LVU-CD-40 LowViscosity Unit CoalescerDiesel

Transcription

1 LVU-CD-40 LowViscosity Unit CoalescerDiesel Operating and Maintenance Instructions English (translation of original instructions) Document No.: a Keep for future reference.

2 Imprint Imprint Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach Sulzbach / Saarland Germany Telephone: Fax: filtersystems@hydac.com Homepage: Court of Registration: Saarbrücken, HRB Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, Sulzbach / Saar Telephone: Fax: 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 and inspected with the greatest care. However, errors cannot be ruled out completely. LVU-CD-40 en(us) Page 2 / 68

3 Content 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 LVU-CD-40 en(us) Page 3 / 68

4 Content 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 LVU-CD-40 en(us) Page 4 / 68

5 Content Technical data...60 Decoding model code...62 EC declaration of conformity...63 Index...64 LVU-CD-40 en(us) Page 5 / 68

6 Preface 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 / 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 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 -> Legal information. LVU-CD-40 en(us) Page 6 / 68

7 Preface 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. Chapter description Produkt / Kapitel Page number HYDAC Filtertechnik GmbH BeWa a de de Seite x 200x-xx-xx Edition date Documentation no. with index/ file name Document language 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. LVU-CD-40 en(us) Page 7 / 68

8 General safety information 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 LVU-CD-40 en(us) Page 8 / 68

9 General safety information Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment LVU-CD-40 en(us) Page 9 / 68

10 General safety information 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 HAZARD SYMBOL Type and source of danger Consequence of the danger Measures to avert danger LVU-CD-40 en(us) Page 10 / 68

11 General safety information 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 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. LVU-CD-40 en(us) Page 11 / 68

12 General safety information 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. LVU-CD-40 en(us) Page 12 / 68

13 General safety information 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 Startup operation operations control troubleshooting, maintenance, decommissioning, disassembly Disposal Auxiliary personnel Auxiliary personnel Specialist personnel Specialist personnel No specialist knowledge required Product-specific knowledge Knowledge about how to handle operating media Safe handling/use of tools Product-specific knowledge Proper and environmentally friendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse LVU-CD-40 en(us) Page 13 / 68

14 Unpacking the unit 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. LVU-CD-40 en(us) Page 14 / 68

15 Transporting the unit 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. LVU-CD-40 en(us) Page 15 / 68

16 Storing the unit 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 Storage duration Storage position Clean, salt-free air, not near oxidizing substances (rust film). 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. Only standing. LVU-CD-40 en(us) Page 16 / 68

17 Decoding the type label 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: LVU-CD-40 en(us) Page 17 / 68

18 Decoding the type label 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 LVU-CD-40 en(us) Page 18 / 68

19 Checking the scope of delivery 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 Operation and Maintenance Instructions (this document) LVU-CD-40 en(us) Page 19 / 68

20 Unit function 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. LVU-CD-40 en(us) Page 20 / 68

21 Identifying components Unit with control type - Eco The Eco version of the unit features the following components: LVU-CD-40 en(us) Page 21 / 68

22 Identifying components Item Designation 100 Clogging indicator, visual, for the filter housing 200 Clogging indicator, visual, for the coalescing housing 1000 Collecting pan 1330 Inlet 2000 Coalescing housing 2110 Sight glass, upper phase boundary 2111 Sight glass, lower phase boundary 2310 Venting, coalescing housing 2560 Outlet 3210 Water drain 3350 Emptying, coalescing housing 4000 Motor pump assembly 4010 Inspection opening 5000 Filter housing (pre-filter) 5001 Air bleed, filter housing 5002 Emptying, filter housing 7000 Main switch with motor protection LVU-CD-40 en(us) Page 22 / 68

23 Hydraulic diagram Hydraulic diagram The unit has the following hydraulic circuit: M Item Designation 100 Clogging indicator, visual, for the filter housing 200 Clogging indicator, visual, for the coalescing housing 1330 Inlet 2000 Coalescing housing 2560 Outlet 3210 Water drain 3350 Emptying, coalescing housing 4000 Motor pump assembly 5000 Filter housing (pre-filter) 7000 Main switch with motor protection LVU-CD-40 en(us) Page 23 / 68

