HYDAC International OLS Manual

OLS
OffLine Separator
Operating and Maintenance Instructions
Doc.: 3329742a

OffLine Separator - OLS
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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
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
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. Any corrections required will be incorporated
in subsequent editions. We welcome any suggestions for improvements.
Technical specifications are subject to change without notice.
All details are subject to technical modifications.
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar, Germany
Germany
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

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Content
1Safety information and instructions..............................................................................7
2Abbreviations and symbols ...........................................................................................7
3Packaging ........................................................................................................................7
4Suitable fluids..................................................................................................................8
5Range of application.......................................................................................................8
6Typical dewatering rates ................................................................................................8
7Dimensions......................................................................................................................9
8Models............................................................................................................................10
9Installation .....................................................................................................................11
9.1 Mounting/arrangement...............................................................................................11
9.2 Suction port connection..............................................................................................11
9.3 Pressure port connection ...........................................................................................11
9.4 Drain water port connection .......................................................................................12
9.5 Electrical connection ..................................................................................................12
10 Operating .......................................................................................................................13
10.1 Working principle........................................................................................................13
10.2 Starting.......................................................................................................................13
10.3 Running and water drainage......................................................................................13
10.4 Filling up.....................................................................................................................14
10.5 Oil sample ..................................................................................................................14
10.6 Stopping and draining ................................................................................................14
11 Filter element replacement........................................................................................... 15
12 Maintenance ..................................................................................................................16
12.1 First month or 700 hours of operation........................................................................16
12.2 First 6 months or 4400 hours of operation .................................................................16
12.3 Daily ...........................................................................................................................16
12.4 Weekly........................................................................................................................16
12.5 Monthly or every 700 hours operation........................................................................16
12.6 12 months or every 8800 hours operation..................................................................16
13 Parts list.........................................................................................................................17
14 General arrangement .................................................................................................... 18
15 Piping diagram ..............................................................................................................19
16 Electric diagram ............................................................................................................20
17 Technical specifications...............................................................................................21
18 Model code ....................................................................................................................22

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Foreword
For you,
as 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 proper/designated use 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 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.
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
Dept.: SFVI, Techn. Documentation
P. O. Box 1251
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
The editor would welcome your involvement.
“Putting experience into practice”

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Customer Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please contact: When contacting us, please always include the model/type
designation and article no. / serial no. / firmware version 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 ÖLegal 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.
1. Look for the table of contents.
2. 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 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 part 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 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.
Productdescription or
Chapter heading
Page no.
Edition date of chapter/section
Documentation no. Index
BeWa Product 12345678a en

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1 Safety information and instructions
Operating- and maintenance may only be carried out by technically skilled and trained
personnel, in compliance to EN60079-17 of 2003 and EN60364. Personnel can first be
entrusted, when they have read this operating and maintenance instruction carefully.
The safe operation of the OffLine Separator OLS 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 OffLine Separator.
In addition to any instructions for safe operation of our OffLine Separator OLS, all national
and provincial workplace safety and health regulations must be observed, as well as in-plant
safety regulations.
Spills of dangerous substances must be contained and disposed in accordance with current
waste disposal legislation.
Water drained from the OffLine Separator OLS is contaminated with the main fluid and must
be treated as chemical waste. The drained water must be disposed in accordance with
current waste disposal legislation.
Before any maintenance or repair work is carried out on the OffLine Separator OLS,
electrical power supply must be disconnected, the filter housing must be de-pressurized and
drained completely.
2 Abbreviations and symbols
The following symbols are used to denote safety precautions and information.
This symbol denotes safety precautions, the non-observance of which can
endanger persons and the environment
This symbol denotes safety precautions, the non-observance of which can
endanger persons by electrical shock.
This symbol marks an important note for the proper use of the unit / software.
The non-observance of these notes can lead to damage or failure of the unit
/ software.
This symbol is followed by user tips and particularly useful information.
3 Packaging
All OffLine Separator Units are tested at the factory for leaks and function. They are then
carefully packaged for shipment.
The fluid connections are all sealed to prevent the intrusion of contaminants during transport.
Upon receipt of the unit, check for any damage from transportation.
The packaging material should be re-used/re-cycled as appropriate for your area.
These Operating and Maintenance Instructions are a component part of the OffLine
Separator OLS.

