Hydac OLF-5, Installation And Maintenance Instructions Manual

Page 1: ...OffLine Filter Compact OLF 5 Series Installation and Maintenance Instructions English translation of original operating instructions Document no 3433222b ...

Page 2: ...he 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 technic...

Page 3: ... Energy 11 Electrical Hazards 11 What to Do in Case of Emergency 11 Modifications to the Filter Unit 11 Checking the Scope of Delivery 12 OLF Features 13 OLF 5 13 OLF 5 4 13 OLF 5 15 13 Restrictions pertaining to use 13 Fastening Mounting the OLF 14 Hydraulic Connection of the OLF 15 Electrical Connection of the OLF 17 Starting up the OLF 18 OLF with flow control valve only OLF 5 E Z 19 Setting th...

Page 4: ...ment Parts OLF 5 xx T 37 Dimensions Schematic OLF 5 S 38 Dimensions Schematic OLF 5 F Z 39 Dimensions Schematic OLF 5 15 S 40 Dimensions Schematic OLF 5 E Z 41 Dimensions Schematic OLF 5 4 SP 42 Dimensions Schematic OLF 5 4 S 42 Dimensions Schematic OLF 5 x T 43 Accessories OfflineFilter Tank Connection Kit OLF 5 TAK 44 Model Code 45 Motor capacity voltages 45 Filter element filter cartridge 46 Cl...

Page 5: ...oduct so it is always at your fingertips Sometimes the information contained in the documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting edge Consequently there might be deviations in technical details illustrations and dimensions If you discover errors while reading the documentation or have suggestions or other ...

Page 6: ...t 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 When making modifications or performing repair work to components affecting the safety of the product the product may not be put back into operation until it has been examined and released by a HYDAC representative Please notify us immedi...

Page 7: ...HAT do you want to know I determine which topic I am looking for WHERE can I find the information I m looking for The document has a table of contents at the beginning 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 o...

Page 8: ...ognized safety regulations Nevertheless hazard may be posed to the life and limb of the individual using the product or to third parties The filter unit is to be used solely for its designated use only when in a safe perfect condition Immediately remedy any malfunctions that might impair safety Our General Terms and Conditions apply They are provided to the owner upon conclusion of purchase of the...

Page 9: ...ng oil 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 use Proper or designated use of the product extends to the following Filtering oils Maintaining adherence to all the instructions contained herein Performing requisite inspection and maintenance work Improper Use...

Page 10: ... properly trained and instructed personnel The areas of responsibility of your staff must be established in a clear cut manner Staff undergoing training may not use the filter unit unless supervised by an experienced staff member Individuals Individuals undergoing training Individuals with technical training engineering background Electrician Supervisor with the appropriate authority Activity Pack...

Page 11: ...are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system Electrical Hazards DANGER Electric shock Danger of fatal injury Any work involving the electrical system may only be done by a properly trained certified electrician What to Do in Case of Emergency In the event of an emergency immediately disconnect the filter unit from th...

Page 12: ...ivered packed and ready for use Please check the unit for possible damage before putting it into operation Immediately report any damage in transit to the forwarding agent or the HYDAC department in charge Do not put the unit into operation The following items are supplied Item Qty Description 1 1 Off Line Filter OLF 5 Type according to order 1 Installation and Maintenance Instructions this docume...

Page 13: ... with a contamination retention capacity of up to 200g ISOMTD OLF 5 4 The OffLine Filter of the OLF 5 4 lubrication series was especially designed for use with lubrication systems gear boxes with a tank volume of up to 300 liters This filter unit functions with a flow rate of 4 l min OLF 5 15 The OffLine Filter of the OLF 5 15 hydraulics series was especially designed for use with hydraulics syste...

Page 14: ...pending on the version Please also ensure that sufficient clearance is present for replacing the filter element Mounting via the mounting base Mounting via the engine base Dimensions connections and circuit diagrams for the respective version can be found starting on page 38 If the oil level is higher than the filtration unit mount additional locking features at the inlet port IN outlet port OUT T...

