Hydac FluidAqua Mobil FAM 15 Manual

FAM 15/30/50/70
FluidAqua
Mobil
With integrated heater
Operating and maintenance instructions
English (translation of original instructions)
Document no.: 3117080d

FluidAqua Mobil - FAM-15/30/50/70 with integrated heater
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2008 by
HYDAC Filtertechnik GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to
compensation.
Exclusion of liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, no liability is assumed for any
errors or deficiencies inherent in this document, including consequential damage or
loss. The content of the manual is checked regularly. Any corrections required will
be incorporated in subsequent editions. We welcome any suggestions for
improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Service Technology Division / Filter Systems
PO Box 12 51
66273 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
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Contents
Preface ....................................................................................................................................5
Customer Service.................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty...............................................................................................................................6
Using the documentation......................................................................................................7
1Safety information and instructions..............................................................................8
1.1 Obligations and Liability .............................................................................................8
1.2 Explanation of Symbols and Warnings.......................................................................9
1.2.1 Basic Symbols........................................................................................................9
1.3 General safety information .........................................................................................9
1.4 Proper/Designated Use..............................................................................................9
1.5 Improper Use............................................................................................................10
1.6 Safety Devices .........................................................................................................10
1.7 Informal Safety Precautions .....................................................................................10
1.8 Training and Instruction of Personnel.......................................................................11
1.9 Safety Measures for Normal Operation....................................................................11
1.10 Electrical Hazards ....................................................................................................11
1.11 Maintenance, Servicing and Troubleshooting..........................................................12
1.12 Modifications to FluidAqua Mobil..............................................................................12
1.13 How to behave in an emergency..............................................................................12
2Checking the scope of delivery...................................................................................13
3Description of the system............................................................................................14
3.1 Suitable Fluids..........................................................................................................14
3.2 System components.................................................................................................15
3.3 Performance.............................................................................................................16
3.4 Functioning...............................................................................................................17
3.5 Possible applications................................................................................................19
3.5.1 Bypass purification...............................................................................................19
3.5.2 Transfer by pumping ............................................................................................19
4Transport, Setup, Connection, Start-up......................................................................21
4.1 Transportation and Packing .....................................................................................21
4.2 Setting up.................................................................................................................21
4.3 Connection...............................................................................................................22
4.3.1 Suction port connection........................................................................................22
4.3.2 Pressure port connection .....................................................................................22
4.3.3 Water connection (optional) .................................................................................22
4.3.4 Electrical Installation.............................................................................................23
4.3.5 Initial filling of the vacuum pump..........................................................................23
4.3.5.1 Water ring vacuum pump (FAM-x-x-x-x/xxxx-x-x-x-S/SW-x-/x).....................23
4.3.5.2 Rotary vane vacuum pump (FAM-x-x-x-x/xxxx-x-x-x-D-x-/x).........................24
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4.4 Commissioning.........................................................................................................25
4.4.1 Switching on the FCU...........................................................................................25
4.4.2 Setting the vacuum pressure................................................................................26
4.4.3 Bleeding the fluid filter..........................................................................................26
4.4.4 Setting the fluid temperature................................................................................26
4.4.5 Switching off.........................................................................................................27
5Operation.......................................................................................................................28
5.1 Operating the unit with the control panel..................................................................28
5.2 Main menu................................................................................................................28
5.3 Menu for manual operation ......................................................................................29
6Performing maintenance..............................................................................................30
7Shutdown, storage and disposal.................................................................................30
7.1 Shutdown and storage .............................................................................................30
7.2 Disposing of the FAM...............................................................................................31
8Troubleshooting............................................................................................................32
9Technical data...............................................................................................................34
10 Spare parts ....................................................................................................................35
11 Type label.......................................................................................................................36
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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.
Sometimes the information contained in the documentation cannot always keep up
with changes made to the product as we attach considerable importance to keeping
our products cutting-edge. 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 Filtertechnik GmbH
Division Service technology / Filter systems
Technical Documentation Department
PO Box 12 51
66273 Sulzbach/Saar - Germany
Fax: ++49 (0) 6897 509 846
E-mail: [email protected]
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: ++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
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com ÖLegal information.
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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.
HYDAC Filtertechnik GmbH en Page 7
Product
Page number
Version date
Document language
Documentation No.
with Index
/
File name
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented every time the
manual is revised or changed.
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1 Safety information and instructions
These operating instructions contain the most important notes for operating the FluidAqua
Mobil FAM 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.
1.1 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.
• Additionally, all local accident prevention instructions and regulations must be observed.
• 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. The FluidAqua Mobil is only
to be used:
• solely for its designated use
• only in accordance with the designated equipment group, equipment category and zone
• 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 apply. They are provided to the owner upon conclusion
of 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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1.2 Explanation of Symbols and Warnings
1.2.1 Basic Symbols
This symbol denotes safety information, the nonobservance of which can
endanger persons and the environment.