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4 Suitable fluids
Warning:
Use of aggressive or explosive fluids in the pump-motor group is prohibited.
The OffLine Separator OLS is intended to be used with lubricating and mineral oils or mineral
oil based fluids or biodegradable liquids – based on synthetic ester.
Consult the manufacturer in case of questions for use with other fluids.
5 Range of application
The OffLine Separator OLS is a stationary Oil treatment unit for indoor use only. The OffLine
Separator OLS is for installation in an off-line loop, but are also suitable for filling and transfer
applications.
Viscosity range 12 - 20.000 mm²/s (cSt)
Pmax: 6 bar (86 psi)
Tmax: 80° C (176°F)
Tambient: 10 - 60° C (50 – 140°F)
Use without motor-pump group It is important to ensure that the fluid flow is pulsation
f
ree.
6 Typical dewatering rates
Öltyp
Fluid type
Type du fluide
Volumenstrom
Volume flow rate
Débit volume
(l/min)
Temperatur
Temperature
Température
(°C)
Elementenanzahl
Element quantity
Nombre
d‘éléments
Wassergehalt
Water content
Teneur d’eau
(Vol.-%)
Entwässerungsrate (Ø)
Dewatering rate (Ø)
Taux de déshydratation (Ø)
(l/h)
2,0 5,0
ISO VG 320 5 50 11 0,5 0,6
2,0 0,5
ISO VG 32 5 40 11 0,5 0,02

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7 Dimensions
510
ca. 1380
600
360 Ε12
Vorderansicht
Front view
Seitenansicht
Side view
Draufsicht
Top view
ca.418
410
G1/2"

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8 Models
The OffLine Separator OLS is offered in a wide range of standard models, all based of 4
main groups. For each main groups different items can be selected, e.g. depending upon the
viscosity of the fluid, volume of the system to be treated and demand of different control
options.
Main group Item Range/Variant
Vane pump 15 - 250 mm²/s (cSt)
Gear pump 15 -1.000 mm²/s (cSt)
Centrifugal pump 1 -20 mm²/s (cSt)
Pump Type
Without pump 1 - 1.000 mm²/s (cSt)
Size 10", 20" and 30"
Filter Element(s) Filtration rating 5μ(absolute)
Without
Man. motor starter
Motor protection
Control box
Manual
Water drainage Automatic *
Visual
Electric f. alarm signal
Operations control
Clogging indicator
Visual/electric f. alarm signal
Without -
Electrical ** 1 - 4 kW, (1,5 W/cm2)
Preheating
Water (heat
exchanger)
Depending on accessible
heating source.
* Only models with electric control box.
Consult the manufacturer in case of selection of an OffLine Separator OLS for a specific
application/system.

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9 Installation
9.1 Mounting/arrangement
The OffLine Separator OLS must be mounted in level and on a flat surface. No special
mounting is required. The standard pump is designed for ambient temperatures at 10 - 40°C
(50 - 104°F). In order to prevent the motor from overheating, adequate cooling air must be
provided.
Sufficient room to remove the filter element(s) must be left around and above the
housing.
9.2 Suction port connection
The suction port may be connected to a flexible hi-collapse hose, or to hard piping. If the
OffLine Separator OLS is connected to hard piping, precautions must be taken to ensure that
no stresses or vibrations are transmitted to the pump/filter housing. It may be necessary to
install flexible dampeners.
Constrictions in the connections and lines should be avoided to prevent compromising
suction output (⇒Cavitation danger).
The suction hose or pipe must be connected at the reservoir bottom (lowest point),
to secure efficient water removal from the main system.
9.3 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 pressure drop must nevertheless be
higher than 2 bar (29 psi) with a clean filter element
The nominal size of the connected hoses/piping, must be at least as large as the
inlet port sizes of the pump.
If large contaminant particles are present (>100 µm), an appropriate strainer must
be installed in the suction line to protect the pump.
If the OffLine Separator OLS is installed below the fluid level of the reservoir, shut
off valves must be installed in order to allow filter element replacement.
If a model without a pump-motor group is used, it is important to ensure that no
pressure pulsation is transmitted to the OffLine Separator OLS.
For back pressure above 1 bar (14.5 psi), a differential clogging indicator should
be installed.

