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FAM 10/15-P

FluidAqua Mobil

Operating and Maintenance Instructions

English (translation of original operating instructions)

Document no.: 3193324b

FluidAqua Mobil - FAM 10/15-P Trademarks

HYDAC FILTER SYSTEMS GMBH en(us) / 80

BEWA FAM10-15-P 3193324b en-us 2011-01-19.doc 2011-01-19

Trademarks

The trademarks of other companies are exclusively used for the products of those companies.

Copyright © 2011 by HYDAC FILTER SYSTEMS GMBH all rights reserved

All rights reserved. This manual may not be reproduced in part or whole without the express written consent of HYDAC Filter Systems GmbH. Contraventions are liable to compensation.

Exclusion of liability

We made every endeavor to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in future editions. We welcome any suggestions for improvements.

All details are subject to technical modifications.

Technical specifications are subject to change without notice.

HYDAC Filter Systems GmbHPostfach 12 5166273 Sulzbach / Saar

Germany

Documentation Representative

Günter Harge

c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar

Telephone: ++49 (0)6897 509 1511

Fax: ++49 (0)6897 509 1394

E-mail: [email protected]

FluidAqua Mobil - FAM 10/15-P Content



Content

Trademarks ...............................................................................................................2

Documentation Representative...............................................................................2

Content......................................................................................................................3

Preface ......................................................................................................................6

Technical Support...................................................................................................7

Modifications to the Product ...................................................................................7

Warranty .................................................................................................................7

Using the Documentation .......................................................................................8

Safety Information and Instructions.......................................................................9

Obligations and Liability..........................................................................................9

Explanation of Symbols and Warnings, etc. .........................................................10

General Safety Precautions..................................................................................11

Proper/Designated Use ........................................................................................11

Improper Use ........................................................................................................11

Safety Devices......................................................................................................11

Informal Safety Precautions..................................................................................12

Training and Instruction of Personnel ...................................................................13

Safety Measures to Be Followed during Normal Operation..................................13

Electrical Hazards.................................................................................................14

Maintenance, Servicing and Troubleshooting.......................................................14

Modifications to the FluidAqua Mobil ....................................................................14

How to Behave in case of Emergency..................................................................15

Unpacking the FAM................................................................................................15

Transporting the FAM ............................................................................................16

Fork lift ..................................................................................................................16

Crane ....................................................................................................................16

Train/truck.............................................................................................................17

Scope of Delivery ...................................................................................................18

FAM Description.....................................................................................................19

FAM Versions .......................................................................................................19

Performance .........................................................................................................20

FAM system components .....................................................................................21

Suitable fluids .......................................................................................................23

Dimensions .............................................................................................................24

Stationary version .................................................................................................24

Mobile version.......................................................................................................25




Hydraulic diagram ..................................................................................................26

Function description..............................................................................................28

Possible applications ............................................................................................29

Bypass purification (dewatering, filtration and degassing). ...............................29

Transfer by pumping (dewatering, filtration and degassing) .............................29

FAM Set-up and Connection .................................................................................30

Setting up the FAM ...............................................................................................30

Notes on Piping / Hosing ......................................................................................30

Connecting the inlet (IN) ...................................................................................32

Connect outlet (OUT) ........................................................................................32

Preparing the Vacuum Pump................................................................................33

Filling up the rotary vane vacuum pump........................................................34

Electrical connection of the FAM ..........................................................................35

Checking the settings on the heater (optional) .....................................................36

Filling the condensate separator .......................................................................36

Starting up the FAM ...............................................................................................37

Switching on the FAM...........................................................................................37

Draining the filterhousing ......................................................................................38

Shut off FAM .....................................................................................................38

Operating the FAM .................................................................................................39

Main Menu ............................................................................................................39

Manual menu 1 .................................................................................................40

Manual Menu 2 .................................................................................................41

Troubleshooting .....................................................................................................42

Electrical fuses......................................................................................................43

Vacuum chamber overfilled ..................................................................................44

Level switch 01/02(02/03).....................................................................................45

V-pump fill level min/max......................................................................................46

Change fluid filter..................................................................................................47

Float switch...........................................................................................................48

E/V/R pump motor protection ...............................................................................49

Dry run drain pump ...............................................................................................50

Dry running E-pump..............................................................................................51

Outlet (OUT) clogged............................................................................................52

Inlet (IN) clogged ..................................................................................................53

FCU plug missing (only in conjunction with accessory FCU)................................54

Reset safety thermostat on the heater..................................................................55

Performing maintenance .......................................................................................56

Maintenance Intervals...........................................................................................57

Changing the air filter............................................................................................59




Vacuum pump.......................................................................................................59

Changing oil and oil filter...................................................................................59

Replacing the Air De-oiling Element .................................................................60

Change the active carbon filter cartridge ..........................................................61

Condensate separator ..........................................................................................62

Changing the filter element on the condensate separator ................................62

Checking the fill level on the condensate separator..........................................63

Filling the condensate separator .......................................................................63

Cleaning the suction strainer ................................................................................64

Replacing the filter element in the fluid filter .........................................................65

Checking the settings on the heater (optional) .....................................................69

Spare Parts .............................................................................................................70

FAM - 10 ...............................................................................................................70

Fluid filter (OLF 5/10)............................................................................................70

Rotary Vane Vacuum Pump .................................................................................71

Condensate separator ..........................................................................................71

Contact / Service ....................................................................................................72

Storing the FAM/Taking it out of Operation .........................................................73

Disposing of the FAM ............................................................................................73

Type label................................................................................................................73

Technical data ........................................................................................................74

Model code..............................................................................................................75

EU Declaration of Conformity ...............................................................................76

FluidAqua Mobil - FAM 10/15-P 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 will acquaint you with the product and assist you in using it as intended in an optimal manner.

Keep it in the vicinity of the product so it is always available.

Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.There may be deviations in technical details, figures, and dimensions as a result.

If you discover errors while reading the documentation or have additional comments or suggestions, contact us at:

HYDAC FILTER SYSTEMS GMBHTechnische DokumentationPostfach 12 5166273 Sulzbach / Saar

Germany

We look forward to receiving your input.

Our motto: “Putting experience into practice”




Technical Support Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product:

Fax: ++49 (0) 6897 / 509 - 846


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.

After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician.

Please notify us immediately of any modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH.

Refer to these at www.hydac.com General terms and conditions.

http://www.hydac.com/�




Using the Documentation

Please note that the method described above of locating specific information does not release you from your responsibility for carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals later on.

