OF5 mini Filtromat - HYDAC

transcript

OF5 mini Filtromat

Installation Manual English (translation of original instructions)

Documentation no.: 3126812c

From series no.: 0502-1-0592

OF5 mini Trademarks

HYDAC Filter Systems GmbH en Page 2 / 32

BEWA OF5mini 3126812c en 2009-09-16.doc 2009-09-16

Trademarks The trademarks of other companies are exclusively used for the products of those companies.

Exclusion of Liability We made every endeavor to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in future editions. We welcome any suggestions for improvements.

All details are subject to technical modifications.

Technical specifications are subject to change without notice.

HYDAC Filter Systems GmbH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany

Documentation Representative: 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: guenter.harge@hydac.com

OF5 mini Content

Content

Trademarks ...............................................................................................................2 Documentation Representative: .............................................................................2

Content......................................................................................................................3

Preface ......................................................................................................................5 Customer Service ...................................................................................................6 Modifications to the Product ...................................................................................6 Warranty .................................................................................................................6 Using the Documentation .......................................................................................7

Safety Information and Instructions .......................................................................8 Explanation of Symbols and Warnings ...................................................................8 Observe the notes in the operating instructions .....................................................8 Proper/Designated Use ..........................................................................................9 Informal Safety Precautions....................................................................................9 Electrical Hazards...................................................................................................9 Maintenance and Servicing ....................................................................................9 Modifications to the OF5 mini ...............................................................................10

Unpacking the OF5 mini ........................................................................................10

Checking the Scope of Delivery............................................................................10

Description of Unit .................................................................................................11 Components of the OF 5 mini ...............................................................................12

Installing the OF5 mini ...........................................................................................13 Notes on Piping / Hosing ......................................................................................14

Connecting the suction port..................................................................................15

Connecting the pressure port ...............................................................................16

Connecting the electrical system .........................................................................17

Modes of Operation................................................................................................18

Commissioning the OF5 mini................................................................................19

Performing Maintenance........................................................................................20 Filter clogging indicator.........................................................................................20

Installing / changing the filter element.................................................................21

Errors and Troubleshooting..................................................................................24

Disposing of the OF5 mini .....................................................................................24

Dimensions .............................................................................................................25

Spare Parts .............................................................................................................26

OF5 mini Content

Spare Parts List ....................................................................................................27 Technical Data ........................................................................................................28

Type label ................................................................................................................28

Model Code .............................................................................................................29

OF5 mini 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”

OF5 mini Preface

Customer Service Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product:

Fax: ++49 (0) 6897 / 509 - 846

E-mail: filtersystems@hydac.com

Modifications to the Product We would like to point out that changes to the product (e.g. purchasing additional options, etc.) may mean that the information in the operating instructions is no longer applicable or adequate.

After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician.

Please notify us immediately of any modifications made to the product whether by you or a third party.

Warranty We assume warranty in accordance with the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH.

Refer to these at www.hydac.com General terms and conditions.

OF5 mini 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.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

Description of chapter

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.

OF5 mini Safety Information and Instructions

Safety Information and Instructions

Explanation of Symbols and Warnings 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.

NOTICE NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

Observe the notes in the operating instructions The basic prerequisite for the safe and proper handling and operation of the OF5 mini is knowledge of the safety instructions and warnings.

This manual contains important instructions for a safe handling of the OF5 mini.

Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used.

OF5 mini Safety Information and Instructions

Proper/Designated Use The Filter OF5 mini is designed to comply with latest technological and safety standards. Nevertheless its usage can pose danger to the user or third persons. In addition the OF5 mini may be damaged by transport or by improper handling.

The filter must only be used:

• for the specified correct usage.

• when in a safe, perfect condition.

• Any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately.

Informal Safety Precautions Keep this manual near the OLF5 mini.

In addition to the manual the general and the local regulations concerning accident prevention and environment (and conservation respectively) should be provided and observed.

Ensure that the notes concerning safety precautions and sources of danger on the OF5 mini are always legible.

Electrical Hazards

DANGER Electric shock

Danger of fatal injury

► Pull the power plug before performing work on live parts.

All work on the electrical equipment of the OF5 mini may only be carried out by a qualified electrician.

Check the electrical equipment of the filtration unit regularly. Any loose electrical connections or damaged cables are to be replaced immediately.

