HYDAC International FluidAqua Mobil FAM 15-P Manual

FAM 10/15-P
FluidAqua Mobil
Operating and Maintenance Instructions
English (translation of original operating instructions)
Document no.: 3193324b

FluidAqua Mobil - FAM 10/15-P Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2011 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC Filter Systems GmbH. 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 Filter Systems Gmb
H
Postfach 12 51
66273 Sulzbach / Saa
r
Germany
Documentation Representative
Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-mail: [email protected]

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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................6
Technical Support...................................................................................................7
Modifications to the Product ...................................................................................7
Warranty .................................................................................................................7
Using the Documentation .......................................................................................8
Safety Information and Instructions.......................................................................9
Obligations and Liability..........................................................................................9
Explanation of Symbols and Warnings, etc. .........................................................10
General Safety Precautions..................................................................................11
Proper/Designated Use ........................................................................................11
Improper Use ........................................................................................................11
Safety Devices......................................................................................................11
Informal Safety Precautions..................................................................................12
Training and Instruction of Personnel ...................................................................13
Safety Measures to Be Followed during Normal Operation..................................13
Electrical Hazards.................................................................................................14
Maintenance, Servicing and Troubleshooting....................................................... 14
Modifications to the FluidAqua Mobil ....................................................................14
How to Behave in case of Emergency..................................................................15
Unpacking the FAM................................................................................................15
Transporting the FAM ............................................................................................16
Fork lift ..................................................................................................................16
Crane ....................................................................................................................16
Train/truck.............................................................................................................17
Scope of Delivery ...................................................................................................18
FAM Description.....................................................................................................19
FAM Versions .......................................................................................................19
Performance .........................................................................................................20
FAM system components .....................................................................................21
Suitable fluids .......................................................................................................23
Dimensions .............................................................................................................24
Stationary version .................................................................................................24
Mobile version.......................................................................................................25

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Hydraulic diagram ..................................................................................................26
Function description..............................................................................................28
Possible applications ............................................................................................29
Bypass purification (dewatering, filtration and degassing). ...............................29
Transfer by pumping (dewatering, filtration and degassing) .............................29
FAM Set-up and Connection .................................................................................30
Setting up the FAM ...............................................................................................30
Notes on Piping / Hosing ......................................................................................30
Connecting the inlet (IN) ...................................................................................32
Connect outlet (OUT) ........................................................................................32
Preparing the Vacuum Pump................................................................................ 33
Filling up the rotary vane vacuum pump........................................................34
Electrical connection of the FAM ..........................................................................35
Checking the settings on the heater (optional) .....................................................36
Filling the condensate separator .......................................................................36
Starting up the FAM ...............................................................................................37
Switching on the FAM...........................................................................................37
Draining the filterhousing ......................................................................................38
Shut off FAM .....................................................................................................38
Operating the FAM .................................................................................................39
Main Menu ............................................................................................................39
Manual menu 1 .................................................................................................40
Manual Menu 2 .................................................................................................41
Troubleshooting .....................................................................................................42
Electrical fuses......................................................................................................43
Vacuum chamber overfilled ..................................................................................44
Level switch 01/02(02/03).....................................................................................45
V-pump fill level min/max......................................................................................46
Change fluid filter..................................................................................................47
Float switch...........................................................................................................48
E/V/R pump motor protection ...............................................................................49
Dry run drain pump ...............................................................................................50
Dry running E-pump..............................................................................................51
Outlet (OUT) clogged............................................................................................52
Inlet (IN) clogged ..................................................................................................53
FCU plug missing (only in conjunction with accessory FCU)................................ 54
Reset safety thermostat on the heater.................................................................. 55
Performing maintenance .......................................................................................56
Maintenance Intervals...........................................................................................57
Changing the air filter............................................................................................59

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Vacuum pump.......................................................................................................59
Changing oil and oil filter...................................................................................59
Replacing the Air De-oiling Element .................................................................60
Change the active carbon filter cartridge ..........................................................61
Condensate separator ..........................................................................................62
Changing the filter element on the condensate separator ................................62
Checking the fill level on the condensate separator..........................................63
Filling the condensate separator .......................................................................63
Cleaning the suction strainer ................................................................................64
Replacing the filter element in the fluid filter .........................................................65
Checking the settings on the heater (optional) .....................................................69
Spare Parts .............................................................................................................70
FAM - 10 ...............................................................................................................70
Fluid filter (OLF 5/10)............................................................................................70
Rotary Vane Vacuum Pump ................................................................................. 71
Condensate separator ..........................................................................................71
Contact / Service ....................................................................................................72
Storing the FAM/Taking it out of Operation .........................................................73
Disposing of the FAM ............................................................................................73
Type label................................................................................................................73
Technical data ........................................................................................................74
Model code..............................................................................................................75
EU Declaration of Conformity ...............................................................................76

FluidAqua Mobil - FAM 10/15-P 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 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 FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”

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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/type designation, serial no.
and part-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.
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 Filter Systems GmbH.
Refer to these at www.hydac.com General terms and conditions.

