Bühler technologies FCT User manual

Fluidcontrol
Installation and Operation Instructions
Original instructions
Fluidcontrolterminal FCT
BE100006
02/2022
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
E-Mail: [email protected]
Internet: www.buehler-technologies.com

Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
Tel. [phone] / 49 89-0, Fax: [phone] / 49 89-20
Internet: www.buehler-technologies.com
E-Mail: [email protected]
Read this instruction carefully prior to installation and/or use. Pay at-
tention particularly to all advises and safety instructions to prevent in-
juries. Bühler Technologies can not be held responsible for misusing
the product or unreliable function due to unauthorised modifications.
All rights reserved. Bühler Technologies GmbH 2023
Document information
Document No......................................................... BE100006
Version.........................................................................02/2022

Fluidcontrolterminal FCT
Contents
1 Introduction.....................................................................................................................................................................................................................2
1.1 Intended Use.........................................................................................................................................................................................................2
1.2 Product Description............................................................................................................................................................................................ 2
1.3 Model Key .............................................................................................................................................................................................................. 3
1.4 Scope of Delivery..................................................................................................................................................................................................3
2 Safety instructions .........................................................................................................................................................................................................4
2.1 Important advice .................................................................................................................................................................................................4
2.2 General hazard warnings ................................................................................................................................................................................. 5
3 Transport and storage ..................................................................................................................................................................................................6
4 Installation and connection ........................................................................................................................................................................................ 7
4.1 Installation ............................................................................................................................................................................................................ 7
4.2 Level Switch Electrical Connections ............................................................................................................................................................... 7
4.3 Information on the correct operation of reed contacts in Bühler level switches.............................................................................8
4.4 Vacuum Switch Electrical Connection ..........................................................................................................................................................9
4.5 Sampling Port.......................................................................................................................................................................................................9
4.6 Filling Coupler Connection...............................................................................................................................................................................9
5 Operation and control ................................................................................................................................................................................................10
5.1 Level Switch.........................................................................................................................................................................................................10
5.2 Sampling..............................................................................................................................................................................................................10
5.2.1 Sampling From the Tank..................................................................................................................................................................10
5.2.2 Sampling From The Return Filter ..................................................................................................................................................10
5.3 Manual Filling .....................................................................................................................................................................................................11
6 Maintenance and repair............................................................................................................................................................................................. 12
6.1 Filter Change....................................................................................................................................................................................................... 12
7 Service and repair......................................................................................................................................................................................................... 13
8 Disposal ........................................................................................................................................................................................................................... 14
9 Appendices ......................................................................................................................................................................................................................15
9.1 Technical Data.....................................................................................................................................................................................................15
9.2 Airflow/Back Pressure Table .......................................................................................................................................................................... 16
10 Attached documents ....................................................................................................................................................................................................17
iBühler Technologies GmbHBE100006 ◦ 02/2022

Fluidcontrolterminal FCT
1 Introduction
1.1 Intended Use
The fluid control terminal is a compact adapter flange with several connection options for individual applications.
The design of the fluid control terminal allows for flexible equipment so the device can easily be adapted to the requirements of
the specific application. The required space and installation are minimal.
Please note the technical data in the appendix for the specific intended use, existing material combinations, as well as temper-
ature limits.
WARNING
All device models are solely intended for industrial applications. They are not safety com-
ponents. The devices must not be used if failure or malfunction thereof jeopardises the
safety and health of persons.
Use in explosive areas is prohibited.
1.2 Product Description
The fluid control terminal consists of a compact adapter flange with circuit diagram as per DIN24557Part 2 and offers connec-
tions for a filling coupler, a vacuum switch and a sampling port. A level- and temperature switch with vent filter is integrated.
The fluid control terminal installs directly to the tank.
If needed, different filling couplings, contamination indicators and sampling ports can be added on. The following illustration
shows the fluid control terminal with the equipment options:
Fig.1:
1 Flange with connection options 4 Filling port
2 Sampling port 4a Filling port type Walther (optional)
2a Minimess (optional) 4b Filling port type Stäubli with G3/4 to G1/2 reducer
(optional)
2b Hose coupling with sleeve (optional) 5 Port for vacuum switch (optional)
3 Level- and temperature switch with vent filter
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1.3 Model Key
Length (max. 1420 mm)
280
370
500
Option 1: Sampling port
PSK
PMM
Hose coupling (DN 5)
Minimess coupling(M16)
VUS
VBS
Vacuum switch (elec.)