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.

The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index number is incremented upward by one number every time the manual is revised or changed.

Chapter description

Page number

Edition date

Document language Documentation no.with index/

file name

FluidAqua Mobil - FAM 10/15-P Safety Information and Instructions



Safety Information and Instructions

These operating instructions contain the key instructions for properly and safely operating the FluidAqua Mobil.

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 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 herein are limited solely to using the FluidAqua Mobile.

The FluidAqua Mobil has been designed and constructed in accordance with the current state-of-the-art and recognized safety regulations. Nevertheless, hazards may be posed to the life and limb of the individual using the product or to third parties, and risk of damage may be posed to the product or other equipment and property.

The FluidAqua Mobil is to be used:

Solely for its designated use

only when in a safe, perfect condition

Any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately.

Our General Terms and Conditions (AGB) apply. They are made available to the owner upon concluding purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes:

Improper use of the FluidAqua Mobil or use deviating from its designated use

Improper commissioning, operation and maintenance of the FluidAqua Mobil

Operating the FluidAqua Mobil when the safety systems are defective

Modifications to the FluidAqua Mobil made by the user or purchaser

Improper monitoring of unit components that are subject to wear and tear

improperly performed repair work




Explanation of Symbols and Warnings, etc.

DANGER DANGER denotes situations which can lead to death if safety precautions are not observed.

WARNING WARNING denotes situations which can lead to death if safety precautions are not observed.

CAUTION CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed.

CAUTION NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

This hazard symbol indicates which hazard the product poses: — dangerous to health / irritant

This symbol prescribes a specific conduct: — protective gloves are to be worn

This symbol prescribes a specific conduct: — protective eyewear is to be worn

This symbol prescribes a specific conduct: — protective clothing is be worn




General Safety Precautions

Maintenance work is to be carried out only by trained personnel.

The safe operation of this unit can only be ensured if it is used for the purpose it was intended. If there is any question about the use, please contact the manufacturer. The manufacturer will not accept responsibility for damages resulting from misuse of this equipment.

The following applies to all work performed using the unit: adherence to pertinent national regulations pertaining to accident prevention and safety at the workplace in addition to any applicable internal rules and regulations of the owner/operator, even though they are not specifically cited herein.

Leaks of dangerous materials must be properly collected and disposed of so as not to harm any persons or the environment. The corresponding statutory regulations are to be followed.

Proper/Designated Use

The FAM was developed for the dewatering, filtration and degassing of hydraulic and lubricating oils. The FAM removes free water, emulsified water and a large proportion of the water contained in solution.

Any other use shall be deemed to be improper and not in keeping with the product's designated use; the manufacturer accepts no liability for any damage resulting from such use.

Proper or designated use of the product extends to the following:

Maintaining adherence to all the instructions contained herein.

Performing requisite inspection and maintenance work.

Improper Use

Any use deviating from the proper/designated use described above is prohibited.

Improper use may result in hazard to life and limb. Examples of improper use:

Operation with a non-approved fluid.

Operation under non-approved conditions.

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 at all times. If necessary, replace the instruction sheets.

FluidAqua Mobil components may not be opened except in normal, non-contaminated environments. The mains cable must be pulled out before the FluidAqua Mobil is opened. Tests conducted with the housing open may only be performed by properly trained, certified electricians. This also applies to all repair work or to any modifications to electrical components approved by us.

Check the hoses and connectors for leaks on a daily basis.

Check the electrical equipment of the FluidAqua Mobil on a monthly basis. Replace any loose connections or damaged cables immediately.

WARNING Hydraulic systems are under pressure

Bodily injury

► The hydraulic system must be depressurized before performing any work on the hydraulic system.




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.

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Activity

Packing / transportation X X X

Commissioning X X X

Operation X X X X

Troubleshooting/ locating the source of malfunction

X X X

Remedying of mechanical faults

X X

Remedying of electrical faults X X

maintenance X X X X

Repair work X

Decommissioning / Storage X X X X

Safety Measures to Be Followed during Normal Operation

Do not put the FAM into operation unless all the safety devices function properly.

The unit is to be checked once a day for visible external damage and for the proper functioning of the safety devices.




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.

Check the FAM electrical equipment on a monthly basis. Immediately replace loose connections, damaged cables and hoses with original spare parts.

Maintenance, Servicing and Troubleshooting

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

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

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

Always check the product to see that it functions properly when performing maintenance and servicing work.

Modifications to the FluidAqua Mobil

Do not make any modifications (design modifications, extensions) to the FluidAqua Mobil without the prior consent of the manufacturer.

Any conversion modifications require written permission from HYDAC Filter Systems GmbH.

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

Only use original spare parts and consumables.

FluidAqua Mobil - FAM 10/15-P Unpacking the FAM



How to Behave in case of Emergency

In the event of an emergency, turn the main switch by 90° to the "OFF" position. The entire system is then voltage-free downstream from this switch.

Normal pressure is restored to the vacuum column after ~ 1 minute.

Unpacking the FAM

The FAM is inspected for leaks and proper functioning at the factory, then carefully packed for shipment. The connectors/ports are closed off so that no contamination can enter the unit while it is in transit.

When receiving and unpacking the unit check it for damage in transit. Report any damage to the forwarding agent immediately.

The packaging material should be disposed of or recycled as appropriate for your area.

FluidAqua Mobil - FAM 10/15-P Transporting the FAM



Transporting the FAM

CAUTION High empty weight (~ 400 - 850 kg, depending on the version)

Bodily injury

► Use at least 2 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.

Shift the FAM manually using the rollers. When doing so, use only the grips provided on the FAM frame for pushing.

Before shifting the unit, make sure to release the hand brake on the swivel casters.

Once the FAM is in its new position, actuate the hand brake on the swivel casters.

Fork lift

Use the lift eyes when transporting the unit with a forklift.

Crane

NOTICE

FluidAqua Mobil - FAM 10/15-P Transporting the FAM



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 FAM to such an extent that the rollers are subjected to no load pressure.

The FAM is to be secured with suitable belts.

