Hydac OLSW Manual

OffLine Separator Water
OLSW
Operating and Maintenance Instructions
English (translation of original operating instructions)
Documentation no.: 3310795c

OffLine Separator Water - OLSW Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2010 by
HYDAC FILTER SYSTMES 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 content 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
Postfach 12 51
66273 Sulzbach / Saar
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]
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OffLine Separator Water - OLSW Content
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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Technical Support...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
General Safety Precautions.....................................................................................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
What to Do in Case of Emergency .......................................................................12
Modifications to the OLSW ...................................................................................12
Fire Fighting..........................................................................................................12
What to Do in Case of Emergency .......................................................................12
Transporting the OLSW ......................................................................................... 13
Storing the OLSW...................................................................................................13
Storage conditions ................................................................................................13
Checking the scope of delivery.............................................................................14
OLSW Features.......................................................................................................15
Coalescing procedure...........................................................................................15
Procedural limitations:.......................................................................................15
Items supplied.......................................................................................................16
OLSW design........................................................................................................ 17
Dimensions/connections.......................................................................................18
Hydraulic schematic.............................................................................................. 19
OLSW setup / connection...................................................................................... 20
OLSW setup ......................................................................................................... 20

OffLine Separator Water - OLSW Content
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Notes on the hydraulic connection........................................................................ 20
Installing the suction port connection.................................................................... 21
Installing the pressure port connection ................................................................. 21
Establishing an electrical connection.................................................................... 22
Starting up the OLSW ............................................................................................ 23
Operating elements of the electric controller ...................................................... 24
Performing Maintenance........................................................................................25
Emptying the oil tanks ........................................................................................... 25
Emptying the coalescing container water............................................................26
Replacing the filter element on the prefilter ........................................................ 28
Changing the coalescing elements ...................................................................... 30
Decommissioning the OLSW ................................................................................ 35
Disposing of the OLSW..........................................................................................35
Spare Parts List ...................................................................................................... 36
Technical data ........................................................................................................ 37
EU Declaration of Conformity ............................................................................... 38

OffLine Separator Water - OLSW 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 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
We look forward to receiving your input.
“Putting experience into practice”
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OffLine Separator Water - OLSW 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:
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
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC Filtertechnik GmbH.
Refer to these at www.hydac.com General terms and conditions.

OffLine Separator Water - OLSW 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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Product
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.

OffLine Separator Water - OLSW General Safety Precautions
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General Safety Precautions
These operating instructions contain the most important information for operating
the OLSW in a proper, safe manner.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the OLSW
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 OLSW.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety guidelines listed here are restricted to use of the OLSW.
The OLSW 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 OLSW is only to be used as follows:
Solely for its designated use
Only when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly repaired
or remedied immediately.
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 assembly/installation, start up, operation and maintenance of the
OLSW
Operating the OLSW when the system equipment or systems are defective
Modifications to the OLSW 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 Water - OLSW General Safety Precautions
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.
TIP
TIP denotes situations which
can lead to property damage if
safety precautions are not
observed.
Proper/Designated Use
The OLSW is a stationary filter product which is used to separate oil from watery
fluids.
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 OLSW with a non-authorized fluid
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OffLine Separator Water - OLSW General Safety Precautions
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 OLSW are to also be regularly checked (visual check
once a month). Replace any loose connections or damaged cables immediately.
Safety Measures to Be Followed during Normal Operation
The OLSW may only be operated if all of the safety devices function properly.
Check the product for visible damage and properly functioning safety equipment at
least once a day.
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
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OffLine Separator Water - OLSW General Safety Precautions
Training and Instruction of Personnel
The OLSW 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 OLSW unless supervised by an
experienced staff member.
Individuals Individuals undergoing training Individuals with technical training/engineerin
g
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
WARNING
Electric shock
Bodily injury
Pull the power plug before performing work on live
parts
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OffLine Separator Water - OLSW General Safety Precautions
What to Do in Case of Emergency
In the event of an emergency, immediately disconnect the OLSW from the power
supply.
Modifications to the OLSW
Do not make any modifications (design modifications, extensions) to the OLSW
without the approval of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Use only original spare parts. 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 the event of an emergency, turn the main switch by 90° in
a counter-clockwise direction to shut down the entire unit.
The entire unit downstream of this switch is de-energized
and depressurized.
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OffLine Separator Water - OLSW Transporting the OLSW
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Transporting the OLSW
The OLSW 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 OLSW
The OLSW must not be placed into storage until it has been completely emptied,
cleaned and rinsed and the coalescing elements have been removed. The OSLW
should be stored in an upright position.
Storage under suitable conditions may be done for a maximum of 6 months.
Generally speaking, recommissioning during this period is possible.
Before recommissioning the OLSW, make sure that there is no corrosion and
replace all seals and gaskets.
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 Indefinite.
Before the unit is started up again after being stored for a
fairly long time (> 2 years), all seals must be replaced.

