Introduction: The Most Costly Wear is the One You Can't See

In heavy industries like steel, wind power, and injection molding, hydraulic systems are the "muscles" and "blood vessels" of equipment. Yet, the most expensive failures often stem from the tiniest enemies: contaminants in the hydraulic fluid. Statistics indicate that over 75% of hydraulic system failures can be attributed to fluid contamination. HYDAC, a global leader in fluid filtration technology, offers not just a filter element, but the "immune system" for the long-term health of your equipment. Today, we provide an in-depth guide on how to correctly use HYDAC filter elements and which components they must "partner" with to achieve maximum effectiveness.

Part 1: Three Key Usage Principles for HYDAC Filter Elements

1. Precise Selection is 80% of Success
   The first step is not installation, but scientific selection. Focus on three core aspects:

   • Filtration Rating: This is the most critical parameter, such as the common 10 micron (μm) or 5 micron rating in the 0660 series. It determines the size of particles that can be filtered. A rating too coarse offers insufficient protection, while one too fine may cause excessive pressure drop and frequent clogging. The decision should be based on the tolerance of the most precise component in your system (e.g., servo valve clearances are typically 1-5μm).

   • Flow Rate and Port Size: The filter must match the system's flow requirements. An insufficient flow rate creates high resistance and pressure drop, affecting system efficiency. Always verify that the filter's rated flow exceeds the system's maximum flow.

   • Media and Material Compatibility: Ensure the filter media (e.g., glass fiber) is fully compatible with your hydraulic fluid (mineral oil, water-glycol, phosphate ester, etc.) to avoid corrosion or dissolution.

2. Correct Installation is the Foundation of Safety

   • Safety First: Before installation, always isolate system power and fully depressurize the circuit!

   • Cleanliness is Paramount: Clean the surrounding area before opening the new filter's packaging and the filter housing. During installation, apply a layer of clean hydraulic oil to the filter's sealing gasket to facilitate installation and ensure an initial seal.

   • Direction and Tightening: Observe the flow direction arrow; never install it backwards. When securing the filter housing, use a torque wrench to tighten evenly to the recommended torque, avoiding leaks caused by over- or under-tightening.

3. Scientific Maintenance Guarantees Longevity

   • Monitor Pressure Differential (Δp): Filter housings are typically equipped with a Δp indicator or clogging indicator. When the Δp reaches the yellow warning zone, plan for replacement; when it reaches the red alarm zone, replace immediately. Avoid blind replacement based solely on time intervals.

   • Regular Replacement: Even if the Δp hasn't triggered an alarm, establish a preventive replacement schedule based on oil analysis reports and equipment operating hours.

   • Record and Analyze: Log the Δp and operating hours at each replacement. Abnormally short filter life may indicate abnormal system wear or ingression contamination, requiring further investigation.

Part 2: HYDAC Filter Elements Never Work Alone – Essential Pairings

A filter element is never an isolated part; its effectiveness is inseparable from the entire filter unit and system design.

1. Core Partner One: The Filter Housing

   • Relationship: The filter element must be installed in a correctly specified housing, which provides structural support, sealing surfaces, and inlet/outlet ports.

   • Key Point: Ensure the housing's pressure rating and port size match the system, and that its internal design ensures even fluid flow through the media, avoiding bypass.

2. Core Partner Two: The Bypass Valve and Indicator

   • Bypass Valve: This is the safety insurance. When the filter is severely clogged and the Δp is extremely high, the bypass valve opens automatically, allowing fluid to circulate around the filter (unfiltered) to prevent system damage from fluid starvation. This buys you crucial time for scheduled maintenance.

   • Clogging Indicator: This is your maintenance eye. It provides a visual or electrical signal, forming the key component for implementing preventive maintenance.

3. System-Level Partners: Breathers and Coolers

   • Breather (Air Filter): Hydraulic reservoirs are not fully sealed; they need to "breathe." Installing a HYDAC fine breather on the reservoir vent prevents airborne particles and moisture from entering during tank breathing—a critical frontline measure for controlling contamination sources.

   • Cooler: High temperatures accelerate oil oxidation, creating sludge and acids. An effective oil cooler maintains optimal oil temperature, reducing the generation of endogenous contaminants at the source and significantly extending the life of both the filter and the oil.

Part 3: Choose a Reliable Supplier for Accessible Professional Filtration Solutions

Understanding the technical principles enables smarter procurement decisions. As your professional partner in international industrial parts trade, YW DKE TRADING COMPANY, operating the FittingsPneumatic.com platform, is dedicated to translating top-tier filtration technology into a stable safeguard within your supply chain.

We can supply not only HYDAC OEM-quality filter elements (including the full 0660 series and others), filter housings, and complete filter units but also provide preliminary selection advice and efficient logistics support based on our experience. We understand that in global operations, a timely, reliable, and cost-effective spare part is the lifeline of your production continuity.

Conclusion

The correct use and maintenance of HYDAC filter elements represent a highly profitable investment. By protecting expensive core hydraulic components, reducing unplanned downtime, and extending oil life, they continuously create value for your operation. Inspect your equipment's filtration setup now, or contact us anytime for professional support.

                                                                                                                                              Sherlyn