White OMS User manual

User Manual
ATEX instruction for OMS

Contents
Chapter 1: Introduction........................................................................................... 5
General information.............................................................................................................................................. 6
Intended use...........................................................................................................................................................6
Marking of ATEX motors......................................................................................................................... 6
Maximum surface temperature for OMS.................................................................................................. 8
Chapter 2: Technical information......................................................................... 11
Product description..............................................................................................................................................12
Operating principle for OMS motors...................................................................................................... 12
Technical specification for OMS motors............................................................................................................ 12
Oil types / Operating fluids................................................................................................................................. 12
Mineral oils for OMS motors.................................................................................................................. 12
Temperature and viscosity...................................................................................................................................12
Ambient temperature...............................................................................................................................13
Oil temperature........................................................................................................................................13
Viscosity..................................................................................................................................................13
Filtering............................................................................................................................................................... 13
Painting of the motor...........................................................................................................................................13
Chapter 3: Installation, operation and maintenance........................................... 15
Installation...........................................................................................................................................................16
Installation of OMS motor to the system................................................................................................ 16
Hydraulic connections for OMS motors................................................................................................. 17
Operation.............................................................................................................................................................17
Pre start up controls for OMS motors..................................................................................................... 17
Start up.................................................................................................................................................... 18
Maintenance........................................................................................................................................................ 19
Service and repair of OMS motors..........................................................................................................19
Chapter 4: Declaration........................................................................................... 21
ATEX Certified Orbital Motors | Contents | iii

Chapter
1
Introduction
Topics:
• General information
• Intended use

General information
Purpose of this document
This User Manual has been prepared by the manufacturer in order to provide important information regarding the safe
installation, operation and maintenance of ATEX certified motors.
This User Manual is a supplement to existing product instruction as ATEX components are subjected to some
limitations compared to standard components. The limitations are described in this ATEX instruction.
It is intended for machine/system manufacturers, fitters and service technicians. Please read this User Manual
carefully before you work with and start-up the motor.
This User Manual must lie close to the motor.
Manufacturer responsibility
The manufacturer declines any responsibility in case of:
• Use of the product not according to safety regulations and legislation valid in the user’s country.
• Use of the product in operating conditions not allowed according to the product technical documentation.
• Improper installation: the instructions given in this User Manual are not followed or not properly followed.
• Hydraulic system problems.
• Modification of the product.
• Operations executed by personnel not properly trained or not assigned to such a kind of operations.
Product safety
The safety of the product depends upon the strict observation of the indications given in this User Manual: in
particular, it is necessary to:
• Always operate within allowed product working operating conditions (please refer to the Technical Information of
the motor in usage).
• Always perform an accurate ordinary maintenance activity.
• Assign the inspection activity as well as maintenance activity to duly trained personnel.
• Only use original spares.
• Always use the product according to the indications you find in this manual.
Intended use
Hydraulic motor converts hydraulic energy (pressure, oil flow) into mechanical energy (torque and speed). They are
designed for mobile and stationary applications.
The motors fulfill the explosion requirements with the Directive 2014/34/EU for the category shown on the name
plate.
The OMS motors have an identifying name plate. The name plate provides essential information and specification for
correct and safe use.
This identifying plate has to be maintained so that the data can be clearly read; consequently, a periodic cleaning of
the plate is required.
Marking of ATEX motors
The OMS motor is marked for application in gaseous and dusty environments according to the below:
ATEX Certified Orbital Motors | Introduction | 6

Figure 1: Example label only
Key to label image:
1. CE Conformity marking
2. EU marking (per 2014/34/EU) - Directive part
Description EU Marking
CE conformity marking CE
Explosion protection marking
Equipment group II
Equipment Category 2G / 2D
3. EU marking (per EN ISO 80078-36.2016 Standard part)
Description EU Marking
Protection principle h
Explosion protection marking Ex
Equipment group II / III
Equipment protection level (EPL) Gb / Db
OMS Gas T5...T3
Dust T75°C...T125°C
OMSS Gas T5...T3
Dust T85°C...T125°C
ATEX Certified Orbital Motors | Introduction | 7

