Hydac OXiStop OXS 150LID Installation And Maintenance Instructions Manual Download

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General Safety Information

OXiStop OXS-LID

Page 10 / 112

MoWa OXS-LID 3992764e en-us 2018-08-10.docx

2018-08-10

Structure of the general safety information

All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.

Warning instructions listed before an activity 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

Summary of Contents for OXiStop OXS 150LID

Page 1: ...OXiStop OXS LID Installation and Maintenance Instructions English translation of original instructions Document no 3992764e ...

Page 2: ...sentative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Phone 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 distributed using electronic systems without the written consent of the ...

Page 3: ...fications of personnel target group 13 Wear suitable clothing 14 Observe regulatory information 14 Transporting the unit 15 Transporting the unit with the crane 16 Storing the unit 17 Decoding the model code label 18 Checking the scope of delivery 20 Description of unit 21 Achievable degassing rate residual water content 22 Calculating differential operating volume ΔV 22 Available sizes 23 Unit co...

Page 4: ...ng unit 65 Manual bleeding during commissioning optional accessories 66 Checking the clogging indicator on the breather filter 67 Replacing the breather filter element 68 Checking the visual clogging indicator on the bypass flow filtration unit 70 Replace the filter element on the OLF 5 bypass flow filtration element 71 Replace protective screen on the OLF 5 bypass flow filtration unit 75 Clean re...

Page 5: ...Content OXiStop OXS LID en Page 5 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Technical Data 101 Model code 103 Index 104 ...

Page 6: ...ontractual obligation 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 code serial no and part no of the product Fax 49 0 6897 509 9046 E mail filtersystems hydac com Modifications to the Pro...

Page 7: ...mine 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 mainten...

Page 8: ...ess 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 indicate parti...

Page 9: ...a hazardous situation with a high level of risk which 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 minor or moderate inj...

Page 10: ...word indicate the severity of the danger Warning instructions listed before an activity 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 environmen...

Page 11: ... integrated diaphragm prevents direct contact with the ambient air This effectively vacuum packs the fluid The OXS can therefore be used in very dusty and damp environments NOTICE Impermissible operating media The unit will be destroyed Use the unit only in conjunction with mineral oils compliant with DIN 51524 Proper or designated use of the product extends to the following Maintaining adherence ...

Page 12: ...om 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 or use deviating from intended may result in hazards and or will damage the unit Examples of improper use Operation in potentially explosive atmospheres Operation with a non approved medium Operation u...

Page 13: ...nt and accessories for transporting machinery and machine parts in addition to hydraulic units 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 able to assess and perform the work assigned to them the...

Page 14: ...ured or killed Wear close fitting clothing Do not wear any rings chains or any other jewelry Wear work safety shoes Wear gloves Observe the information relating to personal protection equipment in the safety data sheet of the operating medium Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and loca...

Page 15: ...ling lifting The unit will be damaged Never use the components to push or pull the unit Drain the unit and its components completely before transport and use suitable sealing plugs to seal all connections Support the OXS for transport with the immersion pipes unobstructed and free from stress Secure the unit with lashing straps without stressing damaging the components ...

Page 16: ...ting accessories The unit components will be damaged destroyed Use only suitable lifting accessories to raise or lash the unit Take care to ensure that the lifting accessories do not cause any pressures to be brought to bear against the components on the unit Lift the unit only at the permitted attachment points The unit has the following permitted attachment points ...

Page 17: ...ith corresponding blind plugs Store the unit in accordance with the storage conditions listed in the chapter Technical Data If the storage period is expected to exceed six months then the following tasks are to be carried out Check all of the cables and seals prior to re commissioning for damage and replace damaged parts After a storage period of greater than 2 years replace all seals before re co...

Page 18: ...g the model code label Details for identifying the OLF 5 bypass flow filtration unit can be found on the name plates on the unit and the components Item Description 1 Name plate OXS 2 Model code for details see page 103 3 Name plate for the OLF 5 bypass flow filtration unit 4 Name plate for the fluid filter s electric motor ...

Page 19: ...wing information can be found on the name plate of the unit Row Description Part No Part number S N Serial number year of production Diff operating volume Differential Volume Weight Empty weight Viscosity range Permissible viscosity range Temp oil Permissible oil temperature range Temp amb Permitted ambient temperature range ...