Maintenance and Servicing All safety installations must be in place and fully functional before starting up the system.

OF5 mini Unpacking the OF5 mini

Modifications to the OF5 mini Do not carry out any alterations, conversions or additions to the OLF5 without the consent of the manufacturer.

No modifications may be made to the components without the express prior written approval of HYDAC Filtertechnik GmbH.

Immediately replace any 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.

Unpacking the OF5 mini All OF5 mini units are tested at the factory for leaks and function. They are then carefully packaged for shipment.

Upon receipt of the unit, check for any damage from transportation.

The fluid connections are all sealed with plugs to prevent the intrusion of contaminants during transport. Remove them before commencing installation.

The packaging material should be reused/recycled as appropriate for your area.

Checking the Scope of Delivery The Filter unit OLF5 mini is delivered packed and ready for use. Before commissioning the filter unit, check the contents of the consignment to make sure everything is present.

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:

Item Quantity Designation

- 1 OF5 mini

- 1 Operating and Maintenance Instructions

OF5 mini Description of Unit

Description of Unit The offline filter unit OF5 mini is a stationary filter-pump unit used for the offline filtration of hydraulic tanks.

In addition to offline filtration, a simple transfer by pumping can be performed with or without filtration, e.g. for filling or emptying hydraulic tanks, with the built-in change-over function.

NOTICE Impermissible operating conditions

The unit will be damaged

► The unit may be used only in connection with mineral oils (or mineral oil-based raffinates).

► The permitted viscosity range is 15 - 500mm²/s

► The maximum operating temperature of 80°C may not be exceeded.

OF5 mini Description of Unit

Components of the OF 5 mini

Item Designation

1 Filter bowl

2 Filter cover

3 Clogging indicator

4 Air bleed plug [Air bleed]

5 Star knob screw

6 Electric motor

7 Terminal box

8 Pump

9 Lever with detent pin

10 Base

11 Type label

OF5 mini Installing the OF5 mini

Installing the OF5 mini

Mount the unit in a horizontal position. Use the 4 through holes (∅ 8.5 mm) in the base plate to mount the unit.

Please be advised that for technical reasons, the locking screws underneath the base stand out ≈ 6 mm.

Secure the unit in a raised position.

Use flat iron bars (at least 10 mm, recommended 40 mm) or buffers: see figure (x).

A buffer mounting set can be purchased from HYDAC, part no. 3124658.

It consists of: The 4 x buffers including nuts and washers

In order to prevent the motor from overheating, adequate cooling air must be provided.

Make sure to leave sufficient room around the housing to remove the filter element (at least 260 mm).

OF5 mini Installing the OF5 mini

Notes on Piping / Hosing In order to keep the pressure loss as low as possible, use as few threaded connections as possible.

The pressure loss in a hydraulic line depends upon:

• Flow rate

• Kinematics viscosity

• Pipe dimensions

• Fluid density

The pressure differential can be estimated for hydraulic oils as follows:

Δp ≈ 6.8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = pipe length [m]

d = internal pipe diameter [mm]

Q = flow rate [l/min]

V = kinematics viscosity [mm²/s]

D = Density [kg/dm³] Mineral oil based hydraulic fluid has a density of ≈ 0.9 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 oil level in the tank as minimal as possible.

Hoses must be suitable for suction pressures of at least -0.5 bar.

Constrictions in the connections and lines should be avoided. This could compromise suction output and cause cavitation.

Take note that the nominal size of the connected hoses/piping must be at least as large as the inlet port sizes.

Make sure that no tension or vibrations are carried over to the pump or filter housing when the pipes are connected. Use hoses or expansion joints if necessary.

OF5 mini Connecting the suction port

Connecting the suction port

Make the suction-side connection with a flexible hose that is resistant to negative pressure or with pipelines. If the OF5 mini is connected to hard piping, precautions must be taken to ensure that no stresses or vibrations are transmitted to the pump/filter housing. Use hoses and expansion joints as may be necessary.

Constrictions in the connections and lines should be avoided. This could compromise suction output and cause cavitation. The nominal size of the connected hoses/piping must be at least as large as the inlet port sizes of the OF5 mini.

NOTICE Overpressure at the suction port connection

► The maximum pressure on the suction port connection IN must be -0.4 bar ... 0.6 bar at most

NOTICE Severe contamination

► Do not prime directly at the bottom of the tank

► Do not prime in the sump

► Suction strainer with 100 µm provided in the suction line

The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank.