Table 1: EPL/Equipment category
Definition Level of
protection
Typical
zone of
application
EN ISO EU
EPL Group Category Group
Gas
atmosphere
Very high 0 Ga II 1G II
High 1 Gb 2G
Enhanced 2 Gc 3G
Dust
atmosphere
Very high 20 Da III 1D II
High 21 Db 2D
Enhanced 22 Dc 3D
4. See item 3
5. Min and max ambient temperature
6. Manufacturer
7. Motor type and displacement
8. Code number
9. Production number, date, and series number
Example of item 9: N95123094
NManufacturing location (N = Nordborg)
9Year 2019
51 Week 51
2Tuesday (1 = Monday)
3094 Consecutive number
Maximum surface temperature for OMS
Classification of maximum surface temperatures for Group II equipment
Temperature class Maximum surface temperature
°C [°F]
T3 200 [392]
T4 135 [275]
T5 100 [212]
Note:
For Group II with T4 classification it is acceptable that small surface areas (total areas ≥ 20 mm2 and ≤ 1000 mm2)
can have surface temperature up to 200 °C.
For T5 classification it is acceptable that small surface areas (total areas ≤ 1000 mm2) can have surface temperature
up to 150 °C.
ATEX Certified Orbital Motors | Introduction | 8

Maximum surface temperature – Dusty environment (Group III)
Table 2: OMS motors - Maximum surface temperatures
Maximum oil
temperature
Maximum ambient temperature
≤ 20 °C [68 °F] ≤ 40 °C [104 °F] ≤ 60 °C [140 °F]
≤ 40 °C [104 °F] 115 [239] 135 [275] 155 [311]
≤ 60 °C [140 °F] 130 [266] 150 [302] 170 [338]
≤ 80 °C [176 °F] 145 [293] 165 [329] 185 [365]
Table 3: OMSS motors (short motor) - Maximum surface temperature
Maximum oil
temperature
Maximum ambient temperature
≤ 20 °C [68 °F] ≤ 40 °C [104 °F] ≤ 60 °C [140 °F]
≤ 40 °C [104 °F] 85 [185] 95 [203] 105 [221]
≤ 60 °C [140 °F] 100 [212] 110 [230] 120 [248]
≤ 80 °C [176 °F] 115 [239] 125 [257] 135 [275]
Note: Above maximum surface temperatures are without any deposited dust on the motors. The possible insulation
effect of a dust layer on the surface has to be taken into account by the safety margin to the minimum ignition
temperature of the dust concerned. For up to 5 mm [1.97 in] layer thickness the safety margin is 75 °C [167 °F]. For
further information please see IEC 60079-14.
Warning: The above operating temperatures (ambient and oil) of the motor must be guaranteed by the end
user.
Warning: It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface
temperature of the motor. See also Oil types / Operating fluids on page 12
ATEX Certified Orbital Motors | Introduction | 9

Chapter
2
Technical information
Topics:
• Product description
• Technical specification for OMS
motors
• Oil types / Operating fluids
• Temperature and viscosity
• Filtering
• Painting of the motor

