OLS 10/12 /-C277 OffLine separator - Start: HYDAC – The signal word indicates a hazardous...

OLS 10/12 /-C277 OffLine separator

Installation and Maintenance Instructions English (translation of original instructions)

Document No.: 4256274 Keep for future reference.

Imprint

Imprint

Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Telephone: +49 6897 509 01 Fax: +49 6897 509 9046 E-mail: [email protected] Homepage: www.hydac.com Court of Registration: Saarbrücken, HRB 17216 Executive director: Mathias Dieter,

Dipl.Kfm. Wolfgang Haering

Documentation Representative

Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: [email protected]

© 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 publisher. These documents have been created and inspected with the greatest care. However, errors cannot be ruled out completely.

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MoWa OLS10-12-C277 4256274 en-us 2017-08-11.docx 2017-08-11

Content

Content

Imprint ............................................................................................................ 2

Documentation Representative ................................................................... 2

Content .......................................................................................................... 3

Preface ........................................................................................................... 5

Technical Support ........................................................................................ 5 Modifications to the Product ........................................................................ 5 Warranty ...................................................................................................... 5 Using the documentation ............................................................................. 5

Safety information ........................................................................................ 7

Hazard symbols ........................................................................................... 7 Signal words and their meaning in the safety information and instructions .................................................................................................. 8 Structure of the safety information and instructions ..................................... 9 Proper/Designated Use ............................................................................. 10 Improper Use or Use Deviating from Intended Use ................................... 11 Qualifications of personnel / target group .................................................. 12 Wear suitable clothing ............................................................................... 13 Observe regulatory information ................................................................. 13

Unpacking housing ..................................................................................... 13

Transporting the housing .......................................................................... 14

Transporting with the crane ....................................................................... 14

Storing housing .......................................................................................... 14

Decoding the type label .............................................................................. 15

Checking the scope of delivery ................................................................. 17

Housing features ......................................................................................... 17

Coalescing procedure ................................................................................ 17

Identifying components ............................................................................. 18

Hydraulic circuit .......................................................................................... 20

Housing dimensions ................................................................................... 22

Setting up / Connecting housing ............................................................... 23

Notes on pipes/hosing ............................................................................... 24 Connecting the suction port (INLET) ......................................................... 25 Checking flow rate ..................................................................................... 25 Connecting the pressure connection (OUTLET) ........................................ 25 Connecting the water drainage (WATER DRAIN) ..................................... 26 Connecting the device / sensors ................................................................ 27

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Content

Connecting phase limit sensor ............................................................... 27 Phase limit sensor - Monitoring signal .................................................... 27 Connecting up clogging indicator ........................................................... 27 Clogging indicator - Monitoring signal .................................................... 27 Connecting the water drainage valve ..................................................... 27

Commissioning the housing ...................................................................... 28

Performing maintenance ............................................................................ 29

Maintenance intervals ................................................................................ 29 Perform visual check ................................................................................. 29 Replacing hydraulic hoses ......................................................................... 30 Changing the coalescing elements ............................................................ 30 Breather maintenance ............................................................................... 35

Check breather functionality ................................................................... 36 Cleaning breather / Replacing parts ....................................................... 37

Help with errors on the breather .......................................................... 38

Customer Service / Service ........................................................................ 39

Decommissioning the housing .................................................................. 39

Shutting down housing .............................................................................. 39

Disposing of housing ................................................................................. 39

Spare parts list ............................................................................................ 40

Technical details ......................................................................................... 41

Model code .................................................................................................. 42

Index ............................................................................................................ 43

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Preface

Preface

These operating instructions were made to the best of our knowledge. Nevertheless and despite the greatest care, it cannot be excluded that mistakes could have crept in. Therefore please understand that, in the absence of any provisions to the contrary hereinafter, our warranty and liability – for any legal reasons whatsoever – are excluded in respect of the information in these operating instructions. 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 injury and damage to health. If we negligently breach any material contractual 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 6897 509 9046 E-mail: [email protected]

Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient. 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 modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the terms of delivery of HYDAC FILTER SYSTEMS GMBH. You will find these under www.hydac.com -> Legal information.

