Related Manuals for Hydac FCU 5000-T001
Summary of Contents for Hydac FCU 5000-T001
- Page 1 FCU 5000 /-T001 FluidControl Unit Installation and Maintenance Instructions English (translation of original instructions) Documentation no.: 4609526 Keep for future reference.
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Page 2: Table Of Contents
Content Content Content ......................2 General ......................4 Imprint..................... 4 Documentation Representative ............4 Purpose of this manual ..............4 Target group of the manual ............5 Target group - Required qualifications / knowledge ......6 Illustrations in the manual ............... 7 Illustration of the layout ............... - Page 3 Content Commissioning ................28 Integration of Modbus TCP and Profinet ........28 Operation ..................... 28 Switching on / off ................28 User levels of the FCU 5000 ............29 Layout and arrangement of the display (English language setting) ..................30 Left navigation bar - Sidebar .............
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Page 4: General
Court of registration: Saarbrücken, HRB 17216 Executive directors: Mathias Dieter, Dipl.Kfm. Wolfgang Haering Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: +49 6897 509 1511 Fax: +49 6897 509 1394 E-mail: guenter.harge@hydac.com Purpose of this manual... -
Page 5: Target Group Of The Manual
General the design and protective measures may not be effective or not fully effective. Target group of the manual This manual was created for the following target group. Target group Tasks Owner This manual and the associated documents must be kept accessible at the installation location of the product and also for later use. -
Page 6: Target Group - Required Qualifications / Knowledge
General Target group - Required qualifications / knowledge Persons who work on the product must be aware of the hazards associated with its use. Auxiliary and specialist personnel must have read and understood the operating instructions, in particular the safety information and instructions, and applicable regulations before beginning work. -
Page 7: Illustrations In The Manual
General Illustrations in the manual You will find illustrations in this manual. You can find details regarding these in the following chapters. Illustration of the layout Chapter description Page number Edition date Seite x 200x-xx-xx Documentation language Documentation no. with index / file name The documentation number with its index enables you to order another copy of the operating instructions. -
Page 8: Representation Of Procedural Instructions
General Representation of procedural instructions The following two illustrations differ with regard to procedural instructions: Procedural instructions with a fixed sequence Procedural instructions, whose sequence must be complied with without fail, are listed with sequential numbering (1., 2., 3., etc.). An example of procedural instructions with a fixed sequence: 1. -
Page 9: Signal Words And Their Meaning In The General Safety Information
General Signal words and their meaning in the general safety information In these instructions you will find the following signal words: DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result in death or serious injury. WARNING WARNING –... -
Page 10: Representation / Explanation Of Pictograms
General Representation / explanation of pictograms The following safety symbols / pictograms can be found in this manual. They indicate specific dangers to persons, property or to the environment. Observe these safety symbols / pictograms and act with particular caution in such cases. Always keep all symbols / pictograms complete and legible. -
Page 11: Supplementary Symbols
General operating instructions that refer to particular dangers to persons, property or the environment. Disconnect before maintenance or repair Signs used for the required specialist personnel These symbols show the required training / knowledge for installation work and / or maintenance work. -
Page 12: Exclusion Of Liability / Warranty
You can also find them → General Terms and Conditions. under www.hydac.com This manual was prepared to the best of our knowledge. Nevertheless and despite the greatest care, it is possible that it may contain errors. Therefore please understand that, in the absence of any provisions to the contrary hereinafter, our warranty and liability –... -
Page 13: Product Overview
Product overview Product overview The FCU 5000 is a stationary online measurement device to monitor the essential fluid parameters in water-based cooling lubricant systems. This includes the pH value, conductivity, refractive index, and temperature. Automated additional metering of the cooling lubricant concentrate (optional) ensures that the required concentration can be maintained at an almost constant level in the system. -
Page 14: Scope Of Delivery
Product overview Item Designation Consumer Cooling lubricant concentrate pH stabilizer Bypass line Metering pump 1 Metering pump 2 Needle valve Protective filter Belt filter Central reversing pump Dirt tank Clean tank Central system Public water supply (with backflow preventer) Scope of delivery The FCU 5000 is packed and delivered in a pre-assembled condition. -
Page 15: Dimensions
Product overview Dimensions All dimensions in mm. Connections and components Page 15 / 60 FCU 5000/-T001 en(us) MoWa FCU5000 T001 4609526 en-us 2021-10-11.docx 2021-10-11... - Page 16 Product overview Item Designation Components Operating unit and touch panel (option) with electrical connections Sensor unit with hydraulic connections Electrical connectors Main switch Ethernet interface to communicate via the web server and the desktop application Profinet / Modbus TCP interface for data transmission (option) 4 –...
