Hydac VMU 1 Operating And Maintenance Instructions Manual Download Page 9

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Safety information

Signal words and their meaning in the safety information and

instructions

In these instructions you will find the following signal words:

DANGER

DANGER – The signal word indicates a hazardous situation with a high level

of risk, which, if not avoided, will result lethal or serious injury.

WARNING

WARNING – The signal word indicates a hazardous situation with a medium

level of risk, which, if not avoided, can result lethal or serious injury.

CAUTION

CAUTION – The signal word indicates a hazardous situation with a low level

of risk, which, if not avoided, can result in minor or moderate injury.

NOTICE

NOTICE – The signal word indicates a hazardous situation with a high level

of risk, which, if not avoided, will result in damage to property.

VMU 1 ATEX II 2G IIC T4

en(us)

Page 9 / 68

BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc

2017-03-07

Summary of Contents for VMU 1

Page 1: ...VarnishMitigation Unit VMU 1 ATEX II 2G IIC T4 Operating and Maintenance Instructions English translation of original instructions Document no 10000649233 ...

Page 2: ...national GmbH Industriegebiet 66280 Sulzbach Saar Phone 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 electronic systems without the written consent of the publisher These documents have been created a...

Page 3: ... Explosion protection as per EU Directive 14 Improper Use or Use Deviating from Intended Use 15 Qualifications of personnel target group 16 Wear suitable clothing 18 Stoppage in an emergency EMERGENCY STOP 18 Transporting the unit 19 Transport with a crane 20 Transport with train truck 20 Decoding the name plate 21 Checking the scope of delivery 23 Characteristics of the unit 24 Unit components 25...

Page 4: ...nging the prefilter safety filter element 44 Replacing the filling level limit switch 48 Cleaning the suction screen in the lance 49 Storing the unit taking it out of operation 50 Disposing of the unit 50 Disposing of VME filter elements 50 Spare parts 51 VarnishMitigation Elements 57 Filter elements for pre filter and contamination filter 57 Technical Data 58 Model Code 60 Customer Service Servic...

Page 5: ...ility 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 code serial no and part no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Modifications to the Product We would like to point out that changes to the product e g purchasing options etc may result in th...

Page 6: ...ation 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 maintenance instructions The index is incremented every time the manual is revised or changed Chapter ...

Page 7: ...quipment 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 hazards to persons property or the environment Observe these instructions and act with particular cautio...

Page 8: ...s or irritants Danger from explosive atmosphere Danger of explosion in explosive atmospheres This symbol marks safety indications that refer particularly to explosion protection VMU 1 ATEX II 2G IIC T4 en us Page 8 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 9: ...nal word indicates a hazardous situation with a medium level of risk which if not avoided can result lethal or serious injury CAUTION CAUTION The signal word indicates a hazardous situation with a low level of risk which if not avoided can result in minor or moderate injury NOTICE NOTICE The signal word indicates a hazardous situation with a high level of risk which if not avoided will result in d...

Page 10: ...ut as follows HAZARD SYMBOL SIGNAL WORD Type and source of danger Consequence of the danger Measures to avert danger 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 VMU 1 ATEX II 2G IIC...

Page 11: ...n the following The VarnishMitigation Unit VMU is used to condition mineral oil based turbine oils by effective removal of oil degradation product Varnish Proper designated use of the product extends to the following observing all instructions contained in the instruction manual performing inspection and maintenance work operation in explosion hazard areas in accordance with explosion protected ex...

Page 12: ...connection with use in areas posing an explosion hazard on site equipment group equipment category explosion hazard subgroup temperature class Ensure that vapors gases or mists occurring at the place of operation belong to explosion groups IIA to IIC Make sure that during installation of the unit no potentially explosive atmosphere oils acids gases vapors or radiation are present Make sure that th...

Page 13: ...ions The installation and maintenance personnel thus carries particular responsibility Exact knowledge of the applicable regulations and conditions is required Please note Observe the characteristic curves and measurement operating conditions of the rating plates and data plates Damage to the devices can nullify the explosion protection The unit may be operated only when the switch cabinet is comp...

