HYDAC FILTER SYSTEMS FCU 2000-4 Series Manual

FCU 2000-4 series
FluidControl Unit
Operating and maintenance instructions
Valid from firmware versions 3.22 up
English (translation of original instructions)
Keep for future reference.
Document No.: 3109987h

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saar
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive director:
Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
Technical specifications are subject to change without notice.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Changes to the manual ................................................................................7
Preface...........................................................................................................8
Technical Support........................................................................................8
Modifications to the Product ........................................................................8
Warranty......................................................................................................8
Using the documentation.............................................................................9
Safety information ......................................................................................10
Hazard symbols.........................................................................................10
Signal words and their meaning in the safety information and
instructions ................................................................................................11
Structure of the safety information and instructions...................................12
Observe regulatory information .................................................................12
Proper/Designated Use .............................................................................13
Improper Use or Use Deviating from Intended Use...................................14
Qualifications of personnel / target group ..................................................15
FCUtransporting .........................................................................................16
Storing the FCU...........................................................................................17
Decoding the model code label .................................................................18
Checking the scope of delivery .................................................................19
Description of the FCU ...............................................................................20
Operating elements / Dimensions..............................................................21
Hydraulic diagram.......................................................................................22
FCUFunction description ...........................................................................23
Adjusting the carry and support handle .....................................................26
Working ergonomically ...........................................................................26
FCUElectrical connection ..........................................................................28
Connecting "POWER INPUT"....................................................................28
Connecting "POWER INPUT PUMP" ........................................................29
Connecting the "PC" interface ...................................................................30
Serial RS232 Interface (Standard) .........................................................30
Serial RS485 Interface (OPTIONAL)......................................................30
"Control" – Connecting the control port......................................................31
Contact assignment (switching position when the FCU is ready
for operation)..........................................................................................31
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Content
Relay Functions......................................................................................32
Adjustable limit values FCU 20xx...........................................................35
Adjustable limit values FCU 21xx / FCU 22xx ........................................36
FCU hydraulic connection .........................................................................37
Conducting measurements via the High-Pressure Port (INLET) ............38
Conducting measurements via the integrated pump - SUCTION
INLET .....................................................................................................39
Switching on the FCU.................................................................................41
Selecting the Viscosity Range ...................................................................41
Commissioning the FCU ............................................................................42
Conducting Measurements via the High-Pressure Port INLET..................42
Conducting measurements via the integrated pump SUCTION
INLET ........................................................................................................42
Operating FCU.............................................................................................43
Function of the Keys..................................................................................43
Menu and Number Keys (red) ...................................................................44
Key Combinations .....................................................................................44
FCU menus..................................................................................................45
MODE – Selecting operating mode ...........................................................45
MODE "M1: Measure" ............................................................................46
MODE "M2: Measure and switch" ..........................................................46
MODE "M3:: Filter to" (performance of automatic filtration)....................46
MODE "M4:: Filter from to" (performance of automatic filtration)............47
MODE "M5: Measure Autostop".............................................................47
MODE "M6: Autostop pump"..................................................................47
MEMORY menu ........................................................................................48
Designating the measurement point.......................................................49
Setting the averaging interval.................................................................51
Selective deletion ...................................................................................52
Delete all ................................................................................................54
Change meas. – point ............................................................................55
Setting save mode..................................................................................56
Overwrite.............................................................................................56
Stop if full ............................................................................................56
PRINT menu..............................................................................................57
Logs .......................................................................................................58
PRINT Contents .....................................................................................61
PRINT All parameters ............................................................................61
Paper feed..............................................................................................62
Online printout........................................................................................62
Print out, cancel......................................................................................63
LIMITS menu.............................................................................................63
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Content
MODE M2 ..............................................................................................64
MODE M3 ..............................................................................................65
MODE M4 ..............................................................................................65
Limit values table ................................................................................66
MODE M5 ..............................................................................................66
MODE M6 ..............................................................................................67
SETUP menu.............................................................................................68
Autostart.................................................................................................69
Abort at Q=0...........................................................................................70
