Hydac RFX User manual

RFX
Reducer of Fluid oXidation
Installation and Maintenance Instructions
English (translation of original instructions)
Document No.: 3570845

Reducer of Fluid oXidation Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2010 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC FILTER SYSTEMS GMBH. 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, 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 future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC FILTER SYSTEMS GMBH
Industriegebiet
66280 Sulzbach / Saar
Germany
Contact person for documentation
Mr. Günter Harge Department: ZQW
Telephone: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-mail: [email protected]

Reducer of Fluid oXidation Content
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Content
Trademarks ...............................................................................................................2
Contact person for documentation.......................................................................... 2
Content......................................................................................................................3
Preface ...................................................................................................................... 4
Technical Support...................................................................................................5
Modifications to the Product ...................................................................................5
Warranty .................................................................................................................5
Using the Documentation .......................................................................................6
Safety Information and Instructions....................................................................... 7
Obligations and Liability.......................................................................................... 7
Explanation of Symbols and Warnings, etc. ...........................................................8
Proper/Designated Use .......................................................................................... 8
Improper Use .......................................................................................................... 8
Informal Safety Precautions.................................................................................... 9
Electrical Hazards...................................................................................................9
Training and Instruction of Personnel ...................................................................10
Storing the RFX ...................................................................................................... 11
Storage conditions ................................................................................................11
Description of the RFX...........................................................................................12
Introduction ............................................................................................................ 13
Function ..................................................................................................................14
Installation .............................................................................................................. 15
Start up.................................................................................................................... 17
Normal function...................................................................................................... 18
Maintenance and regular checkups......................................................................20
Empty out ................................................................................................................ 22
Decommissioning the RFX.................................................................................... 23
Disposing of the RFX ............................................................................................. 23
Technical data ........................................................................................................ 24
Customer Service................................................................................................... 25

Reducer of Fluid oXidation Preface
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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 will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
The editorial department looks forward to receiving your input.
“Putting experience into practice”

Reducer of Fluid oXidation Preface
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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 part-no. of the product:
Telefax: ++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 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
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com General terms and conditions.

Reducer of Fluid oXidation Preface
Using the Documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior 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.
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Chapter description
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.

Reducer of Fluid oXidation Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely
operating the Unit.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the unit is
knowledge of the basic safety instructions and safety regulations.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the Unit.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety instructions listed here are restricted to use of the unit.
The RFXhas 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 using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
The Unit is to be used only:
solely for its designated use
only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
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 unit or use deviating from its designated use
improper assembly/installation, start up, operation and maintenance of the unit
modifications to the Unit made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

Reducer of Fluid oXidation Safety Information and Instructions
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to mortal
injury if safety precautions are
not observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The TransformerCare Unit was designed for stationary, continual degassing and
dewatering of transformer oil.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use; the manufacturer accepts no liability for any damage resulting from
such use.
Proper or designated use of the product extends to the following:
Permanent degassing and dewatering of transformer oil
Maintaining adherence to all the instructions contained herein.
Improper Use
Improper use may result in hazard to life and limb.
Examples of improper use:
Improper connection of the Unit voltage and sensor cables.
Operation with non-approved fluids.
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Reducer of Fluid oXidation Safety Information and Instructions
Informal Safety Precautions
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 is to be maintained to them.
Make sure that the safety and hazard symbols and warnings on the unit are always
in a legible condition. Replace them if necessary.
Check the connection parts for leaks on a daily basis.
Check The RFXelectrical equipment on a monthly basis. Immediately replace loose
connections, damaged cables and hoses with original spare parts.
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Electrical Hazards
DANGER
Electric shock
Bodily injury leading to death
►Any work involving electrical equipment may only
be done by a properly trained, certified electrician.
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Reducer of Fluid oXidation Safety Information and Instructions
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Training and Instruction of Personnel
The Unit may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the unit unless supervised by an experienced
staff member.
Individuals
Persons undergoing training
I
n
di
v
id
ua
l
s w
ith
technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Troubleshooting, mechanical
problem X X
Troubleshooting, electrical problem X X
Maintenance X X X X
Repair work X
Shutdown /
decommissioning X X X X

Reducer of Fluid oXidation Storing the RFX
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Storing the RFX
Make sure to store The RFX in a clean, dry place, in the original packing, if possible.
Do not remove the packing until you are ready to install the unit.
Storage conditions
Storage temperature: -40°C ... +80°C / -40°F ... 176°F
Relative humidity: max. 95%, non-condensing