Page 14: ...I Potentially explosive atmospheres in which vapours or gas air mixtures are likely to occur Usage in mining is not permitted Equipment category 2G Equipment guaranteeing a high degree of safety Designated for cases in which atmospheres posing an explosion hazard from gases vapours mist or dust air mixes can be expected to occur occasionally Explosion group IIC Typical gases Hydrogen ethyne acetyl...

Page 15: ... the owner Improper use may result in hazards and or will damage the unit Examples of improper use Operation in potentially explosive atmospheres other than the identified one Operation with an impermissible fluid Operation at an impermissible fluid temperature ambient temperature Operation under non approved operational conditions Operation when the safety devices are defective Operation in minin...

Page 16: ...le regulations are to kept so they are accessible for operating and specialist personnel These operating instructions are intended for Operating personnel such persons have been instructed in power unit operation and are aware of potential hazards due to improper use Specialist personnel such persons with corresponding specialist training and several years work experience They are able to assess a...

Page 17: ...raulic lines and connections Fitting and connection of electrical lines electrical machinery sockets etc Checking the phase sequence Product specific knowledge Operation Operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating fluids Knowledge about contamination due to solids and water Disposal Specialist personnel Proper and environmentally frien...

Page 18: ...r jewelry Wear work safety shoes Stoppage in an emergency EMERGENCY STOP In the event of an emergency turn the main switch by 90 in a counter clockwise direction to shut down the entire unit The entire system is then voltage free downstream from this switch VMU 1 ATEX II 2G IIC T4 en us Page 18 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 19: ...the suction and pressure hose and the connection cable and fasten them in place NOTICE Using components for pushing pulling The unit will be damaged Never use the components to push or pull the unit Use the grips provided for shifting VMU 1 ATEX II 2G IIC T4 en us Page 19 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 20: ... cause any pressures to be brought to bear against the components on the unit When transporting by crane only use suitable lifting accessories band loops Transport with train truck For transport by rail or truck supports must be placed under the mobile unit so that the rollers are subjected to no load pressure The unit is to be secured with suitable belts VMU 1 ATEX II 2G IIC T4 en us Page 20 68 B...

Page 21: ...oding the name plate Identification details for the VMU can be found on the name plates on the unit and the components VMU 1 ATEX II 2G IIC T4 en us Page 21 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 22: ...t Current consumption Protections class Protection class Pressure max Maximum operating pressure Pressure IN Permissible pressure at IN port Pressure OUT Permissible pressure at OUT port Weight Empty weight Flow Rate Flow rate Temp Oil Permitted fluid temperature range Temp Amb Permitted ambient temperature range Visc Range Permissible viscosity range VMU 1 ATEX II 2G IIC T4 en us Page 22 68 BeWa ...

Page 23: ...nt or the department in charge immediately the unit may not be commissioned until this damage is properly remedied The following items are supplied Qty Designation 1 VarnishMitigation Unit 1 Documentation for the unit consisting of Operating and maintenance instructions this document CE Declaration of Conformity Test certificate VMU 1 ATEX II 2G IIC T4 en us Page 23 68 BeWa VMU_1_ATEX II2GIICT4_10...

Page 24: ...can be filterable gels or solid paint type deposits The VMU series of units are used in the bypass flow The removal of varnish is based on adsorption on an active surface The advantages of the VMU are Inexpensive oil conditioning Low component wear Longer service life of the oil Quick and easy cartridge exchange Low operating costs Compact construction less space requirement Lower disposal costs O...

Page 25: ... motor protection 7 Filling level limit switch 8 Ground cable 10 Chassis 11 Inlet IN 12 Outlet OUT 13 Pressure gauge varnish exchanger column 14 Venting varnish exchanger column BLEED 15 Prefilter Safety filter air vent BLEED 16 Wheels 17 Swivel caster with brake 18 Sliding grip 19 Hose Cable holder VMU 1 ATEX II 2G IIC T4 en us Page 25 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc...

