FluidAqua Mobil

FAM 10
FAM 45E/75E
FAM 25/45/60/75/95

Comfort Control
Operating and maintenance instructions, part
2/2
English (translation of original instructions)

Keep for future reference.

Document No.: 4166128f
Valid from program version V 1.55
 Imprint

Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone: +49 6897 509 01
Fax: +49 6897 509 9046
E-mail: [email protected]
Homepage: www.hydac.com

Court of registration: Saarbrücken, HRB 17216

Executive directors: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering

Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone: +49 6897 509 1511
Fax: +49 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 ................................................................................................. 6
Product modification .............................................................................................. 6
Warranty ............................................................................................................... 6
Using the documentation....................................................................................... 7
Scope of these operating and maintenance instructions ....................................................... 10
"Comfort" Control Concept .................................................................................. 10
Operating elements on the unit............................................................................................. 11
Starting up the unit ............................................................................................................... 12
Switching on the unit ........................................................................................... 13
Setting the date and time .................................................................................... 14
Start screen and menu layout ....................................................................... 15
Starting unit ......................................................................................................... 16
Setting the pressure in the vacuum column ......................................................... 18
Suggested pressure settings ........................................................................... 18
Pressure information in the vacuum range....................................................... 20
Bleeding the filter housing fluid filter .................................................................... 21
Stopping operation ............................................................................................................... 22
Switching off the unit ........................................................................................... 24
Possible operating states of the unit ..................................................................................... 25
Displaying measured values and status of the components ................................................. 27
Menu Start screen - Measured values % saturation, temperature and
pressure .............................................................................................................. 27
Circuit diagram menu - Status of the components ...................................... 29
Cleanliness class menu - acc. to ISO, SAE or NAS (optional) .................... 31
Measured value curve ......................................................................................... 32

Settings Menu ............................................................................................................... 34

Operating mode menu – Dewatering, % saturation limit

values ................................................................................................................. 35

Operating mode menu - Filtering, Cleanliness class limit

values ................................................................................................................. 37

Operating mode menu - Heating, target temperature

(optional) ............................................................................................................. 39

Operating mode menu - Pressure limit values ............................. 40

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 Content

Operating mode menu – Time control, external AquaSensor ......... 41

Manual Operation Menu ...................................................................... 42

Messages menu - Error and system messages ..................... 44

Messages menu - User-guided troubleshooting ........................... 45

Options menu - Pressure and temperature units........................ 46

Menu options - Language ............................................................ 46

Options menu - Hiding % saturation, factory reset .................... 47

Help menu ?- Information and operating hours ................................................................... 48
Error messages ? and Troubleshooting ............................................................................ 49
Error messages .................................................................................................................... 51
?
1. CS and CS- pump ((M4)) were switched off. The last 10
measurements did not provide any measured values. ......................................... 51
2. Flow at the inlet section (IN) too low for 5 minutes. ......................................... 52
?
3. Outlet connection (OUT) clogged for 5 minutes ............................................... 53
4. Float switch of the vacuum pump defective. Fill level minimum and
?
overflow are reported at the same time. Fill level minimum and overflow
are reported at the same time. ............................................................................ 54
?
7. Float switch of the vacuum pump defective. Fill level minimum and
maximum are reported at the same time. ............................................................ 54
?
8. Float switch of the vacuum pump defective. Filling level overflow is
reported, but Filling level Max. is not. Filling level overflow is reported, but
Filling level Max. is not. ....................................................................................... 54
?
5. Level sensor in the vacuum column faulty. Filling level overflow is
reported, but Filling level Max. is not. .................................................................. 55
?
6. Level sensor in the vacuum column faulty. Fill level minimum and
maximum are reported at the same time. Fill level minimum and
maximum are reported at the same time. ............................................................ 55
?
9. Automatic water feed of the vacuum pump faulty. ........................................... 56
10. Automatic water feed of the vacuum pump faulty. ......................................... 57
?
11. Temperature sensor T(OUT) of the heater reports no measured value ......... 58
12. AquaSensor (AS) reports no measured value for the temperature ................ 58
?
13. AquaSensor (AS) reports no measured value for the temperature for
% saturation ........................................................................................................ 58
?
15. Pressure sensor(P) reports no measured value for the pressure in the
vacuum column ................................................................................................... 58
14. ContaminationSensor does not report any measured value for purity
level. ................................................................................................................... 60
16. No defined value from the CS (error is not issued by the CS!) ....................... 60
17. No measured value from CS. It is not possible to determine the flow
rate...................................................................................................................... 60

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 Content

18. / 19. / 20. / 21. / 22. Motor protection switch Q… (…pump M…) has
tripped. ................................................................................................................ 61
23. Filter element in fluid filter is contaminated -> Change filter element ............. 63
24. Oil tank of vacuum pump is empty................................................................. 64
25. Oil tank of the vacuum pump has been overfilled with oil for 10
minutes ............................................................................................................... 65
26. Heater safety thermostat triggered ................................................................ 66
27. Fuse F2 has tripped ...................................................................................... 69
28. Motor protection switch Q7 (heater) has tripped ............................................ 70
29. Power supply has the wrong phase sequence ............................................... 71
Phase relay ..................................................................................................... 72
30. ContaminationSensor reports flow is too low ................................................. 73
31. ContaminationSensor reports device error .................................................... 73
32. The evacuation pump is dry-running ............................................................. 74
33. Vacuum column is overfilled .......................................................................... 75
34. Leak alarm of the drip trip triggered ............................................................... 77
35. Water tank of the vacuum pump is empty ...................................................... 78
36. Water tank of the vacuum pump has been overfilled for 10 minutes .............. 79
37. Saturation oil >= 90%. Measurement with CS 1xxx not possible! .................. 80
Changing and entering values in menus ............................................................................... 81
Connection of an external AquaSensor AS(EXT) ................................................................. 83
Network connection (optional) .............................................................................................. 84
Connection of Ethernet cable .............................................................................. 84
Commissioning ................................................................................................... 85
Assembly A5 (Ethernet switch, CSM 1277) ..................................................... 85
Assembly A6 (Communication Processor CP 1243-1, from program
version V 1.56) ................................................................................................ 85
Web server.......................................................................................................... 85
External standard interfaces ................................................................................................. 88
Terminal connection and function of external interfaces ...................................... 88
Inputs .............................................................................................................. 88
Outlets (isolated contacts): .............................................................................. 90
Device ready ................................................................................................ 90
Operating state............................................................................................. 90
FAM without heater (FAM-xx-x-x-x-xx-x-Z-x-xxx-x) ................................... 90
FAM with heater (FAM-xx-x-x-x-xx-x-H-x-xxx-x) ....................................... 91
Logic of auxiliary contacts ......................................................................... 92
Maintenance and care of the operating panel ....................................................................... 93
Abbreviations ....................................................................................................................... 94

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 Preface

Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. Therefore please understand that, in the
absence of any provisions to the contrary hereinafter, our warranty and
liability – for any legal reasons whatsoever – are excluded in respect of the
information in these operating instructions. In particular, we shall not be liable
for lost profit or other financial loss. This exclusion of liability does not apply
in cases of intent and gross negligence. Moreover, it does not apply to
defects which have been fraudulently concealed or whose absence has been
guaranteed, nor in cases of culpable harm to life, physical injury and damage
to health. If we negligently breach any material contractual obligation, our
liability shall be limited to foreseeable damage. Claims due to product liability
shall remain unaffected.

Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model code, serial
no. and part no. of the product:
Fax: +49 6897 509 9046
E-mail: [email protected]

Product modification
We would like to point out that changes to the product (e.g. purchasing
options, etc.) may result in the information in the operating instructions no
longer being completely accurate or sufficient.
After modification or repair work that affects the safety of the product has
been carried out on components, the product may not be returned to
operation until it has been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product
whether by you or a third party.

Warranty
For the warranty provided by us, please refer to the terms of 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 documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.

Chapter description
tel
Produkt / Kapi

Page number
HYDAC Filtertechnik GmbH
BeWa 123456a de
de Seite x
200x-xx-xx
Edition date

Documentation no. Document language

with index/
file name

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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 Preface

Safety information
The product was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by general safety information and
instructions and are described in the operating instructions.
Observe all safety and warning instructions attached to the product. They
must always be complete and legible.
Do not operate the product unless all the safety devices are present.
Secure the hazardous areas which may arise between the product 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.

Signal words and their meaning in the general safety information

In these instructions you will find the following signal words:

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.

WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.

CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.

NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

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 Preface

Structure of the general safety information and instructions

All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:

SIGNAL WORD
Type and source of danger
HAZARD SYMBOL
Consequence of the danger

Measures to avert the danger

Warning signs used

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

Danger from electrical voltage

Risk of burns due to hot surfaces

Exposed electrical components

Danger due to electric shock

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 Scope of these operating and maintenance instructions

Others symbols used

Required tools

Tip for handling the product

Scope of these operating and maintenance instructions

In this operating and maintenance instructions, you will find the following chapters:
 Operation
 Commissioning
 Switching on and off
 Error messages and fault-finding

"Comfort" Control Concept

Whether or not your unit is equipped with a "Comfort" control concept with a
Siemens KTP 400 TFT operating panel can be seen on the display or on the model
code of the unit (see name plate):
Model code: FAM-xx-x-x-x-xx-x-x-Cx-x-x

"Comfort" Control Concept

This manual contains information about operation, commissioning, switching on and

off, error messages and fault-finding.
All additional information regarding safety instructions, possible applications, setup
and connection, maintenance, spare parts, storage, decommissioning, disposal and
technical data can be found in the Operation and Maintenance Instructions, Part 1/2
of the power unit.

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 Operating elements on the unit

Operating elements on the unit

The following operating elements can be found on the unit:

FAM-10 FAM-45E/75E FAM-25/45/60/75/95

Item Function
A Main switch with E-STOP function
B Alarm signal lamp (yellow)
C Control panel (for details see page 13)
D Needle valve to set the pressure in the vacuum column

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 Starting up the unit

Starting up the unit

NOTICE

Automatic mode

The unit starts and stops automatically in the "Dewater until" and "Filter until"
operating modes.

► Depending on the local General Safety Information, a notice must be

attached to the unit stating that the unit starts and stops automatically.

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 Starting up the unit

Switching on the unit

Switch on the unit using the main switch (position: ON) .
The lamp test (ERROR lamp lights up briefly) and boot-up procedure of the control
are run.

Screen display during boot-up:

NOTICE

Do not press any buttons during boot-up

Unintended actions

► Wait until the Start screen appears

NOTICE

Using the operating panel with unsuitable objects

Pointed or sharp objects damage the surface of the operating panel.

► Only use your fingers or a suitable pen to operate the operating panel.

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 Starting up the unit

Setting the date and time

Date and time are only relevant for a detailed display of the measured value
developments (see chapter "Measured value curve") and have no effect on the
function of the unit.
If the unit is disconnected from the network for longer than three weeks, then it is
required to reset the date and time.

After switching the FAM

on, select the key
"Settings" on the start
screen for setting the date
and time.

1. Select the symbol

"Date & Time"

2. Click the key "Date &

Time"

3. Set the desired date,

time and time
difference via the
selector wheels.

The resulting local time

will be displayed under
"Local time".

4. Click the key "Start" to

complete the process.

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 Starting up the unit

Start screen and menu layout

The unit's start screen will be displayed if the power unit was booted up without
error.

