Hydac LVU-CD-40 Operating And Maintenance Instructions Manual Download Page 1

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LVU-CD-40
LowViscosity Unit
CoalescerDiesel

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 4035823a

Keep for future reference.

Summary of Contents for LVU-CD-40

Page 1: ...LVU CD 40 LowViscosity Unit CoalescerDiesel Operating and Maintenance Instructions English translation of original instructions Document No 4035823a Keep for future reference ...

Page 2: ...as Dieter Dipl Kfm Wolfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com HYDAC FILTER SYSTEMS GMBH All rights reserved No part of this work may be reproduced in any form print photocopy or by other means or processed duplicated or distributed using...

Page 3: ...ructure of the safety information and instructions 10 Proper Designated Use 11 Improper use or use deviating from intended use 12 Qualifications of personnel target group 13 Wear suitable clothing 14 Observe regulatory information 14 Stoppage in an emergency EMERGENCY STOP 14 Unpacking the unit 14 Transporting the unit 15 Transporting with the crane 15 Storing the unit 16 Decoding the type label 1...

Page 4: ...ndicator 34 Observing checking phase limits 36 Draining off the free water 37 Operating Setting Standard Premium control type 38 Switching the main switch on off 39 Reading LED status 39 Setting interval control with Premium control type only 40 Adjusting the time selector switch 41 Checking the motor protection switch 41 Switching unit on off 41 Automatic water drainage 41 Performing maintenance ...

Page 5: ...Content LVU CD 40 en us Page 5 68 BeWa LVU CD 40 4035823a en us 2016 01 08 doc 2016 01 08 Technical data 60 Decoding model code 62 EC declaration of conformity 63 Index 64 ...

Page 6: ...all be limited to foreseeable damage Claims due to Product Liability shall remain unaffected Technical support 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 9046 E mail filtersystems hydac com Modifications to the product We would like to poin...

Page 7: ...ine 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 de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the operating and maintena...

Page 8: ...l the safety devices are present Secure the hazardous areas which may arise between the unit and other equipment Maintain the unit inspection intervals prescribed by law Document the results in an inspection certificate and keep it until the next inspection Hazard symbols These symbols are listed for all safety information and instructions in these operating instructions which indicate particular ...

Page 9: ...al safety information LVU CD 40 en us Page 9 68 BeWa LVU CD 40 4035823a en us 2016 01 08 doc 2016 01 08 Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment ...

Page 10: ...injury if not avoided CAUTION CAUTION indicates a danger with a low risk which can lead to minor injury if not avoided NOTICE NOTICE indicates a danger which will lead to damage to property if not avoided Structure of the safety information and instructions All warning instructions in this manual are highlighted with pictograms and signal words The pictogram and the signal word indicate the severi...

Page 11: ...l The limit of application is obtained at a maximum of 10 free water DANGER Unacceptable fluid temperature Risk of bodily injury due to burns Observe the maximum fluid temperature of 50 C and at least 10 C below the flash point of the fluid used DANGER Dry running of the pump Risk of bodily injury due to burns Ensure that the pump does not run dry NOTICE Impermissible operating media The unit will...

Page 12: ...with permissible media Any use extending beyond this or deviating therefrom shall not be considered intended use HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use The risk is borne exclusively by the machine owner Improper use may result in hazards and or will damage the unit Examples of improper use Operation with an impermissible fluid Operation in potenti...

Page 13: ...ch persons have been instructed in power unit operation and are aware of potential hazards due to improper use Specialist personnel such persons have corresponding specialist training and several years work experience They are able to assess and perform the work assigned to them and they are also able to recognize potential hazards Activity Person Knowledge Transport storage Auxiliary personnel No...

Page 14: ...ormation relating to personal protection equipment in the safety data sheet of the operating fluid Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulations Stoppage in an emergency EMERGENCY STO...

Page 15: ...016 01 08 Transporting the unit Empty the unit completely before transport including the coalescing and filter housings Pull out the power plug and securely fasten the power cord to the unit Transporting with the crane Fasten suitable band loops to the base support for transporting with the crane ...