FluidAqua Mobil - FAM 10/15-P Scope of Delivery



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 included:

Item Qty. Description

1 1 FluidAqua Mobil, ready for connection with suction and pressure hose

2 1 Tool, square 6 mm for switch box

- 1 Operating and Maintenance Instructions

- - Supplementary operating instructions (depending on FAM design)

- 1 Operating and maintenance instructions for vacuum pump

1

2

FluidAqua Mobil - FAM 10/15-P FAM Description



FAM Description

The FluidAqua FAM-P was developed for dewatering, filtration and degassing of aviation phosphoric acid esters e.g. Skydol® or Hyjet®. The FAM removes free water, emulsified water and a large proportion of the water contained in solution. The integrated fluid filter ensures an efficient separation of solid particles.

Degassing of the medium is also achieved via the vacuum installed in the vacuum chamber.

FAM Versions

Stationary (FAM-xx-1-..) Mobil (FAM-xx-2-..)

In comparison to the stationary version, the mobile version of the FAM has:

- 2 swivel casters, 2 rigid casters

- Suction hose, L= 5 m

- Return hose , L= 5 m

- Connection cable 10m




Performance

The FAM is able to dewater the fluids described in the "Suitable fluids" section to a water content of less than 1000 PPM.

Typical dewatering rates:

FAM - 10 ~ 0.8 l/h

FAM10/15 ~ 1.0 l/h

The dewatering speed is dependent on:

Dewatering rate

Water content

Fluid temperature

Detergent additives

Flow rate of the FAM

As an approximate guideline, the dimensioning of the FluidAqua Mobil can be defined in accordance with the tank volume.

Tank volume in liters Size

< 2,000 FAM - 10

2,000 – 7,000 FAM10/15

Note that free water, e.g. on the bottom of the tank, can have an influence on the entire water content in the system. Drain off free water before taking a sample.

For the determination of the water content, the sample should be extracted from the system to be cleaned at a test connection during operation if at all possible.




FAM system components




Item Designation

1 Frame

2 Swivel caster with brake

3 Swivel caster

4 Rigid caster

5 Type label

6 Float switch

7 Emptying pump

8 3/2-directional control valve

9 Rotary Vane Vacuum Pump

10 Vacuum pump drain

11 Filling pump (OLF 5)

12 Fluid filter for separating solid particles

13 Vacuum chamber drain

14 Vacuum chamber level sensor

15 Suction strainer

16 Vacuum chamber

17 Heater mounted in vacuum chamber (Option)

18 Air filter and dryer

19 control cabinet with control panel consisting of: - main switch - alarm signal lamp - control panel with display - component diagram

20 Regulating valve to regulate the necessary vacuum in the vacuum chamber

21 Vacuum gauge

22 Inlet (INLET)

23 Outlet (OUTLET)

24 Motor-pump assembly for the ContaminationSensor

25 ContaminationSensor CS 2000

26 AquaSensor AS2000

27 Active carbon filter

28 Condensate separator

29 Check valve

30 Venting valve

31 Silencer




Suitable fluids

NOTICE

Impermissible operating conditions

The unit will be damaged

► The unit may only be used in combination with Skydrol.

FluidAqua Mobil - FAM 10/15-P Dimensions



Dimensions

Stationary version

FluidAqua Mobil - FAM 10/15-P Dimensions



Mobile version

FluidAqua Mobil - FAM 10/15-P Hydraulic diagram



Hydraulic diagram




Item Designation

6 Float switch

7 Emptying pump

8 3/2-directional control valve

9 Rotary Vane Vacuum Pump

10 Vacuum pump drain

11 Filling pump (OLF 5)

12 Fluid filter for separating solid particles

13 Vacuum chamber drain

14 Vacuum chamber level sensor

15 Suction strainer

16 Vacuum chamber

17 Heater mounted in vacuum chamber (Option)

18 Air filter and dryer

19 control cabinet with control panel consisting of: - main switch - alarm signal lamp - control panel with display - component diagram

20 Regulating valve to regulate the necessary vacuum in the vacuum chamber

21 Vacuum gauge

22 Inlet (INLET)

23 Outlet (OUTLET)

24 Motor-pump assembly for the ContaminationSensor

25 ContaminationSensor CS 2000

26 AquaSensor AS2000

27 Active carbon filter

28 Condensate separator

29 Check valve

30 Venting valve

31 Silencer




Function description

After the FAM has been switched on, the filter pump unit 1 starts to draw the fluid from the tank to be cleaned and transfers it with a flow rate of 15 l/min into the vacuum chamber 3. At the same time, the vacuum pump 7 creates a vacuum inside the vacuum chamber. The fluid to be cleaned trickles downward through special filling materials. These filling materials are responsible for forming a thin fluid film and reducing the speed of the trickle. At the same time, a stream of air flowing upward from below against this current assimilates the water from the fluid and conveys it to the outside by means of the vacuum pump. Once level 02 is reached on the level switch, emptying pump 5 is switched on in order to convey around 15 l/min to the outlet. The filling level falls until level 01 is reached, after which solenoid valve 6 switches on and the two pumps convey into the vacuum chamber. The filling level continues to rise until level 02 is reached, after which the solenoid valve shuts back off again, the filling level falls again, etc.

After actuating the stop switch, the filter-pump unit stops and the evacuation pump empties the vacuum chamber.

Switching the main switch to "OFF" renders all engines and valves voltage-free.

The vacuum pressure, and thus also the air flow rate, in the vacuum chamber is regulated with the throttle valve 8.

For the purpose of odor reduction, the suctioned airflow is fed to the vacuum pump via a condensate separator, which is filled with vacuum pump oil (VE101). The exhaust air from the vacuum pump is released back into the environment via an active carbon filter.




Possible applications

Bypass purification (dewatering, filtration and degassing).

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 (dewatering, filtration and degassing)

The FAM is connected to a 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.

Contaminated oil

Clean oil

FluidAqua Mobil - FAM 10/15-P FAM Set-up and Connection



FAM Set-up and Connection

Setting up the FAM

The following points are to be observed when setting up the FAM:

Place the unit on a horizontal and level surface. Special mounting is not required.

The locking brakes on the wheels must be locked to avoid unintended movement of the unit (only on the mobile version).

Position the FAM in the immediate vicinity of the tank to be cleaned. Observe the maximum permitted suction pressure. See page 32.

Observe the ambient temperature on the type label of the FAM.

Sufficient room to operate and maintain the unit must be left around the main switch.

An area of at least 0.8 m must be kept free for maintenance purposes on both the left hand and right hand sides of the FAM.

Take care to ensure free access to the control panel and that the control cabinet can be opened completely.

