Equipment No.

: 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

Keep this operation instruction manual for future use

CUSTOMER : SAMSUNG ENGINEERING

ORDER NO : 4500045551

LUBE OIL CONSOLE

FOR
Reactor Feed Pump

MANUFACTURER :
DAEDONG ENTEC CO., LTD
ADD : #1500-23 , SONGJUNG-DONG, KANGSEO-GU,
BUSAN,618-270,KOREA
TEL)+82 051 832 1123
FAX)+82 051 832 1369/1370
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

CONTENTS
1. GENERAL INSTRUCTIONS
Intended Purpose
Statutory documents
1.2.1 Manufacturer's declaration / Declaration of conformity
Certificates / Confirmations
Significance of the operating instructions

2. TECHNICAL DATA
2.1 Technical data of the lube oil system

3. INSTALLATION AND FUNCTIONAL PRINCIPLES

3.1 Monitoring and inspection
3.2 Contamination check
3.3 Noise emission (only when stipulated)

4. SAFETY
4.1 Proper utilization
4.2 Dangers if the safety instructions are disregarded
4.3 Safety instructions for the operator
4.4 Consequences of unauthorized modification

5. TRANSPORT, STORAGE AND CONSERVATION

5.1 Packing and transport
5.2 Storage and conservation

6. INSTALLATION
6.1 General instructions
6.2 Installation conditions
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

6.3 Installation of the pipelines

6.4 Installation of the electrical connections

7. COMMISSIONING
7.1 Description of the commissioning procedure
7.1.1 Filling the hydraulic system
7.1.2 Instruction for switching on the electric motor
7.1.3 Venting of the pump
7.1.4 Venting of the hydraulic system
7.1.5 Purging the hydraulic system
7.1.6 Liquid level
7.1.7 Plants with accumulator (pressurized storage tank)
7.2 Required personnel
7.3 Training and instruction of the operation personnel
7.4 Required consumable materials

8. MAINTENANCE AND REPARIS

8.1 Maintenance and Inspection
8.1.1 General instructions
8.1.2 Maintenance after commissioning
8.1.3 Maintenance in normal operation
8.2 Repairs and dismantling of the hydraulic system

9. TROUBLE SHOOTING

10. REPLACEMENT PARTS

10.1 Customer service addresses

11. ANNEX
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

System Diagram
11.1 Test certificates and confirmations
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

1. GENERAL INSTRUCTIONS
1.1 Intended Purpose
: Please comply with this operation instruction strictly unless otherwise be stipulated
for the purpose of designed life time and performance.
1.2 Statutory documents
The hydraulic system described in this operating instructions manual has been manufactured

complying with the standards according to DIN EN982, DIN EN ISO 12100-1/2, DIN EN 414,

DIN EN 418, DIN EN 1050 as well as DIN EN 60204-1 and fulfils the regulations according to

the Machinery Directive 98/37/EG, provided that it is utilized according to the specifications

contained in this operation instructions manual. Commissioning is forbidden until it has been

determined that the machine in which this product is to be incorporated complies with the

stipulations of the EC directive specified above.

1.2.1 Manufacturer's declaration / Declaration of conformity

CIRCUIT POSITION TYPE OF CERTIFICATE CERTIFYING ORGANIZATION

U.K. ISO 9001:2008 GUARDIAN

1.3 Certificates / Confirmations

□ The corresponding certificates and confirmations are listed in the Annex in Section
11.1
1.4 Significance of the operation instructions
This operating instructions manual is part of the hydraulic system and
● should always be kept ready until disposal of the system.
● I.e. it must be passed on in the case of sale or other transfer of the system.
This hydraulic system can entail unavoidable residual hazards for persons and
material objects. Therefore every person involved in work with this machine and
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

concerned with transport, installation, operations, maintenance and repair of the

