Hydac FCU 1310 Manual

FCU1310
FluidControl Unit
Operating and Maintenance Instructions
English • (translation of original instructions)
Document No. : 3371346g • 1/16/2019
Follow these instructions for proper and safe use.
Keep for future reference.

1 | Imprint HYDAC FILTER SYSTEMS GMBH
2 / 148 BeWa FCU1310 3371346g en-us lq
1 Imprint
Manufacturer / publisher and responsible for the content:
Address of the manufacturer Contact address
HYDAC FILTER SYSTEMS
GMBH
Industriegebiet
66280 Sulzbach / Saar
HYDAC FILTER SYSTEMS
GMBH
Justus-von-Liebig-Str., Werk
20
66280 Sulzbach / Saar
Germany Germany
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken , HRB 17216
Executive director: Mathias Dieter ,
Dipl.Kfm. Wolfgang Haering
Tab.1: Impressum
1.1 Documentation Representative
The contact data of the person authorized with the documenta-
tion is:
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280
Sulzbach / Saar
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Tab.2: Documentation Representative

HYDAC FILTER SYSTEMS GMBH Table of Contents
BeWa FCU1310 3371346g en-us lq iii
Table of Contents
1 Imprint ....................................................................................................................... 2
1.1 Documentation Representative........................................................................ 2
2 General ..................................................................................................................... 7
2.1 Warranty........................................................................................................... 7
2.2 © HYDAC FILTER SYSTEMS GMBH, 2018.................................................... 7
2.3 Using this manual............................................................................................. 8
3 Safety information ................................................................................................... 10
3.1 Signal words and their meaning in the safety information and instructions ... 11
3.2 Design of Warning - / General Safety Information ......................................... 12
3.3 Safety symbols / pictograms .......................................................................... 12
3.4 Observe regulatory information...................................................................... 15
3.5 Stoppage in an emergency (EMERGENCY STOP)....................................... 15
3.6 Fire-fighting / extinguishing a fire ................................................................... 15
4 Overview ................................................................................................................. 16
4.1 Counting contaminant particles optically (light blockade procedure) ............. 18
4.2 Proper/Designated Use.................................................................................. 20
4.2.1 Periodic intermittent duty – operating mode S3................................. 21
4.3 Improper Use or Use Deviating from Intended Use ....................................... 23
4.4 Checking the scope of delivery ...................................................................... 24
4.5 Decoding the model code label...................................................................... 25
4.5.1 Model Code ....................................................................................... 27
4.6 Technical Data ............................................................................................... 28
4.7 Dimensions .................................................................................................... 31
4.8 Hydraulic circuit.............................................................................................. 32
4.9 Opening / closing the case............................................................................. 33
4.10 How it works: ................................................................................................. 34
5 Transporting / storing the FCU................................................................................ 36
5.1 Preparing the FCU for transport..................................................................... 36

Table of Contents HYDAC FILTER SYSTEMS GMBH
iv BeWa FCU1310 3371346g en-us lq
5.2 Transporting the FCU..................................................................................... 39
5.3 Storing the FCU ............................................................................................. 40
6 Putting the FCU into operation................................................................................ 41
6.1 Connecting / disconnecting the power supply................................................ 41
6.1.1 Disconnecting the power supply........................................................ 41
6.2 Plug in/Detach return hose............................................................................. 43
6.3 Configuring / setting FCU (PowerUp)............................................................. 44
6.3.1 DAT.TIM – Setting the date/time ....................................................... 45
6.3.2 ADRESS - Set bus address............................................................... 46
6.3.3 DEL.MEM – Deleting the measurement report memory.................... 47
6.3.4 M.TIME - Set measuring time............................................................ 48
6.3.5 CALIB – Selecting the calibration type .............................................. 49
6.3.6 DFAULT – Reset to default settings .................................................. 50
6.3.7 CANCEL - Cancel.............................................................................. 51
6.3.8 SAVE – Saving settings / data........................................................... 52
6.3.9 Factory settings ................................................................................. 53
6.4 Selecting the measurement location .............................................................. 54
7 Operation ................................................................................................................ 55
7.1 Overview of control panel/operating elements ............................................... 55
7.1.1 Reading the display and operating the keyboard .............................. 57
7.1.2 Scrolling through the display ............................................................. 59
7.1.3 Displaying measured variables.......................................................... 62
7.1.4 Display service variables ................................................................... 63
7.2 Operating/Setting measuring menu ............................................................... 64
7.2.1 RECORD – Record measurements................................................... 65
7.2.2 MEMORY – Displaying free measurement report memory ............... 68
7.2.3 ED.MPNT – Change name of measurement point ............................ 69
7.2.4 TP.UNIT - Set temperature unit......................................................... 71
7.2.5 CANCEL - Cancel.............................................................................. 73
7.2.6 SAVE – Saving settings / data........................................................... 74
7.3 Select the operating modes / measurement method according to the pressure
involved .......................................................................................................... 75
7.3.1 Measuring from unpressurized containers ........................................ 76
7.3.2 Measuring up to max. 45bar/650psi with hydraulic fluids .............. 79
7.3.3 Measuring in the range 5to345bar / 217to5000psi with oil .......... 82

