HYDAC International FMMP Manual

FMMP
FluidMonitoring
Module Pressure
Operating and Maintenance Instructions
English (Translation of original manual)
Documentation no.: 3360764

FMMP Safety Guidelines and Instructions
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Trademarks
The trademarks of other companies designate the products of those companies
exclusively.
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 have made every endeavor to ensure the accuracy of the content of this
document. However, errors cannot be ruled out. Consequently, we accept no liability
for such errors as may exist in this document nor for any damage or loss
whatsoever which may arise as a result of such errors. The information in this
manual is checked regularly and the required corrections shall be contained in
subsequent editions. We welcome any suggestions for improvement.
We reserve the right to make technical changes.
All content of this manual is subject to revision without notice.
HYDAC Filter Systems GmbH
Industriegebiet
66280 Sulzbach / Saar
Germany
Telephone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 - 846

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St
H
Erro
D
Sp
Te
Content
Preface ...................................................................................................................... 4
Customer service....................................................................................................5
Product modification ...............................................................................................5
Warranty .................................................................................................................5
Using the documentation ........................................................................................6
Safety Guidelines and Instructions ........................................................................7
Obligations and liability ...........................................................................................7
Explanation of symbols and notes ..........................................................................8
Intended use ...........................................................................................................8
Improper use...........................................................................................................8
Informal safety precautions.....................................................................................9
Personnel training and instruction ........................................................................10
Safety precautions for normal operation...............................................................10
Maintenance, servicing and troubleshooting ........................................................11
Modifications to the FMMP Unit............................................................................ 11
oring the FMMP................................................................................................... 11
Checking the scope of delivery ............................................................................12
Technical specifications ........................................................................................ 13
FMMP components............................................................................................... 14
Restrictions pertaining to use ............................................................................... 14
Dimensions ...........................................................................................................15
Hydraulic schematic.............................................................................................. 15
Attaching the FMMP mechanically .......................................................................16
CS display continuously variable ......................................................................16
ydraulic connection of the FMM .........................................................................17
Connecting the FMMP to Your System............................................................. 18
r messages / Troubleshooting....................................................................... 19
Performing maintenance ....................................................................................... 20
Changing the Filter Element .................................................................................20
ecommissioning FMMP ....................................................................................... 22
Disposing of the FMMP ........................................................................................22
are parts and accessories................................................................................. 22
Spare parts ...........................................................................................................22
Accessories .......................................................................................................... 23
chnical details .................................................................................................... 23
Customer service ................................................................................................... 24

FMMP Safety Guidelines and Instructions
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reface
We have compiled the most important instructions for the operation and
maintenance of our product for you, its user, in this documentation.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
refers to its status at the time of publication. There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC Filter Systems GmbH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
Fax: ++49 (0) 6897 / 509 - 846
E-Mail: [email protected]
The editorial board would welcome your contributions.
“Putting experience into practice”
P

FMMP Safety Guidelines and Instructions
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service
tact our technical sales department if you have any questions on our product.
cting us, please always include the model/type designation, serial no.
nd part-no. of the product:
Produc
e would like to point out that changes to the product (e.g. purchasing additional
he safety of the product has been
arried out on components, the product may not be returned to operation until it has
een checked and released by a HYDAC technician.
Warran
accordance with the General Terms of Sale and Delivery of
lter Systems GmbH.
efer to these at www.hydac.com ÖGeneral terms and conditions.
Customer
Con
When conta
a
Fax: ++49 (0) 6897 / 509 - 846
E-Mail: [email protected]
t modification
W
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects t
c
b
Report any modifications carried out on the product by you or a third party
immediately.
ty
We assume warranty in
HYDAC Fi
R

FMMP Safety Guidelines and Instructions FMMP Safety Guidelines and Instructions
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HYDAC Filter Systems GmbH en Page 6 / 28
Using the documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior to starting the unit up for the first time and at regular
interva
hat do I want to know?
I determine the topic I am looking for.
The documentation no. with index is used for identifying and reordering the
instructions. The index is incremented every time the manual is revised or changed.
ls in the future.
W
Where can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
BeWa FMMP 33BeWa FMMP 3360764 en 2009-06-05.doc 2009-06-05
Chapter description
Page number
Document language
Documentation no.
with index
Edition date
/
file name

