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
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
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:
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 may mean that the information in the operating instructions is no
longer applicable or adequate.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.
Product
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p
a
K
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P
ilt
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1
4
5
6
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a
Documentation no.
de
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Document language
with index
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
Page 9 / 80
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
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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