Dummy plug
Option 3: Vacuum switch
Type: Walther (DN 19)
Type: Stäubli (DN 11)
Dummy plug
BWA
BST
BBS
Option 2: Filling port
FCT-G3/4-
Variable (please specify)
Type designation/port
---
1.4 Scope of Delivery
– Fluid control terminal
– Product documentation
– Connection/mounting accessories (optional)
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2 Safety instructions
2.1 Important advice
Operation of the device is only permitted if:
– the product is used under the conditions described in the installation- and operation instruction, the intended application
according to the type plate and the intended use. In case of unauthorized modifications done by the user Bühler Technolo-
gies GmbH can not be held responsible for any damage,
– when complying with the specifications and markings on the nameplates.
– the performance limits given in the datasheets and in the installation- and operation instruction are obeyed,
– monitoring devices and safety devices are installed properly,
– service and repair is carried out by Bühler Technologies GmbH,
– only original spare parts are used.
This manual is part of the equipment. The manufacturer keeps the right to modify specifications without advanced notice. Keep
this manual for later use.
Signal words for warnings
DANGER
Signal word for an imminent danger with high risk, resulting in severe injuries or death if not avoided.
WARNING
Signal word for a hazardous situation with medium risk, possibly resulting in severe injuries or death if not
avoided.
CAUTION
Signal word for a hazardous situation with low risk, resulting in damaged to the device or the property or
minor or medium injuries if not avoided.
NOTICE
Signal word for important information to the product.
Warning signs
These instructions use the following warning signs:
Warns of a general hazard Unplug from mains
Voltage warning Wear respiratory equipment
Warns not to inhale toxic gasses Wear a safety mask
Warns of corrosive liquids Wear gloves
General information
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2.2 General hazard warnings
The equipment must be installed by a professional familiar with the safety requirements and risks.
Be sure to observe the safety regulations and generally applicable rules of technology relevant for the installation site. Prevent
malfunctions and avoid personal injuries and property damage.
The operator of the system must ensure:
– Safety notices and operating instructions are available and observed,
– The respective national accident prevention regulations are observed,
– The permissible data and operational conditions are maintained,
– Safety guards are used and mandatory maintenance is performed,
– Legal regulations are observed during disposal,
– compliance with national installation regulations.
Maintenance, Repair
Please note during maintenance and repairs:
– Repairs to the unit must be performed by Bühler authorised personnel.
– Only perform conversion-, maintenance or installation work described in these operating and installation instructions.
– Always use genuine spare parts.
– Do not install damaged or defective spare part. If necessary, visually inspect prior to installation to determine any obvious
damage to the spare parts.
Always observe the applicable safety and operating regulations in the respective country of use when performing any type of
maintenance.
The method for cleaning the devices must be adapted to the IP protection class of the devices. Do not use cleaners which could
damage the device materials.
DANGER Toxic, acidic gases/liquids
Protect yourself from toxic, corrosive gasses/liquids when performing any type of work.
Wear appropriate protective equipment.
DANGER Electrical voltage
Electrocution hazard.
a) Disconnect the device from power supply.
b) Make sure that the equipment cannot be reconnected to mains unintentionally.
c) The device must be opened by trained staff only.
d) Regard correct mains voltage.
DANGER Potentially explosive atmosphere
Explosion hazard if used in hazardous areas.
The device is not suitable for operation in hazardous areas with potentially explosive at-
mospheres.
Do not expose the device to combustible or explosive gas mixtures.
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3 Transport and storage
Only transport the product inside the original packaging or a suitable alternative.
The equipment must be protected from moisture and heat when not in use. It must be stored in a covered, dry, dust-free room
at room temperature.
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4 Installation and connection
DANGER Electric voltage
Risk of electric shock
a) Always disconnect the unit from the mains before performing work.
b) Secure the equipment from accidental restarting.
c) The equipment may only be installed, maintained and put into operation by instruc-
ted, competent personnel.
d) Always observe the applicable safety regulations for the operating site.
CAUTION Wrong mains voltage
Wrong mains voltage may damage the device.
Regard the correct mains voltage as given on the type plate.
4.1 Installation
The fluid control terminal resp. filling and vent adapter comes fully assembled and can be mounted to the tank using the in-
cluded screws and seals.
Please be sure to leave enough space between the tank wall and add-ons during installation.
The mounting hole pattern as per DIN24557Part 2 with six mounting holes allows installation rotated by 60° each. If your unit
has a filling coupler and/or Minimess coupler or hose coupling, arrange these to ensure free access to these parts at all times.
6x Ø6
Ø73
Ø90
Ø60
Installation opening
as per DIN 24557/Part 2
Fig.2: Flange
4.2 Level Switch Electrical Connections
For information on connecting the level switch, please refer to the operating instructions included with the level switch.
