HYDAC FILTER SYSTEMS OF7 Manual

OF7
Filtration unit
Operating and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Document no.: 3430048e

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
[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
Telephone:
[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.
The content of this manual is subject to change without notice.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................6
Product modification ....................................................................................6
Warranty......................................................................................................6
Using the documentation.............................................................................7
Safety precautions........................................................................................8
Hazard symbols...........................................................................................8
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions ..................................11
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................12
Improper Use or Use Deviating from Intended Use...................................13
Qualifications of personnel / target group..................................................14
Unit with hoses / lances for mobile use .....................................................15
Unit to be integrated into a system for stationary use................................16
Wear appropriate clothing/personal protection equipment ........................17
What to Do in Case of Emergency ............................................................17
Firefighting/Extinguishing Fires ..............................................................18
Unpacking the unit......................................................................................18
Decoding the name plate ...........................................................................19
Transporting the unit..................................................................................20
Storing the unit ...........................................................................................21
Checking the scope of delivery .................................................................22
Characteristics of the unit..........................................................................23
OF7K Additional Feature ...........................................................................23
OF7S90PX2 Additional Feature ................................................................24
The components of the OF7S10 unit.........................................................25
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Content
The components of the OF7S90 unit.........................................................26
Working principle of the unit .....................................................................28
Select operating mode ...............................................................................29
Circulation pumping with filtration ..............................................................29
Circulation pumping without filtration.........................................................29
Hydraulic diagram.......................................................................................30
Dimensions .................................................................................................31
OF7S10 / OF7K10.....................................................................................31
OF7S90PX2 ..............................................................................................32
Preparing the unit for operation ................................................................33
Emptying unit - preventing oil mixing .........................................................33
Setting up the unit......................................................................................34
Connecting the motor-pump group............................................................34
Connecting electrically (230 V or 110 V, single phase) ..........................35
Connecting electrically (400 V, 3 phase) without an on/off switch
or motor protection .................................................................................36
Connecting electrically (400 V, 3 phase) with an on/off switch
and motor protection ..............................................................................37
Pneumatically connecting - compressed air motor (optional).................38
Attaching/connecting the pressure and vacuum hoses .............................39
Unit in operation .........................................................................................40
Avoid siphoning .........................................................................................41
Performing maintenance............................................................................42
Changing the filter cartridge ......................................................................43
Cleaning/replacing the suction strainer......................................................46
Suction strainer cleaning interval ...........................................................47
Removing/installing the hose coupling ...................................................48
Removing/installing the suction strainer ....................................................50
Suction strainer, 300 µm ........................................................................50
Suction strainer, 100 µm ........................................................................50
Cleaning the suction strainer .....................................................................50
Errors and troubleshooting .......................................................................51
Customer service........................................................................................53
Taking the unit out of operation ................................................................53
Shutting down the unit ...............................................................................53
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Content
Disposing of the unit ..................................................................................53
Locating spare parts...................................................................................54
Overview of spare parts for the OF7S10 ...................................................54
Spare parts list OF7S10 ............................................................................55
Overview of spare parts for the OF7S90 ...................................................57
Spare parts list OF7S90 ............................................................................58
OF 7 - wiring diagram with signaling relay...............................................60
Technical data.............................................................................................61
Model code ..................................................................................................62
EC declaration of conformity.....................................................................63
Index ............................................................................................................64
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Preface
Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. Therefore please understand that, in the
absence of any provisions to the contrary hereinafter, our warranty and
liability – for any legal reasons whatsoever – are excluded in respect of the
information in these operating instructions. In particular, we shall not be
liable for lost profit or other financial loss. This exclusion of liability does not
apply in cases of intent and gross negligence. Moreover, it does not apply to
defects which have been deceitfully concealed or whose absence has been
guaranteed, nor in cases of culpable harm to life, physical injury and damage
to health. In the event that we should negligently breach any material
contractual obligation, our liability shall be limited to the foreseeable loss.
Claims due to Product Liability shall remain unaffected.
Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model/type
designation, serial no. and article no. of the product:
Fax:
[phone] - 9046
E-Mail:
filtersy[email protected]
Product modification
We would like to point out that changes to the product (e.g. purchasing
additional options, etc.) may mean that the information in the operating
instructions is no longer applicable or adequate.
After modification or repair work that affects the safety of the product has
been carried out on components, the product may not be returned to
operation until it has been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product
whether by you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale
and Delivery of HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> General terms and conditions.
OF7S / OF7K en(us) Page 6 / 68
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Preface
Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
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
Se ite x
Produkt/Kapitel
200x-xx- xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name
OF7S / OF7K en(us) Page 7 / 68
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Safety precautions
Safety precautions
The unit was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety precautions
Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Danger from explosive atmosphere
Use the necessary tool
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Safety precautions
Signal words and their meaning in the safety information and
instructions
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not av
oided, 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.