FMMP Safety Guidelines and Instructions
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Safety Guideli
These opera
FMMP sa l
Obliga
The b and trouble-free operation of the FMMP
knowledge of the basic safety guidelines and regulations.
s in particular, are to be
In add tion
listed here are restricted to the use of the FMMP.
signed and constructed in accordance with the technical
tate of the art and recognized safety rules and regulations. Nevertheless, hazards
ay be posed to the life and limb of the individual using the product or to third
arties, and risk of damage may be posed to the product or other equipment and
roperty.
se the FMMP:
Solely for its intended use
Only when in safe, perfect condition.
mediately remedy any malfunctions that might impair safety.
ur general terms and conditions apply. They are provided to the owner upon
onclusion of purchase of the unit at the latest. Any and all warranty and liability
laims for personal injury and damage to property shall be excluded in the event
ey are attributable to one or more of the following causes:
Use of the FMMP deviating from its intended use
Improper assembly/installation, start up, operation and maintenance of the
FMMP
Unauthorized modification of the FMMP
Improper monitoring of unit components that are subject to wear and tear
Improperly performed repair work
nes and Instructions
ting instructions contain the most important notes for operating the
y.fe
tions and liability
asic prerequisite for the safe handling
is
These operating instructions, and the safety guideline
observed by all those who work with the FMMP.
ition, adherence is to be maintained to pertinent accident preven
applicable at the site where the product is used.regulations
The safety guidelines
The FMMP has been de
s
m
p
p
U
•
•
Im
O
c
c
th
•
•
•
•
•

FMMP Safety Guidelines and Instructions
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d for hazards and warnings in this
Explanation of symbols and notes
The following designations and symbols are use
manual:
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
t
which can lead to death if
safety precautions are no
observed.
CAUTION
CAUTION denotes situations
verewhich can lead to se
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if instructions are not
followed.
Intended us
easures can be
duct also includes:
tained herein.
Improper use
Any use other than described above is prohibited.
Hazards may result from improper use.
Examples of improper use:
• Improper connection of the pressure and return flow lines.
e
The FluidMonitoring Module Pressure FMMP was developed to monitor particulate
contamination in hydraulic systems.
By determining the type, size and quantity of contamination, quality standards can
be verified and documented, and the required optimization m
implemented.
Any other use shall be deemed not in keeping with the product's intended use. The
manufacturer is not liable for any damage resulting from this use.
Intended use of the pro
• Maintaining adherence to all the instructions con
• Performing requisite inspection and maintenance work.

FMMP Safety Guidelines and Instructions
Informal safety precautions
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n to the operating instructions, the general and local regulations on
accident prevention and environmental protection are to be made available and
observed.
ard symbols and w ible
heck the hoses and connection parts for leaks on a daily basis. Replace any loose
connections or damaged cables immediately.
Always keep the operating instructions in the vicinity of the device.
In additio
Make sure that the safety and haz
condition.
arnings are always in a leg
C
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing
.
any work on the hydraulic
system

FMMP Safety Guidelines and Instructions
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ction
personnel.
r.
ay only use the FMMP when supervised by an experienced individual.
Personnel training and instru
The FMMP may only be operated by properly trained and instructed
The areas of responsibility of your staff must be established in a clear-cut manne
Trainees m
Individuals Individuals undergoing training Individuals with technical training Electricians Supervisors with required expertise
Activity
Packing Transport X X X
Start up X X X
Operation X X X X
Troubleshooting X X X
Remedying mechanical faults X X
Remedying electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning/storage X X X X
Safety precautions for normal operation
Do not operate the FMMP unless all the safety devices function properly.
Check the product for visible damage and properly functioning safety equipment at
least once a day.

FMMP Storing the FMMP
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shooting
When performing maintenance, inspection or repair work, disconnect the FMMP
from the power supply and protect the entire system from being inadvertently
switched on.
Make sure that all screwed fittings w removed are secured.
After carrying out maintenance and work, always check that the safety equipment is
functioning properly.
Modifications to the FMMP Unit
Do not modify the design of the FMMP without the prior consent of the
manufacturer.
Any e written permission from HYDAC Filter Systems GmbH.
Immediately replace any machine components which are not in perfect condition.
Only use original spare parts and consumables.
Storin
Store the FMMP in a clean, dry place, in the original packing if possible. Do not
r cking until you are ready to install the unit.
C before it is p into storage for an extended period of
with n-heptane if necessary) to prevent it from gumming up.
Properly dispose of the cleaning agents and flushing oils used.
Maintenance, servicing and trouble
Conduct the specified setting, maintenance and inspection work according to
schedule.
Protect all operating media from accidental start up.
hich have been undone/
modifications requir
g the FMMP
emove the pa
ompletely drain the FMMP ut
time (flush

FMMP Checking the scope of delivery
Checking the scope of delivery
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onitoring Module Pressure FMMP arrives packed and ready for
check no items are missing
The Fluid M
operation. Before commissioning the FMMP, please
from the package.
The following items are included:
Item Pc. Description
1 1 FluidMonitoring Module Pressure — FMMP
2 1 Socket plug, 8-pole, M12x1, screened
3 1 CD with:
- CoCoS 1000 PC software package and
- Operating instructions CoCoS 1000
- Operating and maintenance instructions CS1000
4 1 Operating and Maintenance Instructions FMMP (this document)
5 1 Calibration certificate CS1000

