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HYDAC International FCU 1000 Series Operating And Maintenance Instructions Manual

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FCU 1000 Series
FluidControl Unit
Operating and Maintenance Instructions
English (Translation of original)
Valid from firmware versions V 1.10 up
Doc.: 3371346a / 2007-12-03

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Summary of Contents for HYDAC International FCU 1000 Series

  • Page 1 FCU 1000 Series FluidControl Unit Operating and Maintenance Instructions English (Translation of original) Valid from firmware versions V 1.10 up Doc.: 3371346a / 2007-12-03...
  • Page 2 FluidControl Unit - FCU 1000 Series Trademarks The trademarks of other companies are exclusively used for the products of those companies. Copyright © 2007 by HYDAC Filtertechnik GmbH all rights reserved All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filtertechnik.

  • Page 3: Table Of Contents

    FluidControl Unit - FCU 1000 Series Contents Contents..........................3 What's New — Document History..................5 Preface ............................ 6 Customer Service ......................... 7 Modifications to the Product ....................7 Warranty ..........................7 Using the documentation ...................... 8 General Safety Precautions ................... 9 Obligations and Liability .....................
  • Page 4 FluidControl Unit - FCU 1000 Series Display and keypad elements .................. 28 7.1.1 Measured variables..................29 7.1.1.1 Measured variable "ISO"................29 7.1.1.2 Measured variable "SAE"................29 7.1.1.3 Measured variable "NAS"................29 7.1.1.4 Measured variable "Water saturation"............29 7.1.1.5 Measured variable "Temperature" ..............30 7.1.2...

  • Page 5: What's New - Document History

    FluidControl Unit - FCU 1000 Series 13.1 Accessories ......................53 14 Technical Data....................... 54 15 ISO 4406 / SAE AS 4059 and NAS 1638 Classes ............56 15.1 ISO 4406:1999 ......................56 15.1.1 ISO 4406 table ....................56 15.1.2 Overview of the differences between ISO 4406:1987 and ISO 4406:1999... 57 15.2 SAE AS 4059 ......................

  • Page 6: Preface

    FluidControl Unit - 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.

  • Page 7: Customer Service

    FluidControl Unit - FCU 1000 Series Customer Service 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 Email: filtersysteme@hydac.com...

  • Page 8: Using The Documentation

    FluidControl Unit - FCU 1000 Series Using the documentation Please note that the method described above of locating specific information does not release you from your responsibility for carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals later on.

  • Page 9: General Safety Precautions

    FluidControl Unit - FCU 1000 Series General Safety Precautions These operating instructions contain the key instructions for properly and safely operating the FCU. Obligations and Liability • The basic prerequisite for the safe and proper handling and operation of the FCU is knowledge of the safety instructions and warnings.

  • Page 10: Explanation Of Symbols And Warnings, Etc

    FluidControl Unit - FCU 1000 Series Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.: 1.2.1 Basic Symbols DANGER denotes situations which can DANGER lead to death if safety precautions are not observed.

  • Page 11: Improper Use

    FluidControl Unit - FCU 1000 Series Improper Use Improper use may result in hazard to life and limb. Examples of improper use: • Long-term measurement of system cleanliness • improper connection of the FluidControl Unit pressure and return flow hoses.

  • Page 12: Electrical Hazards

    FluidControl Unit - FCU 1000 Series Electrical Hazards WARNING Electric shock The power plug must be pulled before performing work on live parts Any work involving the power supply may only be done by a properly trained, certified electrician. Make sure to check the electrical equipment of the product on a regular basis. Any loose connections or damaged cables are to be remedied/replaced immediately.

  • Page 13: Transportation/Package/Storage

    FluidControl Unit - FCU 1000 Series Transportation/Package/Storage Packing / transportation Unpack the unit and check it for damage in transit. Report any damage to the forwarding agent immediately Storage Make sure to store the FCU in a clean, dry place.

  • Page 14: Checking The Scope Of Delivery

    FCU, check the contents of the consignment to make sure everything is present. The following items are supplied: Pos. Description FluidControl Unit FCU 1000 Series, including attachable bag for cables and hoses 24 V DC / 5 A power supply Connection cable (Europe, USA/Canada, UK, Australia, Japan) INLET suction hose, open end, clear-transparent, L = 0.3 m (11.81 inch)

  • Page 15: Using The Fcu

    FluidControl Unit - FCU 1000 Series Using the FCU The FCU 1000 is a portable service unit for the temporary measurement of particulate contamination in hydraulic systems. With the integrated AquaSensor AS 1000, the measurements can be expanded to include the saturation level of water in hydraulic media in % and temperature.

  • Page 16: Mode Of Function

    FluidControl Unit - FCU 1000 Series Mode of Function Display Keypad Contamination Sensor INLET OUTLET From the oil source (either a pressure port or a bottle sample), a continuous oil current is established through the INLET connector by an electrically controlled gear pump (16).
  • Page 17 FluidControl Unit - FCU 1000 Series The electronic evaluation module provides for the continuous monitoring of the following: • the particle sensor function • the oil flow • the power supply voltage When a malfunction occurs, an error message automatically appears in the display and interrupts the measurement.

  • Page 18: Operation Panel

    FluidControl Unit - FCU 1000 Series Operation panel Item Description Display and Keypad For details see chapter 7.1 Pump ON / OFF switch Switches the internal pump on / off Power supply connector 24 V DC Data interface (DATA) Connection, 5-pole, M12x1...

  • Page 19: Dimensions

    FluidControl Unit - FCU 1000 Series Dimensions ca. 330 ca. 450 FCU open FCU closed Hydraulic schematic INLET OUTLET INLET, test connector type 1604 ContaminationSensor Unit Suction screen, 400 µm Counter balance valve Gear pump AquaSensor AS 1000 Electric motor...

  • Page 20: Preparing The Fcu

    FluidControl Unit - FCU 1000 Series Preparing the FCU Before operation, the FCU must first be hydraulically and electrically connected, as described below. Attaching OUTLET quick-action coupling OUTLET Place the quick-action coupling on the nipple and push it until it audibly locks in place.

  • Page 21: Connection At The Measurement Point Up To Max. 45 Bar

    FluidControl Unit - FCU 1000 Series 6.2.1 Connection at the measurement point up to max. 45 bar WARNING Hydraulic systems are under pressure Oil can start to flow through the FCU as soon as the system has been connected to the pressure fitting.Oil can start to flow through the FCU as soon as the system has been connected to the pressure fitting.
  • Page 22 FluidControl Unit - FCU 1000 Series 2. Now connect the other end of the hose to the OUTLET port of the FCU. OUTLET 3. Now connect the INLET pressure hose (color: black) to the INLET port of the FCU. INLET 4.

  • Page 23: Connection At The Measurement Point With 45

    FluidControl Unit - FCU 1000 Series 6.2.2 Connection at the measurement point with 45 ... 345 bar WARNING Hydraulic systems are under pressure Oil can start to flow through the FCU as soon as the system has been connected to the pressure fitting.Oil can start to flow through the FCU as soon as the system has been connected to the pressure fitting.
  • Page 24 FluidControl Unit - FCU 1000 Series Make sure to follow the sequence specified here:Make sure to follow the sequence specified here: 1. First connect the open end of the OUTLET return hose (color: clear-transparent) to the system reservoir or to a waste oil canister.

  • Page 25: Selecting The Measurement Point

    FluidControl Unit - FCU 1000 Series 6.2.3 Selecting the measurement point The measurement point has to be selected so that the measured volume is taken from a turbulent flow area, i.e. a pipe bend. This ensures that a typical sample is analyzed.

  • Page 26: Connection At The Measurement Point - Non-Pressurized Tank

    FluidControl Unit - FCU 1000 Series 6.2.4 Connection at the measurement point - non-pressurized tank INLET OUTLET FCU 1000 0 bar / 0.5 bar max. 0 psi 7.5 psi max. We recommend filling the FCU before measurement. This ensures immediate and accurate measurements results.

  • Page 27: Electrical Connection Of The Fcu

    FluidControl Unit - FCU 1000 Series Electrical connection of the FCU A 3-pole connector for connecting a 24 V DC power supply is located on the operating surface of the FCU. Plug in the 3-pole jack plugs óf the adaptor (included in the FCU delivery).

