HYDAC International OF 5 C Manual

OF5 C
Filtromat
Operating and maintenance instructions
English (translation of original German
instructions)
Document No.: 3160333a

Filtromat – OF5 C
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2008 by
HYDAC Filtertechnik GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to
compensation.
Exclusion of liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, no liability is assumed for any
errors or deficiencies inherent in this document, including consequential damage or
loss. The content of the manual is checked regularly. Any corrections required will
be incorporated in subsequent editions. We welcome any suggestions for
improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Hydac Service Technology Division / Filter Systems
Industriegebiet
D-66280 Sulzbach / Saar
Germany
Tel.: ++49 (0) 6897 / 509 - 01
Fax: ++49 (0) 6897 / 509 - 846
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Filtromat – OF5 C
Contents
Preface ....................................................................................................................................5
Customer Service.................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty...............................................................................................................................6
Using the documentation......................................................................................................7
1Safety information and instructions..............................................................................8
1.1 Obligations and Liability .............................................................................................8
1.2 Explanation of Symbols and Warnings, etc................................................................9
1.3 General Safety Precautions .......................................................................................9
1.4 Proper/Designated Use..............................................................................................9
1.5 Improper Use............................................................................................................10
1.6 Safety Devices .........................................................................................................10
1.7 Informal Safety Precautions .....................................................................................11
1.8 Training and Instruction of Personnel.......................................................................12
1.9 Safety Measures to Be Followed during Normal Operation .....................................12
1.10 Electrical Hazards ....................................................................................................12
1.11 Maintenance, Servicing and Troubleshooting..........................................................13
1.12 Modifications to the Filtromat ...................................................................................13
1.13 How to behave in an emergency..............................................................................13
2Checking the scope of delivery...................................................................................14
3Connecting the OF5 C ..................................................................................................15
3.1 Suction port connection............................................................................................15
3.2 Pressure port connection .........................................................................................15
3.3 Electrical Installation.................................................................................................16
3.4 Mode of Function......................................................................................................17
4Starting up the OF5 C...................................................................................................18
4.1 Inserting the filter element........................................................................................18
4.2 Filling the pump........................................................................................................18
4.3 Venting the filter housing..........................................................................................18
4.4 Switching on the OF5 C ...........................................................................................19
4.5 OF5 C in operation...................................................................................................19
4.6 Measuring the cleanliness code...............................................................................20
5Performing maintenance..............................................................................................21
5.1 Changing the Filter Element.....................................................................................21
5.2 Clean the suction strainer.........................................................................................23
5.3 Shutting down the OF5 C.........................................................................................24
5.4 Disposing of the OF5 C............................................................................................24
6Errors and Troubleshooting.........................................................................................24
7Spare parts ....................................................................................................................25
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Filtromat – OF5 C
8Technical data...............................................................................................................27
8.1 Model Code..............................................................................................................28
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Filtromat – OF5 C
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Sometimes the information contained in the documentation cannot always keep up
with changes made to the product as we attach considerable importance to keeping
our products cutting-edge. Consequently, there might be deviations in technical
details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC Filtertechnik GmbH
Division Service technology / Filter systems
Technical Documentation Department
PO Box 12 51
66273 Sulzbach/Saar - Germany
Fax: ++49 (0) 6897 509 846
E-mail: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”
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Filtromat – OF5 C
Customer Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: ++49 (0) 6897 509 846
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.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
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 Filtertechnik GmbH.
They are available at: www.hydac.com Legal information.
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Filtromat – OF5 C
Using the documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
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 document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
HYDAC Filtertechnik GmbH en Page 7
Product
Page number
Edition date
Document language
Documentation No.
with Index
/
File name
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.
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Filtromat – OF5 C
1 Safety information and instructions
These operating instructions contain the key instructions for properly and safely
operating the Filtromat OF5 C.
The safety of the Filtromat OF5 C largely depends on maintenance. Regular
required maintenance is described in this manual. We will support you if the unit
needs repair and will provide original spare parts.
1.1 Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the OF5 C
is knowledge of the safety instructions and warnings.
