HYDAC International FMMP Manual

FMMP Unit
FluidMonitoringModule
Pressure Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Dokument No.: 3429971

FMMP Unit Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2008 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.
Exclusion of Liability
We have made every endeavor 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 future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Industriegebiet
D-66280 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846
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FMMP Unit Contents
Contents
Trademarks ........................................................................................................................ 2
Contents............................................................................................................................. 3
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Technical Support............................................................................................................ 5
Modifications to the Product ............................................................................................ 5
Warranty .......................................................................................................................... 5
Using the Documentation ................................................................................................ 6
General Safety Precautions.............................................................................................. 7
Obligations and Liability................................................................................................... 7
Explanation of Symbols and Warnings, etc. .................................................................... 7
Basic Symbols.............................................................................................................. 8
Proper/Designated Use ................................................................................................... 8
Improper Use ................................................................................................................... 8
Informal Safety Precautions............................................................................................. 9
Safety Measures to Be Followed during Normal Operation............................................. 9
Modifications to the FMMP Unit....................................................................................... 9
Training and Instruction of Personnel............................................................................ 10
Maintenance, Servicing and Troubleshooting................................................................ 10
Checking the Scope of Delivery..................................................................................... 11
FMMP Unit Properties ..................................................................................................... 12
Storing the FMMP Unit.................................................................................................... 12
Construction................................................................................................................... 13
Restrictions pertaining to use ........................................................................................ 14
Dimensions .................................................................................................................... 14
Hydraulic schematic....................................................................................................... 14
Hydraulic Installation ...................................................................................................... 15
Flow regulation........................................................................................................... 15
Electrical Installation ...................................................................................................... 16
Connecting the FMMP Unit to Your System ................................................................. 17
Disconnecting the FMMP Unit from Your System........................................................ 19
Error Messages ............................................................................................................... 21
Performing Maintenance ................................................................................................ 22
Maintenance Intervals.................................................................................................... 22
Changing the Filter Element .......................................................................................... 22
Disposing of the FMMP Unit........................................................................................... 24
Spare Parts List ............................................................................................................... 24
Accessories List.............................................................................................................. 24
Technical Data ................................................................................................................. 25
Customer Service............................................................................................................ 25

FMMP Unit Contents
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 Filtertechnik GmbH
Division Service technology / Filter systems
Technical Documentation Department
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”
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FMMP Unit Contents
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
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC Filtertechnik GmbH.
Refer to these at www.hydac.com General terms and conditions.
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FMMP Unit Contents
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.
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.
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Documentation No.
with Index
/
File name
Document language
Page number
Edition date
Product description /
Chapter heading

FMMP Unit General Safety Precautions
General Safety Precautions
These operating instructions contain the key instructions for properly and safely
operating the FMMP Unit.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the FMMP
Unit 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 FMMP Unit.
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 FMMP.
The FMMP Unit 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 FMMP Unit is only 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 FMMP Unit or use deviating from its designated use
• improper assembly, installation, commissioning, operation and maintenance of
the FMMP Unit
• Modifications to the FMMP Unit 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.
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The following designations and symbols are used in this manual to designate
hazards, etc.:

FMMP Unit General Safety Precautions
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 death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
TIP
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The FluidMonitoring Modul Pressure FMMP Unit was developed to monitor
particulate contamination in hydraulic systems.
Analyzing the type, 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; the manufacturer accepts no 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.
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:
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• improper connection of the FMMP Unit pressure and return flow lines.

FMMP Unit General Safety Precautions
Informal Safety Precautions
Always keep the operating instructions in the vicinity of the measurement unit.
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 is to be maintained to them.
All safety guidelines and hazard warnings on the FMMP Unit must be maintained in
legible condition and replaced as required.
Check the hoses and connection fittings for leakage daily (visual check). Replace
any loose connections or damaged cables immediately.
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WARNING
Hydraulic systems are under pressure

The hydraulic system must be depressurized
before performing any work
Safety Measures to Be Followed during Normal Operation
Do not operate the FMMP Unit 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.
Modifications to the FMMP Unit
Do not modify the design of the FMMP Unit 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.

FMMP Unit General Safety Precautions
Training and Instruction of Personnel
The FMMP Unit 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 FMMP Unit unless supervised by an
experienced staff member.
Individuals
Activity
Individuals
undergoing
training
Individuals
with technical
training/
engineering
background
Electrician Supervisor
with the
appropriate
authority
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
Decommissionin
g
Storage
X X X X
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
All operating media are to be protected in case the product is accidentally started
up.
The FMMP Unit is to be disconnected from the power supply, depressurized and
protected against being inadvertentlly switched back on when perfoming any
maintenance , servicing, inspection or repair work.
Make sure that all screwed fittings which have been undone/removed are secured.
Always check the product to see that it functions properly when performing
maintenance and servicing work.
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FMMP Unit Checking the Scope of Delivery
Checking the Scope of Delivery
The FluidMonitoring Module Pressure FMMP Unit comes packed and factory-
assembled.
Before commissioning the FMMP Unit, check the contents of the consignment to
make sure everything is present.
The following items are supplied:
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Item Qty. Description
1 1 FluidMonitoring Module Pressure Unit – FMMP Unit
2 1 Power supply unit 100 ... 240 V AC including 3 adaptors with 1.8
m cable -> socket plug (female), 8-pin, M12x1
3 1 PVC pouch for storing the power supply unit
4 1 Operating and Maintenance Instructions FMMP Unit (this
document)
5 1 CD-ROM containing:
- Operating and maintenance instructions CS 1000
- Operating Manual CoCoS 1000
- CoCoS 1000 Software
6 1 Calibration certificate CS 1000

