HYDAC International FCU 1000 Series Manual

FCU 1000 Series
Fluid Control Unit
Operating and Maintenance Instructions
English
Valid from firmware versions V 1.25 up
Doc.: 3278229a

FCU 1000 Series
HYDAC Filtertechnik GmbH en Page 2
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Warenzeichen
Die verwendeten Warenzeichen
anderer Firmen bezeichnen
ausschliesslich die Produkte dieser
Firmen.
Trademarks
The trademarks of other
companies are exclusively used for
the products of those companies.
Marchi di fabbrica
I marchi di fabbrica di altre ditte qui
utilizzati si riferiscono
esclusivamente ai prodotti di
queste ditte.
Copyright © 2004 by
HYDAC Filtertechnik GmbH
all rights reserved
Alle Rechte vorbehalten.
Nachdruck oder Vervielfältigung
dieses Handbuchs, auch in Teilen,
in welcher Form auch immer, ist
ohne ausdrückliche schriftliche
Genehmigung von HYDAC
Filtertechnik nicht erlaubt.
Zuwiderhandlungen verpflichten zu
Schadenersatz.
Copyright © 2004 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.
Copyright © 2004 by
HYDAC Filtertechnik GmbH
all rights reserved
Tutti i diritti riservati. È vietata la
ristampa o riproduzione, anche
parziale, in qualsiasi forma, di
questo manuale senza espressa
autorizzazione scritta di HYDAC
Filtertechnik. Le violazioni
comportano l’obbligo di
risarcimento dei danni.
Haftungsausschluss
Wir haben unser Möglichstes
getan, die Richtigkeit des Inhalts
dieses Dokuments zu
gewährleisten, dennoch können
Fehler nicht ausgeschlossen
werden. Deshalb übernehmen wir
keine Haftung für Fehler und
Mängel in diesem Dokument, auch
nicht für Folgeschäden, die daraus
entstehen können. Die Angaben in
dieser Druckschrift werden
regelmässig überprüft, und
notwendige Korrekturen sind in den
nachfolgenden Auflagen enthalten.
Für Anregungen und
Verbesserungsvorschläge sind wir
dankbar.
Technische Änderungen bleiben
vorbehalten.
Inhaltliche Änderungen dieses
Handbuchs behalten wir uns ohne
Ankündigung vor.
Exclusion of liability
We made ervery endeavour 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
subsequent editions. We welcome
any suggestions for improvements.
All details are subject to technical
modifications.
Esclusione della responsabilità
Abbiamo fatto tutto il nostro
possibile per garantire la
correttezza del contenuto di
questo documento, tuttavia non è
possibile escludere errori. Perciò
decliniamo ogni responsabilità per
errori e carenze in questo
documento ed ugualmente per i
danni indiretti da essi derivanti. Il
contenuto di questo manuale viene
regolarmente controllato e le
correzioni necessarie sono
integrate nelle edizioni seguenti.
Saremo grati di ogni proposta di
miglioramento. Con riserva di
modifiche tecniche.
Ci riserviamo il diritto di apportare
senza preavviso modifiche al
contenuto di questo manuale.
Copyright © by
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar
Germany
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
Copyright © by
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar
Germany
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
Copyright © by
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar
Germany
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
D
GB
I

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Contents
Foreword .................................................................................................................................5
Customer Service ................................................................................................................6
Modifications to the Product ................................................................................................6
Warranty ..............................................................................................................................6
1. General Safety Precautions .......................................................................................8
1.1. Obligations and Liability .............................................................................................8
1.2. Explanation of Symbols and Warnings, etc................................................................8
1.2.1. Basic Symbols...................................................................................................8
1.3. Proper/Designated Use ..............................................................................................9
1.4. Improper Use..............................................................................................................9
1.5. Safety Devices ...........................................................................................................9
1.6. Informal Safety Precautions .......................................................................................9
1.7. Instructions to Be Followed in the Event of an Emergency ......................................10
1.8. Safety Measures to Be Followed in Normal Operation.............................................10
1.9. Electrical Hazards ....................................................................................................10
1.10. Maintenance, Servicing and Troubleshooting ..........................................................10
1.11. Modifications to the FCU ..........................................................................................11
1.12. Cleaning the FCU and Disposal of the Media and Agents Used..............................11
2. Transportation, Packing, Storage ...........................................................................12
2.1. Transportation & Packing .........................................................................................12
2.2. Storage.....................................................................................................................12
2.2.1. Storage conditions ..........................................................................................12
3. Model code / Product identification ........................................................................12
4. Scope of Delivery...................................................................................................... 13
5. Description of the FCU.............................................................................................14
5.1. Product Description ..................................................................................................14
5.2. Performance Features..............................................................................................14
5.7. Functional Description..............................................................................................15
5.8. Restrictions Pertaining to the Use of the FCU..........................................................16
5.9. Operation elements ..................................................................................................17
5.9.1. Display rotatable/adjustable as needed ..........................................................17
5.10. Dimensions...............................................................................................................18
5.11. Hydraulic Diagram....................................................................................................18
6. Installation & Commissioning .................................................................................19
6.1. Unpacking ................................................................................................................19
6.2. Hydraulic Installation ................................................................................................19