1 FAM ready for operation. Please press START.

2
% saturation Pressure Temperature
[absolute] OUT
3

Operating mode: Dewater + Filter + Heat

4
5 6 7 8
Operation is possible via the four function buttons (5, 6, 7 and 8) and by light finger
pressure on the touch screen.

As a basic rule, all of the menus have the following layout:

No. Function Details
1 Display of the current operating state (status) of the unit Page 25
2 Buttons for switching between submenus
3 Content of the current menu
4 Display of the currently selected operating mode Page 35 to 41
5 Page 16 and 21
: START/STOP of the unit ?
6 Page 27
? SCREEN
: Switch to the START
?
7 Page 34
?to the SETTINGS
: Switch
?
8
? : Switch ? Page 48
? ?to the Help menu

? ? ?
?
? part
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? ?
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? ? ?
?
? ?
 Starting up the unit

Starting unit
1. Check all hydraulic and electrical connections of the unit in accordance with
the Operation and Maintenance Instructions enclosed with it, Part 1/2.
2. After switch-on, the most FAM ready for operation. Please press
recently selected START.
operating mode will be
shown in the display.
% saturation Pressure Temperature
If required, change the [absolute] OUT
operating mode, as
described on page 35 to
41.

Operating mode: Dewater + Filter + Heat

Recommendation: Select an operating mode with heater from a viscosity

≥ 350 mm²/s (FAM Eco viscosity ≥ 800 mm²/s) or for oil temperatures
<40°C.
If the temperature of the fluid is raised by 10-20°C, then the dewatering
capacity increases by up to 50 %. The ideal temperature for dewatering
is approx. 50 … 60 °C and ideally >10°C above the ambient
temperature. See page 39.
3. To start, press the FAM ready for operation. Please press
function key . START.

% saturation Pressure Temperature OUT

[absolute]

Operating mode: Dewater + Filter + Heat

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 Starting up the unit

4. The startup phase of the FAM in operation. Startup phase.

unit begins: The vacuum
pump starts up, the
filling pump conveys and
% saturation Pressure [absolute] Temperature OUT
the vacuum column is
filled.

Operating mode: Dewater + Filter + Heat

5. Set the required pressure in the vacuum column. See page 18.
6. The emptying spume FAM in Automatic mode, heater on
switches on once the
MAX level in the vacuum
column is reached. This
% saturation Pressure Temperature OUT
means that the startup [absolute]
phase has ended and
the unit is in Automatic
mode.

Operating mode: Dewater + Filter + Heat

7. Vent the filter housing of the fluid filter. See page 21.

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 Starting up the unit

Setting the pressure in the vacuum column

The current pressure in the vacuum column can be seen on the operating panel
(FAM-10, FAM-25/45/60/75/95) or on the pressure gauge (FAM-45E/75E).
Use the needle valve (D) to set the pressure in the vacuum column.
Note that the pressure to be set in the vacuum column is dependent, for example,
on the operating medium, operating viscosity, oil temperature, the air and water
content.

FAM-10 FAM-45E/75E FAM -25/45/60/75/95

Suggested pressure settings

NOTICE

A vacuum setting of 500 mbar (abs.) is suitable for the majority of

applications and operating conditions.

► An excessively high vacuum (absolute pressure too low) can lead to function
problems

 Start with 500 mbar (abs.) = -0.5 bar.

 Observe saturation level (%Sat.) (AquaSensor).
 If the degree of saturation exceeds 80%, continue to operate the power unit
with 500 mbar (abs.) = -0.5 bar.
 The vacuum can be increased to for example, 350 mbar (absolute) = -0.65
bar after the level falls below 80% (absolute pressure reduced).
o Lower residual water and residual gas contents are achieved.
o The residual water content also depends on the air moisture of the
absorbed air
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 Starting up the unit

 Pay special attention to foam formation and function problems, particularly

with low-viscosity operating medium and operating medium with a high air
and water content.
With a lower pressure (e.g. 350 mbar (abs.)), you achieve a lower residual water
content. With a higher pressure (e.g. 500 mbar (abs.)), you achieve a faster
dewatering, especially with free water.
By closing the needle valve (D) you reduce the absolute pressure and also the air-
flow rate for dewatering the operating medium.
If the needle valve (D) is completely closed, dewatering takes place exclusively with
the air released in the operating medium. The dewatering rate is then reduced to a
minimum.
Some oils foam intensively when they enter the vacuum column. This effect
particularly occurs in case of very high water contents and oil temperatures. This
effect is to be observed even in case of older oils or very low-viscosity media. A high
gas proportion in the oil also stimulates foam formation.
If error 3 or 33 is displayed after a certain amount of time, this will usually be the
result of excessively high vacuum (very low absolute pressure).
If this is the case, reduce the vacuum, e.g. from 350 mbar (abs.) to 450 mbar (abs.).
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 500 mbar (abs.) in such cases.

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 Starting up the unit

Pressure information in the vacuum range

[1] [2] [3] [4] [5]
Vacuum Absolute Absolute Relative Relative
pressure pressure (gauge) (gauge)
% mbar bar pressure
mbar pressure
bar
… … … …
+ 5000 5 + 4000 4

[7] Relative pressure

- 4000 4 3000 3
3000 3 2000 2
2000 2 1000 1
[6] Absolute pressure

0 1000 1 0 0 [8] Atmospheric pressure

10 900 0,9 -100 -0,1
20 800 0,8 -200 -0,2
30 700 0,7 -300 -0,3
40 600 0,6 -400 -0,4
50 500 0,5 -500 -0,5
60
70
400
300
0,4
0,3 - -600
-700
-0,6
-0,7
75 250 0,25 -750 -0,75
80 200 0,2 -800 -0,8
90 100 0,1 -900 -0,9
100 0 0 -1000 -1 [9] Absolute Vacuum

No. Description
[1] Vacuum in percent: 100% = absolute vacuum, 0% = atmospheric
pressure
[2] Absolute pressure: Pressure in comparison to the zero pressure in
[3] the empty space (vacuum)
[4] Relative pressure: Pressure in comparison to the respective
[5] atmospheric pressure (air pressure).
[6] Absolute pressure range
[7] Relative pressure range
[8] Atmospheric pressure
[9] Absolute (ideal) vacuum

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 Starting up the unit

Bleeding the filter housing fluid filter

WARNING
Hot fluid

Danger of burns

► Make sure that hot fluid can exit when bleeding.

NOTICE

Air in the fluid filter

The filter element is not utilized completely

► Bleed the fluid filter after each shut-down/filter element replacement

The fluid filter is to be bled through the air-vent plug (A) in the cover until fluid
emerges. Using an Allen key wrench, carefully open the air-vent plug (A) in the
cover.
It is not necessary to unscrew the air-vent plug (A) completely – it contains
ventilation slots.

A
A

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 Stopping operation

Stopping operation
1.a) In the case of the operating modes "Dewater until" and "Filter until", the
power unit stops automatically after the set limit values have been reached
and starts once again automatically after the test interval time has expired or
the limit value for switch-on has been reached.
If this independent operation is to be stopped entirely, press the function key
. The power unit starts the after-run phase.
1.b) For the remaining FAM in Automatic mode, heater off
operating modes,
press the function key
. The power unit % saturation Pressure Temperature OUT
starts the after-run [absolute]
phase.

Operating mode: Dewater + Filter + Heat

2. Version with FAM in operation: Cooling-off time, heater

integrated heater: startup phase.
The heater is switched
off. The power unit % saturation Pressure Temperature OUT
continues operation in [absolute]
order to cool down the
heater. The cooling-
down time can be
adjusted in the
Operating mode menu
Operating mode: Dewater + Filter + Heat
. See page 39.
The remaining cooling-
down time is shown in
the display.

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 Stopping operation

3. The after-run phase of FAM in operation: After-run phase

the power unit begins.
All of the pumps will be
switched off, except for
% saturation Pressure [absolute] Temperature OUT
the evacuation pump.

Operating mode: Dewater + Filter + Heat

4. The evacuation pump FAM ready for operation. Please press START.
runs until the "Min" fill
level in the vacuum
column is reached.
% saturation Pressure [absolute] Temperature OUT
This means that the
after-run phase has
ended and the power
unit is once again
ready for operation.

Operating mode: Dewater + Filter + Heat

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 Stopping operation

Switching off the unit

The power unit can be switched off as follows after operations are stopped.
1.

Switch off the unit using the main switch (position: OFF)
2. Close all locking features in the inlet and outlet lines.

NOTICE

Immediate switching back on at the main switch

Uncontrolled behavior of the control

► Before switching back on, wait at least 30 seconds since the control
components require different shutdown times.

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 Possible operating states of the unit

Possible operating states of the unit

FAM in Automatic mode, heater on

% saturation Pressure Temperature OUT

[absolute]

Operating mode: Dewater + Filter + Heat

Depending on the version and the operating mode, the unit may have one of the
following operating statuses, as will be shown in the upper part of the display:
Status Description
Configure FAM. The unit is not ready for operation and must be
reconfigured. Contact Customer Service.
FAM in Manual operation Manual operation is activated. See page 42
Malfunction An error is present. The FAM is not ready for
operation. See pages 44 and 49.
FAM in operation: Start-up The FAM is in Start-up phase. The vacuum pump
phase starts up, the filling pump conveys and the vacuum
column is filled.
FAM in operation: Cooling- The FAM is in the cooling-down phase of the
off time, heater heater. See page 39.
The remaining cooling-down time is displayed in
seconds.
FAM in operation: After-run The FAM is stopped and is the after-run phase. All
phase of the pumps will be switched off, except for the
evacuation pump. The evacuation pump runs until
the "Min" fill level in the vacuum column is reached.
FAM ready for operation. For the operating modes "Dewater" and/or "Filter":
Please press START.
The FAM is ready for operation and can be started.
See page 16.
FAM waiting for test interval For the operating modes "Dewater until" and/or
"Filter until":
The FAM is not in operation but is ready for

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 Possible operating states of the unit

Status Description
operation. The test interval is running. The
remaining time in minutes is displayed. See page
41
FAM in Automatic mode The FAM is in Automatic mode.
FAM in Automatic mode, The FAM is in Automatic mode. An external
external AS AquaSensor has been attached and activated. In
the "Dewater until" operating mode, the power unit
is controlled directly via the prescribed limit values.
FAM in Automatic mode, Version with integrated heater only:
heater on
The FAM is in operation. The heater is switched on.
FAM in Automatic mode, Version with integrated heater only:
heater off
The FAM is in operation. The heater is switched off.

