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HYDAC International FCU 2110-5 Operating And Maintenance Instructions Manual

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FluidControl Unit
FCU 2110 - 5
FCU 2210 - 5
Operating and Maintenance Instructions
Ed. 1.1/12.2000

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Summary of Contents for HYDAC International FCU 2110-5

  • Page 1 FluidControl Unit FCU 2110 - 5 FCU 2210 - 5 Operating and Maintenance Instructions Ed. 1.1/12.2000...
  • Page 2 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 I.I General Remarks Trademarks The trademarks used herein of other companies exclusively designate the products of these companies. Copyright © 1997 by HYDAC Filtertechnik GmbH. All rights reserved Every effort has been taken to ensure that the information provided herein is correct, however errors cannot be precluded.
  • Page 3 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Copyright © 1999 by HYDAC FILTERTECHNIK GmbH Industriegebiet D-66280 Sulzbach/Saar Germany Voice: +49 - 681/509 - 01 Fax: +49 - 681/509 - 846 Printed in Germany HYDAC Filtertechnik GmbH...

  • Page 4: Table Of Contents

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 I.II Contents Explanation of Symbols and Warnings, etc................6 General Safety Precautions and Remarks................. 7 SCOPE OF DELIVERY ......................10 Restrictions Pertaining the Use of the FCU ................11 Technical Description.......................
  • Page 5 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.2.2 Entering the Measurement Point and Initiating Measurement with Averaging ....39 7.2.3 Deleting Data from Memory ..................39 7.3 Printing ..........................41 7.3.1 Printing Online Logs (only when measurement is in progress) ........41 7.3.2 Printing Logs Stored in Memory ..................

  • Page 6: Explanation Of Symbols And Warnings, Etc

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 1 Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.: This symbol designates safety instructions whose non- observance may result in injury to individuals.

  • Page 7: General Safety Precautions And Remarks

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 2 General Safety Precautions and Remarks Observe and follow the instructions contained herein The basic prerequisite for the safe and proper handling and operation of the FCU is knowledge of the safety instructions and warnings.
  • Page 8 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Maintenance, Servicing and Troubleshooting The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a timely fashion. Operating personnel is to be informed prior to performing any maintenance and servicing work.
  • Page 9 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Summary of the General Safety Precautions • Maintenance work may only be performed by properly trained personnel using the right tools for the job. • No maintenance or servicing work may be done on the FCU unless it has been shut down and disconnected from the power supply and the hydraulic facility.

  • Page 10: Scope Of Delivery

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 3 SCOPE OF DELIVERY The FCU fluid control unit comes packed and factory-assembled. Before commissioning it, please check the contents of the package to make sure everything is present.

  • Page 11: Restrictions Pertaining The Use Of The Fcu

    The FCU Fluid Control Unit is used to continuously monitor the solid particle loading of mineral oils. • The FCU enables the purity ratings according to NAS 1638 (only for FCU 2110-5) or ISO- 4406 to be recorded, saved and displayed fully automatically during continuous operation. •...

  • Page 12: Hydraulic Diagram

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.3 Hydraulic Diagram Pressure line 1 - 350 bar / 5000 psi Suction hose Minimess hose Reservoir Fixed flow control valve Shut-off valve Suction pump Ball-valve FCU 2110-5...

  • Page 13: Principle Of Operation

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.4 Principle of Operation Relays Display Evaluation Keypad module RS232 Printer interface Suction inlet Pressure inlet Outlet A continuous oil current flows through an optical sensor (1), the sensor consisting of an infrared semiconductor LED (2) and a receiver diode (3) opposite of it.
  • Page 14 The electronic evaluation module (4) continuously measures the particle counts, computes the NAS (only for FCU 2110-5) or ISO purity ratings for the prescribed reference volume of 100ml on the basis of the measurement signals of the optical sensor and the flow rate meter.
  • Page 15 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 • flow rate meter • supply voltage • internal evaluation module Relay 3 (normally closed contact) thus functions as a DEVICE READY contact: During normal (fault-free) operation, these contacts are always closed, meaning they only open when a fault is detected.

  • Page 16: Description Of The Display And Control Elements

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.5 Description of the Display and Control Elements 5.5.1 Front View LC Display Keypad Flow control valve mode memory print limits setup Partikel Flow Control Figure 2 : Front View...

  • Page 17: Rear View

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.5.2 Rear View Suction Inlet Pump Power Switch Outlet Pressure Inlet On/Off Switch Power Input 24 V DC PC Interface Control Connector Power Input 24 V DC Filter Element Cover...

