HYDAC FILTER SYSTEMS OLFP-3 Series Page 75 Installation And Maintenance Instructions Manual Download

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Summary of Contents for OLFP-3 Series

Page 1: ...e Installation and Maintenance Instructions English translation of original instructions Document No 3819798a 4 7 2020 Follow these instructions for proper and safe use Keep for future reference Valid from series no up 0002S02452N0000027 ...

Page 2: ...presentation of warning general safety information 9 1 5 6 Signal words and their meaning in the general safety information 10 1 6 Hazard symbols pictograms 11 1 7 Supplementary symbols 12 1 8 Exclusion of liability warranty 13 1 9 Notes on copyright 13 1 10 Validity of this manual 14 2 Safety information 15 3 Filter housing overview 18 3 1 Proper designated use 19 3 2 Improper Use or Use Deviatin...

Page 3: ... indicator 42 5 6 Checking the installation 42 6 Operation 43 7 Performing maintenance 44 7 1 Maintenance table 44 7 2 Changing the filter element OLFP 3 44 7 3 Changing the filter element OLFP 6 50 8 Appendix 58 8 1 Locating spare parts 58 8 2 Clogging indicators technical data 62 8 2 1 Differential pressure indicator visual VM x B x 62 8 2 2 Differential pressure indicator visual VM x BM x 64 8 ...

Page 4: ...MS 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 Indu...

Page 5: ... 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 6: ...ll find the following information on the title page of this manual Short name of the product 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 inst...

Page 7: ... These are absolutely required for carrying out a work activity on the product and are marked with a check mark and are in bold in the text An example for 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 ...

Page 8: ...entation of intermediate results results In the case of some activities 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 fina...

Page 9: ...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 10: ...ich 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 haz...

Page 11: ...al 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 Signs used for giving orders 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 t...

Page 12: ...have 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 they are also able to recognize potential dange...

Page 13: ...ct 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 negligen...

Page 14: ...dity 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 15: ...ice must be observed DANGER Dangerous electrical voltage warning Danger of fatal injury u All electrical jobs must be carried out by specialists with the respective knowledge for the job u Pull the power plug and ensure the unit is deenergized DANGER Danger due to unintended use Bodily injury and damage to property u Never operate the filter unit in potentially explosive atmos pheres u Use the fil...

Page 16: ...spill u Remove the ends of the hoses from the reservoir after op eration or shut the shut off device in the suction line NOTICE Pressure port Outlet OUT closed The filter unit filter housing will be damaged destroyed u Make sure that the pressure port is always open during operation NOTICE Incorrect storage The clogging indicator will be damaged destroyed u Make sure that the clogging indicator is...

Page 17: ...e clogging indicator will be damaged destroyed u Grip the filter unit filter housing with your hands on the fil ter housing to transport or to store it NOTICE Impermissible operating medium The filter housing filter unit will be damaged destroyed u Use the filter housing filter unit only together with mineral oils and mineral oil based raffinates respectively ...

Page 18: ... The TriMicron filter elements used have the following proper ties Optimum adsorption of oil degradation products in the filter material without rapid clogging Very high contamination retention capacity through a pro nounced depth structure The advantages of the Offline Filter Pressure OLFP are Longer life expectancy for the main flow filter Improvement in component lifetime Higher machine availab...

Page 19: ...g inspection and maintenance work NOTICE Impermissible operating medium The filter housing filter unit will be damaged destroyed u Use the filter housing filter unit only together with mineral oils and mineral oil based raffinates respectively Claims for defects or liability regardless of the legal founda tion do not apply with incorrect or improper installation com missioning usage handling stora...

Page 20: ...use beyond this shall not be considered intended use HYDAC FILTER SYSTEMS GMBH 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 Operation when the safe...

Page 21: ...mmediately report any damage in transit to the forwarding agent or the HYDAC department in charge Commissioning may not be performed if the filter housing filter unit is dam aged Item Qty Description 1 1 OffLine Filter Pressure OLFP x x 2 1 Locking cap for filter element 3 1 Emptying the filter housing DRAIN 4 1 Clogging indicator optional 1 Installation and Maintenance Instructions this document ...

