HYDAC FILTER SYSTEMS FCU 1210 Manual

FCU 1210
FluidControl Unit
Operating and Maintenance Instructions
English • (Translation of original instructions)
Document No. : 3545830b • 12/6/2018
Follow these instructions for proper and safe use.
Keep for future reference.

1 | Imprint HYDAC FILTER SYSTEMS GMBH
2 / 92 BeWa FCU1210 3545830b en-us lq
1 Imprint
Manufacturer / publisher and responsible for the content:
Address of the manufacturer Contact address
HYDAC FILTER SYSTEMS
GMBH
Industriegebiet
66280 Sulzbach / Saar
HYDAC FILTER SYSTEMS
GMBH
Justus-von-Liebig-Str., Werk
20
66280 Sulzbach / Saar
Germany Germany
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken , HRB 17216
Executive Director: Mathias Dieter ,
Dipl.Kfm. Wolfgang Haering
Tab.1: Impressum
1.1 Documentation Representative
The contact data of the person authorized with the documenta-
tion is:
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280
Sulzbach / Saar
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Tab.2: Documentation Representative

HYDAC FILTER SYSTEMS GMBH Table of Contents
BeWa FCU1210 3545830b en-us lq iii
Table of Contents
1 Imprint ....................................................................................................................... 2
1.1 Documentation Representative........................................................................ 2
2 General ..................................................................................................................... 6
2.1 Warranty........................................................................................................... 6
2.2 © HYDAC FILTER SYSTEMS GMBH, 2018.................................................... 6
2.3 Using this manual............................................................................................. 7
3 General Safety Information ....................................................................................... 9
3.1 Signal words and their meaning in the general safety information................. 10
3.2 Design of Warning - / General Safety Information ......................................... 11
3.3 Safety symbols / pictograms .......................................................................... 11
3.4 Observe regulatory information...................................................................... 14
3.5 Stoppage in an emergency (EMERGENCY STOP)....................................... 14
3.6 Fire-fighting / extinguishing a fire ................................................................... 14
4 Overview ................................................................................................................. 15
4.1 Counting contaminant particles optically (light blockade procedure) ............. 16
4.2 Proper/designated use ................................................................................... 18
4.2.1 Periodic intermittent duty – operating mode S3................................. 19
4.3 Improper Use or Use Deviating from Intended Use ....................................... 20
4.4 Checking the scope of delivery ...................................................................... 21
4.5 Decoding the model code label...................................................................... 22
4.5.1 Model code ........................................................................................ 24
4.6 Technical Data ............................................................................................... 25
4.7 Dimensions .................................................................................................... 28
4.8 Hydraulic diagram .......................................................................................... 29
4.9 Opening / closing the case............................................................................. 30
4.10 How it works: ................................................................................................. 31
5 Transporting / storing the FCU................................................................................ 33
5.1 Transporting the FCU..................................................................................... 33

Table of Contents HYDAC FILTER SYSTEMS GMBH
iv BeWa FCU1210 3545830b en-us lq
5.2 Storing the FCU ............................................................................................. 34
6 Putting the FCU into operation................................................................................ 35
6.1 Connecting / disconnecting the power supply................................................ 35
6.1.1 Disconnecting the power supply........................................................ 35
6.2 Plug in/Detach return hose............................................................................. 37
6.3 Selecting the measurement location .............................................................. 38
7 Operation ................................................................................................................ 39
7.1 Overview of control panel/operating elements ............................................... 39
7.1.1 Reading the display and operating the keyboard .............................. 41
7.1.2 Scrolling through the display ............................................................. 43
7.1.3 Displaying measured variables.......................................................... 45
7.1.4 Display service variables ................................................................... 45
7.1.5 Display FREEZE................................................................................ 47
7.2 Select the operating modes / measurement method according to the pressure
involved .......................................................................................................... 49
7.2.1 Measuring from unpressurized containers ........................................ 50
7.2.2 Measuring oil up to max. 45bar/650psi.......................................... 53
7.2.3 Oil between 15 ... 345 bar / 217 ... Measuring 5000 psi .................... 56
7.3 Performing Measurements............................................................................. 59
7.4 Restarting/resetting ........................................................................................ 60
7.5 Using the BatteryPack (accessory) ................................................................ 61
8 Performing maintenance......................................................................................... 62
8.1 Maintenance table.......................................................................................... 62
8.2 Clean the suction strainer. ............................................................................. 63
8.3 Calibrating FCU.............................................................................................. 66
8.4 High-pressure adapter maintenance.............................................................. 67
8.4.1 Cleaning/changing the strainer.......................................................... 67
8.4.2 Cleaning / changing the flow control valve ........................................ 69
9 Rinsing / cleaning the FCU ..................................................................................... 72
9.1 FCU flushing .................................................................................................. 72
9.2 Cleaning the FCU........................................................................................... 75

