Hydac OLF 15 User manual

OffLine Filter
OLF 15/30 ATEX
II 2G IIB T4
II 2G IIC T4
Installation and Maintenance Instructions
English (translation of original instructions)
Document No.: 3604146a

OLF 15/30/45/60 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: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-Mail: [email protected]
0
© 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.
All details are subject to technical modifications. Technical specifications are subject
to change without notice.
The trademarks of other companies designate the products of those companies
exclusively.

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Content
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Technical Support...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
Safety information and instructions.......................................................................8
Obligations and liability ...........................................................................................8
Explanation of Symbols and Warnings, etc. ........................................................... 9
General Safety Precautions.................................................................................. 10
Proper/Designated Use ........................................................................................ 11
Improper Use ........................................................................................................11
Informal Safety Precautions..................................................................................11
Training of personnel ............................................................................................12
Safety measures to be followed in normal operation............................................ 13
Hazards Posed by Stored Residual Energy .........................................................13
Electrical hazards ................................................................................................. 13
Transporting the OLF............................................................................................. 14
Storing the OLF ...................................................................................................... 15
Checking the scope of delivery.............................................................................16
Description..............................................................................................................17
OLF with pump (optional) .....................................................................................17
Operating limitations .............................................................................................18
OLF environment as per ATEX..............................................................................19
Explosion protection as per ATEX 95................................................................... 20
Element differential pressure ................................................................................21
OLF components ..................................................................................................22
Dimensions ...........................................................................................................23
Hydraulic diagram................................................................................................. 24
OLF (filter only) .....................................................................................................24
OLF with pump and motor .................................................................................... 24
OLF set up ............................................................................................................25
Notes on pipes and hoses ....................................................................................26
Connecting the connection (INLET) .....................................................................28

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Connecting the connection (OUT) ........................................................................ 28
Connecting the connection (OUT TANK) .............................................................29
Electrical connection of the OLF .......................................................................... 30
Connecting the motor-pump assembly ................................................................. 30
Connecting the filling level limit switch (anti-dry running protection) ....................32
Electrical connection FEL 56............................................................................. 32
Output signal ..................................................................................................... 33
Failure signal.....................................................................................................34
Connectable load (burden)................................................................................34
Display and user interface (FEL 56)..................................................................34
Display elements (LED) ....................................................................................34
Connecting terminals ........................................................................................35
Switches (Safety switching) .............................................................................. 35
Starting up the OLF................................................................................................ 36
Performing maintenance .......................................................................................37
Overview of maintenance intervals.......................................................................38
Changing the filter element................................................................................... 39
Replacing the filling level limit switch....................................................................43
Disposal of OLF...................................................................................................... 44
Disposing of the OLF ............................................................................................. 44
OLF spare parts...................................................................................................... 45
Technical data ........................................................................................................ 50
OffLine Filter .........................................................................................................50
Pump and motor combinations (optional) ............................................................. 50
Model code ...........................................................................................................51

OLF 15/30/45/60 Preface
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 obtaining maximum benefit in
the applications for which it is designed.
Keep the manual in the vicinity of the device for immediate reference.
Please note, the information about the technology contained in this documentation
corresponds to the time of issue of this documentation.Consequently, there might be
deviations in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have additional
suggestions or notes, 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.
Our motto: “Putting experience into practice”
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Technical Support
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: ++49 (0) 6897 / 509 - 846
E-mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC FILTER SYSTEMS GmbH.
Refer to these at www.hydac.com General terms and conditions.

OLF 15/30/45/60 Preface
Using the Documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
WHAT do I want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
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Product description /
Chapter heading
Page number
Edition date
Document language
Documentation No.
with Index /
File name
Die Dokumentation-Nr. mit Index dient zur Identifizierung und Nachbestellung der
Anleitung. The index is incremented by one every time the manual is revised or
changed.

