Hydac OLFP-1, Installation And Maintenance Instructions Manual

Page 1: ...fLine Filter Pressure Installation and Maintenance Instructions English translation of original instructions Document No 4469047 10 24 2019 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ...s 8 1 5 5 Representation of warning general safety information 9 1 5 6 Signal words and their meaning in the general safety information 10 1 6 Hazard symbols pictograms 11 1 7 Supplementary symbols 12 1 8 Exclusion of liability warranty 13 1 9 Notes on copyright 13 1 10 Validity of this manual 14 2 Safety information 15 3 Filter housing overview 18 3 1 Proper designated use 19 3 2 Improper Use or ...

Page 3: ... 39 5 6 Putting the filter housing into operation 39 5 7 Checking the installation 40 6 Operation 41 7 Performing maintenance 42 7 1 Maintenance table 42 7 2 Changing the filter element N1TMxxx 42 8 Appendix 47 8 1 Locating spare parts 47 8 2 Clogging indicators technical data 51 8 2 1 Differential pressure indicator visual VM x B x 51 8 2 2 Differential pressure indicator visual VM x BM x 53 8 2 ...

Page 4: ...TEMS GMBH Justus von Liebig Str Werk 20 66280 Sulzbach Saar Germany Germany E mail filtersystems hydac com Homepage www hydac com Court of Registration Saarbrücken HRB 17216 Executive directors Mathias Dieter Dipl Kfm Wolfgang Haering Tab 1 Impressum 1 2 Documentation Representative The contact data of the person authorized with the documenta tion is Mr Günter Harge c o HYDAC International GmbH In...

Page 5: ...se re fer to it every time you require decisive details This manual informs and warns you of risks against which the risk reduction through the design and protective measures may not be effective or not fully effective 1 4 Target group of the manual This manual was created for the following target group Target group Tasks Owner This manual and the associated docu ments must be kept accessible at t...

Page 6: ...oduct Product name Operating and Maintenance Instructions 12345678 English translation of original instructions Valid from from s no 1 5 2 4 3 Fig 1 Overview labeling of the title page 1 Short name of the product product name 2 Type of document 3 Language 4 Document no Index Date of printing 5 Supplementary instructions regarding the validity of the manual optional Please note that you can directl...

Page 7: ... for the representation of requirements ü he product is assembled and connected ü The product is switched off 1 Switch the product on 1 5 3 Representation of procedural instructions In the case of procedural instructions there are the two follow ing representations Procedural instructions with a fixed sequence Procedural instructions whose sequence must be complied with without fail are listed wit...

Page 8: ...activities it is necessary to carry out work steps with intermediate results and end results Intermediate results are the consequence of activities they are marked with an indented arrow End results represent the end of an activity and are repre sented with a flag An example for a procedural instruction with intermediate re sult and final result 1 Switch the product on ð The display lights up 2 Pr...

Page 9: ...y information in this manual are highlighted with pictograms and signal words The pictogram and the signal word give you an indication of the severity of the danger Warning general safety information which are placed ahead of each activity are represented as follows CAUTION Type and source of danger Hazard symbol Consequence of the danger Measures to avert danger ...

Page 10: ...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 mi nor or moderate injury NOTICE NOTICE The signal word indicates a h...

Page 11: ...eral safety information and in structions in these operating instructions which indicate partic ular dangers to persons property or the environment Danger point warning Dangerous electrical voltage warning Mandatory action symbols used These symbols are listed for all general safety information and instructions in these operating instructions that refer to particu lar dangers to persons property o...

Page 12: ...have specific 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 dangers Specialist personnel Mechanic Such persons have specific specialist training and several years work experience They are able to assess and perform the work assigned to them and they are also able to recognize poten tial ...

Page 13: ...spect of the information in this manual 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 in jury and damage to health If we negli...

Page 14: ...lidity of this manual The diagrams and visualizations in this manual are meant for general illustration purposes Therefore representations and functional options can deviate from the delivered product We reserve the right to changes to the contents of this manual without prior notice ...

