Hydac FAM 5 FluidAqua Mobil Manual

FAM
5
FluidAqua Mobil
Operating and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 4166129

Imprint
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.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................7
Technical Support........................................................................................7
Product modification ....................................................................................7
Warranty......................................................................................................7
Using the documentation.............................................................................8
Safety information ........................................................................................9
Hazard symbols...........................................................................................9
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions...................................10
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................11
Improper Use or Use Deviating from Intended Use ...................................12
Qualifications of personnel / target group ..................................................13
Wear suitable clothing ...............................................................................14
Stoppage in an emergency (EMERGENCY STOP)...................................14
Unpacking the FAM ....................................................................................15
Transporting the FAM.................................................................................15
Horizontal transport ...................................................................................15
Vertical transport .......................................................................................16
Transport suspended on a crane...............................................................17
Checking the scope of delivery .................................................................17
FAM description..........................................................................................18
FAM Versions ............................................................................................18
FAM features .............................................................................................19
FAM system components ..........................................................................20
Dimensions – stationary unit .....................................................................22
Dimensions – mobile unit ..........................................................................23
Hydraulic circuit..........................................................................................24
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Content
Working principle of FAM ..........................................................................25
Possible applications .................................................................................26
Bypass purification .................................................................................26
Transfer by Pumping ..............................................................................26
FAM set-up and connection.......................................................................27
Setting up the FAM....................................................................................27
Notes on pipes and hoses .........................................................................28
Connecting the inlet (IN).........................................................................30
Connect outlet (OUT) .............................................................................31
Preparing the Vacuum Pump.....................................................................31
Check air outlet of the vacuum pump .....................................................32
Electrical connection of the FAM ...............................................................32
Check direction of rotation.........................................................................33
Operating elements on the FAM................................................................34
Starting up the unit .....................................................................................36
Switching on the FAM................................................................................36
FAM start screen (HOME) and menu layout..............................................37
Starting operation of the FAM....................................................................38
Setting the pressure in the vacuum column...............................................40
Recommended vacuum setting..............................................................40
Pressure information in the vacuum range..........................................42
Venting the filter housing ...........................................................................43
Switching on the heater / Checking setting (optional)................................43
Stopping operation of the FAM..................................................................45
Switching off FAM.......................................................................................46
Selecting operating mode ..........................................................................46
"Dewater" operating mode (optional).........................................................47
"Filter" operating mode (optional) ..............................................................49
Limits on ContaminationSensor CS........................................................49
ContaminationSensor CS1000 menu layout ..........................................51
Setting times for "Dewater/Filter until" (optional) .......................................52
"Heat" operating mode (optional)...............................................................53
Manual Operation ......................................................................................54
Emptying the vacuum column ................................................................54
Manually controlling components ...........................................................55
Settings – Language, operating hours, program version .......................56
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Content
Loading new program version/language version ....................................57
Inserting micro-SD card and loading program ...........................................57
Configuration menu....................................................................................58
Changing configuration..............................................................................59
Exiting the Configuration menu..................................................................59
FAM menu layout ........................................................................................60
Changing values and parameters in menus.............................................61
Connection of an external AquaSensor AS(EXT).....................................61
Network connection (Ethernet)..................................................................62
Web server ................................................................................................62
Troubleshooting..........................................................................................66
Error notifications.......................................................................................68
03 Empty vacuum column ......................................................................69
04 Vacuum pump level sensor ...............................................................70
05 Vacuum column sensor.....................................................................71
12 Measured AS temp value/13 Measured AS %S value ......................72
