MAFH-E - Hydac
Contents
1. NE EI DEN AA AWA 13 7 1 6 Percent Water Saturation History Screen oss aa KA AA AA A Era ae EENS 13 7 1 7 Automatic Mode System Status on e he memes e ene ne eee ens 14 7 1 8 Fluid Oscillation in Automatic Mode esee 14 1 1 9 Spray Loop Drive Settings t AE RO dex gre quo LO area E IN ERI 15 757210 BIEN EE 15 KAN Mantal Mode EE 16 1 112 System Fauls cm 16 7 1 13 Maintenance Functions Guides 17 8 Maintenance Instructions O knee A ORA ge HK BOA dee EAR 18 8 1 Servicing Filter Elements tes A aaa 18 8 2 Servicingithe Air Breathers EE 18 lte E 18 8 4 Ee UE I LEE 18 8 5 Inspection and Maintenance Schedule eese se een 19 EIE AO TERR m I TID EM 20 Appendix 1A Hydraulic Schematic 2 21 Appendix 2A Electrical Schematic a d oea aE E EA A a EE EA Pa a eme s e eterne e ener 22 Appendix Floor Mounting Holes 44 26 Appendix 4A Troubleshooting e e e ne ee e tern 27 HYDAC En TOC L 4138 MAFH User Manual 1 INTRODUCTION HYDAC International s patent pending Dehy2. wh lt gt MAINTENANCE INFORMATION SOMPASSIONING I SCHEDULE Tecnica para DATA TROUBLESHOOTING SN SPARE PARTS gp TOUCHSCREEN REVISION REV 00 The MAFH Maintenance screen allows the user to review select sections of the user s manual on the touch panel m Safety Information Provides basic safety information and instructions the user must follow while operating the MAFH m Maintenance Schedule This section provides the user the schedule that needs to be followed to ensure correct maintenance There are inspection and maintenance schedules in the following categories General Fluid Filter Electrical Functional Test and Drain Spray Pumps m Maintenance Procedures This section provides the user with step by step maintenance procedures to follow to ensure correct maintenance m Troubleshooting This section of the manual provides information regarding basic problems encountered while operating the MAFH On these screens the user can find the cause and remedy of the problem by locating the error message m Commissioning This section of the manual provides information regarding transport and packing set up connection start up and storage m Spare Parts This section of the manual provides information regarding spare parts It contains a list of basic components of the MAFH with their HYDAC part number Contact HYDAC with any part not listed or with a per inquiry part number m Scree
3. 1AK61 RSS SRR SS EE 271 CBL 41 X4 MBL FTG C CBL 62 264 NOTES 1 ALL OTHER PARAMETERS ARE THE DEFAULT VALUES 2 50HZ MOTORS ONLY SET PARAMETERS 48 FIRST THEN PROCEED WITH THE OTHER ADJUSTMENTS 3 60Hz MOTORS 1740RPM 208 230V 460V 9 6 4 8FLA TEFC 3PH 182TC 54 4 50Hz MOTORS 1456RPM 208 415V 8 89 4 44FLA TEFC 3PH 182TC IP54 250 251 252 253 6FT X4 3450RPM TEFC 265 208 230V 460V 3PH 60HZ 266 4 2 2 1FLA HEATER 267 268 269 270 5 PUSH PULL COMM 1 CBL 52 GRACE PORT P N P Q3 H3RO PWR 1 SIEMENS P N 6EP1331 1SHO2 12 5KW 460V 3PH 272 A A A 60HZ 23 2 a 5 V 274 Ae v 275 ka gt gt 65 6 o 120VAC 24VDC OVDC 120 MATERIAL DEC TOLERANCES ALL DIMENSIONS IN INCHES UN REV CARD 12105 ELECTRICAL SCHEMATIC OF EDITION ELI REV DRAWING NO 2 PL APP C PRESNAR 1 7 10 REV DATE 10 02 12 CREDO po SUL NOT p q 3 PL CHK C PRESNAR 1 7 10 B M 460V TDS E WITH HEATER of DENON GE HYDAC 5 D 11208 ANG DWNJA BoST 1 5 10 P N 5 10036 POWER DISTRIBUTION Suncor To RETURN UPON RE SCALE 3 4 1 SHT 1 OF 1 HYDAC En 22 L 4138 MAFH User Manual APPENDIX 2A ELECTRICAL SCHEMATIC SHEET 1 OF 3 575VAC Units Only 200 20
4. 20 LEVEL SWITCH FLOAT vacuum GUAGE 21 STRANERY FRAME 22 VAWESAMPLERHOSE CASTERFXED Ines 0 7 Pump GEAR 24 DIRTALARM ELECTRIC SENSOR WATER 25 VALVE CHECK INLINE aater 2 3 IE NN 5 8 Lg 10 o O32 8 HYDAC User Manual MAFH L 4138 6 Components Component reference view W C ey NL do BABE S Number Description Filter Support Dirt Alarm Electric Valve Sample Ez Fitercap SES HYDAC En L 4138 MAFH User Manual 7 Operating Instructions External Panel Components 1 Main Disconnect Move the main switch to the position and wait until the touch panel displays the main screen 2 Operator Interface Touch panel and six hard keys F1 thru F6 described in section 6 2 3 Fault light System Faults will cause the Red Light to Flash 4 Status light CYCLE COMPLETE Solid Amber Light HEATER ACTIVE Flashing Amber Light 5 Emergency stop Push to employ the hard stop Pull to release the E stop and press hard key F3 to reset the fault 6 Grace port 120VAC 3Amps Laptop Receptacle right side access door Ethernet Communications Port connected to PLC Network 10 En HYDAC User Manual MAFH L 4138 7 1 Operator Interface Controls 7 1 1 MAIN SCREEN Hl RT Simulator 100 MAFH E Dehydration HY
5. The timer automatically resets each time a new cycle is started 7 1 6 Percent Water Saturation History Screen E RT Simulator 100 HYDAC This screen can be accessed by pressing the SAT TREND button in the AUTO screen 7 1 3 or 96 button in the SYSTEM STATUS screen 7 1 7 m This read only screen will record the elapsed time of the current cycle it took the percent water saturation to reach ten benchmarks 10 10096 in 1096 increments m The running time stamps are retained until a new Auto Mode cycle is started by pressing the hard key F2 even if the power is lost m The system will not record values during a short interval at start up to allow the system to complete flush therefore preventing false readings En 13 L 4138 MAFH User Manual 7 1 7 Automatic Mode System Status EI RT Simulator 100 This screen can be accessed by pressing the SYSTEM STATUS button in the AUTO screen 7 1 3 goof a m This screen provides a summary of the inputs and FILTER DPG outputs current status m Active outputs are highlighted by v checkmarks em es GO W gt The F1 button is the stop button available on every screen It will stop the spray pump immediately but the drain pump will continue for a short amount of time to try to empty the reactor Use the E Stop to shutdown all pumps instantly 7 1 8 Fluid Oscillation
6. Warranty 20 Warranty Limitation of Liability and Remedies THERE 1 NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE WITH RESPECT TO ANY OF THE PRODUCTS NOR IS THERE ANY OTHER WARRANTY EXPRESS OR IMPLIED EXCEPT AS PROVIDED FOR HEREIN For a period of twelve months from the date of delivery from Seller or three thousand hours of use whichever occurs first the Warranty Period Seller warrants that products manufactured by Seller when properly installed and maintained and operated at ratings specifications and design conditions will be free from defects in material and workmanship By way of explanation and not limitation the Seller does not warrant the service life of the filter elements as this is beyond the Seller s control and depends upon the condition of the system into which the filter is installed Seller s liability under any warranty is limited solely in Seller s discretion to replacing FOB original ship point repairing or issuing credit for products that become defective during the Warranty Period Purchaser shall notify Seller promptly in writing of any claims and provide Seller with an opportunity to inspect and test the product claimed to be defective Buyer shall provide Seller with a copy of the original invoice for the product and prepay all freight charges to return any products to Seller s factory or other facility designated by Seller All claims must be accompanied by full particulars includi
7. 1 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 60Hz MOTORS VFD PARAMETERS NOIES PARA PARAMETER NAME SETTING 1 ALL OTHER PARAMETERS ARE THE DEFAULT VALUES 1 LINE VOLTAGE HIGH 01 575V 2 50 Hz MOTORS ONLY SET PARAMETERS 48 FIRST 5 SPEED SOURCE 4 20mA 04 THEN PROCEED WITH THE OTHER ADJUSTMENTS 6 18 14 OUTPUT RUN 02 575 Face Ae 20 DECELERATION TIME 5 SEC 28 623 an 23 MIN FREQUENCY 6 250 04 t 24 MAX FREQUENCY 68 4 ES t 251 PMR uf uf uf SEE NOTES 1 amp 2 252 T lt 14 BLK gt ST pa 024 5 VFD SP SPRAY PUMP L1 FL1 1 L2 T lt 12 BLK gt 10 04 H MOTOR 253 con 12 Pu R2 1 Je M SP _ 4 Ss lt 12 BLK gt FUG FTG A CBL 62 6 FT x4 254 lt 14 gt pied 1740RPM TEFC 10 0A 13 lt T2BIR gt m 575V 255 FUOS 3P
8. AL CONTROL PANEL DEHYDRATION UNIT HYDAC 21 MAFH E OUTLET CONNECTION K9 FILTER d SHP 1740RPM m SAE IN 460V 3 60HZ 1 En DRIP PAN LEVEL SHUTOFF FS PF DRAIN LOOP C NOTES 1 MAXIMUM VISCOSITY EQUALS 2000 SUS 2 FILTER BYPASS EQUALS 50 PSI 3 SPRAY LOOP CIRCUIT VFD MOTOR 4 DRAIN LOOP CIRCUIT FIXED MOTOR ORAWING NO CTaNOVNCS D 11619 Tes HYDAC User Manual MAFH L 4138 APPENDIX 2A ELECTRICAL SCHEMATIC 460VAC Unit Only 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 60Hz MOTORS VFD PARAMETERS Papa PARAMETER NAME SETTING LB SPEED SOURCE 4 20mA 04 TB 14 OUTPUT RUN 02 20 DECELERATION TIME MIN FREQUENCY MAX FREQUENCY SEE NOTES 1 amp 2 lt 14BIK 957 M SP GC FTG A CBL 62 X4 254 261 262 1 82 54 C BL A 2 L1 3 ib 17 lt RES BLOWER MOTOR 263 SPRAY_PUMP MOTOR 27 SEE NOTE 3 255 256 DRAIN PUMP 25 ms MOTOR SES M DP GC gt FTG B CBL 62 259 5 ee 260 3RVIO21 1GAT0 3RT1015 1AK61 wm SEE NOTE 3 FC i ae 33 mi e di 3RV1021 1CA10 3RT1015
9. DAC Station D From the MAIN SCREEN the user has the option of entering Operation Functions Maintenance Functions or System Information screens SYSTEM INFORMATION includes touch screen calibrations program transfers touch screen user administration and the touch screen s model information 7 1 2 Operation Mode Hi RT Simulator 100 OPERATION MODE AUTO MODE MAFH E Dehydration HOA Station The OPERATION screen gives the user the choice between automatic and manual operation Back will take the user to the Main Screen A WARNING During initial start up of the MAFH unit the suction line should be flooded with fluid to prime the MAFH pump Do not run the pump without fluid in the suction line or pump damage will occur HYDAC En 11 L 4138 MAFH User Manual 7 1 3 Automatic Mode NOTE Once started the MAFH will continue to run in Auto Mode unless the user enters the MANUAL MODE Screen 7 1 11 The hard keys F1 F3 at the bottom of the screen allow the user to control the unit and explore the Maintenance Functions and Guides 7 1 13 m Default temperature and saturation set points need to be entered to run in automatic mode Select Set Point under Saturation and enter your value Select Set Point under Temperature to enter the desired default temperature value The temperature set point is only available on units E RT Simulator 100 ms equipped wit
10. H 60HZ 3 9FLA 256 257 FB DP 45 634 m DRAIN_PUMP L1 FL1 2 EE MOTOR 10 0 5 T 1280 WE Ra Wiere 258 12 FL2 2 12 2 TB aal fd m T 12800 UE Dees 259 n P REES FTG B CBL 62 9 FT X4 aiw TER 1 1740RPM TEFC 260 zum FUO 3RV1021 1FA10 3RT1024 1AK60 575V Eis daszki RUA 261 zmer ia E SERE EH LA FR XFMR ec TB2 i 120V 182 BLOWER MOTOR 263 Giese EM e T F3 FL2 2 12 3 Ge 1 CBL 62 6 FO CR ES 5 2 jp 3 3450RPM TEFC 265 a E Cx 4 PUSH PULL 3RV1021 1AA10 3RT1024 1AK60 575V o NM 3PH 60HZ SR 1 7FLA FB HTR SC 1 Fui SB HEATER outer COMM 1 CBL 52 02500 268 t 3 0K ZTEREDS 6 1 GRACE PORT FU10 12 FL2 3 P N 03 T lt To BLK gt 125 0 269 FUOB L3 FL3 3 PWR 1 25 04 H N 10 BLK 270 H 24VDC TOR fuos 3RT1317 1AK60 RMSE 2 2 tee SIEMENS P N POWER SUPPET 6EP1331 1SH02 271 L GO 1 CBL 41 9 FT X4 12 5KW 575V 3PH 272 60HZ 5 275 lt TEBLU gt GIE Y 2 g 274 v V u tej X a z 275 250 50 250 65 850 575VAC 120VAC 24VDC OVDC 120 MATERIAL DEC TOLERANCES ALL DIMENSIONS IN INCHES WN REV CARD 12360 ELECTRICAL SCHEMATIC OF EH REV DRAWING NO PERSE 2 JAPP CPRESNAS 26 1 REV DAE 10 02 12 575V TDS E WITH A HEATER E LI LAT 2 D 11575 ANG DWNJG HORTON 5 26 11 P N 5 10129 POWER D
11. ISTRIBUTION Ergo uu sad m SCALE 3 4 1 SHT 3 OF 6 23 En HYDAC User Manual MAFH L 4138 APPENDIX 2A ELECTRICAL SCHEMATIC SHEET 2 OF 3 5 e L lt 16 BLU gt bosh GR 5 SPRAY PUMP oi VFD CONTROL RELAY DRAIN PUMP VFD STATUS a DRAIN PUMP BLOWER STARTER BLOWER STATUS HEATER CONTACTER 3PH MONITORING RELAY SPARE FILTER PRESSURE INDICATOR FTG D CBL 40 HEATER PRESENT FAULT LIGHT STATUS LIGHT CYCLE COMPLETE LOW LEVE REMOTE STATUS FTG E CBL 40 HIGH FLUID LEVEL SPARE DRIP PAN FULL FTG G CBL 40 REMOTE START SPARE 59 SPARE 5 v ER DES enc A masas adus i s 240 ELECTRICAL SCHEMATIC OF BEING REV DRAWING NO 2 5 eS 15 DEHYDRATION STATION HYDAC D 11621 ANG DWN A BOST B 9 11P N PLS DIGITAL 1 0 HYDAC porn cr d SGALE Seat HYDAC En 24 L 4138 MAFH User Manual APPENDIX 2A ELECTICAL SCHEMATIC SHEET 3 OF 3 400 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 24VDC L lt 16 BLU gt 419 420 CR VFD SP 4200 421 422 WS 1 WATER SENSOR ben d H BLU VFD SP SF430 CPU1214C ANALOG INPUT
12. L 4138 GAVNB INTERNATIONAL MAFH E Operating Maintenance and Troubleshooting Manual US Patent Pending GUAS L 4138 Created 9 2012 User Manual MAFH L 4138 TABLE OF CONTENTS 1 Introduction EE 4 2 Warnings Cautions andNotes Ie ese e I sehe e e hehe nenne e 3er 2 5 3 COMMISSIONING 6 3 1 Transport and PackIng 6 3 2 SOL UP Ss 6 4 Connection cete ete 7 4 1 SUCTION port e 7 4 2 Pressure port connection eo eso E bred epa onn 7 4 3 Electrical Connection 7 5 7 6 COMPONENTS ee eebe lefu eub uetus er a Det Anc atr teu e ed 8 7 Operating Instructions 10 7 1 Operator interface 4 E ae 11 inet MS 11 ele iren Bee 11 721 5 ER COP N udine 12 7 1 4 Setting the Fluid Temperature m memes mh he memememem seen ne ene enne 13 7 1 5 Recorded lime Screen
13. Manual Mode A Manual mode is intended as a diagnostic tool only The system can be damaged by improper use or left unsupervised The processor will shut down the system after 15 minutes The three motors can be controlled individually to cycle fluid in and out of the reactor by pressing the icon MAFH units equipped with a heater can manually heat the fluid if the Spray Pump is running and the temperature is below 135 F Similar to the SYSTEM STATUS screen 7 1 7 this screen also displays the status of the float switches The user can toggle between the Fill Speed and Drain Speed flow rates 7 1 12 System Faults E RT Simulator 100 This screen can only be accessed when a fault is present A Fault Present button will appear in the bottom right corner of the majority of the screens described here m Press hard key F3 to reset all faults at one time If the fault condition was not corrected the description will reappear m By pressing the faults description the user will be taken to the Troubleshooting section of the touch screen This page will provide instructions to clear known fault conditions m For a complete description of all the faults refer to APPENDIX TROUBLESHOOTING 16 En HYDAC User Manual MAFH L 4138 7 1 13 MAINTENANCE FUNCTIONS GUIDES E RT Simulator 100 HYDAC MAINTENANCE oo oo SOFTWARE REVISION REV 0 0
14. OLES OPTIONAL 30 00 26 En HYDAC User Manual APPENDIX 4A Troubleshooting Unit is connected to power source but motors will not start Spray Pump Drove Failure Drain Pump Motor Overload Blower Overload No Inlet Flow No Discharge Flow Fluid Overflow Drip Pan Full Phase Check Wiring Extreme Fluid Temperature HYDAC Cause Verify which fuse is blown and replace Blown Fuses with the recommended size MAFH L 4138 Solution Verify wiring checking for short circuits or damaged wires Reset overload Verify wiring checking for short circuits or damaged cables If issue reoccurs contact factory to view Fault History Parameters Verify wiring checking for short circuits or damaged cables The pumps overload has tripped The spray motor s drive has a fault The drain motor overload has tripped Verify overload setting and reset Verify wiring checking for short circuits or damaged cables The blower s overload has tripped Verify overload setting and reset Verify that the inlet to the system is not blocked Verify that the oil being dehydrated is within the acceptable viscosity range Inspect hose for cracks or cuts Check for loose inlet fittings Repair or replace as needed Eliminate restriction or add some fluid to inlet hose and elevate to prime dry pump Eliminate excess fittings valved couplings or any
15. S 6ES72141BE500XBO 1 M lt 16 B W gt M lt 16 gt SB1232 ANALOG OUTPUTS 6ES72324HA300XBO 423 424 425 L lt 16 BLU gt 9 24VDC L 16 BLU 8 M lt 16 B W gt LOAD RESISTOR SEE NOTES FTG H VDP 177 FLUID SATURATION PERCENTAGE FLUID TEMPERATURE SUCTION PUMP VFD SPEED CONTROL CBL 56 OPERATOR INTERFACE 450 24VDC 423 CSM1277 ETHERNET SWITCH 66K72771AAOOOAAO 3 o S 9 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 M lt 16 87W gt lt 16 8LU 2 00 COMM 2 L lt 16 BLU gt CUSTOMER S TERMINALS CR RM 47041 NOTES 1 Ruw VDC 10V 20 Rum 470 M lt 16 B W gt DEC TOLERANCES ALL DIMENSIONS IN INCHES ui REV CARD ELECTRICAL SCHEMATIC OF REV DRAWING NO KEE 15 DEHYDRATION STATION Exe GNEJNB D 11622 1 B 18 11B M Err ANG DWN A BOST 8 9 11P N PLC ANALOG 1 0 HYDAC eae SCALE 3 4 1 SHT 1 OF 1 25 En HYDAC L 4138 MAFH User Manual APPENDIX FLOOR MOUNTING H
16. damaged The emergency stop button has been Deactivate the switch If switch is activated not activated verify wiring or replace switch The system has been in manual mode Diagnostic mode is for troubleshoot for longer than 15 minutes ing please refrain from using the system in manual mode for extended periods of time Clear faults to reset the timer The PLC is no longer receiving a valid Verify the cable is connected and not signal from the water temperature damaged sensor Replace Cable Replace Water Temperature Sensor Fluid viscosity high Heat fluid until maximum rated fluid viscosity of unit is reached Discharge line restriction Eliminate excess fittings valved couplings or any other source of high differential pressure Replace Pump Obstruction in the suction line Check the suction line fittings and eliminate restrictions Open external suction shutoff valve if installed Fluid viscosity high Heat fluid until maximum rated fluid viscosity of unit is reached Suction line restriction Eliminate excess fittings valved couplings or any other source of high differential pressure Blocked suction element Remove and clean suction elements En HYDAC COTS INTERNATIONAL Internet www hydac com E Mail filtersystems hydac com
17. dration Station is the first of its kind on the market The MAFH offers fully automated dewatering of hydraulic fluids and a variety of other petroleum based fluids The operating principle of the MAFH differs from existing dewatering methods The MAFH is a positive pressure system that uses 100 mass transfer to remove water from the operating fluid Room air is heated using a proprietary method to improve the ability of the air to absorb water vapor This heated air is then distributed upwards in the reaction chamber through cascading droplets of operating fluid The heated air stream removes free emulsified amp dissolved water and some dissolved gases In most traditional industrial vacuum dehydrators mass transfer is also the means to dewater A mild medium vacuum expands the room air and proportionately reduces the relative humidity of the air The air flow is limited to the displacement of the vacuum pump Higher efficiency vacuum units use a closed cycle to seal operating fluid with high heat and high vacuum to boil off water These units have high efficiency but have low flow rates and can potentially damage the operating fluid over time Since the air flow rate of the HYDAC MAFH is not limited by vacuum pump displacement it is more effective in dewatering operating fluids under similar conditions and flow rates than the above technologies In addition the MAFH does not have the initial and maintenance economic disadvantages of a
18. e History be viewed by pressing one of buttons on the bottom left half of the screen m Each time the power is cycled the default Auto Tuning Function will be enabled This function uses the Cycle Time History data to synchronize the pump speeds m Users can disable the Auto Tuning Function by pressing the button on the bottom right half of the screen m With a Users password the flow rates can be adjusted in the following ranges Fill Speed Flow Rate 15 5 16 5GPM Flow Rate Offset 2 5GPM m Authorized users can modify these settings for Diagnostic purposes outside this range These valves will return to their default valves after the power is cycled and if the Auto Tuning Function is disabled The flow rates should only be adjusted if repetitive faults are present Contact the factory for the correct password This read only screen displays the Drain Cycle time information in minutes m Similar to Saturation History Screen 7 1 6 the longest cycle time is marked by a running time stamp elapsed time of the current cycle m In addition the time during the Drain Cycle when the high float switch is energized is recorded m All information is retained until a new Auto Mode cycle is started by pressing the hard key F2 but if the power is lost the data is reset Note Identical information is stored for the Fill Cycle on a separate screen En 15 L 4138 MAFH User Manual 7 1 11
19. e fluid from the sump of the tank where high contamination may affect the operation of the unit 4 2 Pressure port connection m The return line must also be installed below the fluid level in order to prevent air being introduced into the system again 4 3 Electrical connection m The voltage and frequency given on the type plate must agree with that of the power supply m Connection 3 x L PE Conductor is not necessary regulations and codes must be adhered to 5 Specifications Dimensions Dry Mass Inlet Connections Outlet Connections Flow Rate Inlet Pressure Outlet Pressure Fluid Service Temperature Fluid Viscosity Power Supply Relative Humidity Display Attainable Water Content Construction HYDAC En The electrical connection must be carried out by a qualified electrician All local and national electrical 32 W x 59 L x 70 25 H 1000 Ibs 453 kg 1 1 2 MJIC 1 1 4 MJIC 900 gallons hour Atmospheric to 125 psi 8 62 Bar BO 7 tto 175 10 C to 79 C 70 2000 SUS 460V 3 60Hz 7Amps 460V 3 60Hz 22 5 Amps w heater 575V 3 60Hz 5 5 Amps 575V 3 60Hz 18 Amps w heater Standard 0 99 Range 50 PPM Base Frame Carbon Steel Vessel Stainless Steel Seals Viton L 4138 MAFH User Manual 6 Components Number Description Number Description HOUSING 14 COUPLING HALF MOTOR BREATHER 15 COUPLINGHALF PUMP CONRTOLPANEL 19 CASTER WNEL
20. e procedure before doing work Work area should level clean and dry Before servicing machine Position machine on a level surface Allow to cool if hot Keep all parts in good condition and properly installed Fix damage immediately Replace worn or broken parts Remove any buildup of grease oil or debris Handle Chemical Products Safely Direct exposure to hazardous chemicals can cause serious injury Potentially hazardous chemicals used with equipment include such items as lubricants coolants paints and adhesives A Material Safety Data Sheet MSDS provides specific details on chemical products physical and health hazards safety procedures and emergency response techniques Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment Contact Schroeder Industries prior to using with fluids other than hydraulic fluids Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job Operating equipment safety requires the full attention of the operator Do not wear radio or music headphones while operating the machine Service Machines Safely Tie long hair behind your head Do not wear a necktie scarf loose clothing or necklace when you work near machine tools or moving parts If these items were to get caught severe injury could result Remove rings and oth
21. er jewelry to prevent electrical shorts and entanglement in moving parts En 5 L 4138 MAFH User Manual Illuminate Work Area Safely Illuminate your work area adequately but safely Use a portable safety light for working inside or under the machine Make sure the bulb is enclosed by a wire cage The hot filament of an accidentally broken bulb can ignite spilled fuel or oil Work In Clean Area Before starting a job Clean work area and machine Make sure you have all necessary tools to do your job Have the right parts on hand Read all instructions thoroughly do not attempt shortcuts Use Proper Tools Use tools appropriate to the work Makeshift tools and procedures can create safety hazards For loosening and tightening hardware use the correct size tools DO NOT use U S measurement tools on metric fasteners Avoid bodily injury caused by slipping wrenches Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology Use leak proof containers when draining fluids Do not use food or beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down a drain or into any water source 3 Commissioning 3 1 Transport and packing 3 2 m All MAFH units are tested at the factory for leaks and function They are then carefully packaged for shipment m The fluid connections are all sealed with plugs to prevent the intrusion of contaminants d
22. ert symbol DANGER identifies the most serious hazards General precautions are on CAUTION labels Follow Safety Instructions Read the safety messages in this manual and on the machine Follow these warnings and instructions carefully Review them frequently Be sure all operators of this machine understand every safety message Replace safety labels immediately if missing or damaged Operate Only If Qualified Do not operate this machine unless you have read the operator s manual carefully and you have been qualified by supervised training and instruction Familiarize yourself with the job site and your surroundings before operating Inspect Machine Inspect the equipment carefully before each use Keep all parts in good condition and properly installed Fix damage and replace worn or broken parts immediately Pay special attention to hydraulic hoses and electrical power cord Handle Fluids Safely Avoid Fires Filtering of fuel or other flammable liquids is not recommended Store flammable fluids away from fire hazards Do not incinerate or puncture pressurized containers Make sure machine is clean of trash grease and debris Do not store oily rags they can ignite and burn spontaneously Prepare for Emergencies Be prepared if a fire starts Keep a first aid kit and fire extinguisher handy Keep emergency numbers for doctors ambulance service hospital and fire department near your telephone Practice Safe Maintenance Understand servic
23. h a heater m The MAFH will operate without any user AUTO MODE intervention until the fluid saturation is below the rx CUm set point for longer than two minutes m The current saturation can then be observed SATURATION 27 on the scale All values during testing can be reset Gan o by selecting the appropriate Set Point again A 0 420 440 460 490 50 15 minute trend history can be view by clicking the G gt W gt scale m The SAT TREND button will display detailed history of the current cycle s saturation levels refer to section 7 1 6 for more details m If the fault light turns on during automatic mode you will be directed to the corresponding SYSTEM FAULTS screens 7 1 6 to observe and reset the cause of the alarm The F1 button is the stop button available on every screen It will stop the spray pump immediately but the drain pump will continue for a short amount of time to try to empty the reactor The F2 button is the start command for Auto Mode and is only available on select screens The F3 push button is used to reset any System Faults A cause for the shut down will be listed on the SYSTEM FAULTS 7 1 12 The MAFH unit is equipped with a Remote Start Option to start Auto Mode remotely connect a 120VAC maintained signal to terminals 470A1 and A70A2 refer to APPENDIX 2A ELECTRICAL SCHEMATIC The unit will only stop remotely if t
24. here is a remote start signal is present and then it is removed All local controls can override the remote start signal Entering the Manual Mode Screen 7 1 11 will exit Auto Mode and shutdown the motors 12 En HYDAC User Manual 7 1 4 Setting the Fluid Temperature E RT Simulator 100 EIS 7 1 5 Recorded Time Screen Ef RT Simulator 10096 MAFH L 4138 Set the fluid temperature by following these steps through the touch panel m Click on OPERATION on the main screen shown in section 7 1 2 m Click on AUTO MODE on the operation functions screen shown in section 7 1 3 m Click on the I O field shown as 0 below Set Point in the Temperature section on the MAFH automatic mode screen The following keypad will display m Type the desired temperature followed by enter Note The maximum allowed temperature is 135 F This screen can be accessed by pressing below ELAPSED TIME on the AUTO MODE screen 7 1 3 m HOUR METER Records the total operation time of the MAFH m TRIP METER reset able operation timer Useful for Preventative Maintenance schedules m CYCLE COMPLETE Records the time the MAFH has remained inoperative due to the fluid s Saturation being below the user s set point m FAULT TIME Records the time the MAFH has remained inoperative due a system fault m AUTO MODE TIME Records the time the has operated continuously in Auto Mode
25. in Automatic Mode The system fluid is cycled through the reaction chamber in between two level switches During the first cycle fluid is pumped and gently sprayed on top of the loose reticulated media until the fluid level in the sump triggers the high float Switch The fluid is then pumped from the sump and returned to the customer s reservoir After the initial cycle the spray and drain pumps are synchronized to continuously pump fluid in both directions The MAFH E controls are designed with a staged start up sequence in Auto Mode to help reduce the current spikes associated with motors start up When the reaction chamber is empty the normal sequence is the spray pump will ramp up to speed slowly followed by the blower motor and then the optional heater if necessary will engage If the cycle was stopped with the fluid above the top float switch at the next start up the Drain pump will operate independently until the fluid is within the normal levels 14 En HYDAC User Manual 7 1 9 Spray Loop Drive Settings Efl RT Simulator 100 DRIVE SETTINGS m CYCLE TIMES Juz Rebs lt 7 1 10 Drain Cycle Time Screen E RT Simulator 100 VIEW CYCLE II FLUID Fl 84 EMP 13 50 HYDAC MAFH L 4138 This screen can be accessed by pressing in the AUTO screen 7 1 3 the STATUS screen 7 1 7 or MANUAL screen 7 1 11 m Cycle Tim
26. n Maintenance To update screen software adjust contrast and calibrate the screen m Technical Data This section of the manual provides information regarding basic technical data of the spray pump drain pump heater and the MAFH unit m Contact HYDAC International This screen provides all information needed to contact HYDAC for product information technical support or for any suggestions for improvement related to the maintenance instructions En 17 L 4138 MAFH User Manual 8 Maintenance Instructions No maintenance operations should be carried out while the unit is running Before starting any other maintenance operations ensure that the system is shut down and electrically isolated 8 1 Servicing Filter Elements Do not run the system without a filter element installed Use only specified replacement filter elements Access to the fluid filter element is from the side of the unit See section 4 for location 8 2 Servicing the Air Breathers The air breathers are simply hand tightened Used breathers may require a wrench to remove The 2 air breathers used are identical Breather element or entire unit may be replaced 8 3 AC Motors The motor should be inspected at regular intervals every 500 hours of operation or every 3 months whichever occurs first Keep the motor clean and the ventilation openings clear During operation listen for unusual noises especially in the areas around the bearings Rumbling or rubbing n
27. ng system operating conditions if applicable Seller shall not be liable for any product altered outside of the Seller s factory except by Seller or Seller s authorized distributor and then as to the latter only for products which have been assembled by the distributor in accordance with Seller s written instructions Nor shall Seller be liable for a product subjected to misuse abuse improper installation application operation maintenance or repair alteration accident or negligence in use storage transportation or handling In no event will Seller be liable for any damages incidental consequential or otherwise whether arising out of or in connection with the manufacture packaging delivery storage use misuse or non use of any of its products or any other cause whatsoever SERVICE Shipping Address for Recalibrating and Repair Work HYDAC International 2260 City Line Rd Bethlehem PA 18017 En HYDAC L 4138 MAFH User Manual APPENDIX 1A HYDRAULIC SCHEMATIC OPTIONAL HEATER les 12KW HEATER 460V 3 60HZ 1 SHP 1740RPM 460V 3 60HZ VACUUM S GAUGE 20 MESH e STRAINER JL a e MAFH E INLET CONNECTION SPRAY LOOP EXHAUST BREATHER ASSEMBLY RETICULATED MEDIA LEVEL SWITCH DIFFUSER I FS Hi Fs tow FS LOW DRIP PAN MOUNTING FRAME gt gt INLET BREATHER lt BLOWER ASSEMBLY 1HP 3450RPM 460V 3 60HZ CENTR
28. oises could be signs of internal damage 8 4 Replacement Parts Since minimum repair service is generally required on these units it is recommended that any failed parts be replaced with new parts See the following parts list Component Part Number Filter Element 02094523 02094524 Air Breather 02062754 2 REQ D Please refer to component list drawings in section 6 for locations of replacement parts WARNING Performance of the MAFH E is based upon the use of HYDAC filter elements The MAFH E is designed around the pressure drops and specifications of the specified HYDAC elements 18 En HYDAC User Manual MAFH L 4138 8 5 Inspection and Maintenance Schedule The schedule listed below is intended to be an indication of the inspections and maintenance work to ensure a long lifetime and faultless operation TASK DAILY 24 HRS MONTHLY 500 HRS 1 2 YR 3000 HRS YEARLY 6000 HRS ICHECKFORLEAKAGE X THOSE amp PIPESFORWEAR a 1 REPLACE AIR BREATHERS Il REPLACE CLEAN SUCTION STRAINER INSPECT4GLEANFAN cn E DRAN FILTERHOUSNG sid R CHECK CABLE GROMMETS E CE EE CHECK amp COMPARE MOTOR CURRENT CONSUMPTION ELECTRICAL SAFETY TEST PER DIN VDE O702 OR EQUAL REGULATION CHECK amp COMPARE HEATER CURRENT CONSUMPTION CHECK REACTOR LEVEL X SWITCH CHECK FLOAT SWITCH IN X PAN TEST ALL COMPONENTS IN X MANUAL OPERATION HYDAC En 19 L 4138 MAFH User Manual 9
29. other source of high differential pressure Heat fluid until maximum rated fluid viscosity of unit is reached The system is running but there is little or no flow into the reactor chamber Air Leak in suction hose Pump not priming The system is running but there is little Verify that the system discharge is not or no flow out of the vacuum chamber blocked Verify proper operation of the discharge pump Verify proper operation of the chamber float switch Check for leaks tighten any fittings that are loose If there is no oil in the pan check wiring or replace the float switch Wrong Phase Sequence Switch any two legs of the main three PMR Red LED is Flashing phase power to reverse the phase Phase Failure or Under Voltage PMR 4 Red LED is Solid y wiring g for correct ampere load Confirm heater is operating correctly Confirm temperature sensor is correct The reactor s fluid level is higher than normal operation There is oil in the drip pan Fluid temperature is above the operating range En 27 L 4138 28 Replace Element Message E Stop Activated Manual Mode Timer Expired Check Sensor Cable Excessive discharge fluid pressure Excessive pump noise or decreased system flow Excessive suction fluid pressure MAFH User Manual Solution Element has reached a bypass or Replace Filter Element If fault con clogged condition tinues confirm the cable is connected and not
30. uring transport m Upon receipt of the unit check for any damage from transportation m The packaging material should be re used re cycled as appropriate for your area m These Operating and Maintenance Instructions are a component part of the MAFH m To lift the MAFH please use the ring bolts m If it is not necessary to lift the MAFH its wheels may be sufficient to push it to its new emplacement m Take care to evacuate the reactor and the fluid filter and to close the drain valve before transport As the MAFH weighs more than 1000 Ibs we recommend transporting with two people Set up m The unit must be mounted level and on flat surface Do not tilt beyond 15 degrees No special mounting is required the brakes at the wheels must be blocked m The MAFH should be located near the tank length of the hoses 15ft max difference in height between the tank and the MAFH is 7 feet maximum m Sufficient room to operate and maintain the unit must be left around the MAFH m No positive or back pressure En HYDAC User Manual 4 Connection 4 1 Suction port connection MAFH L 4138 m The suction port may be connected to a flexible hi collapse hose or to hard piping The nominal size of the connected hoses piping must be at least as large as the inlet outlet port sizes of the MAFH in order to prevent an excessively high negative suction pressure m Make sure that the tank connection is always below the fluid level m Do not prime th
31. vacuum pump based system The MAFH uses a regenerative air injection system to heat and distribute room air into the reaction chamber Any residual fluid mist is mechanically separated from the moist air stream before it is vented from the chamber The system fluid is cycled through the reaction chamber via a system of two gear pumps one speed regulated one fixed speed then filtered During a cycle fluid is pumped from a customer reservoir through an inlet strainer with the speed regulated pump and gently sprayed on top of the loose reticulated media The fluid is pumped fixed speed pump from the sump through a 3 micron filter and returned to the customer reservoir The VFD constantly regulates the motor speed to provide a constant flow of oil to the reaction chamber thereby affording a continuous water removal process The MAFH control system monitors system functions and manages the cycle operation An on board water sensor 51000 senses the relative humidity of the operating fluid and displays the actual humidity value at the control panel 4 En HYDAC User Manual MAFH L 4138 2 WARNINGS CAUTIONS AND NOTES Recognize Safety Information HYDAC This is the safety alert symbol When you see this symbol on your machine or in this manual be alert for the potential of personal injury Follow the precautions and safe operating practices highlighted by this symbol A signal word DANGER WARNING or CAUTION used with the safety al
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