Hydac FluidCleaner Mobil FCM Series, Operating And Maintenance Instrutions

Page 1: ...FCM FluidCleaner Mobil Operating and Maintenance Instructions English translation of original instructions Document no 3160267d ...

Page 2: ...on Representative Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 0 6897 509 1511 Telefax 49 0 6897 509 1394 E Mail guenter harge hydac com HYDAC FILTER SYSTEMS GMBH 2012 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 writt...

Page 3: ... Devices 10 Informal Safety Precautions 10 Training and Instruction of Personnel 11 Safety measures to be followed in normal operation 12 Hazards Posed by Stored Residual Energy 12 Maintenance Servicing and Troubleshooting 12 Modifications to the FCM 12 Fire Fighting 12 Storing the FCM 13 Transporting the FCM 13 By hand 13 Train truck 13 Crane 13 Checking the scope of delivery 14 FCM features 15 O...

Page 4: ...ptional 23 Controlling FCM via the clogging indicator optional 24 Flow rate indicator accessories 24 Pump nozzle accessories 24 Switching on the FCM 25 Selecting operating mode optional 25 Performing Maintenance 26 Maintenance intervals 26 Changing the Filter Element 27 Change the filter element 28 Clean the suction strainer 32 Disposing of the FCM 33 Errors and troubleshooting 33 Spare parts list...

Page 5: ...mation on the unit s engineering contained in the documentation was that available at the time of publication Consequently there might be deviations in technical details illustrations and dimensions If you discover errors while reading the documentation or have additional comments or suggestions contact us at HYDAC Filter Systems GmbH Technische Dokumentation Postfach 12 51 66273 Sulzbach Saar Ger...

Page 6: ...t 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 im...

Page 7: ...re 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 HYDAC FILTER SYSTEMS GMBH en us Page 7 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 Chapter Page number Edition date Document language Documentation no with index file name The documentation number with its ind...

Page 8: ...zard may be posed to the life and limb of the individual using the product or to third parties Nevertheless hazard may be posed to the life and limb of the individual using the product or to third parties The FCM is to be used as follows solely for its designated use only when in a safe perfect condition any faults or malfunctions which might impair safety are to be properly repaired or remedied i...

Page 9: ...ted Use The FCM is a mobile filtration unit designed for circulation pumping with or without filtering fluids at the same time Any other use 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 Maintaining adherence to...

Page 10: ...ty of the product Apart from the operating instructions any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance to be maintained to them All safety guidelines and hazard warnings on the machine must be maintained in legible condition and replaced as required The hoses and connection fittings are to be checked ...

Page 11: ...anner Staff undergoing training may not use the FCM unless supervised by an experienced staff member Individuals Individuals undergoing training Individuals with technical training engineering background Electricians Supervisor with the appropriate authority Activity Packing transportation X X X Commissioning X X X Operation X X X X Troubleshooting locating the source of malfunction X X X Troubles...

Page 12: ...ucted in a timely fashion Secure all operating media against accidental start up The FCM is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance servicing inspection or repair work Check that released threaded joints were refit tightly Always check the safety devices to see that they function properly after performing m...

Page 13: ...unit and secure them Transporting the FCM By hand The unit may be grasped only on the handles provided and shifted by hand Train truck When transported by truck train the unit must be lashed securely to a pallet Crane For transport by crane the unit has an eyelet provided Only use suitable lifting accessories HYDAC FILTER SYSTEMS GMBH en us Page 13 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01...

Page 14: ...transit to the transport company or the responsible agent immediately Do not put the unit into operation The following items are supplied Qty Name 1 FluidCleaner Mobil 1 Filter element 1 Suction hose 1 Pressure hose 1 Operation and Maintenance Instructions this document 1 Certificate HYDAC FILTER SYSTEMS GMBH en us Page 14 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 15: ...unit is a mobile filtration pumping unit designed for oil servicing which depending on the version with or without the change over feature can be used for pumping or pumping and filtering fluids Operating limitations NOTICE Impermissible operating media The unit will be damaged The unit is only to be used with mineral oils or mineral oil based raffinates ...

