HYDAC FILTER SYSTEMS FMM-P-L Technical specifications

FMM-P-L
FluidMonitoring Module
Installation and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 3874982a
(Valid from series no.: 0002S01827N0000401)

Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Telefax: [phone]
E-Mail: [email protected]
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: [email protected]
© 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.
All details are subject to technical modifications. Technical specifications are
subject to change without notice.

Documentation Representative
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Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Preface...........................................................................................................5
Technical Support........................................................................................5
Modifications to the Product ........................................................................5
Warranty ......................................................................................................5
Using the documentation .............................................................................6
Safety information and instructions............................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions.....................................8
Observe regulatory information ...................................................................9
Proper/Designated Use ...............................................................................9
FMM-P-L-0-CS1xx0.....................................................................................9
FMM-P-L-1-CS1xx1.....................................................................................9
Improper Use or Use Deviating from Intended Use ...................................10
Qualifications of personnel / target group ..................................................11
Unpacking the FMM ....................................................................................13
Storing the FMM..........................................................................................13
Decoding the model code label .................................................................13
Checking the scope of delivery .................................................................15
FMM Features..............................................................................................15
Components ..............................................................................................16
Dimensions..................................................................................................17
Hydraulic diagram.......................................................................................17
Attaching the FMMP mechanically ............................................................18
FMM hydraulic installation.........................................................................19
Connecting FMM with the hydraulic system ............................................21
Error messages / Troubleshooting............................................................22

Documentation Representative
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Performing Maintenance ............................................................................23
Maintenance interval..................................................................................23
Changing the filter element........................................................................23
Decommissioning the FMM........................................................................24
Disposing of the FMM.................................................................................24
Contact / Service.........................................................................................25
Spare Parts and Accessories.....................................................................26
Spare parts ................................................................................................26
Accessories ...............................................................................................27
Technical details .........................................................................................28
Model Code..................................................................................................29
Index ............................................................................................................30

Preface
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Preface
This operating manual was 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 this operating
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 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/type designation and article no. of the
product:
Fax: [phone] / 509 - 9046
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.
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 General Terms of Sale
and Delivery of HYDAC FILTER SYSTEMS GmbH.
You'll find this under www.hydac.com -> General terms and conditions.

Preface
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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 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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seit e 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

Safety information and instructions
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Safety information and instructions
The module 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 module. They
must always be complete and legible.
Do not operate the module unless all the safety devices are present.
Secure the hazardous areas which may arise between the module 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 operating pressure
Risk of burns due to hot surfaces

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Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a danger with a high risk and which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a danger with a medium risk and which can lead to
death or serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor
injury if not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.
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:
SIGNAL WORD
Type and source of danger
Consequence of the danger
HAZARD SYMBOL
►Measures to avert danger

Safety information and instructions
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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
Proper/Designated Use
Use the module only for the application described in the following:
The FluidMonitoring Module FMM is for monitoring solid particle
contamination in hydraulic systems.
FMM-P-L-0-CS1xx0
NOTICE
Impermissible operating fluid
The FluidMonitoring Module will be destroyed
►The FMM may only be used with mineral oils or mineral oil-based
raffinates.
FMM-P-L-1-CS1xx1
NOTICE
Impermissible operating fluid
The FluidMonitoring Module will be destroyed
►The FMM may only be used with HDFR fluids (phosphoric acid
esters, e.g. Skydrol, Fryquel, Hyjet).
Proper or designated use of the product extends to the following:
observing all instructions contained in the operating manual.
performing inspection and maintenance work.

Safety information and instructions
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Improper Use or Use Deviating from Intended Use
DANGER
Hazard due to use of the module other than
that intended
Bodily injury and damage to property will result
when operated improperly.
►Never operate the module in potentially
explosive atmospheres.
►The module 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 module.
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 module made by the user or purchaser
Inadequate monitoring of parts that are subject to wear and tear
Improperly performed repair work / maintenance.

Safety information and instructions
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Qualifications of personnel / target group
Persons who work on the module must be aware of the associated hazards
when using the module.
Operating 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:
Operating personnel: such persons have been instructed in module 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.

