Hydac OLS 10-Z Series, Installation And Maintenance Instructions Manual

Page 1: ...eparator with automatic water drainage Installation and Maintenance Instructions English translation of original instructions Document No 4573340 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ... E mail filtersystems hydac com Homepage www hydac com Court of Registration Saarbrücken HRB 17216 Executive directors Mathias Dieter Dipl Kfm Wolfgang Haering Documentation Representative The contact data of the person authorized with the documentation is Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Germany Telephone 49 6897 509 1511 Fax 49 6897 509 1394 E Mail gu...

Page 3: ...ing general safety information 10 1 2 7 Signal words and their meaning in the general safety information 11 1 3 Exclusion of liability warranty 12 1 4 Notes on copyright 12 2 Safety 13 2 1 Target group Required personnel qualification 13 2 2 Hazard symbols pictograms 16 2 3 Danger notifications 18 2 4 Observing regulatory information 21 2 5 Observing environmental precautions 21 3 Piping and produ...

Page 4: ...WATER 37 5 3 4 Installing the clogging indicator 38 5 3 5 Installing the pre filter 38 5 4 Electrical connection 39 5 4 1 Connecting the water drainage valve 39 5 4 2 Monitoring the water drain valve 41 5 4 3 Connecting the phase boundary sensor 41 5 4 4 Monitoring the phase boundary sensor 41 5 5 Commissioning 43 5 5 1 Setting checking the flow rate 43 6 Operation 44 6 1 Draining water automatica...

Page 5: ...s web v 9 2 Final Decommissioning 51 9 3 Disposal Recycling 51 A Appendix 52 A 1 Contacting Customer Service 52 A 2 Finding spare parts and accessories 53 A 2 1 Spare parts 53 A 2 1 1 Coalescing elements 53 A 3 Documentation regarding the components 53 Glossary 67 Index 68 ...

Page 6: ...s manual are meant for gen eral illustration purposes Therefore representations and func tional options can deviate from the delivered product We reserve the right to modifications to the contents of this man ual without prior notice 1 1 Target group of the manual This manual was created for the following target group Target group Tasks Owner Keep this manual and the applicable docu ments at the i...

Page 7: ...oduct name Operating and Maintenance Instructions Document no 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 5 Supplementary instructions regarding the validity of the man ual optional Please note that you can directly access inf...

Page 8: ...sembled and connected ü The product is switched off 1 Switch the product on 1 2 3 Representation of procedural instructions In the case of procedural instructions there are the two following representations Procedural instructions with a fixed sequence Procedural instructions whose sequence must be complied with without fail are listed with sequential numbering 1 2 3 etc An example for procedural ...

Page 9: ...ermediate 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 represented with a flag An example for a procedural instruction with intermediate result and final result 1 Switch the product on ð The display lights up 2 Press the button O The product is now ready for use 1 2 3 4 5 6...

Page 10: ... handling the product Required tools 1 2 6 Representation of warning general safety information All the warning general safety information in this manual are highlighted with pictograms and signal words The pictogram and the signal word give you information of the risk level of the danger Warning General Safety Information which is placed ahead of each activity are represented as follows CAUTION T...

Page 11: ... 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 mod erate 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 E...

Page 12: ...ormation 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 injury and damage to health If we negligently breach any...

Page 13: ...hooting on the prod uct An owner is the person who operates the product himself herself for commercial or economic purposes or provides it to a third party for use application and bears the legal product responsibility to protect the user the personnel or the third party The obligations of the owner are To know and apply the applicable health and safety regulations To determine the hazards arising...

Page 14: ...s Product specific knowledge is re quired Commissioning Specialist personnel Mechanical Specialist personnel Electrical Safe handling use of tools Product specific knowledge is re quired Handling operation operation monitoring Operating personnel General Product specific knowledge is re quired Knowledge about handling the test liq uid is required Troubleshooting Maintenance Decom missioning Disas ...

