Hydac FluidAqua Mobil Series Manual

FAM 10/15 Series
FluidAqua Mobil
+ AquaSensor AS1000
+ ContaminationSensor CS 1000
Operating and Maintenance Instructions
English (translation of German original)
Dokumentation no.: 3417360

FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Trademarks
HYDAC Filtertechnik GmbH en Page 2 / 80
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2008 by
HYDAC Filtertechnik GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to
compensation.
Exclusion of liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, we accept no liability for such
errors as may exist nor for any damage or loss whatsoever which may arise as a re-
sult of such errors. The content of the manual is checked regularly. Any corrections
required will be incorporated in future editions. We welcome any suggestions for im-
provements.
All details are subject to technical modifications.
Technical specifications are 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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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Contents
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Contents
Trademarks.............................................................................................................................2
Contents..................................................................................................................................3
Preface ....................................................................................................................................6
Customer Service .................................................................................................................7
Modifications to the Product .................................................................................................7
Warranty ...............................................................................................................................7
Using the documentation ......................................................................................................8
Safety Information and Instructions.....................................................................................8
Obligations and Liability........................................................................................................9
Explanation of Symbols and Warnings ................................................................................. 9
General Safety Precautions................................................................................................10
Proper/Designated Use ......................................................................................................11
Improper Use ......................................................................................................................11
Safety Devices....................................................................................................................11
Informal Safety Precautions................................................................................................ 12
Training and Instruction of Personnel................................................................................. 13
Safety Measures to Be Followed during Normal Operation................................................13
Electrical Hazards...............................................................................................................14
Maintenance, Servicing and Troubleshooting..................................................................... 14
Modifications to the FluidAqua Mobil ..................................................................................14
How to behave in case of emergency................................................................................. 15
Packing, Transportation......................................................................................................15
Unpacking the FAM ............................................................................................................15
Transporting the FAM ......................................................................................................... 15
Moving the FAM .............................................................................................................. 16
Scope of Delivery.................................................................................................................17
FAM Description...................................................................................................................18
FAM components................................................................................................................ 19
Hydraulic schematic............................................................................................................20
Technical specifications...................................................................................................... 21
Suitable Fluids ....................................................................................................................21
FAM Function description ................................................................................................... 22
Possible Applications..........................................................................................................22
Bypass purification (dewatering, filtration and degassing).............................................. 23
Transfer by pumping (dewatering, filtration and degassing) ...........................................23
FAM Set-up and Connection ...............................................................................................24
Setting up the FAM .............................................................................................................24
Hydraulic Connection of the FAM .......................................................................................24
Connecting the suction port connection (IN)................................................................... 24
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Connecting the return port connection (OUT) ................................................................. 24
Preparing the Vacuum Pump.............................................................................................. 25
Checking the settings on the heater (optional) ................................................................... 26
Electrical Connection of the FAM .......................................................................................27
Starting up the FAM.............................................................................................................28
Switching on the FAM.........................................................................................................28
Shutting off the FAM ...........................................................................................................29
Control Panel - SIMATIC PANEL .......................................................................................30
Operating the FAM from the Control Panel ........................................................................30
Start screen.....................................................................................................................31
Menu1 .............................................................................................................................32
Menu2 .............................................................................................................................32
Operating Mode (OM) .....................................................................................................33
Manual Menu (MANUAL) ................................................................................................ 34
OPERATOR (MANUAL1)................................................................................................35
OPERATOR (MANUAL2)................................................................................................35
LANGUAGE ....................................................................................................................36
RH+P (Relative Humidity + Pressure).............................................................................37
Contamination (Selection Contamination).......................................................................38
ISO..................................................................................................................................38
Intervals...........................................................................................................................39
an operating-hours counter, and..................................................................................... 40
Operating Mode "Cleaning until" ..................................................................................... 40
General Operating Instructions - SIEMENS PANEL...........................................................41
System Keys ................................................................................................................... 41
Entries and Help.............................................................................................................. 42
