HYDAC FILTER SYSTEMS FluidAqua Mobil FAM 15 ATEX Manual

FluidAqua Mobil
FAM 15-70 /-EX02
II 2G IIB+H2T4 (+10°C<Ta<40°C)
Operating and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 4510066

Imprint
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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:
++49 (0)6897 509 1511
Fax:
++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.

Content
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Content
Imprint.....................................................................................................................2
Documentation Representative .............................................................................2
Content....................................................................................................................3
Preface ....................................................................................................................5
Technical Support.................................................................................................6
Product modification..............................................................................................6
Warranty...............................................................................................................6
Using the Documentation......................................................................................7
General Safety Information....................................................................................8
Hazard symbols ....................................................................................................8
Signal words and their meaning in the general safety information.......................10
Structure of the general safety information and instructions ................................11
Observing regulatory information ........................................................................11
Intended Use.......................................................................................................12
Explosion protection according to EU directive 2014/34/EU................................14
Improper Use or Use Deviating from Intended Use.............................................15
Qualifications of personnel / target group............................................................16
Wear suitable clothing.........................................................................................18
Stoppage in an emergency (EMERGENCY STOP).............................................18
Transporting the FAM...........................................................................................19
Fork lift truck .......................................................................................................19
Crane..................................................................................................................20
Train/truck...........................................................................................................20
Checking the scope of delivery ...........................................................................21
FAM description....................................................................................................22
Performance features..........................................................................................22
FAM overview .......................................................................................................23
FAM components................................................................................................25
Description of function.........................................................................................26
Hydraulicdiagram .................................................................................................27
Using the FAM ......................................................................................................29
Bypass purification..............................................................................................29
Transfer by Pumping...........................................................................................29
Connecting the FAM.............................................................................................30
Notes on pipes and hoses...................................................................................31
Connecting the (IN) suction port......................................................................33
Connecting the pressure connection / return flow line (OUT)...........................34
Electrical connection of the FAM.........................................................................35
Rotating field ...................................................................................................36
Preparing the rotary vane pump..........................................................................37
Filling the vacuum pump .....................................................................................37
Filling the seal chamber of the evacuation pump ..............................................38

Content
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Operating elements on the unit...........................................................................39
Starting up the unit...............................................................................................41
Setting the vacuum pressure...............................................................................41
Venting the filter housing.....................................................................................42
Switching off FAM...............................................................................................43
FAM in manual operation....................................................................................43
Error messages / troubleshooting.......................................................................44
[H5] If the vacuum column is overfilled,...............................................................46
[H6] Entry (IN) blocked........................................................................................47
[H7] Outlet (OUT) blocked...................................................................................48
[H8] V-pump temperature....................................................................................49
[H9] Wrong phase sequence...............................................................................50
[H10] Change fluid filter.......................................................................................51
[H11] Float switch................................................................................................52
[H12] E/V/R pump motor protection.....................................................................53
[H13] Dry-running, E-pump .................................................................................54
[H14] Level switch 01/02(02/03)..........................................................................55
[H15] V-pump pressure.......................................................................................56
Performing maintenance / inspection.................................................................57
Visual checks......................................................................................................58
Overview of maintenance intervals......................................................................59
Electrical inspection ............................................................................................62
Filling the seal chamber of the evacuation pump.................................................64
Lubricating lock on the electrical cabinet.............................................................65
Replacing the filter element on the fluid filter.......................................................66
Checking the fault indicator lamp ........................................................................71
Cleaning the suction strainer...............................................................................72
Changing the air filter element.............................................................................73
Vacuum pump maintenance................................................................................74
Filling the vacuum pump .....................................................................................76
Additional maintenance instructions....................................................................76
Checking the vacuum column level sensor ....................................................77
Testing the float switch in the oil pan...................................................................79
Replacing filter element on the oil mist separator................................................80
Replacing the filter element on the oil mist separator.......................................81
Spare parts and accessories list .........................................................................82
Customer Support/Service...................................................................................83
Storing the FAM/Taking it out of Operation........................................................84
FAM disposal........................................................................................................84
Technical data.......................................................................................................85
Model Code...........................................................................................................86

Preface
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Preface
For you,as the owner of our product, we have produced this documentation
with the most important notices for operation and maintenance.
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:
HYDACFILTERSYSTEMSGMBH
TechnischeDokumentation
Postfach12 51
66273 Sulzbach /Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”

Preface
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Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model code, serial
no. and part no. of the product:
Fax:
++49 (0) 6897 / 509 - 01
E-mail:
[email protected]
Product modification
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.
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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under 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 documentation has a table of contents at the beginning. There, 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

General Safety Information
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General Safety Information
The unit was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by general safety information and
instructions and are described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
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.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure

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Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Danger of explosion in explosive atmospheres
This symbol marks safety indications that refer particularly
to explosion protection.

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Signal words and their meaning in the general safety information
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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Structure of the general safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert the danger
Observing regulatory information
Observe the following regulatory information and directives:
Legal and local regulations for accident prevention
Legal and local regulations for environmental protection
Country-specific regulations, organization-specific regulations

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Intended Use
Use the unit only for the application described below.
The FAM is for dewatering, filtering and degassing hydraulic and lubricating
oils. In addition, it removes free water, emulsified water and a large
percentage of the water found in solution.
Proper or designated use of the product extends to the following:
Observing all instructions in the instruction manual.
Performing inspection and maintenance work.
DANGER
Fluid temperature > 60°C
Risk of explosion
►Note the maximum permissible hydraulic fluid
temperature of 60°C.
If necessary, install a cooler in front of the
unit.
DANGER
Ambient temperature >40 °C
Risk of explosion
►Observe the maximum permissible ambient
temperature of 40°C.