Using the documentation

Note that the method described for locating specific information does not release you from your responsibility of carefully reading these instructions prior to starting the unit up for the first time and

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http://www.hydac.com/

Preface

at regular 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.

deHYDAC Filtertechnik GmbHBeWa 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 maintenance instructions. The index is incremented every time the manual is revised or changed.

Chapter heading

Page number Edition date

Document language Documentation No. with Index /

File name

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Safety information

Safety information

The housing was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements. Any residual hazards are indicated by safety information and instructions and are described in the operating instructions. Observe all safety and warning instructions attached to the housing. They must always be complete and legible. Do not operate the housing unless all the safety devices are present. Secure the hazardous areas which may arise between the housing 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 in these operating instructions which indicate particular hazards to persons, property or the environment. Observe these instructions and act with particular caution in such cases. Pass all safety information and instructions on to other users.

General hazard

Danger due to electrical voltage / current

Danger due to operating pressure

Risk of burns due to hot surfaces

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Safety information

Flammable

Harmful to the environment

Signal words and their meaning in the safety information and instructions

The following signal words are to be found in these instructions.

DANGER DANGER – The signal word indicates 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 injury.

NOTICE NOTICE - The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result in damage to property.

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Safety information

Structure of the safety information and instructions 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

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Safety information

Proper/Designated Use Claims for defects or liability, regardless of the legal foundation, do not apply with incorrect or improper installation, commissioning, usage, handling, storage, maintenance, repair, use of unsuitable components or other circumstances for which HYDAC is not responsible. HYDAC is not responsible for the installation, integration, selection of interfaces to / into your system nor for the use or functionality of your system. Use the housing only for the application described in the following: The OffLine Separator OLS is a dewatering unit for hydraulic oils and gear lubrication oil with densities < 950 kg/m³. To drain, heat the operating fluid with a viscosity >100 mm/s2. Residual water contents of ≈ 100 ppm are possible.

NOTICE

Impermissible operating media.

The housing will be damaged.

► Use the housing only in conjunction with mineral oils for a water content < 15 filling volume %.

Proper/designated use of the product extends to the following:

• Observing all instructions contained in the operating instructions.

• Adhering to maintenance work.

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Safety information

Improper Use or Use Deviating from Intended Use Any use extending beyond this 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 risk is borne solely by the owner. Improper use may result in hazards and/or will damage the housing. Examples of improper use:

• Operation with an impermissible fluid.

• Operation under non-approved operational conditions.

• Operation when the safety devices are defective.

• Modifications to the housing made by the user or purchaser.

• Inadequate monitoring of parts that are subject to wear and tear.

• Improperly performed repair work.

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Safety information

Qualifications of personnel / target group Persons who work on the housing must be aware of the associated hazards when using it. Operating and specialist personnel must have read and understood the operating instructions, in particular the safety information and instructions, and applicable regulations before beginning work. The operating instructions and applicable regulations are to kept so they are accessible for operating and specialist personnel. These operating instructions are intended for: Auxiliary personnel: such persons have no specialized knowledge and perform work as instructed. Operating personnel: such persons have been instructed in housing 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, they are also able to recognize potential hazards. Activity Person Knowledge

Transport / storage Auxiliary personnel

No specialist knowledge required

Startup operation, operation Operations control

Operating Personnel

Product-specific knowledge Knowledge about how to handle operating media.

Troubleshooting, Maintenance, Decommissioning, Disassembly

Specialist personnel

Safe handling/use of tools Product-specific knowledge

Disposal Specialist personnel

Proper and environmentally friendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse

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Unpacking housing

Wear suitable clothing Loose-fitting clothing increases the risk of being caught or being drawn in on rotating parts, and the risk of getting caught on protruding parts. You can be severely injured or killed.

• 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 fluid.

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

Unpacking housing

Prior to delivery, the housing is function-tested and leak-tested in the factory. When unpacking the unit, check it for damage in transit.

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Transporting the housing

Transporting the housing

Drain the housing completely before transporting.

Transporting with the crane Fasten suitable band loops to the base support for transporting with the crane.

