Hydac Filtromat OF5 C with FCU Operating And Maintenance Instructions Manual Download Page 15 | Manualshive

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Hydac Filtromat OF5 C with FCU Operating And Maintenance Instructions Manual Download Page 15

Transporting the unit

Filtromat – OF5 C with FCU

en(us)

Page 15 / 44

BeWa OF5C 3160333b en-us 2014-07-28.doc

2014-07-28

Transporting the unit

Always transport the unit upright on its own wheels or lashed safely to a
pallet.
Strap the unit down securely and take care to ensure that no components are
damaged.

NOTICE

Incorrect lashing

The unit will be damaged

►

Strap the unit down securely.

►

Take care to ensure that none of the components are damaged.

Storing the unit

Remove all filter elements and empty the filter housing completely prior to
storage. Clean and flush the filter unit. Always store the unit in an upright
position.

Storage temperature:

5 … 30 °C / 41 … 86 °F

Humidity:

up to 80% relative humidity, non-condensing

Air:

Clean, salt-free air, not near oxidizing substances
(rust film).

Storage duration:

Unlimited
Before the unit is started up again after a storage
period of greater than 2 years, all seals must be
replaced.

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Summary of Contents for Filtromat OF5 C with FCU

Page 1: ...Filtromat OF5 C with FCU Operating and Maintenance Instructions English translation of original instructions D Do oc cu um me en nt t n no o 3 31 16 60 03 33 33 3b b ...

Page 2: ...Mathias Dieter Dipl Kfm Wolfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 0 6897 509 1511 Fax 49 0 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 distribu...

Page 3: ...bserve regulatory information 9 Proper Designated Use 10 Improper Use or Use Deviating from Intended Use 11 Qualifications of personnel target group 12 Wear suitable clothing 13 Structural modifications 13 What to Do in Case of Emergency 14 Firefighting Extinguishing fires 14 Transporting the unit 15 Storing the unit 15 Decoding the model code label 16 Checking the scope of delivery 18 Working pri...

Page 4: ...ontrolled by FCU OFF 25 Operating mode Controlled by FCU ON 25 Unit in operation 26 Venting the filter housing 28 Measuring the cleanliness class 29 Performing maintenance 30 Changing the filter element 30 Cleaningthe suction strainer 34 Errors and troubleshooting 36 Taking the unit out of operation 36 Disposing of the unit 36 Spare parts 37 Customer Service 39 Technical data 39 Model Code 40 EC d...

Page 5: ...bligation our liability shall be limited to foreseeable damage Claims 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 part no of the product Fax 49 0 6897 509 9046 E mail filtersystems hydac com Modifications to the Pro...

Page 6: ...etermine which topic I am looking for Where can I find the information I m looking 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 mai...

Page 7: ...unit unless all the safety devices are present Secure the hazardous areas which may arise between the 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 indica...

Page 8: ...information and instructions DANGER DANGER indicates a hazard with a high risk and which will lead to death or serious injury if not avoided WARNING WARNING indicates a hazard with a medium risk and which can lead to death or serious injury if not avoided CAUTION CAUTION indicates a danger with a low risk and which can lead to minor injury if not avoided NOTICE NOTICE indicates a danger which will...

Page 9: ... the signal word indicate the severity of the danger Warning instructions listed before an activity are laid out as follows SIGNAL WORD Type and source of danger Consequence of the danger HAZARD SYMBOL 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 fo...

Page 10: ...is also designed for pumping out unfiltered hydraulic and lubrication oils and draining hydraulic tanks During this work the integrated FluidControl Unit measures particulate solid particle contamination in order to monitor and document the oil cleanliness Proper or designated use of the product extends to the following observing all instructions contained in the instruction manual performing insp...

Page 11: ... Any use extending beyond or deviating therefrom shall not be considered intended use HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such 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 with a non approved medium Operation under impermissible operating con...

Page 12: ...ue to improper use Specialist personnel such persons with corresponding 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 hazards Activity Person Knowledge Transport storage Forwarding agent Specialist personnel Proof of knowledge of cargo securing instructions Safe handling operation of hoi...

Page 13: ...tating parts and the danger of getting snagged on projecting parts You can be severely injured or killed Wear close fitting clothing Do not wear any rings chains or any other jewelry Wear work safety shoes Structural modifications Do not make any modifications to the product without the prior consent of the manufacturer Any modifications require written permission from HYDAC Filter Systems GmbH Us...

Page 14: ...rgency In case of an emergency switch the unit off at the main switch or unplug the power connector Firefighting Extinguishing fires Use a powder extinguisher the corresponds to fire class B as per EN 2 to extinguish any fires Maintain a minimum safe distance from electrical components For a mains voltage of up to 1000 V the minimum safe distance is 1 m ...

Page 15: ...Strap the unit down securely Take care to ensure that none of the components are damaged Storing the unit Remove all filter elements and empty the filter housing completely prior to storage Clean and flush the filter unit Always store the unit in an upright position Storage temperature 5 30 C 41 86 F Humidity up to 80 relative humidity non condensing Air Clean salt free air not near oxidizing subs...

