HYDAC International FCU 1000 Series Manual

FCU 1000 Series
FluidControl Unit
Operating and Maintenance Instructions
English (Translation of original)
Valid from firmware versions V 1.10 up
Doc.: 3371346a / 2007-12-03

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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2007 by
HYDAC Filtertechnik GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the explicit
written agreement from HYDAC Filtertechnik. Contraventions are liable to compensation.
Exclusion of liability
We 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.
We welcome any suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Hydac Service Technology Division / Filter Systems
P.O. Box 12 51
66273 Sulzbach / Saar - Deutschland
Tel.: ++49 (0) 6897 / 509 - 01
Fax: ++49 (0) 6897 / 509 - 846

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Contents
Contents..................................................................................................................................3
What's New — Document History.........................................................................................5
Preface ....................................................................................................................................6
Customer Service .................................................................................................................7
Modifications to the Product .................................................................................................7
Warranty ...............................................................................................................................7
Using the documentation ...................................................................................................... 8
1General Safety Precautions ...........................................................................................9
1.1 Obligations and Liability .............................................................................................9
1.2 Explanation of Symbols and Warnings, etc..............................................................10
1.2.1 Basic Symbols............................................................................................... 10
1.3 Proper/Designated Use ............................................................................................10
1.4 Improper Use............................................................................................................ 11
1.5 Informal Safety Precautions .....................................................................................11
1.6 How to behave in case of emergency ......................................................................11
1.7 Safety measures to be followed in normal operation................................................11
1.8 Electrical Hazards .................................................................................................... 12
1.9 Maintenance, Servicing and Troubleshooting ..........................................................12
1.10 Modifications to the FCU ..........................................................................................12
1.11 Cleaning the FCU and disposal of the media and agents used ...............................12
2Transportation/Package/Storage.................................................................................13
2.1 Packing / transportation............................................................................................ 13
2.2 Storage..................................................................................................................... 13
2.2.1 Storage conditions ........................................................................................13
3Decoding the model code label...................................................................................13
4Checking the scope of delivery...................................................................................14
5Using the FCU ...............................................................................................................15
5.1 Mode of Function...................................................................................................... 16
5.2 Operation panel........................................................................................................18
5.3 Dimensions............................................................................................................... 19
5.4 Hydraulic schematic .................................................................................................19
6Preparing the FCU.........................................................................................................20
6.1 Attaching OUTLET quick-action coupling................................................................. 20
6.2 Hydraulic connection of the FCU.............................................................................. 20
6.2.1 Connection at the measurement point up to max. 45 bar .............................21
6.2.2 Connection at the measurement point with 45 ... 345 bar............................. 23
6.2.3 Selecting the measurement point.................................................................. 25
6.2.4 Connection at the measurement point - non-pressurized tank ..................... 26
6.3 Electrical connection of the FCU ..............................................................................27
7Operating the FCU ........................................................................................................28

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7.1 Display and keypad elements ..................................................................................28
7.1.1 Measured variables....................................................................................... 29
7.1.1.1 Measured variable "ISO"...............................................................................29
7.1.1.2 Measured variable "SAE"..............................................................................29
7.1.1.3 Measured variable "NAS".............................................................................. 29
7.1.1.4 Measured variable "Water saturation"........................................................... 29
7.1.1.5 Measured variable "Temperature" ................................................................30
7.1.2 Service variables...........................................................................................30
7.1.2.1 Service variables "Flow"................................................................................ 30
7.1.2.2 Service variables "Drive"...............................................................................30
7.1.3 Switching the display..................................................................................... 31
7.1.4 Activate / deactivate keypad lock. ................................................................. 31
7.2 Modes and menus....................................................................................................32
7.2.1 Power Up Menu ............................................................................................ 32
7.2.2 Measuring Menu ISO / SAE ..........................................................................33
7.2.3 Menu structure ISO / SAE.............................................................................34
7.2.4 Measuring Menu ISO / NAS.......................................................................... 34
7.2.5 Menu structure ISO / NAS............................................................................. 35
8Performing a measurement..........................................................................................35
8.1 Restrictions pertaining to use ................................................................................... 35
9Dismantling the FCU.....................................................................................................36
10 FCU interfaces...............................................................................................................37
10.1 DATA (HYDAC Sensor Interface - HSI) ...................................................................37
10.1.1 Connecting the FCU with HMG 510 / HMG 3000 .........................................38
10.1.2 Connecting the FCU with CSI-B-2 ................................................................ 39
10.2 Bluetooth interface ................................................................................................... 40
10.2.1 Installing the Bluetooth USB adaptor ............................................................41
10.2.2 Connecting the FCU via Bluetooth................................................................ 41
10.3 Measurement value readouts with FluMoS .............................................................. 41
11 Conducing maintenance ..............................................................................................42
11.1 Cleaning the FCU.....................................................................................................42
11.2 Rinsing the FCU ....................................................................................................... 42
11.2.1 Performing a rinsing ...................................................................................... 42
11.3 Cleaning the suction strainer.................................................................................... 43
11.4 Checking the high pressure adaptor ........................................................................47
11.4.1 Cleaning / changing the strainer in the high pressure adaptor...................... 47
11.4.2 Cleaning / changing the strainer in the high pressure adaptor...................... 48
11.5 Disposing of the FCU ............................................................................................... 48
12 FCU status messages...................................................................................................49
12.1 Status LED / Display ................................................................................................49
12.2 Error Message..........................................................................................................49
12.3 Exceptions Errors .....................................................................................................50
13 Spare Parts....................................................................................................................51

