ols 10/15 /-c277 offline separator - start: hydac ols10-15-c277 4114093a en-us 2016-06-09.docx...

OLS 10/15 /-C277 OffLine Separator

Operating and Maintenance Instructions English (translation of original instructions)

Document No.: 4114093a Keep for future reference.

Imprint

OLS10/15 /-C277 en(us) / 60

BeWa OLS10-15-C277 4114093a en-us 2016-06-09.docx 2016-06-09

Imprint

Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Telephone: +49 6897 509 01 Fax: +49 6897 509 9046 E-mail: [email protected] Homepage: www.hydac.com Court of Registration: Saarbrücken, HRB 17216 Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang

Haering

Documentation Representative

Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: [email protected]

© 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 publisher. These documents have been created and inspected with the greatest care. However, errors cannot be ruled out completely.

Content

OLS10/15 /-C277 en(us) / 60


Content

Imprint ............................................................................................................ 2

Documentation Representative ................................................................... 2

Content .......................................................................................................... 3

Preface ........................................................................................................... 5

Technical Support ........................................................................................ 5 Product modification .................................................................................... 5 Warranty ...................................................................................................... 5 Using the documentation ............................................................................. 5

Safety information ........................................................................................ 7

Hazard symbols ........................................................................................... 7 Signal words and their meaning in the safety information and instructions .................................................................................................. 9 Structure of the safety information and instructions ..................................... 9 Proper/Designated Use ............................................................................. 10 Improper Use or Use Deviating from Intended Use ................................... 10 Qualifications of personnel / target group .................................................. 11 Wear suitable clothing ............................................................................... 12 Observe regulatory information ................................................................. 12 Stoppage in an emergency (EMERGENCY STOP) ................................... 12

Unpacking the unit ...................................................................................... 12

Transporting the unit .................................................................................. 13

Transporting with the crane ....................................................................... 13

Storing the unit ........................................................................................... 14

Decoding the name plate ........................................................................... 15

Checking the scope of delivery ................................................................. 17

Characteristics of the unit .......................................................................... 18

Coalescing procedure ................................................................................ 18

Identifying components ............................................................................. 19

Hydraulic diagram ....................................................................................... 21

Unit dimensions .......................................................................................... 22

Unit setup/connection ................................................................................ 23

Notes on pipes/hosing ............................................................................... 24 Connecting the suction port (INLET) ......................................................... 25 Checking/setting the flow rate .................................................................... 25 Connecting the pressure connection (OUTLET) ........................................ 25 Connecting the water drainage (WATER DRAIN) ..................................... 26

Content

OLS10/15 /-C277 en(us) / 60


Electrical connection of the unit ................................................................. 27 Checking the direction of rotation at the electric motor ........................... 27 Connecting the remote control line ......................................................... 28 Connection box / connect interface (optional) ........................................ 30

Connection terminals - Start/Stop external .......................................... 30 Connection terminals - Device active .................................................. 31 Connection terminals - Device OK ...................................................... 31 Connection terminals – Clogging indicator VM1, prefilter clogged ............................................................................................... 31 Connection terminals – Clogging indicator VM2, coalescing element clogged .................................................................................. 31 Remote control / Interval control Prioritization ..................................... 33

Operating / adjusting the control unit ....................................................... 34

Switching the main switch on / off .............................................................. 34 Reading LED status ................................................................................... 35 Adjusting the interval control ...................................................................... 36 Adjusting the time selector switch .............................................................. 37 Checking the motor protection switch ........................................................ 37 Switching unit on/off .................................................................................. 37 Automatic water drainage .......................................................................... 37

Starting up the unit ..................................................................................... 38

Performing maintenance ............................................................................ 40

Maintenance intervals ................................................................................ 40 Perform visual check ................................................................................. 40 Replacing hydraulic hoses ......................................................................... 41 Replacing the filter element in the filter housing ........................................ 41 Changing the coalescing elements ............................................................ 46

Status LED / Causes and remedies ........................................................... 52

Customer Service / Service ........................................................................ 55

Taking the unit out of operation ................................................................ 55

Shutting down the unit ............................................................................... 55

Disposing of the unit .................................................................................. 55

Spare parts list ............................................................................................ 55

Technical data ............................................................................................. 56

Model code .................................................................................................. 57

Index ............................................................................................................ 58

Preface

OLS10/15 /-C277 en(us) / 60


Preface

These operating instructions were made to the best of our knowledge. Nevertheless and despite the greatest care, it cannot be excluded that mistakes could have crept in. Therefore please understand that, in the absence of any provisions to the contrary hereinafter, our warranty and liability – for any legal reasons whatsoever – are excluded in respect of the information in these operating instructions. 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 material contractual obligation, our liability shall be limited to foreseeable damage. Claims due to Product Liability shall remain unaffected.

Technical Support 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 article no. of the product: Fax: +49 (0) 6897 / 509 - 9046 E-mail: [email protected]

Product modification 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. After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician. 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. You will find these under www.hydac.com -> General terms and conditions.

Using the documentation

Note that the method described for locating specific information does not release you from your responsibility of carefully reading all these instructions prior to starting the unit up for the first time

http://www.hydac.com/

Preface

OLS10/15 /-C277 en(us) / 60


and at regular intervals in the future. 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.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

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.