24 Unit dimensions Unit dimensions The unit has the following dimensions, using the Eco version as an example: A = Required dismantling space for changing the coalescing elements B = Recommended working range All dimensions in mm. LVU-CD-40 en(us) Page 24 / 68

25 Unit setup/connection Unit setup/connection NOTICE Danger of tipping over / danger of slipping due to vibrations The unit will be damaged Prior to operation, place the unit on a stable, horizontal surface. Place the unit on a horizontal and level surface which is well ventilated. Install 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 damaged, replace it immediately. 2. Check the connecting lines for leaks. Eliminate any leakages immediately. 3. Check and insert the filter element. For details, see page Check and insert the coalescing element. For details, see page The unit is ready for the next steps on the following pages. LVU-CD-40 en(us) Page 25 / 68

26 Unit setup/connection Notes on pipes/hosing Make sure that no vibrations or stresses are carried over to the filtration unit when connecting the piping. Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filtration unit. Use hoses or expansion joints if necessary. The pressure loss in a hydraulic line depends upon: flow rate Kinematic viscosity Pipe dimensions Density of the fluid The pressure loss can be estimated for hydraulic oils as follows: p p 6.8 * L / d 4 * Q * V * D = Pressure differential in [bar] L d Q V = Pipe length [m] = Internal pipe diameter [mm] = Flow rate [l/min] = Kinematic viscosity [mm²/s] D = Density [kg/dm³] Diesel has a density of approx kg/dm³ 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 hoses/piping must be at least as large as the inlet port sizes. LVU-CD-40 en(us) Page 26 / 68

27 Unit setup/connection Connecting the suction port (IN) For the suction port connection, use a flexible hose that is resistant to negative pressure. Avoid constrictions in the connecting lines, as they compromise suction performance and increase the risk of cavitation. NOTICE Overpressure at the suction port connection The unit will be damaged The pressure on the suction port connection IN must not be more than -0.9 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 element is > 1 bar, use a differential pressure clogging indicator. NOTICE Excess pressure at the pressure port connection The unit will be damaged The pressure at the OUT connection must not be more than a maximum of 3 bar. LVU-CD-40 en(us) Page 27 / 68

28 Unit setup/connection Connecting the water outlet Connect the water outlet to a depressurized reservoir without cross-section reduction. Reservoir height max. 1.5 m and no higher than the fluid level in the tank. The separated water can contain some parts of fuel. Dispose of the water-fuel mixture in an environmentally friendly manner. NOTICE Excess pressure at the water outlet The unit will be damaged 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. Plug the power plug into a suitable, earthed, protected power outlet. Match the specifications for the power supply and frequency on the unit with the network specifications. The filtration unit has a thermal motor protection switch to protect it from electrical overload. LVU-CD-40 en(us) Page 28 / 68

29 Unit setup/connection Connecting remote control line (control type standard / premium only) The unit provides a connection for remote monitoring and a start/stop function. This lets you monitor, start and stop the unit from a control centre. 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. NOTICE Incorrect voltage / current at the relay contact The control will be destroyed. Take note of the maximum voltage and current permitted in the relay contacts of 24 V DC / 2 A. Only use cables with a cable cross section of > 0.5 mm². Use a free screw type conduit fitting on the lower side to connect the control line. Connect the pilot line and monitoring line to the X3 terminal according to the following description: LVU-CD-40 en(us) Page 29 / 68

30 Unit setup/connection Pin Function Description 1-2 Output Device ACTIVE 3-4 Output Device OK Potential-free relay contact. This is closed when the motor pump group is running. Potential-free relay contact. This is closed when there is no pending error. Can be used, for example, to issue an error notification when contact opens. Opens, for example when the voltage drops, motor protection responded, filter clogged, collecting pan too full, etc. 5-6 Output Reserve Potential-free relay contact. Has no function 7-8 Input Input for potential-free push-button to switch motor-pump group on/off. No voltage is to be applied here Input Reserve A voltage of 24V is to be applied here (optocoupler input) to start a function. No function set yet. LVU-CD-40 en(us) Page 30 / 68

