Hydac LVU-CD-10 Operating And Maintenance Instructions Manual Download

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LVU-CD-10
LowViscosity Unit
CoaleserDiesel

with control type: Eco

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 4067271

Keep for future reference.

Summary of Contents for LVU-CD-10

Page 1: ...LVU CD 10 LowViscosity Unit CoaleserDiesel with control type Eco Operating and Maintenance Instructions English translation of original instructions Document No 4067271 Keep for future reference ...

Page 2: ...hias 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 usi...

Page 3: ...ctions 9 Structure of the safety information and instructions 9 Proper designated use 10 Improper use or use deviating from intended use 11 Qualifications of personnel target group 12 Wear suitable clothing 13 Observe regulatory information 13 Stoppage in an emergency EMERGENCY STOP 13 Unpacking the unit 13 Transporting the unit 14 Carry by hand 14 Storing the unit 15 Decoding the name plate 16 Ch...

Page 4: ...ndicator prepare 27 Pre filling filling the unit 28 Starting up the unit 31 Observe the clogging indicator 32 Performing maintenance 33 Maintenance intervals 33 Perform visual check 34 Checking emptying water supply tank 35 Changing the filter element 36 Errors and troubleshooting 40 Customer Service 43 Taking the unit out of operation 43 Shutting down the unit 43 Disposing of the unit 43 Spare pa...

Page 5: ...igation our liability shall 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 6897 509 9046 E Mail filtersystems hydac com Modifications to the Product...

Page 6: ...termine 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 main...

Page 7: ...afety 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 hazards...

Page 8: ...Safety Information LVU CD 10 en us Page 8 52 BeWa LVU CD 10 Eco 4067271 en us 2016 01 08 doc 2016 01 08 Flammable Harmful to the environment ...

Page 9: ...y if not avoided CAUTION CAUTION indicates a danger with a low risk and 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 severit...

Page 10: ...5 as per ISO CD 16332 and the dewatering rate is 12 l h at 5 water in the diesel 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 th...

Page 11: ...to fire Never operate the unit in potentially explosive atmospheres The unit is only to be used with permissible media Any use extending beyond 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 user alone shall assume any and all associated risk Improper use may result in hazards and or will dam...

Page 12: ...are instructed in the job 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 have corresponding specialist training and several years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential hazards Activity Person Knowle...

Page 13: ...nformation 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 S...

Page 14: ...the unit completely before transport including the filter and coalescing casing Pull out the power plug to the unit and place the power cord into the collecting pan Carry by hand Only transport the unit by carrying the frame or with it standing on its feet When transporting the unit never pick it up by its attachment parts or components ...

Page 15: ...nd coalescing casing Pull out the power plug and securely fasten the power cord to the unit Permitted storage temperature range 0 45 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 16: ...en us 2016 01 08 doc 2016 01 08 Decoding the name plate 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 47 ...

Page 17: ...ow Description Part No Part number S N Serial number year of production Power Power consumption Voltage Grid Voltage power supply Frequency Frequency Current Current consumption Pressure max Operating pressure maximum Weight Weight when empty Flow rate Flow rate Temp Fluid Permitted fluid temperature range Temp Amb Permissible ambient temperature range Volume Fluid volume in unit ...

Page 18: ... 01 08 doc 2016 01 08 Checking the 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 10 Eco 1 Operation and Maintenance Instructions this document ...

Page 19: ... microorganisms such as bacteria algae fungus etc Both can quickly lead to blockage of the machine filter and to damage to diesel injection system components The consequence impermissibly high levels of dangerous emissions 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 sys...

Page 20: ...6 01 08 Operating elements identifying the version The unit has the following components Item Designation 1 Inlet 2 Filter and coalescing housing 2 1 Ventilation air bleed screw 3 Clogging indicator visual 4 Water collecting tank 4 1 Water drain plug 5 Motor pump assembly 6 Outlet 20 Frame 21 Main switch 23 Collecting pan ...

Page 21: ...10 Eco 4067271 en us 2016 01 08 doc 2016 01 08 Hydraulic diagram The unit has the following hydraulic circuit Item Designation 1 Inlet IN 2 Filter and coalescing housing 3 Clogging indicator visual 4 1 Water drain plug DRAIN 5 Motor pump assembly 6 Outlet OUT ...