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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 switch cabinet is completely
closed.
Conversions and modifications to the devices and components that affect
the explosion protection are not allowed.
Depending on the version (see model code), use the FAM only in connection
with the following media:
NOTICE
Impermissible operating conditions
The unit will be damaged
►The unit may be used only in connection with the media mentioned
below.
Depending on the version (see model code), the FAM may only be used for
the following media (see model code):
FAM-xx-M-x-x/xxxx-xxx-xx-x-x-x
Mineral oils acc. to DIN 50524
Gear oils acc. to DIN 51517, 51524
Other hydraulic and lubrication oils which
require or are compatible with NBR
seals.
FAM-xx-B-x-x/xxxx-xxx-xx-x-x-x
Synthetic esters (HEES) DIN 51524/2
Vegetable oils (HETG, HTG)
Hydraulic and lubrication oils which
require or are compatible with Viton
seals.

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Explosion protection according to EU directive 2014/34/EU
The dewatering unit FluidAqua Mobil of the FAM-ATEX series meets the
requirements of the new EU Directive 2014/34EU for areas in which
explosive gas atmospheres can occur.
The designation of the explosion-proof ATEX-compliant FAM is:
II 2G IIB+H2T4 (+10°C<Ta<40°C)
This means that the FAM may be used only in accordance with:
Equipment group
II
Potentially explosive atmospheres in
which vapors or gas/air mixtures are likely
to occur.
Equipment category
2G
Equipment providing for a standard
degree of safety.
Designated for cases in which
atmospheres posing an explosion hazard
can be expected to occur very rarely and,
if so, only briefly.
Explosion hazard
subgroup
IIB+H2
Typical gases:
Town gas, acrylonitrile, ethylene, ethylene
oxide, ethylene glycol, hydrogen sulfide,
ammonia, methane, ethane, propane,
ethyl alcohol, cyclohexane, n-butane, n-
hexane and hydrogen
Ensure that the vapors, gases or mist
occurring at the operation location as well
as possible gases present in the liquid, are
allocated to the explosion groups IIA to
IIB+H2. Gas mixtures must also be
allocated to the explosion groups IIA to
IIB+H2.
To this effect, it must also be taken into
account that vapors, gases and mists
present in the environment around the unit
can mix with the gases in the liquid to be
cleaned inside the unit and can form a
another explosive atmosphere there.
Temperature class
T4
Maximum permissible surface
temperature: 135°C

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Improper Use or Use Deviating from Intended Use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result
when operated improperly.
►Never operate the unit in potentially explosive
atmospheres.
►The unit is only to be used with permissible
media.
Any use extending beyond this or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. This risk is borne solely by the owner.
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
Operation in a potentially explosive surrounding atmosphere other than
the identified one.
Operation in a potentially explosive interior atmosphere, due to gasses
escaping from the liquid, other than the identified one.
Operation with a non-approved medium.
Operation with a non-approved medium temperature >60°C.
Operation with a non-approved ambient temperature >40°C.
Operation under non-approved operational conditions.
Operation when the safety devices are defective.
Operation in mining or in dust-exposed zones
Unauthorized structural modification to the unit.
Inadequate monitoring of parts that are subject to wear and tear.
Improperly performed repair work.

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Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Operating and specialist personnel must have read and understood the
operating instructions, in particular the general safety information, 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:
Operating personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Specialist personnel: These persons have 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
Specialist
personnel
Proof of knowledge of cargo
securing instructions
Safe handling/operation of
hoisting and lifting equipment
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.
Checking the phase sequence
Comprehensive product-
specific knowledge
Comprehensive knowledge for
current status of the
technology regarding the unit
Comprehensive knowledge
according to ATEX 2014
Operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to
handle operating media.
Knowledge about
contamination due to solids

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and water
Disposal
Specialist
personnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse

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Wear suitable clothing
Loosely worn clothing increases the danger of getting caught or wound up in
rotating parts and the danger of getting snagged on projecting parts. You can
be severely injured or killed.
Wear close-fitting clothing.
Do not wear any rings, chains or any other jewelry.
Wear work safety shoes.
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, turn the main
switch by 90° in a counter-clockwise direction to
shut down the entire unit. The entire unit
downstream of this switch is voltage-free and
depressurized.
Normal pressure is reset to the vacuum column after ≈1 minute.

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 pushing.
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 fasten them in place.
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 steering
rollers.
Once the FAM is in its new position, actuate the hand brake on the steering
rollers.
Fork lift truck
Use the lift eyes when transporting the unit with a fork lift truck.

Transporting the FAM
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Crane
NOTICE
Unsuitable lifting accessories
The unit will be damaged / Components will be damaged / destroyed
►Use only suitable lifting accessories to raise or lash the FAM.
►Ensure that no forces from the lifting accessories are exerted on the
components on the FAM.
Train/truck
For transport by rail or truck, supports must be placed under the mobile FAM
so that the rollers are subjected to no load pressure.
The FAM is to be secured with suitable belts.