FMMP Technical specifications
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for the
all of the required ports and can thus be easily connected to
The FMMP is typically applied to 15 ... 300 bar pressure circuits.
Adv tages ere
• st-effe ve s
• Early warning of critical machine sta
• Continuous oil
•
Technical specifications
The FluidMonitoring Module Pressure FMMP is a rugged, stationary system
on-line measurement of particulate contamination in hydraulic fluids.
The FMMP features
existing hydraulic circuits.
an off d by the FMMP:
Co cti olution
tes
condition monitoring
Condition-based maintenance planning

FMMP Technical specifications
FMMP components
2
1
4
5
2
3
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Item Designation
1 FMMP manifold block
2 Test point 1604 (IN/OUT)
3 Filter element insert
4 ContaminationSensor CS1000 series
5 Socket plug, 8-pole, M12x1, with screw clamp
Restrictions pertaining to use
NOTICE
Impermissible operating fluid
The unit will be damaged
►The unit may only be used with mineral oils (or raffinates whose basis is
mineral oil).

FMMP Technical specifications
Dimensions
ca. 193
ca.200
52
83
ø9
82,5
Hydraulic schematic
CS
IN OUT
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FMMP Technical specifications
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FMMP mechanically
Note that the direction of flow has to be from bottom to top during installation.
When selecting the installation site, check the ambient conditions such as
temperature, dust, water, etc. The CS1000 has protection rating IP67 according to
DIN 40050 / EN60529 / IEC 529 / VDE 0470.
The FMMP can be mounted and secured via the two mounting holes on the CS1000
using 2x cylindrical screw M8 x 55 mm according to ISO 4762.
Attaching the
CS display continuously variable
The CS 1000 display can be continuously rotated
by a total of 270°. 180° counterclockwise and 90°
clockwise.
Rotate the display by hand in the direction
esired.d
Do not use any tools to rotate the display.

FMMP Technical specifications
Hydraulic connection of the FMM
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WARNING
Impermissible operating pressure
Bodily injury
►The maximum operating pressure of 300 bar
may not be exceeded.
NOTICE
The minimum differential pressure is < 15 bar
If the minimum differential pressure is not given, measuring errors will occur.
►Observe the minimum differential pressure of 15 bar
Note that the direction of flow has to be from bottom (IN) to top (OUT) during
installation. This prevents measurement errors resulting from trapped air in the
system.
The FMMP is supplied with two test points (type 1604) on the inlet (IN) and outlet
UT). Remove the test points to connect via the connector thread G1/4 according
ISO 228.
(O
to
Test point 1604 Connector thread: G1/4, ISO 228

FMMP Technical specifications
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e hydraulic system and see whether it is within
the permissible flow range for the CS1000 for the FMMP inlet.
Ensure the flow rate is cont led by alve and is
regulated to the measurement volum
CS1000 does not correspond t
Connecting the FMMP to Your Sy
Determine the system pressure of th
rol the integrated flow control v
e of the CS1000. The flow rate displayed by the
o the total flow through the FMMP.
stem
WARNING
H e under pressureydraulic systems ar
Bodily injury
►The hydraulic system must be depressurized
system.
before performing any work on the hydraulic
Connect the FMMP with the hydraulic system as follows:
ector thread G1/4 ISO 228 or test connection 1604).
Use an internal Ø ≥4mm for the return flow line.
4. Now connect the other end of the return line to the system tank, for
example.
5. Connect the measurement line to the inlet port (IN) of the FMMP.
(connector thread G1/4 ISO 228 of test connection 1604)
Use an internal Ø ≤4mm to prevent particle deposit.
6. Connect the other end of the measurement line to the measurement point.
7. The hydraulic installation of the FMMP is now complete.
1. Check the pressure at the measurement site. It must be within the
permissible range.
2. Depressurize the system.
3. Connect the return flow line with the outlet port (OUT) of the FMMP
(conn

FMMP Error messages / Troubleshooting
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Error messages / Troubleshooting
The following error messages may result when the CS 1000 is combined with the
FMMP manifold block.
LED Blink code /
Display /
Analog output /
Switch out
Status Action
Red
4.4 mA / 2.2 V*
Open
Flow too low
Check flow
Increase inlet pressure
or check outlet pressure
at the measurement
point.
The has to be atpΔ
least 15 bar -> if OK,
change the filter element.
Red
19.9 mA / 9.95 V*
Open
Flow specification 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.
The has to be atpΔ
least 15 bar -> if OK,
change filter element.
For
ins
othe tenance
tructi
r error messages, please refer to your CS1000 operating and main
ons.

FMMP Performing maintenance
Performing maintenance
Replace the filter element at least every six months.
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Changing th lemente Filter E
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system m e d
before performing any w
system.
ust b epressurized
ork on the hydraulic
Item Designation
10 O-ring 10.77x 2.62
20 Filter element 25 µm
30 O-ring 20x 2
40 Support ring Ø 20
50 Endplate