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 Displaying measured values and status of the components

Displaying measured values and status of the components

Menu Start screen - Measured values % saturation, temperature and

pressure
FAM in Automatic mode, heater on

% saturation Pressure Temperature OUT

[absolute]

1 3 4

2 Operating mode: Dewater + Filter + Heat

No. Description Description

1 % saturation IN Display of the current saturation level in percent at the
inlet section of the unit (internal AquaSensor).
% saturation EXT Display of the current degree of saturation in percent in
the system (external AquaSensor).
In the corresponding operating mode, two arrows are
used to display the set limit values (see page 35) and
the color of the bar changes to green (inside the limits)
or red (outside the limits). This display can be
deactivated in the settings. See page 47.
Value range: 0 to 100%
2 TIN Display of the current fluid temperature at the inlet
section of the unit (internal AquaSensor)
TEXT Display of the current fluid temperature in the system
(external AquaSensor).
Value range: 0°C to 100°C or 0°F to 200°F
3 Pressure Only FAM-10 and FAM-25/45/60/75/95:
[absolute]
Display of the current pressure in the vacuum column.
Two arrows are used to display the set limit values (see
page 40) and the color of the bar changes to green
(inside the limits) or red (outside the limits).
Value range: 0 to 1000 mbar / 0 to 100 kPa / 0 to 15 PSI
4 Temperature OUT Version with integrated heater only:
(optional) Display of the current fluid temperature in the vacuum

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 Displaying measured values and status of the components

No. Description Description

column after passage through the optional heater.
In the corresponding operating mode, one arrow is used
to display the target temperature (see page 39) and the
color of the bar changes to green (≥ target) or red (<
target).
Value range: 0 to 100°C, 0 to 200°F

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 Displaying measured values and status of the components

Circuit diagram menu - Status of the components

FAM in Automatic mode

The individual components can have the following statuses:

 Gray: Error-free and inactive
 Green: Error-free and active/in operation
 Flashing yellow: Fault/error

Symbol Description
M1: Motor of the filling pump
M2: Motor of the vacuum pump
M3: Motor of the evacuation pump
M4: Motor for the CS1000 pump (Optional)
M5: Motor of the return pump (Optional)
AquaSensor AS1000
 AS (IN): Installed at the inlet section of the unit
(internal)
 AS (EXT): Installed outside of the unit (external)
Heater in the vacuum column (Optional)

Temperature sensor in the vacuum column after passing

through the heater (optional)

Differential pressure switch for filter monitoring of the fine

filter
Pressure sensor for measuring the set vacuum in the
vacuum column (not FAM-45E/75E)

Fill level display (Min, Max) in the vacuum column

"ALARM" level sensor in the vacuum column

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 Displaying measured values and status of the components

ContaminationSensor CS1000 (optional)

Leakage sensor, drip tray

Y1: Feedback valve

Y2: Overflow valve, water ring vacuum pump (Optional)

Y3: Supply valve, water ring vacuum pump (Optional)

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 Displaying measured values and status of the components

Cleanliness class menu - acc. to ISO, SAE or NAS (optional)

FAM in Automatic mode

Cleanliness class (CS) acc. to ISO4406:1999

1 av:
3 Targe
t:

FAM in Automatic mode

Cleanliness class (CS) to SAE4059

Targe
2 t:
Targe 3
t:
Targe
t:
Targe
t:

No. Description Description

1 Actual (as per Display of the current cleanliness class of the
ISO) ContaminationSensor CS1000 in accordance with
ISO4406:1999
2 Actual (as per Display of the current cleanliness class of the
SAE and NAS) ContaminationSensor CS1000 in accordance with SAE
4059 or NAS 1638
3 Target Display of the set limit values (only with corresponding

operating mode). See Operating mode menu on

page 37

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 Displaying measured values and status of the components

Measured value curve

The measured values are recorded when the main switch is used to switch on the
power unit. They are then deleted again each time the main switch is used to switch
the power unit back off again.

FAM in Automatic mode, heater on

% saturation Pressure Temperature

[absolute] OUT

1 2 3

Operating mode: Dewater + Filter + Heat

FAM in Automatic mode

Cleanliness class (CS) acc. to ISO4406:1999

4 av:
Targe
t:

No. Description Recording duration

1 % saturation IN and TIN  200 values over 10 hours (3-minute
% saturation EXT and interval)
TEXT
 200 values over 4 days (30-minute
interval)
2 Pressure [absolute]  200 values over 4 days (30-minute
interval)
3 Temperature OUT Version with integrated heater only:
(optional)
 200 values over 4 days (30-minute
interval)
4 Cleanliness class ISO,  200 values over 3 hours (1-minute
NAS and SAE interval)
 200 values over 4 days (30-minute
interval)

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 Displaying measured values and status of the components

The display of the saved measured values is accessed by touching the respective
button.
Here depicted for example for the measured values of the saturation and the
temperature. The START/STOP and HELP function keys are deactivated in this
menu.

3
1 %-Saturation and temperature IN in °C
4
2 2

No. Description
1 Designation of the displayed measured values and their unit.
2 Display of the current measured value. The background color and the color
of the graphs match.
3 Button for switching the display between long and short recording duration.
The recording itself is not influenced by this selection.
4 Button for exiting this menu.

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 Settings Menu

Settings Menu
All settings can be changed during operation of the power unit.
A change of operating mode will take place immediately.
In the "Dewater until" and "Filter until" operating modes, the unit starts automatically
after the test interval time has elapsed.

FAM in Automatic mode

1 Operating mode 2 Manual Operation

3 Messages 4 Options

Operating mode: Dewater + Filter + Heat

No. Description Details

Operating mode: Changing the operating mode and
1 Page 35 to 41
the limit values
Manual operation: Manual control of the individual
2 Page 42
components
Messages: Display of the pending error and system
3 Page 44 and 45
messages and the user-guided error elimination
Options: Change the units, language and %
4 Page 46 to 47
saturation display. Perform a factory reset.

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 Settings Menu

Operating mode menu – Dewatering, % saturation limit values

FAM waiting for test interval

6
1 Permanent dewatering
6
2 Vacuum pump 2
Switching on Switching off
from 4 from 5
3 Do not dewater
Operating mode: Dewater + Filter + Heat

No. Description
1 Operating mode: Dewater
The operating medium is dewatered uninterruptedly.
2 Operating mode: Dewater until
The operating medium is dewatered until the set limit value for switch-off (5)
is reached. Afterwards, the unit or only the vacuum pump switches off.
 Internal AquaSensor AS (IN): Now the test interval (6) starts, the time
until the unit switches back on. Once this has run through, the unit
switches back on automatically and runs for a specified minimum
testing duration (6).
If the switch-on limit (4) is reached/exceeded after this time, the unit
will continue to run until the limit for switch-off is reached once again.
The unit switches itself off again and the test interval runs once more.
If the limit continues to not be reached after this time, the unit will
switch itself off again and the test interval will run once more.
 External AquaSensor AS (EXT): The unit starts as soon as the limit
for switch-on is reached (4) and stops as soon as the limit for switch-
off (5) has been reached.
If Filter until has also been activated, then the limit values specified in the
two menus must be reached before switch-off takes place.
See page 47 for selecting the installation site of AquaSensor.
3 The operating medium is not dewatered. The vacuum pump is not in
operation.
4 Limit value, % saturation for switch-on
This value is only taken into account in operating mode Dewater until (2).
Value range: 0 to 99%
Factory setting: 45%

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 Settings Menu

5 Limit value, % saturation for switch-off

This value is only taken into account in operating mode Dewater until (2).
Value range: 0 to 99%
Factory setting: 30%
6 Switch over to the Operating mode control menu for adjusting the settings
for switching back on. See page 41.
Only with the operating modes Dewater until (2) or Filter until (see page 37)
active.

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 Settings Menu

Operating mode menu - Filtering, Cleanliness class limit

values

FAM waiting for test interval

4
1 Permanent filtration

2 Switch off FAM, starting from ISO value

of
3
4
Operating mode: Dewater + Filter + Heat

No. Description
1 Operating mode: "Permanent filtration"
The operating medium is filtered uninterruptedly.
2 Operating medium: "Switch off FAM, from ISO value of" (optional)
The operating medium is filtered until the set limit value (3) is reached.
Afterwards, the unit will switch off.
Now the test interval (4) starts, a time until the unit switches back on. Once
this has run through, the unit switches back on automatically and runs for a
specified minimum testing duration (4). If the limit value (3) is exceeded after
this time, the unit will continue to run until the limit value for switching off is
reached once again. The unit switches off again and the test interval runs
once more.
If Dewater until has also been activated, then the limit values specified in the
two menus must be reached before switch-off takes place.
The "Filter until" operating mode is possible only up to a saturation level of
90%. At > 90% or with free water, the CS will be switched off and a change
will be made to the "Filter" operating mode. The CS does not restart until
after the saturation level is once again ≤90% and the error has been
acknowledged (see page 49.)
3 Limit values for Cleanliness class (Optional)
These values are taken into account only with the "Filter until" (2) operating
mode.
Value range ISO 9/8/7 to 25/24/23
Factory setting ISO: 17/15/12
Range of values SAE and NAS: 0.1 to 14.0
Default settings SAE and NAS 7.0

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 Settings Menu

4 Switching to the Operating mode control for changing the test interval and
the minimum test duration. See page 41.
Visible only with the operating mode "Filter until" (2) or "Dewater until" (see
page 35).

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 Settings Menu

Operating mode menu - Heating, target temperature

(optional)
FAM waiting for test interval

1 Switch heater off, from 3

Switch-on delay (hysteresis) 4
Cooling-off time, heater 5
2 Do not heat
Operating mode: Dewater + Filter + Heat

No. Description
1 Operating mode: Heat
The operating medium is heated up until it reaches the specified target
temperature (3). The heater then switches off afterwards. If the temperature
is still below the target temperature minus the hysteresis (4), then the heater
will switch back on. The measurement of the temperature takes place in the
vacuum column (TOUT).
Recommendation: Select an operating mode with heater from a viscosity ≥
350 mm²/s (FAM Eco viscosity ≥ 800 mm²/s) or for oil temperatures <40°C.
If the temperature of the fluid is raised by 10-20°C, then the dewatering
capacity increases by up to 50%. The ideal temperature for dewatering is
approx. 50 … 60 °C and ideally >10°C above the ambient temperature.
2 The operating medium is not heated. The heater is not in operation.
3 Target temperature
The operating medium temperature to be reached in the Heating operating
mode (1).
Value range: 0 to 80°C, 32 to 176°F
Factory setting: 50°C / 122°F
Remark: The safety thermostat integrated in the heater is set to 95°C or
203°F.
4 Switch-on delay (hysteresis)
The temperature by which the switching back on of the heater is delayed in
the Heating (1) operating mode.
Value range: 3 to 15°C, 5 to 30°F
Factory setting: 5°C / 10°F

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 Settings Menu

5 Cooling-off time, heater

If the power unit is stopped, then first of all the heater will be switched off.
The power unit continues operation for the cooling-down time specified here
(cooling-down phase). If the power unit is stopped, then first of all the heater
will be switched off. The power unit continues operation for the cooling-down
time specified here (cooling-down phase).
During the cooling-down time, the input is deactivated and the remaining
cooling-down time in seconds is displayed.
Value range: 1-10 minutes
Factory setting: 1 minute

Operating mode menu - Pressure limit values

FAM waiting for test interval

Pressure [absolute]

Pressure [absolute] - upper limit 1

Pressure [absolute] - lower limit 2

Operating mode: Dewater + Filter + Heat

No. Description
1 The upper limit of the pressure in the vacuum column displayed in the Start
screen menu .
Value range: 0…999 mbar / 0…99 kPa / 0.0…15.0 PSI
Factory setting: 600 mbar / 60 kPa / 8.7 PSI
2 The lower limit of the pressure in the vacuum column displayed in the Start
screen menu .
Value range: 0…999 mbar / 0…99 kPa / 0.0…15.0 PSI
Factory setting: 250 mbar / 25 kPa / 3.6 PSI

The limit values are intended solely for information purposes and not for controlling
the power unit. The color of the bar changes to green (inside the limits) or red
(outside the limits).

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 Settings Menu

Operating mode menu – Time control, external AquaSensor

If the "Dewater until" operating mode (see page 35) or the "Filter until" operating
mode (see page 37) is selected, then this menu will be available.