OLF 15/30/45/60 Safety information and instructions
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Safety information and instructions
These operating instructions contain the most important information for operating
the OffLine Filter unit in a proper, safe manner.
Obligations and liability
The basic prerequisite for the safe and proper handling and operation of the OLF is
knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the OLF.
In addition, the accident prevention rules and regulation applicable at the location of
use are to be observed.
The safety precautions listed herein are limited solely to using the OLF.
The OLF 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 using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property
The OLF is to be used as follows:
solely for its designated use
Only when in 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 injury 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 OLF or use deviating from its designated use
improper assembly, installation, commissioning, operation and maintenance of
the OLF
operating the OLF when the system equipment or systems are defective
modifications to the OLF made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
Improperly performed repair work

OLF 15/30/45/60 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 death 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.
This symbol designates safety indications whose non-observance may
pose a hazard to individuals due to hot surfaces.
This symbol designates safety indications whose non-observance may
pose a hazard to individuals and the environment due to explosion.
This symbol marks safety indications that refer particularly to explosion
protection.
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OLF 15/30/45/60 Safety information and instructions
General Safety Precautions
Maintenance work may only be carried out by personnel who are familiar with these
Operation and maintenance Instructions.
The safe operation of this unit can only be ensured if it is used for the purpose it was
intended. If there is any question about the use, please contact the manufacturer.
The manufacturer will not accept responsibility for damages resulting from misuse of
this equipment.
The following applies to all work performed using the unit: adherence to pertinent
national regulations pertaining to accident prevention and safety at the workplace in
addition to any applicable internal rules and regulations of the owner/operator, even
though they are not specifically cited herein.
Leaks of dangerous materials must be properly collected and disposed of so as not
to harm any persons or the environment. The corresponding statutory regulations
are to be followed.
Before any maintenance or repair work is carried out on the unit, electrical power to
the unit must be disconnected, and all hydraulic pressures relieved.
When work is done in explosion-prone areas, the safety of persons and
equipment depends on the observance of all relevant safety regulations. The
installation and maintenance personnel thus carries particular responsibility. Exact
knowledge of the applicable regulations and conditions is required.
Please note:
Observe the characteristic curves and measurement operating conditions of the
rating plates and datum plates.
Damage to the devices can nullify the explosion protection.
The unit may be operated only when the control cabinet is completely closed.
Conversions and modifications to the devices and components that affect the
explosion protection are not allowed.
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Proper/Designated Use
The OLF Compact is a stationary filter unit used for filtering hydraulic or lubricating
oils.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
The manufacturer will not assume liability for any damage resulting from such use.
Proper or designated use of the product extends to the following:
Observing all the notes contained in these operating instructions
Performing requisite inspection and maintenance work.
Improper Use
Any use other than described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
Operation with non-approved fluids.
Operation in a danger zone where the ATEX classification of the device does not
apply.
Operation in mining or in dust-exposed zones
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the unit.
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance to be maintained to them.
All safety guidelines and hazard warnings on the machine must be maintained in
legible condition and replaced as required.
Check the hoses and port fittings for leakage daily (visual check). The electrical
components of the OLF are also to be regularly checked (visual check once a
month). Any loose connections or damaged cables are to be replaced immediately.

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Training of personnel
The OLF may be operated only 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 OLF unless supervised by an experienced
staff member.
Individuals Instructed individuals Personnel with technical training/ engineering background Electrician Supervisors with required expertise
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
Remedying of electrical faults X X
maintenance X X X X
Servicing X
Decommissioning/storage X X X X