Chapter description

Page number Edition date

Document language Documentation no. with index/

file name

Safety information

OLS10/15 /-C277 en(us) / 60


Safety information

The unit was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements. Any residual hazards are indicated by safety information and instructions and are described in the operating instructions. Observe all safety and warning instructions attached to the unit. They must always be complete and legible. Do not operate the unit unless 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 particular hazards to persons, property or the environment. Observe these instructions and act with particular caution in such cases. Pass all safety information and instructions on to other users.

General hazard

Danger due to electrical voltage / current

Exposed electrical components Danger of electrical shock

Danger due to operating pressure

Safety information

OLS10/15 /-C277 en(us) / 60


Risk of burns due to hot surfaces

Flammable

Danger from explosive atmosphere

Harmful to the environment

Safety information

OLS10/15 /-C277 en(us) / 60


Signal words and their meaning in the safety information and instructions

The following signal words are to be found in these instructions.

DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, 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 minor or moderate 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.

Structure of the safety information and instructions All warning instructions in this manual are highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger. Warning instructions listed before an activity are laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

► Measures to avert danger

Safety information

OLS10/15 /-C277 en(us) / 60


Proper/Designated Use Use the unit only for the application described in the following. The OffLine Separator OLS is a dewatering unit for hydraulic oils and gear lubrication oil with densities < 950 kg/m³. To drain, heat the operating fluid with a viscosity >100 mm/s2. Residual water contents of ≈ 100 ppm are possible.

NOTICE

Impermissible operating media.

The unit will be damaged.

► Use the unit only in conjunction with mineral oils for a water content < 15 filling volume %.

Proper or designated use of the product extends to the following:

• Observing all instructions contained in these operating instructions.

• Adhering to maintenance work.

Improper Use or Use Deviating from Intended Use Any use extending beyond this 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 with an impermissible fluid.

• Operation under non-approved operational conditions.

• Operation when the safety devices are defective.

• Modifications to the power unit made by the user or purchaser.

• Inadequate monitoring of parts that are subject to wear and tear

• Improperly performed repair work.

Safety information

OLS10/15 /-C277 en(us) / 60


Qualifications of personnel / target group Persons who work on the power unit must be aware of the associated hazards when using the power unit. Operating and specialist personnel must have read and understood the operating instructions, in particular the safety information and instructions, and applicable regulations before beginning work. The operating instructions and applicable regulations are to kept so they are accessible for operating and specialist personnel. These operating instructions is intended for: Auxiliary personnel: such persons have no specialized knowledge and perform work as instructed. Operating personnel: such persons have been instructed in power unit operation and are aware of potential hazards due to improper use. Specialist personnel: such persons have 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 Auxiliary personnel

No specialist knowledge required

Startup operation Operations control

Operating Personnel

Product-specific knowledge Knowledge about how to handle operating media.

Troubleshooting, Maintenance, Decommissioning, Disassembly

Specialist personnel

Safe handling/use of tools Product-specific knowledge

Disposal Specialist personnel

Proper and environmentally-friendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse

Unpacking the unit

OLS10/15 /-C277 en(us) / 60


Wear suitable clothing Loose-fitting clothing increases the risk of being caught or being drawn in on rotating parts, and the risk of getting caught 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.

• Wear gloves.

• Observe the information relating to personal protection equipment in the safety data sheet of the operating fluid.

Observe regulatory information Observe the following regulatory information and guidelines:

• Legal and local regulations for accident prevention

• Legal and local regulations for environmental protection

• Country-specific regulations, organization-specific regulations

Stoppage in an emergency (EMERGENCY STOP) In an emergency, switch the unit off at the main on/off switch or unplug the power connector.

Unpacking the unit

Prior to delivery, the unit is function and leak-tested in the factory. When unpacking the unit, check it for damage in transit.

Transporting the unit

OLS10/15 /-C277 en(us) / 60


Transporting the unit

Empty the unit completely before transport, including the coalescing and filter housings. Pull out the power plug and securely fasten the power cord to the unit.

Transporting with the crane Fasten suitable band loops to the base support for transporting with the crane.

Storing the unit

OLS10/15 /-C277 en(us) / 60


Storing the unit

Empty the unit completely before storage, including the coalescing and filter housings. Pull out the power plug and securely fasten the power cord to the unit. Permitted storage temperature range

See chapter “Technical data“, page 56.

Permitted air humidity See chapter “Technical data“, page 56.

Air Clean, salt-free air, not near oxidizing substances (rust film).

Storage duration Unrestricted, but in any case before the unit is started up again: after a storage period of greater than 2 years, all seals must be replaced.

Storage position Only standing.

Decoding the name plate

OLS10/15 /-C277 en(us) / 60



Details for identifying the filtration unit can be found on the name plates on the unit and the components.

