 30.000 Accumulator Technology
18
 Outriggers & hydraulic power units
Stable placement
and flexible drive power.

Using the modules for outrigger systems, which are scaled for safety, we can, in partnership with you, develop practically any outrigger
system to suit any application, and to any safety requirement from a single source. We can also provide the necessary support in selecting
the best control concept.
Modules can be used to depict PL b to PL d:
For different performance classes
For different safety requirements
For different control types
Interfaces for working area restriction and load moment limitation

Power units for HDD systems

Examples of applications
For all mobile machines that have an outrigger or levelling system, symmetrical or asymmetrical, remote-controlled or directly actuated.
Can be supplied if required with interfaces to sensors, display instruments, data loggers, load safety systems and working range limita-
tions.
In accordance with the standard EN ISO
13849-1 Safety of Machines, the machine
builder must determine the control
category that is relevant for his machine,
referred to as the Performance Level (PL).
The safety-related parts of the control
must thereby fulfil the requirements of the
Sliding outrigger rails Pivoting outrigger beams Vertical outriggers respective Performance Level.
Based on the system modules for
outriggers that are scaled in accordance
with safety requirements, the machine
builder, together with our application
engineers, can select the hardware
components that fulfil the requirements of
the control category of his machine.
Outrigger base
detection Levelling systems
Hydraulic power units
Function Advantages
HYDAC hydraulic power units provide a reliable drive unit z Robust and construction site-suitable technology
for your machine. As auxiliary power units, they ensure great
z High-performance and reliable transmission drives with
flexibility and can be operated with various different devices. proven HYDAC control technology
Our power unit system modules guarantee you superb quality, a z Worldwide service on location
high level of availability and short development times. We offer
you a suitable and cost-effective solution for your application. z Suitable solution from one source
Versatile applications for drives and auxiliary power units
for drilling operations:
z 20-50 kW class: break-out tong, mixers, small flushing pumps,
pipe handlers, loading crane, winches, emergency power units
z 100-300 kW class: power units for drill rigs or attachments,
e.g. deep vibrators, milling drives, pile drivers and shakers,
pumps
z 400-800 kW class: power units for HDD systems, deep level
drilling rigs, solids pumps, triplex pumps
Power unit versions:

Supports & Hydraulic power units

z In lightweight or heavy-duty series, depending on customer
requirement and area of application
z Various drive concepts: diesel, gas, benzene, electric motor,
In 4 stages: hybrid

Design examples for controlling an outrigger system z Fixed/variable displacement pump systems max. 420 bar with
integrated control and valve technology
The control examples* in stages 1-4 differ depending on the type of machinery and the statutory standards and directives. The functional z Power unit solutions from the fully operational motor assembly
safety in the control increases with each stage. The machine builders' product ideas and designs form the basis for designing an appropriate unit to complete drive solutions
control. The requirements are defined by the manufacturer and our application engineers support him by advising him on the selection of z Container power units in 8´/10´/20´/30´/40´ transport
suitable hardware components. containers, as mobile drive units Mobile small power units - heavy-duty series

Stage 1 Stage 2 Options or special requests for all power units:

The outrigger system is actuated manually via a lever
by the operator in accordance with visual assessment
(using spirit level). There is no sensory feedback information
from the hydraulic system or the outrigger cylinders.
Stage 4
Support and levelling of the vehicle is carried out automatically
at the touch of a button using certified levelling, pressure and
position detection sensors. Only certified controllers are used for
E 10.152.0/02.15
The outrigger system is activated via remote control or a rocker z ATEX versions
switch, the hydraulics only operating for as long as the operator z Approvals by various certification companies, e.g.
activates them. The system is operated without electronic Germanischer Lloyd, DNV,....
monitoring and feedback, purely on visual assessment
(sight of spirit level or an electronic level) by the operator. z Various temperature versions (Arctic, Desert)
z Offshore capability
z GPS monitoring
z Additional noise protection [< 60 dB(A)]
z 3G modem remote service
Stage 3
z Oil pan, including monitoring and walkway grids,
Support and levelling of the vehicle is carried out
automatically at the touch of a button, taking into account
z Special paint jobs (RAL)
levelling sensors and, where used, outrigger pressure z With lifting and/or lashing points

E 10.152.0/02.15
the electro-hydraulic control. This includes piston position monitoring
in the control block, outrigger pressure monitoring and outrigger base
monitoring. The control operates, however, without the use z Underbody in skid design
detection to operate the outriggers. A high resolution display for visual of certified electronic components and without implementing a
control can also be included as an option. redundant safety system on the vehicle.

See Brochure 10.153 - Components, systems and service for mobile power units Piggyback power unit for crawler drill rig

20 21
 Additional solutions Fluid Conditioning Systems
Perfectly tailored to the To provide flexible servicing on machines, there
are convenient mobile units for removing solid Customer benefits:
Ö Clean filling and flushing

HYDAC Technology Platform.

particles
- Portable filtration units Ö Versatile design – can be used on a
- Mobile filtration units variety of systems
- Built-in filtration units (offline) Ö Relief for the main filter
Ö Greater system availability
Ö Reduction in Life Cycle Cost

Cabin air filter for very fine and nano dust:

CabinAirCare.
Drill rigs and vehicles must not be used in
contaminated areas unless the driver's cab is
equipped with filtration and/or compressed air
systems to ensure an air supply of sufficient
breathing quality.
For tasks such as landfill sealing or encapsulation
or land rehabilitation, a CabinAirCare module
can be retrofitted to existing drill rigs, to provide
optimum protection for the rig driver without having
to make drastic changes to the existing air-
conditioning system or the cab.
For a healthy and productive work environment,
HYDAC Filter Technology already offers highly
effective air filtration systems as original
equipment or for retrofitting.
See Brochure 7.016.1 - CACR CabinAirCare
Customer benefits:
Ö Easy to install and expand (on existing A/C or filter systems) See Catalogue 79.000 - Filter Systems
Ö Sufficient system reserve (fan power, media sizing) for common
cabin sizes in construction and agriculture
Ö Robust and simple construction FluidCareCenter
Ö Filters airborne pollutants, including nano-particles and gases
We get involved in the process early on.
With our clean room in the FluidCareCenter, we
promise you exceptional cleanliness
from the components to the system:
Technical Cleanliness is becoming ever more
important in mobile hydraulics. Phrases such
as "reduction and prevention of production-
stage breakdowns" and the difficulty of longer
warranty periods are driving up the demands for
component cleanliness.
Active carbon filter HEPA filter Fine dust filter
Mobile filter systems
Customer benefits:
Ö By understanding the relevant
cleanliness data of your components, you
will be a step ahead of your competitors.
Ö A laboratory approved and recommended
by well-known automotive suppliers
Ö Many years' experience in the area of
technical cleanliness owing to active
collaboration on VDA Volume 19 and
ISO 16232
Ö Analysis with the help of extraction units
developed at HYDAC
Ö Sophisticated analysis equipment

Accessories for every sector Ö Continual advances in equipment

and processes to meet the increasing
requirements and needs of customers
To make hydraulic systems complete
Customer benefits:
z Standard fittings and ball valves
HYDAC is your expert for modifications and
(high pressure)
special solutions at all times, and especially
z Mounting clamps for hydraulic hoses and when custom jobs are required because
pipes, cylinders, electrical cables and standard parts are unsuitable. HYDAC's
accumulators in-house engineering, coupled with our See Brochure 7.128 - FluidCareCenter
multidisciplinary approach and worldwide FluidCareCenter
z Tamper-proof inductive proximity switch
(high pressure resistance) know-how, guarantee state-of-the-art
z Fluid level sensors technology and rapid development times.
z Temperature switch TSE
HYDAC accessories provide the final perfect Condition monitoring, Teleservice
z Standard clamp 3015 air/water reservoir touch to your machine with a broad range
clamping bands of standard and special components, also Constantly growing demands for operational
z Test points available in stainless steel. availability, reduction in downtime, detailed
z Quick-release couplings load and service management (economy, wear
& tear, service, warranty) require innovative
z Special clamps for particle filters monitoring, service and control concepts. A Customer ANALYSIS SENSORS
Ball valves variety of sensors provides the ideal basis for (Option)
See Accessories brochure no. 61.000 Pressure:
the development of such integrated system - HDA 4700
solutions. - Initial Startup
Cylinder systems Oil condition, e.g. ageing or presence of
- Customer Service
- HYDAC Service
Oil Condition:

Additional solutions
Our cylinder systems are notable for their contaminating fluids can be determined via - HYDACLAB®

Communication
versatility and extreme compactness. Customer benefits: the saturation level, temperature, change in Satellite HMG 3010
electrical conductivity, change in dielectric Mobile (SMS)
We offer cylinder drives with integrated valve Our own Service Center offers you a Internet
technology and guarantee optimal operation of comprehensive customer service. constant (HYDACLAB®) Contamination:
- CS 1000
your machine, even with increased operational We support you with the design, assembly, Saturation level (AS):
loads: maintenance and commissioning of your Particle contamination (CS)
z Crowd cylinders with integrated functionality system. We begin working closely with the Pressure (HDA)
Telescoping cylinder (11 m) with semi-integrated hydraulic
for load holding, load compensation and customer right from the development stage. control Flow rate (EVS)
length compensation Because of our knowledge, we can achieve Fluid level (ENS, HNT)
the best cylinder solution for your product,
z Outrigger cylinders with relief, e.g. by using special surface coatings for In combination with portable measuring
z Mast inclination and kinematics cylinders the piston rod. FE simulations or fatigue instruments (HMG series), this data can be
z Locking and clamping cylinders strength calculations also come under our recorded and analysed to supplement the
Engineering Standard.
E 10.152.0/02.15

The cylinders can also be weight-optimised and machine electronics (service).

E 10.152.0/02.15
GSM Modem GPS Joysticks Displays Keyboards Data Storage
they can be supplied with an integrated distance
measurement system.
Outrigger cylinder
See brochure HS-D 10.102 - Hydraulic cylinders and cylinder systems for mobile hydraulics See Brochure 10.122 - Condition Monitoring for an efficient Life Cycle Cost Management

22 23
 Accumulator Technology 30.000
Global Presence.
Local Expertise.
www.hydac.com
Filter Technology 70.000
Process Technology 77.000
Filter Systems 79.000
Compact Hydraulics 53.000

HYDAC Head Office

HYDAC Companies
HYDAC Sales and Service Partners
Accessories 61.000

HYDAC International Industriegebiet

GMBH 66280 Sulzbach/Saar
Germany
Electronics 180.000

Telephone:
+49 6897 509-01
Fax:
+49 6897 509-577
E-mail: info@hydac.com
Internet: www.hydac.com
E 10.152.0/02.15

Note
Cooling Systems 57.000

The information in this brochure

relates to the operating conditions
and applications described.
For applications and/or
operating conditions not described,
please contact the relevant technical department.
Subject to technical modifications.