Page 20: ...elivery Immediately report any damage in transit to the forwarding agent or the HYDAC department in charge The following items are supplied Qty Designation 1 OXS LID design as per order 1 Flat gasket 1 HYLOMAR M sealing compound 1 Technical documentation comprising installation and maintenance instructions OXS this document instructions for the components declaration of incorporation ...

Page 21: ...nk solution for hydraulic systems with an integrated hydraulically driven degassing and dewatering power unit and continuous separation of solids The OXS Lid series represents a tank lid solution for the customer specific design tanks and contain all of the components required for degassing and the separation of solids Example illustration OXS 30LID ...

Page 22: ...al required volume for the thermal expansion of the oil and any continuous oil leakage Double this nominal volume for safety reasons Use the following formula to calculate the differential operating volume for the OXiStop ΔV Σ VShell 2 Σ ΔVCyl Σ ΔVHoses Σ ΔVTemp ΔV Difference volume Differential Volume Σ VShell Σ Shell volume Σ Casing volume of the hydraulic accumulators Σ ΔVHoses Σ Δ Volume hoses...

Page 23: ...8 08 10 docx 2018 08 10 Available sizes The unit is available in the following sizes Installation size Differential operating volume ΔV OXS 30LID 30 liters OXS 45LID 45 liters OXS 70LID 70 liters OXS 150LID 150 liters OXS 250LID 250 liters OXS 325LID 325 liters OXS 500LID 500 liters ...

Page 24: ...Description of unit OXiStop OXS LID en Page 24 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Unit components The unit has the following components Position overview of unit components ...

Page 25: ...ng and dewatering unit 3 6 Pressure sensor EDS electric Pressure gauge visual optional 4 1 Valve and connection block 4 7 Selector valve 5 93 Fluid level temperature sensor HNS electrical B 08 Filling port B 09 Draining connection B 12 Pressure measurement point pressure line OLF 5 B 15 Connection for visual tank fluid level indicator B 20 Connection for electronic temperature sensor ETS B 22 Brea...

Page 26: ...Description of unit OXiStop OXS LID en Page 26 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Hydraulic diagram The unit has the following hydraulic diagram ...

Page 27: ...2 Suction screen 3 1 MiniOX MOX degassing and dewatering unit 3 6 Pressure sensor EDS electric Pressure gauge visual optional 4 1 Valve and connection block 4 7 Selector valve 5 93 Fluid level temperature sensor HNS electrical B 08 Filling port B 09 Draining connection B 12 Pressure measurement point pressure line OLF 5 B 15 Connection for visual tank fluid level indicator B 20 Connection for elec...

Page 28: ... 28 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Dimensions The unit is produced in a variety of sizes the dimensions are given in the following drawing and the accompanying table The following dimensions are dependent on the size ...

Page 29: ...500 362 395 395 5 74 45 625 5 524 610 472 395 395 5 74 70 625 5 524 820 682 395 395 5 74 150 1015 680 610 472 795 595 5 14 250 1015 680 820 682 795 595 5 14 325 1415 880 607 472 1195 795 8 121 500 1415 880 817 682 1195 795 8 121 OXS LID Installation size a1 a2 b1 b2 d n n1 n2 30 45 70 86 5 605 5 84 504 10 26 7 6 150 250 99 5 995 82 5 660 10 36 10 8 325 500 116 25 1395 86 860 10 44 12 10 ...

Page 30: ... filter 6 4 When the unit is started up degassing and dewatering unit 3 1 also removes the air remaining in the tank above the oil surface and raises the oil until it is underneath the tank cover Integrated diaphragm 6 1 rests on the oil like a protective skin in the tank preventing the oil from making direct contact with the environmental air regardless of the oil level The interior of the diaphr...

Page 31: ...or repair and maintenance purposes Observe the permissible ambient temperature on the name plate of the unit Make sure there is sufficient ventilation around the area where the unit is set up Connect all electric components in accordance with the applicable operating instructions Check the sealing surface between the tank and the OXS LID The sealing surface must be fully even and free from any tre...

Page 32: ...unt the OXS_LID using an external detachable threaded connection air tight welded threaded bolts or with an air tight welded connection flange Secure the screw connection against coming loose e g by using locknuts or similar Item Designation 1 OXS LID 700 Tank 715 Flat gasket a Screw connection b Threaded bolt welded air tight c Welding flange ...

