Hydac FluidCarrier Compact Series Manual

FCC-CM
FluidCarrier Compact
with ConditionMonitoring
Operating and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Document No.: 3648206

Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive director:
Mathias Dieter, Dipl.Kfm. Wolfgang
Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© 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.
Technical specifications are subject to change without notice.

Content
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Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Product modification ....................................................................................5
Warranty......................................................................................................5
Using the documentation.............................................................................6
Safety information ........................................................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions.....................................8
Proper/Designated Use ...............................................................................9
Improper Use or Use Deviating from Intended Use ...................................11
Qualifications of personnel / target group ..................................................12
Wear suitable clothing ...............................................................................13
Observe regulatory information .................................................................13
What to Do in Case of Emergency ............................................................14
Firefighting/Extinguishing Fires ..............................................................14
Unpacking the unit......................................................................................14
Transporting the unit..................................................................................15
Storing the unit ...........................................................................................15
Decoding the name plate ...........................................................................16
Checking the scope of delivery .................................................................18
Characteristics of the unit..........................................................................19
Filtration unit components..........................................................................19
Filtration unit dimensions...........................................................................21
Filtration unit hydraulicsschematic.............................................................22
Setting up the unit ......................................................................................23
Attaching/connecting the suction hose ......................................................24
Attaching/connecting the pressure hose....................................................24
Avoid siphoning .........................................................................................25
Selecting operating modes ........................................................................26
Filling the unit ............................................................................................27
Filtering the unit contents...........................................................................28
Draining the unit / filling tanks or systems..................................................29

Content
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Flushing an external tank or system ..........................................................30
Switching on the unit..................................................................................31
Observe the clogging indicator ..................................................................31
Viewing and resetting the optical clogging indicator...............................31
Observing electrical clogging indicator...................................................31
Operating the volume meter (optional accessories)................................32
Replacing the battery.................................................................................32
Resetting the volume meter - RESET........................................................32
Functional monitoring ................................................................................32
Calibrating the totals counter.....................................................................33
Programming the volume meter ................................................................34
Correcting/setting the measurement accuracy .......................................36
Performing maintenance............................................................................38
Cleaning the unit........................................................................................38
Tilt out the hose retainer............................................................................38
Changing the filter element........................................................................39
Change the breather filter..........................................................................44
Cleaning/replacing the suction strainer......................................................45
Suction strainer cleaning interval............................................................45
Replacing the protective screen to the Contamination Sensor ..................48
Errors and troubleshooting........................................................................50
Spare parts ..................................................................................................50
Taking the unit out of operation ................................................................51
Shutting down the unit ...............................................................................51
Disposing of the unit ..................................................................................51
Customer Service / Service........................................................................51
Model code ..................................................................................................52
Technical Data.............................................................................................53
EC declaration of conformity.....................................................................54
Index ............................................................................................................55

Preface
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Preface
These operating instructions were made to the best of our knowledge. Never-
theless and despite the greatest care, it cannot be excluded that mistakes
could have crept in. Therefore please understand that, in the absence of any
provisions to the contrary hereinafter, our warranty and liability – for any legal
reasons whatsoever – are excluded in respect of the information in these op-
erating instructions. In particular, we shall not be liable for lost profit or other
financial loss. This exclusion of liability does not apply in cases of intent and
gross negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we negligent-
ly breach any material contractual obligation, our liability shall be limited to
foreseeable damage. Claims due to Product Liability shall remain unaffected.
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:
[phone]
E-mail:
[e-mail]
Product modification
We would like to point out that changes to the product (e.g. purchasing addi-
tional options, etc.) may mean that the information in the operating instruc-
tions 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 opera-
tion 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.
You will find these under www.hydac.com -> General Terms and Conditions.

Preface
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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
all 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
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 eve-
ry time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

Safety information
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Safety information
The unit was built according to the statutory provisions valid at the time of de-
livery and satisfies current safety requirements.
Any residual hazards are indicated by 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 in-
spection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards 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

Safety information
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Risk of burns due to hot surfaces
Signal words and their meaning in the safety information and instruc-
tions
The following signal words are to be found in these instructions.
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.
Structure of the 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 danger

Safety information
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Proper/Designated Use
Use the filtration unit only for the application described in the following.
The filtration unit is a portable fluid service unit for filling hydraulic systems,
flushing small hydraulic systems, for offline filtration and recirculation with
simultaneous filtration.
Proper or designated use of the product extends to the following:
•Observing all instructions contained in the instruction manual.
•performing inspection and maintenance work.
NOTICE
Unpermitted operating media
The filtration unit will be destroyed.
►Use the filtration unit only in conjunction with lubricating and mineral
oils and/or media that are based on mineral oil or biologically fast de-
gradable fluids based on synthetic ester (HEES).
Permitted operating fluids:
Mineral oils acc. to
DIN 50524
Gear oils acc. to
DIN 51517, 51524
Synthetic esters (HEES) acc. to
DIN 51524/2
NOTICE
Operation in a slanted position / in direct sunlight
The filtration unit will be destroyed.
►Operate the filtration unit only in a horizontal position.
►Note the permitted ambient temperature range of: 0 … 40°C.