Item -> Description

(1) -> Name plate of filtration unit

(2) -> Name plate of electric motor

(3) -> Model code; for details, see page


OLS10/15 /-C277 en(us) / 60


The following information can be found on the name plate of the unit: Row -> Description

Part No. -> Part number

S/N -> Serial number / year of production

Power -> Power consumption

Voltage/Grid -> Voltage / power supply

Frequency -> Frequency

Current -> Current consumption

Pressure max. -> Maximum permitted operating pressure

Pressure IN -> Permissible operating pressure at IN connection

Pressure OUT -> Permissible operating pressure at OUT connection

Weight -> Weight when empty

Flow rate -> Flow rate

Temp. oil -> Permitted fluid temperature range

Temp. amb. -> Permissible ambient temperature range

Volume -> Fluid volume in unit

Checking the scope of delivery

OLS10/15 /-C277 en(us) / 60


Checking the scope of delivery

The filtration unit comes factory-assembled. Check that the filtration unit is complete before starting up. The following items are supplied: Qty Description

1 OffLine separator

1 Operation and Maintenance Instructions (this document)

Characteristics of the unit

OLS10/15 /-C277 en(us) / 60


Characteristics of the unit

The OffLine Separator OLS is a dewatering unit for hydraulic oils and gear lubrication oil with densities below 950 kg/m3. The OLS is installed in the bypass flow; a pre-filter is available as an option.

Coalescing procedure The dewatering works according to the coalescence principle, during which water collects on the fibers of the coalescing element and is conveyed deeper into the coalescing element by the fluid flow. Smaller drops unite to form larger ones at the fiber nodes during this process. Larger drops settle downwards and can be drained off by opening a valve. The coalescing process is 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 is used in the bypass flow. The use of a micro-filtration system is expedient to ensure the maximum possible service life of the coalescing elements.

Identifying components

OLS10/15 /-C277 en(us) / 60



Additional details regarding the versions can be found in the following.


OLS10/15 /-C277 en(us) / 60


Item Description

A Inlet oil INLET OIL

B Outlet oil OUTLET OIL

C Outlet Water OUTLET WATER

D Filter housing drain DRAIN filter housing

E Draining – coalescing housing DRAIN coalescer housing

90 Clogging indicator, electrical, for the coalescing housing

91 Clogging indicator, electrical, for the filter housing

100 Coalescing housing

102 Housing clamp

200 Filter housing (pre-filter)

202 Housing clamp

301 Water drainage valve

400 Motor pump assembly

240 Air bleed, filter housing

700 Control with main switch

800 Connection box / electrical interface

2110 Sight glass, upper phase boundary

2111 Sight glass, lower phase boundary

2310 Venting, coalescing housing

Hydraulic diagram

OLS10/15 /-C277 en(us) / 60


Hydraulic diagram

The unit has the following hydraulic circuit:

Item Description

A Inlet oil INLET OIL

B Outlet oil OUTLET OIL

C Outlet Water OUTLET WATER

D Filter housing drain DRAIN filter housing

E Draining – coalescing housing DRAIN coalescer housing

90 Clogging indicator, electrical, for the coalescing housing

91 Clogging indicator, electrical, for the filter housing

100 Coalescing housing

200 Filter housing (pre-filter)

301 Water drainage valve

400 Motor pump assembly

Unit dimensions

OLS10/15 /-C277 en(us) / 60


Unit dimensions

The unit has the following dimensions: a = Required dismantling space for changing the coalescing elements

B = Recommended working range

All dimensions in mm.

Unit setup/connection

OLS10/15 /-C277 en(us) / 60



NOTICE

Danger of tipping over / danger of slipping due to vibrations

The unit will be damaged

► Before starting it up, put the unit on a stable, horizontal surface.

Place the unit on a horizontal and level surface which is well ventilated. Install the suction port connection at the lowest part of the tank. This ensures that the water phase located at the base of the tank is reached. Install the return line as far as possible from the suction point in order to obtain an optimum intermixing of the tank contents. Take the following steps to prepare the unit for operation:

1. Check that the power supply cable is undamaged. Replace damaged cables immediately.

2. Check the connecting lines for leaks. Eliminate any leakages immediately.

3. Check and insert the filter element. For details, see page 41.

4. Check and insert the coalescing element. For details, see page 46.

5. The unit is ready for the next steps on the following pages.


OLS10/15 /-C277 en(us) / 60


Notes on pipes/hosing Make sure that no vibrations or stresses are carried over to the filtration unit when connecting the piping. Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filtration unit. Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filtration unit. Use hoses or expansion joints if necessary. The pressure loss in a hydraulic line depends upon:

• flow rate

• kinematic viscosity

• Pipe dimensions

• Density of the fluid The pressure loss can be estimated for hydraulic oils as follows:

Δp ≈ 6.8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = Pipe length [m]

d = Internal pipe diameter [mm]

Q = Flow rate [l/min]

V = Kinematic viscosity [mm²/s]

D = Density [kg/dm³] Mineral oil-based hydraulic fluid has a density of ≈ 0.9 kg/dm³.

This applies to straight pipelines and hydraulic oils. Additional threaded 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. Constrictions in the connections and lines should be avoided. This could compromise suction output and cause cavitation . Take note that the nominal size of the connected hoses/piping must be at least as large as the inlet port sizes.


