Hydac OLS 10/Z Series Installation And Maintenance Instructions Manual
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- Page 1 OLS 10/Z... OffLine Separator Installation and Maintenance Instructions English (translation of original instructions) Document No. : 4525255 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...
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Page 3: Table Of Contents
HYDAC FILTER SYSTEMS GMBH Table of Contents Table of Contents General ........................ 5 Target group of the manual ................ 5 Illustrations in the manual................ 6 1.2.1 Illustration on the title page .............. 6 1.2.2 Representation of requirements............ 7 1.2.3 Representation of procedural instructions ......... 7 1.2.4... - Page 4 Table of Contents HYDAC FILTER SYSTEMS GMBH Setup and mounting .................. 34 Connecting the hydraulics ................ 34 5.3.1 Installing the shut-off valves............. 35 5.3.2 Connecting the suction port – INLET OIL ........ 35 5.3.3 Connecting the pressure port – OUTLET OIL........ 36 5.3.4 Connecting the water drainage - (DRAIN WATER) ...... 36 Commissioning ..................... 38...
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Page 5: General
HYDAC FILTER SYSTEMS GMBH General | 1 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 proce- dure in the respective chapters. -
Page 6: Illustrations In The Manual
1 | General HYDAC FILTER SYSTEMS GMBH 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... -
Page 7: Representation Of Requirements
HYDAC FILTER SYSTEMS GMBH General | 1 Please note that you can directly access information through the directories. However, this does not release you from the obligation to read this manual fully before commissioning. The document no. with the index (4) is meant for identifying and reordering the manual. -
Page 8: Representation Of Intermediate Results/Results
1 | General HYDAC FILTER SYSTEMS GMBH Procedural instructions with a random sequence Procedural instructions that have a random sequence are listed as bullet points (-). An example of a procedural instruction with a random se- quence: – Clean the display. -
Page 9: Supplementary Symbols
HYDAC FILTER SYSTEMS GMBH General | 1 1.2.5 Supplementary symbols You will find the following symbols in the manual as additional details: [▶ ] Cross reference to a page / a chapter / a section or another document. Glossary Terms in grey font are explained in the glossary. -
Page 10: Signal Words And Their Meaning In The General Safety Information
1 | General HYDAC FILTER SYSTEMS GMBH 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 11: Exclusion Of Liability/Warranty
HYDAC FILTER SYSTEMS GMBH General | 1 1.3 Exclusion of liability/warranty For the warranty provided by us, please refer to the Terms of Delivery. 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 12: Safety
2 | Safety HYDAC FILTER SYSTEMS GMBH 2 Safety The product is designed as safe. In spite of that, there is dan- ger in some actions that can only be avoided by using the right procedures. These correct procedures and points, which must be followed, are described in this manual. - Page 13 HYDAC FILTER SYSTEMS GMBH Safety | 2 – To train the personnel at regular intervals and to inform them of the hazards – To provide the necessary protective equipment to the per- sonnel Personnel who work with the product must be aware of the...
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Page 14: Tab. 2 Target Group / Required Personnel Qualification
2 | Safety HYDAC FILTER SYSTEMS GMBH Activity Personnel Knowledge Disposal Specialist personnel Knowledge of envi- - General ronmentally friendly disposal of materi- als and matter is re- quired. Knowledge of de- contamination of contaminants is re- quired. Knowledge of recy- cling is required. -
Page 15: Hazard Symbols / Pictograms
HYDAC FILTER SYSTEMS GMBH Safety | 2 2.2 Hazard symbols / pictograms The following are the safety symbols / pictograms in this man- ual. They indicate specific dangers to persons, property or to the surroundings. Observe these safety symbols / pictograms and act with particular caution in such cases. - Page 16 2 | Safety HYDAC FILTER SYSTEMS GMBH Take note of the slinging points. Used GHS symbols These symbols can be found for all safety and warning instruc- tions in this manual which indicate particular dangers to per- sons, property or the environment.
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Page 17: Danger Notifications
HYDAC FILTER SYSTEMS GMBH Safety | 2 Specialist personnel - Electrician Such persons have specific specialist training and several years' work experience. They are able to as- sess and perform the work assigned to them, they are also able to recognize potential dangers. - Page 18 2 | Safety HYDAC FILTER SYSTEMS GMBH NOTICE Excess pressure at the water outlet The coalescing tank will be damaged. u Guide the water outlet into a depressurized reservoir. Life phase - Commissioning / Operation The following risks could arise during the Commissioning / Op-...