OLF 15/30/45/60 Safety information and instructions
Safety measures to be followed in normal operation
Use the OLF only with functioning safety device.
The unit is to be checked once a day for visible external damage.
Hazards Posed by Stored Residual Energy
Note that the unit may pose a hazard as the result of possible residual stored
mechanical and electrical energy. Take the proper precautions when instructing
personnel on the use of the unit. Detailed information is provided in the respective
sections of this manual.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work
Electrical hazards
DANGER
Electric shock
Danger of fatal injury
►Any work involving electrical equipment may only
be done by a properly trained, certified electrician.
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OLF 15/30/45/60 Transporting the OLF
Transporting the OLF
Transport the OLF in an upright
position only.
For transportation using a crane or
forklift, use two slings on the specified
anchor points between the filter
housing and the base.
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OLF 15/30/45/60 Storing the OLF
Storing the OLF
Completely drain the OLF and remove all filter elements before putting into storage.
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 Indefinite.
Before the unit is started up again after being stored for
more than two years, all seals must be replaced.
Store the OLF in an upright position
only.
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OLF 15/30/45/60 Checking the scope of delivery
Checking the scope of delivery
Upon receiving the OLF check it for any damage in transit. Do not put the OLF into
operation unless it is in perfect condition. Any damage in transit is to be reported to
the forwarding agent or the HYDAC department in charge immediately; the unit may
not be commissioned until this damage is properly remedied.
The following items are included in the scope of delivery:
Item Qty. Designation
1 1 OffLine Filter 15/30/45/60 ATEX
- 1 Operation and Maintenance Instructions (this document)
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OLF 15/30/45/60 Description
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Description
The filters of the OLF 15/30/45/60 series are sturdy filters for stationary applications
in hydraulic and lubrication systems with large volumes of fluid.
Features of the DIMICRON®filter elements used in these filters are their particularly
high contamination retention capacity and an environmentally safe method of
disposal (incinerable).
OLF with pump (optional)
The OLF is produced as standard in the 4 filter sizes 15/30/45/60, with different
types of pumps for different viscosities.
Pump types Viscosity
Gear pump 15 …1000 mm²/s
Without pump -

OLF 15/30/45/60 Description
Operating limitations
DANGER
Medium temperature >70°C / 158°F
Risk of explosion / Danger of fatal injury
►Please note the maximum temperature of 70°C /
158°F.
►Install a cooler upstream of the OLF if necessary.
WARNING
Fire hazard
Danger of bodily injury
►With the OLF, you may filter / pump only media /
fluids with a flash point 56°C / 133°F
NOTICE
Impermissible operating media
The filtration unit will be destroyed.
►The OLF is to be used only with mineral oils or mineral oil-based raffinates.
►Do not filter any caustic or explosive media.
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OLF 15/30/45/60 OLF environment as per ATEX
OLF environment as per ATEX
DANGER
Wrong area of utilization
Danger of fatal injury
►The OLF may be used only in the indicated
equipment group, equipment category, and zone.
►Potentially explosive atmospheres in which
vapors or gas/air mixtures may occur only rarely
and briefly.
►Maximum permissible surface temperature on
components of the OLF must not exceed 135°C
/ 275°F.
Are the following specifications on the type label of the unit
permissible in connection with use in areas posing an explosion
hazard on site?
- equipment group
- equipment category
- explosion subgroup classification
- temperature classification
Ensure that vapors, gases or mists occurring at the place of
operation belong to explosion groups IIA to IIC.
Is it ensured that during installation of the unit no potentially
explosive atmosphere, oils, acids, gases, vapors or radiation are
present?
Is it ensured that the unit is sufficiently ventilated and no external
heat input is present?
The cooling air must not exceed a temperature of 40°C /104°F.
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OLF 15/30/45/60 Explosion protection as per ATEX 95
Explosion protection as per ATEX 95
The OLF-ATEX series satisfy the requirements of the new EU directive 94/9/EC,
ATEX 95 applicable to areas in which potentially explosive gas mixtures are likely to
occur.
Depending on the version, the ATEX designation of the OLF reads:
II 2G IIB T4 or II 2G IIC T4
This label in particular means that utilization is permitted only for:
Equipment group II Potentially explosive atmospheres in which
vapors or gas/air mixtures are likely to occur.
Equipment category 2G Equipment providing for a standard degree of
safety.
Designated for cases in which atmospheres
posing an explosion hazard can be expected to
occur very rarely and, if so, only briefly.
Explosion group IIB Typical gases:
Town gas, acrylonitrile, ethylene, ethylene
oxide, ethylene glycol, hydrogen sulfide.
Ammonia, methane, ethane, propane, ethyl
alcohol, cyclohexane, n-butane, n-hexane.
Ensure that vapors, gases or mists occurring at
the place of operation belong to explosion
groups IIA to IIB.
IIC Typical gases:
Hydrogen, ethyne (acetylene).
Temperature
classification
T4 Maximum permissible surface temperature:
135°C / 275°F
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