OLS10/15 /-C277 en(us) / 60


Connecting the suction port (INLET) For the suction port connection, use a flexible hose that is resistant to negative pressure. Avoid constrictions in the connecting lines, as they compromise suction performance and increase the risk of cavitation.

NOTICE

Overpressure at the suction port connection


► The pressure on the suction port connection IN must not be more than -0.4 to 4 bar.

Checking/setting the flow rate Set the maximum permissible volumetric flow for external motor-pump assembly. The maximum permissible flow rate can be found on the name plate. This is specified in the model code for the unit. (see the chapter “Model code”). The permitted tolerance is ± 10%, e.g.: Maximum permissible flow rate OLS 10/5 = 5 l/min ± 10% OLS 10/15 = 15 l/min ± 10%

Connecting the pressure connection (OUTLET) Make sure that the nominal width of the pressure line corresponds to the connector thread of the filter housing. Install the return line below the fluid level to prevent air from entering the fluid in the tank

If the clogging indicator pressure displayed for the a clean filter element is > 1 bar, use a differential pressure clogging indicator.

To prevent air from entering the medium, make sure that the pressure hose with lance is always below the oil level in operation.


OLS10/15 /-C277 en(us) / 60


Connecting the water drainage (WATER DRAIN)

NOTICE

Excess pressure at the water outlet


► Guide the water outlet into a depressurized reservoir.

Connect the water outlet to a depressurized reservoir without cross-section reduction. Reservoir height max. 1.5 m and no higher than the fluid level in the tank. Connect the water connection to a depressurized reservoir. Take care to ensure than no pressure can prevail and/or develop. The nominal size of the connecting line must match the cross-section of the threaded connection.

The separated water can contain some parts of operating medium. Dispose of the water-oil mixture in an environmentally friendly manner.


OLS10/15 /-C277 en(us) / 60


Electrical connection of the unit The filtration unit has a connector cable with a power plug.

DANGER

Exposed electrical terminals in the terminal box on the electric motor

Danger of fatal injury due to electric shock

► Any work involving the electrical system may only be done by a properly trained, certified electrician.

Unwind the connector cable fully. Plug the power plug into a suitable, earthed, protected power outlet. Match the specifications for the power supply and frequency on the unit with the network specifications. The filtration unit has a thermal motor protection switch to protect it from electrical overload.

Checking the direction of rotation at the electric motor Start the motor by switching it on for a short time (jog mode). The arrow on the fan cover shows the correct direction of rotation. If the rotation is in the opposite direction, reverse it by means of the phase inverter in the connection plug.


OLS10/15 /-C277 en(us) / 60


Connecting the remote control line The unit provides a connection for remote monitoring and a start/stop function. This lets you monitor, start and stop the unit from a control centre. Unscrew both screws to the cover (615) for connection. Remove the cover (615). The description of the connection clamps can be found on the rear.

NOTICE

Incorrect voltage / current at the relay contact

The control will be destroyed.

► Take note of the maximum voltage and current permitted in the relay contacts of 24 V DC / 2 A.

► Only use cables with a cable cross section of > 0.5 mm².

Use a free screw type conduit fitting on the lower side to connect the control line.


OLS10/15 /-C277 en(us) / 60


Connect the pilot line and monitoring line to the X2 and X3 terminal according to the following description: Terminal: Pin

Function Description

X3:1-2 Output Device ACTIVE

Potential-free relay contact. It is closed when the motor pump assembly is running.

X3:3-4 Output Device OK

Potential-free relay contact. This is closed when there is no pending error. Can be used, for example, to issue an error notification when contact opens. Opens, for example if the voltage drops, the motor protection responds, the filter is clogged, the collecting pan is too full, etc.

X2:5-6 Output Reserve Potential-free relay contact. Has no function

X3:7-8 Input Input for potential-free push-button to switch motor-pump group on/off. No voltage is to be applied here.

X3:9-10 Input Reserve A voltage of 24V is to be applied here (opto-coupler input) to start a function. No function set yet.


OLS10/15 /-C277 en(us) / 60


Connection box / connect interface (optional) This interface is located in the auxiliary box (800) with the designation +A2-A3. See circuit diagram with No. 4131413.

Connection terminals - Start/Stop external Pressing this push-button changes the current operating state. This means from operating state Stop -> Start and operating state Start becomes Stop. Terminal Line cross-section

X1:1 Potential-free push-button 0.5 … 2.5 mm²

X1:2 Potential-free push-button 0.5 … 2.5 mm²


OLS10/15 /-C277 en(us) / 60


Connection terminals - Device active If the unit is in operation, the NO contact is closed. Terminal Voltage Current Line cross-section

X1:3 U = 24 V DC

0.5 A 0.5 … 2.5 mm²

X1:4 U = 24 V DC

0.5 A 0.5 … 2.5 mm²

Connection terminals - Device OK

If the unit is fault-free, the NO contact is closed. Terminal Voltage Current Line cross-section

X1:5 U = 24 V DC

0.5 A 0.5 … 2.5 mm²

X1:6 U = 24 V DC

0.5 A 0.5 … 2.5 mm²

Connection terminals – Clogging indicator VM1, prefilter clogged

Utilization category AC-15 in accordance with EN 60947 Terminal Voltage Current Line cross-section

X1:7 Base contact 230 V AC 3 A 0.5 … 2.5 mm²

X1:8 NC contact 230 V AC 3 A 0.5 … 2.5 mm²

X1:9 NO contact 230 V AC 3 A 0.5 … 2.5 mm² If the clogging indicator VM1 responds, the toggle switch switches. If the signal is present for longer than 60 seconds, the unit is switched off and the toggle switch returns to the starting position.