Page 15: ...st be observed DANGER Dangerous electrical voltage warning Danger of fatal injury u All electrical jobs must be carried out by specialists with the respective knowledge for the job u Pull the power plug and ensure the unit is deenergized DANGER Danger due to unintended use Bodily injury and damage to property u Never operate the filter unit in potentially explosive atmos pheres u Use the filter ho...

Page 16: ...il spill u Remove the ends of the hoses from the reservoir after op eration or shut the shut off device in the suction line NOTICE Pressure port outlet OUT closed The filter unit filter housing will be damaged destroyed u Make sure that the pressure port is always open during operation NOTICE Incorrect storage The clogging indicator will be damaged destroyed u Make sure that the clogging indicator...

Page 17: ... The clogging indicator will be damaged destroyed u Grip the filter unit filter housing with your hands on the fil ter housing to transport or to store it NOTICE Impermissible operating medium The filter housing filter unit will be damaged destroyed u Use the filter housing filter unit only together with mineral oils and mineral oil based raffinates respectively ...

Page 18: ...ces The TriMicron filter elements used have the following proper ties Optimum adsorption of oil degradation products in the filter material without rapid clogging Very high contamination retention capacity through a pro nounced depth structure The advantages of the Offline Filter Pressure OLFP are Longer life expectancy for the main flow filter Improvement in component lifetime Higher machine avai...

Page 19: ...ming inspection and maintenance work NOTICE Impermissible operating medium The filter housing filter unit will be damaged destroyed u Use the filter housing filter unit only together with mineral oils and mineral oil based raffinates respectively Claims for defects or liability regardless of the legal founda tion do not apply with incorrect or improper installation com missioning usage handling st...

Page 20: ...ng use beyond this shall not be considered intended use HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use This risk is borne solely by the owner Improper use may result in hazards and or will damage the fil ter unit Examples of improper use Operation in potentially explosive atmospheres Operation under non approved operational conditions Operation when the s...

Page 21: ...ilter housing for any damage when it is deliv ered Immediately report any damage in transit to the forwarding agent or the HYDAC department in charge Commissioning may not be performed if the filter housing is damaged Qty Description 1 OffLine Filter Pressure OLFP 1 x design de pending on the order 1 Installation and Maintenance Instructions this docu ment Tab 4 Scope of delivery Fig 2 Scope of de...

Page 22: ...he filter housing see the name plate Fig 3 Decoding model code Item Description 1 Filter unit nameplate 2 Filter unit model code Part no Part number S N Serial number year of manufacture Power Power consumption Voltage Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Operating pressure maximum Weight Empty weight ...

Page 23: ...ER SYSTEMS GMBH Filter housing overview 3 MoWa OLFP 1 T002 4469047 en us lq 23 64 Flow rate Flow rate Temp oil Permitted fluid temperature range Temp amb Permitted ambient temperature range Volume Volume content ...

Page 24: ...oring 1 Size 1 1x filter element 3 Size 3 1x filter element 6 Size 6 2x filter elements O with orifice for flow see figure volumetric flow through the orifice G with gear pump only for sizes 3 6 Z without M MCS 14xx MetallicContamination Sensor A AS 1000 AquaSensor Z without E Standard clogging indicator B Differential pressure gauge optical VM2BM x C Differential pressure gauge electrical VM2C x ...

Page 25: ...mitted ambient tempera ture range 30 40 C Permitted fluid temperature range 30 80 C Permitted storage tempera ture range 40 30 C Permitted relative humidity during storage 80 Storage duration Indefinitely Exchange all seals after a stor age period of 2 years Survival temperature 40 C Filter head material Aluminum Filter bowl material Aluminum Filter housing volume 9 liter Empty weight 21 kg Tab 5 ...

Page 26: ...iscosity of 0 200 mm s can be found as follows Pressure bar Flow rate l min Fig 5 Nominal flow rate diagram TYPE Nominal flow rate Orifice Line type OLFP x 2 2 l min A OLFP x 3 3 l min B OLFP x 6 6 l min C OLFP x z variable Tab 6 Orifice Nominal flow rate The diagram shows the flow rate of a clean unused filter ele ment ...

Page 27: ... 3 6 Dimensions In this chapter you will find the drawings with the dimensions of the different designs of the filter units filter housings Fig 6 Dimensions of OLFP 1 x T 002 IN Inlet OUT Outlet DPI Clogging indicator DRAIN Drain VENT Air bleed X Required space for removing the filter element ...