Page 16: ...nd filter housings Pull out the power plug and securely fasten the power cord to the unit Permissible storage temperature range 0 50 C Air Clean salt free air not near oxidizing substances rust film Storage duration Unrestricted but in any case before the unit is started up again after a storage period of greater than 2 years all seals must be replaced Storage position Only standing ...

Page 17: ...ding the type label Details for identifying the filtration unit can be found on the name plates on the unit and the components Item Description 1 Name plate of filtration unit 2 Name plate of electric motor 3 Model code for details see page 62 The following information can be found on the type label of the unit ...

Page 18: ...e Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Maximum permitted operating pressure Pressure IN Permissible operating pressure at IN connection Pressure OUT Permissible operating pressure at OUT connection Weight Weight when empty Flow rate Flow rate Temp fluid Permitted fluid temperature range Temp amb Permissible ambient temperature range Volume Fluid vo...

Page 19: ... scope of delivery The filtration unit comes factory assembled Check that the filtration unit is complete before starting up The following items are supplied Qty Designation 1 LowViscosity Unit LVU CD 40 version in accordance with your order check the name plate on page 17 1 Operation and Maintenance Instructions this document ...

Page 20: ...lockage of the machine filter and to damage to diesel injection system components The consequence impermissibly high levels of pollutants from the combustion engine This leads to high costs for down time replacement parts maintenance and repairs The use of the LowViscosity Unit LVU minimizes contamination to a system and prevents expensive system down time It also helps to avoid the necessity of e...

Page 21: ...Identifying components LVU CD 40 en us Page 21 68 BeWa LVU CD 40 4035823a en us 2016 01 08 doc 2016 01 08 Unit with control type Eco The Eco version of the unit features the following components ...

Page 22: ...lescing housing 1000 Collecting pan 1330 Inlet 2000 Coalescing housing 2110 Sight glass upper phase boundary 2111 Sight glass lower phase boundary 2310 Venting coalescing housing 2560 Outlet 3210 Water drain 3350 Emptying coalescing housing 4000 Motor pump assembly 4010 Inspection opening 5000 Filter housing pre filter 5001 Air bleed filter housing 5002 Emptying filter housing 7000 Main switch wit...

Page 23: ... 200 100 4000 5000 2000 3210 3350 1330 2560 7000 Item Designation 100 Clogging indicator visual for the filter housing 200 Clogging indicator visual for the coalescing housing 1330 Inlet 2000 Coalescing housing 2560 Outlet 3210 Water drain 3350 Emptying coalescing housing 4000 Motor pump assembly 5000 Filter housing pre filter 7000 Main switch with motor protection ...

Page 24: ... CD 40 4035823a en us 2016 01 08 doc 2016 01 08 Unit dimensions The unit has the following dimensions using the Eco version as an example A Required dismantling space for changing the coalescing elements B Recommended working range All dimensions in mm ...

Page 25: ...his ensures that the water phase located at the base of the tank is reached Install the return line as far as possible from the suction point in order to obtain an optimum intermixing of the tank contents Prepare the unit for operation by following the following steps 1 Check the connector cable for damage If the connector cable is damaged replace it immediately 2 Check the connecting lines for le...

Page 26: ...e pressure loss can be estimated for hydraulic oils as follows p 6 8 L d4 Q V D p Pressure differential in bar L Pipe length m d Internal pipe diameter mm Q Flow rate l min V Kinematic viscosity mm s D Density kg dm Diesel has a density of approx 0 84 kg dm This applies to straight pipelines and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep t...

Page 27: ...aged The pressure on the suction port connection IN must not be more than 0 9 to 0 2 bar Connecting the pressure port OUT Make sure that the nominal width of the pressure line corresponds to the connector thread of the filter housing Install the return line below the fluid level to prevent air from entering the fluid in the tank If the clogging indicator pressure displayed for the a clean filter e...

Page 28: ...l be damaged Guide the water outlet into a depressurized reservoir Electrical connection The filtration unit has a connector cable with a power plug DANGER Exposed electric terminals in the terminal box of the electric motor Danger of fatal injury due to electric shock Any work involving the electrical system may only be done by a properly trained certified electrician Unwind the connector cable f...