Page 26: ...Unit dimensions Unit dimensions All dimensions in mm VMU 1 ATEX II 2G IIC T4 en us Page 26 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 27: ... 5 11 12 7 Item Designation 1 Motor pump assembly 2 Pre filter 3 Varnish exchanger column 4 Drain DRAIN 5 Protective filter 6 On Off switch with motor protection 7 Filling level limit switch 11 Inlet IN 12 Outlet OUT VMU 1 ATEX II 2G IIC T4 en us Page 27 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 28: ...ts VME flow through at a precisely determined flow rate During this flow through the oil degradation products in the fluid are removed Dimensioning size Model Reservoir volume VMU 1 16 000 liters VMU 4 16 000 50 000 liters VMU 1 ATEX II 2G IIC T4 en us Page 28 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 29: ...mediate vicinity of the reservoir to be cleaned Observe the ambient temperature range of 10 40 C Make sure that access to the main switch is unimpeded at all times Observe that a minimum clearance of 0 8 m must remain free to the right and left of the unit to allow unimpeded access for performing servicing work The feet of the power unit are electrically conductive Do not place them on an insulati...

Page 30: ... 10 2 Ω Identification of the hose with the symbol Ω Limit value 10 6 Ω The hose connection must ensure a highly conductive transition between the hose and power unit as well as between the hose and reservoir If this is not the case all conducting parts such as the metal mouth piece at the end of the hose are to be grounded separately Connecting conductive hoses with fittings to hose tubes require...

Page 31: ...y The pressure loss in straight pipes P line can be calculated 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 Kinematic viscosity mm s D Density kg dm HFD R 1 14 kg dm HFD U 0 92 kg dm Additional threaded connections and pipe bends increase the pressure differential and must be taken into account Keep the height differen...

Page 32: ... the bottom of the tank All impurities and other particles are deposited on the bottom of the tank The suction pressure at the VMU inlet must be in the range of 0 4 1 bar Use a negative pressure resistant flexible hose or a pipe for the suction side connection Make sure that the cross section of the connected hoses piping is at least as large as the cross section of the inlet outlet port sizes The...

Page 33: ...ure that all of the locking fixtures at the outlet are in open position each time before start up To prevent air from entering the medium make sure that the pressure hose with lance is always below the oil level in operation Use pressure hoses that are suitable for a pressure of at least 10 bar VMU 1 ATEX II 2G IIC T4 en us Page 33 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017...

Page 34: ...d socket for operation Switch the pump on and off briefly to check the direction of rotation jog mode In the event of incorrect direction of rotation reverse the polarity of two phases When viewing from the motor fan side the direction of rotation is to the right in clockwise direction The rotating field of the connection socket must be clockwise If this is not the case then the phases can be rota...

Page 35: ...g the unit for operation The power unit is delivered with no VME element or prefilter and safety filter element installed Before commissioning check that all VMU elements and pre filter and safety filter elements are inserted To do so proceed as described on the pages Changing VME elements Page 40 Changing the prefilter safety filter element Page 44 Note the maximum storage time for VME elements i...

Page 36: ...ch it off Pre fill the power unit using the pump or using the suction hose when the motor is off Switch the unit on again and monitor the suction action 9 3 6 12 max 5 min During operation always monitor the clogging indicator differential pressure gauge on the pre filter and safety filter so as to know when to replace used filter elements in good time Check the service life of the VME elements us...

Page 37: ...completely It has ventilation slots If fluid leaks out tighten the air bleed screw 1 again Bleed the housing every time you change the element or on draining Bleeding the pre filter and safety filter To bleed carefully open the air bleed screw Air Bleed on the filter bowl cover If fluid leaks out tighten the air bleed screw Air Bleed again VMU 1 ATEX II 2G IIC T4 en us Page 37 68 BeWa VMU_1_ATEX I...

Page 38: ...of bodily injury The hydraulic system must be depressurized before performing any work on it Switch the unit off at the main switch and unplug the power connector Close all shut off devices from and to the power unit If defects which affect explosion protection are discovered during check ups or maintenance then the unit is to be taken out of service until the defect is remedied Repair and servici...

Page 39: ... and collect the escaping fluid with a suitable container The visual back pressure indicator shows the pressure in the housing Do not open the housing until you have depressurized it and the pressure gauge shows no pressure VMU 1 ATEX II 2G IIC T4 en us Page 39 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 40: ...ssure of max 8 bar on the pressure gauge of the varnish exchanger column There may still be fluid in the filter bowl depending on the type of connections to the unit Let this fluid out via the lower ball valve DRAIN 1 Switch off the unit at the main switch 2 Close all shut off devices at the inlet IN and outlet OUT 3 Empty the varnish exchange column completely via the drain ball valve DRAIN 4 Ope...