HYDAC FILTER SYSTEMS GMBH Table of Contents
BeWa FCU1210 3545830b en-us lq v
10 Finding / rectifying errors......................................................................................... 76
11 Removing / Disposal ............................................................................................... 80
12 Attachment.............................................................................................................. 81
12.1 Finding spare parts / accessories .................................................................. 81
12.2 Finding a Customer Service team.................................................................. 83
12.3 EC declaration of conformity .......................................................................... 84
Glossary.................................................................................................................. 88
Index ....................................................................................................................... 89

2 | General HYDAC FILTER SYSTEMS GMBH
6 / 92 BeWa FCU1210 3545830b en-us lq
2 General
This manual was prepared to the best of our knowledge. Nev-
ertheless and despite the greatest care, it cannot be excluded
that mistakes could have crept in. Therefore, please under-
stand 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 this
manual. 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 in-
jury and damage to health. If we negligently breach any mate-
rial contractual obligation, our liability shall be limited to fore-
seeable damage. Claims due to the Product Liability shall re-
main unaffected.
2.1 Warranty
For the warranty provided by us, please refer to the Terms of
Delivery. They are made available to you at the conclusion of
the contract at the latest. You will also find these under
www.hydac.com -> General Terms and Conditions (T&C).
2.2 © HYDAC FILTER SYSTEMS GMBH, 2018
Distributing and copying this document and utilizing and dis-
closing its content is not permitted, except where this has been
agreed upon explicitly. Any infringement will entail liability for
damages. All rights reserved in the case of a patent being
granted or a utility model or the design being registered.
We reserve the right to changes to the contents of this manual
without prior notice.

HYDAC FILTER SYSTEMS GMBH General | 2
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2.3 Using this manual
You will find the following information on the title page of this
manual:
Short name of the product
Product name
Operating and Maintenance Instructions
12345678 ● ##.##.####
English (translation of original instructions)
Valid from: - from s/no. - ... ... - ... ...
1
5
2
4
3
Fig.1: Overview / labeling of the title page
1 Short name of the product / product name
2 Type of document
3 Language
4 Document no./Index ● Date of printing
5 Supplementary instructions regarding the validity of the
manual (optional)
Please note that you can directly access information
through the directories. However, this does not re-
lease you from the obligation to read this manual
fully before commissioning.
The document no. with the index (4) is meant for identifying
and reordering the manual. The index is incremented every
time the manual is revised or changed.

2 | General HYDAC FILTER SYSTEMS GMBH
8 / 92 BeWa FCU1210 3545830b en-us lq
The manual contains a table of contents, a list of tables and
figures, an index and a glossary.
You will find the following symbols in the manual as additional
details:
Tip for handling the product
Required tools

HYDAC FILTER SYSTEMS GMBH General Safety Information | 3
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3 General Safety Information
The product was built according to the statutory directives, reg-
ulations and standards valid at the time of delivery and satis-
fies current safety requirements. Any residual hazards are indi-
cated by the general safety information and are described in
this manual.
Observe all safety and warning instructions attached to the
product and keep them always complete and easily legible.

3 | General Safety Information HYDAC FILTER SYSTEMS GMBH
10 / 92 BeWa FCU1210 3545830b en-us lq
3.1 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 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 avoided, can result in mi-
nor or moderate injury.
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.

HYDAC FILTER SYSTEMS GMBH General Safety Information | 3
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3.2 Design of Warning - / General Safety Information
All the warning / general safety information in this manual are
highlighted with pictograms and signal words. The pictogram
and the signal word give you an indication of the severity of the
danger.
Warning / general safety information, which are placed ahead
of each activity, are represented as follows:
CAUTION
Type and source of danger
Hazard symbol
Consequence of the danger
Measures to avert danger
►
3.3 Safety symbols / pictograms
The following are the safety symbols / pictograms in this man-
ual. 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 intact and legible.
Warning signs used
These signs are listed for all safety information and instructions
in these operating instructions which indicate particular haz-
ards to persons, property or the environment.
Danger point warning
Dangerous electrical voltage warning

3 | General Safety Information HYDAC FILTER SYSTEMS GMBH
12 / 92 BeWa FCU1210 3545830b en-us lq
Hot surface warning
Signs used for giving orders
These symbols are listed for all General Safety Information
and instructions in these operating instructions which indicate
particular hazards to persons, property or the environment.
Follow the instructions.
Disconnect before working.
Signs used for the required specialist personnel
These symbols show the required training/knowledge for in-
stallation work and/or maintenance work.
Specialist personnel / operators
Such persons have had the corresponding spe-
cialist training and several years' work experi-
ence. They are able to assess and perform the
work assigned to them, they are also able to rec-
ognize potential hazards.
Specialist personnel - Mechanic
Such persons have specific 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.