Page 22: ...dimensions LVU CD 10 en us Page 22 52 BeWa LVU CD 10 Eco 4067271 en us 2016 01 08 doc 2016 01 08 Unit dimensions The unit has the following dimensions H Filter element dismantling height All dimensions in mm ...

Page 23: ...the suction port connection at the lowest part of the tank This 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 damage...

Page 24: ... dm This applies to straight pipelines 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 low as possible 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...

Page 25: ...rpressure at the suction port connection The unit will be damaged The pressure on the suction port connection IN must not be more than 0 4 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 NOTICE E...

Page 26: ...aged 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 fully Plu...

Page 27: ... doc 2016 01 08 Optical clogging indicator prepare Prepare the visual clogging indicator by cutting off the top of the sealing plug before commissioning NOTICE Clogging indicator not prepared The visual clogging indicator is not working Cut the top of the sealing plug off before commissioning ...

Page 28: ...In order to optimize the suction characteristic during first commissioning pre fill the unit Proceed as follows to fill the unit 1 Open the cover 2 1 of the filter and coalescing casing counterclockwise with a fork wrench wrench size 46 2 Remove the cover 2 1 and filter element 2 4 by lifting it up out of the filter and coalescing casing ...

Page 29: ...he filter and coalescing housing 2 with fluid 4 Lightly wet the O ring 2 3 with medium Place the cover 2 1 and filter element 2 4 into the filter and coalescing casing and turn this clockwise by hand 5 Tighten the cover 2 1 of the filter and coalescing casing using a fork wrench size 46 in a clockwise direction with 50 Nm ...

Page 30: ...on LVU CD 10 en us Page 30 52 BeWa LVU CD 10 Eco 4067271 en us 2016 01 08 doc 2016 01 08 6 Tighten the breather screw 2 2 in a clockwise direction 7 The filling procedure for the filter and coalescing housing is completed ...

Page 31: ...eliminate leaks Proceed as follows to commission the unit 1 You have performed all preparations outlined in chapter Unit setup connection on pages 23 to 28 2 Switch on the unit at the main switch 21 and monitor the suction pump characteristics of the unit 3 If the unit does not pump any fluid after more than 3 minutes of operation switch off the unit Check installation and refill the unit as descr...

Page 32: ...7271 en us 2016 01 08 doc 2016 01 08 Observe the clogging indicator The unit has a clogging indicator 3 that indicates when the contamination retention capacity of the filter element has been reached Change the filter element at a suction pressure of 0 4 bar at the latest ...

Page 33: ...of the subsequent maintenance work WARNING Hot surfaces Danger of burns Allow the unit to cool before any maintenance work Maintenance intervals Adhere to the following maintenance intervals See page for details 12 h 24 h 3 months When indicated Perform visual check 34 X Checking emptying water supply tank 35 X Changing the filter element 36 X ...

Page 34: ...ntenance LVU CD 10 en us Page 34 52 BeWa LVU CD 10 Eco 4067271 en us 2016 01 08 doc 2016 01 08 Perform visual check Check the unit for leaks brittle hoses and cables daily Replace damaged or brittle parts immediately ...

Page 35: ...16 01 08 Checking emptying water supply tank Check the fill level of the water supply tank 4 multiple times daily Completely empty the water reservoir via the water drain plug 4 1 The separated water can contain some parts of fuel Dispose of the water fuel mixture in an environmentally friendly manner ...

Page 36: ... 08 Changing the filter element Proceed as follows to replace the filter element 1 Vent the filter and coalescing casing by opening the breather screw 2 2 in an anti clockwise direction 2 Start the unit using the control for approx 20 seconds so that the filter and coalescing casing is emptied by the pump ...

Page 37: ... 01 08 3 Open the cover 2 1 of the filter and coalescing housing counterclockwise with a fork wrench wrench size 46 4 Remove the cover 2 1 and filter element 2 4 by lifting it up out of the filter and coalescing housing 5 Pull the filter element 2 4 off the cover 2 1 Remove the O ring 2 3 from the cover ...

Page 38: ...he used filter element 2 4 and the O ring 2 3 in an environmentally correct manner 7 Clean the cover 2 1 and the inside of the filter and coalescing casing with a lint free cloth 8 Mount the O ring 2 3 from the scope of delivery of the new filter element onto the cover 2 1 Clip the new filter element 2 4 onto the cover 2 1 ...

