HYDAC International FluidAqua Mobil FAM 10 Operating manual

FAM10/15/30/50/70 with
Contamination Sensor CS
Additional instructions :
English (translation of original instructions)
Document-no.: 3189702b

Trademarks
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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.
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. 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
Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-mail: [email protected]

Content
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Content
Trademarks ............................................................................................................................. 2
Documentation Representative ............................................................................................2
Content....................................................................................................................................3
Preface ....................................................................................................................................4
Technical Support.................................................................................................................5
Modifications to the Product .................................................................................................5
Warranty ...............................................................................................................................5
Using the documentation ...................................................................................................... 6
Introduction ............................................................................................................................7
Abbreviations and symbols................................................................................................... 7
Description..............................................................................................................................8
Measuring system.................................................................................................................8
Controlling the FAM through the CS2000 (optional)........................................................... 9
Activating Automatic Switch-off .......................................................................................... 14
Remedying malfunctions..................................................................................................... 15

Preface
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Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It is intended to help you become acquainted with the ins and outs of the product
and use it properly.
You should keep it in the vicinity of the product so it is always at your fingertips.
Sometimes the information contained in the documentation cannot always keep up
with changes made to the product as we attach considerable importance to keeping
our products cutting-edge. Consequently, there might be deviations in technical
details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC Filter Systems GmbH
Abteilung: Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar - Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
Our motto: “Putting experience into practice”

Preface
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Technical Support
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: ++49 (0) 6897 509 846
Email: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
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 ÖAGB

Preface
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.
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Product description /
Chapter heading
Page number
Edition date
Document language
Documentation No.
with Index
/
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented every time the
manual is revised or changed.
File name

Introduction
Introduction
These operating instructions are intended as a supplement to the documentation
"Operating and maintenance instructions FAM" and "Operating and maintenance
instructions CS2000 Series“.
Please consult the corresponding documentation for safety precautions and general
operating and warning instructions.
Abbreviations and symbols
The following symbols are used in these supplementary operating instructions to
designate instructions of particular importance:
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This symbol marks an important note for the proper handling and
operation of the unit / software. Nonobservance of these notes can lead
to damage or failure of the unit / software.
This symbol identifies tips for usage and other particularly useful
information.
 Information and instructions which are to be obtained from other
documentation are marked by this symbol.

Description
Description
The Contamination Sensor enables particulate contamination to be continuously
monitored and the fluid to be automatically cleaned up to a specified cleanliness
rating.
The dedusting of the fluid up to a set cleanliness class can thereby be carried out
automatically. The control of the FAM is handled through the ContaminationSensor
CS2000 for this purpose.
Measuring system
The ContaminationSensor continuously records the cleanlinessof the fluid suctioned
in by the FAM. The current degree of contamination is shown on the display in the
control cabinet.
The measuring system is comprised of:
1
23 Option
Item Description
1 Display for showing the cleanliness class values measured and the flow
rate through the CS.
2 Selector switch for switching between the display on the monitor and
programming the CS. Only when controlling the FAM through the
CS2000.
3 Reset button for restarting the CS subsequent to configuring parameter
settings.
- ContaminationSensor CS2000
- Motor-pump assembly with pressure relief valve
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Controlling the FAM through the CS2000
(ti l)
Controlling the FAM through the CS2000 (optional)
In addition to the FAM's standard mode of operation it can also be controlled by way
of the fluid cleanliness.
This is done by specifying on the Contamination Sensor a cleanliness class rating to
be achieved (cleanliness class rating according to ISO 4406, NAS 1838 or SAE
AS4059, depending on the model).
Setting the contamination class to be achieved
Setting the cleanliness class rating to be achieved is done via the display/parameter
configuration interface of the CS. To this end, a laptop with a free COM port and a
terminal program (e.g. HyperTerminal) are required.
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1.
Switch off the FAM via the button.
2. Set the main switch to OFF.
3. The parameterization cable required for parameterization can be found,
already connected, in the control cabinet of the FAM. Connect it to your PC or
laptop computer.
4. Change the selector switch setting from "Display" to "Progr".
5. Start your PC and call up a terminal program.
Configure the COM port as follows:
6. Set the main switch of the FAM to ON.
7. The CS is now in display mode. Pressing the Enter key moves you from
display mode to operating mode.
The following display appears after operating mode starts:
HYDAC Filter Systems GmbH
Contamination Sensor CS2230
Hardware Version 3.0
Firmware Version V4.10 / 27.03.2008

