FAM 10 FAM 10/15 - Start: HYDAC · FAM 10 FAM 10/15 FluidAqua Mobil ... HYDAC FILTER SYSTEMS GMBH ... this manual, comprising the most important instructions for its operation and

FAM 10 FAM 10/15

FluidAqua Mobil

Operating and Maintenance Instructions

English (translation of original operating instructions)

Document No.: 3843186 (Valid from modification ID ≥ 2 (FAM-10-x-x-x-xx—x-x-x-x-2))

Imprint

FluidAqua Mobil - FAM 10 en(us) Page 2/124

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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: [email protected]

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


© 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.

Content


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Content

Imprint............................................................................................................2

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

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

Preface...........................................................................................................7

Technical Support........................................................................................8

Modifications to the Product ........................................................................8

Warranty ......................................................................................................8

Using the documentation .............................................................................9

Safety information ......................................................................................10

Hazard symbols.........................................................................................10

Signal words and their meaning in the safety information and instructions ................................................................................................11

Structure of the safety information and instructions...................................12

Observe regulatory information .................................................................12

Proper/Designated Use .............................................................................13

Improper Use or Use Deviating from Intended Use ...................................14

Qualifications of personnel / target group ..................................................15

Wear suitable clothing ...............................................................................17

Stoppage in an emergency (EMERGENCY STOP)...................................17

Unpacking the FAM ....................................................................................17

Transporting the FAM.................................................................................18

Fork lift.......................................................................................................18

Crane.........................................................................................................19

Rail / Truck ................................................................................................19

Checking the scope of delivery .................................................................20

FAM Description .........................................................................................21

FAM Versions ............................................................................................21

Technical Specifications ............................................................................22

FAM system components ..........................................................................23

Dimensions..................................................................................................25

Stationary version......................................................................................25

Mobile version ...........................................................................................26

Content


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Hydraulic diagram.......................................................................................27

Function description ..................................................................................29

Possible Applications of the FAM ..............................................................31

Cleaning in Bypass Flow ...........................................................................31

Purifying and transferring by pumping .......................................................31

FAM Set-up and Connection......................................................................32

Setting up the FAM....................................................................................32

Connection overview .................................................................................33

Notes on pipes and hoses .........................................................................34

Connecting the inlet (IN).........................................................................36

Connect outlet (OUT) .............................................................................36

Preparing the Vacuum Pump.....................................................................37

Filling rotary vane vacuum pump ........................................................38

Electrical Connection of the FAM ..............................................................39

Check direction of rotation......................................................................40

Operating Elements on the FAM................................................................41

Starting up the FAM....................................................................................42

Switching on the FAM................................................................................43

Setting the pressure in the vacuum column...............................................44

Shutting off the FAM...................................................................................46

Control Panel Basic (SIMATIC PANEL).....................................................47

Overview of operating modes and abbreviations.......................................48

Overview of menu structure.......................................................................49

Changing / entering values ........................................................................51

Menu 1.......................................................................................................52

Start screen............................................................................................53

RH+P (Relative Humidity + Pressure) ....................................................54

T (Temperature) .....................................................................................55

Selection Contamination (CONT.) ..........................................................56

Operating Mode - OM................................................................................57

Operating modes - Brief overview / Brief description..............................58

Operating mode - Dewater to / Filter to......................................................61

Operating mode - MANU ...........................................................................62

Operating mode - MANU – OPERATOR (MANU1) ................................62

Operating mode - MANU - OPERATOR (MANU2).................................63



Content


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Operating mode - SETTINGS (SET) .........................................................65

Set units .................................................................................................65

Set temperature......................................................................................66

Set pressure...........................................................................................66

Menu 2.......................................................................................................67

Set (repeat testing interval) times...........................................................68

Read operating-hours counter................................................................68

Reset safety thermostat on the heater.......................................................69

Performing maintenance............................................................................70

Function testing of the fault indicator lamp ................................................73

Changing the Air Filter ...............................................................................73

Checking the AquaSensor .........................................................................73

Clean the suction strainer. .........................................................................74

Rotary vane vacuum pump components ...................................................75

Performing an oil change .......................................................................76

Replacing the Air De-oiling Element.......................................................77

Replacing the filter element on the fluid filter .............................................78

Testing the Float Switch in the Oil Pan......................................................83

Checking the settings on the heater (optional) ..........................................83

Error messages / troubleshooting.............................................................84

1. CS+pump switched off. CS fault. Start 10 new attempts with Reset! ........................................................................................................85

2. Flow at FAM inlet has been too low for 5 minutes. Check the FAM inlet. ..................................................................................................86

3. FAM outlet is blocked ............................................................................87

4. Error, float switch of rotary vane vacuum pump at fill level Min. / fill level Overflow........................................................................................88

5. / 6. Error, float switch of vacuum column at fill level Max and/or fill level Overflow........................................................................................89

11. / 12. / 14. / 15. Cable break .................................................................90

16. No defined value from CS....................................................................92

17. No measured value from CS. Check for flow.......................................93

18. / 19. / 20. / 21. / 22. Motor protection switch Qx has tripped................94

23. Oil filter contaminated -> replace oil filter.............................................96

24. Oil tank of rotary vane vacuum pump is empty -> refill oil ...................97

25. Oil tank of rotary vane vacuum pump is too full -> drain oil .................98

26. Heater safety thermostat triggered ......................................................99

27. Fuse F2 has tripped...........................................................................102

Content


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28. Heater fuse has tripped .....................................................................103

29. Check phase sequence .....................................................................105

30. Malfunction CS flow too low...............................................................107

31. Fault, CS device error........................................................................107

32. Dry-running Evacuation Pump...........................................................108

33. Vacuum column overflow -> drain vacuum column and troubleshoot cause ..................................................................................109

34. Oil pan too full -> drain oil pan and seal leak.....................................111

37. Saturation oil >= 90%. Measurement with CS 1xxx not possible! ..................................................................................................112

Spare parts ................................................................................................113

FAM 10 ....................................................................................................113

Fluid filter (OLF 5)....................................................................................113

Vacuum pump .........................................................................................113

Contact/Service.........................................................................................114

Taking the unit out of operation ..............................................................115

Disposing of the unit ................................................................................115

Finding the type label ...............................................................................115

Technical data ...........................................................................................116

Model Code................................................................................................117

EU Declaration of Conformity ..................................................................118

Index ..........................................................................................................119

Preface


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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 obtaining maximum benefit in the applications for which it is designed.

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 GMBHTechnische DokumentationPostfach 12 5166273 Sulzbach / Saar

Germany

We look forward to receiving your input.

“Putting experience into practice”

Preface


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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


Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient.

When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative.

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

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

You will find these under www.hydac.com -> General terms and conditions.

http://www.hydac.com/�

Preface


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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 you 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 is incremented every time the manual is revised or changed.

Chapter description

Page number

Edition date

Document language Documentation no.with index/

file name

Safety information


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Safety information

The unit was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements.

Any residual hazards are indicated by safety information and instructions and are described in the operating instructions.

Observe all safety and warning instructions attached to the unit. They must always be complete and legible.

Do not operate the unit unless all the safety devices are present.

Secure the hazardous areas which may arise between the unit and other equipment.

Maintain the unit inspection intervals prescribed by law.

Document the results in an inspection certificate and keep it until the next inspection.

Hazard symbols

These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons, property or the environment.

Observe these instructions and act with particular caution in such cases.

Pass all safety information and instructions on to other users.

General hazard

Danger due to electrical voltage / current

Exposed electrical components

Danger of electrical shock

Danger due to operating pressure

Safety information


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Risk of burns due to hot surfaces

Substances that are health hazards or irritants

Signal words and their meaning in the safety information and instructions

DANGER DANGER indicates a danger with a high risk and which will lead to death or serious injury if not avoided.

WARNING WARNING indicates a danger with a medium risk and which can lead to death or serious injury if not avoided.

CAUTION CAUTION indicates a danger with a low risk and which can lead to minor injury if not avoided.

NOTICE NOTICE indicates a danger which will lead to damage to property if not avoided.

Safety information


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Structure of the safety information and instructions

All warning instructions in this manual are highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger.

Warning instructions listed before an activity are laid out as follows:

SIGNAL WORD

Type and source of danger

Consequence of the danger

HAZARD SYMBOL

► Measures to avert danger

Observe regulatory information

Observe the following regulatory information and guidelines:

Legal and local regulations for accident prevention.

Legal and local regulations for environmental protection.

Country-specific regulations, organization-specific regulations.

Safety information


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Proper/Designated Use

Use the unit only for the application described in the following.

The FAM is for dewatering, filtering and degassing hydraulic and lubricating oils. In addition, it removes free water, emulsified water and a large percentage of the water found in solution.

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

observing all instructions contained in the instruction manual.

performing inspection and maintenance work.

Depending on the version (see model code), the FAM may be used only for the following media:

FFAAMM--xxxx--MM--……

FFAAMM--xxxx--II--……

MMiinneerraall ooiillss aacccc.. ttoo DDIINN 5500552244

GGeeaarr ooiillss aacccc.. ttoo DDIINN 5511551177 aanndd DDIINN 5511552244

OOtthheerr hhyyddrraauulliicc aanndd lluubbrriiccaattiioonn ooiillss wwhhiicchh rreeqquuiirree oorr aarree ccoommppaattiibbllee wwiitthh NNBBRR sseeaallss

FFAAMM--xxxx--BB--…… ssyynntthheettiicc eesstteerr ((HHEEEESS)) DDIINN 5511552244//22

VVeeggeettaabbllee ooiillss ((HHEETTGG,, HHTTGG))

HHyyddrraauulliicc aanndd lluubbrriiccaattiioonn ooiillss wwhhiicchh rreeqquuiirree oorr aarree ccoommppaattiibbllee wwiitthh VViittoonn sseeaallss..

FFAAMM--xxxx--XX--…… HHFFDD ooppeerraattiinngg fflluuiiddss ((nnoott ffoorr ppuurree pphhoosspphhaattee eesstteerrss wwhhiicchh rreeqquuiirree EEPPDDMM sseeaallss))..