Notes on Piping / Hosing

NOTICE

Non-permitted pressure at the inlet IN / outlet OUT

Failure malfunction

► Determine the pressure to be anticipated at the inlet / outlet with the prescribed values.

Note that the cross-section of the connected hoses/piping, must be 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.

The pressure at the inlet/outlet depends on the height differential between the FAM fluid surface in the tank port (aspiration 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 connection on the FAM and the fluid surface in the tank.

The pressure differential in a hydraulic line (P(line)) depends on the following:

Flow rate

Kinematics viscosity

Pipe dimensions

density of fluid

The pressure loss in straight pipes (P(line)) can be calculated as follows:

Δp ~ 6,8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = pipe length [m]

d = internal pipe diameter [mm]

Q = Flow rate [l/min]

V = kinematics viscosity [mm²/s]

D = Density [kg/dm³] Mineral oil based hydraulic fluid has a density of ~ 0.9 kg/dm³.

Skydrol® has a density (D) of 0.9 ... 1.1 kg / dm3.

Additional threaded connections and pipe bends increase the pressure differential and must be taken into account.

Keep the height difference between the pump and the oil level in the tank as low as possible.

Avoid constrictions in the connected hoses. They compromise output and increase the risk of cavitation.

Make sure that no tension or vibrations are carried over to the pump or filter housing when the pipes are connected. Use hoses or expansion joints if necessary.




Connecting the inlet (IN)

The suction pressure at the FAM inlet must be in the range of -0.4 bar.

Use a negative pressure-resistant, flexible hose or a pipe for the suction-side connection.

Note that the cross-section of the connected hoses/piping, must be 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.

NOTICE

Severe contamination


► Do not prime directly at the bottom of the tank

► Do not prime in the sump

► Never prime without a built-in suction screen

The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank.

Connect outlet (OUT)

Take care to ensure that the maximum pressure of 2 bar is not exceeded at the outlet.

NOTICE

OUT connection closed off

The unit will be destroyed

► 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 medium, make sure that the pressure hose with lance is always below the oil level in operation.




Preparing the 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.

The maximum filling amount for vacuum pump oil VE101 is 0.3 liters.

The water level is monitored automatically by the integrated float switch while the FAM is in operation. A message will appear on the control panel when the MIN MAX filling level has been reached.

Synthetic vacuum pump oil in accordance with DIN 51506, Group VDL, ISO VG100 must be used for topping up.

Vacuum pump oil is available from HYDAC under the following part no.

Description Part no.:

Vacuum pump oil VE101 DIN 51506, Group VDL, ISO VG100, synthetic

1 liter 06018128

Vacuum pump oil VE101 DIN 51506, Group VDL, ISO VG100, synthetic

5 liter 06018129




Filling up the rotary vane vacuum pump

Remove the safety screw for the plug at the level switch (1).

Remove the plug (2) for the level switch.

Unscrew the level switch (3) from the vacuum pump.

Fill up with vacuum pump oil VE101 through the filling nozzle (4).

Check the oil level through the inspection glass (5).

Fill up the vacuum pump oil no higher than the MAX marking.

We recommend filling up to a level between the MIN and MAX markings.

The suction strainer is re-mounted in reverse order.

12

34

5




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 indicated 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.




Checking the settings on the heater (optional) If necessary the desired fluid temperature can now be set.

For this, the upper cover of the heater must be opened with appropriate equipment and the desired operating temperature set. (The working temperature is preset to 55°C; if 80°C is exceeded, then the safety thermostat will shut the device off.)

(A) Fluid temperature 55°C

(B) Safety thermostat 80°C

Filling the condensate separator

Prior to start up, fill the condensate separator with 1.5 liters of vacuum pump oil (VE101), as described on page 63.

FluidAqua Mobil - FAM 10/15-P Starting up the FAM



Starting up the FAM

NOTICE

Connection IN / OUT closed

The unit 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.

Switching on the FAM

Move main switch to the "ON" position and wait until the "Fault" lamp lights up briefly (lamp test) and this message: appears on the display.

Ready for operation

--> Press start

Press the key. Now the system starts with the starting phase.

FluidAqua operating

Starting

1. Vacuum pump starts,

2. Inlet valve opens and the vacuum chamber is filled.

3. When the vacuum chamber is filled to filling level 02, the evacuation pump is started up and the starting period is finished.

4. Automatic mode is active:

FluidAqua operating

Automatic mode

Now regulate the vacuum pressure with the throttle valve on the right of the vacuum gauge, depending on the operating viscosity.

Operating viscosity Pressure setting (absolute pressure)

50 mm2/s hydraulic oil 300 mbar / 30 kPa

300 mm2/s lubrication oil 400 mbar / 40 kPa

50 mm2/s ester oil 400 mbar / 40 kPa

Some oils begin to foam intensively when they enter the vacuum chamber. This can especially be the case when the water content is very high, but also when the oil is old or high viscosity media are used. If too much foam is caused, it is drawn in by the vacuum pump.

In this case, for example, reduce the vacuum from 300mbar to 400mbar.

FluidAqua Mobil - FAM 10/15-P Starting up the FAM



Draining the filterhousing

WARNING Hot fluid

Risk of burns

► Note that hot fluid may exit during draining.

The fluid filter is to be bled through the air-vent plug until fluid emerges. Using an Allen wrench carefully open the air-vent plug in the cover.

Shut off FAM

Press the key. Now the system starts the run-down phase:

FluidAqua operating

Run-down

1. The inlet valve closes

2. The vacuum pump is switched off

3. The filter-pump unit runs until the vacuum chamber is emptied.

Wait until the message appears on the display. Now move the main switch to the position "0". The system is now switched off.

Ready for operation

--> Press start

FluidAqua Mobil - FAM 10/15-P Operating the FAM



Operating the FAM

Except for the regulation of the vacuum pressure, each function is assigned to a key or a key combination on the control panel. The functions on the upper part of the keys (or those on the keys with only one assignment) can be triggered directly by pressing the respective key. To select the function on the lower part of the keys

(double allocation of keys), you must press beforehand.

The key assignments and the descriptions of the Main and Manual Menus are described below.

Main Menu

Function key Function

Start FAM. Start and transition in Automatic mode.

Stop FAM (run-down and evacuation of the vacuum chamber)

Acknowledging all rectified malfunctions.

Button for special functions (depending on version)

+

Select German language (or other languages depending on version).

+

Select English language (or other languages depending on version).

Text line 1

Text line 2




Manual menu 1

In order to access Manual Menu 1 from the Main Menu, press the following keys in succession.

