Operating Maintenance and Troubleshooting Manual
Contents
1. LHS b q1v2 alms d ES EET yi 7 x1 S ave A3 41 ou AC ish Oe A9 SHON mal ad SDIT n S T ij i i 1 Dez H TBAIMS NOldO H3ISY e Hyd HIEI j YS OSA HIH SAA 33H83 3 ONISCOH SALTA AllOvevo HOIH el Zug dl i dH OSZI dH Z HOlO J siet IH Mau V lldlHOS3 Sluv 21 13 En HYDAC User Manual OFX7 L 4219 Z JO c 1HS L v TWS 29911 d ON _SNIMVUG ASH aw a MOX MA OL caren NOLLNEIMLSIG Y3MOd pis pees MIH HLM dHZ ZH 09 OV O9v EE WilMVIS 90 X JO OLVW3HOS WOLONI LS S3 N dj1 92 6 010SNOO NMQ xo CONV 8 LL70 6 NVNS3Hid If AHI AVO Agu L L 0 6 YVNS3Yd 2 ddv QUv9 AJY NN SSHONI NI SOS TW SSONVUTIOL 20 cle uz DLE E 692 892 10d q33ds e 992 s e sa E l S9Z v9 9 29 19 092 esc 8S2 Lec 9ec Sec Cd ES eec Vv zx NX EI one O aon o xm OH HT ree zn Y oz de SNOLLO3NNOO IS T2. Y ez NO Nava SOC zzz x v un LEE MOLOVINOO iu id NY E 2 MalV3H MOIOZL TN VE A J o 1 ozz 70 WHN WH ae 6z Na ONINNY HOLON Sein Sh r egiz AR diuo LZ dind NIV wow Si OA EL ene E H SL ANN GHA dH Z N L Bz ioe now us d Ble NP ee sz f T Sanw oo x zx Ix ax n viz wae we L H MJ amp l 0 902 ocz joor z Sany v bod n HRE Sy HL lt I eR ne I D oz E O Ht E ded Her E eoz WHUeL Si So vn ZHO09 Hd A097 e T B el El nl bd re soz YALVIH MANZE m kee amp Gelb De Le eg wr mg Ln X LOZ ANH OMVOHE L o Hien EN OMVOL c ul NOR 902 xoa ZGISNI 1109 diHM SL BLT Tm wave T AVN es He a soz SE Maes d Paws a A lt u del we rd ber e 02 MOLONN mm wie Siwe sl Trn M em aves ANH OM Vr HIE SIMON 602 ova OMV h c aida jn xoa SCISNI 7109 dIHM 9 5 om J J4 1 102 alo oo Pea Yve YY 002 ZH 09 Hd A09y HYDAC En 14 Notes SVO TDS INTERNATIONAL Internet www hydacusa com
3. is running CHANGE ELEMENT light will illuminate when the filter is in bypass indicating it is time to change the element Removing the filter element Equipment required 1 72 box end or socket wrench a container to hold dirty elements and fluid from the filter housing and a small cup of grease Step 1 Attach the provided micro bore bleeder hose to the HYDAC bleed port fitting in the filter housing cap to eliminate any trapped pressure Step 2 Remove filter housing cap using the 1 77 wrench and inspect the O ring Step 3 Remove element Discard the elements with synthetic or cellulose media Clean thoroughly and dry metal re usable elements Step 4 Drain the high capacity filter housing using the drain plug in the base Discard the fluid Installing a new element Step 1 Lubricate grommets located at each end of the replacement element s NOTE DO NOT USE GREASE LUBRICANT IF FIRE RESISTANT FLUIDS ARE UTILIZED IN THE SYSTEM Step 2 Install element into the filter housing making sure element is positioned correctly on the bushing in the porting head Step 3 Secure filter cap to filter housing using the 1 72 wrench Step 4 Bleed air during initial operation loosening the bleed plug located in the filter housing cap Take care not to completely unscrew the bleed plug After all air is purged and oil is observed at the bleed plug re tighten the plug WARNING Performance of HYDAC Filtration Skids are based
4. prior to opening the starter box or motor conduit box or servicing of any electrical component WARNING Do not let unit operate without flow through the pump Priming of the pump may be required Refer to Operating Instructions page 9 WARNING Before starting the unit following a filter element change be sure all shut off valves are open Refer to the Changing Elements section on page 10 En HYDAC User Manual OFX7 L 4219 HYDAC WARNING Qualified personnel must carry out all mechanical and electronic installation and maintenance work on the X Skid Do NOT attempt to perform any maintenance and repair work on the powered X Skid The input cable carries high voltage when power is applied regardless of motor operation There can be dangerous voltages from external controlled circuits when drive power is shut off Exercise appropriate care when working on the unit WARNING Do not tamper with existing circuitry or change the relief valve settings WARNING Filtration performance of the X Skid is dependent on the proper use of HYDAC filter elements Deviating from this can severely compromise the unit s performance Contact HYDAC for recommendations on the appropriate selection of the element media WARNING If the unit is not equipped with a starter box the power source for the motor must be equipped with adequate motor starter controls and overload protection Also if the unit requires a power source for instrumentat
5. L 4219 COTS INTERNATIONAL OFX7 Operating Maintenance and Troubleshooting Manual HY DAC L 2999 Created 9 2012 User Manual OFX7 L 4219 Table of Contents lare 4 Customer Service Eden Ee dodges a digaet M eege geed etn re bd br Du a 4 Modifications to the Product eps Eeer rr eie er rd pis cane Greer o Pe iban exu e esl ad Cle eaa SAT lU er ER NES EEN 4 NEEN DN ECT A ns Ts Oe E 5 Safety Instructions ceteri ER cae e n RR RR A A Fr RON EEN ho i e ERE ENA RU Rn 6 Operating Instructons Imm ee meme meme se eene eme meme e e nene memes eene nns 8 Connect Disconnect Procedures eden eere ka epe rad Fe Y aaa essa LES Ee tu EAA M er exa o A da UP EN RER EE Es 8 Fouer Cleaning Dm 8 Changing elements eerren ai ene re memet ee EAR ese eene ens 9 Removing nstalling Elements cass 2 rrr ta e eroe ster eer ere tu SNE EEN SEENEN rrr 9 SWItChINg FIWIAS ER 10 Taking Fluid Sampl s eoe res rn ee daca Up RR e Uni eve ERR EE EEAS vats Lai dorus SEENEN 11 Product Photo EE 12 APPONGICES imeem 13 Appendix A Electrical Schematic e e esses ese ee sse ese nne e ehe ne e e e nnns 14 Ve 16 HYDAC En TOC L 4219 OFX7 User Manual 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 is intended to help you become acquainted with the ins and outs of the product and use it prop