Safety information


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Improper Use or Use Deviating from Intended Use

DANGER

Danger due to unanticipated use of the unit

Bodily injury and damage to property will result when operated improperly.

► Never operate the unit in potentially explosive atmospheres.

► The unit is only to be used with permissible media.

NOTICE

Impermissible operating conditions

The unit will be damaged

► The unit may be used only in connection with the media mentioned below.

Any use extending beyond or deviating therefrom shall not be considered intended use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use. The user alone, shall assume any and all associated risk

Improper use may result in hazards and/or will damage the unit. Examples of improper use:

Operation in potentially explosive atmospheres.

Operation with a non-approved medium.

Operation under non-approved operational conditions.

Operation when the safety devices are defective.

Modifications to the power unit made by the user or purchaser.

Inadequate monitoring of parts that are subject to wear and tear

Improperly performed repair work.

Safety information


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Qualifications of personnel / target group

Persons who work on the power unit must be aware of the associated hazards when using the power unit.

Operating and specialist personnel must have read and understood the operating instructions, in particular the safety information and instructions, and applicable regulations before beginning work.

The operating instructions and applicable regulations are to be kept so they are accessible for operating and specialist personnel.

These operating instructions are intended for:

Operating personnel: such persons have been instructed in power unit operation and are aware of potential hazards due to improper use.

Specialist personnel: such persons with corresponding specialist training and several years work experience. They are able to assess and perform the work assigned to them, they are also able to recognize potential hazards.

Safety information


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Activity Person Knowledge

Transport / storage Forwarding agent

Specialist personnel

Proof of knowledge of cargo securing instructions

Safe handling/operation of hoisting and lifting equipment

Hydraulic / electrical installation,

first commissioning,

maintenance,

troubleshooting,

repair,

decommissioning,

disassembly


Safe handling/use of tools

Fitting and connection of hydraulic lines and connections

Fitting and connection of electrical lines, electrical machinery, sockets, etc.

Checking the phase sequence

Product-specific knowledge

Operation

operations control


Product-specific knowledge

Knowledge about how to handle operating media.

Knowledge about contamination due to solids and water

Disposal Specialist personnel

Proper and environmentally-friendly disposal of materials and substances

Decontamination of contaminants

Knowledge about reuse

Unpacking the FAM


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Wear suitable clothing

Loosely worn clothing increases the danger of getting caught or wound up in rotating parts and the danger of getting snagged on projecting parts. You can be severely injured or killed.

Wear close-fitting clothing.

Do not wear any rings, chains or any other jewelry.

Wear work safety shoes.

Stoppage in an emergency (EMERGENCY STOP)

In the event of an emergency, turn the main switch by 90° in a counter-clockwise direction to shut down the entire unit. The entire unit downstream of this switch is voltage-free and depressurized.

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

Unpacking the FAM

Before delivery, the FAM is inspected for leaks and proper functioning at the factory, then carefully packed for shipment.

When receiving and unpacking the unit, check it for damage in transit. Dispose of the packaging material in an environmentally-friendly manner.

Transporting the FAM


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CAUTION

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

Danger of bodily injury

► Use at least 2 persons to shift the FAM.

NOTICE

Using components for pushing/pulling

The unit will be damaged.

► Never use the components to push or pull the unit.

► Use only the grips provided for shifting.

Drain the unit completely before transport. Seal off the inlets and/or outlets.

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 steering rollers.

Once the FAM is in its new position, actuate the hand brake on the steering rollers.

Fork lift

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



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Crane

The unit has four eyelets on the frame for fastening lifting accessories

NOTICE

Unsuitable lifting accessories

The unit will be damaged / Components will be damaged / destroyed

► Use only suitable lifting accessories to raise or lash the unit.

► Take care to ensure that the lifting accessories do not cause any pressures to be brought to bear against the components on the unit.

Rail / Truck

For transport by rail or truck, supports must be placed under the mobile unit so that the rollers are subjected to no load pressure.

The unit is to be secured with suitable belts.

Checking the scope of delivery


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Checking the scope of delivery

Upon receiving the FAM check it for any damage in transit. The FAM may not be set up and installed unless it is in perfect order. Any damage in transit is to be reported to the forwarding agent or the department in charge immediately; the unit may not be commissioned until this damage is properly remedied.

The following items are supplied:

Qty Designation

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

1

Technical Documentation, const. of:

- Operating and maintenance instructions - Electrical wiring diagram - Test protocol - Manufacturer's declaration / Declaration of conformity

- Vacuum pump oil, 1 liter

1 Four-sided hollow socket key, 6 mm

FAM Description


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FAM Description

The FluidAqua Mobil was developed for the dewatering, filtration and degassing of hydraulic and lubricating oils. It removes free water, emulsified water and a large percentage of the water to be found in solution. The integrated fluid filter ensures an efficient separation of solid particles.

The drying and degassing of the medium is achieved by the neg. pressure in the vacuum column.

FAM Versions

Stationary (FAM-xx-1-…) Mobile (FAM-xx-2-…)

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

- 2 casters, 2 bock rolls

- Suction hose, length 5 m

- Return hose, length = 5 m

- Connection cable, electric, length 10 m

FAM Description


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Technical Specifications

The FAM is able to dewater authorized fluids down to a water content of less than 100 ppm and transformer oils down to less than 10 ppm.

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

Tank volume in liters Filter Size

< 1,500 FAM 5

1,000 – 7,000 FAM10/15

7,000 – 15,000 FAM 25

15,000 – 25,000 FAM 45

25,000 – 35,000 FAM 60

35,000 – 45,000 FAM 75

> 45,000 FAM 95

Generally speaking, however, it must be taken into account that the design depends on the application, the fluid and the ambient temperature, the fluid amount and the water input into the system.

These exercise a great influence over the dewatering performance. It is for that reason that the specifications can serve only as a starting point.

The dewatering performance is dependent upon:

Dewatering performance

Water content

Fluid temperature

Detergent additives

Volumetric flow of the FAM

FAM Description


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FAM system components

FAM Description


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Item Designation

1 Suction strainer

2 AquaSensor AS 1000

3 Filling pump

4 Check valve

5 Vacuum column

6 Heater (Option)

7 Evacuation pump

8 Check valve at the outlet

9 Fluid filter for the separation of solid particles

11 Fluid filter drainage

13 Air filter and dryer

14 Throttle valve for vacuum setting

15 Pressure sensor for vacuum measurement

16 Vacuum pump 19 Vacuum column level sensor

24 Float switch, oil pan

25 Vacuum column drainage

27 Temperature sensor (optional for heater)

28 Vacuum pump drainage

29 Level sensor for vacuum pump

30 Ball valve at the inlet (IN)

40 Switch cabinet

41 Main switch / E-STOP

42 Fault indicator lamp

43 Control panel, SIEMENS

44 SensorMonitoring Unit SMU1200 (optional)

45 Cable holder

46 Hose retainer

51 Caster with immobilization brake

52 Rigid caster

55 Sliding grip

Dimensions


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Dimensions

The different versions of the FAM series have the following illustrated dimensions.

Stationary version

Dimensions


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Mobile version

Hydraulic diagram


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Hydraulic diagram

Hydraulic diagram


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Item Designation

1 Suction strainer

2 AquaSensor AS 1000

3 Filling pump

4 Check valve

5 Vacuum column

6 Heater (Option)

7 Evacuation pump

8 Check valve at the outlet

9 Fluid filter for the separation of solid particles

10 Differential pressure switch for filter monitoring

11 Fluid filter drainage

13 Air filter and dryer

14 Throttle valve for vacuum setting

15 Pressure sensor for vacuum measurement

16 Vacuum pump

19 Vacuum column level sensor

20 Pump to the ContaminationSensor CS1000 (optional)

21 ContaminationSensor CS1000 (Optional)

22 Pressure relief valve CS1000 (optional)

23 Pressure relief valve CS1000 (optional)

24 Float switch, oil pan

25 Vacuum column drainage

26 Return valve

27 Temperature sensor (optional for heater)

28 Vacuum pump drainage

29 Level sensor for vacuum pump

30 Ball valve at the inlet (IN)

Hydraulic diagram


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Function description

AS

M

M

M

CS

M

OUT IN

16

29

2827*

6*

5

13

14

15

25

7

24

26

3

2

1

20*

21*

23*

22*

* Option

Option Contamination Sensor

9

4

8 30

19

19

19

10

11

Connect up the power unit in bypass flow with the tank that is to be cleaned.

After the unit is switched on, the filling pump (3) begins to convey the fluid from the tank through the suction filter (1) into the vacuum column (5). The vacuum pump (16) sets up the negative pressure in the vacuum column (5) required for dewatering and degassing.

The negative pressure is regulated by the negative pressure setting (14), continuously measured at the negative pressure sensor (15) and displayed on the SIMATIC operating panel in the control cabinet.

The fluid percolates downwards in the vacuum column over a special tower packing and collects in the lower area. After reaching the Max level [02], the evacuation pump (7) switches on and now permanently conveys the fluid out through the fine filter (9) to the outlet.

As a result of the greater volume flow of the evacuation pump, the filling level in the vacuum column drops down to the Min level [01]. Once this is reached, the return valve (2/2 -way solenoid valve) (26) opens and a partial volume flow is returned into the vacuum column. The return valve (2/2-way solenoid valve) (26) closes once again after the Max level [02] has been reached.

Air is drawn in through the air filter (13) as a result of the negative pressure in the vacuum column (5). In the counter flow, this air absorbs the moisture of the fluid and is then drawn off by the vacuum pump (16) through an oil mist separator (17).

Hydraulic diagram


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The saturation level of the sucked in fluid is measured continuously by the built-in AquaSensor (2) and displayed on the SIMATIC panel. The saturation level indicates what percent of maximum possible water is dissolved in the oil. A value of 0% would indicate water-free oil and 100% would mean oil that is completely saturated with water. It is possible to use the saturation level to control the power unit.

