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

Hydac OLS 10-Z Series Installation And Maintenance Instructions Manual

Offline separator with automatic water drainage
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OLS 10-Z-x
OffLine Separator
(with automatic water drainage)
Installation and Maintenance Instructions
English (translation of original instructions)
Document No. : 4573340
Follow these instructions for proper and safe use.
Keep for future reference.

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Summary of Contents for Hydac OLS 10-Z Series

  • Page 1 OLS 10-Z-x OffLine Separator (with automatic water drainage) Installation and Maintenance Instructions English (translation of original instructions) Document No. : 4573340 Follow these instructions for proper and safe use. Keep for future reference.
  • Page 2 Executive directors: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative The contact data of the person authorized with the documentation is: Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Germany Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-Mail: guenter.harge@hydac.com...

  • Page 3: Table Of Contents

    HYDAC FILTER SYSTEMS GMBH Table of Contents Table of Contents 1 General.......................... 6 1.1 Target group of the manual.................. 6 1.2 Illustrations in the manual ................... 7 1.2.1 Illustration on the title page................ 7 1.2.2 Representation of requirements ................  8 1.2.3 Representation of procedural instructions ............ 8 1.2.4 Representation of intermediate results/results ..........
  • Page 4 Table of Contents HYDAC FILTER SYSTEMS GMBH 3.7 Hydraulic diagram ..................... 32 3.8 Components...................... 33 4 Transportation / Storage.................... 34 5 Assembly/Installation...................... 35 5.1 Mounting the drip tray (accessory)................ 35 5.2 Setup and mounting .................... 35 5.3 Connecting the hydraulics.................. 35 5.3.1 Connecting the suction port – INLET OIL ............ 36 5.3.2 Connecting the pressure port –...
  • Page 5 HYDAC FILTER SYSTEMS GMBH Table of Contents 9.2 Final Decommissioning ..................... 51 9.3 Disposal/Recycling.................... 51 A Appendix...........................  52 A.1 Contacting Customer Service ................... 52 A.2 Finding spare parts and accessories ................ 53 A.2.1 Spare parts ......................  53 A.2.1.1 Coalescing elements ................ 53 A.3 Documentation regarding the components ............... 53 Glossary ...........................

  • Page 6: General

    1 | General HYDAC FILTER SYSTEMS GMBH 1 General Before you use this product for the first time, read this manual at least up to the chapter "Operation". If you would like to carry out maintenance or troubleshooting, you can find the procedure in the respective chapters.

  • Page 7: Fig. 1 Overview / Labeling Of The Title Page

    HYDAC FILTER SYSTEMS GMBH General | 1 1.2 Illustrations in the manual You will find illustrations in this manual. You can find details re- garding these in the following chapters. 1.2.1 Illustration on the title page You will find the following information on the title page of this man-...

  • Page 8: Representation Of Requirements

    1 | General HYDAC FILTER SYSTEMS GMBH The document no. with the index (4) is meant for identifying and reordering the manual. The index is incremented every time the manual is revised or changed. The manual contains a table of contents, a list of tables and fig- ures, an index and a glossary.

  • Page 9: Representation Of Intermediate Results/Results

    HYDAC FILTER SYSTEMS GMBH General | 1 1.2.4 Representation of intermediate results/results In the case of some activities, it is necessary to carry out work steps with intermediate results and end results. Intermediate results are the consequence of activities; they are marked with an indented arrow.

  • Page 10: Supplementary Symbols

    1 | General HYDAC FILTER SYSTEMS GMBH 1.2.5 Supplementary symbols You will find the following symbols in the manual as additional de- tails: [▶   ] Cross reference to a page / a chapter / a section or another document. Glossary Terms in grey font are explained in the glossary.

  • Page 11: Signal Words And Their Meaning In The General Safety Information

    HYDAC FILTER SYSTEMS GMBH General | 1 1.2.7 Signal words and their meaning in the general safety information In these instructions you will find the following signal words: 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.

  • Page 12: Exclusion Of Liability/Warranty

    1 | General HYDAC FILTER SYSTEMS GMBH 1.3 Exclusion of liability/warranty For the warranty provided by us, please refer to the Terms of De- livery. They are made available to you at the conclusion of the contract at the latest. You will also find these under www.hydac.com ->...

