Hydac FCU 1310 Operating And Maintenance Instructions Manual
FluidControl Unit
FCU 1310
Operating and maintenance instructions
English (translation of original instructions)
Valid from firmware version V 3.00 up
Valid from series no. (S/N) 0002S01831K0001000
Keep for future reference.
Document No.: 3371346f
Imprint
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saar
Germany
Phone:
+49 6897 509 01
Fax:
+49 6897 509 9046
E-mail:
filtersystems@hydac.com
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive director:
Mathias Dieter,
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone:
+49 6897 509 1511
Fax:
+49 6897 509 1394
E-mail:
guenter.harge@hydac.com
Imprint
Publisher and responsible for the content:
Dipl.Kfm. Wolfgang Haering
Documentation representative
© 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.
Technical specifications are subject to change without notice.
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Content
Content
Imprint ............................................................................................................ 2
Documentation representative .................................................................... 2
Content .......................................................................................................... 3
What's New — Changes to the manual ....................................................... 7
Preface ........................................................................................................... 8
Safety information ...................................................................................... 10
Technical Support ........................................................................................ 8
Modifications to the Product ........................................................................ 8
Warranty ...................................................................................................... 8
Using the documentation ............................................................................. 9
Hazard symbols ......................................................................................... 10
Signal words and their meaning in the safety information and
instructions ................................................................................................ 11
Structure of the safety information and instructions ................................... 12
Observe regulatory information ................................................................. 12
Proper/Designated Use ............................................................................. 13
Periodic intermittent duty - operating mode S3, (as per DIN EN
60034-1 / DIN VDE 0530, part 1) ........................................................... 14
Improper Use or Use Deviating from Intended Use ................................... 15
Qualifications of personnel / target group .................................................. 16
Wear personal protection equipment ......................................................... 17
Stoppage in an emergency (EMERGENCY STOP) ................................... 17
FCUOpening/Closing .................................................................................. 18
FCUtransporting ......................................................................................... 19
FCUstoring .................................................................................................. 20
Decoding the model code label ................................................................. 21
Checking the scope of delivery ................................................................. 23
What can the product do? .......................................................................... 24
Counting contaminant particles ................................................................. 25
How the product works .............................................................................. 27
Overview of control panel/operating elements ........................................... 28
Dimensions ................................................................................................ 29
Hydraulic diagram ...................................................................................... 30
Using the BatteryPack (accessory) ........................................................... 31
Preparing the FCU for measurement ........................................................ 36
Connecting/Disconnecting the FCU electrically ......................................... 36
Plug in/Detach return hose ........................................................................ 37
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Content
Selecting the measurement location .......................................................... 38
Select the measurement method according to the pressure
involved ..................................................................................................... 39
Measuring up to max. 45 bar / 650 psi....................................................... 40
Measuring in the range 5 to 345 bar / 217 to 5000 psi .............................. 43
Measuring from unpressurized containers ................................................. 47
FCUoperating .............................................................................................. 49
Display and keypad elements .................................................................... 49
Clicking through the display ....................................................................... 51
- Display ............................................................................. 51
- Display ............................................................................. 52
Displaying measured variables .................................................................. 53
" " measured variable ........................................................................ 53
" " measured variable ....................................................................... 53
" " measured variable ....................................................................... 53
" " measured variable .................................................. 53
" " measured variable ......................................................... 53
Display service variables ........................................................................... 54
" " service variable ........................................................................... 54
" " service variable .......................................................................... 54
Select operating level / configuration menu ............................................. 55
Operate / Set up menu .............................................................. 56
– Setting date/time ............................................................. 57
- Set bus address ............................................................... 57
- Delete memory ................................................................ 58
- Set measuring time ............................................................. 58
– Select calibration type ........................................................ 59
– Reset to default settings.................................................. 59
- Cancel .............................................................................. 60
– Save data .............................................................................. 60
Operating/Setting measuring menu ........................................................... 61
– Record measurements .................................................... 62
- Display free memory ........................................................ 63