Page 15: ... dm This formula applies to straight pipe runs and hydraulic oils Particularly with regard to the suction sided connection bear in mind that additional screw 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 Hoses must be suitable for suction pressures of at least 0 5 bar Constrictions in the c...

Page 16: ...nection 1 Connect the outlet port OUT of the filtration unit with the corresponding hydraulic reservoir 2 Connect the inlet port IN of the filtration unit with the hydraulic system If the filtration unit is not fitted with a motor pump unit then connect the inlet port IN with the return flow line of the hydraulic unit If coarse contamination 100 µm such as weld spatter or similar material is to be...

Page 17: ...t voltage and frequency of the power supply are correct Check the rating plate and information label in the control box of the filter unit for this information Install a motor protection switch tailored to the nominal current of the motor upstream of the unit Star Y connection Delta connection In jog mode check the direction of rotation at the motor An arrow on the housing shows the correct direct...

Page 18: ...n 2 Check the suction and pumping power 3 a If the pump transfers the medium proceed to Step 4 b If the pump is not pumping medium after 2 minutes switch off the OLF Fill the pump via the suction line proceed to Step 1 4 Commissioning successfully completed For OL5 5 4 please note If the pump is not pre filled and has an operating viscosity 200 mm s the unit only reaches the maximum flow rate of 4...

Page 19: ...ntrol valve only OLF 5 E Z The flow control valve keeps the exiting flow constant due to a controlling process The flow rate is almost entirely independent of the pressure and viscosity The flow rate is factory set to 5 l min The flow control valve s setting range ranges from 4 0 5 2 l min A B IN OUT Item Description A Adjustment screw B lock nut ...

Page 20: ...rtain range NOTICE Setting by force The flow control valve will be destroyed Do not forcefully turn the adjustment screw above the setting limit To do so proceed as follows 1 Loosen the lock nuts B by turning them in a counter clockwise direction with an open jaw wrench A B 2 Set the desired flow rate on the adjustment screw A 3 Hold the adjustment screw in position Check the position by tightenin...

Page 21: ...the hydraulic system Intervals for Changing the Filter Element To monitor the degree of contamination in the filtration unit it is equipped with an optical or electric clogging indicator If the clogging indicator shows that 2 bar have been reached visual differential pressure gauges will show an outer red marking the filter element should be replaced If the filter has an electrical clogging indica...

Page 22: ...rtently switched back on during maintenance work 2 Put a suitable container 1 in place to catch exiting medium Depressurize the filter housing Carefully open the drain plug 2 on the filter bowl and empty the filter housing completely using the drain screw SW 6mm on the bottom of the filter housing The volume is 2 liters After draining replace the drain plug on the filter bowl 3 Undo the housing cl...

Page 23: ...nt DIMICRON HYDAC FILTER SYSTEMS GMBH en Page 23 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 4 Pull the filter bowl including filter element downwards 5 Remove 2 the filter element from the filter bowl by turning slightly 1 ...

Page 24: ...433222b en us 2011 11 14 doc 2011 11 14 6 Clean the inside of the filter bowl of dirt and deposits 7 Check the O ring on the filter bowl for damage Replace it if necessary Moisten the O ring on the filter bowl with the operating medium 8 Moisten the O rings on the new filter element with the operating medium ...

Page 25: ...ER SYSTEMS GMBH en Page 25 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 9 Turning it slightly press the new filter element down into the mount on the filter bowl 10 Push the filter bowl with the filter element up into the mount on the filter head ...

Page 26: ...he housing clamp 1 up around the filter bowl over the bead on the filter bowl filter head Tighten the housing clamp with an Allen wrench SW 6mm in a clockwise direction The tightening torque is 5 Nm 12 Check that the drain plug on the filter bowl is secure 13 The filter element change is now complete After commissioning check the filtration unit for leaks ...

Page 27: ...sure that the unit cannot be put into operation again during maintenance work 4 Now release the filter cartridge using a strap wrench by rotating it counterclockwise and unscrew it carefully from the holder Operating fluid could escape 5 1 5 liters of residual oil remain in the filter cartridge Properly dispose of the element and the oil located inside it 6 Moisten the sealing ring of the new filt...

