Hydac Filtromat OF5 C with FCU Manual

Filtromat
OF5 C with FCU
Operating and Maintenance Instructions
English (translation of original instructions)
D
Do oc cu um me en nt t n no o. .: : 3 31 16 60 03 33 33 3b b

Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive director: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.

Content
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Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Modifications to the Product ........................................................................5
Warranty ......................................................................................................5
Using the documentation .............................................................................6
Safety information and instructions............................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions.....................................9
Observe regulatory information ...................................................................9
Proper/Designated Use .............................................................................10
Improper Use or Use Deviating from Intended Use ...................................11
Qualifications of personnel / target group ..................................................12
Wear suitable clothing ...............................................................................13
Structural modifications .............................................................................13
What to Do in Case of Emergency ............................................................14
Firefighting/Extinguishing fires................................................................14
Transporting the unit..................................................................................15
Storing the unit ...........................................................................................15
Decoding the model code label .................................................................16
Checking the scope of delivery .................................................................18
Working principle of the unit ......................................................................19
Preparing the unit for operation ................................................................20
Hanging/connecting the suction hose........................................................20
Hanging/connecting the pressure hose .....................................................21
Electrical connection of the unit .................................................................21
Checking the direction of rotation ...........................................................21
Operating Elements on the unit.................................................................22

Content
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Operating elements on the switch box .....................................................23
Switching on the unit..................................................................................24
Operating selector switch - Controlled by FCU ON/OFF ...........................25
Operating mode – Controlled by FCU "OFF"..........................................25
Operating mode – Controlled by FCU "ON" ...........................................25
Unit in operation .........................................................................................26
Venting the filter housing ...........................................................................28
Measuring the cleanliness class ...............................................................29
Performing maintenance............................................................................30
Changing the filter element........................................................................30
Cleaningthe suction strainer ......................................................................34
Errors and troubleshooting........................................................................36
Taking the unit out of operation .................................................................36
Disposing of the unit ..................................................................................36
Spare parts ..................................................................................................37
Customer Service .......................................................................................39
Technical data.............................................................................................39
Model Code..................................................................................................40
EC declaration of conformity.....................................................................41
Index ............................................................................................................42

Preface
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Preface
This operating manual was made to the best of our knowledge. Nevertheless
and despite the greatest care, it cannot be excluded that mistakes could have
crept in. Therefore please understand that in the absence of any provisions
to the contrary hereinafter our warranty and liability – for any legal reasons
whatsoever – are excluded in respect of the information in this instruction
manual. In particular, we shall not be liable for lost profit or other financial
loss. This exclusion of liability does not apply in cases of intent and gross
negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to Product Liability shall remain
unaffected.
Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model/type
designation, serial no. and part-no. of the product:
Fax: [phone] - 9046
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
For the warranty provided by us, please refer to the General Terms of Sale
and Delivery of HYDAC Filter Systems GmbH.
You will find these under www.hydac.com -> Legal information.

Preface
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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.
de
HYDACFiltertechnikGmbH
BeWa12
34
56a
d
e
Seit e x
Produkt/Kapitel
200x-xx- xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

Safety information and instructions
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Safety information and instructions
The unit was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Danger due to operating pressure
Exposed electrical components
Danger of electrical shock

Safety information and instructions
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Risk of burns due to hot surfaces
Danger from explosive atmosphere
Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a hazard with a high risk and which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a hazard with a medium risk and which can lead to
death or serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor
injury if not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.

Safety information and instructions
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Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
SIGNAL WORD
Type and source of danger
Consequence of the danger
HAZARD SYMBOL
►Measures to avert danger
Observe regulatory information
Observe the following regulatory information and guidelines:
Legal and local regulations for accident prevention
Legal and local regulations for environmental protection
Country-specific regulations, organization-specific regulations

Safety information and instructions
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Proper/Designated Use
Use the unit only for the application described in the following.
The mobile filtration unit is designed to fill/filter hydraulic & lubrication tanks
and to filter offline whereby the contamination can be monitored. It is also
designed for pumping out unfiltered hydraulic and lubrication oils, and
draining hydraulic tanks.
During this work, the integrated FluidControl Unit measures particulate solid
particle contamination in order to monitor and document the oil cleanliness.
Proper or designated use of the product extends to the following:
observing all instructions contained in the instruction manual.
performing inspection and maintenance work.
NOTICE
Impermissible operating media
The unit will be damaged
►The unit is only to be used with mineral oils or mineral oil-based
raffinates.

Safety information and instructions
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Improper Use or Use Deviating from Intended Use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result
when operated improperly.
►Never operate the unit in potentially
explosive atmospheres.
►The unit is only to be used with permissible
media.
Any use extending beyond or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. The user alone, shall assume any and all
associated risk
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
Operation with a non-approved medium.
Operation under impermissible operating conditions.
Modifications to the power unit made by the user or purchaser.
Inadequate monitoring of parts that are subject to wear and tear
Improperly performed repair work.
Operation in potentially explosive atmospheres.

