Hydac FCU 8000 Series Manual

FCU 8000 series
FluidControl Unit
Operating and Maintenance Instructions
Valid from firmware versions 3.22 up
English (translation of original instructions)
Document no.: 3109776d

FCU 8000 series Trademarks
HYDAC FILTER SYSTEMS GMBH en(us) Page 2/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Trademarks
The trademarks of other companies designate the products of those companies
exclusively.
Copyright © 2011 by
HYDAC FILTER SYSTEMS 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 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 FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saa
r
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 8000 series Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 3/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................7
Customer service....................................................................................................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 ..................................................................11
Proper/Designated Use ........................................................................................11
Improper Use ........................................................................................................12
What to Do in Case of Emergency .......................................................................12
Maintenance, Servicing and Troubleshooting.......................................................12
Modifications to the FCU ......................................................................................12
Training of personnel ............................................................................................13
Checking the Scope of Delivery............................................................................14
Description of the FCU ..........................................................................................15
Operating elements / Dimensions.........................................................................16
Restrictions on use – FCU 8110 / 8210................................................................17
Restrictions on use – FCU 8111 / 8211................................................................17
Hydraulic diagram ..................................................................................................18
FCU Function Description.....................................................................................19
Electrical connection of the FCU ..........................................................................22
Connecting the "POWER INPUT".........................................................................22
Connecting the "PC" interface ..............................................................................23
Serial RS 232 Interface (Standard) ...................................................................23
Serial RS 485 Interface (OPTIONAL) ...............................................................23
"Control" – Connecting the control port.................................................................24
Contact assignment (switched position when the FCU is ready for
operation) ..........................................................................................................24
Relay Functions ................................................................................................25
Adjustable limit values.......................................................................................28
FCU in online operation.........................................................................................29
FCU in BSU operation (only for FCU 8110 / 8210) ...............................................31

FCU 8000 series Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 4/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Diagram of the BottleSampling Unit ..................................................................33
Perform basic settings for bottle sampling operation ........................................34
Flushing BottleSampling Unit ............................................................................35
Measurement with BottleSampling Unit.........................................................36
Switching on the FCU ............................................................................................39
Switching on the FCU ...........................................................................................39
Selecting the Viscosity Range ..............................................................................39
Starting up the FCU................................................................................................40
Conducting Measurements via the High-Pressure Port (INLET) ..........................40
Operating the FCU..................................................................................................40
Function of the Keys .............................................................................................40
Menu and Number Keys (red) ..............................................................................41
Key Combinations.................................................................................................41
FCU menus .............................................................................................................42
MODE - select operating mode ............................................................................42
MODE "M1: Measure".......................................................................................43
MODE "M2: Measuring and switching" .............................................................43
MODE "M3: Filter to" (performance of automatic filtration) ...............................43
MODE "M4: Filtering from to" (performance of automatic filtration) ..................44
MODE "M5: Flushing BS"..................................................................................44
MODE "M6: Bottle Sampler" .............................................................................44
MEMORY Menu....................................................................................................45
Designating the measurement point .................................................................46
Setting the averaging interval............................................................................47
Selective deletion ..............................................................................................48
Delete all ...........................................................................................................50
Change meas. – point .......................................................................................51
Setting the memory mode .................................................................................52
Overwrite .......................................................................................................52
Stop if full.......................................................................................................52
PRINT menu .........................................................................................................53
Logs ..................................................................................................................54
BS-Logs ............................................................................................................59
PRINT Contents ................................................................................................63
PRINT All parameters .......................................................................................63
Paper feed.........................................................................................................64
Online printout...................................................................................................64
Print out, cancel ................................................................................................65
LIMITS menu ........................................................................................................65
MODE M2 .........................................................................................................66

