HYDAC FILTER SYSTEMS | FAM-5-M-2-A-05-R-H-B-Z-1 | User manual | FluidAqua Mobil

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HYDAC FILTER SYSTEMS | FAM-5-M-2-A-05-R-H-B-Z-1 | User manual | FluidAqua Mobil | Manualzz
FAM 5
FluidAqua Mobil
Operating and Maintenance Instructions
English (translation of original operating instructions)
Documentation no.: 3667663b
Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
+49 (0)6897 509 01
Telefax:
+49 (0)6897 509 846
E-Mail:
[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
E-Mail:
[email protected]
© 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.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support........................................................................................7
Modifications to the Product ........................................................................7
Warranty ......................................................................................................7
Using the documentation .............................................................................8
Safety information ........................................................................................9
Hazard symbols...........................................................................................9
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions...................................11
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................12
Improper use or use deviating from intended use......................................12
Qualifications of personnel / target group ..................................................14
Wear suitable clothing ...............................................................................16
Stoppage in an emergency (EMERGENCY STOP)...................................16
Unpacking the FAM ....................................................................................16
Transporting the FAM.................................................................................17
Horizontal transport ...................................................................................18
Vertical transport .......................................................................................19
Transport suspended on a crane...............................................................20
Checking the scope of delivery .................................................................21
FAM Description .........................................................................................22
FAM Versions ............................................................................................22
FAM features .............................................................................................23
FAM system components ..........................................................................25
Dimensions – stationary unit .....................................................................27
Dimensions – mobile unit ..........................................................................28
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Content
Hydraulic diagram.......................................................................................29
Working principle of FAM ..........................................................................31
Possible applications .................................................................................32
Bypass purification .................................................................................32
Transfer by pumping ..............................................................................32
FAM Set-up and Connection ......................................................................33
Setting up the FAM ....................................................................................33
Notes on pipes and hoses .........................................................................35
Connecting the inlet (IN).........................................................................37
Connect outlet (OUT) .............................................................................38
Preparing the Vacuum Pump.....................................................................38
Check air outlet of the vacuum pump .....................................................39
Electrical connection of the FAM ...............................................................40
Check direction of rotation .........................................................................41
Operating Elements on the FAM................................................................42
Starting up the unit .....................................................................................44
Starting unit ...............................................................................................44
Setting the underpressure in the vacuum column......................................45
Switching on the heater / Checking setting (optional) ................................46
Venting the filter housing ...........................................................................47
Stopping/switching off unit .........................................................................48
Troubleshooting..........................................................................................50
Signal lamp "Fault / Unit off" lights up........................................................50
Performing maintenance ............................................................................54
Maintenance intervals................................................................................54
Check fault signal lamps............................................................................57
Empty oil pan.............................................................................................57
Emptying the vacuum column....................................................................58
Empty vacuum column using the ball valve............................................58
Emptying the vacuum column using the pump .......................................60
Emptying the heater ..................................................................................62
Change Air filter.........................................................................................64
Vacuum pump ...........................................................................................65
Checking the oil level .............................................................................66
Filling/Refilling vacuum pump oil ...........................................................68
Emptying the vacuum pump ...................................................................71
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Content
Changing the oil of the vacuum pump ....................................................73
Replacing the air de-oiling element of the vacuum pump.......................74
Clean the suction strainer. .........................................................................75
Replacing the filter element on the fluid filter .............................................76
Heater maintenance (optional) ..................................................................81
Inspecting/Cleaning the heating element ...............................................81
Removing/Installing the heating element ............................................82
Resetting the safety thermostat..............................................................84
Checking the AquaSensor AS1000 ...........................................................86
Checking the float switch in the oil pan......................................................86
Spare parts ..................................................................................................87
FAM ...........................................................................................................87
Fluid filter (OLF 5/10).................................................................................87
Vacuum pump ...........................................................................................87
heater ........................................................................................................88
Contact / Service.........................................................................................89
Storing the FAM/Taking it out of Operation..............................................90
Disposing of the FAM .................................................................................90
Technical Data.............................................................................................91
Connection overview .................................................................................93
Model Code..................................................................................................95
EC declaration of conformity .....................................................................96
Index ............................................................................................................97
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Preface
Preface
For you, as the owner of a product manufactured by us, we have produced
this manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in obtaining maximum
benefit in the applications for which it is designed.
Keep this documentation in the vicinity of the product for immediate
reference.
Note that the information on the unit's engineering contained in the
documentation was that available at the time of publication.Consequently,
there might be deviations in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions
or other useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
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Preface
Technical Support
If you have any questions, suggestions, or encounter any problems of a
technical nature, please don't hesitate to contact us. When contacting us,
please always include the model/type designation and article no. of the
product:
Fax:
+49 (0) 6897 509 - 846
E-Mail:
[email protected]
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.
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Preface
Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
these instructions prior to starting the unit up for the first time and
at regular intervals in the future.
WHAT do I want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the
chapter I'm looking for and the corresponding page number.
Chapter description
Page number
Edition date
Documentation No.
with Index /
File name
Document language
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
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Safety information
Safety information
The unit was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety information
Risk of burns due to hot surfaces
Substances that are health hazards or irritants
Danger from explosive atmosphere
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
NOTE indicates a danger which will lead to damage to property if not
avoided.
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Safety information
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
SIGNAL WORD
HAZARD SYMBOL
Type and source of danger
Consequence of the danger
► Measures to avert danger
Observe regulatory information
Observe the following regulatory information and guidelines:

Legal and local regulations for accident prevention

Legal and local regulations for environmental protection

Country-specific regulations, organization-specific regulations
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Safety information
Proper/Designated Use
Use the unit only for the application described in the following.
The FAM is for dewatering, filtering and degassing hydraulic and lubricating
oils. In addition, it removes free water, emulsified water and a large
percentage of the water found in solution.
Proper or designated use of the product extends to the following:
 observing all instructions contained in the instruction manual.
 performing inspection and maintenance work.
Mineral oil, tested with mineral oil.
 Mineral oils acc. to DIN 50524
 Gear oils according to DIN 51517, 51524
 Other hydraulic and lubrication oils which
require or are compatible with NBR seals
FAM-xx-I-… Insulation oil, checked with (e.g. Shell Diala).
 Mineral oils acc. to DIN 50524
 Gear oils according to DIN 51517, 51524
 Other hydraulic and lubrication oils which
require or are compatible with NBR seals
FAM-xx-B-… Biologically tested with fast-biodegrading
fluid on an ester basis.
 synthetic ester (HEES) DIN 51524/2
 Vegetable oils (HETG, HTG)
 Hydraulic and lubrication oils which
require or are compatible with Viton seals.
FAM-xx-X-… HFD-R fluids, tested with (e.g. Fyrquel).
Not for phosphate esters that require EPDM
seals.
Hoses
FAM-xx-M…
Sealing
material
Suitable
operating
medium
FAM Typ
Depending on the version (see model code), you may use the FAM only in
connection with the following media:
NBR
NBR
NBR
NBR
FKM
(FPM,
Viton®)
NBR
FKM
(FPM,
Viton®)
UPE/
PEPA
Improper use or use deviating from intended use
DANGER
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Safety information
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.
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 fluid.
 Operation under non-approved conditions.
 Operation when the safety devices are defective.
 Modifications to the unit made by the user or purchaser.
 Inadequate monitoring of parts that are subject to wear and tear
 Improperly performed repair work.
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Safety information
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Operating and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions is 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.
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
 Proof of knowledge of cargo
securing instructions
Specialist
personnel
 Safe handling/operation of
hoisting and lifting equipment
Specialist
personnel
 Safe handling/use of tools
Hydraulic / electrical
installation,
first commissioning,
maintenance,
 Fitting and connection of
hydraulic lines and
connections
repair,
 Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
decommissioning,
 Checking the phase sequence
Taking the unit apart
 Product-specific knowledge
troubleshooting,
Operation
Operations control
Specialist
personnel
 Product-specific knowledge
 Knowledge about how to
handle operating media.
 Knowledge about
contamination due to solids
and water
Disposal
Specialist
personnel
 Proper and environmentallyfriendly disposal of materials
and substances
 Decontamination of
contaminants
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Safety information
 Knowledge about reuse
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Unpacking the FAM
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.
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Transporting the FAM
Transporting the FAM
NOTICE
Using components for pushing / pulling
The FAM will be damaged
► Never use the components to push or pull the FAM.
► Use the grips provided for shifting.
Wind the suction and pressure hose and the connection cable around the
holders provided for this purpose and either fasten them in place or remove
the hoses from the FAM.
Move the FAM manually using the rollers. Only ever use the FAM's handles
to move it.
Before shifting the unit, make sure to release the hand brake on the swivel
casters.
Once the FAM is in the new, desired position, actuate the hand brake on the
swivel casters.
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Transporting the FAM
Horizontal transport
Completely empty the FAM as well as the vacuum pump before truck
transport, and close off all connections.
Close the air outlet of the vacuum pump using the matching suitable screw
plugs.
Ensure the FAM is fixed tight to the car using load restraint belts at the
suitable lashing points in the car.
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Transporting the FAM
Vertical transport
For transport by rail or truck, supports must be placed under the mobile FAM
so that none of the rollers are subjected to load pressure. Secure the FAM
with suitable belts.
Stationary version
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Transporting the FAM
Transport suspended on a crane
NOTICE
Unsuitable lifting accessories
The unit/components will be damaged/destroyed
► Use only suitable lifting accessories to raise or lash the FAM.
► Make sure that the lifting accessories do not cause any force to be
exerted on the components on the FAM.
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Checking the scope of delivery
Checking the scope of delivery
Upon receiving the FAM check it for any damage in transit. Immediately
report any damage in transit to the forwarding agent or the HYDAC
department in charge.
The following items are included in the scope of delivery:
Qty.
Designation
1
FluidAqua Mobil
1
Key to the control cabinet
1
Vacuum pump oil, 1 liter
1
Hose nipple with hose for emptying the vacuum pump
1
Suction and return hose
(only for mobile version FAM5-x-2-…)
1
Operation and Maintenance Instructions (this document)
1
Electrical wiring diagram situated in the control cabinet
1
EC declaration of conformity
1
Test certificate
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FAM Description
FAM Description
The FluidAqua FAM 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.
Degassing of the medium is also achieved via the vacuum installed in the
vacuum chamber.
FAM Versions
Stationary (FAM-x-1-..)
Mobil (FAM-x-2-..)