hydraulic unit must be duly instructed and aware of the possible dangers.
For this purpose of the operating instructions manual and, in particular, the safety
instructions must be read attentively and understood.
Non-existing or inadequate knowledge of the operating instructions invalidates all
claims under liability against the company Deadong Entec.
2. Technical Data
2.1 Technical data of the hydraulic system
OIL TANK : 426〔gal〕■ STEEL □ ALUMINIUM
FEED RATING : 24〔gal/min〕
OPERATING PRESSURE : 145〔paig〕
ELECTRIC MOTOR : 4〔kw〕 1500〔rpm〕 440〔V〕50〔Hz〕
HEATING POWER : N/A --〔kw〕 〔V〕 〔Hz〕
COOLING POWER : N/A -- 〔kw〕 for dT =
AMBIENT TEMPERATURE : 49-115℉
WATER TEMPERATURE IF WATER COOLED : ---
CONTROL VOLTAGE : N/A Foundation Field Bus Signal
OPERATING MEDIUM : ISO VG 46
VISCOSITY AREA : 41.4-51.6 cst at 40℃
FILTER UNIT CLASS ACCORDING TO ISO
19/17/14
4406 :
OIL FILL : ■NO □YES

ACCUMULATOR ACCEPTANCE TEST :N/A ---

PAINTING : BS4800(14E51) Green
□ The hydraulic system was designed and projected for the technical data specified
above.
□ Further hydraulic and electrical characteristics are contained in the data sheets for
the individual components.
3. INSTALLATION AND FUNCTIONAL PRINCIPLES
3.1 Monitoring and inspection
The contractually agreed warranty performance does not relieve the operator of this
hydraulic system form the responsibility and duty of carrying out preventive
maintenance and repair tasks as from commissioning time.
WARNING

Improperly maintained hydraulic systems can cause severe accident. Therefore you must make

quite sure that the recommended maintenance and repair tasks are carried out adequately!
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

3.2 Contamination check

□ Unless contrary instructions are explicitly contained in this operating instructions
manual, regularly check that the hydraulic fluid corresponds to the nominal purity as
specified in the table " Frequency of the hydraulic fluid checks".
Frequency of the hydraulic fluid checks
Systems in Cleanliness Class 17/15/12 or lower
System pressure <140 bar 140 to 210 bar >210 bar
<8 hours per day 4 months 3 months 3 months
>8 hours per day 3 months 2 months 2 months
Systems in Cleanliness Class 18/16/13 or higher
System pressure <140 bar 140 to 210 bar >210 bar
<8 hours per day 6 months 4 months 4 months
>8 hours per day 4 months 3 months 2 months
Commissioning or conversion/repair
Large systems(more than 2000 liters) and systems with servo valves
- before start up
- within the first few days
Fluid sample
- after one week
- after one month
Other systems
- within the first few days
Fluid sample
- one month after commissioning
System fault
e.g. increased temperatures, incorrect
- immediately
switching, etc
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

3.3 Noise emission (will be determined only when stipulated)

Operating state of the hydraulic unit Measured sound pressure level(dBA) :
e.g.: Pump 1, Pump 2, Pump 1 and 2,
Side 1 Side 2 Side 3 Side 4
operating pressure, feed rate

The tabulated values were measured at a distance of 1 m form the respective side of
the hydraulic unit.
4. Safety
4.1 Proper utilization
□ The hydraulic system has been designed and constructed according to the state of
technology and the approved safety and technical regulations. Nevertheless,
utilization of this hydraulic system can entail dangers for life and limb of the operator
and/or other persons, or damage of the hydraulic system and other objects,
especially if the instructions and regulations in this operating instructions manual are
not obeyed.
□ This hydraulic system is designed exclusively for the application specified by the
contract giver and may be operated only when in technically perfect condition, for the
intended purpose and with ‘due awareness of the safety requirements and hazards,
thereby observing the contents of this operating instructions manual.
4.2 Dangers if the safety instructions are disregarded
□ Unauthorized modifications or supplements of the hydraulic system are forbidden
for safety reasons. The manufacturer is not liable for damage resulting from
infringement of this rule.
The risk must be carried by the user alone. The EC conformity declaration and the
EC manufacturer's declaration become invalid in the case of modifications or
supplements of the hydraulic system which we have not approved.
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

4.3 Safety instructions for the operator

□ Machines which are subject to the Accident Prevention Regulations are safe only
when the hydraulic and electric controls comply with the Accident Prevention
Regulations.
□ All pipeline, hosepipe and valve connections as well as screw fittings must be
checked for leakage and externally recognizable damage.
□ Damage must be repaired immediately.
□ Squirting out oil can cause injuries and fire.
□The warning instructions contained in this manual for maintenance and repair tasks
on the hydraulic system must be observed.
□ Replacing components, pay attention to the warning instructions under Section 8.2.