Reducer of Fluid oXidation
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Drain connection with hose adapter
Pressure inlet
with safety screen
A-distance
measured while
supply pressure is
off
Return outlet
Bottom block
Main block
RFX vacuum chamber
Empty out plug
4 x M12 Threaded
holes for
fastening bolts
Top block
Glass tube
Float
Piston rod
Cool
connection
Description of the RFX
The RFX is an abbreviation of REDucer of Fluid OXidation and is a hydraulic powered
degassing and dewatering unit. The RFX demands only small space, has low power
consumption and low weight. The RFX is made for permanent installations in mobile
machines as well as in stationary systems, where the oil condition is of great concern.

Reducer of Fluid oXidation Introduction
Introduction
In hydraulic systems or in other technical systems where oil is used for power transmission,
lubrication or insulation, the absorption of air and water has a poisioning affect. Air and water
reduce not only the lifetime of the oil but also function and reliability of the system. This
poisoning effect is spontaneously added through the oil’s contact with the atmospheric air
and cannot be avoided without special arrangements.
100% oil
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%
10%ai
r
1
000 ppm water
New oil contains air and water. The size is proportional.
Oil absorbs at normal atmospheric pressure approximately 10 % air by volume.
An oil reservoir with 100 dm3 clear oil can through vacuum treatment release 10 dm3air of
atmospheric pressure. The same oil can also contain between 100–1000 ppm water
depending on its base stock. The oil in the reservoir can therefore contain 10–100 cm³ water
and still be clear.
The RFX continuousely treats oil with vacuum and reduces air and water level in oil to
harmless levels. The RFX is simple to install as an integrated part of the system and needs
only low power that most of the time can be delivered by the system itself.
The RFX is used when the demands of oil conditon are high, when reliability and long life of
the hydraulic system are important and/or the reduction of volume and weight for the
hydraulic installation is wanted.
Examples:
Forestry machines
Paper industry
Lubrication systems
Transformer systems

Reducer of Fluid oXidation Function
Function
The RFX works in 2–4 minutes long working cycles where every cycle has two phases.
During the whole cycle the oil is under vacuum. This is shown by foaming that is more or less
significant depending on the oil condition and air content.
Phase II
Maximum oil level
durin
g
o
p
eration Piston rod in lower
position
Piston rod in
upper position
Minimum oil level
Phase I
Phase I
In the first phase oil is supplied at the same time as the centrally positioned piston rod moves
to its upper position. When this position is reached, the oil free space inside the glass tube is
connected to an inner cylinder which has in this position its largest volume and lowest
pressure. When the connection is made, pressure equalization starts. Air and steam flow
down to the inner cylinder. This phase is ended when the liquid level float changes to a new
firm position relative to the piston rod.
Phase II
The second phase is started when the piston rod moves downwards to its lower position and
the oil suction starts. When the piston rod leaves the top block, the connection between the
two chambers is closed. Air is compressed and leaves the unit through a check valve in the
drain adapter. The phase is finished when the float changes its position to a lower firm level
and oil is supplied again.
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Reducer of Fluid oXidation Installation
Installation
To ensure correct function and reliable running, The
RFX needs to work under special conditions, which
can be achieved by correct installation. Warranty can
be denied if an approval is not received. Approval is
made by the manufacturer or its representant.
The RFX may not have a larger angle
during function than 25
 .
Mechanical installation
* Placement: The RFX is an instrument in proactive
maintenance and should be easy to inspect daily. Its
drain adapter must be easy to reach. The RFX shall
be put up vertically so that the angle in normal cases
never exceeds 25o.
Maximum 3 mm thickness
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* Temperature: The RFX should be mounted so that
the roof is kept cold but never below zero. The
bottom of the RFX should be mounted so that the
temperature is as cold as possible but never during
runtime below zero. Therefore The RFX should not
be mountened close to warm radiation.
* Vibrations: The RFXshould never be placed in
direct contact with vibrating devices. If vibrations
cannot be avoided the fastening shall be made with
rubber elements that reduce the vibrations.
Mounting block: The fastening of The RFX is done in
four threaded holes in the bottom. Screw dimension
M12. Maximal length in block 18mm. The mounting
plate must allow
space for the drain
connection. A hole
with minimum diameter of 30 mm is demanded. If the
console is torsion weak so that the top will oscillate in the
horisontal plane, it is recommended that the top is stayed
by a central bolt. Note that the top staying is only allowed
to take small vertical forces. The stayplate thickness
should not be more than 3 mm. The centrally positioned
hole in the top is threaded with M8 length 12 mm.
If The RFX is vibrating attach it with
rubber elements and stay the top.
Minimum 30 m
m

Reducer of Fluid oXidation Installation
M
Hydrostat
Charge pump
RFX
Normal connection of the RFX in forestry
machines.
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Reducer of Fluid oXidation Start up
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Hydraulic installation:
To run the RFX a flow of 3 liter/min is needed. The RFX is in standard adapted to a supply
pressure of 20-25 bar.
1. When supply pressure is connected it is of great importance that the RFXis supplied with
the correct flow restrictor. Control can be made through dealers by giving them the serial
number.
Function with wrong pressure can result in
malfunctions and can damage the unit.
2. The outlet should be connected to the return line before the return filter. Connection to the
suction line or directly to the reservoir is also possible. The pressure must be less than 0,5
bar at normal working temperature.
* The inlet and outlet ports have dimension BSP G3/4’’.
* The pressure line should have an inside diameter of at least 6 mm and the outlet line
should have a minimum diameter according to length listed below (@40cSt).
Hose length Minimum
diameter
Pressure drop
bar
Recommended
diameter
Pressure drop
bar
2m
4m 3/8” 0,3 3/8”
6m 3/8” 0,45 1/2” 0,2
8m 1/2” 0,3 1/2”
10m 1/2” 0,35 1/2”
12m 1/2” 0,45 3/4” 0,07
14m 3/4” 0,1 3/4”
20m 3/4” 0,14 3/4”
Start up
First time:
With the correct pressure and flow, the the RFX is started without any help. At cold oil
temperature and with free air in the oil the start process can take long time.
The start up can then be helped by the following procedure:

Reducer of Fluid oXidation Normal function
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1. Localize the drain connection, take off the
drain hose if mounted. Attach the M3
screw (M3x55) to the right threaded check
valve element.
2. Pull the screw to check the connection.
You can feel a small spring force 5
Newton (approximately 0.5 kg).
3. Start the system and pull the screw gently
downwards and hold it there so that the
valve is kept open. When the RFX gets
supply pressure the oil level will rise inside
the glass tube. At the same time the piston
rod moves upwards to its upper position.
Check that the piston rod reaches the top
block. If not, help it by pulling the M3 screw connected to the check valve shortly. The
piston rod will then more easily reach the top. Let the screw go when the float
changes to the upper position. The RFX will then start oil suction.
Check valve
Hose adapter
Drain connection
M3x55 screw
Safety ring
Drawing of check valve and drain connection.
4. When the oil is in the lower position, the float will change position again and oil filling
starts again.
5. Check that the piston rod reaches the top block again. If not repeat from #3.
6. Let the unit work a few cycles and if necessary repeat #3.
7. The RFX will now proceed by itself. Let the unit work a few cycles and after that
unscrew the M3 screw. The screw can be useful later so put the screw in its position
in the main block. Replace the drain hose.
Normal function
The RFX cyclical work is easy to watch through the transparent glass tube. Oil level and
piston rod shall move up and down as described previously on page 4. Oil level is steady
only when it has no supply pressure. Changing level is therefore an indication that The RFX
is working correctly. When the supply pressure is stopped the oil level shall rise close to the
top and the stop level shall be maintained until next start. If there is no oil level change when
the supply pressure is on or if the piston rod is not moving the the RFX needs inspection.
See page Fehler! Textmarke nicht definiert. concerning maintenance.
Conclusion of normal working conditions:
1. After the start up it normally takes only a few cycles before dissolved gases leave the
oil and a foam is built up. Depending on oil temperature the cycle-time varies between
2-4 minutes. Warmer (thinner) oil and oil with high air content gives shorter cycle time
as well as a higher supply pressure.
2. The foaming can be quite huge at the beginning. Even if the RFX is totally filled with
foam and the oil has no visibility at all the foaming will be reduced after a while. After
a running period of 2-3 hours per 100 dm3 oil volume, the oil should start to get clear
at the bottom of the glass tube. If the foam after this period still is filling up the entire
glass tube, there is a reason to suspect that air is suctioned into the pump in the
suction line or that the oil has not enough foam inhibitors.
3. After a start up the foam thickness will grow according to the rising vacuum pressure.
The time to reduce the pressure depends on the air content in the oil and on the air
ingestion.. With a large oil volume it takes a longer time to reach low pressures than
with a small. A large contact area, reservoir surface, between the oil and the
atmosphere works in the same way. Since the capacity of the RFX is nearly constant,

