HYDAC FILTER SYSTEMS LVU-CD-10, Operating And Maintenance Instructions Manual

Page 1: ... LowViscosity Unit CoaleserDiesel with control type Standard or Premium Operating and Maintenance Instructions English translation of original instructions Valid Series no 0002S03302K0000010 Document No 3993633a ...

Page 2: ...athias Dieter Dipl Kfm Wolfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 0 6897 509 1511 Fax 49 0 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 distribut...

Page 3: ...ety 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 Carry by hand 15 Transporting with the crane 16 Storing the unit 17 Decoding the model code la...

Page 4: ...itch on off 37 Reading status LEDs 38 Checking the motor protection switch 38 Using setting operating the Premium control type 39 Switching the main switch on off 39 Reading status LEDs 40 Adjusting the interval control 41 Adjusting the time selector switch 42 Checking the motor protection switch 42 Starting up the unit 43 Observe the clogging indicator only with the Standard version 43 Performing...

Page 5: ...LVU CD 10 en us Page 5 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Overview of spare parts 59 Spare parts list 60 Technical details 61 Model Code 63 EC declaration of conformity 64 Index 65 ...

Page 6: ...lity shall be limited to foreseeable damage Claims due to Product Liability shall remain unaffected Technical Support If you have any questions suggestions or encounter any problems of a technical nature please don t hesitate to contact us When contacting us please always include the model type designation and article no of the product Fax 49 0 6897 509 9046 E mail filtersystems hydac com Modifica...

Page 7: ...w I determine which topic I am looking for WHERE can I find the information I m looking for The document has a table of contents at the beginning 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 maintenan...

Page 8: ... 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 hazar...

Page 9: ...y Information LVU CD 10 en us Page 9 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment ...

Page 10: ...jury 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 seve...

Page 11: ... 95 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 ...

Page 12: ...e 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 d...

Page 13: ...ons 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 and perform the work assigned to them they are also able to recognize potential hazards Activity Person Knowledge Transport storage Auxiliary personnel No specialist...

Page 14: ... 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...

Page 15: ...it Empty the unit completely before transport including the filter and coalescing casing Pull out the power plug and securely fasten the power cord to the unit 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 16: ...sporting the unit LVU CD 10 en us Page 16 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Transporting with the crane For transport with a crane fasten the correct band loops on the frame ...

Page 17: ... and 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 18: ...a en us 2015 08 26 doc 2015 08 26 Decoding the model code 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 63 ...

Page 19: ...e unit 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 Operating pressure maximum Weight Empty weight Flow rate Flow rate Temp Fluid Permitted fluid temperature range Temp Amb Permitted ambient temperature range Volume Fluid volume in unit ...

Page 20: ...very 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 version in accordance with your order check the name plate on page 18 1 Operation and Maintenance Instructions this document Example Figure LVU CD 10 Standard ...

Page 21: ...15 08 26 Operating elements identifying the version The unit is provided in the versions Eco Standard or Premium Additional details regarding the versions can be found in the following Version Control type For details see Eco version See Operation and Maintenance Instructions for unit with Eco control Standard 22 Premium 24 ...

Page 22: ... Standard version LVU CD 10 en us Page 22 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Standard version The Standard version of the unit features the following components ...

Page 23: ...2015 08 26 Item Designation 1 INLET 2 Filter and coalescing housing 3 Clogging indicator visual 4 Water drain 5 Motor pump assembly 6 OUTLET 7 Water supply tank 5 liter 8 Test point 20 Frame 21 Control unit for details see page 37 22 Float switch 23 Collecting pan 24 Inspection glass phase boundary ...

Page 24: ... Premium version LVU CD 10 en us Page 24 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Premium version The Premium version of the unit features the following components ...

Page 25: ...5 08 26 Item Designation 1 INLET 2 Filter and coalescing housing 3 Clogging indicator electrical 4 Water drain 5 Motor pump assembly 6 OUTLET 7 Water supply tank 5 liter 8 Test point 20 Frame 21 Control unit for details see page 39 22 Float switch 23 Collecting pan 24 Inspection glass phase boundary ...