  • Page 13: Safety

    HYDAC FILTER SYSTEMS GMBH Safety | 2 2 Safety The product is designed as safe. In spite of that, there is danger in some actions that can only be avoided by using the right proce- dures. These correct procedures and points, which must be followed, are described in this manual.
  • Page 14 2 | Safety HYDAC FILTER SYSTEMS GMBH Personnel who work with the product must be aware of the dan- gers involved in handling it, must be over 14 years of age and must be without any physical impediments in regard to the indus- trial environment.

  • Page 15: Tab. 2 Target Group / Required Personnel Qualification

    HYDAC FILTER SYSTEMS GMBH Safety | 2 Activity Personnel Knowledge Knowledge of recy- cling is required. transport Commis- Specialist personnel - Service personnel / sioning, Operation, Service / Administra- Administrator / HY- Troubleshooting DAC Service. Maintenance Dis- Extensive experience posal of the product.

  • Page 16: Hazard Symbols / Pictograms

    2 | Safety HYDAC FILTER SYSTEMS GMBH 2.2 Hazard symbols / pictograms The following are the safety symbols / pictograms in this manual. They indicate specific dangers to persons, property or to the sur- roundings. Observe these safety symbols / pictograms and act with particular caution in such cases.
  • Page 17 HYDAC FILTER SYSTEMS GMBH Safety | 2 Used GHS symbols These symbols can be found for all safety and warning instructions in this manual which indicate particular dangers to persons, prop- erty or the environment. Hazardous to the environment Others symbols used...

  • Page 18: Danger Notifications

    2 | Safety HYDAC FILTER SYSTEMS GMBH These persons have been trained by the manufacturer and are authorized to perform service. 2.3 Danger notifications The following residual risks can occur in the various life phases of the product: Life phase - Transport/Storage...
  • Page 19 HYDAC FILTER SYSTEMS GMBH Safety | 2 WARNING Hot surfaces Danger of burns uAllow the product to cool before any maintenance work. NOTICE Excessively high input pressure at the INLET OIL connection The coalescing housing will be damaged. uNote the maximum permissible operating pressure, see Techni- cal Data [} 25].
  • Page 20 2 | Safety HYDAC FILTER SYSTEMS GMBH WARNING Hot surfaces Danger of burns uAllow the product to cool before any maintenance work. 20 / 72 MoWa OLS10-Z-x 4573340 en-us web...

  • Page 21: Observing Regulatory Information

    HYDAC FILTER SYSTEMS GMBH Safety | 2 2.4 Observing regulatory information Observe the following regulatory information and directives: – Legal and local regulations for accident prevention – Legal and local regulations for environmental protection and environmental requirements – Country-specific regulations, organization-specific regulations –...

  • Page 22: Piping And Product Description

    3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 3 Piping and product description The OffLine Separator OLS is a dewatering unit that separates water from oils through a coleasing processs. According to the coalescence principle, water collects on the fibers of the coalescing element and is conveyed deeper into the coa- lescing element by the fluid flow.

  • Page 23: Intended Use

    HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 3.2 Intended Use Use the product only for the application described below. The OffLine Separator OLS is a dewatering unit that dewaters hy- draulic oils, turbine lubricating oils and/or gear oils in bypass stream using the coalescing principle with ≤...

  • Page 24: Improper Use Or Use Deviating From Intended Use

    Intended Use Any other or extending use beyond this shall not be considered in- tended use. HYDAC FILTER SYSTEMS GMBH will assume no lia- bility for any damage resulting from such use. This risk is borne solely by the owner.

  • Page 25: Technical Data

    HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 3.4 Technical data If you are aware of the technical data of the product, you will be able to use it optimally. This section contains the technical details for the product: This has the following technical data depending on the type of the Offline Separator.

  • Page 26: Tab. 4 Technical Data - Hydraulic Data

    3 | Piping and product description HYDAC FILTER SYSTEMS GMBH Housing draining and Drain and vent nozzles, see assembly venting drawing Design service life The design service life of the product is not limited if the service and mainte- nance intervals are complied with.

