HYDAC FILTER SYSTEMS OF7 Operating And Maintenance Instructions Manual Download Page 12

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Safety precautions

Proper/Designated Use

Use the unit only for the application described in the following.
The OF 7 filtration unit is a service unit for filling hydraulic systems, flushing

small hydraulic systems and for offline filtration and recirculation with or

without simultaneous filtration, depending on the cartridge.
Proper or designated use of the product extends to the following:

•

observing all instructions contained in the instruction manual.

•

performing inspection and maintenance work.

NOTICE

Impermissible operating media

The unit will be destroyed

►

Operate the unit using only:

- the mineral oils specified in DIN 51524; DIN 51525 or

- mineral-oil-based fluids as specified in DIN 1524-1 to DIN 1524-3,

HLPD.

►

Never pump:

- water

- aggressive fluids

- acids

- solvents

- oily sludge or sediment in the oil tank

►

Never operate the unit without a suction strainer.

OF7S / OF7K

en(us)

Page 12 / 68

BeWa OF7 3430048e en-us 2016-04-28.doc

2016-04-28

Summary of Contents for OF7

Page 1: ...OF7 Filtration unit Operating and Maintenance Instructions English translation of original instructions Keep for future reference Document no 3430048e ...

Page 2: ...Industriegebiet 66280 Sulzbach Saar Telephone 49 6897 509 1511 Fax 49 6897 509 1394 E Mail guenter harge hydac com HYDAC FILTER SYSTEMS GMBH All rights reserved No part of this work may be reproduced in any form print photocopy or by other means or processed duplicated or distributed using electronic systems without the written consent of the publisher These documents have been created and inspect...

Page 3: ...m Intended Use 13 Qualifications of personnel target group 14 Unit with hoses lances for mobile use 15 Unit to be integrated into a system for stationary use 16 Wear appropriate clothing personal protection equipment 17 What to Do in Case of Emergency 17 Firefighting Extinguishing Fires 18 Unpacking the unit 18 Decoding the name plate 19 Transporting the unit 20 Storing the unit 21 Checking the sc...

Page 4: ...cting electrically 400 V 3 phase with an on off switch and motor protection 37 Pneumatically connecting compressed air motor optional 38 Attaching connecting the pressure and vacuum hoses 39 Unit in operation 40 Avoid siphoning 41 Performing maintenance 42 Changing the filter cartridge 43 Cleaning replacing the suction strainer 46 Suction strainer cleaning interval 47 Removing installing the hose ...

Page 5: ...10 54 Spare parts list OF7S10 55 Overview of spare parts for the OF7S90 57 Spare parts list OF7S90 58 OF 7 wiring diagram with signaling relay 60 Technical data 61 Model code 62 EC declaration of conformity 63 Index 64 OF7S OF7K en us Page 5 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 6: ...s due to Product Liability shall remain unaffected Technical Support Contact our technical sales department if you have any questions on our product When contacting us please always include the model type designation serial no and article no of the product Fax 49 6897 509 9046 E Mail filtersystems hydac com Product modification We would like to point out that changes to the product e g purchasing ...

Page 7: ... for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the operating and maintenance instructions The index is incremented every time the manual is revised or...

Page 8: ... unit and other equipment Maintain the unit inspection intervals prescribed by law Document the results in an inspection certificate and keep it until the next inspection Hazard symbols These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or the environment Observe these instructions and act with ...

Page 9: ...ons Risk of burns due to hot surfaces Substances that are health hazards or irritants Danger from explosive atmosphere Use the necessary tool OF7S OF7K en us Page 9 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 10: ...tes a hazardous situation with a medium level of risk which if not avoided can result lethal or serious injury CAUTION CAUTION The signal word indicates a hazardous situation with a low level of risk which if not avoided can result in minor or moderate injury NOTICE NOTICE The signal word indicates a hazardous situation with a high level of risk which if not avoided will result in damage to proper...

Page 11: ...tivity are laid out as follows HAZARD SYMBOL SIGNAL WORD Type and source of danger Consequence of the danger Measures to avert danger Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulations OF7...

Page 12: ... extends to the following observing all instructions contained in the instruction manual performing inspection and maintenance work NOTICE Impermissible operating media The unit will be destroyed Operate the unit using only the mineral oils specified in DIN 51524 DIN 51525 or mineral oil based fluids as specified in DIN 1524 1 to DIN 1524 3 HLPD Never pump water aggressive fluids acids solvents oi...