Page 41: ...nish exchange column This pushes the cover of the varnish exchange column up 7 Take the cover off and remove the VME element 8 Clean the inside of the housing from coarse dirt as well as the sealing surfaces on the housing and the cover VMU 1 ATEX II 2G IIC T4 en us Page 41 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 42: ...c 11 Check the O ring on the cover for damage and replace it if necessary Lightly wet the O ring on the cover with medium 12 Put the cover on Observe correct placement of the O ring on the cover while doing so It must not be damaged 13 Fold the four screws up and turn them clockwise evenly crosswise VMU 1 ATEX II 2G IIC T4 en us Page 42 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc...

Page 43: ...ng through the air bleed screw in the cover Do not unscrew the air bleed screw completely It has ventilation slots Check the unit for any leaks 17 The varnish exchanger column is ready for operation VMU 1 ATEX II 2G IIC T4 en us Page 43 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 44: ...ockwise or counterclockwise to separate it from the element receptacle 1 Switch off the system make sure that no operating fluid can flow out of the lines into the OLF 5 and make sure that the unit cannot be switched on again during maintenance Depressurize the filter housing To accomplish this carefully open the drain screw Air Bleed on the filter bowl cover Be careful when the operating medium f...

Page 45: ... Turn it slightly clockwise This ensures that the filter element remains locked on the cover Turn counterclockwise to detach the element from the cover and the dirt catch tray from the element 5 Remove the dirt catch tray 6 Remove the filter element from the filter bowl cover Dispose of the old filter element according to local regulations and guidelines VMU 1 ATEX II 2G IIC T4 en us Page 45 68 Be...

Page 46: ...edia 8 Now place the filter bowl cover on the new filter element and lock it in the bayonet mount 9 Attach the dirt catch tray to the lower end of the filter element and lock it in place by turning it 90 counterclockwise 10 Place the filter element with the cover and dirt catching tray in the filter bowl 11 Install the tensioning clamps Observe the tightening torque of max 5 Nm VMU 1 ATEX II 2G II...

Page 47: ...nit on 13 Bleed the filter bowl through the air bleed screw X in the cover Bleed the varnish exchanger column through the air bleed screw X 14 The prefilter safety filter is ready for operation VMU 1 ATEX II 2G IIC T4 en us Page 47 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 48: ...switch When replacing the filling level limit switch 190 observe the position of the sensors A Align the sensor A parallel to the direction of flow VMU 1 ATEX II 2G IIC T4 en us Page 48 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 49: ...n is installed in the suction lance Clean the suction strainer at regular maintenance intervals Check Clean the suction strainer immediately in the event of insufficient suction or delivery action Clean the suction strainer by washing it out or by blowing it out with compressed air Item Description 1 Hose 2 Suction lance 3 O ring 4 Suction strainer 5 Protection pipe 6 Suction screen set VMU 1 ATEX...

Page 50: ...a clean dry environment Disposing of the unit Dispose of the packaging material in an environmentally friendly manner After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly manner Disposing of VME filter elements Dispose of the VME elements in an environmentally friendly manner Disposal information can be found in the safety data sheet of...

Page 51: ...lowing are illustrations of the individual parts with positioning Not all individual parts can be supplied as spare parts VMU 1 ATEX II 2G IIC T4 en us Page 51 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 52: ...Retainer 162 Screw 163 Washer 164 Spring washer 165 Nut 166 Washer 167 Nut available on request Item Designation Part no 90 Pipeline 100 Cutting ring 110 Coupling nut 120 130 Retainer available on request VMU 1 ATEX II 2G IIC T4 en us Page 52 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 53: ...Spare parts VMU 1 ATEX II 2G IIC T4 en us Page 53 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 54: ...ement 5 µm N5DM005 3068101 Filter element 10 µm N5DM010 3102924 O ring to the cover FPM 460 Safety filter device Filter element 5 µm N5DM005 3068101 Filter element 10 µm N5DM010 3102924 O ring to the cover FPM available on request VMU 1 ATEX II 2G IIC T4 en us Page 54 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 55: ...g ring FPM 607755 420 Screw connection 608119 421 O ring 15 4 2 1 FPM 612295 470 Screw 616608 480 Screw 6024288 490 Nut 611473 510 Screw 6024287 520 Screw 635641 530 Hose assembly DN20 L 500 mm 6119195 540 Screw connection 608475 541 Sealing ring FPM 607756 550 Screw connection 607980 551 O ring 18 2 FPM 601101 560 Screw connection 6034414 570 Buffer 686027 available on request VMU 1 ATEX II 2G II...

