HYDAC International FMMHP Manual

FMMHP
FluidMonitoring Module
High Pressure
Operating and maintenance instructions
English (translation of original instructions)
Document No.: 3386918a

FluidMonitoring Module High
Pressure
Trademarks
HYDAC Filter Systems GmbH en Page 2 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2009 by
HYDAC Filter Systems GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
explicit written agreement from HYDAC Filter Systems. 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, no liability is assumed for any
errors or deficiencies inherent in this document, including consequential damage or
loss. 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.
Technical specifications are subject to change without notice.
HYDAC Filter Systems GmbH
Industriegebiet, Werk 6
66280 Sulzbach / Saar
Germany
Telephone: ++49 (0)681 509 - 01
Telefax: ++49 (0)681 509 - 846
E-Mail: [email protected]

FluidMonitoring Module High
Pressure
Contents
HYDAC Filter Systems GmbH en Page 3 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Contents
Trademarks ............................................................................................................................. 2
Contents..................................................................................................................................3
Preface ....................................................................................................................................5
Customer Service .................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty ...............................................................................................................................6
Using the documentation ...................................................................................................... 7
General Safety Precautions...................................................................................................8
Obligations and Liability........................................................................................................8
Explanation of Symbols and Warnings, etc. .........................................................................8
Basic Symbols...................................................................................................................9
Proper/Designated Use ........................................................................................................9
Improper Use ........................................................................................................................9
Informal Safety Precautions................................................................................................ 10
Training and Instruction of Personnel.................................................................................11
Safety Measures to Be Followed during Normal Operation................................................11
Maintenance, Servicing and Troubleshooting..................................................................... 11
Modifications to the FMMHP............................................................................................... 12
Storage ..................................................................................................................................12
Checking the scope of delivery ..........................................................................................13
FMM Features .......................................................................................................................14
Instructions for use .............................................................................................................14
Continuously rotatable display............................................................................................14
Hydraulic schematic ............................................................................................................15
Dimensions ...........................................................................................................................15
FMMHP components............................................................................................................ 16
Attaching FMMHP mechanically .........................................................................................17
FMMHP hydraulic installation ............................................................................................. 18
Connecting FMMHP with the hydraulic system ................................................................19
Error messages / Troubleshooting..................................................................................... 20
Performing maintenance ..................................................................................................... 20
Maintenance interval...........................................................................................................20
Changing the Filter Element ...............................................................................................21

FluidMonitoring Module High
Pressure
Contents
HYDAC Filter Systems GmbH en Page 4 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Taking the FMMHP out of operation................................................................................... 22
Disposing of the FMMHP .....................................................................................................22
Spare parts and accessories...............................................................................................23
Technical Data ......................................................................................................................24
Customer Service.................................................................................................................24

FluidMonitoring Module High
Pressure
Preface
HYDAC Filter Systems GmbH en Page 5 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
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 Filter Systems GmbH
Abteilung: Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
Telephone: ++49 (0)681 509 - 01
Telefax: ++49 (0)681 509 - 846
E-Mail: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”

FluidMonitoring Module High
Pressure
Preface
HYDAC Filter Systems GmbH en Page 6 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
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:
Telefax: ++49 (0)681 509 - 846
E-Mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC Filter Systems GmbH.
They are available at: www.hydac.com ÖGeneral Terms and Conditions.

FluidMonitoring Module High
Pressure
Preface
HYDAC Filter Systems GmbH en Page 7 / 28
Using the documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
WHAT do you want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Chapter description
Page numb
Edition date
Document language
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented by one number
every time the manual is revised or changed.
Documentation No.
with Index
/
File name
er

FluidMonitoring Module High
Pressure
General Safety Precautions
HYDAC Filter Systems GmbH en Page 8 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
General Safety Precautions
These operating instructions contain the key instructions for properly and safely
operating the FMMHP.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the
FMMHP is knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the FMMHP.
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 FMMHP.
The FMMHP has been designed and constructed in accordance with the current
state of the art and recognized safety regulations. Nevertheless, hazard may be
posed to the life and limb of the individual using the product or to third parties.
The FMMHP 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 provided to the owner upon
conclusion of purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
• Improper use of the FMMHP or use deviating from its intended use
• Improper assembly/installation, start up, operation and maintenance of the
FMMHP
• Modifications to the FMMHP made by the user or purchaser
• Improper monitoring of unit components that are subject to wear and tear
• Improperly performed repair work
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:

FluidMonitoring Module High
Pressure
General Safety Precautions
HYDAC Filter Systems GmbH en Page 9 / 28
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 mortal injury
if safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The FluidMonitoring Module High Pressure FMMHP was developed for the
continuous monitoring of particulate contamination and water content 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's
designated use.
Proper or designated use of the product extends to the following:
• Maintaining adherence to all the instructions contained herein.
• Performing requisite inspection and maintenance work.
Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
• Improper connection of the pressure and return lines of the FMMHP.
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08

FluidMonitoring Module High
Pressure
General Safety Precautions
HYDAC Filter Systems GmbH en Page 10 / 28
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 them is to be maintained.
Make sure to keep the safety and hazard symbols and warnings on the FMMHP in a
legible condition.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FMMHP are to also be regularly checked (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

FluidMonitoring Module High
Pressure
General Safety Precautions
HYDAC Filter Systems GmbH en Page 11 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Training and Instruction of Personnel
The FMMHP may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the FMMHP unless supervised by an
experienced staff member.
Individuals Individuals who have received instruction
I
n
di
v
id
ua
l
s w
it
h
technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning / storage X X X X
Safety Measures to Be Followed during Normal Operation
Do not operate the FMMHP unless all the safety devices function properly.
The product is to be checked once a day for external damage and the proper
functioning of the safety devices.
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
Disconnect the FMMHP from the power supply and protect the entire system from
being inadvertently switched on when performing maintenance, inspection or repair
work.

FluidMonitoring Module High
Pressure
Storage
HYDAC Filter Systems GmbH en Page 12 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Check any screwed fittings which have been removed to see that they have been
properly secured.
Always check the product to see that it functions properly when performing
maintenance and servicing work.
Modifications to the FMMHP
Do not make any modifications (design modifications, extensions) to the FMMHP
without the prior consent of the manufacturer.
Any modifications require written permission from HYDAC Filter Systems GmbH.
Immediately replace any machine components which are not in perfect condition.
Use only original spare parts.
Storage
Store the FMMHP in a clean, dry place, in the original packing if possible. Do not
remove the packing until you are ready to install the unit.
Drain the FMMHP completely before putting it into storage. If necessary, rinse the
FMMHP with n-heptane to prevent it from gumming up.
Use and dispose of used cleaning agents and flushing oils properly.

FluidMonitoring Module High
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Checking the scope of delivery
HYDAC Filter Systems GmbH en Page 13 / 28
Checking the scope of delivery
The Fluid Monitoring Modul High Pressure FMMHP Unit comes packed and factory-
assembled.
Before starting up the FMMHP, check that the content of the package is complete.
The following items are supplied:
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Item Qty Description
1 1 FluidMonitoring Module High Pressure FMMHP
2 1 Connector (female) with 8-pole, M12x1, shielded
3 1 Connector (female), 5-pole, M12x1
- 1 FMMHP Operation and Maintenance Instructions (this document)
- 1 Operating and maintenance instructions AS1000
- 1 CD-ROM with:
- Software CoCoS 1000
- Operation and maintenance instructions CS 1000
- 1 CD-ROM with FluMoS Light software
- 1 Calibration certificate CS1000

FluidMonitoring Module High
Pressure
FMM Features
HYDAC Filter Systems GmbH en Page 14 / 28
FMM Features
The FluidMonitoring Module FMMHP Series combines HYDAC's Condition
Monitoring Products ContaminationSensor CS 1000 and AquaSensor AS 1000 in
one system.
The FMMHP 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 FMMHP features all of the requisite connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits.
The FMMHP is suitable for the following operating pressures:
FMMHP with pressure accumulator 15 ... 250 bar
FMMHP without pressure accumulator 15 ... 300 bar
Advantages offered by the FMMHP:
• Cost-effective solution
• Early warning of critical machine states
• Continuous fluid monitoring
• Condition-based maintenance planning
Instructions for use
NOTICE
Impermissible operating conditions
The FMMHP will be destroyed
►The FMMHP may only be used with mineral oils or raffinates whose basis is
mineral oil.
►Do not exceed the maximum operating pressure.
Continuously rotatable display
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
The CS 1000 display can be continuously rotated by
a total of 270°; 180° counterclockwise and 90°
clockwise.
To rotate the display, grasp the cover plate with your
hand and turn in the desired direction.
No tools are required for rotating the display.

