HYDAC International OLF-5 Series Manual

OffLine Filter Compact
OLF-5
with Temperature Sensor
Operating and Maintenance Instructions
English
Doc.: 3321664a

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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2006 by
HYDAC Filtertechnik GmbH
All rights reserved
This manual may not be reproduced in part or whole without the explicit written consent of
HYDAC Filtertechnik. Any violation hereof will be prosecuted to the maximum extent
possible under the law.
Exclusion of Liability
Every effort has been taken to ensure that the information provided herein is correct,
however, errors cannot be ruled out. Consequently, we accept no liability for such errors as
may exist nor for any damage or loss whatsoever which may arise as a result of such errors.
The content of the manual is checked regularly, with any corrections required being
incorporated in subsequent editions.
Technical specifications are subject to change without notice.
All details are subject to technical modification.
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar, Germany
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

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Contents
Contents ...............................................................................................................3
Preface..................................................................................................................4
1General Safety Information.................................................................................7
1.1 Explanation of Symbols and Warnings .................................................................... 7
1.2 General Remarks Pertaining to This Manual........................................................... 7
1.3 Hazards ................................................................................................................... 7
1.4 General Safety Remarks..........................................................................................8
1.5 Electrical Hazards.................................................................................................... 8
1.6 Maintenance and Servicing .....................................................................................8
1.7 Instructions to Be Followed in the Event of an Emergency......................................8
1.8 Structural Modifications ........................................................................................... 8
2Included with the Unit as Supplied ....................................................................9
3Description.........................................................................................................10
3.1 OLF 5/4-x...............................................................................................................10
3.2 OLF-5/15-x.............................................................................................................10
3.3 Restrictions Pertaining to the Use of the OLF 5 ....................................................10
3.4 Dimensions ............................................................................................................11
3.5 Hydraulic Schematic ..............................................................................................12
4Notes on Piping / Hoses....................................................................................12
5Connection and Commissioning......................................................................13
5.1 Electrical Installation ..............................................................................................13
5.2 Installation of the Temperature Sensor..................................................................13
5.3 Hydraulic Connection............................................................................................. 13
6Maintenance.......................................................................................................14
6.1 Maintenance Measures ......................................................................................... 14
6.2 Intervals for Changing Filter Elements................................................................... 14
6.2.1 Changing the Filter Element (DIMICRON®): ..........................................................14
6.2.2 Changing the Cartridge/Spin-on Filter Elements (MA, MG)...................................15
7Errors and Troubleshooting .............................................................................16
8Spare Parts and Accessories ...........................................................................17
9Decommissioning and Disposal.......................................................................18
10 Technical Specification.....................................................................................18
10.1 Product Key ...........................................................................................................19
10.1.1 Motor Power Rating / Motor Voltage............................................................... 19
10.1.2 Filter Element..................................................................................................19
10.1.3 Clogging Indicator........................................................................................... 20
11 Annex..................................................................................................................21
11.1 Wiring Diagram — 3313022 (3-phase version)......................................................21
11.2 Wiring Diagram — 3154019 (1-phase version)......................................................21

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Preface
We have compiled this documentation for you, the user of our product. It contains the
most important information relating to operation and maintenance.
It is intended to help you become acquainted with the ins and outs of the product and
use it properly.
Sometimes the information contained in this 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.
In these cases we go to every effort to keep your documentation current by sending
you updates (see “What’s New”).
But we need your help. Please make sure that you incorporate the updates in your
documentation and that non-current sections are removed.
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
SVFI, Techn. Documentation Dept.
P.O. Box 1251
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”

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Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please contact us. When contacting us, please always include the model/type
designation and article no. of the product:
Fax: ++49 (0) 6897 509 846
Email: [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 Conditions of Sale and
Delivery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com => E-Business => Legal information.