Page 39: ...dium Place the cover 2 1 and filter element 2 4 into the filter and coalescing casing and turn this clockwise by hand 10 Tighten the cover 2 1 of the filter and coalescing housing using a fork wrench size 46 in a clockwise direction with 50 Nm 11 Tighten the breather screw 2 2 in a clockwise direction 12 The filter element change is now complete ...

Page 40: ...ff but the power supply is on Check the main switch The is no power at the electric motor The power outlet used is free of voltage The mains connector is not plugged in Plug in the power plug Inspect the unit supply line for damage If the unit supply line is defective replace it immediately The mains voltage or frequency do not correspond to the specifications on the unit Use a unit that is suitab...

Page 41: ...ng The is no power to the electric motor Check the unit supply line for damage Check the motor protection switch in the main switch Replace it if necessary The electric motor pump is defective Contact HYDAC The transport seals have not been removed Remove the transport seals Transport seals are the yellow plastic plugs The pressure loss in the suction line is too great Ensure that the pressure at ...

Page 42: ...ds 2 5 bar The suction line at the inlet is generating too much loss of pressure Ensure that the pressure at the inlet is within the permitted range Leakage on the unit filter housing Empty the collecting pan and eliminate the leak on the unit Wrong missing or defective sealing ring Check the sealing ring on the filter element Replace it if necessary The filter element is insufficiently tightened ...

Page 43: ... 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 attach it to the unit Detach the suction and pressure hose Shutting down the unit See chapter Taking the unit out of operation Disposing of the unit Dispose of the packaging material in an environ...

Page 44: ...016 01 08 Spare parts The following spare parts may be ordered for the unit Item Qty Part no Designation 1 Motor pump assembly 1 3891597 Filter element 5 µm N7ON DC005 CA62H 1 3891598 Filter element 10 µm N7ON DC010 CA62H 1 3891599 Filter element 30 µm N7ON DC030 CA62H available on request ...

Page 45: ...aximum 3 bar Permissible suction pressure at suction port 0 4 0 2 bar Permissible pressure at pressure port connection 3 bar Permissible pressure at the water drain 0 bar Connection suction and pressure side M26x1 5 18L external thread Water drain Drain plug manually operable Water collecting tank volume 0 4 liter Volume filter and coalescing housing 1 7 liter Permitted fluid temperature range 5 t...

Page 46: ...neral data Dimensions 317 x 454 x 551 mm Material substance Frame Steel with surface protection Filter and coalescing housing Aluminum Collecting pan Polypropylene Seals HNBR FKM Permissible ambient temperature range 5 to 40 C or at least 10 C below the flash point of the fluid used Weight when empty 17 kg ...

Page 47: ...X others on request Water drain 1 Manual 2 Automatic Control type E Eco with On Off switch including motor protection visual clogging indicator S Standard with On Off switch including motor protection visual clogging indicator P Premium with on off switch inc motor protection programmable operating times electrical clogging indicator automatic shut down if filter element contaminated Clogging indi...

Page 48: ...ined 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 1 a 2015 03 24 Dr Andreas Schunk Date Name CE official Executive director Documentation Representative Mathias Dieter ...

Page 49: ...ug 45 E EC declaration of conformity 4 48 Electrical data 45 emptying 4 33 35 Error 40 F filling 4 28 30 31 Filter 11 20 21 22 44 46 Filter element 22 44 filtration 16 18 19 24 26 Filtration 48 Flow rate 17 24 H Hazard symbol 3 7 Hydraulic data 45 Hydraulic diagram 3 21 I Imprint 2 3 IN 4 21 25 Inlet 20 21 installation 23 31 Internal pipe diameter 24 IP 45 ISO 10 45 M Main switch 20 Maintenance 1 ...

Page 50: ...08 doc 2016 01 08 S select 6 Serial no 48 Service 4 43 Signal word 3 9 signal words 9 Spare part 4 44 Spare parts 4 44 Specialist personnel 12 storing 15 Supply voltage 47 switching on 19 T Transport 12 41 transporting 14 troubleshooting 4 40 Troubleshooting 12 W Weight 17 46 ...

Page 51: ......

Page 52: ...ebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 6897 509 01 Central Fax 49 6897 509 9046 Technical Department Fax 49 6897 509 577 Sales Department Internet www hydac com E mail filtersystems hydac com ...

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