Hydac OLS 10 Operating And Maintenance Instructions Manual Download

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OffLine Separator
OLS 10

Operating and Maintenance Instructions

English (translation of original operating instructions)

Documentation no.: 3248771

Summary of Contents for OLS 10

Page 1: ...OffLine Separator OLS 10 Operating and Maintenance Instructions English translation of original operating instructions Documentation no 3248771 ...

Page 2: ...e contents of this document However errors cannot be ruled out Consequently we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject to technica...

Page 3: ...y Devices 10 Informal Safety Precautions 10 Safety Measures to Be Followed during Normal Operation 10 Hazards Posed by Stored Residual Energy 10 Training and Instruction of Personnel 11 Electrical Hazards 11 Structural Modifications to the OLS 12 Fire Fighting 12 What to Do in Case of Emergency 12 Transporting the OLS 13 Storing the OLS 13 Storage conditions 13 Checking the Scope of Delivery 14 OL...

Page 4: ...ion with operation panel 30 Version with on off switch PKZ 31 Draining water manually 32 Draining water automatically optional 33 Water drainage by means of phase boundary sensor automatic 33 Pushbutton operated manual water drainage 33 Checking the heater temperature optional 34 Error description troubleshooting 35 Performing Maintenance 36 Replacing the filter element on the prefilter 37 Changin...

Page 5: ...optimal manner Keep it in the vicinity of the product so it is always available Note that the information on the unit s engineering contained in the documentation was that available at the time of publication There may be deviations in technical details figures and dimensions as a result If you discover errors while reading the documentation or have additional comments or suggestions contact us at...

Page 6: ...o the product e g purchasing additional options etc may mean that the information in the operating instructions is no longer applicable or adequate After modification or repair work that affects the safety of the product has been carried out on components the product may not be returned to operation until it has been checked and released by a HYDAC technician Please notify us immediately of any mo...

Page 7: ...ar intervals in the future What do I want to know I determine 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 The documentation number with its index enables you to order another copy of the operating and maintenance instructions The ...

Page 8: ...he current state of the art and recognized safety regulations Nevertheless hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property The OLS is only to be used as follows solely for its designated use only when in a safe perfect condition Immediately remedy any malfunctions that might...

Page 9: ...can lead to property damage if safety precautions are not observed Proper Designated Use The OLS is a stationary filter product which is used to separate water from hydraulic oils gear lubrication oils and diesel fuels Any other uses shall be deemed to be improper and not in keeping with the product s designated use The manufacturer will not assume any liability for any damage resulting from such ...

Page 10: ...fittings for leakage daily visual check The electrical components of the OLS must also be regularly checked visual inspection once per month Replace any loose connections or damaged cables immediately Safety Measures to Be Followed during Normal Operation The OLS may only be operated if all of the safety devices function properly The product is to be checked once a day for visible external damage ...

Page 11: ...enced staff member Individuals Individuals undergoing training Individuals with technical training engineering background Electrician Supervisor with the appropriate authority Activity Packing Transportation X X X Commissioning X X X Operation X X X X Troubleshooting locating the source of malfunction X X X Troubleshooting mechanical problem X X Troubleshooting electrical problem X X Maintenance X...

Page 12: ...ed that they have been designed and manufactured so as to comply with loading and safety requirements Fire Fighting When fighting a fire make sure to disconnect the unit from the power supply otherwise an electrical fire cannot be effectively dealt with What to Do in Case of Emergency In case of emergency disconnect the unit from the electrical power supply and depressurize the system Turn the mai...

Page 13: ... the unit check for any damage from transportation The packaging material should be reused recycled as appropriate for your area Storing the OLS Empty remove the filter elements clean and rinse the OLS completely before putting it into storage The OLS must be stored in an upright position Storage conditions Storage temperature 5 C to 30 C Humidity Maximum 80 relative humidity Air Clean salt free a...

Page 14: ...n transit Do not set up or put the OLS into operation unless it is in perfect condition Any damage in transit is to be reported to the forwarding agent or the department in charge immediately the unit may not be commissioned until this damage is properly remedied The following items are supplied Qty Designation 1 OffLine Separator Water type of elements depending on the order 1 Operating and Maint...

Page 15: ...n the fibers of the coalescing element and is conveyed deeper into the coalescing element by the fluid flow Smaller drops unite to form larger ones at the fibre nodes during this process Larger drops settle downwards and can be drained off by opening a valve The coalescing process is mostly used in systems in which small quantities of free water cause no damage or in which fluids are used which ex...