31 Unit setup/connection Relationships: Remote control/interval control (with Premium control type only) After switching on the LVU, the set interval and the run up time will be started. Using the remote control, the motor-pump group can be switched on/off using the remote control. The timer with the interval and the switch-on time will continue to run in the background (remote control has priority). If the motor-pump group is switched off via the remote control, it starts automatically once the interval is over and runs time controlled via the timer. If the motor-pump group is switched on via the remote control, it stops once the interval is over. The timer has priority when switching off. Thus, the set interval and the switch-on time are not influenced by the remote control. Instead the timer assumes control again once the interval is over. LVU-CD-40 en(us) Page 31 / 68

32 Finding/selecting the control type Finding/selecting the control type Three different control types can be selected for the unit. The selection of the control is made at the time the unit is ordered and cannot be changed afterwards. Different cyclical testing and maintenance intervals apply and the operation of the unit changes, depending on the control type. You will find a detailed description of each of the controls on the following pages. Control type E = Eco 3333 S = Standard 3838 P = Premium 3838 See page for details LVU-CD-40 en(us) Page 32 / 68

33 Using / setting / operating the "Eco" control type Using / setting / operating the "Eco" control type The unit has the following control unit and operating elements: Item Designation 100 Clogging indicator, visual, for the filter housing 200 Clogging indicator, visual, for the coalescing housing 2110 Sight glass, upper phase boundary 2111 Sight glass, lower phase boundary 3210 Water drain 4010 Inspection opening 7000 Main switch with motor protection LVU-CD-40 en(us) Page 33 / 68

34 Using / setting / operating the "Eco" control type Switching unit on/off Switch the unit on or off at the main switch (7000). The integrated motor protection switch protects the electric motor against damage caused by overloading. Observe the optical clogging indicator The unit features two visual clogging indicators with displays of when the filter element in the filter housing and the coalescing elements are exhausted. The visual clogging indicator display then switches from green to red. Item Designation Remedy for red display 100 Clogging indicator, visual, for Replace the filter element in the LVU-CD-40 en(us) Page 34 / 68

35 Using / setting / operating the "Eco" control type the filter housing 200 Clogging indicator, visual, for the coalescing housing filter housing as described in the chapter "Replacing the filter element in the filter housing" on page 45. Replace the coalescing element as described in chapter "Changing the coalescing elements" on page 48. Actuate the Reset button of the clogging indicator to reset the notification. LVU-CD-40 en(us) Page 35 / 68

36 Using / setting / operating the "Eco" control type Observing / checking phase limits Check the phase limit between fluid and water through the upper (2110) and lower (2111) sight glass. If the phase limit is visible in the upper sight glass (2110), drain off the free water as described in chapter "Draining off the free water" on page 37. LVU-CD-40 en(us) Page 36 / 68

37 Using / setting / operating the "Eco" control type Draining off the free water Check the level of the phase limit several times daily at the upper (2110) and lower (2111) sight glasses. If the phase limit is visible in the upper sight glass (2110), drain off the free water at the valve (3210) The separated water can contain some parts of fuel. Dispose of the water-fuel mixture in an environmentally friendly manner. LVU-CD-40 en(us) Page 37 / 68

38 Operating / Setting "Standard / Premium" control type Operating / Setting "Standard / Premium" control type The unit has the following control unit and operating elements: Item Designation 610 Main switch See page 39 for details 611 Motor protection switch See page 41 for details 612 Interval control (with "Premium" control type only) See page 40 for details 613 Status LEDs See page 39 for details LVU-CD-40 en(us) Page 38 / 68

39 Operating / Setting "Standard / Premium" control type 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. Reading LED status The status LEDs with the symbols indicate operating status, service status and errors. The icons are explained below. Icon An illuminated LED means the following: Supply voltage is available 54 For details on remedies, see page: 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 water outlet. 54 The maximum differential pressure in the coalescing housing or filter housing has been reached. 48 LVU-CD-40 en(us) Page 39 / 68

