Hydac FluidAqua Mobil FAM 25 Manual

FluidAqua Mobil
FAM 25/45/60/75/95
Operating and maintenance instructions, part 1/2
English (translation of original instructions)
Keep for future reference.
Document No.: 4170100a

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

Content
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Content
Imprint............................................................................................................2
Documentation Representative...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................6
Product modification....................................................................................6
Warranty......................................................................................................6
Using the documentation.............................................................................7
General safety information ..........................................................................8
Hazard symbols...........................................................................................8
Signal words and their meaning in the general safety information
and instructions ...........................................................................................9
Structure of the general safety information and instructions......................10
Observe regulatory information .................................................................10
Proper/Designated Use .............................................................................11
Improper Use or Use Deviating from Intended Use...................................13
Qualifications of personnel / target group..................................................14
Wear suitable clothing...............................................................................16
Electrical Hazards......................................................................................17
Modifications to the FluidAqua Mobil.........................................................17
Stoppage in an emergency (EMERGENCY STOP)...................................18
Unpacking the unit......................................................................................18
Transporting the unit..................................................................................18
Transporting the FAM - mobile FAM (FAM-xx-2-…)..................................19
Transporting with the fork lift truck..........................................................19
Transporting with the crane....................................................................20
Transporting by train / truck....................................................................20
Decoding the model code label.................................................................21
Checking the scope of delivery.................................................................23
Description of unit......................................................................................23
FAM version – stationary (FAM-xx-1-…) ...................................................24
FAM version – mobile (FAM-xx-2-…) ........................................................24
System Components FAM 25-45...............................................................25
System Components FAM 60-95...............................................................27
Unit dimensions..........................................................................................29
FAM 25-45 – stationary (FAM-xx-1-…)......................................................29
FAM 25-45 – mobile (FAM-xx-2-…)...........................................................30
FAM 60-95 with OFU – stationary (FAM-xx-1-x-x-26-…)...........................31

Content
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FAM 60-95 with OFU – mobile (FAM-xx-x-x-x-26-…)................................32
FAM 60-95 with MRF – stationary (FAM-xx-1-x-x-40-…)...........................33
FAM 60-95 with MRF – mobile (FAM-xx-2-x-x-40-…)................................34
Hydraulic circuit..........................................................................................35
Technical specifications ............................................................................37
Function description ..................................................................................38
Power unit with water ring vacuum pump..................................................39
Power unit of the rotary vane vacuum pump.............................................39
Cleaning in Bypass Flow ...........................................................................40
Purifying and transferring by pumping.......................................................40
Unit setup and connection.........................................................................41
Setting up the unit......................................................................................41
Connection overview .................................................................................41
Notes on pipes and hoses.........................................................................43
Connecting the inlet (IN).........................................................................45
Connecting the outlet (OUT)...................................................................45
Selecting a fluid filter element....................................................................46
Preparing vacuum pump for operation ......................................................47
Preparing water ring vacuum pump (FAM-xx-x-x-x-xx-W/WA-x
…) ..........................................................................................................47
Preparing rotary vane vacuum pump (FAM-xx-x-x-x-xx-R-x …).............49
Filling up the rotary vane vacuum pump at the FAM 25......................50
Filling up the rotary vane vacuum pump at the FAM 45-95.................50
Electrical connection of the unit.................................................................51
Rotating field ..........................................................................................52
Operating elements on the FAM................................................................53
Switching on / switching off / commissioning and error messages ......53
Performing maintenance............................................................................54
Function testing of the fault indicator lamp ................................................58
Change the air filter...................................................................................58
Testing the AquaSensor............................................................................58
Suction line filter – Cleaning/changing the filter element...........................59
Maintaining the water ring vacuum pump (FAM-xx-x-x-xx-W/WA-
…)..............................................................................................................61
Checking/Cleaning the level switch........................................................61
Switching Status - Level Sensor Water Ring Vacuum Pump/PLC..........61
Replacing the Water Filter......................................................................61
Cleaning the Cooling Fins......................................................................63
Flushing/Cleaning the vacuum pump.....................................................63
Cleaning the condensation cooler of the vacuum pump.........................67
Water filter combination (FAM-xx-x-x-xx-WA-...) maintenance..................69

Content
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Back-Flush Water Filter Combination.....................................................69
Checking / setting the downstream pressure .........................................70
Servicing the rotary vane vacuum pump (FAM-25-x-x-xx-R-…)................71
Replacing oil and oil filter (FAM 25)........................................................72
Replacing the air de-oiling element (FAM 25)........................................73
Rotary vane vacuum pump (FAM 45/60/75/95-xx-x-x-xx-R-…).................74
Changing vacuum pump oil and oil filter (FAM 45-95)............................75
Replacing the air de-oiling element of the vacuum pump (FAM
45-95).....................................................................................................76
Replacing the filter element on the fluid filter.............................................77
Filter housing 2600 (FAM-xx-x-x-x-26-…) – Changing filter
element ..................................................................................................77
OLF-5 Toploader (FAM-xx-x-x-x-10-…) – Replacing the filter
element ..................................................................................................80
MRF filter housing (FAM-xx-x-x-x-40-…) – Changing the filter
elements.................................................................................................84
Checking the vacuum column level sensor................................................86
Testing the float switch in the oil pan.........................................................89
Oil mist separator maintenance.................................................................90
Replacing the filter element on the oil mist separator.............................91
Replacement Parts and Accessories List.................................................92
FAM25 - Consumables for 2-year operation..............................................94
FAM45 - Consumables for 2-year operation..............................................95
FAM60 / 75 / 95 - Consumables for 2-year operation................................96
Storing the unit / taking it out of operation ..............................................97
Unit disposal ...............................................................................................97
Technical Data.............................................................................................98
Appendix ...................................................................................................101
Customer Service / Service.....................................................................101
Model Code.............................................................................................102
Explanation of terms and abbreviations...................................................103
Index........................................................................................................106

Preface
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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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> General terms and conditions.