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Page 17: Hydraulic Diagram Of The Sensor Unit
Product overview Hydraulic diagram of the sensor unit The complete hydraulic circuit of the FCU 5000 is included in the scope of delivery of the device. Item Designation Port 1 for the cooling lubricant RINSE I Port 2 for the device flushing medium RINSE II Port 3 for the refractometer flushing medium Port 4 for the return line to the tank... -
Page 18: Proper/Designated Use
Product overview Proper/Designated Use Use the unit only for the application described below. The FCU 5000 is a stationary online measurement device to determine the fluid state in cooling lubricant systems. Proper/designated use of the product extends to the following: Maintaining adherence to all the instructions contained herein. -
Page 19: Hazard Warnings
Product overview Hazard warnings NOTICE No pre-filtration The FCU 5000 can be damaged. ► The FCU 5000 may only be operated with adequate pre-filtration. ► NOTICE Pressure buildup in the return line The FCU 5000 can be damaged. ► The FCU 5000 must not be operated if there is pressure of more than 1.5 bar at the outlet of the device. -
Page 20: Improper Use Or Use Deviating From Intended Use
Product overview Improper use or use deviating from intended use Any other use or extended use shall not be considered intended use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use. This risk is borne solely by the owner. -
Page 21: Technical Data
Product overview Technical data Height = 654 mm Dimensions Width = 300 mm Depth = 300 mm Weight when empty 44 kg Power supply 24 V DC / 5 A Power consumption 120 W ≤ 67 dBA Noise level Permitted ambient temperature 10 …... - Page 22 Product overview Item Description Part no. Serial number Date Year/week of production and hardware index Flow rate Flow rate Weight Weight when empty Pressure IN Permitted operating pressure at the IN port Pressure OUT Permitted operating pressure at the OUT port Temperature Fluid Permitted fluid temperature range Temperature Ambient...
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Page 23: Model Code
Product overview Model Code The model code is created according to the following model code. FCU - 5 - 3 - 3 - 7 - 0 - 1 - 1 - U - 1 / Type = Fluid Control Unit Series = 5000 series Measured variables... -
Page 24: Transportation And Storage
Transportation and storage Transportation and storage Remove all the electrical and hydraulic connections for transportation. Transport the FCU 5000 on a pallet. Support the device with beams and fix it to the pallet with suitable clamping tools. Proceed as follows to store the device: 1. -
Page 25: Assembly, Installation And Commissioning
Assembly, installation and commissioning Assembly, installation and commissioning CAUTION Cooling lubricants Hazardous to health ► Note the information in the safety data sheet for the cooling lubricants. Design and placement Bring the FCU 5000 to the installation site by means of a suitable lifting device. Place the FCU 5000 on a flat and sufficiently firm surface. -
Page 26: Electrical Installation / Assembly
Assembly, installation and commissioning ENVIRONMENTALLY TIP Note that, if using water from the public water supply system as a flushing medium, a backflow preventer must be installed in accordance with the Wasserhaushaltsgesetz Electrical installation / assembly DANGER Electric shock Injury due to the effect of the electric current ►... - Page 27 FCU 5000. The ports 7 and 8 have been provided for this. Compatibility exists only with the use of HYDAC metering pump kits. The kits included in the accessories contain all the necessary cables.
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Page 28: Commissioning
Operation Commissioning After completing the installation, switch on the FCU 5000 with the main switch. Control the FCU 5000 using the touch panel or, alternatively, the supplied desktop program Cooltools. Integration of Modbus TCP and Profinet Refer to the manuals included in the scope of delivery for this. They provide all the necessary information and steps. -
Page 29: User Levels Of The Fcu 5000
Operation User levels of the FCU 5000 During the operation, the user can choose between the USER and ADMIN levels. The ENGINEER level is reserved to the manufacturer. Symbol User level Executable functions USER View of the measured values Establishing a connection with the FCU 5000 ADMIN Changing the access password*... -
Page 30: Layout And Arrangement Of The Display (English Language Setting)
Operation Layout and arrangement of the display (English language setting) The display layout of the FCU 5000 is described with the aid of the main window (Home). Item Designation Description Header Device name or designation of the currently open window. Information on the date and time. - Page 31 Operation the navigation bar (C and E) change depending on the menu called. Besides the main window (Home) displayed, the following menus and buttons can be selected: Symbol Designation Description Home To go to the main window. Measured To display the current measured values. values Data memory To display the measured value memory.
