HYDAC FILTER SYSTEMS FluidAqua Mobil FAM 10, Operating And Maintenance Instructions, Part

Page 1: ...M 10 FAM 10 15 FluidAqua Mobil Operating and maintenance instructions part 1 2 English translation of original instructions Keep for future reference Document no 4170097b Valid for FAM xx x x x xx x C x x ...

Page 2: ...Imprint FAM 10 Instructions part 1 2 en US Page 2 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 ...

Page 3: ...tion Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com 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 o...

Page 4: ...tory information 10 Proper Designated Use 11 Improper Use or Use Deviating from Intended Use 13 Qualifications of personnel target group 14 Wear suitable clothing 16 Stoppage in an emergency EMERGENCY STOP 16 Unpacking the unit 16 Transporting the unit 17 Transporting with a forklift 17 Transporting with a crane 18 Transporting by train truck 18 Checking the scope of delivery 19 Description of uni...

Page 5: ...cator lamp 44 Change the air filter 44 Testing the AquaSensor 44 Cleaning the suction strainer 45 Rotary vane vacuum pump components 46 Performing an oil change 46 Replacing the Air De oiling Element 47 Replacing the filter element on the fluid filter 48 Maintaining the oil mist separator optional 53 Replacing the filter element on the oil mist separator 55 Testing the float switch in the oil pan ...

Page 6: ...ny material contractual obligation our liability shall be limited to foreseeable damage Claims due to Product Liability shall remain unaffected Technical Support Contact our technical sales department if you have any questions on our product When contacting us please always include the model code serial no and part no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Product modif...

Page 7: ...know I determine which topic I am looking for WHERE can I find the information I m looking for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the operating...

Page 8: ...t 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 general safety information and instructions in these operating instructions which i...

Page 9: ...zardous 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 ...

Page 10: ...am 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 directives Legal and local regulations for accident prevention Legal and local regulati...

Page 11: ...lication described in the following The FAM is for dewatering filtering and degassing hydraulic and lubricating oils In addition it removes free water emulsified water and a large percentage of the water found in solution Intended use of the product also extends to the following Observing all instructions contained in the instruction manual Performing inspection and maintenance work ...

Page 12: ... NBR NBR FAM xx I Insulation oil checked with e g Shell Diala Mineral oils acc to DIN 51524 Gear oils acc to DIN 51517 51524 Other hydraulic and lubrication oils which require or are compatible with NBR seals NBR NBR FAM xx B Biologically tested with fast biodegrading fluid on an ester basis Synthetic ester HEES DIN 51524 2 Vegetable oils HETG HTG Hydraulic and lubrication oils which require or ar...

Page 13: ...ed only in connection with the media mentioned below 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 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 atmos...

Page 14: ... safety information 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 suc...

Page 15: ... 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 media Know...

Page 16: ...elry 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 unit downstream of this switch is voltage free and depressurized Normal pressure is restored to the vacuum column after 1 minute Unpacking the unit Before delivery the FAM is inspected for leaks and prop...

Page 17: ...ged Never use the components to push or pull the unit Use only the grips provided for shifting Drain the unit completely before transport Seal off the inlets and or outlets Shift the FAM manually using the rollers When doing so use only the grips provided on the FAM frame for pushing Before shifting the unit make sure to release the hand brake on the steering rollers Once the FAM is in its new pos...

Page 18: ...s The unit will be damaged Components will be damaged 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 Transporting by train truck For transport by rail or truck supports must be placed under the mobile unit so that the rollers are subjected ...

Page 19: ... agent or the department in charge immediately the unit may not be commissioned until this damage is properly remedied The following items are supplied Qty Designation 1 FluidAqua Mobil ready for connection with suction and pressure hose 1 Technical documentation consisting of Operating and maintenance instructions Part 1 2 Operating and maintenance instructions Part 2 2 Electrical circuit diagram...

Page 20: ...sified water and a large percentage of the water to be found in solution The integrated fluid filter ensures an efficient separation of solid particles The drying and degassing of the medium is achieved by the negative pressure in the vacuum column Unit designs Stationary FAM xx x 1 Mobile FAM xx x 2 In comparison to the stationary version the mobile version of the FAM has 2 casters 2 fixed caster...

