HYDAC International FCU 2110-5 Manual

FluidControl Unit
FCU 2110 - 5
FCU 2210 - 5
Operating and Maintenance Instructions
Ed. 1.1/12.2000

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 2 of 52
I.I General Remarks
Trademarks
The trademarks used herein of other companies exclusively designate the products of these
companies.
Copyright © 1997 by HYDAC Filtertechnik GmbH. All rights reserved
Every effort has been taken to ensure that the information provided herein is correct, however errors
cannot be precluded. The information contained herein does not represent a commitment on the part
of the authors. Consequently no liability is assumed for any errors or deficiencies inherent in this
document, including consequential damage or loss. The information provided herein is checked on a
regular basis, with corrections being entered in subsequent editions. Any remarks or suggestions for
improvement you might have would be appreciated.
Liability
Every effort has been taken to ensure that the information provided herein is correct, however errors
cannot be precluded. Consequently no liability is assumed for any errors or deficiencies inherent in
this document, including consequential damage or loss. The information provided herein is checked
on a regular basis, with corrections being entered in subsequent editions. We would appreciate any
remarks or suggestions for improvement you might have. Subject to technical modifications without
notice.
The contents of this manual is subject to change without notice.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 3 of 52
Copyright © 1999 by
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar
Germany
Voice: +49 - 681/509 - 01
Fax: +49 - 681/509 - 846
Printed in Germany

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 4 of 52
I.II Contents
1 Explanation of Symbols and Warnings, etc................................................................................6
2 General Safety Precautions and Remarks.................................................................................7
3 SCOPE OF DELIVERY............................................................................................................10
4 Restrictions Pertaining the Use of the FCU .............................................................................11
5 Technical Description...............................................................................................................11
5.1 Performance Features..........................................................................................................11
5.2 Design Features...................................................................................................................11
5.3 Hydraulic Diagram................................................................................................................12
5.4 Principle of Operation...........................................................................................................13
5.5 Description of the Display and Control Elements.................................................................16
5.5.1 Front View.....................................................................................................................16
5.5.2 Rear View......................................................................................................................17
5.5.3 Function of Keys............................................................................................................18
5.6 Connector Pin Assignments.................................................................................................20
5.6.1 PC Connector: (Subminiature D, 15-pin, male).............................................................20
5.6.2 Control Connector (Relays) (Subminiature D, 15-pin, female)......................................20
5.6.3 Relay Functions.............................................................................................................21
5.6.4 Programmable Relay- Limits.........................................................................................23
5.6.5 Supply Voltage Plug:.....................................................................................................22
6 Installation and Operation of the FCU......................................................................................24
6.1 Electrical Installation.............................................................................................................24
6.2 Hydraulic Installation and Commissioning............................................................................25
6.2.1 Measurements with Suction INLET...............................................................................25
6.2.2 Measurements with High Pressure Inlet, (max. 350 bar)..............................................27
6.3 The Display of the FCU........................................................................................................28
7 Using the FCU..........................................................................................................................29
7.1 Measurement Operation.......................................................................................................29
7.1.1 M1: “Measure” Function ................................................................................................29
7.1.2 M2: "Measure + Switch" Function .................................................................................29
7.1.3 M3: "Filter to" Function (performing automatic cleaning/flushing).................................34
7.1.4 M4: "Filter from to" Function (performing automatic cleaning/flushing).........................35
7.1.5 M5: "Measure+autostop" Function................................................................................36
7.2 Using the MEMORY Functions.............................................................................................38
7.2.1 Entering the Measurement Point and Initiating Measurement without Averaging.........38

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 5 of 52
7.2.2 Entering the Measurement Point and Initiating Measurement with Averaging..............39
7.2.3 Deleting Data from Memory ..........................................................................................39
7.3 Printing .................................................................................................................................41
7.3.1 Printing Online Logs (only when measurement is in progress).....................................41
7.3.2 Printing Logs Stored in Memory....................................................................................42
7.4 SETUP Menu........................................................................................................................43
7.5 "POWER UP" Menu .............................................................................................................44
8 Error Messages and Troubleshooting......................................................................................44
9 Maintenance and Servicing of the FCU ...................................................................................48
9.1 Filter Element Exchange: .....................................................................................................48
9.2 Changing the ink ribbon cartridge.........................................................................................48
9.3 Inserting a new paper roll.....................................................................................................49
10 Recalibration............................................................................................................................49
11 Spare Parts..............................................................................................................................50
12 FCU, Accessories ....................................................................................................................50
13 Decommissioning and Final Disposal......................................................................................50
14 Explanation of Terms Used in Measurement and Instrumentation Systems ...........................51
15 Technical Data and Specifications...........................................................................................51

