Hydac OXiStop OXS-LID/C202 User manual

OXiStop
OXS-LID/C202
Installation and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 4461688
Keep for future use.

Content
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Content
Content ..........................................................................................................2
General ..........................................................................................................4
Imprint..........................................................................................................4
Documentation Representative ...................................................................4
Purpose of this manual................................................................................5
Target group of the manual.........................................................................5
Target group - Required qualifications/training............................................6
Illustrations in the manual............................................................................7
Illustration of the layout ............................................................................7
Representation of procedural instructions................................................8
Representation of warning/general safety information .............................8
Signal words and their meaning in the general safety information ...........9
Representation/explanation of pictograms...................................................9
Supplementary symbols ............................................................................11
Exclusion of liability/warranty.....................................................................12
Notes on copyright.....................................................................................12
Validity of this manual................................................................................12
General Safety Information........................................................................13
Product overview........................................................................................14
Scope of delivery.......................................................................................16
Dimensions................................................................................................17
Connections and components...................................................................19
Hydraulicdiagram.......................................................................................21
Proper/designated use...............................................................................23
Improper use .............................................................................................24
Technical Data...........................................................................................25
Decoding the type label.............................................................................27
Model code.............................................................................................28
Storage and transport ................................................................................29
Assembly, installation and commissioning .............................................32
Preparations..............................................................................................32
Mechanical installation/assembly ..............................................................34
Tightening sequence..............................................................................34
Installing the fluid level display (optional/accessory)..............................38
Hydraulic installation/assembly..................................................................39
Starting up the unit.....................................................................................40
Switching off the unit .................................................................................40
Operation.....................................................................................................41

Content
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How it works: .............................................................................................41
Monitoring the unit's sensors/displays.......................................................42
Monitoring unit function..........................................................................44
Fluid level indicator, visual – min / max..................................................47
Electronic fluid level / temperature sensor HNS.....................................48
Maintenance................................................................................................49
Maintenance intervals................................................................................50
Filling the hydraulic tank with oil (first filling/oil change).............................51
Refilling the hydraulic tank with oil.............................................................55
Partially emptying the hydraulic tank.........................................................57
Completely emptying the hydraulic tank for transport, oil change,
etc..............................................................................................................59
Emptying the degassing unit......................................................................61
Manual bleeding during commissioning (optional/accessories).................62
Bleeding the OLF 5 bypass flow filtration unit............................................63
Clean/replace the suction strainer on the OLF 5 bypass flow
filtration unit...............................................................................................64
Checking the clogging indicator on the breather filter................................66
Replacing the breather filter element.........................................................67
Checking/setting the electronic pressure switch (EDS).............................69
Checking/setting electronic fluid level/temperature sensor HNS ...............71
Replacing the diaphragm...........................................................................73
Removing the diaphragm .......................................................................73
Installing the diaphragm.........................................................................75
Customer Service / Service.......................................................................78
Troubleshooting/fault rectification............................................................79
Removing / Disposal...................................................................................80
Appendix .....................................................................................................81
Spare Parts and Accessories ....................................................................81
Index ............................................................................................................90

General
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General
In this chapter, you will find helpful notes on handling these instructions.
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of registration:
Saarbrücken, HRB 17216
Executive directors:
Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]

General
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Purpose of this manual
Please read this manual before you use this product for the first time or if you
have been asked to carry out other work on the product
The use and the handling of the product described in the following, as well as
its use, are not self-explanatory and are described in detail in this manual
and the associated technical documentation.
This manual will help you to use the product as intended, properly,
effectively, and safely. Therefore, you are requested to read the following
chapters attentively and carefully. Please refer to it every time you require
decisive details.
This manual informs and warns you of risks, against which the risk reduction
through the design and protective measures may not be effective or not fully
effective.
Target group of the manual
This manual was created for the following target group.
Target group
Tasks
Owner
This manual and the associated documents must be kept
accessible at the installation location of the product and
also for later use.
Ask the employees to read and follow the manual and the
documents delivered along with it, in particular, the safety
and warning instructions.
Observe the additional product-related instructions and
requirements.
Specialist
personnel
Read, observe and follow this manual and the associated
documents, in particular, the safety and warning
instructions.