  • Page 28: Operating The Fcu

    FluidControl Unit - FCU 1000 Series Operating the FCU As soon as the FCU 1000 is switched on, HYDAC FCU 1### appears in the display in moving letters, followed by the firmware version, which is illuminated for 2 seconds. WAIT 99 to WAIT 0 This is followed by a countdown: .

  • Page 29: Measured Variables

    FluidControl Unit - FCU 1000 Series The keyboard consists of six buttons. These buttons are used to operate the FCU and to navigate through the menus (hierarchically structured). Keyboard Description one level down o.k. confirm changed value (lowest level) confirm when changes are to be saved or canceled (top level)

  • Page 30: Measured Variable "Temperature

    FluidControl Unit - FCU 1000 Series Continuous measurement and display of the measurement value as relative humitidy of the fluid in % saturation 7.1.1.5 Measured variable "Temperature" Display Description Continuous measurement and display of the temperature in °C Celsius or °F Fahrenheit (according to setting) 7.1.2...

  • Page 31: Switching The Display

    FluidControl Unit - FCU 1000 Series 7.1.3 Switching the display The active display can be operated with the keypad. Press the following keys to make selections in the display. Buttons Description 2=1(1% Changing the active display 7.1.4 Activate / deactivate keypad lock.

  • Page 32: Modes And Menus

    FluidControl Unit - FCU 1000 Series Modes and menus The sensor features two operating modes, each mode with a menu of its own: Menus Mode Description Power Up Menu Power Up mode For basic settings Starts automatically after powering up...

  • Page 33: Measuring Menu Iso / Sae

    FluidControl Unit - FCU 1000 Series ISOSAE ISO 4406:1999 / SAE ISONAS ISO4406:1987 / NAS Discard changes and CANCEL exit SAVE Save changes and exit For internal CODE Activate use only service menu 7.2.2 Measuring Menu ISO / SAE The measuring menu allows you to change settings during operation.

  • Page 34: Menu Structure Iso / Sae

    FluidControl Unit - FCU 1000 Series 7.2.3 Menu structure ISO / SAE Power Up Menu Measuring time (mTIME) Set value (60) Bus address (ADRESS) HECOM3b address (HECOM) Set value (A) Factory defaults (DFAULT) Calibration (CALIB) ISO99/SAE (ISoSAE) ISO87/NAS (ISoNAS) Cancel (CANCEL)

  • Page 35: Menu Structure Iso / Nas

    LED lights up green permanently. Restrictions pertaining to use The FCU 1000 Series may only be used with mineral oils or mineral oil-based raffinates. Permissible viscosity range: 10 – 350 mm²/s or 46 – 1622 SUS (ISO VG 68) The FCU 1000 is designed for short time operation and NOT for continuous operation (S4 according to DIN EN 60034 / VDE 0530).

  • Page 36: Dismantling The Fcu

    FluidControl Unit - FCU 1000 Series Dismantling the FCU CAUTION Hot fluid at the OUTLET Before removing, allow the FCU to cool off When dismantling the FCU, make sure to follow the sequence specified here: To stop the measurement, press the red "Pump off" button.

  • Page 37: Fcu Interfaces

    FluidControl Unit - FCU 1000 Series FCU interfaces The FCU 1000 has the following interfaces for configuration and the transmission of measurement data. 18…35 V DC Customer System FCU 1000 ZBE 08S-xx DATA Bluetooth 10.1 DATA (HYDAC Sensor Interface - HSI) The HSI interface has connection plug M12x1, 5-pole, in accordance with DIN VDE 0627.

  • Page 38: 10.1.1 Connecting The Fcu With Hmg 510 / Hmg 3000

    FluidControl Unit - FCU 1000 Series 10.1.1 Connecting the FCU with HMG 510 / HMG 3000 The following portable data recorders (HMGs) can be used to give a readout of the FCU 1000 via the DATA interface. HMG 510 (with firmware version 2, release 15 or higher)

  • Page 39: Connecting The Fcu With Csi-B-2

    FluidControl Unit - FCU 1000 Series 10.1.2 Connecting the FCU with CSI-B-2 The FCU 1000 can be connected to a PC with CSI-B-2 and RS 232. 18…35 V DC Customer FCU 1000 System ZBE 08S-xx HYDAC Filtertechnik GmbH Page 39 BeWa_FCU1000_3371346a_en.doc...

