Hydac FluidAqua Mobil FAM 15 Operation Instructions Manual Download Page 14

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FAM 15/30/50/70

Safety Information and Instructions

HYDAC Filter Systems GmbH

Page

14 /

BEWA FAM15-70Siem 3099574e en 2009-10-08.doc

2008-10-06

Electrical Hazards

DANGER

Electric shock

Danger of fatal injury

►

Any work involving electrical equipment 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.

Maintenance, Servicing and Troubleshooting

The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in accordance with the respective schedules.

Disconnect the FluidAqua Mobil from the power supply when performing any
maintenance, inspection or repair work. Protect the FAM from being inadvertently
switched back on.

Any screwed fittings which have been undone/removed are to be checked to see
that they have been properly resecured.

Always check the product to see that it functions properly when performing
maintenance 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 conversion modifications require written permission from HYDAC Filter Systems
GmbH.

Immediately replace any machine components which are not in perfect condition.

Only use original spare parts and consumables.

Summary of Contents for FluidAqua Mobil FAM 15

Page 1: ...FAM 15 30 50 70 FluidAqua Mobil Operation Instructions English translation of original instructions Documentation no 3099574e ...

Page 2: ...f 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 result 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 improvements All details are subject to technical modificati...

Page 3: ...e 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 What to Do in Case of Emergency 15 Unpacking the FAM 15 Transporting the FAM 16 Fork lift 16 Crane 17 Train truck 17 Checkin...

Page 4: ...ry vane vacuum pump only for model code FAM xx x x x xxx xxx xx xx D x x xxx 33 Filling up the rotary vane vacuum pump FAM 15 30 34 Filling up the rotary vane vacuum pump FAM 50 70 34 Retransfer pump only for versions with retransfer pump external pump 34 Electrical Connection of the FAM 35 Starting up the FAM 36 Switching on the FAM 36 Setting the fluid temperature only with heater option 37 Sett...

Page 5: ...ncorrect phase sequence 54 Dry running E pump 55 Outlet OUT clogged 56 Inlet IN clogged 57 Overflow V pump 58 Heater safety thermostat triggered 59 Contact Service 61 Technical data 61 Spare Parts 61 Storing the FAM Taking it out of Operation 62 Disposing of the FAM 62 Type label 62 Model Code 63 EU declaration of conformity only for mobile version 64 ...

Page 6: ...n optimal 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 ...

Page 7: ... 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 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 ...

Page 8: ... 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 HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the operatin...

Page 9: ...Aqua 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 product or to third parties Risk of damage may be posed to the product or other equipment and property The FluidAqua Mobil is to be used solely for its designated use only when in a safe per...

Page 10: ...recautions Maintenance work is to be carried out only by 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 un...

Page 11: ...ning 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 Examples of improper use Operation with a non approved fluid Operation under non approved conditions Safety Devices Prior to starting up the FAM uni...

Page 12: ...e condition at all times If necessary replace the instruction sheets FluidAqua Mobil components may not be opened except in normal non contaminated environments The mains cable must be pulled out before the FluidAqua Mobil is opened Tests conducted with the housing open may only be performed by properly trained certified electricians This also applies to all repair work or to any modifications to ...

Page 13: ...als undergoing training Individuals with technical training engineering background Electrician Supervisor with the appropriate authority Activity Packing transportation X X X Commissioning X X X Operation X X X X Troubleshooting locating the source of malfunction X X X Remedying of mechanical faults X X Remedying of electrical faults X X Maintenance X X X X Repair work X Decommissioning Storage X ...

Page 14: ... with the respective schedules Disconnect the FluidAqua Mobil from the power supply when performing any maintenance inspection or repair work Protect the FAM from being inadvertently switched back on Any screwed fittings which have been undone removed are to be checked to see that they have been properly resecured Always check the product to see that it functions properly when performing maintenan...

Page 15: ...n voltage free downstream from this switch Normal pressure is restored to the vacuum column after 1 minute 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...

Page 16: ...s provided for shifting Drain the unit completely before transport Seal off the inlets and or outlets On the mobile FAM wind the suction and pressure hose and the connection cable around the holders provided for this purpose and fasten them in place Shift the FAM manually using the rollers When doing so use only the grips provided on the FAM frame for pushing Before shifting the unit make sure to ...

Page 17: ...ts will be damaged destroyed Use only suitable lifting accessories to raise or lash the FAM Take care to ensure that the lifting accessories does not cause any pressures to be brought to bear against the components on the FAM 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 The FAM is to be secured with su...