General
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Target group - Required qualifications/training
Persons who work on the product must be aware of the hazards associated
with its use.
Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel:such persons have been instructed about the sensor
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 dangers.
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Auxiliary
personnel
•No specialist knowledge
required
Hydraulic / electrical
installation,
first commissioning,
Maintenance
Troubleshooting
repair,
Decommissioning
Disassembly
Specialist
personnel •Safe handling/use of tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Product-specific knowledge
Operation
Operations control
Specialist
personnel •Product-specific knowledge
•Knowledge about how to
handle operating media.
Disposal
Specialist
personnel •Knowledge about reuse

General
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Illustrations in the manual
You will find illustrations in this manual. You can find details regarding these
in the following chapters.
Illustration of the layout
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx-xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
The manual contains a table of contents, an index and a glossary.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

General
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Representation of procedural instructions
There are these two following representations in the case of procedural
instructions:
Procedural instructions with a fixed sequence
Procedural instructions, whose sequence must be complied with without fail
are listed with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence
Procedural instructions that have a random sequence are listed as bullet
points (-).
An example of a procedural instruction with a random sequence:
- Clean the display
- Rinse the product
Representation of warning/general safety information
All the warning / general safety information in this manual are highlighted with
pictograms and signal words. The pictogram and the signal word indicate the
severity of the danger.
Warning/general safety information is listed before an activity and is laid out
as follows.
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert the danger

General
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Signal words and their meaning in the general safety information
In these instructions you will find the following signal words:
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.
Representation/explanation of pictograms
The following are the safety symbols / pictograms in this manual. They
indicate specific dangers to persons, property or to the environment. Observe
these safety symbols / pictograms and act with particular caution in such
cases. Always keep all symbols / pictograms intact and legible.

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Warning signs used
These signs are listed for all general safety information and instructions in
these operating instructions which indicate particular dangers to persons,
property or the environment.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Danger of explosion in explosive atmospheres

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Signs used for giving orders
These symbols are listed for all general safety information and instructions in
these operating instructions that refer to particular dangers to persons,
property or the environment.
Signs used for the required specialist personnel
These symbols show the required training/knowledge for installation work
and/or maintenance work.
Specialist personnel - Electrical
Such persons have specific 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 dangers.
Specialist personnel - Mechanical
Such persons have specific 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 dangers.
Supplementary symbols
You will find the following symbols in the manual as additional details:
Tip for handling the product
Required tools

General
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Exclusion of liability/warranty
For the warranty provided by us, please refer to our terms of delivery. They
are made available to you at the conclusion of the contract at the latest. In
addition, you will find these under www.hydac.com -> General terms and
conditions.
This manual was prepared 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 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 the Product Liability shall
remain unaffected.
Notes on copyright
All copyrights for this manual lies with the manufacturer. Any part of this
manual may cannot be reproduced, used or copied in any form with the help
of electronical systems without the written consent of the manufacturer. Any
infringements of the above shall be liable to damage compensation.
Validity of this manual
The diagrams and visualizations in this manual are meant for general
illustration purposes. Therefore, representations and functional options can
deviate from those of the delivered product.
We reserve the right to changes to the contents of this manual without prior
notice.

General Safety Information
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General Safety Information
The product has been built according to the provisions, directives and
standards valid at the time of delivery and satisfies the current safety
requirements. Any residual hazards are indicated by the general safety
information and are described in this manual.
Observe all the safety and warning instructions attached to the product and
always keep them up to date and easily legible.
NOTICE
Impermissible operating media
The unit will be destroyed.
►Use the unit only in conjunction with mineral oils compliant with DIN
51524.

Product overview
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Product overview
The OXiStop (OXS) is a tank solution for hydraulic systems with an
integrated hydraulically driven degassing and dewatering power unit and
continuous separation of solids.
The OXS-LID series represents a tank lid solution for the customer-specific
tanks and contain all of the components required for degassing and the
separation of solids.
Modification of C202: OXS/OXS-LID with a separately enclosed OLF 5
bypass flow filtration unit, without hoses and a
mounting bracket, bore diameter enlarged on the
primary body for mounting on a tank
Example illustration: OXS-LID /-C202

