HYDAC FILTER SYSTEMS FCC, Operating And Maintenance Instructions Manual

Page 1: ...FCC FluidCarrier Compact Operating and Maintenance Instructions English translation of original instructions Document no 3160328g Keep for future reference ...

Page 2: ... Supplementary symbols 11 Exclusion of liability warranty 12 Notes on copyright 12 Validity of this manual 12 General Safety Information 13 Firefighting Extinguishing Fires 14 Product overview 15 Scope of delivery 16 Dimensions 17 Connections and components 18 Hydraulicdiagram 20 Proper Designated Use 22 Improper use or use deviating from intended use 24 Technical data 25 Decoding the type label 2...

Page 3: ...r 40 Programming the flow meter 41 Correcting setting the measurement accuracy 43 Observing the clogging indicator 45 Viewing and resetting the optical clogging indicator 45 Observing electrical clogging indicator 45 Maintenance 46 Cleaning the unit 46 Changing the filter element 47 Replacing the breather filter 52 Cleaning replacing suction strainer 53 Suction strainer cleaning interval 53 Custom...

Page 4: ...BH Postfach 1251 66273 Sulzbach Saarland Germany Phone 49 6897 509 01 Fax 49 6897 509 9046 E mail filtersystems hydac com Homepage www hydac com Court of registration Saarbrücken HRB 17216 Executive directors Mathias Dieter Dipl Kfm Wolfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Phone 49 6897 509 1511 Fax 49 6897 509 1...

Page 5: ... Please refer to it every time you require decisive details This manual informs and warns you of risks against which the risk reduction through the design and protective measures may not be effective or not fully effective Target group of the manual This manual was created for the following target group Target group Tasks Owner This manual and the associated documents must be kept accessible at th...

Page 6: ...ntial hazards that can result from 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 dangers Activity Person Knowledge Transport storage Forwarding agent Auxiliary personnel No specialist knowledge required Hydraulic electrica...

Page 7: ...ex enables you to order another copy of the operating and maintenance instructions The index is incremented every time the manual is revised or changed 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 The manua...

Page 8: ...e product 3 Switch the product on Procedural instructions with a random sequence Procedural instructions that have a random sequence are listed as bullet points An example of a procedural instruction with a random sequence Clean the display Rinse the product Representation of warning general safety information All the warning general safety information in this manual are highlighted with pictogram...

Page 9: ...ich 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 haza...

Page 10: ...ls pictograms intact and legible Warning signs used These signs are listed for all general safety information and instructions in these operating instructions which indicate particular dangers to persons property or the environment Danger point warning Danger due to operating pressure Danger of electrical shock Signs used for giving orders These symbols are listed for all general safety informatio...

Page 11: ...d several years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential dangers Specialist personnel Mechanical Such persons have specific 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 dangers Supplementary symbols You will ...

Page 12: ...es 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 the Product Liability shall rem...

Page 13: ...afety and warning instructions attached to the product and always keep them up to date and easily legible NOTICE Impermissible operating media The unit will be destroyed Only use the FCC in connection with lubrication and mineral oils or mineral oil based media or biological fluids that can be broken down quickly and are based on synthetic esters HEES DANGER Hazard due to use of the product other ...

Page 14: ...1 25 docx 2019 11 25 Firefighting Extinguishing Fires Use a powder extinguisher that corresponds to fire class B as per EN 2 to extinguish any fires Maintain a minimum safe distance from electrical components For a mains voltage of up to 1000 V the minimum safe distance is 1 m ...

Page 15: ...r unit has been developed for the maintenance of processing machines with tank volumes of up to 200 liters The filter unit allows you to transport and refill filtered quantities of oil with monitored oil cleanliness Smaller containers or systems in the bypass flow can be filtered or cleaned using the filter unit ...

Page 16: ...s 2019 11 25 docx 2019 11 25 Scope of delivery The following items are supplied Qty Description 1 The FCC ready for connection with the suction and pressure hose power supply cord including the power plug 1 Operation and Maintenance Instructions this document ...

Page 17: ...Product overview FCC en Page 17 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 Dimensions All dimensions in mm ...

Page 18: ...Product overview FCC en Page 18 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 Connections and components ...

Page 19: ...et OUT Outlet 2 Sliding grip 3 Hose retainer 4 Fluid level gauge 6 Electrical switch box with main switch 7 Nose wheel with immobilization brake 8 Suction screen 9 Inspection opening for the tank container 10 Chassis 11 1 Air filters 50 Filtration unit 51 Clogging indicator 100 Ball valve IN 101 Ball valve OUT ...