Numerical Values ........................................................................................................42
Alphanumerical Values................................................................................................ 42
Date and Time ............................................................................................................. 42
Entering and Modifying Numerical and Alphanumerical Values..................................43
Enter Value.................................................................................................................. 44
Partial Value Changes................................................................................................. 44
Character Call-up Sequence ....................................................................................... 44
Entering and Changing Date and Time ....................................................................... 46
Safety Queries.............................................................................................................46
Error messages....................................................................................................................48
Vacuum Chamber Overflow................................................................................................52
FAM tray too full..................................................................................................................53
FAM outlet blocked .............................................................................................................54
FAM entry blocked..............................................................................................................55
Dry-running Evacuation Pump............................................................................................ 56
Dry run drain pump .............................................................................................................57
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Fault on vacuum column level probe .................................................................................. 58
Level switch in the vacuum pump....................................................................................... 59
Oil filter contaminated .........................................................................................................60
Motor Protection Switch......................................................................................................61
Cable break ........................................................................................................................63
Safety thermostat................................................................................................................65
Electrical fuses....................................................................................................................67
Reset safety thermostat on the heater (Optional)............................................................... 68
Maintenance..........................................................................................................................69
Visual checks......................................................................................................................69
Vacuum pump.....................................................................................................................69
Rotary Vane Vacuum Pump ............................................................................................... 70
Changing oil and oil filter.................................................................................................71
Replacing the Air De-oiling Element ...............................................................................71
Clean the suction strainer. .................................................................................................. 72
Fluid filter (OLF-5)...............................................................................................................72
Changing the Filter Element............................................................................................ 72
Heater (Option) ...................................................................................................................73
Storing the FAM....................................................................................................................73
Disposing of the FAM ..........................................................................................................73
Technical data ......................................................................................................................74
Type label ...........................................................................................................................75
Spare parts............................................................................................................................76
FAM 10 ...............................................................................................................................76
Fluid filter (OLF 5/10)..........................................................................................................76
Vacuum pump.....................................................................................................................76
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Preface
HYDAC Filtertechnik GmbH en Page 6 / 80
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and mainte-
nance.
It will acquaint you with the product and assist you in using it as intended in an opti-
mal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication. There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC Filtertechnik GmbH
Division Service technology / Filter systems
Technical Documentation Department
Postfach 12 51
66273 Sulzbach/Saar - Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
“Putting experience into practice”
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Preface
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Customer Service
Contact our technical sales department if you have any questions on our product.
When contacting us, please always include the model/type designation, serial no.
and part-no. of the product:
Fax: ++49 (0) 6897 509 846
Email: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects the safety of the product has been car-
ried 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 De-
livery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com Legal information.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions
HYDAC Filtertechnik GmbH en Page 8 / 80
Using the documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these in-
structions prior to starting the unit up for the first time and at regular
intervals in the future.
What do I want to know?
I assign the information I require to a subject area.
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
BeWa12
34
56a
d
e
Seit e x
Produkt/Kapitel
200x-xx- xx
Product
Page number
Edition date
Document language
Documentation no.
with index
/
file name
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented every time the
manual is revised or changed.
Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely op-
erating the FluidAqua Mobil.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Safety Information and Instructions
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The safety of the FAM largely depends on maintenance. Regular required mainte-
nance is described in this manual. We will support you if the unit needs repair and
will provide original spare parts.
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 operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the FluidAqua Mobil.
Adherence is to be maintained to pertinent accident prevention regulations applica-
ble at the site where the product is used.
The safety precautions listed herein are limited solely to using the FluidAqua Mobil.
The FluidAqua Mobil has been designed and constructed in accordance with the
current state of the art and recognized safety regulations. Nevertheless, hazard may
be posed to the life and limb of the individual using the product or to third parties.
The FluidAqua Mobil is only to be used:
• solely for its designated use
• only in accordance with the designated equipment group, equipment category
and zone indicated above
• only when in a safe, perfect condition
• Any faults or malfunctions which might impair safety are to be properly re-
paired 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 FluidAqua Mobil or use deviating from its designated use
• Improper commissioning, operation and maintenance of the FluidAqua Mobil
• Operating the FluidAqua Mobil when the safety systems are defective
• Modifications to the FluidAqua Mobil made by the user or purchaser
• Improper monitoring of unit components that are subject to wear and tear
• improperly performed repair work
Explanation of Symbols and Warnings
Basic Symbols
DANGER DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING WARNING denotes situa-
tions which can lead to
death if safet
y
p
recautions
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are not observed.