Page 29: ...ews to the cover 615 for connection Remove the cover 615 The description of the connection clamps can be found on the rear NOTICE Incorrect voltage current at the relay contact The control will be destroyed Take note of the maximum voltage and current permitted in the relay contacts of 24 V DC 2 A Only use cables with a cable cross section of 0 5 mm Use a free screw type conduit fitting on the low...

Page 30: ... there is no pending error Can be used for example to issue an error notification when contact opens Opens for example when the voltage drops motor protection responded filter clogged collecting pan too full etc 5 6 Output Reserve Potential free relay contact Has no function 7 8 Input Input for potential free push button to switch motor pump group on off No voltage is to be applied here 9 10 Input...

Page 31: ...he timer with the interval and the switch on time will continue to run in the background remote control has priority If the motor pump group is switched off via the remote control it starts automatically once the interval is over and runs time controlled via the timer If the motor pump group is switched on via the remote control it stops once the interval is over The timer has priority when switch...

Page 32: ...for the unit The selection of the control is made at the time the unit is ordered and cannot be changed afterwards Different cyclical testing and maintenance intervals apply and the operation of the unit changes depending on the control type You will find a detailed description of each of the controls on the following pages Control type See page for details E Eco 3333 S Standard 3838 P Premium 383...

Page 33: ...o control type The unit has the following control unit and operating elements Item Designation 100 Clogging indicator visual for the filter housing 200 Clogging indicator visual for the coalescing housing 2110 Sight glass upper phase boundary 2111 Sight glass lower phase boundary 3210 Water drain 4010 Inspection opening 7000 Main switch with motor protection ...

Page 34: ...ch protects the electric motor against damage caused by overloading Observe the optical clogging indicator The unit features two visual clogging indicators with displays of when the filter element in the filter housing and the coalescing elements are exhausted The visual clogging indicator display then switches from green to red Item Designation Remedy for red display 100 Clogging indicator visual...

Page 35: ...using filter housing as described in the chapter Replacing the filter element in the filter housing on page 45 200 Clogging indicator visual for the coalescing housing Replace the coalescing element as described in chapter Changing the coalescing elements on page 48 Actuate the Reset button of the clogging indicator to reset the notification ...

Page 36: ... 2016 01 08 doc 2016 01 08 Observing checking phase limits Check the phase limit between fluid and water through the upper 2110 and lower 2111 sight glass If the phase limit is visible in the upper sight glass 2110 drain off the free water as described in chapter Draining off the free water on page 37 ...

Page 37: ...the free water Check the level of the phase limit several times daily at the upper 2110 and lower 2111 sight glasses If the phase limit is visible in the upper sight glass 2110 drain off the free water at the valve 3210 The separated water can contain some parts of fuel Dispose of the water fuel mixture in an environmentally friendly manner ...

Page 38: ...perating Setting Standard Premium control type The unit has the following control unit and operating elements Item Designation 610 Main switch See page 39 for details 611 Motor protection switch See page 41 for details 612 Interval control with Premium control type only See page 40 for details 613 Status LEDs See page 39 for details ...

Page 39: ...ng LED status The status LEDs with the symbols indicate operating status service status and errors The icons are explained below Icon An illuminated LED means the following For details on remedies see page Supply voltage is available 54 The unit is switched on 54 No malfunction no error 54 The collecting pan is full 54 The motor protection switch has tripped 54 The fluid is dry 54 Error message fr...

Page 40: ... using the two interval control and time selector switches The interval control and symbols indicate operating status service status and errors The icons are explained below Icon Description Permanent operation time selector switch does not function One time operation time adjustment using time selector switch Once in 24 hours operation time adjustment using time selector switch Once in 7 days ope...

Page 41: ...ligned and adjusted at the installed electric motor at the works It is not necessary to correct the setting If the motor protection switch triggers proceed as indicated in the chapter Status LED on page 54 Switching unit on off Switch the unit on at the main switch 610 and select the operating duration using interval control Automatic water drainage If the water sensor signals 5 seconds the drain ...

Page 42: ...ns Allow the unit to cool before any maintenance work Maintenance intervals Adhere to the following maintenance intervals See page for details 12 h Daily Every 3 months 1 year When indicated Perform visual check 42 X Checking the pump for leaks 43 X Replacing the filter element in the filter housing 45 X X Changing the coalescing elements 48 X X Perform visual check Check the unit for leaks brittl...