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Page 32: Left Navigation Bar - Sidebar
Operation Left navigation bar - Sidebar The most important functions can be reached via quick access using the sidebar function of the FCU 5000. System limits Action limits, minimum and maximum values, and reference values for the flushing operation are entered here. Warning thresholds, when exceeded or Action limits undershot, result in a warning in the error list... -
Page 33: Measured Values
Operation Measured values The current measured values of the FCU 5000 are displayed in this menu. Item Designation Description Concentration / Refractive Display of the current concentration index of the cooling lubricant in the fluid and the refractive index. The conversion is done as follows: K = RF * BI K –... - Page 34 Operation RF – R factor BI – Refractive index Conductivity Display of the current conductivity of the fluid. Flow rate Display of the current flow rate. pH value Display of the current pH value of the fluid. Temperature Display of the current fluid temperature.
- Page 35 Operation Item Designation Description Button switch Switching between the display for the concentration and the refractive index Mode 1 Continuous measurement, see page 38 Mode 2 Interval measurement, see page 38 Start / Pause Starting and pausing the measurement Flushing Pressing this button initiates a flushing operation of the FCU 5000.
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Page 36: Data Memory
Operation Data memory The measured values are displayed in this menu. The display of the different measured values can be selected using the buttons in the blue area of the menu on the right side. The display can be updated using the button. -
Page 37: System Settings
Operation Settings on the FCU 5000 can be configured in the following menus. System settings This menu can be reached as follows: HOME → SETUP → SETTINGS → SYSTEM In this menu, the Autostart function can be selected or deselected and the refractometer factor (R factor) can be set. -
Page 38: Timer Settings
Operation The Autostart function is used to automatically start or continue the measurement after the FCU 5000 is switched on or after a drop in voltage. Timer settings This menu can be reached as follows: HOME → SETUP → SETTINGS → TIMER In this menu, the timer values of the Flush and Measure functions can be adjusted. -
Page 39: Additional Metering Settings
Operation Additional metering settings This menu can be reached as follows: HOME → SETUP → SETTINGS → METERING The settings of the metering pump can be adjusted in this menu. The concentration of the cooling lubricant can be maintained at a constant value by activating a metering pump (option). -
Page 40: Measurement And Autostart
Operation 4. The measured values are now saved in the database of the FCU 5000. Measurement and Autostart Proceed as follows to start the measurement: 1. In the main window, press the Online Data button. 2. Select the appropriate measurement mode with the checkmark on the top right. -
Page 41: Downloading The Measured Values
Operation (1) again. If the measurement has to be started and carried out automatically after switching on the FCU 5000, operate the FCU 5000 in Autostart mode (see chapter System Settings). To activate the Autostart mode, set a checkmark on "Autostart" in HOME → SETUP →... -
Page 42: Maintenance
Maintenance Maintenance The maintenance work to be carried out periodically on the FCU 5000 is described below. The operational readiness, safety of operation and service life of the FCU 5000 depend largely on performing the maintenance regularly and carefully. WARNING Hydraulic system is under pressure Danger of bodily injury ►... -
Page 43: Maintenance Intervals
Maintenance Maintenance intervals Adhere to the following maintenance intervals. After 6000 After 100 hours As needed or hours of of operation or after … at the operation or weekly latest yearly Checking the sensor unit for leakage and brittleness Cleaning the refractometer 1 month lens Checking the tightness of... -
Page 44: Replacing / Cleaning The Sensors
Maintenance Replacing / Cleaning the sensors To replace / clean the sensors, proceed as follows: 1) Remove all the hoses / connections. 2) Disconnect the device from the network. 3) Remove the upper and the lower cover. 4) Loosen the star knob screws at the bottom of the device. 5) Loosen the hydraulic unit with the screws on the right side. -
Page 45: Checking The Pre-Filter
Maintenance 2) Remove the sensor. 3) Clean the sensor or replace it if there is any damage. Conductivity sensor pH electrode Refractometer Removing the Removing the Removing the 4) Mount the sensor. (Max. tightening torque 3 Nm) 5) Attach the sensor to the plug. 6) Reattach the cladding parts. -
Page 46: Customer Service / Service
Regular inspection and maintenance work is indispensable for ensuring trouble-free operation and long service life of the product. You can reach the HYDAC Customer Service using the following contact data: HYDAC SERVICE... - Page 47 Troubleshooting / Error elimination replace the cable if necessary Faulty valve Replace the valve No display on the Device not switched on Check the power plug touchscreen connection, switch on the device with the main switch Loose DVI connector Attach the DVI connector on the touch screen Loose power supply Fasten the power supply...