Page 18: ... 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 included in the scope of delivery Item Qty Description 1 1 FluidAqua Mobil FAM 1 Four sided hollow socket key 6 mm 1 Technical Documentation Operation Instructions FAM Service and maintenance i...

Page 19: ... and lubricating oils It removes free water emulsified water and a large proportion of the water in solution The integrated fluid filter ensures efficient particulate separation The fluid is degassed through a vacuum in the vacuum chamber FAM Versions without heater Stationary FAM xx 1 Mobil FAM xx 2 In addition to the stationary version the mobile FAM has 2 casters 2 bock rolls Suction hose L 5 m...

Page 20: ...mance The FAM is able to reduce the water content of those fluids described in the chapter Suitable fluids to less than 100 PPM Typical dewatering rates FAM 15 1 0 l h FAM 30 1 7 l h FAM 50 2 2 l h FAM 70 2 6 l h The dewatering speed is dependent on Dewatering rate Water content Fluid temperature Detergent additives Volumetric flow of the FAM ...

Page 21: ...ration panel consiting of Main switch and emergency switch Error indicator light Tesxt display TD 200 Schema of components 2 Vacuum gauge with regulating valve to regulate the necessary vacuum in the reactor 3 Hinged box for the recipients collecting the condensation water 4 Vacuum chamber 5 Inlet valve 2 2 directional valve 6 Suction strainer FAM 15 30 50 only 7 Vacuum pump 8 Evacuation pump 9 Fl...

Page 22: ...ion only use the FAM for the following fluids see model code FAM xx M x x xxxx xxx xx x x x Mineral oils acc to DIN 50524 Gear oils acc to DIN 51517 and DIN 51524 Other hydraulic and lubrication oils which require or are compatible with NBR seals FAM xx B x x xxxx xxx xx x x x Synthetic esters HEES DIN 51524 2 Vegetable oils HETG HTG Hydraulic and lubrication oils which require or are compatible w...

Page 23: ...e en 2009 10 08 doc 2008 10 06 Hydraulic plan without heater Item Description 1 Suction strainer FAM 15 30 50 only 2 Inspections glass 3 Solenoid valve inlet 4 Vacuum chamber 5 Vacuum pump 6 Cannister 7 Air filter 8 Underpressure control 9 Vacuum chamber filling level 10 Evacuation pump 11 Oil filter 12 Draining ...

Page 24: ...tems GmbH en Page 24 68 BEWA FAM15 70Siem 3099574e en 2009 10 08 doc 2008 10 06 Dimensions Stationary version FAM70 with OLF without heater 1787 390 139 446 936 1852 780 Mobile version FAM70 with OLF without heater 1787 390 139 936 1852 446 780 ...

Page 25: ...e procedure begins again The vacuum in the vacuum chamber 2 sucks air out through the air filter 3 This air absorbs the moisture of the fluid and is then sucked out by the vacuum pump 4 With a special cooling system1 the air is cooled and partially dried within the vacuum pump The resulting condensed water is fed to the operating water using the water operated vacuum pump If more water is extracte...

Page 26: ...pump When the stop button is pressed the directional valve 1 closes and the drain pump empties the vacuum chamber empty When the emergency stop is pressed the vacuum pump and the evacuation pump are switched off and the 2 2 directional valve is closed by a spring Possible Applications Purification operation dewatering degassing and filtration IN OUT The FAM continuously purifies the bypass fluid i...

Page 27: ...the left hand and right hand sides of the FAM Take care to ensure free access to the control panel and that the control cabinet can be opened completely Notes on Piping Hosing NOTICE Non permitted pressure at the inlet IN outlet OUT Failure malfunction Determine the pressure to be anticipated at the inlet outlet with the prescribed values Note that the cross section of the connected hoses piping m...

Page 28: ...e length m d internal pipe diameter mm Q Flow rate l min V kinematics viscosity mm s D Density kg dm Mineral oil based hydraulic fluid has a density of 0 9 kg dm The density D is Mineral hydraulic oil HLP 0 85 0 90 kg dm Phosphate ester HFDR 1 00 1 10 kg dm Insulating oil 0 90 1 00 kg dm Lubrication oil 0 90 0 95 kg dm Additional threaded connections and pipe bends increase the pressure differenti...

Page 29: ...up in such a way that it will always be lower than the level of the oil NOTICE Severe contamination The unit will be damaged Do not prime directly at the bottom of the tank Do not prime in the sump Never prime without a built in suction screen The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Connect outlet OUT ...

