Hydac IXU 1 Series Manual

Ion eXchange Unit
IXU 1 Series
IXU 4 Series
Operating and Maintenance Instructions
English (translation of original instructions)
Document No.: 3471971a

IXU 1 / IXU 4 Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
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
Telefax: ++49 (0)6897 509 1394
E-mail: [email protected]
© 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.
All details are subject to technical modifications. Technical specifications are subject
to change without notice.
The trademarks of other companies are exclusively used for the products of those
companies.

IXU 1 / IXU 4 Contents
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Contents
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Contents....................................................................................................................3
Preface ......................................................................................................................5
Customer Service ...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the documentation ........................................................................................7
Safety Information and Instructions.......................................................................8
Obligations and Liability..........................................................................................8
Explanation of Symbols and Warnings, etc. ...........................................................9
General Safety Precautions....................................................................................9
Proper/Designated Use ........................................................................................10
Improper Use ........................................................................................................10
Safety Devices......................................................................................................10
Informal Safety Precautions..................................................................................11
Training and Instruction of Personnel ...................................................................12
Electrical Hazards.................................................................................................13
Modifications to the IoneXchangeUnit IXU ...........................................................13
What to Do in Case of Emergency .......................................................................13
Transporting the IXU..............................................................................................14
Crane ....................................................................................................................15
Train/truck.............................................................................................................16
Checking the scope of delivery.............................................................................17
IXU features ............................................................................................................18
Components - IXU 1 stationary ............................................................................. 19
Dimensions - IXU 1 stationary...............................................................................20
Components - IXU 1 mobile...................................................................................21
Dimensions - IXU 1 mobile ....................................................................................22
Components - IXU 4 stationary ............................................................................. 23
Dimensions - IXU 4 stationary...............................................................................24
Components - IXU 4 mobile...................................................................................25
Dimensions - IXU 4 mobile ....................................................................................26
Hydraulic diagram ..................................................................................................27
Using the IXU ..........................................................................................................28

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Restrictions pertaining to use ...............................................................................28
IXU setup and connection .....................................................................................29
Hydraulic connection of the IXU ...........................................................................29
Notes on Piping / Hosing ......................................................................................29
Connecting the inlet (IN) ...................................................................................31
Connect outlet (OUT) ........................................................................................32
Electrical connection of the IXU............................................................................33
Inserting IXE element / prefilter and safety filter element .....................................34
Switching the IXU on and off.................................................................................35
Bleeding the ion exchange column.......................................................................36
Bleeding the prefilter and safety filter ...................................................................36
Performing Maintenance........................................................................................37
Depressurizing......................................................................................................38
Changing IXE elements ........................................................................................39
Changing the prefilter / safety filter element .........................................................42
Cleaning the suction screen in the lance.............................................................45
Decommissioning/Storing the IXU........................................................................46
Disposing of the IXU ..............................................................................................46
Disposing of IXE elements ....................................................................................46
Spare Parts List ......................................................................................................47
Ion eXchange housing ..........................................................................................47
Filter element for prefilter and contamination filter................................................47
Specifications .........................................................................................................48
Model Code .............................................................................................................50
Type label................................................................................................................51
Customer service ...................................................................................................51
Germany ...............................................................................................................51
USA ......................................................................................................................52
EU Declaration of Conformity ...............................................................................53

IXU 1 / IXU 4 Preface
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Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.Consequently, there might be deviations
in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”

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Customer Service
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: [phone] / 509 - 846
E-mail: [email protected]
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 -> Legal information

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Using the documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
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.
de
HYDACFiltertechnikGmbH
Be
Wa12
3456a
d
e
Se ite x
Produkt/Kapitel
200x-xx-xx
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.
Chapter
Page number
Edition date
Document language
Documentation No.
with Index /
File name

IXU 1 / IXU 4 Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely
operating the Ion eXchange Unit IXU.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the IXU is
knowledge of the safety instructions and warnings.
These Operating Instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the IXU.
Please adhere to pertinent accident prevention regulations applicable at the site
where the product is used.
The IXU has been designed and constructed in accordance with the current state of
the art and recognized safety regulations. Nevertheless, hazard may be posed to
the life and limb of the individual using the product or to third parties.
Only use the IXU for its designated use when it is in a safe, perfect condition.
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply. They are made available to the owner
upon concluding purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
Improper use of the IXU:
- Improper commissioning, operation and maintenance of the IXU
- Operating the IXU when the safety equipment is defective
- Modifications to the IXU made by the user or purchaser
- Improper monitoring of unit components that are subject to wear and tear
- Improperly performed repair work

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Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in these operating instructions to
designate hazards, etc.
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
General Safety Precautions
Operation, adjustment and calibration work may only be carried out by technically
skilled and trained personnel.
The safe operation of this unit can only be ensured if it is used for the purpose it was
intended. If there is any question about the use, please contact the manufacturer.
The manufacturer will not accept responsibility for damages resulting from misuse of
this equipment.
The following applies to all work performed using the unit: adherence to pertinent
national regulations pertaining to accident prevention and safety at the workplace in
addition to any applicable internal rules and regulations of the owner/operator, even
though they are not specifically cited herein.
Leaks of dangerous materials must be properly collected and disposed of so as not
to harm any persons or the environment. The corresponding statutory regulations
are to be followed.
Before beginning any work, you must depressurize the unit.