- Page 19 HYDAC FILTER SYSTEMS GMBH Safety | 2 Environmentally tip Operating medium is released into the soil or water Environmental hazard u Remove any leaked operating medium immediately dis- pose of it in an environmentally sound manner. Life phase - Maintenance/Troubleshooting...
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Page 20: Observing Regulatory Information
2 | Safety HYDAC FILTER SYSTEMS GMBH 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 regula- tions –... -
Page 21: Piping And Product Description
HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 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 coalescing element by the fluid flow. -
Page 22: Intended Use
3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 3.2 Intended Use Use the product only for the application described below. The OffLine Separator OLS is a dewatering unit that dewaters hydraulic oils, turbine lubricating oils and/or gear oils in bypass stream using the coalescing principle with ≤... -
Page 23: Improper Use Or Use Deviating From Intended Use
3.3 Improper Use or Use Deviating from Intended Use Any other or extending use beyond this shall not be considered intended use. HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use. This risk is borne solely by the owner. -
Page 24: Technical Data
3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 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 25: Tab. 4 Technical Data - Hydraulic Data
HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 Storage duration Unlimited. Replace all the seals before commis- sioning after a storage duration of ≥2 years. Sealing material Housing material Stainless Housing draining and Drain and vent nozzles, see assembly... -
Page 26: 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 [} 28]... - Page 27 HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 Flow rate Flow rate Temp. of the Permissible fluid temperature fluid Temp. amb. Permissible ambient temperature Volume Volume MoWa OLS10-Z 4525255 en-us web 27 / 56...
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Page 28: Model Code
3 | Piping and product description HYDAC FILTER SYSTEMS GMBH 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 29: Dimensions
HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 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 7.1 Air vent VENT Inspection glass phase boundary... -
Page 30: 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 manual water drain 1 Coalescing housing 3 Oil inlet INLET OIL 4 oil outlet OUTLET OIL... -
Page 31: Components
HYDAC FILTER SYSTEMS GMBH Piping and product description | 3 3.8 Components The OLS has the following components: Fig. 5: Components of the OLS10/Z with manual water drain 1 Coalescing housing 3 Oil inlet INLET OIL 4 oil outlet OUTLET OIL 5 Water drain DRAIN WATER... -
Page 32: 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 completely. -
Page 33: 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 34: Setup And Mounting
5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH 5.2 Setup and mounting 5.3 Connecting the hydraulics To reach the optimal performance of the product, an important component is the hydraulic connection/the right integration. – Install the suction port connection at the lowest part of the tank. -
Page 35: Installing The Shut-Off Valves
HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 Observe the following points for hydraulic connection: – Keep the height difference of the product to the oil level in the reservoir as small as possible. – Use a suction hose that is suitable for a vacuum of ≥... -
Page 36: Connecting The Pressure Port - Outlet Oil
5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH NOTICE Excessively high input pressure at the INLET OIL connection The coalescing housing will be damaged. u Note the maximum permissible operating pressure, see Technical Data [} 24]. 5.3.3 Connecting the pressure port – OUTLET OIL Make sure that the nominal width of the pressure line corre- sponds to the connector thread of the housing. - Page 37 HYDAC FILTER SYSTEMS GMBH Assembly/Installation | 5 Environmentally tip The separated water can contain some parts of operating fluid Environmental hazard u Dispose of the water-oil mixture in an environmentally friendly manner. MoWa OLS10-Z 4525255 en-us web 37 / 56...
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Page 38: Commissioning
5 | Assembly/Installation HYDAC FILTER SYSTEMS GMBH 5.4 Commissioning Proceed as follows for commissioning: 1. Insert the coalescing element in the coalescing housing. see Changing the coalescing elements [} 44]. 2. Open the shut off valve on the INLETOIL port. 3. Shut the shut off valve on the OUTLETOIL port. -
Page 39: Operation
HYDAC FILTER SYSTEMS GMBH Operation | 6 6 Operation Open the shut off devices to the coalescing housing and switch the pump on. Monitor the filling level or the phase limit daily by visual inspec- tion via the two sight glasses (10) on the coalescing housing. - Page 40 6 | Operation HYDAC FILTER SYSTEMS GMBH 2. Open the installed shut-off valve at the DRAIN WATER connection and allow the water to drain in a controlled way. 3. Shut the shut-off valve at the WATER connection as soon as the phase boundary is visible in the lower sight glass (10).
