HYDAC FILTER SYSTEMS OXiStop OXS User manual

OXiStop
OXS
Installation and Maintenance Instructions
English (translation of original instructions)
Document no.: 3992763e

Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
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:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© 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
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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
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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
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Technical Data...........................................................................................101
Model code................................................................................................103
Index ..........................................................................................................104

Preface
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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:
[e-mail]
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.

Safety Information
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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 t
o 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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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)

Decoding the model code label
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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
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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