In comparison to the stationary version, the mobile version of the FAM also
has:
-
2x
Wheels
-
2x
Swivel casters
-
1x
Suction hose
-
1x
Return hose
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FAM Description
FAM features
The FAM is able to reduce fluids described in the chapter "Suitable fluids"
typically to the following attainable Residual water contents:
Hydraulic and lubrication oils
< 100ppm
Turbine oil (ISO VG32/46)
< 50 ppm
Transformer oil
(The FAM5 is not suitable for online or onload operation)
< 10 ppm
The typical dewatering rate is up to 0.8l/h at 1% (10,000 ppm) water content
(ISO VG32, 50°C).
Dewatering performance/Dewatering speed depends in particular on the oil
type, oil temperature, oil quantity, tank condition, water content and the
environmental conditions and can differ considerably from the indicated
values depending on use.
The dewatering speed is dependent on:
Dewatering speed
Water content
Fluid temperature
Detergent additives
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FAM Description
As an approximate guideline, the dimensioning of the FluidAqua Mobil can be
defined in accordance with the tank volume.
Tank volume in liters
Size
< 1,500
FAM 5
1,000 … 7,000
FAM 10, FAM 10/15
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
Note that free water, e.g. on the bottom of the tank, can have an influence on
the entire water content in the system and thus on the length of time it takes
to dewater. Drain off free water completely.
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FAM Description
FAM system components
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FAM Description
Item
Designation
1.0
Oil pan
2.21
Pneumatic tire
(mobile version only)
2.30
Swivel caster
(mobile version only)
3.0
Vacuum column
3.68
Vacuum gauge
(underpressure setting in the vacuum
column)
3.73
Air Filter
3.85
3/2 directional valve
4.0
Motor pump assembly
5.0
ContaminationSensor CS
(Optional)
6.0
Fluid filter for separating solid particles
OLF5
7.0
Vacuum pump
8.0
heater
(Optional)
10.0
SensorMonitoring Unit SMU
(Optional)
11.0
ConditionSensor Interface CSI-F-10
(Optional)
12.0
AquaSensor AS
(Optional)
13.0
Electrical switch box with main switch
20.1
INLET
IN
20.2
OUTLET
OUT
30.0
Holder for lances
31.0
Lifting eye
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Dimensions – stationary unit
Dimensions – stationary unit
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Dimensions – mobile unit
Dimensions – mobile unit
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Hydraulic diagram
Hydraulic diagram
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Hydraulic diagram
Item
Designation
1.0
Oil pan
1.04
Float switch in oil pan
3.0
Vacuum column
3.37
Vacuum pressure gauge
3.38
Level switch in the vacuum column
3.43
Fluid level indication of the vacuum column
3.68
Vacuum gauge
(underpressure setting in the vacuum column)
3.73
Air Filter
3.85
3/2 directional valve
4.0
Motor pump assembly
4.02
Suction strainer
4.54
Flow divider
4.70
Orifice
5.0
ContaminationSensor CS
(Optional)
6.0
Fluid filter for separating solid particles
OLF5
6.23
Check valve
7.0
Vacuum pump
8.0
heater
(Optional)
12.0
AquaSensor AS
(optional)
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Working principle of FAM
Working principle of FAM
After you switch on the FAM, the motor pump assembly (4.0), depending on
the fill level in the vacuum column, starts to suck either from the vacuum
column or the tank via the suction strainer (4.02) or from the vacuum column
and the 3/2 directional valve (3.85).
The flow rate is split up in the flow divider (4.54). One part is transported via
the optional heater (8.0) into the vacuum column (3.0), the other back into the
tank via the fluid filter (6.0).
The vacuum pump (7.0) builds up the negative pressure in the vacuum
column (3.0) required for dewatering and degassing.
The underpressure is set using the vacuum gauge (3.68) and shown in the
pressure gauge on the cover of the vacuum column (3.0).
The fluid percolates downwards in the vacuum column (3.0) over a special
tower packing and collects in the lower area. After reaching the maximum
level (3.38), the 3/2 directional valve (3.85) will switch and the motor pump
assembly (4.0) will start sucking the oil out of vacuum column (3.0).
Air is drawn in through the air filter (3.73) as a result of the negative pressure
in the vacuum column (3.0). This air absorbs the moisture of the fluid and is
then sucked out by the vacuum pump (7.0). The gases removed from the
fluid as well as the water that is absorbed (as water vapor) is expelled from
the vacuum pump.
With the optional AquaSensor (12), the degree of saturation of the sucked-in
fluid is continuously measured and shown directly on the sensor or through
the SensorMonitoring Unit. 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.
After the STOP button is pressed, the motor pump assembly (4.0) and the
vacuum pump (7.0) switch off immediately.
The FAM is voltage-free downstream from the main switch when the FAM is
switched off with the main switch.
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Working principle of FAM
Possible applications
Bypass purification
Attach the FAM to the tank which is to be cleaned by means of a suction and
pressure line and switch it on. The permanent bypass purification means you
always get optimum purity results.
Transfer by pumping
Connect up the FAM to a contaminated oil tank by means of a suction line
and pump the fluid into the clean oil tank via the FAM.
To avoid overfilling the tank (B), permanently monitor the oil level.
In order to achieve optimum purity results, always operate the
FAM in bypass current after transfer by pumping.
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FAM Set-up and Connection
FAM Set-up and Connection
Setting up the FAM
CAUTION
Danger of tipping on inclines
Crushing hazard
► Operate the power unit only on an even, level
surface.
► Do not set the unit down on an inclined
surface.
► Always set the brakes on the swivel casters.
CAUTION
Outlet air of the vacuum pump
Hazardous to health
► Always make sure there is sufficient
ventilation in the surrounding area of the unit.
Observe the following points when setting up the unit:

Place the unit on a horizontal and level surface.
Special mounting is not required.

Keep an area of at least 0.8 m around the unit free for maintenance
purposes.

Mobile version only - Lock the immobilization brakes on the wheels to
avoid unintended movement/rolling away of the unit.

Position the unit in the immediate vicinity of the tank to be cleaned.
Observe the maximum permitted suction pressure. See page 37.

Observe the ambient temperature on the type label of the unit.

Ensure that the main switch is free and accessible at all times.

Make sure there is sufficient ventilation around the area where the unit is
set up.
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FAM Set-up and Connection
Air coming out of the vacuum pump can contain particles of vacuum pump oil
and/or the fluid.
Depending on the composition of the oil and the composition of the gas,
there is a danger of damage to health if the emergent gas is inhaled over an
extended period of time.
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FAM Set-up and Connection
Notes on pipes and hoses
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
► The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
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 few threaded
connections.
The pressure at the inlet/outlet depends on the height differential between
the suction connection on the FAM and the fluid surface in the tank
(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.
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FAM Set-up and Connection
The pressure differential in a hydraulic line (  P(line)) depends on the
following:

Flow rate

kinematic viscosity

Pipe dimensions

Fluid density
The pressure loss in straight pipes (  P(line)) can be calculated as follows:
Δp ~ 6,8 * L / d4 * Q * V * D
Δp = Pressure differential in [bar]
L
= pipe length [m]
d
= internal pipe diameter [mm]
Q
= Flow rate [l/min]
V
= 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 HFD-R
1.00 … 1.10 kg/dm³
Insulating oil
0.90 … 1.00 kg/dm³
Lubricant
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
small 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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FAM Set-up and Connection
Connecting the inlet (IN)
NOTICE
Moving unsecured hoses / lances in the tank
The hoses/lances fall out of the tank
► Attach the hoses/lances to the tank and secure them against falling
out.
NOTICE
Contamination in the medium too high
The FAM will be damaged
► Do not prime directly at the bottom of the tank
► Do not prime in the sump
► Never prime without a built-in suction screen
► Never suck in free water
The greatest contamination is found on the bottom of the tank.
All impurities like water or solid particles are deposited on the
bottom of the tank. Drain out the deposited, free water at the
bottom of the tank.
The suction pressure at the FAM inlet must be -0.2 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.
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FAM Set-up and Connection
Connect outlet (OUT)
NOTICE
Moving unsecured hoses / lances in the tank
The hoses/lances fall out of the tank
► Attach the hoses/lances to the tank and secure them against falling
out.
NOTICE
The out connection is closed
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.
Take care to ensure that the maximum pressure of 2 bar is not exceeded at
the outlet.
Preparing the Vacuum Pump
After delivery/transport by car, check the vacuum pump for the following
points and prepare it accordingly for operation in compliance with the
following steps:
Step
Designation
Details on
page
1.
Check air outlet
39
2.
Checking the oil level
66
3.
Filling/Refilling vacuum pump oil
68
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FAM Set-up and Connection
Check air outlet of the vacuum pump
NOTICE
Clogged air outlet of the vacuum pump
The vacuum pump will be destroyed
► Before each startup, check the air outlet of the vacuum pump for
possible clogging.
► Before each startup, remove the screw plug or other clogs at the air
outlet of the vacuum pump.
Check that the air outlet of the vacuum pump freely lets the air out and
remove the screw plugs for transport safety.
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FAM Set-up and Connection
Electrical connection of the FAM
DANGER
Exposed electrical components in the switch
cabinet
Danger of fatal injury due to electric shock
► Any work involving the electrical system may
only be done by a properly trained, certified
electrician.
The electrical connection of units without connection plugs to the power
supply module may only be performed by a technician with corresponding
knowledge and skills.
Compare the voltage and frequency specifications on the FAM type label with
the existing network specifications. Protect the feed to the FAM by using
automatic fuses with triggering characteristic "C".
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FAM Set-up and Connection
Check direction of rotation
Check the direction of rotation of the motor by switching it on briefly (jog
mode).
The FAM requires a clockwise rotating field at the connecting socket.
NOTICE
Incorrect phase sequence / rotation direction of the motor
The pumps will be destroyed.
► In jog mode, check the direction of rotation of the motors.
► A rotation direction arrow on the fan cover of the motor identifies the
correct direction of rotation.
If rotation is in the opposite direction, rotate the phases using the phase
inverter in the connection plug.
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Operating Elements on the FAM
Operating Elements on the FAM
The following operating elements can be found on the FAM:
Item
Designation
3.37
Underpressure display
3.48
Ball valve for emptying the vacuum column
3.68
Throttle valve for vacuum in the vacuum column
7.27
Ball valve for emptying/filling the vacuum pump
8.0
Heater thermostat (optional)
10.0
SensorMonitoring Unit SMU (optional)
13.0
Main switch, on/off switch, signal lamp
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Operating Elements on the FAM
The control and display elements on the switch box have the following
functions:
Item
Control/display element
1
Main switch
-> EMERGENCY STOP button
2
On switch
-> Switch on unit
3
Stop switch
-> Switch off unit
4
Keys
-> Emptying the vacuum column
(Details see page 60)
Signal lamp
-> Fault / Unit off
5
Signal lamp
-> Unit switched on
6
Signal lamp
-> Filter contaminated
7
Signal lamp
(optional)
-> Heater switched on
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Starting up the unit
Starting up the unit
NOTICE
Connection IN / OUT closed
The unit will be destroyed
► Check to be sure that all of the locking fixtures at the inlet / outlet are
in "open" position each time before start-up.
Starting unit
To switch on the unit, proceed as follows:
1.
Switch on the unit at the main switch
lamp "Fault / Unit off" lights up.
and wait until the signal
2.
Start up the unit by pressing the on switch
3.
.
Depending on the filling level in the vacuum column, the motor pump
assembly (4.0) starts to suck either from the vacuum column or the
tank via the suction strainer (4.02) and the 3/2 directional valve
(3.85).
The flow rate is split up in the flow divider (4.54). One part is funneled
to the vacuum column (3.0), the other back to the tank via the fluid
filter (6.0).
The vacuum pump (7.0) builds up the negative pressure in the
vacuum column (3.0) required for dewatering and degassing.
4.
Set the required underpressure using the vacuum gauge (3.68). See
page 45 for details.
5.
Vent the filter housing. See page 47 for details.
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Starting up the unit
Setting the underpressure in the vacuum column
Use the vacuum gauge (3.68) to set the underpressure in the vacuum
column and check the vacuum on the vacuum pressure gauge (3.37).
Note that the pressure to be set in the vacuum column is dependent on the
operating viscosity, the water content and the air content.
The following settings are guiding values:
Medium
Operating viscosity
Pressure setting
Hydraulic oil
50 mm²/s
-0.6 bar = 400 mbar (absolute)
Lubricant
300 mm²/s
-0.4 bar = 600 mbar (absolute)
Some oils foam intensively when they enter the vacuum chamber. This effect
is particularly pronounced with high water or gas 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. In this case,
reduce the vacuum from -0.6 to -0.4 bar.
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. Reduce the vacuum to -0.3 bar in such cases.
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Starting up the unit
Switching on the heater / Checking setting (optional)
NOTICE
Oils with high viscosity
The pump will be damaged.
► Switch the heater to approx. 50°C with oil of a viscosity ≥ 350 mm²/s.
To increase the drainage performance, switch on the heater
even with oils of a viscosity ≤ 350 mm²/s.
Set the desired heater temperature using the adjustment wheel. The heater
has a safety thermostat to protect against overheating. This switches off the
heater when it reaches 110°C. The safety thermostat has to be reset
manually.
See page 84 for details.
The markings on the adjustment wheel correspond with the desired heater
temperature in Celsius [°C].
-
=
Heater OFF
F
=
Setting for frost protection
30 … 80
=
Heater temperature in °C
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Starting up the unit
Venting the filter housing
WARNING
Hot fluid
Risk of burns
► Note that hot fluid may exit during bleeding.
NOTICE
Air in the fluid filter
The filter element is not utilized completely
► Bleed the fluid filter after each shut-down / filter element replacement.
Bleed the fluid filter through the air bleed screw (X) until fluid comes out. To
do so, slightly unscrew the air bleed screw (X) in the cover counterclockwise
using an SW 6 mm Allen wrench. Tighten the bleed screw (X) clockwise after
venting.
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Starting up the unit
Stopping/switching off unit
To switch off the unit, proceed as follows:
1.
Press the key (4) "Empty
vacuum column" and hold it
down until the vacuum column
has been emptied. Always
observe the fill level indication
of the vacuum column during
the emptying.
2.
If no fluid is visible in the fill
level indicator, press the OFF
button (3), and release the
"Empty vacuum column" button.
The motor pump assembly (4.0)
and the vacuum pump (7.0) will
be switched off.
3.
The signal lamp "Fault / Unit off"
lights up.
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Starting up the unit
4.
Then switch off the unit at the
main switch (1).
5.
Close all valves at the inlet and
outlet (IN / OUT)
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Troubleshooting
Troubleshooting
DANGER
Electric shock
Danger of fatal injury
► Any work involving electrical equipment may
only be done by a properly trained, certified
electrician.
Signal lamp "Fault / Unit off" lights up
The "Fault / Unit off" signal lamp lights up as soon as the unit is switched on
at the main switch, but not in operation (operationally ready). The signal lamp
also comes on if the unit was automatically stopped by a fault or starting is
blocked.
If the unit cannot be started using the on button after being started with the
main switch or if the unit switches off automatically after three seconds in
operation, a fault is present.
The unit cannot be started or switches off after 3
seconds in operation. The signal lamp "Fault / Unit off"
lights up.
Remedy:
Perform the following steps:
Step
Cause:
Description
1.
Start the FAM by pressing the on switch.
2.
3.
4.
The FAM starts and runs
>a. normally. The signal lamp
"Fault / Unit off" goes out.
-> No fault is present.
The FAM does not start. The
>b. signal lamp "Fault / Unit off"
stays on.
-> proceed to Step 3.
The signal lamp "Filter
>a. contaminated" lights up.
-> proceed to Step 4.
No additional signal lamps light -> proceed to Step 7.
>b. up.
Switch off the unit at the main switch and switch filter element on
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Troubleshooting
the fluid filter.
See page 76 for details.
5.
6.
7.
8.
Switch on the unit at the main switch and start the unit by
pressing the on switch.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit stops after 3 seconds
>b. and the "Fault / Unit off" signal
lamp comes on.
-> proceed to Step 7.
Check the oil level in the oil pan.
The float switch in the oil
>a. collecting pan triggered due to
the oil.
-> proceed to Step 9.
There is no oil/fluid in the oil
>b. collecting pan.
-> proceed to Step 12.
9.
Look for and fix the leak immediately.
10.
Empty the oil collecting pan. See page 57.
11.
12.
13.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit does not start and the
>b. "Fault / Unit off" signal lamp
comes on.
-> proceed to Step 12.
Check the oil level in the vacuum pump. See page 66.
Oil level in the vacuum pump
>a. outside the MIN / MAX
markings.
-> proceed to Step 14.
Vacuum pump oil level OK.
>b. Within the MIN / MAX mark.
-> proceed to Step 17.
14.
Fill the vacuum pump (see page 68 ) or drain the vacuum pump
oil slightly (see page 71).
15.
Start the unit by pressing the on switch.
16.
17.
18.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit stops and the signal
-> proceed to Step 17.
>b. lamp "Fault / Unit off" lights up.
Check the vacuum column.
If the level of the vacuum
>a. column is above the mark that
has been applied.
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Troubleshooting
The level of the vacuum
>b. column is below the mark that
has been applied.
-> proceed to Step 22.
19.
Empty the vacuum column. See page 58.
20.
Start the unit by pressing the on switch.
21.
22.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit stops and the signal
-> proceed to Step 22.
>b. lamp "Fault / Unit off" lights up.
The unit has a heater.
>a.
-> proceed to Step 23.
The unit does not have a
>b. heater.
-> proceed to Step 29.
23.
Switch off the unit at the main switch.
24.
Disconnect the unit from the power supply.
25.
Check the heater.
26.
Reset the safety thermostat on the heater. See page 84.
27.
Connect the unit to the power supply.
28.
Switch on the unit at the main switch.
29.
Start the unit by pressing the on switch.
30.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit does not start or
>b. switches off after 3 seconds in
operation and the "Fault / Unit
off" signal lamp comes on.
-> proceed to Step 31.
31.
Switch off the unit at the main switch.
32.
Disconnect the unit from the power supply.
33.
Open the switch box on the unit.
Check the motor protection switch and fuses in the unit switch
box.
34.
35.
A motor protection switch or a
>a. fuse has tripped.
-> proceed to Step 35.
All motor protection switches /
>b. fuses are switched on.
-> proceed to Step 101.
Synchronize the settings on the motor protection switch with the
specifications on the motor type label.
If necessary, correct the settings on the motor protection switch
and switch it on again.
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Troubleshooting
Close the control cabinet.
36.
Connect the unit to the power supply.
37.
Switch on the unit at the main switch.
38.
Start the unit by pressing the on switch.
39.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit does not start or
>b. switches off after 3 seconds in
operation and the "Fault / Unit
off" signal lamp comes on.
-> proceed to Step 40.
40.
Switch off the unit at the main switch.
41.
Disconnect the unit from the power supply.
42.
Open the switch box.
Check the motor protection switch and the fuses in the switch
box as well as the cabling and the motor in detail. Test the
components.
43.
Connect the unit to the power supply.
44.
Switch on the unit at the main switch.
45.
Start the unit by pressing the on switch.
46.
The unit starts and runs
>a. normally.
-> proceed to Step 100.
The unit does not start or
>b. switches off after 3 seconds in
operation and the "Fault / Unit
off" signal lamp comes on.
-> proceed to Step 101.
100.
The fault is repaired.
101.
Contact the HYDAC Service Department.
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Performing maintenance
Performing maintenance
WARNING
FAM in operation
Danger of bodily injury
► Switch off the unit before any maintenance
work.See page 48 for details.
The safety of all persons coming into contact with the FAM and the
availability of the unit for use are dependent on regular servicing and
maintenance.
Maintenance intervals
The inspection and maintenance works listed here are necessary conditions
for ensuring both long service life and error-free operation of the FAM.
6000 hours /
annually
24 hours /
daily
3000 hours /
every six months
See page
500 hours /
monthly
In addition, you will find further information in the operating manuals
published by the manufacturers of the components which are supplied with
the FAM.
Check the FAM for any leaks
(visual check).
-
X
Check the screwed fittings to see
that they have been properly
resecured.
-
X
Check the testing method /
Vacuum pressure gauge in the
vacuum column /
Differential pressure gauge on the
fluid filter
-
X
FAM
Check the fault signal lamps
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Change Air filter
64
Clean the suction strainer.
75
Check the AquaSensor
86
6000 hours /
annually
3000 hours /
every six months
500 hours /
monthly
24 hours /
daily
See page
Performing maintenance
X
X
X
Check the float switch in the oil pan
X=
other
voltag
e
86
Vacuum pump
Checking the oil level
66
Replace the oil and air de-oiling
element
73
X
Check and clean the ventilator
hood
-
X
-
X=
other
voltag
e
76
X=
other
voltag
e
-
X
X
Motor pump assembly
Check and clean the ventilator
hood
Main Filter
Changing the Filter Element
Heater (Option)
Check that the connectors are in
contact and tight
Clean the heating element
Synchronize the electricity
consumption of the heater by
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6000 hours /
annually
3000 hours /
every six months
500 hours /
monthly
24 hours /
daily
See page
Performing maintenance
comparing the current values with
those on the type label. (Optional)
Electrics
Check the cable conduits for
damage
-
X
Synchronize the electricity
consumption of the motors by
comparing the nominal values on
the type labels.
-
X
Perform an electrical safety
inspection in accordance with DIN
VDE 0702 and/or corresponding
national regulation.
X=
other
voltag
e
-
Replace all hoses no later than after 5 years.
Perform the following work as needed:
FAM
For details see page
Empty oil pan
57
Empty vacuum columns
58
Emptying the heater
62
All pictures and illustrations in the descriptions are examples. They do not
represent all of the different product variants.
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Performing maintenance
Check fault signal lamps
To check the fault signal lamp, switch on the FAM at the main switch. The
signal lamp "Fault / Unit off" then lights up.
Empty oil pan
Empty the oil collection pan by opening the screw plug (X). Dispose of the
draining oil in an environmentally-friendly manner.
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Performing maintenance
Emptying the vacuum column
Empty the vacuum column using the ball valve or with the pump. To do this,
proceed as follows.
Empty vacuum column using the ball valve.
Make sure that a suitable container is available. Open the ball valve and
collect the fluid that comes out. Once no more fluid escapes, close the ball
valve. Fill the oil back into the tank or dispose of it in an environmentallyfriendly manner.
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Performing maintenance
Check the level in the vacuum column via the fill level display. If no fluid is
visible in the fill level indicator, close the ball valve.
Fill the oil back into the tank or dispose of it in an environmentally-friendly
manner.
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Performing maintenance
Emptying the vacuum column using the pump
When emptying the vacuum column via the pump, the fluid is pumped out of
the vacuum column and fed to the return circuit.
To empty the vacuum column via the pump, proceed as follows:
1.
If the unit is switched off, switch
on the unit at the main
switch (1).
2.
Start the unit by switching it on
at the on switch (2)
Press the key (4) "Empty
vacuum column," and hold it
down until the vacuum column
has been emptied. Always
observe the fill level indication
of the vacuum column during
the emptying.
3.
If no fluid is visible in the fill
level indicator, press the OFF
button (3), and release the
"Empty vacuum column" button
(4).
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Performing maintenance
4.
The signal lamp "Fault / Unit off"
lights up.
5.
Then switch off the unit at the
main switch (1).
6.
Close all valves at the inlet and
outlet (IN / OUT)
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Performing maintenance
Emptying the heater
Empty the heater via the drain screw. Fill the oil back into the tank or dispose
of it in an environmentally-friendly manner.
To empty the heater, proceed as follows:
1.
Stop the unit at the off switch and switch
off the FAM at the main switch.
2.
Pull out the plug / Disconnect the FAM
from the power supply.
3.
Allow the heater to cool down.
4.
Always drain the vacuum column first.
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Performing maintenance
5.
Screw the drain screw clockwise out of
the heater.
6.
Collect the escaping fluid in a suitable
container.
Fill the oil back into the tank or dispose
of it in an environmentally-friendly
manner.
7.
Screw the drain plug counterclockwise
into the filter bowl and tighten it firmly.
8.
Emptying the heater is now complete.
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Performing maintenance
Change Air filter
Replace the air filter (3.73) every six months. If the FAM is in a very
dusty/damp environment, the replacement intervals shorten accordingly.
To replace the air filter, proceed as follows:
1.
Unscrew the air filter (3.73) by hand counterclockwise.
2.
Dispose of the used air filter in an environmentally-friendly manner.
3.
Screw in the new air filter (3.73) clockwise by hand and tighten it only
by hand.
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Performing maintenance
Vacuum pump
The vacuum pump possesses the components described below:
Item
Designation
a
Oil filler neck
c
Oil drain
d
Oil sight glass
g
Oil separator
h
Suction port connection
i
Air vent
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 maintenance
Checking the oil level
NOTICE
Operation without vacuum pump oil
The vacuum pump will be destroyed
► As operating fluid, the vacuum pump solely requires synthetic vacuum
pump oil in accordance with DIN 51506, Group VDL, ISO VG100.
► Check the oil level before start-up, topping up with vacuum pump oil if
necessary.
Check the oil fill level of the vacuum pump on a monthly basis. If necessary,
fill up with vacuum pump oil. Max. capacity is approx. 0.3 liters.
The level switch monitors the oil level of the vacuum pump in operation. If the
fill level reaches the MIN / MAX level, it will switch off and the signal lamp
"Fault / Unit off" will light up.
To fill up the vacuum pump, proceed as described on page 68.
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Performing maintenance
You may only use synthetic vacuum pump oil in accordance with DIN 51506,
Group VDL, ISO VG100 when topping up.
Vacuum pump oil is available from HYDAC under the following part no.:
Description
Part no.:
Vacuum pump oil VE101
DIN 51506, Group VDL, ISO VG100, synthetic
1 liters
06018128
Vacuum pump oil VE101
DIN 51506, Group VDL, ISO VG100, synthetic
5 liters
06018129
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Performing maintenance
Filling/Refilling vacuum pump oil
WARNING
Hot surfaces
Risk of burns
► Keep distant from hot surfaces.
► Allow the vacuum pump to cool down before
performing any work.
Proceed as follows to fill the vacuum pump:
1.
Switch the unit off at the
main switch and unplug the
power connector.
Allow the vacuum pump to
cool down.
2.
Remove the threaded
coupling (k) for the plug at
the level switch.
Remove the plug (I) for the
level switch in an upward
direction.
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Performing maintenance
3.
Unscrew the level switch
(m) from the vacuum pump
by turning counterclockwise
using a 24 mm open-ended
wrench.
Carefully remove the level
switch from the vacuum
pump in an upward
direction.
4.
Fill the vacuum pump with
vacuum pump oil VE 101
via the filler neck (a).
5.
Check the oil level through
the inspection glass (d). Fill
the vacuum pump to no
higher than the MAX mark.
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Performing maintenance
6.
Insert the level sensor into
the vacuum pump from
above. To facilitate
installation, lift up the lower
float.
Screw the level switch (m)
into the vacuum pump by
turning clockwise using a 24
mm open-ended wrench
and tighten it.
7.
Insert the plug (l) into the
level switch and secure it by
tightening the threaded
coupling (k).
8.
The vacuum pump filling is
complete.
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Performing maintenance
Emptying the vacuum pump
WARNING
Hot surfaces
Risk of burns
► Keep distant from hot surfaces.
► Allow the vacuum pump to cool down before
performing any work.
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Performing maintenance
To empty the vacuum pump, proceed as follows:
1.
Switch the unit off at the main switch and unplug the power
connector.
Wait until the vacuum pump has cooled off.
2.
Keep a suitable container on the floor under the drain tap to catch ~ 1
liter of vacuum pump oil.
3.
Unscrew the screw plug from the drain fitting.
4.
Screw the hose nipple with hose onto the drain fitting. Place the hose
in the container and hold it securely during the entire process.
5.
Open the ball valve and allow the vacuum pump oil to drain
completely.
6.
Once no more vacuum pump oil escapes, close the ball valve.
7.
Unscrew the hose nipple with hose from the drain fitting.
8.
Screw the screw plug back into the drain fitting.
9.
The filter element is to be disposed of in an environmentally correct
manner.
10. Emptying the vacuum pump is complete.
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Performing maintenance
Changing the oil of the vacuum pump
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)
To change the oil on the vacuum pump, proceed as follows:
1.
Empty the vacuum pump as described on page 71.
2.
Remove the old oil filter and dispose of it in an environmentally friendly
manner.
3.
Install the new oil filter.
4.
Fill the vacuum pump as described on page 68.
5.
The oil change and oil filter change is complete.
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Performing maintenance
Replacing the air de-oiling element of the vacuum pump
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 perform these tasks, you will need the following tools and
equipment:

Maintenance set, comprising oil filter, air deoiling element,
ventilation cover seal (for part-no., see replacement parts list).

Fork wrench, size 10 mm
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 Oring.
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 approx. 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 deoiling element has been replaced is therefore quite normal.
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Performing maintenance
Clean the suction strainer.
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 disassemble/install the suction strainer, proceed as follows:
3
2
1
1. Unscrew the screw plug (1) counterclockwise with an open-jaw wrench.
2. Remove strainer insert (3).
3. Clean the strainer insert, flush it out and then blow-flush it using
compressed air.
4. Check strainer insert (3) and sealing ring (2) on the screw plug for
damage. Replace it if necessary.
5. Insert the strainer insert (3).
6. Manually screw in the screw plug (1) clockwise.
Tighten the screw plug (1) with a open-jaw wrench.
7. Check the suction strainer fitting for leaks after commissioning.
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Performing maintenance
Replacing the filter element on the fluid filter
If the signal lamp "Change fluid filter" lights up, replace the filter element as
described in the following:
1.
Switch off the FAM at the main switch
and close the shut-off valve at the inlet
and outlet in order to prevent the oil from
flowing back out of the tank.
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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Performing maintenance
4.
Pull the filter bowl including filter element
downwards.
5.
Remove (2) the filter element from the
filter bowl by turning slightly (1).
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Performing maintenance
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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Performing maintenance
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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Performing maintenance
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.
Bleed the filter housing as described on
page 47.
After commissioning, check the filtration
unit for leaks.
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Performing maintenance
Heater maintenance (optional)
WARNING
Hot surfaces
Risk of burns
► Allow the heater to cool down before
performing any work.
The use of different oils can lead to a build-up of a layer of film on the heating
element. Regularly inspect and clean the heating element.
Inspecting/Cleaning the heating element
NOTICE
Layer of film on the heating element
The heating element will be destroyed.
► Clean the heating element annually.
If the heating element is covered in a layer of film, this will prevent the heat
from being transferred to the oil and may cause the heating element to burn
out and power requirements to increase.
Clean the heating element using suitable means. In so doing, make sure
there is compatibility with seals and plastics.
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Performing maintenance
Removing/Installing the heating element
To remove the heating element, proceed as follows:
1.
Stop the unit at the off switch and switch
off the FAM at the main switch.
2.
Pull out the plug / Disconnect the FAM
from the power supply.
3.
Allow the heater to cool down.
4.
Empty the vacuum column.
See page 58 for details.
5.
Empty the heater.
See page 62 for details.
6.
Pull the setting switch of the heater up and
off. And remove the two covering stoppers
of the screw holes.
7.
Unscrew and remove the two screws
(Torx 20).
8.
Disconnect all electrical connections to the
heater and pull the cable from the cable
fittings.
This work may only be done by
authorized technical staff.
9.
Rotate the heating element
counterclockwise out of the sheathing
using a fork wrench SW = 65 mm.
10. Pull the heating element up and out of the
sheath.
11. Clean the connecting thread of old sealing
material.
12. Clean the heating element completely with
citric acid.
13. Check the heating element for
overheating. This can be seen in a bent
heater core or sheath and in crack
formations.
If required, replace the heating element or
the sheath. Contact HYDAC in this regard.
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Performing maintenance
14. As a seal, wrap Teflon tape around the
connecting thread on the heating element.
15. Insert the heating element into the sheath
from above and screw on the heating
element clockwise by hand.
16. Continue to screw on the heating element
clockwise using a fork wrench SW = 65
mm into the sheath and tighten it.
17. Insert all cabling through the cable fittings
and attach all electrical connections to the
heater.
This work may only be done by
authorized technical staff.
18. Attach the cover to the heater.
Screw in both screws (Torx 20) and
tighten them firmly.
19. Attach the setting switch and the two
covering stoppers for the screw holes.
20. Plug the mains plug or connect the FAM
up to the main electricity supply.
21. Switch on the FAM at the main switch and
start the unit by pressing the on switch.
22. Check the heater for any leaks while in
operation.
21. Cleaning/Replacing the heater is
complete.
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Performing maintenance
Resetting the safety thermostat
If the heater reaches a temperature of 110°C, the safety thermostat will
trigger. The safety thermostat then needs to be reset manually. To do so,
proceed as follows:
Detach the cover from the heater:
1.
Stop the unit at the off switch and switch
off the FAM at the main switch.
2.
Pull out the plug / Disconnect the FAM
from the power supply.
3.
Let the unit / FAM and the heater cool
down.
4.
Pull the setting switch of the heater up and
off. And remove the two covering stoppers
of the screw holes.
5.
Unscrew and remove the two screws
(Torx 20).
6.
Pull the upper heater part up and out.
7.
Press the pin / lever (T) on the safety
thermostat with a small screwdriver.
8.
Attach the upper heater part onto the
heater from above.
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Performing maintenance
9.
Attach the upper heater part tight by
screwing in the two screws.
10. Attach the setting switch of the heater onto
the shaft from above.
Note that the adjustment switch only fits
one way onto the shaft.
11. Plug the mains plug or connect the FAM
up to the main electricity supply.
12. Switch on the FAM at the main switch and
start the unit by pressing the on switch.
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Performing maintenance
Checking the AquaSensor AS1000
Check the AquaSensor annually with the calibration and adjustment set. This
can be acquired from HYDAC under item no. 3122629.
You can find further information in the calibration and adjustment set
instruction manual.
Replace the AquaSensor if it exhibits great deviations.
Checking the float switch in the oil pan
Proceed as follows to test the float switch:
1.
Use your fingers to raise the float switch in
the oil pan.
2.
The FAM must shut down after ~ 3
seconds and the "Fault / Unit off" signal
lamp comes on.
3.
Release the float switch and acknowledge
the fault message by pressing the
key.
4.
The FAM resumes operation.
5.
The function of the float switch is thus
ensured and the check has been
successfully completed.
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Spare parts
Spare parts
Make sure to indicate the entire unit designation from the unit designation
and the serial number when ordering spare parts.
FAM
Quantit Designation
y
Part no.
1
Breather filters
0030 MG 020
300873
1
Motor pump assembly
*
1
Suction strainer 1/2 assy.,
consisting of:
6019635
1x strainer insert, 250µm
-
1x sealing ring
6033967
1
Vacuum pressure gauge
639989
1
3/2 directional valve
3595115
1
Pressure hose, Length = 5 m
6013308
1
Suction hose, Length = 5 m
6004781
1
Level sensor (vacuum chamber)
1204801
*) available on request
Fluid filter (OLF 5/10)
Quantit Designation
y
Part no.
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
*) available on request
Vacuum pump
Quantit Designation
y
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Spare parts
1
Vacuum pump
*
1
Screw plug for the air outlet
*
1
Filling and draining hose
*
1
Ball valve for draining
551093
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
*) available on request
heater
Quantit Designation
y
Part no.
1
O-ring for housing
*
1
Adjustment switch
*
1
Seals
*
*) available on request
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Contact / Service
Contact / Service
For product information, technical support or if you have comments or
suggestions concerning this manual, please contact:
HYDAC FILTER SYSTEMS GMBH
Telephone:
++49 (0) 6897 509 1174
Telefax:
++49 (0) 6897 509 846
E-Mail:
[email protected]
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
Friedrichstaler Straße 15a, Werk 13
66540 Neunkirchen-Heinitz
Germany
Telephone:
++49 (0) 681 509 883
Telefax:
++49 (0) 681 509 324
E-Mail:
[email protected]
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Storing the FAM/Taking it out of Operation
Storing the FAM/Taking it out of Operation
Drain the unit completely, including all of its components, the same way it is
done before putting it into storage, as described under maintenance.
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: -20 … 60°C
Disposing of the FAM
Please 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.
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Technical Data
Technical Data
Refer to the type label for specific data of the unit.
Flow rate at 50 Hz
~ 5 l/min
Permitted fluids**
Fluids compatible with NBR seals:
Mineral oils to DIN 50524
Gear oils to DIN 51517, 51524
Fluids compatible with FKM (FPM, Viton®)
seals:
Synthetic esters (HEES) DIN 51524/2
Vegetable oils (HETG, HTG)
HFD-R fluids (not for phosphate esters that
require EPDM seals).
Sealing material
see model code
Filter size of fine filter
OLF 5
Filter elements
N5DMxxx
Clogging indicator
Differential pressure switch with shutdown
of the unit when the filter is clogged.
Pump type
Rotary vane vacuum pump
Pump type Filling & Draining
Gear pump
Operating pressure
0 … 8 bar / 0 … 116 psi
Permissible suction pressure
at suction port.
-0,2 … +1 bar / -2,9 … 14,5 psi
Permissible
15 … 350 mm²/s (without integrated heater)
Operating viscosity range **
15 ... 550 mm²/s (with integrated heater)
Permissible viscosity range for 15 … 200 mm²/s - with technical
the particle measurement
measurement equipment (ACS)
Fluid temperature range**
10 … 80 °C / 50 … 176 °F
Ambient temperature **
10 … 40 °C / 32 … 104 °F
Storage temperature range**
10 … 40 °C / 32 … 104 °F
Relative ambient humidity
maximum 90%, non-condensing
Electrical power consumption
(without heater) / required
external fuse*
~ 1 kW / 16 A use automatic fuses with
triggering characteristic C
Heating output (optional)
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Technical Data
IP class
IP54
Length of electronic cable /
plug
10 m / CEE (depending on the nominal
voltage)
Length of connection hoses
5 m (only in mobile version)
Material hoses
see model code
Hydraulic connectors
See Connection Overview table, on page 93
Empty weight
~ 120 kg
Noise level according to
VBG121
< 70 dB(A) at 1 m distance
Achievable residual water
content
< 100 ppm - Hydraulic and lube oils
< 50 ppm - Turbine oils (ISO VG 32/46)
< 10 ppm - Transformer oils ***
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Technical Data
Connection overview
Item
FAM 5
1
FAM inlet
connector
42L / M52x2
(external thread)*
2
Adapter
Adapter G1 ½ A
(external thread)**
3
FAM outlet
connector
28L / M36x2
(external thread)*
4
Adapter
Adapter G1 A
(external thread)**
5
Suction hose
connection
42L / M52x2
(internal thread)***
6
Adapter
Adapter G1 ½ A
(external thread)**
7
Pressure hose
connection
28L / M36x2
(internal thread)***
8
Adapter
Adapter G1 A
(external thread)**
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Technical Data
*)
Output drive type D according to ISO 8434-1 Series L (corresponds
to ISO 12151, Form S, Series L)
**)
Stud end according to ISO 1179-2 (Form E)
***) Output drive type N according to ISO 8434-4 Series L (corresponding
to ISO 12151, Form SWS, Series L)
Contained within the scope of supply of the stationary FAM items 1 .... 4. In
the scope of supply of the mobile FAM you also receive with the connection
hoses the items 5 … 8.
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Model Code
Model Code
FAM
- 5 - M - 2 - A - 05
- R - H
-
B - Z - 1 /
-
Product
FAM
=
FluidAqua Mobil
=
~ 5 l/min
Size
5
Operating fluid
M
=
Mineral oil – NBR seals, checked with
mineral oil*
I
= Insulation oil – NBR seals, checked with
insulation oil*
X
= HFD-R phosphoric acid ester fluids –
FPM seals checked with HFD-R fluid*
B
= Rapidly biodegradable (ester-based) –
FKM seals, NBR hoses, checked with
rapidly biodegradable fluid on an ester
basis*
*Residues of test liquid will remain in the unit after
testing.
Mechanical type
1
2
=
=
Stationary, with feet
Mobile, with rollers) / wheels
Voltage / Frequency / Power supply
A
B
E
H
K
M
O
P
S
AD
X
=
=
=
=
=
=
=
=
=
=
=
400 V, 50 Hz, 3 Ph+PE
415 V, 50 Hz, 3 Ph+PE
220 V, 60 Hz, 3 Ph+PE
1)
440 V, 60 Hz, 3 Ph+PE
1)
480 V, 60 Hz, 3 Ph+PE
230 V, 50 Hz, 1 Ph+PE
1)
460 V, 60 Hz, 3 Ph+PE
230 V, 60 Hz, 1 Ph+PE
380 V, 50 Hz, 3 Ph+PE
220 V, 60 Hz, 3 Ph+PE
other voltage
Filter size fluid filter
05
=
OLF-5
Vacuum pump
R
=
Rotary vane vacuum pump
=
=
without heater
Heater (for 200 … 359 V = 1 kW, for 360 … 690 V = 2.4 kW)
heater
Z
H
Control concept
B
=
Basic
Instrumentation
Z
A
C
ACS
=
=
=
=
none
AquaSensor (AS)
ContaminationSensor (CS)
AquaSensor + ContaminationSensor + SensorMonitoring Unit
(to display and save the measured values)
Modification number
00
=
Version. (You will always receive the current version.)
Supplementary details
Without details
= Series
GSM = with GSM radio module (HYDAC CSI-F-10)
V
= Sealing material FKM
*
Maximum specification (depending on equipment).
**
Other fluids, viscosities or temperature ranges on request.
*** Unit is not suitable for "Online" and "Onload" operation (transformer in
operation and connected to grid
1)
Delivery without connection plug.
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2012-12-12
EC declaration of conformity
EC declaration of conformity
HYDAC FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saar
Germany
Industriegebiet
66280 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 509 01
Internet: www.hydac.com
EC declaration of conformity
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
Type
Part no.
Serial no.
FluidAqua Mobil
FAM 5 - Series
-
EU-Machinery Directive
EU Electrical Equipment Regulations
EU-Directive on Electromagnetic Compatibility
Safety of machinery and devices
2006/42/EC
2006/95/EC
2004/108/EC
EN 12100-1/2
2012-05-30
Date
(CE official)
Dr. Andreas Schunk
Name
Executive director:
Documentation Representative:
Mathias Dieter, Dipl.Kfm. Wolfgang Haering
Gunter Harge
Registered seat of company: 66280 Sulzbach / Saar - Germany
c/o IHYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Registry Court: Saarbrücken, HRB 17216
Value added tax identification number: DE 815001609
Tax number : 040/110/50773
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2012-12-12
Index
Index
A
E
AquaSensor · 26
Ausschalter · 43
Einschalter · 43
C
S
SensorMonitoring Unit · 26
ContaminationSensor · 26
D
Drosselventil · 42
FAM 5
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V
Vakuumpumpe
Luftaustritt · 39
en(us)
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2012-12-12
HYDAC FILTER SYSTEMS GMBH
Industriegebiet
Postfach 1251
66280 Sulzbach/Saar
66273 Sulzbach/Saar
Germany
Germany
Phone: +49 (0) 6897 509 01
Fax:
+49 (0) 6897 509 846
Fax:
+49 (0) 6897 509 577
Internet: www.hydac.com
E-Mail: [email protected]
Central
(Technical Department)
(Sales Department)

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