Hydac LVU-CD-40 Operating And Maintenance Instructions Manual

Brand: Hydac

Model: LVU-CD-40

Type: Operating And Maintenance Instructions Manual

LVU-CD-40

LowViscosity Unit

CoalescerDiesel

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 4035823a

Keep for future reference.

Imprint

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Imprint

Publisher and responsible for the content:

HYDAC FILTER SYSTEMS GMBH

Postfach 1251

66273 Sulzbach / Saarland

Germany

Telephone: +49 6897 509 01

Fax: +49 6897 509 9046

E-mail: [email protected]

Homepage: www.hydac.com

Court of Registration: Saarbrücken, HRB 17216

Executive director: Mathias 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: [email protected]

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 and inspected with the greatest care.

However, errors cannot be ruled out completely.

Content

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Content

Imprint............................................................................................................2

Documentation Representative ...................................................................2

Content ..........................................................................................................3

Preface...........................................................................................................6

Technical support ........................................................................................6

Modifications to the product.........................................................................6

Warranty ......................................................................................................6

Using the documentation .............................................................................7

General safety information ..........................................................................8

Hazard symbols...........................................................................................8

Signal words and their meaning in the safety information and

instructions ................................................................................................10

Structure 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..............................................................................17

Checking the scope of delivery .................................................................19

Unit function................................................................................................20

Identifying components .............................................................................20

Unit with control type - Eco ........................................................................21

Hydraulic diagram.......................................................................................23

Unit dimensions ..........................................................................................24

Unit setup/connection ................................................................................25

Content

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Notes on pipes/hosing ...............................................................................26

Connecting the suction port (IN) ................................................................27

Connecting the pressure port (OUT) .........................................................27

Connecting the water outlet .......................................................................28

Electrical connection..................................................................................28

Connecting remote control line (control type standard / premium

only) .......................................................................................................29

Relationships: Remote control/Interval control (with Premium

control type only).................................................................................31

Finding/selecting the control type.............................................................32

Using / setting / operating the "Eco" control type ...................................33

Switching unit on/off...................................................................................34

Observe the optical clogging indicator .......................................................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............................................................................42

Maintenance intervals................................................................................42

Perform visual check .................................................................................42

Checking the pump for leaks

.....................................................................43

Replacing the filter element in the filter housing

........................................45

Changing the coalescing elements ............................................................48

Status LED / Causes and remedies ...........................................................54

Customer service........................................................................................58

Taking the unit out of operation ................................................................58

Shutting down the unit ...............................................................................58

Disposing of the unit ..................................................................................58

Spare parts list............................................................................................59

Content

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Technical data .............................................................................................60

Decoding model code.................................................................................62

EC declaration of conformity.....................................................................63

Index ............................................................................................................64

Preface

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Preface

This operating manual was made to the best of our knowledge. Nevertheless

and despite the greatest care, it cannot be excluded that mistakes could have

crept in. Therefore please understand that in the absence of any provisions

to the contrary hereinafter our warranty and liability – for any legal reasons

whatsoever – are excluded in respect of the information in this operating

manual. In particular, we shall not be liable for lost profit or other financial

loss. This exclusion of liability shall not apply to gross negligence or wilful

misconduct. Moreover, it does not apply to defects which have been

deceitfully concealed or in cases of culpable harm to life, physical injury and

damage to health. If we negligently breach any material contractual

obligation, 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 (0) 6897 / 509 - 9046

E-mail: [email protected]

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.

After modification or repair work that affects the safety of the product has

been carried out on components, the product may not be returned to

operation until it has been checked and released by a HYDAC technician.

Please notify us immediately of any modifications made to 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 FILTER SYSTEMS GMBH.

You will find these under www.hydac.com -> Legal information.

Preface

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Using the documentation

Note that the method described for locating specific information

does not release you from your responsibility of carefully reading

these instructions prior to starting the unit up for the first time and

at regular intervals in the future.

What do I want to know?

I determine 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.

Se ite x

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 description

Page number

Edition date

Document language

Documentation no.

with index/

file name

General safety information

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General safety information

The unit was built according to the statutory provisions valid at the time of

delivery and satisfies current safety requirements.

Any residual hazards are indicated by safety information and instructions and

are described in the operating instructions.

Observe all safety and warning instructions attached to the unit. They must

always be complete and legible.

Do not operate the unit unless all 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 hazards to persons, property

or the environment.

Observe these instructions and act with particular caution in such cases.

Pass all safety information and instructions on to other users.