Install a shut-off valve on the suction / pressure side in order to allow filter element change.

OF5 mini Connecting the pressure port

Connecting the pressure port

NOTICE Pressure port closed

► The pressure port must always be open

The nominal size of the pressure hose should be equal to that of the filter housing port whenever possible. If a smaller hose size is used, the back pressure must nevertheless be > 2 bar with a clean filter element.

Install the return line or return hose below the oil level to prevent air from entering the fluid.

If the back pressure is > 1 bar, a differential pressure clogging indicator must be installed.

OF5 mini Connecting the electrical system

Connecting the electrical system

DANGER Electric shock

Danger of fatal injury

► The electrical connection must be carried out by a qualified electrician. Regulations according to the EMV Directive 89/336 EWG und the Low Voltage Directive 73/23/EWG, as well as corresponding EN norms such as VDE/EVU Directives and local or national regulations, must be adhered to.

The voltage and frequency indicated on the rating plate must coincide with the voltage supply present.

The pump motor must be protected from overloading, in accordance with VDE 0113.

Depending on the voltage supply, the motor has to feature a star or delta connection (cf. rating plate on the motor).

Star (Y-) connection Delta connection

OF5 mini Modes of Operation

Modes of Operation The OF5 mini can be used for three different types of operation. Change-over is carried out by the switching lever on the front side of the unit.

To change over, turn the switching lever to the right or left until it engages or is locked in centre position.

The switching lever can be changed only when the detent pin on the front side of the switching lever is pulled out.

The different switching positions are illustrated on the type label at the front of the base.

Position I Pump out tank without filtration, Detained lever position, suctioning via connection A, outlet connection B

Position II Offline filtration, lever in detained centre position, Suction via

connection A , outlet connection T

Position III Fill tank with filtration, Right detained lever position, suctioning via

connection A, outlet connection T

OF5 mini Commissioning the OF5 mini

Commissioning the OF5 mini After the unit has been completely installed, it can be put into operation.

1. Check if a filter element is installed.

If necessary, install a filter element according to the chapter on page 21.

2. Check the direction of rotation of the electric motor. To do this, switch on the unit briefly (jog mode) and check the direction of rotation of the fan wheel on the motor. An arrow on the fan cover of the motor shows the direction of rotation. When looking at the fan wheel, it should turn in a clockwise direction. If the direction of rotation needs to be changed, exchange two phases in the terminal box of the motor.

3. If the unit is not feeding medium after several minutes of operation, you must pre-fill the pump.

Pre-filling is done with the motor switched off. Depending on the kind of installation, you must do it via either port A or port B.

Pay attention to the position of the lever: - when refilling through A, it must be in position II, and - when refilling through B, it must be in position III.

4. Vent the filter housing. Loosen the vent plug in the cover plate while the pump is running. It only needs to be unscrewed enough to allow the air to escape from the filter housing. As soon as oil emerges, the screw must be re-tightened.

Vent the filter housing each time it is opened.

5. The unit is now ready for use.

OF5 mini Performing Maintenance

Performing Maintenance

WARNING Operating pressure

Bodily injury

► Depressurize the system before performing any work on it.

Filter clogging indicator To monitor the filter element, the OF5 mini is equipped with a pressure clogging indicator installed in the filter cover plate. The pressure clogging indicator only responds when fluid is flowing through the filter.

When the clogging indicator reaches the red marked area (2.5 bar), the filter element must be replaced.

OF5 mini Installing / changing the filter element

Installing / changing the filter element

WARNING Hydraulic system is under pressure

Bodily injury

► Depressurize the system before performing any work on it.

The filter housing must be relieved of pressure, i.e. the pressure gauge built in the filter cover must show “0 bar”. Otherwise, open the vent plug in the cover to relieve the pressure.

To install or change the filter element you need 2 slotted screwdrivers.

When changing the filter element, proceed as follows:

1. Loosen both star knobs (A) on the cover counterclockwise.

Then fold the star knobs (A) under.

2. Place the two screwdrivers between the eye screw and filter.

Use both screwdrivers to lift off the cover from the filter housing.

3. Pull the cover together with the filter

element up out of the filter housing.

4. Remove the filter element by slightly

turning the cover.

Dispose of the used oil properly.

5. Moisten the O-rings on the new filter

element with the operating medium.