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... and now for a few tips on using this documentation.
The following example shows you how you can access the information you are looking for
quick and easy.
WHAT do I want to know?
WHERE can I find the information I’m looking for?
The documentation is subdivided into chapters and sections.
Look for the table of contents.
Skim the boldfaced section headings.
HOW can I find the section and page I’m looking for?
Page through the operating instructions, keeping your eyes focussed on the lower right
corner.
As soon as you see the page number you are looking for, stop paging.
The chapter/section heading is featured in the upper right corner of each
page.
The documentation number/edition and index are featured in the lower left corner of each
page and on the cover sheet of the instructions. This information features the following
format:
The documentation no. is a p/no. which is used to order the instructions.
The index is increased every time the instructions are revised or changed.
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.
Product
Page no.
Edition date of chapter/section
Documentation no. Index
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1 General Safety Information
1.1 Explanation of Symbols and Warnings
The following designations and symbols for hazards are used in this manual:
This symbol denotes safety precautions whose non-observance may pose a
hazard to individuals.
This symbol designates safety instructions whose non-observance may result
in injury of individuals by electric shock.
This symbol points to an important note for the proper use of the OLF-5. Non-
observance of these notes may lead to damage to the OLF-5.
This symbol is followed by user tips and particularly useful information. This
information helps you to optimally utilize all the features offered by your OLF.
This symbol prescribes a specific conduct to be followed:
- Switch the power unit off.
1.2 General Remarks Pertaining to This Manual
The basic prerequisite for the safe and proper handling and operation of the filter unit is
knowledge of the safety instructions and warnings.
This manual contains important instructions for safely handling the filter unit.
Adherence is to be maintained to pertinent accident prevention regulations applicable at the
site where the filter unit is used.
1.3 Hazards
The filter unit has been designed and constructed in accordance with the current state of the
art and recognized safety regulations. Nevertheless, hazards may be posed to the life and
limb of the individual operating the unit or to third parties. Risk of damage may be posed to
the unit or other property. In addition the filter unit may be damaged during transportation or
by improper handling.
The filter is to be used as follows:
• solely for its designated use
• only when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly repaired or remedied
immediately.

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1.4 General Safety Remarks
Keep this manual near the filter unit at all times.
Apart from the manual, observance is to be maintained to any and all general and local
regulations pertaining to accident prevention and environmental protection.
Make sure to keep the safety and hazard symbols and warnings on the filter unit in a legible
condition at all times.
1.5 Electrical Hazards
All work on the electrical equipment of the filter unit may only be carried out by a
qualified electrician.
Check the electrical equipment of the filter unit regularly. Any loose
connections or damaged cables are to be replaced immediately.
1.6 Maintenance and Servicing
All safety devices and equipment must be in place and fully functional before starting up the
filter unit.
1.7 Instructions to Be Followed in the Event of an Emergency
In case of emergency press the emergency off button on the filter unit.
1.8 Structural Modifications
Do not carry out any modifications, conversions or additions to the filter unit without the
written consent of HYDAC Filtertechnik GmbH.
No modifications may be made to the components without HYDAC Filtertechnik GmbH’s
express prior written approval.
Immediately replace any unit components which are not in perfect condition.
Only use original replacement parts. 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.
Refer to the instructions given in Maintenance below.

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2 Included with the Unit as Supplied
The filter unit is delivered packed. Before commissioning the filter unit, check the contents of
the consignment to make sure everything is present.
When receiving and unpacking the unit, check it for damage in transit. Report any damage to
the forwarding agent immediately.
The following items are supplied:
Item Qty. Designation
1 1 Off-Line Filter OLF-5 (model as ordered)
- 1 Operating and maintenance instructions

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3 Description
The OLF-5 series is based on the DIMICRON®off-line filtration concept.
Using the OLF-5 results in fewer oil changes, extension of the system filter life and service
life of components, and higher availability of machinery and equipment.
The unit can be equipped with filter elements with a filtration rating of up to 2 µm absolute,
with a contamination retention capacity of up to 200 g acc. to ISOMTD.
3.1 OLF 5/4-x
The OLF-5/4 filter unit range was especially designed for hydraulic lubrication systems (gear
boxes) with reservoir volumes of up to ca. 300 liters (85 US gal.). The filter units work with a
flow rate of 4 l/min. (1.01 US gal/min).
3.2 OLF-5/15-x
The OLF-5/15 range was especially designed for hydraulic systems with reservoir volumes of
up to ca. 2,000 gal. The filters work with a flow rate of between 5 and 15 l/min.
3.3 Restrictions Pertaining to the Use of the OLF 5
We recommend operating the filter unit with mineral oils or mineral oil-
based media in accordance with DIN 51524, 51525. Do not use other
operating fluids without our consent.
Contact us before using other fluids.