Page 33: ...ened as follows Number of screws n 26 nominal torque Mn 7 Nm 1 Tighten screws 1 6 with 20 of the nominal torque 2 Check plane parallelism 3 Tighten screws 1 6 with 60 of the nominal torque 4 Tighten screws 1 6 with 105 of the nominal torque 5 Tighten screws 7 n with 105 of the nominal torque 6 Tighten screws 1 n with 105 of the nominal torque 7 Check screws 1 n with 100 of the nominal torque ...

Page 34: ...llows Number of screws n 36 nominal torque Mn 7 Nm 1 Tighten screws 1 8 with 20 of the nominal torque 2 Check plane parallelism 3 Tighten screws 1 8 with 60 of the nominal torque 4 Tighten screws 1 8 with 105 of the nominal torque 5 Tighten screws 9 n with 105 of the nominal torque 6 Tighten screws 1 n with 105 of the nominal torque 7 Check screws 1 n with 100 of the nominal torque ...

Page 35: ...ows Number of screws n 44 nominal torque Mn 7 Nm 1 Tighten screws 1 16 with 20 of the nominal torque 2 Check plane parallelism 3 Tighten screws 1 16 with 60 of the nominal torque 4 Tighten screws 1 16 with 105 of the nominal torque 5 Tighten screws 17 n with 105 of the nominal torque 6 Tighten screws 1 n with 105 of the nominal torque 7 Check screws 1 n with 100 of the nominal torque ...

Page 36: ...the upper connector 7 25 in the air tight welded sleeve Connect the top screw connection 7 25 directly to connection B15 on valve block 4 1 Ensure that top connector 7 25 is not connected to the insides of the tank Use a special connector to the fluid level display for this purpose See chapter Accessories on page 98 Item Designation 1 Diaphragm cage on the OXS LID primary body 4 1 Valve and connec...

Page 37: ...om electrocution Any work involving the electrical system may only be done by a properly trained certified electrician Compare the voltage and frequency specifications on the unit name plate with the existing network specifications Check the direction of rotation of the electric motor by switching it on briefly jog mode NOTICE Incorrect phase sequence rotation direction of the electric motor The p...

Page 38: ...ays OXiStop OXS LID en Page 38 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Monitoring the unit s sensors displays The hydraulic unit may be fitted with the following clogging indicators and sensors depending on the design ...

Page 39: ... CI Visual clogging indicator at the OLF 5 bypass flow filtration unit 70 CS ContaminationSensor CS on the OLF 5 bypass flow filtration unit optional 46 AS AquaSensor AS on the OLF 5 bypass flow filtration unit optional 45 3 6 EDS electronic pressure sensor or vacuum gauge optional 40 5 93 Electronic level temperature sensor HNS 44 6 45 Visual clogging indicator on the breather filter 67 7 24 Visu...

Page 40: ...unction Use the electronic pressure sensor EDS or the optional visual vacuum gauge to monitor the unit function The vacuum gauge or the pressure sensor on the degassing and dewatering unit is used to monitor the function of the OXiStop and the hydraulic system Explanations regarding how to interpret the display measured values are given below ...

Page 41: ...sure curve while free air is to be found under the tank lid is depicted on the left hand side of the diagram In doing so the negative pressure in the degassing unit reaches a value of 0 5 bar 500 mbar absolute This kind of pressure curve is to be observed among other times during commissioning with larger sized air intakes or when there are leaks Once the free air has been removed from the tank a ...

Page 42: ...gas content in lowest negative pressure in mbar abs Note that this graph is based on the total gas content in the oil Additionally the graph gives the estimated air content only for oils with low water contents 30 saturation at 40 C with constant utilization of OXS It is thus possible to monitor the function of the degassing unit regular cycles the total gas content in the oil the integrity of the...

Page 43: ...0 Fluid level indicator visual Min Max marking Visual fluid level indicator 7 24 is used to monitor and check the diaphragm The column of fluid in the fluid level indicator corresponds to the current position of the underside of the diaphragm Accordingly the higher the column rises the more the diaphragm is being folded up ...

Page 44: ...the diaphragm The sensor is located in the valve block and it is used to monitor the diaphragm stroke and thus the differential operating volume available in the tank If the oil level is too high or too low the sensor issues an alarm signal to switch off the unit The temperature of the oil is monitored via the integrated electric temperature sensor Details on connection and the terminal allocation...

Page 45: ...the sucked in fluid is continuously measured and shown directly on the sensor The water saturation indicates what percent of maximum possible water is dissolved in the oil A value of 0 would indicate water free oil and 100 would mean oil that is completely saturated with water Example illustration AS 3000 Details on connection and the terminal allocations and settings can be found in the instructi...

