HYDAC FILTER SYSTEMS OFU Filtromat Operating And Maintenance Instructions Manual Download

Page: 46 / 72

7 | Performing maintenance

HYDAC FILTER SYSTEMS GMBH

46 / 72

BeWa OFU 3120755d en-us lq

7 Performing maintenance

7.1 Maintenance table

Monthly

Annually

As required

Additional information

1 - Operating personnel; 2 - Specialist personnel – Mechanical

7.2 Changing the filter element

In this chapter, you will find the procedure for changing the fil-
ter element.

1x Allen wrench

= 5 mm

Suitable receiver bin for collecting the oil from
the filter housing.

Switch the filter unit off and close the shut-off valve at in-

let (IN) and outlet (OUT).

Secure the filter unit during maintenance from being

switched on accidentally.

Summary of Contents for OFU Filtromat

Page 1: ...U Filtromat Operating and Maintenance Instructions English translation of original instructions Document No 3120755d 10 24 2019 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ...eral safety information 10 1 5 6 Signal words and their meaning in the general safety information 11 1 6 Hazard symbols pictograms 12 1 7 Supplementary symbols 13 1 8 Exclusion of liability warranty 14 1 9 Notes on copyright 14 1 10 Validity of this manual 15 2 Safety information 16 2 1 Fire fighting extinguishing a fire 17 2 2 Stoppage in an emergency EMERGENCY STOP 18 2 3 Observing regulatory in...

Page 3: ...connections 37 5 4 1 Connecting the filter unit with a three phase electric motor 37 5 5 Connecting the suction pressure port 38 5 6 Attaching connecting the suction pressure hoses Accessories 40 5 7 Inserting the filter element 41 5 8 Commissioning 41 6 Operation 43 6 1 Activating the main switch 44 6 2 Observing the optical clogging indicator optional 45 7 Performing maintenance 46 7 1 Maintenan...

Page 4: ...nical data 56 9 3 1 Differential pressure indicator visual VM x B x 56 9 3 2 Differential pressure indicator visual VM x BM x 58 9 3 3 Differential pressure gauge electric VM x C x 60 9 3 4 Differential pressure gauge electric VM x D x L xx 62 9 4 Finding a Customer Service team 64 Glossary 67 Index 68 ...

Page 5: ...S GMBH Justus von Liebig Str Werk 20 66280 Sulzbach Saar Germany Germany E mail filtersystems hydac com Homepage www hydac com Court of Registration Saarbrücken HRB 17216 Executive directors Mathias Dieter Dipl Kfm Wolfgang Haering Tab 1 Impressum 1 2 Documentation Representative The contact data of the person authorized with the documenta tion is Mr Günter Harge c o HYDAC International GmbH Indus...

Page 6: ...re fer to it every time you require decisive details This manual informs and warns you of risks against which the risk reduction through the design and protective measures may not be effective or not fully effective 1 4 Target group of the manual This manual was created for the following target group Target group Tasks Owner This manual and the associated docu ments must be kept accessible at the ...

Page 7: ...ct Product name Operating and Maintenance Instructions 12345678 English translation of original instructions Valid from from s no 1 5 2 4 3 Fig 1 Overview labeling of the title page 1 Short name of the product product name 2 Type of document 3 Language 4 Document no Index Date of printing 5 Supplementary instructions regarding the validity of the manual optional Please note that you can directly a...

Page 8: ...r the representation of requirements ü he product is assembled and connected ü The product is switched off 1 Switch the product on 1 5 3 Representation of procedural instructions In the case of procedural instructions there are the two follow ing representations Procedural instructions with a fixed sequence Procedural instructions whose sequence must be complied with without fail are listed with s...

Page 9: ...vities it is necessary to carry out work steps with intermediate results and end results Intermediate results are the consequence of activities they are marked with an indented arrow End results represent the end of an activity and are repre sented with a flag An example for a procedural instruction with intermediate re sult and final result 1 Switch the product on ð The display lights up 2 Press ...