Page 20: ...Product overview FCC en Page 20 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 Hydraulicdiagram ...

Page 21: ...ion hose 3 Suction screen 4 Ball valve 5 Flow meter 6 Filter 7 Motor pump assembly 8 Clogging indicator 9 Air filters 10 Maintenance opening 11 Fluid level gauge 12 Tanks 13 Port for FCU 14 Bypass valve 15 Pressure relief valve SE Drain TE Drain TS Suction port connection TR Return line S Suction side P Pressure side X Option ...

Page 22: ...ly for the application described in the following The filter unit is used as a service unit for filling and emptying hydraulic systems cleaning or filtering the fluid in the bypass flow and recirculating with simultaneous filtration Proper or designated use of the product extends to the following Observing all instructions in the instruction manual Performing inspection and maintenance work NOTICE...

Page 23: ...osition under exposure to the sun The unit will be destroyed Operate the FCC in horizontal position only Observe the permissible ambient temperature range of 0 40 C NOTICE Operation without a suction strainer The unit will be destroyed Never operate the unit without a suction screen Clean the suction strainer regularly ...

Page 24: ...ered intended use HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use This risk is borne solely by the owner Improper use may result in hazards and or will damage the unit Examples of improper use Operation in potentially explosive atmospheres Operation under non approved operational conditions Operation when the safety devices are defective Modifications to t...

Page 25: ...um flow rate 4 l min 15 l min Permissible viscosity range 200 1000 mm s 15 500 mm s Permitted fluid temperature range 0 80 C 0 80 C Permitted ambient temperature range 0 40 C 0 40 C Permissible storage temperature range 0 50 C 0 50 C Empty weight 63 kg 63 kg Filtration rating 2 µm absolute 2 µm absolute Contamination retention capacity when using filter element N5DM002 200 g ISO MTD 200 g ISO MTD ...

Page 26: ... 25 docx 2019 11 25 Decoding the type label Details on the product identification are provided on the name plates on the product and the components Item Description 1 Name plate of the filter unit 2 Name plate of the electric motor 3 Model code for details see page 28 ...

Page 27: ...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 Empty weight Flow rate Flow rate Temp oil Permitted fluid temperature range Temp amb Permitted ambient temperature ...

Page 28: ...LEC HD472 S1 at 50 Hz Filter element N5DM002 DIMICRON filtration rating 2 µm absolute N5DM005 DIMICRON filtration rating 5 µm absolute N5DM010 DIMICRON filtration rating 10 µm absolute N5DM020 DIMICRON filtration rating 20 µm absolute N5AM002 AQUAMICRON filter rating 2 µm absolute N5AM020 AQUAMICRON filter rating 20 µm absolute Clogging indicator BM Differential pressure indicator visual VM2BM 1 C...

Page 29: ...Product overview FCC en Page 29 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 FCU Prepared for connection E E control for controlling the FCC with FCU including option FA1 FCU ...

Page 30: ...nnection cord and both hoses onto the hose retainer Push the filtration unit only at the grip Transport the filtration unit upright and in secure packaging Drain the filter unit completely including the tank contents before putting it into storage Pull out the power plug and fasten the hoses and power cord onto the hose retainer Store the unit in an upright position in a clean dry non condensing s...

Page 31: ...ly at the bottom of the tank Do not prime in the sump The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Using the lance put the suction hose into the appropriate reservoir without tension or twist and secure the suction hose against falli...

Page 32: ...Δh between the suction side and pressure side reservoir a suction effect can develop in the hose that is lower down causing the fluid levels to equalize in accordance with a principle of communicating vessels siphoning This siphoning effect also occurs when fluid is pumped in a pre pressurized reservoir When the unit is switched off the height difference primary pressure can cause flow to occur bo...

Page 33: ...e FCU purity controller to the FCC In order to do this position the ball valve KH3 in position I so that the operating pressure necessary for FCU can be built up Connect the intake of the FCU to the Minimess port 13 on the filter console Connect the return line of the FCU to the Minimess port 13 of the ball valve KH3 The FCU can now be used in connection with the FCC For information on using the F...

Page 34: ...ush the product multiple times after recirculating and filtering oil that contains water with oil that does not contain water before shutting it down Note that the AQUAMICRON filter elements have a limited water retention capacity Selecting the operating modes The unit has the following operating modes Description Page Emptying external containers system 35 Cleaning the tank content 36 Filling ext...

