HYDAC FILTER SYSTEMS FCC Manual

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

Content
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Content
Content ..........................................................................................................2
General ..........................................................................................................4
Imprint.............................................................................................4
Documentation Representative ......................................................4
Purpose of this manual...................................................................5
Target group of the manual ............................................................5
Target group - Required qualifications/training...............................6
Illustrations in the manual...............................................................7
Illustration of the layout ...............................................................7
Representation of procedural instructions...................................8
Representation of warning/general safety information ................8
Signal words and their meaning in the general safety
information ..................................................................................9
Representation/explanation of pictograms....................................10
Supplementary symbols ...............................................................11
Exclusion of liability/warranty........................................................12
Notes on copyright........................................................................12
Validity of this manual...................................................................12
General Safety Information........................................................................13
Firefighting/Extinguishing Fires.....................................................14
Product overview........................................................................................15
Scope of delivery..........................................................................16
Dimensions...................................................................................17
Connections and components......................................................18
Hydraulicdiagram..........................................................................20
Proper/Designated Use ................................................................22
Improper use or use deviating from intended use.........................24
Technical data..............................................................................25
Decoding the type label................................................................26
Model Code...............................................................................28
Storage and transport ................................................................................30
Assembly, installation and commissioning .............................................31
Design and placement..................................................................31
Hydraulic installation/assembly.....................................................31
Attaching/connecting the suction hose......................................31
Attaching/connecting the pressure hose ...................................31
Avoiding siphoning....................................................................32
Preparation for commissioning.....................................................33
Connecting FCU to the FCC (option) ........................................33

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Operation.....................................................................................................34
Selecting the operating modes .....................................................34
Emptying external containers / system......................................35
Cleaning the tank content..........................................................36
Filling an external container/system..........................................37
Cleaning an external container..................................................38
Operating the flow meter (optional accessory) .............................39
Replacing the battery ................................................................39
Resetting the flow meter - RESET.............................................39
Function monitoring...................................................................39
Totalizer ....................................................................................40
Programming the flow meter .....................................................41
Correcting/setting the measurement accuracy.......................43
Observing the clogging indicator ..................................................45
Viewing and resetting the optical clogging indicator..................45
Observing electrical clogging indicator......................................45
Maintenance................................................................................................46
Cleaning the unit...........................................................................46
Changing the filter element...........................................................47
Replacing the breather filter..........................................................52
Cleaning/replacing suction strainer...............................................53
Suction strainer cleaning interval...............................................53
Customer Service / Service..........................................................55
Troubleshooting/fault rectification............................................................56
Removing / Disposal...................................................................................57
Appendix .....................................................................................................58
Spare Parts and Accessories .......................................................58
Spare Parts ...............................................................................58
Glossary ......................................................................................................59
Explanation of terms and abbreviations........................................59
Index ............................................................................................................60

General
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General
In this chapter, you will find helpful notes on handling these instructions.
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[email protected]
Homepage:
www.hydac.com
Court of registration:
Saarbrücken, HRB 17216
Executive directors:
Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone:
[phone]
Fax:
[phone]
E-mail:
[email protected]

General
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Purpose of this manual
Before you use this product for the first time or if you have been asked to
carry out other work on the product, please read this manual
The use and the handling of the product described in the following, as well as
its use, are not self-explanatory and are described in detail in this manual
and the associated technical documentation.
This manual will help you to use the product as intended, properly,
effectively, and safely. Therefore, you are requested to read the following
chapters attentively and carefully. Please refer to it every time you require
decisive details.
This manual informs and warns you of risks, against which the risk reduction
through the design and protective measures may not be effective or not fully
effective.
Target group of the manual
This manual was created for the following target group.
Target group
Tasks
Owner
This manual and the associated documents must be kept
accessible at the installation location of the product and
also for later use.
Ask the employees to read and follow the manual and the
documents delivered along with it, in particular, the safety
and warning instructions.
Observe the additional product-related instructions and
requirements.
Specialist
personnel
Read, observe and follow this manual and the associated
documents, in particular, the safety and warning
instructions.

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Target group - Required qualifications/training
Persons who work on the product must be aware of the hazards associated
with its use.
Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the General Safety Information and
instructions, 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:
Auxiliary personnel: such persons have been instructed about the product
and informed about potential hazards that can result from improper use.
Specialist personnel: such persons with corresponding specialist training and
several years' work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential dangers.
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Auxiliary
personnel
No specialist knowledge
required
Hydraulic / electrical
installation,
First commissioning
Maintenance
Troubleshooting
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.
Product-specific knowledge
Operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
Knowledge about reuse

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Illustrations in the manual
You will find illustrations in this manual. You can find details regarding these
in the following chapters.
Illustration of the layout
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx-xx
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.
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
these instructions prior to starting the unit up for the first time and
at regular intervals in the future.
The manual contains a table of contents, an index and a glossary.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

