Hydac VarnishMitigation Unit Manual

VarnishMitigation Unit
VMU 4 ATEX
II 2G IIC (T4)
Operating and Maintenance Instructions
English (translation of original instructions)
Document no.: 4066057

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: [phone]
Fax: [phone]
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.

Contents
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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 ..................................................................................................9
Structure of the safety information and instructions...................................10
Observe regulatory information .................................................................10
Proper/designated use...............................................................................11
Explosion protection as per EU Directive 94/9/EC .................................14
Improper use or use deviating from intended use......................................15
Qualifications of personnel / target group ..................................................16
Wear suitable clothing ...............................................................................18
Stoppage in an emergency (EMERGENCY STOP)...................................18
Transporting the unit..................................................................................19
Transport with a crane...............................................................................20
Transport with train / truck .........................................................................20
Decoding the name plate ...........................................................................21
Checking the scope of delivery .................................................................23
Unit features................................................................................................24
Unit components.........................................................................................25
Unit dimensions ..........................................................................................27
Hydraulic diagram.......................................................................................28
Installing power unit ...................................................................................29
Setting up the unit ......................................................................................29

Contents
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Connecting the unit ....................................................................................30
Notes on pipes/hosing ...............................................................................31
Connecting the inlet port (IN).....................................................................32
Connecting outlet (OUT) port .................................................................33
Electrical connection of the unit .................................................................34
Preparing the unit for operation ................................................................35
Control / display elements on the electrical switch cabinet ........................35
Switching unit on/off ..................................................................................36
Bleeding the ion exchange column............................................................37
Bleeding the pre-filter and safety filter .......................................................37
Performing maintenance............................................................................38
Depressurizing...........................................................................................39
Changing VME elements ...........................................................................40
Changing the prefilter / safety filter element ..............................................44
Replacing the filling level limit switch .........................................................48
Cleaning the suction screen in the lance ...................................................49
Storing the unit / taking it out of operation ..............................................50
Disposing of the unit ..................................................................................50
Disposing of VME / filter elements ............................................................50
Spare parts ..................................................................................................51
Technical details .........................................................................................53
Model code ..................................................................................................55
Customer Service .......................................................................................56
Germany....................................................................................................56
USA ...........................................................................................................56
EU Declaration of Conformity....................................................................56
Index ............................................................................................................57

Preface
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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
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]
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 will find these under www.hydac.com -> Legal information.

Preface
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Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
these instructions prior to starting the unit up for the first time and
at regular intervals in the future.
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 instructions are revised or changed.
Chapter heading
Page number
Edition date
Document language
Documentation no.
with Index /
File name

Safety Information
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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. 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 Information
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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.

Safety Information
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Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a danger with a high risk and which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a danger with a medium risk and which can lead to
death or serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor
injury if not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.

Safety Information
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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
Consequence of the danger
HAZARD SYMBOL
►Measures to avert danger
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

Safety Information
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Proper/designated use
Use the unit only for the application described in the following.
The VarnishMitigation Unit VMU is used to condition mineral oil-based
turbine oils by effective removal of oil aging product (Varnish).
Proper or designated use of the product extends to the following:
observing all instructions contained in the instruction manual
performing inspection and maintenance work
operation in explosion-hazard areas in accordance with explosion-
protected execution / labelling of the power unit
DANGER
Exceeding the permissible surface
temperature
Surface temperature > 135 °C
Risk of explosion
►Observe the maximum permissible fluid and
ambient temperature.

Safety Information
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DANGER
Wrong ATEX area of utilization
Danger of fatal injury
►The power unit may be used only in the
indicated equipment group, equipment
category, and zone.
►Potentially explosive atmospheres in which
vapors or gas/air mixtures may occur only
rarely and briefly.
►Maximum permissible surface temperature
on components of the VMU must not exceed
135°C / 275°F.
Are the following specifications on the type label of the unit
permissible in connection with use in areas posing an
explosion hazard on site?
- equipment group
- equipment category
- explosion hazard subgroup
- temperature class
Ensure that vapors, gases or mists occurring at the place of
operation belong to explosion groups IIA to IIC.
Make sure that during installation of the unit no potentially
explosive atmosphere, oils, acids, gases, vapors or radiation
are present.
Make sure that the unit is sufficiently ventilated and no
external heat input is present.
Make sure that the ambient temperature is does not exceed
40°C/104°F.