Page 28: ...3 Filter housing overview HYDAC FILTER SYSTEMS GMBH 28 64 MoWa OLFP 1 T002 4469047 en us lq All dimensions in mm ...

Page 29: ...FP 1 T002 4469047 en us lq 29 64 3 7 Hydraulic circuit In this chapter you will find the hydraulic diagram of the differ ent designs of the filter housings Fig 7 Hydraulic diagram OLFP 1 T002 IN Inlet OUT Outlet DPI Clogging indicator DRAIN Drain VENT Air bleed ...

Page 30: ...469047 en us lq 3 8 Components The filter housing has the following components Fig 8 Components of the OLFP 1 T002 1 Filter connection piece 2 Filter housing 3 Filter cover 4 Air bleed plug Air bleed 5 Drain ball valve 6 Clogging indicator optional 7 Adapter with orifice option ...

Page 31: ... OLFP 1 T002 4469047 en us lq 31 64 4 Transportation storage Fully empty the filter unit filter housing before transporting it or putting it into storage Remove the used filter element and clean the inside of the filter housing Fig 9 Lifting OLFP with strap ...

Page 32: ...H 32 64 MoWa OLFP 1 T002 4469047 en us lq Store the filter housing filter unit in a standing position in clean and dry rooms without condensing humidity The permit ted storage conditions are available in chapter Technical Data Fig 10 Storing the OLFP ...

Page 33: ...hydraulically and electrically 5 1 Fastening mounting the filter housing During installation make sure that the direction of flow through the filter is correct The connections are labeled IN OUT Install the filter housing only when it is in an upright position Fasten the OLFP using the four Ø 9 mm bores on the filter connector according to the following diagram Fig 11 Fastening mounting the filter...

Page 34: ...ations are transmitted to the filter housing Use hoses or expansion joints if necessary Fig 12 Observing the removal space Make sure there is adequate removal space X for changing the filter element In order to make the filter element change easier install shut off devices in the immediate vicinity of the filter housing B ...

Page 35: ...g containers systems This siphoning effect also occurs when fluid is pumped in a pre pressurized reservoir Fig 13 Avoiding siphoning NOTICE Siphoning effect Reservoir overflowing leaking oil spill u Remove the ends of the hoses from the reservoir after op eration or shut the shut off device in the suction line After the filter unit is switched off the height difference primary pressure can cause f...

Page 36: ...e mineral oil based hydraulic oil has a density of 0 9 kg dm This formula applies to straight pipe runs Particularly with re gard to the suction side connection note that additional con nectors and pipe bends increase the pressure differential Observe the following points for hydraulic connection Keep the height difference between the pump and the oil level in the reservoir as small as possible Us...

Page 37: ...talling 5 MoWa OLFP 1 T002 4469047 en us lq 37 64 Make sure that the connection hoses piping suction side pressure side do not cause any tension or vibrations to be carried over to the filter unit Use hoses or expansion joints if necessary ...

Page 38: ...e as well as the measurement point is critical as shown in the following diagram Fig 15 Measure or display dynamic pressure differential pressure p Total of the pressures p1 Differential pressure p1 Back pressure p2 Differential pressure p2 Back pressure p3 Differential pressure p3 Back pressure p4 Differential pressure p4 Back pressure In the example the back pressure at the first measurement poi...

Page 39: ...tor connect it to your control center in accordance with the switching logic See also 2 Clogging indicators technical data 51 5 6 Putting the filter housing into operation The filter housing is delivered without any fitted filter element ü Install the filter element before starting up the unit 1 Switch the pump on and chect the installation for any leaks 2 Vent the filter housing at the VENT conne...

Page 40: ...UT closed The filter unit filter housing will be damaged destroyed u Make sure that the pressure port is always open during operation 5 7 Checking the installation Check all the electric hydraulic connections screwed connec tions and components for firm seating After commissioning check all the functions and for leaks ...

Page 41: ...ectric Visually check the optical clogging indicator daily See chapter Observing the optical clogging indicator optional The electric clogging indicator signals the required filter ele ment change through an electric switch which notifies the re mote control or another sensor When the clogging indicator has responded change the filter element filter cartridge Information on changing the filter ele...