Page 22: ...s of the filter housing see the name plate Fig 3 Decoding the type label Item Description 1 Filter unit nameplate 2 Filter unit model code Part no Part number S N Serial number year of manufacture Power Power consumption Voltage Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Operating pressure maximum ...

Page 23: ...EMS GMBH Filter housing overview 3 MoWa OLFP 3 6 3819798a en us 23 76 Weight Empty weight Flow rate Flow rate Temp oil Permitted fluid temperature range Temp amb Permitted ambient temperature range Volume Volume content ...

Page 24: ...ng 1 Size 1 1x filter element 3 Size 3 1x filter element 6 Size 6 2x filter elements O with orifice for flow see figure volumetric flow through the orifice G with gear pump only for sizes 3 6 Z without M MCS 14xx MetallicContamination Sensor A AS 1000 AquaSensor Z without E Standard clogging indicator B Differential pressure gauge optical VM2BM x C Differential pressure gauge electrical VM2C x D3 ...

Page 25: ...ulic connection sizes 27 Connection OUT See Hydraulic connection sizes 27 Sealing material FKM NBR Permissible ambient tem perature range 30 40 C Permissible fluid tempera ture range 30 80 C Permitted storage tempera ture range 40 30 C Permitted relative humidity during storage 80 Storage duration Indefinitely Exchange all seals after a stor age period of 2 years Survival temperature 40 C Filter h...

Page 26: ...flow rate The nominal flow rate is limited by an orifice The type of orifice used can be seen on the model code for example OLFP x 2 2 l min orifice A The nominal low rate at a viscosity of 0 200 mm s can be found as follows Pressure bar Flow rate l min Fig 5 Nominal flow rate diagram TYPE Nominal flow rate Orifice Line type OLFP x 2 2 l min A OLFP x 3 3 l min B OLFP x 6 6 l min C OLFP x z variabl...

Page 27: ...Z TM NZ SAE according to ISO 228 or G according to ISO 228 OLFP 3 3 ZZ Z TM NZ G according to ISO 228 OLFP 6 3 ZZ Z TM NZ SAE according to ISO 228 OLFPCM 6 3 GN MA TM NZSAE according to ISO 228 Tab 7 Hydraulic connection sizes Connection IN Type code Connection OUT OLFP 3 Z ZZ Z TM NZ G according to ISO 228 OLFP 3 3 ZZ Z TM NZ G according to ISO 228 OLFP 6 3 ZZ Z TM NZ G according to ISO 228 OLFPC...

Page 28: ...er you will find the drawings with the dimensions of the different designs of the filter units filter housings Fig 6 Dimensions of OLFP 3 Z OLFP 6 Z IN Inlet OUT Outlet DPI Clogging indicator DRAIN Drain VENT Air bleed X Required space for removing the filter element z Fixture for wall mounting All dimensions in mm ...

Page 29: ...Wa OLFP 3 6 3819798a en us 29 76 3 7 Hydraulic circuit In this chapter you will find the hydraulic diagram of the differ ent designs of the filter housings Fig 7 Hydraulis diagram OLFP 1 IN Inlet OUT Outlet DPI Clogging indicator DRAIN Drain VENT Air bleed ...

Page 30: ... Components The filter housing has the following components Fig 8 Components of OLFP 3 x O Z OLFP 3 x Z Z IN Inlet OUT Outlet 1 Filter housing 2 Filter cover with handles 3 Air bleed plug Air bleed VENT 4 Drain ball valve DRAIN 5 Clogging indicator optional 6 Assembly board 7 Screw disc nut ...

Page 31: ...LFP 3 6 3819798a en us 31 76 Fig 9 Components of OLFP 6 x O Z OLFP 6 x Z Z IN Inlet OUT Outlet 1 Filter housing 2 Filter cover with handles 3 Air bleed plug Air bleed VENT 4 Drain ball valve DRAIN 5 Clogging indicator optional 6 Assembly board 7 Screw disc nut ...

