Hydac FAM 10, FAM 15 Operating And Maintenance Instructions Manual

FAM 10/15 Series FluidAqua Mobil
+ AquaSensor AS1000
+ ContaminationSensor CS 1000
Operating and Maintenance Instructions
English (translation of German original)
Dokumentation no.: 3417360
FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Trademarks

Trademarks

The trademarks of other companies are exclusively used for the products of those companies.
Copyright © 2008 by HYDAC Filtertechnik GmbH all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to compensation.

Exclusion of liability

We made every endeavor to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a re­sult of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in future editions. We welcome any suggestions for im­provements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Industriegebiet
D-66280 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Contents

Contents

Trademarks.............................................................................................................................2
Contents..................................................................................................................................3
Preface ....................................................................................................................................6
Customer Service ................................................................................................................. 7
Modifications to the Product .................................................................................................7
Warranty ............................................................................................................................... 7
Using the documentation ...................................................................................................... 8
Safety Information and Instructions.....................................................................................8
Obligations and Liability........................................................................................................9
Explanation of Symbols and Warnings ................................................................................. 9
General Safety Precautions................................................................................................ 10
Proper/Designated Use ......................................................................................................11
Improper Use ......................................................................................................................11
Safety Devices....................................................................................................................11
Informal Safety Precautions................................................................................................ 12
Training and Instruction of Personnel................................................................................. 13
Safety Measures to Be Followed during Normal Operation................................................ 13
Electrical Hazards............................................................................................................... 14
Maintenance, Servicing and Troubleshooting..................................................................... 14
Modifications to the FluidAqua Mobil ..................................................................................14
How to behave in case of emergency................................................................................. 15
Packing, Transportation......................................................................................................15
Unpacking the FAM ............................................................................................................ 15
Transporting the FAM ......................................................................................................... 15
Moving the FAM ..............................................................................................................16
Scope of Delivery.................................................................................................................17
FAM Description...................................................................................................................18
FAM components................................................................................................................ 19
Hydraulic schematic............................................................................................................20
Technical specifications......................................................................................................21
Suitable Fluids .................................................................................................................... 21
FAM Function description ................................................................................................... 22
Possible Applications.......................................................................................................... 22
Bypass purification (dewatering, filtration and degassing).............................................. 23
Transfer by pumping (dewatering, filtration and degassing) ........................................... 23
FAM Set-up and Connection ...............................................................................................24
Setting up the FAM ............................................................................................................. 24
Hydraulic Connection of the FAM .......................................................................................24
Connecting the suction port connection (IN)................................................................... 24
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Contents
Connecting the return port connection (OUT) ................................................................. 24
Preparing the Vacuum Pump.............................................................................................. 25
Checking the settings on the heater (optional) ................................................................... 26
Electrical Connection of the FAM .......................................................................................27
Starting up the FAM.............................................................................................................28
Switching on the FAM......................................................................................................... 28
Shutting off the FAM ........................................................................................................... 29
Control Panel - SIMATIC PANEL .......................................................................................30
Operating the FAM from the Control Panel ........................................................................30
Start screen..................................................................................................................... 31
Menu1 ............................................................................................................................. 32
Menu2 ............................................................................................................................. 32
Operating Mode (OM) ..................................................................................................... 33
Manual Menu (MANUAL) ................................................................................................ 34
OPERATOR (MANUAL1)................................................................................................ 35
OPERATOR (MANUAL2)................................................................................................ 35
LANGUAGE .................................................................................................................... 36
RH+P (Relative Humidity + Pressure)............................................................................. 37
Contamination (Selection Contamination)....................................................................... 38
ISO.................................................................................................................................. 38
Intervals...........................................................................................................................39
an operating-hours counter, and..................................................................................... 40
Operating Mode "Cleaning until" ..................................................................................... 40
General Operating Instructions - SIEMENS PANEL........................................................... 41
System Keys ................................................................................................................... 41
Entries and Help.............................................................................................................. 42
Numerical Values ........................................................................................................42
Alphanumerical Values................................................................................................ 42
Date and Time ............................................................................................................. 42
Entering and Modifying Numerical and Alphanumerical Values.................................. 43
Enter Value.................................................................................................................. 44
Partial Value Changes................................................................................................. 44
Character Call-up Sequence .......................................................................................44
Entering and Changing Date and Time .......................................................................46
Safety Queries............................................................................................................. 46
Error messages....................................................................................................................48
Vacuum Chamber Overflow................................................................................................ 52
FAM tray too full..................................................................................................................53
FAM outlet blocked ............................................................................................................. 54
FAM entry blocked..............................................................................................................55
Dry-running Evacuation Pump............................................................................................ 56
Dry run drain pump .............................................................................................................57
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Contents
Fault on vacuum column level probe .................................................................................. 58
Level switch in the vacuum pump....................................................................................... 59
Oil filter contaminated .........................................................................................................60
Motor Protection Switch...................................................................................................... 61
Cable break ........................................................................................................................ 63
Safety thermostat................................................................................................................65
Electrical fuses....................................................................................................................67
Reset safety thermostat on the heater (Optional)............................................................... 68
Maintenance..........................................................................................................................69
Visual checks...................................................................................................................... 69
Vacuum pump.....................................................................................................................69
Rotary Vane Vacuum Pump ...............................................................................................70
Changing oil and oil filter.................................................................................................71
Replacing the Air De-oiling Element ...............................................................................71
Clean the suction strainer. .................................................................................................. 72
Fluid filter (OLF-5)...............................................................................................................72
Changing the Filter Element............................................................................................ 72
Heater (Option) ................................................................................................................... 73
Storing the FAM....................................................................................................................73
Disposing of the FAM ..........................................................................................................73
Technical data ......................................................................................................................74
Type label ........................................................................................................................... 75
Spare parts............................................................................................................................76
FAM 10 ............................................................................................................................... 76
Fluid filter (OLF 5/10)..........................................................................................................76
Vacuum pump.....................................................................................................................76
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Preface