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6.2.1. General selection guidelines for Measurement Points....................................19
6.2.2. Performing Measurements on pressurized test points....................................20
6.2.3. Performing Measurements on Sample Bottles................................................22
6.3. Electrical Installation.................................................................................................23
6.4. Commissioning.........................................................................................................23
7. Description of the Measuring Modes...................................................................... 24
7.1. Mode M1: Measure continuously .............................................................................24
7.2. Modes M2, M3, M4, M5 - not applicable for FCU1000.............................................24
8. Operation...................................................................................................................24
8.1. Display and Keypad Elements .................................................................................24
8.2. Modes and Menus....................................................................................................25
8.2.1. Power Up Menu ..............................................................................................25
8.2.2. Measuring Menu .............................................................................................27
9. Status LED / Error codes .........................................................................................28
10. Factory default settings / Basic settings................................................................29
10.1. Power Up menu........................................................................................................29
10.2. Measuring menu.......................................................................................................29
11. Removing the FCU from the Hydraulic System .....................................................29
12. Maintenance .............................................................................................................. 29
12.1. Cleaning the Suction Strainer...................................................................................30
12.2. Disposal / Recycling and Decommissioning.............................................................30
13. Spare Parts................................................................................................................31
14. Accessories............................................................................................................... 31
15. Technical data........................................................................................................... 31
16. ISO 4406 and SAE AS 4059 Classes .......................................................................33
16.1. ISO 4406:1999 .........................................................................................................33
16.2. ISO 4406 table .........................................................................................................33
16.3. SAE AS 4059 ...........................................................................................................34
16.3.1. SAE AS 4059 table: ........................................................................................34
17. Explanation of Terms Used in Measurement Systems ......................................... 35
18. Recalibration / Service .............................................................................................35
18.1. Shipping Address for Recalibration and Repair Work ..............................................35

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Foreword
This manual is compiled for you, the user of our product. It contains key information
relating to 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.
In these cases we go to every effort to keep your documentation current by sending
you updates.
But we need your help. Please make sure that you incorporate the updates in your
documentation and that non-current sections are removed.
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
Dept.: SVFI, Technical Documentation
P. O. Box 1251
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
The editor would welcome any contributions you might have.
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 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 Conditions of Sale and
Delivery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com ÖE-Business ÖLegal information.

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And now for a few tips on using this documentation.
The following example shows you how you can access the information you are looking
for quick and easy.
WHAT do I want to know?
WHERE can I find the information I’m looking for?
The documentation is subdivided into chapters and sections.
1. Look for the table of contents.
2. Skim the boldfaced section headings.
HOW can I find the section and page I’m looking for?
Page through the operating instructions, keeping your eyes focussed on the lower right
corner.
As soon as you see the page number you are looking for, stop paging.
The product Description is featured in the upper right corner of each
page.
The documentation number/edition and index are featured in the lower left corner of
each page and on the cover sheet of the instructions.
This information features the following format:
The documentation no. is a part no. which is used to order the instructions.
The edition no. is a consecutive number reflecting product modifications.
The index is increased every time the instructions are revised or changed.
Please note that the method described above of locating specific
information does not release you from 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.
Product Description
Page no.
Edition date of
cha
p
ter/section
Documentation no. Edition no. Index
-
BeWa Product 12345678-01a en

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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 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 product 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
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
This symbol designates safety instructions whose non-observance may
pose a hazard to individuals.
This symbol designates safety instructions whose non-observance may
result in the injury of individuals by electric shock.

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This symbol provides important instructions and tips for the proper
handling and operation of the FCU.
Non-adherence to these instructions may result in damage to the FCU or
in damage to its immediate surroundings.
This symbol designates tips for usage and other particularly useful
information.
This information helps you to optimally utilize all the features offered by
your FCU.
1.3. Proper/Designated Use
The Contamination Sensor (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:
•Maintaining adherence to all the instructions contained herein.
•Performing requisite inspection and maintenance work.
1.4. 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 FluidControl Unit pressure and return flow hoses.
1.5. Safety Devices
•Prior to starting up the product each time, make sure that all the safety devices are
properly fitted to the hydraulic system in which the product is to be used and are in
proper working order.
•Safety devices may not be removed until the product has been shut down and
secured against being restarted (e.g. warning sign or padlock on the main switch).
•When the product is supplied in partial consignments, the safety devices are to be
applied by the operator as specified by law/pertinent regulations.
1.6. Informal Safety Precautions
•Make sure to always keep the operating instructions in the vicinity of the product.
•Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance to be maintained to them.
•Make sure to keep the safety and hazard symbols and warnings on the product in a
legible condition.