Page 32: ... 6 3819798a en us 4 Transportation storage Fully empty the filter unit filter housing before transporting it or putting it into storage Remove the used filter element and clean the inside of the filter housing Fig 10 Transporting the OLFP Fig 11 Lifting OLFP with strap ...

Page 33: ...ge 4 MoWa OLFP 3 6 3819798a en us 33 76 Store the filter housing filter unit in a standing position in clean and dry rooms without condensing humidity The permit ted storage conditions are available in chapter Technical Data Fig 12 Storing the OLFP ...

Page 34: ...astening mounting the filter housing Before completing the installation ensure the correct direction of flow through the filter The connections are labeled IN OUT Install the filter housing only when it is in an upright position Fasten the OLFP using the 4 Ø 13 mm bore holes in the base Fig 13 Fastening mounting the filter housing at the base Example OLFP 3 x O Z or fasten the filter housing using...

Page 35: ...lling 5 MoWa OLFP 3 6 3819798a en us 35 76 Fig 14 Fastening mounting the filter housing via wall holder Example OLFP 3 x O Z Make sure that no stresses or vibrations are transmitted to the filter housing Use hoses or compensators if necessary ...

Page 36: ...s adequate removal space A for changing the filter element In order to make the filter element change easier install shut off devices in the immediate vicinity of the filter housing B OLFP 3 x O Z OLFP 6 x O Z Fig 15 Take note of the removal space for the filter element OLFP 3 A 400 mm OLFP 6 A 650 mm ...

Page 37: ...ow lying line can develop a suction effect and trigger the siphoning effect be tween the communicating containers systems This siphoning effect also occurs when fluid is pumped in a pre pressurized reservoir Fig 16 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 ...

Page 38: ...MS GMBH 38 76 MoWa OLFP 3 6 3819798a en us After the filter unit is switched off the height difference pri mary pressure can cause flow to occur both in the feed direc tion and against the feed direction and the fluid can leak un controllably ...

Page 39: ...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 Observe the following points for hydraulic connection Keep the height difference between the pump and the oil level in the reservoir as small as possible Use ...

Page 40: ...R SYSTEMS GMBH 40 76 MoWa OLFP 3 6 3819798a en us 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 compensators if necessary ...

Page 41: ...ifferential pressure and also the measurement point are cru cial as shown below Fig 18 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 measurement poin...

Page 42: ...filter housing filter unit has been fitted with an electrical clogging indicator connect it to your control center in accor dance with the switching logic 5 6 Checking the installation Check all the electric hydraulic connections screwed connec tions and components for firm seating After commissioning check all the functions and for leaks ...

Page 43: ...e optical or electric Visually check the optical clogging indicator daily See chapter Observing the optical clogging indicator optional The electric clogging indicator signals the required filter ele ment change through an electric switch which notifies the re mote control or another sensor When the clogging indicator has responded change the filter element filter cartridge Refer to Performing mai...

Page 44: ...draulic system is under pressure during operation Danger of bodily injury u The hydraulic system must be depressurized before per forming any work on it 7 1 Maintenance table 7 2 Changing the filter element OLFP 3 In this chapter you will find the procedure for changing the fil ter element 1x Allen wrench 10 mm 2x Wrench 30 mm To change the filter element proceed as follows 1 Switch off the pump i...

Page 45: ...rain ball valve to empty the filter housing Collect the escaping fluid 27 liters in a suitable con tainer Fill the oil back into the tank of the hydraulic sys tem or dispose of it in an environmentally friendly man ner Drain the filter housing only via the drain ball valve with the air bleed screw opened Only open the filter housing after no fluid escapes from the drain ball valve 4 Loosen the fou...