  • Page 18: Function Of Keys

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.5.3 Function of Keys 5.5.3.1 Control keys (gray) Confirm entries, start Start measurement Cancel entries, stop Stop measurement Scroll through menus Toggle particle counts display (C or D)
  • Page 19 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.5.3.3 Special key combinations To edit the measuring point: start Press keys ok/start and scroll right simultaneously :Insert character when editing measurement point in memory menu start Press keys ok/start and scroll left simultaneously :Delete character when editing...

  • Page 20: Connector Pin Assignments

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.6 Connector Pin Assignments On the rear of the FCU are various electrical connectors whose function and pin assignments are described in this section 5.6.1 PC Connector: (Subminiature D, 15-pin, male)

  • Page 21: Relay Functions

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.6.3 Relay Functions Function mode Relay 1 Relay 2 M1: Measure Contacts 7 and 8 are closed Contacts 14 and 15 are when measurement has started closed when a flow rate and is ongoing.

  • Page 22: Supply Voltage Plug

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 M5: Measure+autostop Contacts 7 and 8 are closed Not in operation when measurement has started and is ongoing. Contacts 6 and 8 are closed when the FCU not in service.

  • Page 23: Programmable Relay- Limits

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 5.6.5 Programmable Relay- Limits FCU 2110-5 Mode M2 2 µm Channel NAS 5 µm Channel NAS 15 µm Channel NAS 25 µm Channel NAS 2 µm Channel ISO 5 µm Channel ISO...

  • Page 24: Installation And Operation Of The Fcu

    Sockets. The line adapters themselves have to be connected to mains voltage. Because the shut-off valve for measurements with high pressure inlet and the pump for measurements with suction inlet need 24 V DC supply, FCU 2110-5 / FCU 2210-5 can not be operated independently of an external power supply.

  • Page 25: Hydraulic Installation And Commissioning

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 6.2 Hydraulic Installation and Commissioning 6.2.1 Measurements with Suction INLET Figure 5 : Setup for measurements with suction inlet After measurements with high pressure inlet you should wait some...
  • Page 26 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 suction pressure Figure 6 : Ball Valve Position "Suction" Plug the suction hose onto the connector on the back panel (suction) and route it into the reservoir. Switch the FCU on, wait until it is ready, select Mode M5 (see chapter 7.1 Measurement Operation), then press the START key.

  • Page 27: Measurements With High Pressure Inlet, (Max. 350 Bar)

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 6.2.2 Measurements with High Pressure Inlet, (max. 350 bar) Figure 7 : Setup for measurements with high pressure inlet Plug the return hose (DN 7) onto the "Outlet" connector on the back panel and route it into a suitable container, e.g.

  • Page 28: The Display Of The Fcu

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 6.3 The Display of the FCU 19 / 15 / 10 Q: 70 ml 68%D 2µ: 120345 Q: 70 ml 5µ: 47342 The FCU is working in mode M1 (purity rating measurement).

  • Page 29: Using The Fcu

    Possible reference values for triggering a switching sequence: 1. Sensor flow rate 2. Purity rating of the hydraulic fluid (indicated according to NAS (only FCU 2110-5) or ISO) Typical Application Signal switching relayed to a control panel of fully automatic test stands.
  • Page 30 Various setting examples are shown below for the purpose of illustrating how the “measure switch” function works. (Examples are shown for relay 1 of FCU 2110-5. Procedure is the same for relay 2 and both relays of FCU 2210-5. On FCU 2210-5 the NAS channels are not...
  • Page 31 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Operation Setting the Limits (relay 2) Example 1: Switching of a lamp ("good" indicator) within a certain oil purity range (upper and lower limit) R2 meas. channel Switch func.:...
  • Page 32 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Example 3: Switching of a lamp ("bad" indicator) when exceeding a certain oil purity rating (upper and lower limit) Contacts 14 and 15 are closed when ISO Code >2µm is higher than 18, they are opened again when ISO Code is smaller than 14.
  • Page 33 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Example 5: Disabling the switching functions of relay 1 R2 meas. channel Switch func.: limits within range LIMITS flow rate start outside range start start M2:Relay2 2µm NAS chan.

  • Page 34: M3: "Filter To" Function (Performing Automatic Cleaning/Flushing)

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.1.3 M3: "Filter to" Function (performing automatic cleaning/flushing) Purpose This function of the MODE menu enables immediate control of an external filter pump unit (e.g. OF5C) to be performed without the switching relays. This is illustrated by the following example.