Connection terminals – Clogging indicator VM2, coalescing element clogged Utilization category AC-15 in accordance with EN 60947 Terminal Voltage Current Line cross-section

X1:10 Base contact 230 V AC 3 A 0.5 … 2.5 mm²

X1:11 NC contact 230 V AC 3 A 0.5 … 2.5 mm²

X1:12 NO contact 230 V AC 3 A 0.5 … 2.5 mm²


OLS10/15 /-C277 en(us) / 60


If the clogging indicator VM2 responds, the toggle switch switches. If the signal is present for longer than 60 seconds, the unit is switched off and the toggle switch returns to the starting position.


OLS10/15 /-C277 en(us) / 60


Remote control / Interval control Prioritization After switching on the unit, the set interval and the switch-on time will be started. Using the remote control, the motor-pump group can be switched on/off using the remote control. The timer with the interval and the switch-on time will continue to run in the background (remote control has priority). If the motor-pump group is switched off via the remote control, it starts automatically once the interval is over and runs time controlled via the timer. If the motor-pump group is switched on via the remote control, it stops once the interval is over. The timer has priority when switching off. Thus, the set interval and the switch-on time are not influenced by the remote control. Instead the timer assumes control again once the interval is over.

Operating / adjusting the control unit

OLS10/15 /-C277 en(us) / 60



The unit has the following control unit and operating elements:

Item Description

610 Main switch See page 34 for details

611 Motor protection switch See page 37 for details

612 Interval control See page 36 for details

613 Status LEDs See page 35 for details

Switching the main switch on / off Switch the unit on or off at the main switch on the control unit. If the unit is switched off, all components up to the main switch are deenergized.


OLS10/15 /-C277 en(us) / 60


Reading LED status The status LEDs with the symbols indicate operating status, service status and errors. The icons are explained below.

Icon An illuminated LED means the following: For details on remedies, see page:

Supply voltage is available 52

The unit is switched on 52

No malfunction / no error. 52

The motor protection switch has tripped. 52

The maximum differential pressure at the prefilter has been reached. 46

The maximum differential pressure at the coalescing elements has been reached. 46

Error message from water outlet. 52


OLS10/15 /-C277 en(us) / 60


Adjusting the interval control Operating intervals and the operating duration are specified using the two interval control and time selector switches

The interval control and symbols indicate operating status, service status and errors. The icons are explained below. Icon Description

Permanent operation, time selector switch does not function.

One-time operation, time adjustment using time selector switch.

Once in 24 hours operation, time adjustment using time selector switch.

Once in 7 days operation, time adjustment using time selector switch.


OLS10/15 /-C277 en(us) / 60


Adjusting the time selector switch The operating duration is set at the time selector switch. Icon Time setting

1 hour

2 hours

4 hours

8 hours

Checking the motor protection switch The motor protection switch is aligned and adjusted at the installed electric motor at the works. It is not necessary to correct the setting. If the motor protection switch triggers, proceed as indicated in the chapter "Status LED /" on page 52.

Switching unit on/off Switch the unit on at the main switch (610) and select the operating duration using interval control.

Automatic water drainage If the water sensor signals > 10 seconds, the drain level has been reached and the water drain value will be opened for approx. 12 seconds. This will result in approx. 3 liters of water draining out.

Starting up the unit

OLS10/15 /-C277 en(us) / 60



Before the unit is put into operation, it must first be connected hydraulically and electrically, as described in the above chapters. Note that the OLS unit contains no coalescing elements when it leaves the factory. If necessary, install the coalescing elements. Proceed as follows for commissioning:

1. Open the "INLET OIL" ball valve Close the "OUTLET OIL" ball valve.

2. Bleed the unit while filling.

3. Open the air-vent plug (x) on the prefilter.

4. Open the air-vent plug X1 on the coalescing

container.

5. Switch on the unit at the main switch.

6. If an external boost pump is present, switch

it on. Determine the flow rate present and adjust it in accordance with the permissible flow


OLS10/15 /-C277 en(us) / 60


rate (see type plate).

7. Observe the maximum primary pressure to the pump on the OLS.

8. Switch the pump on.

9. If the prefilter has been bled, then close the air bleed plug. If the coalescing container has been bled, then close the air bleed plug X1.

10. Open the "OUTLET OIL" ball valve.

11. The unit is ready for operation.

Performing maintenance

OLS10/15 /-C277 en(us) / 60



Perform all of the subsequent maintenance work regularly. Perform all of the subsequent maintenance work.

WARNING

Hot surfaces

Danger of burns

► Allow the unit to cool before any maintenance work.

Maintenance intervals Adhere to the following maintenance intervals.