Page 43: ...The pump contains a sealing medium between the pump mechanism and the shaft seal This sealing medium prevents diesel from exiting through the shaft and collecting above the electric motor under certain circumstances where it could possibly catch fire Check the pump for leakage through the inspection opening at least every three months ...

Page 44: ...l down 2 Remove the four screws and the cover of the inspection opening 4010 3 Using a lamp for illumination check for oil or diesel Use a finger to feel for oil or diesel a If the pump is dry proceed to Step 5 b If the pump is wet moist due to oil or diesel proceed to Step 4 4 Shut down the unit and contact HYDAC 5 Screw the cover tightly with the four screws 6 The test has been successfully comp...

Page 45: ... make sure that the unit cannot be switched on again during maintenance Depressurize the filter housing To accomplish this carefully open the drain plug Air Bleed on the filter housing cover do not unscrew completely Be careful when the operating fluid flows out 2 Put a suitable container in place to catch the fluid in the filter housing The content is 3 or 6 liters Empty the filter housing throug...

Page 46: ...irt catch tray from the element and the element from the cover 5 Remove the dirt catch tray 6 Remove the filter element from the filter housing cover Dispose of the old filter element according to local regulations and guidelines 7 Clean the removed parts and examine them for any possible damage Check the O ring on the filter bowl cover for damage Replace it if necessary Moisten the O rings on the...

Page 47: ...of the filter element 10 Check the O ring on the cover for correct seating Place the filter element with the cover and dirt catch tray in the filter housing 11 Secure the cover with the housing clamp The tightening torque is a maximum of 5 Nm 12 Screw in the drain screw Drain at the connection part of the unit and tighten Switch the filtration unit on Bleed the filter housing through the air bleed...

Page 48: ...rize the unit Carefully screw the air vent plug out of the cover with the aid of a size 10 mm Allen wrench 4 Open the ball valve at the DRAIN connection 3350 to empty the coalescing housing Collect the free water oil in a suitable container and dispose of it in an environmentally friendly manner Once the coalescing housing is completely emptied close the DRAIN connection 3350 5 Loosen the upper te...

Page 49: ...823a en us 2016 01 08 doc 2016 01 08 6 1 Remove the housing clamp 2400 2 Remove the cover by lifting it upward and set it down to the side 7 Remove the element set from the coalescing housing Use both handles to accomplish this 8 Rotate the element set on the head by 180 ...

Page 50: ... Page 50 68 BeWa LVU CD 40 4035823a en us 2016 01 08 doc 2016 01 08 9 Undo the 3 wing nuts and remove the holding plate 10 Pull the coalescing elements out of the element receptacles and dispose of them in an environmentally friendly manner ...

Page 51: ...16 01 08 doc 2016 01 08 11 Moisten the O ring on the element lightly with the operating fluid 12 Insert the new coalescing elements into the element receptacles by screwing them in carefully Do not use a hammer etc 13 Mount the element holding plate and tighten the 3 wing nuts firmly ...

Page 52: ...he element set fits only in one position Z in the coalescing housing 15 Clean the sealing surface on the cover Check the O ring for damage Replace it if necessary 16 1 Place the cover on the coalescing housing 2 Place the housing clamp over the coalescing housing 17 Use an SW 13 fork wrench to tighten the tensioning clamps evenly to a maximum of 20 Nm Screw open the lock nut and secure the connect...

Page 53: ...D 40 4035823a en us 2016 01 08 doc 2016 01 08 18 Open the ball valves INLET 1330 and OUTLET 2560 19 Bleed the filtration unit A 20 Bleed the coalescing housing through the air vent plug 2310 at the cover 21 The replacement of the coalescing element is completed ...

Page 54: ...ch off the unit at the main switch for at least three seconds Status LED Cause s Remedy LED is dark LED is off No power supply Check the feed line and plug The main switch is switched off but the power supply is on Check the main switch LED flashing The main switch is switched on during operation there was a drop in voltage restart protection Switch off the unit at the main switch for 3 seconds LE...