  • Page 27: Decoding The Type Label

    3.5 Decoding the type label Details for identifying the product are found on the name plates on the product as well as their components. Always mention the part no. and the serial no. when contacting HYDAC. Pos. Description (1) Name plate for the product (2) Model code, see Model code [} 29]...
  • Page 28 3 | Piping and product description HYDAC FILTER SYSTEMS GMBH Temp. of the Permissible fluid temperature fluid Temp. amb. Permissible ambient temperature Volume Volume 28 / 72 MoWa OLS10-Z-x 4573340 en-us web...

  • Page 29: Model Code

    HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 3.5.1 Model code The product is defined by the following model code: OLS 10 / 5 - G - N - P - 1 - D4 - Z - 2 - Z...

  • Page 30: Dimensions

    3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 3.6 Dimensions The OLS has the following dimensions: Fig. 3: Dimensions in mm Coalescing housing Oil inlet INLET  OIL oil outlet OUTLET  OIL Water drain DRAIN WATER 6.1 drain DRAIN 7.1 Air vent...
  • Page 31 HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 Phase boundary sensor Water drainage valve Required dismantling space for the co- alescing elements MoWa OLS10-Z-x 4573340 en-us web 31 / 72...

  • Page 32: Hydraulic Diagram

    3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 3.7 Hydraulic diagram The OLS has the following hydraulic diagram: Fig. 4: Hydraulic diagram of the OLS10/Z with automatic water outlet 1 Coalescing housing 3 Oil inlet INLET  OIL 4 oil outlet OUTLET  OIL...

  • Page 33: Components

    HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 3.8 Components The OLS has the following components: Fig. 5: Components of the OLS 10/Z with automatic water outlet 1 Coalescing housing 3 Oil inlet INLET  OIL 4 oil outlet OUTLET  OIL 5 Water drain DRAIN WATER...

  • Page 34: Transportation / Storage

    4 | Transportation / Storage HYDAC FILTER SYSTEMS GMBH 4 Transportation / Storage You will find the respective notice on the prevention of damage to the product during transport or storage in this chapter. Before transportation/storage, empty the coalescing housing com- pletely.

  • Page 35: Assembly/Installation

    HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 5 Assembly/Installation 5.1 Mounting the drip tray (accessory) Mount the drip tray, which is available as an accessory, as de- scribed below. 1x wrench  = 19 mm Fig. 8: Mounting the drip tray Mount the drip tray with the supplied assembly material.

  • Page 36: Connecting The Suction Port - Inlet Oil

    5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH – Kinematic viscosity – Pipe dimensions – Fluid density The pressure loss can be estimated as follows for mineral oil- based hydraulic oils: Fig. 9: Pressure loss formula Δp Pressure differential [bar] L Line length...

  • Page 37: Connecting The Pressure Port - Outlet Oil

    HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 Install the suction port connection at the lowest part of the oil tank. Through this, you ensure that the water phase located at the base of the tank is reached and drawn off.

  • Page 38: Installing The Clogging Indicator

    5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH 5.3.4 Installing the clogging indicator We recommend operating the coalescing housing with the clog- ging indicator as a differential pressure indicator. Install a differen- tial pressure clogging indicator between the connections IN- LET OIL and OUTLET OIL.

  • Page 39: Electrical Connection

    HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 5.4 Electrical connection Connect the components according to the requirements in the component description. 5.4.1 Connecting the water drainage valve Connect the water drain valve according to the following steps. Fig. 10: Connecting the water drainage valve...

  • Page 40: Fig. 11 Terminal Assignment Of The Water Drain Valve (Assignment Of The Dosing Insert)

    5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH – Mount the gasket (6) and dossing insert (5) congruent to the magnets. Fig. 11: Terminal assignment of the water drain valve (assignment of the dosing insert) 7 Terminal 1 8 Terminal 2 9 Protective conductor terminal 1.

  • Page 41: Monitoring The Water Drain Valve

    HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 8. Tighten the central screw (3) to a maximum of 40 Ncm. NOTICE! Avoid visible deformation of the housing of the connector plug. 9. The water drain valve is electrically connected. 5.4.2 Monitoring the water drain valve Check the closing function of the water drain valve.
  • Page 42 5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH If the phase boundary sensor detects water at the upper switch point L1 for ≥ 22 seconds, an error message must occur, followed by switching off the motor pump group. Check that the phase boundary sensor is functioning.

