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OXiStop OXS

Installation and Maintenance Instructions

English (translation of original instructions)

Document no.: 3992763e

Imprint

OXiStop OXS en / 108

MoWa OXS 3992763e en-us 2018-08-10.docx 2018-08-10

Imprint

Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Phone: +49 (0) 6897 509 01 Fax: +49 (0) 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 Phone: +49 (0) 6897 509 1511 Fax: +49 (0) 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. All details are subject to technical modifications. Technical specifications are subject to change without notice.

Content



Content

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

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

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

Preface ........................................................................................................... 6

Technical Support ........................................................................................ 6 Modifications to the Product ........................................................................ 6 Warranty ...................................................................................................... 6 Using the documentation ............................................................................. 7

Safety Information ........................................................................................ 7

Hazard symbols ........................................................................................... 8 Signal words and their meaning in the general safety information ............... 9 Structure of the general safety information ................................................ 10 Observe regulatory information ................................................................. 10 Proper/designated use............................................................................... 11 Improper Use or Use Deviating from Intended Use ................................... 12 Qualifications of personnel / target group .................................................. 13 Wear suitable clothing ............................................................................... 14 Observe regulatory information ................................................................. 14

Transporting the unit .................................................................................. 15

Transporting the unit with the crane .......................................................... 16

Storing the unit ........................................................................................... 17

Decoding the model code label ................................................................. 18

Checking the scope of delivery ................................................................. 20

Description of unit ...................................................................................... 21

Achievable degassing rate/residual water content ..................................... 22 Calculating differential operating volume ΔV .............................................. 22 Available sizes ........................................................................................... 23 Unit components ........................................................................................ 24 Hydraulic diagram ...................................................................................... 26 Dimensions ................................................................................................ 29

Unit Operating Principle ............................................................................. 31

Unit setup/connection ................................................................................ 32

Hydraulic installation of the unit ................................................................. 32 Electrically clamping the OLF 5 bypass flow filtration unit ......................... 33 Electrical connection of the heat exchanger's electric motor (optional) .................................................................................................... 34

Monitoring the unit's sensors/displays ..................................................... 35

Content



Monitoring unit function.............................................................................. 37 Fluid level indicator, visual – Min/Max marking .......................................... 40 Connecting electronic fluid level/temperature sensor HNS ........................ 41 Connecting AquaSensor AS (optional) ...................................................... 42 Connecting ContaminationSensor CS1000 (optional) ............................... 43

Starting up the unit ..................................................................................... 44

Switching off the unit ................................................................................. 44

Troubleshooting .......................................................................................... 45

Performing Maintenance ............................................................................ 47

Maintenance intervals ................................................................................ 48 Filling the hydraulic tank with oil (first filling/oil change) ............................. 50 Refilling the hydraulic tank with oil ............................................................. 55 Partially emptying the hydraulic tank ......................................................... 57 Completely emptying the hydraulic tank for transport, oil change, etc. ............................................................................................................. 59 Emptying the degassing unit ...................................................................... 61 Manual bleeding during commissioning (accessories) .............................. 62 Checking the clogging indicator on the breather filter ................................ 63 Replacing the breather filter element ......................................................... 64 Checking the visual clogging indicator of the fluid filter ............................. 65 Replace the filter element on the OLF 5 bypass flow filtration element ...................................................................................................... 66 Replacing the protective screen on the OLF 5 bypass flow filtration unit (optional) ............................................................................................. 70 Clean/replace the suction strainer on the OLF 5 bypass flow filtration unit ............................................................................................... 72 Bleeding the OLF 5 bypass flow filtration unit ............................................ 74 Checking/setting the electronic pressure switch (EDS) ............................. 75 Check / adjust electronic level / temperature sensor HNS ......................... 77 Performing maintenance on the heat exchanger (optional) ....................... 79 Changing the filter element of the return line filter (optional) ..................... 80 Recalibrating the ContaminationSensor .................................................... 82 Testing the AquaSensor AS ...................................................................... 82 Replacing the diaphragm ........................................................................... 83

Removing the diaphragm ....................................................................... 83 Installing the diaphragm ......................................................................... 84

Taking the unit out of operation ................................................................ 87

Disposing of the unit .................................................................................. 87

Customer Service/ Service ......................................................................... 88

Spare parts list ............................................................................................ 89

Accessories ................................................................................................. 98

Content



Technical Data........................................................................................... 101

Model code ................................................................................................ 103

Index .......................................................................................................... 104

Preface



Preface

This operating manual was 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 code, serial no. and part no. of the product: Fax: +49 (0) 6897 / 509 - 9046 E-mail: [email protected]

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. 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 terms of delivery of HYDAC FILTER SYSTEMS GMBH. You will find these under www.hydac.com -> Legal information.

http://www.hydac.com/

Safety Information



Using the documentation

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

Safety Information

The unit was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements.

Chapter description

Page number Edition date

Document language Documentation no. with index/

file name

Safety Information



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 general safety information on to other users.

General hazard

Danger due to electrical voltage / current

Exposed electrical components Danger of electrical shock

Danger due to operating pressure

Risk of burns due to hot surfaces

Safety Information



Substances that are health hazards or irritants

Danger of explosion in explosive atmospheres

Signal words and their meaning in the general safety information

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.

Safety Information



Structure of the general safety information 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

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

Safety Information



Proper/designated use Use the unit only for the application described in the following. The OXS is a tank system with an integrated diaphragm and a hydraulically driven degassing and dewatering unit. The integrated diaphragm prevents direct contact with the ambient air. This effectively "vacuum-packs" the fluid. The OXS can therefore be used in very dusty and damp environments.

NOTICE

Impermissible operating media

The unit will be destroyed.

► Use the unit only in conjunction with mineral oils compliant with DIN 51524.

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

• Maintaining adherence to all the instructions contained in the operation and maintenance manual.

• Performing inspection and maintenance work.

Safety Information



Improper Use or Use Deviating from Intended Use

DANGER

Danger due to unanticipated use of the unit

Bodily injury and damage to property will result when operated improperly.

► Never operate the unit in potentially explosive atmospheres.

► The unit is only to be used with permissible media.

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 or use deviating from intended may result in hazards and/or will damage the unit. Examples of improper use:

• Operation in potentially explosive atmospheres.

• Operation with a non-approved medium.

• 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



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 general safety information, 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 are intended for: Auxiliary personnel for transport and storage: These individuals must be familiar with and have received instruction in the handling of lifting equipment and accessories for transporting machinery and machine parts, in addition to hydraulic units. 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 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 Auxiliary personnel

No specialist knowledge required

Operation Operations control

Operating personnel

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

Commissioning 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

Safety Information



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 medium.

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

Transporting the unit




NOTICE

Using components for pushing/pulling/lifting

The unit will be damaged

► Never use the components to push or pull the unit.

Drain the unit and its components completely before transport and use suitable sealing plugs to seal all connections. Secure the unit with lashing straps without stressing/damaging the components.




Transporting the unit with the crane

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. ► Lift the unit only at the permitted attachment points.

The unit has the following permitted attachment points:

Storing the unit



Storing the unit

Pull out the power plug and securely fasten the power cord to the unit. Drain the unit completely, including all of its components, before putting it into storage. Remove the used filter element and dispose of it properly. Close all connections with corresponding blind plugs. Store the unit in accordance with the storage conditions listed in the chapter "Technical Data". If the storage period is expected to exceed six months, then the following tasks are to be carried out:

• Check all of the cables and seals prior to (re)commissioning for damage and replace damaged parts.

