HYDAC FILTER SYSTEMS OFU-10-P-2-N-2-B-05-B/-, Operating And Maintenance Instructions Manual

Page 1: ...OFU ATEX Pump transfer unit II 2G IIC T1 Operating and maintenance instructions English translation of original instructions Document No 3838730 ...

Page 2: ...tive Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 0 6897 509 1511 Fax 49 0 6897 509 1394 E Mail guenter harge hydac com 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 p...

Page 3: ...rmation and instructions 11 Observe regulatory information 11 Proper Designated Use 12 Improper Use or Use Deviating from Intended Use 14 Qualifications of personnel target group 15 Wear suitable clothing 17 Unpacking the unit 17 Transporting the unit 18 Storing the unit 20 Checking the scope of delivery 21 Technical Description 22 Explosion protection as per ATEX 95 22 Unit components 23 Operatin...

Page 4: ...ling the pump 34 Venting the filter housing 34 Clogging indicator 35 Performing maintenance 36 Maintenance Intervals 37 Changing the filter element 37 Cleaning replacing suction strainer 41 Disposing of the unit 43 Taking the unit out of operation 43 Errors and Troubleshooting 43 Spare Parts 44 Spare Parts List 48 Contact Service 49 Technical Data 50 Model Code 51 EC declaration of conformity 52 I...

Page 5: ... the applications for which it is designed Keep this documentation in the vicinity of the product for immediate reference Note that the information on the unit s engineering contained in the documentation was that available at the time of publication There may be deviations in technical details figures and dimensions as a result If you discover errors while reading the documentation or have additi...

Page 6: ...ing 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 immediately of any modifications made to t...

Page 7: ...ture What do I want to know I determine which topic I am looking for WHERE can I find the information I m looking for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number The documentation number with its index enables you to order another copy of the operating and maintenance instructions The index is incremented e...

Page 8: ...ss all the safety devices are present Secure the hazardous areas which may arise between the unit 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 and instructions in these operating instructions which indicate partic...

Page 9: ... OFU ATEX en us Page 9 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Risk of burns due to hot surfaces Substances that are health hazards or irritants Danger from explosive atmosphere Risk of explosion Explosion protection symbol ...

Page 10: ... indicates a danger with a high risk and which will lead to death or serious injury if not avoided WARNING WARNING indicates a danger with a medium risk and which can lead to death or serious injury if not avoided CAUTION CAUTION indicates a danger with a low risk and which can lead to minor injury if not avoided NOTICE NOTICE indicates a danger which will lead to damage to property if not avoided...

Page 11: ...nal word indicate the severity of the danger Warning instructions listed before an activity are laid out as follows SIGNAL WORD Type and source of danger Consequence of the danger HAZARD SYMBOL Measures to avert danger Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for enviro...

Page 12: ... Risk of explosion Danger of fatal injury Only operate the unit in the indicated equipment group equipment category and zone Maximum permissible surface temperature on components of the unit must not exceed 135 C 275 F WARNING Fire hazard Danger of bodily injury With the unit you may filter pump only media fluids with a flash point 56 C 133 F NOTICE Impermissible operating media The filtration uni...

Page 13: ...osed Conversions and modifications to the devices and or components are not permitted Are the following specifications on the type label of the unit permissible in connection with use in areas posing an explosion hazard on site equipment group equipment category explosion hazard subgroup temperature class Ensure that vapors gases or mists occurring at the place of operation belong to explosion gro...

Page 14: ... 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 user alone shall assume any and all associated risk Improper use may result in hazards and or will damage the unit Examples of improper use Operation in a potentially explosive atmosphere other than the intended one Operation with a non approved...

Page 15: ...in power unit 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 Forwarding agent Specialist personnel Proof of knowledge o...

Page 16: ...05 16 2013 05 16 Operation operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating media Disposal Specialist personnel Proper and environmentally friendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse ...

Page 17: ...ht 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 Unpacking the unit Before delivery the unit is inspected for leaks and proper functioning at the factory then carefully packed for shipment When receiving and unpacking the unit check it for damage in transit Dispose of the packaging mate...

Page 18: ...ge 18 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Transporting the unit NOTICE Using components for pushing pulling The unit will be damaged Never use the components to push or pull the unit Use only the handles provided for moving ...

Page 19: ...013 05 16 NOTICE Unsuitable lifting accessories The unit components will be damaged destroyed Use only suitable lifting accessories to raise or lash the unit Take care to ensure that the lifting accessories do not cause any pressures to be brought to bear against the components on the unit ...

Page 20: ...56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Storing the unit Make sure to store the unit in a clean dry place on rollers wheels Engage the hand brake on both casters Storage temperature 10 40 C Relative humidity max 95 non condensing ...

Page 21: ...unit comes packed and pre assembled Before commissioning the unit check the contents of the package to make sure everything is present The following items are supplied Qty Description 1 OFU Model in acc with the order see model code 1 Filter element filtration rating in acc with the order 1 Operation and Maintenance Instructions this document ...