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4.3 Information on the correct operation of reed contacts in Bühler level switches
Based on their construction, reed contacts are very long lasting and reliable components. Yet the following should be considered
when using them:
Life of reed switches
The life of reed switches can be up to 109 cycles. This is reduces by high stress and / or incorrect or the absence of protective cir-
cuits when switching inductive, capacitive or lamp loads.
It’s therefore important to ensure NEVER to exceed one or several of the maximum approved limits, even temporarily, and to
install a contact protective circuit for loads which are not purely ohmic. Using test lamps when installing the devices is also pro-
hibited, as these can temporarily allow too much current to flow, which can damage the reed contacts. In this case non-volatile
testing equipment should always be used.
Contact protective circuits for reed switches
For direct current voltage a recovery diode per figure A must be connected parallel to the contact.
For alternating current voltage an RC circuit per Figure B and Table 1 must be connected parallel to the contact.
A B
Load
Contact
Recovery diode
Load
Contact
RC circuit
Load in VA 10 25 50
Voltage at contact V R/Ohm C/µF R/Ohm C/µF R/Ohm C/µF
24 22 0.022 1 0.1 1 0.47
60 120 0.0047 22 0.022 1 0.1
110 470 0.001 120 0.0047 22 0.022
230 470 0.001 470 0.001 120 0.0047
Please note the max. voltage/load ratings of the respective level contacts!
Voltages and currents
All Bühler level contacts with reed switch can switch minimal Switching voltages of 10µV and minimal switching currents of
1µA.
The maximum values specified for the respective contact types apply.
Level contact with reed switches can therefore be used for SPS applications as well as for high loads (within the maximum lim-
its) without hesitation.
Contact material
All reed switches in Bühler level contacts use rhodium as the contact material for the actual contact areas.
Magnetic fields
Avoid external magnetic fields, including from electric motors. These can interfere with the function of the reed switches.
Mechanical loads
Do not expose the level switch to strong blows or bending.
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4.4 Vacuum Switch Electrical Connection
An optional vacuum switch or dummy plug may be installed.
The vacuum switch is equipped with a snap-action switch to only switch signals when the full limits are reached continuously.
NOTICE!With the filling and ventilation adapter, only the vacuum switch requires electrical start-up.
Technical data: Connection diagram
Safe against overpressure up to: 0.1 bar
Gauge pressure: -50 mbar ± 4
Contact type: NO contact
Switching capacity: 24 V/6 W *
IP rating: IP54 - with protective cap
Electrical connections: AMP 6.3 DIN 46248
for sleeve as per DIN46247
Switching type; 2-pin
* with resistive load
4.5 Sampling Port
Minimess coupling G1/8 with M16x2 screw plug or DN5 hose coupling with hose fitting. This connection severs oil sampling and
typically requires no special maintenance. Simply ensure a tight connection when connecting and free access.
4.6 Filling Coupler Connection
Filling coupler type Walter (DN19) or Stäubli (DN11) or dummy plug. This connection serves as filling port. Please also observes
the notes for the sampling port here.
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5 Operation and control
5.1 Level Switch
The following level switches are available for the fluid control terminal:
– NV 77/NV 77D
– NV 74/NV 74D
– NV 73
– NV 71
For additional information on the built-in level switch, please refer to the operating instructions included with the level switch.
5.2 Sampling
To ensure the fluid still has its original performance characteristics and is still suitable for all workloads, regularly sampling the
fluid for analysis is advisable.
Depending on the configuration, the sampling port will be equipped with quick-release couplers or Minimess couplers. A hand
pump with the corresponding mating component for coupling is required for sampling.
When using the Minimess coupler, we recommend modifying the coupler on the pump with a transverse slot. This increases the
suction cross-section to make pumping down considerably easier.
The sampling point is fixed based on the immersion depth of the terminal, ruling out any depth-related measuring errors. Be
sure the instruments and the sample bottle are clean to ensure reliable sampling.
During sampling, residual old oil may still be in the pipe. In this case a second oil sample should be taken.
5.2.1 Sampling From the Tank
When sampling from the oil tank, it can empirically be assumed the sample will be the representative average oil quality.
Depending on the configuration, the sampling port will be equipped with quick-release couplers or Minimess couplers. A hand
pump with the corresponding mating component for coupling is required for sampling.
When using the Minimess coupler, we recommend modifying the coupler on the pump with a transverse slot. This increases the
suction cross-section to make pumping down considerably easier.
The sampling point is fixed based on the immersion depth of the terminal, ruling out any depth-related measuring errors. Be
sure the instruments and the sample bottle are clean to ensure reliable sampling.
5.2.2 Sampling From The Return Filter
To obtain additional information about the condition of the oil it can be helpful to also analyse the unmixed oil from the return
flow. The return filter housing has two bores for this purpose for attaching a Minimess coupler.