Page 10: ...nformation in this manual are highlighted with pictograms and signal words The pictogram and the signal word give you an indication of the severity of the danger Warning general safety information which are placed ahead of each activity are represented as follows CAUTION Type and source of danger Hazard symbol Consequence of the danger Measures to avert danger ...

Page 11: ...ch if not avoided will result lethal or serious injury WARNING WARNING The signal word indicates 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 mi nor or moderate injury NOTICE NOTICE The signal word indicates a haza...

Page 12: ... safety information and in structions in these operating instructions which indicate partic ular dangers to persons property or the environment Danger point warning Dangerous electrical voltage warning Mandatory action symbols used These symbols are listed for all general safety information and instructions in these operating instructions that refer to particu lar dangers to persons property or th...

Page 13: ... specific specialist training and several years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential dangers Specialist personnel Mechanic Such persons have specific specialist training and several years work experience They are able to assess and perform the work assigned to them and they are also able to recognize poten tial dang...

Page 14: ...t of the information in this manual In particular we shall not be liable for lost profit or other financial loss This exclusion of liability does not apply in cases of intent and gross negligence Moreover it does not apply to defects which have been deceitfully concealed or whose absence has been guaranteed nor in cases of culpable harm to life physical in jury and damage to health If we negligent...

Page 15: ...ity of this manual The diagrams and visualizations in this manual are meant for general illustration purposes Therefore representations and functional options can deviate from the delivered product We reserve the right to changes to the contents of this manual without prior notice ...

Page 16: ...ed use Bodily injury Damage to property u Never operate the filter unit in potentially explosive atmos pheres u The filter unit is to be used only with the permissible oper ating media NOTICE Impermissible operating media The filter unit will be damaged u Use the filter unit only with mineral oils and mineral oil based raffinates ...

Page 17: ...local accident prevention specifica tions and general safety regulations that apply for the area of operation of the device must be observed 2 1 Fire fighting extinguishing a fire Use a powder extinguisher that corresponds to fire class B as per EN 2 to extinguish any fires to fight fires Fig 2 Fire protection class B Maintain a minimum safe distance from electrical components For a mains voltage ...

Page 18: ...ns for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regula tions 2 4 Wear suitable clothing Loose fitting clothing increases the danger of being caught or being drawn in on rotating parts and the risk of getting caught on protruding parts You can be severely injured or killed in these cases Wear closely fitting clot...

Page 19: ...HYDAC FILTER SYSTEMS GMBH Overview of the filtration unit 3 BeWa OFU 3120755d en us lq 19 72 3 Overview of the filtration unit ...

Page 20: ...draulic tanks Intended use of the product also extends to the following Observing all instructions in the instruction manual Complying with inspection and maintenance work Claims for defects or liability regardless of the legal founda tion do not apply with incorrect or improper installation com missioning usage handling storage maintenance repair use of unsuitable components or other circumstance...

Page 21: ...H will assume no liability for any damage resulting from such use This risk is borne solely by the owner Improper use may result in hazards and or will damage the fil ter unit Examples of improper use Operation in potentially explosive atmospheres Operation under non approved operational conditions Modifications to the filter unit made by the user or pur chaser Inadequate monitoring of parts that ...

Page 22: ...ck the contents of the package to make sure everything is present The following items are included in the scope of delivery Qty 1 OFU including the suction and pressure hose and the power supply cable with the power plug model according to the purchase order see the model code 1 Filter element according to the purchase order 1 Operation and Maintenance Instructions this doc ument 1 EC declaration ...

Page 23: ...HYDAC FILTER SYSTEMS GMBH Overview of the filtration unit 3 BeWa OFU 3120755d en us lq 23 72 Fig 4 Checking the scope of delivery ...

