HYDAC FILTER SYSTEMS FMM-A-S Series User manual

FMM-A-S
FluidMonitoring Module
Installation and Maintenance Instructions
English (translation of original instructions)
Document No.: 3492449

FMM-A-S Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2011 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC FILTER SYSTEMS GMBH. Contraventions are
liable to compensation.
Exclusion of Liability
We have made every endeavor to ensure the accuracy of the contents of this
document. However, errors cannot be ruled out. Consequently, we accept no
liability for such errors as may exist nor for any damage or loss whatsoever which
may arise as a result of such errors. The content of the manual is checked regularly.
Any corrections required will be incorporated in future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saa
r
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet , 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-mail: [email protected]
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FMM-A-S Content
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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Technical Support...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
Safety Information and Instructions....................................................................... 8
Obligations and Liability.......................................................................................... 8
Explanation of Symbols and Warnings, etc. ...........................................................9
Proper/Designated Use .......................................................................................... 9
Improper Use .......................................................................................................... 9
Informal Safety Precautions.................................................................................. 10
Training and Instruction of Personnel ...................................................................11
Safety Measures to Be Followed during Normal Operation.................................. 11
Maintenance, Servicing and Troubleshooting....................................................... 11
Modifications to the FMM-A-S ..............................................................................12
Storage ....................................................................................................................12
Checking the Scope of Delivery............................................................................ 13
FMM Features ......................................................................................................... 14
Restrictions pertaining to use ............................................................................... 14
Hydraulic diagram .................................................................................................. 15
Dimensions – FMM-A-S … -1.................................................................................15
Dimensions – FMM-A-S … -2.................................................................................16
Components of the FMM-A-S … -1 .......................................................................17
Components of the FMM-A-S … -2 .......................................................................18
Installing / deinstalling the FMM-A-S....................................................................19
Connecting the FMM-A-S with the hydraulic system.......................................... 20
Setting flow rate .....................................................................................................21
Error messages / Troubleshooting.......................................................................22
Performing Maintenance .......................................................................................22
Maintenance interval............................................................................................. 22
Changing the filter element (FMM-A-S … -1) ....................................................... 23

FMM-A-S Content
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Changing the filter element (FMM-A-S … -2) ....................................................... 25
Decommissioning the FMM-A-S............................................................................26
Disposing of the FMM-A-S..................................................................................... 26
Spare Parts and Accessories................................................................................27
FMM-A-S … -1...................................................................................................... 27
FMM-A-S … -2...................................................................................................... 27
Technical data ........................................................................................................ 28
Customer Service................................................................................................... 28
Model Code ............................................................................................................. 28

FMM-A-S Preface
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep this documentation in the vicinity of the product for immediate reference.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.Consequently, there might be deviations
in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”
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FMM-A-S Preface
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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/type designation and article no. of the product:
Fax: ++49 (0) 6897 / 509 - 846
E-mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
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.
Refer to these at www.hydac.com ð General terms and conditions.

FMM-A-S Preface
Using the Documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
WHAT do you 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.
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Chapter description
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.
Documentation No.
with Index /
File name
Page number
Edition date
Document language

FMM-A-S Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the most important notes for operating the
FMM-A-S safely.
Obligations and Liability
The basic prerequisite for the safe and proper handling and problem-free operation
of the FMM-A-S is knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the FMM-A-S.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed herein are limited solely to using the FMM-A-S.
The FMM-A-S has been designed and constructed in accordance with the current
state of the art and recognized safety regulations. Nevertheless, hazard may be
posed to the life and limb of the individual using the product or to third parties.
The FMM-A-S is only to be used as follows:
solely for its designated use
only when in a safe, perfect condition
Any faults or malfunctions which might impair safety are to be properly repaired or
remedied immediately.
Our General Terms and Conditions apply. They are provided to the owner upon
conclusion of purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
Improper use of the FMM-A-S or use deviating from its designated use
Improper assembly, installation, commissioning, operation and maintenance of
the FMM-A-S
Modifications to the FMM-A-S made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

FMM-A-S Safety Information and Instructions
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The FluidMonitoring Module FMM-A-S was developed for the continuous monitoring
of solid particle contamination and water content in hydraulic systems.
Analyzing the type, size and quantity of contamination enables quality standards to
be verified and documented, and the requisite optimization measures to be
implemented.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
Proper or designated use of the product extends to the following:
Maintaining adherence to all the instructions contained herein.
Performing requisite inspection and maintenance work.
Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
Improper connection of the pressure and return lines of the FMM-A-S.
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FMM-A-S Safety Information and Instructions
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
In addition to the operating instructions, the general and local regulations on
accident prevention and environmental protection are to be made available and
observed.
Make sure to keep the safety and hazard symbols and warnings on the FMM-A-S in
a legible condition.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FMM-A-S are also to be regularly checked (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.
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WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

FMM-A-S Safety Information and Instructions
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Training and Instruction of Personnel
The FMM-A-S may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the FMM-A-S unless supervised by an
experienced staff member.
Individuals Individuals undergoing training
I
n
di
v
id
ua
l
s w
ith
technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning/storage X X X X
Safety Measures to Be Followed during Normal Operation
Do not operate the FMM-A-S unless all the safety devices function properly.
The product is to be checked once a day for external damage and the proper
functioning of the safety devices.
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
Any screwed fittings which have been undone/removed are to be checked to see
that they have been properly resecured.