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13.1 Accessories ..............................................................................................................53
14 Technical Data...............................................................................................................54
15 ISO 4406 / SAE AS 4059 and NAS 1638 Classes........................................................56
15.1 ISO 4406:1999 .........................................................................................................56
15.1.1 ISO 4406 table ..............................................................................................56
15.1.2 Overview of the differences between ISO 4406:1987 and ISO 4406:1999... 57
15.2 SAE AS 4059 ...........................................................................................................58
15.2.1 SAE AS 4059 table ....................................................................................... 58
15.2.2 Cleanliness classes according to SAE..........................................................58
15.2.2.1 Absolute particle count larger than a defined particle size............................ 58
15.2.2.2 Specifying a cleanliness class for each particle size.....................................59
15.2.2.3 Specifying the highest cleanliness class measured ......................................59
15.3 NAS 1638 .................................................................................................................59
16 Service ...........................................................................................................................60
16.1 Shipping Address for Recalibration and Repair Work ..............................................60
16.2 Calibrating the FCU..................................................................................................60
17 EC declaration of conformity.......................................................................................61
What's New — Document History
The index is featured on the cover sheet of the operating and maintenance manual and in
the lower left corner of each page after the part number.
Index "a" - from firmware version V 1.10
- Change in scope of delivery
- Change in Bluetooth device name in "FCU1310"

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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 is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Sometimes the information contained in the documentation cannot always keep up
with changes made to the product as we attach considerable importance to keeping
our products cutting-edge. 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 Filtertechnik GmbH
SVFI, Technical Documentation Department
Postfach 12 51
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
E-mail: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”

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Customer Service
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
Email: [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 Filtertechnik GmbH.
They are available at: www.hydac.com Legal information.

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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 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
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.
Product designation
Page number
Edition date
Document language
Documentation Nr.
with Index
/
File name

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1 General Safety Precautions
These operating instructions contain the key instructions for properly and safely operating the
FCU.
1.1 Obligations and Liability
• The basic prerequisite for the safe and proper handling and operation of the FCU is
knowledge of the safety instructions and warnings.
• These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the FCU.
• 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 FCU.
The FCU has been designed and constructed in accordance with the current state of the art
and recognized safety regulations. Nevertheless, hazards may be posed to the life and limb
of the individual using the product or to third parties. Risk of damage may be posed to the
product or other equipment and property. The FCU 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 made available to the owner upon
concluding 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 FCU or use deviating from its designated use
• improper assembly, installation, commissioning, operation and maintenance of the
FCU
• operating the FCU when the system equipment or systems are defective
• modifications to the product made by the user or purchaser
• improper monitoring of product components subject to wear and tear
• improperly performed repair work

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1.2 Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate hazards, etc.:
1.2.1 Basic Symbols
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.
TIP TIP denotes situations which can lead to
property damage if safety precautions
are not observed.
1.3 Proper/Designated Use
The FCU was developed for the continuous monitoring of particulate contamination in
hydraulic systems.
Analyzing the 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
designated use. The manufacturer will not assume any liability for any damage resulting from
such use.
Proper or designated use of the product extends to the following:
• Typical application: Short-time measurement of system cleanliness
• Maintaining adherence to all the instructions contained herein.
• Performing requisite inspection and maintenance work.