Page 21: ...ilter Size 2 000 FAM5 1 000 7 000 FAM10 15 7 000 15 000 FAM25 15 000 25 000 FAM 45 FAM 45E 25 000 35 000 FAM60 35 000 45 000 FAM 75 FAM 75E 45 000 FAM95 Generally speaking however it must be taken into account that the design depends on the application the fluid and the ambient temperature the fluid amount and the water input into the system These exercise a great influence over the dewatering per...

Page 22: ...continuously using the negative pressure sensor 15 and displayed on the control panel in the control cabinet The fluid percolates downwards in the vacuum column over a special tower packing and collects in the lower area The evacuation pump 7 switches on after the Max 19 center level is reached As a result of the higher flow rate of the evacuation pump the filling level in the vacuum column drops ...

Page 23: ...e displayed in plain text in the correspondingly available national language All E STOP messages will lead to a direct switch off of the unit After the FluidAqua Mobil is shut down using the control panel the filling pump and the rotary vane of the vacuum pump and the supply pump in the existing ContaminationSensor are switched off Exception If the heater is switched on then a cooling phase of 60 ...

Page 24: ...tinuous operation Purifying and transferring by pumping The FAM is connected to the contaminated oil tank with the suction hose and pumps the fluid into the tank for the purified oil while cleaning it at the same time A Waste oil tank B Pure oil tank The fill level of the clean oil tank is to be monitored constantly during this process to prevent overfilling You achieve permanently better levels o...

Page 25: ...Description of function FAM 10 Instructions part 1 2 en US Page 25 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 Unit system components ...

Page 26: ...ilter drainage 13 Air filter and dryer 14 Needle valve for vacuum setting 15 Pressure sensor for vacuum measurement 16 Vacuum pump 19 Vacuum column level sensor 24 Float switch oil pan 25 Vacuum column drainage 27 Temperature sensor optional for heater 28 Vacuum pump drainage 29 Level sensor for vacuum pump 30 Ball valve at the inlet IN 40 Switch cabinet 41 Main switch E STOP 42 Fault indicator la...

Page 27: ... 10 Instructions part 1 2 en US Page 27 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 Unit dimensions The different versions of the FAM series have the following illustrated dimensions Stationary version ...

Page 28: ...Unit dimensions FAM 10 Instructions part 1 2 en US Page 28 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 Mobile version ...

Page 29: ...Hydraulicdiagram FAM 10 Instructions part 1 2 en US Page 29 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 Hydraulicdiagram ...

Page 30: ...re switch for filter monitoring 11 Fluid filter drainage 13 Air filter and dryer 14 Needle valve for vacuum setting 15 Pressure sensor for vacuum measurement 16 Vacuum pump 19 Vacuum column level sensor 20 Pump to the ContaminationSensor CS1000 optional 21 ContaminationSensor CS1000 optional 22 Pressure relief valve CS1000 optional 23 Pressure relief valve CS1000 optional 24 Float switch oil pan 2...

Page 31: ...rgent gas is inhaled over an extended period of time Setting up the unit Observe the following points when setting up the unit Set up the unit horizontally on a level surface Special mounting is not required Lock the immobilization brakes on the wheels to avoid unintended movement of the unit Set up the unit directly beside the tank that is to be cleaned Observe the maximum permitted suction press...

Page 32: ...ead 2 Adapter Adapter G1 A external thread 3 FAM outlet connector 18L M26x1 5 external thread 4 Adapter Adapter G1 2 A external thread 5 Suction hose connection 28L M36x2 internal thread 6 Adapter Adapter G1 A external thread 7 Pressure hose connection 18L M26x1 5 female thread 8 Adapter Adapter G1 2 A external thread Connection type D in accordance with ISO 8434 1 series L corresponds to ISO 1215...

Page 33: ...Pa depends on the height differential between the FAM fluid surface in the tank port aspiration height P height and the line losses P line If the FAM is above the fluid surface in the tank determine the pressure as follows Pe P height P line Pa P height P line If the FAM is below the fluid surface in the tank determine the pressure as follows Pe P Height P Line Pa P height P line Caution Pe perm P...