Page 42: ...ic system is under pressure during operation Danger of bodily injury u The hydraulic system must be depressurized before per forming any work on the hydraulic system 7 1 Maintenance table 7 2 Changing the filter element N1TMxxx In this chapter you will find the procedure for changing the fil ter element 1x Allen wrench 5 mm 1x Allen wrench 6 mm To change the filter proceed as follows 1 Switch off ...

Page 43: ...g this hold the adapter by means of a wrench 19 mm 3 Open the drain ball valve to empty the filter housing Collect the escaping fluid 9 liters in a suitable con tainer Fill the oil back into the tank of the hydraulic sys tem or dispose of it in an environmentally friendly man ner 4 Loosen the filter lid counterclockwise Unscrew the filter lid fully by hand CAUTION Due to spring force the filter li...

Page 44: ...n an environmentally friendly manner 6 Apply pressure to the new filter element by screwing it in slightly into the element mount NOTICE Do not use a hammer or similar tools for this 7 Check the O ring for damage and replace it if neces sary Coat the threads in the filter lid with aluminum paste The part no can be found in the spare parts list ...

Page 45: ... clockwise onto the filter housing Tighten the filter lid up to the stop 9 Undo the filter cover by a 1 4 turn or by 90 in counter clockwise direction 10 I Open the shut off device at the inlet IN slowly to avoid pressure shocks to the filter and fill the filter housing II During the filling process take note of the vent bore III Shut the shut off device at the inlet IN as soon as fluid escapes ...

Page 46: ...n wrench 6 mm Tighten the vent screw with a torque of 20 Nm II Open the shut off device at the inlet IN III Open the shut off device at the outlet OUT 12 Open the shut off device II at the outlet OUT slowly After commissioning check the filter unit for leaks O The filter element change is now complete The filter housing is ready for operation ...

Page 47: ...4 8 Appendix 8 1 Locating spare parts Use only original spare parts and accessories When ordering spare parts and accessories make sure to always indicate the exact model code and the serial number The following spare parts are available for the product Fig 16 Spare parts 1 2 ...

Page 48: ...8 Appendix HYDAC FILTER SYSTEMS GMBH 48 64 MoWa OLFP 1 T002 4469047 en us lq Fig 17 Spare parts 2 2 ...

Page 49: ...e clamp 7 1 1 Dowel pin 7 2 1 Disk for the clamp 8 0 2 O ring NBR 604001 8 0 2 O ring FKM 604002 9 0 2 Sealing plugs G3 4 NBR 607167 9 0 2 Sealing plugs G3 4 FKM 613726 10 0 1 Screw plug 3586426 10 1 1 profile seal ring NBR 411600 10 1 1 profile seal ring FKM 413429 10 2 1 O ring NBR 604075 10 2 1 O ring FKM 610433 11 0 1 Clogging indicator VM 2 BM 1 V 303200 12 0 1 Adapter SAE 2 12 1 4 Cylinder h...

Page 50: ... 1 O ring NBR 604086 14 1 1 O ring FKM 610555 15 0 1 Screw plug G NBR 608658 15 0 1 Screw plug G FKM 615003 17 0 1 Screw connection 18 0 1 Screw connection 19 0 1 Ball valve 551094 20 0 1 Filter element 3 µm N1TM003 3284980 1 Aluminum paste 1 kg 3090398 Tab 7 Spare Parts On demand Not available as a spare part ...

Page 51: ...housing filter unit 8 2 1 Differential pressure indicator visual VM x B x The optical differential pressure gauge reacts to the increasing pressure difference at the increasing contamination level of the filter element 30 Fig 18 Differential pressure indicator visual VM x B x Type of indication Visual display with a green red field automatic reset Weight 55 g Response pressure and indi cation rang...

Page 52: ...002 4469047 en us lq Permissible operating over pressure 210 bar Permitted temperature range 30 100 C Connector threads G Installation space required According to HN 28 22 Maximum tightening torque 33 Nm Tab 8 Differential pressure indicator visual VM x B x ...