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9.4 Drain water port connection
Connect the drain water port connection to an open downgrade pipe system or connect the
port to a receiver/can that regularly are emptied to a disposal drum.
If the drain water port is connected to a downgrade pipe system, it is
recommended to make a visual inspection point at the OffLine Separator OLS
e.g. with a funnel.
9.5 Electrical connection
The electrical connection must be carried out by a qualified electrician. All
local and national electrical regulations and codes must be adhered to. If any
electrical or electromagnetic disturbances are likely in the supply system,
please inform the manufacturer.
• The voltage, frequency and fuse size stated in specifications, must agree with the
installations at the electric power supply to the OffLine Separator OLS.
• Turn the Main Switch to position "OFF" and connect the electrical power supply to the
control box according to the wire diagram.
• Connect the electrical power supply and check that the correct voltage are
represented at the terminals.
• If so, turn the Main Switch to position "ON" shortly and check direction of rotation on
the motor. The correct rotation is indicated by an arrow on the fan cover.
• If the direction are wrong, disconnect the power supply, change two phases at three
phase motors or position of capacitor at single phase motors and re-connect the
electrical power supply.
If the OffLine Separator OLS are delivered without control box or manual motor
protection, care must be taken to protect the motor from overload.

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10 Operating
10.1 Working principle
The OffLine Separator OLS are divided in two chambers by means of the sealing flange. The
upper housing, the filter chamber, contains the offline filter element where impurities are
removed from the oil. The lower housing, the separator chamber, contains spacers,
guidepipe and drip catcher filter. In the lower housing water is separated from the oil and
collected at the bottom of the housing.
The pump draw oil from the main reservoir, discharge it into the filter chamber and through
the offline filter element into the centre hole. From the centre hole the clean oil are lead down
to the separation chamber, out to the periphery of the housing and down through the
spacers, where water particles are collected to tiny drops and sticks to the surface of the
spacers. At end of the guidepipe, the oil changes direction and flows upwards and leaves the
separator chamber through the drip catcher filter.
10.2 Starting
• Close the drain valve.
• Install the bleed plug, but leave it open.
• Open the shutoff valve if installed.
• Start the pump and observe, that air is bleeded from the bleed plug.
• Fill the housing completely, keeping the bleed port open until fluid escapes.
• Observe that the differential pressure rises on the clogging indicator.
10.3 Running and water drainage
It is recommended to keep the OffLine Separator OLS running fulltime, even though the main
system is stopped. Hereby a high degree of purity and low degree of water content are
obtained.
If the oil is contaminated, the removed impurities will clog the offline filter element and
causing a slowly rising differential pressure. When the differential pressure rises to about 3
bar, the offline filter element must be replaced.
If water is present in the oil, the water are collected at the bottom of the separation chamber
and can be drained at the drain port. Place a bucket under the drain port outlet and carefully
open the drain valve slightly. Observe the drained fluid and leave the valve open as long as
water is drained. Close the drain valve when oil are present.
Warning:
The drained water is contaminated with the main fluid and shall be treated as
chemical waste.

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10.4 Filling up
The OffLine Separator OLS can be delivered with a change over valve at the suction line, so
the can draw oil either from the main reservoir or from a barrel for filling up.
• Connect a hose to the filling up port and place the other end under the surface in the
barrel.
• Start the pump, if not running.
• Turn the lever on the change over valve to the filling up position. The pump will now
draw oil from the barrel and discharge it to the main system through the offline filter
element.
• Return the lever on the change over valve to the inlet position at normal level in the
main reservoir, or when the barrel are empty.
• Remove the hose from the filling port.
10.5 Oil sample
The oil sample point are connected to pressure line from the pump and before the offline
filter element, so oil from the sampling point represents the condition in the main reservoir.
Oil samples are drawn out as dynamic samples.
• Start the pump if not running, and wait at least 1 hour to secure that the oil in the inlet
line represents the oil in the main reservoir.
• Place a bucket under the sampling point.
• Open the sampling point valve slightly and let the oil drain to the bucket for at least 30
seconds.
• Place the clean sample glass in the oil squirt and remove it (do not close the valve!)
when the glass is full.
• Close the sampling point valve.
• Seal the sampling glass with the top and wipe off the glass.
• Mount the protection plug and remove the bucket.
• Fill in sampling information on the label and stick it to the sampling glass.
10.6 Stopping and draining
• Stop the pump.
• Close the shut off valves.
• Place a clean bucket/barrel under the sampling point and drain valve.
• Open the valves.
• Unscrew and remove the bleed plug.
• Close the valves when the housing is empty.