Caution!
The hydraulic fluid can cause skin rash and other health damage. Avoid prolonged skin contact.
After contact, wash thoroughly. Always observe the safety and handling instructions povided by
the hydraulic fluid supplier.

□All hydraulic hosepipes must be replaced regularly according to the national

regulations of the country in which the hydraulic system is operated. If no such
regulations exist, we recommend replacement after about 6 years.

Warning
Hydraulic systems may be operated under high pressure. If it is dismantled improperly they can
explode and thereby cause severe accidents. To reduce this risk of explosion, it is essential to
depressurize the systems before dismantling them.

Caution!
Protect the environment!
Handling and disposal of hydraulic fluids and products operated or soaked with hydraulic fluids
is subject to statutory regulations.

4.4 Consequences of unauthorized modification

 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□ Unauthorized modifications of or addition to hydraulic systems are forbidden for

safety reasons. The manufacturer is not liable for damage caused by such
unauthorized actions, for which the user alone is responsible.
The EC conformity declaration/ EG manufacturer's declaration become invalid in the
case of modifications of or additions to the hydraulic system without our approval.
□ No modifications of the hydraulic system are permitted without the approval of the
manufacturer.
5. Transport, storage and conservation
5.1 Packing and transport
□ Carton / wooden crate / remove film.
□ Remove screws / fixing tape / etc, attach the hydraulic system on the pallet.
5.2 Storage and conservation
□ Observe our storage and transport regulations for hydraulic systems for
conservation, storage and transport before commissioning.
6. Installation
6.1 General instruction
□ Commissioning, maintenance and repairs may be carried out only by trained or
duly instructed personnel with special knowledge of and experience with hydraulic
systems.
□ Work on the electrical system and electric connections of the solenoid valves may
be carried out only by trained or duly instructed personnel with special knowledge of
and experience with electrical / electronic systems.
6.2 Installation conditions
□ Before installation on site, make sure that the foundation or mounting surface is flat
and firm in order to avoid mechanical distortion and/or vibrations.
□ Use the provided screw threads and mounting bores for attaching the hydraulic
unit to the foundation.
6.3 Installation of the pipelines
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□ The hydraulic pipelines to the consumer devices (hydraulic cylinders, hydraulic