FCU 8000 series Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 5/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Measurement channel table ..........................................................................68
MODE M3 .........................................................................................................68
MODE M4 .........................................................................................................69
MODE M5 .........................................................................................................70
MODE M6 .........................................................................................................70
SETUP menu........................................................................................................72
Autostart............................................................................................................73
Abort at Q=0......................................................................................................74
Setting the pump start delay .............................................................................75
Setting the date and time ..................................................................................76
Set bus address ................................................................................................77
Display operating hours ....................................................................................77
BS pressure supply ...........................................................................................78
Additional test....................................................................................................78
Check the battery status ...................................................................................79
POWERUP menu .................................................................................................80
M6: Bottle Sampler............................................................................................81
Selecting the language......................................................................................82
Setting the viscosity range ................................................................................82
Setting the measured volume ...........................................................................83
FCU Display ............................................................................................................84
Brief Overview of the Menu Structure ..................................................................86
Error Messages and Troubleshooting..................................................................89
Performing maintenance .......................................................................................94
Cleaning the FCU .................................................................................................94
Changing the FCU Filter Element.........................................................................94
Back-flushing the FCU..........................................................................................97
Internal dot-matrix impact printer – replace paper roll / ink ribbon........................97
Disposing of the FCU.............................................................................................99
Storing the FCU ......................................................................................................99
Storage conditions ................................................................................................99
Calibrating the FCU................................................................................................99
Customer service .................................................................................................100
Germany .............................................................................................................100
USA ....................................................................................................................100
Australia..............................................................................................................100
Brazil...................................................................................................................101
China ..................................................................................................................101
Spare parts............................................................................................................102

FCU 8000 series Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 6/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
FCU 8xx0 (version for mineral oil) ......................................................................102
FCU 8xx1 (version for HFD fluids)......................................................................102
FCU 8xxx ............................................................................................................103
Accessories ..........................................................................................................103
Explanation of the measuring technology terms used.....................................104
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes............................. 105
ISO 4406:1999....................................................................................................105
ISO 4406 table ................................................................................................105
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 .......................................................................................................106
SAE AS 4059......................................................................................................107
SAE AS 4059 table .........................................................................................107
Cleanliness codes according to SAE ..............................................................107
Absolute particle count larger than a defined particle size ..........................107
Specifying a cleanliness code for each particle size....................................108
Specifying the highest cleanliness code measured.....................................108
NAS 1638 ...........................................................................................................108
Technical data ......................................................................................................109
Factory default settings.......................................................................................111

FCU 8000 series Preface
HYDAC FILTER SYSTEMS GMBH en(us) Page 7/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
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 will acquaint you with the product and assist you in obtaining maximum benefit in
the applications for which it is designed.
Keep the manual in the vicinity of the device for immediate reference.
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 additional
suggestions or notes, contact us at:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
The editorial department looks forward to receiving your input.
Our motto: “Putting experience into practice”

FCU 8000 series Preface
HYDAC FILTER SYSTEMS GMBH en(us) Page 8/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Customer service
Contact our technical sales department if you have any questions on our product.
When contacting us, please always include the model/type designation and article
no. of the product:
Fax: [phone] / 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.
They are available at: www.hydac.com -> Legal information.

FCU 8000 series Preface
HYDAC FILTER SYSTEMS GMBH en(us) Page 9/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
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 the topic I am looking for.
WHERE can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
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 by one every time
the manual is revised or changed.
Chapter
Page number
Edition date
Document language
Documentation No.
with Index /
File name

FCU 8000 series Safety information and instructions
HYDAC FILTER SYSTEMS GMBH en(us) Page 10/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
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 basic safety instructions and regulations.
These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the FCU.
In addition, the accident prevention rules and regulation applicable at the location of
use are to be observed.
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.
Use the FCU:
Solely for its designated use
Only when in safe, perfect condition.
Immediately remedy any malfunctions that might impair safety.
Always keep the operating and maintenance instructions near the measurement
device.
In addition to the operating instructions, the general and local regulations on
accident prevention and environmental protection are to be made 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. Replace them if necessary.
Check the hoses and connectors for leaks on a daily basis.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►Depressurize the system before performing any
work on it.