All of the functions on the SIMATIC panel can be selected, except for the regulation of the vacuum pressure. The electrical control of the Siemens S7 series monitors the functioning of the unit. Malfunction and error messages are displayed in plain text in the correspondingly available national language. All E-STOP messages will lead to a direct switch-off of the unit.

After the FAM is shut down using the control panel, the filling pump and the rotary vane vacuum pump - together with its switching conveyor pump when a CS is present - are also switched off.

Exception: If the heater is switched on, then a cooling phase of 60 seconds will intervene during which the heater is first shut off. Afterwards, all of the pumps will be switched off, except for the evacuation pump.

The evacuation pump runs until the "Min" fill level in the vacuum column is reached. The run-down phase status is shown in the display

If the fill level "Min" in the vacuum column is reached, the power unit will be switched off.

The absorbed water is expelled as water vapor from the rotary vane vacuum pump.

Hydraulic diagram


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Possible Applications of the FAM

Cleaning in Bypass Flow

The FAM is connected with suction and pressure lines to the tank and cleans the medium to be found there in continuous operation.

Purifying and transferring by pumping

The FAM is connected to the contaminated oil tank with the suction hose and pumps the fluid into the tank for the purified oil while cleaning it at the same time.

(A) = Waste oil tank

(B) = Pure oil tank

The fill level of clean-oil tank is to be monitored constantly during this process to prevent overfilling.

You achieve permanently better levels of purity by operating the system continuously in bypass flow.

FAM Set-up and Connection


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CAUTION

Rotary vane vacuum pump

Hazardous to health

► Always make sure there is sufficient ventilation in the surrounding area of the unit.

Air coming out of the rotary vane 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.

Setting up the FAM

Observe the following points when setting up the unit:

Set up the unit horizontally on a level surface. Special mounting is not required.

Lock the immobilization brakes on the wheels to avoid unintended movement of the unit.

Set up the unit directly beside the tank that is to be cleaned. Observe the maximum permitted suction pressure.

Make sure to note the ambient temperature on type label of the unit.

Ensure that the main switch is freely accessible at all times.

Keep an area of at least 0.8 m around the unit free for maintenance purposes.

Make sure that the control panel is always freely accessible and that the control cabinet can be opened fully.



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Connection overview

The stationary and mobile FAM versions have different scopes of delivery. The stationary FAM has positions 1-4, while the mobile FAM has positions 5-8.

Item

1 FAM inlet connector 28L / M36x2 (external thread)*

2 Adapters Adapter G1 A (external thread)**

3 FAM outlet connector

18L / M26x1.5 (external thread)*

4 Adapters Adapter G1/2 A (external thread)**

5 Suction hose connection

28L / M36x2 (internal thread)***

6 Adapters Adapter G1 A (external thread)**

7 Pressure hose connection

18L / M26x1.5 (internal thread)***

8 Adapters Adapter G1/2 A (external thread)**

*) Output drive type D to ISO 8434-1 Series L (corresponds to ISO 12151, Form S, Series L)

**) Stud end to ISO 1179-2 (Form E)

***) Output drive type N to ISO 8434-4 Series L (corresponding to ISO 12151, Form SWS, Series L)



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Notes on pipes and hoses

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. Connect all connectors to the unit without initial stress.

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 [m] / 10. h stands here for the distance between the suction connection on the FAM and the fluid surface in the tank and is given in meters.

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

Flow rate

Kinematic viscosity

Pipe dimensions

Fluid density



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

∆p ~ 6.8 * L / d4 * Q * V * D ∆p = Pressure differential in [bar]

L

= Pipe length [m]

d = Internal pipe diameter [mm]

Q = Flow rate [l/min]

V = Kinematic viscosity [mm²/s]

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

The density (D) is:

Mineral hydraulic oil HLP 0.85 … 0.90 kg / dm³

Phosphate ester HFDR 1.00 … 1.10 kg / dm³

Insulating oil 0.90 … 1.00 kg / dm³

Lubrication oil 0.90 … 0.95 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.



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Connecting the inlet (IN)

The suction pressure at the FAM inlet must be -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

Contamination too high

The unit will be damaged

► Do not prime directly at the bottom of the tank

► Do not prime in the sump

► Never prime without a built-in suction strainer

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

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.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Preparing the Vacuum Pump

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 star-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.

HYDAC vacuum pump oil with following part no.:

Description Part no.:

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

1 liters 06018128

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

5 liters 06018129



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Filling 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



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Electrical Connection of the FAM

DANGER

Exposed electrical components in the switch cabinet

Danger of fatal injury due to electric shock

► Any work involving the electrical system may only be done by a properly trained, certified electrician.

The electrical connection of units without connection plugs to the power supply module may only be performed by a technician with corresponding knowledge and skills.

Make sure that the voltage and frequency specifications on the FAM type label correspond to the existing mains voltage.

If a plug is present on the FAM or if a plug is mounted, then the FAM is to be operated from a correspondingly fused socket.



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Check direction of rotation

Check the direction of rotation of the motor by switching it on briefly (jog mode). The FAM requires a clockwise rotating field at the connecting socket.

NOTICE

Incorrect phase sequence / rotation direction of the motor

The pumps will be destroyed.

► In jog mode, check the direction of rotation of the motors.

► A rotation direction arrow on the fan cover of the motor identifies the correct direction of rotation.

Make sure there is a clockwise rotating field. If this is not the case, then the phases can be rotated in the 16A / 32 A connection plug with the aid of the phase changing switch in the plug. For the 63A version, the two phases must be switched on the terminal block S0 (e.g. L1 and L2).

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.

Operating Elements on the FAM


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Operating Elements on the FAM

The following operating elements are to be found on the FAM:

Item Description

A Main switch with E-STOP function

B Alarm signal lamp (yellow)

C Control panel (for details see page 47)

D Vacuum gauge to set the pressure in the vacuum column.

E SensorMonitoring Unit SMU1200 (for details see the corresponding operating instructions)

Starting up the FAM


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Starting up the FAM

NOTICE

Connection IN / OUT closed

The FAM will be destroyed

► Check to be sure that all of the locking fixtures at the inlet / outlet are in "open" position each time before start-up.

Starting up the FAM


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Switching on the FAM

Move main switch to the "ON" position and wait until the "Fault" lamp lights up briefly (lamp test) and the following start screen will appear after 30 seconds.

The most recently selected operating mode will be shown in the display.

Select an operating mode with heater in the presence of viscosities ≥350 mm²/s.

It is not mandatory that the heater be switched on in the presence of lower viscosities, but it would contribute decisively to the enhancement of dewatering performance.

Select the operating mode (OM) as described on page 57.

F1 F2 F3 F4

F1 = start FAM

F4 = switch to MENU1

Press the START key. The FAM begins with the starting phase.

The power unit control switches to the RF+D menu.

The vacuum pump starts up, the filling pump conveys and the vacuum column is filled.

Set the required negative pressure in the vacuum column. See page 44.

The evacuation pump is switched on and the starting period is finished when the vacuum chamber is filled to the MAX filling level.

The FAM controller switches over to automatic operation.

Bleed the filter housing as described on page Fehler! Textmarke nicht definiert..

Operating mode: Dewatering + Filtration

START MENU1

Ready for operation, please press Start

Starting up the FAM


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Setting the pressure in the vacuum column

For the current pressure in the vacuum column, consult the control panel.

F1 F2 F3 F4

Pressure in the vacuum column

Use the vacuum gauge (D) to set the pressure in the vacuum column.

Note that the pressure to be set in the vacuum column is dependent on the operating viscosity and the water content.

Medium Operating viscosity Pressure setting (absolute pressure)

Hydraulic oil 50 mm2/s ~ 350 mbar

Lubrication oil 300 mm2/s ~ 500 mbar

START MENU1

RH+P

Rel. moisture: Nominal:30% Actual:33%

T 22°C P 970Ready for operation. Please press Start STOP RESET

Starting up the FAM


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With a lower pressure (such as 250 mbar), you achieve an lower residual water content. With a higher pressure (such as 500 mbar), you achieve a faster dewatering, especially with free water.

By closing the vacuum gauge (D) you reduce the absolute pressure and the required air-flow rate for dewatering the fluid.

If the vacuum gauge is completely closed, dewatering takes place exclusively with the air released in the fluid. The dewatering speed is then reduced to a minimum.

We recommend relative saturation (relative moisture) for water contents > 100%. With free water this means starting with higher pressure (such as 500 mbar), and reducing the pressure (to 250 mbar, for example) only after the level has fallen below the saturation point (<100%).

Some oils foam intensively when they enter the vacuum chamber. This effect is particularly pronounced with high water contents. This effect is also to be observed with older oils or extremely high-viscosity media.

If too much foam is caused, it is drawn in by the vacuum pump. Increase the vacuum in such cases, e.g. from 250 mbar to 350 mbar.

Water condensation can also occur in the connecting hose between the vacuum pump and the vacuum column in the presence of a very high water content in the oil. The water is separated out into the vacuum pump storage container. Raise the vacuum to 500 mbar in such cases.

Shutting off the FAM


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Shutting off the FAM

F1 F2 F3 F4

F2 = STOP

F4 = back to "MENU1"

Press the "STOP" key. The power unit starts the after-run phase.

All of the pumps will be switched off, except for the evacuation pump.Exception: If the heater is switched on, then a cooling phase of 60 seconds will intervene during which the heater is first shut off. Afterwards, all of the pumps will be switched off, except for the evacuation pump.

The evacuation pump runs until the "Min" fill level in the vacuum column is reached. The run-down phase status is shown in the display The run-down phase status is shown in the display

The FAM is once again ready for operation when the Start screen appears on the display.

F1 F2 F3 F4

Close all locking features in the inlet and outlet lines.

Switch off the unit at the main switch.

MENU1

RH+P


T 22°C P 970Automatic mode

STOP


START MENU1


Control Panel Basic (SIMATIC PANEL)


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F1 F2 F3 F4

SHIFT

INSDEL

TAB

+/-

HELP

ENTER

ACK

ESC

All functions are input and controlled using this control panel. Due to the size of the display it is necessary to radically shorten the texts relating to the operating modes and the functions. For an overview of the corresponding abbreviations, refer to the following pages.