These operating instructions, and the safety guidelines in particular, are to be
observed by all those who work with the Filtromat.
Additionally, all local accident prevention instructions and regulations must be
observed.
The safety precautions listed herein are limited solely to using the Filtromat.
The Filtromat has been designed and constructed in accordance with the technical
state of the art and recognized safety rules and regulations. Nevertheless, hazard
may be posed to the life and limb of the individual using the product or to third
parties. The Filtromat is to be used
• solely for its designated use
• only in accordance with the designated equipment group, equipment category
and zone indicated above
• only when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly repaired or
remedied immediately.
Our General Terms and Conditions apply. They are made available to the owner
upon concluding purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
• improper use of the Filtromat or use deviating from its intended use
• improper assembly, installation, commissioning, operation and maintenance of
the Filtromat
• operating the Filtromat when the system equipment or systems are defective
• unauthorized modifications to the Filtromat made by the user or purchaser
• improper monitoring of unit components that are subject to wear and tear
• improperly performed repair work
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Filtromat – OF5 C
1.2 Explanation of Symbols and Warnings, etc.
DANGER DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING WARNING denotes situations
which can lead to fatal injury if
safety precautions are not
observed.
CAUTION CAUTION denotes situations
which can lead to severe injury
if safety precautions are not
observed.
TIP NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
1.3 General Safety Precautions
Operation, adjustment and calibration work may only be carried out by technically
skilled and trained personnel.
The safe operation of this unit can only be ensured if it is used for the purpose it was
intended. If there is any question about the use, please contact the manufacturer.
The manufacturer will not accept responsibility for damages resulting from misuse of
this equipment.
The following applies to all work performed using the unit: adherence to pertinent
national regulations pertaining to accident prevention and safety at the workplace in
addition to any applicable internal rules and regulations of the owner/operator, even
though they are not specifically cited herein.
Leaks of dangerous materials must be properly collected and disposed of so as not
to harm any persons or the environment. The corresponding statutory regulations
are to be followed.
Before any maintenance or repair work is carried out on the unit, electrical power to
the unit must be disconnected, and all hydraulic pressures relieved.
1.4 Proper/Designated Use
The OF5 C was developed for the dewatering, filtration and degassing of hydraulic
and lubricating oils. It removes free water, emulsified water and a large percentage
of the water in solution.
Any other use shall be deemed to be improper and not in keeping with the product
designated use. The manufacturer will not assume any liability for any damage
resulting from such use.
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Filtromat – OF5 C
Proper or designated use of the product extends to the following:
• Observing all the notes contained in these operating instructions.
• Performing requisite inspection and maintenance work.
1.5 Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
• Operation with non-approved fluids.
1.6 Safety Devices
Before starting up the OF5 C unit each time, make sure that all the protective safety
devices are properly installed and are in proper working order.
Safety devices may not be removed until the product has been shut down and
secured against being restarted (e.g. warning sign or padlock on the main switch).
When the product is supplied in partial consignments, the safety devices are to be
applied by the operator as specified by law/pertinent regulations.
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Filtromat – OF5 C
1.7 Informal Safety Precautions
Always keep the operating instructions in the vicinity of the Filtromat.
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance to be maintained to them.
All safety guidelines and hazard warnings on the Filtromat must be maintained in
legible condition and replaced as required.
Filtromat components may not be opened except in normal, non-contaminated
environments. The mains cable must be pulled out before the Filtromat is opened.
Tests conducted with the housing open may only be performed by properly trained,
certified electricians. This also applies to all repair work or to any modifications to
electrical components approved by HYDAC.
Check the hoses and connection fittings for leakage daily (visual check). The
electrical components of theFiltromat are to also be regularly checked (visual check
once a month). Replace any loose connections or damaged cables immediately.
WARNING
Hydraulic systems are under pressure

The hydraulic system must be depressurized
before performing any work
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Filtromat – OF5 C
1.8 Training and Instruction of Personnel
The Filtromat may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established clearly.