Page 13: ...uch use The user alone shall assume any and all associated risk Improper use may result in hazards and or will damage the unit Examples of improper use Operation in potentially explosive atmospheres Operation under non approved operational conditions Operation when the safety devices are defective Modifications to the power unit made by the user or purchaser Inadequate monitoring of parts that are...

Page 14: ...ions and applicable regulations are to kept so they are accessible for operating and specialist personnel These operating instructions is intended for Operating personnel such persons have been instructed in power unit operation and are aware of potential hazards due to improper use Specialist personnel such persons with corresponding specialist training and several years work experience They are ...

Page 15: ...g troubleshooting maintenance decommissioning Disassembly Specialist personnel Safe handling use of tools Fitting and connection of hydraulic lines and connections Fitting and connection of electrical lines electrical machinery sockets etc Checking the phase sequence Product specific knowledge Operation Operations control Auxiliary personnel Product specific knowledge Knowledge about how to handle...

Page 16: ...roubleshooting maintenance decommissioning disassembly Specialist personnel Safe handling use of tools Fitting and connection of hydraulic lines and connections Fitting and connection of electrical lines electrical machinery sockets etc Checking the phase sequence Product specific knowledge Operation Operations control Auxiliary personnel Product specific knowledge Knowledge about how to handle op...

Page 17: ...n be severely injured or killed Observe the information relating to personal protection equipment in the safety data sheet of the oil Wear close fitting clothing Do not wear any rings chains or any other jewelry Wear work safety shoes Wear eye protection What to Do in Case of Emergency In case of emergency switch off the power unit or disconnect it OF7S OF7K en us Page 17 68 BeWa OF7 3430048e en u...

Page 18: ...s checked for leaks and proper functioning at the factory and is then properly packed When receiving and unpacking the unit check it for transport damage Dispose of the packaging material in an environmentally friendly manner When the unit is supplied without a filter element the ports on the underside of the filter inlet and outlet are also closed off with plastic plugs Dispose of the packaging m...

Page 19: ...ng HYDAC Item Description 1 Name plate of filtration unit 2 Name plate of electric motor 3 Model code for details see page 62 Part No Part number S N Serial no Power Power Voltage Grid Voltage number of phases Frequency Voltage frequency Current Current consumption Pmax Operating pressure maximum Flow Rate Flow rate Weight Empty weight OF7S OF7K en us Page 19 68 BeWa OF7 3430048e en us 2016 04 28 ...

Page 20: ... unit Only transport the unit using its handle or with it standing on its rubber feet When transporting the unit never pick it up by its attachments or components OF7S OF7K en us Page 20 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 21: ... in a clean dry non condensing space Permitted storage temperature range 20 60 C Humidity up to 80 relative humidity non condensing Air Clean salt free air not near oxidizing substances rust film Storage duration Indefinite Before the unit is started up again after being stored for more than 2 years we recommend replacing all seals and especially the hoses OF7S OF7K en us Page 21 68 BeWa OF7 34300...

Page 22: ... comes packed and ready to use Check that the filtration unit is complete before starting up The following items are supplied Qty Description 1 Filtration Unit OF7 1 Operation and Maintenance Instructions this document OF7S OF7K en us Page 22 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 23: ...e vane pump Dry running protection is enabled by the return line thin plastic tube leading from the filter back to the pump For this before starting up the unit the filter cartridge has to be at least half filled with the fluid to be pumped The maximum operating pressure is 3 5 bar Suction screen and reducer from G to G A 100 µm strainer is screwed into the reducer to protect the pump from coarse ...

Page 24: ...l Feature Due to its higher design for the larger electric motor with 370 Watt drive power the OF7S90PX 2 unit is also suitable to take the larger 180 size filter cartridge OF7S OF7K en us Page 24 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 25: ... with lance 10 Filter cartridge 20 Motor pump group 21 Clogging indicator back pressure indicator 22 On Off switch applies to 110V 230V model only 23 Power plug applies to the 110V 230V model only 24 Type label 25 Oil pan 26 Rubber foot to reduce vibration 27 Hose coupling 28 Carrying handle OF7S OF7K en us Page 25 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 26: ...The components of the OF7S90 unit The components of the OF7S90 unit OF7S OF7K en us Page 26 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 27: ...hose with lance 9 Suction hose with lance 10 Filter cartridge 20 Motor pump group 21 Clogging indicator back pressure indicator 22 On off switch 23 Pull power plug 24 Type label 25 Oil pan 27 Hose coupling 28 Carrying handle OF7S OF7K en us Page 27 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 28: ...0 V version that you will find an on off switch 22 on the electric motor s terminal box with a motor protection relay to protect it from overload and a power cable with a mains plug 23 The motor pump assembly is flanged onto the head part The head part contains the following components A pressure relief valve to protect against overloading It is located between the suction and pressure side of the...

