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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.
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]
© 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 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.
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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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