– Change name of measurement point .............................. 64
- Set temperature unit ........................................................ 65
- Cancel .............................................................................. 66
– Save data .............................................................................. 66
Performing measurements ........................................................................ 67
Reading internal measurement memory ................................................... 68
Read out measured values via DATA interface ......................................... 69
Connecting FCU with a CSI-B-2 kit ........................................................ 69
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Content
Pins used on the DATA interface (HYDAC Sensor Interface –
HSI) ........................................................................................................ 69
Connecting FCU with HMG 510 / HMG 3000 / 4000 .............................. 70
Reading out USB interface measured values ............................................ 71
Copying measurements onto a USB data stick ...................................... 71
- Data transmission failed ..................................... 74
Reading out measured values via Bluetooth interface ............................... 75
Installing the Bluetooth USB adaptor ...................................................... 76
Guarantee and liability for the USB adapter ........................................ 76
Connecting/Linking the FCU via Bluetooth ............................................. 76
Evaluating measurement records ............................................................. 77
Measurement record directories according to measurement point ............ 77
Measurement report file names ................................................................. 77
Opening measurement reports .................................................................. 78
The measurements are shown as dates ................................................ 80
Evaluating/Reading measurement reports with FluMoS ......................... 82
Preparing the FCU for transport ................................................................ 83
Performing maintenance ............................................................................ 87
FCUcleaning .............................................................................................. 87
FCU flushing .............................................................................................. 88
Clean the suction strainer .......................................................................... 92
Checking the high pressure adapter .......................................................... 96
Cleaning / changing the strainer in the high pressure adapter ............... 97
Cleaning / changing the strainer in the high pressure adapter ............... 98
Identifying and interpreting status/error messages ................................ 99
Restarting/resetting .................................................................................. 103
Taking the FCU out of operation ............................................................. 103
Shutting down the FCU............................................................................ 103
FCUdisposing .......................................................................................... 103
Locating spare parts ................................................................................. 104
Selecting accessories .............................................................................. 105
Checking the measuring accuracy .......................................................... 107
FCUcalibrating ......................................................................................... 107
Technical Data........................................................................................... 108
Appendix ................................................................................................... 110
Model Code ............................................................................................. 110
Finding Customer Service / Service stations ........................................... 111
Germany .............................................................................................. 111
USA ...................................................................................................... 111
Australia ............................................................................................... 111
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Content
Brazil .................................................................................................... 112
Factory default settings............................................................................ 112
Overview / Definition of the cleanliness classes ...................................... 113
Cleanliness class acc. to ISO 4406:1999 ............................................. 113
ISO 4406 overview table ................................................................... 114
Difference between ISO4406:1987 and ISO4406:1999 ....................... 115
Cleanliness class acc. to SAE AS 4059 ............................................... 116
SAE AS 4059 overview table ............................................................ 116
Display cleanliness classes according to SAE Absolute particle
count larger than a defined particle size ............................................... 117
Specifying a cleanliness code for each particle size ......................... 117
Specifying the highest cleanliness code measured ........................... 117
Cleanliness class acc. to NAS 1638 ..................................................... 118
EC declaration of conformity .................................................................... 119
Explanation of terms and abbreviations ................................................... 121
Index ........................................................................................................ 122
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What's New — Changes to the manual
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"
- Restrictions on use of fluid with flash point < 55 °C added
- Spare parts list adapted
- "Transporting FCU" section updated
- Filling the hose lines before measuring is no longer necessary.
Index "e" from firmware version V 3.00
- From firmware V3.00 / from series no. 0002S01831K0001000
- Update / corrections / reworking
- Index added
Index "f" from firmware version V 3.00
- Update / corrections / reworking
What's New — Changes to the manual
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.
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Preface
Fax:
+49 6897 509 9046
E-mail:
filtersystems@hydac.com
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
deceitfully 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
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 code, serial no. and part no. of the product:
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.
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
Note that the method described for locating specific information
de
HYDAC F
iltertechnik GmbH
BeWa 123456a de
Seite x
P
r
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u
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t
/
K
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200x-xx-xx
Chapter description
Page number
Document language
Documentation no.
Using the documentation
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
What do I want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter
I'm looking for and the corresponding page number.