Page 22: ...EX 95 applicable to areas in which potentially explosive gas mixtures are likely to occur Depending on the version the ATEX designation of the unit reads II 2G IIC T1 This label in particular means that utilization is permitted only for Equipment group II Potentially explosive atmospheres in which vapors or gas air mixtures are likely to occur Equipment category 2G Equipment providing for a standa...

Page 23: ...Technical Description OFU ATEX en us Page 23 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Unit components ...

Page 24: ...housing drain DRAIN 7 Filter housing vent VENT 8 Switch cabinet 9 Enclosed switch cabinet 10 Main switch 11 Signal lamps 12 Ground cable 13 Back pressure indicator 14 Swing bolts with star grip 15 Differential pressure indicator 16 Drip tray drain DRAIN 17 Suction screen 18 Limit indicator 19 Axle with wheels 20 Swivel caster 21 Sliding grip 22 pressure relief valve 23 Hose Cable holder 24 Cable h...

Page 25: ...BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Operating elements Display elements Item Description 1 Main switch Q1 2 Switch pump on H1 S1 3 Switch pump off S2 4 Fault dry running of the pump H2 5 Fault the motor protection switch has tripped H3 ...

Page 26: ...Technical Description OFU ATEX en us Page 26 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Unit dimensions ...

Page 27: ...cription 2 Motor pump assembly 3 Filter housing 4 Inlet INLET 5 Outlet OUTLET 6 Filter housing drain DRAIN 7 Filter housing vent VENT 8 Switch cabinet 9 Enclosed switch cabinet 13 Back pressure indicator 15 Differential pressure indicator 16 Drip tray drain DRAIN 17 Suction screen 18 Limit indicator 22 Pressure relief valve ...

Page 28: ...is no explosive air environment present Use only spark free tools for installation in an explosive air environment To set up the unit proceed as follows 1 Set up the unit horizontally on a level surface 2 Make sure that there is sufficient space above the filter housing to replacing the filter elements 3 Engage the hand brakes on the casters 4 In the case of an application below the fluid level we...

Page 29: ...een The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Put the suction hose without tension or twist into the appropriate tank and secure it against falling out Hanging connecting the pressure hose Put the pressure hose without tension or twist into the appropriate tank and secure it against falling out To avoid ...

Page 30: ...ithout connection plugs to the power supply module may only be performed by a technician with corresponding knowledge and skills Compare the voltage and frequency specifications on the unit type label with the existing network specifications Plug the power plug of the unit into a suitable power outlet The unit has a motor protection switch in the on off switch If the nominal current is exceeded th...

Page 31: ...l in accordance with the the explosion protection in effect at the installation site Prior to start up earth the unit using the ground bond Prior to starting up the unit connect the ground bond between the unit and the tank to be cleaned Check the connection between the tank unit and the ground potential for good conductivity ...

Page 32: ...m jog mode only if the pump has been pre filled Check the direction of rotation of the motor by switching it on briefly jog mode The unit requires a clockwise rotating field at the connecting socket NOTICE Incorrect phase sequence rotation direction of the motor The pump will be destroyed In jog mode check the direction of rotation of the motors A rotation direction arrow on the fan cover of the m...

Page 33: ...n hose If the unit is not feeding medium after several minutes of operation the pump must be pre filled Switch the motor off and fill the pump via the suction hose The special element receptacle renders it unnecessary to vent the filter housing Pay particular attention to the clogging indicator during operation As soon as the clogging indicator enters the red zone the filter element must be change...

Page 34: ...es not convey any fluid switch the motor off and fill the unit using the suction hose Venting the filter housing If the unit has started and is pumping properly the filter housing has to be vented If the unit has started and is pumping properly the filter housing has to be vented While the pump is running loosen the vent plug A in the cover plate of the filter housing As soon as oil leaks out reti...

Page 35: ... red green or a scale in the filter cover The version with switchover may have an optional differential pressure indicator 1 Change the filter element as soon as the dynamic pressure indicator or differential pressure indicator is in the red area The clogging indicator may respond briefly when there is a cold start if a higher back pressure arises due to low temperatures and the resulting high vis...

Page 36: ...e performing any work on the hydraulic system Conduct the prescribed settings maintenance servicing and inspection work in accordance with the respective schedules Secure the unit against accidental start up Any screw connections which have been undone removed are to be checked to see that they have been properly resecured Once maintenance work is complete check that the safety devices are working...

Page 37: ...ilter element X Changing the filter element 1 Switch the unit off Pull power plug 2 Depressurize the filter housing Remove the air bleed plug 1 in the filter cover for this purpose The residual oil is drained through the drain ball valve 2 into a suitable container 3 Loosen the four screws on the cover counterclockwise 4 Fold the screws down and press them against the filter housing This pushes th...

Page 38: ... 16 2013 05 16 5 Take the cover off and remove the filter element 6 Clean the inside of the filter bowl of coarse dirt the sealing surfaces on the filter head and on the cover 7 For easier installation of the filter element wet the O ring on the filter element with the operating medium ...