Page 35: ...ppropriate container with clean oil and secure the suction hose to prevent it from falling out and floating 3 Plug the power plug into a suitable power outlet 4 Switch on the FCC at the main switch 5 Monitor the filling level in the FCC via the filling level display on the rear of the container at all times 6 Switch off the unit at the main switch once it has reached the Max mark 7 Take the suctio...

Page 36: ...I into the corresponding position 2 Plug the power plug into a suitable power outlet 3 Switch on the FCC at the main switch 4 Cleaning a tank content of 70 liters requires approx 3 4 circulations For a flow rate of 5 l min this corresponds to a duration of approx 60 min 5 After filtration switch off the unit at the main switch 6 Pull the plug out of the socket and wind the connection cord onto the...

Page 37: ...se without stretching and twisting it in the appropriate container and secure it to prevent it from falling out and floating 3 Plug the power plug into a suitable power outlet 4 Switch on the FCC at the main switch 5 Monitor the filling level in the container to be filled at all times 6 Switch off the unit at the main switch once it has reached the desired filling level 7 Take the return hose out ...

Page 38: ...the lance insert the suction hose without stretching and twisting it in the appropriate container and secure it to prevent it from falling out and floating 4 Plug the power plug into a suitable power outlet 5 Switch on the FCC at the main switch 6 Cleaning the container content requires approx 3 4 circulations Observe the maximum flow rate of the pump unit 7 Switch off the unit using the main swit...

Page 39: ... meter RESET The display of the batch register memory can be set to ZERO by pushing the RESET button Resetting is not possible during an operating cycle Resetting the totalizer is only possible through internal programming Function monitoring The RESET command automatically triggers a self test of the meter The LCD shows all of the 8 display segments Volumetric impulses that come in during the sel...

Page 40: ...actor The correction factor programmed Ex factory is a result of the exactness test of the basic meter with an electronic display attached Example Quantity dispensed 4 2 liters Quantity displayed 4 0 liters Correction factor k 4 2 4 0 1 05 Pressing the TOTAL and the RESET button simultaneously in this sequence will cause the programmed correction factor to be displayed as long as both buttons are ...

Page 41: ...ement in the following sequence QT GAL L PT After selecting the required unit of measurement this part of the program can be exited from by pressing the TOTAL button At the same time the unit of measurement selected in this way is saved as the current value 3 The value switched last is saved as the current value in the program by pressing the TOTAL button 4 Every time the RESET button is pressed t...

Page 42: ... unit of measurement are saved redundantly for safety reasons The content of the totalizer is also retained after reprogramming as long as the unit of measurement is not changed If the programming referred to in point 8 is completed with a new measurement unit the totalizer is automatically reset to zero After enabling the programming button the micro processor switches off all of the functions in...

Page 43: ...o be changed flashes in this case the 0 6 Press the RESET key repeatedly until the desired value is reached once in this case to reach 1 7 Press the TOTAL button until the next number to be changed flashes in this case the first 9 8 Press the RESET key repeatedly until the desired value is reached once in this case to reach 0 9 Press the TOTAL button until the next number to be changed flashes in ...

Page 44: ...Operation FCC en Page 44 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 16 Mount the counter back onto the basic meter After programming the RESET button must be pressed to activate the LCD ...

Page 45: ...clogging indicator The filter housing is equipped with an optical clogging indicator for monitoring the contamination of the filter element When the clogging indicator is red 1 change the filter element 2 Reset the clogging indicator by pressing the reset button 3 Observing electrical clogging indicator With the electrical clogging indicators an electrical signal is emitted when the filter element...

Page 46: ...ily injury Depressurize the system before performing any work on it Cleaning the unit We recommend cleaning the entire interior of the container once a year To do so remove the container lid and clean the interior mechanically Clean all the dismounted parts and examine them for any possible damage Replace those components if necessary ...

Page 47: ...time to replace the filter element To change the filter element proceed as follows 1 Switch off the system and close the locking devices at the inlet and outlet ports Make sure that the unit cannot be inadvertently switched back on during maintenance work 2 Place a suitable container 1 to collect the catch the operating medium Depressurize the filter housing Open the drain plug 2 on the filter bow...

Page 48: ...ance FCC en Page 48 64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 4 Pull the filter bowl including filter element downwards 5 Remove 2 the filter element out of the filter bowl by turning it 1 slightly ...

Page 49: ... 11 25 6 Clean the inside of the filter bowl of dirt and deposits 7 Check the O ring on the filter bowl for damage Replace it if necessary Moisten the O ring on the filter bowl with the operating medium 8 Moisten the O rings on the new filter element with the operating medium ...

