HYDAC FILTER SYSTEMS FluidAqua Mobil FAM 15 ATEX Instruction sheet

FluidAqua Mobil
FAM 15/30 ATEX
II 2G IIB+H2T4 (+10°C<Ta<40°C)
II 2G IIB+H2160°C (+10°C<Ta<40°C)
Operating and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 3197970c

FAM 15/30 ATEX Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Telefax: [phone]
E-Mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive director: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. 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: [email protected]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
All details are subject to technical modifications. Technical specifications are subject
to change without notice.
The trademarks of other companies are exclusively used for the products of those
companies.

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Content
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................6
Customer Service ...................................................................................................7
Modifications to the Product ...................................................................................7
Warranty .................................................................................................................7
Using the documentation ........................................................................................8
Changes to the manual............................................................................................9
Preface ....................................................................................................................10
Technical Support.................................................................................................11
Modifications to the Product .................................................................................11
Warranty ...............................................................................................................11
Using the documentation ......................................................................................12
Safety information and instructions.....................................................................13
Obligations and liability .........................................................................................13
Explanation of Symbols and Warnings, etc. .........................................................14
General Safety Precautions..................................................................................14
Proper/Designated Use ........................................................................................15
Improper Use ........................................................................................................15
Safety Devices......................................................................................................16
Informal Safety Precautions..................................................................................16
How to behave in case of emergency...................................................................17
Electrical Hazards.................................................................................................17
Training and Instruction of Personnel ...................................................................18
Maintenance, Servicing and Troubleshooting.......................................................18
Modifications to the FluidAqua Mobil ....................................................................19
Transporting the FAM ............................................................................................20
Forklift ...................................................................................................................20
Crane ....................................................................................................................21
Train/truck.............................................................................................................21
Checking the scope of delivery ............................................................................22
FAM Description.....................................................................................................23
Performance features ...........................................................................................23
Restrictions pertaining to use ...............................................................................24
FAM components ...................................................................................................25

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FAM components ...................................................................................................26
Description of function ..........................................................................................27
Hydraulic diagram ..................................................................................................28
Using the FAM ........................................................................................................29
Bypass purification................................................................................................29
Transfer by pumping.............................................................................................29
Explosion protection as per ATEX 95...................................................................30
Setting up the FAM.................................................................................................31
Connecting the FAM ..............................................................................................32
Notes on pipes and hoses ....................................................................................33
Connecting the suction port ..............................................................................34
Connecting the pressure port / return-flow line .................................................34
Electrical connection of the FAM ..........................................................................35
Preparing the rotary vane vacuum pump..............................................................36
Filling the vacuum pump.......................................................................................36
Filling the seal chamber of the evacuation pump ...............................................37
Operating Elements on the control panel ............................................................ 38
Starting up the FAM ...............................................................................................39
Setting the vacuum pressure ................................................................................39
Venting the filter housing ......................................................................................40
Shut off FAM.........................................................................................................41
FAM in manual operation......................................................................................41
Error messages / troubleshooting........................................................................42
[H5] Vacuum chamber overfilled...........................................................................44
[H6] Inlet (IN) clogged...........................................................................................45
[H7] Outlet (OUT) clogged ....................................................................................46
[H8] V-pump temperature .....................................................................................47
[H9] Wrong phase sequence ................................................................................48
[H10] Change fluid filter ........................................................................................49
[H11] Float switch .................................................................................................50
[H12] E/V/R pump motor protection......................................................................51
[H13] Dry-running, E-pump...................................................................................52
[H14] Level switch 01/02(02/03) ...........................................................................53
[H15] V-pump pressure.........................................................................................54
Performing maintenance / inspection ..................................................................55
Visual checks........................................................................................................56
Overview of maintenance intervals.......................................................................57
Electrical inspection ..............................................................................................60

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Filling the seal chamber of the evacuation pump .................................................61
Replacing the filter element on the fluid filter........................................................62
Replacing the filter element on the fluid filter ....................................................63
Checking the fault indicator lamp..........................................................................67
Clean the suction strainer. ....................................................................................68
Changing the air filter element..............................................................................69
Vacuum pump maintenance .................................................................................70
Filling the vacuum pump.......................................................................................72
Additional maintenance instructions .....................................................................72
Testing the level sensor of the vacuum chamber .................................................73
Switching Status - Level Sensor Vacuum Column/SPS .......................................74
Checking the float switch of the oil pan ................................................................74
Replacing filter element on the oil mist separator.................................................75
Replacing the filter element on the oil mist separator .......................................76
Replacement Parts and Accessories List ............................................................77
Customer Service...................................................................................................79
Storing the FAM/Taking it out of Operation .........................................................80
Disposing of the FAM ............................................................................................80
Technical data ........................................................................................................81

FAM 15/30 ATEX Preface
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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
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Note that the information 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 suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”

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Customer Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: [phone] / 509 - 846
E-Mail: [email protected]
Modifications to the Product
We would like to point out 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.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
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 Filter Systems GmbH.
You'll find this under www.hydac.com -> Legal information

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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 determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
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.
Chapter
Page number
Edition date
Document language
Documentation No.
with Index /
File name

FAM 15/30 ATEX Changes to the manual
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Changes to the manual
The index is featured on the cover sheet of the operating and maintenance manual
and in the lower left corner of each page after the part number.
Index "a"
-Manual revised
Index "b"
-Manual revised
Index "c"
-Manual revised

FAM 15/30 ATEX Preface
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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
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Note that the information 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 suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”

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Technical Support
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: ++49 (0) 6897 / 509 - 846
E-Mail: [email protected]
Modifications to the Product
We would like to point out 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.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC Filter Systems GmbH.
Refer to these at www.hydac.com General terms and conditions.