Staff undergoing training may not use the Filtromat unless supervised by an
experienced staff member.
Individuals
Activity
Individuals
undergoing
training
Individuals
with
technical
training/
engineering
background
Electrician Supervisor
with the
appropriate
authority
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source
of malfunction X X X
Troubleshooting
and remedying,
mechanical
problem
X X
Troubleshooting,
electrical problem X X
Maintenance X X X X
Repair work X
Decommissioning /
storage X X X X
1.9 Safety Measures to Be Followed during Normal Operation
Do not operate the OF5 C unless all the safety devices function properly.
The product is to be checked once a day for external damage and the proper
functioning of the safety devices.
1.10 Electrical Hazards
Any work involving the power supply may only be done by a properly trained,
certified electrician.
Make sure to check the electrical equipment of the unit on a regular basis. Any loose
connections or damaged cables are to be replaced immediately.
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Filtromat – OF5 C
If work on live components is required, a second individual should be present to
switch off the unit if necessary.
1.11 Maintenance, Servicing and Troubleshooting
Perform the adjustment, maintenance/servicing and inspection work specified
according to schedule.
Secure all operating media against accidental start up.
Disconnect the Filtromat from the power supply and protect the entire system from
being inadvertently switched on when performing maintenance, inspection or repair
work.
Check any screwed fittings which have been removed to see that they have been
properly secured.
After performing maintenance and servicing work, always check the safety features
of the product to see that they function properly.
1.12 Modifications to the Filtromat
Do not make any modifications (design modifications, extensions) to the Filtromat
without the prior consent of the manufacturer.
Design modifications may not be made without HYDAC Filtertechnik GmbH’s
express prior written approval.
Immediately replace any machine components which are not in perfect condition.
Only use original (OEM) spare parts and consumables. When using non-OEM
components it cannot be ensured that they have been designed and manufactured
so as to comply with loading and safety requirements.
1.13 How to behave in an emergency
In the event of an emergency, rotate the main and E-STOP switches 90° to the left
in order to shut down the entire system.
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Filtromat – OF5 C
2 Checking the scope of delivery
The OF5 C filter unit is delivered packed and ready for use. Before commissioning
the filter unit, check the contents of the consignment to make sure everything is
present.
Any damage in transit is to be reported to the forwarding agent or the department in
charge immediately; the unit may not be commissioned until this damage is properly
remedied.
The following items are supplied:
Item Qty. Description
- 1 Filtromat OF5 C
- 1 Operating and maintenance instructions
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Filtromat – OF5 C
3 Connecting the OF5 C
3.1 Suction port connection
Make the suction-side connection with a flexible hose that is resistant to negative
pressure or with pipelines. The nominal size of the connecting lines must be at least
as large as the cross-section of the unit in order to prevent excessively high
pressure loss.
Connection to the tank must be done in a manner so that it is always below the oil
level.
TIP
 The medium may not be drawn in directly from the bottom of the tank
where deposited impurities or clogging may impair the function of the unit.
3.2 Pressure port connection
The nominal size of the pressure hose should be equal to that of the filter housing
port whenever possible. If a smaller hose size is used, the back pressure must
nevertheless be > 2 bar with a clean filter element.
Install the return line or return hose below the oil level to prevent air from entering
the fluid.
For back pressures of >1 bar (14.5 psi), a differential clogging indicator should be
installed.
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Filtromat – OF5 C
3.3 Electrical Installation
WARNING
Electric shock

The power plug must be pulled before
performing work on live parts
The voltage and frequency indicated on the OF5 C rating plate must coincide with
the voltage supply present.
The direction of rotation of the electric motor is checked by
switching the motor on briefly (jog mode). An arrow on the
fan cover of the motor shows the direction of rotation; when
looking at the fan wheel it must be turning in a clockwise
direction. Any reversal of the direction of rotation that may
be required is accomplished by switching two phases in the
terminal box of the engine or, in the event that the device is
equipped with an electric plug with phase switcher, by
rotating two phases in the plug.
The plug does not need to be dismantled to do this.