Page 16: ...33b en us 2014 07 28 doc 2014 07 28 Decoding the model code label Details for identifying the filtration unit can be found on the name plates on the unit and the components Item Description 1 Name plate of filtration unit 2 Name plate of electric motor 3 Model code for details see page 40 ...

Page 17: ...e unit Row Description Part No Part number S N Serial number year of production Power Power consumption Voltage Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Operating pressure maximum Weight Weight when empty Flow rate Flow rate Temp Oil Permissible oil temperature range Temp Amb Permitted ambient temperature range Volume Fluid volume in unit ...

Page 18: ...elivery The filtration unit comes factory assembled Check the scope of delivery for completeness prior to start up The following items are supplied Qty Designation 1 Filtromat OF5 with FCU 1 Filter element acc model code see page 40 1 Operation and Maintenance Instructions OF5 this document 1 Operation and Maintenance Instructions FCU 2000 Series ...

Page 19: ...the pressure hose Part of the pressure fluid that is drawn in is diverted to the Fluid Control Unit FCU by an auxiliary pump The FCU continuously monitors the fluid s purity In the Controlled by FCU ON operating mode the filtration unit automatically shuts off with a deceleration of 5 minutes once the desired fluid purity has been attained Alternatively you can use the MODE 4 function on the FCU t...

Page 20: ...an find details on inserting the filter element on page 30 Hanging connecting the suction hose NOTICE Severe contamination The unit will be destroyed Do not prime directly at the bottom of the tank in the sump The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Pull the suction hose thick hose with lance out of th...

Page 21: ...he oil level in operation Electrical connection of the unit Check or compare the local mains voltage and frequency specifications with the specifications on the type label of the unit Plug the power plug of the OF5 into a suitable power outlet The unit has a motor protection switch in the on off switch If the nominal current is exceeded the motor protection switch trips Checking the direction of r...

Page 22: ...ng Elements on the unit Item Designation 1 Filter housing 2 Electric motor 3 Suction hose 4 Pressure hose 5 FluidController Unit FCU 2000 6 Clogging indicator back pressure indicator 7 Needle valve for bleeding 8 Switch box with operating elements for details see page 9 Connector cable with plug 10 Wheels 11 Caster 13 Sliding grip ...

Page 23: ... with FCU en us Page 23 44 BeWa OF5C 3160333b en us 2014 07 28 doc 2014 07 28 Operating elements on the switch box Item Designation 81 Main switch 82 On Off switch 83 Selector switch Controlled by FCU ON OFF 84 Fault indicator lamp filter element clogged ...

Page 24: ...ters on page 20 21 switch the pump on at the on switch 82 in order to pump the fluid After switching on the pump monitor the suction action via the transparent suction hose If the unit is not pumping medium after 5 minutes pre fill the pump Switch the motor off and fill the pump via the suction hose If the filter element is worn out the unit shuts down and the Filter clogged fault indicator lamp 8...

Page 25: ...witch between the Controlled by FCU ON and Controlled by FCU OFF operating modes Operating mode Controlled by FCU OFF The unit filters in continuous operation until the filter element is worn out The current fluid purity level is shown on the FCU display Operating mode Controlled by FCU ON The unit filters until the fluid purity level entered in the FCU has been attained or the filter element is w...

Page 26: ...ill the unit using the suction hose NOTICE Restarting after a power failure The unit restarts automatically following a power failure Switch off the unit at the main switch in case of a power failure Once the power has returned switch on the unit at the main switch and start it up Observe the permissible viscosity of the medium being pumped during operation The filtration unit has a suction strain...

Page 27: ...ity 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 the filter cartridge as increasing contamination leads to increasing flow resistance of the filter element For visual representation the pressure gauge has a green area and a red area If the pointer le...

Page 28: ... the unit has started and is pumping fluid bleed the filter housing To do this open the air bleed screw A while the pump is running so that the air can escape from the filter housing If fluid leaks out close and tighten the air bleed screw A A Bleed the filter housing after each time the unit has run empty or a filter element has been changed ...

Page 29: ...shown on the display Open the pressure compensated flow control valve on the front of the FCU by turning it clockwise as far as it will go This sets the filtration unit to flush the measured section immediately once the unit is switched on It may take a few minutes until the air has been forced out of the system and the flow rate has stabilized Once this process is complete set the flow rate on th...

Page 30: ...8 doc 2014 07 28 Performing maintenance Changing the filter element NOTICE Unsuitable incorrect filter element The medium is not filtered Use only filter elements with the type code suffix KB for example 1300 R 003 BN4HC KB The unit has an optical back pressure indicator red green in the filter cover ...

Page 31: ...ize the filter housing Remove the air bleed plug 1 in the filter cover for this purpose The residual oil is drained through the drain ball valve 2 into a suitable container 3 Loosen the four screws on the cover counterclockwise 4 Fold the screws down and press them against the filter housing This pushes the cover of the filter housing up 5 Take the cover off and remove the filter element ...