18 H pump motor protection switch/19 V pump motor protection
switch V-pump........................................................................................73
23 Filter clogged.....................................................................................74
24 V pump min. ......................................................................................75
25 V pump max. .....................................................................................75
26 Heater thermostat..............................................................................76
28 Heater motor protection switch..........................................................77
32 Fill column .........................................................................................79
33 Vacuum column alarm.......................................................................80
34 Drip tray full .......................................................................................81
Performing maintenance...........................................................................82
Maintenance intervals................................................................................82
Check fault signal lamps............................................................................85
Change Air filter.........................................................................................85
Vacuum pump ...........................................................................................85
Replace the active carbon filter cartridge (accessory)............................85
Rotary vane vacuum pump FAM-5-x-x-x-xx-R-x-x-x-x ...........................86
Checking the oil level ..........................................................................87
Filling/Refilling vacuum pump oil ........................................................88
Emptying the vacuum pump................................................................90
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Content
Changing the vacuum pump oil...........................................................91
Replacing the air de-oiling element of the vacuum pump....................92
Dry-running rotary vane vacuum pump FAM-5-x-x-x-xx-RD-x-x-x-
x .............................................................................................................93
Replacing the filter ..............................................................................94
Blowing off the filter.............................................................................94
Inspecting/replacing vanes..................................................................95
Clean the suction screen ...........................................................................96
Replacing the filter element on the fluid filter.............................................96
Heater maintenance (optional) ................................................................101
Inspecting/Cleaning the heating element .............................................101
Removing/Installing the heating element ..........................................101
Emptying the heater .............................................................................103
Checking the AquaSensor AS1000 .........................................................104
Checking the float switch in the oil pan....................................................104
Spare parts ................................................................................................106
FAM.........................................................................................................106
Fluid filter (OLF 5/10)...............................................................................106
Vacuum pump .........................................................................................106
Rotary vane vacuum pump FAM-5-x-x-x-xx-R-x-x-x-x .........................106
Dry-running rotary vane vacuum pump FAM-5-x-x-x-xx-RD-x-x-x-
x ...........................................................................................................107
Contact / Service.......................................................................................107
Storing the unit / taking it out of operation ............................................107
Disposing of the unit ................................................................................108
Technical data ...........................................................................................108
Connection overview................................................................................110
Model code ................................................................................................111
EC declaration of conformity...................................................................112
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Preface
Preface
These operating instructions were made to the best of our knowledge.
Nevertheless 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 operating 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 negligently 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
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
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.
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Safety information
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
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation No.
with Index /
File name
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Safety information
Safety information
The unit was built according to the statutory provisions valid at the time of
delivery 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
inspection.
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
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Safety information
Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Danger from explosive atmosphere
Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a danger with a high risk which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a danger with a medium risk which can lead to death or
serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk which can lead to minor injury if
not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.
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:
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Safety information
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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
Proper/Designated Use
Use the unit only for the application described in the following.
The FAM is for dewatering, filtering and degassing hydraulic and lubricating
oils. In addition, it removes free water, emulsified water and a large
percentage of the water found in solution.
Proper or designated use of the product extends to the following:
•Observing all instructions contained in the instruction manual.
•performing inspection and maintenance work.
Depending on the version (see model code), you may use the FAM only in
connection with the following media:
F
F
A
AM
M
t
ty
yp
pe
e
S
S
u
ui
it
ta
ab
bl
le
e
o
o
p
pe
er
ra
at
ti
in
ng
g
m
m
e
ed
di
iu
um
m
Sealing material
Hoses
F
FA AM M- -x xx x- -M M- -
…
…
M
Mi in ne er ra al l o oi il l, , t te es st te ed d w wi it th h m mi in ne er ra al l o oi il l. .
•
• M Mi in ne er ra al l o oi il ls s a ac cc c. . t to o D DI IN N 5 50 05 52 24 4
•
• G Ge ea ar r o oi il ls s a ac cc c. . t to o D DI IN N 5 51 15 51 17 7, , 5 51 15 52 24 4
•
• O Ot th he er r h hy yd dr ra au ul li ic c a an nd d l lu ub br ri ic ca at ti io on n o oi il ls s w wh hi ic ch h
NBR
NBR
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Safety information
r
re eq qu ui ir re e o or r a ar re e c co om mp pa at ti ib bl le e w wi it th h N NB BR R s se ea al ls s
F
FA AM M- -x xx x- -I I- -… …
I
In ns su ul la at ti io on n o oi il l, , c ch he ec ck ke ed d w wi it th h ( (e e. .g g. . S Sh he el ll l D Di ia al la a) ). .
