Hydac FCU 1000 Series Manual

FCU 1000 Series
FluidControl Unit
Operating and Maintenance Instructions
English (translation of original instructions)
Valid from firmware versions V 2.00 up
Document no.: 3371346d

FCU 1000 Series Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2010 by
HYDAC FILTER SYSTMES GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC FILTER SYSTEMS GMBH. 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, 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. 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
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-Mail: [email protected]

FCU 1000 Series Contents
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Contents
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Contents....................................................................................................................3
What's New — Document History...........................................................................6
Preface ......................................................................................................................7
Technical Support...................................................................................................8
Modifications to the Product ...................................................................................8
Warranty .................................................................................................................8
Using the Documentation .......................................................................................9
Safety Information and Instructions.....................................................................10
Obligations and Liability........................................................................................10
Explanation of Symbols and Warnings, etc. .........................................................11
Proper/Designated Use ........................................................................................11
Improper Use or Use Deviating from Intended Use..............................................12
Informal Safety Precautions..................................................................................12
What to Do in Case of Emergency .......................................................................12
Training and Instruction of Personnel ...................................................................13
Transporting the FCU ............................................................................................14
Storing the FCU ......................................................................................................15
Decoding the model code label ............................................................................16
Checking the scope of delivery ............................................................................17
What the FCU 1000 can do ....................................................................................18
Restrictions on the use of the FCU 1000..............................................................19
Counting particles in the FCU 1000......................................................................20
How the FCU 1000 functions.................................................................................21
User interface of the FCU 1000 ............................................................................22
Dimensions of the FCU 1000................................................................................23
Hydraulic diagram.................................................................................................24
Using the BatteryPack (accessory) ......................................................................25
Preparing the FCU for measurement....................................................................28
Connecting/disconnecting the FCU electrically.....................................................28
Connecting/disconnecting the OUTLET hose.......................................................29
Selecting the measurement point .........................................................................30
Select the measurement method according to the pressure involved ..................31
Measuring up to max. 45 bar / 650 psi..................................................................32
Measuring in the range 5 to 345 bar / 217 to 5000 psi.........................................35
Measuring from unpressurized containers.......................................................... 38
Operating the FCU..................................................................................................40
Display and keypad elements...............................................................................40
Clicking through the display .................................................................................42
ISO.SAE display................................................................................................42

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ISO.SAE display................................................................................................43
Measured variables ................................................................................................44
Measured variable "ISO"...................................................................................44
Measured variable "SAE"..................................................................................44
Measured variable "NAS"..................................................................................44
Measured variable "Water saturation"...............................................................44
Measured variable "Temperature".....................................................................45
Service variables ..................................................................................................45
Service variables "Flow"....................................................................................45
Service variables "Drive"...................................................................................45
FCU configuration menus .....................................................................................46
Power Up Menu ....................................................................................................46
DAT.TIM – date / time .......................................................................................47
ADRESS - Bus address ....................................................................................47
DEL.MEM – Delete Memory .............................................................................48
M.TIME – Measurement Time...........................................................................48
CALIB – Select calibration type.........................................................................49
DFAULT – reset to factory settings ...................................................................49
CANCEL............................................................................................................50
SAVE – store data.............................................................................................50
Measuring Menu ...................................................................................................51
RECORD - recording measurements................................................................52
MEMORY – display free memory......................................................................53
ED.MPNT – Change the name of measurement points....................................54
TP.UNIT – change the temperature units °C / °F..............................................55
CANCEL............................................................................................................55
SAVE - save data..............................................................................................55
Performing a measurement...................................................................................56
Restrictions pertaining to use ...............................................................................56
Internal measurement memory .............................................................................56
DATA - interface .....................................................................................................57
Connecting the FCU with CSI-B-2 kit ...................................................................57
Pins used on the DATA interface (HYDAC Sensor Interface – HSI) ....................57
Connecting the FCU with HMG 510 / HMG 3000 .................................................58
USB interface..........................................................................................................59
Copying measurements onto a USB data stick ....................................................59
Data transmission failed - "ERROR COPY"..........................................................61
Bluetooth interface.................................................................................................62
Installing the Bluetooth USB adaptor....................................................................63
Guarantee and liability for the USB adapter......................................................63
Connecting the FCU via Bluetooth .......................................................................63
Evaluating stored records .....................................................................................64
Directories to store the records by measurement points ......................................64
Record file names.................................................................................................64
Evaluating the file containing the measurements .................................................65