Page 50: ...64 BeWa FCC 3160328g en us 2019 11 25 docx 2019 11 25 9 Turning it slightly press the new filter element down into the mount on the filter bowl 10 Push the filter bowl with the filter element up into the mount on the filter head ...

Page 51: ...e filter bowl to the top over the bead on the filter bowl filter head Tighten the housing clamp with an Allen wrench SW 6mm in a clockwise direction The tightening torque is 5 Nm 12 Check that the drain plug on the filter bowl is secure 13 The filter element change is now complete After commissioning check the filtration unit for leaks ...

Page 52: ...nment the replacement intervals shorten accordingly Replace the filter element of the breather filter as follows 1 Unscrew cover 11 1 of the breather filter by hand in a counterclockwise direction 2 Remove used filter element 11 2 and dispose of it in an environmentally correct manner 3 Insert new filter element 11 2 and screw on cover 11 1 by hand in a clockwise direction 4 Replacement of the bre...

Page 53: ...n strainer regularly To protect the pump from coarse contaminant particles there is a suction strainer in the suction port Clean the suction strainer regularly Suction strainer cleaning interval The suction screen 2 42 has a much larger absorption capacity at a mesh width of 300 µm Cleaning intervals depending on the previous inlet every 250 hours monthly with each filter element replacement For h...

Page 54: ...essed via the hose coupling 2 41 7 Remove the suction screen 2 42 from the hose coupling 2 41 8 Clean the suction strainer 2 42 by washing it out and then blowing it out with compressed air Replace a defective suction strainer 6 Insert the new or the cleaned suction strainer 2 42 into the hose coupling 2 41 9 Attach the hose coupling 3 1 to the counterpart on the unit 2 41 and turn the hose coupli...

Page 55: ... be found on our website at www hydac com Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life of the product You can reach the HYDAC customer service at the following contact data HYDAC SERVICE GMBH Friedrichsthaler Str 15A Werk 13 66540 Neunkirchen Heinitz Germany Phone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com ...

Page 56: ...tification The filter is clogged Medium is heavily contaminated the filter element is clogged Replace the filter element The viscosity of the medium is too high Heat up the oil Leaks at the filter bowl The drain plug at the filter bowl or the tensioning clamp have not been tightened adequately Retighten the drain plug and tensioning clamp on the filter bowl ...

Page 57: ...g all the components before decommissioning Pull out the power plug and securely fasten the hoses and power cord to the unit Dispose of the packaging material in an environmentally friendly manner After dismantling the product and separating its various materials into categories dispose of all parts in an environmentally friendly manner ...

Page 58: ...ising of Filter bowl O ring Drain plug Tensioning clamp NBR 349692 OLF repair kit comprising of O rings Radial shaft seal Fastening screws NBR 3054619 Filter element N5DM002 2 µm 349494 Filter element N5DM005 5 µm 3068101 Filter element N5DM020 20 µm 3023508 Replacement pump OLF 5 4 with seals NBR 3052460 Replacement pump OLF 5 15 with seals NBR 3052462 Filter element for breather filter 0007 L 00...

Page 59: ...ched on OFF Off and switched off AC Alternating current DC Direct current MIN Minimum MAX Maximum INLET Inlet OUTLET Outlet AIR BLEED VENT Ventilation air bleed port DRAIN Draining connection DN Nominal Diameter DIN German standard EN European standard ISO International standard BEWA Operating and Maintenance Instructions MOWA Installation and Maintenance Instructions UA Conversion instructions ...

Page 60: ...22 59 Disposal 6 57 Documentation Representative 4 DRAIN 59 drain plug 47 51 56 Drain plug 58 draining 47 E Empty weight 25 27 emptying 22 F filling 22 35 37 Filter 21 28 58 Filter element 28 58 filtration 22 28 30 34 36 51 54 Filtration 19 25 Flow rate 27 Forwarding agent 6 G Glossary 59 H Hazard symbol 8 I Imprint 4 IN 19 27 Inlet 19 59 INLET 59 Inspection 19 installation 5 6 11 22 31 ISO 25 59 ...

Page 61: ...39 52 53 S Scope of delivery 16 Service 55 setting 43 Signal word 8 9 signal words 8 9 Specialist personnel 5 6 11 Suction hose 21 Suction port connection 21 Suction screen 19 21 58 Synthetic ester 22 T Target group 5 6 Transport 6 30 Troubleshooting 6 56 V Vane pump 28 VENT 59 W Weight 27 ...

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Page 64: ...H Industriegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Central Fax 49 6897 509 9046 Technology Fax 49 6897 509 577 Sales Internet www hydac com E mail filtersystems hydac com ...