Preface

For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and mainte- nance.
It will acquaint you with the product and assist you in using it as intended in an opti­mal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation was that available at the time of publication. There may be deviations in technical details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments or suggestions, contact us at:
HYDAC Filtertechnik GmbH
Division Service technology / Filter systems Technical Documentation Department Postfach 12 51 66273 Sulzbach/Saar - Germany
Fax: ++49 (0) 6897 509 846 Email: filtersysteme@hydac.com
We look forward to receiving your input.
“Putting experience into practice”
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Preface

Customer Service

Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product:
Fax: ++49 (0) 6897 509 846 Email: filtersysteme@hydac.com

Modifications to the Product

We would like to point out that changes to the product (e.g. purchasing additional options, etc.) may mean that the information in the operating instructions is no longer applicable or adequate.
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 Filtertechnik GmbH.
They are available at:
www.hydac.com Legal information.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions
/

Using the documentation

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.
What do I want to know?
I assign the information I require to a subject area.
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.
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file name
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.

Safety Information and Instructions

These operating instructions contain the key instructions for properly and safely op­erating the FluidAqua Mobil.
200x-xx-xx
Page number
Seite x
Edition date
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions
y p
The safety of the FAM largely depends on maintenance. Regular required mainte­nance is described in this manual. We will support you if the unit needs repair and will provide original spare parts.

Obligations and Liability

The basic prerequisite for the safe and proper handling and operation of the FAM is knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the FluidAqua Mobil.
Adherence is to be maintained to pertinent accident prevention regulations applica­ble at the site where the product is used.
The safety precautions listed herein are limited solely to using the FluidAqua Mobil.
The FluidAqua Mobil has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazard may be posed to the life and limb of the individual using the product or to third parties. The FluidAqua Mobil is only to be used:
solely for its designated use
only in accordance with the designated equipment group, equipment category
and zone indicated above
only when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly re-
paired or remedied immediately.
Our General Terms and Conditions apply. They are made available to the owner upon concluding purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes:
Improper use of the FluidAqua Mobil or use deviating from its designated use
Improper commissioning, operation and maintenance of the FluidAqua Mobil
Operating the FluidAqua Mobil when the safety systems are defective
Modifications to the FluidAqua Mobil made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

Explanation of Symbols and Warnings

Basic Symbols

DANGER denotes situations which can lead to death if
DANGER
WARNING
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safety precautions are not observed.
WARNING denotes situa­tions which can lead to death if safet
recautions
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions
are not observed.
CAUTION denotes situa­tions which can lead to se-
CAUTION
NOTE
vere injuries if safety pre­cautions are not observed.
TIP denotes situations which can lead to property damage if safety precau­tions are not observed.