FCU 1000 Series Contents
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The measurements are shown as dates ...........................................................67
Measurement value readouts with FluMoS.......................................................... 68
Preparing the FCU for transport ...........................................................................69
Performing maintenance ......................................................................................72
Cleaning the FCU .................................................................................................72
Rinsing the FCU ...................................................................................................72
Clean the suction strainer. ....................................................................................75
Checking the high pressure adaptor.....................................................................78
Cleaning / changing the sieve in the high pressure adapter .............................79
Cleaning / changing the strainer in the high pressure adapter..........................80
FCU status messages / error messages ............................................................. 81
Restart / Resetting the FCU...................................................................................84
Disposing of the FCU.............................................................................................84
Spare Parts List ......................................................................................................85
Accessories for the FCU.......................................................................................86
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes............................... 89
ISO 4406:1999......................................................................................................89
ISO 4406 table ..................................................................................................89
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 .........................................................................................................90
SAE AS 4059........................................................................................................91
SAE AS 4059 table ...........................................................................................91
Cleanliness codes according to SAE ................................................................91
Absolute particle count larger than a defined particle size ............................91
Specifying a cleanliness class for each particle size .....................................92
Specifying the highest cleanliness code measured.......................................92
NAS 1638 .............................................................................................................92
Checking the measuring accuracy of the FCU.................................................... 93
Calibrating the FCU................................................................................................93
Customer service ...................................................................................................94
Germany ...............................................................................................................94
USA ......................................................................................................................94
Australia................................................................................................................94
Brazil.....................................................................................................................95
Factory default settings.........................................................................................95
Technical Data ........................................................................................................96
Model Code .............................................................................................................98
Compatible USB sticks - overview .......................................................................99
EC declaration of conformity ..............................................................................100

FCU 1000 Series What's New — Document History
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What's New — Document History
The index is featured on the cover sheet of the operating and maintenance manual
and in the lower left corner of each page after the part number.
Index "a" - from firmware version V 1.10
-Change to the items delivered
-Change of Bluetooth device name to "FCU1310"
Index "b" — from firmware version V 2.00
-Change to the items delivered
-"USB connection" chapter added
-Additions made to user interface chapters
-Additions made to "BatteryPack" chapter
Index "c"
-Index adapted
Index "d"
-Restrictions on use of fluid with flash point < 55°C added
-Spare parts list adapted
-"Transporting FCU“ updated
-Filling the hose lines before measuring is no longer necessary.

FCU 1000 Series 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
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”

FCU 1000 Series 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
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
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com ð General terms and conditions.

FCU 1000 Series Preface
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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 I 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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx- xx
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.
Chapter description
Page number
Edition date
Document language
Documentation Nr.
with Index /
File name

FCU 1000 Series Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the key instructions for properly and safely
operating the FCU.
Obligations and Liability
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 in general, and the safety precautions in particular, are
to be adhered by all those who work with the FCU.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed here are limited solely to 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 using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
The FCU is only to be used as follows:
Only for proper or designated use.
Only when in safe, perfect condition.
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply. They are made available to the owner
upon concluding 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.

FCU 1000 Series Safety Information and Instructions
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Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:
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.
NOTICE
NOTICE denotes situations
which can lead to property
damage if instructions are not
followed.
Proper/Designated Use
The fluid control unit, FCU, was developed to intermittently monitor solid particle
contamination, temperature und % saturation level 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:
Typical application: Short-time measurement of system cleanliness
Maintaining adherence to all the instructions contained herein.
Performing requisite inspection and maintenance work.

FCU 1000 Series Safety Information and Instructions
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Improper Use or Use Deviating from Intended Use
Improper use may result in hazards like the following:
Use of the FCU 1000 for permanent monitoring (i.e. continuous operation)
Improper connection of the FCU pressure or return hoses.
It is not permitted to operate the FCU1000 on a measurement point where the
pressure exceeds 345 bar.
Operation of the FCU on board networks without central "Load Dump" fuse.
Informal Safety Precautions
Always keep the operating and maintenance instructions near the measurement
device.
In addition to the manual, the general and local regulations concerning accident
prevention and protection of the environment should be available and observed.
Ensure that all information relating to safety and potential hazards of the FCU are
kept in a legible condition. Replace them if necessary.
Check the hoses and connectors for leaks on a daily basis.
The product is to be checked once a day for visible external damage and for the
proper functioning of the safety devices.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►Depressurize the system before performing any
work on it.
What to Do in Case of Emergency
In the event of an emergency, disconnect the FCU from the power supply and from
the hydraulic system.

FCU 1000 Series Safety Information and Instructions
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Training and Instruction of Personnel
The owner is obliged to only let persons work on the FCU, who:
are familiar with the fundamental occupational safety and accident prevention
regulations and have been properly instructed in the use of the FCU.
have read and understood these operating instructions.
Only properly trained and instructed personnel may work with the FCU.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff who are still being trained may only work on the FCU when supervised by a
suitably experienced person.
Individuals Individuals undergoing training
Individuals
with
technical training/ engineering background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Start up 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

FCU 1000 Series Transporting the FCU
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Transporting the FCU
Transport the FCU only when it is closed position; carry it flat or by the handle.

FCU 1000 Series Storing the FCU
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Storing the FCU
Drain and rinse the FCU completely before putting it into storage. See page 72 for
details on rinsing the FCU.
Observe the following storage conditions:
Storage temperature: -40 … +80°C / -40 … +176°F
Relative humidity: max. 90%, non-condensing
Store the FCU closed and in a horizontal position in a dry, clean place. If stored in
an vertical position, the FCU must not be exposed to any shaking or vibration.

