LVU-CD-10 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
Imprint Imprint Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Telephone: +49 (0) 6897 509 01 Fax: +49 (0) 6897 509 9046 E-mail: filtersystems@hydac.com 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 (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 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-10 en(us) Page 2 / 68
Contents Contents Imprint...2 Documentation Representative...2 Contents...3 Preface...6 Technical Support...6 Modifications to the Product...6 Warranty...6 Using the documentation...7 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 Carry by hand...15 Transporting with the crane...16 Storing the unit...17 Decoding the model code label...18 Checking the Scope of Delivery...20 Operating elements / identifying the version...21 "Standard" version...22 "Premium" version...24 Working principle of the unit...26 Filter element working principle...27 LVU-CD-10 en(us) Page 3 / 68
Contents Hydraulic diagram...28 Unit dimensions...29 Unit setup/connection...31 Notes on pipes / hosing...32 Connecting the suction port (IN)...33 Connecting the pressure port (OUT)...33 Checking the water connection / water reservoir...34 Electrical connection...34 Connecting the remote control line...35 Preparing a visual clogging indicator - only for initial commissioning...36 Using / setting / operating the "Standard" control type...37 Switching the main switch 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 Maintenance...44 Maintenance intervals...44 Perform visual check...45 Checking / emptying water supply tank...46 Checking the pump for leaks...47 Changing the filter element...49 Errors and troubleshooting...54 Customer Service...57 Taking the unit out of operation...58 Shutting down the unit...58 Disposing of the unit...58 Spare parts...59 LVU-CD-10 en(us) Page 4 / 68
Contents Overview of spare parts...59 Spare parts list...60 Technical details...61 Model Code...63 EC declaration of conformity...64 Index...65 LVU-CD-10 en(us) Page 5 / 68
Preface Preface These operating instructions were 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 these operating instructions. In particular, we shall not be liable for lost profit or other financial loss. This exclusion of liability does not apply in cases of intent and gross negligence. Moreover, it does not apply to defects which have been deceitfully concealed or whose absence has been guaranteed, nor 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 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 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. When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative. 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'll find this under www.hydac.com -> General terms and conditions. LVU-CD-10 en(us) Page 6 / 68
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 you want to know? 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. Chapter description Produkt / Kapitel Page number HYDAC Filtertechnik GmbH BeWa 123456a 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-10 en(us) Page 7 / 68
Safety Information 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-10 en(us) Page 8 / 68
Safety Information Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment LVU-CD-10 en(us) Page 9 / 68
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 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 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-10 en(us) Page 10 / 68
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 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 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. LVU-CD-10 en(us) Page 11 / 68
Safety Information Proper or designated use of the product extends to the following: observing all instructions contained in these operating instructions. adhering to maintenance work. The unit is only suitable for suction operation mode Operation is only permitted at an earthed power supply. Not to be operated in the open air 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 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 damage the unit. Examples of improper use: Operation with a non-approved medium. Operation in potentially explosive atmospheres. Operation under non-approved operational 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-10 en(us) Page 12 / 68
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 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 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 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 environmentallyfriendly disposal of materials and substances Decontamination of contaminants Knowledge with regard to recycling LVU-CD-10 en(us) Page 13 / 68
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-10 en(us) Page 14 / 68
Transporting the unit Transporting the unit 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. LVU-CD-10 en(us) Page 15 / 68