/

The key assignment in the Manual Menu 1 is as follows:

Evacuation pump off / on

Vacuum pump off / on

3/2 directional valve close / open

Key Key assignment in Manual Menu 1

Function

Manual menu 2 Switches in the Manual Menu 2

"E-Pump off" Switches evacuation pump off

"E-Pump on" Switches evacuation pump on

(Press the buttons one after the other)

"V-pump off" Switches vacuum pump off

"V pump on" Switches vacuum pump on


„Valve close“ Closes the 3/2-directional control valve.

"Valve open“ Opens the 3/2 directional valve.


Exit With this key combination you can exit the Manual Menu

This menu also switches itself off automatically after 15 minutes.




Manual Menu 2

Press this key to change from Manual Menu 1 to Manual Menu 2:

The key assignment in the Manual Menu 1 is as follows:

Feed pump filter unit on / off

Key Key assignment in Manual Menu 1

Function

"Feed pump-filter unit off"

Switches the Feed pump-filter unit off

"Feed pump-filter unit on"

Switches the Feed pump-filter unit on


Back -> Manual Menu 1

Pressing these keys in succession allows you to exit Manual Menu 2 to go back to Manual Menu 1

Back ->

Exit

Pressing these keys in succession allows you to exit Manual Menu 2 to go back to the Main Menu

The menu for manual operation switches itself off automatically after 15 minutes.

FluidAqua Mobil - FAM 10/15-P Troubleshooting



Troubleshooting

Error message Cause Remedy (also see following detailed description)

Vacuum chamber overfilled

Maximum filling level 03 in the vacuum chamber exceeded.

Empty vacuum chamber and restart FAM 10.

Level switch 02/03 Level switch defective Check sensor and replace if necessary

Level switch 01/02 Level switch defective Check sensor and replace if necessary

Filling pos. V-Pump Min Insufficient oil in the vacuum pump.

Top up the oil until the fill level between min. and max. on the inspection glass is reached.

Filling pos. V-Pump Max.

Too much oil in vacuum pump

Drain oil so that the level is in between max and min

Replacing fluid filters Maximum differential pressure at the filter reached

Changing the Filter Element

Float switch Oil pan of the FAM filled Empty oil pan, check FAM 10 for leakage

E/B/V pump motor protection

Electric motor of the evacuation or feed or vacuum pump overloaded

Switch on the motor protection in the E controller, check operating viscosity

Incorrect phase sequence

Engines have incorrect direction of rotation

Rotate two phase wire on power cord 180°.

Dry running E-pump Vacuum chamber is being filled too slowly, flow into vacuum chamber is smaller than flow rate of the evacuation pump.

Clean the suction screen in front of the inlet valve, check the viscosity of the operating medium and the cross-section of the suction hose length, check the filling pump, check the dirt indicator of the fluid filter

Outlet clogged No operating fluid is pumped out of the FAM 10

Check shut-off devices in return line, check 3/2 valve

Inlet clogged No operating fluid is pumped into the FAM 10

check shut-off devices in suction line, check pump-filter unit

Plug FCU missing The FCU operating mode Connect plug or change




Error message Cause Remedy (also see following detailed description)

was selected without connecting the Sub D plug of the FCU.

operating mode.

Heater fault (only with option heater)

Oil too hot due to interruption of oil flow or faulty thermostat.

Reset the safety thermometer. Remove the cover of the heater to do so. Clean the suction screen, possibly shortening the length of the suction hose.

No parameter block Setup settings of the TD200 deleted.

Reenter setup values.

(Please contact our Technical Sales Office. For contact information, see the chapter "Foreword")

Electrical fuses Automatic safety devices have been installed into the control cabinet for the security of the operating voltage transformer.

Fuse

F1 The primary side of the transformer has 2A 400V

F2 The primary side of the transformer has 2A 400V

F3 The secondary side of the transformer has 3A 250V

F4 The secondary side of the transformer (control current circuit) has 1A 250V

F5 The secondary side of the transformer (control current circuit) has 1A 250V

F6 Contamination Sensor Display CSD (Optional)

F7 Contamination Sensor CS (Optional)




Vacuum chamber overfilled

Ste

p

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?

->a. Yes -> proceed to Step 5. 4.

->b. No -> proceed to Step 6.

5. Excessive foaming -> vacuum in the vacuum chamber too high – reduce vacuum (e.g. from 300 mbar(abs) -> 400 mbar(abs))

6. Check the evacuation pump for proper functioning

7. The failure is repaired.




Level switch 01/02(02/03)

Ste

p

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

->a. Switching points are available -> proceed to Step 5. 4.

->b. Switching points not available -> proceed to Step 6.

5. Inspect the plug and the cable to and in the control cabinet for the PLC. Functioning?

-> proceed to Step 7.

6. Replace level switch

->a. Function available -> proceed to Step 8. 7.

->b. Function not available -> proceed to Step 9.

8. The PLC is defective.

9. Replace the damaged parts




V-pump fill level min/max

Ste

p

Description

Malfunction:

"Filling level V-pump min/max"

1. Press RESET key

->a. Error message lapsed -> proceed to Step 6. 2.

->b. Error message still illuminated -> proceed to Step 3.

3. Check oil level; fill up or drain oil as necessary

Check level sensor of the vacuum pump and the supply lines

->a. Fault recurs -> proceed to Step 5. 4.

->b. The fault does not recur -> proceed to Step 6.

5. Replace damaged parts





Change fluid filter

Ste

p

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?



11. Check differential pressure switch and supply lines





Float switch

Ste

p

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?



7. Check float switch and supply lines





E/V/R pump motor protection

Ste

p

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.

->a. The fault recurs -> proceed to Step 4. 3.

->b. The failure does not recur -> proceed to Step 8.

4. Measure the current consumption of the engines whose motor protection switch or fuse has tripped.

5. Close switch cabinet door, main switch to "On", start FAM



7. Check the operating viscosity of the medium (only for motor protection switch), perform maintenance work on the vacuum pump





Dry run drain pump

Ste

p

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



6. Pull out mains plug, check mains cable and plug, replacing as necessary


NOTICE

Direction of rotation, electric motor


► After replacing electric motors, check the direction of rotation in manual operation before commissioning.




