Filtromat Operating and Maintenance Instructions English (translation of original instructions) Document No.: 3594726a
Trademarks Trademarks The trademarks of other companies designate the products of those companies exclusively. Copyright 2011 by HYDAC Filter Systems GmbH all rights reserved All rights reserved. This manual may not be reproduced in part or whole without the express written consent of HYDAC FILTER SYSTEMS GMBH. Contraventions are liable to compensation. Exclusion of liability We have made every endeavor to ensure the accuracy of the 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 technical modifications. All content of this manual is subject to revision without notice. HYDAC FILTER SYSTEMS GMBH Postfach 12 51 66273 Sulzbach / Saar Germany Documentation Representative 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 en(us) Page 2/36
Contents Contents Trademarks...2 Documentation Representative...2 Contents...3 Preface...5 Customer Service...6 Modifications to the Product...6 Warranty...6 Using the Documentation...7 Safety information and instructions...8 Obligations and Liability...8 Explanation of Symbols and Warnings, etc....9 Proper/Designated Use...9 Improper Use...10 Informal Safety Precautions...10 Structural modifications to the unit...10 Training of personnel...11 Electrical hazards...11 Transporting the OF5...12 Storing the OF5...12 Checking the scope of delivery...13 OF5 Features...14 Restrictions Pertaining...14 OF5 Lxx...14 OF5 dimensions...15 OF5 components/dimensions...16 Hydraulic diagram...17 Preparing the OF5 for operation...18 Inserting the filter element...18 Hanging / connecting the suction hose...18 Hanging / connecting the pressure hose...18 Electrical connection of the OF5...19 Switching on the OF 5...20 Performing Maintenance...21 Cleaningthe suction strainer...22 HYDAC FILTER SYSTEMS GMBH en(us) Page 3/36
Contents Changing the filter element...23 Errors and troubleshooting...29 Spare parts...30 filter...31 Disposing of the OF5...32 Technical Data...33 Model Code...34 EC declaration of conformity...35 HYDAC FILTER SYSTEMS GMBH en(us) Page 4/36
Preface Preface For you as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance. It will acquaint you with the product and assist you in obtaining maximum benefit in the applications for which it is designed. Keep the manual in the vicinity of the device 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 additional suggestions or notes, contact us at: HYDAC FILTER SYSTEMS GMBH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany The editorial department looks forward to receiving your input. Our motto: Putting experience into practice HYDAC FILTER SYSTEMS GMBH en(us) Page 5/36
Preface Customer Service Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product: Fax: ++49 (0) 6897 / 509 846 E-Mail: filtersystems@hydac.com 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. 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 the product whether by you or a third party. Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC FILTER SYSTEMS GmbH. Refer to these at www.hydac.com General terms and conditions. HYDAC FILTER SYSTEMS GMBH en(us) Page 6/36
Preface Using the Documentation Please note that the method described above of locating specific information does not release you from your responsibility for carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals later on. 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. Chapter description Page number Edition date Documentation No. with Index / File name Document language 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 7/36
Safety information and instructions Safety information and instructions These operating instructions contain the most important information for operating the unit in a proper, safe manner. Obligations and Liability The basic prerequisite for the safe and proper handling and operation of the unit is knowledge of the basic safety instructions and safety regulations. These operating instructions in general, and the safety instructions in particular, are to be adhered by all those who work with the unit. Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used. The safety instructions listed here are restricted to use of the unit. The OF has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazards may be posed to the life and limb of the individual using the product or to third parties. Risk of damage may be posed to the product or other equipment and property. Ensure that the unit is 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 made available to the owner upon concluding purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes: improper use of the unit or use deviating from its designated use improper assembly/installation, start up, operation and maintenance of the unit operating the unit when the system equipment or systems are defective modifications to the unit made by the user or purchaser improperly performed repair work HYDAC FILTER SYSTEMS GMBH en(us) Page 8/36