Product description
Operating principle for OMS motors
Hydraulic orbital motors convert hydraulic energy (pressure, oil flow) into mechanical energy (torque and speed). The
orbital motors are of fixed displacement high-torque design. For a given oil flow and given pressure the displacement
(size of motor) determines the speed and torque. For a given displacement (size of motor) the speed is determined by
the oil flow rate and the torque is determined by the pressure differential.
The operating principle of the motor is based on an internal gear design, consisting of a fixed external gear reaching
against an internal gear through which the output torque and speed are transmitted. The distributor valve in OMS
motors is of the disc valve design which is driven synchronously by the internal gear through a cardan shaft ensuring
that the individual chambers of the motor are filled and emptied precisely.
All parts included in the motors are designed to provide long service life, i.e. long service life with high efficiency
and a minimum level of required service.
Technical specification for OMS motors
All necessary design information for instance maximum pressure rating, maximum flow, maximum radial load etc. is
provided in the Technical Information catalogues.
The rated data which we publish in our Technical Information is based on the use of premium mineral based
hydraulic oil with a viscosity of 35 mm2/s.
Oil types / Operating fluids
In a hydraulic system the most important task of the oil is to transfer energy. At the same time the oil must lubricate
moving parts in hydraulic components, protect them from corrosion, and transport dirt particles and heat out of the
system. To ensure that hydraulic components operate without problems and have long operating life it is therefore
vital to select the correct oil type with the necessary additives.
Ratings and performance data are based on operating with hydraulic fluids containing oxidation, rust and foam
inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear, erosion and corrosion of
motor components.
Mineral oils for OMS motors
For systems containing mineral hydraulic oil with anti-wear additives, type HLP [DIN 51524] or HM (ISO 11158)
must be used.
Mineral oils without anti-wear additives or engine oils can also be used, provided operating conditions are suitable.
Warning: It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface
temperature of the motor. Maximum surface temperature can be found under:Maximum surface temperature
for OMS on page 8.
Mixing oils of different brands or different oils of the same brand may lead to the formation of sediment and sludge.
Consequently a rapid, irreversible deterioration of the system is induced.
Temperature and viscosity
ATEX Certified Orbital Motors | Technical information | 12

Ambient temperature
Maximum ambient temperature depends on the requested ATEX class needed – please see Maximum surface
temperature for OMS on page 8.
In general, the ambient temperature should be between -30 °C [-22 °F] and +60 °C [+140 °F].
Oil temperature
Maximum oil temperature depends on the requested ATEX class needed. See Maximum surface temperature for OMS
on page 8.
Under normal operating conditions it is recommended to keep the temperature in the range of 30 °C [86 °F] to 60 °C
[140 °F].
Fluid temperature affects the viscosity of the fluid and resulting lubricity and film thickness. High temperatures can
also limit seal life, at most nonmetallic materials are adversely affected by use at elevated temperatures.
Fluids may break down or oxidize at high temperature, reducing their lubricity and resulting in reduced life of the
unit. Oil life is greatly reduced if its temperature exceeds +60 °C [+140 °F]. As a general rule, oil life is halved for
each 8 °C [46 °F] its temperature exceeds +60 °C [+140 °F].
Viscosity
Maintain fluid viscosity within the recommended range for maximum efficiency and bearing life. Minimum viscosity
should only occur during brief occasions of maximum ambient temperature and severe duty cycle operation.
Maximum viscosity should only occur at cold start. Limit speeds until the system warms up.
Table 4: Fluid viscosity limits
Conditions mm2/s (cSt) SUS
Minimum 12 66
Continuous 20 - 80 98 - 370
Maximum 1500 6950
We recommend the use of an oil type having a viscosity of 35 mm2/s at the actual operating temperature.
Filtering
It is necessary to keep the level of oil contamination at an acceptable level to ensure problem-free operation. The
recommended maximum level of contamination in systems in the hydraulic motor is 22/20/16 (ISO 4406-1999).
Painting of the motor
Warning: ATEX certified motors are without painting. In case of additional painting of the motor please
make sure that the thickness is in accordance with the relevant standards.
ATEX Certified Orbital Motors | Technical information | 13

Chapter
3
Installation, operation and maintenance
Topics:
• Installation
• Operation
• Maintenance
This section is intended for personnel assigned to install the motor on the
machine or system for which the unit has been purchased. Therefore the
importance of this section is emphasized since the optimum operation of
group machine/system – motor is the consequence of correct assembly of the
parts; the correct installation will limit the sources of danger for people
working near to the structure.