Since the return line is in part pressurised, a hand pump is not required for sampling. In this case the Minimess tube can be
used to directly draw into the sample bottle.
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5.3 Manual Filling
There are two types of connections for filling:
A Stäubli receptacle and a Walther coupler. Oil can be added manually via these ports.
Stäubli SBA 11/CN (receptacle) with G3/4 to G1/2 reducer
82
64.5
14
G1/2
Ø33.5
Walther MD-019 (filling coupler)
20
Ø54
83
17
G3/4
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6 Maintenance and repair
6.1 Filter Change
DANGER Toxic, corrosive media
The media used can be harmful to the health.
a) If necessary, ensure the medium is discharged safely.
b) Use protection when handling toxic/acidic mediums. Wear suitable protective equip-
ment.
c) Observe the relevant regulations on handling corrosive or toxic mediums.
Maintenance is limited to replacing the filter element in the vent filter. This only needs to be replaced as needed, at least 1x an-
nually. Please refer to the operating and installation instructions of the respective level switch for detailed instructions.
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7 Service and repair
This chapter contains information on troubleshooting and correction should an error occur during operation.
Repairs to the unit must be performed by Bühler authorised personnel.
Please contact our Service Department with any questions:
Tel.: [phone] or your agent
If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected
by the manufacturer. Please send the equipment inside suitable packaging to:
Bühler Technologies GmbH
- Reparatur/Service -
Harkortstraße 29
40880 Ratingen
Germany
Please also attach the completed and signed RMA decontamination statement to the packaging. We will otherwise be unable to
process your repair order.
You will find the form in the appendix of these instructions, or simply request it by e-mail:
[email protected].
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8 Disposal
The applicable national laws must be observed when disposing of the products. Disposal must not result in a danger to health
and environment.
The crossed out wheelie bin symbol on BühlerTechnologiesGmbH electrical and electronic products indicates special disposal
notices within the European Union (EU).
The crossed out wheelie bin symbol indicates the electric and electronic products bearing the symbol
must be disposed of separate from household waste. They must be properly disposed of as waste elec-
trical and electronic equipment.
BühlerTechnologiesGmbH will gladly dispose of your device bearing this mark. Please send your
device to the address below for this purpose.
We are obligated by law to protect our employees from hazards posed by contaminated devices. Therefore please understand
that we can only dispose of your waste equipment if the device is free from any aggressive, corrosive or other operating fluids
dangerous to health or environment. Please complete the "RMA Form and Decontamination Statement", available on our web-
site, for every waste electrical and electronic equipment. The form must be applied to the packaging so it is visible from the
outside.
Please return waste electrical and electronic equipment to the following address:
Bühler Technologies GmbH
WEEE
Harkortstr. 29
40880 Ratingen
Germany
Please also observe data protection regulations and remember you are personally responsible for the returned waste equipment
not bearing any personal data. Therefore please be sure to delete your personal data before returning your waste equipment.
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9 Appendices
9.1 Technical Data
Basic data Dimensions
Operating pressure: max. 1 bar
Rubberised
cork seal
Optical analogue vacuum
indicator display range
0.35 bar (optional)
14656
4
50
180
L
3.5
Level switch
example:
shown Nivovent 74
with M3 plug
Filling port without
fittings shown
A
G3/4
Operating temperature: max. +80 °C
Weight at L = 500 mm: approx. 5 kg
Dimensions L*: 280, 370, 500 (Standard)
variable to max. 1420 mm
* Please note, the dimension L of the filling port and the selected
level switch must be identical!
Material
Stilling tube Brass
Flange: Galvanised steel
Option 1 Sampling
Hose coupling (DN 5): PSK
Minimess coupler (M16): PMM
Option 2 Filling coupler
Type: Walther (DN 19): BWA
Type: Stäubli (DN 11): BST
Dummy plug: BBS
Option 3 Contamination indicator
Vacuum switch (elec.): VUS
Dummy plug: VBS
View "A"
Vacuum switch
(electric)
67
Filling coupler type:
Walther (DN 19)
Option 2
G1/8
M10x1
Filling coupler type:
Stäubli (DN 11)
(incl. G3/4 to G1/2
reducer)
Option 1
Hose coupling
DN 5 with hose
fitting
Option 3
6x Ø6
Ø73
Ø90
Ø60
Installation opening
as per DIN 24557/Part 2
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9.2 Airflow/Back Pressure Table
with SM-L filter
with MIC filter
m bar
L/min
Airflow - Back pressure - Table fluid control terminal
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10 Attached documents
– Declaration of Conformity KX100024
– RMA - Decontamination Statement
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