conversion to cover with housing clamp for nf conversion kit lvh-f for nf en(us) page 2 / 28 ma...

Conversion to cover with housing clamp for NF

Installation Manual English (translation of original instructions)

Keep for future reference. Documentation no.: 4159269a

Imprint

Conversion kit LVH-F for NF en(us) / 28

MA LVH-F-NF 4159269a en-us 2016-08-29.docx 2016-08-29

Imprint

Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Phone: +49 6897 509 01 Fax: +49 6897 509 9046 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 6897 509 1511 Fax: +49 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.

Content



Content

Imprint ............................................................................................................ 2

Documentation Representative ................................................................... 2

Content .......................................................................................................... 3

Preface ........................................................................................................... 4

Technical Support ........................................................................................ 4 Product modification .................................................................................... 4 Warranty ...................................................................................................... 4 Using the documentation ............................................................................. 5

Safety information ........................................................................................ 6

Hazard symbols ........................................................................................... 6 Signal words and their meaning in the safety information and instructions .................................................................................................. 8 Structure of the safety information and instructions ..................................... 9 Observe regulatory information ................................................................... 9 Proper/Designated Use ............................................................................. 10 Improper Use or Use Deviating from Intended Use ................................... 11 Qualifications of personnel / target group .................................................. 12 Wear appropriate clothing/personal protection equipment ........................ 14 Observe regulatory information ................................................................. 14

Unpacking conversion kit .......................................................................... 15

Transporting the conversion kit ................................................................ 15

Storing the conversion kit .......................................................................... 15

Checking the scope of delivery ................................................................. 16

Conversion kit characteristics ................................................................... 17

Performing conversion ............................................................................... 18

Spare parts list ............................................................................................ 24

Disposing of the conversion kit / filter / filter element ............................. 26

Customer Service / Service ........................................................................ 26

Technical Data............................................................................................. 26

Index ............................................................................................................ 27

Preface



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: +49 6897 509 9046 E-mail: [email protected]

Product modification 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. 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.

http://www.hydac.com/

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. 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.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite 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 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. 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 operating pressure

Risk of burns due to hot surfaces

Flammable

Safety information



Hazardous to health. Inhalation or skin absorption can cause damage to health. Can cause irritation to the respiratory system, skin and eyes. Temporary disorders (dizziness, headaches, nausea, concentration problems) possible. If diesel fuel is swallowed, it can enter the lungs and result in potentially fatal pneumonia.

Irritant.

Harmful to the environment. Avoid penetration into the ground, water and sewage system.

Flammable. Liquid and vapor are flammable. Increased risk of ignition in the case of soaked material (e.g. clothing, cloths)

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 – 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 moderate 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.

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:

HAZARD SYMBOL

SIGNAL WORD Type and source of danger

Consequence of the danger

► 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



Proper/Designated Use Only use the conversion kit for the application described in the following. The conversion kit is only for NF filters from HYDAC. By performing this conversion you will change the filter considerably. Following conversion, the maximum operating pressure will be 10 bar. Also observe the local laws, standards and guidelines. Any other uses 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.

NOTICE

Impermissible operating media/conditions

The filter housing will be damaged.

► Only use the filter in combination with the permitted operating media and in the permitted operating conditions.

Safety information



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.

► Never operate the filter in potentially explosive atmospheres.

► Only use the filter with the permitted media.

Any use extending beyond this 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 or use deviating from intended may result in hazards and/or will damage the unit. Examples of improper use:

• Operation in potentially explosive atmospheres.

• Operation with a non-approved medium.

• 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 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. The operating instructions and applicable regulations are to 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 have 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



Activity Person Knowledge

Transport / storage Forwarding agent Specialist personnel

• No specialist knowledge required

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.

• Product-specific knowledge

Operation Operations control

Operating Personnel

• Product-specific knowledge

• Knowledge about how to handle operating media

Disposal Specialist personnel

• Proper and environmentally-friendly disposal of materials and substances

• Decontamination of contaminants

• Knowledge about reuse

Safety information



Wear appropriate clothing/personal protection equipment Loosely worn clothing increases the danger of getting caught or wound up in rotating parts and the danger of getting snagged on projecting 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 operating 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

Unpacking conversion kit



Unpacking conversion kit

When receiving and unpacking the conversion kit, check it for damage in transit. Dispose of the packaging material in an environmentally-friendly manner.

Transporting the conversion kit

Transport the conversion kit in a horizontal position.

Storing the conversion kit

Store the conversion kit in its original packaging under the following conditions: Permissable storage temperature

See chapter “Technical Data”, page 26.

Permitted air humidity See chapter “Technical Data“, page 26. Air Clean, salt-free air, not near oxidizing substances

(rust film). Storage duration Indefinite.

Before the unit is started up again after being stored for more than two years, all seals must be replaced.

Checking the scope of delivery



Checking the scope of delivery

When the conversion kit is delivered, check it for any damage. Immediately report any damage in transit to the forwarding agent or the HYDAC department in charge. Only put undamaged filter housings into operation. The following items are supplied:

Item Qty Description 1 1 Name plate label

10 1 "Warning sign 10 bar" label

44 1 "Air Bleed" label

1011 2 O-ring

1040 1 Adapter

2000 1 Cover, complete

3000 1 Housing clamp

- 1 Installation and Maintenance Instructions (this document)

Conversion kit characteristics



Conversion kit characteristics

DANGER Excessive operating pressure

Bodily injury and damage to property will result when operated improperly.

► Observe the maximum permitted operating pressure.

As a result of conversion, the pressure range of the overall filter and the procedure for changing filter elements changes.