• After a storage period of greater than 2 years, replace all seals before (re)commissioning.

• Every four weeks, turn the running wheel of the motor-pump group several revolutions by hand in order to avoid seal adhesions and damage to the bearings.

Decoding the model code label




Details for identifying the power unit can be found on the type labels on the unit and the components.

Item -> Description

(1) -> Name plate OXS

(2) -> Model code; for details, see page 103

(3) -> Name plate for the OLF 5 bypass flow filtration unit

(4) -> Name plate for the electric motor on the OLF 5 bypass flow filtration unit

(5) -> Name plate for the heat exchanger's electric motor (optional)

(6) -> Name plate for the heat exchanger (optional)

(7) -> Type label for the return line filter (optional)




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

Part No. -> Part numberPart number

S/N -> Serial number / year of production

Diff. operating volume -> Differential Volume

Weight -> Empty weight

Viscosity range -> Permissible viscosity range

Temp. oil -> Permissible oil temperature range

Temp. amb. -> Permitted ambient temperature range

Tank volume -> Reservoir volume

Checking the scope of delivery



Checking the scope of delivery

Check the unit for any damage upon delivery. Immediately report any damage in transit to the forwarding agent or the HYDAC department in charge. The following items are supplied: Qty Designation

1 OXS, version as per order

1

Technical documentation, comprising: - installation and maintenance instructions, OXS (this document) - instructions for the components - declaration of incorporation

Description of unit



Description of unit

The OXiStop (OXS) is a tank solution for hydraulic systems with an integrated hydraulically driven degassing and dewatering power unit and continuous separation of solids. The OXS-Lid series represents a tank lid solution for the customer-specific design tanks and contain all of the components required for degassing and the separation of solids.

Description of unit



Achievable degassing rate/residual water content The achievable degassing rate is: ≈ 8 l/h at 20% air content ≈ 4 l/h at 10% air content ≈ 0.8 l/h at 2% air content The achievable residual water content is ≤50 ppm (depending on the fluid). The degassing capacity/degassing speed depend, in particular, on the oil type, oil temperature, oil quantity, tank properties, residual air content and the environmental conditions. Considerable deviations may occur depending on the application.

Calculating differential operating volume ΔV Calculate the required OXS size/differential operating volume in accordance with the actual volume differences of the hydraulic system's cylinders, accumulators and hoses. Take into account an additional required volume for the thermal expansion of the oil and any continuous oil leakage. Double this volume for safety reasons. Use the following formula to calculate the differential operating volume for the OXiStop:

ΔV = Σ VShell + 2(Σ ΔVCyl + Σ ΔVHoses + Σ ΔVTemp)

ΔV = Difference volume -> Differential Volume

Σ VShell = Σ Shell volume -> Σ Casing volume of the hydraulic accumulators

Σ ΔVHoses = Σ Δ Volume hoses -> Σ Δ Volume of hose lines

Σ ΔVTemp = Σ Δ Volume temperature expansion

-> Σ Δ Volume arising from thermal expansion

When configuring/selecting the size, also note the following: - The typical 10-fold reduction in the oil volume reduces the oil's mean

dwell time in the tank. This causes the mixing-completion temperature/steady-state temperature to be reached more quickly. Attach the OXS in such a way that the oil that is fed to the cooling circuit is removed directly from the tank's return line area with no mixing occurring in the tank beforehand, which would result in a lower temperature difference in the cooling circuit.

Description of unit



Available sizes The unit is available in the following sizes: Installation size Differential operating volume ΔV

OXS 30 ≤ 30 liters



Description of unit



Unit components The unit has the following components:

Description of unit



Position overview of unit components:

Item Designation

1 OXS-LID primary body

2.1 OLF 5 bypass flow filtration unit

CI Clogging indicator at filtration unit OLF5

CS ContaminationSensor CS (optional)

AS AquaSensor AS (optional)

3.1 MiniOX (MOX) degassing and dewatering unit

3.6 Pressure sensor EDS, electric Pressure gauge, visual

(optional)

4.1 Valve and connection block

4.7 Selector valve

5.93 Fluid level/temperature sensor HNS, electrical

B.08 Filling port

B.09 Draining connection

B.12 Pressure measurement point (pressure line OLF 5)

B.15 Connection for visual tank fluid level indicator

B.20 Connection for electronic temperature sensor ETS

B.22 Breather fitting / connection for rapid bleeding

B.23 Connection for additional HNS

6.3 Sight glass

6.4 Breather filters

7.1 Tank

7.24 Fill level indicator, visual

7.55 Drain fitting

8.10 return line filter (optional)

9.10 Motor-pump assembly for heat exchanger (optional)

9.15 Heat exchanger (optional)

T.A../T.B../T.C

Hydraulic connections

Description of unit



Hydraulic diagram The unit has the following hydraulic diagram:

Description of unit



Position overview of hydraulic diagram:

Item Designation


2.1 OLF 5 bypass flow filtration unit

CI Clogging indicator at filtration unit OLF5

CS ContaminationSensor CS

CS.1 Protective screen

AS AquaSensor AS

2.42 Suction screen

3.1 MiniOX (MOX) degassing and dewatering unit (optional)

3.6 Pressure sensor EDS, electric Pressure gauge, visual

4.1 Valve and connection block

4.7 Selector valve

5.93 Fluid level/temperature sensor HNS, electrical

B.08 Filling port

B.09 Draining connection

B.12 Pressure measurement point (pressure line OLF 5)

B.15 Connection for visual tank fluid level indicator (optional)

B.20 Connection for electronic temperature sensor ETS (optional)

B.22 Breather fitting / connection for rapid bleeding

B.23 Connection for additional HNS

6.1 Diaphragm

6.3 Sight glass (optional)

6.4 Breather filters (optional)

7.1 Tank

7.24 Fill level indicator, visual

7.55 Drain fitting

8.10 return line filter (optional)

9.10 Motor-pump assembly for heat exchanger (optional)

Description of unit



9.15 Heat exchanger (optional)

T.A../T.B../T.C

Hydraulic connections

Description of unit



Dimensions The unit is produced in a variety of sizes – the dimensions are given in the following drawing and the accompanying table.

Description of unit



The following dimensions are dependent on the size: Variable dimensions in mm Installation size

A B C D E

OXS 30 625.5 524 630 645.5 160

OXS 45 625.5 524 750 645.5 160

OXS 70 625.5 524 990 645.5 200

The following dimensions are dependent on the size. The size of return line filter NF is specified in the model code (see page 103). Variable dimensions in mm F G H

NF 160 205 160 G1 ¼"

NF 240 264 220 G1 ¼"

NF 280 445 400 G1 ¼"

NF 330 271 170 SAE 1 ½“ 3000 PSI

NF 500 352 250 SAE 1 ½“ 3000 PSI

NF 750 702 600 SAE 1 ½“ 3000 PSI

Unit Operating Principle



Unit Operating Principle

After the OLF 5 bypass flow filtration unit (2.1) has been switched on, the fluid is pumped from the tank to degassing and dewatering unit (3.1) via the valve and connection block (4.1) and the fluid filter. In degassing and dewatering unit (3.1) the fluid surface is used as a hydraulic piston to create a vacuum and thus remove gases and solid matter from the fluid. The gas and water that is removed from the oil is conveyed to the diaphragm via the pipe system and then released to the atmosphere as water vapor via breather filter (6.4). When the unit is started up, degassing and dewatering unit (3.1) also removes the air remaining in the tank above the oil surface and raises the oil until it is underneath the tank cover. Integrated diaphragm (6.1) rests on the oil like a protective skin in the tank, preventing the oil from making direct contact with the environmental air regardless of the oil level. The interior of the diaphragm is ventilated through the breather filter. Atmospheric pressure in the interior of the diaphragm is ≈ 1 bar absolute. A slight drop in pressure ensues on the oil side, based on the difference in height between the diaphragm floor and the cover plate. This pressure difference is purely the result of the geodesic height of the raised oil level. The result of this is that the outer side of the diaphragm now adheres or sticks completely to the diaphragm cage.