OF7S / OF7K en(us) Page 10 / 68
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Safety precautions
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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
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Safety precautions
Proper/Designated Use
Use the unit only for the application described in the following.
The OF 7 filtration unit is a service unit for filling hydraulic systems, flushing
small hydraulic systems and for offline filtration and recirculation with or
without simultaneous filtration, depending on the cartridge.
Proper or designated use of the product extends to the following:
•observing all instructions contained in the instruction manual.
•performing inspection and maintenance work.
NOTICE
Impermissible operating media
The unit will be destroyed
►Operate the unit using only:
- the mineral oils specified in DIN 51524; DIN 51525 or
- mineral-oil-based fluids as specified in DIN 1524-1 to DIN 1524-3,
HLPD.
►Never pump:
- water
- aggressive fluids
- acids
- solvents
- oily sludge or sediment in the oil tank
►Never operate the unit without a suction strainer.
OF7S / OF7K en(us) Page 12 / 68
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Safety precautions
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 or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. The user alone, shall assume any and all
associated risk
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
•Operation in potentially explosive atmospheres.
•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.
•Operation with a non permissible media or fluid, such as for example:
with water, acids, solvents, aggressive liquids, oil sludge or sediment.
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Safety precautions
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Operating and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions is intended for:
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.
OF7S / OF7K en(us) Page 14 / 68
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Safety precautions
Unit with hoses / lances for mobile use
This unit is available in several variants. For the use of the mobile unit,
including its hoses and lances, we require that it will be used by the following
target groups with the corresponding knowledge:
Activity
Person
Knowledge
Transport / storage
Auxiliary
personnel
•No specialist knowledge
required
Hydraulic / electrical
installation,
Auxiliary
personnel
•Product-specific knowledge
Commissioning
troubleshooting,
maintenance,
decommissioning,
Disassembly
Specialist
personnel
•Safe handling/use of tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Checking the phase sequence
•Product-specific knowledge
Operation
Operations control
Auxiliary
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
•Proper and environmentally-
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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Safety precautions
Unit to be integrated into a system for stationary use
This unit is available in several variants. For the use of the unit integrated
into a system for stationary use, we presume that it will be used by the
following target group with the corresponding knowledge:
Activity
Person
Knowledge
Transport / storage
Auxiliary
personnel
•No specialist knowledge
required
Hydraulic / electrical
installation,
first commissioning,
commissioning,
troubleshooting,
maintenance,
decommissioning,
disassembly
Specialist
personnel
•Safe handling/use of tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Checking the phase sequence
•Product-specific knowledge
Operation
Operations control
Auxiliary
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
•Proper and environmentally-
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
OF7S / OF7K en(us) Page 16 / 68
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Safety precautions
Wear appropriate clothing/personal protection equipment
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.
•Observe the information relating to personal protection equipment in
the safety data sheet of the oil.
•Wear close-fitting clothing.
•Do not wear any rings, chains or any other jewelry.
•Wear work safety shoes.
•Wear eye protection
What to Do in Case of Emergency
In case of emergency, switch off the power unit or disconnect it.
OF7S / OF7K en(us) Page 17 / 68
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Unpacking the unit
Firefighting/Extinguishing Fires
Use a powder extinguisher that corresponds to fire class B as per EN 2 to
extinguish any fires.
Maintain a minimum safe distance from electrical components. For a mains
voltage of up to 1000 V, the minimum safe distance is 1 m.
Unpacking the unit
Before delivery, the unit is checked for leaks and proper functioning at the
factory, and is then properly packed.
When receiving and unpacking the unit, check it for transport damage.
Dispose of the packaging material in an environmentally friendly manner.
When the unit is supplied without a filter element, the ports on the underside
of the filter — inlet and outlet — are also closed off with plastic plugs.
Dispose of the packaging material in an environmentally friendly manner.
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Decoding the name plate
Decoding the name plate
Details for identifying the filtration unit can be found on the name plates on
the unit and the components. Always mention the part no. and the serial no.
when contacting HYDAC.
Item
->
Description
(1)
->
Name plate of filtration unit
(2)
->
Name plate of electric motor
(3)
->
Model code; for details, see page 62
Part No.
->
Part number
S/N
->
Serial no.
Power
->
Power
Voltage/Grid
->
Voltage / number of phases
Frequency
->
Voltage frequency
Current
->
Current consumption
Pmax
->
Operating pressure, maximum
Flow Rate
->
Flow rate
Weight
->
Empty weight
OF7S / OF7K en(us) Page 19 / 68
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Transporting the unit
Transporting the unit
Only transport the unit using its handle or with it standing on its rubber feet.
When transporting the unit, never pick it up by its attachments or
components.
OF7S / OF7K en(us) Page 20 / 68
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