Page 28: ...BH en Page 28 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 direction After contact with the sealing surface tighten the filter cartridge manually with a turn 10 After switching it on check the filter unit for any leaks Tighten the filter cartridge if necessary ...

Page 29: ...perating fluid can flow out of the lines into the filtration unit and make sure that the unit cannot be switched on again during maintenance Depressurize the filter housing To accomplish this carefully open the air bleed screw Air Bleed on the filter housing cover do not unscrew completely Be careful when the operating medium flows out 2 Put a suitable container in place to catch the medium in the...

Page 30: ...lement and the element from the cover 5 Remove the dirt catch tray 6 Remove the filter element from the filter housing cover Dispose 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...

Page 31: ...10 Place the filter element with the cover and dirt catch tray in the filter housing Observe correct placement of the O ring on the cover while doing so 11 Secure the cover with the housing clamp The tightening torque is a maximum of 5 Nm 12 Tighten the drain plug Drain on the connection part of the unit Switch the filtration unit on Bleed the filter housing through the air bleed screw Air Bleed i...

Page 32: ...functioning after 5 min pre fill the pump via the suction line with the medium to be pumped No oil flow Operating viscosity 200 mm s and pump not filled In this viscosity range the pump requires approx 10 minutes to reach the maximum flow rate Medium heavily contaminated Filter element lifetime exceeded Replace filter element Filter contaminated Clogging indicator appears Viscosity of the fluid is...

Page 33: ...85 NBR 3052462 2 1 x 1 Repair kit OLF 5 15 consisting of wing unit pump 6x O ring 4x screw FPM 3075886 120V 60Hz 6008059 230V 50Hz 6008058 2 2 1 Electric motor 400V 50 Hz 609070 4 1 Filter element 2 µm DIMICRON N5DM002 349494 4 1 Filter element 5 µm DIMICRON N5DM005 3068101 4 1 Filter element 10 µm DIMICRON N5DM010 3102924 4 1 Filter element 20 µm DIMICRON N5DM020 3023508 4 1 Filter element 2 µm A...

Page 34: ...ation direction Motor 3252700 Replacement Parts Only for OLF 5 T Toploader Item Qty Description Part no NBR 617095 1 11 1 Drain screw with sealing ring DRAIN FPM 630700 3 2 1 Housing clamp 3233965 3 6 1 Filter housing cover complete Alu FPM 3233899 NBR 628963 3 6 2 1 O Ring for filter housing FPM 6011252 NBR 615002 3 6 3 1 Air bleed plug with sealing ring AIR BLEED FPM 615003 4 1 1 Dirt catch tray...

Page 35: ... HYDAC FILTER SYSTEMS GMBH en Page 35 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Diagram of Replacement Parts OLF 5 3 4 2 3 2 2 1 16 1 15 3 1 1 91 1 1 1 7 1 8 1 3 1 31 1 32 1 33 1 4 1 6 1 5 1 9 3 2 3 3 4 3 5 1 81 1 2 1 21 2 1 ...

Page 36: ...6 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Diagram of Replacement Parts OLF 5 x 3 10 3 20 3 30 3 40 1 16 1 11 1 11 1 11 1 30 1 31 1 32 1 33 1 40 1 41 1 42 1 43 1 50 1 60 1 61 1 62 1 63 1 64 1 70 2 20 2 10 1 20 2 21 2 22 3 50 1 10 2 30 2 23 2 31 1 70 4 00 4 00 ...

Page 37: ...OLF 5 Series Spare Parts and Accessories HYDAC FILTER SYSTEMS GMBH en Page 37 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Diagram of Replacement Parts OLF 5 xx T ...

Page 38: ...2 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 S Item Description 1 Inlet 2 Differential pressure indicator option 3 Clogging indicator 4 Outlet 5 Housing clamp 6 Filter bowl 7 Drain 8 Filter element 9 Electric motor M OUT G1 2 IN G1 2 3 5 bar ...