Unit setup/connection




Observe the following points when setting up the unit: - Keep an area facing upwards of at least 1.5 m above the unit

unobstructed for repair and maintenance purposes. It must also be possible to access the individual components for repair and maintenance purposes.

- Ensure that the respective tank securing measures are in place when using hydraulic accumulators in the overall hydraulic system.

- Observe the permissible ambient temperature on the name plate of the unit.

- Make sure there is sufficient ventilation around the area where the unit is set up.

- Connect all electric components in accordance with the applicable operating instructions.

Hydraulic installation of the unit Connect the hydraulic tank to your hydraulic system at the corresponding connections. Optional: Connecting the heat exchanger Connect your cooling circuit with the plate heat exchanger (A2->A1). In order to achieve high thermal efficiency and high heat transfer rates, it is better to install the plate heat exchanger in counter-flow direction.




Electrically clamping the OLF 5 bypass flow filtration unit

DANGER

Exposed electrical components in the switch cabinet

Risk of fatal injury from electrocution

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

Compare the voltage and frequency specifications on the unit name plate with the existing network specifications. Check the direction of rotation of the electric motor by switching it on briefly (jog mode).

NOTICE

Incorrect phase sequence / rotation direction of the electric motor

The pump will be destroyed

► In jog mode, check the direction of rotation of the electric motor. ► A rotation direction arrow on the fan cover of the electric motor

identifies the correct direction of rotation.




Electrical connection of the heat exchanger's electric motor (optional)

DANGER

Exposed electrical components in the switch cabinet

Risk of fatal injury from electrocution

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

Compare the voltage and frequency specifications on the unit name plate with the existing network specifications. Check the direction of rotation of the electric motor by switching it on briefly (jog mode).

NOTICE

Incorrect phase sequence / rotation direction of the electric motor

The pump will be destroyed

► In jog mode, check the direction of rotation of the electric motor. ► A rotation direction arrow on the fan cover of the electric motor

identifies the correct direction of rotation.

Monitoring the unit's sensors/displays




The hydraulic unit may be fitted with the following clogging indicators and sensors, depending on the design:




Details for the individual sensors/indicators are given on the following pages:

Item Designation For details, see page

CI Visual clogging indicator at the OLF 5 bypass flow filtration unit

65

CS ContaminationSensor CS on the OLF 5 bypass flow filtration unit (optional)

43

AS AquaSensor AS on the OLF 5 bypass flow filtration unit (optional)

42

3.6 EDS electronic pressure sensor or vacuum gauge (optional)

37

5.93 Electronic level/temperature sensor HNS 41

6.45 Visual clogging indicator on the breather filter 63

7.24 Visual fluid level indicator on the tank 40




Monitoring unit function Use the electronic pressure sensor EDS or the optional visual vacuum gauge to monitor the unit function. The vacuum gauge or the pressure sensor on the degassing and dewatering unit is used to monitor the function of the OXiStop and the hydraulic system. Explanations regarding how to interpret the display/measured values are given below.




In fault-free operation, the measured pressure oscillates between approx. -0.98 bar negative pressure and 0.5 bar positive pressure (20 mbar absolute and 1500 mbar absolute). The cycle time can range from 20 to 120 seconds and it is dependent on the fluid temperature and the air content. The longer the cycle time and the lower the negative pressure, the lower the air content is in the oil.

Pre

ssur

e [b

ar]

Time [s]

A typical pressure curve while free air is to be found under the tank lid is depicted on the left-hand side of the diagram. In doing so, the negative pressure in the degassing unit reaches a value of > -0.5 bar (> 500 mbar absolute). This kind of pressure curve is to be observed, among other times, during commissioning, with larger-sized air intakes or when there are leaks. Once the free air has been removed from the tank, a pressure curve arises that is similar to that on the right-hand side of the diagram. In doing so, the negative pressure in the degassing unit reaches a value of < -0.8 bar (< 200 mbar absolute).

Item Designation

A Positive pressure during the degassing phase

B Negative pressure with high air content

C Negative pressure with low air content

D Cycle time




There is a direct relationship between the lower pressure measured in the degassing unit and the approximate air content in the oil.

estim

ated

tota

l gas

con

tent

in %

lowest negative pressure in mbar (abs)

Note that this graph is based on the total gas content in the oil. Additionally, the graph gives the estimated air content only for oils with low water contents (< 30% saturation at 40°C) with constant utilization of OXS. It is thus possible to monitor the function of the degassing unit (regular cycles), the total gas content in the oil, the integrity of the diaphragm (rise in the lower pressure) and air entering the hydraulic system.




Fluid level indicator, visual – Min/Max marking Visual fluid level indicator (7.24) is used to monitor and check the diaphragm. The column of fluid in the fluid level indicator corresponds to the current position of the underside of the diaphragm. Accordingly, the higher the column rises, the more the diaphragm is being folded up.




Connecting electronic fluid level/temperature sensor HNS The unit is equipped with a float-based sensor with an integrated fluid level/temperature sensor.

The surface of the fluid in the fluid level suction tube corresponds to the current position of the underside of the diaphragm. The sensor is located in the valve block and it is used to monitor the diaphragm stroke and thus the differential operating volume available in the tank. If the oil level is too high or too low, the sensor issues an alarm signal to switch off the unit. The temperature of the oil is monitored via the integrated electric temperature sensor. Details on connection and the terminal allocations can be found in the instructions for the HNS. Check the settings in accordance with the specifications given in chapter "Check / adjust electronic level / temperature sensor HNS" on page 77.




Connecting AquaSensor AS (optional) With the optional AquaSensor, the water saturation of the sucked-in fluid is continuously measured and shown directly on the sensor. The water saturation indicates what percent of maximum possible water is dissolved in the oil. A value of 0% would indicate water-free oil and 100% would mean oil that is completely saturated with water. Example illustration: AS 3000.

Details on connection and the terminal allocations and settings can be found in the instructions for the AS.




Connecting ContaminationSensor CS1000 (optional) The optional ContaminationSensor measures the level of solid contamination in the fluid. Example illustration: CS1x2x (with display)

Details on connection and the terminal allocations and settings can be found in the instructions for the CS.

Starting up the unit



Starting up the unit

After you have connected the unit and the components hydraulically and electrically as described in the relevant chapters, start up the unit as follows:

1. Check that a suitable filter element is installed in all filter housings.

2. Fill and bleed the unit with oil as described in the chapter "Filling the hydraulic tank with oil (first filling/oil change)" on page 50.

3. Check all the settings of the sensors/indicators – see: - Checking/setting the electronic pressure switch (EDS), see page 75 for details. - Check / adjust electronic level / temperature sensor HNS, see page 77 for details.

4. Switch on the unit's components.

Switching off the unit

To switch off the unit, switch off all of the components such as the OLF 5 bypass flow filtration unit, sensor, etc. or disconnect the electricity to them.

Troubleshooting



Troubleshooting

The following errors could arise during operation. The possible causes for the errors are listed below, along with how the errors can be remedied.