Safety information and instructions Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.: DANGER WARNING CAUTION NOTICE DANGER denotes situations which can lead to death if safety precautions are not observed. WARNING denotes situations which can lead to death if safety precautions are not observed. CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed. NOTICE denotes situations which can lead to property damage if safety precautions are not observed. Proper/Designated Use The unit is a mobile filter unit used for simultaneously circulating and filtering oil. Any other use shall be deemed to be improper and not in keeping with the product's designated use. The manufacturer will not assume liability for any damage resulting from such use. Proper or designated use of the product extends to the following: Maintaining adherence to all the instructions contained herein. Performing requisite inspection and maintenance work. HYDAC FILTER SYSTEMS GMBH en(us) Page 9/36
Safety information and instructions Improper Use Any use other than described above is prohibited. Improper use may result in hazards to life and limb. Example of improper use: Commissioning without a suction strainer Operation with non-approved fluids Informal Safety Precautions Always keep the operating instructions in the vicinity of the unit. Apart from the operating instructions, any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance is to be maintained to them. All safety guidelines and hazard warnings on the machine must be maintained in legible condition and replaced as required. Structural modifications to the unit Do not make any modifications (design modifications, extensions) to the OF without the approval of the manufacturer. Immediately replace any unit components which are not in perfect condition. Only use original (OEM) spare parts and consumables. When using non-oem components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements. HYDAC FILTER SYSTEMS GMBH en(us) Page 10/36
Safety information and instructions Training of personnel The OF may only be operated by 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 OF unless supervised by an experienced staff member. Individuals Instructed individuals Personnel with technical training/ engineering background Electricians Supervisors with required expertise Activity Packing / transportation X X X Commissioning X X X Operation X X X X Troubleshooting/ locating the source of malfunction X X X Troubleshooting, mechanical problem X X Remedying of electrical faults X X maintenance X X X X Servicing X Decommissioning / Storage X X X X Electrical hazards DANGER Electric shock Danger of fatal injury Pull power plug before performing any work. HYDAC FILTER SYSTEMS GMBH en(us) Page 11/36
Transporting the OF5 Transporting the OF5 Transport the unit upright on the built-in wheels or by rolling it. Storing the OF5 Remove the filter element and drain the unit completely before putting it into storage. Pull out the power plug to the unit and wind up the power cord. Wind up the suction and pressure hoses and secure them to the unit. Store the unit upright in a clean, dry place. HYDAC FILTER SYSTEMS GMBH en(us) Page 12/36
Checking the scope of delivery Checking the scope of delivery The filtration unit is supplied ready for connection and immediate operation with hoses and a mains connection. Check the unit for damage upon delivery. A unit may only be put into operation if it shows no signs of damage. Report any damage in transit to the forwarding agent or responsible party. The following items are supplied: Item Qty. Designation 1 1 OF5 with power cable, suction hose and pressure hose - 1 filter element - 1 Operating and Maintenance Instructions 1 HYDAC FILTER SYSTEMS GMBH en(us) Page 13/36
OF5 Features OF5 Features The mobile filtration unit OF5 is used for filtered filling, offline filtration. Restrictions Pertaining NOTICE Impermissible operating media The unit will be damaged The unit is only to be used with mineral oils or mineral oil-based raffinates. OF5 Lxx HYDAC FILTER SYSTEMS GMBH en(us) Page 14/36
OF5 dimensions OF5 dimensions All dimensions in mm. HYDAC FILTER SYSTEMS GMBH en(us) Page 15/36
OF5 components/dimensions OF5 components/dimensions Item Designation 1 Handle 2 On/off switch with motor protection 3 Power cables 4 Electric motor with gear pump 5 Floor plate with oil pan 7 Pressure hose 8 Suction hose 9 Quick coupling HYDAC FILTER SYSTEMS GMBH en(us) Page 16/36
Hydraulic diagram Hydraulic diagram CI = contamination indication HYDAC FILTER SYSTEMS GMBH en(us) Page 17/36