For d

etai

ls, s

ee p

age

12 h

Dai

ly

Eve

ry 3

mon

ths

1 ye

ar

6 ye

ars

Whe

n in

dica

ted:

Perform visual check 40 - X - - - -

Replacing hydraulic hoses 41 - - - - X -

Replacing the filter element in the filter housing

41 - - - X - X

Changing the coalescing elements

46 - - - X - X

Perform visual check Check the unit for leaks, brittle hoses and cables daily. Replace damaged or brittle parts immediately.


OLS10/15 /-C277 en(us) / 60


Replacing hydraulic hoses Replace the hydraulic hoses every six years at the latest. The six operating years include two years storage duration for normal requirements in accordance with the rules of the Employers Liability Insurance Association BGR 237 for normal requirements.

Replacing the filter element in the filter housing To change the filter elements, proceed as follows:

1. Switch off the unit and make sure that it cannot be inadvertently switched back on.

2. Close all shut-off valves at the inlet and

outlet.

3. Unscrew the air bleed screw (x) completely using a 10 mm Allen wrench.

4. (1) Have a suitable drip tray on hand to

catch the operating fluid. (2) Open the drain fitting, and collect the escaping fluid in the tray. Once the housing has been completely drained, close the drain fitting.


OLS10/15 /-C277 en(us) / 60


5. Screw in the air bleed screw (x) by hand in a clockwise direction and tighten it firmly using a 10 mm AF Allen wrench.

6. Release the housing clamp and remove it.

Lift off the cover upwards.

7. Turn the element locking cap on the top filter

element by 90° in counterclockwise direction and lift off the locking cap.


OLS10/15 /-C277 en(us) / 60


8.

Dispose of the used filter elements in an environmentally friendly manner.

8. Clean the inside of the filter housing of

coarse dirt. Check the O-rings on the filter housing for damage. If necessary, replace them.

10. Insert the filter element into the bayonet

fitting (1), and lock the filter element by turning it 90° in the clockwise direction (2).


OLS10/15 /-C277 en(us) / 60


11. Place the element locking cap on the upper filter element (1). Turn the locking cap 90° in the clockwise direction to lock it in place.

No element locking cap = no filtration.

12. Place the cover at the top on the filter

housing. Mount the tensioning clamp and tighten it with a torque of 20 Nm. Secure using the lock nut.

We recommend applying lubricant containing a slip additive to the threads of the housing tensioning clamp each time filters are changed so that it remains easy to remove. Lubricant containing a slip additive – HYDAC p/no. 3066287

13. Open all shut-off valves at the inlet and outlet. If a pump is present, switch it on.

14. Fill the filter housing slowly. Slightly undo the air bleed screw (x). The air in the filter housing can escape via the slot on the air bleed screw. Bleed the filter housing through the air bleed screw (x) until operating fluid comes out. Tighten the air bleed screw.

15. The filter element change is now complete.


OLS10/15 /-C277 en(us) / 60



OLS10/15 /-C277 en(us) / 60


Changing the coalescing elements To replace the coalescing elements, proceed as follows:

1. Switch off the unit at the main switch.

2. Close the INLET (1330) and OUTLET (2560) ball valves

3. Depressurize the unit.

Carefully screw the air-vent plug out of the cover with the aid of a size 10 mm Allen wrench.

4. Open the ball valve at the DRAIN

connection (3350) to empty the coalescing housing. Collect the free water/oil in a suitable container and dispose of it in an environmentally friendly manner. Once the coalescing housing is completely emptied, close the "DRAIN" connection (3350)

5. Loosen the upper tensioning clamp on

the coalescing housing with a size 13 mm fork wrench by turning it counterclockwise.


OLS10/15 /-C277 en(us) / 60


6. 1 - Remove the housing clamp (2400). 2 - Remove the cover by lifting it upward and set it down to the side.

7. Remove the element set from the

coalescing housing. Use both handles to accomplish this.

8. Rotate the element set on the head by

180°.


OLS10/15 /-C277 en(us) / 60


9. Undo the 3 wing nuts and remove the holding plate.

10. Pull the coalescing elements out of the

element receptacles and dispose of them in an environmentally friendly manner.

11. Moisten the O-ring on the element

lightly with the operating fluid.


OLS10/15 /-C277 en(us) / 60


12. Insert the new coalescing elements into the element receptacles by screwing them in carefully.

Do not use a hammer, etc.

13. Mount the element holding plate and

tighten the 3 wing nuts firmly.

14. Rotate the element set by 180°.

Insert the element set into the coalescing housing. Note that the element set fits only in one position (Z) in the coalescing housing.


OLS10/15 /-C277 en(us) / 60


15. Clean the sealing surface on the cover. Check the O-ring for damage. Replace it if necessary.

16. 1 - Place the cover on the coalescing housing. 2 - Place the housing clamp over the coalescing housing.

17. Use an SW 13 fork wrench to tighten

the tensioning clamps evenly to a maximum of 20 Nm. Screw open the lock nut and secure the connection.

18. Open the ball valves INLET (1330)

and OUTLET (2560).


OLS10/15 /-C277 en(us) / 60


19. Bleed the filtration unit.

20. Bleed the coalescing housing through

the air-vent plug (2310) at the cover.