Transporting the unit Transporting with the crane For transport with a crane, fasten the correct band loops on the frame. LVU-CD-10 en(us) Page 16 / 68
Storing the unit Storing the unit Before storing, empty the unit completely, including the filter 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 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-10 en(us) Page 17 / 68
Decoding the model code label 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 LVU-CD-10 en(us) Page 18 / 68
Decoding the model code label The following information can be found on the name plate of the 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 LVU-CD-10 en(us) Page 19 / 68
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-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" LVU-CD-10 en(us) Page 20 / 68
Operating elements / identifying the version 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 LVU-CD-10 en(us) Page 21 / 68
"Standard" version "Standard" version The "Standard" version of the unit features the following components: LVU-CD-10 en(us) Page 22 / 68
"Standard" version 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 LVU-CD-10 en(us) Page 23 / 68
"Premium" version "Premium" version The "Premium" version of the unit features the following components: LVU-CD-10 en(us) Page 24 / 68
"Premium" version 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 LVU-CD-10 en(us) Page 25 / 68
Working principle of the unit Working principle of the unit The following contains a description of how the unit functions, using the example of the Standard version unit. 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, spare 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. LVU-CD-10 en(us) Page 26 / 68
Working principle of the unit The applications are, for example: Portable and stationary emergency generators e.g. in hospitals, shopping centers, power plants. Tanks on portable machines, e.g. 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 layer on the screen tubing increases the size of the water drops which have formed. LVU-CD-10 en(us) Page 27 / 68
Hydraulic diagram 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 LVU-CD-10 en(us) Page 28 / 68
Unit dimensions Unit dimensions The unit has the following dimensions, using the "Standard / Premium" version as an example: All dimensions in mm. LVU-CD-10 en(us) Page 29 / 68
Unit dimensions Item Designation 1 Inlet (IN) 6 Outlet (OUT) 9 Element removal height 10 Working area for operating and service staff LVU-CD-10 en(us) Page 30 / 68
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. See page 49 for details. 4. The unit is ready for the next steps on the following pages. LVU-CD-10 en(us) Page 31 / 68
Unit setup/connection Notes on pipes / hosing Make sure that no vibrations or stress/loading from other machinery and equipment are carried over to filter housing. If necessary, use expansion joints. The pressure loss in a hydraulic line depends upon: Flow rate Kinematic viscosity Pipe dimensions Fluid density 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. 0.84 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. Make sure that no vibrations or stresses are carried over to filtration unit when connecting the piping. Use hoses or expansion joints if necessary. LVU-CD-10 en(us) Page 32 / 68
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. NOTE Overpressure at the suction port connection The unit will be damaged The pressure on the suction port connection IN must not be more than -0.4 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 element is > 1 bar, use a differential pressure clogging indicator. NOTE Excess pressure at the pressure port connection The unit will be damaged The pressure on the suction port connection OUT must not be more than a maximum of 3 bar. LVU-CD-10 en(us) Page 33 / 68
Unit setup/connection Checking the water connection / water reservoir Check the water reservoir for damage. Empty the water reservoir completely and place the hose from the water outlet into the water reservoir. NOTE Excess pressure at the water outlet The filteration 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-10 en(us) Page 34 / 68
Unit setup/connection Connecting the remote control line The unit has a connection for a remote control line. You can use this to start or 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. 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 start the unit from stand-by or to stop the unit during operation. LVU-CD-10 en(us) Page 35 / 68
Unit setup/connection Preparing a visual clogging indicator - only for initial 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. LVU-CD-10 en(us) Page 36 / 68
Using / setting / operating the "Standard" control type Using / setting / operating the "Standard" control type 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. LVU-CD-10 en(us) Page 37 / 68