Installation
Installation of OMS motor to the system
When assembling the motor in the machine/system it is the builder’s responsibility that the parts used conform to the
ATEX directive and that the components are assembled and running according to the operational data/design found in
product data sheets and instructions.
Only use the motor as required by the explosion protection shown on the name plate.
Always ensure that the following is maintained:
• The supporting frame, chassis, or structure of equipment containing the motor shall be constructed of electrically
conducting material and shall be so arranged as to provide a leakage path to earth (ground) for any static
electricity which occurs on the motor.
• It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface temperature of
the motor. Maximum surface temperature for Group II and III can be found under Maximum surface temperature
for OMS on page 8.
• Make sure that all type of accessory installed on the motor are ATEX certified and have been installed in
accordance with ATEX requirements.
• There are no creeping metal elements external to the motor.
• There are no plastic parts that might accumulate electrostatic; or they are shielded.
• The maximum permissible oil and ambient temperature is monitored and not exceeded for the category and
temperature class of the associated zone.
• For installation in zones 21 and 22 the user has to adopt a scheduled periodic clearing plan of the motor surface
and recesses to prevent more than 5 mm thickness of dust deposits.
Regarding the assembly flange on the machine/system where the motor has to be installed: the relevant surface has to
be perfectly smooth, completely de-greased and non-deforming.
It is necessary to verify the perfect alignment between the motor output shaft and the counter part – the fitment
between motor shaft and application’s driven shaft must be executed so that no radial or axial pre-load is generated –
these extra loads reduce the bearings expected lifetime.
151-2062.10
151-2063.10
ATEX Certified Orbital Motors | Installation, operation and maintenance | 16

Hydraulic connections for OMS motors
Main inlet hoses connections (Y)
The motor has two port connections on the end cover which can be both inlet or outlet ports depending on the
application.
Drain line connection (Z)
The drain line relieves the pressure on the shaft seal to tank. The tank pressure must be less than or equal to the
maximum permissible seal pressure – see seal graph shown in the Technical Information catalogue.
151-1091.10
Y
Z
The following main rules apply to drain lines fitted to hydraulic motors:
• We recommend a drain line when the maximum pressure on the shaft seal is exceeded, i.e. the life of the shaft seal
can otherwise be significantly reduced.
• We always recommend a drain line when
• A short motor (bearing less motor) is built together with e.g. a gear.
• The motor is used in hydrostatic transmissions that do not have a separate flushing valve.
Tightening torque
The recommended tightening torque for the hoses are shown in the table below.
Table 5: Maximum tightening torque
Screwed
connection
G 1/4 G 1/2 G 3/4 G 1
- with steel washer 40 N•m [350 lbf•in] 130 N•m [1,150
lbf•in]
210 N•m [1,850
lbf•in]
280 N•m [2,500
lbf•in]
- with cutting edge 40 N•m [350 lbf•in] 130 N•m [1,150
lbf•in]
210 N•m [1,850
lbf•in]
280 N•m [2,500
lbf•in]
Operation
The purpose of this section is to indicate the necessary procedures to perform the motor start up.
Pre start up controls for OMS motors
Before performing the first motor start up, the following points have to be checked:
• Hydraulic components must be installed in accordance with their individual instruction.
ATEX Certified Orbital Motors | Installation, operation and maintenance | 17

