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Summary of Contents for Hydac LVU-CD-40
- Page 1 LVU-CD-40 LowViscosity Unit CoalescerDiesel Operating and Maintenance Instructions English (translation of original instructions) Document No.: 4035823a Keep for future reference.
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Page 2: Imprint
Court of Registration: Saarbrücken, HRB 17216 Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: guenter.harge@hydac.com © HYDAC FILTER SYSTEMS GMBH All rights reserved. -
Page 3: Table Of Contents
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 Page 3 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 4 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 Page 4 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 5 Content Technical data .....................60 Decoding model code.................62 EC declaration of conformity ..............63 Index ......................64 LVU-CD-40 Page 5 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 6: Preface
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. -
Page 7: Using The Documentation
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 Page 7 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 8: General Safety Information
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 Page 8 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 9 General safety information Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment LVU-CD-40 Page 9 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 10: Signal Words And Their Meaning In The Safety Information And Instructions
Warning instructions listed before an activity are laid out as follows: SIGNAL WORD Type and source of danger HAZARD SYMBOL Consequence of the danger Measures to avert danger ► LVU-CD-40 Page 10 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 11: Proper/Designated Use
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 Page 11 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 12: Improper Use Or Use Deviating From Intended Use
► 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. -
Page 13: Qualifications Of Personnel / Target Group
Safe handling/use of tools personnel maintenance, Product-specific knowledge decommissioning, disassembly Disposal Specialist Proper and environmentally personnel friendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse LVU-CD-40 Page 13 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 14: Wear Suitable Clothing
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 Page 14 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 15: Transporting The Unit
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 Page 15 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 16: Storing The Unit
Unrestricted, but in any case before the unit is started up again: after a storage period of greater than 2 years, all seals must be replaced. Storage position Only standing. LVU-CD-40 Page 16 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 17: Decoding The Type Label
Name plate of filtration unit -> Name plate of electric motor -> Model code; for details, see page 62 The following information can be found on the type label of the unit: LVU-CD-40 Page 17 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 18 -> 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 Page 18 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 19: 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 LowViscosity Unit LVU-CD-40, version in accordance with your order, check the name plate on page 17. Operation and Maintenance Instructions (this document) LVU-CD-40... -
Page 20: Unit Function
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 Page 20 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 21: Unit With Control Type - Eco
Identifying components Unit with control type - Eco The Eco version of the unit features the following components: LVU-CD-40 Page 21 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 22 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 Page 22 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 23: Hydraulic Diagram
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 Page 23 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 24: Unit Dimensions
The unit has the following dimensions, using the Eco version as an example: Required dismantling space for changing the coalescing elements Recommended working range All dimensions in mm. LVU-CD-40 Page 24 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 25: Unit Setup/Connection
3. Check and insert the filter element. For details, see page 45. 4. Check and insert the coalescing element. For details, see page 48. 5. The unit is ready for the next steps on the following pages. LVU-CD-40 Page 25 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 26: Notes On Pipes/Hosing
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 Page 26 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 27: Connecting The Suction Port (In)
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 Page 27 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 28: Connecting The Water 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 Page 28 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 29: Connecting Remote Control Line (Control Type Standard / Premium Only)
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 Page 29 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 30 9 - 10 Input Reserve A voltage of 24V is to be applied here (opto- coupler input) to start a function. No function set yet. LVU-CD-40 Page 30 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 31: Relationships: Remote Control/Interval Control (With Premium Control Type Only)
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 Page 31 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 32: Finding/Selecting The Control Type
You will find a detailed description of each of the controls on the following pages. Control type See page for details E = Eco 3333 S = Standard 3838 P = Premium 3838 LVU-CD-40 Page 32 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 33: Using / Setting / Operating The "Eco" Control Type
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 Page 33 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 34: Switching Unit On/Off
The visual clogging indicator display then switches from green to red. Item Designation Remedy for red display Clogging indicator, visual, for Replace the filter element in the LVU-CD-40 Page 34 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 35 Replace the coalescing element the coalescing housing 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 Page 35 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 36: Observing / Checking Phase Limits
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 Page 36 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 37: Draining Off The Free Water
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 Page 37 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 38: Operating / Setting "Standard / Premium" Control Type
See page 39 for details Motor protection switch See page 41 for details Interval control See page 40 for details (with "Premium" control type only) Status LEDs See page 39 for details LVU-CD-40 Page 38 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 39: Switching The Main Switch On / Off
The motor protection switch has tripped. The fluid is dry. Error message from water outlet. The maximum differential pressure in the coalescing housing or filter housing has been reached. LVU-CD-40 Page 39 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 40: Setting Interval Control (With Premium Control Type Only)
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 Page 40 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 41: Adjusting The Time Selector Switch
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 Page 41 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 42: Performing Maintenance
Replacing the filter element in the filter housing Changing the coalescing elements Perform visual check Check the unit for leaks, brittle hoses and cables daily. Replace damaged or brittle parts immediately. LVU-CD-40 Page 42 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 43: Checking The Pump For Leaks
Check the pump for leakage through the inspection opening at least every three months. LVU-CD-40 Page 43 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 44 -> If the pump is wet / moist due -> proceed to Step 4. to oil or diesel Shut down the unit and contact HYDAC. Screw the cover tightly with the four screws. The test has been successfully completed. LVU-CD-40...