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 6 of 52
1 Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate hazards, etc.:
This symbol designates safety instructions whose non-
observance may result in injury to individuals.
This symbol designates safety instructions whose non-
observance may result in the injury of individuals by high
voltages.
This symbol provides important instructions and tips for the
proper handling and operation of the FCU.
Non-observance of these instructions may result in damage
to the FCU or to damage to the surrounding systems or
equipment and the environment.
This symbol designates tips for usage and other particularly
useful information. It helps you to optimally utilize all the
features offered by your FCU.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 7 of 52
2 General Safety Precautions and Remarks
Observe and follow the instructions contained herein
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 contain the most
important instructions for properly and safely operating the FCU.
The safety precautions contained herein are to be followed by any and all persons operating
the FCU. In addition, local accident prevention regulations are to be adhered to as well.
Hazards Posed by 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 operating the unit or to third parties.
In addition, the FCU may incur damage, e.g. in transit or as the result of improper handling.
In any event it has to be ensured that the FCU is not operated unless it is in perfect working
order from the point of view of safety. Any faults or malfunctions, e.g. loose screwed
connections or exposed wires or cables which might impair safety are to be properly attended
to immediately.
Safety Devices
Prior to starting up the FCU each time, make sure that all the safety
devices are properly installed in the hydraulic facility to be monitored
and are in proper working order.
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the FCU.
Apart from the operating instructions, any and all generally applicable 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 FCU in a readable
condition.
Hazards Posed by Electrical Power
Any work involving the power supply may only be performed by a
properly trained, certified electrician.
Make sure to check the electrical equipment of the FCU on a regular
basis. Replace any loose connections or damaged cables immediately.
If work to live components is required, make sure to disconnect the
unit from the power supply first.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 8 of 52
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion. Operating personnel is to be informed prior to performing
any maintenance and servicing work.
INSTRUCTIONS TO BE FOLLOWED IN THE EVENT OF AN EMERGENCY
In the event of an emergency, immediately disconnect the FCU
from the power supply!
Modifications to the FCU
Do not make any modifications (including retrofitting, extensions) to the FCU without the prior
approval of the manufacturer.
No modifications or extensions may be made without HYDAC Filtertechnik GmbH’s express
prior written approval.
Immediately replace any unit components which are not in perfect condition.
Only use original replacement 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.
Please also refer to 9 Maintenance and Servicing of the FCU for information on maintenance
and servicing of the FCU.
Cleaning the FCU and Disposal of the Media and Agents Used
Some cleaning agents may pose a health hazard, especially when
undiluted.
Properly use and dispose of the cleaning agents and flushing oil used.
In so doing, make sure to follow the manufacturer’s instructions:
• with regard to wearing protective clothing and gear
• concerning proper disposal

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 9 of 52
Summary of the General Safety Precautions
• Maintenance work may only be performed by properly trained personnel using the right
tools for the job.
• No maintenance or servicing work may be done on the FCU unless it has been shut down
and disconnected from the power supply and the hydraulic facility.
• When connecting the FCU to the power supply system (including when using the unit in
connection with a filter pump unit), adherence is to be maintained to local power company
safety regulations and provisions.
• The operator/owner is to ensure adherence to the National Water Resources Act as well as
local water resource laws and other related regulations.
• Adherence is to be maintained to statutory accident prevention regulations, safety
regulations and safety data sheets for fluids.
• When working directly on or in the vicinity of hydraulic systems, there is to be no smoking
or open flames/fire, with every effort being taken to prevent the generation of sparks.
• Collecting basins, suction/extraction equipment and binding agents are to be made
available.
• Hydraulic media and water-polluting fluids must not be allowed to soak into the soil, seep
into bodies of water or the sewage system. Ensure that hydraulic media are disposed of in
an environmentally safe manner. Adherence is to be maintained to pertinent national and
local regulations pertaining to groundwater protection and the disposal of waste/spent oil
and (hazardous) waste.
• Work on hydraulic systems may involve leaking hot oil which may cause injury and scalding
as result of its high pressure and/or temperature.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 10 of 52
3 SCOPE OF DELIVERY
The FCU fluid control unit comes packed and factory-assembled. Before commissioning it,
please check the contents of the package to make sure everything is present.
The scope of delivery extends to the following:
Pos. Pieces Designation
1 1 FluidControl Unit FCU 2110-5 or FCU 2210-5
2 2 Line Adapter
3 1 High pressure hose ID 4,
with Minimess connector 1604 – 1620,
2000 mm long
4 1 Suction hose ID 5,with CPC quick disconnect,
1000 mm long
5 1 Suction hose ID 5,with CPC quick disconnect,
~200 mm long
6 1 Return hose ID 7,with quick disconnect,
2000 mm long
7 1 Operating and Maintenance Instructions
8 1 Calibration Certificate
621
7
3
4
5
Figure 1: Scope of delivery