FAM waiting for test interval

Time control % saturation and Cleanliness class

Test interval Minimum testing
3 duration 4
1 %-Saturation, time-controlled ASEXT
2 % saturation controlled via ASEXT
Operating mode: Dewater + Filter + Heat

No. Description
1 % saturation with time control
See page 47 only in case of external selection AS.
The unit is switched back on in the "Dewater until" operating mode after the
test interval that has been set elapses (3). The unit remains in operation
afterwards for the minimum test duration (4). See page 35.
2 % saturation without time control
See page 47 only in case of external selection AS.
In the "Dewater until" operating mode, the unit starts as soon as the limit
value for switch-on is reached and stops as soon as the limit value for
switch-off has been reached. See page 81.
3 Test interval
The amount of time after which the unit switches back on to check the
contamination of the operating media with the operating modes Dewater
until and Filter until.
Value range: 2-360 minutes
Factory setting: 60 minutes

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 Settings Menu

4 Minimum testing duration

The amount of time during which the unit remains at least in operation.
 If the switch-on limit is reached/exceeded after this time, the unit will
continue to run until the limit for switch-off is reached once again.
The unit switches off again and the test interval runs once more.
If the limit continues to not be reached after this time, the unit will
switch off again and the test interval will run once more.
Value range: 3…30 minutes
Factory setting: 10 minutes

Manual Operation Menu

In this menu, it is possible to control the individual unit components manually.

NOTICE

Damage to the pumps

Operation of the pumps without operating medium leads to premature wearing

and a prohibited increase in heat.

► Avoid allowing the pumps to run without medium.

The individual components could have the following color status:

 Gray: Error-free and inactive
 Green: Error-free and active/in operation
 Flashing yellow: Fault/error

FAM ready for operation. Please press START.

1
Manual Operation control object

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 Settings Menu

No. Function
1 Activate and deactivate manual mode. This will stop or restart Automatic
mode on the FAM. This will stop or restart Automatic mode on the unit.
Manual mode is deactivated when the menu is exited.
2 The following components can be started/stopped by touching the symbols:
M1: Motor of the filling pump
M2: Motor of the vacuum pump
M3: Motor of the evacuation pump
M4: Motor for the CS1000 pump (Optional)
M5: Motor of the return pump (Optional)
Heater (Optional). Can be switched on only when the
filling pump is in operation.

Y1: Feedback valve

Y2: Overflow valve, vacuum pump (Optional)

Y3: Supply valve, vacuum pump (Optional)

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 Settings Menu

Messages menu - Error and system messages

All pending error or system messages are displayed in this menu.

Malfunction
1 2 7 6
ove
Error message r
15 Pressure sensor (P) reports no measured value for the pressure
AS in the vacuum
column.
3 05 Level sensor of the vacuum column faulty. EXT
Filling level overflow is reported, but Filling level Max. is not.

32 Vacuum column has been empty for two minutes.

5 4
ove
r
AS
Item Function
EXT

1
Menu of the pending error messages of the unit.
2
Menu of the pending system messages of the PLC. This will not be
addressed in any greater detail in this documentation.
3 List of all pending error messages. The errors are displayed in the sequence
of their occurrence: The most recently occurring message is shown at the top.
In this example, it is messages nos. 15, 05 and 32.
Long error message are not displayed in their entirety. This is signaled by
three periods (...) at the end of the line. Selecting the message causes the
entire message text to be displayed. Here for example with messages nos. 05
and 32.
4 Button for acknowledging the currently selected message. In this example,
message no. 05 is activated for acknowledgement.
The errors must be eliminated and acknowledged before the power unit can
be started again.
5 Button for displaying the user-guided troubleshooting of the currently selected
message. In this example, it is message no. 05. See page 45.
6 This symbol/button is displayed in all of the menus when an error has
occurred. The number of pending errors is displayed in the lower section.
This button can be used to display and hide the list (3) of all pending error
messages.
7 User-guided troubleshooting

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 Settings Menu

Messages menu - User-guided troubleshooting

Malfunction

1
Error number:
Opening Troubleshooting
2
Switching off the power unit during troubleshooting may be necessary.
Read the Troubleshooting all the way through before switch-off and/or
comply with the Instruction manual.

Operating mode: Dewater + Filter + Heat

3
Malfunction
Troubleshooting 22
Motor protection switch Q6 has tripped.
Cause
The motor protection switch has tripped, due to an overload in the
motor-pump group. FAM switches off after 1.8 seconds.

Continue

No Function
.
1 Number of the pending error message.
2 Start the troubleshooting for the error number entered.
3 Cancel and close the troubleshooting feature.

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 Settings Menu

Options menu - Pressure and temperature units

FAM ready for operation. Please press START.

1 Temperature

2 Pressure

Operating mode: Dewater + Filter + Heat

No Function
.
1 Switching the unit of temperature between °C and °F
Factory setting: °C
2 Switching the unit of pressure between mbar, kPa and PSI
Factory setting: mbar

Menu options - Language

FAM ready for operation. Please press START.

Language

Operating mode: Dewater + Filter + Heat

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 Settings Menu

Options menu - Hiding % saturation, factory reset

No Function
.
1 Activation or deactivation of the measured values for the % saturation of the
AquaSensor in the Start screen menu .
The "Dewater until" operating mode is not available when the display is
deactivated. Deactivation of the display causes a switchover to "Dewater"
operating mode.
Factory setting: "Display" is selected
This can be used with a defective AquaSensor until it is replaced.
2 Installation site of AquaSensor AS:
 Internal (IN): Installation at the inlet (IN) of unit (internal AquaSensor)
 External (EXT): Installation in system/equipment is customer-based
(external AquaSensor)
3 Performing a factory reset
All of the settings are reset to the default settings.
In addition, the following settings are implemented:
Operating mode: Dewater + Filter or Dewater + Filter + Heat (for version with
heater)
Operating mode control: permanent dewatering
Interface language: English

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 Help menu - Information and operating hours

Help menu ?- Information and operating hours

?
FAM ready for operation. Please press
START.
1 ?
?
Version:
2
?
? 129.42.14.142
3 Operating hours Hour Minutes
?Operating mode: Dewater + Filter + Heat
?
No. Content
1 Display of HYDAC contact information
?
2 Display of program version of the PLC and the display
3 ?
Display of the operating time of the power unit in hours and minutes.
The only time that is recorded is when the motor of the filling, emptying or
?
vacuum pump is in operation.

?
?

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 Error messages and Troubleshooting

Error messages and Troubleshooting

If an error occurs, the following will take place:
 the unit switches over to "Error" status
 the unit ceases operation
 the fault indicator lamp flashes
 the following symbol 1 is shown on the display in all of the menus. This
method can be used to display and hid the error list 2.

Malfunction
Pending and non-acknowledged messages 1
32 Vacuum column has been empty for two minutes. The evacuation
2 pump is dry-running. Remedy: Check the flow rate on the ….-.
05 Level sensor of the vacuum column faulty.
Filling level overflow is reported, but Filling level Max. is not.

15 Pressure sensor (P) reports no measured value for the pressure in

the vacuum column.

4 3

No Function
.
1 This symbol/button is displayed in all of the menus when an error has
occurred. The number of pending errors is displayed in the lower section.
This button can be used to display and hide the list (2) of all pending error
messages.
2 List of all pending error and system messages. The errors are displayed in the
sequence of their occurrence: The most recently occurring message is shown
at the top.
In this example, it is messages nos. 32, 05 and 15.
Long error message are not displayed in their entirety. This is signaled by
three periods (...) at the end of the line. Selecting the message causes the
entire message text to be displayed.
All of the error messages shown in the display are equipped with a number.
Using this number makes it very easy to find the error message once again in
this manual in the context of user-guided troubleshooting.

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 Error messages and Troubleshooting

3 Button for acknowledging the currently selected message. In this example,

message no. 05 is activated for acknowledgement.
The errors must be eliminated and acknowledged before the power unit can
be started again.
4 Button for displaying the user-guided troubleshooting of the currently selected
message. In this example, it is message no. 05. See page 45.

NOTICE

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

The main switch will be destroyed.

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

Proceed as follows to restart the power unit:

1. Eliminate error. Information on troubleshooting/error elimination can be found
in the user-guided troubleshooting (4 or Error messages menu on page
44) or the following pages.
2. Acknowledging errors on the display (3).
3. Restart power unit. See page 16.

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 Error messages

Error messages
1. CS and CS- pump ((M4)) were switched off. The last 10 measurements
did not provide any measured values.
Trigger for the After 10 activation attempts, each 4 minutes, with an interrupt
message: time of 15 seconds, the CS still has not returned a measured
value.
If one or more of the error messages 14, 16, 17, 30 or 31
appear, then they must be remedied first!
For example:
Error message 17 "Oil is very dirty" is displayed. Oil is very
dirty, so that the CS does not receive any measured value
and the error message will be displayed. Nevertheless, the
unit continues to run. The CS is switched off for 15 seconds
and subsequently a new measurement is conducted. This is
repeated ten times. If after ten attempts, a measured value is
still not present, then additionally the error message 1 "CS
and CS-pump (M4) have been switched off" will be displayed.
The oil must first be cleaned so that the error message 17
does not appear anymore in combination with the error
message 1. The unit nevertheless continues the operation.
Remedy: Perform the following steps:
Step

Description
1. Message:
1. CS and CS- pump ((M4)) were switched off. The last 10
measurements did not provide any measured values.
2. Acknowledge the error.
3. The measurement starts again. Ten activation attempts, each 4
minutes long, with an interrupt time of 15 seconds will start. Automatic
mode is not interrupted.
If none of the error messages 14, 16, 17, 30 and 31 appear, but the
switch-off occurs again with error message 1, then contact HYDAC
Service.

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 Error messages

2. Flow at the inlet section (IN) too low for 5 minutes.

Trigger for the The message appears if, during the start-up phase, the MAX
message: switch point in the vacuum column was not reached after 5
minutes have elapsed.
If this error arises after repairs have been made, then it is
advisable to fill the filling pump in advance with 0.25 liters of
oil. To accomplish this, remove the plug on the AS and then
remove the AS by unscrewing it. The oil is filled in through
this opening. The AS and the plug are mounted once again
afterwards in order to restart the unit.
Remedy: Perform the following steps:
Step

Description
1. Message:
2. Flow at the inlet section (IN) too low for 5 minutes.
2. Check all of the locking features in the suction line for flow and make
sure that the medium in use does not exceed the viscosity limit.
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 11.
6. Clean the suction filter.
Check the seal of the hose between the suction filter and filling pump.
Check the filling pump for proper functioning. (drive speed, nominal
current)
7. Acknowledge the error.
8. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 10.
9.
->b. The fault is not repeated. -> proceed to Step 11.
10. Contact the HYDAC Service Department.
11. The error is repaired.

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3. Outlet connection (OUT) clogged for 5 minutes

Trigger for the The level must reach the MIN switch point within 5 minutes
message: once the MAX switch point in the vacuum column has been
reached.
This time of five minutes was exceeded.
Remedy: Perform the following steps:
Step

Description
1. Message:
3. Outlet connection (OUT) clogged for 5 minutes
2. Check all of the shut-off devices in the return line for flow.
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 15.
6. Check: That the evacuation pump is working (drive speed, nominal
current), the return valve is fully closed, the pressure relief valve of the
evacuation pump is clean, the filter allows a flow and that the level
sensor of the vacuum column is working.
Increase the pressure (absolute), for example, from 300 mbar to
400 mbar in the column. If not possible, change the air filter element.

7. Acknowledge the error.

8. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 10.
9.
->b. The fault is not repeated. -> proceed to Step 15.
10. Check that the level switch of the vacuum column works. For details, see
Operating and Maintenance instructions, Part 1/2.
->a. Level switch is OK. -> proceed to Step 14.
11.
->b. Level switch is not OK. -> proceed to Step 12.
12. Replace the level switch. For details, see Operating and Maintenance
instructions, Part 1/2, under the chapter Spare parts and accessories list.
The item number specified there for the level giver contains modification
instructions.
->a. The fault is repeated. -> proceed to Step 14.
13.
->b. The fault is not repeated. -> proceed to Step 15.
14. Contact the HYDAC Service Department.
15. The error is repaired.

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 Error messages

4. Float switch of the vacuum pump defective.

Fill level minimum and overflow are reported at the same time.
Fill level minimum and overflow are reported at the same time.
7. Float switch of the vacuum pump defective.
Fill level minimum and maximum are reported at the same time.
8. Float switch of the vacuum pump defective.
Filling level overflow is reported, but Filling level Max. is not.
Filling level overflow is reported, but Filling level Max. is not.
Trigger for the Two switch points on the float switch of the vacuum pump
message: were reached at the same time, which are conflictive or do
not follow each other logically.
The PLC outputs a message on the display.
Remedy: Perform the following steps:
Step

Description
1. Message:
4. Float switch of the vacuum pump defective.
Fill level minimum and overflow are reported at the same time.
Fill level minimum and overflow are reported at the same time.
7. Float switch of the vacuum pump defective.
Fill level minimum and maximum are reported at the same time.
8. Float switch of the vacuum pump defective.
Filling level overflow is reported, but Filling level Max. is not.
Filling level overflow is reported, but Filling level Max. is not.
2. Switch off the unit at the main switch.
3. Check that the level switch of the vacuum column works. For details,
see Operating and Maintenance Instructions, Part 1/2.
->a. Level switch is OK. -> proceed to Step 5.
4.
->b. Level switch is not OK. -> proceed to Step 7.
5. Check the plug to the level switch.
Check the cable from the level switch to the control cabinet and in the
control cabinet to the PLC.
->a. The cable and plug are OK. -> proceed to Step 9.
6.
->b. The cable and plug are not OK. -> proceed to Step 8.
7. Replace the level switch. -> proceed to Step 10.
8. Replace the damaged parts. -> proceed to Step 10.
9. The PLC is faulty. Contact the HYDAC Service Department.
10. The error is repaired.

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5. Level sensor in the vacuum column faulty.

Filling level overflow is reported, but Filling level Max. is not.
6. Level sensor in the vacuum column faulty.
Fill level minimum and maximum are reported at the same time.
Fill level minimum and maximum are reported at the same time.
Trigger for the Two switch points on the float switch of the vacuum column
message: were reached at the same time, which are conflictive or do not
follow each other logically.
The PLC outputs a message on the display.
Remedy: Perform the following steps:
Step

Description
1. Message:
5. Level sensor in the vacuum column faulty.
Filling level overflow is reported, but Filling level Max. is not.
6. Level sensor in the vacuum column faulty.
Fill level minimum and maximum are reported at the same time.
Fill level minimum and maximum are reported at the same time.
2. Switch off the unit at the main switch.
3. Check that the level switch of the vacuum column works.
For details, see Operating and Maintenance Instructions, Part 1/2.
->a. Level switch is OK. -> proceed to Step 5.
4.
->b. Level switch is not OK. -> proceed to Step 7.
5. Check the plug to the level switch.
Check the cable from the level switch to the control cabinet and in the
control cabinet to the PLC.
->a. The cable and plug are OK. -> proceed to Step 9.
6.
->b. The cable and plug are not OK. -> proceed to Step 8.
7. Replace the level sensor. For -> proceed to Step 10.
details, see Operating and
Maintenance instructions, Part 1/2,
under the chapter Spare parts and
accessories list. The item number
specified there for the level giver
contains modification instructions.
8. Replace the damaged parts. -> proceed to Step 10.
9. The PLC is faulty. Contact the HYDAC Service Department.
10. The error is repaired.

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 Error messages

9. Automatic water feed of the vacuum pump faulty.

Trigger for the The MIN switch point in the water ring vacuum pump was
message: exceeded, the MAX switch point was not reached within 15
minutes, despite valve Y3 being open.
Remedy: Perform the following steps:
Step

Description
1. Message:
9. Automatic water feed of the vacuum pump faulty.
2. Check:
The pressure reducer is set correctly.Is an inlet pressure of 5 bar
present?
Is the water line connected and also open?
->a. If the test is OK -> proceed to Step 6.
->b. If the test is not OK -> proceed to Step 3.
3. Open the locking features in the supply line. Set the downstream
pressure. For details, see Operating and Maintenance Instructions, Part
1/2.
4. Start the unit by pressing the F1 key.
5. ->a. The fault is repeated. -> proceed to Step 6.
->b. The failure does not recur -> proceed to Step 14.
6. Switch the unit off at the main switch and unplug the power connector.
7. Check the cables and plugs of the corresponding valve up to the PLC.
->a. The cable and plug are OK. -> proceed to Step 9.
8.
->b. The cable and plug are not OK. -> proceed to Step 13.
9. Check the valve for proper functioning. Replace the valve if necessary.
10. Plug the power plug into the power outlet. Switch the unit on using the
main switch and start operation by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 12.
11.
->b. The fault is not repeated. -> proceed to Step 14.
12. The PLC is faulty. Contact the HYDAC Service Department.
13. Replace the cable and/or the plug. -> proceed to Step 10.
14. The error is repaired.

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10. Automatic water feed of the vacuum pump faulty.

Trigger for the The MIN switch point in the water ring vacuum pump was not
message: exceeded within 3 minutes of opening valve Y3.
Remedy: Perform the following steps:
Step

Description
1. Message:
10. Automatic water feed of the vacuum pump faulty.
2. Check the pressure reducer for correct setting.
Is an inlet pressure of 5 bar present?
Check the water line. Is the water line connected and are all shut-off
devices open?
->a. If the test is OK -> proceed to Step 6.
->b. If the test is not OK -> proceed to Step 3.
3. Open the locking features in the supply line. Set the downstream
pressure. For details, see Operating and Maintenance Instructions,
Part 1/2.
4. Start the unit by pressing the F1 key.
5. ->a. The fault is repeated. -> proceed to Step 6.
->b. The fault is not repeated. -> proceed to Step 14.
6. Switch the unit off at the main switch and unplug the power connector.
7. Check the cables and plugs of the corresponding valve up to the PLC.
->a. The cable and plug are OK. -> proceed to Step 9.
8.
->b. The cable and plug are not OK. -> proceed to Step 13.
9. Check the valve for proper functioning. Replace the valve if necessary.
10. Plug the power plug into the power outlet.
Switch the unit on using the main switch and start operation by
pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 12.
11.
->b. The fault is not repeated. -> proceed to Step 14.
12. The PLC is faulty. Contact the HYDAC Service Department.
13. Replace the cable and/or the plug. -> proceed to Step 10.
14. The error is repaired.

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11. Temperature sensor T(OUT) of the heater reports no measured value

12. AquaSensor (AS) reports no measured value for the temperature
13. AquaSensor (AS) reports no measured value for the temperature for
% saturation
15. Pressure sensor(P) reports no measured value for the pressure in the
vacuum column
Trigger for the One of the two sensors named above does not return any
message: measured value for the PLC.
However, the unit runs further with the following exceptions:
Sensor has a controlling character, for example, if the
operating mode "Dewater until" is set regarding the AS. If the
AS does not provide any measured valued for saturation,
then CS will be deactivated. If the pressure sensor does not
report back any pressure, the unit will go into the after-
running phase and switch off. The unit can only be operated
in an operating mode without dewatering.
Remedy: Perform the following steps:
Step

Description
1. Message:
11. Temperature sensor T(OUT) of the heater reports no measured
value
12. AquaSensor (AS) reports no measured value for the temperature
13. AquaSensor (AS) reports no measured value for % saturation
14. ContaminationSensor reports no measured value for the
contamination class
15. Pressure sensor(P) reports no measured value for the pressure in
the vacuum column
2. Switch the unit off at the main switch and unplug the power connector.
3 Check the cables and plugs of the corresponding sensor up to the
PLC.
->a. The cable and plug are OK. -> proceed to Step 5.
4.
->b. The cable and plug are not OK. -> proceed to Step 9.
5. Check / replace the sensor. If the measuring cell is contaminated, then
clean it with compressed air.
6. Plug the power plug into the power outlet.
Switch the unit on using the main switch and start operation by
pressing the F1 key.
7. ->a. The fault is repeated. -> proceed to Step 8.

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 Error messages

->b. The fault is not repeated. -> proceed to Step 13.

8. The PLC is faulty. -> proceed to Step 12.
9. Replace the cable and/or the plug.
10. Plug the power plug into the power outlet.
Switch the unit on using the main switch and start operation by
pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 5.
11.
->b. The fault is not repeated. -> proceed to Step 13.
12. Contact the HYDAC Service Department.
13. The error is repaired.

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 Error messages

14. ContaminationSensor does not report any measured value for purity
level.
16. No defined value from the CS (error is not issued by the CS!)
17. No measured value from CS. It is not possible to determine the flow
rate.
Trigger for the The CS has been reporting "no measured value from CS" for
message: 4 minutes.
Message will be displayed in KTP400 Display. The unit
continues to run. The CS is switched off for 15 seconds, after
which a new measurement is started.
If measured values are recorded again after restarting the
CS, the error message must nevertheless be acknowledged.
Repeat the process 10x if any measured values have not
been recorded after restarting the CS. The error message 1
appears after 10x.
Remedy: Oil too dirty. Continue cleaning in continuous
operation.
Measuring cell is
contaminated. Blow with compressed air.
Check the flow by CS. Possible air in the suction pipe of
CS pump.
Measuring cell is faulty.
Replace CS 1000.
Normal FAM operation is possible.

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18. / 19. / 20. / 21. / 22. Motor protection switch Q… (…pump M…) has
tripped.
Trigger for the The motor protection switch has tripped, due to an overload
message: in the motor-pump group. The unit switches off after 1.8
seconds.
Remedy: Perform the following steps:
Step

Description
1. Message:
18. Motor protection switch Q2 (filling pump M1) has tripped
19. Motor protection switch Q3 (vacuum pump M2) has tripped
20. Motor protection switch Q4 (evacuation pump M3) has tripped
21. Motor protection switch Q5 (CS--pump ) has tripped
22. Motor protection switch Q6 (return pump M5) has tripped
2. Switch off the unit at the main switch.
3. Open the control cabinet door.
Switch the tripped motor protection switch back on.
Check the setting on the motor protection switch with the specifications
on the motor type label. Correct the settings if necessary.
4. Plug the power plug into the power outlet.
Switch the unit on using the main switch and start operation by
pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 13.
6. Check the current consumption of the motor with the nominal current
specification on the motor type plate (I ≤ IN).
Make sure the that the medium in use does not exceed the viscosity
limit.
Only with water ring vacuum pump -> Clean the tank of the water ring
vacuum pump.
7. Close the control cabinet door. Switch the unit on using the main switch
and start operation by pressing the F1 key.
->a. The fault recurs -> proceed to Step 9.
8.
->b. The fault does not recur -> proceed to Step 13.
9. Replace motor protection switch and/or the fuse.
10. Close the control cabinet door.
Switch the unit on using the main switch and start operation by

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 Error messages

pressing the F1 key.

->a. The fault is repeated. -> proceed to Step 12.
11.
->b. The fault is not repeated. -> proceed to Step 13.
12. Contact the HYDAC Service Department.
13. The error is repaired.

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 Error messages

23. Filter element in fluid filter is contaminated -> Change filter element
Trigger for the The differential pressure display signal has been active for 5
message: minutes. The unit switches to the reset phase and switches
off.
Remedy: Perform the following steps:
Step

Description
1. Message:
23. Filter element in fluid filter is contaminated -> Change filter element
2. Close all the locking features in the feed and return flow lines.
3. Empty the filter housing via the drain ball valve.
4. Replace the filter elements. Details are described in the Operating and
Maintenance Instructions, Part 1/2 section.
5. Open all the locking features in the feed and return flow lines.
6. Acknowledge the error.
7. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 9.
8.
->b. The fault is not repeated. -> proceed to Step 13.
9. Switch the unit off and unplug it.
Check clogging indicator, plug and supply line. Replace the parts if
necessary.
10. ->a. The test resulted in no errors. -> proceed to Step 12.
->b. The errors found were eliminated. -> proceed to Step 6.
12. The PLC is faulty. Contact the HYDAC Service Department.
13. The error is repaired.

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 Error messages

24. Oil tank of vacuum pump is empty

Trigger for the The MIN switch point in the oil tank of the rotary vane vacuum
message: pump has been reached.
The message appears at once on the display.
The unit switches to the reset phase and switches off.
Remedy: Perform the following steps:
Step

Description
1. Message:
24. Oil tank of vacuum pump is empty
2. Fill up the rotary vane vacuum pump with vacuum pump oil. For details
see the instructions part 1/2 in chapter "Set up and connect unit",
section "Prepare rotary vane vacuum pump".
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
5. The error is repaired.

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

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 Error messages

25. Oil tank of the vacuum pump has been overfilled with oil for 10
minutes
Trigger for the The MAX switch point in the oil tank of the rotary vane
message: vacuum pump has been reached for 10 minutes. The
message appears on the display. The unit switches to the
reset phase and switches off.
Remedy: Perform the following steps:
Step

Description
1. Message:
25. Oil tank of the vacuum pump has been overfilled with oil for 10
minutes
2. Empty the oil tank of the rotary vane vacuum pump until the level in the
inspection glass is between MIN and MAX. To drain, use the drain ball
valve on the vacuum pump.
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
5. The error is repaired.

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

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 Error messages

26. Heater safety thermostat triggered

Trigger for Thermostat trips during operating mode with heater. The unit
the switches to the reset phase and switches off.
message:
If an operating mode is selected for which no heater is switched on,
then it is possible to operate the unit. The message will however be
displayed as a reminder with red triangle. If the unit is in Automatic
mode and a switchover to an operating mode with a heater is
carried out while the thermostat is still tripped, then the unit will go
into the after-running phase and switch off.
This error message may be because of a preceding error message
and the resulting triggering of the safety thermostat.
Resetting: Allow the heater to cool down before resetting.
Undo the screws and remove the cover from the heater terminal
box.
Actuate the button/directional spool valve for resetting the safety
thermostat.

The mechanism is tripped by a bi-metal. This bi-metal must first cool

down in order to recover. The cooling phase can indeed take up to
2 hours, depending on ambient conditions.
Remedy: If this is not an inherited error, then proceed as follows:

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 Error messages

Step
Description
1. Message:
26. Heater safety thermostat triggered.
2. Check whether the safety thermostat has tripped.Check whether the
safety thermostat has tripped.
The factory setting is 95°C.
3. ->a. The safety thermostat has -> proceed to Step 4.
triggered.
->b. The safety thermostat has not -> proceed to Step 10.
triggered.
4. Reset a safety thermostat.
5. ->a. Safety thermostat reset. -> proceed to Step 7.
->b. Safety thermostat reset not yet -> proceed to Step 6.
possible after 3 hours.
6. The safety thermostat at the
heater must be replaced. Contact
the HYDAC Service Department.
7. Acknowledge the error.
8. ->a. Error reset -> proceed to Step 21.
9. ->b. Resetting fault not possible. -> proceed to Step 10.
10. Switch off the unit at the main switch. Pull power plug.
11. Check the safety thermometer cable up to the PLC.
->a. The cable is defective. -> proceed to Step 17.
12.
->b. The cable is not defective. -> proceed to Step 13.
13. Replace the K7 relay.
14. Plug the power plug back in. Switch the unit on using the main switch
and start operation by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 16.
15.
->b. The fault is not repeated. -> proceed to Step 21.
16. The PLC is faulty. -> proceed to Step 20.
17. Replace the cable and/or plug.
18. Plug the power plug back in. Switch the unit on using the main switch
and start operation by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 13.
19.
->b. The fault is not repeated. -> proceed to Step 21.
20. Contact the HYDAC Service Department.

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21. The error is repaired.

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 Error messages

27. Fuse F2 has tripped

Trigger for the The F2 fuse triggers. (Possibly a short circuit at at least one
message: of the digital outs of the PLC output cards). A notification
appears on the display. The unit switches off immediately.
The fault indicator lamp is not flashing.
Remedy: Perform the following steps:
Step

Description
1. Message:
27. Fuse F2 has tripped
2. Switch the unit off at the main switch and unplug the power connector.
3. Determine the cause of the excessive flow with F2 and try to remedy it.
(See circuit) or contact HYDAC Service.
4. Switch on the unit at the main switch.
->a. The fault is repeated. -> proceed to Step 2.
5.
->b. The fault is not repeated. -> proceed to Step 6.
6. The error is repaired.

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 Error messages

28. Motor protection switch Q7 (heater) has tripped

Trigger for the The heater fuse has tripped. The unit goes into the reset
message: phase and switches off.
Remedy: Select an operating mode without heater. The message will
however be displayed and can be reduced with ESC.
Perform the following steps:
Step

Description
1. Message:
28. Motor protection switch Q7 (heater) has tripped.
2. Switch off the unit at the main switch.
3. Open the door to the switching cabinet and switch the motor protection
switch and/or the circuit breaker back on. Close the control cabinet
door and plug the power plug back in.
4. Switch the unit on using the main switch and start operation by
pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 15.
6. Measure the consumption of the heater at which the motor protection
switch tripped and compare this against the specifications on the
heater's type label.
7. ->a. If the measured current I <= IN. -> proceed to Step 9.
->b. If the measured current I >= IN. -> proceed to Step 8.
8. Replace the defective heater. -> proceed to Step 9.
9. Close the control cabinet door. Switch the unit on using the main switch
and start operation by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 11.
10.
->b. The fault is not repeated. -> proceed to Step 15.
11. Replace the motor protection switch Q7 (heater).
12. Close the control cabinet door. Switch the unit on using the main switch
and start operation by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 14.
13.
->b. The fault is not repeated. -> proceed to Step 15.
14. Contact the HYDAC Service Department.
15. The error is repaired.

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 Error messages

29. Power supply has the wrong phase sequence

Trigger for the After switch-on and during the entire operation, the phase
message: sequence relay checks the correct phase sequence and whether
there is a phase failure.
Whether a phase failure or an incorrect phase sequence is
present, can be determined by assessment of the phase sequence
relay. For this, open the control cabinet.
For identifying the error phase failure and phase sequence, note
page 72.
Remedy: Correct the phase sequence or remedy the phase failure.
Perform the following steps:
Step

Description
1. Message:
29. Power supply has the wrong phase sequence
2. Switch the unit off at the main switch and unplug the power connector.
->a. Check the supply voltage whether there is a phase failure. If no, then
step 3b.
3.
->b. Exchange 2 phases at the power connector (power connector up to 32
A with phase changer)
4. Plug in the power connector and switch the unit on at the main switch.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 13.
6. Pull power plug.
Check the functioning of the power supply cable and the connection
plug.
7. Plug in the power connector and switch the unit on at the main switch.
8. ->a. The fault is repeated. -> proceed to Step 9.
->b. The fault is not repeated. -> proceed to Step 13.
9. Switch the unit off at the main switch and unplug the power connector.
Replace the phase sequence relay. (A1)
10. Plug in the power connector and switch the unit on at the main switch.
11. ->a. The fault is repeated. -> proceed to Step 12.
->b. The fault is not repeated. -> proceed to Step 13.
12. Contact the HYDAC Service Department.
13. The error is repaired.

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 Error messages

Phase relay
After switch-on, a phase sequence relay checks the correct phase sequence and a
possible phase failure of one of the three phases in a three-phased network. The
asymmetric threshold is 10 %.

If the supply voltage is switched on, then the LED "coil symbol" (6) illuminates in
green. Operate the output relay if the phase sequence is correct at the clamps L1-
L2-L3. In case of an incorrect phase sequence, the LED "Phase sequence / Phase
failure" (5) blinks red and the output relay remains in the rest position.
In case of a phase failure, the LED "Phase sequence / Phase failure" continuously
lights up in red and the output relays drop to protect the application from secondary
damage.
In case of an incorrect phase sequence as well as in case of a phase failure, the
error message no. 29 is additionally displayed on the control panel.
The device has the auto-reset function. This function resets the output relay after an
error message and eliminates the occurred error to the original status.
The red LED "Phase sequence / Phase failure" is an error diagnosis
display and does not show the current relay status.

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 Error messages

30. ContaminationSensor reports flow is too low

Trigger for the The charge pump for the CS runs for 2 minutes in automatic
message: mode.
The CS has been reporting that the "Flow is too low" for 4
minutes.
The unit continues to run.
The CS is switched off for 15 seconds, after which a new
measurement is started and it then switches automatically to
the operating mode Continuous Filtering.
Troubleshooting: CS clogged. Remedy clogging. Blow with compressed air.
CS- pump defective. Replace CS- pump.
Hose from/to CS defective. Replace hose.

31. ContaminationSensor reports device error

Trigger for the The CS has been reporting "Device error" for 4 minutes.
message:
The unit continues to run.
The CS is switched off for 15 seconds, after which a new
measurement is started and it then switches automatically to
the operating mode Continuous Filtering.
Troubleshooting: CS faulty, large particles in the Testcell and/or generally not
ready for operation.
Clean the measuring cell with compressed air. If nothing
happens, then exchange the CS and / or contact the HYDAC
Service.

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 Error messages

32. The evacuation pump is dry-running

Trigger for the The evacuation pump is running and the MIN switch point in
message: the vacuum column was reached/was not reached and not
exceeded inside 2 minutes. The unit switches off
immediately.
Remedy: Perform the following steps:
Step

Description
1. Message:
32. Dry-running evacuation pump
2. Check all of the locking features in the supply line for flow / freedom of
passage. Open them if necessary.
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 10.
6. Clean the suction filter.
Check the seal of the hose between the suction filter and filling pump.
Check the filling pump for proper functioning.
Check whether the vacuum is too low -> Evacuation pump does not
convey any volume anymore, increase the vacuum (for example, from
500 mbar -> 400 mbar)
Check if the viscosity is too high -> Oil needs too long to arrive at the
sump.
->a. The fault is repeated. -> proceed to Step 8.
7.
->b. The fault is not repeated. -> proceed to Step 10.
8. Check the axial valve for proper functioning. If possible, clean the valve
or replace it.
->a. The fault is repeated. -> proceed to Step 11.
9.
->b. The fault is not repeated. -> proceed to Step 10.
10. The error is repaired.
11. Contact the HYDAC Service Department.

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 Error messages

33. Vacuum column is overfilled

Trigger for the The E-STOP MAX switch point in the vacuum column was
message: reached. All pumps up to the evacuation pump are switched off.
The timer runs for 4 minutes and 10 seconds. The switch point
MAX did not fall below during this time, unit switches off
immediately, message appears on the display.
If the switch point MAX fell short, then the FAM switches again
to the auto-operation mode. Filling and vacuum pumps are
switched on again.
Remedy: Perform the following steps:
Step

Description
1. Message:
33. Vacuum column is overfilled.
2. Start the evacuation pump using the Manual menu.
3. Monitor the evacuation time on the basis of the table below.
->a. Emptying duration is correct. -> proceed to Step 6.
4.
->b. Emptying duration is not correct. -> proceed to Step 5.
5. Check the evacuation pump for -> proceed to Step 7.
proper functioning.
6. The vacuum in the vacuum Increase the vacuum (e.g. from
column is too low. 300 mbar -> 400 mbar)
Start automatic operation.
7. ->a. The fault is repeated. -> Proceed to step 8.
->b. The fault is not repeated. -> proceed to step 13.
8. Check the axial valve for correct closing function. Remove the axial
valve for this.
Start automatic operation.
9. ->a. The fault is repeated. -> Proceed to step 10.
->b. The fault is not repeated. -> Proceed to step 13.
10. Vent the filter housing.
Start automatic operation.
11. ->a. The fault is repeated. -> Proceed to step 12.
->b. The fault is not repeated. -> Proceed to step 13.
12. Contact the HYDAC Service Department.
13. The error is repaired.

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 Error messages

Emptying duration for the vacuum column in seconds:

Voltage with 50 Hz Voltage with 60 Hz
See level sensor See level sensor
E-STOP E-STOP
FAM MIN MAX MAX MIN MAX MAX
25 31.8 39.7 50.8 29.4 36.8 47.0
45 19.6 24.5 31.3 18.7 23.3 29.8
60 23.4 29.2 37.3 21.0 26.3 33.6
75 18.1 22.6 28.9 16.8 21.0 26.9
95 15.6 19.5 24.9 15.0 18.8 24.0
(Applies for VG 32 at 40°C.)

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 Error messages

34. Leak alarm of the drip trip triggered

Trigger for the The float switch in the tray was actuated.
message: The message appears on the display after 1.8 seconds, and
the unit switches itself off.
Remedy: Perform the following steps:
Step

Description
1. Message:
34. Oil pan too full -> drain oil pan and seal leak.
2. Empty the oil pan on the unit.
3. Check the unit for any leaks and eliminate any that are found.
4. Acknowledge the error.
5. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 7.
6.
->b. The fault is not repeated. -> proceed to Step 8.
7. Check the float switch in the drip -> proceed to Step 4.
tray, see Operation and
Maintenance Instructions, Part 1/2.
Check the supply line to the float
switch. If necessary, replace them.
8. The error is repaired.

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 Error messages

35. Water tank of the vacuum pump is empty

Trigger for the The MIN switch point in the water ring vacuum pump has been
message: reached. The message appears at once on the display. The
unit switches to the reset phase and switches off.
Remedy: Perform the following steps:
Step

Description
1. Message:
35. Water tank of the vacuum pump is empty
2. Fill the water ring vacuum pump with water. For details, see Operating
and Maintenance Instructions, Part 1/2.
3. Acknowledge the error.
4. Start the unit by pressing the F1 key.
->a. The fault is repeated. -> proceed to Step 6.
5.
->b. The fault is not repeated. -> proceed to Step 7.
6. Check the float switch in the -> proceed to Step 3
vacuum pump. For details, see
Operating and Maintenance
Instructions, Part 1/2.
Check the supply line to the float
switch. If necessary, replace them.
7. The error is repaired.

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 Error messages

36. Water tank of the vacuum pump has been overfilled for 10 minutes
Trigger for the A signal is active, the overflow valve is opened.
message: The level in the water ring vacuum pump did not fall below the
"Overflow" switch point for 10 minutes.
The message appears on the display, the fault indicator lamp
flashes, the unit goes into the after-running phase and
switches off.
Remedy: Perform the following steps:
Step

Description
1. Message:
36. Water tank of the vacuum pump has been overfilled for 10 minutes.
2. Check the fill level in the water collecting canister and in the vacuum
pump and drain the canister if necessary.
Only empty the vacuum pump to the fill level max.
->a. Water does not flow out of the -> proceed to Step 4.
vacuum pump
3.
->b. Water flows out of the vacuum -> proceed to Step 5.
pump
4. Check the overflow valve and the -> proceed to Step 6.
hose for correct functioning.
Replace the parts if necessary.
5. Check the float switch in the vacuum pump. For details see Operation
and Maintenance Instructions, part 1/2.
Check the supply line to the float switch. If necessary, replace them.
6. Acknowledge the error.
7. Start the unit by pressing the F1 key.
8. ->a. The fault is repeated. -> proceed to Step 11.
9. ->b. The fault is not repeated. -> proceed to Step 10.
10. The error is repaired.
11. Contact the HYDAC Service Department.

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 Error messages

37. Saturation oil >= 90%. Measurement with CS 1xxx not possible!
Trigger for the Error-free measurement of contamination with the CS is not
message: possible with a water content >=90%. The charge pump of the
CS is switched off. If you selected an operating mode for which
the CS controls the unit, then the unit will automatically switch
into the same operating mode without control by the CS.
Example: From "Dewater + Filter to" to "Dewater + Filter"
The display flashes and shows "Operating mode changed".
It will not be possible to reset this error message until the
relative humidity is <90%.
It is not possible to select operating modes in which the CS
controls the unit until the relative humidity is <90%.
Remedy: clean/dewater the water content to <90% so that the CS1000 switches on
again.

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 Changing and entering values in menus

Changing and entering values in menus

The objects displayed with a green background on the touch screen enable the
entering or editing of values. An alphanumerical or a numerical monitor screen
keyboard is displayed for this purpose.

The following keys are present on the monitor screen keyboard.

Key Name Function
Cursor to the left

Cursor to the right

Delete character on the left

<ESC> Cancel entry

<DEL> Delete character on the right

<RETURN> Confirm entry

<SHIFT> Change over to upper-case letters for the next

character to be entered
<CAPS LOCK> Permanent changeover to upper-case letters

<123> Change over to numerical keyboard

<ABC> Change over to alphanumerical keyboard

1. Touch the desired operating object.

2. The keyboard is opened.The set value is applied in the display line of the
keyboard. In the case of the numerical keyboard, the permissible limit values
(Min and Max) are displayed.
3. Change or overwrite the value.
4. Confirm the entry with <RETURN> or discard the entry with the <ESC> key.
The monitor screen keyboard will then be closed in both cases.

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 Changing and entering values in menus

5. The numerical keyboard is used to test the limit values.

If you enter a value that lies outside of these border, then that value will not
be applied. A system message will be output and the original value will be
displayed again in the operating object.

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 Connection of an external AquaSensor AS(EXT)

Connection of an external AquaSensor AS(EXT)

Instead of the AquaSensor AS1000 installed in the power unit (at the inlet of the
unit), an external AS can be connected in the hydraulics/lubrication system.
This means that the power unit is controlled via the actual water content in the
system and the prescribed limits for switch-on and switch-off.
Periodic starting of the power unit during the test interval time is therefore not
required.
If at all possible, the external AS must be installed in an area where the oil
temperature deviates by no more than a maximum of ± 5°C from the oil temperature
aspirated by the power unit, because the oil temperature plays a role in the control
of the heater.
In the case of temperature differences >5°C, correct the target temperature of the
heater (see page 39) as follows:
- If the temperature at the external AS is > than the input temperature at the
unit, then increase the temperature at the heater.
- If the temperature at the external AS is lower than the input temperature at
the unit, reduce the temperature at the heater.
The external AS is connected electrically in the switch cabinet instead of the internal
AquaSensor.
See in this connection the wiring diagram enclosed with the power unit.

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.

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 Network connection (optional)

Network connection (optional)

The units optionally have an Ethernet interface (RJ45) and an integrated webserver
ex works or by means of retrofitting.
Depending on the version, in addition, one of the two Ethernet interfaces use
assemblies:
- Assembly A5 - Ethernet switch, CSM 1277
o Ex works: FAM-xxx-x-x-x-x-xx-x-x-xx-x-xx/-17
- Assembly A6 - Communication Processor CP 1243-1
(from program version V 1.56)
o Ex works: FAM-xxx-x-x-x-x-xx-x-x-xx-x-xx/-15

Contact us for retrofit kits. In addition, please specify

- Part no.
- Serial number

- Program version of SPS and of display (see menu Help ?) of the unit.
Connection of Ethernet cable
?
Before connecting the Ethernet cable, disconnect the FAM from the supply voltage
and ensure that it cannot be established again during work.
?
Connect an Ethernet cable to the Ethernet interface - assembly A6 or A5 - at the
provided slot, which you connect with the Ethernet. Any free cable bushing can be
used to insert it into the control cabinet. ?
?
?
?
?
?
?
?
?
?

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 Network connection (optional)

Commissioning

Assembly A5 (Ethernet switch, CSM 1277)

1. Establish the supply voltage and switch on the FAM.
2. Now establish access to the web server. The access data are as follows:
a. IP address: 192.168.0.32
b. Subnet mask: 255.255.255.0
3. The commissioning is complete.
Fixed IP addresses of the SPS and of the control panel
For internal communication, the SPS (192.168.0.32) and the integrated
control panel (192.168.0.33) have their own IP addresses. Both IP
addresses must be available in the network or must be released.
Please contact us if you require another IP address.

Assembly A6 (Communication Processor CP 1243-1, from program version

V 1.56)
1. Establish the supply voltage and switch on the FAM.
2. Now establish access to the web server. Therefore, you require the MAC
address of the Ethernet CP 1243-1 assembly A6. These can be found on the
assembly. For example, it is structured as follows: "20-87-56-2B-5B-D1".
3. Assign a fixed IP address to the MAC address of Ethernet-CP 1243-1 assembly
(for example, by your network administrator or your IT department).
4. You can establish access to the web server by retrieving this IP address.
5. The commissioning is complete.
Web server
The webserver runs as a program in the background of the SPS of the unit and
transfers information on the operating status of the unit to a web browser.
The following can be used as the web browser:
- Internet Explorer from Version 9
- Mozilla Firefox from Version 22
- Google Chrome from Version 33
- Mobile Safari and Chrome for iOS from iOS 8
- Android browser and Android Chrome
Remote access to the webserver
The login process in case of remote access to the webserver may take
several seconds.
If the login fails, click the update key or button in your browser to try

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 Network connection (optional)

again.
Access to an individual device can be done simultaneously via multiple
web server clients. However, this strain on the memory can limit the
performance of the PLC and lead to malfunctions.

If the unit is integrated in a network, then the integrated webserver can be accessed
via the corresponding IP address (depending on the assembly, see above) with the
extension…/awp. Example:

http://192.168.0.32/awp/
The webserver is in German, English and French only.
The website of the unit contains the following information:

3 4

No. Function
1 Language change GERMAN <-> ENGLICH <-> FRENCH
2 Stopping the unit (only available if the unit is in operation).
3 Description of the displayed information.

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 Network connection (optional)

4 Display of
 Operating status of the power unit
 Operating mode
 Pending errors
 Current measured values
 Operating status of the individual components:

o BLACK/OFF: Out of operation / inactive

o GREEN/ON: In operation / active.

o YELLOW/!: Error

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 External standard interfaces

External standard interfaces

The units of FAM-10/15 and FAM-25..95 series, by default have external interfaces
to the remote control/remote monitoring by external control system/control
technology or button/indicator light.
The units of the FAM-Economy series can be retrofitted by means of a retrofit kit:
FAM-Eco retrofit kit ext. interfaces. Part number 4361210. Installation required by
electrically qualified person (customer or HYDAC).
The control system has the following inputs and outputs with the external standard
interfaces:
Inputs: FAM Start/Stop
Outputs: Operating state FAM in operation

Device ready Ready for operation (no error, main switch ON)

Terminal connection and function of external interfaces

Inputs
FAM scope of delivery

FAM terminal
strip

Start/stop signal
(trigger)

+ Supply voltage 24
- V DC

The control system of FAM reacts to the pulse at this input. This is determined by
whether the FAM is in operation or in operation-ready state.

FAM start
The FAM starts if:
o The FAM is ready for operation - see output "Device Ready"
o FAM is not in operation – see output "Operating state"
o The + 24V DC is connected through at input X4/13 (FAM-10, 25...95), X4/21
(FAM-Eco):
 Signal will only be detected in case of a rising edge – button version is
required
 Required pulse duration: min. 2 seconds.
FAM stop

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 External standard interfaces

FAM starts the follow-up phase and then stops if:

o FAM is in operation
o The + 24V DC is connected through at input X4/13 (FAM-10, 25...95), X4/21
(FAM-Eco):
 Signal will only be detected in case of a rising edge – button version is
required
 Required pulse duration: min. 2 seconds.
Follow-up phase:
1. For FAMs with integrated heaters, this is switched off. The unit continues the
operation for cooling the heater. The remaining cooling downtime is shown in the
display.
The cooling down time can be adjusted in the menu "Operating mode".
Duration of the cooling down phase (only for integrated and activated
heater):
 Value range: 1-10 minutes
o Factory setting: 1 minute
2. After the cooling down phase or for units without a heater, all the pumps outside
of the evacuation pump are switched off directly after a subsequent stop signal.
The unit runs further until the fill level "MIN" is reached in the vacuum column.
 Duration of the emptying phase: max. 50 seconds.
3. Once the "Min" fill level is reached, the reset phase ends, the pumps stops and
the unit is ready for operation.

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 External standard interfaces

Outlets (isolated contacts):

Device ready
FAM scope of delivery

FAM terminal
strip
NO, closes if the main
switch is ON and there is no
error. Unit is ready for
operation.
Output, e.g. to PLC

Operating state
The units have a filling and emptying pump. The FAM is in operation if one of the
two pumps is in operation. For evaluation, auxiliary contacts at the motor contactors
K1 and K3 are available.
FAM without heater (FAM-xx-x-x-x-xx-x-Z-x-xxx-x)
FAM scope of delivery
FAM auxiliary contact, motor
contactor
NO, closes if the filling
pump is in operation.

Operating status of filling pump

Output, e.g. to PLC

FAM auxiliary contact, motor

contactor
NO, closes if the emptying
pump is in operation.

Operating status of emptying

pump
Output, e.g. to PLC

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 External standard interfaces

FAM with heater (FAM-xx-x-x-x-xx-x-H-x-xxx-x)

FAM scope of delivery

FAM auxiliary contact,

contactor
NO, closes if the filling
pump is in operation.

Operating status of filling pump

Output, e.g. to PLC

FAM auxiliary contact,

contactor
NO, closes if the emptying
pump is in operation.

Operating status of emptying

pump
Output, e.g. to PLC

Notes on follow-up phase:

o Both the outlets remain closed further during the cooling down phase of the
unit (only for integrated and activated heater).
 Duration of the cooling down phase (only for integrated and activated
heater):
 Value range: 1-10 minutes
o Factory setting: 1 minute
o During the emptying phase, the outlet of K3 remains closed further and only
opens after completion and standstill of pumps.
 Duration of the emptying phase: max. 50 seconds

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 External standard interfaces

Logic of auxiliary contacts

As soon as one of the two contactors K1 or K3 is switched, the FAM is switched on
and is in operation. Example:
FAM scope of delivery
FAM auxiliary contact, motor
contactor
NO, closes if the filling
pump is in operation.

Output, e.g. to PLC

Operating status FAM

FAM auxiliary contact, motor
contactor
NO, closes if the emptying
pump is in operation.

Please see the electrical circuit diagram for more information.

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 Maintenance and care of the operating panel

Maintenance and care of the operating panel

The operating panel is designed for low-maintenance operation. Touch screen and
keyboard foil should be kept clean.
Use a damp cleaning cloth with cleaning agent for cleaning. Use only dishwashing
detergent or foam monitor screen cleaning agents for cleaning.

NOTICE

Unintended reaction

Touching the keys while cleaning the touch screen can trigger an unintended
reaction in the control.

► Switch off the power unit prior to cleaning in order to avoid unintended
reactions.

Damage caused by non-approved cleaning agents

► The operating panel could become damaged if compressed air, steam jets,
aggressive solvent or abrasives are used for cleaning.

► Do not use compressed air or steam jets to clean the operating panel. Do not
use any aggressive solvents or abrasives.

Proceed as follows:
1. Switch off the power unit.
2. Spray the cleaning agent directly on the cleaning cloth. Do not spray directly onto
the operating panel.
3. Clean the display.
When cleaning the display, wipe inwards from the edge of the monitor screen.

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 Abbreviations

Abbreviations
Abbreviation Description
FAM FluidAqua Mobil
CS ContaminationSensor
AS AquaSensor
T(IN) Operating medium temperature at the inlet of the unit.
T(EXT) Operating medium temperature at the external AquaSensor.
T(OUT) Operating medium temperature in the vacuum column of the unit
downstream of the integrated heater.
M1 Motor of the filling pump
M2 Motor of the vacuum pump
M3 Motor of the evacuation pump
M4 Motor for the ContaminationSensor CS1000 (optional)
M5 Motor of the return pump (optional)
Y1 Feedback valve
Y2 Overflow valve, vacuum pump (Optional)
Y3 Supply valve, vacuum pump (Optional)

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 Abbreviations

Index
A F
ambient temperature ....................... 16, 39 Factory setting .. 35, 36, 37, 39, 40, 41, 42,
46, 47, 89, 91
AquaSensor 18, 26, 27, 29, 35, 41, 47, 58,
83, 94 filling .17, 25, 29, 43, 48, 52, 61, 74, 90, 94
B Filter.12, 22, 25, 34, 35, 36, 37, 38, 41, 47,
63, 80
bleeding ................................................ 21
Filter element ........................................ 63
C
Filter to.................................................. 80
care ............................................... 2, 6, 93
filtration ................................................. 37
cleaning ........................................... 60, 93
Float switch ........................................... 54
Cleanliness................................ 31, 32, 37
H
connecting ....................................... 19, 84
Hazard symbol ........................................ 9
Connection ...................................... 83, 84
Heater .................................. 29, 43, 66, 67
Contamination class .................. 31, 32, 37
I
ContaminationSensor ....30, 31, 58, 60, 73,
94 Imprint..................................................... 2
Content ....................................... 3, 15, 48 IN ........... 27, 29, 32, 35, 47, 52, 61, 70, 94
Control ........................................ 1, 10, 11 installation ............................................. 35
D Interface................................................ 47
Date ...................................................... 14 IP 85, 86
default setting ........................................ 47 ISO ............................................ 31, 32, 37
Description .. 20, 25, 27, 29, 31, 32, 33, 34, ISO4406 ............................................... 31
35, 37, 39, 40, 41, 51, 52, 53, 54, 55,
1999 .................................................. 31
56, 57, 58, 61, 63, 64, 65, 67, 69, 70,
71, 74, 75, 77, 78, 79, 86, 94 L
Device error........................................... 73 Language .........................................46, 86
dewatering......................16, 19, 39, 47, 58 Level sensor ......................................... 55
Dewatering ............................................ 35 Level switch ............................... 53, 54, 55
Differential pressure .............................. 29 Limit value.................................. 35, 36, 37
Display ... 15, 27, 31, 33, 34, 47, 48, 60, 87 M
Documentation Representative ............... 2 Main switch ........................................... 11
E Maintenance 10, 16, 53, 54, 55, 56, 57, 63,
77, 78, 79, 93
emptying ........................17, 48, 89, 90, 91
Malfunction ........................................... 25
Error . 10, 29, 42, 44, 49, 50, 51, 67, 80, 87
Measure ................................................ 70
Error message ..................... 10, 49, 50, 51
Measured value ......................... 14, 27, 32
Ethernet .......................................... 84, 85

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 Abbreviations

Measurement ........................................ 80 replacement .......................................... 21

Measures ................................................ 9 report ...............................................58, 60
measuring ................................. 29, 58, 73 S
Model code............................................ 10 SAE ........................................... 31, 32, 37
Motor protection switch.................... 61, 70 Safety thermostat .................................. 67
N select ........................................... 7, 14, 80
NAS........................................... 31, 32, 37 Sensor .................................................. 58
O Service .. 25, 51, 52, 53, 54, 55, 56, 57, 59,
62, 63, 67, 69, 70, 71, 73, 74, 75, 79
OFF ........................................... 24, 50, 87
setting ............................ 14, 18, 57, 61, 67
Oil pan................................................... 77
Signal word ..........................................8, 9
operating . 6, 7, 8, 9, 10, 11, 12, 13, 15, 16,
18, 19, 22, 25, 26, 27, 28, 31, 34, 35, signal words .........................................8, 9
36, 37, 38, 39, 41, 42, 47, 48, 58, 66,
Spare part ........................................53, 55
70, 73, 80, 81, 82, 85, 93
Spare parts ......................................53, 55
Operating elements ............................... 11
switching off .......................................... 37
Operation ................. 10, 15, 16, 42, 77, 79
switching on .......................................... 10
Out ........................................................ 87
T
OUT ...............................27, 32, 53, 58, 94
Temperature ........................ 27, 29, 32, 58
Outlet .................................................... 53
Temperature sensor .........................29, 58
P
Thermostat............................................ 66
Pressure sensor .............................. 29, 58
Time.................................................14, 41
Publisher ................................................. 2
troubleshooting .................... 44, 45, 49, 50
R
Troubleshooting ...............................49, 73
Range of values .................................... 37
V
Remedy . 51, 52, 53, 54, 55, 56, 57, 58, 60,
61, 63, 64, 65, 66, 69, 70, 71, 73, 74, Vacuum ...........................................20, 75
75, 77, 78, 79, 80 Vacuum column .................................... 75
repairs ................................................... 52 vacuum pump oil ................................... 64

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HYDAC FILTER SYSTEMS GMBH
Industriegebiet Postfach 1251
66280 Sulzbach/Saar 66273 Sulzbach/Saar
Germany Germany

Tel: +49 (0) 6897 509 01 Central

Fax: +49 (0) 6897 509 9046 Technical Department
Fax: +49 (0) 6897 509 577 Sales

Internet: www.hydac.com
E-mail: [email protected]