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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 determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
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.
Chapter description
Page number
Edition date
Document language
Documentation No.
with Index /
File name

FAM 15/30 ATEX Safety information and instructions
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Safety information and instructions
These operating instructions contain the most important notes for operating the
FluidAqua Mobil safely.
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 to 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 here 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.
Risk of damage may be posed to the product or other equipment and property.
The FluidAqua Mobil is 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 safe, perfect condition.
any faults or malfunctions which might impair safety are to be properly repaired 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 intended 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

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Explanation of Symbols and Warnings, etc.
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING indicates
hazardous situations which
can result in fatal injuries if
not complied with.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTE denotes situations
which can lead to property
damage if safety precautions
are not observed.
This symbol designates safety indications whose non-observance may
pose a hazard to individuals due to hot surfaces.
This symbol designates safety indications whose non-observance may
pose a hazard to individuals and the environment due to explosion.
This symbol marks safety indications that refer particularly to explosion
protection.
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.

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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.
When work is done in explosion-prone areas, the safety of persons and
equipment depends on the observance of all relevant safety regulations. The
installation and maintenance personnel thus carries particular responsibility. Exact
knowledge of the applicable regulations and conditions is required.
Please note:
Observe the characteristic curves and measurement operating conditions of the
rating plates and data plates.
Damage to the devices can nullify the explosion protection.
The unit may be operated only when the control cabinet is completely closed.
Conversions and modifications to the devices and components that affect the
explosion protection are not allowed.
Proper/Designated Use
The FAM was designed for the dewatering, filtration and degassing of hydraulic and
lubricating oils. It removes free and emulsified water and most of the water which is
in solution.
Any other use shall be deemed to be improper and not in keeping with the product's
designated 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.
Operation in a danger zone where the ATEX classification of the device does not
apply.
Operation in mining or in dust-exposed zones

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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.
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 and replace them as necessary.
FluidAqua Mobil components may not be opened except in normal, non-
contaminated environments. The mains cable must be unplugged before the
FluidAqua Mobil is opened. Tests conducted with the housing open may only be
performed by properly trained, certified electricians. The same applies to repairs or
modifications carried out with our approval on electrical system parts.
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.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

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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 will return to the vacuum chamber
after ~ 1 minute.
Electrical Hazards
DANGER
Electric shock
Bodily injury leading to death
►Any work involving electrical equipment may only
be done by a properly trained, certified electrician.
Any work involving the power supply may only be done by a properly trained,
certified electrician.
Make sure to check the electrical equipment of the product on a regular basis. Any
loose connections or damaged cables are to be remedied/replaced immediately.
If work on live components is required, have a second individual be present to
switch off the unit if necessary.

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Training and Instruction of Personnel
The FAM 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 FAM unless supervised by an
experienced staff member.
Individuals Individuals undergoing training Personnel 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
Troubleshooting, mechanical
problem X X
Remedying of electrical faults X X
Maintenance X X X X
Servicing X
Decommissioning / Storage X X X X
Maintenance, Servicing and Troubleshooting
The specified adjustment, maintenance, and inspection work is to be conducted in a
timely fashion.
All operating media is to be protected/isolated for the event that 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,
inspection or repair work.
Check any screwed fittings which have been removed to see that they have been
properly secured, and tighten them if necessary.
Always check the safety devices to see that they function properly after performing
maintenance work.

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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 modifications require written permission from HYDAC Filter Systems GmbH
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.

FAM 15/30 ATEX Transporting the FAM
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Transporting the FAM
CAUTION
High empty weight
(~ 640 - 680 kg, depending on the version)
Danger of bodily injury
►Use at least two persons to shift the mobile FAM.
NOTICE
Using components for pushing / pulling
The FAM will be damaged
►Never use the components to push or pull the FAM.
►Use the grips provided for shifting.
Drain the unit completely before transport. Seal off the inlets and/or outlets.
On the mobile FAM, wind the suction and pressure hose and the connection cable
around the holders provided for this purpose and secure them.
Move the FAM manually using the rollers. When doing so, use only the grips
provided on the FAM frame for pushing.
Before shifting the unit, make sure to release the hand brake on the swivel casters.
Once the FAM is in its new position, actuate the hand brake on the swivel casters.
Forklift
Use the lift eyes when transporting the unit with a forklift.