Page 16: ...ater content 15 by volume Procedural limitations The use of the coalescing procedure with the OLS has the following limitations The permissible operating viscosity is 2 320 mm s2 Use a heater when dewatering mineral oils with a viscosity 100 mm s2 The dewatering of mineral oil and diesel fuel is possible down to a residual water content of 100 ppm Use a prefilter to protect the coalescing elements...

Page 17: ...Dimensions HYDAC Filter Systems GmbH en Page 17 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 Dimensions OLS with large drip pan 1000 910 4x Ø 12 1000 1000 1810 360 421 535 500 500 135 285 150 210 210 210 135 135 1 2 8 0 ...

Page 18: ...ne Separator OLS Dimensions HYDAC Filter Systems GmbH en Page 18 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 OLS with small drip pan 510 4x Ø 12 600 360 1810 421 1000 1000 285 650 1280 500 210 135 1 5 0 ...

Page 19: ...raulics Plan maximum equipment 2 5 6 8 1 4 7 G1 INLET OIL G1 2 DRAIN WATER G1 OUTLET OIL M max 6 bar 3 9 10 Item Designation 1 Inlet INLET OIL 2 Motor pump group 3 Prefilter 4 Clogging indicator prefilter element 5 Heater 6 Coalescing tank 7 Clogging indicator coalescing tank 8 Water drainage valve 9 Outlet OUTLET OIL 10 Water outlet DRAIN WATER ...

Page 20: ...009 12 16 doc 2009 12 16 OLS Components 1 2 7 8 4 6 3 5 9 8 Item Designation 1 Inlet INLET OIL 2 Motor pump group 3 Prefilter 4 Clogging indicator prefilter element 5 Heater 6 Coalescing tank 7 Clogging indicator coalescing tank 8 Water drainage valve 9 Outlet OUTLET OIL 10 Water outlet DRAIN WATER ...

Page 21: ...tting up the unit The unit must be set up on an even level surface Special mounting is not required Take care to ensure that the ambient temperature around the pump remains in the range of 10 40 C Note that sufficient room must be allowed for above the filter housing optional and the coalescing housing for the removal of elements ...

Page 22: ...mm s D Density kg dm Mineral oil based hydraulic fluid has a density of 0 9 kg cm This applies to straight pipe runs and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep the height difference between the pump and the oil level in the tank as minimal as possible Hoses must be suitable for suction pressures of at least 0 5 bar Constrictions in the...

Page 23: ...fference between the OLS and the fluid level as small as much as possible Make sure that no tension or vibrations are carried over to the unit or the filter housing when the pipes are connected Use hoses or expansion joints if necessary NOTICE Overpressure at the suction port connection The unit will be damaged The maximum pressure on the suction port connection IN must be no more than 0 4 bar 0 6...

Page 24: ...n no pressure can be in effect and or arise The nominal width of the connecting pipeline must match the connecting thread cross section When disposing of the drained off water observe all local guidelines and regulations pertaining to occupational safety and environmental protection AltölV Used Oil Regulation Installing the pressure port connection The nominal width of the pressure hose must be eq...

Page 25: ...ug the power plug into a suitable power outlet Check that the voltage and frequency are correct The unit has a motor protection switch in the on off switch If the nominal current is exceeded the motor protection switch trips Jog mode for checking the direction of rotation Start the motor by switching it on for a short time jog mode The arrow on the fan cover shows the correct direction of rotation...

Page 26: ...lically and electrically as described in the above chapters Note that the OLS contains no coalescing elements when it leaves the factory If necessary install the coalescing elements Proceed as follows for commissioning 1 Open the INLET OIL ball valve Close the OUTLET OIL ball valve 2 Bleed the unit while filling 3 Open the ventilation plug on the prefilter A 4 Open the ventilation plug X1 on the c...

Page 27: ...nal feed pump is present switch it on Determine the present volumetric flow and adjust it in accordance with the permissible volumetric flow see type label 9 Observe the maximum primary pressure to the pump on the OLS 10 Switch the pump on Press the Actuation ON button The unit will be filled 11 If the prefilter has been bled then close the air bleed plug If the heater optional has been bled then ...