FMMP Unit FMMP Unit Properties
FMMP Unit Properties
The FluidMonitoring Module Pressure FMMP is a rugged, mobile system for the on-
line measurement of particulate contamination in hydraulic fluids.
The FMMP Unit features all of the required connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits via the measurement coupling.
Typical applications of the FMMP Unit are pressure circuits between 15 ... 300 bar.
Advantages offered by the FMMP Unit:
o Mobility of the system
o Early warning in the case of critical machine states
o Continuous fluid monitoring
o Condition-based maintenance planning
o FMMP integrated in a stable case
o Comes ready-to-use including measurement lines
Storing the FMMP Unit
Make sure to store the FMMP Unit in a clean, dry place, in the original packing, if
possible. Do not remove the packing until you are ready to install the unit.
Completely drain the FMMP Unit before it is put into storage for an extended period
of time (flush with n-heptane if necessary) to prevent it from gumming up.
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FMMP Unit Storing the FMMP Unit
Construction
Item Description
1 Case
2 FMMP (FMMP installation block with CS 1000)
3 Filter element mount
4 High-pressure hose (IN) with test connector type 1620
5 Return line hose (OUT) with test connector type 1620
6 Power supply unit with cable, length = 2 m with coupling socket, 8-pin,
M12x1
7 FMMP retaining plate with hose mount
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FMMP Unit Storing the FMMP Unit
Restrictions pertaining to use
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TIP
The FMMP Unit may only be used with mineral oils (or raffinates whose basis is
mineral oil).
Dimensions
340
390
420
340
150
280
open closed
Hydraulic schematic

FMMP Unit Hydraulic Installation
Hydraulic Installation
Direction of flow through the FMMP Unit from (IN) to (OUT).
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Determine the system pressure of the hydraulic system and see whether it is within
the permissible flow range for the CS at the inlet port of the FMMP.
Measurement errors may result when the pressure drops below the minimum
differential pressure of 15 bar.
TIP
The maximum operating pressure of 300 bar may not be exceeded.
Flow regulation
The flow rate through the FMMP Unit is controlled by the integrated flow control
valve and regulated to the measurement volume of the CS1000.

FMMP Unit Electrical Installation
Electrical Installation
Plug the power supply unit into a corresponding network connection socket. Then
connect the 8-pin socket (B) with the CS by inserting it and rotating it until it is tight.
If voltage is present, then the display of the CS begins to light up and the unit is
autotest mode. The CS begins measurement operation once this is completed.
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FMMP Unit Connecting the FMMP Unit to Your System
Connecting the FMMP Unit to Your System
CAUTION
As soon as the FMMP Unit is linked to a connecting
line, oil begins to flow.
 Connect the FMMP Unit in accordance with the
sequence described below.
Connect the FMMP Unit to your system as follows:
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1. First open the case, ...
2. Carefully remove the hydraulic
connector lines from the retaining
mounts inside the case.
The hoses may not be
buckled. Replace any damaged hoses
immediately.
The high-pressure connector is
indicated by a red marking.
3.
No pressure whatsoever may
be present at the return-flow
connection port. The hydraulic system
must be completely depressurized.
Connect the hydraulic OUT port to a

FMMP Unit Connecting the FMMP Unit to Your System
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non-pressurized connector of the
reservoir (e.g. with the system tank of
the hydraulic system) or an external
collection receptacle.
4.
Check the pressure at the
measurement point. It has to be within
the permissible range of 15 ... 300 bar.
The system fluctuations
during measurement operation may
not exceed 20 bar (machine in stand-
by).
Connect the high-pressure line (IN,
with the red marking) with the type
1620 test connector on the hydraulic
system.
5. Plug the power supply unit into a
corresponding network connection
socket. Then connect the 8-pin socket
(B) with the CS by inserting it and
rotating it until it is tight.
The display of the CS begins to light up and the unit is autotest mode. The CS
begins measurement operation once this is completed.
Stable measured values aren't obtained until after several measurement cycles.

FMMP Unit Disconnecting the FMMP Unit from Your System
Disconnecting the FMMP Unit from Your System
CAUTION
As soon as the FMMP Unit is linked to a connecting
line, oil begins to flow.
 Connect the FMMP Unit in accordance with the
sequence described below.
Disconnect the FMMP from your system as follows:
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1. Remove the electric connection.
2.
Slight quantities of oil may
exit, consequently the tank line should
not be completely depressurized.
Disconnect the high-pressure line (IN,
with the red marking) from the test
connector on the hydraulic system.
Seal off the suction connector with the
attached dust cap.
3.
No pressure whatsoever may
be present at the connection port. The
hydraulic system must be completely
depressurized.
Disconnect the OUT hydraulic
connector from the test connector on
the hydraulic system.

FMMP Unit Disconnecting the FMMP Unit from Your System
Seal off the suction connector with the
attached dust cap.
4. Roll up the hydraulic connector lines
and place them in the case.
Make sure that the hose connectors
are sealed off using the attached dust
cap. This ensures that the connectors
are protected against the ingress of dirt
and contamination and exiting fluid.
5. Affix the hydraulic connector lines at
their designated place inside the case.
The power supply unit has to be stored
in the protective pouch so that no oil
gets on it.
Before closing the case, make
sure that no connection fittings, lines,
plugs, cables, etc. damage the CS
1000.
Close the case and secure it using the
two latches.
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