  • Page 40: Bluetooth Interface

    FluidControl Unit - FCU 1000 Series 10.2 Bluetooth interface The Bluetooth interface of the FCU 1000 is based on the Bluetooth Version 1.2, Class 3. This means that: Bluetooth Version 1.2: is less sensitive to static disturbances (e.g. WLAN), the maximum data transfer rate is 732.2 kBit/s...

  • Page 41: 10.2.1 Installing The Bluetooth Usb Adaptor

    FluidControl Unit - FCU 1000 Series 10.2.1 Installing the Bluetooth USB adaptor If the PC already has a Bluetooth interface, use this only to establish a connection to the FCU - See chapter 10.2.2. Prior to the installation of new Bluetooth software, we strongly recommend deinstalling all existing Bluetooth drivers.

  • Page 42: Conducing Maintenance

    FluidControl Unit - FCU 1000 Series Conducing maintenance Conduct the suggested maintenance/servicing and inspection work every six months, or if an error indication recommends it. All operating media are to be protected/isolated in case the product is accidentally started up.

  • Page 43: Cleaning The Suction Strainer

    FluidControl Unit - FCU 1000 Series 11.3 Cleaning the suction strainer A suction screen is fitted under the INLET measurement point union and protects the pump from coarse-particle contamination. The suction strainer must be cleaned at regular intervals according to the prescribed maintenance intervals.
  • Page 44 FluidControl Unit - FCU 1000 Series 2. Unscrew the INLET measurement point by hand. INLET 3. Insert your finger in the hole to remove the suction strainer. INLET HYDAC Filtertechnik GmbH Page 44 BeWa_FCU1000_3371346a_en.doc 2007-12-04...
  • Page 45 FluidControl Unit - FCU 1000 Series 4. Remove the suction strainer. To clean the suction strainer (A), remove the insert and clean it by washing it or rinsing it with compressed air. Before inserting the INLET test point union (B) check the sealing ring...
  • Page 46 FluidControl Unit - FCU 1000 Series 6. Insert the INLET test point union by hand and screw it in by turning it in a clockwise direction. INLET 7. Screw the INLET test point union tight using a wrench (size = 19 mm / ¾...

  • Page 47: Checking The High Pressure Adaptor

    FluidControl Unit - FCU 1000 Series 11.4 Checking the high pressure adaptor A 400 µm strainer is built into the high pressure adaptor to protect the flow control valve. We recommend cleaning this strainer twice a year. We recommend shortening the maintenance interval according to the degree of contamination of the tested fluid.

  • Page 48: 11.4.2 Cleaning / Changing The Strainer In The High Pressure Adaptor

    FluidControl Unit - FCU 1000 Series 11.4.2 Cleaning / changing the strainer in the high pressure adaptor The flow control valve regulates the flow to ≈ 0.55 ... 0.7 l/min. If the flow through the high pressure adaptor is low, the flow control valve must be cleaned or replaced.

  • Page 49: Fcu Status Messages

    FluidControl Unit - FCU 1000 Series FCU status messages 12.1 Status LED / Display Error Blink code / Status To do Display / Gree FCU o.k. <)<(</ The FCU is below its measurement range < ISO 9/8/7 “CLEAN 12.2 Error Message...

  • Page 50: Exceptions Errors

    FluidControl Unit - FCU 1000 Series 12.3 Exceptions Errors Blink code / Status To do Error Display Check supply voltage for no digits displayed no function Contact HYDAC Reset device (re-supply Firmware error voltage to sensor) or -1...-19 contact HYDAC...

  • Page 51: Spare Parts

    FluidControl Unit - FCU 1000 Series Spare Parts Part no. Description Figure INLET high pressure hose with screwed joint, for 349150 measurement point type 1620, color: black, L = 2 m (78.74 inch) INLET suction hose with open end, color: clear-transparent, 3297276 Length = 1.5 m (59.06 inch)
  • Page 52 FluidControl Unit - FCU 1000 Series Part no. Description Figure Power adaptor (without power cord) primary: 6059933 100-240 V AC secondary: 24 V DC, 5A, cable with 3-pole plug, Length = 1.6 m (62.99 inch) 6008448 Connection cable for power adaptor European plug, Length = 2 m (78.74...