Controlling the FAM through the CS2000
(ti l)
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HYDAC Contamination Sensor offline!
Measuring cycle stopped
x - Restart Measurement
p - Enter Parameter Mode
Enter key (x, p) and Return!
8. Press the "p" key and then Return to switch to Parameter Mode. The following
display appears after Parameter mode starts:
Parameter Mode:
x - Go back
t - Measuring cycle time
m - Measuring mode
2 - Limits Mode M2
3 - Limits Mode M3
4 - Limits Mode M4
b - Set DIN-Bus Address and Name (for CS models with DIN-Bus module only)
p - Pump protection
o - PLC Output Format
r - RS232-Display Output Format
i - Current Output Format (for CS models with analog module only)
c - Check Current Output (for CS models with analog module only)
f - Flow check
s - Sensor check
d - Recover Factory Default Settings
Enter key (x, t, m, 2, 3, 4, b, p, o, r, i, c, f, s ,d) and Return!
The gray-highlighted items are relevant for controlling the FAM. They are
described below.
9. t = Measuring cycle time is used to set the measurement interval (20 to 120
seconds). The current cleanliness class is shown in the display after each
measurement interval. A default value of 60 seconds should be set.
Now press "t" and then Return. The following then appears, for example:
actual measuring cycle time (s) set to: 20
New value for measuring cycle time (s) (enter 'Return' to keep setting): 60
actual measuring cycle time (s) set to: : 60
The measurement interval has been increased in the example from 20s to 60s.
10. Only Measuring Mode M2 (measurement and switching) is used for controlling
the FAM.
Now press "m" and then Return. The following then appears, for example:
actual Mode: 3
1=M1, 2=M2, 3=M3, 4=M4
Enter key (1, 2, 3, 4) and Return (enter 'Return' to keep setting) 2

Controlling the FAM through the CS2000
(ti l)
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Actual value for Mode: 2
The measurement mode has been changed in the example from M3 to M2.
11. The cleanliness class at which the FAM is switched off is set under "Limits
mode 2":
Measurement channel for relay 1 (alarm relay):
CS 2030 CS 2130 CS 2230
AS/SAE channel 0/A
nel
8 ISO Code
nt
it for relay 1 (alarm lay)
0 N 5 … 15 µm 2 … 5 µm > 4 µm
1 NAS/SAE channel 1/B 15 … 25 µm 5 … 15 µm > 6 µm
2 NAS/SAE channel 2/C 25 … 50 µm 15 … 25 µm > 14 µm
3 NAS/SAE channel 3/D > 50 µm > 25 µm > 21 µm
4 ISO channel 0 > 5 µm > 2 µm > 4 µm
5 ISO channel 1 > 15 µm > 5 µm > 6 µm
6 ISO channel 2 > 25 µm > 15 µm > 14 µm
7 NAS/SAE chan 0 ... 3
A ... D
0 / 1
0 ... 3
A ... D
0 / 1 / 2
0 ... 3
A ... D
0 / 1 / 2
9 Flow rate
10 LED curre
Lim value function re
e exceeded (lower limit value for hysteresis)
)
0 -> No function
1 -> Within range
2 -> Outside range
3 -> Upper limit valu
4 -> Value below lower limit value (upper limit value for hysteresis
Limit values for selected measuring channel relay 1 (alarm relay)
Depending on the selected measuring channel, first the lower limit value(s)
then the upper limit value(s) are entered.