Using / setting / operating the "Standard" control type Reading status LEDs The status LEDs and 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 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. If the motor protection switch triggers, proceed as indicated in the chapter "Errors and troubleshooting" on page 54. LVU-CD-10 en(us) Page 38 / 68
Using / setting / operating the "Premium" control type Using / setting / operating the "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 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 deenergized. LVU-CD-10 en(us) Page 39 / 68
Using / setting / operating the "Premium" control type Reading status LEDs The status LEDs and 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 the coalescing and separation unit The maximum differential pressure on the coalescing and separation element has been reached. 54 49 LVU-CD-10 en(us) Page 40 / 68
Using / setting / operating the "Premium" control type Adjusting the interval control 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-10 en(us) Page 41 / 68
Using / setting / operating the "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 Errors and troubleshooting on page 54. LVU-CD-10 en(us) Page 42 / 68
Starting up the unit Starting up the unit Switch the unit on at the main 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. LVU-CD-10 en(us) Page 43 / 68
Performing Maintenance Performing Maintenance 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 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 LVU-CD-10 en(us) Page 44 / 68
Performing Maintenance Perform visual check Check the unit for leaks, brittle hoses and cables daily. Replace damaged or brittle parts immediately. LVU-CD-10 en(us) Page 45 / 68
Performing Maintenance 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. LVU-CD-10 en(us) Page 46 / 68
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-10 en(us) Page 47 / 68
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 (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 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-10 en(us) Page 48 / 68
Performing Maintenance Changing the filter element Proceed as follows to replace the filter element: LVU-CD-10 en(us) Page 49 / 68
Performing Maintenance 1. Vent the filter and coalescing casing by opening the breather screw (2.2) in an anti-clockwise direction. 2. Start the unit using the control for ~ 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. LVU-CD-10 en(us) Page 50 / 68
Performing Maintenance 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. LVU-CD-10 en(us) Page 51 / 68
Performing Maintenance 8. Mount the O-ring (2.3) from the scope of delivery of the new filter element onto the cover (2.1). Clip the new filter element (2.4) onto the cover (2.1). 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. LVU-CD-10 en(us) Page 52 / 68
Performing Maintenance 11. Tighten the breather screw (2.2) in a clockwise direction. 12. The filter element change is now complete. LVU-CD-10 en(us) Page 53 / 68
Errors and troubleshooting Errors and troubleshooting 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. Error 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-10 en(us) Page 54 / 68
Errors and troubleshooting Error 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 have not been 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-10 en(us) Page 55 / 68
Errors and troubleshooting Error Cause(s) Remedy Filter contaminated (The clogging indicator appears) Collecting pan too full. The suction hose is not suitable for negative pressure. The fluid is heavily contaminated. The contamination retention capacity of the filter element has been reached. The viscosity of the fluid is too high. The suction line at the inlet is generating too much loss of pressure. Leakage on the unit / filter housing Wrong, missing, or defective sealing ring. Use a hose that is resistant to negative pressure. Replace the filter element. 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. Empty the collecting pan and eliminate the leak on the unit. Check the sealing ring on the filter element. Replace it if necessary. The cover on the filter and coalescing casing is not tight enough. Tighten the cover on the filter and coalescing casing by hand. The water drainage valve has a malfunction. The water drainage valve jams. The fluid is dewatered. Contact HYDAC. No remedy required. blinks Error message from filter and coalescing casing. Contact HYDAC. LVU-CD-10 en(us) Page 56 / 68
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 13 66540 Neunkirchen-Heinitz Germany Telephone: +49 (0) 6897 509 883 Fax: +49 (0) 6897 509 324 E-mail: service@hydac.com LVU-CD-10 en(us) Page 57 / 68
Taking the unit out of operation Taking the unit out of operation Drain the unit completely, including all 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. LVU-CD-10 en(us) Page 58 / 68