Page 29: ...r the filtration unit Select operating mode The filtration unit does not have an operating mode selector You select the operating mode by changing between a filter cartridge and an empty cartridge Circulation pumping with filtration For Circulation pumping without filtration mode use the appropriate filter cartridge with the desired filtration rating Circulation pumping without filtration For Circ...

Page 30: ... OF7K Item Description 5 Suction strainer 6 Strap wrench 8 Pressure hose with lance 9 Suction hose with lance 10 Filter cartridge 20 Motor pump group 21 Clogging indicator back pressure indicator OF7S OF7K en us Page 30 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 31: ...Dimensions Dimensions OF7S10 OF7K10 All dimensions in mm OF7S OF7K en us Page 31 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 32: ...Dimensions OF7S90PX2 All dimensions in mm OF7S OF7K en us Page 32 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 33: ...nd completely empty the unit in order to prevent mixing with the residual oil in the filtration unit If different oils are mixed the oil properties can change as follows Higher risk of cavitation More seal wear Modified anti wear properties Poorer filtration Reduced filter element service lives Modified friction characteristics Modified response to water More deposits due to additive reactions Mor...

Page 34: ...th the type of oil to be pumped If you are not sure what sort of oil is in the pump or if you would like to pump a different type of oil to that previously pumped completely empty the unit and replace the filter element 6 Only for the OF7K version Fill the filter cartridge at least halfway with the fluid to be pumped to ensure protection from dry running 7 Please note the following steps to connec...

Page 35: ...e connector cable from its holder and unwind it completely Before plugging in the power plug make sure that the on off switch is in the 0 or OFF position Plug the power plug into a suitable power outlet Check that the voltage and frequency are correct Refer to the electrical data indicated on the motor type label Switch the filtration unit on or off using the switch on the motor terminal box The f...

Page 36: ... Danger of fatal injury due to electric shock Any work involving the electrical system may only be done by a properly trained certified electrician Check that the voltage and frequency are correct Refer to the electrical data indicated on the motor type label For the 400 V 180 Watt 3 phase version wire in a motor protection switch matched to the motor s nominal current Star Y connection Delta conn...

Page 37: ...g the electrical system may only be done by a properly trained certified electrician Compare the voltage and frequency specifications on the type label with the specifications for the available network Plug the power plug into a suitable power outlet Check the direction of rotation of the motor by switching it on briefly jog mode The rotational direction is indicated by an arrow on the fan cover I...

Page 38: ...ensure that the compressed air supply is at 5 7 bar NOTICE Dry running Danger of tipping The unit will be damaged The unit begins to pump once connected to the compressed air Please make sure that the unit begins to pump after connection to the compressed air Install a shut off device in the supply line to switch the unit on off OF7S OF7K en us Page 38 68 BeWa OF7 3430048e en us 2016 04 28 doc 201...

Page 39: ...ttom of the tank Prevent aeration of the medium by fully immersing the lance in the medium Make sure that the lance is always below the oil level in operation Check the hoses for damage and brittleness Replace damaged or brittle hoses immediately in order to prevent leakages during operation Put the hoses with the lance without any tension and or twist into the corresponding tank Secure the hose s...

Page 40: ... see page 47 A back pressure indicator on the filtration unit shows the degree of contamination of the filter cartridge When operating the filtration unit with a new filter cartridge and a fluid viscosity of 100mm s the pressure gauge shows minimal pressure at most The pressure gauge measures the back pressure upstream of the filter cartridge and is an indication of the degree of contamination of ...

Page 41: ... hose that is lower down causing the fluid levels to equalize in accordance with a principle of communicating vessels siphoning This siphoning effect also occurs when fluid is pumped in a pre pressurized tank When the unit is switched off the height difference primary pressure can cause flow to occur both in the feed direction and against the feed direction and the fluid can leak uncontrollably OF...

Page 42: ...ccurring This means that the clogging indicator may even show some back pressure for a clean fresh filter cartridge For example for an operating viscosity of 40 50 mm s the back pressure for a new filter cartridge may not exceed 1 bar Change the filter cartridge when the back pressure is approx 2 5 bar at the beginning of the red field Before changing the filter cartridge depressurize it Once depr...