Error Cause(n) Remedy

Degassing unit is failing to degas; the lower pressure does not drop below 500 mbar (absolute)

Excess air introduction. Bypass flow filtration unit is not conveying sufficient fluid to the degassing unit or the required pressure of 8 to 10 bar is not being reached. Tank or interfaces on the tank are leaking Diaphragm is leaking.

Ensure that the hydraulic system is free of leaks. Check the OLF 5 bypass flow filtration unit.

The degassing cycle of the degassing unit is >3 minutes and/or there is no pressure change at the degassing unit

The float valve is defective. Pressure relief valve is defective or incorrectly set.

Replace any defective valves immediately.

Degassing cycle is considerably shortened, during which the pressure in the degassing unit alternates back and forth in one-second cycles

The float valve is defective. Pressure relief valve is defective. Bypass flow filtration unit is not conveying sufficient fluid to the degassing unit.

Check the OLF 5 bypass flow filtration unit.

Oil level too low The unit has a leak. Ensure that the hydraulic system is completely free of leaks.

Troubleshooting



Error Cause(n) Remedy

The hydraulic system was not filled with sufficient oil.

Top up the oil – see page 55.

Too much oil on the inside/on the diaphragm

The hydraulic tank is overfilled. The diaphragm is leaking.

Exchange the diaphragm. See page 83 for details.

Further details can be found in the instructions for the components.

Performing Maintenance




WARNING

Working overpressure

Danger of bodily injury

► Switch off the hydraulic system before performing any maintenance work and depressurize the system.

The safety of all persons coming into contact with the unit and the availability of the unit for use are dependent on regular servicing and maintenance. All pictures and descriptions given in these instructions are examples. These examples do not represent all of the different product variants.




Maintenance intervals The inspection and maintenance work listed here is a necessary condition for ensuring both long service life and error-free operation of the unit.

See

pag

e

24 h

ours

/ da

ily

500

hour

s /

mon

thly

3000

hou

rs /

ever

y si

x m

onth

s

6000

hou

rs /

annu

ally

Unit

Check the unit for leaks (visual check). - X

Check the screwed fittings to see that they have been properly resecured.

- x

Check the pressure sensor on the degassing unit and the fill level and temperature sensors

- X

Replacing the breather filter 64 X

Clean the suction strainer. - X

Check the AquaSensor (optional) 82

Check the ContaminationSensor (optional) 82

Diaphragm

Checking the diaphragm (visual check) - X

Replace the diaphragm. For life cycle, see chapter "Technical Data" on page 101

83

OLF 5 bypass flow filtration unit

Clogging indicator (visual) X

Changing the filter element 66

Protective screen (optional) 70 X

Suction screen 72 X

Heat exchanger (optional)




See

pag

e

24 h

ours

/ da

ily

500

hour

s /

mon

thly

3000

hou

rs /

ever

y si

x m

onth

s

6000

hou

rs /

annu

ally

Cleaning the heat exchanger 79 X

Return line filter (optional)

Changing the filter element 80 X

Electrical installation

Check the cables and cable conduits for damage. (Visual inspection)

- X

Synchronize the electricity consumption of the motors by measuring with the nominal values on the name plates.

- X

Perform an electrical safety inspection in accordance with DIN VDE 0702 and/or corresponding national regulation.

- X

After five years replace all the unit's hoses.




Filling the hydraulic tank with oil (first filling/oil change) This chapter describes how to fill the hydraulic tank for commissioning / oil change or maintenance via the OLF 5 bypass flow filtration unit (2.1). Filling through the OLF 5 bypass flow filtration unit (2.1) ensures that the hydraulic oil is always filled with clean, filtered oil. As an alternative, fill the hydraulic tank with an external filling pump through the port (B.08) or through a suitable port on the tank. Ensure that only clean, filtered oil is filled in, during which the selector valve (4.7) is to be found at position (a) and the screw plug (B22) is screwed out in accordance with the instruction contained in Step 1. Then follow the procedures beginning with Step 7.

NOTICE

Filling the unit via the breather filter

The unit/the breather filter will be damaged

► Do not fill the unit via the breather filter (6.4).




To fill the hydraulic tank via the OLF 5 bypass flow filtration unit (2.1), proceed as follows:

1. Fully unscrew screw plug (B.22) to bleed air from the hydraulic tank. Optional: Unscrew the screw plug (Z1) on the "Connection kit for rapid bleeding for OXS" and open the ball valve (Z2) (see also page 62).

2. Unscrew the screw plug (B.08) on the valve block (connection B08). Mount a suction hose to this connection (G ¾") and insert the other end into an unpressurized external oil container to suck out the oil.

3. Open the selector valve (4.7) by switching from position (a) to position (b).

4. Move all working cylinders to a position in which they are filled with the least amount of oil.

5. Switch on the OLF 5 bypass flow filtration unit (2.1) on. The oil is now pumped into the hydraulic tank. Fill the hydraulic tank up to the

marking on the fluid level indicator (7.24).

6. Close the selector valve (4.7) by switching from position (b) to position (a).

7. Start the hydraulic system with a low fluid flow rate and a low system pressure. This gives the air bubbles in the tank sufficient time to rise. We recommend: - each 100 liters of tank volume ≈ differential flow rate < 30 l/min - each 1000 liters of tank volume ≈ differential flow rate < 300 l/min Bleed air from the hydraulic system by moving each individual working cylinder back and forth several times in succession. Operate the components, e.g. hydraulic motors or cylinders, at reduced speed.

8. During the topping up process, return the working cylinders to the same initial position they were in before filling. Define and document the positions of working cylinders, hydraulic accumulators, etc., by means of markings or notes on the hydraulic system for subsequent fluid level monitoring.




9. Switch off the system as soon as the oil level reaches the

mark in the hydraulic tank. Move the cylinder into the marked initial position and top it off with oil up to 2/3 full. If necessary, repeat the step several times until the whole hydraulic system is filled with sufficient oil.

10. Once the hydraulic system has been filled and adequately bled of air,

close the breather fitting (B.22) on the unit. Remove the hoses that were attached for the filling procedure, move the selector valve (4.7) on the valve block to position (a) and start the OLF 5 bypass flow fluid filtration unit (2.1).

11. To bleed the OLF 5 bypass flow filtration unit (2.1), mount a 1602 measurement hose to the gauge port (2.7) on the cover of the OLF 5 bypass flow filtration unit (2.1). Insert the other end into the unpressurized external oil container. Switch the filtration unit (2.1) on. If oil escapes at the open hose end but no air or air bubbles, unscrew the measurement hose and switch the OLF 5 bypass flow filtration unit (2.1) off.

12. The free air trapped in the hydraulic tank will be suctioned off at the start with the aid of the degassing unit. This will cause the oil level in the hydraulic tank to rise. Depending on the size of the hydraulic tank and its design and geometry, the suctioning off of the free air will take ≈ 1 hour or longer. Once the free air has been removed, the degassing of the air that is dissolved in the oil begins. The diaphragm is now completely up against the walls of the diaphragm cage. The pressure displayed on the pressure sensor then drops below the 500 mbar limit.

13. Slowly increase the nominal flow and the system pressure up to the required operating conditions. Note that the oil level in the fluid level indicator (7.24) must be within

the markings / .




If the oil level reaches the mark , top up with more oil; for details, see the chapter "Refilling the hydraulic tank with oil" on page 55.

If the mark is reached, drain oil off, for details, see chapter "Partially emptying the hydraulic tank" on page 57.