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Using the Documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
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 number is incremented upward
by one number every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

FluidAqua Mobil - FAM 10/15-P Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely
operating the FluidAqua Mobil.
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 Mobile.
The FluidAqua Mobil has been designed and constructed in accordance with the
current state-of-the-art and recognized safety regulations. Nevertheless, hazards
may be posed to the life and limb of the individual using the product or to third
parties, and 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 when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly repaired or
remedied immediately.
Our General Terms and Conditions (AGB) 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

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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 denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
CAUTION
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
This hazard symbol indicates which hazard the product poses:
— dangerous to health / irritant
This symbol prescribes a specific conduct:
— protective gloves are to be worn
This symbol prescribes a specific conduct:
— protective eyewear is to be worn
This symbol prescribes a specific conduct:
— protective clothing is be worn

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General Safety Precautions
Maintenance work is to be carried out only by 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.
Proper/Designated Use
The FAM was developed for the dewatering, filtration and degassing of hydraulic
and lubricating oils. The FAM removes free water, emulsified water and a large
proportion of the water contained 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. Examples of improper use:
Operation with a non-approved fluid.
Operation under non-approved conditions.
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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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 at all times. If necessary, replace the
instruction sheets.
FluidAqua Mobil components may not be opened except in normal, non-
contaminated environments. The mains cable must be pulled out before the
FluidAqua Mobil is opened. Tests conducted with the housing open may only be
performed by properly trained, certified electricians. This also applies to all repair
work or to any modifications to electrical components approved by us.
Check the hoses and connectors for leaks on a daily basis.
Check the electrical equipment of the FluidAqua Mobil on a monthly basis. Replace
any loose connections or damaged cables immediately.
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

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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 Instructed individuals Individuals with technical training/ engineering background Electrician 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
Remedying of
mechanical faults X X
Remedying of electrical faults X X
maintenance X X X X
Repair work X
Decommissioning / Storage X X X X
Safety Measures to Be Followed during Normal Operation
Do not put the FAM into operation unless all the safety devices function properly.
The unit is to be checked once a day for visible external damage and for the proper
functioning of the safety devices.

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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.
Check the FAM electrical equipment on a monthly basis. Immediately replace loose
connections, damaged cables and hoses with original spare parts.
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in accordance with the respective schedules.
Disconnect the FluidAqua Mobil from the power supply when performing any
maintenance, inspection or repair work. Protect the FAM from being inadvertently
switched back on.
Any screwed fittings which have been undone/removed are to be checked to see
that they have been properly resecured.
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 conversion modifications require written permission from HYDAC Filter Systems
GmbH.
Immediately replace any machine components which are not in perfect condition.
Only use original spare parts and consumables.

FluidAqua Mobil - FAM 10/15-P Unpacking the FAM
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How to Behave in case of Emergency
In the event of an emergency, turn the main switch by 90° to the "OFF" position. The
entire system is then voltage-free downstream from this switch.
Normal pressure is restored to the vacuum column after ~ 1 minute.
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 disposed of or recycled as appropriate for your
area.

FluidAqua Mobil - FAM 10/15-P Transporting the FAM
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Transporting the FAM
CAUTION
High empty weight
(~ 400 - 850 kg, depending on the version)
Bodily injury
►Use at least 2 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 fasten them in place.
Shift 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.
Fork lift
Use the lift eyes when transporting the unit with a forklift.
Crane
NOTICE

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Unsuitable lifting accessories
The unit will be damaged / Components will be damaged / destroyed
►Use only suitable lifting accessories to raise or lash the FAM.
►Take care to ensure that the lifting accessories does not cause any
pressures to be brought to bear against the components on the FAM.
Train/truck
For transport by rail or truck, supports must be placed under the FAM to such an
extent that the rollers are subjected to no load pressure.
The FAM is to be secured with suitable belts.

FluidAqua Mobil - FAM 10/15-P Scope of Delivery
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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 included:
Item Qty. Description
1 1 FluidAqua Mobil, ready for connection with suction and
pressure hose
2 1 Tool, square 6 mm for switch box
- 1 Operating and Maintenance Instructions
- - Supplementary operating instructions (depending on FAM
design)
- 1 Operating and maintenance instructions for vacuum pump
1
2

FluidAqua Mobil - FAM 10/15-P FAM Description
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FAM Description
The FluidAqua FAM-P was developed for dewatering, filtration and degassing of
aviation phosphoric acid esters e.g. Skydol®or Hyjet®. The FAM removes free
water, emulsified water and a large proportion of the water contained in solution.
The integrated fluid filter ensures an efficient separation of solid particles.
Degassing of the medium is also achieved via the vacuum installed in the vacuum
chamber.
FAM Versions
Stationary (FAM-xx-1-..) Mobil (FAM-xx-2-..)
In comparison to the stationary version, the mobile version of the FAM has:
- 2 swivel casters, 2 rigid casters
- Suction hose, L= 5 m
- Return hose , L= 5 m
- Connection cable 10m

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Performance
The FAM is able to dewater the fluids described in the "Suitable fluids" section to a
water content of less than 1000 PPM.
Typical dewatering rates:
FAM - 10 ~ 0.8 l/h
FAM10/15 ~ 1.0 l/h
The dewatering speed is dependent on:
Dewatering rate
Water content
Fluid temperature
Detergent additives
Flow rate of the FAM
As an approximate guideline, the dimensioning of the FluidAqua Mobil can be
defined in accordance with the tank volume.
Tank volume in liters Size
< 2,000 FAM - 10
2,000 – 7,000 FAM10/15
Note that free water, e.g. on the bottom of the tank, can have an influence on the
entire water content in the system. Drain off free water before taking a sample.
For the determination of the water content, the sample should be extracted from the
system to be cleaned at a test connection during operation if at all possible.