General Safety Precautions

Operation, adjustment and calibration work may only be carried out by technically skilled and trained personnel.
The safe operation of this unit can only be ensured if it is used for the purpose it was intended. If there is any question about the use, please contact the manufacturer. The manufacturer will not accept responsibility for damages resulting from misuse of this equipment.
The following applies to all work performed using the unit: adherence to pertinent national regulations pertaining to accident prevention and safety at the workplace in addition to any applicable internal rules and regulations of the owner/operator, even though they are not specifically cited herein.
Leaks of dangerous materials must be properly collected and disposed of so as not to harm any persons or the environment. The corresponding statutory regulations are to be followed.
Before any maintenance or repair work is carried out on the unit, electrical power to the unit must be disconnected, and all hydraulic pressures relieved.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions

Proper/Designated Use

The FAM was developed for the dewatering, filtration and degassing of hydraulic and lubricating oils. It removes free water, emulsified water and a large percentage of the water to be found in solution.
Any other use shall be deemed to be improper and not in keeping with the product's designated use; the manufacturer accepts no liability for any damage resulting from such use.
Proper or designated use of the product extends to the following:
Maintaining adherence to all the instructions contained herein.
Performing requisite inspection and maintenance work.

Improper Use

Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
Operation with non-approved fluids.

Safety Devices

Prior to starting up the FAM unit each time, make sure that all the protective safety devices are properly installed and are in proper working order.
Safety devices may not be removed until the product has been shut down and se­cured against being restarted (e.g. warning sign or padlock on the main switch).
When the product is supplied in partial consignments, the safety devices are to be applied by the operator as specified by law/pertinent regulations.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions

Informal Safety Precautions

Make sure to always keep the operating instructions in the vicinity of the FluidAqua Mobil unit.
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.
Make sure to keep the safety and hazard symbols and warnings on the FluidAqua Mobil in a legible condition.
FluidAqua Mobil components may not be opened except in normal, non­contaminated environments. The mains cable must be pulled out before the Flui­dAqua Mobil is opened. Only trained specialist electricians may be carry out tests with the housing opened. This also applies to repair work and to modifications of electrical system parts that we have approved.
The hoses and connection fittings are to be checked daily for leakage (visual check). The electrical components of the FluidAqua Mobil are to also be regularly checked (visual check once a month). Any loose connections or damaged cables are to be replaced immediately.
DANGER
Hydraulic systems are under pressure
The hydraulic system must be depressurized
before performing any work
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions

Training and Instruction of Personnel

The FluidAqua Mobil may only be operated by properly trained and instructed per­sonnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the FluidAqua Mobil unless supervised by an experienced staff member.
Individuals
Activity
Individuals
undergoing
training
Individuals with techni­cal training/ engineering
Electrician Supervisor
background
Packing Transporta­tion
Commissioning
Operation
X X
X X X
X X X X
Troubleshooting / locating the source of
X X X
malfunction
Remedying of me­chanical faults
Remedying of electri­cal faults
Maintenance
X
X X X X
Repair work
with the
appropriate
authority
X
X
X X
X
Shutdown/ decommissioning
X X X X

Safety Measures to Be Followed during Normal Operation

Do not operate the FAM unless all the safety devices function properly.
The product is to be checked once a day for external damage and the proper func­tioning of the safety devices.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions

Electrical Hazards

DANGER
Electric shock
All work on the voltage-carrying parts may only
be carried out by a qualified electrician.
The electrical equipment of the product must be checked on a regular basis. Any loose connections or damaged cables must be remedied/replaced immediately.

Maintenance, Servicing and Troubleshooting

The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a timely fashion.
All operating media are to be protected in case the product is accidentally started up.
The FluidAqua Mobil 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 any screwed fittings which have been removed to see that they have been properly secured.
Always check the product to see that it functions properly when performing mainte­nance and servicing work.

