Hydac FluidCleaner Mobil FCM Series User manual

FCM
FluidCleaner Mobil
Operating and Maintenance Instructions
English (translation of original instructions)
Document no.: 3160267d

FCM Series Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Telefax: [phone]
E-Mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive director: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
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]
© HYDAC FILTER SYSTEMS GMBH - 2012
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
All details are subject to technical modifications. Technical specifications are subject
to change without notice.

FCM Series Content
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Content
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Customer Service ...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
Safety information and instructions.......................................................................8
Obligations and liability ...........................................................................................8
Explanation of Symbols and Warnings, etc. ...........................................................9
Proper/Designated Use .......................................................................................... 9
Improper Use .......................................................................................................... 9
Safety Devices......................................................................................................10
Informal Safety Precautions.................................................................................. 10
Training and Instruction of Personnel ...................................................................11
Safety measures to be followed in normal operation............................................12
Hazards Posed by Stored Residual Energy .........................................................12
Maintenance, Servicing and Troubleshooting....................................................... 12
Modifications to the FCM ......................................................................................12
Fire Fighting..........................................................................................................12
Storing the FCM......................................................................................................13
Transporting the FCM ............................................................................................ 13
By hand................................................................................................................. 13
Train / truck...........................................................................................................13
Crane ....................................................................................................................13
Checking the scope of delivery ............................................................................14
FCM features........................................................................................................... 15
Operating limitations .............................................................................................15
Dimensions .............................................................................................................16
Overview of FCM modules .................................................................................... 17
Hydraulic schematic.............................................................................................. 18
Preparing the FCM for operation .......................................................................... 19
Inserting the filter element ....................................................................................19
Notes on pipes and hoses ....................................................................................20
Hanging / connecting the suction hose.................................................................21

FCM Series Content
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Hanging / connecting the pressure hose ..............................................................21
Electrical connection of the FCM ..........................................................................22
Checking direction of rotation in jog mode............................................................ 22
Pole changer (optional)......................................................................................... 23
Wiring diagram of the pole changer (optional) ..................................................23
Controlling FCM via the clogging indicator (optional)........................................24
Flow rate indicator (accessories) .........................................................................24
Pump nozzle (accessories) ...................................................................................24
Switching on the FCM............................................................................................ 25
Selecting operating mode (optional) .....................................................................25
Performing Maintenance .......................................................................................26
Maintenance intervals ........................................................................................... 26
Changing the Filter Element.................................................................................. 27
Change the filter element ..................................................................................28
Clean the suction strainer. .................................................................................... 32
Disposing of the FCM ............................................................................................33
Errors and troubleshooting................................................................................... 33
Spare parts list ....................................................................................................... 34
Technical Data ........................................................................................................36
Model code.............................................................................................................. 37
Type code 'Filter concept' .....................................................................................38
EC declaration of conformity ................................................................................39

FCM Series Preface
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. Consequently, there might be
deviations in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC Filter Systems Gmb
H
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”
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FCM Series Preface
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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, 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
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC Filter Systems GmbH.
You'll find this under www.hydac.com -> General terms and conditions

FCM Series Preface
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.
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Chapter
Page number
Edition 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.

FCM Series Safety information and instructions
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Safety information and instructions
These operating instructions contain the key instructions for properly and safely
operating your FCM.
Obligations and liability
The basic prerequisite for the safe and proper handling and operation of the FCM 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 FCM.
In addition, the accident prevention rules and regulation applicable at the location of
use are to be observed.
The safety precautions listed herein are limited solely to using the FCM.
The FCM 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. Nevertheless,
hazard may be posed to the life and limb of the individual using the product or to
third parties.
The FCM is to be used as follows:
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 FCM or use deviating from its designated use
improper assembly, installation, commissioning, operation and maintenance of the
FCM
operating the FCM when the system equipment or systems are defective
modifications to the FCM made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

FCM Series Safety information and instructions
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, 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.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The FCM is a mobile filtration unit designed for circulation pumping with or without
filtering fluids at the same time.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
The manufacturer will not assume any 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 other than described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
-Commissioning the unit without a dirt trap
-Using the unit with the wrong media
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FCM Series Safety information and instructions
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Safety Devices
Prior to starting up the product, make sure that all the safety devices are properly
fitted to the hydraulic system and are in proper working order.
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
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.
All safety guidelines and hazard warnings on the machine must be maintained in
legible condition and replaced as required.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FCM are to also be regularly checked (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.