Safety information
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NOTICE
Suction strainer missing / operating without a suction strainer
The filtration unit will be destroyed
►Never operate the filtration unit without a suction strainer
►Clean the suction strainer regularly.

Safety information
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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 or deviating therefrom shall not be considered in-
tended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. The owner alone, shall assume any and all
associated risk
Improper use or use deviating from intended may result in hazards and/or will
damage the unit. Examples of improper use:
•Operation in potentially explosive atmospheres.
•Operation under non-approved operational conditions.
•Operation when the safety devices are defective.
•Modifications to the power unit made by the user or purchaser.
•Inadequate monitoring of parts that are subject to wear and tear
•Improperly performed repair work.
Operation with non-permitted media / fluids such as water, acids, solvents,
aggressive fluids, oily sludge or sediment.

Safety information
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Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated haz-
ards when using the power unit.
Operating and specialist personnel must have read and understood the op-
erating instructions, in particular the safety information and instructions, 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:
Auxiliary personnel: such persons have no specialized knowledge and per-
form work as instructed.
Operating personnel: such persons have been instructed in power unit opera-
tion and are aware of potential hazards due to improper use.
Specialist personnel: such 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 hazards.
Activity
Person
Knowledge
Transport / storage
Auxiliary per-
sonnel
No specialist knowledge requi-
red
Startup operation
Operations control
Operating Per-
sonnel
Product-specific knowledge
Knowledge about how to handle
operating media.
troubleshooting,
maintenance,
decommissioning,
Disassembly
Specialist per-
sonnel
Safe handling/use of tools
Product-specific knowledge
Disposal
Specialist per-
sonnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of contami-
nants
Knowledge about reuse

Safety information
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Wear suitable clothing
Loose-fitting clothing increases the risk of being caught or being drawn in on
rotating parts, and the risk of getting caught on protruding 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.
•Wear gloves.
•Observe the information relating to personal protection equipment in
the safety data sheet of the operating fluid.
Observe regulatory information
Observe the following regulatory information and guidelines:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations

Unpacking the unit
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What to Do in Case of Emergency
In case of emergency, switch off the power unit or disconnect it.
Firefighting/Extinguishing Fires
Use a powder extinguisher that corresponds to fire class B as per EN 2 to ex-
tinguish any fires.
Maintain a minimum safe distance from electrical components. For a mains
voltage of up to 1000 V, the minimum safe distance is 1 m.
Unpacking the unit
Prior to delivery, the product is function- and leak-tested in the factory.
When unpacking the product, check it for damage in transit.

Transporting the unit
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Transporting the unit
Release the hoses at the couplings and drain the contents of the hoses back
to the tank or dispose of the contents in an environmentally-friendly way.
Wind the power connection chord and both hoses to the hose retainer.
Push the filtration unit only at the grip.
Transport the filtration unit upright and in secure packaging.
Storing the unit
Drain the filter unit completely, including the tank contents, before putting it
into storage. Pull out the power plug and fasten the hoses and power cord on
the hose retainer.
Store the unit in an upright position in a clean, dry (non-condensing) space.
The permissible storage temperature is stated in the Chapter "" on page .

Decoding the name plate
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Decoding the name plate
Details for identifying the filtration unit can be found on the name plates on
the unit and the components.
Item
->
Description
(1)
->
Name plate of filtration unit
(2)
->
Name plate of electric motor
(3)
->
Model code; for details, see page 52

Decoding the name plate
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The following information can be found on the name plate of the unit:
Row
->
Description
Part No.
->
Part number
S/N
->
Serial number / year of production
Power
->
Power consumption
Voltage/Grid
->
Voltage / power supply
Frequency
->
Frequency
Current
->
Current consumption
Pressure max.
->
Operating pressure, maximum
Weight
->
Weight when empty
Flow rate
->
Flow rate
Temp. oil
->
Permissible oil temperature range
Temp. amb.
->
Permitted ambient temperature range
Volume
->
Fluid volume in unit

Checking the scope of delivery
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Checking the scope of delivery
The FluidCarrier Compact FCC is ready for operation upon delivery. Before
putting the filtration unit into operation, check it for possible damage.
The following items are supplied:
Qty
Designation
1
FCC, ready for connection with suction and pressure hose,
power chord including power plug
1
Operation and Maintenance Instructions (this document)

Characteristics of the unit
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Characteristics of the unit
The filtration unit has been developed for the maintenance of machine tools
with tank volumes up to 200 liters. The filtration unit allows you to transport
and refill filtered quantities with a monitored oil purity grade.
The filtration unit allows offline filtration and/or flushing of small tanks or sys-
tems.
Filtration unit components
The filtration unit has the following components:

Characteristics of the unit
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Item
Designation
IN
Inlet
OUT
Outlet
2
Sliding grip
4
Fluid level indication
3
Hose retainer
6
Electrical switch box with main switch
7
Nose wheel with immobilization brake
8
Suction strainer
9
Inspection opening for tank
10
Chassis
11.1
Breather filter
50
Filtration unit
51
Clogging indicator
60
Contamination Sensor
100
Ball valve IN
101
Ball valve OUT