Page 46: ...08 10 docx 2018 08 10 Connecting ContaminationSensor CS1000 optional The optional ContaminationSensor measures the level of solid contamination in the fluid Example illustration CS1x2x with display Details on connection and the terminal allocations and settings can be found in the instructions for the CS ...

Page 47: ...Fill and bleed the unit with oil as described in the chapter Filling the hydraulic tank with oil first filling oil change on page 53 3 Check all the settings of the sensors indicators see Checking setting the electronic pressure switch EDS see page 80 for details Checking setting electronic fluid level temperature sensor HNS see page 82 for details 4 Switch on the unit s components Switching off t...

Page 48: ...king Diaphragm is leaking Ensure that the hydraulic system is free of leaks Check the OLF 5 bypass flow filtration unit The degassing cycle of the degassing unit is 3 minutes and or there is no pressure change at the degassing unit The float valve is defective Pressure relief valve is defective or incorrectly set Replace any defective valves immediately Degassing cycle is considerably shortened du...

Page 49: ...use n Remedy The hydraulic system was not filled with sufficient oil Top up the oil see page 58 Too much oil on the inside on the diaphragm The hydraulic tank is overfilled The diaphragm is leaking Exchange the diaphragm See page 85 for details Further details can be found in the instructions for the components ...

Page 50: ...itch off the hydraulic system before performing any maintenance work and depressurize the system The safety of all persons coming into contact with the unit and the availability of the unit for use are dependent on regular servicing and maintenance All pictures and descriptions given in these instructions are examples These examples do not represent all of the different product variants ...

Page 51: ...eck X Check the screwed fittings to see that they have been properly resecured x Check the pressure sensor on the degassing unit and the fill level and temperature sensors X Replacing the breather filter 68 X Clean the suction strainer X Check the AquaSensor optional 84 Check the ContaminationSensor optional 84 Diaphragm Checking the diaphragm visual check X Replace the diaphragm For life cycle se...

Page 52: ...six months 6000 hours annually Check the cables and cable conduits for damage Visual inspection X Synchronize the electricity consumption of the motors by measuring with the nominal values on the name plates X Perform an electrical safety inspection in accordance with DIN VDE 0702 and or corresponding national regulation X After five years replace all the unit s hoses ...

Page 53: ...he hydraulic oil is always filled with clean filtered oil As an alternative fill the hydraulic tank with an external filling pump through the port B 08 or through a suitable port on the tank Ensure that only clean filtered oil is filled in during which the selector valve 4 7 is to be found at position a and the screw plug B22 is screwed out in accordance with the instruction contained in Step 1 Th...

Page 54: ...Performing Maintenance OXiStop OXS LID en Page 54 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 ...

Page 55: ...low filtration unit 2 1 on The oil is now pumped into the hydraulic tank Fill the hydraulic tank up to the marking on the fluid level indicator 7 24 6 Close the selector valve 4 7 by switching from position b to position a 7 Start the hydraulic system with a low fluid flow rate and a low system pressure This gives the air bubbles in the tank sufficient time to rise We recommend each 100 liters of ...

Page 56: ...ass flow filtration unit 2 1 Insert the other end into the unpressurized external oil container Switch the filtration unit 2 1 on If oil escapes at the open hose end but no air or air bubbles unscrew the measurement hose and switch the OLF 5 bypass flow filtration unit 2 1 off 12 The free air trapped in the hydraulic tank will be suctioned off at the start with the aid of the degassing unit This w...

Page 57: ...018 08 10 If the oil level reaches the mark top up with more oil for details see the chapter Refilling the hydraulic tank with oil on page 58 If the mark is reached drain oil off for details see chapter Partially emptying the hydraulic tank on page 61 14 The filling of the hydraulic tank is completed ...

Page 58: ...r describes how to refill the hydraulic tank via the OLF 5 bypass flow filtration unit 2 1 Note that initial filling comes before refilling and that no intake of air caused by the opening of screw plugs etc is desirable NOTICE Filling the unit via the breather filter The unit the breather filter will be damaged Fill the unit exclusively via the filling valve ...

Page 59: ...Performing Maintenance OXiStop OXS LID en Page 59 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 ...

