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Summary of Contents for Hydac VMU Series
- Page 1 VarnishMitigation Unit VMU 1 ATEX II 2G IIC (T4) Operating and Maintenance Instructions English (translation of original instructions) Document no.: 10000649233...
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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 Phone: +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
Contents Contents Imprint ......................2 Documentation Representative ..............2 Contents ......................3 Preface ......................5 Technical Support..................5 Modifications to the Product ................ 5 Warranty ...................... 5 Using the documentation ................6 Safety information ..................7 Hazard symbols ................... 7 Signal words and their meaning in the safety information and instructions .................... - Page 4 Contents Connecting up unit ..................30 Notes on pipes and hoses ................. 31 Connecting the inlet port (IN) ..............32 Connecting outlet (OUT) port ..............33 Electrical connection of the unit ..............34 Preparing the unit for operation ..............35 Switching unit on/off ..................
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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
Preface Using the documentation Note that the method described for locating specific information does not release you from your responsibility of carefully reading all 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. -
Page 7: Safety Information
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. - Page 8 Safety information Risk of burns due to hot surfaces Substances that are health hazards or irritants Danger from explosive atmosphere Danger of explosion in explosive atmospheres This symbol marks safety indications that refer particularly to explosion protection. VMU 1 ATEX II 2G IIC T4 en(us) Page 8 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc...
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Page 9: Signal Words And Their Meaning In The Safety Information And Instructions
Safety information Signal words and their meaning in the safety information and instructions In these instructions you will find the following signal words: DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result lethal or serious injury. WARNING WARNING –... -
Page 10: Structure Of The Safety Information And Instructions
Safety information 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 Type and source of danger HAZARD SYMBOL... -
Page 11: Proper/Designated Use
HYDAC is not responsible. HYDAC is not responsible for the installation, integration, selection of interfaces to / into your system nor for the use or functionality of your system. - Page 12 Safety information DANGER Wrong ATEX area of utilization Danger of fatal injury The power unit may be used only in the ► indicated component group, equipment category, and zone. Potentially explosive atmospheres in which ► vapours or gas/air mixtures may occur only rarely and briefly.
- Page 13 Safety information Depending on the version (see model code), you may only use the power unit only for the following fluid: NOTICE Impermissible operating media The unit will be damaged Only use the VMU with mineral oil-based turbine oils. ► Do not use the VMU in combination with pure phosphate ester media.
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Page 14: Explosion Protection As Per Eu Directive
Safety information Explosion protection as per EU Directive The power unit satisfies the requirements of the EU Directive, applicable to areas in which potentially explosive gas mixtures are likely to occur. The designation of the explosion-proof ATEX-compliant unit is: This label in particular means that utilization is permitted only for: Equipment group Potentially explosive atmospheres in which vapours or gas/air mixtures are likely to... -
Page 15: Improper Use Or Use Deviating From Intended Use
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. This risk is borne solely by the owner. Improper use may result in hazards and/or will damage the unit. Examples of improper use: •... -
Page 16: Qualifications Of Personnel / Target Group
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. - Page 17 Safety information Activity Person Knowledge Transport / storage Forwarding • Proof of knowledge of cargo agent securing instructions Specialist • Safe handling/operation of personnel hoisting and lifting equipment Hydraulic / electrical Specialist • Safe handling/use of tools installation, personnel • Fitting and connection of first commissioning, hydraulic lines and connections...
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Page 18: Wear Suitable Clothing
Safety information Wear suitable clothing CAUTION Loose-fitting clothing Danger of getting caught Wear close-fitting clothing ► Do not wear any rings, chains or any other ► jewelry Wear work safety shoes ► Stoppage in an emergency (EMERGENCY STOP) In the event of an emergency, turn the main switch by 90°... -
Page 19: Transporting The Unit
Transporting the unit Transporting the unit Evacuate the power unit completely before transporting it and close the inlets and outlets. Coil up the suction and pressure hose and the connection cable and fasten them in place. NOTICE Using components for pushing/pulling The unit will be damaged. -
Page 20: Transport With A Crane
Transporting the unit Transport with a crane NOTICE Unsuitable lifting accessories The unit will be damaged / components will be damaged or destroyed Use only suitable lifting accessories to raise or lash the unit. ► Take care to ensure that the lifting accessories do not cause any ►... -
Page 21: Decoding The Name Plate
Decoding the name plate Decoding the name plate Identification details for the VMU can be found on the name plates on the unit and the components. VMU 1 ATEX II 2G IIC T4 en(us) Page 21 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc 2017-03-07... - Page 22 Decoding the name plate Item -> Description -> Name plate of filtration unit -> Name plate of electric motor -> Model code; for details, see page 60 -> ATEX classification of the power unit Power -> Power consumption, electrical Voltage / Grid ->...