FCU 1000 Series Decoding the model code label
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Decoding the model code label
For identification of the FluidControl Unit, see the type label. The label shows
product ID and major technical application data.
See page 98.for more details on the model code.

FCU 1000 Series Checking the scope of delivery
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Checking the scope of delivery
The FluidControl Unit FCU comes packed and ready for operation. Before
commissioning the FCU, check the contents of the consignment to make sure
everything is present.
The following items are supplied:
Item Qty Description
1 1 FluidControl Unit FCU 1000 Series, including attachable bag
for cables and hoses
2 1 Power supply, primary: 90-240 V AC / secondary: 24 V DC, 5
A
3 4 Connection cable (Europe, USA/Canada, UK, Australia,
Japan)
4 1 INLET suction hose, open end, clear-transparent, L = 0.3 m
(11.81 inch)
5 1 INLET high pressure hose with test connector type 1620,
color: clear-transparent, length = 2 m
6 1 High pressure adaptor
7 1 OUTLET return hose, transparent, L = 2 m
8 1 Operating and maintenance instructions
9 1 Certificate of calibration
10 1 CD-ROM with FluMoS Software
11 1 Pocket for documents
12 1 USB stick with operating and maintenance instructions (PDF
file) in additional languages
- 1 "Getting started" guide
A Bluetooth adapter is a free gift and is not part of the delivery.

FCU 1000 Series What the FCU 1000 can do
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What the FCU 1000 can do
The FCU 1000 is a portable service unit for hydraulic systems for intermittent
measurement of the particulate contamination, the moisture content in % saturation
and the temperature of the fluid.
The integral pump and hoses supplied can be used on:
Control circuits
Pressure circuits
non-pressurized tanks
Applications for the FCU include the servicing and repair of mobile hydraulic
systems.
The internal data memory enables measurements to be recorded together with a
time-stamp.
The USB interface can be used to copy all measurements to a USB memory stick,
for subsequent evaluation on a PC using Excel or the fluid monitoring software
FluMoS Light.
Additional features include:
Optical measurement of the degree of solid particle contamination
Capacitive measurement of the relative humidity in % saturation.
Resistive measurement of the temperature
Applicable for hydraulic fluids (up to ISO VG 68) 10 … 350 mm²/s / 16 … 1622
Sus
Automatic measurement and display of cleanliness ratings in accordance with:
ISO 4406:1987; NAS 1638
ISO 4406:1999; SAE AS 4059 (D)
Measurement accuracy +/- ½ ISO code in the calibrated range
Supply voltage of 24 V DC / 4 A for operation on mobile machine on-board
power supplies
Network adapter 90 - 240 V AC / 24 V DC 5 A included in the scope of delivery
Operating pressure without high-pressure adapter max. 45 bar / max. 650 psi,
Operating pressure with high-pressure adapter max. 345 bar / max. 5000 psi
Integrated pump for the automatic control of oil flow

FCU 1000 Series What the FCU 1000 can do
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Restrictions on the use of the FCU 1000
NOTICE
Impermissible operating conditions
The FCU will be destroyed
►Use the FCU with mineral oils or mineral oil-based raffinates whose flash
point is higher than 55°C/131°F.
►Observe the permissible viscosity range (up to ISO VG 68):
10 ... 350 mm²/s or 46 ... 1622 SUS
►Only operate the FCU 1000 for brief periods of time (S4 to DIN EN 60034 /
VDE 0530).
►When the pump has been operating for 30 minutes, shut off the FCU 1000
for at least 10 minutes to cool down.
NOTICE
Connection of the FCU to board networks
The FCU will be destroyed
►Use the FCU only on board networks which have a central "Load Dump"
fuse.
The Load Dump with a maximum of 30 V DC must be installed and effective.

FCU 1000 Series Counting particles in the FCU 1000
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Counting particles in the FCU 1000
The measuring principle of the light blocade procedure is shown in simplified form in
the following sketch.
The light source transmits monochromatic light through the flow of oil to a photo
detector, which produces a particular electrical signal. If a particle gets between the
light source and the photo detector, then a shadow will be cast on the photo
detector.
This shadow causes a change in the electrical signal generated by the photo
detector. This change makes it possible to determine the size of the shadow cast by
the particle and thus to gauge the size of the particle itself.
This procedure makes it possible to determine the cleanliness class according to
ISO 4406:1987, ISO 4406:1999, NAS 1638 and SAE AS 4059.
The disruption factors of this measurement principle are foreign fluids and small gas
bubbles that lead to refractions, thus causing them to be counted as particles as
well.
Each of the signal peaks corresponds to the shadow cast by one particle. The signal
height or amplitude reflects the particle size. Thresholds are used to classify the
particle sizes >2, >5, >15, >25 µm or >4, >6, >14, >21 µm(c).
Threshold values
Time
Flow of oil Flow of oil Particles
Photo detector
Light source Light source
Photo detector