6. erly You should keep it in the vicinity of the product so it is always at your fingertips Sometimes the information contained in the documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting edge Consequently there might be deviations in technical details illustrations and dimensions If you discover errors while reading the documentation or have suggestions or other useful information please don t hesitate to contact us HYDAC 2260 City Line Road Bethlehem PA 18017 Fax 610 266 0100 www hydacusa com We look forward to receiving your input Our motto Putting experience into practice Customer Service 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 type designation and article no of the product Fax 610 266 0100 www hydacusa com 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 When making modifications or performing repair work to components affecting the safety of the product the product may not be put back into operation until it has been examined and released by a HYDAC representative Please notify us immediately of any modifications made t
7. ion this power source must be supplied at the required voltage AC or DC ON OFF switch and overload protection WARNING This is a recirculating filtration system but with initial use a dry unit will draw oil from the system The system must be allowed to vent breathe Priming of the pump may be required this can be accomplished by holding the suction line higher than the pump and pouring fluid into the hose En 7 L 4219 OFX7 User Manual Operating Instructions Connect Disconnect Procedure 3 Phase Electrical Power Connections Ensure that the power source is turned off and locked out Connect the 3 phase power to the motor or to the starter box being sure to abide by all pertinent federal state and local codes Ensure correct pump rotation as indication by the arrow Turn power on at the source or engage the Start push button at the starter box WARNING If unit is not equipped with a starter box the power source for the motor must be equipped with adequate motor starter controls and overload protection Also if the unit requires a power source for instrumentation this power source must be supplied at the required voltage AC or DC ON OFF switch and overload protection Single Phase Power Connections Ensure that the on off switch is in OFF position Plug the cord into a grounded outlet The unit is now ready to be switched to the ON position Connecting and Operating the Filter Skid Refer t
8. nt level of at least 2 decades lower than the expected sample as qualified per the American National Standard Procedure for Qualifying and Controlling Cleaning Methods for Hydraulic Fluid Power Sample Containers ANSI B93 20 1972 ISO 3722 1976 Step 4 After removing the cap and plastic film from sample bottle place the bottle under the stream of fluid Step 5 Take a sample of not more than 90 nor less than 50 of the sampling bottle volume Step 6 To terminate the sampling process remove the bottle from the fluid stream and close the sample valve after removing the sample bottle from the fluid stream Step 7 Recap the sample bottle immediately after withdrawing the hose En L 4219 L 4219 Product Photo i d j L OFX7 User Manual Relief Valve Heater optional a vem rJ d a X Ze A og Outlet Inlet En HYDAC L 4219 OFX7 User Manual edix A Electrical Schematic A
9. o product photo on page13 Be sure to lock the wheels in place if the skid is caster mounted Connect suction and pressure lines to the system for off line filtration Note OFX7 amp OFX8 skids must have flooded suction lines without any line restrictions Open suction pressure shut off valves and close sampling and bleed plug valves Check for leaks Shut unit off and tighten fittings repairs as necessary For heater operation please refer to Appendix A The filtration skid is equipped with pop up indicator and or differential pressure gauges and indicator lights When the pressure approaches the bypass setting 40 or 50 psi the indicator will be triggered and it is time to change the filter element Refer to the section entitled Changing Elements Disconnecting the Filter Skid Engage the Stop at the starter box or turn the ON OFF switch to the OFF position to cut the unit s power Disconnect the cord from the power source For 3 phase models turn off power at the source and close all shut off valves Disconnect suction and pressure hoses Caps and or plugs should be used to cover protect and mini mize leakage Routine Cleaning The X Skid should be kept clear of excessive dirt and debris En HYDAC User Manual OFX7 L 4219 HYDAC Changing Elements If the unit equipped with the standard starter option there are two indicator lights MOTOR ON indicator light will illuminate when motor pump