Preparing the OF5 for operation Preparing the OF5 for operation Consult and observe the following chapter in order to prepare the unit for operation. Inserting the filter element The unit has no filter element installed upon delivery from the factory. Prior to start up, check to see whether a filter element is contained in the filter housing. Information on changing a filter element can be found on page 23. Hanging / connecting the suction hose NOTICE Severe contamination The unit will be destroyed Do not prime directly at the bottom of the tank (in the sump). The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank. Pull the suction hose with lance out of the mounting in the floor plate. Put the suction hose with lance, without tension and or twist, into the appropriate container and secure it. Hanging / connecting the pressure hose Pull out the pressure hose with lance from the mounting in the floor plate and insert it in the appropriate container. Put the pressure hose with lance, without tension and or twist, into the appropriate container and secure it. To prevent air from entering the medium, make sure that the pressure hose with lance is always below the oil level in operation. HYDAC FILTER SYSTEMS GMBH en(us) Page 18/36
Preparing the OF5 for operation Electrical connection of the OF5 Check or compare the local mains voltage and frequency specifications with the specifications on the type label of the unit. Plug the power plug into a suitable power outlet. The unit has a motor protection switch in the on / off switch. If the nominal current is exceeded, the motor protection switch trips. HYDAC FILTER SYSTEMS GMBH en(us) Page 19/36
Switching on the OF 5 Switching on the OF 5 After switching on the OF5, monitor the suction action via the transparent suction 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. It is not necessary to bleed 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 changed immediately. The pressure relief valve in the pump returns the medium to the suction side if the maximum operating pressure is exceeded. The motor protection switch contained in the main switch permanently monitors the nominal current and switches the unit off in case of overload. HYDAC FILTER SYSTEMS GMBH en(us) Page 20/36
Performing Maintenance Performing Maintenance WARNING The unit is pressurized Danger of bodily injury Depressurize the system before performing any work on it. DANGER Electric shock Danger of fatal injury Disconnect the power plug before performing any work on the unit. HYDAC FILTER SYSTEMS GMBH en(us) Page 21/36
Cleaningthe suction strainer Cleaningthe suction strainer NOTICE Operation without a suction strainer The unit will be destroyed Never operate the filtration unit without a suction strainer. Clean the suction strainer regularly. To protect the pump from coarse contamination or foreign bodies, a suction strainer is installed at the inlet of the pump. Clean the suction strainer regularly and check it immediately in the event of insufficient suction or delivery action. Item x Description Suction strainer HYDAC FILTER SYSTEMS GMBH en(us) Page 22/36
Changing the filter element Changing the filter element The red/green optical differential pressure gauge, shows the red area from a differential pressure of 5 bar. Change the filter element as soon as the differential pressure gauge is in the red area. HYDAC FILTER SYSTEMS GMBH en(us) Page 23/36
Changing the filter element To change the filter, proceed as follows: 1. Switch the unit off. 2. Empty the filter housing through the drain plug (1) in the filter bowl using an Allen wrench, size 10. Catch the residual oil (~ 1.5 liters) in a suitable container (2). Screw in the drain plug (1) counterclockwise again and tighten it. HYDAC FILTER SYSTEMS GMBH en(us) Page 24/36
Changing the filter element 3. (1) Unscrew the filter bowl using an open-jaw wrench, opening width 36 mm in a counterclockwise direction. (2) Now pull the filter element downwards carefully out of the bowl. Dispose of the used filter element in an environmentally correct manner. 4. Clean: the inside of the filter bowl of coarse dirt the sealing surfaces on the filter head and cover. Check the O-ring on the filter bowl for damage. Replace it if necessary. HYDAC FILTER SYSTEMS GMBH en(us) Page 25/36
Changing the filter element 5. Moisten the O-ring on the filter bowl lightly with operating medium. 6. Moisten the O-ring on the filter element lightly with operating medium. 8. Press the new filter element up into the filter mount by turning it slightly. Do not use excessive force or a hammer, etc. HYDAC FILTER SYSTEMS GMBH en(us) Page 26/36
Changing the filter element 10. Manually turn the filter bowl clockwise from below into the filter head. 11. Pull in the filter bowl as far as it will g. HYDAC FILTER SYSTEMS GMBH en(us) Page 27/36