Page 39: ...t by turning it slightly Do not use striking tools for this 9 Check the O ring on the cover for damage and replace it if necessary Lightly wet the O ring on the cover with medium 10 Put the cover on Observe correct placement of the O ring on the cover while doing so It must not be damaged 11 Fold the four screws up and turn them clockwise evenly crosswise ...

Page 40: ...nance OFU ATEX en us Page 40 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 12 Close the drain valve 13 Plug in the power plug Switch the unit on 14 Check the unit for any leaks 15 The unit is ready for operation ...

Page 41: ...lacing suction strainer NOTICE Operation without a suction strainer The pump will be destroyed Never use operate the unit without a suction strainer Clean the suction strainer regularly To protect the pump from coarse contamination particles and other foreign bodies a suction strainer is fitted at the pump inlet ...

Page 42: ... washing it out with solvent or air cleaning it using compressed air 3 Check strainer insert 3 and sealing ring 2 on the screw plug 1 for damage Replace it if necessary 4 Install the new strainer insert 3 in the suction strainer 5 Screw in the screw plug 1 by hand in a clockwise direction with a wrench 50 mm and tighten it securely 6 Check the suction strainer for leaks after commissioning The ent...

Page 43: ...nit Make sure to store the unit in a clean dry place Errors and Troubleshooting Error Cause s Remedy Medium is heavily contaminated Replace the filter element The contamination retention capacity of the filter element has been reached Replace the filter element Differential pressure 2 bar The viscosity is too high Warm the medium The pump is conveying in the wrong direction Check the rotational di...

Page 44: ...Spare Parts OFU ATEX en us Page 44 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 Spare Parts ...

Page 45: ...Spare Parts OFU ATEX en us Page 45 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 ...

Page 46: ...Spare Parts OFU ATEX en us Page 46 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 ...

Page 47: ...Spare Parts OFU ATEX en us Page 47 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 ...

Page 48: ...263060 Filter element 1300 R 005 BN4HC KB 5 µm NBR 1263061 Filter element 1300 R 010 BN4HC KB 10 µm NBR 1263062 Filter element 1300 R 020 BN4HC KB 20 µm NBR 1267699 Filter element 1300 R 040 AM KB 40 µm NBR 39173 Pressure gauge 0 16 bar 303191 Differential pressure indicator NBR 635055 Dirt trap cpl 6010807 Strainer insert 250 µm for dirt trap 06034076 Sealing ring for dirt trap ...

Page 49: ... Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your FluidAqua Mobil Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your FluidAqua Mobil Our HYDAC Servicenter offers you these tasks within agreed upon time frames and at fixed prices HYDAC SERVICE GMBH Frie...

Page 50: ...ge 0 80 C Permitted ambient temperature range 10 40 C Permitted storage temperature range 10 40 C Sealing material NBR IP class IP54 Length of electronic cable 10 m Filter element type Betamicron AQUAMICRON Filter element size 1300 Clogging indicator Differential pressure indicator Pump types Gear pump Supply voltage 400V 50 Hz 3 ph Power consumption 1 5 kW Hydraulic connection Inlet ANSI B16 5 2 ...

Page 51: ...wer supply N 380 420 V 50 Hz 3 Ph PE 440 480 V 60 Hz 3 Ph PE S 500 600 V 50 60 Hz 3 Ph PE X other voltage Filter element size 2 1300 Filter element 3 2600 Filter element Filter element material B Betamicron BN4HC a AQUAMICRON BN AM AM Filtration rating 03 3 µm BN4HC BN AM 05 5 µm BN4HC 10 10 µm BN4HC BN AM 20 20 µm BN4HC 40 40 µm AM Clogging indicator B Differential pressure indicator visual C Dif...

Page 52: ...s listed below Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Name Filtration Unit Type OFU series Part no Serial no EU Machinery Directive 2006 42 EC EU Electrical Equipment Regulations 2006 95 EC EU directive on electromagnetic compatibility 2004 108 EC Applied standards EN 12100 1 2 2009 12 22 Dr Andreas Schunk Date N...

Page 53: ... filling 4 22 34 Filter 6 14 21 24 27 48 50 51 Filter element 21 48 50 51 Filter element type 50 filtration 12 21 22 Filtration 51 52 Forwarding agent 15 G Gear pump 50 H Hazard symbol 3 8 Hydraulic connection 50 Hydraulic diagram 3 27 I Imprint 2 3 Inlet 24 27 50 INLET 24 27 installing 28 IP class 50 M Main switch 24 25 Maintenance 4 21 37 N Noise level 50 O operating 6 7 8 12 13 15 16 33 38 50 O...

Page 54: ...Index OFU ATEX en us Page 54 56 BeWa OFU ATEX 3838730 en us 2013 05 16 2013 05 16 T Temperature 22 Transport 15 Troubleshooting 4 43 V VENT 24 27 ...

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