Safety Information
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Depending on the version (see model code), you may only use the power
unit only for the following fluid:
NOTICE
Unpermitted 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.
When work is done in explosion-prone areas, the safety of persons
and equipment depends on the observance of all relevant safety regulations.
The installation and maintenance personnel thus carries particular
responsibility. Exact knowledge of the applicable regulations and conditions
is required.
Please note:
Observe the characteristic curves and measurement operating
conditions of the rating plates and datum plates.
Damage to the devices can nullify the explosion protection.
The unit may be operated only when the control cabinet is completely
closed.
Conversions and modifications to the devices and components that
affect the explosion protection are not allowed.

Safety Information
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Explosion protection as per EU Directive 94/9/EC
The power unit satisfies the requirements of the EU directive 94/9/EC,
applicable to areas in which potentially explosive gas mixtures are likely to
occur.
The designation of the explosion-proof ATEX-compliant unit is:
I II I 2 2G G I II IC C T T4 4
This label in particular means that utilization is permitted only for:
Equipment group II Potentially explosive atmospheres in which
vapors or gas/air mixtures are likely to
occur.
Usage in mining is not permitted.
Equipment category 2G Equipment guaranteeing a high degree of
safety.
Designated for cases in which atmospheres
posing an explosion hazard from gases,
vapors, mist or dust/air mixes can be
expected to occur occasionally.
Explosion group IIC Typical gases:
Hydrogen, ethyne (acetylene).
Temperature class T4 Maximum permissible surface temperature:
≤135°C / 275°F

Safety Information
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Improper use or use deviating from intended use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result
when operated improperly.
►Only operate the unit in the atmospheres
allowed.
►The unit is only to be used with permissible
fluids.
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 risk is borne exclusively by the
machine owner.
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
Operation in potentially explosive atmospheres other than the
identified one.
Operation with an impermissible fluid.
Operation at an impermissible fluid temperature / ambient
temperature.
Operation under non-approved operational conditions.
Operation when the safety devices are defective.
Operation in mining or in dust-exposed zones
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 Information
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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 be kept so they
are accessible for operating and specialist personnel.
These operating instructions are 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.

Safety Information
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Activity Person Knowledge
Transport / storage Forwarding
agent
Specialist
personnel
Proof of knowledge of cargo
securing instructions
Safe handling/operation of
hoisting and lifting equipment
Hydraulic/electrical
installation,
first commissioning,
Maintenance,
Troubleshooting
repair,
Decommissioning
Disassembly
Specialist
personnel
Safe handling/use of tools
Fitting and connection of
hydraulic lines and
connections
Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
Checking the phase sequence
Product-specific knowledge
Operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to
handle operating fluids.
Knowledge about
contamination due to solids
and water
Disposal Specialist
personnel
Proper and environmentally
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse

Safety Information
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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° in a counter-clockwise direction to
shut down the entire unit. The entire system is
then voltage-free downstream from this switch.

Transporting the unit
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Transporting the unit
Evacuate the power unit 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 unit will be damaged.
►Never use the components to push or pull the unit.
►Use the grips provided for shifting.
Shift the unit manually using the rollers/wheels. When doing so, use only the
grips provided on the chassis.
Before shifting the unit, make sure to release the hand brake on the swivel
casters. Once the power unit is in its new position, actuate the hand brake on
the steering rollers.

Transporting the unit
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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
pressures to be brought to bear against the components on the unit.
When transporting by crane, only use suitable lifting accessories/band loops.
Transport with train / truck
For transport by rail or truck, supports must be placed under the mobile unit
so that the rollers are subjected to no load pressure. The unit is to be
secured with suitable belts.