Reducer of Fluid oXidation Normal function
the final air content reached depends on the amount of air entering the system. The
vacuum function effect can be checked by the A-distance.
4. The A-distance is measured when the supply pressure for the RFX is off. When the
RFX is off power the vacuum inside the glass tube will fetch oil from The reservoir
until equalization is achieved. When the oil level sets, the A-distance can be
measured as a distance between the oil level and the top square (see page 12). This
distance should be more or less constant, if the working conditions have not been
changed. Note that the A-distance is only measured while the supply pressure is off.
5. The cycle time varies between 2-4 minutes depending on supply pressure and oil
condition. A high supply pressure as well as a low oil viscosity reduces the cycle
time. To a small extent the cycle time is reduced by a higher degree of vacuum.
During constant conditions the cycle time should be constant. This is a checkpoint in
proactive maintenance.
0
2
4
0,5 1 1,5 2 2,5 3 3,5 4
A-distance (cm) REDFOX C
6
8
10
12
Air content (%)
(60°C)
(20°C)
Diagram that showing the connection between air content in oil and the A-distance.
Normal air content is 10% at 20 degrees centigrade. The diagram is valid at
atmospheric pressure.
6. Foam thickness varies with a lot of factors as air content, water content, temperature,
pressure, impurities and oil type. The foam thickness is therefore not an easy way to
describe normal conditions. Foam indicates that the RFX is working and that there is
water and air ingested in the oil. Variations in foam thickness from one day to another
indicate that there have been changes. A rising water level or a rising air content can
be the reason. Check the A-distance if there are any doubts.
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Reducer of Fluid oXidation Maintenance and regular checkups
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Maintenance and regular checkups
The RFX has no wear details or other details which need continuous maintenance or
exchange.
Proactive maintenance for The RFX is therefore only control and cleanliness. Most of the
points can be checked at once. Check if the following six points are normal.
1. Working period with 2-4 minutes cycle time
Oil level variation shall follow the patch described on page 4. Check the supply pressure with
a gauge.
* Too low inlet pressure: The piston is not reaching the upper position.
* Too high inlet pressure: The oil level is constant or rising even if the liquid level float
changes to its upper position.
2. Normal foam thickness
This is a check that can be made daily. If there are changes you must figure out what the
cause to this change is.
a. Foam thickness is higher than normal foam thickness
* If the oil temperature is steady, this can be a sign of air entering the system somewhere or
that the system recently has been maintained leaving entrapped air in the system. This can
be verified by a larger A-distance than normal. In that case check the suction lines of the
pumps.
* Exceeded foam thickness can also be a sign of water entering the system. Check the
system or the oil. If temperature on the top or bottom block is lower than normal, the foam
thickness will be high due to exceeded water release. The water level can therefore be
normal but the the THE RFX unit is working under better conditions.
b. Foam thickness is lower than normal or totally missing
This can be a normal effect if the temperature is rising on the top or bottom block. Check the
A-distance. If the distance is normal, there is no reason to make any changes. A new normal
condition is achieved. If the A-distance is larger than it used to be there is a reason to check
that the the the THE RFX unit is working correctly by the following procedure:
Check if the piston rod reaches the top block (See point 5 in start up). Two reasons are
possible if it does not reach the top:
* Supply pressure is low. Check with a pressure gauge and adjust if necessary.
* A high pressure >1 atmosphere inside the glass tube. A sign of this is a large A-distance,
>100 mm. Try to make a new start up procedure for the RFX described on page 6.
The next step is to check the vacuumpump. Put your finger on the drain adapter. When the
piston rod moves downwards air should come out through the drain adapter. If you cannot
feel this put a transparent hose on the hose adapter and fill it with some fluid. Hold the hose
like a U. Air should now come out when the piston rod moves downwards and no air shall go
backwards when the piston rod is moving upwards. If there is no motion at all in the fluid
there can be two reasons:
1. The adapter is not sealed by its o-ring. Check that the o-ring 14x3 mm is correct. Repeat
the U-test after mounting.
2. An inner check valve is damaged. The unit needs repairment. Send it to the dealer.