Depending on the voltage supply, the motor has to feature a star or delta connection
(cf. rating plate on the motor).
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Filtromat – OF5 C
3.4 Mode of Function
FCU
Saugschlauc
h
Suction hose
Druckschlauch
Pressure hose
KE 1310
Using the OF5C suction hose, the oil drawn in from a tank at zero pressure is
pumped through the filter and purified.
The purified oil exits the filter unit through the pressure hose. Part of the oil drawn in
is diverted to Fluid Control Unit FCU 2010/2110/2210 by auxiliary pump KE 1310.
This enables the purity of the oil drawn in to be constantly verified in accordance
with NAS 1638 and ISO 4406. Through the control functions of the FCU
2010/2110/2210, the filter unit can be switched off after it achieves a specified
cleanliness code. In addition, the system cleanliness can be kept within a specified
range (the user defines an upper and lower cleanliness limit using the MODE 4
function of the FCU2010/2110/2210).
If the required oil purity is (not) achieved, the OF5C automatically switches (on) off
after a delay of approx. 5 min.
If the filter element is clogged, the OF5C also switches off automatically. At the
same time, a signal lamp in the control cabinet lights up.
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Filtromat – OF5 C
4 Starting up the OF5 C
4.1 Inserting the filter element
When the filter unit is delivered, the filter element required is delivered in a separate
package. The filter element must be installed first.
Proceed according to chapter 5.1 "Replacing the filter element"
4.2 Filling the pump
If the unit is not feeding medium after several minutes of operation, the pump must
be pre-filled. Switch the motor off and fill using the suction hose.
4.3 Venting the filter housing
If the unit has started and is pumping properly, the filter housing has to be vented.
While the pump is running, loosen the vent plug (A) in the cover plate of the filter
housing. Open the cover plate only far enough to allow the air to vent from the filter
housing. As soon as oil leaks out, tighten the plug.
(A)
Vent each time the filter housing has run dry: after every filter element change, and
probably after a lengthy shutdown as well.
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Filtromat – OF5 C
4.4 Switching on the OF5 C
Use the main switch of the unit to switch on and off.
First, however, you must check the direction of rotation. To do this, start the motor
by switching it on for a short time (jog mode). An arrow on the fan cover shows the
direction of rotation: when looking at the fan wheel it must be turning in a clockwise
direction. If the direction of rotation needs to be changed, this can be done via the
phase inverter in the connection plug. The plug does not need to be dismantled to
do this.
The hoses (suction hose = thicker transparent hose, pressure hose = thinner one)
are immersed into the tank of the hydraulic system to be cleaned.
Make sure that the distance between the immersed hoses is as large as possible.
Set the OF5 C main switch at the control cabinet to position "I" and press the
OK/Start key of the FCU.
4.5 OF5 C in operation
After switching on the motor, check the suction action via the transparent suction
hose. It is not normally necessary to vent the filter housing because of the special
element locating spigot.
During operation, monitor the clogging indicator and the operating pressure.
When the visual clogging indicator responds, the filter element must be changed as
soon as possible.
Do not leave the unit unattended during operation.
Turn the flow rate control at the front of the FCU clockwise until it stops. When the
filter unit is switched on, this sets an immediate flush of the measured section.
After a brief flush, set a measured flow rate between 50 and 150 ml.
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Filtromat – OF5 C
4.6 Measuring the cleanliness code
When the OF5 C is switched on using the main switch of the control cabinet, the
FCU 2110-4 is switched on at the same time.
After a short time, the display of the FCU 2110-4 shows:
OK/Start measurement
Cancel Stop
Press the OK/Start key of the FCU. The measured flow rate appears on the display.
Now make the fine adjustment of the flow rate control to (typical case) approx. 100
+/50 ml/min.
If air is also drawn in during the suction process of conditioning unit KE 1310, it must
be vented to avoid distorting the measurement results.
It can take several minutes until the air has been removed from the system and the
flow rate has stabilized.
For a more detailed explanation of the special control menus available for controlling
the filter unit through the FluidControl Unit, see the operating instructions of the
FCU.
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