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Page 23: Checking The Scope Of Delivery
Checking the scope of delivery Checking the scope of delivery Upon receiving the VMU check it for any damage. The VMU may not be set up and installed unless it is in perfect order. Any damage in transit is to be reported to the forwarding agent or the department in charge immediately;... -
Page 24: Characteristics Of The Unit
These can be filterable gels or solid paint-type deposits. The VMU series of units are used in the bypass flow. The removal of varnish is based on adsorption on an active surface. -
Page 25: Unit Components
Unit components Unit components The VMU mobile has the following components: Item Designation Motor pump assembly Pre-filter Varnish exchanger column Drain DRAIN Protective filter On/Off switch with motor protection Filling level limit switch Ground cable Chassis Inlet Outlet Pressure gauge varnish exchanger column Venting varnish exchanger column BLEED Prefilter/Safety filter air vent... -
Page 26: Unit Dimensions
Unit dimensions Unit dimensions (All dimensions in mm) VMU 1 ATEX II 2G IIC T4 en(us) Page 26 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc 2017-03-07... -
Page 27: Hydraulic Circuit
Hydraulic circuit Hydraulic circuit 8 bar / 116 psi 3 bar / 44 psi Austritt Eintritt Outlet Inlet Reservoir Reservoir Item Designation Motor pump assembly Pre-filter Varnish exchanger column Drain DRAIN Protective filter On / Off switch with motor protection Filling level limit switch Inlet Outlet... -
Page 28: Installing Power Unit
Installing power unit Installing power unit The VMUI is connected with bypass flow to an existing tank. The varnish exchanger elements VME flow through at a precisely determined flow rate. During this flow-through, the oil degradation products in the fluid are removed. -
Page 29: Setting Up The Unit
Setting up the unit Setting up the unit Observe the following points when setting up the unit: Set up the unit horizontally on a level surface. Special mounting is not required. Mobile power unit: activate the hand brake on the swivel casters or secure the power unit against rolling away. -
Page 30: Connecting Up Unit
Connecting up unit Connecting up unit Observe the following points for hydraulic connection: All hoses on the power unit must be sufficiently conductive in regard to electrostatic charge build-up. If hoses are used, the ohmic resistance between the fittings, in this case between the power unit and the tank, may not exceed a limit value depending on the respective hose type. -
Page 31: Notes On Pipes And Hoses
Connecting up unit Notes on pipes and hoses NOTICE Non-permitted pressure at the inlet IN / outlet OUT Risk of malfunctions Determine the pressure to be anticipated at the inlet/outlet with the ► prescribed values. Make sure that the cross-section of the connected hoses/piping is at least as large as the cross-section of the inlet/outlet port sizes. -
Page 32: Connecting The Inlet Port (In)
Connecting up unit Make sure that no tension or vibrations are carried over to the pump or filter housing when the pipes are connected. Use hoses or expansion joints if necessary. Connecting the inlet port (IN) NOTICE Contamination too high The unit will be damaged Do not prime directly at the bottom of the tank ►... -
Page 33: Connecting Outlet (Out) Port
Connecting up unit Connecting outlet (OUT) port Take care to ensure that the maximum pressure of 1 bar is not exceeded at the outlet. NOTICE OUT connection closed off The unit will be destroyed Check to be sure that all of the locking fixtures at the outlet are in ►... -
Page 34: Electrical Connection Of The Unit
Connecting up unit Electrical connection of the unit DANGER Electric shock Danger of fatal injury due to electric shock Any work involving the electrical system may ► only be done by a properly trained, certified electrician. Check that the voltage and frequency information on the power unit type label coincides with the predominant voltage supply. -
Page 35: Preparing The Unit For Operation
Preparing the unit for operation Prior to start up, earth the unit using the ground bond. Prior to starting up the unit, connect the ground bond between the unit and the tank to be cleaned. Check the connection between the tank, unit and the ground potential for good conductivity. -
Page 36: Switching Unit On/Off
Switching unit on/off Switching unit on/off 1) Pre-fill the power unit using the pump or using the suction hose when the motor is off. Without prefilling, the anti-dry running protection will activate and it will not be possible to switch on the power unit. 2) Switch the VMU on or off at the on/off switch. -
Page 37: Venting Varnish Exchanger Column
Switching unit on/off Venting varnish exchanger column WARNING Hot fluid Risk of burns Make sure that hot fluid can exit when ► bleeding. Bleed the varnish exchanger column through the air bleed screw (1) in the cover. Do not unscrew the air bleed screw (1) completely. -