40 Operating / Setting "Standard / Premium" control type Setting interval control (with Premium control type only) Operating intervals and the operating duration are specified using the 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, time adjustment using time selector switch. LVU-CD-40 en(us) Page 40 / 68

41 Operating / Setting "Standard / Premium" control type Adjusting the time selector switch The operating 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 "Status LED /" on page 54. Switching unit on/off Switch the unit on at the main switch (610) and select the operating duration using interval control. Automatic water drainage If the water sensor signals > 5 seconds, the drain level has been reached and the water drain value will be opened for approx. 10 seconds. This will result in approx. 3 liters of water draining out. LVU-CD-40 en(us) Page 41 / 68

42 Performing maintenance Performing maintenance Perform all of the subsequent maintenance work regularly. Perform all 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 Daily Every 3 months 1 year When indicated: Perform visual check 42 - X Checking the pump for leaks X - - Replacing the filter element in the filter housing Changing the coalescing elements X X X X Perform visual check Check the unit for leaks, brittle hoses and cables daily. Replace damaged or brittle parts immediately. LVU-CD-40 en(us) Page 42 / 68

43 Performing maintenance Checking the pump for leaks 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. LVU-CD-40 en(us) Page 43 / 68

44 Performing maintenance Proceed as follows: 1. Switch off the unit at the main switch and allow the motor-pump group to cool down. 2. Remove the four screws and the cover of the inspection opening (4010). 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 4. Shut down the unit and contact HYDAC. 5. Screw the cover tightly with the four screws. 6. The test has been successfully completed. -> proceed to Step 4. LVU-CD-40 en(us) Page 44 / 68

45 Performing maintenance Replacing the filter element in the filter housing The filter element has a bayonet seal - this simplifies changing the element. The only intervention required is to turn the element or its mounting parts 90 clockwise or counterclockwise. 1. Switch off the installation, make sure that no operating fluid can flow out of the lines into the filtration unit, and make sure that the unit cannot be switched on again during maintenance. Depressurize the filter housing. To accomplish this, carefully open the drain plug (Air Bleed) on the filter housing cover (do not unscrew completely). Be careful when the operating fluid flows out. 2. Put a suitable container in place to catch the fluid in the filter housing. The content is 3 or 6 liters. Empty the filter housing through the drain screw (Drain) on the connection part. Without the proper drainage equipment, the draining fluid could flow downward to the electric motor. 3. Loosen the tensioning clamp on the filter housing cover by completely unscrewing the nut. Remove the housing clamp. LVU-CD-40 en(us) Page 45 / 68

46 Performing maintenance 4. Carefully lift up the filter housing cover to remove it. While doing this, turn it slightly clockwise so that the filter element remains locked on the cover. Turn counterclockwise to detach the dirt catch tray from the element and the element from the cover. 5. Remove the dirt catch tray. 6. Remove the filter element from the filter housing cover. Dispose of the old filter element according to local regulations and guidelines. 7. Clean the removed parts and examine them for any possible damage. Check the O-ring on the filter bowl cover for damage. Replace it if necessary. Moisten the O-rings on the filter bowl cover and on the new filter element with operating fluid. media. Never use grease or other LVU-CD-40 en(us) Page 46 / 68

47 Performing maintenance 8. Now place the filter bowl cover on the new filter element and lock it in place. 9. Fasten the dirt catch tray to the bottom end of the filter element. 10. Check the O-ring on the cover for correct seating. Place the filter element with the cover and dirt catch tray in the filter housing. 11. Secure the cover with the housing clamp. The tightening torque is a maximum of 5 Nm. 12. Screw in the drain screw (Drain) at the connection part of the unit and tighten. Switch the filtration unit on. Bleed the filter housing through the air bleed plug (Air Bleed) in the filter cover. LVU-CD-40 en(us) Page 47 / 68