Page 15: ...nowledge of recy cling is required transport Commis sioning Operation Troubleshooting Maintenance Dis posal Specialist personnel Service Administra tor Service personnel Administrator HY DAC Service Extensive experience of the product Tab 2 Target group Required personnel qualification 1 2 3 4 5 6 7 8 9 A ...

Page 16: ...egible Warning signs used These marks can be found for all safety and warning instructions in this manual which indicate particular dangers to persons prop erty or the environment Danger point warning Dangerous electrical voltage warning Signs used for giving orders These symbols can be found for all safety and warning instructions in this manual which indicate particular dangers to persons prop e...

Page 17: ...nowledge for installa tion work and or maintenance work Specialist personnel operators Such persons have had the 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 dangers Specialist personnel Electrician Such persons have specific specialist training and sev eral years work exp...

Page 18: ...e phase Installation Assembly Maintenance and Troubleshooting The following risks could arise during the installation assembly life phase NOTICE Excessively high input pressure at the INLET OIL connection The coalescing housing will be damaged uNote the maximum permissible operating pressure see Techni cal Data 25 NOTICE Excess pressure at the water outlet The coalescing tank will be damaged uGuid...

Page 19: ...r outlet The coalescing tank will be damaged uGuide the water outlet into a depressurized reservoir Environmentally tip Operating medium is released into the soil or water Environmental hazard uRemove any leaked operating medium immediately dispose of it in an environmentally sound manner Life phase Maintenance Troubleshooting The following dangers could arise during the life phase of mainte nance...

Page 20: ...2 Safety HYDAC FILTER SYSTEMS GMBH 20 72 MoWa OLS10 Z x 4573340 en us web WARNING Hot surfaces Danger of burns uAllow the product to cool before any maintenance work 1 2 3 4 5 6 7 8 9 A ...

Page 21: ...vironmental requirements Country specific regulations organization specific regulations Occupational safety rules 2 5 Observing environmental precautions Take all measures to protect the environment Ensure that no op erating medium is released into the environment soil or water Environmentally tip Operating medium is released into the soil or water Environmental hazard uRemove any leaked operating...

Page 22: ...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 takes place in bypass flow In lorder to have the longest possible service life of the coalescing elements a prefilter for the finest of filtration is sensibler 3 1 Checking the scope of delivery T...

Page 23: ...ata 25 chapter Proper or designated use of the product extends to the following Observing all instructions in the instruction manual Performing inspection and maintenance work 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 circumstan...

Page 24: ...y damage resulting from such use This risk is borne solely by the owner Improper use may result in hazards and or will damage the prod uct Examples of improper use are for example Operation with an impermissible fluid Operation in potentially explosive zones Operation under non approved operational conditions Modifications to the product made by the user or purchaser Inadequate monitoring of parts...

Page 25: ...Mineral oils according to DIN 51524 or gear oils according to DIN 51517 with a density 950 kg m and a water content of 15 volume Permissible pressure at port DRAINWATER 0 bar Permissible viscosity range 5 l min 15 500 mm s 15 l min 15 200 mm s Permitted fluid tempera ture range 0 to 80 C ice formation is not permitted Permitted operating pressure 6 bar Permitted ambient tem perature range 10 70 C ...

Page 26: ... and mainte nance intervals are complied with Weight when empty 40 kg Tab 4 Technical data Hydraulic data Power supply 24 V DC Current consumption 0 5 A Wattage 12 Watt Protection class IP65 according to IEC EN 60529 DIN 40050 Tab 5 Technical data Water drainage valve Power supply 24 V DC Current consumption 2 5 A Switching power 60 Watt Protection class IP67 according to IEC EN 60529 DIN 40050 Ta...

Page 27: ... the serial no when contacting HYDAC Pos Description 1 Name plate for the product 2 Model code see Model code 29 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 Maximum operating pressure Pressure IN Permissible pressure at port IN Pressure OUT Permissible pressure at po...