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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Edition date
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Safety information
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 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 product inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety information
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 avoid
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.
Risk of burns due to hot surfaces
Signal words and their meaning in the safety information and instructions
In these instructions you will find the following signal words:
ed, can result in minor or moderate injury.
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Safety information
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
► Measures to avert danger
Observe regulatory information
Observe the following regulatory information and guidelines:
• Legal and local regulations for accident prevention
• Legal and local regulations for environmental protection
• Country-specific regulations, organization-specific regulations
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Safety information
Proper/Designated Use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Use the product only for the application described below.
The FluidControl Unit FCU is a portable service unit for taking short-term
measurements of the solid particle contamination, temperature und %
saturation level in hydraulic systems.
Proper/designated use of the product extends to the following:
• Observing all the instructions contained in these operation and
maintenance instructions.
• Ensuring the execution of all inspection and maintenance work.
NOTICE
Impermissible operating conditions
The FCU will be destroyed
► Use the FCU with mineral oils or mineral oil-based raffinates whose
flash point is higher than 55°C / 131°F.
► Flush the FCU with low-viscosity mineral oils or mineral oil-based
raffinates (e.g. diesel) whose flash point is higher than 55°C / 131°F.
► Never flush the FCU with universal thinners or other degreasing fluids.
► Observe the permissible viscosity range (up to ISO VG 68):
10 - 350 mm²/s / 46 - 1622 SUS.
► Only operate the FCU in periodic intermittent duty (S3) with a relative
duty cycle of 40%
(S3 as per DIN EN 60034 / VDE 0530).
► Never use the FCU without a suction strainer.
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Safety information
which have a central
(PN)S3
=
Nominal power, operating mode S3
t = Time
t0 = Period (operation t1 + cooling phase t2)
t1 = Operation
t2 = Cooling phase (downtime)
°C (°F)
=
Temperature
NOTICE
Connection to 24 V DC on-board networks without load dump
The FCU will be destroyed.
► Use the FCU only on 24 V DC on-board networks
"Load Dump" fuse.
► Before connecting, be sure to check that a load dump is installed with
at least 30 V DC and is effective.
Periodic intermittent duty - operating mode S3, (as per DIN EN 60034-1 / DIN VDE 0530, part 1)
Operation t0 in time t1 at power (PN)S3 interchange periodically with the
cooling phases (downtimes) t2. The relative duty cycle is 40%.
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Safety information
Improper Use or Use Deviating from Intended Use
DANGER
Hazard due to use of the product other than
that intended
Bodily injury and damage to property will result
when operated improperly.
► Never operate the product in potentially
explosive atmospheres.
► Only use the product with permissible media.
Any use extending beyond this or deviating therefrom shall not be considered
intended use. HYDAC FILTER SYSTEMS GmbH will assume no liability for
any damage resulting from such use. The user alone, shall assume any and
all associated risk.
Improper use may result in hazards and/or will damage the product.
Examples of improper use:
• Operation with fluid that has a flash point under 55°C / 131°F.
• Flush with universal thinners or other degreasing fluids
• Operation in potentially explosive atmospheres.
• Operation under non-approved operational conditions.
• Modifications to the product made by the user or purchaser.
• Continuous monitoring of the fluid cleanliness (continuous operation)
• Improper connection of the pressure and return flow hoses.
• Operation at a measurement point with impermissible pressure.
• Operation on 24 V DC on-board networks without central
"Load Dump" fuse.
• Operation with an impermissible fluid.
• Operation with faulty or damaged hoses.
• Operation with damaged connector cable.
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Safety information
Activity
Person
Knowledge
Transport / storage
Auxiliary
• No specialist knowledge
Startup operation
Auxiliary
• Product-specific knowledge
Troubleshooting,
Specialist
• Safe handling/use of tools
Disassembly
Service staff
• Very detailed product-specific
Disposal
Specialist
• Proper and environmentally-
Qualifications of personnel / target group
Auxiliary, operational and specialist personnel must have read and
understood the operating instructions, in particular the safety information and
instructions, and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel: such persons have been instructed about the product
and informed about potential hazards that can result from improper use.