Page 43: ...ty cartridge Circulation pumping without filtration 0160 MG 010 P Circulation pumping with filtration The filter cartridge 01x0 MA 0xx BN comes with a sealing ring Always replace the old sealing ring 1 for the filter element in the connector head with a new sealing ring For the filter cartridge 0160 MG 010 P the sealing ring 2 is already mounted on the filter element OF7S OF7K en us Page 43 68 BeW...

Page 44: ...s supplied 4 Unscrew the filter cartridge by hand In the process the medium present in the top part of the filtration unit drains out over the filter cartridge and collects in the oil pan If the filtration unit is connected to a system operating medium can continue to flow out of the hoses pipes Make sure that there is always 1 liter of medium in the filter cartridge 5 Dispose of the used filter c...

Page 45: ...ress the filter cartridge onto the filter mount by turning it manually in a clockwise direction After contact with the sealing surface tighten the filter cartridge manually with a turn Do not use tools to tighten the filter cartridge 10 Remove and clean the suction strainer 5 1 according to the description on page 46 in the chapter Cleaning replacing the suction strainer Fit the suction strainer a...

Page 46: ...rainer missing operating without a suction strainer The unit will be destroyed Never operate the unit without a suction screen Check clean the suction strainer regularly To protect the pump from coarse contaminant particles there is a suction strainer in the suction port Clean the suction strainer regularly OF7S OF7K en us Page 46 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 47: ...very different cleaning intervals for the different versions Item Mesh size Maintenance interval 5a 300 µm every 25 operating hours at least monthly at every filter change 5b 100 µm every 10 operating hours at least weekly at every filter change For heavily contaminated fluid the maintenance intervals shorten If the effectiveness of the pump falls or if the pump s noise levels increase then check ...

Page 48: ...e the suction and pressure lances from the container and empty them 3 Manually undo the collet 27 3 on the hose coupling 27 2 counterclockwise 4 Turn the hose coupling 27 2 by 90 counterclockwise and remove it 5 The suction strainer is now visible and accessible OF7S OF7K en us Page 48 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 49: ... the coupling 27 2 by 90 clockwise 2 Manually tighten the collet 27 3 on the hose coupling 27 2 clockwise If the collet is not tightened or not sufficiently the pump will take in air via the hose coupling 3 Start up the unit 4 Check the unit for leaks while it is operating OF7S OF7K en us Page 49 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 50: ... None Suction strainer 100 µm To remove the suction screen 5b unscrew it counterclockwise Check the O ring 5 2 for damage Replace it if necessary To assemble first put the O ring 5 2 into the opening and then screw the suction strainer 5b in clockwise Necessary Tools Depending on the version of the suction strainer use a 2 x 16 mm screwdriver or a 12 mm Allen key Cleaning the suction strainer Clea...

Page 51: ...s air in the suction line and the pump Fill the pump via the suction hose hose coupling The viscosity of the fluid is too high Check the viscosity of the medium Heat the medium to reach the permissible viscosity The is no power to the electric motor or no compressed air to the air motor Check the supply line to the filtration unit Replace it if necessary The electric motor or the pump is faulty Co...

Page 52: ...y The unit or filter cartridge is leaking Wrong missing or defective sealing ring Check the filter cartridge s sealing ring Replace it if necessary The filter cartridge has not been tightened enough Manually tighten the filter cartridge some more Follow the instructions on the filter cartridge OF7S OF7K en us Page 52 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 53: ...out of operation Drain the unit completely including all of its components before decommissioning Pull out the power plug and securely fasten the hoses and power cord to the unit Shutting down the unit See chapter Taking the unit out of operation Disposing of the unit Dispose of the packaging material in an environmentally friendly manner After dismantling the unit and separating the various mater...

Page 54: ...n use only original spare parts Make sure to always indicate the part no and the serial number when ordering spare parts See chapter Decoding the name plate page 19 Overview of spare parts for the OF7S10 OF7S OF7K en us Page 54 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 55: ... 50 Hz NBR 4 0 1 Motor pump assembly complete 180W 400 VAC 50 Hz 60Hz NBR 4 0 1 Motor pump assembly complete 180W 110 115 VAC 50 60 Hz NBR 4 1 383941 Repair kit consisting of shaft seal vane O rings NBR 4 1 Ventilator hood electric motor 4 1 On Off switch 110 V 4 1 On Off switch 230 V 4 1 Connector cable with plug 5a 1 37575 Suction screen 320 µm Plug in 5b 1 3098617 Suction screen 100 µm Screw in...