Page 28: ...and product description HYDAC FILTER SYSTEMS GMBH 28 72 MoWa OLS10 Z x 4573340 en us web Temp of the fluid Permissible fluid temperature Temp amb Permissible ambient temperature Volume Volume 1 2 3 4 5 6 7 8 9 A ...

Page 29: ...s 15 15 l min at maximum 200 mm s Z O G Z without E Economy P Premium Pre filter Z no pre filter only for coalescing housing alone 1 pre filter size 1 only for flow rate 5 l min 2 pre filter size 2 only for flow rate 15 l min without pump with orifice only with coalescer housing alone Gear pump Clogging indicator BM D4 Z Heater Z Without without only with coalescer housing alone Clogging indicator...

Page 30: ...Z x 4573340 en us web 3 6 Dimensions The OLS has the following dimensions Fig 3 Dimensions in mm 1 Coalescing housing 3 Oil inlet INLET OIL 4 oil outlet OUTLET OIL 5 Water drain DRAIN WATER 6 1 drain DRAIN 7 1 Air vent VENT 10 Inspection glass phase boundary 1 2 3 4 5 6 7 8 9 A ...

Page 31: ...R SYSTEMS GMBH Piping and product description 3 MoWa OLS10 Z x 4573340 en us web 31 72 11 Phase boundary sensor 12 Water drainage valve x Required dismantling space for the co alescing elements 1 2 3 4 5 6 7 8 9 A ...

Page 32: ...us web 3 7 Hydraulic diagram The OLS has the following hydraulic diagram Fig 4 Hydraulic diagram of the OLS10 Z with automatic water outlet 1 Coalescing housing 3 Oil inlet INLET OIL 4 oil outlet OUTLET OIL 5 Water drain DRAIN WATER 6 1 drain DRAIN 12 Water drainage valve 1 2 3 4 5 6 7 8 9 A ...

Page 33: ...ing components Fig 5 Components of the OLS 10 Z with automatic water outlet 1 Coalescing housing 3 Oil inlet INLET OIL 4 oil outlet OUTLET OIL 5 Water drain DRAIN WATER 6 1 drain DRAIN 7 1 Air vent coalescing housing VENT 10 Inspection glass phase boundary 11 Water sensor 12 Water drainage valve 24 Tensioning clamp 1 2 3 4 5 6 7 8 9 A ...

Page 34: ... in this chapter Before transportation storage empty the coalescing housing com pletely Fasten suitable band loops to the coalescing housing for transporting with a crane Fig 6 Transporting the OLS Store the coalescing housing in a horizontal position only After a storage period of more than 2 years all seals must be re placed before it is taken into operation again Fig 7 Transporting storing the ...

Page 35: ...lescing housing and tighten them to a torque of 40 Nm 5 2 Setup and mounting 5 3 Connecting the hydraulics To reach the optimal performance of the product an important component is the hydraulic connection the right integration Install the suction port connection at the lowest part of the tank Through this you ensure that the water phase located at the base of the tank is reached Install the retur...

Page 36: ...s for hydraulic connection Keep the height difference of the product to the oil level in the reservoir as small as possible Use a suction hose that is suitable for a vacuum of 0 5 bar e g 1 bar Avoid constrictions in the connected hoses This reduces the power and increases the risk of cavitation Note that the nominal size of the connected hose piping must correspond to the cross section of the con...

Page 37: ...ousing Install the return line below the oil level in the oil tank to prevent air from entering the oil in the tank If the clogging indicator pressure displayed for the a clean filter el ement is 1 bar use a differential pressure clogging indicator 5 3 3 Connecting the water drainage DRAIN WATER Connect the water outlet to a depressurized reservoir without cross section reduction Container height ...