Performing conversion




WARNING Working overpressure

Danger of bodily injury

► Depressurize the system before performing any work on it.

CAUTION Operating fluid

Health hazard

► Wear personal protective equipment to install the conversion kit – see operating instructions or safety data sheet for the operating medium.

Tools required to install the conversion kit: Quantity Designation - 1x Hook wrench 205/220 DIN1810B

- 1x Fork wrench 19 mm

- 1x Allen wrench 6 mm - 1x Tube grease or lubricant containing a slip additive (MoS2) To convert the filter housing, proceed as follows:

1. Close the shut-off valve on IN inlet and OUT outlet.




2. Depressurize the filter housing. Unscrew the air bleed screw completely

with a fork wrench 19 mm in a counterclockwise direction.

3. Open the drain ball valve to empty the

filter housing. Collect the escaping fluid in a suitable container and dispose of it in an environmentally friendly manner.

4. Undo the filter cover in a

counterclockwise direction. Completely unscrew the filter cover by hand.




5. Remove the used filter element and dispose of it in an environmentally friendly manner.

6. Lubricate the thread.

Insert the O-ring in the appropriate groove in the adapter. Screw the adapter onto the filter housing with a hook wrench 205/220.

7. Check the clearance 29 between the

upper edge of the adapter and the filter housing. If necessary, correct it by screwing in/out until you reach the clearance including the tolerance.




8.

Remove the pressure specification on the existing name plate without leaving any residue. Stick the name plate (1) from the conversion kit onto the filter housing.

It is not permitted to stick the new name plate over the old one! Stick the safety label (10) onto the filter housing.

9. Press the new filter element into the element mount by applying slight pressure, pressing it downwards and screwing it in.

Do not use excessive force or a hammer, etc.

10. Check the O-ring for damage, and

replace it if necessary. Clean the O-ring groove and the sealing surface on the filter housing and cover.




11. Position the cover on the adapter to the filter housing.

12. Place the housing clamp around the

filter housing and cover and tighten it with a maximum torque of 12 Nm.

Necessary tools: = 6 mm.

13. (I) Open the shut-off device at the IN

inlet slowly in order to prevent pressure surges onto the filter and fill the filter housing. (II) Observe the bleeding bore during filling. (III) Close the shut-off device at the IN inlet as soon as fluid escapes.




14. (I) Screw in the air bleed screw 6 mm in a clockwise direction. Tighten the air bleed screw with a torque = 20Nm. (II) Open the shut-off device on IN inlet. (III) Open the shut-off device at the OUT outlet.

15. The filter is ready for operation.

Check the filter for leaks while in operation.

Spare parts list



Spare parts list

Make sure to always indicate the complete designation / marking from the name plate, as well as the serial number, when ordering spare and wear parts.

Spare parts list



Item Qty Description Material p/no. 1 1 Name plate label 3792300

10 1 "Warning sign 10 bar" label 3458266

44 1 "Air Bleed" label 3233901

1011 2 O-ring FPM 604002

1011 2 O-ring NBR 604001

1040 1 Adapter 4158635

2000 1 Cover, complete 4050791

3000 1 Housing clamp 6174972

- 1 Installation and Maintenance Instructions (this document) 4159269

*) available on request

Use only original spare parts and accessories to ensure safe and reliable operation of the unit.

Disposing of the conversion kit / filter / filter element



Disposing of the conversion kit / filter / filter element

• Dispose of the packaging material in an environmentally friendly manner.

• The conversion kit / filter element is to be disposed of in an environmentally friendly manner.

• After dismantling the filter housing and separating its various materials, dispose of it in an environmentally friendly manner.

Customer Service / Service

HYDAC SERVICE GMBH Friedrichsthaler Straße 15A, Werk 13 66540 Neunkirchen-Heinitz Germany Phone: +49 681 509 883 Fax: +49 681 509 324 E-mail: [email protected]

Technical Data

Technical details

Operating pressure, maximum 10 bar

Coalescing housing material Aluminium anodized, coated steel

Material of sealings FKM (FPM Viton®)

Permissible operating temperature

60°C maximum

Permissible ambient temperature 50°C maximum

Permitted storage temperature range

5 … 30°C

Permissable relative humidity ≤ 80%

Weight of conversion kit ≈ 6 kg

Index



Index

A accident prevention .......................................... 9, 14 ambient temperature ............................................ 27

B bleeding ................................................................ 22

C care .................................................................... 2, 4 Content ................................................................... 3

D Description...................................................... 16, 25 Disposal ................................................................ 13 Documentation Representative .............................. 2

F filling ..................................................................... 22 Filter ..................................................................... 11 Forwarding agent .................................................. 13

H Hazard symbol .................................................... 6, 9

I Imprint .................................................................... 2 IN 18, 22, 23 Inhalation ................................................................ 7 installation............................................................. 13

M Maintenance ................................................... 16, 25

Material of sealings............................................... 27 Measures ................................................................ 9

O operating ............... 4, 5, 6, 10, 12, 13, 14, 17, 18, 27 operating temperature .......................................... 27 Operation ........................................................ 11, 13 Operations control ................................................ 13 OUT ................................................................ 18, 23

P Proper/Designated Use ........................................ 10 Publisher ................................................................ 2

R report .................................................................... 16

S select ...................................................................... 5 Service ................................................................. 26 Signal word ......................................................... 8, 9 signal words ....................................................... 8, 9 Spare part ............................................................. 24 Spare parts ........................................................... 24 Spare parts list ..................................................... 24 Specialist personnel ....................................... 12, 13

T Transport ........................................................ 13, 15 troubleshooting ..................................................... 13

W Weight .................................................................. 27

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: [email protected]

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