Hydac FluidCarrier Compact Series Operating And Maintenance Instructions Manual
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Hydac FluidCarrier Compact Series Operating And Maintenance Instructions Manual

Hydac FluidCarrier Compact Series Operating And Maintenance Instructions Manual

With condition monitoring
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FCC-CM
FluidCarrier Compact
with ConditionMonitoring
Operating and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Document No.: 3648206

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  • Page 1 FCC-CM FluidCarrier Compact with ConditionMonitoring Operating and Maintenance Instructions English (translation of original instructions) Keep for future reference. Document No.: 3648206...

  • Page 2: Imprint

    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 6897 509 1511 Fax: +49 6897 509 1394 E-mail: guenter.harge@hydac.com © HYDAC FILTER SYSTEMS GMBH All rights reserved.

  • Page 3: Table Of Contents

    Content Content Imprint ......................2 Documentation Representative ..............2 Content ......................3 Preface ......................5 Technical Support ..................5 Product modification ..................5 Warranty ...................... 5 Using the documentation ................6 Safety information ..................7 Hazard symbols ................... 7 Signal words and their meaning in the safety information and instructions ....................
  • Page 4 Content Flushing an external tank or system ............30 Switching on the unit .................. 31 Observe the clogging indicator ..............31 Viewing and resetting the optical clogging indicator ....... 31 Observing electrical clogging indicator ........... 31 Operating the volume meter (optional accessories) ........ 32 Replacing the battery .................

  • Page 5: Preface

    After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to opera- tion until it has been checked and released by a HYDAC technician. Please notify us immediately of any modifications made to the product whether by you or a third party.

  • Page 6: Using The Documentation

    Preface Using the documentation Note that the method described for locating specific information does not release you from your responsibility of carefully reading all 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.

  • Page 7: Safety Information

    Safety information Safety information The unit was built according to the statutory provisions valid at the time of de- livery 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.

  • Page 8: Signal Words And Their Meaning In The Safety Information And Instructions

    Safety information Risk of burns due to hot surfaces Signal words and their meaning in the safety information and instruc- tions The following signal words are to be found in these instructions. DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result lethal or serious injury.

  • Page 9: Proper/Designated Use

    Safety information Proper/Designated Use Use the filtration unit only for the application described in the following. The filtration unit is a portable fluid service unit for filling hydraulic systems, flushing small hydraulic systems, for offline filtration and recirculation with simultaneous filtration. Proper or designated use of the product extends to the following: •...
  • Page 10 Safety information NOTICE Suction strainer missing / operating without a suction strainer The filtration unit will be destroyed Never operate the filtration unit without a suction strainer ► Clean the suction strainer regularly. ► en(us) FCC-CM Page 10 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 11: Improper Use Or Use Deviating From Intended Use

    Any use extending beyond or deviating therefrom shall not be considered in- tended use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use. The owner alone, shall assume any and all associated risk Improper use or use deviating from intended may result in hazards and/or will damage the unit.

  • Page 12: Qualifications Of Personnel / Target Group

    Safety information Qualifications of personnel / target group Persons who work on the power unit must be aware of the associated haz- ards when using the power unit. Operating and specialist personnel must have read and understood the op- erating instructions, in particular the safety information and instructions, and applicable regulations before beginning work.

  • Page 13: Wear Suitable Clothing

    Safety information Wear suitable clothing Loose-fitting clothing increases the risk of being caught or being drawn in on rotating parts, and the risk of getting caught on protruding parts. You can be severely injured or killed. • Wear close-fitting clothing. •...

  • Page 14: What To Do In Case Of Emergency

    Unpacking the unit What to Do in Case of Emergency In case of emergency, switch off the power unit or disconnect it. Firefighting/Extinguishing Fires Use a powder extinguisher that corresponds to fire class B as per EN 2 to ex- tinguish any fires.

  • Page 15: Transporting The Unit

    Transporting the unit Transporting the unit Release the hoses at the couplings and drain the contents of the hoses back to the tank or dispose of the contents in an environmentally-friendly way. Wind the power connection chord and both hoses to the hose retainer. Push the filtration unit only at the grip.