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3.4 Dimensions

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3.5 Hydraulic Schematic
4 Notes on Piping / Hoses
In order to keep the pressure differential as low as possible, use as few threaded
connections as possible.
The pressure differential in a hydraulic line depends on
• flow rate
• kinematic viscosity
• pipe dimensions
and can be estimated for hydraulic oils as follows:
υ ×××≈Δ Q
d
L
barp 4 84,5][
L= line length [m]
d= line internal diameter [mm]
Q= flow rate [l/min]
ν = kinematic viscosity [mm²/s]
This applies to straight pipe runs and hydraulic oil. Additional threaded connections and pipe
bends increase the pressure differential.
The difference in height between the pump and the oil level in the tank should be kept as
small as possible.
Hoses must be suitable at minimum for suction pressures of -0.5 bar.
Constrictions in the connections and lines should be avoided so as to prevent compromising
suction output or cavitation. The nominal size of the connected hoses/piping must be at least
as large as the inlet port sizes in order to prevent an excessively high negative suction
pressure.
The suction pressure must be in the range of -0.4 – 0.6 bar.

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5 Connection and Commissioning
Install the unit at a suitable place in the hydraulic system. Use the
integrated mounting base for this purpose.
It is imperative that the unit be installed in a vertical position.
5.1 Electrical Installation
• Ensure that the voltage and frequency of the power supply are correct.
Electric connection is to be done in accordance with local regulations.
Ensure that the voltage and frequency of the power supply are correct.
• The filter unit is available in various electrical versions (1-phase / 3-phase).
• The electric diagram for your filter unit is located in the annex of this operating and
maintenance manual.
• Electrical connection is done by clamping the loose end of the connecting line as
shown in the electrical diagram.
The connecting line is ca. 5 m long.
5.2 Installation of the Temperature Sensor
• Secure the temperature sensor to the suction hose using two cable ties.
Position the sensor on the hose fitting in the vicinity of the suction port of the gear
box.
5.3 Hydraulic Connection
Note the oil level. If necessary, provide for additional shut-off valves
when changing the filter element.
• Connect the outlet port (OUT) of the unit with the hydraulic reservoir or appropriate
container by using a hose or a tube and secure it.
The outlet (OUT) must never be obstructed or closed off during
operation.
• Connect the inlet port (IN) of the unit with a suction hose or tube of the hydraulic
system, and secure it. If the OLF-5 is not fitted with a pump, connect the inlet port (S)
with the return line of the hydraulic system.
If coarse contamination (> 100 µm) is present, such as welding pearls, an appropriate
strainer should be installed in order to protect the pump. When placing the filter unit
below the oil level, a valve is required on the suction side so that the filter element
can be changed.

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The nominal size of the connected hoses/piping must be at least as large
as the inlet/outlet port sizes of the pump.
• If no liquid is pumped by the unit, the pump should be primed. This can be done at
the suction connection when the motor is switched off.
OLF-5/4. For operating viscosities of < 200 mm²/s, the max. flow rate is
not achieved until after approx. 10 minutes when the pump is not primed.
6 Maintenance
Adjustment and maintenance work is to be carried out within the period stipulated.
6.1 Maintenance Measures
Replacement parts have to satisfy the manufacturer's technical requirements. This is
guaranteed for all replacement parts procured from HYDAC Filtertechnik GmbH.
Clean all parts of the disassembled filter. Check if they are damaged or worn out and, if
necessary, replace them.
When replacing the filter element extreme care is to be taken that no dirt or other foreign
matter enters the hydraulic system.
6.2 Intervals for Changing Filter Elements
The filter is equipped with a gauge for monitoring the filter element, the gauge indicating any
pressure drop in the filter housing upstream of the filter element.
The filter element is considered to be contaminated when the differential pressure indicator
reaches 2 bar (the needle gauge enters the red area), in which case the filter element must
be replaced.
If electrical clogging indicators are installed, the right time for changing the filter element is
indicated by an electrical signal.
6.2.1 Changing the Filter Element (DIMICRON®):
• A: Switch the unit off and relieve the filter of pressure by carefully opening the drain
screw (wrench size: 6 mm) on the bottom of the filter housing (do not unscrew the
drain screw completely). Loosen the tensioning clamp on the filter housing and
carefully remove the filter housing.
• When the clogging indicator shows "green" this means that the pressure in the filter
unit has been relieved. Watch out for exiting hydraulic fluid.
• B: Make sure that no further oil from the tubing of the hydraulic system enters the
filter unit and that nobody can switch the unit on again during maintenance work.
• Empty the filter housing completely through the drain screw (volume: approx. 2 liters).