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•The power plug/cord of the product is to always be pulled before opening any
components of the product. 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 electric 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 are to be replaced
immediately.
Warning: Pressurized fluids pose a hazard to life and limb.
Consequently, the safety regulations pertaining to working with
pressurized liquids are to be adhered to at all time!
1.7. Instructions to Be Followed in the Event of an 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.
1.8. Safety Measures to Be Followed in Normal Operation
•Do not operate the FCU 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.
1.9. Electrical Hazards
•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.
•If work to live components is required, a second individual is required who can switch off
the product at the main switch as may prove necessary.
1.10. Maintenance, Servicing and Troubleshooting
•The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
•All operating media is to be protected/isolated for the event that the product is
accidentally started up.
•The FCU is to be disconnected from the power supply and protected against being
inadvertently switched back on when performing any maintenance, servicing, inspection
or repair work.
•Any screwed fittings which have been undone/removed are to be checked to see that
they have been properly resecured.
•Always check the product to see that it functions properly when performing maintenance
and servicing work.

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1.11. 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.
1.12. 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.
•To this end, the manufacturer’s instructions pertaining to possible use, wearing of
protective clothing and gear, and proper disposal are to be adhered to.
Some cleaning agents may pose a health hazard, especially when
undiluted.

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2. Transportation, Packing, Storage
2.1. Transportation & Packing
•The FCU comes wrapped/packed in a cardboard box.
•When receiving and unpacking the unit 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, in the original packing, if possible. Do
not remove the packing until you are ready to install the unit.
•If the FCU is to be put into storage for an extended period of time, it should be completely
drained (if necessary, it should be flushed, using n-heptane) so as to prevent it from
gumming up.
•Any 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. Model code / Product identification
For product identification details see the Model code label. This is located on the rear side.
The labe shows product ID and major technical application data.

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4. Scope of Delivery
The FluidControl Unit FCU comes packed and ready for operation.
Before commissioning the FCU, check the contents of the package to make sure everything
is present.
The FCU comes with the following:
Pos. Qty. Description
1 1 FluidControl Unit FCU 1xxx series
2 1 24V DC power supply cable, L = 10 m
3 1 INLET pressure hose with screw connection 1620, black, L = 2 m
4 1 INLET suction hose open end, clear, L = 1 m
5 1 OUTLET Return hose open end, clear, L = 2 m
- 1 Operating and Maintenance Instructions for FCU 1xxx series
- 1 Calibration certificate

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5. Description of the FCU
5.1. Product Description
The FluidControl Unit FCU 1000 is a cost effective portable solid contamination monitor.
It is designed as a service tool to monitor hydraulic and lubrication oil cleanliness.
The FCU 1000 can be either
•connected directly to a hydraulic system or machine for continuous monitoring
•used to test a bottle sample
•used to test bulk oil of a barrel or a machine reservoir.
The FCU 1000 is designed on the basis of the HYDAC CS1000 ContaminationSensor.
It can be connected to low- or medium-pressure hydraulic and lubrication lines from which a
small flow of oil is diverted for measurement purposes.
The FCU 1000 possesses one hydraulic INLET connector only for easy use.
It can be connected to a hydraulic line through a high pressure hose, or to a reservoir or a
bottle sample through a suction hose.
The integrated pump can be used also to perform measurements on non-pressurized
reservoirs.
The OUTLET connector is routed to a non-pressurized reservoir.
The FCU 1000 is specifically designed for service purposes on mobile hydraulic vehicles and
can be electrically supplied by the 24VDC board voltage of standard vehicle outlets.
5.2. Performance Features
•Particulate contamination detection by use of an optical measurement cell
•Rugged HYDAC CS1000 ContaminationSensor technology
•Automatic measurement and display of cleanliness ratings as
¾ISO Code (4406:1999) or
¾SAE Code AS4059 (D).
Cleanliness classes: >4 µm( c) >6 µm( c) >14 µm( c)>21 µm( c).
•Compatible to standard 24VDC vehicle electrical board outlets
•Compatible with hydraulic system control pressures (max. 30 bar or 435 psi)
•Bottle sample test capability
•Integrated pump for automatic control of measurement oil flow
(between 30 ml/min and 300 ml/min, depending on viscosity)
•Viscosity range 10 ... 350 mm²/s / 46 ... 1622 Sus
•INLET pressure range 0 - 30 bar / 0 - 435 psi