Dry running E-pump

Ste

p

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 the length of the suction hose

- Check the 2/2-directional solenoid valve at the inlet

3. Suction port in the tank sucks in air:

- Position the suction port lower

- Tank to be cleaned is too small

4. Check the functioning of vacuum pump in manual mode

5. Find and remedy corresponding cause

6. To reset the failure, press the RESET key





Outlet (OUT) clogged

Ste

p

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.


4. Malfunction reappears after ~ 4 minutes?



6. Check the pressure relief valve of the evacuation pump for proper functioning.





Inlet (IN) clogged

Ste

p

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


5. Malfunction reappears after ~ 4 minutes?



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





FCU plug missing (only in conjunction with accessory FCU)

Ste

p

Description

1. Fault: "FCU plug missing"

2. Cause: Connection cable to the FluidControl Unit FCU is not connected.

3. Establish the connection with a connection cable


5. Fault appears again?



7. Check connection cable and plug; replace if necessary

8. Fault appears again?







Reset safety thermostat on the heater

The safety thermostat is triggered when the flow of oil through the heater is too low or if the thermostat is damaged.

After the fault has been remedied, the safety thermostat can be reset by pressing the green key (C) in the head. To protect yourself from burns, wait until the heater has cooled down before doing so.

FluidAqua Mobil - FAM 10/15-P Performing maintenance



Performing maintenance

The safety of all persons coming into contact with the FAM and the availability of the unit for use are extremely dependent on service and maintenance.

Routine service and maintenance work is described in the documentation included:

Regular visual inspection of all hoses and conduits for leakage.

Regular visual inspection of the electrical apparatus for possible damage to lines, plugs, sensors or cables and/or devices in the control cabinet.

Regular visual inspections of filling level, vacuum pump

Before carrying out any maintenance work the FAM must be shut down safely. This means:

1. Main switch in position "0",

2. Power cord disconnected.

3. Mains cable wound around cable drum apparatus present on the FAM. (This last as a protection against switching back on again!)




Maintenance Intervals

The inspection and maintenance work listed here are necessary conditions for ensuring both long service life and error-free operation of the unit.

In addition, you will find further information in the operating manuals published by the manufacturers of the components which are supplied with the unit.

See

pag

e

24 h

ou

rs /

dai

ly

500

ho

urs

/

mo

nth

ly

3000

ho

urs

/

ever

y si

x m

on

ths

6000

ho

urs

/

ann

ual

ly

FAM

Visual check for leakage - X

Check threaded joints for fixed seat, tightening them as needed.

- X

Inspection of the measurement technics / Pressure sensor in the vacuum column / Differential pressure manometer at the fluid filter / AquaSensor at the IN port / ETS at the vacuum column (optional)

- X

Fault indicator lamp function X

Change the air filter (if this has not been required earlier)

X

Clean suction filter / X

Rotary Valve Pump Vacuum Pump

Check oil level - X

Replace oil, oil filter and air de-oiling element

59 X1)

Cleaning and inspecting the ventilator hood

60 X

Change the active carbon filter cartridge

61 X

Emptying/filling pump

Cleaning and inspecting the ventilator hood

- X




See

pag

e

24 h

ou

rs /

dai

ly

500

ho

urs

/

mo

nth

ly

3000

ho

urs

/ ev

ery

six

mo

nth

s

6000

ho

urs

/ an

nu

ally

Fluid filter (OLF 5)

Change the filter element (If this has not been required earlier)

65 X

Condensate separator

Check the fill level on the condensate separator

63 X

Change the filter element on the condensate separator

62 X

Electrics

Check cable conduits for damage, replacing as necessary

- X

Measure the engine power consumption of all engines and compare the values with the type label

- X

Checking the AquaSensor - X

Perform electrical safety inspection in accordance with DIN VDE 0702 and/or corresponding national regulation.

- X

Measure power consumption of the heater and compare values with type label (applies only to versions with integrated heater)

- X

Function test

Check and clean the level sensor in the vacuum column.

X

Float switch oil pan - malfunction message and E-STOP function

X

1) The first oil change must take place after 100 operating hours.

Completely replace all of the hoses after 5 years.

The pictures and illustrations in the descriptions are examples. They do not represent all of the different product variants.




Changing the air filter

Replace the air filter (1) every six months.

Change the air filter (1) more frequently if you operate the FAM in a very dusty/humid environment.

Unscrew the air filter (1) by hand.

Screw in the new air filter (1) by hand and tighten it only by hand.

Vacuum pump

Changing oil and oil filter

The first oil change must take place after 100 operating hours. Afterwards, the interval increases to ~ 3000 hours or twice per year.

The vacuum pump must be at operating state temperature when the oil is changed:

Put the FAM into operation for 10 minutes.

Switch off the FAM at the main switch.

Wait until the pressure in the vacuum column has reached atmospheric pressure (~ 1000 mbar absolute).

To perform these tasks, you will need the following tools and equipment:

Compressor oil VE101 (for part-no., see replacement parts list)

Maintenance set, comprising oil filter, air deoiling element, ventilation cover seal (for part-no., see replacement parts list).

Fork wrenches SW 27 / SW 32

To change the oil, proceed as follows:

1. Put a suitable container in place to catch the used oil.

2. Open the oil drain (c) and allow the used oil to drain into the container. Dispose of the used oil properly.

3. Close the screw plug when the flow of oil diminishes. Let the pump run again briefly for a few seconds,

4. Open the plug screw once again and drain off the remaining oil.

5. Screw in the screw plug and tighten it firmly.

6. Remove the oil filter and dispose of it properly.

7. Install the new oil filter.

8. Fill in new oil through the oil filling screw plug (a) until the MAX marking (d) has been reached.




Replacing the Air De-oiling Element

Oil mist or increased electricity consumption by the drive engine (response of the engine protection switch) are signs of a soiled air de-oiling element.

To replace the air de-oiling element, proceed as follows:

1. Remove the ventilation cover (i) from the oil separator (g).

2. Undo the screw in the middle of the filter spring, but do not remove this.

3. Press the filter spring down and rotate it out of the depression.

4. Remove the filter spring from the oil separator (g).

5. Pull the air de-oiling element out of the oil separator (g).

6. Make sure that the new air deoiling element is provided with a new O-ring.

7. Install the air de-oiling element in such a way that the opening is situated correctly in the holder in the oil separator (g).

8. Ensure that the tip of the screw in the middle of the filter spring protrudes ~ 2 – 5 thread turns out of the filter spring.

9. Install the filter spring in such a way that the ends are secured against slipping by lugs in the receptacles in the oil separator (g) and the tip of the screw engages in the depression of the air de-oiling element.