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• Loosen the tensioning clamp by opening the screw, then carefully remove the filter
housing. Clean the housing and check all parts for possible damage. Remove the
filter element by pulling it down. Check the O-ring and, if necessary, replace it.
• The filter element features twistlocks (bayonet or quarter-turn fasteners). This
facilitates changing it. All that needs to be done is to turn the element by 90° in a
clockwise or counterclockwise direction.
• Release the filter element and carefully unscrew it by hand.
When opening the tensioning clamp be careful as there may be
residual oil in the filter housing.
• Wet the O-ring between the filter housing and middle part and the O-rings on the filter
element with clean operating fluid. Now the new filter element can be inserted and
pressed tightly onto the connection piece.
• Check the O-ring of the contamination retainer seal for damage and, if necessary,
replace it.
• Slip the filter housing over the element, making sure that it seals properly and secure
it with the quick-action fastener. Tightening torque for the quick-action fastener: 5
Nm (max. 10 Nm).
• (Make sure that the drain screw located on the underside of the filter housing has
been securely screwed back in.)
6.2.2 Changing the Cartridge/Spin-on Filter Elements (MA, MG)
• Switch the unit off and relieve the filter of pressure by carefully opening the drain
screw (wrench size: 6 mm) on the bottom of the filter housing (do not unscrew the
drain screw completely). Release the filter element and carefully unscrew it by hand.
Watch out for exiting oil.
• Make sure that no further oil from the tubing of the hydraulic system enters the filter
unit and that nobody can switch the unit on again during maintenance.
• Replace all gaskets and seals with the new ones supplied, slightly wet the sealing
ring with oil, and manually screw the filter cartridge tight.
There may be up to 1 liter of oil left in the filter element.

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7 Errors and Troubleshooting
Error Cause(s) Remedy
Pump conveys in the
wrong direction
Check the arrow on the housing — if necessary
change the electrical connection
Air in suction area
and pump
It might take several minutes until the pump has
transported the air off and starts pumping the
fluid. Turning the OLF-5 in a horizontal position
for a few minutes helps.
If the unit is still not pumping the fluid after
approx. 5 min, fill the pump via the suction side.
No oil flow
Operating viscosity
< 200 mm²/s and
pump not primed
Operating condition in which the max. flow rate
is not achieved until after approx. 10 minutes.
Medium heavily
contaminated
Service life of the
filter element
exceeded
Replace filter elementFilter
contaminated
(Clogging indicator
has been
triggered)
Viscosity of the fluid
too high Wait until the oil has been warmed up by pumping within the pump (pressure relief valve
open). After the fluid has been warmed up the
pump starts conveying.
Leakage at the
filter housing
Check if the drain screw or the tensioning
clamp on the filter housing has been tightened.
(Tightening torque for tensioning clamp: 5 Nm
(max. 10 Nm))
Check the O-ring for damage, if necessary
replace it.
For spin-on units, check if the element has
been tightened, or change the seal.

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8 Spare Parts and Accessories
Qty Description p/no.
NBR 303191
1 Clogging indicator VM2BM.1
(differential pressure indicator, visual) FPM 303200
4 O-ring FPM 635966
1 O-ring FPM 634517
NBR 3054619
1
Repair kit pump OLF-5/xx,
consisting of:
O-rings, vanes, shaft seal, screws FPM 3081959
NBR 3052460
1
Repair kit OLF-5/4,
consisting of:
vane pump, 6 O-rings, 4 screws FPM 3075885
NBR 3052462
1
Repair kit OLF-5/15,
consisting of:
vane pump, 6 O-rings, 4 screws FPM 3075886
120V/60Hz 6008059
230V/50Hz 6008058
1 Electric motor
400V/50/Hz 609070
1 Filter element 2 µm, DIMICRON N5DM002 349494
1 Filter element 5 µm, DIMICRON N5DM005 3068101
1 Filter element 10 µm, DIMICRON N5DM010 3102924
1 Filter element 20 µm, DIMICRON N5DM020 3023508
1 Filter element 2 µm, AQUAMICRON N5AM002 349677
1 Filter element 20 µm, AQUAMICRON N5AM020 3040345
1 "HYDAC" label 625925
1 Danger sign "direction of rotation, motor" 3252700