CAUTION CAUTION denotes situa-
tions which can lead to se-
vere injuries if safety pre-
cautions are not observed.
NOTE TIP denotes situations
which can lead to property
damage if safety precau-
tions are not observed.
General Safety Precautions
Operation, adjustment and calibration work may only be carried out by technically
skilled and trained personnel.
The safe operation of this unit can only be ensured if it is used for the purpose it was
intended. If there is any question about the use, please contact the manufacturer.
The manufacturer will not accept responsibility for damages resulting from misuse of
this equipment.
The following applies to all work performed using the unit: adherence to pertinent
national regulations pertaining to accident prevention and safety at the workplace in
addition to any applicable internal rules and regulations of the owner/operator, even
though they are not specifically cited herein.
Leaks of dangerous materials must be properly collected and disposed of so as not
to harm any persons or the environment. The corresponding statutory regulations
are to be followed.
Before any maintenance or repair work is carried out on the unit, electrical power to
the unit must be disconnected, and all hydraulic pressures relieved.
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Proper/Designated Use
The FAM was developed for the dewatering, filtration and degassing of hydraulic
and lubricating oils. It removes free water, emulsified water and a large percentage
of the water to be found in solution.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use; the manufacturer accepts no liability for any damage resulting from
such use.
Proper or designated use of the product extends to the following:
• Maintaining adherence to all the instructions contained herein.
• Performing requisite inspection and maintenance work.
Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
• Operation with non-approved fluids.
Safety Devices
Prior to starting up the FAM unit each time, make sure that all the protective safety
devices are properly installed and are in proper working order.
Safety devices may not be removed until the product has been shut down and se-
cured against being restarted (e.g. warning sign or padlock on the main switch).
When the product is supplied in partial consignments, the safety devices are to be
applied by the operator as specified by law/pertinent regulations.
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Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the FluidAqua
Mobil unit.
Apart from the operating instructions, any and all general and local regulations per-
taining to accident prevention and environmental protection are to be made avail-
able and observance to be maintained to them.
Make sure to keep the safety and hazard symbols and warnings on the FluidAqua
Mobil in a legible condition.
FluidAqua Mobil components may not be opened except in normal, non-
contaminated environments. The mains cable must be pulled out before the Flui-
dAqua Mobil is opened. Only trained specialist electricians may be carry out tests
with the housing opened. This also applies to repair work and to modifications of
electrical system parts that we have approved.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FluidAqua Mobil are to also be regularly checked
(visual check once a month). Any loose connections or damaged cables are to be
replaced immediately.
DANGER
Hydraulic systems are under pressure

The hydraulic system must be depressurized
before performing any work
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Training and Instruction of Personnel
The FluidAqua Mobil may only be operated by properly trained and instructed per-
sonnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the FluidAqua Mobil unless supervised by an
experienced staff member.
Individuals
Activity
Individuals
undergoing
training
Individuals
with techni-
cal training/
engineering
background
Electrician Supervisor
with the
appropriate
authority
Packing Transporta-
tion X X X
Commissioning X X X
Operation X X X X
Troubleshooting /
locating the source of
malfunction
X X X
Remedying of me-
chanical faults X X
Remedying of electri-
cal faults X X
Maintenance X X X X
Repair work X
Shutdown/
decommissioning X X X X
Safety Measures to Be Followed during Normal Operation
Do not operate the FAM unless all the safety devices function properly.
The product is to be checked once a day for external damage and the proper func-
tioning of the safety devices.
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Electrical Hazards
DANGER
Electric shock
 All work on the voltage-carrying parts may only
be carried out by a qualified electrician.
The electrical equipment of the product must be checked on a regular basis. Any
loose connections or damaged cables must be remedied/replaced immediately.
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
All operating media are to be protected in case the product is accidentally started
up.
