FluidAqua Mobil FAM 15/30/50/70 ATEX

Transcription

1 FluidAqua Mobil FAM 15/30/50/70 ATEX II 2G IIB+H2 T3 Operating and Maintenance Instructions English (translation of original instructions) Documentation no.:

2 Imprint Imprint Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach Sulzbach / Saarland Germany Telephone: +49 (0) Fax: +49 (0) filtersystems@hydac.com Homepage: Court of Registration: Saarbrücken, HRB Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, Sulzbach / Saar Telephone: +49 (0) Fax: +49 (0) guenter.harge@hydac.com 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. The content of this manual is subject to change without notice. FAM 15/30/50/70 ATEX en(us) Page 2 / 88

3 Content Content Imprint...2 Documentation Representative...2 Content...3 Preface...6 Technical Support...6 Modifications to the Product...6 Warranty...6 Using the documentation...7 Safety information...8 Hazard symbols...8 Signal words and their meaning in the safety information and instructions...10 Structure of the safety information and instructions...11 Observe regulatory information...11 Proper/designated use...12 Explosion protection as per EU Directive 94/9/EC...14 Improper Use or Use Deviating from Intended Use...15 Qualifications of personnel / target group...16 Wear suitable clothing...18 Stoppage in an emergency (EMERGENCY STOP)...18 Transporting the FAM...19 Fork lift...19 Crane...20 Train/truck...20 Checking the scope of delivery...21 FAM Description...22 Performance features...22 FAM overview...23 FAM components...25 Description of function...26 Hydraulic diagram...27 Possible Applications of the FAM...29 FAM 15/30/50/70 ATEX en(us) Page 3 / 88

4 Content Cleaning in Bypass Flow...29 Purifying and transferring by pumping...29 FAM Set-up and Connection...30 Setting up the unit...30 Connecting the FAM...31 Notes on piping / hosing...32 Connecting suction port (IN)...34 Connecting the pressure port / return-flow line...35 Electrical Connection of the FAM...36 Check direction of rotation...37 Preparing the Vacuum Pump...38 Filling the vacuum pump...38 Filling the seal chamber of the evacuation pump...40 Operating Elements on the unit...41 Starting up the unit...42 Setting the vacuum pressure...42 Venting the filter housing...43 Shut off FAM...44 FAM in manual operation...44 Error messages / troubleshooting...45 [H5] If the vacuum column is overfilled,...47 [H6] Inlet (IN) clogged...48 [H7] Outlet (OUT) clogged...49 [H8] V-pump temperature...50 [H9] Wrong phase sequence...51 [H10] Change fluid filter...52 [H11] Float switch...53 [H12] E/V/R pump motor protection...54 [H13] Dry-running, E-pump...55 [H14] Level switch 01/02(02/03)...56 [H15] V-pump pressure...57 Performing maintenance / inspection...58 Visual checks...59 Overview of maintenance intervals...60 Electrical inspection...63 Filling sealing chamber of the drainage pump...64 Lubricating lock on the electrical cabinet...65 FAM 15/30/50/70 ATEX en(us) Page 4 / 88

5 Content Replacing the filter element on the fluid filter...66 Checking the fault indicator lamp...71 Cleaning the suction strainer...72 Changing the air filter element...73 Vacuum pump maintenance...74 Filling the vacuum pump...76 Further maintenance instructions for the vacuum pump...76 Test vacuum column level sensor...77 Switching Status - Level Sensor Vacuum Column/PLC...78 Testing the Float Switch in the Oil Pan...79 Replacing filter element on the oil mist separator...80 Replacing the filter element on the oil mist separator...81 Replacement Parts and Accessories List...82 Customer Service...83 Storing the FAM/Taking it out of Operation...84 Disposing of the FAM...84 Technical specifications...85 Index...86 FAM 15/30/50/70 ATEX en(us) Page 5 / 88

6 Preface Preface This operating manual was 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 this instruction manual. 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 If you have any questions, suggestions, or encounter any problems of a technical nature, please don't hesitate to contact us. When contacting us, please always include the model/type designation and article no. of the product: Fax: +49 (0) filtersystems@hydac.com Modifications to the Product We would like to point out that changes to the product (e.g., purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient. When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative. Please notify us immediately of any modifications made to the product whether by you or a third party. Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC FILTER SYSTEMS GMBH. You will find these under -> Legal information. FAM 15/30/50/70 ATEX en(us) Page 6 / 88

7 Preface Using the documentation Note that the method described for locating specific information does not release you from your responsibility of carefully reading 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 document has a table of contents at the beginning. I select the chapter I'm looking for and the corresponding page number. Chapter description Produkt / Kapitel Page number HYDAC Filtertechnik GmbH BeWa a de de Seite x 200x-xx-xx Edition date Documentation no. with index/ file name Document language 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. FAM 15/30/50/70 ATEX en(us) Page 7 / 88

8 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 FAM 15/30/50/70 ATEX en(us) Page 8 / 88

9 Safety information Risk of burns due to hot surfaces Substances that are health hazards or irritants Danger from explosive atmosphere Danger of explosion in explosive atmospheres This symbol marks safety indications that refer particularly to explosion protection. FAM 15/30/50/70 ATEX en(us) Page 9 / 88

10 Safety information Signal words and their meaning in the safety information and instructions DANGER DANGER indicates a danger with a high risk and which will lead to death or serious injury if not avoided. WARNING WARNING indicates a danger with a medium risk and which can lead to death or serious injury if not avoided. CAUTION CAUTION indicates a danger with a low risk and which can lead to minor injury if not avoided. NOTICE NOTICE indicates a danger which will lead to damage to property if not avoided. FAM 15/30/50/70 ATEX en(us) Page 10 / 88

11 Safety information 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: SIGNAL WORD HAZARD SYMBOL 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 FAM 15/30/50/70 ATEX en(us) Page 11 / 88

12 Safety information 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. operation in explosion-hazard areas in accordance with explosionprotected execution / labelling of the power unit Operation with a permissible fluid temperature of max. 70 C at an ambient temperature of 40 C or operation with a permissible fluid temperature of max. 60 C at an ambient temperature of 50 C. Operation with a network frequency of max. 50 Hz. DANGER Exceeding the permissible fluid temperature Surface temperature > 200 C Risk of explosion Observe the maximum permissible fluid temperature. FAM 15/30/50/70 ATEX en(us) Page 12 / 88

13 Safety information Depending on the version (see model code), the FAM may only be used for the following fluids (see model code): NOTICE Impermissible operating conditions / Impermissible fluid The unit will be damaged The unit may be used only in connection with the fluids mentioned below. Depending on the version (see model code), the FAM may only be used for the following fluids (see model code): FAM-xx-M-x-x/xxxx-xxx-xx-x-x-x Mineral oils acc. to DIN Gear oils acc. to DIN 51517, 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 ester (HEES) DIN 51524/2 Vegetable oils (HETG, HTG) Hydraulic and lubrication oils which require or are compatible with Viton seals. When work is done in explosion-prone areas, the safety of persons and equipment depends on the observance of all relevant safety regulations. The installation and maintenance personnel thus carries particular responsibility. Exact knowledge of the applicable regulations and conditions is required. Please note: Observe the characteristic curves and measurement operating conditions of the rating plates and data plates. Damage to the devices can nullify the explosion protection. The unit may be operated only when the control cabinet is completely closed. Conversions and modifications to the devices and components that affect the explosion protection are not allowed. FAM 15/30/50/70 ATEX en(us) Page 13 / 88

14 Safety information Explosion protection as per EU Directive 94/9/EC The dewatering units of the FluidAqua Mobile FAM-ATEX series satisfy all the requirements of the new EU Directive 94/9/EC [ATEX 95], applicable to areas in which potentially explosive gas mixtures are likely to occur. The designation of the explosion-proof ATEX-compliant unit is: II 2G IIB+H 2 T3 Operating Limits : - Permissible fluid temperature max. 70 C at an ambient temperature of 40 C - Permissible fluid temperature max. 60 C at an ambient temperature of 50 C - Network frequency of max. 50 Hz This means that the FAM may be used only in accordance with: Equipment group II Potentially explosive atmospheres in which vapors or gas/air mixtures are likely to occur. Equipment category 2G Equipment providing for a standard degree of safety. Designated for cases in which atmospheres posing an explosion hazard can be expected to occur very rarely and, if so, only briefly. Explosion hazard subgroup IIB+H 2 Typical gases: Town gas, acrylonitrile, ethylene, ethylene oxide, ethylene glycol, hydrogen sulphide, ammonia, methane, ethane, propane, ethyl alcohol, cyclohexene, n-butane, n-hexane and hydrogen Ensure that vapors, gases or mists occurring at the place of operation belong to explosion groups IIA to IIB. Temperature class T3 Maximum permissible surface temperature: 200 C FAM 15/30/50/70 ATEX en(us) Page 14 / 88

15 Safety information 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 fluids. Any use extending beyond 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 user alone, shall assume any and all associated risk Improper use may result in hazards and/or will damage the unit. Examples of improper use: Operation in potentially explosive atmospheres other than the identified one. Operation with an impermissible fluid. Operation at an impermissible fluid temperature / ambient temperature. Operation under impermissible operating conditions. Operation when the safety devices are defective. Operation in mining or in dust-exposed zones 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. FAM 15/30/50/70 ATEX en(us) Page 15 / 88

16 Safety information 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. FAM 15/30/50/70 ATEX en(us) Page 16 / 88

17 Safety information Activity Person Knowledge Transport / storage Hydraulic / electrical installation, first commissioning, maintenance, troubleshooting, repair, decommissioning, Disassembly Operation operations control Disposal Forwarding agent Specialist personnel Specialist personnel Specialist personnel Specialist personnel Proof of knowledge of cargo securing instructions Safe handling/operation of hoisting and lifting equipment 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 Product-specific knowledge Knowledge about how to handle operating fluids. Knowledge about contamination due to solids and water Proper and environmentallyfriendly disposal of materials and substances Decontamination of contaminants Knowledge about reuse FAM 15/30/50/70 ATEX en(us) Page 17 / 88

18 Safety information 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. FAM 15/30/50/70 ATEX en(us) Page 18 / 88

19 Transporting the FAM Transporting the FAM CAUTION High empty weight ( kg, depending on the version) Danger of bodily injury Use at least two persons to shift the mobile 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. 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. Move 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 release the hand brake on the steering rollers. Once the FAM is in its new position, actuate the hand brake on the steering rollers. Fork lift Use the lift eyes when transporting the unit with a forklift. FAM 15/30/50/70 ATEX en(us) Page 19 / 88

20 Transporting the FAM Crane NOTICE Unsuitable lifting accessories The unit 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 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 suitable belts. FAM 15/30/50/70 ATEX en(us) Page 20 / 88

21 Checking the scope of delivery Checking the 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. Designation 1 FAM, connection-ready with suction and pressure hose. 2 Drive handle 7x10 (to open the control cabinet) 1 Blasolube 300 dose, 900 grams (to lubricate the control cabinet lock) 1 Documentation, consisting of: - Operating and Maintenance Instructions - FAM - Component instructions - EC declaration of conformity - TÜV statement of conformity FAM 15/30/50/70 ATEX en(us) Page 21 / 88

22 FAM Description FAM Description The FluidAqua Mobil FAM ATEX 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. The integrated fluid filter ensures an efficient separation of solid particles. The degassing of the fluid is achieved using the setup vacuum in vacuum column. Performance features The FAM is able to reduce the water content of those fluids described in the chapter Suitable Fluids to less than 100 ppm. FAM-15 FAM-30 FAM-50 FAM-70 Typical dewatering rates (ISO VG46): 1.0 l/h 1.7 l/h 2.2 l/h 2.6 l/h The dewatering speed is dependent on: Dewatering speed Water content Fluid temperature Detergent additives Flow rate FAM FAM 15/30/50/70 ATEX en(us) Page 22 / 88

23 FAM overview FAM overview FAM 15/30/50/70 ATEX en(us) Page 23 / 88

24 FAM overview Item Designation 1 Suction strainer 2 Inspections glass 3 Inlet valve (2/2 directional control valve) 4 Vacuum column 5 Fluid level indication 6 Level switch 7 Vacuum pressure gauge 8 Ball valve for the manual drainage of the vacuum column 9 Evacuation pump with electrical motor 10 Pressure relief valve 11 Fluid filter for the separation of solid particles 12 Fluid filter differential pressure indicator 13 Ball valve for the manual drainage of the fluid filter 14 Non-return valve 15 Ball valve 16 Float switch in the oil pan 17 Vacuum pump 18 Ball valve 19 Fill level switch (dry-running protection of the evacuation pump) 20 Oil mist separator 21 Air filter and air dryer 22 Needle valve for vacuum setting 23 Vacuum suction nozzle to oil mist separator 24 Operating panel and control cabinet in ATEX configuration, consisting of: - Master switch and Emergency Stop switch - Function keys - Operating status lights - Fault indicator lights 25 Plug acc. CEE FAM 15/30/50/70 ATEX en(us) Page 24 / 88

25 FAM overview FAM components Item Designation 1 Suction strainer 2 Inspections glass 3 Inlet valve (2/2 directional control valve) 4 Vacuum column 6 Level switch 7 Vacuum pressure gauge 9 Evacuation pump with electrical motor 10 Pressure relief valve 11 Fluid filter for the separation of solid particles 16 Float switch in the oil pan 17 Vacuum pump 19 Fill level switch (dry-running protection of the evacuation pump) 21 Air filter and air dryer 22 Needle valve for vacuum setting 24 Operating panel and control cabinet FAM 15/30/50/70 ATEX en(us) Page 25 / 88

26 Description of function Description of function Switch on the FAM at the main switch. After the "Start delay" switch is activated, the inlet valve opens and the vacuum pump builds up the necessary vacuum. This vacuum causes the fluid which is to be purified to be sucked into the vacuum column. The fluid to be cleaned trickles downward through special filling materials. These filling materials multiply the surface in the vacuum column and make it possible to form a fine fluid film. The fluid collects in the bottom of the vacuum column up to the level switch [02]. Then the inlet valve closes, and the evacuation pump conveys the fluid through the fluid filter to the outlet. The filling level in the vacuum column drops down to the level switch [01]. Once the level [01] is reached, the 2/2 directional control valve opens, and fluid passes from the inlet through the suction strainer in vacuum column until the level switch [02] is reached. The 2/2 directional valve closes and the procedure begins again. The vacuum in the vacuum column sucks atmospheric air out through the air filter. This air flows down into the vacuum column and is sucked out by the vacuum pump. By virtue of this flow of air, the air picks up the humidity of the fluid. The monitoring of the vacuum pump is limited to the pressure and the temperature. The oil fill level in the vacuum pump is to be monitored by daily visual inspection. The vacuum in the vacuum column is set with the needle valve (vacuum setting). The evacuation pump is protected against dry running by the fill level limit switch in the vacuum column. The fill level limit switch switches the electric motor of the evacuation pump off when the vacuum column has been emptied. When the "Stop overrun" switch has been pressed, the inlet valve closes and the evacuation pump pumps the vacuum column empty. As soon as the light H2 goes out, the FAM can be switched off via the emergency-off switch. When the emergency-off switch has been put into OFF position, the vacuum pump and evacuation pump are switched off. The inlet valve closes under spring force. FAM 15/30/50/70 ATEX en(us) Page 26 / 88

27 Hydraulic diagram Hydraulic diagram FAM 15/30/50/70 ATEX en(us) Page 27 / 88

28 Hydraulic diagram Item Designation 1 Suction strainer 2 Inspections glass 3 Inlet valve (2/2 directional control valve) 4 Vacuum column 5 Fluid level indication 6 Level switch 7 Vacuum pressure gauge 8 Ball valve for the manual drainage of the vacuum column 9 Evacuation pump with electrical motor 10 Pressure relief valve 11 Fluid filter for the separation of solid particles 12 Fluid filter differential pressure indicator 13 Ball valve for the manual drainage of the fluid filter 14 Non-return valve 15 Ball valve 16 Float switch in the oil pan 17 Vacuum pump 18 Ball valve 19 Fill level switch (dry-running protection of the evacuation pump) 20 Oil mist separator 21 Air filter and air dryer 22 Needle valve for vacuum setting 23 Vacuum suction nozzle to oil mist separator 26 Adapter 27 Adapter 28 Pressure hose 29 Suction hose 30 Adapter 31 Adapter 32 Hose assembly 33 Hose assembly 33 Hose assembly FAM 15/30/50/70 ATEX en(us) Page 28 / 88

29 Possible Applications of the FAM Possible Applications of the FAM Cleaning in Bypass Flow The FAM is connected to the tank using vacuum and pressure hoses and constantly cleans the fluid found within in the bypass flow. IN OUT The FAM is connected to the tank using vacuum and pressure hoses and constantly cleans the fluid found within in continuous operation. Purifying and transferring by pumping The FAM is connected to the contaminated oil tank with the suction hose and pumps the fluid into the tank for the purified oil while cleaning it at the same time. IN Contaminated oil OUT Clean oil The fill level of clean-oil tank is to be monitored constantly during this process to prevent overfilling. You achieve permanently better levels of purity by operating the system continuously in bypass flow. FAM 15/30/50/70 ATEX en(us) Page 29 / 88

30 FAM Set-up and Connection FAM Set-up and Connection CAUTION Outlet air of the vacuum pump Hazardous to health Always make sure there is sufficient ventilation in the surrounding area of the unit. The air exiting the vacuum pump can contain component parts of the vacuum pump oil and/or of the fluid. Depending on the composition of the oil and the composition of the gas, there is a danger of damage to health if the emergent gas is inhaled over an extended period of time. Setting up the unit Observe the following points when setting up the unit: Set up the unit horizontally on a level surface. Special mounting is not required. Lock the immobilization brakes on the wheels to avoid unintended movement of the unit. (mobile version only) Set up the unit directly beside the tank that is to be cleaned. Observe the maximum permitted suction pressure. Make sure to note the ambient temperature on type label of the unit. Ensure that the main switch is freely accessible at all times. Keep an area of at least 0.8 m around the unit free for maintenance purposes. Make sure that the control panel is always freely accessible and that the control cabinet can be opened fully. FAM 15/30/50/70 ATEX en(us) Page 30 / 88

31 FAM Set-up and Connection Connecting the FAM All hoses on the FAM must be sufficiently conductive to properly discharge electrostatic charge buildup. If hoses are used, the ohmic resistance between the fittings in this case between the FAM and the tank may not exceed a limit value depending on the respective hose type. Marking the hose with the symbol "M": Limit value 10 2 Marking the hose with the symbol " ": Limit value 10 6 The hose connection must ensure a highly conductive transition between the hose and FAM tube, as well as between the hose and tank tube. If this is not the case, all conducting parts (such as the metal mouth piece at the end of the hose) are to be grounded separately. Connecting conductive hoses with fittings to hose tubes requires marking and checking per DIN EN Connect the ground clamp of the unit to a suitable grounding source nearby. The grounding lead is 3 m long. FAM 15/30/50/70 ATEX en(us) Page 31 / 88

32 FAM Set-up and Connection Notes on piping / hosing NOTICE Non-permitted pressure at the inlet IN / outlet OUT Risk of malfunctions Determine the pressure to be anticipated at the inlet / outlet with the prescribed values. Make sure that the cross-section of the connected hoses/piping is at least as large as the cross-section of the inlet/outlet port sizes. In order to keep the pressure loss as low as possible, use as few threaded connections as possible. Connect all connectors to the FAM without initial stress. The pressure at the inlet/outlet depends on the height differential between the FAM fluid surface in the tank (suction height P (height) ) and the line losses ( P (line) ). If the FAM is above the fluid surface in the tank, determine the pressure as follows: P = 1 bar - P (height) - P (line) If the FAM is below the fluid surface in the tank, determine the pressure as follows: P = 1 bar + P(height) - P (line) Determine the pressure loss P (height) as follows: P (height) [bar] = h/10. h stands here for the distance between the suction port on the FAM and the fluid surface in the tank. FAM 15/30/50/70 ATEX en(us) Page 32 / 88

33 FAM Set-up and Connection The pressure differential in a hydraulic line ( P (line) ) depends on the following: Flow rate Kinematic viscosity Pipe dimensions Density of fluid The pressure loss in straight pipes ( P (line) ) can be calculated as follows: p p 6,8 * L / d 4 * Q * V * D = Pressure differential in [bar] L d Q V = pipe length [m] = internal pipe diameter [mm] = Flow rate [l/min] = Kinematic viscosity [mm²/s] D = Density [kg/dm³] Mineral oil-based hydraulic oil has a density of 0.9 kg/dm³. This applies to straight pipe runs and hydraulic oils. Additional threaded connections and pipe bends increase the pressure differential. Keep the height difference between the pump and the oil level in the tank as minimal as possible. Hoses must be suitable for suction pressures of at least -0.5 bar. Avoid constrictions in connecting pipelines because they reduce output and increase the risk of cavitation. The nominal size of the connected hoses/piping must be at least as large as the inlet port sizes in order to prevent an excessively high negative suction pressure. FAM 15/30/50/70 ATEX en(us) Page 33 / 88

34 FAM Set-up and Connection Connecting suction port (IN) NOTICE Overpressure at the suction port connection The unit will be damaged The pressure at suction port IN must be in the range from to +2 bar. 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 strainer. The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank. Use a negative pressure-resistant, flexible hose or a pipe for the suction-side connection. Make sure that the cross-section of the connected hoses/piping is at least as large as the cross-section of the inlet/outlet port sizes. The shape of the tank connection should be set up in such a way that it will always be lower than the level of the oil in the tank. FAM 15/30/50/70 ATEX en(us) Page 34 / 88

35 FAM Set-up and Connection Connecting the pressure port / return-flow line NOTICE Return port connection OUT closed off The unit will be damaged Check to be sure that all of the locking fixtures at the outlet are in "open" position each time before start-up To prevent air from entering the fluid, make sure that the pressure hose with lance is always below the operating oil level. FAM 15/30/50/70 ATEX en(us) Page 35 / 88

36 FAM Set-up and Connection Electrical Connection of the FAM 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. The electrical connection of units without connection plugs to the power supply module may only be performed by a technician with corresponding knowledge and skills. Make sure that the voltage and frequency specifications on the FAM type label correspond to the existing mains voltage. 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. In order to keep the keep the temperature increase of th electric motors within the permissible limits, observe range A in EN/IEC (VDE ) (±5% voltage or ±2% frequency deviation, curve shape, network symmetry) in relation to the specified rated voltage, unless otherwise indicated on the type label of the electric motor. FAM 15/30/50/70 ATEX en(us) Page 36 / 88

37 FAM Set-up and Connection Check direction of rotation Check the direction of rotation of the motor by switching it on briefly (jog mode). The FAM requires a clockwise rotating field at the connecting socket. NOTICE Incorrect phase sequence / rotation direction of the motor The pumps will be destroyed. In jog mode, check the direction of rotation of the motors. A rotation direction arrow on the fan cover of the motor identifies the correct direction of rotation. Make sure there is a clockwise rotating field. 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 the terminal block S0 (e.g. L1 and L2). Prior to start up, ground the FAM using equipotential bonding. Prior to starting up the FAM, connect the ground bond to the FAM and the tank to be cleaned. Check the connection between the tank, the FAM and the ground potential for good conductivity. FAM 15/30/50/70 ATEX en(us) Page 37 / 88

38 FAM Set-up and Connection Preparing the Vacuum Pump On delivery of the FAM, the vacuum pump as a rule is not filled with oil. An amount which satisfies the initial filling of compressor oil is included in the scope of delivery. NOTICE Operation without compressor oil The vacuum pump will be destroyed The vacuum pump requires compressor oil as an operating fluid. Check the oil level before start-up. If required, fill with compressor oil. Filling the vacuum pump [a] [b] Max. Min. [c] To fill the vacuum pump, open the fill plug [a]. Fill with compressor oil until the MAX marking on sight gauge [b] has been reached. Check the oil level daily. When the fill level gets down to the MIN mark, add oil. FAM 15/30/50/70 ATEX en(us) Page 38 / 88

39 FAM Set-up and Connection The oil level for initial filling 2.0 liters. The oil level between the MIN and MAX marking is 0.45 Liter. The vacuum pump is certified for operation with synthetic oil "Leybold LVO 210". If a different oil is used, the EC and ATEX certificates are voided. This vacuum pump oil is available from HYDAC under the following part no.: Description Packaging Part no.: Compressor oil - LVO liter Compressor oil - LVO liter FAM 15/30/50/70 ATEX en(us) Page 39 / 88

40 FAM Set-up and Connection Filling the seal chamber of the evacuation pump (1) Before initial commissioning, the seal chamber of the evacuation pump must be filled with the sealing medium ISO VG ISO VG 100. When refilling, use the fluid to be cleaned at a viscosity of between ISO VG 10 and VG 100. This is needed in order to prevent dry running of the shaft seals. Dry running of the pump would result in premature wear and tear and impermissible heating at the sealing lip or dust lip. At the same time, infiltration of air into the fluid is prevented. Check the fill level of the reservoir (1) at least once a week and top off as needed. (2) max. 7 ml (1) Item Designation (1) Reservoir (2) Seal chamber To top off the sealing medium, raise the cover of the reservoir (1) and fill it up. Finally, close the cover of the reservoir (1). FAM 15/30/50/70 ATEX en(us) Page 40 / 88

41 Operating Elements on the unit Operating Elements on the unit To operate the FAM, the following control and indicator elements are located on the control panel: Function Quantity Numbering Function keys 3 S1 - S3 Operating status lamps 4 H1 - H4 Malfunction message lamps 11 H5 - H14 H4 H5 H6 H7 H8 H15 H9 H10 H11 H12 H13 H14 S1/H1 S2/H2 S3/H3 Function keys: S1 S2 S3 Inscription Start delay Stop overrun Malfunction Operating status lamps: Inscription Operating state H1 Start delay Startup phase H2 Stop overrun After-run phase H3 Malfunction Malfunction H4 Fluid Aqua operates Purification operation Function Start FAM, starting and changeover to purification mode. Stop FAM run-down and evacuation of the vacuum column. Acknowledging all corrected malfunctions / Switching from automatic to manual operation FAM 15/30/50/70 ATEX en(us) Page 41 / 88

42 Starting up the unit Starting up the unit NOTICE Connection IN / OUT closed The FAM will be destroyed Check to be sure that all of the locking fixtures at the inlet / outlet are in "open" position each time before start-up. After you have made all connections and completed the preparations for commissioning, switch on the FAM at the main switch. For the lamp test, all lamps light up briefly. Then the FAM goes to malfunction "[H15] V-pump pressure"; the malfunction light [S3] "Malfunction" blinks. This fault message results from the switch position of the "Siguard" (electric circuit diagram = A5) in the control cabinet and is eliminated by pressing the button [S1] "Start delay" or the button [S3] "Malfunction". The system now begins with the starting phase. The vacuum pump starts up, the inlet valve opens, and the vacuum column is filled. When the vacuum chamber is filled to filling level [02], the evacuation pump is started up and the starting phase is finished. The purification operation runs. This is shown by the lighting up of the operating status lamp "FAM operation (H4)". Setting the vacuum pressure Now regulate the vacuum pressure in the vacuum column with the needle valve underneath the vacuum pressure display, depending on the operating viscosity. Oil Operating viscosity Pressure setting (absolute pressure) Hydraulic oil 50 mm²/s 250 mbar / 25 kpa Lubrication oil 300 mm²/s mbar / kpa (depending on foaming behavior) FAM 15/30/50/70 ATEX en(us) Page 42 / 88

43 Starting up the unit Venting the filter housing Hot fluid WARNING Risk of burns Note that hot fluid may exit during bleeding. 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 (X) in the cover until fluid emerges. Use an Allen key wrench to carefully open the ventilation plug (X) in the cover for this purpose. It is not necessary to unscrew the ventilation plug (X) completely out it contains air-vent slits. FAM 15/30/50/70 ATEX en(us) Page 43 / 88

44 Starting up the unit Shut off FAM Press key "Run-down [S2]". Now the unit starts with the after-running phase. The inlet valve closes, the vacuum pump is switched off, and the vacuum column is emptied. Wait until the lamp H2 goes out, then move the main switch to the "Off" position. The system is now switched off. FAM in manual operation The following components can be switched on / off or opened / closed by hand in manual operation: Vacuum pump Evacuation pump 2/2 directional inlet valve Manual operation is very helpful when searching for a fault. You can switch pumps on / off in a targeted way. To switch to manual operation, press the button "Malfunction [S3]" for at least 6 seconds. After you have switched to manual operation, the operating status lamp H4 flashes. In manual operation, the allocation of buttons S1-S3 is as follows: Inscription Description S1 Start delay Switching evacuation pump On/Off S2 Run-down Switching vacuum pump on/off S3 Malfunction Opening/closing inlet valve After a button is pressed, the corresponding operating status lamp lights up. You can perform individual functions for a maximum of 15 minutes. The FAM then automatically switches off. Once all functions have been deactivated, the unit exits manual operation automatically after 10 seconds. FAM 15/30/50/70 ATEX en(us) Page 44 / 88

45 Error messages / troubleshooting Error messages / troubleshooting Signal Inscription Cause Remedy H5 Vacuum column overfilled The fill level [03] (overrun) in the vacuum column has been exceeded. Possibly through foam formation in the vacuum column. Reduce the vacuum in the vacuum column, e.g. from 300 mbar (absolute) to 400 mbar (absolute), increase the heating temperature to reduce the thickness of the oil film in the vacuum column. Note: If the vacuum pressure cannot be reduced any further, replace the air filter. H6 Inlet IN clogged No fluid is being sucked into the vacuum column. Check shut-off device in the suction pipe, check suction strainer, suction hose could have become attached to the floor Check vacuum pump and clean as required. H7 Outlet OUT clogged No fluid is pumped out of the FAM. The vacuum pump is not being emptied. Check shut-off devices in the return line, and check pressure relief valve of the evacuation pump. H8 Temperature V-pump The temperature of the vacuum pump is too high. Check the vacuum pump for dryrunning Check the oil level in the vacuum pump. H9 Incorrect phase sequence Wrong phase sequence or operation voltage too low Check the phase sequence in the connection plug and the supply voltage. H10 Changing the filter element The differential pressure above the filter element is too high. Replace the filter element. FAM 15/30/50/70 ATEX en(us) Page 45 / 88

46 Error messages / troubleshooting Signal Inscription Cause Remedy H11 Float switch The drip tray is filled. Empty the drip tray. Check the unit for leaks. H12 Motor protection switch Q2/Q3 The electric motor of the drain pump or vacuum pump is overloaded. Switch on the motor protection switch. Check the operating viscosity. H13 Dry-running Evacuation Pump Too little fluid is being sucked into the vacuum column. Flow protection of the dewatering pump (dryrunning protection) Check/lean the suction strainer. Check the suction apparatus. The suction hose could have suctioned itself onto the bottom of the tank. Check/Clean the vacuum pump. H14 Level switch 01/02/03 The float switch is faulty. Check the float switch. H15 Pressure V- pump The vacuum in the vacuum pump is too high. Exhaust filter cartridge is used up. Change the exhaust filter cartridge (for details, see instruction manual of the vacuum pump). Error Cause Remedy Oil mist is coming out of the exhaust line of the vacuum pump. The vacuum pump has an unusually high oil consumption. Exhaust filter cartridge is used up. Exhaust filter cartridge is used up. Change the exhaust filter cartridge (for details, see instruction manual of the vacuum pump). Change the exhaust filter cartridge (for details, see instruction manual of the vacuum pump). FAM 15/30/50/70 ATEX en(us) Page 46 / 88

47 Error messages / troubleshooting [H5] If the vacuum column is overfilled, Step Description Malfunction: "Vacuum column overfilled" 1. Press the RESET button. 2. Select manual menu 1, and start the evacuation pump 3. Can the vacuum column be emptied within 3.5 minutes from level 03 to level 01? 4. -> a. Yes -> proceed to Step 5. -> b. No -> proceed to Step Excessive foaming -> Vacuum in the vacuum column too high - > Reduce the vacuum (e.g. from 300 mbar (abs) -> 400 mbar (abs) ) 6. Check the evacuation pump for proper functioning. 7. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 47 / 88

48 Error messages / troubleshooting [H6] Inlet (IN) clogged Step Description 1. Malfunction: "Inlet clogged" 2. Cause: No fluid reaching the vacuum column 3. Check the setting of the shut-off devices in the suction line. If they are closed, then open them. Check/clean the suction strainer. 4. Press the RESET button to acknowledge/reset the fault. 5. Does the fault re-occur after 4 minutes? 6. -> a. Yes -> proceed to Step 7. -> b. No -> proceed to Step Check the following points: - Check the suction pipe for cross-section constriction. - Check the functioning of the vacuum pump in manual mode. - Are all shut-off devices in the suction line open? 8. The failure is repaired. FAM 15/30/50/70 ATEX en(us) Page 48 / 88

49 Error messages / troubleshooting [H7] Outlet (OUT) clogged Step Description 1. Fault: "Outlet clogged" Cause: Fluid cannot drain out of the vacuum column (pressure limiting of evacuation pump = 5 bar) 2. Check the position of the shut-off devices in the return line. If they are closed, then open them. Check/clean the suction strainer. 3. Press the RESET button to acknowledge/reset the fault. 4. Does the fault re-occur after 4 minutes? 5. -> a. Yes -> proceed to Step 6. -> b. No -> proceed to Step Check the pressure relief valve of the evacuation pump for proper functioning. 7. The failure is repaired. FAM 15/30/50/70 ATEX en(us) Page 49 / 88

50 Error messages / troubleshooting [H8] V-pump temperature Step Description 1. Malfunction: "V-pump temperature" Cause: The vacuum pump temperature is too high 2. Check the fill level in the vacuum pump. If necessary, fill up with the correct vacuum pump oil 3. Press the RESET button to acknowledge/reset the fault. 4. Does the malfunction recur after the vacuum pump has started? 5. -> a. Yes -> proceed to Step 6. -> b. No -> proceed to Step The vacuum pump or the controller in the control cabinet is defective. 7. Repair or replace the vacuum pump or the defective parts of the controller. 9. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 50 / 88

51 Error messages / troubleshooting [H9] Wrong phase sequence Step Description Malfunction: "Wrong motor rotation" 1. Switch off and disconnect the power unit. 2 Replace the phases on the mains plug and check the mains voltage. 3. Switch on the power for the unit, and start it by pressing the main switch. 4. Check the direction of rotation of the pumps. -> a. The fault recurs. -> proceed to Step > b. The fault does not recur. -> proceed to Step Switch off the unit at the main switch and check the network cable and plug or the electrical connection to the unit. 7. The fault is repaired. NOTICE Incorrect rotation direction of the pump electric motor The unit will be damaged. After any replacement of the electric motors, check the direction of rotation in manual operation before commissioning. FAM 15/30/50/70 ATEX en(us) Page 51 / 88

52 Error messages / troubleshooting [H10] Change fluid filter Step Description Malfunction: "Replace fluid filter" 1. Press the RESET button to acknowledge/reset the fault. 2. Switch off the unit at the main switch. 3. Close the ball cocks on the IN and OUT connections. 4. Empty the filter housing via the drain ball valve. 5. Replace the filter element according to the description on page Open the ball cocks on the IN and OUT connections. 7. Switch on the unit at the main switch. 8 Does the fault re-occur 4 minutes? 9. -> a. Yes -> proceed to Step 10. -> b. No -> proceed to Step Check the differential pressure switch and the feed lines. 11. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 52 / 88

53 Error messages / troubleshooting [H11] Float switch Step Description Malfunction: "Float switch" 1. Empty the oil collecting pan. 2. Press the RESET button to acknowledge/reset the fault. 3. Start up the unit. 4. Check the unit for leaks, and fix them. 5. Does the fault re-occur after 2 seconds? 6. -> a. Yes -> proceed to Step 7. -> b. No -> proceed to Step Check the float switch and the feed lines. 8. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 53 / 88

54 Error messages / troubleshooting [H12] E/V/R pump motor protection Step Description Malfunction: "E/V/R pump motor protection" 1. Switch off and disconnect the power unit. 2 Open the control cabinet door. Switch the motor protection switch and/or fuse that was tripped back on and check the setting of the motor protection switch and/or the voltage capacity of the fuse in accordance with the motor type plate and/or the heater type plate. 3. -> a. The fault recurs. -> proceed to Step 4. -> b. The fault does not recur. -> proceed to Step Measure the current consumed by the motor. 5. Close the control cabinet door. Supply power to the unit. Switch on the unit at the main switch and start the unit. 6. -> a. The fault recurs. -> proceed to Step 7. -> b. The fault does not recur. -> proceed to Step Check the operational viscosity of the fluid (with motor protection switch only). Execute maintenance works on the vacuum pump. 8. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 54 / 88

55 Error messages / troubleshooting [H13] Dry-running, E-pump Step Description Fault "Dry running, E-pump" 1. Cause: Insufficient inflow into the vacuum column. 2. The suction-side pressure loss is too great. Possible remedies: - Clean the suction strainer. - Lower the suction height. - Reduce the absolute pressure in the vacuum column e.g. from 500 mbar (abs) -> 400 mbar (abs). - Increase the fluid temperature - Increase the cross-section of the suction hose - Shorten the suction hose - Check the 2/2 way solenoid valve on the IN connection 3. Suction port in the tank sucks in air: - Position the suction port lower in the reservoir - The reservoir to be cleaned is too small. 4. Check the function of the vacuum pump in manual mode 5. Find the cause and fix it. 6. Press the RESET button to acknowledge/reset the fault. 7. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 55 / 88

56 Error messages / troubleshooting [H14] Level switch 01/02(02/03) Step Description Malfunction: Level switch 01/02(02/03) 1. Switch off the unit at the main switch. 2 Disconnect plug at the level sensor, and remove the level sensor. 3. Manually check the switching points on the level switch 4. -> a. Switching points are available. -> proceed to Step 5. -> b. Switching points not available. -> proceed to Step Inspect the plug and the cable to and in the control cabinet for the PLC for proper functioning. 6. Replace the level switch. 7. -> proceed to Step 7. -> a. Function is available. -> proceed to Step 8. -> b. Function not available. -> proceed to Step The PLC is faulty. 9. Replace faulty parts. FAM 15/30/50/70 ATEX en(us) Page 56 / 88

57 Error messages / troubleshooting [H15] V-pump pressure Step Description 1. Malfunction: "V-pump pressure" 2. Cause: the pressure in the oil separator for the vacuum pump is too high. 3. The air de-oiling element is used up / clogged. 3. Replace the air de-oiling element. 4. Press the RESET button to acknowledge/reset the fault. 4. Does the malfunction recur after the vacuum pump has started? 5. -> a. Yes -> proceed to Step 6. -> b. No -> proceed to Step The vacuum pump or the controller in the control cabinet is defective. 7. Repair or replace the vacuum pump or the defective parts of the controller. 8. Check the pressure relief valve of the evacuation pump for proper functioning. 9. The fault is repaired. FAM 15/30/50/70 ATEX en(us) Page 57 / 88

58 Performing maintenance / inspection Performing maintenance / inspection DANGER Risk of explosion Danger of fatal injury Perform all maintenance work outside of the ATEX danger zone. WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system. Maintenance, repair and servicing work on the FAM must only be performed by personnel who are both authorized and suitably trained for this purpose. To prevent defects in the system, perform maintenance work regularly. However, the intervals between inspections should not exceed a maximum of one year. When determining the inspection intervals, take the following conditions into consideration. Ambient conditions: Set-up in the open Wind, rain, sunlight The operating conditions: Degree of efficiency of the systems Operator errors Manufacturer information in the technical documentation: Mechanical and electrical service life Relatively large changes in the total system: For example, change in the zone division FAM 15/30/50/70 ATEX en(us) Page 58 / 88

59 Performing maintenance / inspection Clean plastic parts only with a damp cloth. If defects which affect explosion protection are discovered during inspections, then the FAM is to be taken out of service until the defect is remedied. Repair and servicing work is not permitted on damaged flameproof enclosures (evacuation pump motor). In this case, replace the installed component/assembly. Visual checks Daily check all hoses/pipelines for leaks. Regularly check by visual check the electrical equipment for possible damage to lines, the plug, sensors or cabling and the devices in the switch cabinet. Immediately, correct any detected defects. FAM 15/30/50/70 ATEX en(us) Page 59 / 88

60 Performing maintenance / inspection Overview of maintenance intervals See page Daily or 24 hours. Weekly or 100 hours. Monthly or 500 hours. Every six months or 2000 hours Yearly or 4000 hours. FAM Visual check for leaks - X Check to ensure the screwed fittings are securely tightened and retighten if necessary Check the measurement technology equipment / Underpressure manometer / Dynamic pressure manometer at the fluid filter - X - X Check fault indicator lamps 71 X Change the air filter (if this has not been required earlier) 73 X Clean the suction strainer. 72 X Lubricate the electrical cabinet lock. 65 X Vacuum pump Check sealing chamber fill level 64 X Check oil level X Check oil for discoloration. (See operating instructions of vacuum pump) Check that the oil filler neck and drain plug have been properly secured. - - X X Check the vacuum pump for leaks. Check the intake air filter and replace if necessary (See operating instructions of vacuum pump) X X FAM 15/30/50/70 ATEX en(us) Page 60 / 88

61 Performing maintenance / inspection See page Daily or 24 hours. Weekly or 100 hours. Monthly or 500 hours. Every six months or 2000 hours Yearly or 4000 hours. Replace oil, oil filter Clean the vacuum pump of dirt and dust. Fan cover, fan wheels, air grille, cooling fins, etc. Check the flame arrester. (See operating instructions of vacuum pump) Check the measuring and security technology for proper functioning. (See operating instructions of vacuum pump) Change intake air filter, clean intake strainer. (See operating instructions of vacuum pump) X - X - X - X - X Replacing the Air De-oiling Element X Emptying / filling pump Check the filling level of the reservoir to the seal chamber, and top off if necessary. Cleaning and inspecting the ventilator hood 64 X - X Fluid Filter Change the filter element (If this has not been required earlier) 66 X Oil mist separator Changing the filter element 80 X Electrics FAM 15/30/50/70 ATEX en(us) Page 61 / 88

62 Performing maintenance / inspection See page Daily or 24 hours. Weekly or 100 hours. Monthly or 500 hours. Every six months or 2000 hours Yearly or 4000 hours. Perform an electrical inspection 63 X Measure the engine power consumption of all engines and compare the values with the type label Perform electrical safety inspection in accordance with DIN VDE 0702 and/or corresponding national regulation. Measure power consumption of the heater and compare values with type label (applies only to versions with integrated heater) - X - X - X Function test Check and clean the level sensor in the vacuum column. Float switch oil pan - malfunction message and E-STOP function Functional test of all components in manual operation - X - X - X FAM 15/30/50/70 ATEX en(us) Page 62 / 88

63 Performing maintenance / inspection Electrical inspection In order to open the switch cabinet loosen the cover stop bolt and unscrew the cover by using the supplied handles (see picture, 2 pieces). To close the cover carefully screw it in up to the cover stop bolt, then tighten the bolt. General inspections Are the wires in the terminal blocks clamped properly? Are seals, cable glands and cable entries free of damage? Are external connections of the potential equalization conductor intact? Inspecting the outer condition the control panel / unit Is the control panel free of ruptures, holes, bumps, material brittleness or corrosion spots? Inspecting the condition of cable and pipe glands Are the threaded joints tight? (Check them with a fork wrench.) Is the sealing of the threaded joint / entry in satisfactory condition? (Visual inspection) Are the entries tight? (Inspection by pulling) Is the sealing within the entry in satisfactory condition? Inspecting the internal condition of the control panel Is the interior in perfect condition? (Visual inspection) Is the seal system undamaged? (Visual inspection) Are the electrical contact points in perfect condition? (Function test) Is the interior dry and clean? (Visual inspection) Is the insulation free of damage and traces of creep? (Visual inspection) Is the mechanical fastening of the installations intact? (Visual inspection) Is the rise in temperature of electrical contact points within the permissible range? Do the electrical contact points make contact properly? Inspection of the age and condition of installed apparatus Are the devices used in the FAM still within the electrical or mechanical service life as specified by the manufacturer? Inspecting the CONTROL CABINET prior to commissioning Is the control cabinet intact? Is the control cabinet again installed in accordance with regulations? Is it certain that no foreign bodies or impermissible parts are located in the control cabinet? Is the terminal chamber clean? Is the connection performed correctly? Are the cables and leads inserted properly? Are all bolts and nuts tightened firmly? Are cable entries and screw plugs seated correctly? Are all unused openings sealed with certified sealing elements? Are all covers and partition plates associated with energized components in place and FAM 15/30/50/70 ATEX en(us) Page 63 / 88

64 Performing maintenance / inspection firmly attached? Is the ground wire connected? Filling sealing chamber of the drainage pump Check the filling level of the reservoir to the seal chamber weekly; top off if necessary. When refilling, use the fluid to be cleaned at a viscosity of between ISO VG 10 and VG 100. (1) (2) max. 7 ml (1) Item Designation (1) Reservoir (2) Seal chamber FAM 15/30/50/70 ATEX en(us) Page 64 / 88

65 Performing maintenance / inspection Lubricating lock on the electrical cabinet NOTICE Corrosion on the lock of the electrical control cabinet The lock cannot be opened / loss of ATEX approval Regularly inspect the lock for corrosion. Regularly lubricate the threads. To prevent corrosion on the lock (x) of the electrical cabinet, lubricate the threads on the closure regularly (x). To lubricate the threads on the lock (x), lubricating greases according to DIN K1-2 G-45. We recommend: Blasolube 300. You can obtain this lubricant from HYDAC as a spare part; the part no. is in the spare parts list. Proceed as follows to lubricate the threads: 1. Switch the unit off, pull the mains plug and bring the unit out of the area at risk for explosion. 2. Open the lock (x) by turning the driver counterclockwise, and remove it. 3. Remove any residue of the lubricating grease that is present on the lock and on the switch cabinet with a wear-resistant, lint-free and damp cloth. 4. Apply the appropriate new lubricating grease to the threads with a brush. Note here the safety and processing instructions of the respective product. 5. Place the lock (x) on the switch cabinet opening. Screw this in clockwise using the driver, and tighten it. 6. The lubrication of the lock is complete and the unit is ready for operation. FAM 15/30/50/70 ATEX en(us) Page 65 / 88

66 Performing maintenance / inspection Replacing the filter element on the fluid filter If the fault indicator lamp "Replace filter element" [H10]" lights up, replace the filter element on the fluid filter. See page 66 for details. To change the filter element, you need the following: Filter element N15DMxxx (quantity and type dependent on version) Allen wrench, size 6 mm Fork wrench, size 13 mm To change the filter elements, proceed as follows: 1. Switch off the unit at the main switch and make sure it cannot be inadvertently switched back on. 2. Close all shut-off valves at the inlet and outlet. 3. Unscrew the air bleed screw (x) completely using a 10 mm Allen wrench. FAM 15/30/50/70 ATEX en(us) Page 66 / 88

67 Performing maintenance / inspection 4. (1) Have a suitable drip tray on hand to catch the fluid. (2) Open the drain fitting, and collect the escaping fluid in the tray. Once the housing has been completely drained, close the drain fitting. 3. Screw in the air bleed screw (x) by hand in a clockwise direction and tighten it firmly using a 10 mm Allen wrench. 4. Release the housing tensioning clamps (1), and remove them. Remove the cover (a). Remove the intermediate piece (b). FAM 15/30/50/70 ATEX en(us) Page 67 / 88

68 Performing maintenance / inspection 5. Turn the locking cap on the top filter element by 90 in counterclockwise direction (1) and lift the locking cap off (2). 6. Turn all filter elements 90 in a counterclockwise direction, and remove them. FAM 15/30/50/70 ATEX en(us) Page 68 / 88

69 Performing maintenance / inspection 7. Dispose of the old filter elements in an environmentally friendly manner. 8. Clean the inside of the filter housing of coarse dirt. Check the O-rings on the filter housing for damage. Replace them if necessary. 9. Insert the filter element into the bayonet fitting (1), and lock it in place by turning each individual filter element 90 in the clockwise direction (2). FAM 15/30/50/70 ATEX en(us) Page 69 / 88

70 Performing maintenance / inspection 10. Place the locking cap onto the filter element (1). Turn the locking cap 90 in the clockwise direction to lock it in place. No locking cap = no filtration. 11. Put the intermediate piece (b) on the lower section (c). Mount the lower housing tensioning clamp (1), and tighten it with a torque of 20 Nm. Secure using the lock nut. Put the cover (a) on the intermediate piece (b). Mount the upper housing tensioning clamp (2) and tighten it with a torque of 20 Nm. Secure using the lock nut. We recommend applying lubricant containing a slip additive to the threads of the housing tensioning clamp each time filters are changed so that it remains easy to remove. Lubricant containing a slip additive HYDAC part no.: Open all shut-off valves on the FAM (inlet and outlet). Switch on the FAM at the main switch. FAM 15/30/50/70 ATEX en(us) Page 70 / 88

71 Performing maintenance / inspection 13. Fill the filter housing slowly. Slightly undo the air bleed screw (x). The air in the filter housing can escape via the slot on the air bleed screw. Bleed the filter housing through the air bleed screw (x) until operating fluid comes out. Tighten the air bleed screw. 14. The filter element change is now complete. Checking the fault indicator lamp After the FAM is switched on, all fault indicator lamps light up for 2 seconds. Check to see whether all fault indicator lamps light up. Replace any defective lamps immediately. FAM 15/30/50/70 ATEX en(us) Page 71 / 88

72 Performing maintenance / inspection Cleaning the suction strainer NOTICE Operation without a suction strainer The unit will be damaged Never operate the unit without a suction strainer Clean the suction strainer regularly To protect the pump from coarse contamination particles and other foreign bodies, a dirt trap with a strainer insert is fitted at the pump inlet. This strainer insert must be cleaned at regular intervals, e.g. by flushing it with solvent or blow-flushing it with compressed air. 1. Unscrew the screw plug (1) counterclockwise with an openjaw wrench (50 mm). 2. Remove the strainer insert (3) and clean it. 3. Check strainer insert (3) and sealing ring (2) on the screw plug for damage. Replace it if necessary. 4. Insert the strainer insert (3). 5. Screw in the screw plug by hand clockwise, and tighten it using the open-jaw wrench (50 mm). 6. Check the suction strainer fitting for leaks after commissioning FAM 15/30/50/70 ATEX en(us) Page 72 / 88

73 Performing maintenance / inspection Changing the air filter element You will require: Air filter (for part-no., see replacement parts list) Replace the air filter every six months. Replace it more frequently as required by the ambient air conditions (e.g., dusty/humid). Unscrew the air filter by hand Screw on the new air filter by hand FAM 15/30/50/70 ATEX en(us) Page 73 / 88

74 Performing maintenance / inspection Vacuum pump maintenance Also see the supplied operating instructions of the vacuum pump. g h e f d i c b a Item a b c d e F g H i Designation Temperature sensor Suction port connection Grounding connection Outlet Flame arrester Oil filler neck Pressure switch Electrical connection Coupling FAM 15/30/50/70 ATEX en(us) Page 74 / 88

75 Performing maintenance / inspection Maintenance interval Before startup Daily Weekly Monthly Every 6 Months Every six months or every 1500 operating hours Description Check the fill level and the coloration of the compressor oil (for details, see instruction manual of the vacuum pump). Check the fill level and the coloration of the compressor oil (for details, see instruction manual of the vacuum pump). Visual check of the entire vacuum pump for leaks. Check the fill level and the coloration of the compressor oil (for details, see instruction manual of the vacuum pump). Check that the oil filling screw [f] is screwed in tight. Torque max. 35 Nm. Visual check of the entire vacuum pump for leaks. Immediately repair leaks. Check the exterior of the vacuum pump and individual component parts for dirt and dust deposits. If necessary, clean the vacuum pump and the component parts. Clean the fan hoods, the fan wheel, the fan grids and the cooling fins. Carry out an inspection and check the measurements of the electrical connection [i] of the electric motor of the vacuum pump. Execute the circumferential backlash and visual inspection of the coupling [h] (for details, see instruction manual / maintenance plan of the vacuum pump). Change the air suction filter / air dehumidifier (for details, see instruction manual / maintenance plan of the vacuum pump). Check and clean the flame arrester of the vacuum pump (for details, see instruction manual / maintenance plan of the vacuum pump). Replace the compressor oil (for details, see the instruction manual of the vacuum pump). Replace the exhaust filter cartridge (for details, see instruction manual of the vacuum pump). All deposits, such as dirt and dust, threaten the explosion safety of the unit. FAM 15/30/50/70 ATEX en(us) Page 75 / 88

76 Performing maintenance / inspection Filling the vacuum pump [a] [b] Max. Min. [c] To fill the vacuum pump, open the fill plug [a]. Add oil until the level comes up to the MAX mark on the oil level glass [b]. Check the oil level daily. When the fill level gets down to the MIN mark, add oil. The oil level for initial filling 2.0 liters. The oil level between the MIN and MAX marking is 0.45 Liter. The vacuum pump is certified for operation with synthetic oil "Leybold LVO 210". If a different oil is used, the EC and ATEX certificates are voided. This vacuum pump oil is available from HYDAC under the following part no.: Description Packaging Part no.: Compressor oil - LVO liter Compressor oil - LVO liter Further maintenance instructions for the vacuum pump For further information and specific instructions refer to the included component manufacturer's instructions. FAM 15/30/50/70 ATEX en(us) Page 76 / 88

77 Performing maintenance / inspection Test vacuum column level sensor You will require: Philips screwdriver, PH#2 + PH#3 Fork wrench SW13 Performance instructions: Remove the four nuts on the vacuum column cover. Release the safety screw on the level sensor plug. Pull out the plug. Carefully remove the cover together with the level sensor. Attach the cover to the vacuum column as shown. Clean the dirt off of the level sensor Check the functioning of the float level sensor using the PLC inputs. Move the float away by hand. The unit must be switched on for this test. FAM 15/30/50/70 ATEX en(us) Page 77 / 88

78 Performing maintenance / inspection Switching Status - Level Sensor Vacuum Column/PLC If the upper float is shifted upward, then the fault message "Vacuum column overfilled" must appear on the text display. Acknowledge the message with the "RESET" key. Perform the assembly in reversed order of sequence.! Level sensor I0.3 I0.4 I0.5 I0.3 I0.4 I0.5 ON OFF ON OFF ON OFF PLC FAM 15/30/50/70 ATEX en(us) Page 78 / 88

79 Performing maintenance / inspection Testing the Float Switch in the Oil Pan Proceed as follows to test the float switch in the oil pan: 1. Use your fingers to raise the float switch in the oil pan. 2. The unit must switch off and the fault message "Pan overfilled" must appear in display of the control panel. 3. Release the float switch and acknowledge the fault message by pressing the F3 key. 4. The unit continues to operate -> You have tested the function of the float switch positively. 5. If the unit does not switch off after the lifting of the float switch and no fault message appears, contact the HYDAC Service. FAM 15/30/50/70 ATEX en(us) Page 79 / 88

80 Performing maintenance / inspection Replacing filter element on the oil mist separator Item Designation 1 Separator head 2 Separator pot 3 Clogging indicator 4 Filling level display The oil mist separator is located between the vacuum column and the vacuum pump. A filter element is used to retain the oil mist and the oil in the oil mist separator and the oil is collected in the separator pot, where it is continuously suctioned off and returned to the vacuum column. The filter element (for part-no., see replacement parts list) is to be replaced on a regular basis in accordance with the maintenance schedule. The clogging indicator (3) of the oil mist separator is not functioning. FAM 15/30/50/70 ATEX en(us) Page 80 / 88

81 Performing maintenance / inspection Replacing the filter element on the oil mist separator Quit automatic mode of the FAM. Then wait 1 minute until normal pressure (environmental pressure) is reached in the vacuum column. Rotate the separator pot [2] 1/8th of a turn to the left (bayonet seal) and remove from the bottom. Turn the used filter element clockwise to remove and dispose of it in an environmentally correct manner. Insert the new filter element and screw it into the separator head (1) by turning it counterclockwise. Insert the separator pot (2) into the separator head (1), and secure it with a 1/8th turn (bayonet seal). The filter element change is now complete. FAM 15/30/50/70 ATEX en(us) Page 81 / 88