NOTICE

Pressing several keys together at once

Unintended actions

► Do not press more than two buttons simultaneously.



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Overview of operating modes and abbreviations

Abbreviation Description Menu 1:

OM = Operating mode

Hand = Manual menu

Menu 2:

OHM = an operating-hours counter, and

Config = Configuration menu

Buttons:

RH + T = Relative Humidity + Temperature

T = Temperature (only with heater option)

Cont. = Contamination (with the CS option only)

Operating modes: (Only possible operating modes are displayed.)

DW+FT = Dewatering and Filtration

DWT+ FT

= Dewatering up to and Filtration

DWT + FTB = Dewater to + Filter to

EW+H+FT = Dewater + Heat + Filter

DWT + H + FT = Dewater to + Heat + Filter

DWT + H + FTB = Dewater to + Heat + Filter to

FT = Filtration

FT+H = Filtration and Heating

EW+FTB = Dewater + Filter to

EW+H+FTB = Dewater + Heat + Filter to

FTT = Filter to

FTT+H = Filter to + Heat

Manual menu 1:

FP = Filling pump

EP = Evacuation pump

Manual menu 2:

VP = Vacuum pump

RV = Return valve

WDV = Vacuum pump water drainage valve

Manual menu 3:

H = heater

CSP = Charge pump CS

WFV = Water filling valve vacuum pump

Manual menu 4:

RP = Recirculating pump



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Overview of menu structure

Menu 1

RH +P

T Cont. ISO, SAE, NAS OM - Operating

Mode

DW+FT DWT+

FT

DWT + FTB EW+H+FT DWT + H + FT DWT + H + FTB FT FT+H EW+FTB EW+H+FTB FTT FTT+H DW+FT MANU OPERATOR MANU 1 Manual

operation FP EP MANU 2 VP RV WDV MANU 3 H CSP WFV MANU 4 RP Service SET Select

language



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UNITS Temperature Pressure Menu 2

Intervals an operating-hours

counter, and

Configuration



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Changing / entering values

-> Menu keys

-> Function key assignment

F1 F2 F3 F4-> Function keys

The menu keys illustrated can be selected with the keys

DEL INS

or by

means of the key combination SHIFT

+

TAB

, which is marked by framing made up of a line of dashes.

Pressing the key switches over to the selected menu.

Values can be modified during automatic operation.

To modify values, proceed as follows:

1. Press the button.

2. Change the marked value by actuating the keys

TAB

or +/-

.

3. Change the position by actuating the keys

DEL

or INS

.

4. If you have reached the desired value, press the key.

5. The message "Value is applied" will appear in the display.

OM MANU SET MENU2

RH +P

T MENU1

Cont.

Meas. values:



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Menu 1

MENU1

-> Menu keys

-> Function key assignment

F1 F2 F3 F4-> Function keys

The menu keys shown can be selected with the keys

DEL INS

. The selected menu key is marked by a dashed line around its circumference.

Pressing the key switches over to the selected menu.

Menu keys Description see page

RH +P

= Settings for Relative Humidity and display of set pressure in the vacuum column.

54

T = Display and setting of the heater temperature.

55

Cont. = Display and setting of the cleanliness code of the fluid.

56

Function key assignment

Description see page

OM = Select operating mode 57

MANU = Switch to Manual menu 62

SET = Switch to Settings menu 65

MENU2 = Switch to MENU2 67

OM MANU SET MENU2

RH +P

T MENU1

Cont.

Meas. values:



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Start screen

The selected operating mode is shown in the upper line, the middle line shows the current operating status, and the key assignment is displayed in the lower line.

You see this start screen only after switching on the power unit using the main switch.

Start screen

-> currently selected operating mode

-> Operating status

-> Function key assignment F1 F2 F3 F4

-> Function keys

START = Start FAM.

Is displayed only in the operating status "Ready for operation".

After this key has been pressed, the current operating status on the display switches to "Starting phase" and the "RF+D" screen appears.

STOP = Stop FAM.

Is shown during the starting phase and during automatic operation.

RESET = Is displayed only when there is a fault

MENU1 = Switch to MENU1

The most recently selected operating mode will always be shown in the start screen.


START MENU1




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RH+P (Relative Humidity + Pressure)

Start screen -> MENU1 -> RF-D

F1 F2 F3 F4

START = Start FAM

Display in operating status "Ready for operation" and with the error message "Water content ≥ 90%, measurement with CS not possible".

STOP = Stop FAM.

is displayed only in the operating status "Starting phase" and "Automatic operation"

RESET = Reset error messages

Is displayed only in the presence of faults


Display :

Rel. humidity: tgt: = The nominal value can be changed from 0 - 99%.

Factory setting: 30%

Rel.humidity: act: = Display of the current moisture at the FAM inlet. A display of 0 - 100% is possible.

Temp. = Medium temperature at inlet to the FAM.

Pressure = Current pressure (absolute) in the vacuum column

The displayed temperature is measured at the inlet by the AquaSensor.

START MENU1

RH+P


T 22°C P 970Ready for operation. Please press Start STOP RESET



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T (Temperature)

MENU1 -> T

F1 F2 F3 F4

START = Start FAM


STOP = Stop FAM is displayed only in the operating status "Starting phase" and "Automatic operation"




Display :

Hysteresis: = Current hysteresis setting of the heater. The hysteresis range is adjustable from 3 to 15°C.

Factory setting: 5%

Temperature Actual: = The heater temperature nominal value can be set between 0° and 99°C. For details, see page 51.

The safety thermostat responds at 80°C.

Factory setting: 55%.

Temperature Actual: = Current temperature in the vacuum column.

The displayed temperature is measured by a sensor in the sump of the vacuum column.

The temperature setting can be changed during automatic operation.

START MENU1

T Heater: Hysteresis: 5°C

T t N i l 55°CReady for operation. Please press Start STOP RESET



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Selection Contamination (CONT.)

MENU1 -> Cont. -> ISO (example, can also be SAE or NAS depending on sensor)

F1 F2 F3 F4

START = Start FAM


STOP = Stop FAM is displayed only in the operating status "Starting phase" and "Automatic operation"



Display :

ISO: Nominal: = The nominal value can be changed as follows:

4µ channel = 2 … 25



ISO: Actual: = Display of the current contamination at the FAM inlet.

START MENU1

ISOtgt: act:

Ready for operation. Please press Start STOP RESET

4 µ 4 µ

6 µ 6 µ

14 µ 14 µ 20

18 18 16

1514



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Operating Mode - OM

MENU1 -> OM

F1 F2 F3 F4


DWT+ FT


FT = Filtration

NEXT = Other operating modes

Only operating modes that can be selected are displayed.

A change of operating mode is possible at any time during automatic operation. Operating modes are active as soon as they are selected.

In order to return quickly to the start screen while in the Operating Mode OM

menu, SHIFT

+

TAB

can be used to activate a box with dashed lines around

the field "NEXT". Then press the key and MENU1 will be displayed again.


DW+FT NEXT

DWT+ FT FT



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Operating modes - Brief overview / Brief description

The following offers a brief description of the operating modes:

Operating modes:

Description


The fluid will be simultaneously dewatered and filtered.

DWT+ FT


The fluid will be simultaneously dewatered and filtered. The FAM operates until a specified Relative Humidity has been reached (see page 54). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least 2 minutes. If the Relative Humidity is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

DWT + FTB = Dewater to + Filter to

The fluid will be simultaneously dewatered and filtered. The FAM operates until both specified nominal values have been reached (see page 54 / 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least 2 minutes. If the Relative Humidity is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

EW+H+FT = Dewater + Heat + Filter

The fluid will be simultaneously dewatered and filtered and heated up to the prescribed temperature (see page 55).

DWT + H + FT

= Dewater to + Heat + Filter

The fluid will be simultaneously dewatered and filtered and heated up to the prescribed temperature (see page 55). The FAM operates until a specified Relative Humidity has been reached (see page 54). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least 2 minutes. If the Relative Humidity is reached



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once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

DWT + H + FTB

= Dewater to + Heat + Filter to

The fluid will be simultaneously dewatered and filtered and heated up to the prescribed temperature (see page 55). The FAM operates until both specified nominal values have been reached (see page 54 / 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the FAM switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least 2 minutes. If the Relative Humidity is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

FT = Filtration The fluid will only be filtered.

FT+H = Filtration and Heating

The fluid will be simultaneously filtered and heated up to the prescribed temperature (see page 55). Vacuum pump remains switched off.

EW+FTB = Dewater + Filter to

The fluid will be simultaneously dewatered and filtered. The FAM operates until a specified cleanliness code has been reached (see page 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least ~ 2 minutes. If the cleanliness code is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

EW+H+FTB = Dewater + Heat + Filter to

The fluid will be simultaneously dewatered and filtered and heated up to the prescribed temperature (see page 55). The FAM operates until a specified cleanliness code has been reached (see page 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least ~ 2 minutes. If the cleanliness code is reached once again after this time, then the FAM will switch off once again and the



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recurrent inspection interval runs again.

FTT = Filter to The fluid will only be filtered. The FAM operates until a specified cleanliness code has been reached (see page 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least ~ 2 minutes. If the cleanliness code is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.

FTT+H = Filter to + Heat

The fluid will be simultaneously filtered and heated up to the prescribed temperature (see page 55). Vacuum pump remains switched off. The FAM operates until a specified cleanliness code has been reached (see page 56). Then the FAM switches off. Now the recurrent inspection interval starts (time until the unit switches on again, see page 68). After this has run through, the FAM switches on automatically once again and runs for at least ~ 2 minutes. If the cleanliness code is reached once again after this time, then the FAM will switch off once again and the recurrent inspection interval runs again.



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Operating mode - Dewater to / Filter to

The operating mode "Filter to" is possible only up to a relative humidity of 90%. The CS is switched off in situations involving >90% or unmanaged water.

The following message is output when the contamination menu is selected: "Oil saturation >90%. Measurement with CS not possible!"

You can switch off this display by pressing the ESC key, so that you can exit the screen again by selecting Menu1.

If a water saturation level of ≥90% occurs during automatic operation, then the operating mode switches automatically in accordance with the following table:

Selected operating mode: changes automatically after:

FTT => FT

EW+FTB => DW+FT

EW+H+FTB => EW+H+FT

H+FTT => H+FT

The limit values for "Dewater to" are to be set in the RH+P screen, the limit values for "Filter to" in the CONT. screen.

Once the limit values have been reached, the FAM stops automatically. After the set test interval has expired, the FAM starts automatically. If the measured values still fall below the set limit value after 2 minutes, the the FAM will switch off automatically and the testing interval will start again.



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Operating mode - MANU

MENU1 -> MANUAL

F1 F2 F3 F4

OPERATOR = Manual operation for operator

SERVICE = Manual operation for HYDAC Service (password-protected)

MENU1 = Back to MENU1

Operating mode - MANU – OPERATOR (MANU1)

MENU1 -> MANUAL -> Operator

F1 F2 F3 F4

= return to the screen "Selection manual operation"

Manual operation

= Switching manual operation on/off

The OFF displayed below Manual operation indicates that manual operation is switched off.

FP = Switch filling pump On/Off

EP = Switching evacuation pump On/Off

Activate manual mode by pressing the F1 key. Now the individual components can be switched on and off. If you switch from automatic mode back to manual mode, automatic mode will stop. The current status of the pumps is shown. When automatic mode has stopped, the display in manual mode changes to ON.

The operating status of each component is visible on the display.

OPERA- TOR MENU1

SERVICE

SelectionManual oper

OFF NEXT

OFF OFF

Manual 1

Exit

Manual- operation

FP

EP



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Operating mode - MANU - OPERATOR (MANU2)

MENU1 -> MANUAL -> Operator -> Continue

F1 F2 F3 F4

= back to "Manual1" Menu

VP = Switching vacuum pump on/off

RV = Switching return valve on/off

WDV = Switching off the water drainage valve

(present only with water ring vacuum pump)


MENU1 -> MANUAL -> Operator -> Continue -> Continue

F1 F2 F3 F4


H = Switching heater on/off (only with option heater)

CSP = Switching conveyor pump for ContaminationSensor On/Off (option: ContaminationSensor)

WFV = Switch water filling valve On/Off (Optional: only with water ring vacuum pumps with automatic water intake)

The operating menu for Service is password-protected. You are presently in the registration screen, press "CANCEL".

"CANCEL" is accessed by simultaneously pressing the keys TAB

+ +/-

.

Afterwards, press the key and return to the manual mode selection.

OFF NEXT

OFF OFF

Manual 2

Exit

VP

RV

WDV

OFF Cont.

OFF OFF

Manual 3

Exit H CSP WFV



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MENU1 -> MANUAL -> Operator -> Continue -> Continue -> Continue

F1 F2 F3 F4


RP = Recirculating pump

OFF END

Manual 4

Exit RP



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Operating mode - SETTINGS (SET)

MENU1 -> Settings

F1 F2 F3 F4

Select language

= Press the F1 key repeatedly until the desired language appears.

UNITS = Switch over to Units menu


Set units

MENU1 -> Settings -> Units

F1 F2 F3 F4

Temperature = Set units for temperature

Pressure = Set units for pressure

back = Back to Settings menu

Select language MENU1

SET Language selected:

ENGLISHUNITS

Temperature back

UNITS

Pressure



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Set temperature

MENU1 -> Settings -> Units -> Temperature

F1 F2 F3 F4

°C = Temperature display in °C

°F = Temperature display in °F

back = Back to Units menu

Set pressure

MENU1 -> Settings -> Units -> Pressure

F1 F2 F3 F4

mbar = Pressure indicator in mbar

hPa = Pressure indicator in hPa

PSI = Pressure indicator in PSI

back = Back to Units menu

Yes back

No

Temperature °C

°F

Yes back No

Pressure

mbar hPa

No

PSI



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Menu 2

MENU1 -> MENU2

F1 F2 F3 F4

INTER- VALS

= Times for the recurrent inspection interval for the "Cleaning until" and/or "Dewatering to" operating mode

OHM = Display operating hours meter

CONFIG.

= FAM Configuration – Access password-protected

(For HYDAC Service only)


INTER- VALS

OHM CONFIG. MENU1

MENU2



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Set (repeat testing interval) times

F1 F2 F3 F4

Display :

TRG MIN: = Inspection repeating interval:

Is the time after which the FAM switches on again after an automatic switch-off in the operating mode "Dewater to" and "Filter to" in order to check once again the relative humidity and/or the purity of the fluid.

Adjustable from 2 – 360 minutes Factory setting: 60 minutes

The settings apply only for the operating modes FTT and DWT.

Elapsed minutes = Display of the repeat testing interval minutes that have already elapsed


Read operating-hours counter

F1 F2 F3 F4

Display :

Operating hours = Display of the FAM operating hours


---------------------------------------------------------------------------------------------------

MENU2

IntervalsRepeat testing interval: 3 nominal minutes 0 elapsed minutes

MENU2

Operating hours

18 hours 43 minutes



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Reset safety thermostat on the heater

The safety thermometer 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.

Performing maintenance


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Before performing any maintenance work, pull out the plug on the FAM and wind up the power cord to prevent the unit from being switched on again.

The unit is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance, servicing, inspection or repair work.

Once maintenance work is complete, check that the safety devices are still working properly. Any screwed fittings which have been undone/removed are to be checked to see that they have been properly resecured.

See

pag

e

24 h

ours

/ da

ily

500

hour

s /

mon

thly

3000

hou

rs /

ever

y si

x m

onth

s

6000

hou

rs /

annu

ally

FAM

Check the FAM for any leaks (visual check). - X

Check the screwed fittings to see that they have been properly resecured.

- 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

Check the fault indicator lamps / perform a lamp test

73 X

Changing the Air Filter 73 X

Clean the suction strainer. 74 X

Rotary vane vacuum pump

Checking the oil level - X

Changing oil 76 X



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

See

pag

e

24 h

ours

/ da

ily

500

hour

s /

mon

thly

3000

hou

rs /

ev

ery

six

mon

ths

6000

hou

rs /

an

nual

ly

Replacing the Air De-oiling Element 77 X

Check and clean the ventilator hood

- X

Emptying/Filling Pump

Check and clean the ventilator hood

- X

Fluid filter

Changing the filter element 78 X

Emptying and cleaning the filter housing

- X

Electric System

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

Testing the oil pan float switch 83 X



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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.



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Function testing of the fault indicator lamp

To perform the function test of the fault indicator lamp, follow these steps:

1. Switch on the unit at the main switch (A).

2. An automatic lamp test is conducted after the unit has been switched on. The fault indicator lamp (B) lights up briefly during this test.

3. The function test of the fault indicator lamp has been completed.

Changing the Air Filter

Replace the air filter (1) every six months. If you are operating the unit in a very dusty / damp environment, the replacement interval is accordingly shorter.

1. Manually unscrew the air filter (1).

2. Dispose of the air filter in an environmentally friendly manner.

3. Manually screw on the new air filter (1) and tighten this manually until secure.

4. The air filter replacement has been completed.

Checking the AquaSensor

Check the AquaSensor annually with the calibration and adjustment set (HYDAC p/no. 3122629).

Replace the AquaSensor if it exhibits great deviations. The part-no. can be found in the spare parts list.

Clean the suction strainer.


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NOTICE

Operation without a suction strainer

The pump will be destroyed

► The unit may not be operated without the 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.

Clean the suction strainer at regular intervals.

To install / dismount 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. To clean the suction screen, wash it out with solvent and then dry 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. Install the new strainer insert (3).

5. Turn the screw plug (1) clockwise manually.

Firmly screw in the screw plug (1) with the open-jaw wrench.

6. After commissioning, check the suction strainer fittings for leaks.

12

3



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Rotary vane vacuum pump components

l

ma i

g

h

d

c

k

Item Designation

a Oil filler neck

c Oil drain

d Oil sight glass

g Oil separator

H Suction port connection

i Gas outlet

k Safety screw on the plug

l Plug for the level sensor

m Level switch in the vacuum pump

The following descriptions are in reference to these positions.



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Performing an oil change

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 plug screw 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.



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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.



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Replacing the filter element on 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.

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 exiting 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 (SW 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 housing clamp (1) on the filter housing and then remove the housing by moving it downwards (2).

Use an Allen wrench SW 6 mm (1).



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4. Pull the filter bowl including filter element downwards.

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

Dispose of the used filter element in an environmentally correct manner.



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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.



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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.



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

Tighten the housing clamp with an Allen wrench SW 6mm 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.



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Testing the Float Switch in the Oil Pan

Proceed as follows to test the float switch in the oil pan:

1. Use your fingers to raise the float switch in the oil pan.

2. The unit must switch off and the fault message "Pan overfilled" must appear in display of the control panel.

3. Release the float switch and acknowledge the fault message by pressing the F3 key.

4. The unit continues to operate -> You have tested the function of the float switch positively.

5. If the unit does not switch off after the lifting of the float switch and no fault message appears, contact the HYDAC Service.

Checking the settings on the heater (optional)

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

Error messages / troubleshooting


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NOTICE

Switch off the FAM at the main switch before opening the control cabinet door

The main switch will be destroyed.

► Do not open the control cabinet door if the main switch is not in OFF position.

► Do not use force to open the control cabinet door.

If an error occurs, the FAM goes into the status "Fault". This halts all functions. The fault indicator lamp flashes.

To start the FAM, you must correct the error and acknowledge the error message on the control panel.

An exception is the message "F2 fuse tripped", for which the indicator lamp does not flash, the FAM will be switched off and the error message appears on the display.

The fault messages are displayed only in the following screens:

Start screen

RH+P (Relative Humidity + Pressure)

T (Temperature)

Cont. (ContaminationSensor)

If a fault message is not shown in its entirety, then (...) will appear at the end of the line on the display. The message can be displayed in its entirety with

the help of the INS

key.

The fault messages that are relevant to the ContaminationSensor will only be displayed on the "Cont" screen.

An exception is the message "CS1xxx + CS-Zuförderp. Abgeschal. CS1xxxStörung. Start 10 new attempts with Reset." This message will be displayed on all screens.

The operator can switch into the different menus and operate a component in the Manual menu necessary for the elimination of the fault.

No error messages are displayed in the Manual menu.



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If several errors occur, then the most recently occurring message will be

displayed first. One can used the arrow keys TAB

+ +/-

to scroll through the individual fault messages.

All of the error messages shown in the display are equipped with a number. It is very easy to find the error message again in this Chapter by using the number as a reference.

To switch off the error messages, press the button. If the fault indicator lamp is flashing, error messages are present.

To show error messages again, switch to Menu 1 or Menu 2 and then return to the display window.

1. CS+pump switched off. CS fault. Start 10 new attempts with Reset!

Cause: The CS supplies 10 unusable measured values.

The CS and the charge pump are switched off for 15 seconds after each unsuccessful attempt, after which a new measurement is carried out.

After an additional 10 unusable measured values, the CS switches off and can be switched back on only by actuating the Reset key.

The reasons for incorrect measurements could include: no usable values or one of the errors 16, 17, 30, 31.

Remedy: Perform the following steps:

Ste

p

Description

1. Message:

1. CS1xxx + CS-Zuförderp. Abgeschal. CS1xxxStörung. Start 10 new attempts with Reset!

2. Actuate ESC key and reset failure with the F3 key.

3. The measurement starts once again; automatic mode is not interrupted.



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2. Flow at FAM inlet has been too low for 5 minutes. Check the FAM inlet.

Cause: This error can only arise in the starting phase of the FAM, because it is only during this phase that the corresponding timer is running. The message appears if the MAX switch point in the vacuum column is not achieved after 5 minutes have elapsed.

If this error arises at the time of the first start-up or after repairs have been made, then it is advisable to fill the filling pump in advance with ~ ¼ l of oil. To accomplish this, remove the plug on the AS and then remove the AS by unscrewing it. The oil is filled in through this opening. The AS and the plug are mounted once again afterwards in order to restart the FAM.


Ste

p

Description

1. Message:

2. Flow at FAM inlet has been too low for 5 minutes. Check the FAM inlet.

2. Check all of the locking features in the suction line for flow.


4. Start the unit by pressing the F1 key.

->a. The fault is repeated. -> proceed to Step 6. 5.

->b. The fault is not repeated. -> proceed to Step 11.

6. Clean the suction filter.

Check the hose between suction filter and filling pump.

Check the filling pump for proper functioning.





10. Contact the HYDAC Service Department.

11. The fault is repaired.



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3. FAM outlet is blocked

Cause: The level must reach the MIN switch point within 5 minutes once the MAX switch point in the vacuum column has been reached.


Ste

p

Description

1. Message:

3. FAM outlet is blocked

2. Check all of the locking devices in the return line for flow.





6. Check the evacuation pump for proper functioning.

Check the return valve.

Check the suction line for constrictions.

Check the filter for flow.









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4. Error, float switch of rotary vane vacuum pump at fill level Min. / fill level Overflow

Cause: The MIN and Overflow switch points on the float switch of the vacuum pump were reached at the same time. The PLC outputs a message on the display.


Ste

p

Description

1. Message:

4. Error, float switch of rotary vane vacuum pump at fill level Min / fill level Overflow.

2. Switch off the FAM at the main switch.

3. Check that the level switch of the rotary vane vacuum pump is functioning correctly.

->a. Level switch is OK. -> proceed to Step 5. 4.

->b. Level switch is not OK. -> proceed to Step 7.

5. Check the plug to the level switch.

Check the cable from the level switch to the control cabinet and in the control cabinet to the PLC.

->a. The cable and plug are OK. -> proceed to Step 9. 6.

->b. The cable and plug are not OK -> proceed to Step 8.

7. Replace the level switch. -> proceed to Step 10.

8. Replace the damaged parts -> proceed to Step 10.

9. The PLC is defective -> contact the HYDAC Service Department.




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5. / 6. Error, float switch of vacuum column at fill level Max and/or fill level Overflow.

Cause: The MIN and Overflow switch points in the vacuum column were reached at the same time. The PLC outputs a message on the display.


Ste

p

Description

1. Message:

5. Error, float switch of vacuum column at fill level Max and/or fill level Overflow.

6. Error, float switch of vacuum column at fill level Min and/or fill level Max.


3. Check that the level switch is functioning correctly.

->a. Level switch is OK. -> proceed to Step 5. 4.

->b. Level switch is not OK. -> proceed to Step 7.

5. Check the plug to the level switch.

Check the cable from the level switch to the control cabinet and in the control cabinet to the PLC.



7. Replace the level switch. -> proceed to Step 10.

8. Replace the damaged parts -> proceed to Step 10.


10. The failure is repaired.



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11. / 12. / 14. / 15. Cable break

Cause: Error 11. / 12. / 14. / 15.

The signal is immediately active after the lamp test (except with AS temperature: 5 s), error message flashes on the display, the FAM continues however to run. The only exception: if the sensor controls the FAM in the event of a cable break, the FAM will go into the after-running phase and switch off.

Cause: Error 13.

The signal remains active for 5 seconds after the lamp test. The charge pump for the CS is switched off (because no water content is known and it can therefore lead to incorrect measurements by the CS). The FAM continues to run. The only exception: if the sensor controls the FAM, the FAM will go into the after-running phase and switch off.


Ste

p

Description

1. Message:

11. Cable break, heater ETS.

12. Cable break, AS 1000 temperature

13. Cable break, AS 1000 water content

14. Cable break, CS.

15. Cable break, pressure sensor HDA 4145, vacuum column.

2. Switch the FAM off at the main switch and unplug the power connector.

3 Check the cables and plugs of the corresponding sensor up to the PLC.



5. Check / replace the sensor

6. Plug the power plug into the power outlet.

Switch on the FAM at the main switch and start operation by pressing the F1 key.





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8. The PLC is faulty. -> proceed to Step 12.

9. Replace the cable and/or the plug.









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16. No defined value from CS

Cause: The charge pump for the CS runs for 2 minutes in Automatic mode.

The CS has been reporting "no measured value from CS" for 4 minutes.

The message is shown on the CS display. The FAM continues to run. The CS is switched off for 15 seconds, after which a new measurement is started.

Remedy: If the measurement has failed 3 times in the "Filter to" operating mode, then the message "Start screen, RH+P, T and CS" will appear on the display.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

17. No measured value from CS. Check for flow

Cause: The charge pump for the CS runs for 2 minutes in Automatic mode.

The CS has been reporting "no measured value from CS" for 4 minutes.

The message is shown on the CS display. The FAM continues to run. The CS is switched off for 15 seconds, after which a new measurement is started.

Remedy: If the measurement has failed 3 times in the "Filter to" operating mode, then the message "Start screen, RH+P, T and CS" will appear on the display.



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18. / 19. / 20. / 21. / 22. Motor protection switch Qx has tripped.

Cause: The motor protection switch has tripped, due to an overload in the motor-pump group. The FAM switches off after 1.8 seconds.


Ste

p

Description

1. Message:

18. Motor protection switch Q2 has tripped.





2. Switch off the unit at the main switch.

3. Open the control cabinet door.

Switch the tripped motor protection switch back on.

Check the setting on the motor protection switch with the specifications on the motor type plate. Correct the settings if necessary.





6. Check the current consumption of the motor with the nominal current specification on the motor type plate (I ≤ IN).

Check the viscosity of the medium.

Only with water ring vacuum pump -> Clean the tank of the water ring vacuum pump.

7. Close the control cabinet door. Switch on the FAM at the main switch and start operation by pressing the F1 key.

->a. The fault appears again -> proceed to Step 9. 8.

->b. The fault does not appear again -> proceed to Step 13.

9. Replace motor protection switch and/or the fuse.

10. Close the control cabinet door.

Switch on the FAM at the main switch and start operation by



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

pressing the F1 key.







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23. Oil filter contaminated -> replace oil filter

Cause: The differential pressure display signal has been active for 5 minutes. The FAM goes into the after-running phase and switches off.


Ste

p

Description

1. Message:

23. Oil filter contaminated -> replace oil filter

2. Close all the locking features in the feed and return flow lines.

3. Empty the filter housing via the drain ball valve.

4. Replace the filter elements. For details, see page 78.

5. Open all the locking features in the feed and return flow lines.

6. Actuate ESC key and reset failure with the F3 key




9. Switch off the FAM and pull out the power plug.

Check clogging indicator, plug and supply line. Replace the parts if necessary.

10. ->a. The test resulted in no errors. -> proceed to Step 12.

->b. The errors found were eliminated.

-> proceed to Step 6.





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24. Oil tank of rotary vane vacuum pump is empty -> refill oil

Cause: The MIN switch point in the oil tank of the rotary vane vacuum pump has been reached.

The message appears at once on the display.

The FAM goes into the after-running phase and switches off.


Ste

p

Description

1. Message:

24. Oil tank of rotary vane vacuum pump is empty -> refill oil.

2. Fill up the rotary vane vacuum pump with vacuum pump oil. For details, see page 38.




If the failure recurs, even though there is enough vacuum pump oil between the MIN and MAX markings, first check the float switch and afterwards the PLC.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

25. Oil tank of rotary vane vacuum pump is too full -> drain oil

Cause: The MAX switch point in the oil tank of the rotary vane vacuum pump has been reached for 10 minutes. The message appears on the display. The FAM goes into the after-running phase and switches off.


Ste

p

Description

1. Message:

25. Oil tank of rotary vane vacuum pump is too full -> drain oil

2. Empty the oil tank of the rotary vane vacuum pump until the level in the inspection glass is between MIN and MAX. To drain, use the drain ball valve on the vacuum pump.




If the failure recurs, even though there is enough vacuum pump oil in the rotary vane vacuum pump, first check the float switch and afterwards the PLC.



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26. Heater safety thermostat triggered

Cause: Thermostat trips during operating mode with heater. The FAM goes into the after-running phase and switches off.

If an operating mode is selected for which no heater is switched on, then it is possible to operate the FAM. The message will however be displayed and can be reduced with ESC. If the FAM is in Automatic mode and a switchover to an operating mode with a heater is carried out while the thermostat is still tripped, then the FAM will go into the after-running phase and switch off.

This error message can be connected with a preceding error message and with the immediate switch-off of the FAM that takes place as a result..

Resetting: Allow the heater to cool down before resetting.

Undo the 4 screws and remove the cover from the heater terminal box.

Press down the red button (B) so that it engages in the lower position.

The mechanism is tripped by a bi-metal. This bi-metal must first cool down in order to recover. The cooling phase can indeed take up to 2 hours, depending on ambient conditions.

(A) = fluid temperature 55°C

(B) = safety thermostat 80°C

Remedy: If this is not an inherited error, then proceed as follows:



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Ste

p Description

1. Message:

26. Heater safety thermostat triggered.

2. Check whether the safety thermostat has tripped. The factory setting is 80°C.

3. ->a. The safety thermostat has triggered.


->b. The safety thermostat has not triggered.


4. Reset a safety thermostat. See page 99 for details.

5. ->a. Safety thermostat reset. -> proceed to Step 7.

->b. Safety thermostat reset not yet possible after 3 hours.


6. Replace the safety thermostat on the heater.


7. To reset the fault, press the F3 button.

8. ->a. Error reset -> proceed to Step 21.

9. ->b. Resetting fault not possible. -> proceed to Step 10.

10. Switch off the FAM at the main switch. Pull power plug.

11. Check the safety thermometer cable up to the PLC.

->a. The cable is defective. -> proceed to Step 17. 12.

->b. The cable is not defective. -> proceed to Step 13.

13. Replace the K7 relay.

14. Plug the power plug back in. Switch on the FAM at the main switch and start operation by pressing the F1 key.



16. The PLC is faulty. -> proceed to Step 20.

17. Replace the cable and/or plug.

18. Plug the power plug back in. Switch on the FAM at the main switch and start operation by pressing the F1 key.





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BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

27. Fuse F2 has tripped

Cause: The F2 fuse triggers. A message appears on the display. The FAM switches off at once. The fault indicator lamp is not flashing.


Ste

p

Description

1. Message:

27. Fuse F2 has tripped


3. Determine the cause and eliminate it.

4. Switch on the unit at the main switch.






BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

28. Heater fuse has tripped

Cause: The heater fuse has tripped. The FAM goes into the after-running phase and switches off.

Remedy: Select an operating mode without heater. The message will however be displayed and can be reduced with ESC.

Perform the following steps:

Ste

p

Description

1. Message:

28. Heater fuse has tripped.


3. Open the control cabinet door and switch the tripped motor protection switch and/or fuse back on.

Make sure the setting of the current corresponds to the heater type level.

Close the control cabinet door and plug the power plug back in.

4. Switch on the FAM at the main switch and start operation by pressing the F1 key.



6. Check the current consumption of the motor and/or of the heater at which the motor protection switch and/or the fuse has tripped against the specifications on the type label.

7. ->a. If the measured current I <= IN -> proceed to Step 9.

->b. If the measured current I >= IN -> proceed to Step 8.

8. Replace the defective motor/heater.





11. Replace the motor protection switch and/or fuse.


13. ->a. The fault is repeated. -> proceed to Step 14.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05






BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

29. Check phase sequence

Cause: The phase sequence relay checks the correct phase sequence after switch-on.

A message is shown on the display.

Remedy: Check the phase sequence.

Perform the following steps:

Ste

p

Description

1. Message:

Check phase sequence

2. Switch the unit off at the main switch and unplug the power connector.

3 Replacement of 2 phases on the mains plug (mains plug up to 32A with phase changer), check mains voltage.

4. Plug in the power connector and switch the unit on at the main switch.



6. Pull power plug.

Check the functioning of the power supply cable and the connection plug.

7. Plug in the power connector and switch the FAM on at the main switch.




Replace the phase sequence relay.

10. Plug in the power connector and switch the FAM on at the main switch.







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NOTICE

Incorrect phase sequence

The motors / pumps rotate in the wrong direction.

► Using manual operation always check the direction of rotation of the motors after they have been replaced.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

30. Malfunction CS flow too low.

Cause: The charge pump for the CS runs for 2 minutes in automatic mode. The CS reports "Flow too low" or "Device error" for 4 minutes, message appears in the display of the CS. The FAM continues to run. The CS is switched off for 15 seconds.

If the operating mode "Filter to" is set and the fault appears 3x in a row, then the message will also appear in the windows "Start screen, RH+P, T and CS".

No additional limitations.

Remedy: Select a different operating mode, normal mode is possible.

31. Fault, CS device error

Cause: The charge pump for the CS runs for 2 minutes in automatic mode. The CS reports "Flow too low" or "Device error" for 4 minutes, message appears in the display of the CS. The FAM continues to run. The CS is switched off for 15 seconds.

If the operating mode "Filter to" is set and the fault appears 3x in a row, then the message will also appear in the windows "Start screen, RH+P, T and CS".

No additional limitations.

Remedy: Select a different operating mode, normal mode is possible.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

32. Dry-running Evacuation Pump

Cause: The evacuation pump is running and the MIN switch point in the vacuum column was reached/was not reached.

The timer runs 2 minutes and the MIN switch point is not exceeded during this time. The FAM switches off at once, the message appears on the display.


Ste

p

Description

1. Message:

32. Dry-running Evacuation Pump

2. Check all of the locking features in the supply line for flow / freedom of passage. Open them if necessary.

3 Actuate ESC key and reset failure with the F3 key




6. Clean the suction filter.

Check the hose between suction filter and filling pump.

Check the filling pump for proper functioning.






BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

33. Vacuum column overflow -> drain vacuum column and troubleshoot cause

Cause: The E-STOP MAX switch point in the vacuum column was reached. All of the pumps (except the evacuation pump) are switched off.

The timer runs 4 minutes and 10 seconds. The level did not fall below the MAX switch point during the time, the FAM switches off at once, message appears on the display.


Ste

p

Description

1. Message:

33. Vacuum column overflow -> drain vacuum column and troubleshoot cause.

2. Start the evacuation pump using the Manual menu.

3. Monitor the evacuation time on the basis of the table below.

->a. Emptying duration is correct. -> proceed to Step 6.

4. ->b. Emptying duration is not correct.


5. Check the evacuation pump for proper functioning.


6. The vacuum in the vacuum column too low.

-> increase the vacuum (e.g. from 300 mbar -> 400 mbar)

7. Start automatic operation.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Emptying duration for the vacuum column in seconds:

Voltage with 50 Hz Voltage with 60 Hz

Filling level marking Filling level marking

FAM MIN MAX E-STOP MAX MIN MAX

E-STOP MAX

25 31.8 39.7 50.8 29.4 36.8 47.0

45 19.6 24.5 31.3 18.7 23.3 29.8

60 23.4 29.2 37.3 21.0 26.3 33.6

75 18.1 22.6 28.9 16.8 21.0 26.9

95 15.6 19.5 24.9 15.0 18.8 24.0

A deviation of +/- 10 seconds is within the tolerance.



BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

34. Oil pan too full -> drain oil pan and seal leak

Cause: The float switch in the tray was actuated. The message appears on the display after 1.8 seconds, and the FAM switches itself off.


Ste

p

Description

1. Message:

34. Oil pan too full -> drain oil pan and seal leak.

2. Empty the oil pan on the FAM.

3. Check the FAM for any leaks and eliminate any that are found.


5. Restart the FAM by pressing the F1 key.



7. Check the float switch in the oil pan. See page 83.

Check the supply line to the float switch. If necessary, replace them.





BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

37. Saturation oil >= 90%. Measurement with CS 1xxx not possible!

Cause: Error-free measurement of contamination is not possible with a water content ≥90%. The charge pump of the CS is switched off.

If you selected an operating mode for which the CS controls the FAM, then the FAM will automatically jump into a similar operating mode without control by the CS.

Example: Dewater + Filter to => Dewater + Filter

Remedy: The display flashes and shows "Operating mode changed".

It will not be possible to reset this error message until the relative humidity is <90%.

It will not be possible to select operating modes in which the CS controls the FAM until the relative humidity is <90%.

Spare parts


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Spare parts

FAM 10

Qty. Designation Part no.

1 Breather filter 0160 MU 003 M 1265765

1 Suction strainer 1" assy., consisting of:

635624

1x strainer insert, 250µm 6016797

1x sealing ring 6033969

1 Vacuum pressure gauge 639989

1 3/2-directional control valve 6014177

1 Pressure hose, Length = 5 m 6013308

1 Suction hose, Length = 5 m 6004781

1 Level switch (vacuum column) 120 4801

*) available on request

Fluid filter (OLF 5)


1 Filter element, filtration rating 2 µm N5DM002 349494

1 Filter element, filtration rating 5 µm N5DM005 3068101

1 Filter element, filtration rating 10 µm

N5DM010 3102924

1 Filter element, filtration rating 20 µm

N5DM020 3023508


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


Contact/Service


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Contact/Service

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


Telephone: ++49 (0) 6897 509 1174

Telefax: ++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.

Our HYDAC Servicenter offers you these tasks within agreed-upon time frames and at fixed prices.

HYDAC SERVICE GMBH Friedrichsthaler Str. 15A, Werk 13 66540 Neunkirchen-Heinitz

Germany

Telephone: ++49 (0)681 509 883

Telefax: ++49 (0)681 509 324


Taking the unit out of operation


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Taking the unit 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 10–40C.

Disposing of the unit

Dispose of the packaging material in an environmentally-friendly manner.

After dismantling the unit and separating the various materials, dispose of the unit in an environmentally friendly manner.

Finding the type label

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

Technical data


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Technical data

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

FAM 10 FAM10/15

Flow rate 10 l/min @ 50Hz 15 l/min @ 50Hz

Electrical power consumption 1500 W without heater 4400 W with heater

2000 W without heater 4900 W with heater

Empty weight ~ 300 kg ~ 300 kg

Operating pressure 3.5 bar

Permissible suction pressure at suction port (without suction hose)

maximum ± 0.2 bar

Viscosity range 15 … 800 mm²/s

Pump type Vacuum pump = Rotary vane vacuum

pump Filling pump = Vane pump Evacuation pump = Gear pump

Fluid filter size OLF5

Filter element type N5DMxxx

Contamination retention capacity according to ISO 4572

200 g

Clogging indicator VM 2 C.0

Power cable, length 10 m

IP class IP54

Hoses, length 5 m

Hoses, material See the model code, page 117

Connection Inlet/outlet see page33

Material of sealings NBR / FKM (FPM, Viton®)

Fluid temperature range 10 … 80°C

Ambient temperature range 10 … 40°C

Achievable residual water content < 100 ppm - Hydraulic and lube oils < 50 ppm - Turbine oils (ISO VG 32/46) < 10 ppm – Transformer oils (not suitable for online or onload operation)

Noise level according to VBG121 < 70 dB(A) at 1 m distance

Model Code


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Model Code

FAM 75 M 2 A - 40 - R - H - B - A - 00 /-V Product 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 M = Mineral oil – NBR seals

I = Insulation oil – NBR seals

X = HDF-R media – FKM seals

B = Readily biologically degradable (on ester base) FKM seals

Mechanical type 1 = stationary 2 = mobile (with rollers and hose holder) Voltage/Frequency/Power supply A = 400 V, 50 Hz, 3 Ph B = 415 V, 50 Hz, 3 Ph C = 200 V, 50 Hz, 3 Ph D = 200 V, 60 Hz, 3 Ph E = 220 V, 60 Hz, 3 Ph F = 230 V, 60 Hz, 3 Ph G = 380 V, 60 Hz, 3 Ph H = 440 V, 60 Hz, 3 Ph I = 500 V, 50 Hz, 3 Ph K = 480 V, 60 Hz, 3 Ph L

= 220 V, 50 Hz, 3 Ph

N = 575 V, 60 Hz, 3 Ph O = 460 V, 60 Hz, 3 Ph X = other voltage Filter size fluid filter

05 = OLF5 Type of vacuum pump R = Rotary vane vacuum pump heater H = heater z = without heater

Control concept B = Basic (Siemens OP73) Instrumentation A = AquaSensor AC1 = AquaSensor + ContaminationSensor ISO4406:1999 AC2 = AquaSensor + ContaminationSensor SAE AS 4059(D) AC3 = AquaSensor + ContaminationSensor NAS 1638 Modification number 00 = You will always receive the current version. Supplementary details V = FKM seals

EU Declaration of Conformity


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

EU Declaration of Conformity


Postfach 12 51 66273 Sulzbach / Saar Germany

Industriegebiet 66280 Sulzbach / Saar Germany

Telephone: ++49 (0) 6897 509 01

Internet: www.hydac.com

EC declaration of conformity

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.

Designation FluidAqua Mobil

Typ 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 Telefax: ++49 (0) 6897 509 1394

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

Page 1 of 1

Index


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Index

A

Air Filter ...................................................... 5, 71, 74 Ambient temperature range................................ 117 AquaSensor...........5, 24, 28, 30, 55, 71, 72, 74, 118

B

Bock rolls .............................................................. 24 Breather filter ...................................................... 114 Brief overview................................................... 4, 59

C

Cause .86, 87, 88, 89, 90, 91, 93, 94, 95, 97, 98, 99, 100, 103, 104, 106, 108, 109, 110, 112, 113

Changing the filter element................................... 72 Check valve .................................................... 24, 28 cleaning .......................................................... 31, 72 Clogging indicator............................................... 117 Compressor oil ..................................................... 77 connecting ...................................................... 41, 46 Connection ........................4, 21, 33, 34, 40, 43, 117 Connection cable.................................................. 21 Contamination retention capacity ....................... 117 ContaminationSensor ....................... 28, 64, 85, 118 Content ................................................................... 3

D

Date.................................................................... 119 Declaration of conformity...................................... 20 degassing ................................................. 13, 21, 29 Density ................................................................. 36 Description..3, 21, 38, 42, 49, 53, 59, 86, 87, 88, 89,

90, 91, 95, 97, 98, 99, 101, 103, 104, 106, 109, 110, 112

Device error ........................................................ 108 dewatering...............................13, 21, 22, 29, 44, 46 Dewatering ....................................22, 49, 58, 59, 68 Dewatering performance ...................................... 22 Differential pressure ....................................... 28, 71 Dimensions....................................................... 3, 25 Display.....................................53, 55, 56, 57, 68, 69 Disposal................................................................ 15 Documentation Representative .......................... 2, 3 drain plug........................................................ 79, 83

E

EC declaration of conformity............................... 119 Empty weight ...................................................... 117 Error ................................5, 85, 89, 90, 91, 101, 113 Error message.................................................. 5, 85

F

Factory setting...........................................55, 56, 69 Fault indicator lamp .............................................. 24 filling ..29, 30, 38, 39, 44, 49, 63, 64, 77, 78, 87, 109 Filter4, 8, 14, 22, 49, 59, 60, 61, 62, 69, 93, 94, 108,

113, 114, 117, 118 Filter element...............................................114, 117 Filter element type.............................................. 117 Filter to ....4, 49, 59, 60, 61, 62, 69, 93, 94, 108, 113 filtration....................................................21, 83, 114 Filtration...............................................49, 58, 59, 60 Float switch .....................................................24, 28 Flow rate..................................................35, 36, 117 Fluid filter...............................6, 24, 28, 72, 114, 117 Fluid temperature range ..................................... 117 Forwarding agent ................................................. 15 Function description ......................................... 4, 29

G

Gear pump ......................................................... 117

H

Hazard symbol ................................................. 3, 10 HDA...................................................................... 91 Heater..............................5, 6, 24, 28, 100, 101, 104 HFD...................................................................... 13 Hydraulic diagram ............................................ 4, 27 Hydraulic oil .......................................................... 45

I

Imprint ................................................................ 2, 3 IN 4, 24, 28, 35, 37, 43, 71, 95, 104 Inlet .................................................................... 117 Internal pipe diameter........................................... 36 IP class............................................................... 117 ISO ..............................................34, 38, 50, 57, 117 ISO4406 ............................................................. 118

1999 ....................................................................... 118

L

Level sensor ....................................................24, 28 Level switch.......................................76, 89, 90, 114 Lubrication oil ..................................................36, 45

M

Main switch......................................................24, 42 Maintenance..................................................... 1, 77 Material of sealings ............................................ 117

Index


BEWA FAM10-15 3843186 en(us) 2013-07-05 2013-07-05

Measurement............................................ 6, 62, 113 Mineral oil ............................................... 13, 36, 118 Motor protection switch..................................... 5, 95 mounting............................................................... 33

N

NAS ........................................................ 50, 57, 118 Noise level .......................................................... 117

O

OFF ................................................................ 63, 85 Oil filler neck ......................................................... 76 Oil pan ............................................................ 6, 112 Oil separator ......................................................... 76 Oil sight glass ....................................................... 76 operating 1, 4, 5, 8, 9, 10, 13, 14, 15, 29, 32, 38, 42,

44, 45, 48, 49, 51, 53, 54, 55, 56, 57, 58, 59, 62, 63, 64, 68, 69, 74, 77, 81, 84, 93, 94, 100, 104, 108, 113

Operation............................................ 14, 15, 38, 75 OUT...................................................... 4, 35, 37, 43

P

Pressure differential.............................................. 36 Pressure hose .............................................. 34, 114 Pressure setting.................................................... 45 Proper/Designated Use .................................... 3, 13 Publisher ................................................................ 2 Pump .................................4, 6, 28, 38, 72, 109, 117

R

Remedy ....86, 87, 88, 89, 90, 91, 93, 94, 95, 97, 98, 99, 100, 103, 104, 106, 108, 109, 110, 112, 113

Rotary vane vacuum pump....5, 33, 71, 76, 117, 118

S

SAE .........................................................50, 57, 118 Safety thermostat ............................................... 101 select ...............................................................9, 113 Service .6, 50, 63, 64, 68, 84, 87, 88, 89, 90, 92, 96,

97, 102, 105, 106, 114, 115 setting................24, 28, 29, 33, 53, 56, 95, 101, 104 Signal word....................................................... 3, 11 signal words ......................................................... 12 Size ...............................................................22, 118 Spare parts......................................................6, 114 Specialist personnel ............................................. 15 Suction hose............................................21, 34, 114 Suction port connection ........................................ 76 switching on.......................................................... 54

T

Temperature............4, 24, 28, 49, 51, 56, 66, 67, 85 Thermostat ......................................................... 100 Throttle valve...................................................24, 28 to shut down ......................................................... 17 Transformer oil ................................................... 117 Transport .............................................................. 15 transporting .......................................................... 18 Turbine oil........................................................... 117

V

Vacuum ......4, 6, 20, 24, 28, 38, 42, 49, 60, 61, 110, 114, 117

Vacuum column...................................6, 24, 28, 110 Vacuum pressure gauge .................................... 114 Vacuum pump6, 20, 24, 28, 38, 49, 60, 61, 114, 117 vacuum pump oil ...........................33, 38, 39, 98, 99 Vane pump ......................................................... 117 Vegetable oils....................................................... 13 Viscosity ............................................................. 117

W

Water content ......................................22, 55, 56, 57

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]

Documents

FAM 10 FAM 10/15 - Start: HYDAC · FAM 10 FAM 10/15 FluidAqua Mobil ... HYDAC FILTER SYSTEMS GMBH ... this manual, comprising the most important instructions for its operation and