Hydac OLS 10 Manual

OffLine Separator
OLS 10
Operating and Maintenance Instructions
English (translation of original operating instructions)
Documentation no.: 3248771

OffLine Separator - OLS Trademarks
HYDAC Filter Systems GmbH en Page 2 / 56
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2009 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 have 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 Gmb
H
Postfach 12 51
66273 Sulzbach / Saa
r
Germany
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]

OffLine Separator - OLS Content
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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................5
Customer Service ...................................................................................................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
Proper/Designated Use ..........................................................................................9
Improper Use ..........................................................................................................9
Safety Devices......................................................................................................10
Informal Safety Precautions..................................................................................10
Safety Measures to Be Followed during Normal Operation..................................10
Hazards Posed by Stored Residual Energy .........................................................10
Training and Instruction of Personnel ...................................................................11
Electrical Hazards.................................................................................................11
Structural Modifications to the OLS ......................................................................12
Fire Fighting..........................................................................................................12
What to Do in Case of Emergency .......................................................................12
Transporting the OLS.............................................................................................13
Storing the OLS ......................................................................................................13
Storage conditions ................................................................................................13
Checking the Scope of Delivery............................................................................14
OLS Features ..........................................................................................................15
Coalescing procedure...........................................................................................15
Items supplied.......................................................................................................16
Procedural limitations ........................................................................................... 16
Dimensions .............................................................................................................17
OLS with large drip pan ........................................................................................17
OLS with small drip pan........................................................................................18
Hydraulics Plan (maximum equipment) ............................................................... 19
OLS Components ...................................................................................................20
Setting up the unit..................................................................................................21

OffLine Separator - OLS Content
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Notes on piping / hosing .......................................................................................22
Installing the suction port connection.................................................................... 23
Flow rate ...............................................................................................................23
Installing the DRAIN WATER water connection ...................................................24
Installing the pressure port connection ................................................................. 24
Electrical connection of the OLS...........................................................................25
Jog mode for checking the direction of rotation ....................................................25
Starting up the OLS................................................................................................26
Switching off the OLS ............................................................................................29
Operating the OLS..................................................................................................30
Version with operation panel ................................................................................30
Version with on/off switch (PKZ)...........................................................................31
Draining water manually........................................................................................32
Draining water automatically (optional) ............................................................... 33
Water drainage by means of phase boundary sensor (automatic) ....................... 33
Pushbutton-operated manual water drainage....................................................... 33
Checking the heater temperature (optional) ........................................................34
Error description/troubleshooting ........................................................................ 35
Performing Maintenance........................................................................................36
Replacing the filter element on the prefilter ..........................................................37
Changing the coalescing elements.......................................................................41
Check the heater ..................................................................................................47
Cleaning the heater ..............................................................................................47
Dismantling/installing heaters ...........................................................................48
Taking the OLS out of operation...........................................................................49
Disposing of the OLS.............................................................................................49
Spare Parts List ......................................................................................................50
Technical Data ........................................................................................................51
Model Code .............................................................................................................52
EC declaration of conformity ................................................................................53

OffLine Separator - OLS 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 Gmb
H
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saa
r
Germany
We look forward to receiving your input.
“Putting experience into practice”

OffLine Separator - OLS Preface
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Customer Service
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: ++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 ÖGeneral terms and conditions.

OffLine Separator - OLS 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.
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
Page number
Edition date
Document language
Documentation no.
with index
/
file name

OffLine Separator - OLS Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the most important information for operating
the OLS in a proper, safe manner.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the OLS is
knowledge of the safety precautions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the OLS.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed here apply solely to the use of the OLS.
The OLS 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 OLS is only to be used as follows:
• 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 provided to the owner upon
conclusion of 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 assembly, installation, commissioning, operation and maintenance of
the OLS
• Operating the OLS when the system equipment or systems are defective
• Modifications to the OLS made by the user or purchaser
• Improper monitoring of unit components that are subject to wear and tear
• Improperly performed maintenance or repair work

OffLine Separator - OLS Safety Information and Instructions
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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 OLS is a stationary filter product which is used to separate water from hydraulic
oils, gear lubrication oils and diesel fuels.
Any other uses shall be deemed to be improper and not in keeping with the
product's designated use.
The manufacturer will not assume any liability for any damage resulting from such
use.
Proper or designated use of the product extends to the following:
• Maintaining adherence to all the instructions contained herein.
• Performing requisite inspection and maintenance work.
Improper Use
Improper use may result in hazard to life and limb.
Improper use includes:
• Using the OLS with a non-authorized fluid
• Operating the unit outside of the authorized ranges with respect to temperature,
pressure and volumetric flow.

OffLine Separator - OLS Safety Information and Instructions
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Safety Devices
Prior to starting up the product, make sure that all the safety devices are properly
fitted to the hydraulic system and are in proper working order.
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
In addition to the manual, the general and local regulations concerning accident
prevention and protection of the environment should be available and observed.
Make sure to keep the safety and hazard symbols and warnings on the product in a
legible condition.
Check the hoses and connection fittings for leakage daily (visual check). The
electrical components of the OLS must also be regularly checked (visual inspection
once per month). Replace any loose connections or damaged cables immediately.
Safety Measures to Be Followed during Normal Operation
The OLS may only be operated if all of the safety devices function properly.
The product is to be checked once a day for visible external damage and the proper
functioning of the safety devices.
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
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

OffLine Separator - OLS Safety Information and Instructions
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Training and Instruction of Personnel
The OLS 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 OLS unless supervised by an experienced
staff member.
Individuals Individuals undergoing training Individuals with technical training/ engineering back
g
round
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
Decommissioning/storage X X X X
Electrical Hazards
DANGER
Electric shock
Danger of fatal injury
►Any work involving the electrical system may
only be done by a properly trained, certified
electrician.