Page 28: ...he OLS HYDAC Filter Systems GmbH en Page 28 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 12 Open the OUTLET OIL ball valve 13 If a heater optional is present actuate the Heater ON key to activate it 14 The unit is ready for operation ...

Page 29: ...n Page 29 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 Switching off the OLS To switch off the OLS observe the following sequence 1 Press the Actuation OFF button If a heater is present then it will also be switched off 2 Close the ball valves INLET OIL and OUTLET OIL ...

Page 30: ...ifferent versions Version with operation panel C F G A B I D E H K L J Designation Description A Actuation ON Switch on the pump B Actuation OFF The pump is switched off C Motor protection Lights up as soon as the motor protection switch has tripped D Heater ON Switch on the heater E Heater OFF Switching off the heater F Safety thermostat for the heater Lights up as soon as the safety thermostat f...

Page 31: ...ng as the button is pressed I Filter element clogged Lights up as soon as the clogging indicator on the prefilter has tripped Replace the filter element J Coalescing element clogged Lights up as soon as the clogging indicator on the coalescing container has tripped Replace the coalescing elements K Lamp test Press the button to carry out the function test for the lamps L Main switch On Off switch ...

Page 32: ...rain choke Check the inspection glass X2 on the coalescing container If the oil water phase boundary is recognizable then allow the water to drain off manually and in a controlled manner at the DRAIN WATER X1 connection Place a suitable container under the connection Open up the DRAIN WATER X1 choke and allow the water to drain off until the phase boundary can be seen at the lower inspection glass...

Page 33: ...r drainage valve Y1 as soon as the phase boundary reaches the upper inspection glass The water 3 5 l flows out at normal pressure through the DRAIN WATER connection A safety switch feature ensures that the drainage valve is closed after a maximum of 2 minutes and 30 seconds Pushbutton operated manual water drainage The OLS with automatic water drainage has a pushbutton for manual water drainage Pr...

Page 34: ...rs depending on requirements Temperature control proceeds automatically after the heater is switched on In the case of units with motor pump groups it is not possible to switch on the heater until 60 seconds after the pump has been switched on Set the temperature at the outer adjustment wheel Z1 The factory setting is 55 C If the temperature in the heater exceeds 80 C then the safety thermostat wi...

Page 35: ...the heater If the electricity consumption is greater than the specified value then the heater is defective The heater needs to be replaced If this is not the cause then Hydac Service should be consulted The Motor protection actuation lamp lights up The motor protection switch for the motor in the control cabinet has tripped The electricity consumption of the motor is too high Reset the motor prote...

Page 36: ... The hydraulic system must be depressurized before performing any work on the hydraulic system Close all shut off valves at the inlet and outlet The OLS is equipped with clogging indicators for the purpose of monitoring the degree of clogging in the prefilter and in the coalescing elements which evaluate the pressure upstream and downstream from the filter and coalescing elements respectively Repl...

Page 37: ...ly open the drain screw Air Bleed on the filter housing cover do not unscrew completely Caution when the operating medium flows out 2 Put a suitable container in place to catch the medium in the filter housing The volume is 3 liters Empty the filter housing through the drain screw Drain on the connection part Without the proper drainage equipment the draining fluid can flow down to the electric mo...

Page 38: ...of the old 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 fluid Never use grease or other media 8 Now place the filter housing cover on the new filter e...

Page 39: ... 12 16 doc 2009 12 16 9 Fasten the dirt catch tray to the bottom end of the filter element 10 Check the O ring on the cover for correct seating Place the filter element with the cover and dirt catch tray in the filter housing 11 Secure the cover with the housing clamp The tightening torque is a maximum of 5 Nm ...

Page 40: ...ilter Systems GmbH en Page 40 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 12 Tighten the drain screw Drain on the connection part of the unit Switch the filter unit on Bleed the filter housing through the air bleed plug Air Bleed in the filter cover ...

Page 41: ...into the cover with the aid of a size 10 mm Allen wrench 4 Carefully unscrew the ventilation plug on the coalescing container with the aid of a size 10 mm Allen wrench in the cover 5 Open the connection marked DRAIN to empty the coalescing container Collect the escaping water oil in a suitable container and dispose of it in accordance with local regulations 6 Once the coalescing container is compl...

Page 42: ...42 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 4 Remove the housing clamps 2 Remove the cover by lifting it upward and set it down to the side 5 Remove the element set from the coalescing housing Use both handles to accomplish this 6 Rotate the element set on the head by 180 ...

