HYDAC FILTER SYSTEMS FluidControl FCU 8111 Manual

FCU 8111 /-Aviation
FluidControl Unit
Operating and Maintenance Instructions
Valid from firmware versions 3.32 up
English (translation of original instructions)
Keep for future reference.
Document No.: 3690427a

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saar
Germany
Telephone:
[phone]
Telefax:
[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
Telephone:
[phone]
Telefax:
[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
Preface...........................................................................................................7
Technical Support........................................................................................7
Modifications to the Product ........................................................................7
Warranty......................................................................................................7
Using the documentation.............................................................................8
Safety information ........................................................................................9
Hazard symbols...........................................................................................9
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions...................................11
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................12
Improper Use or Use Deviating from Intended Use ...................................13
Qualifications of personnel / target group ..................................................14
Transporting the FCU .................................................................................16
Storing the FCU...........................................................................................17
Checking the Scope of Delivery ................................................................18
Description of the FCU ...............................................................................19
Operating elements / Dimensions..............................................................20
Hydraulic diagram.......................................................................................21
FCU Function Description..........................................................................22
Adjusting the carry and support handle .....................................................25
Working ergonomically ...........................................................................25
Electrical connection of the FCU...............................................................26
Connecting the "POWER INPUT"..............................................................26
Connecting the "PC" interface ...................................................................27
Serial RS 232 Interface (Standard) ........................................................27
Serial RS 485 Interface (OPTIONAL).....................................................27
"Control" – Connecting the control port......................................................28
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Content
Contact assignment (switched position when the FCU is ready
for operation)..........................................................................................28
Relay Functions......................................................................................29
Adjustable limit values............................................................................32
FCU in online operation .............................................................................33
Switching on the FCU................................................................................35
Conducting Measurements via the High-Pressure Port (INLET) ...............35
Operating the FCU ......................................................................................36
Function of the Keys..................................................................................36
Menu and Number Keys (red) ...................................................................37
Key Combinations .....................................................................................37
FCU menus..................................................................................................38
MODE - select operating mode .................................................................38
MODE "M1: Measure" ............................................................................39
MODE "M2: Measuring and switching"...................................................39
MODE "M3: Filter to" (performance of automatic filtration).....................39
MODE "M4: Filtering from to" (performance of automatic
filtration) .................................................................................................40
MODE "M5: Measure+Autostop"............................................................40
MEMORY Menu ........................................................................................41
Designating the measurement point.......................................................42
Setting the averaging interval.................................................................44
Selective deletion ...................................................................................45
Delete all ................................................................................................47
Change meas. – point ............................................................................48
Setting the memory mode ......................................................................49
Overwrite.............................................................................................49
Stop if full ............................................................................................49
PRINT menu..............................................................................................50
Logs .......................................................................................................51
PRINT Contents .....................................................................................56
PRINT All parameters ............................................................................56
Paper feed..............................................................................................57
Online printout........................................................................................57
Print out, cancel......................................................................................58
LIMITS menu.............................................................................................58
MODE M2 ..............................................................................................59
Measurement channel table................................................................62
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Content
MODE M3 ..............................................................................................62
MODE M4 ..............................................................................................63
MODE M5 ..............................................................................................64
SETUP menu.............................................................................................65
Autostart.................................................................................................66
Abort at Q=0...........................................................................................67
Setting the pump start delay...................................................................68
Setting the date and time .......................................................................69
Set bus address .....................................................................................70
Display operating hours..........................................................................70
Check the battery status.........................................................................71
POWERUP menu ......................................................................................72
Selecting the language...........................................................................72
Setting the measured volume.................................................................74
FCU Display.................................................................................................75
Brief Overview of the Menu Structure.......................................................77
Error Messages and Troubleshooting ......................................................79
Performing maintenance............................................................................83
Cleaning the FCU ......................................................................................83
Changing the FCU Filter Element..............................................................83
Replacing the paper roll / ink ribbon in the dot-matrix printer.....................86
Disposing of the FCU .................................................................................89
Calibrating the FCU ....................................................................................89
Spare parts ..................................................................................................90
FCU 8xx1 (version for HFD fluids).............................................................90
FCU 8xxx...................................................................................................90
Accessories.................................................................................................91
Technical data .............................................................................................92
Appendix .....................................................................................................94
Explanation of the measuring technology terms used ...............................94
Customer Service / Service stations around the world ..............................96
Germany ................................................................................................96
USA........................................................................................................96
Australia .................................................................................................96
Brazil ......................................................................................................97
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Content
China......................................................................................................97
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes ...................98
ISO 4406:1999 .......................................................................................98
ISO 4406 table .......................................................................................98
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 ..............................................................................................99
SAE AS 4059...........................................................................................100
SAE AS 4059 table...............................................................................100
Cleanliness codes according to SAE....................................................101
Absolute particle count larger than a defined particle size ................101
Specifying a cleanliness code for each particle size .........................101
Specifying the highest cleanliness code measured...........................101
NAS 1638 ................................................................................................102
Factory default settings............................................................................103
Glossary ..................................................................................................104
Index........................................................................................................106
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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 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.
When making modifications or performing repair work to components
affecting the safety of the product, the product may not be put back into
operation until it has been examined and released by a HYDAC
representative.
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 General Terms of Sale
and Delivery of HYDAC Filter Systems GmbH.
You will find these under www.hydac.com -> General terms and conditions.
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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
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 inj
ury.
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 guidelines:
•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
Use the unit 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:
NOTICE
Impermissible operating media
The FCU will be destroyed
►Only use the FCU in connection with HFD-
R fluids such as phosphate
acid esters (Skydrol, Fyrquel, Hyjet, etc.)
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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.
•Device modifications without authorization.
•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 with 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
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Safety information
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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Transporting the FCU
Transporting the FCU
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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Checking the Scope of Delivery
Checking the Scope of Delivery
The FluidControl Unit FCU comes packed and ready for operation.
Before commissioning the SFC, check the content of the package to make
sure everything is present.
The following items are supplied:
Pc.
Description
1
FluidControl Unit FCU 8111
1
Power supply unit and connection cable (Euro, UK, USA, AUS)
1
hp-hose with mini measurement port DN2, L=5000 mm
1
Return hose DN 7, L = 2000 m
1
Connection cable FCU <-> PC
1
CD-ROM 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 FCU 8111 FluidControl Unit can determine the solid particle
contamination of phosphoric acid ester on a continuous basis.
With the FCU, it is possible to record, save and display the particle numbers
for six particle sizes and the cleanliness class completely automatically
during continuous operation in accordance with NAS 1638 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 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 mini measurement port (System 1620) as an input for
connection with the hydraulic unit, as well as a DN 7 plug nipple a a return
flow.
A flow rate control valve is available for setting the measurement flow rate.
This is protected against larger particle contamination by an upstream filter.
The FCU has a rechargeable battery for ≈ 6 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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Description of the FCU
Operating elements / Dimensions
Item Code
A
High pressure port = INLET
B
Return port connection - OUTLET
C
Switch - On/Off
D
Electrical connection - 24 V DC
E
Serial interface
F
Control port
G
Sealing cover
J
Dot-matrix printer
K
Display
L
Keyboard
M
Flow rate regulator
N
Filter element
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