Preface
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Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
What do I want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite 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

General safety information
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General 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 general 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 general safety information and instructions in
these operating instructions which indicate particular dangers 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

General safety information
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Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Signal words and their meaning in the general safety information and
instructions
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

General safety information
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Structure of the general safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
Observe regulatory information
Observe the following regulatory information and directives:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations

General safety information
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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.
Intended use of the product also extends to the following:
•Observing all instructions contained in the instruction manual.
•Performing inspection and maintenance work.
NOTICE
Impermissible operating media
The unit will be damaged
►Use the FAM only in connection with those media specified by the
model code.
►Do not use the FAM together with water or emulsions with high water
content, which can damage the pumps through low lubricating action.
►Only use operating media that are not aggressive to the materials of
the unit.

General safety information
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Depending on the version (see model code), the FAM may only be used for
the following media (see model code):
FAM type Suitable operating medium Sealing material Hoses
FAM-xx-M-…
Mineral oil, tested with mineral oil.
Mineral oils acc. to DIN 51524
Gear oils acc. to DIN 51517, 51524
Other hydraulic and lubrication oils which
require or are compatible with NBR seals
NBR
NBR
FAM-xx-I-…
Insulation oil*, checked with (e.g. Shell
Diala).
Mineral oils acc. to DIN 51524
Gear oils acc. to DIN 51517, 51524
Other hydraulic and lubrication oils which
require or are compatible with NBR seals
NBR
NBR
FAM-xx-B-…
Biologically tested with fast-biodegrading
fluid on an ester basis.
Synthetic ester (HEES) DIN 51524/2
Vegetable oils (HETG, HTG)
Hydraulic and lubrication oils which require
or are compatible with Viton seals.
FKM
(FPM,
Viton®)
NBR
FAM-xx-X-…
HFD-R fluids, tested with (e.g. Fyrquel).
Not for phosphate esters that require
EPDM seals.
FKM
(FPM,
Viton®)
UPE/
PE-
PA
*Ensure that the unit may only be operated on transformers
which are not in operation and not connected to the power
supply.

General safety information
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Improper Use or Use Deviating from Intended Use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result
when operated improperly.
►
Never operate the unit in potentially explosive
atmospheres.
►The unit is only to be used with permissible
media.
►Do not use the FAM together with water or
emulsions with high water content.
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. This risk is borne solely by the owner.
Improper use 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.

General safety information
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Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Auxiliary 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:
Auxiliary 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 dangers.

General safety information
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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
Disassembly
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 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

General safety information
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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 gloves.
- Wear work safety shoes.

General safety information
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Electrical Hazards
DANGER
Electric shock
Bodily injury leading to death
►Any work involving electrical equipment may
only be done by a properly trained, certified
electrician.
DANGER
Exposed electrical components in the switch
cabinet
Danger of fatal injury due to electric shock
►Any work involving the electrical system may
only be done by a properly trained, certified
electrician.
Check the FAM electrical equipment on a monthly basis. Immediately replace
loose connections, damaged cables and hoses with original spare parts.
These tasks may be performed only by a technician with corresponding
knowledge and skills.
Modifications to the FluidAqua Mobil
Do not make any modifications (design modifications, extensions) to the
FluidAqua Mobil without the prior consent of the manufacturer.
All design modifications require written permission from HYDAC FILTER
SYSTEMS GMBH
Immediately replace any machine components which are not in perfect
condition. Use only original spare parts (OEM).

Unpacking the unit
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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 system is
then voltage-free downstream from this switch.
Normal pressure is restored to the vacuum column after ≈1 minute.
Unpacking the unit
The FAM is inspected for leaks and proper functioning at the factory, then
carefully packed for shipment. The connectors/ports are closed off so that no
contamination can enter the FAM while it is in transit.
When receiving and unpacking the FAM, check it for damage in transit.
Dispose of the packaging material in an environmentally friendly manner.
Transporting the unit
Evacuate the FAM completely before transporting it and close the inlets and
outlets.
Wind the suction and pressure hose and the connection cable around the
holders provided for this purpose and fasten them in place.

Transporting the unit
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Transporting the FAM - mobile FAM (FAM-xx-2-…)
CAUTION
High empty weight
(≈ 400 … 850 kg depending on the version)
Danger of bodily injury
►Use at least 2 persons to shift the position of
the FAM
NOTICE
Using components for pushing/pulling
The FAM will be damaged
►Grip the FAM by the chassis/frame to shift its position.
►Never use the components to push or pull the FAM.
Before shifting the unit, make sure to release the hand brake on the steering
rollers.
Once the FAM is in its new position, actuate the hand brake on the steering
rollers.
Transporting with the fork lift truck
Use the lift eyes when transporting the unit with a forklift.

Transporting the unit
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Transporting with the crane
NOTICE
Unsuitable lifting accessories
The FAM will be damaged / 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.
Use the crane eyes located on the FAM frame when using a crane to
transport the FAM. Use suitable lifting accessories.
FAM 25
FAM 45-95
Transporting by train / truck
For transport by rail or truck, supports must be placed under the mobile FAM
so that the rollers are subjected to no load pressure.
Secure the FAM with suitable means.