Setting the pump start delay...................................................................71
Setting the date and time .......................................................................72
Set bus address .....................................................................................73
Display operating hours..........................................................................73
Pump supply:..........................................................................................74
Checking the battery status...................................................................75
POWERUP Menu ......................................................................................76
Selecting the language...........................................................................77
Setting the viscosity range .....................................................................78
Setting measured volume......................................................................79
FCU display .................................................................................................80
Brief Overview of the Menu Structure.......................................................82
Error Messages and Troubleshooting ......................................................84
Performing maintenance............................................................................89
FCUcleaning..............................................................................................89
Changing the FCU filter element ...............................................................89
Back-flushing FCU.....................................................................................91
Replacing the paper roll / ink ribbon in the dot-matrix printer.....................92
FCU unit disposal .......................................................................................95
FCU calibration ...........................................................................................95
Spare parts ..................................................................................................96
FCUFCU 2xx0-x (version for mineral oil)...................................................96
FCU 2xxx-x (all versions)...........................................................................97
Accessories.................................................................................................98
Technical data .............................................................................................99
Appendix ...................................................................................................102
Model code..............................................................................................102
Explanation of the measuring technology terms used .............................103
Explanation of terms and abbreviations...................................................105
Finding Customer Service / Service stations ...........................................106
Germany ..............................................................................................106
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Content
USA......................................................................................................106
Australia ...............................................................................................106
Brazil ....................................................................................................107
China....................................................................................................107
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes .................108
ISO 4406:1999 .....................................................................................108
ISO 4406 table ..................................................................................108
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 ............................................................................................109
SAE AS 4059...........................................................................................110
SAE AS 4059 table...............................................................................110
Show cleanliness classes to SAE.........................................................110
Absolute particle count larger than a defined particle size ................110
Specifying a cleanliness code for each particle size .........................111
Specifying the highest cleanliness code measured...........................111
NAS 1638 ................................................................................................112
Factory default settings............................................................................113
- EGDeclaration of conformity..................................................................114
Index........................................................................................................116
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Changes to the manual
Changes to the manual
The index is featured on the cover sheet of the Operation and maintenance
Instructions and in the lower left corner of each page after the article number.
Index "d" — from firmware version V 3.2x
-Changes to firmware have been integrated
Index "f" - from firmware version V 3.2x
-Changes to firmware have been integrated
-Document standardization acc. 2006/42/EC
-Defined display for excessively dirty fluid
Index "g" -from firmware version V 3.2x
-Manual revised, CoCos changed to FluMoS.
Index "h" - from firmware version V 3.2x
-Manual revised, keyword index added
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Preface
Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. Therefore please understand 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 these operating instructions. 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 injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to Product Liability shall remain
unaffected.
Technical Support
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 code, serial no. and part no. of the product:
Fax:
[phone]
E-mail:
[e-mail]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing
additional options, etc.) may mean that the information in the operating
instructions is no longer applicable or adequate.
After modification or repair work that affects the safety of the product has
been carried out on components, the product may not be returned to
operation until it has been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product
whether by you or a third party.
Warranty
For the warranty provided by us, please refer to the terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> Legal information.
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Preface
Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
What do I want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter
I'm looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx- xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name
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Safety information
Safety information
The device was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Danger due to operating pressure
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Safety information
Signal words and their meaning in the safety information and
instructions
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 minor 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.
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Safety information
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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 regulations
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Safety information
Proper/Designated Use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Use the device only for the application described in the following.
The FluidControl Unit FCU carries out the temporary or continuous
monitoring of particulate contamination in hydraulic systems.
Proper or designated use of the product extends to the following:
•observing all instructions contained in the instruction manual.
•performing inspection and maintenance work.
Depending on the version (see model code), you may use the FCU only in
connection with the following media:
WARNING
Fire hazard
Danger of bodily injury
►Always consider the flash point when
checking fluids.
►Never test fluids with a fluid temperature
greater than the fluid flash point.
NOTICE
Impermissible operating conditions
The FCU will be destroyed
►The FCU may only be used with mineral oils or mineral oil-based
raffinates.
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Safety information
Improper Use or Use Deviating from Intended Use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result
when operated improperly.
►Never operate the device in potentially
explosive atmospheres.