Storing housing

Before storing, empty the housing completely, including the coalescing casing. Permitted storage temperature range

See chapter “Technical details“, page 41.

Permissible humidity See chapter “Technical details“, page 41.

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

Storage duration Unrestricted, but in any case before the unit is started up again: after a storage period of greater than 2 years, all seals must be replaced.

Storage position Only standing.

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Decoding the type label


Details for identifying the housing can be found on the type labels on the housing and the components.

Item -> Description

(1) -> Name plate for housing

(2) -> Model code; for details, see page 42

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The following information can be found on the name plate of the 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. -> Maximum permitted operating pressure

Pressure IN -> Permissible operating pressure at IN connection

Pressure OUT -> Permissible operating pressure at OUT connection

Weight -> Empty weight

Flow rate -> Flow rate

Temp. oil -> Permitted fluid temperature range

Temp. amb. -> Permitted ambient temperature range

Volume -> Fluid volume in housing

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Checking the scope of delivery

Checking the scope of delivery

The housing comes factory-assembled. Check that the housing is complete before starting up. The following items are supplied: Qty Designation

1 OffLine separator

1 Operation and Maintenance Instructions (this document)

Housing features

The OffLine Separator OLS is a dewatering unit for hydraulic oils and gear lubrication oil with densities below 950 kg/m3. The OLS is installed in the bypass flow; a pre-filter is available as an option.

Coalescing procedure The dewatering works according to the coalescence principle, during which water collects on 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 fiber nodes during this process. Larger drops settle downwards and can be drained off by opening a valve. The coalescing process is used mainly in systems in which small quantities of free water cause no damage, or in which fluids that exhibit good demulsifying properties (the capacity to give off water rapidly) are used. The application is used in the bypass flow. The use of a micro-filtration system is expedient to ensure the maximum possible service life of the coalescing elements.

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Identifying components


Additional details regarding the versions can be found in the following.

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Item Designation

A Inlet oil INLET OIL

B Outlet oil OUTLET OIL

C Outlet Water OUTLET WATER

D Drain DRAIN

1 Ball valve

2 Orifice

3 Pressure gauge isolator valve

4 Pressure gauge

5 Coalescing housing

6 Phase limit sensor

7 Differential pressure indicator

8 Breather valve

9 Pressure relief valve

10 Automatic water drainage

11 Check valve

12 Draining ball valve

13 Housing clamp

14 O-ring

15 Sight glass

16 Float switch

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Hydraulic circuit

Hydraulic circuit

The housing has the following hydraulic circuit:

G1

24

3

9

110

G1/2 G1

7

6

85

12

G1/2

11

A C D B

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Hydraulic circuit

Item Designation

A Inlet oil INLET OIL

B Outlet oil OUTLET OIL

C Outlet Water OUTLET WATER

D Drain DRAIN

1 Ball valve

2 Orifice

3 Pressure gauge isolator valve

4 Pressure gauge

5 Coalescing housing

6 Phase limit sensor

7 Differential pressure indicator

8 Breather valve

9 Pressure relief valve

10 Automatic water drainage

11 Check valve

12 Draining ball valve

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Housing dimensions

Housing dimensions

The housing has the following dimensions:

All dimensions in mm.

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Setting up / Connecting housing


NOTICE

Danger of tipping over / danger of slipping due to vibrations

Housing will be damaged

► Before starting it up, put the housing on a stable, horizontal surface.

Place the housing in an even, level collecting pan (volume ≥ 90 liters), which can collect the tank volume in case of leakage. Install the suction port connection at the lowest part of the tank. This ensures that the water phase located at the base of the tank is reached. Install the return line as far as possible from the suction point in order to obtain an optimum intermixing of the tank contents. Take the following steps to prepare the housing for operation:

1. Check the connecting lines for leaks. Eliminate any leakages immediately.

2. Check and insert the coalescing element. For details, see page 30.

3. The housing is ready for the next steps on the following pages.

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Notes on pipes/hosing Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filtration unit. Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filtration unit. Use hoses or expansion joints if necessary. The pressure loss in a hydraulic line depends upon:

• Flow rate

• kinematic viscosity

• Pipe dimensions

• Density of the fluid The pressure loss can be estimated for hydraulic oils as follows:

Δp ≈ 6.8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = Pipe length [m]

d = Internal pipe diameter [mm]

Q = Flow rate [l/min]

V = Kinematic viscosity [mm²/s]

D = Density [kg/dm³] Diesel has a density of approx. ≈ 0.84 kg/dm³.

This applies to straight pipelines and hydraulic oils. Additional threaded connections and pipe bends increase the pressure differential. 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 low as possible. Constrictions in the connections and lines should be avoided. This could compromise suction output and cause cavitation. Take note that the nominal size of the connected hoses/piping must be at least as large as the inlet port sizes.

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Connecting the suction port (INLET) For the suction port connection, use a flexible hose that is resistant to negative pressure. Avoid constrictions in the connecting lines, as they compromise suction performance and increase the risk of cavitation.

NOTICE

Overpressure at the suction port connection


► The pressure on the suction port INLET must not be more than 5 bar.

Checking flow rate The required volume flow is set using an orifice. To achieve a volume flow of 12 l/min (± 10%), pressure of 5 bar is required at the connection (INLET).

Connecting the pressure connection (OUTLET) Make sure that the nominal width of the pressure line corresponds to the connector thread of the filter housing. Install the return line below the fluid level to prevent air from entering the fluid in the tank.

To prevent air from entering the medium, make sure that the pressure hose with lance is always below the oil level in operation.

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Connecting the water drainage (WATER DRAIN)

NOTICE

Excess pressure at the water outlet


► Guide the water outlet into a depressurized reservoir.

Connect the water outlet to a depressurized reservoir without cross-section reduction. Reservoir height max. 1.5 m and no higher than the fluid level in the tank. Connect the water connection to a depressurized reservoir. Take care to ensure than no pressure can prevail and/or develop. The nominal size of the connecting line must match the cross-section of the threaded connection.

The separated water can contain some parts of operating medium. Dispose of the water-oil mixture in an environmentally friendly manner.

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Connecting the device / sensors In the following, you will read how to electrically connect the components / sensors.

Connecting phase limit sensor Connect the phase limit sensor according to the manufacturer's instructions. You can find the manufacturer's documents for the phase limit sensor in the housing's technical documentation.

Phase limit sensor - Monitoring signal If the phase limit sensor detects water at the upper switch point S2 for 10 seconds, then the water drain value must be opened time-controlled for 3 seconds. If the lower switch point S1 signals inside 3 seconds, then the valve must be closed again immediately (safety function). If the water phase limit sensor detects water at the upper switch point S2 for longer than 13 seconds, an error message must occur, followed by switching off the unit. Check the housing for a malfunctioning water drain valve or phase limit sensor. Replace any defective components immediately.

Connecting up clogging indicator Connect the clogging indicator according to the manufacturer's instructions. You can find the manufacturer's documents for the clogging indicator in the housing's technical documentation. Refer to the name plates of the clogging indicators for the model code.

Clogging indicator - Monitoring signal If the clogging indicator reacts, change the coalescing element.

Connecting the water drainage valve Connect the water drainage valve according to the manufacturer's instructions. You can find the documents in the filtration unit's technical documentation. The model code is: E4323/0801/.12

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Commissioning the housing

Commissioning the housing

Before the housing is put into operation, it must first be connected hydraulically and electrically, as described in the above chapters. Note that the OLS housing 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

2. Bleed the housing while filling.

3. If an external boost pump is present, switch it on.

4. Note the required flow rate, see "Checking flow rate" section on page 25.

5. Switch on the entire system.

6. The housing is now ready for use.

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Performing maintenance


Perform all of the subsequent maintenance work regularly.

WARNING

Hot surfaces

Danger of burns

► Allow the housing to cool before any maintenance work.

Maintenance intervals Adhere to the following maintenance intervals.

For d

etai

ls, s

ee p

age

12 h

Dai

ly

Wee

kly

Eve

ry 3

mon

ths

1 ye

ar

6 ye

ars

Whe

n in

dica

ted:

Perform visual check 29 - X - - - - -

Replacing hydraulic hoses

30 - - - - - X -

Changing the coalescing elements

30 - - - - X - X

Breather 35 - - X - - - -

Perform visual check Check the housing for leaks, brittle hoses and cables daily. Replace damaged or brittle parts immediately.

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Replacing hydraulic hoses Replace the hydraulic hoses every six years at the latest. The six operating years include two years' storage duration for normal requirements in accordance with the rules of the Employers Liability Insurance Association BGR 237 for normal requirements.

Changing the coalescing elements To replace the coalescing elements, proceed as follows:

1. Switch off the hydraulic systems.

2. Close the ball valve INLET.

3. The automatic breather (8) relieves the pressure. Check the pressure detent using the pressure gauge (4).

4. Open the ball valve at the DRAIN (D) connection to empty the coalescing housing. Collect the free water/oil in a suitable container and dispose of it in an environmentally friendly manner. Once the coalescing housing is completely emptied, close the DRAIN (D) connection

5. Loosen the tensioning clamp on the coalescing housing with a size 13 mm fork wrench by turning it counterclockwise.

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6. 1 - Remove the housing clamp (2400). 2 - Remove the cover by lifting it upward and set it down to the side.

7. Remove the element set from the

coalescing housing. Use both handles to accomplish this.

8. Rotate the element set on the head by

180°.

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9. Undo the 3 wing nuts and remove the holding plate.

10. Pull the coalescing elements out of the

element receptacles and dispose of them in an environmentally friendly manner.

11. Moisten the O-ring on the element

lightly with the operating fluid.

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12. Insert the new coalescing elements into the element receptacles by screwing them in carefully.

Do not use a hammer, etc.

13. Mount the element holding plate and

tighten the 3 wing nuts firmly.

14. Rotate the element set by 180°.

Insert the element set into the coalescing housing. Note that the element set fits only in one position (Z) in the coalescing housing.

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15. Clean the sealing surface on the cover. Check the O-ring for damage. Replace it if necessary.

16. 1 - Place the cover on the coalescing housing. 2 - Place the housing clamp over the coalescing housing.

17. Use an SW 13 fork wrench to tighten

the tensioning clamps evenly to a maximum of 20 Nm. Screw open the lock nut and secure the connection.

18. The replacement of the coalescing

element is completed.

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Breather maintenance The breather (N6) is a float-controlled valve whose job it is, once installed, to vent any air or other gases in continuous operation, which have collected to a maximum level in liquid-filled containers or pipes or aerate the system when the fluid level is dropping. This function is automatic - without any additional electrical / pneumatic power. Depending on the level of liquid, a float opens or closes a valve for venting or de-aerating either directly or with a lever ratio. The self-actuating function of the pipe fitting requires maintenance for perfect functioning. Plan and carry out maintenance work at regular intervals.

NOTICE

Faulty breather

The filter area of the filter elements is not being used to its full potential.

► The breather has functional parts which need to remain in smooth operation. Make sure that parts touched by the fluid do not become clogged by deposits or dirt (at the float in particular).

► Adhere to the maintenance intervals.

The breather is not a shut-off device which guarantees a sealed end of the valve. In closed position as per DIN EN 60534-4 and/or ANSI FCI 70-2 it can identify a leakage rate that corresponds to leak classes III or V: - Leakage class III (metallically sealing poppet) = 0.1% Kvs value - Leakage class V (soft-sealing poppet) = 1.8 x 10-5 x Δp x seat

diameter [l/h]

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Check breather functionality

NOTICE

Breather not working

The filter area of the filter elements is not being used to its full potential.

► Check the functionality of the breather at least once a week.

Check the functionality of the breather once a week. 1. The function test can only be carried out when the filtration unit is

running. 2. The air bleed plug has ventilation slots. Loosen the air bleed screw

approx. 2 thread turns. - If fluid exits, the breather is working -> everything is OK. - If air escapes, the function of the breather is disrupted -> Perform the works detailed in chapter "Cleaning breather / Replacing parts" on page 37.

3. Screw in the air bleed screw (134) and tighten it.

4. The function test is complete.

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Cleaning breather / Replacing parts Clean the breather at least once a year. The required replacement parts can be found in a maintenance set on the spare parts list on page 40.

To clean or replace the parts with the repair set, proceed as follows: 1. Detach the drain line to the breather.

2. Detach the breather from the filter housing.

3. Detach the housing clamp (8).

4. Remove one housing half (2).

5. Remove the holding clamp (6)

6. Remove the ball float (4).

7. Gently loosen the screw (9) and remove the poppet seal (5).

8. Clean the float or replace it.

9. Insert a new poppet seal (5).

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10. Tighten the screw (9) to such an extent that a light bowing of the poppet seal comes about.

11. Thoroughly clean all parts.

12. Check the valve seat (3) for damage.

13. Replace the body seal ring (7).

14. Assemble the breather together and tighten the housing clamp (8) with the two screws equally.

15. Attach the breather to the filter housing.

16. Attach the drain line to the breather.

17. Check the leak-tightness of the breather when recommissioning the filter housing.

18. Cleaning/Replacing parts is complete.

Help with errors on the breather The following malfunctions at the breather may come about during operation. Malfunction Cause Measure

Leakage between the housing parts

The housing clamp is not fastened tightly enough.

Retighten the screws (8) of the housing clamp in a clockwise direction.

Leakage at the poppet valve, fluid comes out through the bleed line.

Foreign matter / dirt prevents the full sealing of the valve poppet. The system of rods is stiff due to dirt or corrosion. The float is too heavy because of silting

Detach the breather and clean all parts or exchange them. A repair set can be found in the spare parts list. If the error cannot be remedied, contact HYDAC.

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Customer Service / Service

Customer Service / Service

Regular inspection and maintenance work are indispensable to ensure trouble-free operation and a long service life for your unit. HYDAC SERVICE GMBH Friedrichsthaler Str. 15A, Werk 13 66540 Neunkirchen-Heinitz Germany Telephone: +49 6897 509 883 Fax: +49 6897 509 324 E-mail: [email protected]

Decommissioning the housing

Drain the housing completely, including all of its components, before decommissioning. Pull out the power plug, and securely fasten the hoses and power cord to the housing.

Shutting down housing

See chapter "Decommissioning the housing"

Disposing of housing

Dispose of the packaging material in an environmentally friendly manner. After dismantling the housing and separating its various materials, dispose of it in an environmentally friendly manner.

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Spare parts list

Spare parts list

Additional details regarding the versions can be found in the following.

Item Designation Qty. Part no.

- Phase limit sensor 1 4246927

- Breather valve 1 6166933

- Repair set for breather, consisting of: - Ball float - Poppet seal - Stop clamp - Seal

1 4164032

- Automatic water drainage valve 1 6207776

- Housing clamp for cover 1 6005235

- O-ring 1 6005449

- Coalescing element, 5µm N20WR005-1F 10 3277940

*) available on request, x) not deliverable as spare part

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Technical details

Technical details

Hydraulic data Flow rate 12 l/min Permissible fluids Mineral oil to DIN 50524 Permitted fluid temperature range 0 … 80°C Permissible viscosity range 15 … 320 mm/s² Permitted pressure at inlet (INLET OIL) 5 bar Permissible pressure at the water drain Depressurized Housing material Stainless steel: 1.4301 Material of seal NBR INLET connector G1" OUTLET connector G1" Connection for water drain G 1/2" General data Permitted ambient temperature range -10 … 40°C Permissible humidity during operation 30 … 60 g water / m³ air Permitted storage temperature range 5 … 45°C Permitted relative humidity during storage ≤ 60 % Empty weight ≈ 92 kg