48 Performing maintenance Changing the coalescing elements To replace the coalescing elements, proceed as follows: 1. Switch off the unit at the main switch. 2. Close the INLET (1330) and OUTLET (2560) ball valves 3. Depressurize the unit. Carefully screw the air-vent plug out of the cover with the aid of a size 10 mm Allen wrench. 4. Open the ball valve at the DRAIN connection (3350) to empty the coalescing housing. Collect the free water/oil in a suitable container and dispose of it in an environmentally friendly manner. Once the coalescing housing is completely emptied, close the "DRAIN" connection (3350). 5. Loosen the upper tensioning clamp on the coalescing housing with a 13 mm Allen wrench by turning it counterclockwise. LVU-CD-40 en(us) Page 48 / 68

49 Performing maintenance Remove the housing clamp (2400). 2 - Remove the cover by lifting it upward and set it down to the side. 7. Remove the element set from the coalescing housing. Use both handles to accomplish this. 8. Rotate the element set on the head by 180. LVU-CD-40 en(us) Page 49 / 68

50 Performing maintenance 9. Undo the 3 wing nuts and remove the holding plate. 10. Pull the coalescing elements out of the element receptacles and dispose of them in an environmentally friendly manner. LVU-CD-40 en(us) Page 50 / 68

51 Performing maintenance 11. Moisten the O-ring on the element lightly with the operating fluid. 12. Insert the new coalescing elements into the element receptacles by screwing them in carefully. Do not use a hammer, etc. 13. Mount the element holding plate and tighten the 3 wing nuts firmly. LVU-CD-40 en(us) Page 51 / 68

52 Performing maintenance 14. Rotate the element set by 180. Insert the element set into the coalescing housing. Note that the element set fits only in one position (Z) in the coalescing housing. 15. Clean the sealing surface on the cover. Check the O-ring for damage. Replace it if necessary Place the cover on the coalescing housing. 2 - Place the housing clamp over the coalescing housing. 17. Use an SW 13 fork wrench to tighten the tensioning clamps evenly to a maximum of 20 Nm. Screw open the lock nut and secure the connection. LVU-CD-40 en(us) Page 52 / 68

53 Performing maintenance 18. Open the ball valves INLET (1330) and OUTLET (2560). 19. Bleed the filtration unit. 20. Bleed the coalescing housing through the air-vent plug (2310) at the cover. A 21. The replacement of the coalescing element is completed. LVU-CD-40 en(us) Page 53 / 68

54 Status LED / Causes and remedies Status LED / Causes and remedies The status LEDs only indicate to you the status or an error of the unit in Standard / Premium control type. The following errors could have different causes. The following provides information on which remedial measures are required. To reset the error message on the control, switch off the unit at the main switch for at least three seconds. Status LED Cause(s) Remedy LED is dark = LED is off No power supply. Check the feed-line and plug. LED flashing The main switch is switched off but the power supply is on The main switch is switched on, during operation there was a drop in voltage => restart protection. Check the main switch. Switch off the unit at the main switch for 3 seconds. LED lights up The main switch is on, but the unit is not running. Contact HYDAC. LED flashing LED flashing Electric motor / pump is not running Interval control is active. Only with control type: "Premium". Check the interval settings. LVU-CD-40 en(us) Page 54 / 68

55 Status LED / Causes and remedies Status LED Cause(s) Remedy No flow The is no power at the electric motor. The mains voltage or frequency do not correspond to the specifications on the unit. The unit is switched off at the main switch. The suction hose is kinked or faulty or a shut-off device is closed. There is air in the suction line and the pump. The viscosity of the fluid is too high. The is no power to the electric motor. The electric motor / pump is defective. The transport seals were not removed. The pressure loss in the suction line is too great. 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. Use a unit that is suitable for the mains voltage. Switch on the unit at the main switch. Check the suction hose for flow. Replace it if necessary. Fill the pump via the suction hose / hose coupling. Check the viscosity of the fluid. Heat the fluid to achieve the permissible viscosity. Check the supply line to the filtration unit. Replace it if necessary. Contact HYDAC. Remove the transport seals. Transport seals are the yellow plastic plugs. Ensure that the pressure at the inlet is within the permitted range. LVU-CD-40 en(us) Page 55 / 68