HYDAC FILTER SYSTEMS GMBH General Safety Information | 3
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Specialist personnel - Electrician
Such persons have specific 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.
Others symbols used
These signs are listed for the general safety instructions in
these operating instructions, for example, which indicate a par-
ticular danger to persons, property or the environment.
Danger due to operating pressure

3 | General Safety Information HYDAC FILTER SYSTEMS GMBH
14 / 92 BeWa FCU1210 3545830b en-us lq
3.4 Observe regulatory information
Observe the following regulatory information and directives:
– Legal and local regulations for accident prevention
– Legal and local regulations for environmental protection
– Country-specific regulations, organization-specific regula-
tions
3.5 Stoppage in an emergency (EMERGENCY STOP)
Disconnect the product from all sources of energy in an emer-
gency.
3.6 Fire-fighting / extinguishing a fire
Use a powder extinguisher that corresponds to fire class B as
per EN 2 to extinguish any fires / to fight fires.
Fig.2: Fire protection
class B
Maintain a minimum safe distance from electrical components.
For a mains voltage of up to 1000V, the minimum safe dis-
tance is 1m.
Fig.3: Minimum distance for fire fighting

HYDAC FILTER SYSTEMS GMBH Overview | 4
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4 Overview
The FluidControlUnit FCU is a portable service unit for taking
short-term measurements of the solid particle contamination,
as well as the temperature in the 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
– Depressurized containers
Additional features include:
– Optical measurement of the degree of solid particle con-
tamination
– Measurement of temperature indirectly via housing
– Suitable for hydraulic fluids (up to ISOVG68)
– 2…350 mm²/s / 33…1622Sus
– Automatic measurement and display of cleanliness ratings
in accordance with:
– ISO4406; 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 supplying the FCU with the fluid to be
analyzed

4 | Overview HYDAC FILTER SYSTEMS GMBH
16 / 92 BeWa FCU1210 3545830b en-us lq
4.1 Counting contaminant particles optically (light
blockade procedure)
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 de-
tector.
This shadow causes a change in the electrical signal gener-
ated 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, NAS1638 and SAEAS4059.
The disruption factors of this measurement principle are, for
example, foreign fluids and small gas bubbles that lead to re-
fractions, thus causing them to be counted as particles as well.
Fig.4: Light blockade procedure
1 Light source
2 Contaminant particle
3 Photo detector

HYDAC FILTER SYSTEMS GMBH Overview | 4
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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µm, >5-15µm, >15-25µm, >25µm or >4µm(c), >6µm(c),
>14µm(c), >21µm(c).
time
Threshold values
Fig.5: Signal amplitudes

4 | Overview HYDAC FILTER SYSTEMS GMBH
18 / 92 BeWa FCU1210 3545830b en-us lq
4.2 Proper/designated use
Use the product only for the intended use described below .
The FluidControlUnit FCU is a portable service unit for taking
short-term measurements of the solid particle contamination in
hydraulic systems.
NOTICE
Impermissible operating conditions
The FCU can be damaged.
uUse the FCU with mineral oils or mineral oil-based raffi-
nates with flash points higher than 55°C/131°F.
uFlush the FCU with low-viscosity mineral oils or mineral
oil-based raffinates with flash points higher
than55°C/131°F.
uNever flush the FCU with universal thinners or other de-
greasing fluids.
uObserve the permissible viscosity range (up to
ISOVG68): of 2-350 mm²/s / 33-1622SUS.
uOperate the FCU only in periodic intermittent duty (S3)
with a (relative) duty cycle of 40% in relation to a useful life
of 10 minutes (S3 in accordance with DINEN60034 /
VDE0530).
uNever use the FCU without a suction strainer.
uObserve all the instructions contained in these Operating
and Maintenance Instructions.
uComply with all inspection and maintenance work.
Claims for defects or liability, regardless of the legal founda-
tion, do not apply with incorrect or improper installation, com-
missioning, usage, handling, storage, maintenance, repair, use
of unsuitable components or other circumstances for which the
manufacturer is not responsible.

HYDAC FILTER SYSTEMS GMBH Overview | 4
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The manufacturer assumes no responsibility for determining
the interfaces for installation in a system or the installation, use
or functionality of the product in this system.
4.2.1 Periodic intermittent duty – operating mode S3
Periodic intermittent duty in accordance with DIN EN 60034-1 /
DIN VDE 0530, Part 1, means that, during the period t0, opera-
tion t1 repeats itself periodically in alternation with the power
(PN)S3, followed by the cooling-down phase (downtime) t2. The
relative duty cycle is 40% in relation to a useful life of 10min-
utes.
Fig.6: Operating mode
S3 – Periodic intermittent
duty
(PN)S3 Nominal power, operating mode S3
t time
t0Period
t1Operation
t2Cooling phase (downtime)
°C (°F) Temperature

4 | Overview HYDAC FILTER SYSTEMS GMBH
20 / 92 BeWa FCU1210 3545830b en-us lq
4.3 Improper Use or Use Deviating from Intended Use
Improper use of the product may result in hazards and/or will
damage/destroy the product.
DANGER
Impermissible operating conditions
Danger of bodily injury
uOperation with non-approved fluids.
uOperation with fluids that have a flash point under
55°C/131°F.
uOperate only with fluids whose temperature is not at least
10°C below their individual flash point.
uImproper connection of the pressure and return flow
hoses.
uOperation at a measurement point with impermissible
pressure.
uOperation with damaged connector cable.
uOperation with faulty, damaged hoses.
uModifications to the product made by the user or pur-
chaser.
uOperation in potentially explosive atmospheres.
uContinuous operation.