FMM-A-S Storage
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Modifications to the FMM-A-S
Do not make any modifications (design modifications, extensions) to the FMM-A-S
without the prior consent of the manufacturer.
Any modifications require written permission from HYDAC FILTER SYSTEMS
GMBH.
Immediately replace any machine components which are not in perfect condition.
Use only original spare parts. When using non-OEM components it cannot be
ensured that they have been designed and manufactured so as to comply with
loading and safety requirements.
Storage
Store the FMM-A-S in a clean, dry place, in the original packing if possible. Do not
remove the packing until you are ready to install the unit.
Drain the FMM-A-S completely before putting it into storage. If necessary, rinse the
FMM-A-S with n-heptane to prevent it from gumming up.
Use and dispose of used cleaning agents and flushing oils properly.

FMM-A-S Checking the Scope of Delivery
Checking the Scope of Delivery
The Fluid Monitoring Module FMM-A-S comes packed and factory-assembled.
Before commissioning the FMM-A-S, check the content of the package to make sure
everything is present.
The following items are supplied:
Qty. Designation
1 FluidMonitoring module FMM-A-S
1 Connector (female) with 8-pole, M12x1, shielded
1 Installation and Maintenance Instructions (this document)
1 CD-ROM with operating and maintenance instructions CS 1000
1 CD-ROM with FluMoS Light software
1 Calibration certificate CS1000
FMM-A-S … -1 FMM-A-S … -2
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FMM-A-S FMM Features
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FMM Features
The FMM-A-S is used as a robust and stationary system for online measurement of
solid particle contamination and water content in hydraulic and lubricant fluids (e.g.
for the detection of leakages).
The FMM-A-S features all of the requisite connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits. Due to the adjustable current
regulator, adaptation to the hydraulic conditions can be carried out with ease.
The FMM-A-S is suitable for an operating pressure of 15 … 300 bar.
Advantages offered by the FMM-A-S:
Cost-effective solution
Critical machine conditions are identified in good time
Continuous fluid condition monitoring
Condition-based maintenance planning
Restrictions pertaining to use
NOTICE
Impermissible operating conditions
The FMM-A-S will be destroyed
►The FMM-A-S is only to be used with mineral oils or mineral oil-based
raffinates.
►Do not exceed the maximum operating pressure.

FMM-A-S Hydraulic diagram
Hydraulic diagram
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CS
IN OUT
Dimensions – FMM-A-S … -1

FMM-A-S Dimensions – FMM-A-S … -2
Dimensions – FMM-A-S … -2
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FMM-A-S Components of the FMM-A-S … -1
Components of the FMM-A-S … -1
Item Designation
1 FMM-A-S installation block
2 ContaminationSensor CS 1000 series
3 Connector (female), 8-pole, M12x1
4 Inlet (IN),
Test coupling Type 1604 / female thread G ¼ acc. ISO 228
5 Outlet (OUT),
Test coupling Type 1604 / female thread G ¼ acc. ISO 228
6 Flow control valve (adjustable) / lockable
7 Filter / Filter element
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FMM-A-S Components of the FMM-A-S … -2
Components of the FMM-A-S … -2
Item Designation
1 FMM-A-S installation block
2 ContaminationSensor CS 1000 series
3 Connector (female), 8-pole, M12x1
4 Inlet (IN),
Test coupling Type 1604 / female thread G ¼ acc. ISO 228
5 Outlet (OUT),
Test coupling Type 1604 / female thread G ¼ acc. ISO 228
6 Flow control valve (adjustable) / lockable
7 Filter bowl / Filter element
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FMM-A-S Installing / deinstalling the FMM-A-S
Installing / deinstalling the FMM-A-S
Install the FMM-A-S so that all connections and operating elements are easily
accessible and so that the filter element change can easily be carried out.
When selecting the installation site, check the ambient conditions such as
temperature, dust, water, etc. The CS features a protection rating of IP 67 according
to DIN 40050 / EN60529 / IEC 529 / VDE 0470.
Fastening can be carried out by means of the two holes in the installation block with
2 M6 screws in accordance with ISO 4762 (minimum length 110 mm).
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FMM-A-S Connecting the FMM-A-S with the hydraulic
t
Connecting the FMM-A-S with the hydraulic system
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WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Connect the FMM-A-S with the hydraulic system as follows:
1. Check the pressure at the measurement site. It must be within the
permissible range.
2. The hydraulic system has to be completely depressurized.
3. First connect the return-flow line to the outlet port (OUT) of the FMM-A-S.
We recommend an internal Ø ≥4 mm for the return line.
4. Now connect the other end of the return line to the system tank, for
example.
5. Now connect the measurement line to the inlet port (IN) of the FMM-A-S.
We recommend an internal Ø ≤4mm for the pressure line in order to
prevent particle deposits.
6. Now connect the other end of the measurement line to the measurement
point.
The hydraulic installation of the FMM-A-S is now complete.