6. Using slight pressure and turning, push the new element onto the spigot on the cover.

7. Place the cover together with filter

element into the filter housing by turning and applying slight pressure.

Do not use excessive force or a hammer, etc.

8. Position the cover so that it is aligned

with the star screws (A).

Fold the star screws (A) upward.

Tighten the star screws (A) evenly in a clockwise direction.

Check that both vent plugs in the cover are properly secured.

9. Switch on the unit and check for any

leaks.

10. The OF5 mini is ready for operation.

OF5 mini Errors and Troubleshooting

Errors and Troubleshooting

Error Cause(s) Remedy

Pump transfers in the wrong direction

Make sure that the pump is functioning in the direction shown by the arrows on the housing. If necessary, switch two phases in the motor control box.

Air in suction area and pump

It might take several minutes for the pump to remove the air. It may help to turn the OF5 mini in a horizontal position until the air is removed.

If it is not working after after ≈5 min, pre-fill the pump through the suction side with the medium to be pumped.

No oil flow

Operating viscosity <200 mm²/s and pump not filled

In this viscosity range, the pump requires ≈10 minutes to reach the maximum. flow rate.

Medium is heavily contaminated

Filter element lifetime is exceeded

Replace the filter element Filter contaminated

(Clogging indicator is activated)

The viscosity of the fluid is too high

Wait until the oil has been warmed up by pumping within the pump (pressure relief valve opened). After the fluid has been warmed up the pump starts operation.

Leakages in the filter housing

Retighten the vent plug and the star knob on the filter head.

Disposing of the OF5 mini When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil in the unit, components covered with oil and electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

OF5 mini Dimensions

Dimensions

OF5 mini Spare Parts

Spare Parts

OF5 mini Spare Parts

Spare Parts List Item Qty. Designation Material Part no.

- 1 Buffer mounting kit 3124658

9 1 O-ring 633028

10 1 O-ring 6005405

41 1 Motor-pump group OF5M20V1N 3158008

32 1 O-ring 604336

33 1 O-ring 604198

53 1 O-ring 6005404

55 1 O-ring 604202

416 1 Filter element, 2 µm DIMICRON®

N5DM002 FPM 349494

N5DM005 FPM 3068101

N5DM010 FPM 3102924

N5DM020 FPM 3023508

416 1 Filter element, 1 µm AQUAMICRON®

N5AM001 FPM 3114428

N5AM002 FPM 349677

N5AM020 FPM 3040345

OF5 mini Technical Data

Technical Data Maximum flow rate 15 l/min

Operating pressure 4.5 bar max.

Permissible suction pressure at suction port -0.4 - 0.6 bar

Pump types G-Rotor

Viscosity range 15 – 500 mm2/s

Fluid temperature range -10 – 80°C

Ambient temperature range -20 – 40°C

IP class IP55

Weight ≈ 20 kg

Connector threads A = G1, according to ISO 228

T = G3/4, according to ISO 228

R = G3/4, according to ISO 228

Type label

OF5 mini Model Code

Model Code OF5 M 20 V 1 M 2 N5DM005 E - /-Product OF5

Version M = Stationary with

switchover

Type code 20 = Standard

Sealing material V = FPM (Viton)

Motor-pump group 1 = 15 l/min (at viscosity 40 mm²/s)

Theoretical carrying capacity at 1450 1/min

Voltage L = 115 V, 1 Ph M = 230 V, 1 Ph* N = 400 V, 3 Ph T = 12 V DC U = 24 V DC X = other voltage M60 = Operation at 60 Hz * Standard in Europe per

Filter size 2 = 1 element N5 Filter element N5DM002 = DIMICRON® 2 µm absolute N5DM005 = DIMICRON® 5 µm absolute N5DM010 = DIMICRON® 10 µm absolute N5DM020 = DIMICRON® 20 µm absolute N5AM001 = AQUAMICRON® 1 µm absolute N5AM002 = AQUAMICRON® 2 µm absolute N5AM020 = AQUAMICRON® 20 µm absolute z = without filter element

Clogging indicator E = Dynamic pressure gauge Supplementary details

HYDAC Filter Systems GmbH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 846 Technical Department Fax: +49 (0) 6897 509 577 Sales Department Internet: www.hydac.com E-Mail: filtersystems@hydac.com

OF5 mini Filtromat - HYDAC

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