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9 Decommissioning and Disposal
When decommissioning and/or disposing of the OLF-5, adherence is to be maintained to
local guidelines and regulations pertaining to occupational safety and environmental
protection. This applies in particular to the oil in the unit, components covered with oil and
electronic components.
After disassembling the unit and separating the various materials, they can be reused or
disposed of properly in accordance with local regulations.
10 Technical Specification
Bypass-cracking pressure of filter element approx. 3.5 bar
Operating pressure approx. 4.5 bar
Permissible contamination < NAS 12
acc. to ISO 4406:1999 class 23/21/18
Flow rate 4 l/min OLF-5/4
Viscosity range OLF-5/4:
- 15-7000 mm²/s: operating range
- 15-200 mm²/s: viscosity range in which
the max. flow rate is not achieved until
after approx. 10 minutes when the pump
is not primed.
Permissible pressure at suction port (IN) -0.4 ... +0.6 bar (mineral oil)
Fluid temperature range 0 ... +80°C (32 ...176°F)
Ambient temperature -20 ... +40°C (-4 – 104°F)
IP class IP 54
Weight approx. 16.5 kg
Filtration rating b (2) > 1000 (Δp 2.5 bar) for N5DM filter
elements
Switching temperature, thermostatic
switch 25 °C
Length of line to thermostatic switch approx. 1.2 m
Length of connector line approx. 5.0 m

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10.1 Product Key
OLF 5/xx - S - xxx - x - N5DM002 -BM
Basic type designation
Filter size
5 - Q = 5 l/min
5/4 - Q = 4 l/min
5/15 - Q = 15 l/min
Version
S - Standard — NBR
(with motor-pump assembly)
SV - Standard — FPM
(with motor-pump assembly)
SP - Spin-on filter element
E - With flow control valve
(without motor-pump assembly)
F - Filter version
T - Toploader — NBR
TV - Toploader — FPM
Motor power rating / motor voltage
(see table in section 10.1.1)
Filter element
(see table in section 10.1.2)
Clogging indicator
(see table in section 10.1.3)
10.1.1Motor Power Rating / Motor Voltage
OLF-5 OLF-5/4 OLF-5/15
5 l/min. 4 l/min. 15 l/min.
120-N 120 W, 3x400 V, 50 Hz   
120-M 120 W, 1x230 V, 50 Hz   
120-K 120 W, 1x120 V, 60 Hz   
370-N 370 W, 3x400 V, 50 Hz
370 W, 3x440 ... 480 V, 60 Hz   
370-M 370 W, 1x230 V, 50 Hz   
370-K 370 W, 1x120 V, 60 Hz   
200-U 200 W, 24 V DC   
Z-Z Without motor (version E and F, only)   
10.1.2Filter Element
OLF-5 OLF-5/4 OLF-5/15
5 l/min. 4 l/min. 15 l/min.
N5DM001 DIMICRON, Filter mesh 1 µm absolute   

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OLF-5 OLF-5/4 OLF-5/15
5 l/min. 4 l/min. 15 l/min.
N5DM002 DIMICRON, filter mesh 2 µm absolute   
N5DM005 DIMICRON, filter mesh 5 µm absolute   
N5DM010 DIMICRON, filter mesh 10 µm absolute   
N5DM020 DIMICRON, filter mesh 20 µm absolute   
N5AM002 Aquamicron, filter mesh 2 µm absolute   
N5AM020 Aquamicron, filter mesh 20 µm absolute   
M160B003 Spin-on element, filter mesh 3 µm absolute   
M160B005 Spin-on element, filter mesh 5 µm absolute   
M160B010 Spin-on element, filter mesh 10 µm absolute   
M160B020 Spin-on element, filter mesh 20 µm absolute   
M180B003 Spin-on element, filter mesh 3 µm absolute   
M180B005 Spin-on element, filter mesh 5 µm absolute   
M180B010 Spin-on element, filter mesh 10 µm absolute   
M180B020 Spin-on element, filter mesh 20 µm absolute   
Z Without filter element   
10.1.3Clogging Indicator
OLF-5 OLF-5/4 OLF-5/15
5 l/min. 4 l/min. 15 l/min.
E Pressure gauge   
F Pressure switch, electrical (VR2F.0)   
BM Differential pressure indicator, visual (VM2BM.1) ٭  
C Differential pressure indicator, electrical (VM2C.0) ٭  
D Differential pressure indicator, visual / electrical
(VM2D.0) ٭  
Z Without clogging indicator   
* - not for OLF-5-S