Page 38: ... indicator as a differential pressure indicator Install a differen tial pressure clogging indicator between the connections IN LET OIL and OUTLET OIL Change the coalescing elements at a differential pressure of 0 8 bar 5 3 5 Installing the pre filter In order to protect the coalescing elements install a contamination filter to pre filter with a filtration rating of 2 5 µm 1 2 3 4 5 6 7 8 9 A ...

Page 39: ...ption 5 4 1 Connecting the water drainage valve Connect the water drain valve according to the following steps Fig 10 Connecting the water drainage valve 1 Pressure screw 2 Disks 3 Central screw 4 Body 5 Dosing insert 6 Flat gasket Connect the magnets according to the instructions of electrical engineering Use a round cable with a Ø 5 10 mm with a cross section of 1 5 mm 1 2 3 4 5 6 7 8 9 A ...

Page 40: ...al 9 3 Fasten the other wires to the terminals 7 and 8 of the dos ing insert 5 DANGER Take care of the connections marked with or on the correct pin connection of the energized conduc tor 4 Set the housing 4 in the selected position 9 O clock 12 O clock 3 O clock 6 O clock on the dosing insert 5 5 Turn the pressure screw 1 tightly on the cable introduction NOTICE The cable introduction must be sec...

Page 41: ...undary sensor detects water at the upper switch point L1 for 10 seconds then the water drain valve is opened 12 seconds If the phase boundary sensor detects water at the upper switch point L1 for longer than 22 seconds an error message is output followed by switching off the motor pump assembly group 5 4 3 Connecting the phase boundary sensor Connect the phase boundary sensor details with regard t...

Page 42: ... OLS10 Z x 4573340 en us web If the phase boundary sensor detects water at the upper switch point L1 for 22 seconds an error message must occur followed by switching off the motor pump group Check that the phase boundary sensor is functioning 1 2 3 4 5 6 7 8 9 A ...

Page 43: ...lug X1 on the coalescing housing 6 Switch the external boost pump on NOTICE Follow the maximum permissible operating pressure 7 If the coalescing housing has been bled then close the air bleed plug X1 8 Open the shut off valve on the OUTLETOIL port 9 Check the required flow rate see Setting checking the flow rate 43 O The coalescing housing is now ready for operation 5 5 1 Setting checking the flo...

Page 44: ...cing housing and switch the pump on 6 1 Draining water automatically If the phase boundary sensors connected as described in chapter Monitoring the phase boundary sensor 41 and the water drain valve is connected then during operation the water being re moved is automatically drained via the water drain valve 1 2 3 4 5 6 7 8 9 A ...

Page 45: ...rating the product Error Cause s Rectification Clogging indicator responds The coalescing el ements are clogged Replace the coa lescing elements The viscosity of the fluid is too high Check the viscos ity of the fluid Heat the fluid to achieve the per missible viscosity Leak at the coa lescing housing Wrong missing or defective seal ing ring Check the sealing ring of the filter el ement Replace it...

Page 46: ...fore performing any work on it WARNING Hot surfaces Danger of burns uAllow the product to cool before any maintenance work 8 1 Maintenance table Daily Annually As required Additional information 8 2 Performing a visual check 1 8 3 Changing the coa lescing elements 2 8 3 Changing the coa lescing elements 2 1 Operating personnel 2 Specialist personnel Mechanical 8 2 Performing a visual check Check t...

Page 47: ...t the external pump the unit off 2 Shut the shut off valve on the connection INLET OIL and OUTLET OIL 3 To do this perform a pressure release Carefully unscrew the air vent plug 2310 in the cover using the Allen key 10 mm 4 To drain the coalescing housing open the shut off valve at the connection DRAIN and or DRAINWATER Catch the free water oil with a suitable container and dispose of it in an env...

Page 48: ...it down to the side 8 Remove the coalescing element set from the coalescing housing To do this use the two handles 9 Turn the coalescing element set 180 upside down Loosen the 3 wing nuts and remove the retaining plate 10 Pull the coalescing elements out of the element receptacles and dispose of them in an environmentally friendly manner 1 2 3 4 5 6 7 8 9 A ...