Modifications to the FluidAqua Mobil

Do not make any modifications (design modifications, extensions) to the FluidAqua Mobil without the prior consent of the manufacturer.
Any design modifications or extensions may not be made without HYDAC Fil­tertechnik GmbH’s express prior written approval.
Immediately replace any machine components which are not in perfect condition.
Only use original (OEM) spare parts and consumables. When using non-OEM com­ponents it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Packing, Transportation

How to behave in case of emergency

In the event of an emergency, rotate the main and E-STOP switch 90° to the left in order to shut down the entire system. The entire system is then voltage-free down­stream from this switch.
Normal pressure is restored to the vacuum chamber after about 1 minute.

Packing, Transportation

Unpacking the FAM

The FAM is inspected for leaks and proper functioning at the factory, then carefully packed for shipment. The connectors/ports are closed off so that no contamination can enter the unit while it is in transit.
When receiving and unpacking the unit check it for damage in transit. Report any damage to the forwarding agent immediately.
The packaging material should be re-used/re-cycled as appropriate for your area.

Transporting the FAM

The unit must be evacuated completely and the inlets and outlets must be closed before transport.
Suction and pressure hoses and connection cables are coiled on the holders pro­vided for that purpose and fastened in place.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Packing, Transportation

Moving the FAM

CAUTION
High empty weight ( 400 … 850 kg, depending on the version)
A minimum of 2 persons is required for
transport.
The FAM can be moved manually by pushing thanks to two steerable castors and two fixed castors for heavy loads. The grips for pushing on the frame of the FAM are to be used for this purpose in all cases without exceptions. The immobilization brakes on the steerable castors are to be released prior to transport and then fixed again in place after it has been completed.
None of the components should ever be used as grips for pushing or pulling the FAM, because this will cause damage to it.
Fork lift
If the FAM is moved with a forklift, then this may only be used in conjunction with the forklift eyes located on the device.
Crane
If the FAM is moved with a crane, then this may only be used in conjunction with the crane eyes or the forklift eyes located on the device and with suitable hitching mate­rials.
Train/truck
During transport, the FAMs that have castors must be placed that on supports that are high enough to ensure that there is no load on the castors.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Scope of Delivery

Scope of Delivery

Upon receiving the FAM check it for any damage in transit. The FAM may not be set up and installed unless it is in perfect order. Any damage in transit is to be reported to the forwarding 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 Description
1
FluidAqua Mobil FAM, ready for connection with suction and pres­sure hose
1 Tool, square 6 mm for switch box
1 Operating and maintenance instructions FAM
1 Operating and maintenance instructions Busch vacuum pump
1 Supplementary operating instructions (depending on FAM design)
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description

FAM Description

The FluidAqua Mobil FAM was developed for the dewatering, filtration and de­gassing of hydraulic and lubricating oils. It removes free water, emulsified water and a large percentage of the water to be found in solution. The fluid filter that is installed provides efficient filtering-out of solid materials.
The degassing of the medium is achieved by the vacuum set up in the vacuum con­tainer.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description

FAM components

Item Description
1 control cabinet with control panel consisting of:
2 Regulating valve to regulate the necessary vacuum in the vacuum
3 Vacuum gauge 4 Motor pump unit with fluid filter for the separation of solid particles
5 Vacuum chamber 6 3/2-directional control valve 7 Suction strainer 8 Vacuum pump
9 Evacuation pump 10 Air filter and dryer 11 Heater mounted in vacuum chamber (Option) 12 AS1000 (Optional) 13 CS1000 (Optional) 14 Motor-pump assembly for CS1000 (Optional)
- main switch
- alarm signal lamp
- control panel with display
- component diagram
chamber
(OLF-5)
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description

Hydraulic schematic

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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description

Technical specifications

The FAM is able to dewater authorized fluids down to a water content of less than 100 PPM.
FAM 10/10 0.8 l/h
FAM 10/15 1.0 l/h
The dewatering speed is dependent on:
Water content
Fluid temperature
Detergent additives
Volumetric flow of the FAM
The fluid temperature must be at least 40°C in order to ensure an effective water separation speed.
The sample for the determination of the water content must be extracted from the system to be cleaned during operation.
Typical dewatering rates:
Dewatering rate
Free water on the floor of the tank influences the overall water content. This is to be drained before starting.