Page 16: ...eries Dimensions Dimensions 570 613 690 1250 X2 1118 X1 678 X1 490 X2 925 X1 1300 Filter size X2 2600 Filter size HYDAC FILTER SYSTEMS GMBH en us Page 16 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 17: ... filter 1300 2600 30 Motor pump assembly 40 Contamination indication 80 Suction hose with lance 90 Pressure hose with lance 100 with on off switch and overload protective switch 110 Operating change over Option 120 Suction strainer HYDAC FILTER SYSTEMS GMBH en us Page 17 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 18: ...Hydraulic schematic FCM without change over FCM xxx L x xxx x FCM xxx K x xxx M S P FCM with change over FCM xxx F x xxx x FCM xxx G x xxx M S P HYDAC FILTER SYSTEMS GMBH en us Page 18 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 19: ...267d en us 2012 01 24 doc 2012 01 24 Preparing the FCM for operation Inserting the filter element The unit is delivered with no filter element installed Make sure that there is a filter element in the fluid filter before commissioning You can find details about changing the filter element on page 27 ...

Page 20: ...ernal line diameter mm Q Flow rate l min V Kinematic viscosity mm s D Density kg dm Mineral oil based hydraulic fluid has a density of 0 9 kg dm This applies to straight pipelines and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep the height difference between the pump and the oil level in the tank as low as possible Constrictions in the conne...

Page 21: ...lance out of the seat in the floor plate Put the suction hose with lance without tension and or twist into the appropriate container and secure it Hanging connecting the pressure hose Pull out the pressure hose black hose with lance from the seat in the floor plate and insert it in the appropriate receptacle Put the pressure hose with lance without tension and or twist into the appropriate contain...

Page 22: ...e nominal current is exceeded the motor protection switch trips Checking direction of rotation in jog mode Start the motor by switching it on for a short time jog mode The arrow on the fan cover shows the correct direction of rotation If the rotation is in the opposite direction it must be reversed using the phase inverter in the connection plug HYDAC FILTER SYSTEMS GMBH en us Page 22 40 Bewa FCM ...

Page 23: ...tion speeds and thus two different flow rates To do this observe the position of the selector switch Position of switch Position of switch 0 OFF 1 Motor speed 720 rpm 70 l min 2 Motor speed 1450 rpm 140 l min Wiring diagram of the pole changer optional HYDAC FILTER SYSTEMS GMBH en us Page 23 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 24: ... differential pressure of 2 bar above the filter element is exceeded the clogging indicator switched the motor pump assembly off and the Filter clogged lamp lights up NOTICE Neutral wire missing Unit does not switch off Check if the power outlet has a neutral conductor or have this checked before commissioning Flow rate indicator accessories During operation with the flow rate indicator observe th...

Page 25: ...ation always monitor the filtration unit so that possible leaks can be recognized immediately the clogging indicator so that the filter element can be changed in a timely manner When the visual clogging indicator is red change the filter element immediately if the maximum operating pressure is exceeded the differential pressure relief valve in the pump will direct the medium back to the suction si...

Page 26: ...c shock Danger of fatal injury Any work involving the electrical equipment may only be done by a properly trained certified electrician Pull power plug before performing any work Maintenance intervals Daily Monthly Annually Visual inspection for leakage and damage X Clean the suction strainer X Changing the Filter Element X HYDAC FILTER SYSTEMS GMBH en us Page 26 40 Bewa FCM 3160267d en us 2012 01...

Page 27: ...for example 1300 R 003 BN4HC KB 1 2 The standard model has an optical green red differential pressure indicator 1 and an optical back pressure indicator in the cover of the filter 2 The type of differential pressure indicator 1 back pressure indicator 2 varies according to model code HYDAC FILTER SYSTEMS GMBH en us Page 27 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 28: ...filter cover for this purpose The residual oil is drained through the drain ball valve 2 into a suitable container 3 Loosen the four screws on the cover counterclockwise 4 Fold the screws down and press them against the filter housing This pushes the cover of the filter housing up HYDAC FILTER SYSTEMS GMBH en us Page 28 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 29: ... inside of the filter bowl of coarse dirt the sealing surfaces on the filter head and on the cover 6 For easier installation of the filter element wet the O ring on the filter element with the operating medium HYDAC FILTER SYSTEMS GMBH en us Page 29 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 30: ...ng on the cover for damage and replace it if necessary Lightly wet the O ring on the cover with medium 9 Put the cover on Observe correct placement of the O ring on the cover while doing so It must not be damaged 10 Fold the four screws up and turn them clockwise evenly crosswise HYDAC FILTER SYSTEMS GMBH en us Page 30 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 31: ...ement 11 Close the drain valve 12 Plug in the power plug Switch the unit on 13 Check the unit for any leaks 14 The unit is ready for operation HYDAC FILTER SYSTEMS GMBH en us Page 31 40 Bewa FCM 3160267d en us 2012 01 24 doc 2012 01 24 ...