Page 30: ...ere is a danger of freezing add commercially available automotive antifreeze to the water in the vacuum pump If no vacuum forms after switching on the FAM the intake connection N1 0 should be filled with an additional 2 3 liters of water To do this release the transparent suction hose from the support and fill in the water Re attach the hose afterwards During operation the water filling level is m...

Page 31: ... generally applicable regulations Use a pipe separator if installing on a drinking water line The port is constructed with 1 interior thread at the filter combination The water connection must meet the following conditions Water temperature max 30 C Operation pressure 1 5 16 bar With this version the vacuum pump is filled automatically after the FAM is switched on The unit has a backflow preventer...

Page 32: ...he pipe between the locking features 1 and 2 e g by tapping the water For example using water spigots 3 Loosen the flat blade screw 4 Do not screw out completely 4 Depressurize the nominal value spring by turning the adjustment grip to the left 5 Close the locking feature 2 6 Slowly open the locking feature 1 7 Set the nominal value of 5 bar downstream pressure by rotating the adjustment grip Turn...

Page 33: ...equires oil as its operating medium Check the oil level before star up topping up with vacuum pump oil VE101 if necessary The maximum filling amount for vacuum pump oil VE101 is FAM 25 0 3 liter FAM 45 95 1 0 liter The water level is monitored automatically by the integrated float switch while the FAM is in operation A message will appear on the control panel when the MIN MAX filling level has bee...

Page 34: ...l no higher than the MAX marking We recommend filling up to a level between the MIN and MAX markings The suction strainer is re mounted in reverse order 1 2 3 4 5 Filling up the rotary vane vacuum pump FAM 50 70 Remove the screw plug 1 Fill up with vacuum pump oil VE101 through the filling nozzle 1 Check the oil level through the inspection glass 2 Fill up the vacuum pump oil no higher than the MA...

Page 35: ...age supply present If a plug is present on the FAM or if a plug is mounted then the FAM is to be operated from a correspondingly fused socket The rotating field of the connection socket must be clockwise If this is not the case then the phases can be rotated in the 16A 32 A connection plug with the aid of the phase changing switch in the plug For the 63A version the two phases must be switched on ...

Page 36: ...let valve opens and the vacuum chamber is filled 3 If the fill level 02 is reached the evacuation pump switches on and the starting phase ends 4 Automatic mode is active FluidAqua operating Automatic mode Now regulate the vacuum pressure with the throttle valve on the right of the vacuum gauge depending on the operating viscosity Operating viscosity Pressure setting absolute pressure 50 mm2 s hydr...

Page 37: ... SP1 the heater will be switched on typical temperature value 50 C SP2 upper switching point If the upper switching point SP2 is reached the heater switches off typical setting value 55 C If the Heater signal lamp in the control cabinet is lit up the heater is in operation The display shows the current fluid temperature at the output of the heater Setting the switching points SP1 SP2 PressPress th...

Page 38: ...ng NOTICE Air in the fluid filter The filter element is not utilized completely Bleed the fluid filter after each shut down filter element replacement The fluid filter is to be bled through the bleed port A in the cover until fluid emerges Use an Allen key wrench to carefully open the ventilation plug A in the cover for this purpose It is not necessary to unscrew the ventilation plug A completely ...

Page 39: ...ss the key Now the unit starts the run down phase FluidAqua operating Run down 1 The inlet valve closes 2 The vacuum pump switches off 3 The filter pump unit runs until the vacuum chamber is emptied Wait until the message appears on the display Now move the main switch to the position 0 The system is now switched off Ready for operation Press start ...

Page 40: ...sing the respective key To select the function on the lower part of the keys double allocation of keys you must press beforehand The key assignments and the descriptions of the Main and Manual Menus are described below Main menu Function key Function Start FAM Start and transition in Automatic mode Stop FAM afterrun with evacuation of the vacuum chamber Acknowledge all rectified malfunctions Butto...

Page 41: ...n Key Key assignment in Manual Menu 1 Function Manual Menu 2 Switches in the Manual Menu 2 E Pump off Switches evacuation pump off E Pump on Switches evacuation pump on Press the buttons one after the other V pump off Switches vacuum pump off V pump ON Switches vacuum pump on Press the buttons one after the other Valve close Closes the 2 2 directional control valve Valve open Opens the inlet valve...