This symbol identifies safety guidelines whose non-observance may lead to
injury of individuals through electrical voltage.
This symbol marks an important note for the proper handling and operation of
the unit/software. Nonobservance of these notes can lead to damage or
failure of the unit/software.
This symbol identifies tips for usage and other particularly useful information.
1.3 General safety information
Operation, adjustment and calibration work may only be carried out 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.
All work must be performed in compliance with the existing national regulations on accident
prevention and safety at the workplace in addition to any rules and regulations of the
owner/operator, even if they are not specifically listed in these instructions.
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 connection lines depressurized.
1.4 Proper/Designated Use
The FAM was developed for the dewatering, filtration and degassing of hydraulic and
lubricating oils. It removes free water, emulsified water and a large percentage of the water 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:
• Observing all the notes contained in these operating instructions.
• Performing requisite inspection and maintenance work.
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1.5 Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazards.
Example of improper use:
• Operation with non-approved fluids.
1.6 Safety Devices
Before 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 machine has been shut down and secured
against being restarted (e.g. warning sign or padlock on the main switch).
When partial components are supplied, the safety devices are to be applied by the operator
as specified by law/pertinent regulations.
1.7 Informal Safety Precautions
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 observed.
Keep the safety and hazard symbols and warnings on the FluidAqua Mobil in a legible
condition. Replace them with new ones as required.
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 connection fittings for leakage daily (visual check). The electrical
components of the FluidAqua Mobil are to also be regularly checked (visual check once a
month). Replace any loose connections or damaged cables immediately.
Caution: Pressurized fluids can cause fatal injury. It is therefore
mandatory that you observe all of the safety regulations applicable
to work with pressurized fluids!
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1.8 Training and Instruction of Personnel
The FluidAqua Mobil may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established clearly.
Trainees may only use the FluidAqua Mobil when supervised by an experienced individual.
Individuals
Activity
Individuals
undergoing
training
Individuals
with
technical
training/
engineering
background
Electrician Supervisor
with the
appropriate
authority
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting X X X
Remedying
mechanical
problem X X
Troubleshooting,
electrical
problem X X
Maintenance X X X X
Repair work X
Decommissionin
g / Storage X X X X
1.9 Safety Measures for Normal Operation
Do not operate the FAM unless all the safety devices function properly.
Check the product once a day for external damage and the proper functioning of the safety
devices.
1.10 Electrical Hazards
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, a second individual should be present to switch off
the unit if necessary.
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1.11 Maintenance, Servicing and Troubleshooting
Do the adjustment, maintenance/servicing and inspection work specified according to
schedule.
Secure all operating media against accidental start up.
The FluidAqua Mobil is to be disconnected from the power supply and secured against being
inadvertently switched back on when performing any maintenance, servicing, inspection or
repair work.
Check screwed fittings which have been undone/removed for tightness.
After performing maintenance and servicing work, always check the safety features of the
product to see that they function properly.
1.12 Modifications to FluidAqua Mobil
Do not make any modifications (design modifications, extensions) to the FluidAqua Mobil
without the prior consent of the manufacturer.
Any design modifications or extensions may not be made without HYDAC Filtertechnik
GmbH’s express prior written approval.
Immediately replace any machine components which are not in perfect condition.
Only use original (OEM) spare and wear parts. Non-OEM components have no guarantee
that they have been designed and manufactured so as to comply with loading and safety
requirements.
1.13 How to behave in an emergency
In the event of an emergency, rotate the main and E-
STOP switch 90° to the left in order to shut down the
entire system. The entire system is then voltage-free
downstream from this switch. Normal pressure is
restored to the vacuum chamber after about 1
minute.
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2 Checking the scope of delivery
Upon receiving the FAM check it for any damage in transit. The FAM may not be set up and
installed unless it is in perfect order. Any damage in transit is to be reported to the forwarding
agent or the department in charge immediately; the unit may not be commissioned until this
damage is properly remedied.
The following items are supplied:
Item Pc Designation
1 1 FluidAqua Mobil, ready for connection with suction and pressure hose.
- 1
Four-sided hollow socket key, 6 mm
- 1
Technical documentation:
- Operating instructions FAM
- Service and maintenance instructions FAM
- Electrical wiring diagram
- Operating and maintenance instructions for vacuum pump
Supplementary operating instructions (depending on FAM design)
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3 Description of the system
The FluidAqua FAM was designed for the dewatering, filtration and degassing of hydraulic
and lubricating oils. It removes free water, emulsified water and a large percentage of the
water to be found in solution. The fluid filter that is installed filters out solid materials
effectively.
The fluid is degassed through a vacuum in the vacuum chamber.
3.1 Suitable Fluids
Depending on the version, only use the FAM for the following fluids (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
FAM-xx-X-x-x/xxxx-xxx-xx-D-x-x HFD fluids (not for pure phosphate esters which
require EPDM seals).
Contact the manufacturer for approval before using other operating fluids.