Operating personnel: such persons have been instructed in product
operation and are aware of potential dangers due to improper use.
Specialist personnel: such persons with corresponding specialist training
and several years' work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential hazards.
Operations control
Maintenance,
Decommissioning,
personnel
personnel
personnel
(only with
authorized
HYDAC
Service)
personnel
required
• Knowledge about how to
handle operating media.
• Product-specific knowledge
knowledge
friendly disposal of materials
and substances
• Decontamination of
contaminants
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• Knowledge about reuse
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Safety information
Wear personal protection equipment
Observe the information relating to personal protection equipment in the
safety data sheet of the operations fluid.
• Wear eye protection.
• Wear gloves.
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, disconnect the FCU from the power supply
and from the hydraulic system.
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FCUOpening/Closing
FCUOpening/Closing
Open the FCU by releasing both clips.
Close the FCU using both clips. Make sure that these audibly snap into
place.
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FCUtransporting
FCUtransporting
Transport the FCU only when it is in closed position; carry it flat or by the
handle.
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FCUstoring
FCUstoring
Drain and rinse the FCU completely before putting it into storage. See page
88 in the "FCU flushing" chapter for details on rinsing the FCU.
Observe permissible conditions required for storage on page 108 in the
"Technical Data" chapter.
Store the FCU closed and in a horizontal position in a dry, clean place. If
stored in a vertical position, the FCU must not be exposed to any shaking or
vibration.
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Decoding the model code label
Item
->
Description
(1)
->
Type label for FCU
(2)
->
Model code; for details, see page 110.
Decoding the model code label
For identification details of the FluidControl Unit, see the model code label.
The type label displays the product ID and important technical data.
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Decoding the model code label
Row
->
Description
Model
->
Model code; for details, see page 110.
Date
->
Production year/week
P/N
->
Part number
S/N
->
Serial no.
Flow rate
->
Flow rate
Weight
->
Weight when empty
Viskosity range
->
Permissible viscosity range
Pressures
->
Pressure specifications
In
->
Permissible pressure at port INLET
Out
->
Permissible pressure at port OUTLET
Temperatures
->
Temperature specifications
Oil
->
Permissible oil temperature range
Ambient
->
Permitted ambient temperature range
Power
->
Power consumption
Voltage
->
Voltage
Current
->
Current consumption
The following information can be found on the name plate of the product:
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Checking the scope of delivery
Item
Qty
Description
1
1
FluidControl Unit FCU, including attachable bag for
cables and hoses
2
1
Power supply, primary: 90-240 V AC / secondary:
24 V DC / 5 A
3
4
Connection cable for power adapter (Europe,
USA/Canada, UK, Australia, Japan)
4
1
Suction hose, open end, clear-transparent, L = 0.3 m
5
1
High pressure hose with screwed joint, type 1620, color:
black, L = 2 m
6
1
High-pressure adapter
7
1
Return hose, transparent, L = 2 m
8
1
Operating and maintenance instructions
9
1
Calibration certificate
10
1
CD-ROM with FluMoS software
11
1
Pocket for documents
12
1
USB memory stick with operating and maintenance
instructions (PDF file) in additional languages
-
1
Quick start manual
Checking the scope of delivery
The FluidControl Unit comes factory-assembled. Before commissioning the
FCU, check the contents of the consignment to make sure everything is
present.
The following items are supplied:
A USB bluetooth adapter for the PC is a free gift and is not part of the
delivery.
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What can the product do?
What can the product do?
The FluidControl Unit FCU is a portable service unit for taking short-term
measurements of the solid particle contamination, temperature und %
saturation level in hydraulic systems.
Knowledge on the level and amount of contamination allows you to check
and document quality standards and introduce the required optimization
measures.
The integrated pump and the hoses supplied enable usage with:
• Control circuits
• Pressure circuits
• Depressurised containers
The internal data memory enables measurements to be recorded together
with a time-stamp.
The USB interface can be used to copy all measurements to a USB memory
stick or to send them to a mobile device via Bluetooth where they can be
analyzed using MS Excel or the Fluid Monitoring software FluMoS.