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 11 of 52
4 Restrictions Pertaining the Use of the FCU
It is recommended that the FCU only is used in connection with mineral oils (or
mineral-oil-based raffinates). Please contact us first before using the FCU with
other operating media.
5 Technical Description
5.1 Performance Features
• The FCU Fluid Control Unit is used to continuously monitor the solid particle loading of
mineral oils.
• The FCU enables the purity ratings according to NAS 1638 (only for FCU 2110-5) or ISO-
4406 to be recorded, saved and displayed fully automatically during continuous operation.
• The measured values can be outputted in the form of a table or a graphic online via an
integrated printer or transmitted to a PC via a serial interface (standard RS232,
optional : RS485).
• Control of filter pump units is enabled via relay outputs.
• The FCU can be connected directly to pressure lines or, with the integrated pump, the FCU
is able to measure oil cleanliness of reservoirs.
• The FCU has rechargeable batteries for mains-independent operation for measurements
on high pressure lines (not with the prototype, will be with the series products). For
operation with the integrated pump, an external line adaptor or a 24VDC supply is
necessary.
5.2 Design Features
The FCU features a keyboard, a liquid crystal display (LCD), a dot-matrix printer, control relay
outputs and a serial RS 232 interface. The unit possesses a high pressure Minimess connector
input (system 1604) enabling connection to the hydraulic system, a quick disconnect suction
inlet for connection to reservoirs and a quick disconnect coupling as a return flow output.
A flow control valve enables to adjust the measurement current flow. The flow control valve is
protected against contamination by a hydraulic filter. The housing features 19” subrack
modules and a carrying handle.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 12 of 52
5.3 Hydraulic Diagram
FCU 2110-5
FCU 2210-5
Reservoir or system return line
Particle sensor
Pressure line 1 - 350 bar / 5000 psi
Pulsation attenuator
Fixed
flow
control
valve
Flow counter
A
djuatable
Flow control valve
Protective filter
Minimess hose
Pressure
relief valve
Max. 3 bar / 44 psi
Suction hose
Suction pump
Shut-off valve
Ball-valve
Reservoir

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 13 of 52
5.4 Principle of Operation
Pressure
inlet
Outlet 1
2
3
4
5
6
78
9
11
10
Display
Keypad
Printer
Evaluation
module
13
RS232
interface
12
14 15
Suction inlet
18
17
16
Relays
A continuous oil current 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 dampen the light beam in a pulse-like manner, this being classified and counted as
measurement signals according particle diameter by an evaluation module (4).
The measurement of the flow rate required to determine the purity rating is performed by an integrated
flow rate meter (5), whose signals are also routed to the electronic evaluation module (4).

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 14 of 52
The electronic evaluation module (4) continuously measures the particle counts, computes the NAS
(only for FCU 2110-5) or ISO purity ratings for the prescribed reference volume of 100ml on the basis
of the measurement signals of the optical sensor and the flow rate meter.
The measurement results (up to 3,000) are continuously stored in the evaluation module along with
the date and time in a manner providing for protection in the event of a power outage. This is ensured
by a battery-buffered real-time clock and memory
A flow control valve (7) is featured for adjusting the oil current independently of the line pressure and
pressure fluctuations.
A hydraulic filter (8) featuring an electric clogging indicator is integrated upstream of the flow control
valve to protect it against outage as the result of contaminant particle buildup.
A ball valve (18) allows to switch between the suction inlet and the pressure inlet.
The permanently set valves (9) (800 ml/min max) and (10) (30 bar max.) and the diaphragm
accumulator (15) enable connection to sampling points for a pressure range of 1 - 350 bar at the
pressure inlet. The shut-off valve (17) only opens when a measurement is ongoing.
The pump (16) allows to measure from non-pressurized reservoirs via the suction inlet.
The FCU can be operated via the keypad (12). Measurement parameters can be modified and various
items selected in the LCD (6).
Unless a different setup is entered, the following is continuously shown during measurement by
default:
• Current flow rate
• Current ISO rating classification
• Tendency reading of ISO rating classification (↑=rising level, ↓= falling level)
• Error messages, only in the event of a fault or malfunction (see chapter Error Messages)
In addition, the FCU features 3 integrated relays providing for the following functions:
Relays 1 and 2 Limit contacts (normally open contacts)
For example, a filter pump unit can be controlled using relays 1 and 2.
Relay 3 DEVICE READY signal (normally closed contact)
Relay 3 is used for unit self-monitoring.
The integrated microprocessor provides for continuous monitoring of the following:
•particle sensor
•filter clogging indicator