Page 34: ...lic oil HLP 0 85 0 90 kg dm Phosphate ester HFDR 1 00 1 10 kg dm Insulation oil 0 90 1 00 kg dm Lubricating oil 0 90 0 95 kg dm Find the flow rate in chapter Technical data on page 62 Additional threaded connections and pipe bends increase the pressure differential and must be taken into account Keep the height difference between the pump and the oil level in the tank as low as possible Avoid cons...

Page 35: ... Contamination too high The unit will be damaged Do not prime directly at the bottom of the tank Do not prime in the sump Never prime without a built in suction screen 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 Connecting the outle...

Page 36: ...with vacuum pump oil if necessary The maximum filling volume for vacuum pump oil is 0 3 liters The oil level is monitored automatically by the integrated float switch while the FAM is in operation A message will appear on the control panel when the MIN MAX filling level has been reached Filling up the rotary vane vacuum pump Remove the safety screw for the plug at the level switch 1 Remove the plu...

Page 37: ...nding knowledge and skills Make sure that the voltage and frequency specifications on the FAM type label correspond to the existing mains voltage If a plug is present on the FAM or if a plug is mounted then the FAM is to be operated from a correspondingly fused socket The electrical data on the type label of the unit is binding not that on the type label of the control cabinet Rotating field Make ...

Page 38: ...097b en us 2018 05 23 docx 2018 05 23 A phase sequence relay checks the correct phase sequence after switch on In the event of an incorrect phase sequence error message no 29 is shown on the control panel Additional details can be viewed in part 2 2 of the Operating and maintenance instructions ...

Page 39: ...he following operating elements are to be found on the FAM Item Description A Main switch with E STOP function B Alarm signal lamp yellow C Control panel for details see Operation and Maintenance Instructions part 2 2 D Needle valve to set the pressure in the vacuum column E SensorMonitoring Unit SMU1200 optional See the appropriate operating instructions for details ...

Page 40: ... 1 2 en US Page 40 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 Switching on switching off commissioning and error messages Details on switching on off commissioning and error messages troubleshooting can be found in the Operation and Maintenance Instructions part 2 2 ...

Page 41: ...crewed fittings which have been undone removed are to be checked to see that they have been properly resecured See page 24 hours daily 500 hours monthly 3000 hours every six months 6000 hours annually 26 000 hours 3 years FAM Check the FAM for any leaks visual check X Check the screwed fittings to see that they have been properly resecured X Inspection of the measurement technology Pressure sensor...

Page 42: ...ir De oiling Element 47 X Check and clean the ventilator hood X Emptying filling pump Check and clean the ventilator hood X Fluid filter Changing the filter element 48 X Emptying and cleaning the filter housing X Oil mist separator optional Changing the filter element 53 X Electric System Check cable conduits for damage replacing as necessary X Measure the engine power consumption of all engines a...

Page 43: ...0702 and or corresponding national regulation Measure power consumption of the heater and compare values with type label applies only to versions with integrated heater X Function Test Testing the oil pan float switch 53 X Checking and cleaning the vacuum column level sensor 57 X Completely replace all of the hoses after 5 years The pictures and illustrations in the descriptions are examples They ...

Page 44: ...fault indicator lamp has been completed Change the air filter Replace the air filter 1 every six months If you are operating the unit in a very dusty damp environment the replacement interval is accordingly shorter 1 Manually unscrew the air filter 1 2 Dispose of the air filter in an environmentally friendly manner 3 Manually screw on the new air filter 1 and tighten this manually until secure 4 T...

Page 45: ...r insert is fitted at the pump inlet Clean the suction strainer at regular intervals To install dismount the suction screen proceed as follows 1 Unscrew the screw plug 1 counterclockwise using an open jaw wrench 1 2 3 2 Remove and clean the sieve insert 3 3 To clean the suction screen wash it out with solvent and then dry it using compressed air 3 Check the sieve insert 3 and seal ring 2 on the sc...

Page 46: ... a Oil filler neck c Oil drain d Oil sight glass g Oil separator h Suction port connection i Gas outlet k Safety screw on the plug l Plug for the level sensor m Level switch in the vacuum pump The following descriptions are in reference to these positions Performing an oil change The first oil change must take place after 100 operating hours This increases the interval to approx 3000 hours or ever...