General hazard

Danger due to electrical voltage/current

Exposed electrical components

Danger of electrical shock

Danger due to operating pressure

General safety information

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Risk of burns due to hot surfaces

Flammable

Danger from explosive atmosphere

Harmful to the environment

General safety information

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Signal words and their meaning in the safety information and

instructions

DANGER

DANGER indicates a danger with a high risk and which will lead to death or

serious injury if not avoided.

WARNING

WARNING indicates a danger with a medium risk and which can lead to

death or serious 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 severity of the

danger.

Warning instructions listed before an activity are laid out as follows:

SIGNAL WORD

Type and source of danger

Consequence of the danger

HAZARD SYMBOL

►

Measures to avert danger

General safety information

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Proper/Designated Use

Use the unit only for the application described in the following.

The LowViscosity Unit LVU is used for two-stage offline filtration, with solid

particle contamination and free water being removed from diesel fuel. The

degree of water separation is > 95 % as per ISO CD 16332 and the

dewatering rate is 50 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 that the pump does not run dry.

NOTICE

Impermissible operating media.

The unit will be destroyed.

► The unit may only be used in combination with diesel, .biodiesel

B0 … B100 or fuel oil.

Proper or designated use of the product extends to the following:

observing all instructions contained in these operating instructions.

adhering to maintenance work.

General safety information

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The unit is suitable only for suction operation mode.

Operation is only permitted at an earthed power supply.

Keep the unit away from sources of ignition.

Improper use or use deviating from intended use

DANGER

Danger due to unanticipated use of the unit

Risk of bodily injury due to fire

►

Never operate the unit in potentially

explosive atmospheres.

► The unit is only to be used 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 potentially explosive atmospheres.

Operation under impermissible operating conditions.

Operation when the safety devices are defective.

Modifications to the power unit made by the user or purchaser.

Inadequate monitoring of parts that are subject to wear and tear.

Improperly performed repair work.

General safety information

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Qualifications of personnel / target group

Persons who work on the power unit must be aware of the associated

hazards when using the power unit.

Operating and specialist personnel must have read and understood the

operating instructions, in particular the safety information and instructions,

and applicable regulations before beginning work.

The operating instructions and applicable regulations are to be 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 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 specialist knowledge

required

Startup operation

operations control

Auxiliary

personnel

Product-specific knowledge

Knowledge about how to handle

operating media

troubleshooting,

maintenance,

decommissioning,

disassembly

Specialist

personnel

Safe handling/use of tools

Product-specific knowledge

Disposal Specialist

personnel

Proper and environmentally

friendly disposal of materials

and substances

Decontamination of

contaminants

Knowledge about reuse

Unpacking the unit

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Wear suitable clothing

Loose-fitting clothing increases the risk of being caught or being drawn in on

rotating parts, and the risk of getting caught on protruding parts. You can be

severely injured or killed.

Wear close-fitting clothing.

Do not wear any rings, chains or any other jewelry.

Wear work safety shoes.

Wear gloves.

Observe the information 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 STOP)

In an emergency, switch the unit off at the main on/off switch or unplug the

power connector.

Unpacking the unit

Prior to delivery, the unit is function and leak-tested in the factory.

When unpacking the unit, check it for damage in transit.

Transporting the unit

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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.

Storing the unit

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Storing the unit

Empty the unit completely before storage, including the coalescing and 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.

Decoding the type label

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Decoding 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:

Decoding the type label

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Row -> 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. -> 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 volume in unit

Checking the scope of delivery

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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-40, version in accordance with your

order, check the name plate on page 17.

1 Operation and Maintenance Instructions

(this document)

Unit function

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Unit function

The LowViscosity Unit LVU is intended for offline filtration. The LVU removes

solid particle contamination and free water from diesel fuel.

Diesel fuel is often subject to long storage periods, especially in tanks which

may be used infrequently. As a result, solid particles and water are often

deposited on the bottom of the tank and can then damage pumps and

sensitive components when switching on the motor.

In addition, over an extended period of time free water in a tank provides a

breeding ground for diesel fuel pests (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 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 early and expensive disposal of diesel fuel.

The filtration unit is suitable for diesel maintenance in:

Tanks on mobile / stationary emergency power units

e.g. in hospitals, shopping centers and power plants

Tanks of portable machines, e.g. harvesting and construction machinery

Storage tanks e.g. for agriculture and mining

Tanks on yachts and leisure craft

Identifying components

The unit is constructed in the versions Eco, Standard or Premium. Additional

details regarding the versions can be found in the following.

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Hydac LVU-CD-40 Operating And Maintenance Instructions Manual

Hydac LVU-CD-40 Operating And Maintenance Instructions Manual

Hydac LVU-CD-40 Operating And Maintenance Instructions Manual

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