Page 43: ...Maintenance HYDAC Filter Systems GmbH en Page 43 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 7 Undo the 3 wing nuts and remove the holding plate 8 Remove the coalescing elements from the element mount and dispose of them properly ...

Page 44: ... 3248771 en 2009 12 16 doc 2009 12 16 9 Moisten the O ring on the element with the operating medium 10 Place the new coalescing element into the mount by it screwing it in slightly Do not use excessive force or a hammer etc 11 Replace the element holding plate and tighten the 3 wing nuts firmly ...

Page 45: ...g Note that the element set fits only in one position Z in the coalescing housing Z 13 Clean the sealing surface on the cover Check the O ring for damage Replace it if necessary 14 Place the cover on the coalescing housing Place the housing clamp over the coalescing housing 15 Use an SW 13 open jaw wrench to tighten the tension clamps evenly to a maximum Nm of 20 Screw open the lock nut and secure...

Page 46: ... BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 16 Open the ball valves INLET OIL and OUTLET OIL 17 Bleed the prefilter A 18 Bleed the coalescing container through the ventilation plug X1 19 Open the air bleed plug on the heater X2 optional 20 The element replacement process is complete ...

Page 47: ...eater will be destroyed Remove sludge sediments in the heater on a regular basis If sediments are not removed a heat build up will form which could cause the heating elements to burn out Rinse out the sediments in the lower part of the container Remove sediments which cannot be removed either by rinsing them out manually or by dissolving them Take care to ensure the heating elements do not suffer ...

Page 48: ... to any excessive mechanical stresses If the connection housing or attachments are damaged then they will need to be sent to the manufacturer for inspection 7 Rinse clean the container 8 Remove all deposits completely 8 Check all essential elements i e heating elements temperature monitors temperature limiters overheating protection and in particular the safety relevant components for corrosion If...

Page 49: ...ions 4 Empty the coalescing housing and all other components 5 Remove all of the filter elements from the unit Disposing of the OLS When decommissioning and or disposing of the unit observe all local guidelines and regulations pertaining to occupational safety and environmental protection This applies in particular to the oil in the device to components covered with oil and to electronics componen...

Page 50: ...ignation Part no Total utilized Coalescing element 5 µm N20WR005 1F 3277940 10 Coalescing element 70 µm N20WR0701F 3361569 10 Filter element prefilter 2 µm N5DM002 349494 1 Filter element prefilter 20 µm N5DM020 3023508 1 Filter element prefilter 25 µm N5WHC025 3060493 1 O ring coalescing tank 270 x10 NBR 6005449 2 O ring coalescing tank 270 x10 FPM 3277940 2 O ring prefilter cover 123 42x 3 53 NB...

Page 51: ...2 s Operating pressure 6 bar Permitted pressure at inlet INLET OIL With pump 0 4 0 6 bar Without pump 0 5 2 bar Permissible pressure at the water drain Depressurized Housing material Stainless steel 1 4301 Material of sealings NBR FPM INLET connection G1 OUTLET connection G1 Connection for water drain G 1 2 Electrical data Supply voltage See type label Power consumption 0 4 2 5 kW Required fuse el...

Page 52: ...est z Without electro motor L60 M60 Operation at 60 Hz Standard in Europe according to CENELEC HD472 S1 at 50Hz Element length 20 Coalescing element 20 N20WRxxx Prefilter 1 OLF5 Toploader z Without Clogging indicator BM Differential pressure indicator visual VMxBM 1 C Differential pressure indicator electrical VMxC 0 z Without E Back pressure indication VMF 0 6KO Heater 1 1 kW 2 2 kW z Without Wat...

Page 53: ...ion of this product that is not coordinated with us in writing will cause this declaration to lose its validity Designation Coalescing unit Type OLS Series Part no Serial no EU Machinery Directive 98 37 EG EU Electrical Equipment Regulations 2006 95 EC EU Directive on Electomagnetic Compatibility 2004 108 EC Applied standards EN 12100 1 2 2009 12 03 Dr Andreas Schunk Date Name CE authorized person...

Page 54: ...OffLine Separator OLS EC declaration of conformity HYDAC Filter Systems GmbH en Page 54 56 BEWA OLS 3248771 en 2009 12 16 doc 2009 12 16 Notes ...

Page 55: ......

Page 56: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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