Additional features include:
• Optical measurement of the degree of solid particle contamination
• Capacitive recording of the water saturation in %
• Resistive measurement of the temperature
• Suitable for hydraulic fluids (up to ISO VG 68)
10 - 350 mm²/s / 16 - 1622 Sus
• Automatic measurement and display of cleanliness ratings in
accordance with:
• ISO 4406:1987; NAS 1638
• ISO 4406:1999; SAE AS 4059 (D)
• Measurement accuracy +/- ½ ISO code in the calibrated range
• Supply voltage of 24 V DC / 4 A for operation on mobile machine on-
board networks
• Network adapter 90 - 240 V AC / 24 V DC 5 A included in the scope of
delivery
• Operating pressure without high-pressure adapter max. 45 bar / max.
650 psi,
Operating pressure with high-pressure adapter max. 345 bar / max.
5000 psi
• Integrated pump for the automatic control of oil flow
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What can the product do?
Item
Designation
1
Light source
2
Particle
3
Photo detector
Counting contaminant particles
The measuring principle of the light blockade procedure is shown in
simplified form in the following sketch.
The light source transmits monochromatic light through the flow of oil to a
photo detector, which produces a particular electrical signal. If a particle gets
between the light source and the photo detector, then a shadow will be cast
on the photo detector.
This shadow causes a change in the electrical signal generated by the photo
detector. This change makes it possible to determine the size of the shadow
cast by the particle and thus to gauge the size of the particle itself.
This procedure makes it possible to determine the cleanliness class
according to ISO 4406:1987, ISO 4406:1999, NAS 1638 and SAE AS 4059.
The disruption factors of this measurement principle are foreign fluids and
small gas bubbles that lead to refractions, thus causing them to be counted
as particles as well.
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What can the product do?
Each of the signal peaks corresponds to the shadow cast by one particle.
The signal height or amplitude reflects the particle size. Thresholds are used
to classify the particle sizes >2, >5, >15, >25 µm or >4, >6, >14, >21 µm
(c)
.
Threshold values
Time
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What can the product do?
How the product works
From the oil source (either a pressure port or a bottle sample), a continuous
oil flow is established through the port (1) INLET by an electrically controlled
gear pump (3).
A suction strainer (2) protects the pump from coarse contamination.
The oil current to be analyzed flows through an optical ContaminationSensor
(6). The contaminant particles contained in the oil current cause the light
beam to be darkened in a pulse-like manner. An electronic evaluation module
classifies and counts these measurement signals according to particle
diameter. The evaluation module continuously computes the cleanliness
classes for the reference volume of 100°ml based on the measurement
signals of the optical sensor.
A defined pressure is generated in the oil flow via a counter balance valve
(7). This serves to minimize air bubbles in the system, which could skew the
measurement results.
The pressure relief valve (5) protects the pump and the measuring cell from
excessive pressure.
The oil flow leaves the port (9) OUTLET and is routed by the return hose to a
pressurized tank.
The electronic evaluation module monitors:
• the function of the ContaminationSensors
• the oil flow
• the power supply voltage
• the function of the AquaSensors
When a malfunction occurs, an error message automatically appears in the
display and interrupts the measurement. The evaluation module will
recognize when the cause of error has been corrected, and the unit will reset
automatically and resume the measurement operation.
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What can the product do?
Item
Designation
1
Display of “ISO, SAE/NAS, Flow, Drive” with keypad
2
Display of the percentage "water saturation"
3
"Fluid temperature" display
4
ON / OFF switch for the internal pump
5
Supply voltage 24 V DC
6
Data interface (DATA)
7
Connection OUTLET
8
Connection INLET, type 1604
9
USB interface with cover
-
Bluetooth interface
Overview of control panel/operating elements
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What can the product do?
Dimensions
The FCU has the following dimensions.
All dimensions in mm.
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What can the product do?
Hydraulic diagram
Item Designation
1 INLET, gauge port type 1604
2 Suction screen, 400 µm
3 Gear pump
4 Electric motor
5 Pressure relief valve
6 ContaminationSensor unit
7 Counter balance valve
8 AquaSensor AS1000
9 OUTLET, DN7 Quick coupling nipple
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