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5.7. Functional Description
From the oil source (either a pressure port or a reservoir or a bottle sample) a continuous oil
current is established through the INLET connector by an electrically controlled gear pump.
A suction strainer protects the pump from excessive contamination.
The oil current to be analyzed flows through an optical sensor (1), the sensor consisting of an
infrared semiconductor LED (2) and a receiver diode (3) opposite of it. The contaminant
particles contained in the oil current cause the light beam to be darkened in a pulse-like
manner, this being classified and counted as measurement signals according particle
diameter by an electronic evaluation module (4).
The evaluation module (4) continuously computes the SAE or ISO cleanliness classes for the
reference volume of 100 ml on the basis of the measurement signals of the optical sensor.
The pressure relief valve (10) pressurizes the oil current for better countability
air bubble compression etc.)
The oil current leaves the unit through the OUTLET connector and is routed to a non-
pressurized reservoir.
The FCU can be operated via the keypad (12). Measurement parameters can be modified
and various items selected on the LED display (13).
Unless a different setup is entered, the following is continuously shown during measurement
by default:

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•Instantaneous ISO cleanliness Code according to ISO 4406:1999 (default setting)
•Error messages (only in the event of a fault or malfunction)
The electronic evaluation module provides for continuous monitoring of the following:
•Particle sensor
•Oil current
•Supply voltage
When a fault or malfunction occurs, an error message automatically appears in the display
and measurement is interrupted.
As soon as the error is remedied, this is recognized by the evaluation module, which resets
the error message completely automatically.
This ensures that, in the event that malfunction occurs during continuous online operation,
e.g. as the result of a power outage or flow errors as the result of pressure loss, etc.,
measurement operation is resumed without any operating personal being required after the
fault has been remedied.
5.8. Restrictions Pertaining to the Use of the FCU
The FCU 1xxx-4 series may only be used with:
Mineral oils (or mineral oil-based raffinates).
For synthetic esters or HEES fluids a special model is available.
Please contact us first before using the unit with other fluids.

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5.9. Operation elements
Pump
ON/OFF
switch
Hose transportation box
INLET
port OUTLET
port
Power suppl
y
connector
ContaminationSensor
INLET OUTLET
24 V DC
5.9.1. Display rotatable/adjustable as needed
The display of the FCU1000 can be rotated through 180°
in a counterclockwise direction and through 90° in a
clockwise direction.
To rotate the display, grasp the cover plate with your hand.
No tools may be used for rotating the display, in other
words do not use excessive force to rotate it.

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5.10. Dimensions
5.11. Hydraulic Diagram
1Testpoint connector 4Gear pump
2Suction strainer, 400 µm 5Contamination Sensor CS1000
3Electric motor 6Pressure relief valve

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6. Installation & Commissioning
For operation, the FCU must be hydraulically and electrically installed.
6.1. Unpacking
The FCU comes packed in a cardboard box.
Unpack the unit and check it for damage in transit. Report any damage to the forwarding
agent immediately. Check for scope of delivery.
6.2. Hydraulic Installation
Determine the system pressure of the hydraulic system and see whether it is within the
permissible range for the INLET port.
The pressure at the INLET port may not exceed 30 bar / 435 psi
6.2.1. General selection guidelines for Measurement Points
•The measurement point has to be selected so that the measured volume is taken from a
turbulent flow area, i.e. a pipe bend. This ensures that a representative sample is
measured.
•The FCU has to be installed in the near of the measurement point in order to prevent
sedimentation (formation of particle deposits) in the inlet hose line and achieve short
timed results prevent time delayed results.
Mainflow
Mainflow
to FCU Mainflow Mainflow
to FCU
WRONG OK
Always install the measurement point in a turbulent flow area, i.e. in a pipe bend.
While installing the INLET hose, make sure that no "siphon trap" is created.
WRONG OK

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6.2.2. Performing Measurements on pressurized test points
INLET pressure hose
Color: black
OUTLET Return line hose
Color: clear
INLET
OUTLET
Caution: Pressurized fluids pose a hazard to life and limb. Consequently, the
safety regulations pertaining to working with pressurized liquids are to be
adhered to at all time!
Caution: Make sure to follow the sequence specified here.
1. Connect the open end of the return to the system tank, for example.
2. Now connect the return line hose to the OUTLET port of the FCU.
3. Check the pressure at the measurement point; it has to be within the specified limits.
The pressure at the measurement may not exceed 30 bar / 435 psi.
4. First connect the measurement line to the INLET port of the FCU.
5. Now connect the other end of the measurement line to the measurement point.