Hydac FluidAqua Mobil FAM 15 User manual

FAM 15/30/50/70
FluidAqua Mobil
Operation Instructions
English (translation of original instructions)
Documentation no.: 3099574e

FAM 15/30/50/70 Trademarks
HYDAC Filter Systems GmbH en Page 2 / 68
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2009 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. Contraventions are liable to
compensation.
Exclusion of Liability
We have 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 GmbH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
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]

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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................6
Customer Service ...................................................................................................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..................................................................................10
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
What to Do in Case of Emergency .......................................................................15
Unpacking the FAM................................................................................................15
Transporting the FAM ............................................................................................16
Fork lift ..................................................................................................................16
Crane ....................................................................................................................17
Train/truck.............................................................................................................17
Checking the scope of delivery.............................................................................18
Description of the unit ...........................................................................................19
FAM Versions (without heater) .............................................................................19
Performance .........................................................................................................20
System components .............................................................................................21
Suitable Fluids ......................................................................................................22
Hydraulic plan (without heater).............................................................................23
Dimensions .............................................................................................................24
Stationary version (FAM70 with OLF without heater) ........................................... 24

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Mobile version (FAM70 with OLF without heater)................................................. 24
Function ................................................................................................................25
Possible Applications............................................................................................26
Purification operation (dewatering, degassing and filtration). ...........................26
Retransfer operation (only filtration). Only for versions with retransfer
pump .................................................................................................................26
FAM Set-up and Connection .................................................................................27
Setting up the FAM ...............................................................................................27
Notes on Piping / Hosing ......................................................................................27
Connecting the inlet (IN) ...................................................................................29
Connect outlet (OUT) ........................................................................................29
Preparing the Vacuum Pump................................................................................30
Water ring vacuum pump (only for model code FAM-xx-x-x-x/xxx-xxx-
xx-xx-S/SW-x-x/xxx) ..........................................................................................30
Checking / setting the downstream pressure............................................. 32
Rotary vane vacuum pump (only for model code FAM-xx-x-x-x/xxx-xxx-
xx-xx-D-x-x/xxx)................................................................................................. 33
Filling up the rotary vane vacuum pump (FAM 15-30)...................................34
Filling up the rotary vane vacuum pump (FAM 50-70)...................................34
Retransfer pump (only for versions with retransfer pump, external
pump) ................................................................................................................34
Electrical Connection of the FAM .........................................................................35
Starting up the FAM ...............................................................................................36
Switching on the FAM...........................................................................................36
Setting the fluid temperature (only with heater option)......................................37
Setting the switching points SP1 / SP2..........................................................37
Venting the filter housing ......................................................................................38
Shut off FAM .....................................................................................................39
Operating the FAM .................................................................................................40
Main menu ............................................................................................................40
Manual Menu 1 .................................................................................................41
Manual menu 2 (only with automatic water supply, FAM-Version FAM-
x-x-x-x/xxxx-x-x-x-SW-x-/x) ...............................................................................42
Manual Menu 2 (only with heater option) ..........................................................43
Performing Maintenance........................................................................................44
Troubleshooting .....................................................................................................45
Vacuum chamber overfilled ..................................................................................48
Level switch 01/02(02/03).....................................................................................49
V-pump fill level min/max......................................................................................50
Change fluid filter..................................................................................................51
Float switch...........................................................................................................52

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E/B/V pump motor protection................................................................................53
Incorrect phase sequence ....................................................................................54
Dry running E-pump..............................................................................................55
Outlet (OUT) clogged............................................................................................56
Inlet (IN) clogged ..................................................................................................57
Overflow V-pump ..................................................................................................58
Heater safety thermostat triggered .......................................................................59
Contact / Service ....................................................................................................61
Technical data ........................................................................................................61
Spare Parts...........................................................................................................61
Storing the FAM/Taking it out of Operation .........................................................62
Disposing of the FAM.............................................................................................62
Type label .............................................................................................................62
Model Code .............................................................................................................63
EU declaration of conformity (only for mobile version) .....................................64

FAM 15/30/50/70 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.
“Putting experience into practice”

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Customer Service
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 additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
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
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 ÖGeneral 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
Be
Wa12
3456a
d
e
Se ite 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 description
Page number
Edition date
Document language
Documentation no.
with index
/
file name

FAM 15/30/50/70 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. 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 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 mortal injury
if safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
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.

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Proper/Designated Use
The 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.
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 is 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 Individuals undergoing training 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
Danger of fatal injury
►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.

FAM 15/30/50/70 Unpacking the FAM
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What to Do 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.
Dispose of the packaging material as appropriate for your area.

FAM 15/30/50/70 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 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 steering rollers.
Once the FAM is in its new position, actuate the hand brake on the steering rollers.
Fork lift
Use the lift eyes when transporting the unit with a forklift.

FAM 15/30/50/70 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.
►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 mobile FAM so that
the rollers are subjected to no load pressure.
The FAM is to be secured with suitable belts.

FAM 15/30/50/70 Checking the scope of delivery
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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 included in the scope of delivery:
Item Qty. Description
1 1 FluidAqua Mobil - FAM
- 1 Four-sided hollow socket key, 6 mm
- 1
Technical Documentation:
- Operation Instructions FAM
- Service and maintenance instructions FAM
- Electrial wiring diagram
- Operating and maintenance instructions for vacuum pump
2

FAM 15/30/50/70 Description of the unit
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Description of the unit
The FAM was designed for the dewatering, filtration and degassing of hydraulic and
lubricating oils. It removes free water, emulsified water and a large proportion of the
water in solution. The integrated fluid filter ensures efficient particulate separation.
The fluid is degassed through a vacuum in the vacuum chamber.
FAM Versions (without heater)
Stationary (FAM-xx-1-..) Mobil (FAM-xx-2-..)
In addition to the stationary version, the mobile FAM has:
- 2 casters, 2 bock rolls
- Suction hose, L= 5 m
- Return hose , L= 5 m
- Connection cable 10m

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Performance
The FAM is able to reduce the water content of those fluids described in the chapter
"Suitable fluids" to less than 100 PPM.
Typical dewatering rates:
FAM-15 ≈1.0 l/h
FAM-30 ≈1.7 l/h
FAM-50 ≈2.2 l/h
FAM-70 ≈2.6 l/h
The dewatering speed is dependent on:
Dewatering rate
Water content
Fluid temperature
Detergent additives
Volumetric flow of the FAM