Page 60: ...on the OLF 5 bypass flow filtration unit 2 1 on The oil is now pumped into the hydraulic tank Fill the hydraulic tank up to the marking on the fluid level indicator 7 24 5 Close the selector valve 3 by switching from position b to position a 6 To bleed the OLF 5 bypass flow filtration unit 2 1 mount a 1602 measurement hose to the gauge port 2 7 on the cover of the OLF 5 bypass flow filtration unit...

Page 61: ...en Page 61 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Partially emptying the hydraulic tank This chapter describes how to partly empty the hydraulic tank via the OLF 5 bypass flow filtration unit 2 1 e g with overfilling etc ...

Page 62: ...nto an unpressurized external oil container to collect the oil 2 Switch on the OLF 5 bypass flow filtration unit 2 1 on The oil is pumped out of the hydraulic tank by the valve block Dispose of the oil that has been drained in an environmentally friendly manner 3 Remove only enough oil for the oil level in the fluid level indicator 7 24 to be within the markings 4 Screw all screw plugs back in pla...

Page 63: ...LID 3992764e en us 2018 08 10 docx 2018 08 10 Completely emptying the hydraulic tank for transport oil change etc This chapter describes how to completely empty the hydraulic tank for transport oil change or maintenance via the OLF 5 bypass flow filtration unit 2 1 ...

Page 64: ...ction G and insert the other end into an unpressurized external oil container to collect the oil 4 Switch on the OLF 5 bypass flow filtration unit 2 1 on The oil is pumped out of the hydraulic tank by the valve block Dispose of the oil that has been drained in an environmentally friendly manner 5 Once the oil has stopped emerging switch off the OLF 5 bypass flow filtration unit 2 1 and empty the h...

Page 65: ...degassing unit 3 1 holds 1 5 l oil Empty the degassing unit as follows 1 Unscrew the screw plug X for emptying completely 2 Collect the escaping fluid in a suitable container and dispose of it in an environmentally friendly manner 3 After the unit is empty screw the screw plug X back in again 4 The draining of the degassing unit is completed ...

Page 66: ...S Ball valve closed Ball valve open 1 Fully unscrew the screw plug B 22 on the valve block to bleed air from the hydraulic tank and apply the Connection kit for rapid bleeding for OXS at this position 2 Unscrew the screw plug Z1 on the connection kit completely and open the ball valve Z2 3 Attach an air pump to the free end of the ball valve G 1 2 4 Use the air pump to remove the free air until an...

Page 67: ...x 2018 08 10 Checking the clogging indicator on the breather filter The OLF 5 bypass flow filtration unit is equipped with an optical clogging indicator 6 45 for monitoring the degree of contamination Exchange the filter element when the clogging indicator displays 50 mbar See page 68 for details ...

Page 68: ...st once a year If the unit is in a very dusty damp environment the replacement intervals shorten accordingly Replace the filter element of the breather filter BF7 as follows 1 Unscrew cover 6 41 of the breather filter by hand in counterclockwise direction 2 Remove used filter element 6 42 and dispose of it in an environmentally correct manner 3 Insert new filter element 6 42 and screw on cover 6 4...

Page 69: ... the nut 6 46 and the washer 6 47 out of the breather filter fully 2 Remove the cover 6 41 3 Remove used filter element 6 42 and dispose of it in an environmentally correct manner 4 Insert the new filter element 6 42 and attach the cover 6 41 onto the threaded bolt 5 Screw the nut 6 46 and the washer 6 47 onto the threaded bolt and tighten the nut 6 46 with a maximum torque of 10 Nm ...

Page 70: ... flow filtration unit The OLF 5 bypass flow filtration unit is equipped with an optical or electric clogging indicator for monitoring the degree of contamination Replace the filter element when the red marking becomes visible in the clogging indicator For details refer to chapter Replace the filter element on the OLF 5 bypass flow filtration element on page 71 ...

Page 71: ...hen the operating medium flows out 2 Put a suitable container in place to catch the operating medium to be found in the filter housing The volume is approx 3 liters Empty the filter housing through the drain plug Drain on the connector Without the proper drainage equipment the draining fluid can flow down to the electric motor 3 Loosen the tensioning clamp on the filter housing cover by completely...

Page 72: ... filter element according to local regulations and guidelines 7 Clean the removed parts and examine them for any possible damage Check the O ring on the filter bowl cover for damage Replace it if necessary Moisten the O rings on the filter bowl cover and on the new filter element with operating medium Never use grease or other media 8 Now place the filter bowl cover on the new filter element and l...

