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Summary of Contents for Hydac LVU-CD-40
- Page 1 LVU-CD-40 /-T001 LowViscosity Unit CoalescerDiesel Installation and Maintenance Instructions English (translation of original instructions) Document No.: 4142242a 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
Checking the scope of delivery ..............18 Unit function ....................19 Unit components..................20 Hydraulic diagram ..................22 Unit dimensions ..................23 Unit setup/connection ................24 Notes on pipes/hosing ................25 LVU-CD-40 /-T001 en(us) Page 3 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 4 Shutting down the unit ................44 Disposing of the unit .................. 44 Spare parts list .................... 45 Technical data ..................... 46 Decoding model code ................. 48 Index ......................49 LVU-CD-40 /-T001 en(us) Page 4 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 5: 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 6: 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 /-T001 en(us) Page 6 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 7: Safety Precautions
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 /-T001 en(us) Page 7 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 8 Safety precautions Risk of burns due to hot surfaces Flammable Danger from explosive atmosphere Harmful to the environment LVU-CD-40 /-T001 en(us) Page 8 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 9: 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 /-T001 en(us) Page 9 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 10: Proper/Designated Use
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-40 /-T001 en(us) Page 10 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 11: Improper Use Or Use Deviating From Intended Use
► 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. -
Page 12: 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 /-T001 en(us) Page 12 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 13: Wear Suitable Clothing
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 /-T001 en(us) Page 13 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 14: 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 /-T001 en(us) Page 14 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 15: 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 /-T001 en(us) Page 15 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 16: Decoding The Name Plate
Item -> Description -> Name plate of filtration unit -> Name plate of electric motor -> Model code; for details, see page 48 LVU-CD-40 /-T001 en(us) Page 16 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 17 -> 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 /-T001 en(us) Page 17 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 18: 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. Description LowViscosity Unit LVU-CD-40, version in accordance with your order, check the name plate on page 16. - Installation and Maintenance Instructions (this document). LVU-CD-40 /-T001... -
Page 19: Unit Function
• Tanks of portable machines, e.g. harvesting and construction machinery • Storage tanks e.g. for agriculture and mining • Tanks on yachts and leisure craft LVU-CD-40 /-T001 en(us) Page 19 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 20: Unit Components
Unit function Unit components The unit has the following components: LVU-CD-40 /-T001 en(us) Page 20 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 21 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 /-T001 en(us) Page 21 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 22: Hydraulic Diagram
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 /-T001 en(us) Page 22 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 23: Unit Dimensions
Unit dimensions Unit dimensions The unit has the following dimensions. Required dismantling space for changing the coalescing elements Recommended working range All dimensions in mm. LVU-CD-40 /-T001 en(us) Page 23 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 24: Unit Setup/Connection
3. Check and insert the filter element. For details, see page 35. 4. Check and insert the coalescing element. For details, see page 38. 5. The unit is ready for the next steps on the following pages. LVU-CD-40 /-T001 en(us) Page 24 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 25: Notes On Pipes/Hosing
. 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 /-T001 en(us) Page 25 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 26: 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 /-T001 en(us) Page 26 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 27: Connecting The Water Outlet
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. LVU-CD-40 /-T001 en(us) Page 27 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 28: Connecting The Main Switch / E-Stop
If the sensor is activated in the collecting pan, then the unit must be switched off. Check the unit for leaks or incorrect triggering and/or water sensor or water drain valve malfunctions. Eliminate the leakages immediately and replace any defective components. LVU-CD-40 /-T001 en(us) Page 28 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 29: Connecting Clogging Indicators
Change the filter element / the coalescing elements. Connecting the water drainage valve Connect the water drainage valve according to the manufacturer's instructions. The model code of the water drainage valve is 8253200.8001.02400 LVU-CD-40 /-T001 en(us) Page 29 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 30: Operating The Filter Unit
Clogging indicator, electrical, for the coalescing housing 2110 Sight glass, upper phase boundary 2111 Water sensor 3210 Water drainage valve 4010 Inspection opening 7000 Main switch with motor protection LVU-CD-40 /-T001 en(us) Page 30 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 31: Switching Unit On/Off
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. LVU-CD-40 /-T001 en(us) Page 31 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 32: 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 /-T001 en(us) Page 32 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 33: Checking The Pump For Leaks
Check the pump for leakage through the inspection opening at least every three months. LVU-CD-40 /-T001 en(us) Page 33 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 34 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 /-T001...
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Page 35: 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 /-T001 en(us) Page 35 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 36 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 /-T001 en(us) Page 36 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 37 Switch the filtration unit on. Bleed the filter housing through the air bleed plug (Air Bleed) in the filter cover. LVU-CD-40 /-T001 en(us) Page 37 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 38: 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 /-T001 en(us) Page 38 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 39 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 /-T001 en(us) Page 39 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 40 10. Pull the coalescing elements out of the element receptacles and dispose of them in an environmentally friendly manner. 11. Moisten the O-ring on the element lightly with the operating fluid. LVU-CD-40 /-T001 en(us) Page 40 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 41 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 LVU-CD-40 /-T001 en(us) Page 41 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 42 20 Nm. Screw open the lock nut and secure the connection. 18. Open the ball valves INLET (1330) and OUTLET (2560). LVU-CD-40 /-T001 en(us) Page 42 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 43 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 /-T001 en(us) Page 43 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 44: 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 /-T001 en(us) Page 44 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 45: 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 /-T001 en(us) Page 45 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 46: Technical Data
Electrical data Power supply See motor type plate Power consumption 750 W IP class IP 55 Connector cable, length 10 m with safety plug LVU-CD-40 /-T001 en(us) Page 46 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 47 NBR / FKM Permissible ambient temperature 0 to 50°C and at least 10°C below range the flash point of the fluid used Weight when empty ≈ 77 kg LVU-CD-40 /-T001 en(us) Page 47 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
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Page 48: Decoding Model Code
Measurement technology = without Clogging indicator = Differential pressure gauge, visual = Differential pressure indicator, visual/electrical Type code = (You always receive the latest type) Additional = without LVU-CD-40 /-T001 en(us) Page 48 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... -
Page 49: Index
Flow rate ............17, 25 Power consumption ........17, 46 Pressure differential ..........25 Proper/Designated Use ........10 Publisher ..............2 Pump .............. 46, 48 Gear pump ............. 46, 48 LVU-CD-40 /-T001 en(us) Page 49 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13... - Page 50 Service ..............44 Signal word ............. 9 signal words ............9 Spare part ............. 45 Spare parts ............45 Weight ............17, 47 Spare parts list ............. 45 LVU-CD-40 /-T001 en(us) Page 50 / 52 BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc 2016-05-13...
- Page 52 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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