Details

1. Introduction
The Hydraulic Hose/Tube Proof Test Stand is engineered for rigorous static pressure testing of hydraulic hoses and tubes in industrial and aerospace maintenance environments.
Its dual-chamber, floor-mounted enclosure houses both a high-capacity electric gear pump and an air-driven Haskel pump, delivering up to 690 bar (10 000 psi) of hydraulic pressure.
All hydraulic circuits are routed through multistage filtration and a plate-type heat exchanger to ensure fluid cleanliness and thermal stability during extended test cycles. An integrated safety hood with polycarbonate viewing windows and interlocked limit switch offers full operator protection. The unit’s modular steel cabinet, finished in corrosion-resistant powder coat, sits on adjustable vibration-dampening feet for stability on uneven  floors. Comprehensive instrumentation digital pressure transmitter with 4–20 mA output,
analog gauges, programmable timer, and emergency-stop ensures precise, repeatable testing to meet stringent quality and regulatory requirements.

2. Key Features
Dual-Source Pressurization:
Electric Gear Pump (Rexroth AZPW21004):
 • 4 cc displacement, 5 L/min flow; driven by a 3 HP, 1 420 RPM, three-phase motor for rapid, stable pressurization up to 800 bar.
 • Air-Driven Haskel Pump (MS 188): Delivers up to 1 500 psi for fine manual control or back-up operation; actuated via a simple lever handle.

Advanced Fluid Conditioning:
 • Triple-Stage Filtration: Inline elements rated at 10 μm, 6 μm, and 3 μm remove particulate contamination before high-pressure delivery.
 • Plate-Type Heat Exchanger: Maintains oil temperature within 20–40 °C, protecting seals and ensuring consistent viscosity.

Precision Instrumentation:
 • Digital Pressure Transmitter: 0–1 000 bar range, 4–20 mA loop output to external data acquisition or PLC.
 • Analog Gauges: Bourdon gauge (0–800 bar) & pneumatic gauge (0–16 bar).

Programmable
 • Timer & Selector Switch: Front-panel timer allows test durations from 1 s to 99 h 59 m, with manual or automatic start/stop modes.
Safety & Ergonomics:
 • Enclosed Test Chamber: Double-walled steel safety hood with two tempered-glass windows (250 × 250 mm each), rated to withstand full system pressure.
 • Limit-Switch Interlock: Automatically vents pressure if the hood is opened mid-cycle.
 • Emergency-Stop Mushroom Button: Immediately de-energizes pumps and opens the main relief valve.

Oil Management:
 • Sliding Oil-Collecting Tray: Positioned directly beneath the chamber for rapid removal of drain oil; tray capacity of 5 L.
 • Permanent Drip Tray: Catches overflow or accidental drips, routed to a 2 L sump for easy disposal.

Robust Construction:
 • Cabinet Material: 2 mm mild-steel enclosure with RAL 7032 powder coat; corrosion-resistant and easy to clean.
 • Viewing Windows: 6 mm polycarbonate sheets, UV stabilized and scratch resistant.
 • Mounting: Four adjustable, anti-vibration feet accommodate floor irregularities up to ±10 mm.

3. Applications
 • Aerospace MRO: Proof-testing hydraulic hoses for helicopters, fixed-wing aircraft, and ground-support equipment.
 • Mobile & Heavy-Duty Equipment: Certification of hoses for excavators, cranes, mining vehicles, and agricultural machinery.
 • Industrial Fluid Power Systems: Quality control for assembly shops producing high-pressure hoses and fittings.
 • R&D Laboratories: Validation of novel hose materials and seal designs under static orcyclic loads.
 • Training & Certification: Operator training rigs at technical schools and OEM service centers to demonstrate safe pressure-testing protocols.

4. Technical Specifications

  
Parameter
Specification
  
Maximum Test Pressure
10 000 psi (≈ 690 bar)
  
Electric Pump Working Range
0–800 bar, 5 L/min
  
Air-Driven Pump Range
0–1 500 psi (≈ 103 bar)
  
Fluid Tank Capacity
50 L stainless steel (SS 304), with sight glass and high/low-level switches
  
Filtration
10 µm, 6 µm, 3 µm inline cartridge filters
  
Cooling
Plate-type heat exchanger, 1 kW thermal capacity
  
Pressure Transmitter
Wika S10, 4–20 mA output, 0–1 000 bar
  
Process Indicator
Selec PIC-152N-B, LED for mA input and set-point alarm
  
Analog Gauges
Bourdon (0–800 bar) & pneumatic (0–16 bar)
  