Page 38: Performing Maintenance
Performing maintenance Performing maintenance The safety and availability of the unit depend on performing cyclical maintenance. DANGER Spark formation during dismantling / maintenance Risk of explosion / Danger of fatal injury Carry out maintenance work outside or when ► there is no explosive air environment present. Use only spark-free tools for the installation ►... -
Page 39: Depressurizing
Performing maintenance Depressurizing Carry out the depressurization first via the air bleed screw (1). Then open the drain ball valve (2) and collect the escaping fluid with a suitable container. The visual back-pressure indicator shows the pressure in the housing. Do not open the housing until you have depressurized it and the pressure gauge shows no pressure. -
Page 40: Changing Vme Elements
Performing maintenance Changing VME elements DANGER Spark formation during dismantling / maintenance Risk of explosion / Danger of fatal injury Carry out maintenance work outside or when ► there is no explosive air environment present. Only use spark-free tools when performing ►... - Page 41 Performing maintenance Loosen the four screws on the cover in a counterclockwise direction. Fold the screws down and press them against the varnish exchange column. This pushes the cover of the varnish exchange column up. Take the cover off and remove the VME element.
- Page 42 Performing maintenance For easier installation, wet the O- ring on the VME element with the operating medium. Wear protective gloves when doing so. 10. Put the new VME element in the housing. Do not use a hammer, etc. 11. Check the O-ring on the cover for damage and replace it if necessary.
- Page 43 Performing maintenance 14. Close the drain valve. 15. Switch on the unit at the main switch. 16. Bleed the housing through the air bleed screw in the cover. Do not unscrew the air bleed screw completely. It has ventilation slots. Check the unit for any leaks.
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Page 44: Changing The Prefilter / Safety Filter Element
Performing maintenance Changing the prefilter / safety filter element DANGER Spark formation during dismantling / maintenance Risk of explosion / Danger of fatal injury Carry out maintenance work outside or when ► there is no explosive air environment present. Use only spark-free tools for the installation ►... - Page 45 Performing maintenance equipment, the draining fluid can flow down to the electric motor. Remove the tensioning clamp on the filter bowl cover by completely removing the nut. Remove the housing clamp. Pull off the filter bowl cover carefully in an upwards direction.
- Page 46 Performing maintenance 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.
- Page 47 Performing maintenance 12. Tighten the drain screw (Drain) on the connection part of the unit. Switch the unit on. 13. Bleed the filter bowl through the air bleed screw (X) in the cover. Bleed the varnish exchanger column through the air bleed screw (X). 14.
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Page 48: Replacing The Filling Level Limit Switch
Performing maintenance Replacing the filling level limit switch When replacing the filling level limit switch (190), observe the position of the sensors (A). Align the sensor (A) parallel to the direction of flow. VMU 1 ATEX II 2G IIC T4 en(us) Page 48 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc... -
Page 49: Cleaning The Suction Screen In The Lance
Performing maintenance Cleaning the suction screen in the lance NOTICE Operation without a suction strainer The unit will be destroyed Never operate the unit without a suction screen ► Clean the suction strainer regularly ► To protect the pump from coarse contamination or foreign bodies, a suction screen is installed in the suction lance. -
Page 50: Storing The Unit / Taking It Out Of Operation
Storing the unit / taking it out of operation Storing the unit / taking it out of operation Remove the VME elements as well as the pre-filter and contamination filter elements and drain the unit completely before putting it into storage. Pull power plug. -
Page 51: Spare Parts
Spare parts Spare parts The following are illustrations of the individual parts with positioning. Not all individual parts can be supplied as spare parts. VMU 1 ATEX II 2G IIC T4 en(us) Page 51 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc 2017-03-07... - Page 52 Spare parts Item Designation Part no. VMU, details see next page Screw Chassis Electrical control Retainer Screw Washer Spring washer Washer *) available on request Item Designation Part no. Pipeline Cutting ring Coupling nut Retainer *) available on request VMU 1 ATEX II 2G IIC T4 en(us) Page 52 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc...
