Hydac FluidAqua Mobil FAM-200 User manual

FAM-200
FluidAqua Mobil
Maintenance and Servicing
Manual
English
Doc.: 3373093a / 2007-08-20 Siemens (PG)

Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
HYDAC Filtertechnik GmbH en Page 2
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Trademarks
The trademarks used herein of other companies exclusively designate the products of these
companies.
Copyright © 2007 by
HYDAC Filtertechnik GmbH
All rights reserved
No part of this manual may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying and recording, for any purpose, without the express written
consent of HYDAC Filtertechnik. Any violation hereof will be prosecuted to the maximum extent
possible under the law.
Exclusion of Liability
Every effort has been taken to ensure that the information provided herein is correct, however
errors cannot be precluded. The information contained herein does not represent a commitment on
the part of the authors. Consequently, no liability is assumed for any errors or deficiencies inherent
in this document, including consequential damage or loss. The information provided herein is
checked on a regular basis, with corrections being entered in subsequent editions. Any remarks or
suggestions for improvement you might have would be appreciated.
All technical details are subject to change without notice.
The content of this manual is subject to change without notice.
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

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Contents
Trademarks............................................................................................................................. 2
Preface.................................................................................................................................... 4
Modifications to the Product ................................................................................................. 5
Warranty............................................................................................................................... 5
1General Safety Information..................................................................................... 7
1.1 Obligations and Liability............................................................................................. 7
1.2 Explanation of Abbreviations, Symbols and Warnings, etc. ...................................... 8
2Safety Information and Instructions...................................................................... 9
2.1 Maintenance, Servicing and Troubleshooting ........................................................... 9
2.2 Training and Instruction of Personnel...................................................................... 10
2.3 Electrical Hazards.................................................................................................... 11
2.4 Modifications to the FAM ......................................................................................... 11
2.5 Instructions to Be Followed in the Event of an Emergency ..................................... 12
3Maintenance and Inspection List......................................................................... 13
4Assembly Diagram ................................................................................................ 15
5Description of the Inspection and Maintenance Work....................................... 16
5.1 Function Test of the Fault LED (40) ........................................................................ 16
5.2 Changing the Air Filter (19) ..................................................................................... 16
5.3 Checking and Cleaning the Level Switch of the Vacuum Pump (21) ...................... 17
5.4 Replacing the Injection and Condensate Water Lines (21) ..................................... 18
5.5 Cleaning the Fins of the Water Cooler (21) ............................................................. 18
5.6 Flushing and Cleaning the Vacuum Pump (21)....................................................... 19
5.7 Back-flushing the Water-Filter Assembly (23) ......................................................... 22
5.8 Changing the Filter Element of the Suction Filter (2)............................................... 23
5.8.1 Before Removing the Filter Element ................................................................ 23
5.8.2 Removing the Filter Element ............................................................................ 23
5.8.3 Replacing/Reinstalling the Filter Element......................................................... 23
5.9 Changing the Filter Elementsof the Fine filter (10) .................................................. 24
5.9.1 Before Removing the Filter Elements............................................................... 24
5.9.2 Removing the Filter Elements .......................................................................... 24
5.9.3 Replacing/Reinstalling the Filter Elements....................................................... 25
5.10 Function Test — Level Sensor, Vacuum column (14,15,16) .................................. 26
5.11 Function Test — Float Switch, Oil Pan (29) ........................................................... 27
5.12 Changing the Filter Element of the Oil Mist Separator (35)..................................... 27
6Accessories / Spare Parts List............................................................................. 28
7Contact / Service Information............................................................................... 29

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Preface
We have compiled this manual for you, the user of our product. It contains the most
important information relating to operation and maintenance.
It is intended to help you become acquainted with the proper/designated use 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 pace 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.
In these cases we go to every effort to keep your documentation current by sending you
updates.
But we need your help. Please make sure that you incorporate the updates in your
documentation and that non-current sections are removed.
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
Dept.: SVFI, Technical Documentation
P.O. Box 1251
66273 Sulzbach / Saar
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”

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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 this maintenance and servicing manual 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.

Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
... And now for a few tips on using this documentation.
The following example shows you how you can access the information you are looking for quick
and easy.
WHAT do you want to know?
WHERE can you find the information you're looking for?
The documentation is subdivided into chapters and sections.
Look for the table of contents.
Skim the boldfaced section headings.
HOW can you find the section and page you're looking for?
Page through the maintenance and servicing manual, keeping your eyes focussed on the lower
right corner.
As soon as you see the page number you are looking for, stop paging.
The chapter/section heading is featured in the upper right corner of each
page.
Product
Page no.
Edition date of chapter/section
The documentation number/edition and index are featured in the lower left corner of each page
and on the cover sheet of the manual.
This information features the following format:
Documentation no. Index
BeWa Product 12345678a en
The documentation no. enables you to order another copy of the operating and maintenance
instructions.
The index is incremented every time the manual is revised or changed.
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.
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
1 General Safety Information
This maintenance and servicing manual contains the most important information for operating the
FluidAqua Mobil (FAM) unit in a proper, safe manner.
The FAM’s operational safety and reliability is dependent on proper maintenance. This manual
details routine maintenance and servicing work that has to be performed. In the event of any repair
work which may be required, please don’t hesitate to contact us for advice and support. We can
supply original parts.
We also advise you to have the unit undergo annual servicing
by our HYDAC Servicenter.1
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 maintenance and servicing instructions in general, and the safety precautions in
particular, are to be adhered by all those who work with the FAM.
• Adherence is to be maintained to pertinent accident prevention regulations applicable at the
site where the FAM is used.
• The safety precautions listed herein are limited solely to using the FAM.
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 unit or to third parties. Risk of damage may be posed to the unit or other
equipment and property. The FAM is to be used as follows:
• solely for its designated use
• exclusively in the assembly, category and zone designated
• 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 FAM or use deviating from its designated use
• improper commissioning, operation and maintenance of the FAM
• operating the FAM when the system equipment or systems are defective
• unauthorized modifications to the FAM made by the user or purchaser
• improper monitoring of unit components subject to wear and tear
• improperly performed repair work
1For contact details, see section 7 .
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
1.2 Explanation of Abbreviations, Symbols and Warnings, etc.
This symbol designates safety instructions whose non-observance may pose
a hazard to individuals and the environment.
This symbol designates safety instructions whose non-observance may
result in the injury of individuals by electric shock.
This symbol provides important instructions and tips for the proper handling
and operation of the unit and use of the software. Non-adherence to these
instructions may result in damage to the immediate surroundings or cause
the unit/software to malfunction or discontinue operation.
This symbol designates tips for usage and other particularly useful
information.
Wear protective eyewear. Suitable, approved protective eyegear (safety
goggles) must be worn when working with cleaning tools/agents or
compressed air.
Wear protective gloves. Suitable, approved safety gloves must be worn
when working with cleaning tools/agents or compressed air.
Requisite tools are listed after this symbol.
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
2 Safety Information and Instructions
2.1 Maintenance, Servicing and Troubleshooting
• The inspection, maintenance and repair work specified in the manual is to be performed in a
timely, proper manner. Repair work to the unit which might prove necessary may not be
performed unless the requisite expertise and experience is present, otherwise the
manufacturer's specialists are to be consulted.
• Work may only be performed by qualified personnel possessing the proper education and
training to this end.
• Prior to commencing any such work, the operating personnel is to be informed about the work
to be done and a safety supervisor to be designated.
• The repair area is to be cordoned off and secured insofar as this is necessary.
• In the event that the unit is shut down for maintenance and repair work, measures are to be
taken to ensure that the unit is not switched back on by unauthorized personnel, e.g. by
securing the main and control switch using personal security locks. Make sure to remove the
key and store it in a safe place possessing restricted access.
• Signs are to be affixed to indicate that maintenance, repair or cleaning work is being done to
the unit.
• When removing components and assemblies make sure that no hazard is posed to the repair
crew by virtue of the unexpected movement of valves, pumps, etc. If this hazard cannot be
precluded, precautionary safety measures are to be taken, e.g. by propping or securing the
unit.
• Components and assemblies of the unit aren't to be removed unless the individual charged
with this work has the requisite expertise to complete the task in a proper, safe manner. In
cases of doubt, be sure to contact the manufacturer for information or specialists.
• If hoisting gear is needed to replace components or assemblies, make sure that the
components are secured by the gear and that the load suspension gear features the necessary
load-bearing capacity.
• Only suitable lifting and load suspension gear is to be used which is in proper working order.
• Do not work or stand under suspended loads!
• When performing erection and installation at elevated heights, make sure to use safe climbing
aids and work platforms specifically designed for this purpose. Do not use part of the unit to
support your weight while climbing. All handles, steps, railings, pedestals, platforms, ladders
are to be kept free of dirt at all times.
• Before cleaning the unit with high-pressure cleaners or other cleaning tools, be sure to
close/seal off all openings into which no cleaning agent may be allowed to enter for safety or
function reasons. This applies in particular to electromotors, switchgear, distributor boxes and
switch cabinets.
• After concluding cleaning work make sure to remove all the covers or other material used to
seal the openings shut.
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
• Make sure that the pumps have been switched off when working on piping, hose lines, and
fittings containing or conveying fluids or vapors. The piping, hose lines and fittings must be
allowed to cool completely and depressurize. The shut-off valves upstream and downstream of
the above conduits and fittings have to be closed and secured again being inadvertently
opened. If possible, the medium is to be drained.
• After cleaning check all the piping, hose lines, and fittings for leakage, loose connections,
places subjected to undue abrasion or other damage. Remedy any leakage, abrasion or loose
connections immediately.
• Make sure to tighten any screwed fittings which might have come loose during maintenance
and repair work.
• In the event that safety equipment needs to be removed during maintenance, cleaning or repair
work, be sure to install the equipment back in place and check that it is perfect working order
when work is completed.
2.2 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.
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Individuals
Activity
Individuals
undergoing
training
Individuals with
technical
training/
engineering
background
Qualified
electrician Supervisor with the
appropriate
authority
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the
source of
malfunction
X X X
Troubleshooting,
mechanical
problem
X X
Troubleshooting,
electrical problem X X
Maintenance and
servicing X X X X
Repair work X

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2.3 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 unit on a regular basis. Any loose
connections or damaged cables are to be remedied/replaced immediately.
• If work to live components is required, a second individual is required who can switch off the
unit at the main switch as may prove necessary.
• The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a
timely fashion.
• All operating media is to be protected/isolated for the event that the unit is accidentally started
up.
• The FAM 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.
• Any screwed fittings which have been undone/removed are to be checked to see that they
have been properly resecured.
• Always check the unit to see that it functions properly when performing maintenance and
servicing work.
2.4 Modifications to the FAM
• Do not make any modifications (design modifications, extensions) to the FAM without the
approval 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 parts and consumables. 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.

Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
2.5 Instructions to Be Followed in the Event of an Emergency
In the event of an emergency, turn the main switch by 90° in a counter-clockwise
direction to shut down the entire unit.
Normal pressure is restored in the vacuum column after approx. one minute.
Main Switch
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3 Maintenance and Inspection List
The inspection and maintenance work detailed here is a prerequisite for long service life and
trouble-free, reliable operation.
This section contains a detailed description of the maintenance, inspection and servicing work that
needs to be done.
The numbers in parentheses ( ) are in reference to the drawing in section 4.
For further information, refer to the operating manuals of the component manufacturers, supplied
with the unit.
See
section Every
24 hrs./
day
Every
500 hrs./
month
Every
3000 hrs./
six months
Every
6000 hrs/
year
FAM-200, general
Conduct a visual check for leakage X
Check the screwed fittings to ensure
they are properly secured; if
necessary, tighten them.
X
Check the measurement and
instrumentation system /
vacuum pressure gauge /
back-pressure gauge at the fluid filter
X
Conduct function testing of the fault
LED (40) 5.1 X
Change the air filter (19)
(if not required sooner) 5.2 X
Vacuum pump
Model/type: water ring vacuum
pump
Check the level switch of the vacuum
pump and clean it (21) 5.3 X
Replace the injection and condensate
water lines (21) 5.4 X
Clean the fins of the water cooler (21) 5.5 X
Flush and clean the vacuum pump (21) 5.6 X
Back-flush the water-filter assembly
(23) 5.7 X

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See
section Every
24 hrs./
day
Every
500 hrs./
month
Every
3000 hrs./
six months
Every
6000 hrs/
year
Drain pump/
feed pump/
retransfer pump
Clean and check the ventilator hood X
Suction filter
Change the filter element of the
suction filter (2) if not required earlier 5.8 X
Fine filter
Change the filter of the fine filter (10) X
Oil mist separator
Change the filter element of the oil mist
separator (35) 5.12 X
Electrical work
Check the cable glands for damage, if
necessary, replace them X
Take a measurement of the current
consumption of all motors and
compare the values obtained with the
rating plate
X
Perform a electrical safety check in
accordance with DIN VDE 0702 or
relevant national regulations
X
Function testing
Function Test — Level Sensor,
Vacuum column (14,15,16) 5.10 X
Function Test — Float Switch, Oil Pan
(29) 5.11 X
Function Testing of All Components in
Manual Mode2
X
2See the section on operating the unit via the manual menu in FAM 200 — Operating Instructions. Art-Nr.
3373092

Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
4 Assembly Diagram
1 Ball valve, inlet 21 30 Vacuum pump
2 Suction filter 22 Solenoid valve, filling, vacuum pump
3 Filter clogging indicator 23 Water filter assembly
4 Feed pump (gear pump assembly) 24 Backflow preventer
5 Inspection window 25 Ball valve, water supply, vacuum pump
6 2/2 directional solenoid valve 26 Check valve
7 Vacuum column 27 Ball valve, oil retransfer port
8 Drain pump (gear pump assembly) 28 Retransfer pump (gear pump assembly)
9 Check valve 29 Float switch (leak sensor)
10 Fine filter 31 Ball valve, drainage, fine filter housing
11 Filter clogging indicator 32 Check valve
12 Check valve 33 Backpressure pressure gauge, red/green
13 Ball valve, drainage, vacuum column 34 Solenoid valve, drainage, vacuum pump
14 15 16 Level sensor, vacuum column 35 Oil mist separator
17 Vacuum pressure gauge 36 Vacuum suction nozzle
18 Vacuum setting valve 37 Container
19 Air filter 40 Electrical switch cabinet with
– Main switch
– Fault LED
– Display with 4 keys for operating the FAM
20 Optical fill level gauge, vacuum column
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
5 Description of the Inspection and Maintenance Work
The pictures and explanations in the descriptions below are examples. They don't show all product
variants.
The unit is to be shut off when performing work, except as specifically indicated otherwise:
Steps:
Shut down automatic mode of the FAM via the display. Wait ca. 1 minute until
normal pressure is restored in the vacuum column (ambient pressure).
The FAM can be switched off as soon as the pressure in the vacuum column has
dropped to normal (ambient) pressure.
Secure the unit from being inadvertently switched back on.
5.1 Function Test of the Fault LED (40)
Steps:
 Switch the FAM ON at the main switch.
A lamp test is automatically conducted when switching the unit on,
during which the fault LED lights up briefly.
5.2 Changing the Air Filter (19)
You need:
• Air filter (for stock no. see Replacement Parts List)
Steps:
The air filter has to be changed every six months.
The filter has to be changed more frequently if the FAM is
operated in an extremely dusty or humid environment.
 Unscrew the air filter by hand
 Screw on a new air filter by hand
(O ring not needed)
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
5.3 Checking and Cleaning the Level Switch of the Vacuum Pump (21)
Tools needed:
• Philips head screwdrivers, PH#2 + PH#3
Steps:
 Remove the blue paneling.
 Remove the plug from the level switch.
 Pull out the level switch:
• Remove the 4 retaining screws, then pull out the level
sensor.
 Check the level switch for dirt build-up and damage. If
necessary, clean it.
 Check the function of the float switch(es) at the inputs of the
PLC. (See picture below.) The main switch of the FAM has
to be in the ON position.
 Reassemble components in reverse order.
.0 .3 .4 .0 .3 .4 .0 .3 .4
I 1
on
off
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
5.4 Replacing the Injection and Condensate Water Lines (21)
You need:
• Injection and condensate water lines (for stock no. see Replacement Parts List)
• Compressed air
• Philips head screwdrivers, PH#2 + PH#3
• Slotted screwdriver, 0,6x4,5x100
Steps:
If the entire vacuum pump is to be flushed and cleaned,
then do the cleaning first, then replace the filters.
 Remove the blue paneling.
 Remove the guard.
 Remove the injection water line and replace it.
 Remove the condensate water line and replace it.
 Reassemble components in reverse order.
 After switching the unit back on, slowly fill ca. one liter of
water in the waste air nozzle and observe the water filter
and hoses.
The movement of water in the hoses and filters has to be
visible.
5.5 Cleaning the Fins of the Water Cooler (21)
You need:
• Compressed air
• Philips head screwdrivers PH#2 + PH#3
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
Steps:
 Remove the blue paneling.
 Remove the guard.
 Blow compressed air through the fins of the water
cooler.
 Reassemble components in reverse order.
5.6 Flushing and Cleaning the Vacuum Pump (21)
You need:
• Compressed air
• VacuCleaner (for stock no. see Replacement Parts List)
FAM 200: 4 liters
• Measuring receptacle (5 liters)
• Funnel
• Hot water, ideally 60-65°C
FAM 200: ca. 80 liters
• Philips head screwdrivers PH#2 + PH#3
• Slotted screwdriver, 0,6x4,5x100
• Face pin spanner wrench 3-11-60 (for stock no. see Replacement Parts List)
Steps:
 Drain the vacuum pump via the manual drain line.
 Remove the blue paneling.
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Maintenance and Servicing Manual FAM 200 FluidAqua Mobil
 Remove the retaining screws of the side water cooler
cover paneling.
 Remove the cover paneling of the water cooler.
[1]
 Open the hose clamp of the forward-flow hose.
 Pull off the forward-flow hose [1] off the nozzle.
 Open the hose clamp of the return-flow line (on the pump at the front) and pull the return-
flow line off the bend.
 Carefully blow out the return-flow line with compressed air (see direction of arrow)
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