14. The filling of the hydraulic tank is completed.




Refilling the hydraulic tank with oil This chapter describes how to refill the hydraulic tank via the OLF 5 bypass flow filtration unit (2.1). Note that initial filling comes before refilling and that no intake of air caused by the opening of screw plugs, etc. is desirable.

NOTICE

Filling the unit via the breather filter

The unit/the breather filter will be damaged

► Fill the unit exclusively via the filling valve.




To refill oil in the hydraulic tank, proceed as follows:

1. Unscrew the screw plug (B.08) on the valve block). Mount a suction hose to this connection (G ¾") and insert the other end into an unpressurized external oil container to suck out the oil.

2. Open the selector valve (4.7) by switching from position (a) to position (b).

3. Move all working cylinders to a position in which they are filled with the least amount of oil.

4. Switch on the OLF 5 bypass flow filtration unit (2.1) on. The oil is now pumped into the hydraulic tank. Fill the hydraulic tank up to the

marking on the fluid level indicator (7.24).

5. Close the selector valve (4.7) by switching from position (b) to position (a).

6. To bleed the OLF 5 bypass flow filtration unit (2.1), mount a 1602 measurement hose to the gauge port (2.7) on the cover of the OLF 5 bypass flow filtration unit (2.1). Insert the other end into the unpressurized external oil container. Switch on the OLF 5 bypass flow filtration unit (2.1) on. If oil escapes at the open hose end but no air or air bubbles, unscrew the measurement hose and switch off the OLF 5 bypass flow filtration unit (2.1).

7. The refilling of the hydraulic tank is completed.




Partially emptying the hydraulic tank This chapter describes how to partly empty the hydraulic tank via the OLF 5 bypass flow filtration unit (2.1), e.g. with overfilling, etc.




Empty the tank partially as follows:

1. Unscrew the screw plug (B.09) on the valve block. Mount a return hose to this connection (G ½") and insert the other end into an unpressurized external oil container to collect the oil.

2. Switch on the OLF 5 bypass flow filtration unit (2.1) on. The oil is pumped out of the hydraulic tank by the valve block. Dispose of the oil that has been drained in an environmentally friendly manner.

3. Remove only enough oil for the oil level in the fluid level indicator

(7.24) to be within the markings / .

4. Screw all screw plugs back in place.

5. The partial emptying of the hydraulic tank is now complete.




Completely emptying the hydraulic tank for transport, oil change, etc. This chapter describes how to completely empty the hydraulic tank for transport, oil change or maintenance via the OLF 5 bypass flow filtration unit (2.1).

Empty the hydraulic tank along with the components without the degassing unit as follows:




1. Fully unscrew the screw plug (B.22) on the valve block to bleed air from the hydraulic tank.

2. Drain the components, e.g. the OLF 5 bypass flow filtration unit (2.1), heat exchanger with pump and return line filter at the respective drain plugs.

3. Unscrew the screw plug (B.09) on the valve block). Mount a return hose to this connection (G ½") and insert the other end into an unpressurized external oil container to collect the oil.

4. Switch on the OLF 5 bypass flow filtration unit (2.1) on. The oil is pumped out of the hydraulic tank by the valve block. Dispose of the oil that has been drained in an environmentally friendly manner.

5. Once the oil has stopped emerging, switch off the OLF 5 bypass flow filtration unit (2.1) and empty the hydraulic tank completely through the drain plug (7.55) on the tank. Make sure that ≈ 1.5 liters of oil remain in the degassing unit (3.1). The degassing unit must be dismantled before it can be emptied.

6. Screw all screw plugs back in place.

7. The emptying of the hydraulic tank and its components without degassing unit is now complete.




Emptying the degassing unit The degassing unit (3.1) holds ≈ 1.5 l oil.

Empty the degassing unit as follows:

1. Unscrew the screw plug (X) for emptying completely.

2. Collect the escaping fluid in a suitable container and dispose of it in an environmentally friendly manner.

3. After the unit is empty, screw the screw plug (X) back in again.

4. The draining of the degassing unit is completed.




Manual bleeding during commissioning (accessories) The free air can be removed rapidly from the tank during commissioning with the aid of the "Connection kit for rapid bleeding for OXS"

Ball valve "closed" Ball valve "open" 1. Fully unscrew the screw plug (B.22) on the valve block to bleed air

from the hydraulic tank and apply the "Connection kit for rapid bleeding for OXS" at this position.

2. Unscrew the screw plug (Z1) on the connection kit completely and open the ball valve (Z2).

3. Attach an air pump to the free end of the ball valve (G 1/2). 4. Use the air pump to remove the free air until an oil column has

formed in the sight glass (Z3). 5. Close the ball valve (Z2). 6. Reattach the screw plug (Z1).




Checking the clogging indicator on the breather filter The OLF 5 bypass flow filtration unit is equipped with an optical clogging indicator (6.45) for monitoring the degree of contamination.

Exchange the filter element when the clogging indicator displays 50 mbar. See page 64 for details.




Replacing the breather filter element Change the filter element at the breather filter at the same intervals as for the filter element at the bypass flow filter unit OLF 5, although at least once a year. If the unit is in a very dusty/damp environment, the replacement intervals shorten accordingly. Replace the filter element of the breather filter as follows:

1. Unscrew cover (6.41) of the breather filter by hand in counterclockwise

direction. 2. Remove used filter element (6.42) and dispose of it in an

environmentally correct manner. 3. Insert new filter element (6.42) and screw on cover (6.41) by hand in

clockwise direction. 4. Press the reset button on the clogging indicator (6.45)




Checking the visual clogging indicator of the fluid filter The OLF 5 bypass flow filtration unit is equipped with an optical or electric clogging indicator for monitoring the degree of contamination. Replace the filter element when the red marking becomes visible in the clogging indicator. For details, refer to chapter "Replace the filter element on the OLF 5 bypass flow filtration element" on page 66.




Replace the filter element on the OLF 5 bypass flow filtration element Replace the filter element as described below:

1. Switch off the system and ensure that it will not be possible for the unit to be switched back on during the maintenance work. Perform a depressurization of the filter housing. To do this, attach a measurement hose to the measurement connection on the filter housing cover.

Be careful when the operating medium flows out

2. Put a suitable container in place to catch the operating medium to be found in the filter housing. The volume is approx. 3 liters. Empty the filter housing through the drain plug (Drain) on the connector.

Without the proper drainage equipment, the draining fluid can flow down to the electric motor.

3. Loosen the tensioning clamp on the filter housing cover by completely unscrewing the nut. Remove the housing clamp.

4. Pull off the filter bowl cover carefully in

an upwards direction. While doing so, rotate it slightly clockwise so that the filter element remains engaged at the cover. Turn counterclockwise to detach the dirt catch tray from the element and the element from the cover.




5. Remove the dirt catch tray.

6. Remove the filter element from the filter

housing cover. Dispose of the old filter element according to local regulations and guidelines.

7. Clean the removed parts and examine

them for any possible damage. Check the O-ring on the filter bowl cover for damage. Replace it if necessary. Moisten the O-rings on the filter bowl cover and on the new filter element with operating medium.

Never use grease or other media.

8. Now place the filter bowl cover on the new filter element and lock it in place.




9. Fasten the dirt catch tray to the bottom end of the filter element.

10. Lift the filter element with the cover and

dirt catch tray into the filter housing. Observe correct placement of the O-ring on the cover while doing so.

11 Fasten the cover with the tension clamp.

The tightening torque is a maximum of 5 Nm.

12. Tighten the drain plug (Drain) on the

connection part of the unit. Switch on the OLF 5 bypass flow filtration unit on. Bleed air from the filter housing via the measurement connection in the filter cover.