motors) must be absolutely free from rust and dirt particles internally, and without
burr at the pipe ends. No further welding or brazing is permitted after installation.
□ The pipelines and fittings must conform to the pressure classification for which the
hydraulic system is designed.
□ The dimensions must correspond to the specifications on the circuit diagram.
Utilization of pipes with too small internal diameter, unnecessary length of pipelines
and too many angle screw fittings lead to pressure losses impairing the overall
performance of the hydraulic system.
□ Pipelines must be installed with care and without stress. They must be held in
exactly fitting pipe clamps which exert no unnecessary loading pressure.
□ The connections of the hydraulic pipelines to the units must be made according to
the circuit diagram.
□ Remove the closing plugs which we have fitted on the hydraulic connections of the
unit in the factory, and the cover plates, only immediately before connecting the
corresponding pipelines. This helps to avoid unnecessary contamination.
□ We recommend the installation of measuring screw fittings at the highest points of
pipelines for venting.
6.4 Installation of the electrical connections
□ Before connecting the electric motor and the control lines, check that the electrical
rating showing the type specification plate of the electric motor and on the terminal
connections plan are identical to the ratings of the local mains power supply and of
the electrical control system.
□ The electrical cable connections must be established according to the circuit
diagram and the terminal connections plan.
7. Commissioning
7.1 Description of the commissioning procedure
7.1.1 Filling the hydraulic system
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□ Always use a filter system in filling the hydraulic system, to ensure that the
hydraulic fluid comes into the tank conforming to the specified cleanliness class.
This also applies to filling from new barrels.
7.1.2 Instructions for switching on the electric motor
□ When switching on the electric motor for the first time, let it run for only a short time
to check the rotation direction.
Clockwise rotation of the pump corresponds to anticlockwise rotation of the electric
motor.
7.1.3 Venting of the pump
□ When the electric motor is running in the specified rotation direction, the pump
must be vented according to the instructions of the pump manufacturer.
If any problems are encountered, please get in touch with Deadong Entec.
Attention! Scattering noise implies that there is an intake suction problem with
danger of cavitation.
7.1.4 Venting of the hydraulic system
□ The hydraulic system must be vented thoroughly before adjusting the operating
pressure. This should be done ate a pressure with which the load devices can just
be moved.
□ The venting must be made at the highest point of each hydraulic pipeline and
continued until foam-free medium is coming out.
7.1.5 Purging the hydraulic system
□ In every new hydraulic system from the factory, however carefully constructed,
there are dirt particles in the pipeline system. Hydraulic systems with particularly dirt-
sensitive devices (proportional and servo control valves) must therefore be purged
thoroughly before running them with full working pressure and speed.
□ For the purging process, bypass the connections directly at the load devices with
hosepipe connections and replace particularly sensitive valves with purging plates. It
may be possible to accelerate the purging process by fitting filters in the hosepipe
connections.
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□ When purging, make sure that cleaning filters are not in the subsidiary stream.
Insert new filter elements after purging.
7.1.6 Liquid level
□During commissioning the liquid level in the tank initially falls until the entire pipeline
system including the load devices is filled with hydraulic fluid must be filled in
immediately when required. The bottom mark of the liquid level indicator must never
be undershot.
7.1.7 Plants with accumulator (pressure storage tank)
□Before commissioning hydraulic systems with accumulators (pressure storage
tanks), the operator must check that the accumulator has passed the acceptance
test according to the regulations for pressurized containers.
□ Make sure that the gas pressure corresponds to the specifications in the circuit
diagram.
Attention : Unless explicitly specified differently, only nitrogen may be used as gas
medium!
7.2 Required personnel
□Commissioning, maintenance and repair tasks may be carried out only by trained
or duly instructed personnel with special knowledge of and experience with hydraulic
systems.
7.3 Training and instruction of the operating personnel
□Commissioning, maintenance and repair tasks may be carried out only by duly
trained or instructed persons with special knowledge of and experience with
hydraulic systems.
□Work on the electrical system and the electrical connections of the solenoid valves
may be carried out only by trained or duly instructed persons with special knowledge
of and experience with electrical/electronic systems.
7.4 Required consumable materials
□Only original replacement parts may be fitted..
□Only nitrogen may be used as gas medium in plants with accumulator
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

(pressurized storage tank).

8. Maintenance and repairs
8.1 Maintenance after commissioning
□During the first two months after commissioning the maintenance tasks must be
carried out at shorter intervals. The following points must be checked daily during the
first week, and daily to weekly as from the second week:
◆ Hydraulic lines and connections, tank lid and any oil troughs or leaks.
◆ Tank fill level and temperature of the medium.
◆ Quite running of pumps and motors.
◆ Settings of pressure valves and switches.
□Leaks and fill level deficiencies must be remedied immediately. In the case of
problems which cannot be solved by the maintenance personnel of the operator.
Deadong Entec must be informed immediately.
□Contaminated filter cartridges must be replaced immediately.
□After the first week and then monthly, check all operationally and safety relevant
screw fittings for firm seating, and retighten them if necessary.
□Check the cleanliness of the hydraulic fluid according to our recommendations in
Section.3.2.
□We recommend the first change of the hydraulic fluid after 2 months or 500
operating hours.
8.1.3 Maintenance in normal operation
□Hydraulic screw fittings and couplings must be checked weekly for any leaks.
Leaks must be sealed and escaped hydraulic fluid must be cleaned up.
□Make sure that fill level deficiencies in the hydraulic tank are corrected immediately,
and that contaminated filter elements are replaced immediately. Depending on the
environmental conditions, the venting filter, too, must be replaced once or twice each
year.
□Check at monthly intervals for any damage to the unit, control blocks of the
pipelines, pipeline fixing elements, valves, pressure operated switches, solenoids
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