10. Tighten the screw in the filter spring until the head of the screw impacts against the spring steel sheet.

11. Make sure that the seal under the ventilation cover is clean and undamaged. Replace the seal if necessary.

12. Fasten the ventilation cover (i) with seal and hexagon-head screws to the oil separator (g).

The air de-oiling element becomes saturated with oil during operation. A slight lowering of the oil filling level after the air de-oiling element has been replaced is therefore quite normal.




Change the active carbon filter cartridge

The active carbon filter cartridge absorbs oil vapors, odors and flavoring agents from the exhaust air. The weight of the active carbon filter can be used to determine when the filter is saturated.

Check the weight of the active carbon filter as soon as you notice a deterioration in the quality of the exhaust air.

If the active carbon filter reaches a weight of 1225 g, replace the filter cartridge immediately.

To replace the active carbon filter cartridge, proceed as follows:

1. Turn the active carbon filter cartridge by hand in a counterclockwise direction and remove it from the port on the rotary vane vacuum pump.

2. Place the new active carbon filter cartridge onto the port of the rotary vane vacuum pump and turn it by hand in a clockwise direction.

3. Gently tighten the active carbon filter cartridge by hand.





Changing the filter element on the condensate separator

The condensate separator is installed to support the process of odor neutralization.

The replacement interval for the filter element is therefore linked to the replacement of the active carbon filter cartridge.

The condensate separator comprises the following parts:

Item Name

1 Reservoir

2 Filter element

3 Seals

4 Demister

5 Seals

6 Inspection glass




To replace the filter element on the condensate separator, proceed as follows:

1. Open the profile clamp and remove the base in a downwards direction.

The base contains ~ 1.5 liters of vacuum pump oil (VE101).

2. Remove the used filter element (2).

3. Insert the new filter element (2).

4. Check the two seals (3) for damage, and replace them if necessary.

5. Check the fill level on the inspection glass. If necessary, fill up the condensate separator, as described on page 63.

6. Insert the base upwards into the upper part of the condensate separator and close the profile clamp.

Checking the fill level on the condensate separator

Check the fill level of the vacuum pump oil (VE101) on the inspection glass of the condensate separator.

During downtime (i.e. when the FAM is not in operation), the fill level must be in the middle of the inspection glass.

If necessary, fill up the condensate separator, as described on page 63.

Filling the condensate separator

To fill up the condensate separator, proceed as follows:

1. Open the profile clamp and remove the base in a downwards direction.

The base contains ~ 1.5 liters of vacuum pump oil (VE101).

2. Pour new vacuum pump oil (VE101) into the base via the tube.

3. Check the fill level. At the very least, this should be in the middle of the inspection glass.

4. Insert the base upwards into the upper part of the condensate separator and close the profile clamp.




Cleaning the suction strainer

NOTICE

Operation without a suction screen

The pump will be destroyed

► The FCU may not be operated without the suction strainer.

► Clean the suction screen 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.

Clean the suction screen at regular intervals.

To disassembly/install the suction screen, proceed as follows:

1. Unscrew the screw plug (1) counterclockwise with an open-jaw wrench.

2. Remove strainer insert (3) and clean it.

3. Clean the strainer insert, flush it out and then blow-flush it using compressed air.

3. Check strainer insert (3) and the seal ring (2) on the screw plug for damage and replace if necessary.

4. Insert the strainer insert (3).

5. Manually screw in the screw plug (1) clockwise.

Tighten the screw plug (1) with a open-jaw wrench.

6. Check the suction strainer fitting for leaks after commissioning.

12

3




Replacing the filter element in the fluid filter

As soon as the error message "change fluid filter" appears on the display the filter should be taken out of the housing and be replaced by a new one.

The contaminated filter must to be disposed of according to the local regulations as hazardous waste.

To change the filter element, proceed as follows:

1. Switch off the system and close the locking devices at the inlet and outlet ports

Make sure that the unit cannot be inadvertently switched back on during maintenance work.

2. Put a suitable container (1) in place to catch escaping operating medium.

Depressurize the filter housing.

Carefully open the drain plug (2) on the filter bowl and empty the filter housing completely using the drain screw (6mm) on the bottom of the filter housing.

The volume is ~ 2 liters.

After draining, replace the drain plug on the filter bowl.

3. Undo the tensioning clamp (1) on the filter housing and then remove the housing by moving it downwards (2).

Use a 6 mm Allen wrench (1).




4. Pull the filter bowl including filter element downwards.

5. Remove (2) the filter element from the filter bowl by turning slightly (1).




6. Clean the inside of the filter bowl of dirt and deposits

7. Check the O-ring on the filter bowl for damage.

Replace it if necessary.

Moisten the O-ring on the filter bowl with the operating medium.

8. Moisten the O-rings on the new filter element with the operating medium.




9. Turning it slightly, press the new filter element down into the mount on the filter bowl.

10. Push the filter bowl with the filter element up into the mount on the filter head.




11. Push the tensioning clamp (1) up around the filter bowl over the bead on the filter bowl / filter head.

Tighten the tensioning clamp with a 6 mm Allen wrench in a clockwise direction.

The tightening torque is 5 Nm.

12. Check that the drain plug on the filter bowl is secure.

13. The filter element change is now complete.

After commissioning, check the filtration unit for leaks.

Checking the settings on the heater (optional)

Under normal operating conditions the heater element is maintenance-free.

FluidAqua Mobil - FAM 10/15-P Spare Parts



Spare Parts

FAM - 10

Quantity

Designation Part no.

1 Ventilation filter 0160 MU 003 M 1265765

1 Drain pump incl. motor *

1 Suction strainer 1" assy., consisting of:

0635624

1x strainer insert, 250µm 6016797

1x sealing ring 6033969

1 Vacuum pressure gauge 63 9989

1 3/2-directional control valve 6027956

1 Pressure hose, Length = 5 m 6031686

1 Suction hose, Length = 5 m 6031685

1 Level sensor (vacuum chamber) 120 4801

*) available on request

Fluid filter (OLF 5/10)

Quantity


1 Filter pumps unit OLF 5/10 *

1 Filter element, filtration rating 2 µm N5DM002





FluidAqua Mobil - FAM 10/15-P Spare Parts



Rotary Vane Vacuum Pump

Quantity


1 Rotary Vane Vacuum Pump *

1 Service kit vacuum pump consisting of exhaust filter and seals

6014161

1 Vacuum pump oil VE101, 1 liter 6018128

1 Vacuum pump oil VE101, 5 liter 6018129

1 Active carbon filter cartridge 6078452



Quantity


1 Filter element 6078934

FluidAqua Mobil - FAM 10/15-P Contact / Service



Contact / Service

For product information, technical support or if you have comments or suggestions concerning this manual, please contact:

HYDAC Filter Systems GmbH

Telephone: ++49 (0) 6897 509 1174

Fax: ++49 (0) 6897 509 846


Regular inspection and maintenance work is indispensable for ensuring trouble-free operation and long service life for your FluidAqua Mobil.