HYDAC FILTER SYSTEMS GMBH Table of Contents
BeWa FCU1310 3371346g en-us lq v
7.4 Performing Measurements............................................................................. 85
7.5 Restarting/resetting ........................................................................................ 86
7.6 Using the BatteryPack (accessory) ................................................................ 87
7.6.1 Removing / inserting the BatteryPack ............................................... 89
7.7 Extracting the internal measured value memory............................................ 92
7.7.1 Extracting measurement reports via DATA interface ........................ 93
7.7.2 Extracting / copying measurement reports via USB interface ........... 96
7.7.3 Measurement reports via Bluetooth interface.................................. 102
7.8 Evaluating measurement records ................................................................ 104
7.8.1 Measurement record directories according to measurement point . 104
7.8.2 Measurement report file names....................................................... 104
7.8.3 Opening the measurement report.................................................... 106
7.8.4 The measurements are shown as dates ......................................... 107
7.9 Evaluating/Reading measurement reports with FluMoS .............................. 110
8 Performing maintenance....................................................................................... 111
8.1 Maintenance table........................................................................................ 111
8.2 Clean the suction strainer. ........................................................................... 112
8.3 Calibrating FCU............................................................................................ 115
8.4 High-pressure adapter maintenance............................................................ 116
8.4.1 Cleaning/changing the strainer........................................................ 116
8.4.2 Cleaning / changing the flow control valve ...................................... 118
9 Rinsing / cleaning the FCU ................................................................................... 121
9.1 FCU flushing ................................................................................................ 121
9.2 Cleaning the FCU......................................................................................... 124
10 Finding / rectifying errors....................................................................................... 125
11 Removing / Disposal ............................................................................................. 132
12 Attachment............................................................................................................ 133
12.1 Finding spare parts / accessories ................................................................ 133
12.1.1 Finding accessories......................................................................... 135
12.2 Finding a Customer Service team................................................................ 138
12.3 EC declaration of conformity ........................................................................ 139

Table of Contents HYDAC FILTER SYSTEMS GMBH
vi BeWa FCU1310 3371346g en-us lq
Glossary................................................................................................................ 145
Index ..................................................................................................................... 146

HYDAC FILTER SYSTEMS GMBH General | 2
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2 General
This manual was prepared to the best of our knowledge. Nev-
ertheless and despite the greatest care taken, it may contain
errors. Therefore, please understand that, in the absence of
any provisions to the contrary hereinafter, our warranty and lia-
bility – for any legal reasons whatsoever – are excluded in re-
spect of the information in this manual. In particular, we shall
not be liable for lost profit or other financial loss.
This exclusion of liability does not apply in cases of intent and
gross negligence. Moreover, it does not apply to defects which
have been deceitfully concealed or whose absence has been
guaranteed, nor in cases of culpable harm to life, physical in-
jury and damage to health. If we negligently breach any mate-
rial contractual obligation, our liability shall be limited to fore-
seeable damage. Claims due to the Product Liability shall re-
main unaffected.
2.1 Warranty
For the warranty provided by us, please refer to the Terms of
Delivery. They are made available to you at the conclusion of
the contract at the latest. You will also find these under
www.hydac.com -> General Terms and Conditions (T&C).
2.2 © HYDAC FILTER SYSTEMS GMBH, 2018
Distributing and copying this document and utilizing and dis-
closing its content is not permitted, except where this has been
agreed upon explicitly. Any infringement will entail liability for
damages. All rights reserved in the case of a patent being
granted or a utility model or the design being registered.
We reserve the right to changes to the contents of this manual
without prior notice.