Page 56: ...h 6032467 30 Screw connection 607721 40 Screw connection 611800 50 Screw connection 608119 60 Spacer for filling level limit switch 3715704 70 Washer 602786 80 Screw 6013521 90 Tube Ø 18 2 L 300 mm 626493 100 Cutting ring 626751 110 Screw connection 608401 120 Screw connection 608083 130 Joint plate 3715739 available on request VMU 1 ATEX II 2G IIC T4 en us Page 56 68 BeWa VMU_1_ATEX II2GIICT4_100...

Page 57: ...st VarnishMitigation Elements Designation Part no VME 720 Turbine oils tank volume 4 000 l 1 3940510 VME 730 Turbine oils tank volume 4 000 l 1 3714795 Other VME elements upon request Filter elements for pre filter and contamination filter Designation Part no Filter element 5 µm N5DM005 3068101 Filter element 10 µm N5DM010 3102924 available on request VMU 1 ATEX II 2G IIC T4 en us Page 57 68 BeWa ...

Page 58: ...ring details Power consumption 0 6 kW Ambient conditions Permitted operating temperature range 0 40 C 32 104 F Permitted storage temperature range 0 60 C 32 140 F Permitted relative humidity 0 to 80 non condensing Protection class to DIN 40050 IP 55 General data Length of electrical connection cable for options PKZ FA1 FA2 10 m Length of suction pressure hose without 5 m Sealing material FPM Noise...

Page 59: ...ng to ISO 4406 1999 9A 9B 9C according to SAE AS4059 In order to ensure the required fluid cleanliness we recommend operating with the optional prefilter VMU 1 ATEX II 2G IIC T4 en us Page 59 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

Page 60: ... top loader z Without pre filter Clogging indicator BM Differential pressure indicator optical VM2BM 1 for pre filter and protective filter C Differential pressure indicator electric VM2C 0 for pre filter Differential pressure indicator optical VM2BM 1 for protective filter Supplementary details AS AquaSensor AS1000 The sensor is only connected hydraulically z without Supplementary details S5D5 Su...

Page 61: ...hydac com USA HYDAC Technology Corporation HYCON Division 2260 City Line Road USA Bethlehem PA 18017 P O Box 22050 USA Lehigh Valley PA 18002 2050 Phone 01 610 266 0100 Fax 01 610 231 0445 E mail sales hydacusa com Internet www hydacusa com EU Declaration of Conformity The EU declaration of conformity can be found in the power unit s documentation VMU 1 ATEX II 2G IIC T4 en us Page 61 68 BeWa VMU_...

Page 62: ... HFD 31 Hydraulic data 58 I Imprint 2 IN 22 25 27 31 32 40 Inlet 25 27 INLET 58 installation 11 12 13 17 38 42 44 Internal pipe diameter 31 IP 58 ISO 59 L Limit value 30 M Maintenance 1 Measures 10 Model code 22 Motor pump assembly 25 27 Motor pump group 54 mounting 29 MPC 40 58 N Noise level 58 O Off switch 25 27 operating 5 6 7 13 16 17 22 24 36 40 42 44 46 58 59 operating fluids 17 operating te...

Page 63: ...n screen 49 switching on 36 T Temperature 14 Test certificate 23 to shut down 18 Transport 17 20 transporting 19 20 troubleshooting 17 Turbine oil 57 V Varnish 11 24 25 27 54 Viscosity 58 W Weight 22 VMU 1 ATEX II 2G IIC T4 en us Page 63 68 BeWa VMU_1_ATEX II2GIICT4_10000649233 en us 2017 03 07 doc 2017 03 07 ...

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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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