56 Status LED / Causes and remedies Status LED Cause(s) Remedy The suction hose is not suitable for negative pressure. Use a hose that is resistant to negative pressure. The filter element or the coalescing elements are clogged. (The clogging indicator is responding) If the maximum differential pressure in the filter housing or coalescing housing has been reached, the control will automatically switch off the unit. Once a clogging indicator responds, the unit will be switched off with a time delay of 60 seconds. Switch on the unit and check at which of the two optic-electric clogging indicators the LED illuminates. Change the filter element or the coalescing element depending on which LED of the clogging indicator illuminates. The viscosity of the fluid is too high. The suction line at the inlet is generating too much loss of pressure. Check the viscosity of the fluid. Heat the fluid to achieve the permissible viscosity. Ensure that the pressure at the inlet is within the permitted range. LVU-CD-40 en(us) Page 56 / 68

57 Status LED / Causes and remedies Status LED Cause(s) Remedy Collecting pan too full. Leakage on the unit / filter housing Wrong, missing, or defective sealing ring. The filter element is insufficiently tightened. The fluid is dewatered. No water has drained from the system in eight hours. For this reason, the control reports that the fluid is dewatered. The water drainage valve has a malfunction. The water drainage valve jams. Empty the collecting pan and eliminate the leak on the unit. Check the sealing ring on the filter element. Replace it if necessary. Tighten the filter housing somewhat by hand. This is a status notification. Remediation is not required. Contact HYDAC. LVU-CD-40 en(us) Page 57 / 68

58 Customer service 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 Neunkirchen-Heinitz Germany Telephone: Fax: Taking the unit out of operation Drain the unit completely, including all of its components, before decommissioning. Pull out the power plug and securely fasten the hoses and power cord to 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. LVU-CD-40 en(us) Page 58 / 68

59 Spare parts list Spare parts list Qty Part no. Designation 1 * Motor/pump assembly Seal kit, comprised of: 1x O-ring coalescing housing 1x O-ring filter housing Coalescing element set N20ON-DCZ-CB1F " Filter element, 3 µm N10ON-DF003-FA41F " Filter element, 5 µm N10ON-DF005-FA41F " Filter element, 10 µm N10ON-DF010-FA41F " Filter element, 3 µm N20ON-DF003-FA41F " Filter element, 5 µm N20ON-DF005-FA41F " Filter element, 10 µm N20ON-DF010-FA41F *) available on request LVU-CD-40 en(us) Page 59 / 68

60 Technical data Technical data Dewatering performance Water separation efficiency > 95% acc. to ISO CD Achievable water content Dewatering rate <200 ppm 50 l/h at 5% water in the diesel Hydraulic data Operating limit Maximum flow rate Pump type Operating pressure Permissible suction pressure at suction port. Permissible pressure at pressure port connection Permissible pressure at the water drain Connection (suction and pressure side) Water drain Permitted fluid temperature range Maximum 10% free water 40 l/min Gear pump Maximum 3 bar bar 3 bar 0 bar G1 G1/2 < 50 C and at least 10 C below the flash point of the fluid used. Electrical data Power supply Power consumption See motor type plate 750 W Protection class IP 55 Connector cable, length - Control type eco 10 m with safety plug - with control type: Standard or Premium 0.5 m with safety plug LVU-CD-40 en(us) Page 60 / 68

61 Technical data General data Dimensions See page 24 Material / substance Frame Coalescing housing Seals Permissible ambient temperature range Lacquered steel Stainless HNBR / FKM 0 to 50 C and at least 10 C below the flash point of the fluid used. Weight when empty - Control type eco 80 kg - with control type: Standard or Premium 90 kg LVU-CD-40 en(us) Page 61 / 68