Page 24: ...ion unit HYDAC FILTER SYSTEMS GMBH 24 72 BeWa OFU 3120755d en us lq 3 4 Dimensions Depending on the version the filter housing filter unit has dif ferent dimensions You can find details regarding these in the following chapters ...

Page 25: ...ILTER SYSTEMS GMBH Overview of the filtration unit 3 BeWa OFU 3120755d en us lq 25 72 3 4 1 OFU Dimensions The OFU filter unit has the following dimensions Fig 5 Dimensions of the OFU All dimensions are in mm ...

Page 26: ... on the version 3 6 Decoding the name plate Identification details of the filter unit can be found on the name plates on the filter unit and the components Always mention the part no and the serial no when contacting HYDAC Fig 6 Decoding the type label Item Description 1 Name plate of filter unit 2 Name plate of electric motor 3 Filter unit model code Part no Part number ...

Page 27: ...ture Power Power consumption Voltage Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Operating pressure maximum Weight Empty weight Flow rate Flow rate Temp Oil Permissible oil temperature range Temp Amb Permitted ambient temperature range Volume Oil volume in the filter unit Tab 5 Decoding the type label ...

Page 28: ...nt size Motor pump group 1 100 l min 1450 rpm 3 kW 50 hz 2 200 l min 1450 rpm 4 kW 50 hz Filter material B Differential pressure gauge visual C Differential pressure gauge electrical D Differential pressure gauge visual electrical P NBR Perbunan X other voltage on request N 380 420 V AC 50 Hz 3 Ph N60 440 480 V AC 60 Hz 3 Ph S 500 600 V AC 50 60 Hz 3 Ph 2 1300 3 2600 B Optimicron ON A Aquamicron B...

Page 29: ...755d en us lq 29 72 3 7 Requirements of the workplace working environment Requirements of the workplace as well as the working environ ment can be found in the chapter Technical data under Permitted ambient temperature range Protection class according to DIN EN 60529 IEC 529 ...

Page 30: ...filtration unit HYDAC FILTER SYSTEMS GMBH 30 72 BeWa OFU 3120755d en us lq 3 8 Components Operating elements The filter unit has the following components operating ele ments Fig 8 Components operating elements of the OFU ...

Page 31: ...retainer 20 Filter housing 21 Dynamic pressure gauge 22 Filter housing air vent BLEED 30 Motor pump assembly 40 Differential pressure gauge DPI 80 Suction hose with lance and suction strainer IN 85 Filter housing drain DRAIN 90 Pressure hose with lance OUT 100 Main switch with motor protection switch 120 Protective screen ...

Page 32: ...lement and dispose of it in an environmentally friendly manner Clean the inside of the filter housing NOTICE Improper clamping of the filter unit The filter unit will be damaged u Clamp the filter unit while transporting only via the filter housing Transport the filter unit only in standing position Store the filter unit in a standing position in clean and dry rooms The conditions required for sto...

Page 33: ...t Place the filter unit horizontally on a stable even and hori zontal surface Press the brakes on the rollers if available Make sure that there is sufficient space above the filter housing to replace the filter elements Observe the maximum permissible ambient temperature and constant supply of cooling air to avoid overheating Make sure that there is sufficient space above the filter housing to rep...

Page 34: ... communicating containers systems This siphoning effect also occurs when fluid is pumped in a pre pressurized reservoir Fig 9 Avoiding siphoning NOTICE Siphoning effect Reservoir overflowing leaking oil spill u Remove the ends of the hoses from the reservoir after op eration or shut the shut off device in the suction line After the filter unit is switched off the height difference primary pressure...

Page 35: ...tial pressure as well as the measurement point is critical as shown in the following diagram Fig 10 Measure or display dynamic pressure differential pressure p Total of the pressures p1 Differential pressure p1 Back pressure p2 Differential pressure p2 Back pressure p3 Differential pressure p3 Back pressure p4 Differential pressure p4 Back pressure In the example the back pressure at the first mea...