General
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Representation of procedural instructions
There are these two following representations in the case of procedural
instructions:
Procedural instructions with a fixed sequence
Procedural instructions, whose sequence must be complied with without fail
are listed with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence
Procedural instructions that have a random sequence are listed as bullet
points (-).
An example of a procedural instruction with a random sequence:
- Clean the display
- Rinse the product
Representation of warning/general safety information
All the warning / general safety information in this manual are highlighted with
pictograms and signal words. The pictogram and the signal word indicate the
severity of the danger.
Warning / general safety information is listed before an activity and is laid out
as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert the danger

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Signal words and their meaning in the general safety information
In these instructions you will find the following signal words:
DANGER
DANGER –The signal word indicates a hazardous 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.
NOTICE
NOTICE –The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

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Representation/explanation of pictograms
The following are the safety symbols / pictograms in this manual. They
indicate specific dangers to persons, property or to the environment. Observe
these safety symbols / pictograms and act with particular caution in such
cases. Always keep all symbols / pictograms intact and legible.
Warning signs used
These signs are listed for all general safety information and instructions in
these operating instructions which indicate particular dangers to persons,
property or the environment.
Danger point warning
Danger due to operating pressure
Danger of electrical shock
Signs used for giving orders
These symbols are listed for all general safety information and instructions in
these operating instructions that refer to particular dangers to persons,
property or the environment.
Disconnect before maintenance or repair

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Signs used for the required specialist personnel
These symbols show the required training/knowledge for installation work
and/or maintenance work.
Specialist personnel - Electrical
Such persons have specific specialist training
and several years' work experience. They are
able to assess and perform the work assigned to
them, they are also able to recognize potential
dangers.
Specialist personnel - Mechanical
Such persons have specific specialist training
and several years' work experience. They are
able to assess and perform the work assigned to
them, they are also able to recognize potential
dangers.
Supplementary symbols
You will find the following symbols in the manual as additional details:
Tip for handling the product
Required tools

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Exclusion of liability/warranty
For the warranty provided by us, please refer to our terms of delivery. They
are made available to you at the conclusion of the contract at the latest. In
addition, you will find these under www.hydac.com -> General terms and
conditions.
This manual was prepared to the best of our knowledge. Nevertheless and
despite the greatest care, it cannot be excluded that mistakes could have
crept in. Therefore please understand that, in the absence of any provisions
to the contrary hereinafter, our warranty and liability –for any legal reasons
whatsoever –are excluded in respect of the information in these instructions.
In particular, we shall not be liable for lost profit or other financial loss.
This exclusion of liability does not apply in cases of intent and gross
negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to the Product Liability shall
remain unaffected.
Notes on copyright
All copyrights for this manual lies with the manufacturer. Any part of this
manual may cannot be reproduced, used or copied in any form with the help
of electronical systems without the written consent of the manufacturer. Any
infringements of the above shall be liable to damage compensation.
Validity of this manual
The diagrams and visualizations in this manual are meant for general
illustration purposes. Therefore, representations and functional options can
deviate from those of the delivered product.
We reserve the right to changes to the contents of this manual without prior
notice.

General Safety Information
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General Safety Information
The product has been built according to the provisions, directives and
standards valid at the time of delivery and satisfies the current safety
requirements. Any residual hazards are indicated by the general safety
information and are described in this manual.
Observe all the safety and warning instructions attached to the product and
always keep them up to date and easily legible.
NOTICE
Impermissible operating media
The unit will be destroyed
►Only use the FCC in connection with lubrication and mineral oils or
mineral oil based media or biological fluids that can be broken down
quickly and are based on synthetic esters (HEES).
DANGER
Hazard due to use of the product other than
that intended
Bodily injury and damage to property will result
when operated improperly.
►Never operate the product in potentially
explosive atmospheres.
►Only use the product with permissible media.

General Safety Information
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Firefighting/Extinguishing Fires
Use a powder extinguisher that corresponds to fire class B as per EN 2 to
extinguish any fires.
Maintain a minimum safe distance from electrical components. For a mains
voltage of up to 1000 V, the minimum safe distance is 1 m.

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

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Scope of delivery
The following items are supplied:
Qty.
Description
1
The FCC, ready for connection with the suction and pressure
hose, power supply cord including the power plug
1
Operation and Maintenance Instructions (this document)

Product overview
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Dimensions
All dimensions in mm.

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Connections and components

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Item
Description
IN
Inlet
OUT
Outlet
2
Sliding grip
3
Hose retainer
4
Fluid level gauge
6
Electrical switch box with main switch
7
Nose wheel with immobilization brake
8
Suction screen
9
Inspection opening for the tank container
10
Chassis
11.1
Air filters
50
Filtration unit
51
Clogging indicator
100
Ball valve IN
101
Ball valve OUT

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Hydraulicdiagram