Page 26: ...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 cons...

Page 27: ...agricultural and forestry machinery Storage tanks e g for agriculture and mining Yachts and leisure boats Filter element working principle The filter element works in two stages Stage 1 Solid particle separation and drop coalescence By using purely synthetic filter media a high contamination retention capacity and steady coalescence is guaranteed Stage 2 Water separation A hydrophobic barrier laye...

Page 28: ...33a en us 2015 08 26 doc 2015 08 26 Hydraulic diagram The unit has the following hydraulic circuit Item Designation 1 Inlet IN 2 Filter and coalescing housing 3 Clogging indicator visual electrical 4 Water outlet DRAIN 5 Motor pump assembly 6 Outlet OUT 7 Water supply tank ...

Page 29: ...s LVU CD 10 en us Page 29 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Unit dimensions The unit has the following dimensions using the Standard Premium version as an example All dimensions in mm ...

Page 30: ...nsions LVU CD 10 en us Page 30 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Item Designation 1 Inlet IN 6 Outlet OUT 9 Element removal height 10 Working area for operating and service staff ...

Page 31: ...ion 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 damaged replace it immediately...

Page 32: ...ernal 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 the height difference between the pump and the oil level in the tank as low as possible Constrictions in the connections and lines sh...

Page 33: ...d 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 If the clogging indicator pressure displayed for the a clean filter elem...

Page 34: ...ed 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 Plug the power plug into a suitable earthed prote...

Page 35: ...Unscrew both screws to the cover 615 for connection Remove the cover 615 The description of the connection clamps can be found on the rear Use a free screw type conduit fitting on the lower side to connect the control line The line diameter must be at least 0 5 mm Connect the control line on clamp X3 Remote Start Stop and 4 Use an isolated push button as an impulse generator Use the push button to...

Page 36: ... commissioning Only required for commissioning the unit with control type Standard This model has a visual clogging indicator 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 37: ... The unit has the following control unit and operating elements Item Designation 610 Main switch See page 37 for details 611 Motor protection switch See page 38 for details 613 Status LEDs See page 38 for details Switching the main switch on off Switch the unit on or off at the main switch on the control unit If the unit is switched off all components up to the main switch are deenergized ...

Page 38: ...g 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 Water outlet error message 54 Checking the motor protection switch The motor protection switch is aligned and adjusted at the installed electric motor at the works It is not necessary to correct the setting ...

Page 39: ...ing control unit and operating elements Item Designation 610 Main switch See page 39 for details 611 Motor protection switch See page 42 for details 612 Interval control See page 41 for details 613 Status LEDs See page 40 for details Switching the main switch on off Switch the unit on or off at the main switch on the control unit If the unit is switched off all components up to the main switch are...

Page 40: ...s 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 from the coalescing and separation unit 54 The maximum differential pressure on the coalescing and ...

Page 41: ...e 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 operation ti...

Page 42: ...ng duration is set at the time selector switch Icon Time setting 1 hour 2 hours 4 hours 8 hours Checking the motor protection switch The motor protection switch is aligned 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 Errors and troubleshooting on page 54 ...

Page 43: ... switch 610 and adjust the operating duration for the Premium control type using interval control Observe the clogging indicator only with the Standard version 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 44: ...enance 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 Daily Every 3 months Annually or when indicated Perform visual check 45 Checking emptying water supply tank 46 X Checking the pump for leaks 47 X Changing the filter element 49 X ...

Page 45: ...enance LVU CD 10 en us Page 45 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Perform visual check Check the unit for leaks brittle hoses and cables daily Replace damaged or brittle parts immediately ...

Page 46: ...s 2015 08 26 doc 2015 08 26 Checking emptying water supply tank Check the fill level of the water supply tank multiple times daily Empty the water supply tank daily The separated water can contain some parts of fuel Dispose of the water fuel mixture in an environmentally friendly manner ...

Page 47: ...ks 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 48: ... cool down 2 Remove the four screws and the cover of the inspection opening 5 2 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 c...