Page 36: ...it replace the filter element and empty the filter unit com pletely in order to prevent mixing with the residual oil in the fil ter unit If different oils are mixed the oil properties can change as fol lows 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 d...

Page 37: ...ind it completely 2 Before plugging in the power plug make sure that the main switch is in the 0 or OFF position 3 Check that the voltage and frequency are correct You will find the filter unit s electrical data on the electric mo tor s name plate 4 Plug the power plug into a suitable power outlet 5 Check the direction of rotation of the electric motor by switching it on briefly jog mode The direc...

Page 38: ... 11 Pressure loss formula Δp Pressure differential bar L Line length m d Internal pipe diameter mm Q Flow l min ν Kinematic viscosity mm s D Density kg dm The mineral oil based hydraulic oil has a density of 0 9 kg dm This formula applies to straight pipe runs Particularly with re gard to the suction side connection note that additional con nectors and pipe bends increase the pressure differential...

Page 39: ...72 Note that the nominal size of the connected hose piping must correspond to the cross section of the connection thread Make sure that the connection hoses piping suction side pressure side do not cause any tension or vibrations to be carried over to the filter unit Use hoses or expansion joints if necessary ...

Page 40: ... other parti cles are deposited on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Prevent aeration of the medium by fully im mersing the lance in the medium Make sure that the lance is always below the oil level in operation The IN OUT connection dimensions on the filter unit can be found in the chapter Technical Data Check the hoses for damage an...

Page 41: ...r commissioning ü Install the new filter element in the filter bowl For de tails see Changing the filter element ü Check that the power supply cable is undamaged Re place damaged cables immediately ü Connect the filter unit with the power supply ü Check that the suction and pressure hoses are undam aged Replace damaged hoses immediately ü Check the ambient and fluid temperature ü Prior to each use...

Page 42: ...tch the filter unit on and monitor the suction perfor mance ð If the filter unit is not pumping any fluid after a maxi mum of 5 minutes of operation then switch it off and fill the motor pump group with fluid through the suction hose Subsequently switch the filter unit on again O The filter unit is ready for operation ...

Page 43: ...filter bowl cover to monitor the service life of the filter element Visually check the optical clogging indicator daily See chapter Observing the optical clogging indicator optional 45 The optional visual electrical clogging indicator signals the re quired filter element change with an electrical switch which no tifies the remote control room or another sensor When the contamination display has re...

Page 44: ... lq 6 1 Activating the main switch Depending on the version with a visual or electrical clogging in dicator the main switch differs according to the following fig ure or L Fig 12 Activate the main switch L Main switch E STOP L1 Indicator lamp of filter element is dirty ...

Page 45: ...ndicator optional If the filter unit filter housing is equipped with an optical clog ging indicator then check it daily Fig 13 Observe the opti cal clogging indicator Change the filter element at a permissible differential pressure across the filter element or once the clogging indicator enters the red zone ...

Page 46: ...ement 1 7 2 Changing the fil ter element 1 1 Operating personnel 2 Specialist personnel Mechanical 7 2 Changing the filter element In this chapter you will find the procedure for changing the fil ter element 1x Allen wrench 5 mm Suitable receiver bin for collecting the oil from the filter housing ü Switch the filter unit off and close the shut off valve at in let IN and outlet OUT ü Secure the fil...

Page 47: ...AIN in a suitable container Dispose Recycle the oil in an envi ronmentally safe manner 3 Loosen the four star gripped screws on the filter cover anticlockwise 4 Fold the star gripped screws down and press them fur ther against the filter housing This pushes the filter cover of the filter housing upwards 5 Lift the filter cover up and remove the filter element Dispose the filter element in an envir...

Page 48: ... by turning it slightly NOTICE Do not use striking tool for this 9 Check the O ring on the cover for damage if necessary replace it Slightly moisten the O ring on the cover with an operat ing medium 10 Fit the filter cover NOTICE Pay attention to the O ring in filter cover while doing so It must not be damaged 11 Fold the four star gripped screws upwards and turn the star gripped nuts clockwise sc...