  • Page 16: Decoding The Name Plate

    Decoding the name plate Decoding the name plate Details for identifying the filtration unit can be found on the name plates on the unit and the components. Item -> Description -> Name plate of filtration unit -> Name plate of electric motor ->...
  • Page 17 Decoding the name plate The following information can be found on the name plate of the unit: -> Description Part No. -> Part number -> Serial number / year of production Power -> Power consumption Voltage/Grid -> Voltage / power supply Frequency ->...

  • Page 18: Checking The Scope Of Delivery

    Checking the scope of delivery Checking the scope of delivery The FluidCarrier Compact FCC is ready for operation upon delivery. Before putting the filtration unit into operation, check it for possible damage. The following items are supplied: Designation FCC, ready for connection with suction and pressure hose, power chord including power plug Operation and Maintenance Instructions (this document) en(us)

  • Page 19: Characteristics Of The Unit

    Characteristics of the unit Characteristics of the unit The filtration unit has been developed for the maintenance of machine tools with tank volumes up to 200 liters. The filtration unit allows you to transport and refill filtered quantities with a monitored oil purity grade. The filtration unit allows offline filtration and/or flushing of small tanks or sys- tems.
  • Page 20 Characteristics of the unit Item Designation Inlet Outlet Sliding grip Fluid level indication Hose retainer Electrical switch box with main switch Nose wheel with immobilization brake Suction strainer Inspection opening for tank Chassis 11.1 Breather filter Filtration unit Clogging indicator Contamination Sensor Ball valve IN Ball valve OUT...

  • Page 21: Filtration Unit Dimensions

    Characteristics of the unit Filtration unit dimensions The filtration unit has the following dimensions: All dimensions in mm. en(us) FCC-CM Page 21 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 22: Filtration Unit Hydraulicsschematic

    Characteristics of the unit Filtration unit hydraulicsschematic The filtration unit has the following hydraulic circuit: AS1000/ CS1000 AS3000 11.1 DRAIN Item Designation Inlet Outlet Fluid level indication Suction strainer 11.1 Breather filter Filtration unit Clogging indicator Protective screen to Contamination Sensor Contamination Sensor AquaSensor (optional) Ball valve IN...

  • Page 23: Setting Up The Unit

    Setting up the unit Setting up the unit Set up the unit in such a way that it is secured against unintentional dis- placement. To do so, apply the parking brake on the front wheel. Select the desired operating mode, see Chapter "Selecting operating modes" on page 26.

  • Page 24: Attaching/Connecting The Suction Hose

    Setting up the unit Attaching/connecting the suction hose NOTICE High solid particle contamination in fluid The filtration unit will be destroyed. Never prime without a built-in suction screen. ► Do not prime directly at the bottom of the tank. ► Do not prime in the sump.

  • Page 25: Avoid Siphoning

    Setting up the unit Avoid siphoning NOTICE Siphoning effect Tanks overflowing/leaking = oil spill Remove the ends of the hoses from the tanks after operation. ► If there is a height difference (Δh) between the suction-side and pressure- side tanks, a suction effect can develop in the hose that is lower down, caus- ing the fluid levels to equalize in accordance with a principle of communi- cating vessels (siphoning).

  • Page 26: Selecting Operating Modes

    Selecting operating modes Selecting operating modes The unit has the following two operating modes: Operating mode For details, see page Filling the unit Filtering the unit contents Draining the unit Flushing an external tank or system en(us) FCC-CM Page 26 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 27: Filling The Unit

    Selecting operating modes Filling the unit To fill the unit, proceed as follows: Set both ball valves to the position shown. Using the lance, put the suction hose into the appropriate reservoir with fresh oil without tension or twist, and secure the suction hose against falling out or floating.

  • Page 28: Filtering The Unit Contents

    Selecting operating modes Filtering the unit contents Proceed as follows to filter the unit contents: Set both ball valves to the position shown. Plug the power plug into a suitable power outlet. Make sure that the voltage is correct. Switch on the unit at the main switch. 3 to 4 circulations are necessary to filter the tank contents of 70 liters.

  • Page 29: Draining The Unit / Filling Tanks Or Systems

    Selecting operating modes Draining the unit / filling tanks or systems To fill tanks or systems, proceed as follows: Set both ball valves to the position shown. Using the lance, put the return hose into the appropriate reservoir with- out tension or twist, and secure it against falling out or floating. Plug the power plug into a suitable power outlet.

  • Page 30: Flushing An External Tank Or System

    Selecting operating modes Flushing an external tank or system To filter an external tank or system, proceed as follows: Set both ball valves to the position shown. Using the lance, put the return hose into the appropriate reservoir with- out tension or twist, and secure it against falling out or floating. Using the lance, put the suction hose into the appropriate reservoir without tension or twist, and secure it against falling out or floating.

  • Page 31: Switching On The Unit

    Switching on the unit Switching on the unit Before switching on, select and set the the desired operating mode as de- scribed in Chapter "" as of page and follow the steps stated below. Monitor the filling level display (4) at the filtration unit and clogging indicator (51) during operation.

  • Page 32: Operating The Volume Meter (Optional Accessories)

    Operating the volume meter (optional accessories) Operating the volume meter (optional accessories) The meter housing consists of impact-resistant fiberglass-reinforced plastic. The electronic component is shock-proofed and sealed against oil intrusion. The electronics are powered by a lithium battery with an expected life of ≈ 7 years in normal use.

  • Page 33: Calibrating The Totals Counter

    Operating the volume meter (optional accessories) Calibrating the totals counter Pressing the TOTAL button will cause the accumulator memory value to be displayed for as long as the button is being pressed, but only as long as no volume pulses are coming in (see also calibration or correction factor). The correction factor programmed at the factory shows during the basic me- ter precision test with an electronic display attached.

  • Page 34: Programming The Volume Meter

    Operating the volume meter (optional accessories) Programming the volume meter The units of measurement and the correction factor can be programmed. For programming, a button on the bottom of the meter is actuated and kept switched on during the entire programming process. The programming key is only accessible after the electronic counter has been removed from the measuring chamber.
  • Page 35 Operating the volume meter (optional accessories) saved and ready for confirmation. When the program value is saved as described in section 8), the mi- cro-processor multiplies the now defined correction value with the source value defined according to programming item 2). The factor gained in this way represents the correct volume increment corre- sponding to an input test pulse.

  • Page 36: Correcting/Setting The Measurement Accuracy

    Operating the volume meter (optional accessories) Correcting/setting the measurement accuracy Example: Quantity actually dispensed: 1.6 liters Quantity displayed: 1.52 liters Correction factor k: 1.6 / 1.52 = 1.0526 Display the previously programmed correction factor by pressing and holding the TOTAL key and simultaneously pressing the RESET key. (example: 0.9950) Calculation of the correction factor to be reprogrammed: 0.9950 x 1.0526 = 1.0473...
  • Page 37 Operating the volume meter (optional accessories) saved program values. 16. Replace the meter back onto the basic meter. 17. After programming, press the RESET button to activate the LCD. en(us) FCC-CM Page 37 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 38: Performing Maintenance

    Performing maintenance Performing maintenance WARNING Hydraulic systems are under pressure Danger of bodily injury Pull power plug before performing ► any work. Cleaning the unit We recommend cleaning the entire interior of the reservoir once a year. To do so, remove the tank lid and clean the interior mechanically. Clean all the removed parts and examine them for any possible damage.

  • Page 39: Changing The Filter Element

    Performing maintenance Changing the filter element The filter element has a bayonet lock to make filter exchange easier. To change the filter, proceed as follows: Switch the system / filtration unit off and make sure that no operating medium can flow out of the lines into the filtration unit.
  • Page 40 Performing maintenance (1) Open the tensioning clamp at the fil- ter housing lid by loosening the screw = 6 mm. (2) Tilt the screw outwards. (3) Remove the tensioning clamp. Carefully lift up the filter housing cover to remove it. Turn it slightly clockwise. Turn counterclockwise to detach the dirt catch tray from the element and the ele- ment from the cover.
  • Page 41 Performing maintenance Remove the filter element from the filter housing cover. Dispose of the old filter element accord- ing to local regulations and guidelines. Clean the removed parts and examine them for any possible damage. Check the O-ring on the filter bowl cover for damage.
  • Page 42 Performing maintenance 10. Fasten the dirt catch tray to the bottom end of the filter element. 11. Place the filter element with the cover and dirt catch tray in the filter housing. Observe correct placement of the O-ring on the cover while doing so. 12.
  • Page 43 Performing maintenance 13. Tighten the drain plug (Drain) on the connection part of the unit. Switch the filtration unit on. Bleed the filter housing through the air bleed screw (Air Bleed) in the filter cover. 14. Check the filtration unit for leaks while it is operating.

  • Page 44: Change The Breather Filter

    Performing maintenance Change the breather filter. Replace the filter element of the breather filter at least once a year. If the unit is in a very dusty/damp environment, the replacement intervals shorten ac- cordingly. Replace the filter element of the breather filter as follows: Unscrew cover (11.1) of the breather filter by hand in a counterclock- wise direction.

  • Page 45: Cleaning/Replacing The Suction Strainer

    Performing maintenance Cleaning/replacing the suction strainer NOTICE Danger due to missing suction strainer / operation without a suction strainer The filtration unit will be destroyed. Never operate the filtration unit without a suction strainer ► Check / clean the suction strainer regularly. ►...
  • Page 46 Performing maintenance To replace the suction strainer, proceed as follows: Switch the filtration unit off. Turn the collet (3.2) on the hose coupling (3.1) counterclockwise to unscrew it. Turn the hose coupling (3.1) counterclockwise by ~ 90° and remove it. Drain the fluid in the suction hose back into the tank Remove the suction hose from the tank and wipe off any fluid remain- ing on the suction hose and lance using a cloth.
  • Page 47 Performing maintenance take in air via the hose coupling. Start up the unit. Check the unit for leaks while it is operating. Checking / replacing the suction screen is complete. en(us) FCC-CM Page 47 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 48: Replacing The Protective Screen To The Contamination Sensor

    Performing maintenance Replacing the protective screen to the Contamination Sensor NOTICE Protective strainer missing / operation without the protective strain- The ContaminationSensor will become blocked/clogged. Never operate the filtration unit without a protective screen ► Replace the protective strainer regularly. ►...
  • Page 49 Performing maintenance en(us) FCC-CM Page 49 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...

  • Page 50: Errors And Troubleshooting

    Errors and troubleshooting Errors and troubleshooting Error Cause(s) Remedy Filter contami- Medium is heavily contaminated, Replace the filter ele- nated the filter element is worn. ment. The viscosity of the medium is Warm the oil too high. Leaks at the The drain plug at the filter bowl Tighten the drain plug / filter bowl...

  • Page 51: Taking The Unit Out Of Operation

    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. Customer Service / Service HYDAC Service GmbH Friedrichtaler Str. 15, Werk 15 66540 Neunkirchen - Heinitz Germany...

  • Page 52: Model Code

    Model code Model code FCC-CM - 5/15 - T - N - N5DM002 - BM / -K-FA1 Basic Type FCC-CM = FluidCarrier Compact mit ConditionMonitoring Nominal flow rate = Q = 4 l/min 5/15 = Q = 15 l/min Pump type = Vane pump, top loader Voltage = 230 V, 1 Ph*...

  • Page 53: Technical Data

    Technical Data Technical Data FCC-CM 5/4 FCC-CM 5/15 Tank volume ≈ 70 liters ≈ 70 liters Operating pressure, maximum 3.5 bar 3.5 bar Maximum flow rate 4 l/min 15 l/min Permissible viscosity range 15 … 200 mm²/s 15 … 200 mm²/s Permitted fluid temperature 0 …...

  • Page 54: Ec Declaration Of Conformity

    Documentation Representative: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Günter Harge Registered seat of company: 66280 Sulzbach / Saar - Germany c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Registry Court: Saarbrücken, HRB 17216 Telephone: +49 (0) 6897 509 1511 Value added tax identification number : DE 815001609...

  • Page 55: Index

    Index Index accident prevention ............13 Guideline ............... 54 ambient temperature .......... 9, 17, 53 AQUAMICRON ............... 52 AquaSensor ..............22 Auxiliary personnel ............12 Hazard symbol ............7, 8 Breather filter ............20, 22 Imprint ................2 IN 20, 22 In case of emergency ............
  • Page 56 Index Spare parts ..............50 Specialist personnel ............12 switching on ..............31 Vane pump ..............52 Synthetic ester ..............9 Weight ..............17, 53 Transport ..............12, 15 troubleshooting ............12, 50 en(us) FCC-CM Page 56 / 60 BEWA FCC-CM 3648206 en-us 2016-07-08.docx 2016-07-08...
  • Page 60 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 9046 Technical De- partment Fax: +49 (0) 6897 509 577 Sales De- partment Internet: www.hydac.com E-mail: filtersystems@hydac.com...

This manual is also suitable for:

Fcc-cm 5/4Fcc-cm 5/15

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