Page 32: ...flushing it with solvent or blow flushing it with compressed air 1 Unscrew the screw plug 1 counterclockwise with an open jaw wrench wrench width 50 mm 2 Remove strainer insert 2 and clean it 3 Check strainer insert 2 and the seal ring on the screw plug for damage and replace if necessary 4 Insert strainer insert 2 5 Screw in the screw plug clockwise and tighten it with the open jaw wrench wrench ...

Page 33: ...of the filter element reached Replace filter element Differential pressure 2 bar Viscosity too high Warm medium up The pump is conveying in the wrong direction Check the rotational direction of the motor and if necessary reverse the phases No flow suction hose not deep enough in the container Sufficiently immerse the suction hose in the medium No function Not connected to power supply Check the el...

Page 34: ...3 1300 R 003 BN4AM KB NBR 1267991 2600 filter element 3 µm 3B03 2600 R 003 BN4HC KB NBR 1263071 2600 filter element 3 µm 3B03 2600 R 003 BN4HC V KB FPM 1263784 2600 filter element 5 µm 3B05 2600 R 005 BN4HC KB NBR 1263072 2600 filter element 5 µm 3B05 2600 R 005 BN4HC V KB FPM 1263785 2600 filter element 10 µm 3B10 2600 R 010 BN4HC KB NBR 1263073 2600 filter element 10 µm 3B10 2600 R 010 BN4HC V K...

Page 35: ...or FCM 060 L F 400 V 50 Hz 3 Ph 6014525 Electric motor for FCM 060 L F 230V 50Hz 1Ph 636131 Electric motor for FCM 100 L F 400 V 50 Hz 3 Ph 609085 Vane pump FCM 060 L F 2 2 1 P 90 40 RV6 721009 Vane pump FCM 100 L F 3 3 0 P 100 70 RV6 721231 Repair kit for vane pump M FZP 2 2 1 NBR 382438 Repair kit for vane pump M FZP 3 3 0 NBR 383765 Gear pump assembly KF40RF1 for FCM 060 400V 6000940 Gear pump ...

Page 36: ...15 400 mm s 15 400 mm s Viscosity range Gear type pump 15 1000 mm s 15 1000 mm s Hydraulic fluid temperature 10 80 C 10 80 C Ambient temperature 10 40 C 10 40 C Sealing material NBR FKM NBR FKM Power consumption Vane pump 1 5 kW 2 2 kW Power consumption Gear type pump 2 2 kW 3 0 kW IP class IP 55 IP 55 Length of electrical connection cable 6 m 6 m Hydraulic connectors IN 1 OUT M 36x2 IN 1 OUT M 36...

Page 37: ... 1 Ph PE N 400 V 50 Hz 3 Ph PE S 500 V 50 Hz 3 Ph PE X other voltage Filter concept for details see table on page 38 2 Filter size 1300 3 Filter size 2600 Contamination indication B optical differential pressure indication C Special version electric differential pressure sensor VM 2 C 0 with automatic motor switch off in case of filter contamination Supplementary details Series S5 Suction hose wit...

Page 38: ...ent type 2 3 μm 2B03 1300 R 003 BN4HC 2 5 μm 2B05 1300 R 005 BN4HC 2 10 μm 2B10 1300 R 010 BN4HC 2 20 μm 2B20 1300 R 020 BN4HC 2 40 μm 2A40 1300 R 040 AM 2 10 μm 2A10 1300 R 010 BN4AM 2 3 μm 2A03 1300 R 003 BN4AM 3 3 μm 3B03 2600 R 003 BN4HC 3 5 μm 3B05 2600 R 005 BN4HC 3 10 μm 3B10 2600 R 010 BN4HC 3 20 μm 3B20 2600 R 020 BN4HC 3 40 μm 3A40 2600 R 040 AM 3 3 μm 3A03 2600 R 003 BN4AM ...

Page 39: ...ed in the standards listed below Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Name Filtration unit Typ FCM Series Part no Serial no EU Machinery Directive 2006 42 EC EU Electrical Equipment Regulations 2006 95 EC EU Directive on Electromagnetic Compatibility 2004 108 EC Safety of machinery and devices EN 12100 1 2 2009...

Page 40: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com Email filtersystems hydac com ...