Page 49: ...ch the filter unit on and bleed the filter housing via the connection BLEED Unscrew the bleed screws with four turns and wait till the oil emits on the bleed screws BLEED Subse quently close the bleed screw BLEED 14 Check the filter unit for leaks O The replacement of the filter element is complete ...

Page 50: ...rly NOTICE Operation without a mounted strainer The pump will be damaged destroyed u Never operate the filter unit without a mounted strainer u Clean the strainer regularly 1x Allen wrench 6 mm 1x Wrench 50 mm 1x Oil drain container To check clean the strainer proceed as follows ü The filter unit is switched off at the main switch ü The suction hose and pressure hose are wound up at the unit and n...

Page 51: ... tally safe manner 3 Unscrew the cover 1 of the strainer anticlockwise with the wrench 50 mm 4 Remove the strainer 3 5 Clean the strainer 3 by washing off with a subsequent blowing out with compressed air 6 Check the seal 2 for damage Replace it if necessary 7 Insert the cleaned strainer 3 in the valve 8 Manually screw the cover 1 in with an installed seal 2 clockwise 9 Tighten it with the wrench ...

Page 52: ...ssioning Disconnect or remove the electric pneumatic or hydraulic connections Dispose of the packaging material in an environmentally friendly manner Dispose of the fluid operating medium that has been drained in an environmentally friendly manner After dismantling the product and separating its various materials into categories dispose of all parts in an envi ronmentally friendly manner ...

Page 53: ...t 9 1 EC declaration of conformity The ED declaration of conformity can be found in the Technical Documentation that is part of the scope of delivery for the product 9 2 Locating spare parts Use only original spare parts and accessories When ordering spare parts and accessories make sure to always indicate the exact model code and the serial number ...

Page 54: ... elements of the size 1300 Description Part no Filter element 3 µm 1300 R 003 ON KB NBR 1263059 Filter element 3 µm 1300 R 003 ON V KB FPM 1263760 Filter element 5 µm 1300 R 005 ON KB NBR 1263060 Filter element 5 µm 1300 R 005 ON V KB FPM 1263761 Filter element 10 µm 1300 R 010 ON KB NBR 1263061 Filter element 10 µm 1300 R 010 ON V KB FPM 1263762 Filter element 20 µm 1300 R 020 ON KB NBR 1263062 F...

Page 55: ...00 R 003 ON V KB FPM 1263784 Filter element 3 µm 2600 R 003 AM KB FPM 1268232 Filter element 5 µm 2600 R 005 ON KB NBR 1263072 Filter element 5 µm 2600 R 005 ON V KB FPM 1263785 Filter element 10 µm 2600 R 010 ON KB NBR 1263073 Filter element 10 µm 2600 R 010 ON V KB FPM 1263786 Filter element 20 µm 2600 R 020 ON KB NBR 1263074 Filter element 20 µm 2600 R 020 ON V KB FPM 1263787 Filter element 40 ...

Page 56: ...ing filter unit 9 3 1 Differential pressure indicator visual VM x B x The optical differential pressure gauge reacts to the increasing pressure difference at the increasing contamination level of the filter element 30 Fig 14 Differential pressure indicator visual VM x B x Type of indication Visual display with a green red field automatic reset Weight 55 g Response pressure and indi cation range re...

Page 57: ...5d en us lq 57 72 Permissible operating over pressure 210 bar Permitted temperature range 30 100 C Connector threads G Installation space required According to HN 28 22 Maximum tightening torque 33 Nm Tab 8 Differential pressure indicator visual VM x B x ...

Page 58: ...ure gauge reacts to the increasing pressure difference at the increasing contamination level of the filter element 30 Fig 15 Differential pressure gauge visual VM x BM x Type of indication Visual display by green red field manual reset Weight 55 g Response pressure and indi cation range respectively VM 2 BM x 2 bar 10 VM 3 BM x 3 bar 10 VM 5 BM x 5 bar 10 ...