  • Page 43: Commissioning

    HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 5.5 Commissioning Proceed as follows for commissioning: 1. Insert the coalescing element in the coalescing housing. see Changing the coalescing elements [} 47]. 2. Open the shut off valve on the INLETOIL port. 3. Shut the shut off valve on the OUTLETOIL port.

  • Page 44: Operation

    6 | Operation HYDAC FILTER SYSTEMS GMBH 6 Operation Open the shut off devices to the coalescing housing and switch the pump on. 6.1 Draining water automatically If the phase boundary sensors connected as described in chapter Monitoring the phase boundary sensor [} 41] and the water drain valve is connected, then, during operation, the water being re- moved is automatically drained via the water drain valve.

  • Page 45: Remedying Malfunctions

    HYDAC FILTER SYSTEMS GMBH Remedying malfunctions | 7 7 Remedying malfunctions In order to get quick and immediate assistance in the case of er- rors, you will find the most often occurring errors with their cause and remedy with suitable specialist personnel in this chapter.

  • Page 46: Performing Maintenance

    8 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 8 Performing Maintenance For a long, trouble-free service life of the product, regular mainte- nance activities are required. WARNING Hydraulic system is under pressure Danger of bodily injury uThe hydraulic system must be depressurized before performing any work on it.

  • Page 47: Changing The Coalescing Elements

    HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 8 8.3 Changing the coalescing elements The coalescing elements wear out very dependent on the contami- nation level of the operating medium. This means that the mainte- nance cycle can change accordingly. 1x wrench...
  • Page 48 8 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 7. 1. Remove the housing clamp (2400). 2. Lift the cover upwards and set it down to the side. 8. Remove the coalescing element set from the coalescing housing. To do this, use the two handles.
  • Page 49 HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 8 11. Moisten the O-ring on the coalescing element lightly with the operating fluid. 12. Insert the new coalescing elements into the element recepta- cles by screwing them in lightly. NOTICE! Do not use an impact tool.
  • Page 50 8 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 17. Tighten the housing clamp evenly with the wrench = 13 mm with a maximum of 20 Nm. Screw on the lock nut and secure the connection. 18. Open the shut-off valves at the ports INLET OIL and OUT- LET OIL.

  • Page 51: Decommissioning / Disposal

    HYDAC FILTER SYSTEMS GMBH Decommissioning / Disposal | 9 9 Decommissioning / Disposal In the following chapters, you will be provided with information re- garding temporary shutdown/final decommissioning and disposal of the product. 9.1 Temporary shutdown If the product is being temporarily shut down, the following mea- sures are adequate: 1.

  • Page 52: A Appendix

    Hotline, product support, , , service partners for maintenance, repair and spare parts can be found, always up- dated, on our homepagewww.hydac.com. HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15, Werk 13 66450 Neunkirchen - Heinitz Germany...