OffLine Separator - OLS Safety Information and Instructions
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Structural Modifications to the OLS
Do not make any modifications (design modifications, extensions) to the OLS
without the prior consent of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Use only original spare parts (OEM). When using non-OEM components it cannot
be ensured that they have been designed and manufactured so as to comply with
loading and safety requirements.
Fire Fighting
When fighting a fire make sure to disconnect the unit from the power supply,
otherwise an electrical fire cannot be effectively dealt with.
What to Do in Case of Emergency
In case of emergency, disconnect the unit from the electrical power supply and
depressurize the system.
Turn the main switch by 90° in a counter-
clockwise direction to shut down the entire
unit. The entire system is then voltage-free
downstream from this switch.
Depressurize the unit.
To accomplish this, open the air bleed
plug X1 on the coalescing container.
Hot fluid may exit.

OffLine Separator - OLS Transporting the OLS
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Transporting the OLS
The OLS is inspected for leaks and proper functioning at the factory, then carefully
packed for shipment.
The fluid connections are all sealed with plugs to prevent the intrusion of
contaminants during transport. Upon receipt of the unit, check for any damage from
transportation.
The packaging material should be reused/recycled as appropriate for your area.
Storing the OLS
Empty, remove the filter elements, clean and rinse the OLS completely before
putting it into storage. The OLS must be stored in an upright position.
Storage conditions
Storage
temperature:
+5°C to +30°C
Humidity: Maximum 80% relative humidity
Air: Clean, salt-free air, not near oxidizing substances (rust film).
Storage duration: Practically unlimited.
Before the unit is started up again after prolonged storage
(>2 years), all seals must be replaced.

OffLine Separator - OLS Checking the Scope of Delivery
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Checking the Scope of Delivery
Upon receiving the OLS, check it for any damage in transit. Do not set up or put the
OLS into operation unless it is in perfect condition. Any damage in transit is to be
reported to the forwarding agent or the department in charge immediately; the unit
may not be commissioned until this damage is properly remedied.
The following items are supplied:
Qty. Designation
1 OffLine Separator Water
(type of elements depending on the order)
1 Operating and Maintenance Instructions

OffLine Separator - OLS OLS Features
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OLS Features
The OffLine Separator OLS is a dewatering unit for hydraulic oils, gear lubrication oil
and diesel fuels with densities below 950 kg/m3.
The OLS is installed in the bypass flow, but it can also be used as a transfer unit for
diesel fuel, optionally with a prefilter.
Coalescing procedure
The dewatering functions in accordance with the coalescence procedure, during
which water collects on the fibers of the coalescing element and is conveyed deeper
into the coalescing element by the fluid flow. Smaller drops unite to form larger ones
at the fibre nodes during this process. Larger drops settle downwards and can be
drained off by opening a valve.
The coalescing process is mostly used in systems in which small quantities of free
water cause no damage or in which fluids are used which exhibit excellent
demulsifying properties (the capacity of rapidly giving off quantities of water with
which they have mixed).
Utilization in the bypass flow. The utilization of an extremely fine filtration system
upstream from the coalescing elements is useful for ensuring that they have as long
a service life as possible.

OffLine Separator - OLS OLS Features
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Items supplied
NOTICE
Impermissible operating media
The unit will be damaged
►Use the OLS only in connection with mineral oils or diesel fuels in the
presence of a water content <15% by volume.
Procedural limitations
The use of the coalescing procedure with the OLS has the following limitations:
• The permissible operating viscosity is 2 … 320 mm/s2.
• Use a heater when dewatering mineral oils with a viscosity >100 mm/s2.
• The dewatering of mineral oil and diesel fuel is possible down to a residual water
content of ≈100 ppm.
• Use a prefilter to protect the coalescing elements against dirt particles. The
transport of water drops is not hindered by dirt particles.

OffLine Separator - OLS Dimensions
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Dimensions
OLS with large drip pan
1000
910
(4x) Ø12
1000
1000
1
8
1
0
360
421
535
500
500
≈ 135
≈ 285
≈
150
≈ 210 ≈ 210 ≈ 210
≈ 135 ≈ 135
≈
1280

OffLine Separator - OLS Dimensions
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OLS with small drip pan
510
(4x) Ø 12
600
360
1810
421
1000
1000
≈ 285
≈ 650
≈
1280
≈ 500
≈ 210
≈135
≈
150

OffLine Separator - OLS Hydraulics Plan (maximum equipment)
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Hydraulics Plan (maximum equipment)
2
5
6
8
1
4
7
G1
INLET OIL
G1/2
DRAIN WATER
G1
OUTLET OIL
M
max.6 bar
3
9
10
Item Designation
1. Inlet (INLET OIL)
2. Motor-pump group
3. Prefilter
4. Clogging indicator prefilter element
5. Heater
6. Coalescing tank
7. Clogging indicator coalescing tank
8. Water drainage valve
9. Outlet (OUTLET OIL)
10. Water outlet (DRAIN WATER)

OffLine Separator - OLS OLS Components
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OLS Components
1
2
7
8
4
6
35
98
Item Designation
1. Inlet (INLET OIL)
2. Motor-pump group
3. Prefilter
4. Clogging indicator prefilter element
5. Heater
6. Coalescing tank
7. Clogging indicator coalescing tank
8. Water drainage valve
9. Outlet (OUTLET OIL)
10. Water outlet (DRAIN WATER)