Page 73: ...ng torque is a maximum of 5 Nm 12 Tighten the drain plug Drain on the connection part of the unit Switch on the OLF 5 bypass flow filtration unit on Bleed air from the filter housing via the measurement connection in the filter cover 13 If the bypass flow filtration unit has a ContaminationSensor on the OLF 5 bypass flow filtration unit replace the protective screen for details refer to chapter Re...

Page 74: ...15 Fill the tank with the same volume that you removed to change the filter element For details refer to chapter Refilling the hydraulic tank with oil on page 58 16 Check the fluid filter for leaks while in operation Eliminate any leakages immediately 17 The filter element replacement on the OLF 5 bypass flow filtration unit is now complete ...

Page 75: ...on without the protective screen The ContaminationSensor clogged blocked Never operate the unit without a protective strainer Replace the protective strainer regularly A protective strainer is installed upstream from the ContaminationSensor to protect it from blockage Exchange the protective screen regularly depending on the contamination level of the oil Item Designation CS 1 Protective strainer ...

Page 76: ...cribed in chapter Replace the filter element on the OLF 5 bypass flow filtration element on page 71 3 Loosen the screw connection and remove protective strainer CS 1 between the two O rings CS 2 4 Dispose of protective strainer CS 1 in an environmentally friendly manner 5 Insert a new protective strainer CS 1 between the two O rings CS 2 6 Screw together the connector and fasten it tightly 7 The r...

Page 77: ...ction strainer missing operating without a suction strainer ContaminationSensor MOX pump blocked clogged Never operate the unit without a suction screen Clean the suction strainer regularly A suction strainer is installed upstream to prevent the pump from becoming blocked Clean or replace the suction strainer regularly Item Designation 2 41 O ring 2 42 Suction strainer 320 µm 2 5 Hose assembly ...

Page 78: ... in chapter Replace the filter element on the OLF 5 bypass flow filtration element on page 71 3 Loosen hose assembly 2 5 and remove the suction strainer 2 42 4 Clean the suction strainer 2 42 by washing it out and then blowing it out with compressed air Wear gloves and safety goggles 5 Insert the clean new suction strainer 2 42 with the O ring 2 41 6 Screw together the connector and fasten it tigh...

Page 79: ... in the OLF 5 bypass flow filtration unit The filter element is not utilized completely Bleed air from the OLF 5 bypass flow filtration unit after each standstill filter element replacement protective screen replacement Bleed air from the fluid filter via measurement connection 2 7 until fluid begins to escape To do this attach a measurement hose 1602 to measurement connection 2 7 and place the ot...

Page 80: ...c pressure switch EDS has been replaced check the settings in accordance with the following specifications Check or configure the electronic pressure sensor EDS with the following alarm settings Alarm 1 Error MOX when a pressure higher than 1200 mbar is reached over a period of 99 99 s 1200 mbar 15 mbar Alarm 2 Free air in the tank when a pressure higher than 450 mbar is reached over a period of 2...

Page 81: ...ctronic pressure sensor EDS with the following factory settings Display Possible values Setting SP Win SP SP Win SP ON OFF ON ON OFF ON 0 00 99 99 99 99 0 00 99 99 25 0 00 99 99 0 0 00 99 99 0 ACT Top S P 1 S P 2 OFF ACT 0 300 0 SLOW MEDI FAST Fast BAR PSI Mpa FREE Free 0 0 000 0 0 999 9899 0 0 899 9899 2500 MAMP VOLT MAMP YES NO Nein ...

Page 82: ...pped with a float based sensor with an integrated fluid level temperature sensor The operating principle of the fill level sensor and range of the differential operating volume is shown in the following illustration and table Check the fluid level temperature sensor HNS The settings are dependent on the OXS size Details on setting the sensor can be found in the corresponding instructions ...

Page 83: ...cm 362 mm 5 mm 520 mm 45 42 5 cm 7 cm 472 mm 5 mm 630 mm 70 63 5 cm 7 cm 682 mm 5 mm 840 mm 150 42 5 cm 7 cm 472 mm 5 mm 630 mm 250 63 5 cm 7 cm 682 mm 5 mm 840 mm 325 42 5 cm 7 cm 472 mm 8 mm 630 mm 500 63 5 cm 7 cm 682 mm 8 mm 840 mm Item Designation D Height of the diaphragm cage G Thickness of the assembly plate LS Special length of HNS S Safety buffer X Diaphragm float swing path ...