13. If the bypass flow filtration unit has a

ContaminationSensor on the OLF 5 bypass flow filtration unit, replace the protective screen – for details, refer to chapter "Replacing the protective screen on the OLF 5 bypass flow filtration unit (optional)" on page 70.

14. Clean the suction strainer – for details, refer to chapter "Clean/replace the suction strainer on the OLF 5 bypass




flow filtration unit" on page 72.

15. Fill the tank with the same volume that you removed to change the filter element. For details, refer to chapter "Refilling the hydraulic tank with oil" on page 55.

16. Check the fluid filter for leaks while in operation. Eliminate any leakages immediately.

17. The filter element replacement on the OLF 5 bypass flow filtration unit is now complete.




Replacing the protective screen on the OLF 5 bypass flow filtration unit (optional)

NOTICE

Protective screen missing / operation without the protective screen

The ContaminationSensor clogged / blocked

► Never operate the unit without a protective strainer. ► Replace the protective strainer regularly.

A protective strainer is installed upstream from the ContaminationSensor to protect it from blockage. Exchange the protective screen regularly depending on the contamination level of the oil.

Item Designation

CS.1 Protective strainer, 100 µm

CS.2 O-ring




To replace the protective screen, proceed as follows:

1. Switch off the unit/all components.

2. Empty the OLF 5 bypass flow filtration unit, as described in chapter "Replace the filter element on the OLF 5 bypass flow filtration element" on page 66.

3. Loosen the screw connection and remove protective strainer (CS.1) between the two O-rings (CS.2).

4. Dispose of protective strainer (CS.1) in an environmentally friendly manner.

5. Insert a new protective strainer (CS.1) between the two O-rings (CS.2).

6. Screw together the connector and fasten it tightly.

7. The replacement of the protective screen is now complete.




Clean/replace the suction strainer on the OLF 5 bypass flow filtration unit

NOTICE

Suction strainer missing / operating without a suction strainer

ContaminationSensor, MOX, pump blocked/clogged

► Never operate the unit without a suction screen. ► Clean the suction strainer regularly

A suction strainer is installed upstream to prevent the pump from becoming blocked. Clean or replace the suction strainer regularly.

Item Designation

2.41 O-ring

2.42 Suction strainer, 320 µm

2.5 Hose assembly




To clean/replace the suction strainer, proceed as follows:

1. Switch off the unit/all components.

2. Empty the OLF 5 bypass flow filtration unit, as described in chapter "Replace the filter element on the OLF 5 bypass flow filtration element" on page 66.

3. Loosen hose assembly (2.5) and remove the suction strainer (2.42).

4. Clean the suction strainer (2.42) by washing it out and then blowing it out with compressed air. Wear gloves and safety goggles.

5. Insert the clean/new suction strainer (2.42) with the O-ring (2.41).

6. Screw together the connector and fasten it tightly.

7. Cleaning/exchanging the suction strainer is now complete.




Bleeding the OLF 5 bypass flow filtration unit

WARNING

Hot fluid

Risk of burns

► Make sure that hot fluid can exit when bleeding.

NOTICE

Air in the OLF 5 bypass flow filtration unit

The filter element is not utilized completely

► Bleed air from the OLF 5 bypass flow filtration unit after each standstill / filter element replacement, protective screen replacement.

Bleed air from the fluid filter via measurement connection (2.7) until fluid begins to escape. To do this, attach a measurement hose (1602) to measurement connection (2.7) and place the other end of the hose in a catch tank for the oil.




Checking/setting the electronic pressure switch (EDS) Before the unit is started up, and every time the electronic pressure switch EDS has been replaced, check the settings in accordance with the following specifications.

Check or configure the electronic pressure sensor EDS with the following alarm settings:

Alarm 1: Error MOX (when a pressure higher than 1200 mbar is reached over a period of 99.99 s) -

-> 1200 mbar

-

-> 15 mbar

Alarm 2: Free air in the tank (when a pressure higher than 450 mbar is reached over a period of 25 s) -

-> 450 mbar

-

-> 15 mbar




Check or configure the electronic pressure sensor EDS with the following factory settings:

Display Possible values Setting

SP Win

SP

SP Win

SP

ON OFF

ON

ON OFF

ON

0.00 … 99.99 99.99

0.00 … 99.99 25

0.00 … 99.99 0

0.00 … 99.99 0

ACT Top

S.P.1 S.P.2 OFF

ACT

0 … 300 0

SLOW MEDI FAST

Fast

BAR PSI Mpa

FREE

Free

0 … 0.000 0.0

-999 … 9899 0.0

-899 … 9899 2500

MAMP VOLT

MAMP

YES NO

Nein




Check / adjust electronic level / temperature sensor HNS The unit is equipped with a float-based sensor with an integrated fluid level/temperature sensor.

The operating principle of the fill level sensor and range of the differential operating volume is shown in the following illustration and table. Check the fluid level/temperature sensor HNS. The settings are dependent on the OXS size. Details on setting the sensor can be found in the corresponding instructions.




OXS-LID

Maximum oil level Hi.1

Minimum oil level Lo.1

D G LS

30 31.5 cm 7.6 cm 362 mm 5 mm 520 mm

45 42.5 cm 7 cm 472 mm 5 mm 630 mm

70 63.5 cm 7 cm 682 mm 5 mm 840 mm

Item Designation D Height of the diaphragm cage G Thickness of the assembly plate LS Special length of HNS S Safety buffer X Diaphragm/float swing path




Performing maintenance on the heat exchanger (optional)

WARNING

Hot surfaces

Risk of burns

► Allow the heat exchanger to cool down before performing any work.

When a variety of oils are used, a coating may form on the plates of the heat exchanger. Check and clean the soiled plates regularly. Details can be found in the corresponding instructions for the heat exchanger.




Changing the filter element of the return line filter (optional) This section describes how to change the filter element of the return line filter. Size NF330-750 is used as an example:

Item Designation

NF.1 Filter housing cover

NF.2 Filter element

NF.3 O-ring

NF.4 Air bleed plug [Air bleed]

NF.5 Drain plug




To change the filter element of the return line filter, proceed as follows:

1. Switch off the hydraulic system and close the shut-off devices for the hydraulic system to prevent oil from flowing back out of the system.

2. Relieve pressure by fully unscrewing screw plug (NF4).

3. Drain the filter housing via drain plug (NF.5). Collect the escaping oil in a suitable container.

4. Remove used filter element (NF.2) and dispose of it in an environmentally correct manner.

5. Insert the new filter element (NF.2).

6. Check the O-ring (NF.3) for damage. Replace it if necessary.

7. Refill the oil that was removed.

8. Screw the cover (NF.1) onto the filter housing all the way finger-tight and then turn it 90° backward.

9. Open the shut-off device for the hydraulic system.

10. Switch on the hydraulic system.

11. Check the filter housing for leaks.

12. The filter element change on the return line filter is now complete.




Recalibrating the ContaminationSensor For recalibration, send the ContaminationSensor to an establishment authorized by HYDAC. For details, see the instructions for the ContaminationSensor.

Testing the AquaSensor AS Check the AquaSensor annually with the calibration and adjustment set. The Part no. for ordering can be found in the spare parts list. You can find further information in the calibration and adjustment set instruction manual. Replace the AquaSensor if it exhibits great deviations.




Replacing the diaphragm The service life of the diaphragm is dependent on the fluid temperature – for details see chapter "Technical Data" on page 101. Replace the diaphragm after the specified time to avoid malfunction.