•
• M Mi in ne er ra al l o oi il ls s a ac cc c. . t to o D DI IN N 5 50 05 52 24 4
•
• G Ge ea ar r o oi il ls s a ac cc c. . t to o D DI IN N 5 51 15 51 17 7, , 5 51 15 52 24 4
•
• O Ot th he er r h hy yd dr ra au ul li ic c a an nd d l lu ub br ri ic ca at ti io on n o oi il ls s w wh hi ic ch h
r
re eq qu ui ir re e o or r a ar re e c co om mp pa at ti ib bl le e w wi it th h N NB BR R s se ea al ls s
U
Un ni it t i is s n no ot t s su ui it ta ab bl le e f fo or r " "O On nl li in ne e" " a an nd d " "O On nl lo oa ad d" "
o
op pe er ra at ti io on n o on n t tr ra an ns sf fo or rm me er r. .
NBR
NBR
F
FA AM M- -x xx x- -B B- -… …
B
Bi io ol lo og gi ic ca al ll ly y t te es st te ed d w wi it th h f fa as st t- -b bi io od de eg gr ra ad di in ng g
f
fl lu ui id d o on n a an n e es st te er r b ba as si is s. .
•
• S Sy yn nt th he et ti ic c e es st te er r ( (H HE EE ES S) ) D DI IN N 5 51 15 52 24 4/ /2 2
•
• V Ve eg ge et ta ab bl le e o oi il ls s ( (H HE ET TG G, , H HT TG G) )
•
• H Hy yd dr ra au ul li ic c a an nd d l lu ub br ri ic ca at ti io on n o oi il ls s w wh hi ic ch h
r
re eq qu ui ir re e o or r a ar re e c co om mp pa at ti ib bl le e w wi it th h V Vi it to on n s se ea al ls s. .
FKM
(FPM,
Viton®)
NBR
F
FA AM M- -x xx x- -X X- -… …
H
HF FD D- -R R f fl lu ui id ds s, , t te es st te ed d w wi it th h ( (e e. .g g. . F Fy yr rq qu ue el l) ). .
N
No ot t f fo or r p ph ho os sp ph ha at te e e es st te er rs s t th ha at t r re eq qu ui ir re e E EP PD DM M
s
se ea al ls s. .
FKM
(FPM,
Viton®)
UPE/
PE-
PA
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 this or deviating therefrom shall not be considered
intended 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
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Safety information
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 with a non-approved medium.
•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.
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Operating and specialist personnel must have read and understood the
operating 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:
Operating personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Specialist personnel: such persons with 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
Forwarding
agent
Specialist
personnel
•Proof of knowledge of
cargo securing
instructions
•Safe handling/operation
of hoisting and lifting
equipment
Hydraulic / electrical
installation,
first commissioning,
maintenance,
troubleshooting,
repair,
decommissioning,
Specialist
personnel
•Safe handling/use of
tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Checking the phase
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Safety information
Disassembly
sequence
•Product-specific
knowledge
Operation
Operations control
Specialist
personnel
•Product-specific
knowledge
•Knowledge about how to
handle operating media.
•Knowledge about
contamination due to
solids and water
Disposal
Specialist
personnel
•Proper and
environmentally-friendly
disposal of materials and
substances
•Decontamination of
contaminants
•Knowledge about reuse
Wear suitable clothing
Loosely worn clothing increases the danger of getting caught or wound up in
rotating parts and the danger of getting snagged on projecting 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.
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, turn the main
switch by 90° in a counter-
clockwise direction to
shut down the entire unit. The entire unit
downstream of this switch is voltage-free and
depressurized.
Normal pressure is restored to the vacuum column after ≈ 1 minute.
