Hydac OLSW Troubleshooting guide

OLSW
OffLine Separator
Water
Operation and Maintenance Instructions
English (translation of original instructions)
Document No.: 4268435
Keep for future reference.

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
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:
[e-mail]
© 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.
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Content
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 ........................................................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................9
Structure of the safety information and instructions.....................................9
Proper/Designated Use .............................................................................10
Improper Use or Use Deviating from Intended Use ...................................11
Qualifications of personnel / target group ..................................................12
Wear suitable clothing ...............................................................................13
Observe regulatory information .................................................................13
Stoppage in an emergency (EMERGENCY STOP)...................................13
Unpacking the unit......................................................................................13
Transporting the unit..................................................................................14
Transporting with the crane .......................................................................14
Storing the unit ...........................................................................................15
Decoding the type label..............................................................................16
Checking the scope of delivery .................................................................18
Characteristics of the unit..........................................................................19
Identifying components .............................................................................20
Hydraulic circuit..........................................................................................22
Unit dimensions ..........................................................................................23
Unit setup/connection ................................................................................24
Notes on pipes/hosing ...............................................................................25
Connecting the suction port (INLET WATER)............................................26
Checking/setting the flow rate....................................................................26
Connecting the pressure connection (OUTLET WATER)..........................26
Connecting oil drain (DRAIN OIL)..............................................................27
Electrical connection of the unit .................................................................28
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Content
Checking the direction of rotation at the electric motor...........................28
Connecting the remote control line.........................................................29
Remote control / Interval control Prioritization.....................................31
Operating / adjusting the control unit .......................................................32
Switching the main switch on / off..............................................................33
Checking the motor protection switch........................................................33
Adjusting the interval control......................................................................34
Adjusting the time selector switch..............................................................35
Activating manual oil drain.........................................................................35
Switching unit on/off ..................................................................................36
Automatic oil drain .....................................................................................36
Starting up the unit .....................................................................................37
Status LED / Causes and remedies ...........................................................38
Resetting an error message ...................................................................43
Remedy error / cause at the fluid filter WBF..............................................44
Performing maintenance............................................................................45
Maintenance intervals................................................................................45
Perform visual check .................................................................................45
Replacing hydraulic hoses.........................................................................45
Breather maintenance ...............................................................................46
Check breather functionality...................................................................47
Cleaning breather / Replacing parts.......................................................48
Help with errors on the breather..........................................................49
Changing filter element..............................................................................50
Removing the guide plate.......................................................................57
Changing the coalescing elements............................................................58
Taking the unit out of operation ................................................................61
Stopping the Unit ........................................................................................61
Disposing of the unit ..................................................................................61
Finding spare parts.....................................................................................62
Fluid filter spare parts - WBF..................................................................65
Accessories.................................................................................................68
Technical Data.............................................................................................69
Attachment ..................................................................................................70
Finding a Customer Service team .............................................................70
Glossary ....................................................................................................70
Model code ................................................................................................71
Index..........................................................................................................72
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Preface
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 these operating
instructions. 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
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 code, serial no. and part no. of the product:
Fax:
+49 6897 / 509 - 9046
E-mail:
[e-mail]
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.
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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> Legal information.
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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 you 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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Se ite 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 by
one digit every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation No.
with Index /
File name
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Safety information
Safety information
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
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety information
Risk of burns due to hot surfaces
Flammable
Danger from explosive atmosphere
Harmful to the environment
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Safety information
Signal words and their meaning in the safety information and
instructions
The following signal words are to be found in these instructions.
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if
not avoided, can result in minor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.
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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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Safety information
Proper/Designated Use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Use the unit only for the application described in the following.
The OffLine Separator Water OLSW is a filter unit which is used to separate
oil from watery fluids.
NOTICE
Impermissible operating media.
The unit will be damaged.
►Use the unit only in conjunction with with water-based cleaning fluids
and for oil volumes of < 15 %.
Proper/designated use of the product extends to the following:
•Observing all instructions contained in the instruction manual.