Regular inspection and maintenance work is indispensable for ensuring trouble-free operation and long service life for your FluidAqua Mobil. Our HYDAC Servicenter offers you these tasks within agreed-upon time frames and at fixed prices.

HYDAC Service GmbH Rehgrabenstrasse 3 66128 Saarbrücken -Dudweiler

Germany

Telephone: ++49 (0)681 509 883

Fax: ++49 (0)681 509 324


FluidAqua Mobil - FAM 10/15-P Storing the FAM/Taking it out of Operation



Storing the FAM/Taking it out of Operation

Drain the unit completely, including all of its components, the same way as is done before putting it into storage.

Pull out the power plug and securely fasten the hoses and power cord to the unit.

Store the unit in a clean, dry (non-condensing) space.

Observe the storage temperature range of: –20C … 60C

Disposing of the FAM

When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil in the unit, components covered with oil and electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

Type label

The type plate is located on the front panel. Copy the data from the type label into the following, in order to have at hand when required.

FluidAqua Mobil - FAM 10/15-P Technical data



Technical data

Refer to the type label for specific data of the unit.

FAM10/10 FAM10/15

Filter size OLF5 OLF5

Filter Element N5DMxxx N5DMxxx

Dirt absorption capacity as per ISO 4572

200 g 200 g

Clogging indicator VM 2 C.0 VM 2 C.0

Pump types Vane pump (feed pump), gear pump (drain pump

Vane pump (feed pump), gear pump (drain pump

Flow rate in l/min at 50Hz 10 15

Operating pressure in bar 3.5 3.5

Viscosity range in mm²/s 15 - 800 15 - 800

Electrical power consumption

1500 W without heater 4400 W with heater

2000 W without heater 4900 W with heater

Length of electronic cable in m

10 10

IP class IP 54 IP 54

Length of hoses in m 5 5

Hoses, material NBR NBR

Connection Inlet/outlet G 1 / G 1/2 G 1 / G 1/2

Material of seals EPDM peroxide cross-linked / PTFE

EPDM peroxide cross-linked / PTFE

Fluid temperature in°C 10 - 80 10 - 80

Ambient temperature in °C 10 - 40 10 - 40

Typical dewatering speed l/h

0.8 l/h (without heater at 40°C)

1 l/h (without heater at 40°C)

Minimum water content in ppm

< 100 < 100

FluidAqua Mobil - FAM 10/15-P Model code



Model code

FAM - 10 - M - 1 - A/1900 - 060 - DM - 02 - S - Z - 1Product FAM = FluidAqua Mobil Filter Size 10 = 10 l/min, 50 Hz / 12 l/min, 60 Hz 10/15 = 15 l/min, 50 Hz / 18 l/min, 60 Hz Operating fluid P = Aviation phosphoric acid esters e.g.

Skydrol® or Hyjet®

checked with Skydrol®*

Mechanical type 1 = stationary 2 = mobile Voltage / Frequency / Power supply a = 400 V, 50 Hz, 3 Ph+PE b = 415 V, 50 Hz, 3 Ph+PE C = 200 V, 50 Hz, 3 Ph+PE D = 200 V, 60 Hz, 3 Ph+PE E = 220 V, 60 Hz, 3 Ph+PE F = 230 V, 60 Hz, 3 Ph+PE G = 380 V, 60 Hz, 3 Ph+PE H = 440 V, 60 Hz, 3 Ph+PE J = 230 V, 50 Hz, 3 Ph+PE K = 480 V, 60 Hz, 3 Ph+PE L = 220 V, 50 Hz, 3 Ph+PE M = 230 V, 50 Hz, 1 Ph+PE N = 575 V, 60 Hz, 3 Ph+PE O = 460 V, 60 Hz, 3 Ph+PE X = X = other voltage Filter size fluid filter 05 = OLF-5 Filter material of element DM = Dimicron® Z = without filter element Filtration rating 02 = 2 µm 05 = 5 µm 10 = 10 µm 20 = 20 µm Z = without filter element Type of vacuum pump S = Standard – rotary vane vacuum pump

Instrumentation Z = Ohne A = AquaSensor (AS) C = ContaminationSensor (CS) AC = AquaSensor + ContaminationSensor (CS only with measured value

display)

Modification number 1 Supplementary details Without details = standard

FluidAqua Mobil - FAM 10/15-P EU Declaration of Conformity



EU Declaration of Conformity

HYDAC FILTER SYSTEMS GMBH

Postfach 12 51 66273 Sulzbach / Saar Germany

Industriegebiet 66280 Sulzbach / Saar Germany

Phone: ++49 (0) 6897 509 01

Internet: www.hydac.com

EC declaration of conformity FS / 32 / 09 No.

We hereby declare that the following designated product, on the basis of its design and construction, and in the version which we have brought to market, corresponds to the fundamental safety and health requirements contained in the standards listed below.

Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity.

Name FluidAqua Mobil

Type FAM - series

Part no. -

Serial no. -

EU Machinery Directive 2006/42/EC

EU Electrical Equipment Regulations 2006/95/EC

EU Directive on Electromagnetic Compatibility 2004/108/EC

Applied standards EN 12100-1/2

2009-12-22 Dr. Andreas Schunk Date Name (CE-authorized person)

Executive director: Authorized person for documentation:

Mathias Dieter, Dipl.Kfm. Wolfgang Haering Mr. Günter Harge

Registered seat of company: 66280 Sulzbach / Saar - Germany c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach 7 Saar

Registry Court: Saarbrücken, HRB 17216 Telephone: ++49 (0) 6897 509 1511

Value added tax identification number : DE 815001609 Fax: ++49 (0) 6897 509 1394

Tax number : 040/110/50773 E-mail: [email protected]

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HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 846 Technical Department Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com E-Mail: [email protected]

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