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3.2 System components
1
2
3
4
5
6
7
8
9
10
11
12
13
1. The control cabinet consisting of
- Main switch and emergency off
- -Display with 4 keys (Start, Stop, Fault, Reset)
- HDA 5500 to regulate the temperature of the heater
- Error (yellow)/Heater on (red) indicator lights
2. Air filter
3. Vacuum column
4. Heater
5. Vacuum gauge with throttle valve to set the required vacuum
6. Inlet valve (2/2 directional valve)
7. Fluid filter for separating solid particles
8. Vacuum pump
9. Suction filter
10.Ring bolts for the transport with crane
11.Evacuation pump
12.Charge pump
13.Condensate collection canister
(There can be deviations due to different types.)
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3.3 Performance
The FAM-15/30/50/70 is able to reduce the water content of those fluids described in the
chapter “Suitable fluids” to less than 100 ppm.
Typical dewatering speeds*:
FAM-15 Approx. 1 l/h
FAM-30 Approx. 1.7 l/h
FAM-50 Approx. 2.2 l/h
FAM-70 Approx. 2.6 l/h
*Values are examples. Dewatering speeds depend on the type of oil, water content, temperature or
age of oil, for example.
The dewatering speed is basically dependent on:
Dewatering
speed
Water content
Fluid temperature
Detergent additives
Volumetric flow of the FAM
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3.4 Functioning
Rotary vane
vacuum pump 7
FAM-x-x-x-x/xxxx-x-x-x-D-x-/x
Water ring
vacuum pump
FAM-x-x-x-x/xxxx-x-x-x-S/SW-x-/x
After the FAM-15/30/50/70 is switched on, the feed pump (1) (heater pump) pumps the
operating fluid through the heater (2) and the solenoid valve (3) into the vacuum column (4).
There, the fluid to be purified pours downward over special filling material. This filling material
is there to form a thin flim of fluid. The fluid collects in the lower part of the vacuum column.
When the centre level switch has been reached, the evacuation pump (5) switches on and
now permanently pumps the fluid over the fluid filter (6) to the outlet.
At the same time, the solenoid valve (3) closes and the level in the vacuum column drops to
the lower level switch. When it reaches this switch, the solenoid valve opens and fluid is let
into the vacuum column until it reaches the centre level switch. The solenoid valve closes
and the procedure is repeated.
When the solenoid valve is closed, the fluid above the heater is circulated directly back to the
tank to prevent the fluid in the heater from carbonizing. This partial amount is not dewatered
and filtered.
The vacuum in the vacuum column is set using the regulating valve (9) (vacuum pressure
regulation).
Air is drawn in through the air filter (10) by the vacuum in the vaccum column. In the counter
flow, this air absorbs the moisture of the fluid and is then drawn off by the vacuum pump (7).
Der Füllstand wird dabei automatisch über einen Schwimmerschalter überwachtA special
cooling system 1within the water ring vacuum pump cools the air and dries part of it. The
1Water ring vacuum pump version only (FAM-x-x-x-x/xxxx-x-x-x-S/SW-x-/x). In models with a rotary
vane pump (FAM-x-x-x-x/xxxx-x-x-x-D-x-/x ), water is discharged from the vacuum pump as water
vapor.
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resulting condensed water is fed to the operating water using the water-operated vacuum
pump. If more water is harvested than is consumed by the pump (evaporates), it is drained
through the overflow valve (11) into the condensate canister (8)1. If less water is harvested
than is consumed by the pump, it is automatically topped off via the automatic water
connection2or manually. The level is automatically monitored by a floating switch.
After the Close key is pressed, the heater is switched off, the solenoid valve closes and the
evacuation pump empties the vacuum column. Delaying switch off of the feed pump provides
optimal cooling for the heater.
When the emergency stop is pressed, all motors are switched off and the 2/2 directional
valve is closed at the inlet by a spring.
2Version FAM-x-x-x-x/xxxx-x-x-x-SW-x-/x
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3.5 Possible applications
3.5.1 Bypass purification
The FAM 15/30/50/70 is connected to the tank with suction and pressure hose and
purifies the fluid continuously.
3.5.2 Transfer by pumping
Transfer by pumping can be useful depending on the application, because
part of the fluid isn't filtered before being pumped. See also the function
description at 3.4.
Tank 2
Tank 1
The FAM 15/30/50/70 is connected to the suction line at Tank 1 and pumps the fluid
into Tank 2. Because part of the flow is not filtered before transfer by pumping, Tank
2 has to be cleaned in the bypass flow (see 3.5.1) after transfer.
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In order to avoid to overcharge the tank for the purified oil the oil level
should be monitored.
In order to improve the results of the purification a bypass filtration
according to point 1 should be carried out at the tank with the purified oil
after transfer by pumping.
The electric control supports several operation modes e.g.:
a) - FAM 15/30/50/70 can be switched on/off from a control room
b) - FAM 15/30/50/70 can be switched on/off by a level sensor in
the transfer by pumping operation mode.
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