Page 53: ...essure gauge reacts to the increasing pressure difference at the increasing contamination level of the filter element 30 Fig 19 Differential pressure gauge visual VM x BM x Type of indication Visual display by green red field manual reset Weight 55 g Response pressure and indi cation range respectively VM 2 BM x 2 bar 10 VM 3 BM x 3 bar 10 VM 5 BM x 5 bar 10 ...

Page 54: ...64 MoWa OLFP 1 T002 4469047 en us lq Permissible operating over pressure 210 bar Permitted temperature range 30 100 C Connector threads G Installation space required According to HN 28 22 Tab 9 Differential pressure indicator visual VM x BM x ...

Page 55: ...ential pressure gauge electric VM x C x The electric clogging indicator reacts to the increasing pres sure difference at the increasing contamination level of the fil ter element 30 Fig 20 Differential pressure indicator electrical VM x C x Type of indication Electrical switch Weight 120 g ...

Page 56: ... required According to HN 28 22 Maximum tightening torque 33 Nm Switching type N C or N O change over contacts Maximum switching voltage 230 V Max switching voltage at re sistive load 60 W 100 VA AC Switching capacity ohmic 3 A 24 V DC ohmic 0 03 to 5 A 230 V AC Electrical connection Male connection M20 Female connector to DIN EN 175301 803 Protection class in accordance with DIN 40050 IP 65 only ...

Page 57: ... gauge electric VM x D x L xx The electric clogging indicator reacts to the increasing pres sure difference at the increasing contamination level of the fil ter element 30 Fig 21 Differential pressure indicator electrical VM x D x Lxx Type of indication Visual indicator and electrical switch Weight 150 g ...

Page 58: ... 28 22 Maximum tightening torque 33 Nm Switching type N C or N O change over contacts Maximum switching voltage L24 24 V DC L48 48 V DC L115 115 V AC L230 230 V AC Max switching voltage at re sistive load 60 W 100 VA AC Switching capacity ohmic 3 A 24 V DC ohmic 0 03 to 5 A 230 V AC Electrical connection Male connection M20 Female connector to DIN EN 175301 803 Protection class in accordance with ...

Page 59: ...r the hotline product support customer service branch offices service partners for servicing repair and spare parts can be found always updated at our home page www hydac com HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Str 15 Werk 13 66450 Neunkirchen Heinitz Germany Phone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 12 Customer service in Germany ...

Page 60: ... 1 T002 30 Fig 9 Lifting OLFP with strap 31 Fig 10 Storing the OLFP 32 Fig 11 Fastening mounting the filter housing 33 Fig 12 Observing the removal space 34 Fig 13 Avoiding siphoning 35 Fig 14 Pressure loss formula 36 Fig 15 Measure or display dynamic pressure differential pressure 38 Fig 16 Spare parts 1 2 47 Fig 17 Spare parts 2 2 48 Fig 18 Differential pressure indicator visual VM x B x 51 Fig ...

Page 61: ...Scope of delivery 21 Tab 5 Technical Data 25 Tab 6 Orifice Nominal flow rate 26 Tab 7 Spare Parts 49 Tab 8 Differential pressure indicator visual VM x B x 51 Tab 9 Differential pressure indicator visual VM x BM x 53 Tab 10 Differential pressure indicator electrical VM x C x 55 Tab 11 Differential pressure indicator electrical VM x D x Lxx 57 Tab 12 Customer service in Germany 59 ...

Page 62: ...en sions for the installation space for clogging indicators Trimicron The filter elements of the Trimicron series abbreviation TM were spe cially developed for the combined separation of particulate fines con tamination water and oil degrada tion products from hydraulic and lu brication oils in bypass flow They are a combination of pleated and SpunSpray depth filter elements The filter layers used...

Page 63: ...ectrical VM x C x 56 VM x D x Lxx 58 Differential pressure indicator visual VM x B x 52 VM x BM x 54 differential pressure dynamic pressure 38 dynamic pressure differential pressure 38 E exclusion of liability 13 H Hotline 59 I Imprint 4 M manufacturer 4 P Person authorized with the documenta tion 4 S Service 59 Servicepartners 59 siphoning effect 35 Support 59 T Terms and Conditions 13 Terms of D...

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