Page 49: ...t tool 13 Mount the element holding plate and tighten the 3 wing nuts firmly 14 Turn the coalescing element set by 180 and insert the coa lescing element set into the coalescing housing Note that the coalescing element set only fits into the coa lescing housing in one position Z 15 Clean the sealing surface on the cover Check the O ring for damage Replace it if necessary 16 1 Place the cover on th...

Page 50: ...evenly with the wrench 13 mm with a maximum of 20 Nm Screw on the lock nut and secure the connection 18 Open the shut off valves at the ports INLET OIL and OUT LET OIL 19 Bleed the coalescing housing through the air vent plug 2310 on the cover O The replacement of the coalescing element is completed 1 2 3 4 5 6 7 8 9 A ...

Page 51: ...as follows Empty the product fully including all the components before decommissioning Fully disconnect the product from the surrounding units Slacken or remove the electric pneumatic or hydraulic connec tions insofar as they are present 9 3 Disposal Recycling Dismount and recycle the product that cannot be used any more not as a whole unit but in individual parts and according to the type of the ...

Page 52: ...e numbers e mail and mailing addresses for the Hotline product support service partners for maintenance repair and spare parts can be found always up dated on our homepagewww hydac com HYDAC SYSTEMS SERVICES GMBH Friedrichsthaler Str 15 Werk 13 66450 Neunkirchen Heinitz Germany Telephone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 8 HYDAC Service Deutschl...

Page 53: ...del code and the serial num ber Pos Qty Description Part no 1 O ring for coalescing housing 270x10 FPM 6012630 Tab 9 Spare parts A 2 1 1 Coalescing elements Pos Qty Description Part no 10 Coalescing element 5 µm N20WR005 1F 3277940 10 Coalescing element 70 µm N20WR070 1F 3361669 Tab 10 Coalescing elements A 3 Documentation regarding the components In this chapter you will find further detailed doc...

Page 54: ...A Appendix HYDAC FILTER SYSTEMS GMBH 54 72 MoWa OLS10 Z x 4573340 en us web A 3 1 Instructions for use REED CONTROL FLOAT SWITCH 1 2 3 4 5 6 7 8 9 A ...

Page 55: ...ILTER SYSTEMS GMBH Appendix A MoWa OLS10 Z x 4573340 en us web 55 72 Instructions for use REED CONTROL FLOAT SWITCH Type RCS REED CONTROL FLOAT SWITCH IN EXPLOSION PROOF DESIGN Type RCS EX 1 2 3 4 5 6 7 8 9 A ...

Page 56: ...ion functional check 4 8 Maintenance and disposal 5 9 Hazard notes 5 10 Guidelines 7 11 Temperature class table 7 12 Manufacturer s declaration for type RCS EX 8 13 CE declaration of conformity for type RCS 9 Reed Electronics AG Gewerbering 2 6105 Schachen Switzerland Tel 41 41 499 70 40 Fax 41 41 499 70 45 info reed ch www reed ch A101913 Version 3 Release 14 09 2017 TS Reed Electronics AG 2017 S...

Page 57: ... medium to be monitored 3 Application in EX zone Only devices that are explicitly designated as EX devices can be used in EX zones Float switches in an explosion proof design are suitable for use in zone 0 explosive gas atmospheres Devices featuring the designation Ex ia IIC T6 and EX ia IIIC T80 C are intended for use in normal ambient temperatures and liquid temperatures up to 60 C devices featu...

Page 58: ...he number of switch points The minimum bending radius of a flexible float switch is 85 mm 5 Electrical connection The electrical connection must be in line with the regulations applicable in the country of destination and must only be realised by correspondingly trained specialist personnel The electrical connection must be made in accordance with the type plate attached to the socket or the type ...