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1.4 Improper Use
Improper use may result in hazard to life and limb. Examples of improper use:
• Long-term measurement of system cleanliness
• improper connection of the FluidControl Unit pressure and return flow hoses.
1.5 Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
In addition to the manual, the general and local regulations concerning accident prevention
and protection of the environment should be available and observed.
Make sure to keep the safety and hazard symbols and warnings on the product in a legible
condition.
Before opening any components of the FCU, all electric plugs/cords and hydraulic lines are
to be removed. Tests conducted with the housing open may only be performed by properly
trained, certified electricians. This also applies to all repair work or to any modifications to
electrical / hydraulic components approved by us.
The hoses and connection fittings are to be checked daily for leakage (visual check). The
electrical components of the product are to also be regularly checked (visual check once a
month). Any loose connections or damaged cables or hoses are to be replaced immediately
with original spare parts.
WARNING
Hydraulic systems are under pressure
 The hydraulic system must be depressurized before
performing any work
1.6 How to behave in case of emergency
In the event of an emergency, immediately disconnect the FCU from the power supply and
from the hydraulic system! Properly dispose of any exiting fluid in accordance with
environmental guidelines.
1.7 Safety measures to be followed in normal operation
Do not operate the FCU unless all the safety devices function properly.
The product must be checked once daily for external damage and the proper functioning of
the safety devices.

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1.8 Electrical Hazards
WARNING
Electric shock
 The power plug must be pulled before performing work
on live parts
Any work involving the power supply may only be done by a properly trained, certified
electrician.
Make sure to check the electrical equipment of the product on a regular basis. Any loose
connections or damaged cables are to be remedied/replaced immediately.
1.9 Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in
a timely fashion.
All operating media are to be protected/isolated in case the product is accidentally started up.
Disconnect the FCU from the power supply and protect it from being inadvertently switched
back on when performing any maintenance, servicing, inspection or repair work.
Check any screw fittings which have been removed to see that they have been properly
secured.
After performing maintenance and servicing work, always check the safety features of the
product to see that they function properly.
1.10 Modifications to the FCU
Do not make any modifications (design modifications, extensions) to the FCU without the
prior consent of the manufacturer.
Any design modifications or extensions may not be made without
HYDAC Filtertechnik GmbH’s express prior written approval.
Immediately replace any machine components which are not in perfect condition.
Only use original (OEM) spare parts and consumables. 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.
1.11 Cleaning the FCU and disposal of the media and agents used
The cleaning agents and flushing oils used are to be handled and disposed of properly.
The manufacturers' instructions relating to possible use, personal protective equipment and
appropriate disposal must be observed.

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2 Transportation/Package/Storage
2.1 Packing / transportation
Unpack the unit and check it for damage in transit. Report any damage to the forwarding
agent immediately
2.2 Storage
Make sure to store the FCU in a clean, dry place.
If the FCU is to be put into storage for an extended period of time, it should be completely
drained and flushed to prevent it from gumming up.
The cleaning agents and flushing oils used are to be handled and disposed of properly.
2.2.1 Storage conditions
Storage temperature: -40°C - +80°C / -40°F - + 176°F
Relative humidity max. 90% non-condensing
3 Decoding the model code label
For product identification details see the Model code label. The label shows product ID and
major technical application data.

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4 Checking the scope of delivery
The FluidControl Unit FCU comes packed and ready for operation. Before commissioning the
FCU, check the contents of the consignment to make sure everything is present.
The following items are supplied:
Pos. Qty Description
1 1 FluidControl Unit FCU 1000 Series, including attachable bag for cables and
hoses
2 1 24 V DC / 5 A power supply
3 4 Connection cable (Europe, USA/Canada, UK, Australia, Japan)
4 1 INLET suction hose, open end, clear-transparent, L = 0.3 m (11.81 inch)
5 1 INLET high pressure hose with test connector type 1620,
color: clear-transparent, length = 2 m
6 1 High pressure adaptor
7 1 OUTLET return hose, open end, transparent, length = 1 m (39.37 inch)
8 1 Operating and maintenance instructions
9 1 Certificate of calibration
10 1 CD-ROM with FluMoS Software
11 1 Pocket for documents
3
9
9
10
11
1
2
7
4
5
6