FCU 8000 series Safety information and instructions
HYDAC FILTER SYSTEMS GMBH en(us) Page 11/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Explanation of symbols and warnings
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.
DANGER
DANGER 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 safety precautions
are not observed.
Proper/Designated Use
The Contamination Sensor (FCU) was developed for temporary or continuous
monitoring of 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.

FCU 8000 series Safety information and instructions
HYDAC FILTER SYSTEMS GMBH en(us) Page 12/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Improper Use
Any use other than described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
Improper connection of the FCU pressure and return flow hoses.
Sealing of the FCU return line.
What to Do in Case of Emergency
In the event of an emergency, immediately disconnect the FCU from the power
supply and from the hydraulic system.
Properly dispose of any escaping fluid in accordance with environmental guidelines.
Maintenance, Servicing and Troubleshooting
The specified adjustment, maintenance, and inspection work is to be conducted in a
timely fashion.
Secure all operating media against accidental start up.
When performing any maintenance, servicing, inspection or repair work, disconnect
the FCU from the power supply and ensure that it cannot be switched back on
inadvertently.
Check that released threaded joints were refit tightly.
Always check the safety devices to see that they function properly after performing
maintenance work.
Modifications to the FCU
Do not make any structural modifications (design modifications, extensions) to the
FCU without the prior consent of the manufacturer.
Any conversion modifications require written permission from HYDAC FILTER
SYSTEMS GMBH.
Immediately replace any parts which are not in perfect condition.
Use only original spare parts (OEM).

FCU 8000 series Safety information and instructions
HYDAC FILTER SYSTEMS GMBH en(us) Page 13/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Training 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.
they 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 Instructed individuals
Personnel
with
technical training/engineerin g background Electricians Supervisor with the appropriate authority
Activity
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
Servicing X
Decommissioning/storage X X X X

FCU 8000 series Checking the Scope of Delivery
HYDAC FILTER SYSTEMS GMBH en(us) Page 14/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Checking the Scope of Delivery
The FluidControl Unit FCU comes packed and ready for operation.
Before commissioning the SFC, check the content of the package to make sure
everything is present.
The following items are supplied:
Pc. Description
1 FluidControl Unit FCU 8xxx
2 Mains device and connection cable (configuration depends on the
order)
1 hp-hose with mini measurement port DN2, L=2000 mm
1 Return hose DN 7, L = 2000 m
1 Connection cable FCU <-> PC
1 CD-ROM with FluMoS light software
1 Operating and Maintenance Instructions
1 Calibration certificate

FCU 8000 series Description of the FCU
HYDAC FILTER SYSTEMS GMBH en(us) Page 15/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Description of the FCU
The FCU FluidControl Unit can determine the solid particle contamination of mineral
oils on a continuous basis.
With the FCU, it is possible to record, save and display the particle numbers for six
particle sizes and the cleanliness class completely automatically during continuous
operation in accordance with NAS 1638 and/or SAE AS4059 or ISO 4406.
The measured values can be printed out online in the form of either tables or graphs
by means of the built-in printer or sent via serial interface to a PC or a central
display unit for visualization purposes there.
Filter units can for example be actuated via relay outputs.
For input and output functions, the FCU possesses a keyboard, an LCD (Liquid
Crystal Display), a dot-matrix printer, control relay outputs and a serial data interface
The FCU possesses a mini measurement port (System 1620) as an input for
connection with the hydraulic unit, as well as a DN 7 plug nipple a a return flow.
A flow rate control valve is available for setting the measurement flow rate. This is
protected against larger particle contamination by an upstream filter.
The FCU has a rechargeable battery for ~ 5 hours of operation independent of the
mains network.
The FCU has a measured value memory for up to 3000 measured values, which are
stored in the form of logs (maximum of 100).