- Page 48 Troubleshooting / Error elimination Code Reason Remedy 8200h Conductivity error during zero Check the function of the adjustment conductivity sensor, clean it and, if necessary, replace it 8400h Temperature error during zero Check the function of the adjustment temperature sensor, clean it and, if necessary, replace it 8800h...
- Page 49 Troubleshooting / Error elimination Code Reason Remedy pH sensor error Check the pH sensor for a cable break; if necessary, replace the pH sensor Conductivity sensor error Check the conductivity sensor for a cable break; if necessary, replace the conductivity sensor Refractive index sensor error Check the refractometer sensor for a cable break;...
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Page 50: Decommissioning / Disposal
Decommissioning / Disposal Code Reason Remedy 2000h Profinet configuration error Checking the Profinet settings 4000h Profinet communication error Checking the Profinet connection 8000h ModbusTCP communication error Checking the Modbus TCP connection 10000h Error from customer - PLC Check the higher-level controller 10100h Database - error... -
Page 51: Appendix
Appendix Appendix This Appendix contains additional information on the product. Parts/Materials in contact with fluid Component Materials in contact with fluid Valves Brass, FKM Block Aluminium, anodized, CuZn brass (metering orifice) Block seals Refractometer Sapphire, stainless steel Conductivity sensor PVDF, stainless steel, PP pH electrode HT glass, PTFE ring, PPS HDA pressure sensor... -
Page 52: Accessories
Appendix Accessories Designation Part no. Power supply connection cable, 20 m 4480814 Power supply adapter, 24 V DC, 5 A 4480812 Level switch HNS 3226-3-0730-000 924398 Sensor cable for level monitoring 4628848 HDA 7446-A-010-000 pressure sensor 920478 Sensor cable for pressure monitoring 4632699 Y distributor to connect 2 analog sensors 6167806... -
Page 53: Accessories - Analog Input
Appendix Accessories - Analog input Additional sensors can be connected via the external analog inlet "Analog IN", e.g. an HNS 3000 for level monitoring. The connection is established with the sensor cable 4628848 to the analog inlet "Analog IN". The 8-pin plug is connected to the FCU 5000 and the 5-pin connector to the sensor for this. -
Page 54: Accessories - Digital I/O
Appendix directly to the analog inlet "Analog IN" of the FCU 5000. The two cables for the level and pressure sensor can then be connected to the Y distributor. Accessories - Digital I/O Additional sensors can be connected via the external Digital In/Out, e.g. a differential pressure switch as a clogging indicator such as the VM 2 C.0. - Page 55 Appendix n.c. n.c. Pin 4 Pin 5 n.c. Pin 5 Harting connector +U Pin 1 Digital in Pin 2 Impulse Pin 3 Ground Pin 4 Page 55 / 60 FCU 5000/-T001 en(us) MoWa FCU5000 T001 4609526 en-us 2021-10-11.docx 2021-10-11...
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Page 56: Glossary
Glossary Glossary Explanation of terms and abbreviations An explanation of terms and abbreviations follows below: On or switched on Off or switched off Alternating current Direct current Minimum Maximum INLET Inlet OUTLET Outlet AIR BLEED / VENT Ventilation / air bleed port DRAIN Drainage port German standard... -
Page 57: Index
Index Index Accessories 52, 53, 54 filling 18, 25, 34 ambient temperature 21, 22 Filter 20, 21, 34, 52 Autostart 29, 31, 37, 38, 40, 41 filtration 19, 21, 34 Auxiliary personnel 6 Firmware 29 Flow error 47 Flow rate 22, 34, 47, 48 Forwarding agent 6 BLEED 56 Glossary 56... - Page 58 Index Maintenance interval 43 Maintenance intervals 43 Scope of delivery 14 Measure 38, 46 Sensor 16, 52 Measured value 31, 33 Service 46, 48, 49 Measured variable 23 setting 29, 30, 39 Measurement 29, 40 Setup 31 Measures 8 SETUP 37, 38, 39, 41 Modbus 14, 16, 19, 23, 27, 28, 50 Signal word 8, 9 signal words 8, 9...
- Page 60 HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach / Saar 66273 Sulzbach / Saar Germany Germany Tel: .+49 6897 509 01 Central Fax: +49 6897 509 9046 Technical Department Fax: +49 6897 509 577 Sales Internet: www.hydac.com E-mail: filtersystems@hydac.com...
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