Page 84: ...n establishment authorized by HYDAC For details see the instructions for the ContaminationSensor Testing the AquaSensor AS Check the AquaSensor annually with the calibration and adjustment set The Part no for ordering can be found in the spare parts list You can find further information in the calibration and adjustment set instruction manual Replace the AquaSensor if it exhibits great deviations ...

Page 85: ...64e en us 2018 08 10 docx 2018 08 10 Replacing the diaphragm The service life of the diaphragm is dependent on the fluid temperature for details see chapter Technical Data on page 101 Replace the diaphragm after the specified time to avoid malfunction Removing the diaphragm ...

Page 86: ...tely for details see the chapter Completely emptying the hydraulic tank for transport oil change etc on page 63 3 Remove the piping between valve block and diaphragm cover 6 2 Loosen all nuts 6 6 and washers 6 5 of the diaphragm cover 6 2 4 Take the diaphragm cover 6 2 off 5 Remove diaphragm 6 1 from the diaphragm cage and dispose of it in an environmentally correct manner 6 The removal of the dia...

Page 87: ...Performing Maintenance OXiStop OXS LID en Page 87 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Installing the diaphragm ...

Page 88: ...rface must be free of old sealant residue 2 Apply a thin even layer of HYLOMAR M sealant around sealing surface X The part no can be found in the spare parts list Observe the bleed time in accordance with the operating instructions Use exclusively the recommended sealant to seal the diaphragm This is the only way to ensure material compatibility 3 Insert the new diaphragm 6 1 through the opening i...

Page 89: ...it 5 Put the diaphragm cover 6 2 on 6 Attach washers 6 5 to all threaded bolts and screw the nuts 6 6 onto the threaded bolts by hand in a clockwise direction Always use new locknuts When locknuts are reused they will no longer provide a complete clamping effect 7 Tighten nuts 6 6 crosswise with a maximum torque of 8 Nm Example illustration OXS 150 250LID 8 Mount the pipe of the valve block and ti...

Page 90: ...ponents before putting it out of service as described on page 63 Disconnect all electrical and hydraulic connections from and to the unit Store the unit in a clean dry non condensing space Disposing of the unit Dispose of the packaging material in an environmentally friendly manner After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly ma...

Page 91: ...nual please contact HYDAC FILTER SYSTEMS GMBH Justus von Liebig Straße Plant 20 66280 Sulzbach Saar Germany Phone 49 0 6897 509 1174 Fax 49 0 6897 509 9046 E mail filtersystems hydac com Our HYDAC Servicenter offers you these tasks within agreed upon time frames and at fixed prices HYDAC SERVICE GMBH Friedrichstaler Straße 15a Werk 13 66540 Neunkirchen Heinitz Germany Phone 49 0 681 509 883 Fax 49...

Page 92: ...992764e en us 2018 08 10 docx 2018 08 10 Spare parts list Only use original spare parts and accessories to ensure safe and reliable operation of the unit When ordering spare parts always provide the complete designation type part no serial no year of construction ...

Page 93: ...Spare parts list OXiStop OXS LID en Page 93 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 ...

Page 94: ... 2 65 Hose assembly NBR 6130504 2 7 Threaded coupling NBR 680107 3 1 MOX 1 N OXS NBR 3519092 3 7 Washer 6112446 3 8 Hex Nut ISO7040 6094509 5 11 Screw connection NBR 635490 5 12 Screw connection NBR 607968 5 15 Coupling nut 608399 5 2 Cutting ring 1 4571 6030713 5 3 Screw connection NBR 635486 5 35 Coupling nut 608397 5 4 Cutting ring 1 4571 6107260 5 5 Screw connection NBR 607722 5 6 Cutting ring...

Page 95: ...diaphragm set to OXS 250 4228496 Replacement diaphragm set to OXS 325 4228497 Replacement diaphragm set to OXS 500 4228498 S2 Replacement valve block set comprised of 1x valve block 1x suction tube 1x suction tube 1x change over valve 1x non return valve 1x seal 1x screw set Without HNS Replacement valve block set for OXS 30 4228500 Replacement valve block set for OXS 45 150 325 4228501 Replacemen...