Page 42: ...ollows Inlet vacuum pump closed open Outlet vacuum pump closed open Key Key assignment in Manual Menu 1 Function Manual Menu 1 Back to Manual Menu 1 Close feed V pump Closes the solenoid valve of the vacuum pump Open inlet V pump Opens the solenoid valve of the vacuum pump Close discharge V pump Closes the solenoid valve of the water discharge from the vacuum pump Open discharge V pump Opens the s...

Page 43: ...he Manual Menu 2 is as follows Heater off on Feed pump off on Key Key assignment in Manual Menu 1 Function Manual Menu 1 Back to Manual Menu 1 Heater OFF Closes the water inlet of the vacuum pump Heater ON Opens the water inlet of the vacuum pump Feed pump OFF Closes the water outlet of the vacuum pump Feed pump ON Opens the water outlet of the vacuum pump Exit With this key combination you can ex...

Page 44: ...0 06 Performing Maintenance The safety of all persons coming into contact with the FAM and the availability of the unit for use are extremely dependent on service and maintenance Routine service and maintenance work is described in the documentation included Maintenance and service instructions FAM 15 30 50 70 Document No 3168098 ...

Page 45: ... Level switch defective Check level switch and replace if necessary 49 Level switch 01 02 Level switch defective Check level switch and replace if necessary 49 Min fill level V pump Inlet V pump tank Too much water oil in the vacuum pump Fill vacuum pump from the side with water oil according to the operating instructions Versions with automatic water supply Check the water supply backflush water ...

Page 46: ...ence or operation voltage too low Exchange two of the three phases check the supply voltage 54 Dry running E pump Vacuum chamber is being filled too slowly flow into reactor is smaller than flow rate of the evacuation pump Check suction hose oil level in tank Clean suction filter if installed Check vacuum pump and clean if necessary 55 Outlet OUT clogged No operating fluid is being pumped out of t...

Page 47: ...GENCY OFF key pressed Unlock the key by turning V pump overflow Too much water oil in the vacuum pump Water ring vacuum pump Drain 5 liters of water from the vacuum pump Check the water outlet hose and valve Rotary vane vacuum pump Drain oil Fill level must be between min and max markings 58 No retransfer operation Retransfer operation not possible no retransfer pump connected ...

Page 48: ...ctor overfilled 1 Press RESET key 2 Select manual menu 1 start evacuation pump 3 Can vacuum chamber be emptied within 3 5 minutes from level 03 to level 01 a Yes proceed to Step 5 4 b No proceed to Step 6 5 Excessive foaming vacuum in the vacuum chamber too high reduce vacuum e g from 300 mbar abs 400 mbar abs 6 Check the evacuation pump for proper functioning 7 The failure is repaired ...

Page 49: ... plug at level sensor Remove level sensor 3 Manually check the functioning of the switching points a Switching points are available proceed to Step 5 4 b Switching points not available proceed to Step 6 5 Inspect the plug and the cable to and in the control cabinet for the PLC Functioning proceed to Step 7 6 Replace level switch a Function available proceed to Step 8 7 b Function not available pro...

Page 50: ...lling level V pump min max 1 Press RESET key a Error message lapsed proceed to Step 6 2 b Error message still illuminated proceed to Step 3 3 Check oil level fill up or drain oil as necessary Check level sensor of the vacuum pump and the supply lines a Fault appears again proceed to Step 5 4 b The fault does not recur proceed to Step 6 5 Replace damaged parts 6 The failure is repaired ...

Page 51: ...ousing via the drain ball valve 5 Open filter housing remove filter elements from housing 6 Insert new filter elements close filter housing 7 Open ball faucets on the IN and OUT connections 8 Switch the FAM on with the main switch 9 Does malfunction reappear after 4 minutes a Yes proceed to Step 11 10 b No proceed to Step 12 11 Check differential pressure switch and supply lines 12 The failure is ...

Page 52: ...doc 2008 10 06 Float switch Step Description Malfunction Float switch 1 Empty oil pan 2 Press RESET key 3 Start FAM 4 Carry out leakage check remedy leakages 5 Does malfunction reappear after 2 seconds a Yes proceed to Step 7 6 b No proceed to Step 8 7 Check float switch and supply lines 8 The failure is repaired ...

Page 53: ...motor protection switch and or the voltage capacity of the fuse in accordance with the motor type plate and or the heater type plate a The fault recurs proceed to Step 4 3 b The failure does not recur proceed to Step 8 4 Measure the current consumption of the engines whose motor protection switch or fuse has tripped 5 Close switch cabinet door main switch to On start FAM a The fault recurs proceed...