Page 47: ...f oil diminishes Let the pump run again briefly for a few seconds 4 Open the plug screw once again and drain off the remaining oil 5 Screw in the plug screw and tighten it firmly 6 Remove the oil filter and dispose of it properly 7 Install the new oil filter 8 Fill in fresh vacuum pump oil through the oil filling screw plug a Ensure that the level is in the middle between the MIN and MAX d marking...

Page 48: ...eal if necessary 12 Fasten the ventilation cover i with seal and hexagon head screws to the oil separator g The air de oiling element becomes saturated with oil during operation A slight lowering of the oil filling level after the air de oiling element has been replaced is therefore quite normal Replacing the filter element on the fluid filter As soon as the error message change fluid filter appea...

Page 49: ...s part 1 2 en US Page 49 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 the filter bowl 3 Release the tensioning clamp 1 on the filter housing and remove it downwards 2 Use a 6 mm 1 Allen wrench 4 Pull the filter bowl including filter element downwards ...

Page 50: ...n US Page 50 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 5 Remove 2 the filter element by turning 1 slightly out of the filter bowl Dispose of the used filter element in an environmentally correct manner 6 Clean the inside of the filter bowl of dirt and deposits ...

Page 51: ... 2018 05 23 docx 2018 05 23 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 9 Turning it slightly press the new filter element down into the mount on the filter bowl ...

Page 52: ...e filter bowl with the filter element up into the mount on the filter head 11 Slide the tensioning clamp 1 from the bottom over the 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 ...

Page 53: ... FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 13 The filter element change is now complete After commissioning check the filtration unit for leaks Maintaining the oil mist separator optional Item Designation 1 Separator head 2 Separator pot 3 Clogging indicator 4 Filling level display ...

Page 54: ...uum pump A filter element is used to retain the oil mist and the oil in the oil mist separator and the oil is collected in the separator pot where it is continuously suctioned off and returned to the vacuum column The filter element for part no see replacement parts list is to be replaced on a regular basis in accordance with the maintenance schedule The clogging indicator 3 of the oil mist separa...

Page 55: ...hamber 2 Rotate the separator pot 2 1 8th of a turn to the left bayonet seal and remove from the bottom 3 Turn the used filter element clockwise to remove and dispose of it in an environmentally correct manner The element shown here may vary visually Insert the filter element and screw it into the separator head by turning it counterclockwise Do not use any tools to dismantle or install the filter...

Page 56: ...ingers to raise the float switch in the oil pan 2 The unit must switch off and the fault message Pan overfilled must appear in display of the control panel 3 Release the float switch and acknowledge the fault message by pressing the F3 key 4 The unit continues to operate You have tested the function of the float switch positively 5 If the unit does not switch off after the lifting of the float swi...

Page 57: ...olumn Conditions for the check 1 Pull out the power plug or deenergize the unit Replace the installed level sensor 2 Pull out the level sensor connector 3 Remove the level sensor of the column 4 Now reinsert the connector of the level sensor 5 Carry out the corresponding resistance measurement on the respective PLC inputs To do this remove the single leads from the inputs E 0 3 E 0 4 and E 0 5 ...

Page 58: ...rument lead with 24V DC e g with a crocodile clip 9 Also connect the second instrument lead with the wire from E 0 3 E 0 4 E 0 5 of the contact to be measured e g with a crocodile clip 10 Now bring each float into position by it closing the contact 11 The contact is OK if the unit for measurement displays a resistance of 1 2 Ω after a measuring time of around 5 seconds If there are larger resistan...

Page 59: ...ssure hose Length 5 m 6013308 1 Suction hose Length 5 m 6004781 1 Level sensor vacuum column 4392182 1 Filter element of oil mist separator optional 3584078 available on request Fluid filter OLF 5 Qty Designation Part no 1 Filter element filtration rating 2 µm N5DM002 349494 1 Filter element filtration rating 5 µm N5DM005 3068101 1 Filter element filtration rating 10 µm N5DM010 3102924 1 Filter el...

Page 60: ...re parts FAM 10 Instructions part 1 2 en US Page 60 72 BEWA FAM10 15 1 2 4170097b en us 2018 05 23 docx 2018 05 23 1 Vacuum pump oil 1 liter drum 6018128 1 Vacuum pump oil 5 liter drum 6018129 available on request ...