Suitable Fluids

The FAM may only be used only in connection with lubrication and mineral oils or with mineral oil-based media or with biological fluids that can be broken down quickly - on the basis of synthetic esters (HEES).
Please contact us if you want to use other fluids.
Operation with other media could destroy the FAM.
The FluidAqua Mobil can only be utilised in connection with the following hydraulic fluids:
Mineral oils acc. DIN 50524
Gear oils acc. DIN 51517 and DIN 51524
NOTE
Synthetic esters (HEES) acc. to DIN 51524/2
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description

FAM Function description

After the FAM has been switched on, filter pump unit 1 begins to suction fluid out of the tank to be cleaned out and to pump it through the filter into vacuum chamber 3 at a speed of 10 l/min. Vacuum pump 7
begins at the same time to build up the nec­essary vacuum. The fluid to be cleaned trickles downward through special filling ma­terials. These filling materials are responsible for forming a thing fluid film and reduc­ing the speed of the trickle. At the same time, a stream of air flowing upward from below against this current takes up the fluid and conveys the to the outside by
means of the vacuum pump. Once level 02 is reached on the level switch, emptying pump 5 level falls until level 01 is reached, after which solenoid valve 6
is switched on in order to convey around 15 l/min to the outlet. The filling
switches on and the
two pumps convey into the vacuum chamber. The filling level continues to rise until
level 02 is reached, after which the solenoid valve shuts back off again, the filling
level falls again, etc.
After actuating the stop switch, the filter-pump unit stops and the evacuation pump empties the vacuum chamber.
Switching the main switch to "OFF" renders all engines and valves voltage-free.
The vacuum in the vacuum chamber is regulated with the regulating valve 8
.

Possible Applications

The electric control supports several operation modes e.g.,
the FAM is switched On/Off at a control room.
the general malfunction message can be transmitted to a control room
the operating status can be queried
the FAM can be switched on/off by a level sensor in the transfer by pumping
operation mode.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description
Better cleaning results can be obtained through permanent operation of the FAM in bypass flow.

Bypass purification (dewatering, filtration and degassing).

The FAM is connected with suction and pressure lines to the tank and cleans the medium in continuous operation.

Transfer by pumping (dewatering, filtration and degassing)

The FAM is connected to a contaminated oil tank by means of a suction line and pumps the fluid into the clean oil tank.
The filling level in the clean oil tank must be monitored permanently during this op­erating mode in order to exclude the possibility of overfilling.
Contaminated oil
Clean oil
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Set-up and Connection

FAM Set-up and Connection

Setting up the FAM

The following points are to be observed when setting up the FAM:
The unit has to be set up in a horizontal position on a level surface.
Special mounting is not required.
The immobilization brakes on the wheels must be locked to avoid unintended
movement of the unit.
Place the FAM near the tank to be cleaned (length of the hoses max. 5 m, height
difference max. 2 m).
The ambient temperature may not be below 10°C and may not exceed 40°C.
Access to the main switch has to be unimpeded at all times.
An area of at least 0.8 m must be kept free for maintenance purposes on both
the left hand and right hand sides of the FAM.

Hydraulic Connection of the FAM

Connecting the suction port connection (IN)

Make the suction-side connection with a flexible hose that is resistant to negative pressure or with pipelines. The nominal size of the connecting lines must be at least as large as the cross-section of the unit in order to prevent excessively high pres­sure loss.
Permissible suction pressure: -0.3 to 1 bar.
Connection to the tank must be done in a manner so that it is always below the oil level.
NOTE
The medium may not be suctioned directly from the bottom of the tank.
The greatest amount of impurities in the fluid is to be found at the bottom of
the tank.
High levels of contamination in the fluid can cause damage to the FAM.

Connecting the return port connection (OUT)

The return-flow line or the return-flow hose must be installed below the level of the oil in order to prevent air from entering the medium.
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