Product overview
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Achievable degassing rate/residual water content
The achievable degassing rate is:
≈8 l/h at 20% air content
≈4 l/h at 10% air content
≈0.8 l/h at 2% air content
The achievable residual water content is <50 ppm (depending on the fluid).
The degassing capacity/degassing speed depend, in particular, on the oil
type, oil temperature, oil quantity, tank properties, residual air content and the
environmental conditions. Considerable deviations may occur depending on
the application.
Calculating differential operating volume ΔV
Calculate the required OXS size/differential operating volume in accordance
with the actual volume differences of the hydraulic system's cylinders,
accumulators and hoses.
Take into account an additional required volume for the thermal expansion of
the oil and any continuous oil leakage. Double this nominal volume for safety
reasons.
Use the following formula to calculate the differential operating volume for the
OXiStop:
Δ
V = ΣV
Shell
+ 2(Σ
Δ
V
Cyl
+ Σ
Δ
V
Hoses
+ Σ
Δ
V
Temp
)
Δ
V
=
Difference volume
->
Differential Volume
ΣV
Shell
=
Σ Shell volume
->
ΣCasing volume of the
hydraulic accumulators
Σ
Δ
V
Hoses
=
Σ
Δ
Volume hoses
->
Σ
Δ
Volume of hose lines
Σ
Δ
V
Temp
=
Σ
Δ
Volume
temperature
expansion
->
Σ
Δ
Volume arising from
thermal expansion
When configuring/selecting the size, also note the following:
-
The typical 10-fold reduction in the oil volume reduces the oil's mean
dwell time in the tank. This causes the mixing-completion
temperature/steady-state temperature to be reached more quickly.
Attach the OXS in such a way that the oil that is fed to the cooling circuit
is removed directly from the tank's return line area with no mixing
occurring in the tank beforehand, which would result in a lower
temperature difference in the cooling circuit.
Available sizes

Product overview
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The unit is available in the following sizes:
Filter Size
Differential operating volume ΔV
OXS 30LID
≤30 liters
OXS 45LID
≤45 liters
OXS 70LID
≤70 liters
OXS 150LID
≤150 liters
OXS 250LID
≤250 liters
OXS 325LID
≤325 liters
OXS 500LID
≤500 liters
Scope of delivery
Check the unit for any damage upon delivery. Immediately report any
damage in transit to the forwarding agent or the HYDAC department in
charge.
The following items are included in the scope of delivery:
Qty
Tool
1
OXS-LID, design as per order
1
Flat gasket
1
HYLOMAR M sealing compound
1
Technical documentation, comprising:
- Installation and maintenance instructions for OXS (this
document)
- Instructions on the components

Product overview
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Dimensions
The unit is produced in a variety of sizes – the dimensions are given in the
following drawing and the accompanying table.

Product overview
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The following dimensions are dependent on the size:
OXS-LID
Variable dimensions in mm
Filter Size
A
B
C
D
E
F
G
30
625.5
524
500
362
395
395
5
45
625.5
524
610
472
395
395
5
70
625.5
524
820
682
395
395
5
150
1015
680
610
472
795
595
5
250
1015
680
820
682
795
595
5
325
1415
880
607
472
1195
795
8
500
1415
880
817
682
1195
795
8
OXS-LID
Filter Size
a1
a2
b1
b2
d
n
n1
n2
30/45/70
86.5
605.5
84
504
11.5
26
7
6
150/250
99.5
995
82.5
660
11.5
36
10
8
325/500
116.25
1395
86
860
11.5
44
12
10
OXS-LID
Filter Size
S
P
30/45/70
ISO8434-1-
28L
M36x2
ISO8434-1-
22L
M30x2
150/250
325/500

Product overview
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Connections and components
The unit has the following components:

Product overview
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Position overview of unit components:
Item
Tool
1
OXS-LID primary body
3.1
MiniOX (MOX) degassing and dewatering unit
3.6
Pressure sensor EDS, electric
Pressure gauge, visual (optional)
4.1
Valve and connection block
4.7
Selector valve
5.93
Fluid level/temperature sensor HNS, electrical
B.08
Filling port
B.09
Draining connection
B.12
Pressure measurement point (pressure line)
B.15
Connection for visual tank fluid level indicator
B.20
Connection for electronic temperature sensor ETS
B.22
Breather fitting / connection for rapid bleeding
B.23
Connection for additional HNS
6.3
Sight glass
6.4
Breather filters
S
Interface for pump connection, suction side
P
Interface for pump connection, pressure side