  • Page 35: M4: "Filter From To" Function (Performing Automatic Cleaning/Flushing)

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.1.4 M4: "Filter from to" Function (performing automatic cleaning/flushing) Purpose This function of the MODE menu also enables immediate control of an external filter pump unit (e.g. OF5C) to be performed, also without the switching relays. This is illustrated by the following example.

  • Page 36: M5: "Measure+Autostop" Function

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.1.5 M5: "Measure+autostop" Function Purpose This function of the MODE menu is especially useful for repeated testing of oil cleanliness on different machines. The user can program a number of measurements (from 1 to 255) that are performed automatically.
  • Page 37 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Example 1: Programming 5 measurements after a start up delay of 30 seconds limits LIMITS M5 start delay : M5: Measure+autostop start start [seconds] M5 stop after: start...

  • Page 38: Using The Memory Functions

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.2 Using the MEMORY Functions 7.2.1 Entering the Measurement Point and Initiating Measurement without Averaging Purpose In this operating mode, new measured values are shown immediately in the display on the front of the FCU step by step, followed by their being saved and printed out.

  • Page 39: Entering The Measurement Point And Initiating Measurement With Averaging

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.2.2 Entering the Measurement Point and Initiating Measurement with Averaging Purpose In contrast to the procedure described in section 10.2.1, an averaging interval can be indicated as well. That means reference values from 1 min. to 1440 min. (= 24 hrs.) can be programmed.
  • Page 40 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Purpose: This operating mode enables the user to delete old logs of previous measurements from the FCU’s memory. Typical Application: Sample measurements are conducted by the user whose archiving are of no practical use for subsequent documentation purposes or comparative measurements.

  • Page 41: Printing

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.3 Printing Purpose This function enables the user to print out measured results immediately after the measurement is conducted, for example, or to print out existing values in the form of logs.

  • Page 42: Printing Logs Stored In Memory

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.3.2 Printing Logs Stored in Memory Purpose This function enables the user to retrieve measurements previously performed and print them out. The submenu provides selection to be made according to various search functions.

  • Page 43: Setup Menu

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.4 SETUP Menu Purpose This menu enables the user to enter basic settings or change them. The settings marked in the figure below are preset in the factory and should not be subsequently changed by the user.

  • Page 44: Power Up" Menu

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 7.5 "POWER UP" Menu Purpose: This menu enables the user to enter settings which are not to be changed, also by other users of the unit. The menu is selected by simultaneously pressing both S...
  • Page 45 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Displayed Error Message Cause(s) Remedy You have entered a value which is check the allowed value range with Invalid parameter outside the allowed value range the arrow keys +↑ and -↓ by (i.e.
  • Page 46 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 • There is no oil flowing through 1. Turn flow control valve fully Flow rate error! clockwise. the particle sensor Correct: 0 ml (i.e. only air). 2. Check hydraulic connections.
  • Page 47 Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 • This is not a critical error, Internal designations in EEPROM Device ID defect are lost by a disturbance. because these designations do not influence the proper function of the FCU.

  • Page 48: Maintenance And Servicing Of The Fcu

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 9 Maintenance and Servicing of the FCU The FCU is maintenance free, except for the filter. The filter clogging is monitored by a clogging indicator (2 bar). If the filter is clogged, a warning message shows up in the LC- display.

  • Page 49: Inserting A New Paper Roll

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 9.3 Inserting a new paper roll a) Switch off FCU b) Carry out instructions 9.2 Changing the ink ribbon cartridge a) to c) c) Lift out old paper roll, remove plastic spindle and place it inside new paper roll.

  • Page 50: Spare Parts

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 11 Spare Parts Article number Article designation 126 0891 Filter element for FCU 349 154 filter element – replacement set • filter element, FCU • O ring, cover, 48 x 3, 80 Shore hardness rating, •...

  • Page 51: Explanation Of Terms Used In Measurement And Instrumentation Systems

    Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10 Explanation of Terms Used in Measurement and Instrumentation Systems The name of the location at which the FCU is connected to Measurement point: the hydraulic system. This designation (max. 20 characters) can be entered in the FCU for documentation purposes.
  • Page 52 NAS 2 ... 12 (only FCU 2110-5) The unit is calibrated in these ranges. In addition, values can be indicated above this up to a rating of ISO 25/23/21 or NAS 15 (NAS only with FCU 2110-5). Battery-buffered log memory:...

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Fcu 2210-5

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