Page 54: ...age 3 Plug mains plug back in switch on main switch 4 Check direction of rotation in accordance with the direction of rotation arrow on the pumps a The fault recurs proceed to Step 6 5 b The failure does not recur proceed to Step 7 6 Pull out mains plug check mains cable and plug replacing as necessary 7 The failure is repaired NOTICE Direction of rotation electric motor The unit will be damaged A...

Page 55: ...duce the suction height Reduce absolute pressure in the vacuum chamber e g from 500 mbar abs 400 mbar abs Increase fluid temperature Enlarge the diameter of the suction hose Shorten the length of the suction hose Check the 2 2 directional solenoid valve at the inlet 3 Suction port in the tank sucks in air Position the suction port lower Tank to be cleaned is too small 4 Check the functioning of va...

Page 56: ...use Medium cannot flow out of the vacuum chamber emptying pump pressure limit 5 bar 2 Check locking features in the return flow line Open if blocked 3 To reset the failure press the RESET key 4 Does malfunction reappear after 4 minutes a Yes proceed to Step 6 5 b No proceed to Step 7 6 Check the pressure relief valve of the evacuation pump for proper functioning 7 The failure is repaired ...

Page 57: ... locking features in the suction line Open if blocked Check suction strainer and clean if necessary 4 To reset the failure press the RESET key 5 Does malfunction reappear after 4 minutes a Yes proceed to Step 7 6 b No proceed to Step 8 7 Check the following points Check the suction pipe for cross section constriction Check the functioning of vacuum pump in manual mode Check the position of the shu...

Page 58: ... Pump Water does not flow into the condensation tank Check drain valve and clean if necessary Check functioning of float switch Rotary vane vacuum pump Drain oil until the level is between Min and Max 4 To reset the failure press the RESET key 5 The fault recurs a Yes proceed to Step 7 6 b No proceed to Step 8 7 Check SPS for proper functioningThere may be too much foam in the vacuum chamber Reduc...

Page 59: ... FAM that takes place as a result Resetting Allow the heater to cool down before performing a Reset Undo the 4 screws and remove the cover from the heater terminal box To reset the heater press down the red button B so that it engages in the lower position The mechanism is tripped by a bi metal This bi metal must first cool down in order to recover The cooling phase can indeed take up to 2 hours d...

Page 60: ... F3 key 8 a is possible proceed to Step 21 9 b is not possible proceed to Step 10 10 Switch off the FAM at the main switch Pull power plug 11 Check the safety thermometer cable up to the SPS error on the cable a Yes proceed to Step 17 12 b No proceed to Step 13 13 Replace Kx relay 14 Reconnect mains switch use main switch to switch FAM On and start device with F1 key a The fault recurs proceed to ...

Page 61: ...stems hydac com Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life for your FluidAqua Mobil Our HYDAC Servicenter offers you these tasks within agreed upon time frames and at fixed prices HYDAC Service GmbH Rehgrabenstrasse 3 66128 Saarbrücken Dudweiler Germany Telephone 49 0 681 509 883 Telefax 49 0 681 509 324 E mail service hydac c...

Page 62: ...sing space Observe the storage temperature range of 0 50 C Disposing of the FAM When decommissioning and or disposing of the unit observe all local guidelines and regulations pertaining to occupational safety and environmental protection This applies in particular to the oil in the unit components covered with oil and electronical components After disassembling the unit and separating the various ...

Page 63: ...I 500 V 50 Hz 3 Ph PE K 480 V 60 Hz 3 Ph PE L 220 V 50 Hz 3 Ph PE N 575 V 60 Hz 3 Ph PE O 460 V 60 Hz 3 Ph PE X other voltage Filter size fluid filter 15 OLF 15 1x N15DM0xx 30 OLF 30 2X N15DM0xx 45 OLF 45 3X N15DM0xx 60 OLF 60 4X N15DM0xx 1300 OFU 1300 1x 1300RxxxBN4HC KB 2600 OFU 2600 1x 2600RxxxBN4HC KB z without Filter housing others on request Filter material of element DM Dimicron BN Betamicr...

Page 64: ...t corresponds to the fundamental safety and health requirements contained in the standards listed below Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Description FluidAqua Mobil Type FAM series Part no Serial no EU Machinery Directive 98 37 EG EU Electrical Equipment Regulations 2006 95 EC EU directive on electromagneti...

Page 65: ...Notes ...

Page 66: ...Notes ...

Page 67: ...Notes ...

Page 68: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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