►The device is only to be used with
permissible media.
Any use extending beyond or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. The user alone shall assume any and all
associated risk.
Improper use may result in hazards and/or will damage the device. Examples
of improper use:
•Operation in potentially explosive atmospheres.
•Operation with a non-approved medium.
•Operation under non-approved operational conditions.
•Operation when the safety devices are defective.
•Modifications to the power unit made by the user or purchaser.
•Inadequate monitoring of parts that are subject to wear and tear.
•Improperly performed repair work.
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Safety information
Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
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.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel: such persons have been instructed in power unit
operation and are aware of potential hazards due to improper use.
Specialist personnel: such persons have corresponding 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.
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Specialist
personnel
•Proof of knowledge of cargo
securing instructions
•Safe handling/operation of
hoisting and lifting equipment
Hydraulic / electrical
installation,
first commissioning,
Maintenance,
Troubleshooting,
repair,
Decommissioning,
Disassembly
Specialist
personnel
•Safe handling/use of tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Product-specific knowledge
Operation
Operations control
Specialist
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
•Proper and environmentally-
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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FCUtransporting
FCUtransporting
Transport the FCU in a horizontal or vertical position.
Always carry the FCU by the carry and support handle or transport the FCU
in the appropriate accessory case (see accessory).
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Storing the FCU
Storing the FCU
Drain the FCU completely, remove the filter element and flush the FCU with
n-Heptane before putting it into storage.
Dispose of used cleaning agents and flushing fluids in an environmentally
friendly manner.
Storage temperature:
-20 … 85°C / -4 … 185°F
Humidity:
up to 90% relative humidity, non-condensing
Air:
Clean, salt-free air, not near oxidizing substances
(rust film).
Storage duration:
Indefinite.
Store the FCU upright or horizontally.
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Decoding the model code label
Decoding the model code label
For identification details of the FluidControl Unit, see the model code label.
The type label displays the product ID and important technical data.
Item
->
Description
(1)
->
Type label
(2)
->
Model code; for details, see page 102.
(3)
->
Hardware index
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Checking the scope of delivery
Checking the scope of delivery
The FluidControl Unit FCU comes packed and factory-assembled.
Before commissioning the FCU, check the content of the package to make
sure everything is present.
The following items are supplied:
Item
Qty.
Description
1
1
FluidControl Unit FCU 2xxx-4
2
2
Mains device and connection cable
(configuration depends on the order)
3
1
High pressure hose with mini measurement port DN4,
L=2000 mm
4
1
Suction hose DN 6 with CPC quick-release coupling,
L=1000 mm
5
1
Suction hose DN 6 with CPC quick-release coupling, L=250
mm
6
1
Return hose DN 7, L = 2000 m
7
1
Connection cable FCU <-> PC
8
1
CD with: FluMoS Light software
-
1
Operation and Maintenance Instructions (this document)
-
1
Calibration certificate
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Description of the FCU
Description of the FCU
The FluidControl Unit FCU can determine the solid particle contamination of
mineral oils on a continuous basis.
With the FCU, it is possible to record, save and display the Cleanliness Class
completely automatically during continuous operation in accordance with
NAS 1638 and/or SAEAS4059 or ISO 4406.
The measured values can be printed out online in the form of either tables or
graphs by means of the built-in dot-matrix printer or sent via serial interface
to a PC or a central display unit for visualization purposes there.
Filter units can for example be actuated via relay outputs.
For input and output functions, the FCU possesses a keyboard, an LCD
(Liquid Crystal Display), a dot-matrix printer, control relay outputs and a serial
data interface.
The FCU possesses a measurement port 1604 as an input for connection
with the hydraulic unit, as well as a DN 7 plug nipple as a return flow outlet.
A flow rate control valve is available for setting the measurement flow rate.
This is protected against larger particle contamination by an upstream filter.
Media from a depressurized reservoir can be inspected using the integrated
pump with the enclosed suction hoses (DN8).
The FCU has a rechargeable battery for approx. 5 hours of operation
independent of the mains network.
The FCU has a measured value memory for up to 3000 measured values,
which are stored in the form of logs (maximum of 100).
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