Spare parts Spare parts The following spare parts may be ordered for the unit. Overview of spare parts LVU-CD-10 en(us) Page 59 / 68
Spare parts Spare parts list Item Qty. Part no. Designation 1 1 1304306 Cover 2 1 1304308 Vent screw 3 1 1304307 Inspections glass 4 1 1304313 Seal kit for filter and coalescing casing 5 1 1303275 Clogging indicator, visual 5 1 1270904 Contamination switch, electrical 7 1 3883021 Water collection canister 5 liter 8 1 6094990 Hose 9 1 6092841 Collecting pan float switch 10 1 * Motor/pump assembly Standard control type Premium control type 11 1 3871268 Filter element, 5 µm N7ON-DC005-CA61H 11 1 3871269 Filter element, 10 µm N7ON-DC010-CA61H 11 1 3871271 Filter element, 30 µm N7ON-DC030-CA61H *) available on request LVU-CD-10 en(us) Page 60 / 68
Technical details Technical details Dewatering performance Water separation efficiency > 95% acc. to ISO CD 16332 Achievable water content Dewatering rate <200 ppm 12 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 Maximum 10% free water 10 l/min Gear pump Maximum 3 bar - 0.4 0.2 bar 3 bar 0 bar M26x1.5 (18L) external thread Hose Ø 10mm Water collecting tank volume 5 liter Permitted fluid temperature range 5 50 C or at least 10 C below the flash point of the fluid used/deployed. Electrical data Power supply Power consumption See motor type plate 370 W Protection class IP 54 Connector cable, length 0.5 m with safety plug LVU-CD-10 en(us) Page 61 / 68
Technical details General data Dimensions Material / substance Frame Filter and coalescing housing Seals Permitted ambient temperature range Empty weight 300 x 550 x 816 mm Lacquered steel Aluminum HNBR / FKM 5 50 C or at least 10 C below the flash point of the fluid used/deployed. 38 kg LVU-CD-10 en(us) Page 62 / 68
Model Code Model Code LVU - C D-10 - G M- 2 S E - 1 / - Type LVU = LowViscosity Unit Function C = Filtering and coalescing Operating fluid D = Diesel Nominal flow rate 10 = 10 l/min Pump version G = Gear pump Supply voltage L = 115 V AC, 60 Hz, 1 Ph E = 220 V AC, 50 Hz, 1 Ph M = 230 V AC, 50 Hz, 1 Ph F = 240 V AC, 50 Hz, 1 Ph X = others on request Water drain 1 = Manual 2 = Automatic Control type E = Eco - with On/Off switch including motor protection - visual clogging indicator S = Standard - with On/Off switch including motor protection - visual clogging indicator P = Premium - with on/off switch inc. motor protection - programmable operating times - electrical clogging indicator / automatic shut-down if filter element contaminated Clogging indicator E = Clogging indicator, visual C = Differential pressure switch, electrical (only in connection with Premium control type) Type code 1 = (You always receive the latest type) Additional - = without LVU-CD-10 en(us) Page 63 / 68
EC declaration of conformity EC declaration of conformity HYDAC FILTER SYSTEMS GMBH Postfach 12 51 66273 Sulzbach / Saar Germany Industriegebiet 66280 Sulzbach / Saar Germany Telefon: ++49 (0) 6897 509 01 Internet: www.hydac.com 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 1 a) 2015-03-24 Dr. Andreas Schunk Date Name (CE official) Executive director: Documentation Representative: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Günter Harge Registered seat of company: 66280 Sulzbach / Saar - Germany c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Registry Court: Saarbrücken, HRB 17216 Telephone: +49 (0) 6897 509 1511 Value added tax identification number: DE 815001609 Fax: +49 (0) 6897 509 1394 Tax number : 040/110/50773 E-mail: Huenter.harge@hydac.com LVU-CD-10 en(us) Page 64 / 68
Index Index A ambient temperature... 19, 62 Auxiliary personnel... 13 C care... 2, 6 Cause... 54 CE official... 64 Changing the filter element... 44, 49 Clogging indicator...23, 25, 28, 36, 60, 63 collecting pan... 38, 40, 56 connecting... 31, 32, 33 Connection... 61 Control... 21, 23, 25, 63 D Date... 64 Density... 32 Description... 18, 19, 41 dewatering... 11 Dewatering... 61 Dewatering performance... 61 Dewatering rate... 61 Differential pressure... 63 Dimensions... 62 Disposal... 13 Documentation Representative... 2, 64 DRAIN... 28 E EC declaration of conformity... 64 Electrical data... 61 Empty weight... 19, 62 emptying... 44, 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 Maintenance interval... 44 Maintenance intervals... 44 Measures... 10 Model code... 18 Motor protection switch...37, 39 Motor pump assembly...23, 25, 28 O Off switch... 63 offline filtration...11, 26 operating..6, 7, 8, 11, 12, 13, 14, 30, 37, 38, 39, 40, 41, 42, 43, 63 Operating elements... 21 Operation...12, 20, 21 Operations control... 13 OUT...28, 30, 33 Outlet...28, 30 OUTLET...23, 25 Overview... 59 P Power consumption...19, 61 Pressure differential... 32 Proper/Designated Use... 11 Protection class... 61 LVU-CD-10 en(us) Page 65 / 68
Index Publisher... 2 Pump... 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 LVU-CD-10 en(us) Page 66 / 68
HYDAC FILTER SYSTEMS GMBH Industriegebiet 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