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Model code

Model code

OLS 10 / 12 - S - N - 20 - 1 - BM - Z - Z - Z / V

Type OLS Size 10 = Number of coalescing elements Nominal flow rate 12 = 12 l/min Pump version Z = Without pump G = Gear pump S = Vane pump Power supply B = P = 480 V, 3 Ph C = P = 380 V, 3 Ph G = P = 440 V, 3 Ph L = P = 115 V, 3 Ph M = 230 V, 1 Ph* N = P = 400 V, 3 Ph O = P = 460 V, 3 Ph P = P = 575 V, 3 Ph S = P = 500 V, 3 Ph R = P = 415 V, 3 Ph W = 230 V, 3 Ph* X = Other voltage (on request) 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 Pre-filter 2 = OLF 15-60 Z = without Clogging indicator BM = Differential pressure indicator, visual (VMxBM.1) C = Differential pressure indicator, electrical (VMxC.0) Z = None E = Back-pressure indication VMF 0.6KO Heater 1 = 1 kW 2 = 2 kW Z = none Water drain 1 = Automatic Z = Manual Instrumentation Z = without Additional details PKZ = On-off switch with motor protection switch FA2 = On/Off switch with motor protection switch and switch-off when filter is

clogged. Requires no neutral conductor, all voltages, clogging indicator C required.

V = Seals made of Viton (FPM)

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Index

Index

A accident prevention ...................................................... 13 ambient temperature .............................................. 16, 41 Auxiliary personnel ........................................................ 12

B Back-pressure ................................................................ 42

C care........................................................................ 2, 5, 26 Cause ............................................................................. 38 Check valve .............................................................. 19, 21 Clogging indicator .................................................... 27, 42 collecting pan ................................................................ 23 connecting ......................................................... 23, 25, 26 Connection .................................................................... 41 Content ........................................................................... 3

D Density .......................................................................... 24 Description .............................................................. 15, 16 dewatering .............................................................. 10, 17 Differential pressure ......................................... 19, 21, 42 Differential pressure indicator .......................... 19, 21, 42 DIN .......................................................................... 35, 41 Disposal ......................................................................... 12 Documentation Representative ...................................... 2 DRAIN .......................................................... 19, 21, 26, 30 drain valve ..................................................................... 27

E Empty weight .......................................................... 16, 41

F filling ........................................................................ 10, 28 filtration ...................................................... 17, 24, 27, 36 Float switch ................................................................... 19 Flow rate ........................................................... 16, 24, 41

G gear ......................................................................... 10, 17 Gear pump .................................................................... 42

H Hazard symbol ............................................................. 7, 9 Heater ........................................................................... 42 Hydraulic data ............................................................... 41

I Imprint ............................................................................ 2 IN 16 Inlet ......................................................................... 19, 21 INLET ................................................ 19, 21, 25, 28, 30, 41 installation .................................................................... 10 Internal pipe diameter .................................................. 24

M Maintenance .................................................. 1, 12, 17, 29 Maintenance interval .................................................... 29 Maintenance intervals .................................................. 29 Malfunction................................................................... 38 Measure ........................................................................ 38 Measures ........................................................................ 9 Mineral oil ..................................................................... 41 Model code ............................................................. 15, 42

O Off switch ...................................................................... 42 operating ........................ 5, 6, 7, 10, 12, 13, 16, 26, 30, 32 Operation ...........................................................11, 17, 42 Operations control ........................................................ 12 Orifice ..................................................................... 19, 21 OUT ............................................................................... 16 Outlet ...................................................................... 19, 21 OUTLET......................................................... 19, 21, 25, 41

P Power consumption ...................................................... 16 Pressure differential...................................................... 24 Pressure gauge ........................................................ 19, 21 Proper/Designated Use ................................................. 10 Publisher ......................................................................... 2 Pump ............................................................................. 42

R replacement ............................................................ 34, 37 Residual water content ................................................. 10

S select ............................................................................... 6 Service ........................................................................... 39 Signal word ................................................................. 8, 9 signal words ................................................................ 8, 9 Size ................................................................................ 42 Spare part ..................................................................... 40 Spare parts .................................................................... 40 Spare parts list .............................................................. 40 Specialist personnel ...................................................... 12 storing ........................................................................... 14

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Index

switching off .................................................................. 27

T Transport ....................................................................... 12 transporting................................................................... 14 Troubleshooting ............................................................ 12

V Vane pump .................................................................... 42 venting .......................................................................... 35

W Weight .......................................................................... 16

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HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 6897 509 01 Central Fax: +49 6897 509 9046 Technology Fax: +49 6897 509 577 Sales Department Internet: www.hydac.com E-mail: [email protected]

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