• To avoid contamination, plastic plugs in connection ports must not be removed until just before connections are
made.
• Make sure the motor hydraulic connections allow the motor to rotate in the desired direction. For motors with
standard direction of rotation:
• Clockwise rotation (viewed facing the output shaft) with inlet pressure in the A port.
• Counter-clockwise rotation (viewed facing the output shaft) with inlet pressure in the B port.
B BA A
151-1050.10
• Select the hydraulic fluid as specified in Oil types / Operating fluids on page 12.
• There must be full contact between motor mounting flange and connecting part.
• Avoid pressing the motor into place by tightening the fixing bolts.
• Avoid unsuitable seal materials, for example, twine and Teflon, on threaded unions. Use only the seals supplied,
such as O-rings, steel washers.
• Make sure that all couplings are completely tightened to prevent leakage – never use more torque than max values
given in instructions.
• Check to make sure the purity of the oil is better than 22/20/16 (ISO 4406-1999) and always use a filter when
replenishing the system.
Warning: The motor must be filled with fluid prior to any load applications.
Start up
During and immediately after the motor start up, any hydraulic system must be closely and frequently checked.
1. To assure best motor performance, run the motor for approximately one hour at 30% of rated pressure and speed
before running at full load.
When running make sure the motor and oil temperature and noise level are sufficiently low. High temperature or
noise level might be symptoms of unforeseen operation conditions that have to be analyzed and cleared.
2. Check for system leakage and make sure the system is operating satisfactorily.
3. To ensure that the contamination in the hydraulic system does not damage the motor; the following procedure is
recommended after a brief period in operation:
a) After a brief period in operation, have a hydraulic fluid specimen analyzed for the required cleanliness level.
b) Replace oil filter or change the hydraulic fluid if the required cleanliness level is not reached.
During operation
The product is a component which requires no settings or changes during operation. The machine/system
manufacturer is responsible for the proper project planning of the hydraulic system and its control.
It is recommended to:
• Regularly verify that the temperature of the ambient and the operating oil are those initially determined.
ATEX Certified Orbital Motors | Installation, operation and maintenance | 18

• Do not subject the motor to pressure, pressure drop or speeds exceeding the maximum values stated in the
appropriated catalogues.
• Filter the oil to maintain the grade of contamination at 22/20/16 (ISO 4406-1999) or better.
Maintenance
Warning:
If maintenance has to be performed in an explosive and hazardous atmosphere, an anti-sparking safety tool
must be used.
• With hydraulic systems the main criterion for reliability and operating life is very thorough regularly maintenance.
• Regularly check the system for presence of leakage and the oil level.
• During system’s function, it is necessary regularly to verify that the temperature of the ambient and the operating
oil are those initially determined.
• Replenish and change the oil, the oil and air filters as stated in the respective instructions.
• Regularly check the condition of the oil – viscosity, oxidation, filtration level etc.
Viscosity Verify that the viscosity level is within the recommended values as indicated in Viscosity on
page 13.
Oxidation Mineral oil gets oxidized proportional to the usage degree and operating temperature. The
oxidation of oil is evident because of its change of color, bad smell, acidity increase and
because of the generation of sludge inside the tank. In case symptoms of this kind are
detected, the system oil must be immediately changed.
Water presence The presence of water inside oil can be determined by taking oil samples from the bed of the
oil tank: oil floats on water, if present, water tends to stay on the tank’s bed. If its presence
is determined, water must be regularly purged. Presence of water in the hydraulic system
can severely damage the motor.
Degree of
contamination
A high degree of contamination of the operating oil causes a severe wear of all hydraulic
components: for this reason, the cause of the contamination must be identified and
eliminated. In order to avoid mixing of different oils, when replacing the operating fluid. It
is necessary to empty all the machinery and pipes, clean them carefully and clean the tank.
• For installation in zones 21 and 22 the user has to adopt a scheduled periodic clearing plan of the motor surfaces
and recesses to prevent more than 5mm thickness of dust deposits.
Service and repair of OMS motors
In case a service or repair intervention on the motor is required, it has to be performed according to the information
shown in the respective Repair Instructions.
The Repair Instruction includes the spare part list and information about how dismantling and assembling of the
motor is done properly.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
Take the following general precautions whenever servicing a hydraulic system.
Tools
Warning: It is compulsory to use anti sparking safety tools in case the service/repair activity has to be
performed in explosive hazardous atmosphere.
ATEX Certified Orbital Motors | Installation, operation and maintenance | 19

Unintended machine movement
Warning: Unintended movement of the machine or mechanism may cause injury to the technician or
bystanders. To protect against unintended movement, secure the machine or disable/disconnect the
mechanism while servicing. Follow the manufacturers instructions for securing the machine.
Personal safety
Warning: Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Flammable cleaning solvents
Warning: Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an
area where a source of ignition may be present.
Fluid under pressure
Warning: Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing
serious injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing
with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or
components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.