  • Page 53: Finding Spare Parts And Accessories

    HYDAC FILTER SYSTEMS GMBH Appendix | A A.2 Finding spare parts and accessories The following spare parts as well as accessories are available for the product. A.2.1 Spare parts Use only original spare parts for a long and defect-free life cycle of the product.
  • Page 54 A | Appendix HYDAC FILTER SYSTEMS GMBH A.3.1 Instructions for use - REED-CONTROL FLOAT SWITCH 54 / 72 MoWa OLS10-Z-x 4573340 en-us web...
  • Page 55 HYDAC FILTER SYSTEMS GMBH Appendix | A Instructions for use REED-CONTROL FLOAT SWITCH Type RCS REED-CONTROL FLOAT SWITCH IN EXPLOSION-PROOF DESIGN Type RCS-EX MoWa OLS10-Z-x 4573340 en-us web 55 / 72...
  • Page 56 A | Appendix HYDAC FILTER SYSTEMS GMBH Contents 1. Functional principle 2. Area of application 3. Application in EX zone 4. Mounting 5. Electrical connection 6. Electrical connection in EX zone 7. Initial operation/functional check 8. Maintenance and disposal 9. Hazard notes 10.
  • Page 57 HYDAC FILTER SYSTEMS GMBH Appendix | A 1. Functional principle By means of the magnetic field of the magnet – which is located on the inside of the float housing – the reed contacts (protective gas contacts) ar- ranged in the sliding tube are actuated according to the fill level required.
  • Page 58 A | Appendix HYDAC FILTER SYSTEMS GMBH pes, nuts and bolts suitable for the respective flange are to be used. For sealing purposes, a suitable seal is to be provided (not included in the scope of delivery from Reed). Care must be taken to ensure the correct mounting position.
  • Page 59 HYDAC FILTER SYSTEMS GMBH Appendix | A that no process sequences are unintentionally triggered as a result of the functional check. The operator is responsible for periodically carrying out a functional check or a visual inspection. 8. Maintenance and disposal When used as intended, Reed float switches are maintenance and wear-free.
  • Page 60 A | Appendix HYDAC FILTER SYSTEMS GMBH to any high mechanical loads, vibrations or impacts. They must not be used as lifting equipment, stepping boards or transport equipment. Float switches must be protected against magnetic fields. Any interventions, such as shortening the sliding tube, are to be avoided as the device would otherwise be damaged.
  • Page 61 HYDAC FILTER SYSTEMS GMBH Appendix | A 10. Guidelines RCS-EX The test results show that the devices fulfil the test specifications for simple electrical equipment and therefore do not fall under explosion protection directives 2014/34/EU. By limiting voltage to maximum 30V, Low Voltage Directive does not apply.
  • Page 62 A | Appendix HYDAC FILTER SYSTEMS GMBH 12. Manufacturer’s declaration for type RCS-EX Manufacturer’s declaration Reed Electronics AG, Gewerbering 2, 6105 Schachen, Switzerland declare that the products float switch in explosion-proof design; type RCS-EX level transmitter in explosion-proof design; type RCK-EX fulfil the requirements of explosion protection.
  • Page 63 HYDAC FILTER SYSTEMS GMBH Appendix | A 13. CE declaration of conformity for type RCS MoWa OLS10-Z-x 4573340 en-us web 63 / 72...
  • Page 64 A | Appendix HYDAC FILTER SYSTEMS GMBH A.3.2 Data sheet - REED-CONTROL FLOAT-SWITCH Article 16937 RCS-U-R1"-ES-L204-PV43spez-0,05mPUR/M8 REED-CONTROL FLOAT-SWITCH Mechanical properties Mechanical conn. G1" thread against float Float material PVDF Ø43 spec. min. 0.914g/cm3 and 1g/cm3 A0086 (10bar) Ø 43 Tube material Stainless steel Ø12...
  • Page 65 HYDAC FILTER SYSTEMS GMBH Table of Illustrations Table of Illustrations Fig. 1 Overview / labeling of the title page ................ Fig. 2 Model Code......................29 Fig. 3 Dimensions in mm....................30 Fig. 4 Hydraulic diagram of the OLS10/Z with automatic water outlet ......32 Fig.
  • Page 66 Tab. 5 Technical data - Water drainage valve..............26 Tab. 6 Technical; data - Phase boundary sensor............... 26 Tab. 7 Error/cause/rectification ..................45 Tab. 8 HYDAC Service Deutschland ................. 52 Tab. 9 Spare parts......................53 Tab. 10 Coalescing elements....................53...

  • Page 67: Glossary

    HYDAC FILTER SYSTEMS GMBH Glossary Glossary General Terms and Conditions The General Terms and Conditions are available at our home page www.hy- dac.com ⇨ General Terms and Condi- tions. MoWa OLS10-Z-x 4573340 en-us web 67 / 72...

  • Page 68: Index

    Index HYDAC FILTER SYSTEMS GMBH Index Ambient temperature range  25 Manufacturer  2 Branches  52 Operating fluids  25 Operating pressure  25 calculating pressure loss  35 Current consumption  26 Person authorized with the documentation Customer Service  52  2 Ports hydraulic  25 decommissioning Power consumption  26...
  • Page 69 HYDAC FILTER SYSTEMS GMBH Index Technical data  25 Terms and Conditions  12 Terms of Delivery  12 Transport  34 Viscosity range  25 Warranty  12 Weight when empty  26 MoWa OLS10-Z-x 4573340 en-us web 69 / 72...
  • Page 72 www.hydac.com...

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