Page 32: ... on the filter head and on the cover 7 For easier installation of the filter element wet the O ring on the filter element with the operating medium 8 Press the new filter element down into the filter mount by turning it slightly Do not use excessive force or a hammer etc 9 Check the O ring on the cover for damage and replace it if necessary Lightly wet the O ring on the cover with medium ...

Page 33: ...c 2014 07 28 10 Put the cover on Observe correct placement of the O ring on the cover while doing so It must not be damaged 11 Fold the four screws up and turn them clockwise evenly crosswise 12 Close the drain valve 13 Switch the unit on 14 Check the unit for any leaks 15 The unit is ready for operation ...

Page 34: ...he filtration unit without a suction strainer Clean the suction screen regularly To protect the pump from coarse contamination or foreign bodies a suction screen is installed in the suction lance Clean the suction strainer regularly and check it immediately in the event of insufficient suction or delivery action 1 2 3 4 5 6 Item Description 1 Hose 2 Suction lance 3 O ring 4 Suction screen 5 Protec...

Page 35: ...otection pipe 5 away from the suction lance 2 in a clockwise direction 2 Remove the suction screen 4 from the protection pipe 3 Clean the suction screen 4 by washing it out and then blowing it dry with compressed air 4 Insert the suction strainer 4 into the protection pipe 5 with the tip facing forwards 5 Screw the protection pipe 5 on to the suction lance 2 in a counterclockwise direction ...

Page 36: ...inverter in the connection plug No flow The suction hose is positioned above the fluid Sufficiently immerse the suction hose in the medium No function Nothing shown on the FCU display No electrical connection No voltage available Check the electrical connection plug cable and socket The pump is not sucking or sucking badly There is no oil in the pump Fill the pump via the suction hose Taking the u...

Page 37: ...m FKM 1263061 Filter element 1300 R 010 BN4HC KB 10 µm NBR 1263762 Filter element 1300 R 010 BN4HC V KB 10 µm FKM 1263062 Filter element 1300 R 020 BN4HC KB 20 µm NBR 1263763 Filter element 1300 R 020 BN4HC V KB 20 µm FKM 1267699 Filter element 1300 R 040 AM KB 40 µm NBR 1263071 Filter element 2600 R 003 BN4HC KB 3 µm NBR 1263784 Filter element 2600 R 003 BN4HC V KB 3 µm FKM 1263072 Filter element...

Page 38: ...90 30 FKM 721317 Vane pump 80 20 FKM 721281 Vane pump 90 30 FKM 381465 Pressure hose length 3 m 349004 Pressure hose length 5 m 91061 Pressure hose length 10 m 381464 Suction hose length 3 m 349224 Suction hose length 5 m 36198 Back pressure gauge Green red 39173 Back pressure gauge 0 16 bar 303191 Differential pressure indicator version 1 VM 2 B 1 NBR 303197 Differential pressure indicator versio...

Page 39: ...rmany Telephone 49 0 681 509 883 Fax 49 0 681 509 324 E mail service hydac com Technical data Permissible flow rate 40 l min maximal Operating Pressure Maximum 4 5 bar Maximum permissible viscosity for 30 l min pump 250 mm s for 40 l min pump 300 mm s Permissible operating fluid Mineral oil Permitted fluid temperature range 0 70 C Permitted ambient temperature range 20 40 C Sealing material NBR Pr...

Page 40: ...al P NBR Perbunan Motor pump assembly 3 30 l min 0 75 kW maximum viscosity 250 mm s 6 40 l min 1 5 kW maximum viscosity 300 mm s Motor voltages N 380 420 V 50 Hz 3 Ph PE 440 480 V 60 Hz 3 Ph PE S 500 600 V 50 60 Hz 3 Ph PE X Special voltage Filter size 2 Filter cartridge 1300 Filter material A AQUAMICRON AM B Betamicron BN4HC P Paper P HC Filtration rating 03 3 µm BN4HC BN AM 05 5 µm BN4HC 10 10 µ...

Page 41: ...tal safety and health requirements contained in the standards listed below Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Designation Filtration unit Type OF 5C series Part no Serial no EU Machinery Directive 2006 42 EC EU Electrical Equipment Regulations 2006 95 EC EU directive on electromagnetic compatibility 2004 108 ...

Page 42: ... 18 22 24 37 38 40 Filter element 18 37 38 filtration 10 16 18 19 26 27 29 34 Filtration 40 41 Flow rate 17 Forwarding agent 12 H Hazard symbol 7 I Imprint 2 M Main switch 23 Maintenance 1 18 Mineral oil 39 MODE 19 Model code 16 mounting 20 21 O OFF 23 25 Off switch 23 operating 5 6 7 10 11 12 19 22 25 27 29 32 39 Operating elements 23 Operating Pressure 39 Operation 11 12 18 34 P Power consumptio...

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Page 44: ...iegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 0 6897 509 01 Fax 49 0 6897 509 9046 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E mail filtersystem hydac com ...

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