Safety information and instructions
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Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Specialist personnel: such persons with corresponding specialist training and
several years work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential hazards.
Activity Person Knowledge
Transport / storage Forwarding
agent
Specialist
personnel
Proof of knowledge of cargo
securing instructions
Safe handling/operation of
hoisting and lifting equipment
Hydraulic / electrical
installation,
first commissioning,
maintenance,
troubleshooting,
repair,
decommissioning,
Disassembly
Specialist
personnel
Safe handling/use of tools
Fitting and connection of
hydraulic lines and connections
Product-specific knowledge
Operation
operations control
Auxiliary
personnel
Product-specific knowledge
Knowledge about how to handle
operating media.
Disposal Specialist
personnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse

Safety information and instructions
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Wear suitable clothing
Loosely worn clothing increases the danger of getting caught or wound up in
rotating parts and the danger of getting snagged on projecting parts. You can
be severely injured or killed.
Wear close-fitting clothing.
Do not wear any rings, chains or any other jewelry.
Wear work safety shoes.
Structural modifications
Do not make any modifications to the product without the prior consent of the
manufacturer.
Any modifications require written permission from HYDAC Filter Systems
GmbH
Use only original spare parts (OEM).

Safety information and instructions
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What to Do in Case of Emergency
In case of an emergency, switch the unit off at the main switch or unplug the
power connector.
Firefighting/Extinguishing fires
Use a powder extinguisher the corresponds to fire class B as per EN 2 to
extinguish any fires.
Maintain a minimum safe distance from electrical components. For a mains
voltage of up to 1000 V, the minimum safe distance is 1 m.

Transporting the unit
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Transporting the unit
Always transport the unit upright on its own wheels or lashed safely to a
pallet.
Strap the unit down securely and take care to ensure that no components are
damaged.
NOTICE
Incorrect lashing
The unit will be damaged
►Strap the unit down securely.
►Take care to ensure that none of the components are damaged.
Storing the unit
Remove all filter elements and empty the filter housing completely prior to
storage. Clean and flush the filter unit. Always store the unit in an upright
position.
Storage temperature: 5 … 30 °C / 41 … 86 °F
Humidity: up to 80% relative humidity, non-condensing
Air: Clean, salt-free air, not near oxidizing substances
(rust film).
Storage duration: Unlimited
Before the unit is started up again after a storage
period of greater than 2 years, all seals must be
replaced.

Decoding the model code label
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Decoding the model code label
Details for identifying the filtration unit can be found on the name plates on
the unit and the components.
Item -> Description
(1) -> Name plate of filtration unit
(2) -> Name plate of electric motor
(3) -> Model code; for details, see page 40

Decoding the model code label
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The following information can be found on the name plate of the unit:
Row -> Description
Part No. -> Part number
S/N -> Serial number / year of production
Power -> Power consumption
Voltage/Grid -> Voltage / power supply
Frequency -> Frequency
Current -> Current consumption
Pressure max. -> Operating pressure, maximum
Weight -> Weight when empty
Flow rate -> Flow rate
Temp. Oil -> Permissible oil temperature range
Temp. Amb. -> Permitted ambient temperature range
Volume -> Fluid volume in unit

Checking the scope of delivery
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Checking the scope of delivery
The filtration unit comes factory-assembled. Check the scope of delivery for
completeness prior to start up.
The following items are supplied:
Qty Designation
1 Filtromat - OF5 with FCU
1 Filter element (acc. model code, see page 40)
1 Operation and Maintenance Instructions, OF5 (this document)
1 Operation and Maintenance Instructions, FCU 2000 Series

Checking the scope of delivery
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Working principle of the unit
FCU
Saugschlauc
h
Su ct io n ho se
Druckschlauch
Pr essu re ho se
The pressure fluid is drawn in from a tank at zero pressure by the suction
hose, pumped through the filter and purified.
The purified pressure fluid exits the filtration unit through the pressure hose.
Part of the pressure fluid that is drawn in is diverted to the Fluid Control Unit
FCU by an auxiliary pump. The FCU continuously monitors the fluid's purity.
In the "Controlled by FCU ON" operating mode, the filtration unit
automatically shuts off with a deceleration of ≈5 minutes once the desired
fluid purity has been attained. Alternatively, you can use the MODE 4
function on the FCU to maintain the fluid purity within a specific range.
If the filter element is clogged, the unit also switches off automatically. At the
same time, the fault indicator lamp on the switch box lights up.

Preparing the unit for operation
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Preparing the unit for operation
NOTICE
Damaged/brittle hoses
Leakages in the hose/fluid may escape
►Before start-up, always check the hoses for damage/brittleness.
Prior to start-up, check to see whether there is a filter element in the filter
housing. You can find details on inserting the filter element on page 30.
Hanging/connecting the suction hose
NOTICE
Severe contamination
The unit will be destroyed
►Do not prime directly at the bottom of the tank/in the sump.
The greatest contamination is found on the bottom of the tank. All
impurities and other particles are deposited on the bottom of the tank.
Pull the suction hose (thick hose) with lance out of the mounting in the floor
plate.
Using the lance, put the suction hose into the appropriate reservoir without
tension or twist, and secure the suction hose against falling out or floating.