OffLine Separator Water - OLSW Checking the scope of delivery
Checking the scope of delivery
Upon receiving the OLSW check it for any damage in transit. Do not put the OLSW
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. Name
1 OffLine Separator Water
(type of elements depending on the order)
1 Operating and Maintenance Instructions
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OffLine Separator Water - OLSW OLSW Features
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OLSW Features
The OffLine Separator Water OLSW is used to separate oils from watery fluids.
The OLSW consists of a prefilter, the coalescing tank, and an oil tank where the
separated oil is collected.
The fill level in the coalescing tank can be monitored through the viewing window in
the top of the coalescing tank or by opening the air bleed screw on the head of the
coalescing tank.
When the centrifugal pump is working, the fluid flows through the OLSW at a flow
rate of ≈20 l/min. This creates a pressure of < 0.8 bar in the reservoir. However, the
pressure can be increased through the pipeline at the output of the OLSW to the
system.
The function of oil separation must be monitored indirectly, namely by recording the
amount of oil drained out of the oil tank or by regular determination of the oil content
of the liquid to be cleaned.
Together with the load of the OLSW with oily liquid, these data provide an indication
of the correct operation of the OLSW.
Coalescing procedure
Coalescing is understood as the merging of several small oil drops to large oil drops
by means of special coalescing elements. The oil collects on the fibers of the
coalescing element and is conveyed deeper into the coalescing element by the fluid
flow. Small drops unite to form larger ones at the fiber nodes during this process.
Large oil drops settle upwards and can be removed from the system by opening an
automatic valve or ball valve.
The coalescing process is mostly used in systems in which small quantities of free
oil cause no damage or in which fluids are used which exhibit excellent demulsifying
properties (the capacity of rapidly giving off water). The elements are used 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.
The unit is easy to install in the bypass flow of a system
Procedural limitations:
Unsuitable for the separation of oils whose density is higher than 900 kg/m3,
such as ester-based liquids and polyglycols
Coalescing elements must be protected from contaminant particles by a prefilter
so that the transport of water drops is not obstructed by contaminant particles.

OffLine Separator Water - OLSW OLSW Features
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Items supplied
Note
Impermissible operating media
The unit will be damaged
►The OLSW may be used only in combination with watery fluids that contain
small amounts of mineral oil (water with mineral oil <10% by volume).
►Aggressive or explosive fluids must not be conveyed.
►Please contact us first before using the unit with other fluids.

OffLine Separator Water - OLSW OLSW Features
OLSW design
Item Name
10 Foot
20 Coalescing tank
30 Centrifugal pump
40 Prefilter with flow controller
50 Switch cabinet
60 Oil tank with filling level display
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OffLine Separator Water - OLSW OLSW Features
Dimensions/connections
Item Name
(A) Water inlet G ½
(B) Water outlet G ½
(C) Oil drain G ½
(D) Bleeding G ½
Please note that at least 400 mm free space is required over the OLSW for
changing elements.
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OffLine Separator Water - OLSW OLSW Features
Hydraulic schematic
Item Name
1 Motor-pump assembly
2 Differential pressure gauge, 2.0 bar
3 Prefilter
4 Flow controller, 20 l/min
5 Coalescing tank
6 Differential pressure gauge, 0.8 bar
7 Quick-action coupling
8 2/2 directional valve
9 Oil tank with filling level display
10 Orifice
11 Ball valve after the prefilter
12 Ball valve for draining water (water OUT)
13 Ball valve for draining the collected oil (oil OUT)
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OffLine Separator Water - OLSW OLSW setup / connection
OLSW setup / connection
OLSW setup
The unit must be mounted level and on a flat surface. No special mounting is
required.
The pump is designed for ambient temperatures of 10°C - 40°C. In order to prevent
the motor from overheating, adequate cooling air must be provided.
Sufficient room to remove the elements must be left around and above the housing.
The motor pump group is not self-priming and must therefore be installed below the
tank level.
Notes on the hydraulic connection
Use as few threaded connections as possible in order to keep the pressure loss as
low as possible.
The pressure differential in a pipeline depends on:
Flow rate
Kinematic viscosity
Pipe dimensions
Fluid density
The pressure differential can be estimated for fluids as follows:
  Q
d
L
barp 4 8,6][ 
L= pipe length [m]
d= pipe internal diameter [mm]
Q= flow rate [l/min]
 = kinematic viscosity [mm²/s]
= density [kg/dm³]
fluid .0 kg/dm³
This applies to straight pipe runs and hydraulic oils. Additional threaded connections
and pipe bends increase the pressure differential.
Keep the height difference between the pump and the fluid level in the tank as small
as possible.
Avoid constrictions in connecting pipelines because they reduce capacity and
increase the risk of cavitation.
The nominal size of the connected hoses/piping must be at least as large as the
inlet port sizes in order to prevent an excessively high negative suction pressure.
Make sure that no vibrations or stress/loading from other machinery and equipment
are carried over to the pump or filter housing. Use hoses and expansion joints as
may be necessary.
The OLSW has its own centrifugal pump. The centrifugal pump is not self-priming. It
must be adequately prefilled before commissioning.
For this purpose it is best to incorporate the OLSW into the system so that the
system medium independently gets from the tank to the centrifugal pump; that
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