•Adhering to maintenance work.
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Safety information
Improper Use or Use Deviating from Intended Use
DANGER
Danger due to use of the filter housing other
than that intended
Bodily injury and damage to property will result
when operated improperly.
►Only use the filter in the permitted operating
conditions.
►Only use the filter with the permitted media.
Any use extending beyond this 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 or use deviating from intended may result in hazards and/or will
damage the unit. Examples of improper use:
•Operation with an impermissible fluid.
•Operation under non-approved operational conditions.
•Operation when the safety devices are defective.
•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.
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Safety information
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Operating 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 is intended for:
Auxiliary personnel: such persons have no specialized knowledge and
perform work as instructed.
Operating 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
Auxiliary
personnel
No specialist knowledge
required
Startup operation,
operation
Operations control
Operating
Personnel
Product-specific knowledge
Knowledge about how to handle
operating media.
Troubleshooting,
Maintenance,
Decommissioning,
Disassembly
Specialist
personnel
Safe handling/use of tools
Product-specific knowledge
Disposal
Specialist
personnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse
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Unpacking the unit
Wear suitable clothing
Loose-fitting clothing increases the risk of being caught or being drawn in on
rotating parts, and the risk of getting caught on protruding 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.
•Wear gloves.
•Observe the information relating to personal protection equipment in
the safety data sheet of the operating fluid.
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
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, pull the power plug.
Unpacking the unit
Prior to delivery, the unit is function and leak-tested in the factory.
When unpacking the unit, check it for damage in transit.
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Transporting the unit
Transporting the unit
Empty the unit completely before transport, including the coalescing and filter
housings. Pull out the power plug and securely fasten the power cord to the
unit.
Transporting with the crane
To transport with the crane, fasten suitable band loops to the attachment
points or to the lifting eyes (104).
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Storing the unit
Storing the unit
Empty the unit completely before storage, including the coalescing and filter
housings. Pull out the power plug and securely fasten the power cord to the
unit.
Permitted storage temperature
range
See chapter "Technical Data", on
page 69.
Permitted air humidity
See chapter "Technical Data", on
page 69.
Air
Clean, salt-free air, not near
oxidizing substances (rust film).
Storage duration
Unrestricted, but in any case before
the unit is started up again: after a
storage period of greater than 2
years, all seals must be replaced.
Storage position
Only standing.
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Decoding the type label
Decoding the type 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)
->
Type label for WBF
(4)
->
Model code; for details, see page 71
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Decoding the type label
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.
->
Maximum permitted operating pressure
Pressure IN
->
Permissible operating pressure at INLET
WATER connection
Pressure OUT
->
Permissible operating pressure at OUTLET
WATER connection
Weight
->
Empty weight
Flow rate
->
Flow rate
Temp. oil
->
Permitted fluid temperature range
Temp. amb.
->
Permitted ambient temperature range
Volume
->
Fluid volume in unit
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Checking the scope of delivery
Checking the scope of delivery
The filtration unit comes factory-assembled. Check that the filtration unit is
complete before starting up.
The following items are supplied:
Qty
Designation
1
OffLine SeparatorWater
1
Operation and Maintenance Instructions (this document)
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Characteristics of the unit
Characteristics of the unit
The OffLine Separator Water OLSW is used to remove oil from water-based
washing liquids, which are contaminated with mineral oils (density < 900
kg/m³).
Coalescing procedure
The dewatering works according to the coalescence principle, during which
the oil 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 fiber nodes during this process. Large oil drops climb
upwards and can be removed from the system by opening a valve.
The application is used in the bypass flow. The use of a micro-filtration
system is expedient to ensure the maximum possible service life of the
coalescing elements.
Limits of the coalescing procedure
The unit is unsuitable for the separation of oils whose density is higher than
900 kg/m3, such as ester-based liquids and polyglycols.
The coalescing elements must be protected from contaminant particles by a
pre-filter so that the transport of oil drops is not obstructed by contaminant
particles.
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Identifying components
Identifying components
Additional details regarding the versions can be found in the following.
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