Page 59: ...rating pressure must never exceed the specifications on the data sheet The maximum operating pressure depends on the float Float switches must not be used as safety related limiting devices in the pressure range For float switches with a connecting cable without an earth conductor the switch may be live in the event of a fault In the event of contact phy sical injuries or fatal injuries may occur ...

Page 60: ... steel bracket for the purposes of strain relief Brackets and steel cable are to be purchased from Reed Electronics AG Fire fighting equipment must be attached to the side of the respective system Damage to the Reed float switch as a result of an external fire makes it impossible for the switch to monitor the respective system and perform control tasks Installation in ferromagnetic sockets impairs...

Page 61: ...30V Low Voltage Directive does not apply RCS Devices of type RCS fall under Low Voltage Directive 11 Temperature class table Ambient temperature in the connection area Ambient and liquid temperature in the float area Surface temperature and temperature class T In the connection area In the float area Up to 80 C Up to 68 C 80 C T6 80 C T6 Below 125 C Below 125 C 125 C T4 130 C T4 The values specifi...

Page 62: ...ions are reliably insulated from earth The surface temperature and temperature class T depend on the ambient temperatures and the liquid temperature as follows Ambient temperature in the connection area Ambient and liquid temperature in the float area Surface temperature and temperature class T In the connection area In the float area Up to 80 C Up to 68 C 80 C T6 80 C T6 Below 125 C Below 125 C 1...

Page 63: ...HYDAC FILTER SYSTEMS GMBH Appendix A MoWa OLS10 Z x 4573340 en us web 63 72 9 13 CE declaration of conformity for type RCS 1 2 3 4 5 6 7 8 9 A ...

Page 64: ...ty of medium min 0 914g cm 3 especially with inductive or capacitive loads Pressure Must not be used as a safety related limiting device P max 10 bar float dependent Reed Electronics AG does not accept any responsibility or liability in the case of damage to property or personal injury caused by incorrect installation or connection of the float switch or should the selection of the materials used ...

Page 65: ...30 Fig 4 Hydraulic diagram of the OLS10 Z with automatic water outlet 32 Fig 5 Components of the OLS 10 Z with automatic water outlet 33 Fig 6 Transporting the OLS 34 Fig 7 Transporting storing the OLS 34 Fig 8 Mounting the drip tray 35 Fig 9 Pressure loss formula 36 Fig 10 Connecting the water drainage valve 39 Fig 11 Terminal assignment of the water drain valve assignment of the dosing insert 40...

Page 66: ...group Required personnel qualification 14 Tab 3 Checking the scope of delivery 22 Tab 4 Technical data Hydraulic data 25 Tab 5 Technical data Water drainage valve 26 Tab 6 Technical data Phase boundary sensor 26 Tab 7 Error cause rectification 45 Tab 8 HYDAC Service Deutschland 52 Tab 9 Spare parts 53 Tab 10 Coalescing elements 53 ...

Page 67: ...TER SYSTEMS GMBH Glossary MoWa OLS10 Z x 4573340 en us web 67 72 Glossary General Terms and Conditions The General Terms and Conditions are available at our home page www hy dac com General Terms and Condi tions ...

Page 68: ...n 45 exclusion of liability 12 H Hotline 52 HYDAC Service Germany 52 Worldwide 52 I Imprint 2 M Manufacturer 2 O Operating fluids 25 Operating pressure 25 P Person authorized with the documentation 2 Ports hydraulic 25 Power consumption 26 Power supply 26 Protection class 26 Publisher 2 S Scope of delivery 22 Sealing material 25 Service 52 service life design 26 Service Partners 52 shutting down T...

Page 69: ...YDAC FILTER SYSTEMS GMBH Index MoWa OLS10 Z x 4573340 en us web 69 72 T Technical data 25 Terms and Conditions 12 Terms of Delivery 12 Transport 34 V Viscosity range 25 W Warranty 12 Weight when empty 26 ...

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