Safety information and instructions
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Activity Person Knowledge
Transport / storage Auxiliary
personnel
No specialist knowledge
required
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.
Knowledge about
contamination due to solids
and water
Disposal Specialist
personnel
Proper and environmentally-
friendly disposal of materials
and substances
Decontamination of
contaminants
Knowledge about reuse

Unpacking the FMM
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Unpacking the FMM
Before delivery, the FMM is inspected for leaks and proper functioning at the
factory, then carefully packed for shipment.
When receiving and unpacking the module, check it for damage in transit.
Dispose of the packaging material in an environmentally friendly manner.
Storing the FMM
Store the FMM in a clean, dry place, in the original packing if possible. Do not
remove the packing until you are ready to install the unit.
Always store the FMM in a horizontal or vertical position on the block, without
its original packaging.
Drain the FMM completely before putting it into storage. If necessary, rinse
the FMM with n-heptane to prevent it from gumming up during storage.
Decoding the model code label
For product identification details see the Model code label. This is located on
the back of the unit and contains the exact product description and the serial
number.
Row -> Description
Model -> Model code; for details, see page 29.
P/N -> Part no.
S/N -> Serial-no.
Date -> Year/week of production and hardware index

Decoding the model code label
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Min. INLET press.: -> Minimum operating pressure
Max. INLET press.: -> Maximum operating pressure

Checking the scope of delivery
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Checking the scope of delivery
The FluidMonitoring Module FMM comes packed and factory-assembled.
Before commissioning the FMM, check the contents of the package to make
sure it has not been damaged during transport and that it is complete.
The following items are supplied:
Qty Designation
1 FluidMonitoring Module FMM-P-L
1 Installation and Maintenance Instructions (this document)
1 CD Operating and Maintenance Instructions CS 1000
(A PC with a PDF display program is required for displaying
this.)
1 CD FluMoS light (FluidMonitoring Software)
1 Calibration certificate CS 1000
1 Additional sensor manual (optional)
FMM Features
The FluidMonitoring Module FMM-P-L Series combines HYDAC's Condition
Monitoring Products ContaminationSensor CS 1000 and AquaSensor AS
1000 in one system.
The FMM 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 features all of the requisite connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits.
The FMM is suitable for the following operating pressures:
FMM with pressure accumulator 15 … 250 bar
FMM without pressure accumulator 15 … 300 bar
Advantages offered by the FMM:
Cost-effective solution
Early warning in the case of critical machine states
Continuous fluid monitoring
Condition-based maintenance planning

FMM Features
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Components
The FMM has the following components, depending on the version:
Item Designation
1 FMM Installation block
2 ContaminationSensor CS 1000 series
3 AquaSensor AS 1000 series
4 Inlet (IN), with test connector type 1604 or G ¼ according to ISO
228r
5 Outlet (OUT), with test connector type 1604 or G ¼ according to
ISO 228.
6 Test connection (TP1), test connector type 1604
7 Test connection (TP2), test connector type 1604
8 Hydraulic accumulator (option)
9 Filter element (installed)

Dimensions
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Dimensions
The FMM has the following dimensions, depending on the version and
additional sensor:
Hydraulic diagram
The FMM has the following hydraulic diagram, depending on the version and
additional sensor:

Attaching the FMMP mechanically
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Attaching the FMMP mechanically
We recommend installing the unit vertically, so that the flow direction is from
bottom to top. 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 40.050 / EN60.529 / IEC 529 /
VDE 0470
Fastening can be carried out by means of the four holes in the connection
stock with four M6 screws in accordance with ISO 4762 (minimum length 80
mm).

FMM hydraulic installation
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FMM hydraulic installation
WARNING
Non-permitted operating pressure
Danger of bodily injury
►Note the maximum operating pressure.
NOTICE
The minimum differential pressure is < 15 bar
If the minimum differential pressure is not given, measuring errors will
occur.
►Always observe the minimum differential pressure of 15 bar
To minimize measurement errors resulting from trapped air in the system, we
recommend that the flow direction through the FMM is from bottom (IN) to top
(OUT).
The FMM comes delivered with four test connectors (Type 1604), one at the
inlet (IN) and one at the outlet (OUT) port, as well as at the two testing points
(TP1 / TP2).
If the hydraulic connection is done via the connector thread G 1/4 according
to ISO 228, the test connectors must be removed.

FMM hydraulic installation
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