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Page 45: Replacing The Filter Element In The Filter Housing
Loosen the tensioning clamp on the filter housing cover by completely unscrewing the nut. Remove the housing clamp. LVU-CD-40 Page 45 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 46 Replace it if necessary. Moisten the O-rings on the filter bowl cover and on the new filter element with operating fluid. Never use grease or other media. LVU-CD-40 Page 46 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 47 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 Page 47 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 48: Changing The Coalescing Elements
Once the coalescing housing is completely emptied, close the "DRAIN" connection (3350). Loosen the upper tensioning clamp on the coalescing housing with a 13 mm Allen wrench by turning it counterclockwise. LVU-CD-40 Page 48 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 49 Remove the element set from the coalescing housing. Use both handles to accomplish this. Rotate the element set on the head by 180°. LVU-CD-40 Page 49 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 50 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 Page 50 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 51 Do not use a hammer, etc. 13. Mount the element holding plate and tighten the 3 wing nuts firmly. LVU-CD-40 Page 51 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 52 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 Page 52 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 53 OUTLET (2560). 19. Bleed the filtration unit. 20. Bleed the coalescing housing through the air-vent plug (2310) at the cover. 21. The replacement of the coalescing element is completed. LVU-CD-40 Page 53 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 54: Status Led / Causes And Remedies
LED lights up LED flashing LED flashing Interval control is Check the interval settings. active. Only with control type: Electric motor / "Premium". pump is not running LVU-CD-40 Page 54 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 55 Transport seals are the yellow plastic plugs. The pressure loss Ensure that the pressure at the in the suction line is inlet is within the permitted too great. range. LVU-CD-40 Page 55 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 56 Heat the fluid to achieve the permissible viscosity. The suction line at Ensure that the pressure at the the inlet is inlet is within the permitted generating too range. much loss of pressure. LVU-CD-40 Page 56 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 57 For this reason, the control reports that the fluid is dewatered. The water drainage Contact HYDAC. valve has a malfunction. The water drainage valve jams. LVU-CD-40 Page 57 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 58: Customer Service
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 Page 58 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 59: Spare Parts List
3917983 10" Filter element, 10 µm N10ON-DF010-FA41F 3918332 20" Filter element, 3 µm N20ON-DF003-FA41F 3918333 20" Filter element, 5 µm N20ON-DF005-FA41F 3918334 20" Filter element, 10 µm N20ON-DF010-FA41F *) available on request LVU-CD-40 Page 59 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 60: Technical Data
Protection class IP 55 Connector cable, length - Control type eco 10 m with safety plug - with control type: Standard or 0.5 m with safety plug Premium LVU-CD-40 Page 60 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 61 Weight when empty - Control type eco ≈ 80 kg - with control type: Standard or ≈ 90 kg Premium LVU-CD-40 Page 61 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
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Page 62: Decoding Model Code
Measurement technology = None Clogging indicator = Differential pressure gauge, visual = Differential pressure indicator, visual/electrical Type code = (You always receive the latest type) Additional = None LVU-CD-40 Page 62 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... -
Page 63: Ec Declaration Of Conformity
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... -
Page 64: Index
....17, 19, 20, 26, 28, 45, 47, 53, 55 Power consumption .........18, 60 Filtration..............63 Pressure differential..........26 Flow rate............18, 26 Proper/Designated Use ........3, 11 LVU-CD-40 Page 64 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08... - Page 65 ............15 troubleshooting ............. 13 select ..............7, 41 setting............4, 33, 41 Signal word............3, 10 signal words............10 Weight .............18, 61 Spare parts ............4, 59 LVU-CD-40 Page 65 / 68 en(us) BeWa LVU-CD-40 4035823a en-us 2016-01-08.doc 2016-01-08...
- Page 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 E-mail: filtersystems@hydac.com...
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