  • Page 53: Accessories

    FluidControl Unit - FCU 1000 Series 13.1 Accessories Part no. Description Figure INLET suction hose with open end, color: 3325744 clear-transparent, Length = 1.5 m (59.06 inch) 24 V DC cable with universal plug, including 3306236 8A fuse, Length = 10 m (393.7 inch)

  • Page 54: Technical Data

    FluidControl Unit - FCU 1000 Series Technical Data Contamination Sensor Self-diagnosis continuously with error indication via status LED and display Display LED, 6 / 4 / 4 digits, in 17 segment format Measured values contamination ISO code / SAE class / NAS class Measured values temperature -25 ...
  • Page 55 FluidControl Unit - FCU 1000 Series Electrical data Supply voltage 24 V DC, ± 20%, residual ripple ≤ 10% Wattage / Current 100 W max. / 4 A max. IP class IP 50 (in Operation) IP 67 (closed) Protection class...

  • Page 56: Iso 4406 / Sae As 4059 And Nas 1638 Classes

    FluidControl Unit - FCU 1000 Series ISO 4406 / SAE AS 4059 and NAS 1638 Classes 15.1 ISO 4406:1999 In ISO 4406:1999, particle counts are determined cumulatively, i.e. > 4 µm(c), >6 µm(c) and >14 µm(c) (manually by filtering the fluid through an analysis membrane or automatically using particle counters) and allocated to measurement references.

  • Page 57: 15.1.2 Overview Of The Differences Between Iso 4406:1987 And Iso 4406:1999

    FluidControl Unit - FCU 1000 Series Note: increasing the measurement reference by 1 causes the particle count to double. Example: ISO class 18 / 15 / 11 means: Cleanliness class Particle count / ml Size ranges 1,300 – 2,500 > 4 µm 160 –...

  • Page 58: Sae As 4059

    FluidControl Unit - FCU 1000 Series 15.2 SAE AS 4059 Like ISO 4406, SAE AS 4059 describes particle concentrations in liquids. The analysis methods can be applied in the same manner as ISO 4406:1999. The SAE cleanliness classes are based on particle size, number and distribution. The particle size determined depends on the measurement process and calibration;...

  • Page 59: Specifying A Cleanliness Class For Each Particle Size

    FluidControl Unit - FCU 1000 Series 15.2.2.2 Specifying a cleanliness class for each particle size Example: Cleanliness class according to AS 4059: 7 B / 6 C / 5 D Cleanliness class Particle count / 100 ml Size B ( >5 µm / > 6 µm 38,900 Size C ( >15 µm / >...

  • Page 60: Service

    FluidControl Unit - FCU 1000 Series Service 16.1 Shipping Address for Recalibration and Repair Work Germany HYDAC Service Center HYDAC Technology Corporation Rehgrabenstrasse, Werk 7 Service Department D-66125 Saarbruecken, Germany 2280 City Line Road Bethlehem, PA 18017 Telephone: ++49 (0) 6897 509 01 Telephone: 001 (0) 610 266 0100 16.2...

  • Page 61: Ec Declaration Of Conformity

    FluidControl Unit - FCU 1000 Series EC declaration of conformity HYDAC Filtertechnik GmbH Page 61 BeWa_FCU1000_3371346a_en.doc 2007-12-04...
  • Page 62 FluidControl Unit - FCU 1000 Series Notes HYDAC Filtertechnik GmbH Page 62 BeWa_FCU1000_3371346a_en.doc 2007-12-04...
  • Page 63 FluidControl Unit - FCU 1000 Series Notes HYDAC Filtertechnik GmbH Page 63 BeWa_FCU1000_3371346a_en.doc 2007-12-04...
  • Page 64 HYDAC Filtertechnik GmbH Bereich Servicetechnik / Service Technology Division Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 (0) 6897 509 01 Fax: +49 (0) 6897 509 846 (Technical Department) Fax: +49 (0) 6897 509 577 (Sales Department) Internet: www.hydac.com email: filtersysteme@hydac.com...

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