Removing the diaphragm




To remove the diaphragm, proceed as follows:

1. Switch off the unit and all its components.

2. Drain the unit completely – for details see the chapter "Completely emptying the hydraulic tank for transport, oil change, etc." on page 59.

3. Remove the piping between valve block and diaphragm cover (6.2). Loosen all nuts (6.6) and washers (6.5) of the diaphragm cover (6.2).

4. Take the diaphragm cover (6.2) off.

5. Remove diaphragm (6.1) from the diaphragm cage and dispose of it in an environmentally correct manner.

6. The removal of the diaphragm is now complete.

Installing the diaphragm




To install the diaphragm proceed as follows:

1. Clean sealing surface (X) of diaphragm (6.1) completely. The sealing surface must be free of old sealant residue.

2. Apply a thin, even layer of HYLOMAR M sealant around sealing surface (X). The part no. can be found in the spare parts list.

Observe the bleed time in accordance with the operating instructions. Use exclusively the recommended sealant to seal the diaphragm. This is the only way to ensure material compatibility.

3. Insert the new diaphragm (6.1) through the opening in the tank and

Taking the unit out of operation



align it.

4. Now pull the sealing collar of diaphragm (6.1) carefully and evenly over the threaded bolts. Smooth down the sealing material under the sealing collar, working carefully from the inside to the outside.

No sealant is permitted in the working area of the diaphragms. Sealant in the working area of the diaphragms leads to malfunctions and damage to the unit.

5. Put the diaphragm cover (6.2) on.

6. Attach washers (6.5) to all threaded bolts and screw the nuts (6.6) onto the threaded bolts by hand in a clockwise direction.

Always use new locknuts. When locknuts are reused, they will no longer provide a complete clamping effect.

7. Tighten nuts (6.6) crosswise with a maximum torque of 8 Nm.

8. Mount the pipe of the valve block and tighten it firmly.

9. Fill the unit as described in chapter "Filling the hydraulic tank with oil (first filling/oil change)" on page 50.

10. Start up the unit and watch out for any leaks. Eliminate leakages immediately.

11. The installation of the diaphragm is now complete.





Empty the unit completely, including all of its components, before putting it out of service, as described on page 57. Disconnect all electrical and hydraulic connections from and to the unit. Store the unit in a clean, dry (non-condensing) space.

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.

Customer Service/ Service



Customer Service/ Service

For product information or technical support or if you have comments or suggestions concerning this manual, please contact: HYDAC FILTER SYSTEMS GMBH Justus-von-Liebig Straße, Plant 20 66280 Sulzbach / Saar Germany Phone: +49 (0) 6897 509 1174 Fax: +49 (0) 6897 509 9046 E-mail: [email protected] Our HYDAC Servicenter offers you these tasks within agreed-upon time frames and at fixed prices. HYDAC SERVICE GMBH Friedrichstaler Straße 15a, Werk 13 66540 Neunkirchen-Heinitz Germany Phone: +49 (0) 681 509 883 Fax: +49 (0) 681 509 324 E-mail: [email protected]

Spare parts list



Spare parts list

Only use original spare parts and accessories to ensure safe and reliable operation of the unit. When ordering spare parts, always provide the complete designation (type, part no., serial no., year of construction).

Spare parts list



Spare parts list



Item Designation Part no.

2.1 OLF-5/10-TV-370-N-Z-BM/-10 OLFCM-5/10-TV-370-N-Z-BM/-ACD-10

Without filter element

4376254 4376344

2.4 Screw connection NBR 607723

2.41 O-ring NBR 604073

2.42 Suction screen 37575

2.5 Hose assembly NBR 6181412


2.65 Hose assembly NBR 6130504

2.7 Threaded coupling NBR 680107

3.1 MOX-1-N/-OXS NBR 3519092

3.7 Washer 6112446

3.8 Hex. Nut ISO7040 6094509



5.15 Coupling nut 608399

5.2 Cutting ring 1.4571 6030713


5.35 Coupling nut 608397

5.4 Cutting ring 1.4571 6107260


5.6 Cutting ring 1.4571 6058071


6.3 Sight glass 6148924

6.4 Breather filters BF 7 1279472

6.5 Washer 6112446

6.6 Hex. Nut ISO7040 6094509

7.15 Flat gasket for OXS-30/45/70 NBR 4251854

7.24 Visual fluid level indicator See accessories

Page 98

Spare parts list



7.25 Bolt, M12 3925870

7.50 Sealing plugs 607168


7.60 Hex. Nut ISO7040 6094509

7.65 Washer 6112446

7.70 Hex. Screw 6047698

9.20 Screw connection 607724


9.24 Hose assembly 4047901

9.28 SAE flange half 6028784

9.30 Washer 602787

9.32 Screw 626430

9.34 Washer 6112446

9.36 Hex. Screw 6112528

9.38 Damper, top 6152949

9.40 Damper, bottom 6152950

9.42 Screw 6094383






Spare parts list



Item Designation p/no.

S1 Replacement diaphragm set, comprised of: 1x diaphragm 1x HYLOMAR M sealing compound (80 ml) 1x assembly set

Replacement diaphragm set to OXS-30 4228462



S2 Replacement valve block set, comprised of: 1x valve block 1x suction tube 1x suction tube 1x change-over valve 1x non-return valve 1x seal 1x screw set Without HNS

Replacement valve block set for OXS-30 4228500



S3 Replacement console set, comprised of: 1x console 4x buffer 1x screw set

4228808

S4 EDS with port set for MOX, comprised of: 1x EDS 1x connector set

4228180

S5 Return line filter fastening set for OXS, comprised of: 1x console 1x mounting flange 1x screw set

Return line filter fastening set for NF160/240/280 4258525

Return line filter fastening set for NF330/500/750 4258527

Spare parts list



S6 Plate heat exchanger fastening set for OXS, consisting of: 1x heat exchanger holder for OXS 1x HRGBLPU 25 HEX-615 mounting element 1x screw set

4258324


OXS-LID primary body to OXS-30 4246254



5.93 Fluid level/temperature sensor HNS, without default settings

HNS 312P-8 for OXS-30 924538

HNS 312P-8 for OXS-45 924843

HNS 312P-8 for OXS-70 924844

6.2 Diaphragm cover, suitable for BF7 breather filter

Diaphragm cover for OXS-30/45/70 3864552

7.1 Tank

Tank for OXS-30 4253261



8.10 return line filter

NF 160 D E XX A 2.0 /-RV0.2 1282829

NF 240 D E XX A 2.0 /-RV0.2 1282831

NF 280 D E XX A 2.0 /-RV0.2 1282242

NF 330 D K XX A 2.0 1287340

NF 500 D K XX A 2.0 1286367

NF 750 D K XX A 2.0 1295173

9.15 HYDAC HEX S615 plate heat exchanger

HYDAC HEX S615, 20 plates 3366788

HYDAC HEX S615, 40 plates 3366792

Spare parts list



Designation Material p/no.

Sealing compound HYLOMAR M 3947926

OLF 5 bypass flow filtration unit

Filter element, 2 µm N5DM002 FKM 349494




AquaSensor (AS) AS 3008 NBR 922591

ContaminationSensor (CS) CS1320 FKM 3332066

Clogging indicator (VA) VM 2 BM.1 /-V FKM 303200

Protective screen (CS.1) 558230

O-ring (CS.2) FKM 635966

AquaSensor

Calibration/adjustment set 3122629

Breather filters BF7

Breather filter element (6.42) 310948

return line filter NF

Filter element, 3 µm *




Heat exchanger

Motor-pump assembly (9.10) *

*) on request

Accessories



Accessories

We provide the following fluid level displays as accessories for the unit:

Not that the upper connector (7.25) needs to be glued in.