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5 Using the FCU
The FCU 1000 is a portable service unit for the temporary measurement of particulate
contamination in hydraulic systems. With the integrated AquaSensor AS 1000, the
measurements can be expanded to include the saturation level of water in hydraulic media in
% and temperature.
The installed pump and hoses included in delivery can be applied to:
• Control circuits
• Pressure circuits
• non-pressurized tanks
Performance Features:
• Particulate contamination detection by use of an optical measurement cell
• Applicable for hydraulic fluids 10 … 350 mm²/s / 16 … 1622 Sus (ISO VG 68)
• Integrated AquaSensor AS 1000 for the measurement of humidity and temperature
• Automatic measurement and display of cleanliness ratings as
 ISO 4406:1987; NAS 1638
 ISO 4406:1999; SAE AS 4059 (D)
• Measurement Accuracy +/- ½ ISO code
• Supply voltage 24 V DC / 4 A
• Operating pressure max. 45 bar / max. 650 psi, operating pressure with pressure
adaptor max. 345 bar / max. 5000 psi
• Integrated pump for the automatic control of oil flow

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5.1 Mode of Function
INLET
Contamination
Sensor
12
2
3
16
17
14
10
1
4
13
OUTLET
Display
Keypad
From the oil source (either a pressure port or a bottle sample), a continuous oil current is
established through the INLET connector by an electrically controlled gear pump (16).
A suction screen (17) protects the pump from coarse contamination.
The oil current to be analyzed flows through an optical sensor (1). The contaminant particles
contained in the oil current cause the light beam to be darkened in a pulse-like manner. An
electronic evaluation module (4) classifies and counts these measurement signals according
to particle diameter.
The evaluation module (4) continuously computes the SAE or ISO cleanliness classes. It
computes for the reference volume of 100° ml based on the measurement signals of the
optical sensor.
A defined pressure is generated in the oil flow via a counter balance valve (10). This serves
to minimize air bubbles in the system, which could skew the measurement results.
The pressure relief valve (14) protects the FCU from overly high pressure.
The oil current leaves the OUTLET connector and must be routed by the return-flow hose to
a non-pressurized tank.
The FCU can be operated via the keypad (12). The readout is shown on the display (13).

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The electronic evaluation module provides for the continuous monitoring of the following:
• the particle sensor function
• the oil flow
• the power supply voltage
When a malfunction occurs, an error message automatically appears in the display and
interrupts the measurement. The evaluation module will recognize when the cause of error
has been corrected, and the unit will reset automatically and resume the measurement
operation.

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5.2 Operation panel
Item Description
1 Display and Keypad For details see chapter 7.1
2 Pump ON / OFF switch Switches the internal pump on / off
3 Power supply connector 24 V DC
4 Data interface (DATA) Connection, 5-pole, M12x1
5 OUTLET port DN7 with quick-action coupling nipple
6 INLET connection, Type 1604 with suction strainer 400µm (see chapter 11)
- Bluetooth interface Located inside the FCU

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5.3 Dimensions
ca. 450
ca. 330
410
230
ca. 430
410
FCU open FCU closed
5.4 Hydraulic schematic
INLET
123
4
6789
5
OUTLET
1 INLET, test connector type 1604 6 ContaminationSensor Unit
2 Suction screen, 400 µm 7 Counter balance valve
3 Gear pump 8 AquaSensor AS 1000
4 Electric motor 9 OUTLET, DN7 Quick coupling nipple
5 Pressure control valve

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6 Preparing the FCU
Before operation, the FCU must first be hydraulically and electrically connected, as described
below.
6.1 Attaching OUTLET quick-action coupling
OUTLET
Place the quick-action coupling on the nipple and push it until it audibly locks in place.
Then check that the quick-action coupling is tightly secured.
6.2 Hydraulic connection of the FCU
A measurement point should be selected according to certain criteria. For more information,
see chapter "Selecting the measurement point" 6.2.3.
Establish the operating pressure at the desired measurement point. Select the appropriate
measurement method according to the pressure at the measurement point.
Pressure at the measurement
site. Measurement method Chapter
0 bar 0 psi Connection at the measurement point - non-
pressurized tank
6.2.4
1 ... 45 bar 14 ... 650 psi Connection at the measurement point up to
max. 45 bar
6.2.1
15 ... 345 bar 217 ... 5000 psi Connection at the measurement point with
45 ... 345 bar
6.2.2
TIP
 The return-line connection (OUTLET) must never be obstructed or closed off!