Page 46: ...6 76 MoWa OLFP 3 6 3819798a en us 5 Using the handles take the filter cover off in an upwards direction and place it on a clean surface 6 Using the handle on the locking cap remove the used filter element from the filter housing in an upwards direc tion ...

Page 47: ... Separate the locking cap from the filter element by turn ing it 45 Dispose of the filter element in an environmentally friendly way 8 Place the locking cap onto the new filter element and turn it 45 to connect it 9 Coat the O rings on the filter element lightly with the op erating fluid ...

Page 48: ...t NOTICE Do not use a hammer or similar tools for this During operation the locking cap always re mains on the topmost filter element If assembled without the locking cap no filtration action takes place 11 Check the O ring for damage and replace it if neces sary 12 Put the filter cover from the top onto the filter housing Make sure that the position is correct while doing so ...

Page 49: ...f device slowly at the inlet IN to avoid pressure shocks to the filter and fill the filter housing II During the filling process take note of the vent bore III Shut the shut off device at the inlet IN as soon as fluid escapes 15 I Screw in the vent screw clockwise using an Allen wrench 10 mm Tighten the vent screw with a torque of 20 Nm II Open the shut off device at the inlet IN III Open the shut...

Page 50: ...changing the fil ter element 1x Allen wrench 10 mm 2x Wrench 30 mm To change the filter element proceed as follows 1 Switch off the pump in the hydraulic system or shut the shut off valve at the inlet IN and outlet OUT 2 Carry out the pressure release of the filter housing In order to do so fully screw out the vent screw counter clockwise by means of an Allen wrench 10 mm ...

Page 51: ...rs in a suitable con tainer Fill the oil back into the tank of the hydraulic sys tem or dispose of it in an environmentally friendly man ner Drain the filter housing only via the drain ball valve with the air bleed screw opened Only open the filter housing after no fluid escapes from the drain ball valve 4 Loosen the four screws of the filter cover and unscrew them completely ...

Page 52: ...7 Performing maintenance HYDAC FILTER SYSTEMS GMBH 52 76 MoWa OLFP 3 6 3819798a en us 5 Using the handles take the filter cover off in an upwards direction and place it on a clean surface ...

Page 53: ...3819798a en us 53 76 6 Using the handle on the locking cap remove the used top filter element from the filter housing in an upwards direction 7 Using the handle on the locking cap remove the used bottom filter element from the filter housing in an up wards direction ...

Page 54: ... Separate the locking cap from the filter element by turn ing it 45 Dispose of the filter element in an environmentally friendly way 9 Place the locking cap onto the new filter element and turn it 45 to connect it 10 Coat the O rings on the filter element lightly with the op erating fluid ...

Page 55: ...htly screw the new fil ter element into the element mount NOTICE Do not use a hammer or similar tools for this During operation the locking cap always re mains on the topmost filter element If assembled without the locking cap no filtration action takes place 12 Check the O rings for damage and replace them if nec essary ...

Page 56: ... housing Make sure that the position is correct while doing so 14 Insert the four bolts with washers for the filter cover in the bore holes and screw on the nuts with washers be low by hand Tighten the four bolts 30 mm to a torque of 150 Nm To keep the bolts moving smoothly we rec ommend coating the threaded connection with assembly paste ...

Page 57: ...of the vent bore III Shut the shut off device at the inlet IN as soon as fluid escapes 16 I Screw in the vent screw clockwise using an Allen wrench 10 mm Tighten the vent screw with a torque of 20 Nm II Open the shut off device at the inlet IN III Open the shut off device at the outlet OUT 17 After commissioning check the filtration unit for leaks O The replacement of the filter element is now com...

Page 58: ...798a en us 8 Appendix 8 1 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 The following spare parts are available for the product ...

Page 59: ...GMBH Appendix 8 MoWa OLFP 3 6 3819798a en us 59 76 Fig 19 Spare Parts OLFP 3 OLFP 6 Item Qty Description Part no 10 0 1 Filter housing 11 0 1 Element collet 11 1 1 Filter housing cover flat 11 1 1 Filter housing cover high ...