10. o the product whether by you or a third party Warranty For the warranty provided by us please refer to the General Terms of Sale and Delivery of HYDAC They are available at www hydacusa com 4 En HYDAC User Manual OFX7 L 4219 HYDAC Introduction HYDAC filtration skids are compact self contained filtration systems equipped with high efficiency high capacity elements capable of removing particulate contamination and or water quickly conveniently and economically Over 90 of all hydraulic failures are caused by contaminants in the fluid proper filtration is essential in achieving long component life and efficient system operation HYDAC s filter skids can serve as a supplement to on line filters whenever adequate turnover cannot be achieved in the system as well as for the pre filter and transfer of fluids and system flushing Standard skids include a hydraulic pump electric motor and either a single or dual standard capacity or high capacity housing Many different combinations allow the flexibility to match even the most specific system need Multiple housing lengths give the option of adding additional dirt holding capacity Environmentally friendly The QF15 housing accepts HYDAC s high capacity coreless elements model code 5 31 element series as well as standard high capacity and high capacity elements model code 1 14 element series The all plastic construction of HYDAC coreless elements helps protect the en
11. upon the use of HYDAC filter elements The X series of filter skids is designed around the pressure drops and specifications of HYDAC Betamicron Media En 9 L 4219 10 OFX7 Switching Fluids Cross contamination flushing o oj Remove and discard elements 2p D N emove fluid from housings fluid lines and drainage tray Ok D Co lose cleanup filters and plugs ee D BA urge system and filter s with 5 gallons of new kerosene te Bleed filter s Be careful not to run dry to avoid the possibility of cavitating the pump Run for several minutes t Remove kerosene Wa D o t epeat steps 3 through 6 as required Zo D Cl t Drain the system of kerosene opening all drain ports and filter caps Co D co t Install elements as desired for the next application Co D ko tep 10 Purge system with the new fluid allow 2 to 3 gallons to discharge into a waste container if practical Step 1 Circulate the fluid in the system d Step 12 Bleed the filters En User Manual HYDAC User Manual OFX7 HYDAC Taking Fluid Samples Step 1 To initiate the sampling process locate the sampling valve s at the base of the filter s Step 2 Pass a minimum of 200 mL of fluid through the desired sampling valve into a waste container before collecting the fluid Step 3 Place the sampling bottle in position to collect the fluid Use a sampling bottle having a contamina
12. use or maintain this product The following safety precautions are offered as a guide which if conscientiously followed will minimize the possibility of accidents throughout the life of the filter skid The filter skid should be operated only by those who have been trained and delegated to do so and who have read and understand these instructions Failure to follow these instructions and safety precautions may result in accidents and injuries and can result in premature component failure Never start the filter skid with a known unsafe condition Tag the filter skid and its power unit so others who may not know of the unsafe condition will not attempt to operate it Install and use the filter skid only in full compliance with all pertinent federal state and local codes or requirements Do not modify this filter skid except with written company approval Keep hands arms and other parts of the body and also clothing away from moving parts Make sure all hydraulic connections are made and shut off valves opened prior to operating unit Wear appropriate protective equipment Do not operate the filter skid with system pressure exceeding 150 psi When disconnecting filter skid from the system first be sure all power is off amp shut off valves are closed Power supply to the motor or the starter box motor contactor and primary side of the transformer is the responsibility of the end user This power supply should be disconnected and locked out
13. vironment and saves on disposal costs by reducing metallic waste Coreless elements can be crushed shredded or burned Easy Servicing As base ported filter housings element access for both the K9 and QF15 is through the cap This makes for quick and easy element changeouts with a minimal chance of oil spillage Designed with the operator in mind there is no wrestling with heavy cumbersome filter bowls HYDAC filtration skids provide many benefits to the user including Protects and extends the life of expensive components Minimizes downtime and maintenance costs Many component combinations allow the flexibility to match specific system needs Designed to handle high viscosity oils Availability of all plastic environmentally friendly coreless elements Base ported filter housings provide quick and easy element replacement Portable via the four wheel cart option Drip pan minimizes oil spillage Market leading HYDAC Betamicron media provides for quick efficient clean up with maximum element life Availability of all plastic environmentally friendly coreless elements En 5 L 4219 OFX7 User Manual Safety Instructions Throughout this manual warnings are used to inform of conditions which can if proper steps are not taken lead to serious fault condition physical injury and death The filter skid is designed and manufactured so it can be operated safely However the responsibility for safe operation rests with those who
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