Page 61: ...power plug and securely fasten the hoses and power cord to the unit Store the unit in a clean dry non condensing space Refer to the technical data for the permissible storage temperature range In the case of storage periods greater than 1 year please contact HYDAC FILTER SYSTEMS GMBH Disposing of the unit Dispose of the packaging material in an environmentally friendly manner After dismantling the...

Page 62: ...h heater Weight when empty 300 kg 300 kg Operating pressure 6 bar Permissible suction pressure at suction port without suction hose Pe perm 0 2 0 6 bar Permitted pressure at the outlet without pressure hose Pa perm 0 3 5 bar Viscosity range 15 to 800 mm s Pump type Vacuum pump Rotary vane vacuum pump Rotary vane vacuum pump Filling pump Vane pump Vane pump Evacuation pump Gear pump Gear pump Fluid...

Page 63: ...erature range 10 80 C Permitted ambient temperature range 10 40 C Permissable relative humidity maximum 90 non condensing Permitted storage temperature range 10 50 C Achievable residual water content 100 ppm Hydraulic and lube oils 50 ppm Turbine oils ISO VG32 46 10 ppm Transformer oils not suitable for online or onload operation Noise level according to VBG121 70 dB A at 1 m distance ...

Page 64: ...C FILTER SYSTEMS GMBH Phone 49 6897 509 1174 Fax 49 6897 509 9046 E mail filtersystems hydac com Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your FluidAqua Mobil Our HYDAC Servicenter offers you these tasks within agreed upon time frames and at fixed prices HYDAC SERVICE GMBH Friedrichsthaler Str 15A Werk 13 66540 Neunkirch...

Page 65: ...z 3 Ph D 200 V 60 Hz 3 Ph E 220 V 60 Hz 3 Ph F 230 V 60 Hz 3 Ph G 380 V 60 Hz 3 Ph H 440 V 60 Hz 3 Ph I 500 V 50 Hz 3 Ph K 480 V 60 Hz 3 Ph L 220 V 50 Hz 3 Ph N 575 V 60 Hz 3 Ph O 460 V 60 Hz 3 Ph X other voltage Filter size fluid filter 05 OLF5 Type of vacuum pump R Rotary vane vacuum pump Heater H Heater Z Without heater Control concept C1 Comfort control panel language in de en fr es pt it nl d...

Page 66: ...sphere OM Operating mode BeWa Operating and Maintenance Instructions ContaminationSensor Sensor for solid particle contamination in fluid CS ContaminationSensor DC Direct current DIN Deutsche Industrie Norm German Industry Standard DN Nominal Diameter Drain Drainage port Rotary vane vacuum pump Vacuum pump required as operating material for vacuum pump oil EC European Community ESC Escape EU Europ...

Page 67: ...m Meter MAX Maximum mbar Millibar 1 mbar 0 001 bar MIN Minimum mm Millimeter NAS Classification of the solid particle contamination NBR Nitrile rubber Nm Newton meters torque specification OFF Switched off OLF Offline filter Bypass flow filter unit ON Switched on OUT Outlet OUTLET Outlet Pa Pascal PPM Parts per million psi Pound force per square inch SAE Classification of the solid particle contam...

Page 68: ...Documentation Representative 3 drain plug 48 52 draining 48 F Fault indicator lamp 26 filling 22 23 36 42 47 48 Filter 13 21 59 62 65 Filter element 59 62 Filter element type 62 filtration 20 53 59 Float switch 26 30 Flow rate 33 34 62 Fluid filter 26 30 42 59 62 Fluid temperature 21 Forwarding agent 15 Fyrquel 12 G Gear pump 62 H Hazard symbol 8 10 Heater 26 30 65 HFD 12 66 67 I Imprint 3 IN 26 3...

Page 69: ... select 7 Sensor 66 Service 56 59 64 setting 22 26 30 31 Signal word 9 10 signal words 10 Size 21 65 Solid particle contamination 66 Specialist personnel 14 15 Suction hose 20 32 59 Suction port connection 46 Suction screen 26 30 switching off 40 switching on 40 Synthetic ester 12 T Temperature 26 30 Temperature sensor 26 30 to shut down 16 Transformer oil 63 Transport 15 transporting 17 troublesh...

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Page 72: ...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 ...