21. The replacement of the coalescing

element is completed.

Status LED / Causes and remedies

OLS10/15 /-C277 en(us) / 60



The status LEDs only indicate to you the status or an error of the unit in Standard / Premium control type. The following errors could have different causes. The following provides information on which remedial measures are required. To reset the error message on the control, switch off the unit at the main switch for at least three seconds.

Status LED Cause(s) Remedy

LED is dark = LED is off

No power supply. Check the feed-line and plug.

LED flashing

The main switch is switched off but the power supply is on

Check the main switch.

The main switch is switched on, during operation there was a drop in voltage => restart protection.

Switch off the unit at the main switch for 3 seconds.

LED lights up

LED flashing

LED flashing

The main switch is on, but the unit is not running.

Contact HYDAC.

Electric motor / pump is not running

Interval control is active.

Check the interval settings.


OLS10/15 /-C277 en(us) / 60



The is no power at the electric motor.

The power outlet used is free of voltage. The mains connector is not plugged in. Plug in the power plug. Inspect the unit supply line for damage. If the unit supply line is defective, replace it immediately.

The mains voltage or frequency do not correspond to the specifications on the unit.

Use a unit that is suitable for the mains voltage.

The unit is switched off at the main switch.

Switch on the unit at the main switch.

No flow

The suction hose is kinked or faulty or a shut-off device is closed.

Check the suction hose for freedom of passage. Replace it if necessary.

There is air in the suction line and the pump.

Fill the pump via the suction hose / hose coupling.

The viscosity of the fluid is too high.

Check the viscosity of the fluid. Heat the fluid to achieve the permissible viscosity.

The is no power to the electric motor.

Check the supply line to the filtration unit. Replace it if necessary.

The electric motor / pump is defective.

Contact HYDAC.

The transport seals were not removed.

Remove the transport seals. The transport seals are the yellow plastic bungs.

The pressure loss in the suction line is too great.

Ensure that the pressure at the inlet is within the permitted range.


OLS10/15 /-C277 en(us) / 60



The suction hose is not suitable for negative pressure.

Use a hose that is resistant to negative pressure.

The prefilter element is clogged.

The coalescing elements are clogged. (The clogging indicator is responding)

If the maximum differential pressure in the filter housing or coalescing housing has been reached, the control will automatically switch off the unit. Once a clogging indicator responds, the unit will be switched off with a time delay of 60 seconds.

Replace the filter element or coalescing element depending on which status LED is lit.

The viscosity of the fluid is too high.

Check the viscosity of the fluid. Heat the fluid to achieve the permissible viscosity.

The suction line at the inlet is generating too much loss of pressure.

Ensure that the pressure at the inlet is within the permitted range.

Water drainage error The phase limit sensor is defective or the water drainage valve does not open.

Contact HYDAC.

Customer Service / Service

OLS10/15 /-C277 en(us) / 60


Customer Service / Service

Regular inspection and maintenance work are indispensable to ensure trouble-free operation and a long service life for your unit. HYDAC SERVICE GMBH Friedrichsthaler Str. 15A, Werk 13 66540 Neunkirchen-Heinitz Germany Telephone: +49 6897 509 883 Fax: +49 6897 509 324 E-mail: [email protected]

Taking the unit out of operation

Drain the unit completely, including all of its components, before decommissioning. Pull out the power plug and securely fasten the hoses and power cord to the unit.

Shutting down the unit

See chapter "Taking the unit out of operation".

Disposing of the unit

Dispose of the packaging material in an environmentally friendly manner. After dismantling the unit and separating the various materials, dispose of the unit in an environmentally friendly manner.

Spare parts list

Qty Part no. Description 1 * Motor/pump assembly 10 3277940 Coalescing element, 5 µm N20WR005-1F 2 6005449 O-ring 270x10 (NBR) 1 1251590 Prefilter element, 2 µm N15DM002

*) Upon request

Technical data

OLS10/15 /-C277 en(us) / 60


Technical data

Hydraulic data flow rate 15 l/min Permitted viscosity range 15 … 100 mm/s² Permissible fluids Mineral oil to DIN 50524

Gear lubrication oil to DIN 51517, 51524

Permitted maximum fluid temperature 80°C Operating pressure (setting at pressure relief valve) 6 bar Permitted pressure at inlet (INLET OIL) -0.4 … 4 bar Permissible pressure at the water drain Depressurized Housing material Stainless steel: 1.4301 Material of sealings NBR INLET connector G1" OUTLET connector G1" Connection for water drain G 1/2 " Electrical data Power supply See type label Power consumption See type label Required fuse element 16 Amperes Power cable, length 0.5 m Protection class to DIN 40050 IP 54 General data Permissible ambient temperature range 0 to 45°C Permitted storage temperature range 0 to 45°C Permitted relative humidity during storage ≤ 60 % Weight when empty ≈ 140 kg