Page 56: ... Filter cartridge 160 Filtration rating 10µm 0160 MA 010 BN Betamicron 1 315726 Filter cartridge 180 Filtration rating 10 µm 0180 MA 010 BN Betamicron 1 315485 Filter cartridge 160 Filtration rating 20µm 0160 MA 020 BN Betamicron 1 315623 Filter cartridge 180 Filtration rating 20µm 0180 MA 020 BN Betamicron 1 249005 Filter cartridge 160 Filtration rating 10µm 0160 MG 010 P paper 1 300082 Empty car...

Page 57: ...Locating spare parts Overview of spare parts for the OF7S90 OF7S OF7K en us Page 57 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 58: ... 8 1 349064 Suction hose with lance L 4 0 m PVC 8 1 349288 Suction hose with lance L 5 0 m PVC 9 1 37607 Pressure hose with lance L 2 3 m PVC 9 1 349063 Pressure hose with lance L 4 0 m PVC 9 1 349289 Pressure hose with lance L 5 0 m PVC 9 1 349392 Pressure hose with lance L 10 0 m PVC 12 1 On Off switch 12 1 1 Cable gland 29 1 314609 Filter cartridge 160 Filtration rating 3 µm 0160 MA 003 BN Beta...

Page 59: ...5 Filter cartridge 160 Filtration rating 20µm 0160 MA 020 BN Betamicron 29 1 315623 Filter cartridge 180 Filtration rating 20µm 0180 MA 020 BN Betamicron 29 1 249005 Filter cartridge 160 Filtration rating 10µm 0160 MG 010 P paper 29 1 300082 Empty cartridge for Circulation pumping without filtration 0160 MA 1 1003695 Strap wrench available on request x not deliverable as spare part OF7S OF7K en us...

Page 60: ...OF 7 wiring diagram with signaling relay OF 7 wiring diagram with signaling relay 110V 230 V version OF7S OF7K en us Page 60 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

Page 61: ... 0 80 C 32 176 F 0 80 C 32 176 F Permitted ambient temperature range 20 40 C 4 104 F 20 40 C 4 104 F 20 40 C 4 104 F Sealing material NBR NBR NBR IP class IP 54 IP 54 IP 54 Noise level 65 dBA max 65 dBA max 65 dBA max Connector cable length 2 8 m 10 m 10 15 m Signal cable length 10 m 15 m without depending on how unit is ordered Length of hoses 2 5 m 2 5 m 2 5 m Suction hose DN 20 with lance DN 20...

Page 62: ...umes on request Drive motor D Compressed air motor K 120 V 50 Hz 1 Ph 0 18 kW M 230 V 50 Hz 1 Ph 0 18 kW N 380 420 V 50 Hz 3 Ph PE 0 37 kW 440 480 V 60 Hz 3 Ph PE 0 44 kW T 12 V DC 0 2 kW U 24 V DC 0 2 kW X Other voltage on request Filter size 1 Filter cartridge 160 2 Filter cartridge 180 Filter material B Betamicron BN L Empty cartridge for Circulation pumping without filtration operating method ...

Page 63: ...n of this product that is not coordinated with us in writing will cause this declaration to lose its validity Description Filtration unit Type OF 7 series Serial no EU Machinery Directive 2006 42 EG article 1 a 2014 01 13 Dr Andreas Schunk Date Name CE official Executive director Documentation Representative Mathias Dieter Dipl Kfm Wolfgang Haering Günter Harge Registered seat of company 66280 Sul...

Page 64: ...Hazard symbol 8 Hose coupling 25 27 55 58 Hydraulic diagram 30 I Imprint 2 In case of emergency 17 installation 15 16 installing 48 50 IP 61 IP class 61 M Maintenance 1 22 47 Maintenance interval 47 Measures 11 Model code 19 62 Motor pump group 25 27 30 N Noise level 61 O OFF 35 Off switch 25 55 58 offline filtration 12 22 23 Oil pan 25 27 55 operating 6 7 8 12 14 15 16 23 29 40 42 44 46 47 49 62 ...

Page 65: ...x T Transport 15 16 transporting 20 troubleshooting 15 16 51 Type label 25 27 V Vane pump 58 61 Ventilator hood 55 W Weight 19 61 OF7S OF7K en us Page 65 68 BeWa OF7 3430048e en us 2016 04 28 doc 2016 04 28 ...

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Page 68: ...gebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 6897 509 01 Central Fax 49 6897 509 9046 Technical Department Fax 49 6897 509 577 Sales Department Internet www hydac com Email filtersystems hydac com ...

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