Page 49: ...Performing Maintenance LVU CD 10 en us Page 49 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Changing the filter element Proceed as follows to replace the filter element ...

Page 50: ...eather screw 2 2 in an anti clockwise direction 2 Start the unit using the control for 20 seconds so that the filter and coalescing casing is emptied by the pump 3 Open the cover 2 1 of the filter and coalescing casing 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 casing ...

Page 51: ... 26 doc 2015 08 26 5 Pull the filter element 2 4 off the cover 2 1 Remove the O ring 2 3 from the cover 6 Dispose of the 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 ...

Page 52: ...e new filter element onto the cover 2 1 Clip the new filter element 2 4 onto the cover 2 1 9 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 10 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 53: ...ing Maintenance LVU CD 10 en us Page 53 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 11 Tighten the breather screw 2 2 in a clockwise direction 12 The filter element change is now complete ...

Page 54: ...ee seconds Error 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 LED lights up LED flashing LED flashing The main switch is...

Page 55: ...he 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 electri...

Page 56: ...d The clogging indicator appears 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 cover on the filter a...

Page 57: ... Customer Service Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your unit HYDAC SERVICE GMBH Friedrichsthaler Str 15A Werk 13 66540 Neunkirchen Heinitz Germany Telephone 49 0 6897 509 883 Fax 49 0 6897 509 324 E mail service hydac com ...

Page 58: ... of its components before decommissioning Pull out the power plug and fasten the hoses and power cord on 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 environmentally friendly manner After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly manner ...

Page 59: ...Spare parts LVU CD 10 en us Page 59 68 BeWa LVU CD 10 StdPrm 3993633a en us 2015 08 26 doc 2015 08 26 Spare parts The following spare parts may be ordered for the unit Overview of spare parts ...

Page 60: ...er and coalescing casing 5 1 1303275 Clogging indicator visual Standard control type 5 1 1270904 Contamination switch electrical Premium control type 7 1 3883021 Water collection canister 5 liter 8 1 6094990 Hose 9 1 6092841 Collecting pan float switch 10 1 Motor pump assembly 11 1 3871268 Filter element 5 µm N7ON DC005 CA61H 11 1 3871269 Filter element 10 µm N7ON DC010 CA61H 11 1 3871271 Filter e...

Page 61: ...ar pump Operating pressure Maximum 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 Hose Ø 10mm Water collecting tank volume 5 liter Permitted fluid temperature range 5 50 C or at least 10 C below the flash p...

Page 62: ... 08 26 doc 2015 08 26 General data Dimensions 300 x 550 x 816 mm Material substance Frame Lacquered steel Filter and coalescing housing Aluminum Seals HNBR FKM Permitted ambient temperature range 5 50 C or at least 10 C below the flash point of the fluid used deployed Empty weight 38 kg ...

Page 63: ...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 indica...

Page 64: ...tained 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 Diete...

Page 65: ...46 Error 40 54 56 Error message 40 56 F Filter 12 23 25 27 28 56 60 62 Filter element 27 60 filtration 18 20 32 34 55 Filtration 64 Float switch 23 25 Flow rate 19 32 G Gear pump 61 63 H Hazard symbol 8 Hydraulic data 61 Hydraulic diagram 28 I Imprint 2 IN 28 30 33 Inlet 28 30 INLET 23 25 Inspection 23 25 Internal pipe diameter 32 IP 61 ISO 11 61 M Main switch 37 39 Maintenance 1 20 21 44 Maintena...

Page 66: ...mp 61 63 R Remedy 54 repairs 26 S select 7 Serial no 64 Service 57 setting 37 38 39 42 Signal word 10 signal words 10 Spare parts 59 60 Spare parts list 60 Specialist personnel 13 storing 17 Supply voltage 38 40 63 switching on 26 T Time 42 Transport 13 55 transporting 15 troubleshooting 13 38 42 54 W Weight 19 ...

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Page 68: ...iet 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 Email filtersystems hydac com ...