Timer
1 s–99 h 59 m, digital, front-panel mounted
  
Hood Windows
2 × 250 × 250 mm polycarbonate with rubber seals
  
Electric Motor
3 HP, 1 420 RPM, 3-phase, 415 VAC ± 5 %, TEFC
  
Power Supply
415 VAC three-phase & 220 VAC single-phase; 2 kVA transformer included
  
Control Panel
IP 54, 20° incline, houses switches, gauges, indicators
  
Dimensions (W × D × H)
3 000 × 1 000 × 1 500 mm
  
Weight (Empty)
≈ 850 kg
  
Ambient Range
0–45 °C, 10–90 % RH (non-condensing)
  
Safety Standards
EN 61010-1 & ISO 13849 compliant


5. Bill of Materials (Highlights)

  
Item
Description / Part No.
  
Hydraulic Tank
SS 304, 50 L, welded
  
Filter Cartridges
Hydac 110LEN0040-H10 / -H06 / -H03XL
  
Heat Exchanger
Alfa Laval CB20
  
Gear Pump
Rexroth AZPW21004RORXXMBS0593, 4 cc, 5 L/min
  
Air Pump
Haskel MS 188, up to 1 500 psi
  
Electric Motor
ABB HX100LA4, 3 HP, 415 VAC
  
Pressure Transmitter
Wika S10, 0–1 000 bar
  
Process Indicator
Selec PIC-152N-B
  
Analog Gauges
Wika 111.10; SMC 0–16 bar
  
Timer Module
Omron H5CX
  
Limit-Switch Interlock
Schneider XCKJ
  
Hood Windows
Polycarbonate, UV stabilized
  
Emergency-Stop Button
Siemens 3SU1050-0AA00
  
Cabinet Enclosure
Mild steel, RAL 7032 powder coat
  
Transformer
2 kVA, 415–220 VAC step-down
  
Mounting Feet
Anti-vibration, adjustable ± 10 mm


6. Installation & Commissioning
1. Site Preparation: Level concrete floor rated ≥ 1 000 kg; ambient 0–45 °C, < 90 % RH.
Clearance: 300 mm all around; no direct sun.
2. Power Connections: 415 VAC three-phase (pump); 220 VAC single-phase (controls).
Cable: ≥ 4 mm2 copper; earth-ground < 1 Ω.
3. Hydraulic Hookup: Fill with OM 15 oil to high mark; bleed via pump inlet screw.
4. Functional Checks: Verify motor rotation (CW from rear). Inspect filters, hoses, and
interlocks.
5. Initial Test Run: Dry-run pump 5 min; monitor current < 80 % rated. Pressurize to 100
bar, hold 1 min; inspect for leaks. Execute three 690 bar cycles (2 min hold); pressure drift <
± 5 bar.

7. Maintenance & Troubleshooting
Daily: Inspect, oil-level, gauge zero, E-stop check.
Weekly: Clean, test hood switch, filter Δp < 1 bar.
Monthly: Drain tank, replace 10 μm filter if Δp > 0.5 bar, torque bolts.
Quarterly: Clean exchanger, calibrate transmitter, leak-down test at 500 bar (Δp < 10 bar).
Annual: Overhaul pumps, replace filters, burst-test chamber at 1.25× working pressure.


  
Symptom
Cause
Corrective Action
  

    
No pressure build-up
    
Pump rotation / wiring fault
    
Reverse leads; check starter wiring
  
  

    
Erratic readings
    
4–20 mA loop/transmitter drift
    
Inspect loop; recalibrate transmitter
  
  

    
High oil temp
    
Fouled heat exchanger
    
Clean plates; verify coolant flow
  
  

    
Fittings leak
    
Loose or worn seal
    
Retorque; replace O-ring
  
  

    
Hood won’t start test
    
Limit-switch misaligned
    
Realign/replace switch
  


8. Conclusion
The Hydraulic Hose/Tube Proof Test Stand represents a comprehensive, turn-key solution for high-pressure proof testing in demanding industrial and aerospace environments. By combining dual-source pressurization, advanced fluid conditioning, precision instrumentation, and robust safety features within a corrosion-resistant, ergonomically designed cabinet, it delivers repeatable, accurate results while ensuring operator protection and ease of maintenance. Whether validating hydraulic assemblies for aircraft, heavy-equipment, or R&D applications, the test hydraulic hose stands out for its reliability, versatility, and compliance with international safety standards. Optional PLC integration, extended-capacity chambers, and acoustic enclosures offer further customization to fit unique facility workflows and testing protocols.