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Unpacking the FAM
Unpacking the FAM
Before delivery, the FAM is inspected for leaks and proper functioning at the
factory, then carefully packed for shipment.
When receiving and unpacking the unit, check it for damage in transit.
Dispose of the packaging material in an environmentally friendly manner.
Transporting 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.
Wind the suction and pressure hose and the connection cable around the
holders provided for this purpose and either fasten them in place or remove
the hoses from the FAM.
Move the FAM manually using the rollers. Only ever use the FAMs handle to
move it.
Before shifting the unit, make sure to release the hand brake on the swivel
casters.
Once the FAM is in the new, desired position, actuate the hand brake on the
swivel casters.
Horizontal transport
Completely empty the FAM as well as the rotary vane vacuum pump before
horizontal transport, e.g., in a vehicle, and close off all connections.
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Transporting the FAM
Close the air outlet of the vacuum
pump using the matching suitable
screw plugs.
Ensure the FAM is fixed tight to the car using load restraint belts at the
suitable lashing points in the car.
Vertical transport
For transport by rail or truck, supports must be placed under the mobile FAM
so that none of the rollers are subjected to load pressure. Secure the FAM
with suitable belts.
Stationary version
Mobile version
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Checking the scope of delivery
Transport suspended on a crane
NOTICE
Unsuitable lifting accessories
The unit/components will be
damaged/destroyed
►Use only suitable lifting accessories to
raise or lash the FAM.
►Take care to ensure that the lifting
accessories do not cause any pressures to
be brought to bear against the components
on the FAM.
Checking the scope of delivery
Upon receiving the FAM check it for any damage in transit. Immediately
report any damage in transit to the forwarding agent or the HYDAC
department in charge.
The following items are supplied:
Qty
Designation
1 FluidAqua Mobil
1 Key to the control cabinet
1 Vacuum pump oil, 1 liter (FAM-5-x-x-x-x-R-x-x-x-x only)
1 Suction and return hose (mobile FAM-5-x-2-… only)
1 Operation and Maintenance Instructions (this document)
1 Electrical wiring diagram situated in the control cabinet
1 EC declaration of conformity
1 Test certificate
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FAM description
FAM description
The FluidAqua FAM was developed 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 Fluidfilter that is
installed provides efficient particulate separation.
The fluid is degassed through a vacuum in the vacuum chamber.
FAM Versions
Stationary (FAM-x-1-..) Mobile (FAM-x-2-..)
In comparison to the stationary version, the mobile version of the FAM also
has:
-
2x
Wheels
-
2x
Swivel casters
-
1x
Suction hose
-
1x
Return hose
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FAM description
FAM features
The FAM is able to reduce fluids described in the chapter "Suitable fluids"
typically to the following attainable residual water contents:
Hydraulic and lubrication oils
<100 ppm
Turbine oil (ISO VG32/46)
< 50 ppm
Transformer oil (unit is not suitable for "Online" and
"Onload" operation on transformer)
<10 ppm
The typical dewatering rate is up to 0.8l/h at 1% (10,000 ppm) water content
(ISO VG32, 50°C).
Dewatering performance/Dewatering speed depends in particular on the oil
type, oil temperature, oil quantity, tank condition, water content and the
environmental conditions and can differ considerably from the indicated
values depending on use.
The dewatering speed is dependent on:
Dewatering speed
Water content
Fluid temperature
Detergent additives
As an approximate guideline, the dimensioning of the FluidAqua Mobil can be
defined in accordance with the tank volume.
Tank volume in liters
Filter Size
< 2,000
FAM 5
1,000 … 7,000
FAM 10, FAM 10/15
7,000 … 15,000
FAM 25
15,000 … 25,000
FAM 45 / FAM-45E
25,000 … 35,000
FAM 60
35,000 … 45,000
FAM 75 / FAM-75E
> 45,000
FAM 95
Note that free water, e.g. on the bottom of the tank, can have an influence on
the entire water content in the system and thus on the length of time it takes
to dewater. Drain off free water completely.
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FAM description
FAM system components
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