Page 39: ...5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 F Z 4 3 2 1 5 8 7 6 CI OUT G1 2 IN G1 2 3 5 bar Item Description 1 Inlet 2 Differential pressure indicator option 3 Clogging indicator CI 4 Outlet 5 Housing clamp 6 Filter bowl 7 Drain 8 Filter element 9 Electric motor ...

Page 40: ...Wa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 15 S Item Description 1 Inlet 2 Differential pressure indicator option 3 Clogging Indicator 4 Outlet 5 Housing clamp 6 Filter bowl 7 Drain 8 Filter element 9 Electric motor M VA OUT G1 IN G1 4 5 bar 3 5 bar ...

Page 41: ...BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 E Z CI OUT G1 2 IN G1 2 3 5 bar Item Description 1 Inlet 2 Differential pressure indicator option 3 Clogging indicator CI 4 Outlet 5 Housing clamp 6 Filter bowl 7 Drain 8 Filter element 9 Electric motor ...

Page 42: ...ries Dimensions Schematic OLF 5 4 SP HYDAC FILTER SYSTEMS GMBH en Page 42 52 BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 4 SP Dimensions Schematic OLF 5 4 S IN OUT IN OUT ...

Page 43: ... BeWa OLF5_Serie 3433222b en us 2011 11 14 doc 2011 11 14 Dimensions Schematic OLF 5 x T Item Description 1 Inlet IN 2 Filter housing cover 3 Clogging indicator 4 Outlet OUT 5 Housing clamp 6 Filter bowl 7 Drain plug Drain 8 Filter element 9 Electric motor 10 Air bleed screw Air bleed ...

Page 44: ...Tank Connection Kit TAK is designed for retrofitting available hydraulic systems with an OLF in a quick and uncomplicated manner You can use the TAK in all systems outfitted with breather filters with a connection diagram according to DIN 24557 T2 Description Part no OffLine Filter Tank Adaption Kit OLF 5 TAK 3039235 Item Description Scope of delivery OLF 5 TAK Kit 1 Air filters 2 Adapter 3 Return...

Page 45: ...ridge E with flow control valve without motor pump F Filter Version T Toploader NBR TV Toploader FPM Motor capacity voltage See table page 45 Filter element filter cartridge See table page 46 Clogging indicator See table page 47 Motor capacity voltages OLF 5 OLF 5 4 OLF 5 15 5 l min 4 l min 15 l min 120 N 120 W 3x400 V 50 Hz 120 M 120 W 1x230 V 50 Hz 120 K 120 W 1x120 V 60 Hz 370 N 370 W 3x400 V 5...

Page 46: ... filter mesh 2 µm absolute N5AM020 Aquamicron filter mesh 20 µm absolute M160B003 Spin on filter cartridge filter mesh 3 µm absolute 1 M160B005 Spin on filter cartridge filter mesh 5 µm absolute 1 M160B010 Spin on filter cartridge filter mesh 10 µm absolute 1 M160B020 Spin on filter cartridge filter mesh 20 µm absolute 1 M180B003 Spin on filter cartridge filter mesh 3 µm absolute 1 M180B005 Spin o...

Page 47: ...namic pressure gauge F Pressure switch electrical VR2F 0 BM Differential pressure indicator visual VM2BM 1 C Differential pressure indicator electrical VM2C 0 D Differential pressure indicator visual electrical VM2D 0 z Without clogging indicator not available Disposing of the OLF 5 After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly m...

Page 48: ...amination NAS 12 according to ISO4406 1999 class 23 21 18 Flow rate OLF 5 4 4 l min OLF 5 S 5 l min OLF 5 15 15 l min Viscosity range OLF 5 S 15 150 mm s OLF 5 4 15 7000 mm s OLF 5 15 15 1000 mm s Permissible suction pressure at suction port connection IN 0 4 0 6 bar Fluid temperature range 0 80 C 32 176 F Ambient temperature 20 40 C 4 104 F IP class IP 54 Weight 11 7 kg Filtration rating b 2 1000...

Page 49: ......

Page 50: ......

Page 51: ......

Page 52: ...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 Email filtersystems hydac com ...