Hydac LVU-CD-40 User manual

LVU-CD-40 /-T001
LowViscosity Unit
CoalescerDiesel
Installation and Maintenance Instructions
English (translation of original instructions)
Document No.: 4142242a
Keep for future reference.

Imprint
LVU-CD-40 /-T001 en(us) Page 2 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
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:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© 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.

Content
LVU-CD-40 /-T001 en(us) Page 3 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Product modification ....................................................................................5
Warranty......................................................................................................5
Using the documentation.............................................................................6
Safety precautions........................................................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................9
Structure of the safety information and instructions ....................................9
Proper/Designated Use .............................................................................10
Improper Use or Use Deviating from Intended Use...................................11
Qualifications of personnel / target group..................................................12
Wear suitable clothing ...............................................................................13
Observe regulatory information .................................................................13
Stoppage in an emergency (EMERGENCY STOP) ..................................13
Unpacking the unit......................................................................................13
Transporting the unit..................................................................................14
Transporting with the crane .......................................................................14
Storing the unit ...........................................................................................15
Decoding the name plate ...........................................................................16
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

Content
LVU-CD-40 /-T001 en(us) Page 4 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Connecting the suction port (IN)................................................................26
Connecting the pressure port (OUT) .........................................................26
Connecting the water outlet.......................................................................27
Electrical connection of the unit.................................................................27
Connecting the main switch / E-STOP ...................................................28
Connecting the water sensor..................................................................28
Water sensor - monitoring signal ...........................................................28
Connecting sensor in the collecting pan.................................................28
Sensor in the collecting pan - monitoring signal.....................................28
Connecting clogging indicators ..............................................................29
Clogging indicators - monitoring signal...................................................29
Connecting the water drainage valve .....................................................29
Operating the filter unit ..............................................................................30
Switching unit on/off ..................................................................................31
Performing maintenance............................................................................32
Maintenance intervals................................................................................32
Perform visual check .................................................................................32
Checking the pump for leaks.....................................................................33
Replacing the filter element in the filter housing........................................35
Changing the coalescing elements............................................................38
Customer Service .......................................................................................44
Taking the unit out of operation ................................................................44
Shutting down the unit ...............................................................................44
Disposing of the unit ..................................................................................44
Spare parts list............................................................................................45
Technical data.............................................................................................46
Decoding model code.................................................................................48
Index ............................................................................................................49

Preface
LVU-CD-40 /-T001 en(us) Page 5 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model/type
designation, serial no. and article no. of the product:
Fax:
+49 (0) 6897 / 509 - 9046
E-mail:
filtersy[email protected]
Product modification
We would like to point out that changes to the product (e.g. purchasing
additional options, etc.) may mean that the information in the operating
instructions is no longer applicable or adequate.
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.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale
and Delivery of HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> General terms and conditions.

Preface
LVU-CD-40 /-T001 en(us) Page 6 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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.
WHERE can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
BeWa123456ade
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 description
Page number
Edition date
Document language
Documentation no.
with index/
file name

Safety precautions
LVU-CD-40 /-T001 en(us) Page 7 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Safety precautions
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

Safety precautions
LVU-CD-40 /-T001 en(us) Page 8 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Risk of burns due to hot surfaces
Flammable
Danger from explosive atmosphere
Harmful to the environment

Safety precautions
LVU-CD-40 /-T001 en(us) Page 9 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Signal words and their meaning in the safety information and
instructions
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 – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or m
oderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.
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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger

Safety precautions
LVU-CD-40 /-T001 en(us) Page 10 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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 50 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.

Safety precautions
LVU-CD-40 /-T001 en(us) Page 11 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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 suitable only for suction operation mode.
•Operation is only permitted at an earthed power supply.
•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 an impermissible fluid.
•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.

Safety precautions
LVU-CD-40 /-T001 en(us) Page 12 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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 is 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
Auxiliary
personnel
No specialist knowledge
required
Startup operation
Operations control
Auxiliary
personnel
Product-specific knowledge
Knowledge about how to handle
operating media.
Troubleshooting,
Maintenance,
Decommissioning,
Disassembly
Specialist
personnel
Safe handling/use of tools
Product-specific knowledge
Disposal
Specialist
personnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse

Unpacking the unit
LVU-CD-40 /-T001 en(us) Page 13 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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 operations 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.

Transporting the unit
LVU-CD-40 /-T001 en(us) Page 14 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Transporting the unit
Empty the unit completely before transport, including the coalescing and filter
housings. 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.

Storing the unit
LVU-CD-40 /-T001 en(us) Page 15 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Storing the unit
Empty the unit completely before storage, including the coalescing and filter
housings. Pull out the power plug and securely fasten the power cord to the
unit.
Permitted storage temperature
range
0 … 50 °C.
Air
Clean, salt-free air, not near
oxidizing substances (rust film).
Storage duration
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.

Decoding the name plate
LVU-CD-40 /-T001 en(us) Page 16 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Decoding the name plate
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 48

Decoding the name plate
LVU-CD-40 /-T001 en(us) Page 17 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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.
->
Maximum permitted operating pressure
Pressure IN
->
Permissible operating pressure at IN
connection
Pressure OUT
->
Permissible operating pressure at OUT
connection
Weight
->
Weight when empty
Flow rate
->
Flow rate
Temp. fluid
->
Permitted fluid temperature range
Temp. amb.
->
Permissible ambient temperature range
Volume
->
Fluid volume in unit

Checking the scope of delivery
LVU-CD-40 /-T001 en(us) Page 18 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
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
1
LowViscosity Unit LVU-CD-40, version in accordance with your
order, check the name plate on page 16.
1
- Installation and Maintenance Instructions
(this document).

Unit function
LVU-CD-40 /-T001 en(us) Page 19 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Unit function
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 dangerous emissions from the combustion engine. This leads to
high costs for downtime, spare parts, maintenance and repairs.
The use of the LowViscosity Unit LVU minimizes contamination to a system
and prevents expensive system downtime. It also helps to avoid the
necessity of early and expensive disposal of diesel fuel.
The filtration unit is suitable for diesel maintenance in:
•Tanks on mobile / stationary emergency power units
e.g. in hospitals, shopping centers and power plants
•Tanks of portable machines, e.g. harvesting and construction
machinery
•Storage tanks e.g. for agriculture and mining
•Tanks on yachts and leisure craft

Unit function
LVU-CD-40 /-T001 en(us) Page 20 / 52
BeWa LVU-CD-40-T001 4142242a en-us 2016-05-13.doc
2016-05-13
Unit components
The unit has the following components: