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FCU 1000 Series
FluidControl Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Valid from firmware versions V 2.00 up
Document no.: 3371346d
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FCU 1000 Series
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2010 by HYDAC FILTER SYSTMES GMBH all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC FILTER SYSTEMS GMBH. Contraventions are
liable to compensation.
Exclusion of Liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, we accept no liability for such
errors as may exist nor for any damage or loss whatsoever which may arise as a
result of such errors. We welcome any suggestions for improvements.
Trademarks
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-Mail: guenter.harge@hydac.com
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FCU 1000 Series
Contents
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Contents.................................................................................................................... 3
What's New — Document History........................................................................... 6
Preface ......................................................................................................................7
Technical Support...................................................................................................8
Modifications to the Product ...................................................................................8
Warranty ................................................................................................................. 8
Using the Documentation .......................................................................................9
Safety Information and Instructions..................................................................... 10
Obligations and Liability........................................................................................10
Explanation of Symbols and Warnings, etc. ......................................................... 11
Proper/Designated Use ........................................................................................11
Improper Use or Use Deviating from Intended Use.............................................. 12
Informal Safety Precautions.................................................................................. 12
What to Do in Case of Emergency .......................................................................12
Training and Instruction of Personnel ...................................................................13
Transporting the FCU ............................................................................................14
Storing the FCU ......................................................................................................15
Decoding the model code label ............................................................................16
Checking the scope of delivery ............................................................................17
What the FCU 1000 can do ....................................................................................18
Restrictions on the use of the FCU 1000..............................................................19
Counting particles in the FCU 1000...................................................................... 20
How the FCU 1000 functions................................................................................. 21
User interface of the FCU 1000 ............................................................................22
Dimensions of the FCU 1000................................................................................ 23
Hydraulic diagram.................................................................................................24
Using the BatteryPack (accessory) ...................................................................... 25
Preparing the FCU for measurement.................................................................... 28
Connecting/disconnecting the FCU electrically.....................................................28
Connecting/disconnecting the OUTLET hose....................................................... 29
Selecting the measurement point ......................................................................... 30
Select the measurement method according to the pressure involved ..................31
Measuring up to max. 45 bar / 650 psi.................................................................. 32
Measuring in the range 5 to 345 bar / 217 to 5000 psi.........................................35
Measuring from unpressurized containers..........................................................38
Operating the FCU.................................................................................................. 40
Display and keypad elements............................................................................... 40
Clicking through the display .................................................................................42
ISO.SAE display................................................................................................42
Contents
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FCU 1000 Series
ISO.SAE display................................................................................................43
Measured variables ................................................................................................44
Measured variable "ISO"................................................................................... 44
Measured variable "SAE".................................................................................. 44
Measured variable "NAS".................................................................................. 44
Measured variable "Water saturation"............................................................... 44
Measured variable "Temperature".....................................................................45
Service variables ..................................................................................................45
Service variables "Flow".................................................................................... 45
Service variables "Drive"................................................................................... 45
FCU configuration menus .....................................................................................46
Power Up Menu ....................................................................................................46
DAT.TIM – date / time .......................................................................................47
ADRESS - Bus address .................................................................................... 47
DEL.MEM – Delete Memory .............................................................................48
M.TIME – Measurement Time........................................................................... 48
CALIB – Select calibration type......................................................................... 49
DFAULT – reset to factory settings ...................................................................49
CANCEL............................................................................................................50
SAVE – store data.............................................................................................50
Measuring Menu ...................................................................................................51
RECORD - recording measurements................................................................ 52
MEMORY – display free memory...................................................................... 53
ED.MPNT – Change the name of measurement points.................................... 54
TP.UNIT – change the temperature units °C / °F..............................................55
CANCEL............................................................................................................55
SAVE - save data..............................................................................................55
Performing a measurement................................................................................... 56
Restrictions pertaining to use ...............................................................................56
Internal measurement memory .............................................................................56
DATA - interface .....................................................................................................57
Connecting the FCU with CSI-B-2 kit ...................................................................57
Pins used on the DATA interface (HYDAC Sensor Interface – HSI) ....................57
Connecting the FCU with HMG 510 / HMG 3000 .................................................58
USB interface.......................................................................................................... 59
Copying measurements onto a USB data stick ....................................................59
Data transmission failed - "ERROR COPY"..........................................................61
Bluetooth interface................................................................................................. 62
Installing the Bluetooth USB adaptor.................................................................... 63
Guarantee and liability for the USB adapter...................................................... 63
Connecting the FCU via Bluetooth .......................................................................63
Evaluating stored records .....................................................................................64
Directories to store the records by measurement points ......................................64
Record file names.................................................................................................64
Evaluating the file containing the measurements ................................................. 65
Contents
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FCU 1000 Series
The measurements are shown as dates ...........................................................67
Measurement value readouts with FluMoS..........................................................68
Preparing the FCU for transport ...........................................................................69
Performing maintenance ......................................................................................72
Cleaning the FCU ................................................................................................. 72
Rinsing the FCU ...................................................................................................72
Clean the suction strainer. ....................................................................................75
Checking the high pressure adaptor.....................................................................78
Cleaning / changing the sieve in the high pressure adapter ............................. 79
Cleaning / changing the strainer in the high pressure adapter.......................... 80
FCU status messages / error messages .............................................................81
Restart / Resetting the FCU................................................................................... 84
Disposing of the FCU............................................................................................. 84
Spare Parts List ......................................................................................................85
Accessories for the FCU.......................................................................................86
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes...............................89
ISO 4406:1999......................................................................................................89
ISO 4406 table .................................................................................................. 89
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 ......................................................................................................... 90
SAE AS 4059........................................................................................................91
SAE AS 4059 table ...........................................................................................91
Cleanliness codes according to SAE ................................................................ 91
Absolute particle count larger than a defined particle size ............................91
Specifying a cleanliness class for each particle size .....................................92
Specifying the highest cleanliness code measured....................................... 92
NAS 1638 .............................................................................................................92
Checking the measuring accuracy of the FCU.................................................... 93
Calibrating the FCU................................................................................................ 93
Customer service ...................................................................................................94
Germany ...............................................................................................................94
USA ......................................................................................................................94
Australia................................................................................................................94
Brazil.....................................................................................................................95
Factory default settings......................................................................................... 95
Technical Data ........................................................................................................96
Model Code .............................................................................................................98
Compatible USB sticks - overview .......................................................................99
EC declaration of conformity .............................................................................. 100
Contents
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FCU 1000 Series
What's New — Document History
The index is featured on the cover sheet of the operating and maintenance manual
and in the lower left corner of each page after the part number.
Index "a" - from firmware version V 1.10
- Change to the items delivered
- Change of Bluetooth device name to "FCU1310"
Index "b" — from firmware version V 2.00
- Change to the items delivered
- "USB connection" chapter added
- Additions made to user interface chapters
- Additions made to "BatteryPack" chapter
Index "c"
- Index adapted
Index "d"
What's New — Document History
- Restrictions on use of fluid with flash point < 55°C added
- Spare parts list adapted
- "Transporting FCU“ updated
- Filling the hose lines before measuring is no longer necessary.
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FCU 1000 Series
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Sometimes the information contained in the documentation cannot always keep up
with changes made to the product as we attach considerable importance to keeping
our products cutting-edge. Consequently, there might be deviations in technical
details, illustrations and dimensions.
Preface
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”
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FCU 1000 Series
Technical Support
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: ++49 (0) 6897 / 509 - 846
E-mail: filtersystems@hydac.com
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Preface
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com ð General terms and conditions.
HYDAC FILTER SYSTEMS GMBH
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