2 | General HYDAC FILTER SYSTEMS GMBH
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2.3 Using this manual
You will find the following information on the title page of this
manual:
Short name of the product
Product name
Operating and Maintenance Instructions
12345678 ● ##.##.####
English (translation of original instructions)
Valid from: - from s/no. - ... ... - ... ...
1
5
2
4
3
Fig.1: Overview / labeling of the title page
1 Short name of the product / product name
2 Type of document
3 Language
4 Document no./Index ● Date of printing
5 Supplementary instructions regarding the validity of the
manual (optional)
Please note that you can directly access information
through the directories. However, this does not re-
lease you from the obligation to read this manual
fully before commissioning.
The document no. with the index (4) is meant for identifying
and reordering the manual. The index is incremented every
time the manual is revised or changed.

HYDAC FILTER SYSTEMS GMBH General | 2
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The manual contains a table of contents, a list of tables and
figures, an index and a glossary.
You will find the following symbols in the manual as additional
details:
Tip for handling the product
Required tools

3 | Safety information HYDAC FILTER SYSTEMS GMBH
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3 Safety information
The product was built according to the statutory directives, reg-
ulations and standards valid at the time of delivery and satis-
fies current safety requirements. Any residual hazards are indi-
cated by the general safety information and are described in
this manual.
Observe all safety and warning instructions attached to the
product and keep them always complete and easily legible.

HYDAC FILTER SYSTEMS GMBH Safety information | 3
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3.1 Signal words and their meaning in the safety
information and instructions
In these instructions you will find the following signal words:
DANGER
DANGER – The signal word indicates a hazardous situation
with a high level of risk, which, if not avoided, will result lethal
or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation
with a medium level of risk, which, if not avoided, can result
lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation
with a low level of risk, which, if not avoided, can result in mi-
nor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation
with a high level of risk, which, if not avoided, will result in
damage to property.

3 | Safety information HYDAC FILTER SYSTEMS GMBH
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3.2 Design of Warning - / General Safety Information
All the warning / general safety information in this manual are
highlighted with pictograms and signal words. The pictogram
and the signal word give you an indication of the severity of the
danger.
Warning / general safety information, which are placed ahead
of each activity, are represented as follows:
CAUTION
Type and source of danger
Hazard symbol
Consequence of the danger
Measures to avert danger
►
3.3 Safety symbols / pictograms
The following are the safety symbols / pictograms in this man-
ual. They indicate specific dangers to persons, property or to
the environment. Observe these safety symbols / pictograms
and act with particular caution in such cases. Always keep all
symbols / pictograms intact and legible.
Warning signs used
These signs are listed for all safety information and instructions
in these operating instructions which indicate particular haz-
ards to persons, property or the environment.
Danger point warning
Dangerous electrical voltage warning

HYDAC FILTER SYSTEMS GMBH Safety information | 3
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Hot surface warning
Signs used for giving orders
These symbols are listed for all safety information and instruc-
tions in these operating instructions which indicate particular
hazards to persons, property or the environment.
Follow the instructions.
Disconnect before working.
Signs used for the required specialist personnel
These symbols show the required training/knowledge for in-
stallation work and/or maintenance work.
Specialist personnel / operators
Such persons have had the corresponding spe-
cialist training and several years' work experi-
ence. They are able to assess and perform the
work assigned to them, they are also able to rec-
ognize potential hazards.
Specialist personnel - Mechanic
Such persons have specific specialist training
and several years' work experience. They are
able to assess and perform the work assigned to
them, they are also able to recognize potential
hazards.