The FluidAqua Mobil is to be disconnected from the power supply and protected
against being inadvertently switched back on when performing any maintenance,
servicing, inspection or repair work.
Check any screwed fittings which have been removed to see that they have been
properly secured.
Always check the product to see that it functions properly when performing mainte-
nance and servicing work.
Modifications to the FluidAqua Mobil
Do not make any modifications (design modifications, extensions) to the FluidAqua
Mobil without the prior consent of the manufacturer.
Any design modifications or extensions may not be made without HYDAC Fil-
tertechnik 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 com-
ponents it cannot be ensured that they have been designed and manufactured so as
to comply with loading and safety requirements.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Packing, Transportation
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How to behave in case of emergency
In the event of an emergency, rotate the main and E-STOP switch 90° to the left in
order to shut down the entire system. The entire system is then voltage-free down-
stream from this switch.
Normal pressure is restored to the vacuum chamber after about 1 minute.
Packing, Transportation
Unpacking the FAM
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 unit while it is in transit.
When receiving and unpacking the unit check it for damage in transit. Report any
damage to the forwarding agent immediately.
The packaging material should be re-used/re-cycled as appropriate for your area.
Transporting the FAM
The unit must be evacuated completely and the inlets and outlets must be closed
before transport.
Suction and pressure hoses and connection cables are coiled on the holders pro-
vided for that purpose and fastened in place.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Packing, Transportation
Moving the FAM
CAUTION
High empty weight
(≈400 … 850 kg, depending on the version)
 A minimum of 2 persons is required for
transport.
The FAM can be moved manually by pushing thanks to two steerable castors and
two fixed castors for heavy loads. The grips for pushing on the frame of the FAM are
to be used for this purpose in all cases without exceptions. The immobilization
brakes on the steerable castors are to be released prior to transport and then fixed
again in place after it has been completed.
None of the components should ever be used as grips for pushing or pulling the
FAM, because this will cause damage to it.
Fork lift
If the FAM is moved with a forklift, then this may only be used in conjunction with the
forklift eyes located on the device.
Crane
If the FAM is moved with a crane, then this may only be used in conjunction with the
crane eyes or the forklift eyes located on the device and with suitable hitching mate-
rials.
Train/truck
During transport, the FAMs that have castors must be placed that on supports that
are high enough to ensure that there is no load on the castors.
HYDAC Filtertechnik GmbH en Page 16 / 80
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 Scope of Delivery
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Scope of Delivery
Upon receiving the FAM check it for any damage in transit. The FAM may not be set
up and installed unless it is in perfect order. Any damage in transit is to be reported
to the forwarding agent or the department in charge immediately; the unit may not
be commissioned until this damage is properly remedied.
The following items are supplied:
Qty Description
1 FluidAqua Mobil FAM, ready for connection with suction and pres-
sure hose
1 Tool, square 6 mm for switch box
1 Operating and maintenance instructions FAM
1 Operating and maintenance instructions Busch vacuum pump
1 Supplementary operating instructions (depending on FAM design)
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description
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FAM Description
The FluidAqua Mobil FAM was developed for the dewatering, filtration and de-
gassing of hydraulic and lubricating oils. It removes free water, emulsified water and
a large percentage of the water to be found in solution. The fluid filter that is installed
provides efficient filtering-out of solid materials.
The degassing of the medium is achieved by the vacuum set up in the vacuum con-
tainer.
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FluidAqua Mobil – FAM 10/15 +CS1000 +AS1000 FAM Description
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FAM components
Item Description
1 control cabinet with control panel consisting of:
- main switch
- alarm signal lamp
- control panel with display
- component diagram
2 Regulating valve to regulate the necessary vacuum in the vacuum
chamber
3 Vacuum gauge
4 Motor pump unit with fluid filter for the separation of solid particles
(OLF-5)
5 Vacuum chamber
6 3/2-directional control valve
7 Suction strainer
8 Vacuum pump
9 Evacuation pump
10 Air filter and dryer
11 Heater mounted in vacuum chamber (Option)
12 AS1000 (Optional)
13 CS1000 (Optional)
14 Motor-pump assembly for CS1000 (Optional)
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Hydraulic schematic
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