FluidMonitoring Module High
Pressure
Hydraulic schematic
HYDAC Filter Systems GmbH en Page 15 / 28
Hydraulic schematic
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
Dimensions

FluidMonitoring Module High
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FMMHP components
FMMHP components
Item Description
1 FMMHP connection stock
2 ContaminationSensor CS 1000 series
3 Connector (female), 8-pole, M12x1
4 AquaSensor AS 1000 series
5 Connector (female), 5-pole, M12x1
6 Inlet (IN), with test connector type 1604 or G ¼ according to ISO 228r
7 Outlet (OUT), with test connector type 1604 or G ¼ according to ISO
228.
8 Test connection (TP1), test connector Type 1604
9 Test connection (TP2), test connector Type 1604
10 Pressure accumulator
11 Filter element (installed)
HYDAC Filter Systems GmbH en Page 16 / 28
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08

FluidMonitoring Module High
Pressure
Attaching FMMHP mechanically
HYDAC Filter Systems GmbH en Page 17 / 28
Attaching FMMHP 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
4 M6 screws in accordance with IS= 4762 (minimum length 80 mm).
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08

FluidMonitoring Module High
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FMMHP hydraulic installation
HYDAC Filter Systems GmbH en Page 18 / 28
FMMHP hydraulic installation
To minimize measurement errors resulting from trapped air in the system, we
recommend that the flow direction through the FMMHP is from bottom (IN) to top
(OUT).
The FMMHP 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.
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08

FluidMonitoring Module High
Pressure
Connecting FMMHP with the hydraulic system
HYDAC Filter Systems GmbH en Page 19 / 28
Connecting FMMHP with the hydraulic system
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Connect the FMMHP with the hydraulic system as follows:
1. Check the pressure at the measurement site. It has to be within the
permissible range.
2. The hydraulic system has to be completely depressurized.
3. First connect the return-flow line to the outlet port (OUT) of the FMMHP.
(connector thread G1/4 ISO 228 or test connection 1604)
We recommend an internal Ø ≥4 mm for the return line.
4. Now connect the other end of the return line to the system tank, for
example.
5. Now connect the measurement line to the inlet port (IN) of the FMMHP.
(connector thread G1/4 ISO 228 or test connection 1604)
We recommend an internal Ø ≥4 mm for the jpressure line in order to
prevent particle deposits.
6. Now connect the other end of the measurement line to the measurement
point.
The hydraulic installation of the FMMHP is complete.

FluidMonitoring Module High
Pressure
Error messages / Troubleshooting
HYDAC Filter Systems GmbH en Page 20 / 28
Error messages / Troubleshooting
The following error messages may result when the CS 1000 is combined with the
FMMP manifold block.
BeWa FMMHP 3386918a en 2009-06-08.doc 2009-06-08
LED Blink code /
Display /
Analog output /
Switch out
Status To do
Red
4.4 mA / 2.2 V*
open
Flow too low
Check flow
Increase inlet pressure
or check outlet pressure
at measurement point.
p
Δ
has to be at least 15
bar -> if OK, replace filter
element.
Red
19.9 mA / 9.95 V*
open
Flow determination not
possible
Sensor status is
undefined
Check flow
If the oil quality is below
the measurement limit
(ISO 9/8/7), it may take
several measurement
cycles until measured
values are displayed
Increase inlet pressure
or check outlet pressure
at measurement point.
p
Δ
has to be at least
15 bar -> if OK, replace
filter element.
For other error messages, please refer to your CS 1000 operating and maintenance
instructions.
Performing maintenance
Maintenance interval
Replace the filter element at least every six months.