and electrical connections (e.g. cracks, kinks, detachments, worm locations,

brittleness. etc.). Detected damage must be remedied immediately.
□When replacing components, observe the warning instructions in Section 8.2!
□Get a specialist check whether the hydraulic hosepipes are in proper working
condition. The following criteria must be inspected:
◆ Externally visible damage, such as cracks, kinks, worm locations, detachments,
brittleness, tec.
◆ Torsion/deformation of the hosepipes in the depressurized and pressurized state.
◆ Leaks between the hose and the fitting. Is the hosepipe wandering off the fitting?
Damaged hosepipes must be replaced immediately.
□All hydraulic hosepipes must be replaced regularly according to the national
statutory regulations in the country where the hydraulic system is operated. In the
absence of such regulations we recommend replacement at intervals of about 6
years.
□At regular intervals check the cleanliness of the hydraulic fluid as described in
Section 3.2.
□After about 2000 operating hours let the supplier of your hydraulic system carry out
an analysis of the hydraulic fluid to check for the best time intervals for complete
replacement of the hydraulic fluid.
□It is recommended to let a specialist check the hydraulic fluid every five years after
commissioning, to verify proper condition.

Caution!
The hydraulic fluid can cause skin rash and other damage to health. Therefore avoid prolonged

skin contact. Wash thoroughly after contact. It is essential to obey the safety and handling

i i id d b h h d li fl id li

8.2 Repairs and dismantling of the hydraulic system

□ Depressurize the hydraulic system before commencing repair work or dismantling
it. For this purpose switch off the electric control system at the main switch and, if
possible, remove the key to prevent unintended start up of the hydraulic system.
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□Hydraulic accumulators (pressurized storage tanks) may still be under pressure on

the fluid size even when the electric control system is switched off.
In these cases the accumulator must be depressurized via the respective drain valve.
□Before commencing repair work or dismantling, check on the pressure gauge for
the "pump pressure", and in systems with accumulator also on the "accumulator
pressure" pressure gauge, to make sure that the hydraulic system is depressurized.

Warning
Hydraulic systems are operated under pressure. They can explode, causing severe accidents, if

dismantled improperly. To reduce this explosion risk, it is essential to depressurize the systems

before dismantling them.

□Load devices which could drop down or move in uncontrolled manner when
dismantling the hydraulic system must be supported and secured before
commencing the tasks.
□It is forbidden to enter the pipelines.
□Escaping hydraulic fluid must not be allowed to come into ground water or waste
water.
□Clean up small quantities of hydraulic fluid with rags. Scatter binding agent on
larger quantities and fence off to prevent access. Rags and binding agents soaked
with hydraulic fluid must be disposed of separately.

Caution!

Protect the environment!

Handling and disposal of hydraulic fluid and products operated or soaked with hydraulic fluid is

subject to statutory regulations.

□To avoid functional disturbance, we recommend thorough venting of the hydraulic

system and a check of the fill level in the tank after repair or installation work.
9. Trouble shooting
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

□Personnel entrusted with commissioning, maintenance and repair tasks must have
read this operating instructions manual before commencing work.
□Faults, especially if they could impair safety, must be remedied immediately!
10. Replacement parts
10.1 Customer service address :
- Contact Information -
Name : DAEDONG ENTEC CO., LTD
Address : #1500-23 , SONGJUNG-DONG, KANGSEO-GU, BUSAN,618-270,KOREA
TEL)+82 051 832 1123
FAX)+82 051 832 1369/1370
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

11. Annex
- System diagram –
 Equipment No. : 84P8411A/B

Operation Instruction DOC NO : DDENT-U-002

DATE : 02. 22 . 2010

11.1 Test Certificate and confirmation