Controlling the FAM through the CS2000
(ti l)
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Example:
Relay 1, measuring channel
0=SAE A, 1=SAE B, 2=SAE C, 3=SAE D,
4=ISO ch.0, 5=ISO ch.1, 6=ISO ch.2, 7=SAE A..D,
8=ISO code, 9=flow, 10=LED
current setting: 3
new setting (enter 'Return' to keep setting): 8 'Return'
current setting : 8 (selected: three-part ISO code)
Relay 1,switching function
(0=no function, 1= within range, 2=outside range, 3= exceed, 4=fall below)
current setting: 0
new setting (enter 'Return' to keep setting): 4 'Return'
current setting : 4 (selected: limit fallen short of)
Relay 1, lower limit 1:
current setting: 17
new setting (enter 'Return' to keep setting): 16 'Return'
current setting : 16
Relay 1, upper limit 1:
current setting: 20
new setting (enter 'Return' to keep setting):17 'Return'
current setting : 17
Relay 1, lower limit 2:
current setting: 15
new setting (enter 'Return' to keep setting): 14 'Return'
current setting : 14
Relay 1, upper limit 2:
current setting: 18
new setting (enter 'Return' to keep setting): 15 'Return'
current setting : 17
Relay 1, lower limit 3:
current setting: 13
new setting (enter 'Return' to keep setting): 11 'Return'
current setting : 11
Relay 1, upper limit 3:
current setting: 15
new setting (enter 'Return' to keep setting): 12 'Return'
current setting : 12

Controlling the FAM through the CS2000
(ti l)
Since the ISO code has been selected, a three-part value has to be entered
each for the lower and upper value, i.e. a total of 6 values.
In the example shown above, relay 1 closes as soon as the measured
cleanliness class in all channels is smaller than or equal to the lower limit
(16/14/12) and opens again as soon as a channel is larger than or equal to the
upper limit (20/17/15).
The configuration of relay 2 has no effect on the operation of the
FAM.
12. In Parameter Mode, "RS232-Display Output Format" has to be set to 4 =
Toggle ISO/Flow.
13. When you have entered all the settings, press the "Reset" button
14. Move selector switch from "Progr." to "Display".
15. Now remove the PC and close the switch cabinet.
Details concerning parameterization of the CS2000 can be found in the Operating
and Maintenance Instructions for the CS2000 Series, Chapter "Serial RS232 display
interface“.
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Controlling the FAM through the CS2000
(ti l)
Activating Automatic Switch-off
After switching on the FAM via , use the button to switch into
controlled mode. The following now appears in the display:
FluidAqua is in
operation
Autom. Switch-off
Active
The automatic switch-off via the contamination sensor is not enabled until a
"minimum running time prior to automatic switch-off" (preset to 10 minutes) has
elapsed.
The FAM continues to run after this time until Relay 1 has been closed without
interruption for at least 5 minutes. Afterwards, the FAM switches off.
The minimum running time at delayed-action relay K4 may not be changed.
The unit will switch itself back on again after a preselected "Switching back on time".
The automatic switch-off is now active once again.
The "restart time" can be changed in the switch cabinet via delayed-action relay K5.
K4 = Time up to minimum running time prior to automatic
switch-off.
K5 = Time to switch back on
If switching back on is to be prevented, then this time can be set to infinity (∞).
Press to switch from controlled mode back into normal mode.
Both modes can be stopped via the key.
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Remedying malfunctions
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Remedying malfunctions
In the case of extremely soiled media, the throttle valve may slowly clog up, which
will result in the flow through the CS falling off accordingly.
The valve can be flushed free again by completely opening the throttle valve for a
few minutes.
Additional information can be obtained from the
 CS 2000 Series — Operating and Maintenance Instructions
Section 'Error Messages and Troubleshooting'

HYDAC Filter Systems GmbH
Industriegebiet Postfach 1251
66280 Sulzbach/Saar 66273 Sulzbach/Saar
Germany Germany
Phone: [phone] Central
Fax: [phone] Technical Department
Fax: [phone] Sales Department
Internet: www.hydac.com
E-Mail: [email protected]