Page 60: ... 3 1 Screw plug 12 4 1 Screw plug 13 0 1 Bypass valve complete 14 0 1 Screw connection 14 1 1 Screw connection 14 2 1 Ball valve 551093 14 3 2 Screw plug 14 4 1 Screw plug 21 0 1 Type label 3648259 21 1 IN label 3631511 21 2 OUT label 3631301 21 3 DRAIN label 3130552 21 4 AIR BLEED label 3233901 50 0 Assembly B complete 50 0 1 Assembly C complete 51 1 1 Sealing ring 52 0 1 Screw connection 60 0 1 ...

Page 61: ...411 2 O ring 53 57 x 3 53 70 Sh NBR see seal kit 1 Filter element N3TM003 N 3566060 1 Filter element N3TMxxx 1 Seal kit NBR consisting of items 11 4 11 5 and 411 3747132 1 Seal kit FKM consisting of items 11 4 11 5 and 411 3762535 Tab 9 Spare Parts OLFP 3 OLFP 6 On demand Not available as a spare part ...

Page 62: ...sing filter unit 8 2 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 20 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 r...

Page 63: ...9798a en us 63 76 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 10 Differential pressure indicator visual VM x B x ...

Page 64: ...sure gauge reacts to the increasing pressure difference at the increasing contamination level of the filter element 30 Fig 21 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 65: ...oWa OLFP 3 6 3819798a en us 65 76 Permissible operating over pressure 210 bar Permitted temperature range 30 100 C Connector threads G Installation space required According to HN 28 22 Tab 11 Differential pressure indicator visual VM x BM x ...

Page 66: ...tial 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 22 Differential pressure indicator electrical VM x C x Type of indication Electrical switch Weight 120 g ...

Page 67: ...quired 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 ...

Page 68: ...auge 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 23 Differential pressure indicator electrical VM x D x Lxx Type of indication Visual indicator and electrical switch Weight 150 g ...

Page 69: ... 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 70: ... and mail ing addresses for the product support for maintenance repair and spare parts can be found always updated on our homepagewww 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 14 HYDAC Service Deutschland ...

Page 71: ...fting OLFP with strap 32 Fig 12 Storing the OLFP 33 Fig 13 Fastening mounting the filter housing at the base Example OLFP 3 x O Z 34 Fig 14 Fastening mounting the filter housing via wall holder Example OLFP 3 x O Z 35 Fig 15 Take note of the removal space for the filter element 36 Fig 16 Avoiding siphoning 37 Fig 17 Pressure loss formula 39 Fig 18 Measure or display dynamic pressure differential p...

Page 72: ...ominal flow rate 26 Tab 7 Hydraulic connection sizes Connection IN 27 Tab 8 Hydraulic connection sizes Connection OUT 27 Tab 9 Spare Parts OLFP 3 OLFP 6 59 Tab 10 Differential pressure indicator visual VM x B x 62 Tab 11 Differential pressure indicator visual VM x BM x 64 Tab 12 Differential pressure indicator electrical VM x C x 66 Tab 13 Differential pressure indicator electrical VM x D x Lxx 68...

Page 73: ...sions for the installation space for clogging indicators TRIMICRON The filter elements of the TRIMI CRON series abbreviation TM were specially developed for the combined separation of particulate fines contamination and water and oil degradation products from hy draulic and lubrication oils in bypass flow They are a combination of pleated and SpunSpray depth filter elements The filter layers used ...

Page 74: ...erential pressure indicator electrical VM x C x 67 VM x D x Lxx 69 Differential pressure indicator visual VM x B x 63 VM x BM x 65 Differential pressure vs Back pressure 41 E exclusion of liability 13 H Hotline 70 HYDAC Service Germany 70 Worldwide 70 I Imprint 4 M manufacturer 4 P Person authorized with the documenta tion 4 S Service 70 Service Partners 70 siphoning effect 37 Support 70 T Terms a...

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