62 Decoding model code Decoding model code LVU - C D G - N E - z - BM - 1 / - Type LVU = LowViscosity Unit Function C = Filtering and coalescing Operating fluid D = Diesel Nominal flow rate 40 = 40 l/min Pump version G = Gear pump Supply voltage M = 230 V AC, 50 Hz, 1 Ph N = 400 V AC, 50 Hz, 3 Ph X = others on request Prefilter 1 = Prefilter size 10" 2 = Prefilter size 20" Water drain 1 = Manual 2 = Automatic Control type E = Eco - with On/Off switch including motor protection - visual clogging indicator - manual water drainage S = Standard - with On/Off switch including motor protection - visual clogging indicator - manual water drainage - float switch in the collecting pan - remote control input On/Off P = Standard - with On/Off switch including motor protection - programmable operating times - electrical visual clogging indicator / - automatic water drainage - switch-off when "diesel dry" - float switch in the collecting pan - remote control input On/Off Measurement technology z = None Clogging indicator BM = Differential pressure gauge, visual D4 = Differential pressure indicator, visual/electrical Type code 1 = (You always receive the latest type) Additional - = None LVU-CD-40 en(us) Page 62 / 68

63 EC declaration of conformity EC declaration of conformity HYDAC FILTER SYSTEMS GMBH Postfach Sulzbach / Saar Germany Industriegebiet Sulzbach / Saar Germany Telefon: ++49 (0) Internet: EC declaration of conformity We hereby declare that the following designated product, on the basis of its design and construction, and in the version which we have brought to market, corresponds to the fundamental safety and health requirements contained 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 1a) Dr. Andreas Schunk Date Name (CE official) Executive director: Documentation Representative: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Günter Harge Registered seat of company: Sulzbach / Saar - Germany c/o HYDAC International GmbH, Industriegebiet, Sulzbach / Saar Registry Court: Saarbrücken, HRB Telephone: +49 (0) Value added tax identification number: DE Fax: +49 (0) Tax number: 040/110/ Guenter.harge@hydac.com LVU-CD-40 en(us) Page 63 / 68

64 Index Index A ambient temperature... 18, 61 Auxiliary personnel C care... 2, 6 Cause CE official Clogging indicator...22, 23, 33, 35, 62 collecting pan... 30, 39, 57, 62 connecting... 25, 26, 27 Connection Content... 3 Control... 32, 60, 61, 62 Customer service... 4, 58 D Date Density Description... 17, 18, 30, 40 dewatering Dewatering Dewatering performance Dewatering rate Differential pressure Differential pressure gauge Differential pressure indicator Dimensions disassembly Disposal Documentation Representative... 2, 3, 63 DRAIN drain plug draining... 41, 45 E EC declaration of conformity... 5, 63 Electrical data Error Error message F Filter... 12, 22, 23, 59 Filter element Filter housing... 22, 23 filtration...17, 19, 20, 26, 28, 45, 47, 53, 55 Filtration Flow rate... 18, 26 G Gear pump...60, 62 H Hazard symbol... 3, 8 Hydraulic data Hydraulic diagram... 3, 23 I Imprint... 2, 3 IN 4, 18, 27 Inlet...22, 23 INLET...48, 53 Inspection...22, 33 installation Internal pipe diameter IP 60 ISO...11, 60 M Main switch...22, 23, 33, 38 Maintenance...1, 4, 19, 42 Maintenance interval... 4, 42 Maintenance intervals... 4, 42 Measurement Measurement technology Measures Model code Motor protection switch Motor pump assembly...22, 23 mounting O Off switch offline filtration...11, 20 operating...4, 6, 7, 8, 11, 12, 13, 14, 18, 33, 38, 39, 40, 41, 45, 46, 51, 62 Operation...12, 19 OUT...4, 18, 27 Outlet...22, 23 OUTLET...48, 53 P Power consumption...18, 60 Pressure differential Proper/Designated Use... 3, 11 LVU-CD-40 en(us) Page 64 / 68

65 Index Protection class Publisher... 2 Pump... 60, 62 R Remedy... 34, 54 repairs replacement... 20, 53 S select... 7, 41 setting... 4, 33, 41 Signal word... 3, 10 signal words Spare parts... 4, 59 Spare parts list... 4, 59 Specialist personnel Supply voltage...39, 62 switching off switching on...20, 31 T Time Transport...13, 55 transporting troubleshooting W Weight...18, 61 LVU-CD-40 en(us) Page 65 / 68

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68 HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach Sulzbach/Saar Sulzbach/Saar Germany Germany Phone: +49 (0) Central Fax: +49 (0) (Technical Department) Fax: +49 (0) (Sales Department) Internet: