FluidAqua Mobil FAM 15/30 ATEX II 2G IIB+H2 T4 (+10 C<Ta<40 C) II 2G IIB+H2 160 C (+10 C<Ta<40 C) Operating and Maintenance Instructions English (translation of original instructions) Documentation no.: 3197970c
Imprint Imprint Publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saarland Germany Telephone: +49 (0)6897 509 01 Telefax: +49 (0)6897 509 846 E-Mail: filtersystems@hydac.com Homepage: www.hydac.com Court of Registration: Saarbrücken, HRB 17216 Executive director: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: ++49 (0)6897 509 1511 Telefax: ++49 (0)6897 509 1394 E-Mail: 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. Technical specifications are subject to change without notice. The trademarks of other companies are exclusively used for the products of those companies. HYDAC FILTER SYSTEMS GMBH en(us) Page 2 / 84
Content Content Imprint...2 Documentation Representative...2 Content...3 Preface...6 Customer Service...7 Modifications to the Product...7 Warranty...7 Using the documentation...8 Changes to the manual...9 Preface...10 Technical Support...11 Modifications to the Product...11 Warranty...11 Using the documentation...12 Safety information and instructions...13 Obligations and liability...13 Explanation of Symbols and Warnings, etc....14 General Safety Precautions...14 Proper/Designated Use...15 Improper Use...15 Safety Devices...16 Informal Safety Precautions...16 How to behave in case of emergency...17 Electrical Hazards...17 Training and Instruction of Personnel...18 Maintenance, Servicing and Troubleshooting...18 Modifications to the FluidAqua Mobil...19 Transporting the FAM...20 Forklift...20 Crane...21 Train/truck...21 Checking the scope of delivery...22 FAM Description...23 Performance features...23 Restrictions pertaining to use...24 FAM components...25 HYDAC FILTER SYSTEMS GMBH en(us) Page 3 / 84
Content FAM components...26 Description of function...27 Hydraulic diagram...28 Using the FAM...29 Bypass purification...29 Transfer by pumping...29 Explosion protection as per ATEX 95...30 Setting up the FAM...31 Connecting the FAM...32 Notes on pipes and hoses...33 Connecting the suction port...34 Connecting the pressure port / return-flow line...34 Electrical connection of the FAM...35 Preparing the rotary vane vacuum pump...36 Filling the vacuum pump...36 Filling the seal chamber of the evacuation pump...37 Operating Elements on the control panel...38 Starting up the FAM...39 Setting the vacuum pressure...39 Venting the filter housing...40 Shut off FAM...41 FAM in manual operation...41 Error messages / troubleshooting...42 [H5] Vacuum chamber overfilled...44 [H6] Inlet (IN) clogged...45 [H7] Outlet (OUT) clogged...46 [H8] V-pump temperature...47 [H9] Wrong phase sequence...48 [H10] Change fluid filter...49 [H11] Float switch...50 [H12] E/V/R pump motor protection...51 [H13] Dry-running, E-pump...52 [H14] Level switch 01/02(02/03)...53 [H15] V-pump pressure...54 Performing maintenance / inspection...55 Visual checks...56 Overview of maintenance intervals...57 Electrical inspection...60 HYDAC FILTER SYSTEMS GMBH en(us) Page 4 / 84
Content Filling the seal chamber of the evacuation pump...61 Replacing the filter element on the fluid filter...62 Replacing the filter element on the fluid filter...63 Checking the fault indicator lamp...67 Clean the suction strainer....68 Changing the air filter element...69 Vacuum pump maintenance...70 Filling the vacuum pump...72 Additional maintenance instructions...72 Testing the level sensor of the vacuum chamber...73 Switching Status - Level Sensor Vacuum Column/SPS...74 Checking the float switch of the oil pan...74 Replacing filter element on the oil mist separator...75 Replacing the filter element on the oil mist separator...76 Replacement Parts and Accessories List...77 Customer Service...79 Storing the FAM/Taking it out of Operation...80 Disposing of the FAM...80 Technical data...81 HYDAC FILTER SYSTEMS GMBH en(us) Page 5 / 84
Preface Preface For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance. It is intended to help you become acquainted with the ins and outs of the product and use it properly. You should keep it in the vicinity of the product so it is always at your fingertips. Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.consequently, there might be deviations in technical details, illustrations and dimensions. If you discover errors while reading the documentation or have suggestions or other useful information, please don t hesitate to contact us: HYDAC FILTER SYSTEMS GMBH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany We look forward to receiving your input. Putting experience into practice HYDAC FILTER SYSTEMS GMBH en(us) Page 6 / 84
Preface Customer Service 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) 6897 / 509-846 E-Mail: 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'll find this under www.hydac.com -> Legal information HYDAC FILTER SYSTEMS GMBH en(us) Page 7 / 84
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 Produkt / Kapitel Page number HYDAC Filtertechnik GmbH BeWa 123456a 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 8 / 84
Changes to the manual Changes to the manual The index is featured on the cover sheet of the operating and maintenance manual and in the lower left corner of each page after the part number. Index "a" - Manual revised Index "b" - Manual revised Index "c" - Manual revised HYDAC FILTER SYSTEMS GMBH en(us) Page 9 / 84
Preface Preface For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance. It is intended to help you become acquainted with the ins and outs of the product and use it properly. You should keep it in the vicinity of the product so it is always at your fingertips. Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.consequently, there might be deviations in technical details, illustrations and dimensions. If you discover errors while reading the documentation or have suggestions or other useful information, please don t hesitate to contact us: HYDAC FILTER SYSTEMS GMBH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany We look forward to receiving your input. Putting experience into practice HYDAC FILTER SYSTEMS GMBH en(us) Page 10 / 84
Preface 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) 6897 / 509-846 E-Mail: 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 We assume warranty in accordance with the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH. Refer to these at www.hydac.com General terms and conditions. HYDAC FILTER SYSTEMS GMBH en(us) Page 11 / 84
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 Page number 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 12 / 84
Safety information and instructions Safety information and instructions These operating instructions contain the most important notes for operating the FluidAqua Mobil safely. The safety of the FAM largely depends on maintenance. Regular required maintenance is described in this manual. We will support you if the unit needs repair and will provide original spare parts. Obligations and liability The basic prerequisite for the safe and proper handling and operation of the FAM is knowledge of the safety instructions and warnings. These operating instructions in general, and the safety precautions in particular, are to be adhered to by all those who work with the FluidAqua Mobil. Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used. The safety precautions listed here are limited solely to using the FluidAqua Mobil. The FluidAqua Mobil has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazard may be posed to the life and limb of the individual using the product or to third parties. 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 in accordance with the designated equipment group, equipment category and zone indicated above Only when in safe, perfect condition. any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately. Our General Terms and Conditions apply. They are made available to the owner upon concluding purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes: Improper use of the FluidAqua Mobil or use deviating from its intended use Improper commissioning, operation and maintenance of the FluidAqua Mobil Operating the FluidAqua Mobil when the safety systems are defective Modifications to the FluidAqua Mobil made by the user or purchaser Improper monitoring of unit components that are subject to wear and tear Improperly performed repair work HYDAC FILTER SYSTEMS GMBH en(us) Page 13 / 84
Safety information and instructions Explanation of Symbols and Warnings, etc. DANGER WARNING CAUTION NOTICE DANGER denotes situations which can lead to death if safety precautions are not observed. WARNING indicates hazardous situations which can result in fatal injuries if not complied with. CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed. NOTE denotes situations which can lead to property damage if safety precautions are not observed. This symbol designates safety indications whose non-observance may pose a hazard to individuals due to hot surfaces. This symbol designates safety indications whose non-observance may pose a hazard to individuals and the environment due to explosion. This symbol marks safety indications that refer particularly to explosion protection. General Safety Precautions Operation, adjustment and calibration work may only be carried out by technically skilled and trained personnel. The safe operation of this unit can only be ensured if it is used for the purpose it was intended. If there is any question about the use, please contact the manufacturer. The manufacturer will not accept responsibility for damages resulting from misuse of this equipment. The following applies to all work performed using the unit: adherence to pertinent national regulations pertaining to accident prevention and safety at the workplace in addition to any applicable internal rules and regulations of the owner/operator, even though they are not specifically cited herein. HYDAC FILTER SYSTEMS GMBH en(us) Page 14 / 84
Safety information and instructions Leaks of dangerous materials must be properly collected and disposed of so as not to harm any persons or the environment. The corresponding statutory regulations are to be followed. Before any maintenance or repair work is carried out on the unit, electrical power to the unit must be disconnected, and all hydraulic pressures relieved. 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. Proper/Designated Use The FAM was designed for the dewatering, filtration and degassing of hydraulic and lubricating oils. It removes free and emulsified water and most of the water which is in solution. Any other use shall be deemed to be improper and not in keeping with the product's designated use. Proper or designated use of the product extends to the following: Maintaining adherence to all the instructions contained herein. Performing requisite inspection and maintenance work. Improper Use Any use deviating from the proper/designated use described above is prohibited. Improper use may result in hazard to life and limb. Example of improper use: Operation with non-approved fluids. Operation in a danger zone where the ATEX classification of the device does not apply. Operation in mining or in dust-exposed zones HYDAC FILTER SYSTEMS GMBH en(us) Page 15 / 84
Safety information and instructions Safety Devices Prior to starting up the FAM unit each time, make sure that all the protective safety devices are properly installed and are in proper working order. Safety devices may not be removed until the product has been shut down and secured against being restarted (e.g. warning sign or padlock on the main switch). When the product is supplied in partial consignments, the safety devices are to be applied by the operator as specified by law/pertinent regulations. Informal Safety Precautions Make sure to always keep the operating instructions in the vicinity of the FluidAqua Mobil unit. Apart from the operating instructions, any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance to be maintained to them. Make sure to keep the safety and hazard symbols and warnings on the FluidAqua Mobil in a legible condition and replace them as necessary. FluidAqua Mobil components may not be opened except in normal, noncontaminated environments. The mains cable must be unplugged before the FluidAqua Mobil is opened. Tests conducted with the housing open may only be performed by properly trained, certified electricians. The same applies to repairs or modifications carried out with our approval on electrical system parts. The hoses and connection fittings are to be checked daily for leakage (visual check). The electrical components of the FluidAqua Mobil are to also be regularly checked (visual check once a month). Any loose connections or damaged cables are to be replaced immediately. WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system. HYDAC FILTER SYSTEMS GMBH en(us) Page 16 / 84
Safety information and instructions How to behave in case of emergency In the event of an emergency, rotate the main and E-STOP switch 90 to the left in order to shut down the entire system. The entire system is then voltage-free downstream from this switch. Normal pressure will return to the vacuum chamber after ~ 1 minute. Electrical Hazards DANGER Electric shock Bodily injury leading to death Any work involving electrical equipment may only be done by a properly trained, certified electrician. Any work involving the power supply may only be done by a properly trained, certified electrician. Make sure to check the electrical equipment of the product on a regular basis. Any loose connections or damaged cables are to be remedied/replaced immediately. If work on live components is required, have a second individual be present to switch off the unit if necessary. HYDAC FILTER SYSTEMS GMBH en(us) Page 17 / 84
Safety information and instructions Training and Instruction of Personnel The FAM may only be operated by properly trained and instructed personnel. The areas of responsibility of your staff must be established in a clear-cut manner. Staff undergoing training may not use the FAM unless supervised by an experienced staff member. Individuals Individuals undergoing training Personnel with technical training/ engineering background Electricians 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 Troubleshooting, mechanical problem X X Remedying of electrical faults X X Maintenance X X X X Servicing X Decommissioning / Storage X X X X Maintenance, Servicing and Troubleshooting The specified adjustment, maintenance, and inspection work is to be conducted in a timely fashion. All operating media is to be protected/isolated for the event that the product is accidentally started up. The FluidAqua Mobil is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance, inspection or repair work. Check any screwed fittings which have been removed to see that they have been properly secured, and tighten them if necessary. Always check the safety devices to see that they function properly after performing maintenance work. HYDAC FILTER SYSTEMS GMBH en(us) Page 18 / 84
Safety information and instructions 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 modifications require written permission from HYDAC Filter Systems GmbH Immediately replace any machine components which are not in perfect condition. Only use original (OEM) spare parts and consumables. When using non-oem components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements. HYDAC FILTER SYSTEMS GMBH en(us) Page 19 / 84
Transporting the FAM Transporting the FAM CAUTION High empty weight (~ 640-680 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 secure them. 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 swivel casters. Once the FAM is in its new position, actuate the hand brake on the swivel casters. Forklift Use the lift eyes when transporting the unit with a forklift. HYDAC FILTER SYSTEMS GMBH en(us) Page 20 / 84
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. Make sure that the lifting accessories do not cause any force to be exerted on 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 21 / 84
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: Item Qty. Designation 1 1 FAM, connection-ready with suction and pressure hose. 2 2 Drive handle 7x10 (to open the control cabinet) - 1 Documentation, consisting of: - FAM ATEX Operating and Maintenance Instructions - Operating and Maintenance Instructions - Vacuum Pump - Operating and Maintenance Instructions - Evacuation Pump - EC Declaration of Conformity - Declaration of Conformity from TÜV 2 1 HYDAC FILTER SYSTEMS GMBH en(us) Page 22 / 84
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 efficient particulate separation. The fluid is degassed through a vacuum in the vacuum chamber. 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 Typical dewatering rates (ISO VG46): ~ 1,0 l/h ~ 1,7 l/h The dewatering speed is dependent on: Dewatering speed Water content Fluid temperature Detergent additives Flow rate FAM HYDAC FILTER SYSTEMS GMBH en(us) Page 23 / 84
FAM Description Restrictions pertaining to use NOTICE Impermissible operating conditions The unit will be damaged The unit may be used only in connection with the media mentioned below. Depending on the version (see model code), the FAM may be used only for the following media: FAM-xx-M-x-x/xxxx-xxx-xx-x-x-x Mineral oils acc. to DIN 50524 Gear oils according to DIN 51517, 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 ester (HEES) DIN 51524/2 Vegetable oils (HETG, HTG) Hydraulic and lubrication oils which require or are compatible with Viton seals. DANGER Fluid temperature > 70 C Risk of explosion Please note the maximum temperature of 70 C. Install a cooler upstream of the FAM if necessary. HYDAC FILTER SYSTEMS GMBH en(us) Page 24 / 84
FAM components FAM components 12 1 5 8 7 4 9 11 2 3 10 Item Designation 1 Control panel and control cabinet in ATEX version, consisting of: - Main switch and Emergency Stop switch - Functions buttons - Operations indicator lamps - Error indicator lamps Vacuum gauge with throttle valve to set the required vacuum in the 2 vacuum chamber 3 Hinged box to hold two 10-liter water canisters 4 Vacuum column 5 Inlet valve (2/2 directional control valve) 7 Suction strainer 8 Inspections glass 9 Vacuum pump 10 Evacuation pump with electrical motor 11 Fluid filter for separating solid particles 12 Air filter and air dryer - Grounding connection with terminal, length 3 m HYDAC FILTER SYSTEMS GMBH en(us) Page 25 / 84
FAM components FAM components Item Designation 1 Control panel and control cabinet in ATEX version, consisting of: - Main switch and Emergency Stop switch - Functions buttons - Operations indicator lamps - Error indicator lamps Vacuum gauge with throttle valve to set the required vacuum in the 2 vacuum chamber 3 Box 4 Vacuum column 5 Inlet valve (2/2 directional control valve) 7 Suction strainer 8 Inspections glass 9 Vacuum pump 10 Evacuation pump with electrical motor 11 Fluid filter for separating solid particles 12 Air filter and air dryer 13 Vacuum setting 14 Fill level switch (dry-running protection of the evacuation pump) 15 Level switch ([01] Min, [02] Max, [03] Emergency Off) 16 Pressure relief valve 17 Float switch in the oil pan HYDAC FILTER SYSTEMS GMBH en(us) Page 26 / 84
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 chamber. The fluid to be cleaned trickles downward through special filling materials. These filling materials multiply the surface in the vacuum chamber and make it possible to form a fine fluid film. The fluid collects in the bottom of the vacuum chamber 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 chamber 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 chamber until the level switch [02] is reached. The 2/2 directional valve closes and the procedure begins again. The vacuum in the vacuum chamber sucks atmospheric air out through the air filter. This air flows down into the vacuum chamber 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 chamber is set with the throttle valve (vacuum setting). The evacuation pump is protected against dry running by the fill level limit switch in the vacuum chamber. The fill level limit switch switches the electric motor of the evacuation pump off when the vacuum chamber has been emptied. When the "Stop overrun" switch has been pressed, the inlet valve closes and the evacuation pump pumps the vacuum chamber 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 27 / 84
Hydraulic diagram Hydraulic diagram HYDAC FILTER SYSTEMS GMBH en(us) Page 28 / 84
Using the FAM Using the FAM Bypass purification IN OUT The FAM is connected with suction and pressure lines to the tank and cleans the medium to be found there in continuous operation. Transfer by pumping IN Contaminated oil OUT Clean oil The FAM is connected to the contaminated oil tank by means of a suction line and pumps the fluid into the clean oil tank. However, better purification results are achieved with bypass purification. Therefore, the FAM should be operated after pumping in the bypass flow. To avoid overfilling the purified oil tank, permanently monitor the oil level. HYDAC FILTER SYSTEMS GMBH en(us) Page 29 / 84
Explosion protection as per ATEX 95 Explosion protection as per ATEX 95 The water extraction 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 FAM is: II 2G IIB+H 2 T4 (+10 C<Ta<40 C) II 2G IIB+H 2 160 C (+10 C<Ta<40 C) 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 sulfide, ammonia, methane, ethane, propane, ethyl alcohol, cyclohexane, 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 T4 Maximum permissible surface temperature: 135 C HYDAC FILTER SYSTEMS GMBH en(us) Page 30 / 84
Setting up the FAM Setting up the FAM Observe the following points when setting up the FAM: Place the unit on a horizontal and level surface. Special mounting is not required. Mobile version only - Lock the immobilization brakes on the wheels to avoid unintended movement/rolling away of the unit. Position the FAM in the immediate vicinity of the tank to be cleaned. Observe the maximum permitted suction pressure. See page Fehler! Textmarke nicht definiert.. Observe the ambient temperature on the type label of the FAM. Ensure that the main switch is free and accessible at all times. Keep an area of at least 0.8 m around the FAM free for maintenance purposes. Make sure there is sufficient ventilation around the area where the FAM is set up. CAUTION Outlet air of the vacuum pump Hazardous to health Always make sure there is sufficient ventilation in the surrounding area of the FAM. Air coming out of the vacuum pump can contain particles of vacuum pump oil and/or 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 31 / 84
Connecting the FAM 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 12 115. Connect the ground clamp of the FAM to a suitable grounding source nearby. The grounding lead is 3 m long. HYDAC FILTER SYSTEMS GMBH en(us) Page 32 / 84
Connecting the FAM Notes on pipes and hoses In order to keep the pressure loss as low as possible, use as few threaded connections as possible. The pressure differential in a hydraulic line ( P (line) ) depends on the following: Flow rate kinematic viscosity Pipe dimensions Fluid density The pressure loss in straight pipes ( P (line) ) can be calculated as follows: Δp Δp ~ 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 fluid 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 33 / 84
Connecting the FAM Connecting the suction port NOTICE Overpressure at the suction port connection The unit is damaged The pressure at suction port IN must be in the range from -0.25 to +2 bar. NOTICE Contamination too high The unit is damaged Do not prime directly at the bottom of the tank Do not prime in the sump The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank. Make the suction-side connection with a flexible hose that is resistant to negative pressure or with pipelines. The nominal size of the connecting lines must be at least as large as the cross-section of the unit in order to prevent excessively high pressure loss. The suction port must be arranged so that it is always below the oil level. Connecting the pressure port / return-flow line NOTICE Return port connection OUT closed off The unit is damaged Close the return port connection OUT To avoid a concentration of air in the medium, the return-flow line must always be located below the oil level. HYDAC FILTER SYSTEMS GMBH en(us) Page 34 / 84
Connecting the FAM Electrical connection of the FAM DANGER Electric shock Danger of fatal injury Any work involving the electrical system may only be done by a properly trained, certified electrician. The voltage and frequency information on the rating plate must coincide with the voltage 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 the terminal block S0 (e.g. L1 and L2). A phase sequence relay checks the correct phase sequence after switch-on. In the event of an incorrect phase sequence, error message no. 29 is shown on the control panel. 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 35 / 84
Connecting the FAM Preparing the rotary vane vacuum pump As a basic rule, the rotary vane vacuum pump is not filled with oil at the time the FAM is delivered. A sufficient amount of vacuum pump oil for the initial filling is included in the scope of delivery. NOTICE Operation without vacuum pump oil The rotary vane vacuum pump will be destroyed. The rotary vane vacuum pump requires oil as its operating medium. Check the oil level before start-up, topping up with vacuum pump oil VE101 if necessary. 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 fill quantity for the initial filling is ~ 2.0 liters. The oil fill quantity between the MIN and MAX marks is ~ 0.45 liters. 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 36 / 84
Filling the seal chamber of the evacuation pump This vacuum pump oil is available from HYDAC under the following part no.: DESCRIPTION Packaging Part no.: Compressor oil - Leybold LVO 210 1 liters 3765250 Compressor oil - Leybold LVO 210 5 liters 3769255 Filling the seal chamber of the evacuation pump Before initial commissioning, the seal chamber of the evacuation pump must be filled with the sealing medium ISO VG 10... ISO VG 100. (1) For topping off, use the medium to be purified having a viscosity of ISO VG 10 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. This also prevents the ingress of air into the fluid. Check the fill level of the reservoir (1) at least once a week and top off as needed. (2) (1) max. 7 ml Item Designation (1) Reservoir (2) Seal chamber To top off the sealing medium, raise the cover of the reservoir (1) and fill it up. After connecting, close the cover of the reservoir (1). HYDAC FILTER SYSTEMS GMBH en(us) Page 37 / 84
Operating Elements on the control panel Operating Elements on the control panel To operate the FAM, the following items 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: Inscription S1 Start delay S2 Stop overrun S3 Malfunction Operating status lamps: Function Start FAM, starting and changeover to purification mode. Stop FAM, run-down with evacuation of the vacuum chamber Acknowledging all corrected malfunctions / Switching from automatic to manual operation Inscription Operating state H1 Start delay Startup phase H2 Stop overrun After-run phase H3 Malfunction Malfunction H4 Fluid Aqua operates Purification operation HYDAC FILTER SYSTEMS GMBH en(us) Page 38 / 84
Starting up the FAM Starting up the FAM After all connections are made and the preparations for commissioning are complete, 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 chamber 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 chamber with the throttle 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 Lubricant 300 mm²/s 250-500 mbar / 52-50 kpa (depending on foaming behavior) HYDAC FILTER SYSTEMS GMBH en(us) Page 39 / 84
Starting up the FAM 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 40 / 84
Starting up the FAM 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 chamber 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 FAM exits manual operation automatically after 10 seconds. HYDAC FILTER SYSTEMS GMBH en(us) Page 41 / 84
Error messages / troubleshooting Error messages / troubleshooting Signal Inscription Cause Remedy H5 Vacuum chamber overfilled Maximum filling level [03] in the vacuum chamber exceeded. Possible foaming in the vacuum chamber. Reduce the vacuum pressure in the vacuum chamber, e.g. from 300 mbar (absolute) to 400 mbar (absolute), and increase the heating temperature to reduce the thickness of the oil film in the vacuum chamber. Note: If the vacuum pressure cannot be reduced any further, replace the air filter. H6 Entry blocked No fluid is being sucked into the FAM H7 Outlet clogged No medium is being pumped out of the FAM. The vacuum pump is not being emptied. 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. Check shut-off devices in the return line, and check pressure relief valve of the evacuation pump. H8 Temperature V-pump Vacuum pump temperature too high. Check dry-running protection of the vacuum pump. Check the oil quantity of the vacuum pump. H9 Wrong phase sequence Wrong phase sequence or operation voltage too low Switch two of the three phases in the connection plug, check the voltage. H10 Changing the Filter Element End differential pressure on filter has been reached. Replace filter element. H11 Float switch Oil pan of the FAM filled. Empty oil pan, check the FAM for leaks. H12 Motor protection switch Q2/Q3 Electric motor of evacuation or vacuum pump overloaded. Switch on motor protection in the electronic control unit, check operating viscosity, drain fluid from vacuum pump, rinse and fill up HYDAC FILTER SYSTEMS GMBH en(us) Page 42 / 84
Error messages / troubleshooting Signal Inscription Cause Remedy with fresh water. H13 Dry-running Evacuation Pump Too little medium is being sucked into the vacuum chamber. Flow protection of the dewatering pump (dryrunning protection) Check suction strainer, check suction pipe, suction hose could be attached to the floor. Check vacuum pump, and clean as required. H14 Level switch 01/02/03 Level switch defective. Check level switch and replace if necessary. H15 Pressure V-pump Pressure in the vacuum pump is too high. Exhaust filter cartridge is used up. Replace exhaust filter cartridge (see operating instructions of 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. Replace exhaust filter cartridge (see operating instructions of vacuum pump) Replace exhaust filter cartridge (see operating instructions of vacuum pump) HYDAC FILTER SYSTEMS GMBH en(us) Page 43 / 84
Error messages / troubleshooting [H5] Vacuum chamber overfilled Step DESCRIPTION Malfunction: "Reactor 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? 4. ->a. Yes -> proceed to Step 5. ->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. HYDAC FILTER SYSTEMS GMBH en(us) Page 44 / 84
Error messages / troubleshooting [H6] Inlet (IN) clogged Step DESCRIPTION 1. Malfunction: "Inlet clogged" 2. Cause: Medium cannot make its way into the vacuum chamber 3. Check 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. Malfunction reappears after ~ 4 minutes? 6. ->a. Yes -> proceed to Step 7. ->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 shut-off device in the suction line 8. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 45 / 84
Error messages / troubleshooting [H7] Outlet (OUT) clogged Step DESCRIPTION 1. Fault: "Outlet clogged" Cause: 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. Malfunction reappears after ~ 4 minutes? 5. ->a. Yes -> proceed to Step 6. ->b. No -> proceed to Step 7. 6. Check the pressure relief valve of the evacuation pump for proper functioning. 7. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 46 / 84
Error messages / troubleshooting [H8] V-pump temperature Step DESCRIPTION 1. Malfunction: "V-pump temperature" Cause: Oil temperature in the vacuum chamber too high 2. Check the oil level in the vacuum chamber; if necessary, top off with oil 3. To reset the failure, press the RESET key 4. Does the malfunction recur after the vacuum pump has started? 5. ->a. Yes -> proceed to Step 6. ->b. No -> proceed to Step 9. 6. Vacuum pump or controller in the control cabinet defective. 7. Repair or replace vacuum pump / exchange parts of the controller. 8. Check the pressure relief valve of the evacuation pump for proper functioning. 9. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 47 / 84
Error messages / troubleshooting [H9] Wrong phase sequence Step DESCRIPTION Malfunction: "Wrong motor rotation" 1. Switch off FAM, pull out mains plug 2 Replacement of two phases on the mains plug, check mains voltage 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 5. ->a. The fault recurs -> proceed to Step 6. ->b. The fault 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 is damaged Each time after the electric motors are replaced, the rotational direction must be checked in manual operation before commissioning. HYDAC FILTER SYSTEMS GMBH en(us) Page 48 / 84
Error messages / troubleshooting [H10] Change fluid filter Step DESCRIPTION Malfunction: "Replace fluid filter" 1. Press RESET key 2. Switch off the FAM at the main switch 3. Close ball faucets on the IN and OUT connections 4. Empty filter housing 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 Malfunction reappears after ~ 4 minutes? 10. ->a. Yes -> proceed to Step 11. ->b. No -> proceed to Step 12. 11. Check differential pressure switch and supply lines 12. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 49 / 84
Error messages / troubleshooting [H11] 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. Malfunction reappears after ~ 2 seconds? 6. ->a. Yes -> proceed to Step 7. ->b. No -> proceed to Step 8. 7. Check float switch and supply lines 8. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 50 / 84
Error messages / troubleshooting [H12] E/V/R pump motor protection Step DESCRIPTION Malfunction: "E/F/V pump motor protection" 1. Switch off FAM at the main switch and pull out mains plug 2 Open the switch cabinet door, switch the motor protection switch and/or fuse back on "I" that has tripped 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 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 6. ->a. The fault recurs -> proceed to Step 7. ->b. The fault does not recur -> proceed to Step 9. 7. Check the operating viscosity of the medium (only for motor protection switch), perform maintenance work on the vacuum pump 8. Remedy malfunction HYDAC FILTER SYSTEMS GMBH en(us) Page 51 / 84
Error messages / troubleshooting [H13] Dry-running, E-pump Step DESCRIPTION Fault "Dry running, E-pump" 1. Cause: Insufficient inflow into vacuum chamber 2. The suction-side pressure loss is too great. Possible remedies: - Cleaning the suction strainer - Reduce the suction height - Reduce the 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 suction hose - Check 2/2-way solenoid valve at intake 3. Suction port in the tank sucks in air: - Position the suction port lower - Tank to be purified too small 4. Check the functioning of vacuum pump in manual mode 5. Find and remedy corresponding cause 6. To reset the failure, press the RESET key 7. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 52 / 84
Error messages / troubleshooting [H14] Level switch 01/02(02/03) Step DESCRIPTION Malfunction: Level switch 01/02(02/03) 1. Switch off the FAM at the main switch. 2 Disconnect plug at level sensor. Remove level sensor 3. Manually check the functioning of the switching points 4. ->a. Switching points are available -> proceed to Step 5. ->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? 6. Replace level switch 7. -> proceed to Step 7. ->a. Function available -> proceed to Step 8. ->b. Function not available -> proceed to Step 9. 8. The PLC is defective. 9. Replace damaged parts HYDAC FILTER SYSTEMS GMBH en(us) Page 53 / 84
Error messages / troubleshooting [H15] V-pump pressure Step DESCRIPTION 1. Malfunction: "V-pump pressure" 2. Cause: Pressure in the oil separator of the vacuum pump too high 3. Air de-oiling element is clogged 3. Replace the air de-oiling element 4. To reset the malfunction, press the S3 "Malfunction" key 4. Does the malfunction recur after the vacuum pump has started? 5. ->a. Yes -> proceed to Step 6. ->b. No -> proceed to Step 9. 6. Vacuum pump or controller in the control cabinet defective. 7. Repair or replace vacuum pump / exchange parts of the controller. 8. Check the pressure relief valve of the evacuation pump for proper functioning. 9. The failure is repaired. HYDAC FILTER SYSTEMS GMBH en(us) Page 54 / 84
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 HYDAC FILTER SYSTEMS GMBH en(us) Page 55 / 84
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. HYDAC FILTER SYSTEMS GMBH en(us) Page 56 / 84
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 threaded joints for fixed seat, tightening them as needed. Check the measurement technology equipment / Underpressure manometer / Dynamic pressure manometer at the fluid filter - X - X Check fault indicator lamps 67 X Change the air filter (if this has not been required earlier) 69 X Clean the suction strainer. 68 X Rotary Valve Pump Vacuum Pump Check oil level Check oil for discoloration. (See operating instructions of vacuum pump) Check that the oil filler neck and drain plug have been properly secured. Check the vacuum pump for leaks. Check the intake air filter and replace if necessary (See operating instructions of vacuum pump) Fehl er! Text mark e nicht defin iert. Replace oil, oil filter Fehl X - - X X X X X HYDAC FILTER SYSTEMS GMBH en(us) Page 57 / 84
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. er! Text mark e nicht defin iert. Clean the vacuum pump of dirt and dust. Fan cover, fan wheels, air grille, cooling fins, etc. Check 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) Replacing the Air De-oiling Element - X - X - X - X Fehl er! Text mark e nicht defin iert. 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 61 X - X HYDAC FILTER SYSTEMS GMBH en(us) Page 58 / 84
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. Fluid Filter Change the filter element (If this has not been required earlier) 62 X Oil mist separator Changing the Filter Element 75 X Electrics Perform an electrical inspection 60 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 chamber - X Float switch oil pan - malfunction message and E-STOP function - X Functional test of all components in manual operation - X HYDAC FILTER SYSTEMS GMBH en(us) Page 59 / 84
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? HYDAC FILTER SYSTEMS GMBH en(us) Page 60 / 84
Performing maintenance / inspection 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 stopping 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 firmly attached? Is the ground wire connected? Filling the seal chamber of the evacuation pump Check the filling level of the reservoir to the seal chamber weekly; top off if necessary. For topping off, use the medium to be purified having a viscosity of ISO VG 10 VG 100. (1) (2) max. 7 ml (1) Item Designation (1) Reservoir (2) Seal chamber HYDAC FILTER SYSTEMS GMBH en(us) Page 61 / 84
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. For details see page 62. 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 HYDAC FILTER SYSTEMS GMBH en(us) Page 62 / 84
Performing maintenance / inspection Replacing the filter element on the fluid filter To change the filter elements, proceed as follows: 1. Switch off the FAM 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. 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 63 / 84
Performing maintenance / inspection 4. Release the housing tensioning clamps (1), and remove them. Remove the cover (a). Remove the intermediate piece (b). 5. Turn the element locking cap on the top filter element 90 in the counterclockwise direction (1), and remove the locking cap (2). HYDAC FILTER SYSTEMS GMBH en(us) Page 64 / 84
Performing maintenance / inspection 6. Turn all filter elements 90 in a counterclockwise direction, and remove them. 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 65 / 84
Performing maintenance / inspection 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). 10. Place the element locking cap on the upper filter element (1). Turn the locking cap 90 in the clockwise direction to lock it in place. No element locking cap = no filtration. HYDAC FILTER SYSTEMS GMBH en(us) Page 66 / 84
Performing maintenance / inspection 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 p/no..: 3066287 12. Open all shut-off valves on the FAM (inlet and outlet). Switch on the FAM at the main switch. 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 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 67 / 84
Performing maintenance / inspection Clean the suction strainer. NOTICE Missing suction strainer Pump is disrupted Replace 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 open-jaw 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, and tighten it using the open-jaw wrench (50 mm). 6. Check the suction strainer fitting for leaks after commissioning. 3 2 1 HYDAC FILTER SYSTEMS GMBH en(us) Page 68 / 84
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 HYDAC FILTER SYSTEMS GMBH en(us) Page 69 / 84
Performing maintenance / inspection Vacuum pump maintenance See also the enclosed operating instructions for the Leybold 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 Detonation flame arrester Oil filler neck Pressure switches Electrical connection Coupling HYDAC FILTER SYSTEMS GMBH en(us) Page 70 / 84
Performing maintenance / inspection Maintenance interval Before startup Daily Weekly Monthly Every 6 Months Every six months or every 1,500 operating hours DESCRIPTION Check the level and the color of the oil (see Vacuum Pump Operating Instructions) Check the level and the color of the oil (see Vacuum Pump Operating Instructions) Visually inspect the entire unit for leaks. Check the level and the color of the oil (see Vacuum Pump Operating Instructions) Check that the oil fill plug (f) is firmly tightened. Max. torque 35 Nm. Check the vacuum pump for oil leaks in case of leaks, immediately remove the vacuum pump from service and have it repaired. Make sure that the unit and individual components are free from dust and dirt, clean if necessary. Also clean the fan cowlings, fan wheels, the ventilation grilles and cooling fins. Check inspection and control measurement of the electrical connection [i] of the electric motor of the vacuum pump. Circumferential backlash and visual inspection of the coupling [h] (see operating manual/maintenance schedule of the vacuum pump) Replace intake air filter / dehumidifier. Change the Oil (see Vacuum pump Operating Instructions) Removal of the detonation flame arrester [e] on the vacuum pump for maintenance according to maintenance schedule (see Vacuum Pump Operating Instructions). All deposits, such as dirt and dust, threaten the explosion safety of the unit. HYDAC FILTER SYSTEMS GMBH en(us) Page 71 / 84
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 fill quantity for the initial filling is ~ 2.0 liters. The oil fill quantity between the MIN and MAX marks is ~ 0.45 liters. 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 - Leybold LVO 210 1 liters 3765250 Compressor oil - Leybold LVO 210 5 liters 3769255 Additional maintenance instructions For further information and specific instructions please refer to the included component manufacturer's instructions. HYDAC FILTER SYSTEMS GMBH en(us) Page 72 / 84
Performing maintenance / inspection Testing the level sensor of the vacuum chamber You will require: Philips screwdriver PH#2 + PH#3 Fork wrench SW13 Performance instructions: Remove 4 nuts from the cover of the vacuum chamber Undo the safety screw of the level sensor plug. Pull out the plug Carefully remove the cover together with the level sensor Hang the cover to the vacuum chamber as shown in the accompanying illustration. Check the level sensor for dirt and clean as needed. Check the functioning of the float level sensor on the basis of the SPS inlets. Move the float away by hand. The main switch of the FAM must be set to "ON" position while doing so. See the illustration below in this connection. HYDAC FILTER SYSTEMS GMBH en(us) Page 73 / 84
Performing maintenance / inspection Switching Status - Level Sensor Vacuum Column/SPS If the upper float is shifted upward, then the fault message "Vacuum chamber overfilled" must appear on the text display. Acknowledge the message with the "RESET" key. Carry out assembly in reverse order.! Level sensor I0.3 I0.4 I0.5 I0.3 I0.4 I0.5 ON OFF ON OFF ON OFF PLC Checking the float switch of the oil pan Performance instructions: Raise the float switch in the oil pan. The FAM must switch off and fault message "Pan overfilled. Please drain and seal leaky site on the FAM" is shown in the display. Acknowledge the fault message with the RESET / F3 key after releasing the switch. HYDAC FILTER SYSTEMS GMBH en(us) Page 74 / 84
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. HYDAC FILTER SYSTEMS GMBH en(us) Page 75 / 84
Performing maintenance / inspection Replacing the filter element on the oil mist separator Quit Automatic mode on the FAM. Afterwards, wait approximately 1 minute, until normal pressure (ambient pressure) has been established in the vacuum chamber. 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. HYDAC FILTER SYSTEMS GMBH en(us) Page 76 / 84
Replacement Parts and Accessories List Replacement Parts and Accessories List To ensure safe and reliable operation of the unit, use only original spare parts and accessories. When ordering spare parts, always indicate the unit designation with: Type / material no. / serial no. / year of manufacture. Item Designation Part no. Quantity FAM 15 30 50 1 Filter element, 2 µm - N15DM002 01251590 1 2 3 1 Filter element, 10 µm - N15DM010 03115180 1 2 3 1 Filter element, 20 µm - N15DM020 00349576 1 2 3 1 Filter element, 30 µm - N15DM030 03048790 1 2 3 - O-Ring for filter housing, 270x10, NBR 6005449 1 2 2 2 Air filter 0160 MU 003 M 01265765 1 1 1 3 Suction strainer assy., consisting of: - Suction strainer - Sealing ring 00635055 06010807 06034076 4 Vacuum pressure gauge 00639989 1 1 1 - Pressure hose Upon request 1 1 1 - Suction hose Upon request 1 1 1 - Filter element oil mist separator 6061300 1 1 1 - Compressor oil VE101, 1 liter 6018128 - - - - Compressor oil VE101, 5 liter 6018129 - - - - Maintenance kit for vacuum pump, consisting of: Oil filter, air de-oiling elements, seal 1 1 1 1 1 1 1 1 1 - - - HYDAC FILTER SYSTEMS GMBH en(us) Page 77 / 84
Replacement Parts and Accessories List 2 1 3 4 HYDAC FILTER SYSTEMS GMBH en(us) Page 78 / 84