Page 96: ...250 4242909 OXS LID primary body to OXS 325 4242913 OXS LID primary body to OXS 500 4240250 5 93 Fluid level temperature sensor HNS Without default settings HNS 312P 8 for OXS 30 924538 HNS 312P 8 for OXS 45 150 325 924843 HNS 312P 8 for OXS 70 250 500 924844 6 2 Diaphragm cover suitable for BF7 breather filter Diaphragm cover for OXS 30 45 70 3864552 6 2 Diaphragm cover suitable for BF5 52 breath...

Page 97: ...unit Filter element 2 µm N5DM002 FKM 349494 Filter element 5 µm N5DM005 FKM 3068101 Filter element 10 µm N5DM010 FKM 3102924 Filter element 20 µm N5DM020 FKM 3023508 AquaSensor AS AS 3008 NBR 922591 ContaminationSensor CS CS1320 FKM 3332066 Clogging indicator VA VM 2 BM 1 V FKM 303200 Protective screen CS 1 558230 O ring CS 2 FKM 635966 AquaSensor Calibration adjustment set 3122629 Breather filter...

Page 98: ...Page 98 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 Accessories We provide the following fluid level displays as accessories for the unit Not that the upper connector 7 25 needs to be glued in Item Designation Part no ...

Page 99: ...icator 7 24 L 381 mm 1x bolt 7 241 2x sealing washer 7 242 1x bolt 7 25 4071801 Fill level indicator set for OXS 45 150 325 comprised of 1x fluid level indicator 7 24 L 500 mm 1x bolt 7 241 2x sealing washer 7 242 1x bolt 7 25 4073619 Fill level indicator set for OXS 70 250 500 comprised of 1x fluid level indicator 7 24 L 700 mm 1x bolt 7 241 2x sealing washer 7 242 1x bolt 7 25 4073620 ...

Page 100: ...op OXS LID en Page 100 112 MoWa OXS LID 3992764e en us 2018 08 10 docx 2018 08 10 We offer the following connection kit as an accessory for the unit Part no Designation 4243219 Connection kit for rapid bleeding for OXS ...

Page 101: ...ox 110 kg OXS 325LID 325 liters approx 152 kg OXS 500LID 500 liters approx 166 kg Permitted operating fluids Mineral oils acc to DIN 51524 Typical gas removal rate 4 l h Permissible viscosity range 15 300 mm s 15 200 mm s with OLFCM Maximum fluid flow rate IN OUT OXS 30LID 45LID 70LID OXS 150LID 250LID OXS 325LID 500LID 900 l min 2700 l min 5400 l min Permitted fluid temperature range 10 80 C Elec...

Page 102: ...e fluid temperature 6 years 60 C fluid temperature 2 years 60 C fluid temperature Permissible ambient temperature range 20 to 40 C Permitted storage temperature range 0 40 C Relative humidity 0 80 non condensing depending on the operating materials used and the degree of dynamic load the service life of the diaphragms can become considerably shortened valid for an installation height 1000 m above ...

Page 103: ...50 l 325LID Differential operating volume 325 l 500LID Differential operating volume 500 l Voltage frequency power supply N 400 V AC 50 Hz 3 Ph Sealing material diaphragm material 1 Sealing material NBR diaphragm material PUR return line filter Z No return line filter installed Plate heat exchanger Z No plate heat exchanger installed Negative pressure monitoring 1 Pressure gauge visual 2 Pressure ...

Page 104: ...Documentation Representative 2 drain plug 64 71 73 draining 65 71 E Electrical data 101 Empty weight 19 101 emptying 56 61 62 63 64 65 86 Error 48 80 F filling 47 53 55 56 57 58 89 Filter 12 97 Filter element 97 filtration 18 25 27 30 37 39 47 48 51 53 55 56 58 60 61 62 63 64 67 70 71 73 74 75 76 77 78 79 97 H Hazard symbol 8 10 Hydraulic data 101 Hydraulic diagram 26 I Imprint 2 IN 101 installati...

Page 105: ...0 docx 2018 08 10 S select 7 Service 91 setting 44 47 80 82 Signal word 9 10 signal words 10 Spare part 92 Spare parts 92 Spare parts list 92 Specialist personnel 13 Suction screen 27 51 94 T Time 41 Transport 13 transporting 13 Troubleshooting 13 48 V Viscosity 19 W Weight 19 ...

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Page 112: ...riegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 0 6897 509 01 Central Fax 49 0 6897 509 9046 Technical Department Fax 49 0 6897 509 577 Sales Internet www hydac com E mail filtersystems hydac com ...

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Hydac OXiStop OXS 150LID, Installation And Maintenance Instructions Manual

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