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 15 of 52
•flow rate meter
•supply voltage
•internal evaluation module
Relay 3 (normally closed contact) thus functions as a DEVICE READY contact:
During normal (fault-free) operation, these contacts are always closed,
meaning they only open when a fault is detected.
When a fault or malfunction occurs, an error message automatically appears in the display and
data recording/saving is interrupted.
As soon as the error is remedied, this is recognized by the microprocessor, which resets the
error message completely automatically, thus causing the contacts of relay 3 to close and
measurement and data saving to be resumed.
This ensures that, in the event malfunction occurs during continuous online operation, e.g. as
the result of a power outage, 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.
All the measured values taken and recorded can be outputted via the RS232 interface (11) ,
e.g. using a PC.
The integrated printer (14) is used to document the measurements in the form of a table or
graphic.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 16 of 52
5.5 Description of the Display and Control Elements
5.5.1 Front View
mode memory
limits
ISO NAS
setup
print
LC Display
Keypad
Flow control valve
Flow Control
Partikel
Figure 2 : Front View

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 17 of 52
5.5.2 Rear View
Suction Inlet
Pump Power Switch
Outlet
Pressure Inlet
On/Off Switch
Power Input 24 V DC
PC Interface
Control Connector
Filter Element Cover
Case Ground Connector
Ball Valve (High Pressure Position)
Ball Valve (Suction Position)
Power Input 24 V DC
Figure 3 : Rear View

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 18 of 52
5.5.3 Function of Keys
5.5.3.1 Control keys (gray)
ok
start
stop
Confirm entries,
Start measurement
Cancel entries,
Stop measurement
Scroll through menus
+
-
Raise/lower
(in input mode)
number/letter
Toggle particle counts
display (C or D)
Scroll through
particle size channels
during measurement
5.5.3.2 Menu and number keys (red)
mode
memory
print
limits
setup
ISO
NAS
select measuring mode
(with/without relay control)
edit log memory
(name of measuring point,
print-out
edit limit switches for control of
universal control signals
edit setup
(autostart, date / time etc.)
display results in ISO-Code
display - illumination on
averaging period, deletion etc.)
(Online, stored logs etc.)
filter pump units or as (this key only acts during
a running measurement)
display results as particle counts
(this key only acts during
a running measurement)
Particle
(this key only acts during
a running measurement)
display results in NAS-Code
1 x auto off after 30 s
2 x permanently on
1 x to switch off
0
123
456
789 For directly entering
(in input mode only)
multi-digit numbers

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 19 of 52
5.5.3.3 Special key combinations
To edit the measuring point:
ok
start +
Press keys ok/start and scroll right simultaneously :Insert character when editing
measurement point in memory menu
ok
start +
Press keys ok/start and scroll left simultaneously :Delete character when editing
measurement point in memory menu
To enter the power up menu:
+Press keys scroll right and scroll left simultaneously.
To lock keypad:
ok
start
+
Press keys illumination on and ok/start simultaneously: key lock on / off
To switch LCD illumination permanently on:
2 x
During operation: Press key illumination on twice: illumination remains switched on until
switched off again by pressing the illumination on key once.

Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5 Edition 1.10
HYDAC Filtertechnik GmbH Page 20 of 52
5.6 Connector Pin Assignments
On the rear of the FCU are various electrical connectors whose function and pin
assignments are described in this section
5.6.1 PC Connector: (Subminiature D, 15-pin, male)
Pin Signal function
1 Shield
2 TXD transmit line
4 RXD receive line
8 GND ground
5.6.2 Control Connector (Relays) (Subminiature D, 15-pin, female)
Relay 1 6 7
8 common
normally closed
11
12
13
14
15
User-programmable
normally openRelay 2
User-programmable
Device ready
Relay 3
normally closed
normally open
common
normally open
common
Maximum load : 2A (max. 24 VDC / 50 V AC, max. 30W / 50 VA)
Pin 1 : 24V Supply Voltage, max. 200 mA
Pin 4 : Ground