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Proper/Designated Use
The IXU was developed to remove aggressive acids from flame-resistant hydraulic
fluids on a phosphate ester basis (HFD-R).
Any other use shall be deemed to be improper and not in keeping with the product's
designated use. The manufacturer will not assume any liability for any damage
resulting from such use.
Proper or designated use of the product extends to the following:
Observing all the notes contained in these operating instructions.
Performing requisite inspection and maintenance work.
Improper Use
Improper use will result in hazard to life and limb.
Examples of improper use include:
Operation with non-approved fluids.
Safety Devices
Before commissioning, check all safety devices for proper functioning.
Safety devices may not be removed until the product has been shut down and
secured against being restarted (e.g. warning sign or padlock on the main switch).
When the product is supplied in partial consignments, the safety devices are to be
applied by the operator as specified by law/pertinent regulations.

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Informal Safety Precautions
Always keep the operating and maintenance instructions near the IXU.
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance to be maintained to them.
Make sure to keep the safety and hazard symbols and warnings on the IXU in a
legible condition and replace these if necessary.
Check the hoses and connectors for leaks on a daily basis. Check the electrical
equipment on a monthly basis. Replace any loose or faulty connections or damaged
cables immediately.
WARNING
Operating pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system

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Training and Instruction of Personnel
The IXU may be operated only by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the IXU unless supervised by an experienced
staff member.
Individuals Individuals undergoing training Individuals with technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing / transportation X X X
Start up X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning / Storage X X X X

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Electrical Hazards
DANGER
Electric shock
Danger of fatal injury
►
A
ny work involving the power supply may only be
done by a properly trained, certified electrician.
►Pull the power plug before performing work on
live parts.
Any work involving the power supply may only be done by a properly trained,
certified electrician.
Check the IXU electrical equipment on a monthly basis. Replace any loose
connections, damaged cables and hoses immediately with original parts.
Modifications to the IoneXchangeUnit IXU
Do not make any modifications (design modifications, extensions) to the IXU without
the prior consent of the manufacturer.
Any modifications require written permission from HYDAC Filter Systems GmbH
Immediately replace any machine components which are not in perfect condition.
Only use original spare parts and consumables.
What to Do in Case of Emergency
In the event of an emergency, immediately disconnect the IXU from the power
supply.

IXU 1 / IXU 4 Transporting the IXU
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Transporting the IXU
Evacuate the IXU completely before transporting it and close the inlets and outlets.
Wind the suction and pressure hose and the connection cable around the holders
provided for this purpose and fasten them in place.
NOTICE
Using components for pushing / pulling
The IXU will be damaged
►Never use the components to push or pull the IXU.
►Use the grips provided for shifting.
Shift the IXU manually using the rollers. When doing so, use only the grips provided
on the IXU chassis.
Before shifting the unit, make sure to release the hand brake on the swivel casters.
Once the IXU is in its new position, actuate the hand brake on the swivel casters.

IXU 1 / IXU 4 Transporting the IXU
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Crane
NOTICE
Unsuitable lifting accessories
The IXU will be damaged / Components will be damaged / destroyed
►Use only suitable lifting accessories to raise or lash the IXU.
►Take care to ensure that the lifting accessories do not cause any pressures
to be brought to bear against the components on the IXU.
When transporting by crane, only use suitable lifting accessories/band loops.
IXU 1 stationary IXU 1 mobile

IXU 1 / IXU 4 Transporting the IXU
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IXU 4 stationary / IXU 4 mobile
Train/truck
For transport by rail or truck, supports must be placed under the IXU 4 to such an
extent that the rollers are subjected to no load pressure. The IXU is to be secured
with suitable belts.

IXU 1 / IXU 4 Checking the scope of delivery
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Checking the scope of delivery
Upon receiving the IXU check it for any damage. The IXU 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; the unit may not be
commissioned until this damage is properly remedied.
The following items are supplied:
Qty. Description
1 Ion eXchange Unit
1 Operation and Maintenance Instructions (this document)
1 EC declaration of conformity
1 Test certificate

IXU 1 / IXU 4 IXU features
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IXU features
The ion exchange unit IXU was developed and constructed to remove aggressive
acids from flame-resistant hydraulic fluids on a phosphate ester basis (HFD-R).
The oil aging for HFD-R fluids is based on hydrolysis. Aggressive acids are
produced as a decomposition product.
Special resins effectively reduce the number of acids and amount of metal soaps.
We additionally recommend continuous dewatering, for example using a FluidAqua
Mobil - FAM.
0.5
0
1.0
1.5
2.0
2.5
t
m
g
KOH/
g
without Ion eXchange Unit
with Ion eXchange Unit
The advantages of the IXU are:
- inexpensive oil conditioning
- low component wear
- longer service life of the oil
- quick and easy cartridge change
- low operating costs
- compact construction, less space requirement
- low disposal costs
- version with optional filling pump
- with prefilter and safety filter

IXU 1 / IXU 4 Components - IXU 1 stationary
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Components - IXU 1 stationary
The IXU 1 stationary has the following components:
Item Description
1 Motor pump assembly
2 Prefilter
3 Ion exchange column
4 Emptying DRAIN
5 Safety filter
6 On/Off switch with motor protection
11 INLET IN
12 OUTLET OUT
13 Ion exchange column pressure gauge
14 Ion exchange column air vent BLEED
15 Prefilter/Safety filter air vent BLEED

IXU 1 / IXU 4 Dimensions - IXU 1 stationary
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Dimensions - IXU 1 stationary
(All dimensions in mm)