- Page 53 Spare parts VMU 1 ATEX II 2G IIC T4 en(us) Page 53 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc 2017-03-07...
- Page 54 Spare parts Item Designation Part no. Motor-pump group Varnish exchanger column O-ring to the cover Prefilter device Filter element, 5 µm N5DM005 3068101 Filter element, 10 µm N5DM010 3102924 O-ring to the cover Safety filter device Filter element, 5 µm N5DM005 3068101 Filter element, 10 µm N5DM010 3102924...
- Page 55 Spare parts Item Designation Part no. 601701 Screw plug 607166 Cable lug 610392 Cable gland 6016116 "High voltage" warning sign 652595 Screw connection 6090467 Sealing ring 607757 Hose assembly DN20, L = 380 mm 6119194 Screw connection 607721 Sealing ring 607755 Screw connection 608119...
- Page 56 Spare parts Item Designation Part no. Ball valve 6119221 Screw connection 607721 Screw plug 305931 Screw connection 607796 *) available on request Item Designation Part no. Manifold block 3715642 Filling level limit switch 6032467 Screw connection 607721 Screw connection 611800 Screw connection 608119 Spacer for filling level limit switch...
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Page 57: Varnishmitigation Elements
Spare parts Item Designation Part no. Valve 6110214 Screw connection 607721 Screw connection 608235 Screw connection 608217 Screw connection 608119 Screw connection 608401 Cutting ring 626751 Tube Ø 18 × 2, L = 1000 mm 626493 *) available on request VarnishMitigation Elements Designation Part no. -
Page 58: Technical Data
Technical Data Technical Data Hydraulic data MPC values achievable < 15 Flow rate ≈ 2.2 l/min Permitted fluid temperature 30 to 60 °C / 86 to 140 °F range Operating pressure max. 8 bar / 116 psi Permissible suction pressure -0.2 –... - Page 59 Technical Data Required fluid cleanliness ISO 19/17/14 according to ISO 4406:1999 9A/9B/9C according to SAE AS4059 In order to ensure the required fluid cleanliness, we recommend operating with the optional prefilter. VMU 1 ATEX II 2G IIC T4 en(us) Page 59 / 68 BeWa VMU_1_ATEX-II2GIICT4_10000649233 en-us 2017-03-07.doc 2017-03-07...
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Page 60: Model Code
Model Code Model Code - 1 - M - G - - 1 - BM - z / -S5D5-PKZ Type VarnishMitigation Unit Filter Size 1x VarnishMitigation element Flow rate ≈ 2.2 l/min 4x VarnishMitigation element Flow rate ≈ 8.9 l/min Mechanical type = mobile SS = stationary... -
Page 61: Customer Service / Service
Friedrichsthaler Straße 15A 66540 Neunkirchen-Heinitz Phone: +49 6897 509 883 Fax: +49 6897 509 324 E-mail: service@hydac.com HYDAC Technology Corporation, HYCON Division 2260 City Line Road USA-Bethlehem, PA 18017 P.O. Box 22050 USA-Lehigh Valley, PA 18002-2050 Phone: +01 610 266 0100 Fax:... -
Page 62: Index
Index Index accident prevention ..........10 Imprint ..............2 ambient temperature ....11, 12, 15, 22, 29 IN 22, 25, 27, 31, 32, 40 AquaSensor ............60 Inlet ..............25, 27 ATEX ..........1, 12, 14, 22, 60 INLET ..............58 installation ...... - Page 63 Index Signal word ............. 9 Transport ............17, 20 signal words ............. 9, 10 transporting ............ 19, 20 Size ..............60 troubleshooting ............. 17 Spare part ............. 51 Turbine oil ............57 Spare parts ............51 Specialist personnel ........16, 17 Suction screen ............
- 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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