Accessories



Item Designation Part no.

7.25 Bolt, M12 3925870

- Fill level indicator set for OXS-30, comprised of: 1x fluid level indicator (7.24), L = 381 mm 1x bolt (7.241) 2x sealing washer (7.242) 1x bolt (7.25)

4071801


4073619


4073620

Accessories



We offer the following connection kit as an accessory for the unit:

Part no. Designation

4243219 Connection kit for rapid bleeding for OXS

Technical Data



Technical Data

The unit has the following technical data: Hydraulic data

Differential Volume

Reservoir volume

OXS 30 ≤ 30 l 110 l OXS 45 ≤ 45 l 135 l OXS 70 ≤ 70 l 185 l

Permitted operating fluids Mineral oils acc. to DIN 51524

Typical gas removal rate 4 l/h

Permissible viscosity range 15 … 300 mm/s² 15 … 200 mm/s² with OLFCM

Maximum fluid flow rate (depending on return filter NFxxx)

≤125 l/min @ NF 160 ≤125 l/min @ NF 240 ≤125 l/min @ NF 280 ≤450 l/min @ NF 330 ≤450 l/min @ NF 500 ≤450 l/min @ NF 750 ≈ 900 l/min o return line filter

Permitted fluid temperature range 10 - 80°C

Electrical data

Power supply, frequency See name plate on the electric motors

Wattage See name plate on the electric motors

Protection class to DIN 40050 See name plate on the electric motors

Technical Data



General data

Sealing material NBR

Diaphragm material PUR

Typical lifetime of the diaphragm* (dependent on the fluid temperature)

≈ 6 years @ ≤60°C fluid temperature ≈ 2 years @ ≥60°C fluid temperature

Permissible ambient temperature range**

–20 to 40 °C

Permitted storage temperature range

0 … 40 °C

Relative humidity 0 … 80%, non-condensing * depending on the operating materials used and the degree of dynamic load, the service life of the diaphragms can become considerably shortened ** valid for an installation height < 1000 m above sea level

Model code



Model code

The unit is ordered in accordance with the following model code: OXS - 30 - N - 1 - Z - Z - 2 - 2 - ACD - /- Product OXS = OXiStop Differential Volume 30 = Differential operating volume

≤30 l

45 = Differential operating volume ≤45 l

70 = Differential operating volume ≤70 l

Voltage/frequency/power supply N = 400 V AC / 50 Hz / 3 Ph Sealing material / diaphragm material 1 = Sealing material NBR

diaphragm material PUR

return line filter 1 = NF 160 2 = NF 240 3 = NF 280 4 = NF 330 5 = NF 500 6 = NF 750 Z = No return line filter installed Plate heat exchanger 1 = 20 plates/vane pump 2 = 40 plates/vane pump Z = No plate heat exchanger installed Negative pressure monitoring 1 = Pressure gauge, visual 2 = Pressure sensor, electric Fluid level/temperature monitoring 2 = Fluid level/temperature sensor, electric

fluid level indicator, visual

Instrumentation ACD = AquaSensor AS + ContaminationSensor CS Z = No measurement equipment installed Supplementary details - = Series

Index



Index

A

Accessories .......................................................... 98 accident prevention ........................................ 10, 14 ambient temperature .............................. 19, 32, 102 AquaSensor ............... 25, 27, 36, 42, 48, 82, 97, 103 Auxiliary personnel ............................................... 13

B

bleeding .................................25, 27, 52, 62, 74, 100 Breather filter ...................................... 25, 27, 93, 97

C

Calibration ............................................................ 97 care .............................................................. 2, 6, 16 Cause ................................................................... 45 change-over.......................................................... 95 Changing the filter element ....................... 48, 49, 80 Clogging indicator ............................... 25, 27, 48, 97 Connection ................................. 25, 27, 52, 62, 100 ContaminationSensor . 25, 27, 36, 43, 48, 68, 70, 72,

82, 97, 103 Content ................................................................... 3

D

default setting ....................................................... 96 degassing . 11, 21, 22, 25, 27, 31, 37, 38, 39, 45, 48,

53, 59, 60, 61 depressurization ................................................... 66 Description................................................ 18, 19, 21 dewatering ...............................11, 21, 25, 27, 31, 37 Dimensions ........................................................... 29 DIN ......................................................... 11, 49, 101 Display .................................................................. 76 Disposal ................................................................ 13 Documentation Representative .............................. 2 drain plug ............................................ 60, 66, 68, 81 Drain plug ............................................................. 80 draining ........................................................... 61, 66

E

Electrical data ..................................................... 101 Empty weight ........................................................ 19 emptying ............................ 53, 57, 58, 59, 60, 61, 84 Error ............................................................... 45, 75

F

filling .................................. 44, 50, 52, 53, 54, 55, 86 Filter ......................................................... 12, 80, 97

Filter element .................................................. 80, 97 Filter housing ........................................................ 80 Filter housing cover .............................................. 80 filtration ..... 18, 25, 27, 31, 33, 36, 44, 45, 48, 50, 52,

53, 55, 56, 57, 58, 59, 60, 63, 65, 66, 68, 69, 70, 71, 72, 73, 74, 97

H

Hazard symbol ................................................. 8, 10 Hydraulic connection ...................................... 25, 28 Hydraulic data .................................................... 101 Hydraulic diagram................................................. 26

I

Imprint .................................................................... 2 installation ................................... 20, 32, 49, 86, 102

M

Maintenance ..........................................1, 13, 47, 48 Maintenance interval ............................................ 48 Maintenance intervals........................................... 48 Measures .............................................................. 10 measuring ............................................................. 49 Mineral oil ........................................................... 101 Model code ................................................... 18, 103 mounting ......................................................... 95, 96

O

OFF ...................................................................... 76 Oil level ................................................................. 45 operating .. 6, 7, 8, 11, 13, 14, 19, 22, 23, 32, 41, 53,

66, 67, 72, 77, 85, 101, 102, 103 operating fluids ................................................... 101 Operation ........................................................ 12, 13 Operations control ................................................ 13

P

Pressure gauge .......................................25, 27, 103 Pressure sensor ......................................25, 27, 103 Protection class .................................................. 101 Publisher ................................................................ 2

R

Relative humidity ................................................ 102 Remedy ................................................................ 45 replacement .........................................64, 69, 71, 74 report .................................................................... 20

Index



return line filter ...... 18, 25, 27, 30, 60, 80, 81, 96, 97, 101, 103

S

SAE ................................................................ 30, 94 Sealing plug .......................................................... 94 select ...................................................................... 7 Service ................................................................. 88 setting ................................................. 32, 44, 75, 77 Signal word ....................................................... 9, 10 signal words.......................................................... 10 Size ...................................................................... 80 Spare part ............................................................. 89 Spare parts ........................................................... 89 Spare parts list ...................................................... 89 Specialist personnel ............................................. 13 Suction screen .......................................... 27, 48, 93

T

Time ..................................................................... 38 Transport .............................................................. 13 transporting .......................................................... 13 Troubleshooting .............................................. 13, 45 Type label ............................................................. 18

V

Viscosity ............................................................... 19

W

Weight .................................................................. 19

HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 9046 Technical Department Fax: +49 (0) 6897 509 577 Sales Internet: www.hydac.com E-mail: [email protected]

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