Page 55: ...n the unit at the main switch The suction hose is kinked or faulty or a shut off device is closed Check the suction hose for flow Replace it if necessary There is air in the suction line and the pump Fill the pump via the suction hose hose coupling The viscosity of the fluid is too high Check the viscosity of the fluid Heat the fluid to achieve the permissible viscosity The is no power to the elec...

Page 56: ...e unit will be switched off with a time delay of 60 seconds Switch on the unit and check at which of the two optic electric clogging indicators the LED illuminates Change the filter element or the coalescing element depending on which LED of the clogging indicator illuminates The viscosity of the fluid is too high Check the viscosity of the fluid Heat the fluid to achieve the permissible viscosity...

Page 57: ...ring Check the sealing ring on the filter element Replace it if necessary Collecting pan too full The filter element is insufficiently tightened Tighten the filter housing somewhat by hand The fluid is dewatered No water has drained from the system in eight hours For this reason the control reports that the fluid is dewatered This is a status notification Remediation is not required The water drai...

Page 58: ...e 49 6897 509 883 Fax 49 6897 509 324 E mail service hydac com Taking the unit out of operation Drain the unit completely including all of its components before decommissioning Pull out the power plug and securely fasten the hoses and power cord to the unit Shutting down the unit See chapter Taking the unit out of operation Disposing of the unit Dispose of the packaging material in an environmenta...

Page 59: ...ng housing 1x O ring filter housing 1 3917919 Coalescing element set N20ON DCZ CB1F 1 3917981 10 Filter element 3 µm N10ON DF003 FA41F 1 3917982 10 Filter element 5 µm N10ON DF005 FA41F 1 3917983 10 Filter element 10 µm N10ON DF010 FA41F 1 3918332 20 Filter element 3 µm N20ON DF003 FA41F 1 3918333 20 Filter element 5 µm N20ON DF005 FA41F 1 3918334 20 Filter element 10 µm N20ON DF010 FA41F availabl...

Page 60: ...mp Operating pressure Maximum 3 bar Permissible suction pressure at suction port 0 9 0 2bar Permissible pressure at pressure port connection 3 bar Permissible pressure at the water drain 0 bar Connection suction and pressure side G1 Water drain G1 2 Permitted fluid temperature range 50 C and at least 10 C below the flash point of the fluid used Electrical data Power supply See motor type plate Pow...

Page 61: ...l data Dimensions See page 24 Material substance Frame Lacquered steel Coalescing housing Stainless Seals HNBR FKM Permissible ambient temperature range 0 to 50 C and at least 10 C below the flash point of the fluid used Weight when empty Control type eco 80 kg with control type Standard or Premium 90 kg ...

Page 62: ...witch including motor protection visual clogging indicator manual water drainage S Standard with On Off switch including motor protection visual clogging indicator manual water drainage float switch in the collecting pan remote control input On Off P Standard with On Off switch including motor protection programmable operating times electrical visual clogging indicator automatic water drainage swi...

Page 63: ...ned in the directives and standards listed below Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Designation Filtration unit Type LVU CD series Part no Serial no EU Machinery Directive 2006 42 EC article 1a 2015 03 24 Dr Andreas Schunk Date Name CE official Executive director Documentation Representative Mathias Dieter Di...

Page 64: ...tion of conformity 5 63 Electrical data 60 Error 39 Error message 39 F Filter 12 22 23 59 Filter element 59 Filter housing 22 23 filtration 17 19 20 26 28 45 47 53 55 Filtration 63 Flow rate 18 26 G Gear pump 60 62 H Hazard symbol 3 8 Hydraulic data 60 Hydraulic diagram 3 23 I Imprint 2 3 IN 4 18 27 Inlet 22 23 INLET 48 53 Inspection 22 33 installation 45 Internal pipe diameter 26 IP 60 ISO 11 60 ...

Page 65: ...er 2 Pump 60 62 R Remedy 34 54 repairs 20 replacement 20 53 S select 7 41 setting 4 33 41 Signal word 3 10 signal words 10 Spare parts 4 59 Spare parts list 4 59 Specialist personnel 13 Supply voltage 39 62 switching off 31 switching on 20 31 T Time 41 Transport 13 55 transporting 15 troubleshooting 13 W Weight 18 61 ...

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Page 68: ...et Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 9046 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E mail filtersystems hydac com ...

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