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
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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