Model code

OLS10/15 /-C277 en(us) / 60


Model code

OLS 10 / 15 - S - N - 20 - 1 - BM - z - z - z / V

Type OLS Filter Size 10 = Number of coalescing elements Nominal flow rate 15 = 15 l/min Pump version z = without pump G = Gear pump GD = Gear pump for diesel fuel S = Vane pump Power supply B = P = 480 V, 3 Ph C = P = 380 V, 3 Ph G = P = 440 V, 3 Ph L = P = 115 V, 3 Ph M = 230 V, 1 Ph* N = P = 400 V, 3 Ph O = P = 460 V, 3 Ph P = P = 575 V, 3 Ph S = P = 500 V, 3 Ph R = P = 415 V, 3 Ph W = 230 V, 3 Ph* X = Other voltage (on request) z = Without electro motor L60, M60 = Operation at 60 Hz * = Standard in Europe according to CENELEC

HD472 S1 at 50Hz

Element length 20 = Coalescing element 20“ – N20WRxxx Prefilter 2 = OLF 15-60 z = without Clogging indicator BM = Differential pressure indicator, visual (VMxBM.1) C = Differential pressure indicator, electrical (VMxC.0) z = Without E = Back-pressure indication VMF 0.6KO Heater 1 = 1 kW 2 = 2 kW z = Without Water drain 1 = Automatic z = Manual Instrumentation z = without Additional details PKZ = On-off switch with motor protection switch FA2 = On/Off switch with motor protection switch and switch-off when filter is

clogged. Requires no neutral conductor, all voltages, clogging indicator C required.

V = Seals made of Viton (FPM)

Index

OLS10/15 /-C277 en(us) / 60


Index

A accident prevention ...................................................... 12 ambient temperature .............................................. 16, 56 Auxiliary personnel ........................................................ 11

B Back-pressure ................................................................ 57

C care........................................................................ 2, 5, 26 Cause ............................................................................. 52 Clogging indicator ........................................ 20, 21, 31, 57 collecting pan ................................................................ 29 connecting ................................................... 23, 24, 25, 26 Connection .................................................. 20, 30, 31, 56 Content ........................................................................... 3 Control .......................................................................... 20

D Density .......................................................................... 24 Description ..................... 15, 16, 17, 20, 21, 29, 34, 36, 55 dewatering .............................................................. 10, 18 Differential pressure ..................................................... 57 Differential pressure indicator ...................................... 57 DIN ................................................................................ 56 Disposal ......................................................................... 11 Documentation Representative ...................................... 2 DRAIN .......................................................... 20, 21, 26, 46 draining ......................................................................... 37

E Electrical data ................................................................ 56 Error .............................................................................. 35 Error message ............................................................... 35

F filling ........................................................................ 10, 38 Filter ............................................................ 10, 20, 21, 57 Filter housing ........................................................... 20, 21 filtration ............................... 15, 17, 18, 24, 27, 44, 51, 53 Flow rate ................................................................. 16, 24

G gear ......................................................................... 10, 18 Gear pump .................................................................... 57

H Hazard symbol ............................................................. 7, 9 Heater ........................................................................... 57 Hydraulic data ............................................................... 56

Hydraulic diagram ......................................................... 21

I Imprint ............................................................................ 2 IN 16, 25 Inlet ......................................................................... 20, 21 INLET .......................................... 20, 21, 25, 38, 46, 50, 56 Internal pipe diameter .................................................. 24 IP 56

M Main switch ................................................................... 34 Maintenance .................................................. 1, 11, 17, 40 Maintenance interval .................................................... 40 Maintenance intervals .................................................. 40 Material of sealings ....................................................... 56 Measures ........................................................................ 9 Mineral oil ............................................................... 24, 56 Model code ........................................................15, 25, 57 Motor protection switch ............................................... 34 Motor pump assembly ............................................ 20, 21

O Off switch ...................................................................... 57 operating 5, 6, 7, 10, 11, 12, 16, 26, 30, 34, 35, 36, 37, 41,

44, 48 Operation ...........................................................10, 17, 57 Operations control ........................................................ 11 OUT ............................................................................... 16 Outlet ...................................................................... 20, 21 OUTLET................................. 20, 21, 25, 38, 39, 46, 50, 56

P Power consumption ................................................ 16, 56 Pressure differential...................................................... 24 Proper/Designated Use ................................................. 10 Protection class ............................................................. 56 Publisher ......................................................................... 2 Pump ............................................................................. 57

R Remedy ......................................................................... 52 replacement .................................................................. 51 Residual water content ................................................. 10

S select ......................................................................... 6, 37 Service ........................................................................... 55 setting ................................................................25, 37, 56 Signal word ..................................................................... 9 signal words .................................................................... 9 Size ................................................................................ 57

Index

OLS10/15 /-C277 en(us) / 60


Spare part ...................................................................... 55 Spare parts .................................................................... 55 Spare parts list ............................................................... 55 Specialist personnel ...................................................... 11 Supply voltage ............................................................... 35 switching off .................................................................. 33 switching on .................................................................. 33

T Time .............................................................................. 37 Transport ....................................................................... 11

transporting .................................................................. 13 Troubleshooting ............................................................ 11

V Vane pump .................................................................... 57

W Weight .................................................................... 16, 56

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 9046 (Technical Department) Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com E-mail: [email protected]

ols 10/15 /-c277 offline separator - start: hydac ols10-15-c277 4114093a en-us 2016-06-09.docx...

Documents