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Page 41: Remedying Malfunctions
HYDAC FILTER SYSTEMS GMBH Remedying malfunctions | 7 7 Remedying malfunctions In order to get quick and immediate assistance in the case of errors, you will find the most often occurring errors with their cause and remedy with suitable specialist personnel in this chapter. -
Page 42: Tab. 5 Error/Cause/Rectification
7 | Remedying malfunctions HYDAC FILTER SYSTEMS GMBH Error Cause(s) Rectification Leak at the coa- Wrong, missing, Check the seal- lescing housing. or defective ing ring of the fil- sealing ring. ter element. Re- place it if neces- sary. The cover on the... -
Page 43: Performing Maintenance
HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 8 8 Performing Maintenance For a long, trouble-free service life of the product, regular maintenance activities are required. WARNING Hydraulic system is under pressure Danger of bodily injury u The hydraulic system must be depressurized before per- forming any work on it. -
Page 44: Performing A Visual Check
8 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 8.2 Performing a visual check Check the product for leaks, brittle hoses and cables daily. Have the brittle or damaged parts replaced immediately. 8.3 Changing the coalescing elements The coalescing elements wear out very dependent on the con- tamination level of the operating medium. - Page 45 HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 8 6. Loosen the upper tensioning clamp on the coalescing housing with a screwdriver = 13 mm by turning it counterclockwise. 7. 1. Remove the housing clamp (2400). 2. Lift the cover upwards and set it down to the side.
- Page 46 8 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 10. Pull the coalescing elements out of the element recepta- cles and dispose of them in an environmentally friendly manner. 11. Moisten the O-ring on the coalescing element lightly with the operating fluid.
- Page 47 HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 8 16. 1. Place the cover on the coalescing housing. 2. Place the housing clamp over the coalescing housing. 17. Tighten the housing clamp evenly with the wrench 13 mm with a maximum of 20 Nm.
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Page 48: Decommissioning / Disposal
9 | Decommissioning / Disposal HYDAC FILTER SYSTEMS GMBH 9 Decommissioning / Disposal In the following chapters, you will be provided with information regarding temporary shutdown/final decommissioning and dis- posal of the product. 9.1 Temporary shutdown If the product is being temporarily shut down, the following... -
Page 49: A Appendix
Contact data such as the telephone numbers, e-mail and mail- ing addresses for the Hotline, product support, , , service part- ners for maintenance, repair and spare parts can be found, al- ways updated, on our homepagewww.hydac.com. HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15, Werk 13... -
Page 50: Finding Spare Parts And Accessories
A | Appendix HYDAC FILTER SYSTEMS GMBH 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 cy- cle of the product. - Page 51 HYDAC FILTER SYSTEMS GMBH Table of Illustrations Table of Illustrations Overview / labeling of the title page ............Fig. 1 Model Code ....................Fig. 2 Dimensions in mm ..................Fig. 3 Hydraulic diagram of the OLS10/Z with manual water drain ....
- Page 52 Index of Tables HYDAC FILTER SYSTEMS GMBH Index of Tables Tab. 1 Target group ..................... Tab. 2 Target group / Required personnel qualification ........Tab. 3 Checking the scope of delivery ..............Tab. 4 Technical data – Hydraulic data ...............
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Page 53: Glossary
HYDAC FILTER SYSTEMS GMBH Glossary Glossary General Terms and Conditions The General Terms and Conditions are available at our home page www.hydac.com ⇨ General Terms and Conditions. MoWa OLS10-Z 4525255 en-us web 53 / 56... -
Page 54: Index
Index HYDAC FILTER SYSTEMS GMBH Index Accessory 50 Hotline 49 Ambient temperature range 24 HYDAC Service Germany 49 Worldwide 49 Branches 49 Imprint 2 calculating pressure loss 34 connections Hydraulic 24 Manufacturer 2 Customer Service 49 Operating media 24 decommissioning Operating pressure 24... - Page 55 HYDAC FILTER SYSTEMS GMBH Index shutting down Temporary 48 Storage 32 Storage duration 25 Storage temperature range 24 Support 49 Technical data 24 Terms and Conditions 11 Terms of Delivery 11 Transport 32 Viscosity range 24 warranty 11 Weight 25...
- Page 56 www.hydac.com...
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