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11 Filter element replacement
The OffLine Separator OLS is supplied with filter element(s) at delivery. At replacement of
Filter element, the electrical power supply must be disconnected, the housing must be de-
pressurized and completely drained.
Replacement procedure is as follows:
• Disconnect the electrical power supply, if the Separator has a pump-motor group
installed,
• Close shut off valves, if installed.
• De-pressurize the housing by carefully opening the bleed plug on the top of the
housing.
• Open the sampling point valve and the drain valve and collect the fluid (follow
regulations for personal protection and environmental protection).
• When the housing is completely drained, open the housing clamp and remove the
upper housing.
• Turn the locking cap 90° in a counterclockwise direction for one element package.
For each additional element package turn an additional 90°.
• Remove the contaminated element(s) and clean the filter (upper) housing.
• Remove the sealing flange for inspection of the separation (lower) housing. Remove
the spacers and outlet demister and clean them if required.
• Inspect the O-ring(s) for damage, and renew if necessary.
• Install drip catcher filter, oil guide filter, spacers, sealing flange and new filter
element(s) in reverse order to the removal sequence.
• Grease and install O-ring. Re-install the upper housing and clamp. Tighten the
housing clamp until the two housing halves seat against each other.
• Re-install the bleed plug, but leave it open.
• Close the sampling point valve and drain valve, open the shutoff valves if installed,
connect the electrical power supply and start the pump.
• Fill the housing completely, keeping the bleed port open until fluid escapes from it.
WARNING:
Do not unscrew the bleed port plug completely. The plug has vent grooves.
• Dispose the contaminated filter element(s) in accordance with local waste disposal
regulations.

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12 Maintenance
12.1 First month or 700 hours of operation
• Tighten up all cutting ring fittings, screws and bolts.
12.2 First 6 months or 4400 hours of operation
After the first 6 months or 4400 hours operation the clutch must be inspected. Remove
inspection cover on clutch housing. If wear is found at the clutchparts, the reason must be
found and eliminated before the OffLine Separator OLS is restarted. See instruction book
from manufacturer of the clutch for further details.
12.3 Daily
• Inspect the OffLine Separator OLS for leaks.
• Observe the clogging indicator. If the backpressure are above 2,5 bar, the Filter
Element must be replaced.
12.4 Weekly
• Observe that the motor-/pumpgroup are running without extreme noise and
vibrations.
12.5 Monthly or every 700 hours operation
• Open bleed plug at top of the housing until oil appears.
• Carefully open the drain valve slightly until oil appears.
12.6 12 months or every 8800 hours operation
• Replace the Filter Element and o-ring.
• Clean all parts in Separation chamber.
• Inspect bearings in motor, replace if needed.
• Inspect bearings and shaftseal in pump, replace if needed.
• Inspect clutch for wear and replace if needed.
• Inspect hoses for damages and crack formations, replace if needed.
• Tighten up all cutting ring fittings, screws, bolts and electric terminals.

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13 Parts list
Description p/no. Qty.
Foot 3299738 1
Bottom piece 3299623 1
Extension piece 3299994 -
Cover, flat 3030462 1
Clamp 6028356 1
O-ring for housing FPM 6012630 2
Filter element, 5µm for coalescence bowl N15OR005-1F 3305651 11
In order to ensure safe and reliable operation, use only original replacement parts
and accessories. When ordering replacement parts, always quote the model and
serial number (see model plate).

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14 General arrangement

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15 Piping diagram

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16 Electric diagram