Page 59: ...BeWa OFU 3120755d en us lq 59 72 Permissible operating over pressure 210 bar Permitted temperature range 30 100 C Connector threads G Installation space required According to HN 28 22 Tab 9 Differential pressure indicator visual VM x BM x ...

Page 60: ...ial pressure gauge electric VM x C x The electric clogging indicator reacts to the increasing pres sure difference at the increasing contamination level of the fil ter element 30 Fig 16 Differential pressure indicator electrical VM x C x Type of indication Electrical switch Weight 120 g ...

Page 61: ...uired According to HN 28 22 Maximum tightening torque 33 Nm Switching type N C or N O change over contacts Maximum switching voltage 230 V Max switching voltage at re sistive load 60 W 100 VA AC Switching capacity ohmic 3 A 24 V DC ohmic 0 03 to 5 A 230 V AC Electrical connection Male connection M20 Female connector to DIN EN 175301 803 Protection class in accordance with DIN 40050 IP 65 only if t...

Page 62: ...uge electric VM x D x L xx The electric clogging indicator reacts to the increasing pres sure difference at the increasing contamination level of the fil ter element 30 Fig 17 Differential pressure indicator electrical VM x D x Lxx Type of indication Visual indicator and electrical switch Weight 150 g ...

Page 63: ...22 Maximum tightening torque 33 Nm Switching type N C or N O change over contacts Maximum switching voltage L24 24 V DC L48 48 V DC L115 115 V AC L230 230 V AC Max switching voltage at re sistive load 60 W 100 VA AC Switching capacity ohmic 3 A 24 V DC ohmic 0 03 to 5 A 230 V AC Electrical connection Male connection M20 Female connector to DIN EN 175301 803 Protection class in accordance with DIN ...

Page 64: ...he hotline product support customer service branch offices service partners for servicing repair and spare parts can be found always updated at our home page www hydac com HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Str 15 Werk 13 66450 Neunkirchen Heinitz Germany Phone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 12 Customer service in Germany ...

Page 65: ...26 Fig 7 Model code OFU 28 Fig 8 Components operating elements of the OFU 30 Fig 9 Avoiding siphoning 34 Fig 10 Measure or display dynamic pressure differential pressure 35 Fig 11 Pressure loss formula 38 Fig 12 Activate the main switch 44 Fig 13 Observe the optical clogging indicator 45 Fig 14 Differential pressure indicator visual VM x B x 56 Fig 15 Differential pressure gauge visual VM x BM x 5...

Page 66: ... delivery 22 Tab 5 Decoding the type label 26 Tab 6 Filter elements size 1300 54 Tab 7 Filter elements size 2600 55 Tab 8 Differential pressure indicator visual VM x B x 56 Tab 9 Differential pressure indicator visual VM x BM x 58 Tab 10 Differential pressure indicator electrical VM x C x 60 Tab 11 Differential pressure indicator electrical VM x D x Lxx 62 Tab 12 Customer service in Germany 64 ...

Page 67: ...ditions The General Terms and Conditions are available at our home page www hydac com General Terms and Conditions HN 28 22 HYDAC standard 28 22 with dimen sions for the installation space for clogging indicators KB marking of filter elements Filter elements with the KB mark ing do not have a bypass ...

Page 68: ...l VM x C x 61 VM x D x Lxx 63 Differential pressure indicator visual VM x B x 57 VM x BM x 59 differential pressure dynamic pressure 35 disposal 52 dynamic pressure differential pressure 35 E exclusion of liability 14 H Hotline 64 I Imprint 5 M main switch EMERGENCY STOP 44 manufacturer 5 P Person authorized with the documenta tion 5 S Service 64 Servicepartners 64 siphoning effect 34 Support 64 T...

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