FCM Series Safety information and instructions
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Training and Instruction of Personnel
The FCM 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 FCM unless supervised by an
experienced staff member.
Individuals Individuals undergoing training Individuals with technical training/ engineering background Electricians 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
Troubleshooting, mechanical
problem X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning / storage X X X X

FCM Series Safety information and instructions
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Safety measures to be followed in normal operation
Do not operate the FCM unless all the safety devices function properly.
Check the product for visible damage and properly functioning safety equipment at
least once a day.
Hazards Posed by Stored Residual Energy
Note that the unit may pose a hazard as the result of residual stored mechanical and
electrical energy. Take the proper precautions when instructing personnel on the
use of the unit. Detailed information is provided in the respective chapters of this
manual.
Maintenance, Servicing and Troubleshooting
The specified adjustment, maintenance, and inspection work is to be conducted in a
timely fashion.
Secure all operating media against accidental start up.
The FCM is to be disconnected from the power supply and protected against being
inadvertently switched back on when performing any maintenance, servicing,
inspection or repair work.
Check that released threaded joints were refit tightly.
Always check the safety devices to see that they function properly after performing
maintenance work.
Modifications to the FCM
Do not make any modifications (design modifications, extensions) to the FCM
without the prior consent of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Use only original spare parts (OEM). When using non-OEM components, it cannot
be ensured that they have been designed and manufactured so as to comply with
loading and safety requirements.
Fire Fighting
When fighting a fire make sure to disconnect the unit from the power supply,
otherwise an electrical fire cannot be effectively dealt with.

FCM Series Storing the FCM
Storing the FCM
Drain the unit completely before putting it into extended storage.
Pull the power plug and wind up the power cord.
Attach the suction and pressure hoses to the unit and secure them.
Transporting the FCM
By hand
The unit may be grasped only on the handles provided and shifted by hand.
Train / truck
When transported by truck / train, the unit must be lashed securely to a pallet.
Crane
For transport by crane, the unit has an
eyelet provided.
Only use suitable lifting accessories.
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FCM Series Checking the scope of delivery
Checking the scope of delivery
Before commissioning the unit, check it for completeness and any possible damage.
Report any damages in transit to the transport company or the responsible agent
immediately. Do not put the unit into operation.
The following items are supplied:
Qty. Name
1 FluidCleaner Mobil
1 Filter element
1 Suction hose
1 Pressure hose
1 Operation and Maintenance Instructions (this document)
1 Certificate
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FCM Series FCM features
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FCM features
The Fluid Cleaner Mobile unit is a mobile filtration-pumping unit designed for oil
servicing which,depending on the version (with or without the change-over feature),
can be used for pumping or pumping and filtering fluids.
Operating limitations
NOTICE
Impermissible operating media
The unit will be damaged
►The unit is only to be used with mineral oils or mineral oil-based raffinates.

FCM Series Dimensions
Dimensions
≈ 570
613
≈ 690
≈
1250
X2 = 1118
X1 = 678 X1 = 490
X2 = 925
X1 = 1300 Filter size
X2 = 2600 Filter size
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FCM Series Overview of FCM modules
Overview of FCM modules
110 110
120
10
40
20
80
30
100
90
Item Name
10 Chassis
20 Fluid filter (1300/2600)
30 Motor-pump assembly
40 Contamination indication
80 Suction hose with lance
90 Pressure hose with lance
100 with on-off switch and overload protective switch
110 Operating change-over (Option)
120 Suction strainer
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FCM Series Overview of FCM modules
Hydraulic schematic
FCM without change-over (FCM xxx Lx xxx x / FCM xxx K x xxx)
M
SP
FCM with change-over (FCM xxx Fx xxx x / FCM xxx G x xxx)
M
S
P
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FCM Series Preparing the FCM for operation
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Preparing the FCM for operation
Inserting the filter element
The unit is delivered with no filter element installed. Make sure that there is a filter
element in the fluid filter before commissioning.
You can find details about changing the filter element on page 27.

FCM Series Preparing the FCM for operation
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Notes on pipes and hoses
Make sure that no vibrations or stress/loading from other machinery and equipment
are carried over to filter housing. If necessary, use expansion joints.
The pressure loss in a hydraulic line depends upon:
Flow rate
Kinematic viscosity
Pipe dimensions
fluid density
The pressure loss can be estimated for hydraulic oils as follows:
Δp ≈6,8 * L / d4* Q * V * D
Δp = Pressure differential in [bar]
L= Line length [m]
d= Internal line diameter [mm]
Q= Flow rate [l/min]
V = Kinematic viscosity [mm²/s]
D = Density [kg/dm³] Mineral oil-based hydraulic fluid has a density
of ≈0.9 kg/dm³.
This applies to straight pipelines and hydraulic oils. Additional threaded connections
and pipe bends increase the pressure differential.
Keep the height difference between the pump and the oil level in the tank as low as
possible.
Constrictions in the connections and lines should be avoided. This could
compromise suction output and cause cavitation .
Take note that the nominal size of the connected hoses/piping must be at least as
large as the inlet port sizes.
Make sure that no vibrations or stress/loading from other machinery and equipment
are carried over to filter unit. Use hoses or expansion joints if necessary.