3 | Safety information HYDAC FILTER SYSTEMS GMBH
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Specialist personnel - Electrician
Such persons have specific specialist training
and several years' work experience. They are
able to assess and perform the work assigned to
them, they are also able to recognize potential
hazards.
Others symbols used
These signs are listed for the general safety instructions in
these operating instructions, for example, which indicate a par-
ticular danger to persons, property or the environment.
Danger due to operating pressure

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3.4 Observe regulatory information
Observe the following regulatory information and guidelines:
– Legal and local regulations for accident prevention
– Legal and local regulations for environmental protection
– Country-specific regulations, organization-specific regula-
tions
3.5 Stoppage in an emergency (EMERGENCY STOP)
Disconnect the product from all sources of energy in an emer-
gency.
3.6 Fire-fighting / extinguishing a fire
Use a powder extinguisher that corresponds to fire class B as
per EN 2 to extinguish any fires / to fight fires.
Fig.2: Fire protection
class B
Maintain a minimum safe distance from electrical components.
For a mains voltage of up to 1000V, the minimum safe dis-
tance is 1m.
Fig.3: Minimum distance for fire fighting

4 | Overview HYDAC FILTER SYSTEMS GMBH
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4 Overview
The FluidControlUnit FCU is a portable service unit for taking
short-term measurements of the solid particle contamination,
the temperature and the water saturation in hydraulic systems.
Knowledge on the level and amount of contamination allows
you to check and document quality standards and introduce
the required optimization measures.
The integrated pump and the hoses supplied enable usage
with:
– Control circuits
– Pressure circuits
– Depressurized containers
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 or to send them to a mobile device via
Bluetooth where they can be analyzed using MS Excel or the
FluMoS FluidMonitoringsoftware.
Additional features include:
– Optical measurement of the degree of solid particle con-
tamination
– Capacitive recording of the water saturation in %
– Resistive measurement of the temperature
– Suitable for hydraulic fluids (up to ISOVG68)
– 2…350 mm²/s / 33…1622Sus
– Automatic measurement and display of cleanliness ratings
in accordance with:
– ISO4406; NAS1638
– ISO4406; SAEAS4059 (D)
– Measurement accuracy +/-½ISO code in the calibrated
range

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– Supply voltage of 24VDC / 4A for operation on mobile
machine on-board networks with LoadDump fuse protec-
tion
– 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 supplying the FCU with the fluid to be
analyzed

4 | Overview HYDAC FILTER SYSTEMS GMBH
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4.1 Counting contaminant particles optically (light
blockade procedure)
The measuring principle of the light blockade 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 de-
tector.
This shadow causes a change in the electrical signal gener-
ated 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, NAS1638 and SAEAS4059.
The disruption factors of this measurement principle are, for
example, foreign fluids and small gas bubbles that lead to re-
fractions, thus causing them to be counted as particles as well.
Fig.4: Light blockade procedure
1 Light source
2 Contaminant particle
3 Photo detector

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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µm, >5-15µm, >15-25µm, >25µm or >4µm(c), >6µm(c),
>14µm(c), >21µm(c).
time
Threshold values
Fig.5: Signal amplitudes

4 | Overview HYDAC FILTER SYSTEMS GMBH
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4.2 Proper/Designated Use
Use the product only for the intended use described below .
The FluidControlUnit FCU is a portable service unit for taking
short-term measurements of the solid particle contamination,
the temperature and the water saturation in hydraulic systems.
NOTICE
Impermissible operating conditions
The FCU can be damaged.
uUse the FCU with mineral oils or mineral oil-based raffi-
nates with flash points higher than 55°C/131°F.
uFlush the FCU with low-viscosity mineral oils or mineral
oil-based raffinates with flash points higher
than55°C/131°F.
uNever flush the FCU with universal thinners or other de-
greasing fluids.
uObserve the permissible viscosity range (up to
ISOVG68): of 2-350 mm²/s / 33-1622SUS.
uOperate the FCU only in periodic intermittent duty (S3)
with a (relative) duty cycle of 40% in relation to a useful life
of 10 minutes (S3 in accordance with DINEN60034 /
VDE0530).
uNever use the FCU without a suction strainer.
uObserve all the instructions contained in these Operating
and Maintenance Instructions.
uComply with all inspection and maintenance work.