Changing the filter element 12. Unscrew the filter bowl by 90 in clockwise direction. 13. Switch the unit on. I OFF ON 14. Check the unit for any leaks. 15. The unit is ready for use. HYDAC FILTER SYSTEMS GMBH en(us) Page 28/36
Errors and troubleshooting Errors and troubleshooting Error Cause(s) Remedy Differential pressure > 5 bar No flow No function The fluid is heavily contaminated. The contamination retention capacity of the filter element has been reached. The viscosity of the fluid is too high. The suction hose is positioned above the fluid. No electrical connection. No voltage available. Replace the filter element. Replace the filter element. Warm the fluid. Sufficiently immerse the suction hose in the medium. Check the electrical connection; plug, cable and socket. HYDAC FILTER SYSTEMS GMBH en(us) Page 29/36
Spare parts Spare parts Description p/no. Suction strainer 320 µm 37575 filter element 0330 D 003 BN4HC 3 µm NBR 1260907 filter element 0330 D 005 BN4HC 5 µm NBR 1260897 filter element 0330 D 010 BN4HC 10 µm NBR 1250493 filter element 0330 D 020 BN4HC 20 µm NBR 1260887 Gear pump assembly 6058383 Pressure hose L= 5 m 639778 Pressure hose L= 15 m 639779 Suction hose L= 2.3 m 37606 Hose between pump and filter housing L= 0.3 m 616848 Differential pressure gauge Green/red 303192 HYDAC FILTER SYSTEMS GMBH en(us) Page 30/36
Spare parts filter HYDAC FILTER SYSTEMS GMBH en(us) Page 31/36
Disposing of the OF5 Item Designation p/no. 1.1 filter element 0330 D 005 BN4HC 1260897 1.2 O-ring 48 x 3 611438 2.1 contamination indication VM5B1 303192 2.2 profile seal ring 411600 2.3 O-ring 15 x 1,5 604075 3.x Repair kit, consisting of item 3.1... 3.6 302270 3.1 O-ring 48 x 3 611438 3.2 O-ring 117 x 4 613078 3.3 Support ring DF 330 413736 3.4 profile seal ring VM 411600 3.5 O-ring 15 x 1,5 604075 3.6 Oil drain plug G1/2 403302 Disposing of the OF5 When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil in the unit, components covered with oil and electronic components. After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations. HYDAC FILTER SYSTEMS GMBH en(us) Page 32/36
Technical Data Technical Data Supply voltage Power consumption Maximum flow rate Pump types Operating Pressure Permissible suction pressure at suction port Viscosity range 1x 230V, 60 Hz, 1 Ph 0.43 kw 15 l/min Gear pump 8 bar maximum -0.4 +0.6 bar 15 1000 mm²/s Fluid temperature 0 80 C Ambient temperature range -10 40 C Seals NBR IP Class IP 54 Length of electronic cable Length of suction / pressure hose Hose connections Weight Filter element type 22 m 2,3 / 5 + 15 m Suction hose NW20 with lance Pressure hose NW 19 with lance ~ 75 kg Betamicron BN4HC Filter element size LF 330 contamination indication Differential pressure gauge 5 bar (VM5B1) HYDAC FILTER SYSTEMS GMBH en(us) Page 33/36
Model Code Model Code Basic type OF 5 Version L = Mobile without switchover Type code xx = Special model Sealing material P = NBR (Perbunan) Motor-pump group x = 15 l/min / to max. 1000 mm²/s Electromotor voltage M = 230 V / 60 Hz (1 Ph + PE) Filter size x = Filter size LF 330 Filter material b = Betamicron BN4HC Filtration rating 03 = 3 µm BN4HC 05 = 5 µm BN4HC 10 = 10 µm BN4HC 20 = 20 µm BN4HC contamination indication b = Differential pressure gauge standard OF5 L xx P x M x b 05 b HYDAC FILTER SYSTEMS GMBH en(us) Page 34/36
EC declaration of conformity EC declaration of conformity HYDAC FILTER SYSTEMS GMBH Postfach 12 51 66273 Sulzbach / Saar Germany Industriegebiet 66280 Sulzbach / Saar Germany Telefon: ++49 (0) 6897 509 01 Internet: www.hydac.com EC declaration of conformity FS / 37 / 09 No. We hereby declare that the following designated product, on the basis of its design and construction, and in the version which we have brought to market, corresponds to the fundamental safety and health requirements contained in the standards listed below. Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity. Designation Filtration Unit Type OF 5 mobile series p/no. - Serial no. - EU Machinery Directive 2006/42/EC EU Electrical Equipment Regulations 2006/95/EC EMC Guideline 2004/108/EC Safety of machinery and devices EN 12100-1/2 2009-12-22 Dr. Andreas Schunk Date Name (CE official) Executive director: Documentation Representative: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Mr. Günter Harge Registered seat of company: 66280 Sulzbach / Saar - Germany c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Registry Court: Saarbrücken, HRB 17216 Phone: ++49 (0) 6897 509 1511 Value added tax identification number: DE 815001609 Fax: ++49 (0) 6897 509 1394 Tax number: 040/110/50773 E-Mail: guenter.harge@hydac.com Page 1 / 1 HYDAC FILTER SYSTEMS GMBH en(us) Page 35/36
HYDAC FILTER SYSTEMS GMBH Industriegebiet 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