FCU 8000 series Description of the FCU
HYDAC FILTER SYSTEMS GMBH en(us) Page 16/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Operating elements / Dimensions
Item Designation
A High pressure port = INLET
B Return port connection - OUTLET
C Switch - On/Off
D Electrical connection - 24 V DC
E Serial interface
F Control port
G Sealing cover
J Dot-matrix printer
K Display
L Keyboard
M Flow rate regulator
N Filter element

FCU 8000 series Description of the FCU
HYDAC FILTER SYSTEMS GMBH en(us) Page 17/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Restrictions on use – FCU 8110 / 8210
NOTICE
Impermissible operating conditions
The FCU will be destroyed
►The FCU may only be used with mineral oils or mineral oil-based raffinates.
Restrictions on use – FCU 8111 / 8211
NOTICE
Impermissible operating conditions
The FCU will be destroyed
►Only operate the FCU in conjunction with HFD-R operating fluids
(phosphoric acid esters e.g. Skydrol, Fyrquel, Hyjet).

FCU 8000 series Hydraulic diagram
HYDAC FILTER SYSTEMS GMBH en(us) Page 18/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
Hydraulic diagram
9
15 1
8
7
5
10
OUTLET
INLET
Item Designation
1 Optical sensor
5 Flow rate sensor
7 Flow rate control valve (adjustable)
8 Filter
9 Flow control valve
10 Pressure relief valve
15 Pressure accumulator

FCU 8000 series Hydraulic diagram
HYDAC FILTER SYSTEMS GMBH en(us) Page 19/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
FCU Function Description
Item Designation
1 Optical sensor
2 Laser light source
3 Photodetector
4 Evaluation electronics
5 Flow rate sensor
6 Display
7 Flow rate control valve (adjustable)
8 Filter
9 Flow control valve
10 Pressure relief valve
11 Serial interface
12 Keyboard
13 Relay
14 Printer
15 Pressure accumulator

FCU 8000 series Hydraulic diagram
HYDAC FILTER SYSTEMS GMBH en(us) Page 20/112
BEWA FCU8000 3109776d en-us 2011-06-10.doc 2011-06-10
A continuous flow of oil runs through an optical sensor (1) comprised of a laser light
source (2) and a photo receiver (3). The contamination particles present in the flow
of oil cause pulse-like darkenings of the light beam, which are both classified as
measurement signals in accordance with particle size and counted by an evaluation
electronics system (4).
The measurement of the flow rate, which is necessary for specifying the
contamination class, is carried out by a built-in flow rate sensor (5), the signals from
which are also channeled to the electronic evaluation system (4).
Ultimately, the evaluation electronics (4) calculate on a continuous basis the particle
counts and the SAE / NAS or ISO contamination classes for the reference volume of
100 ml, based on the measurement signals from the optical sensor and the flow rate
sensor.
Here the measured values (up to 3000) are also stored on a continuous basis as
they arise, together with date and time, in a manner that is safe from network
outages. A battery-buffered real-time clock is available for this purpose.
A flow control valve (7) is available for adjusting the pressure fluctuation-
independent flow of oil.
A hydraulic filter (8) with electrical contamination indicator is positioned upstream
from this for the purpose of protecting against failure due to contamination.
The permanently adjusted valves (9) and (10) and the diaphragm memory (15)
enable the connection to extraction points for the pressure range of 1 ... 350 bar at
the "Inlet" access point.
The FCU can be operated via keyboard (12). Characteristic values for the
measurement can be modified and various kinds of presentation can be selected in
the LCD display (6).
If not set otherwise, the following information is continuously displayed during the
measurement (see also in this connection the chapter "The Display of the FCU"):
selected measurement mode
Progress of the ongoing measurement
Current value of the measurement results for 2 of the 4 particle size channels
Tendency: increasing or decreasing 
Current flow value
only in the event of fault -> Error messages
Furthermore, the FCU also possesses 3 built-in relays with the following functions:
Relays 1 and 2 are limit value switches (change-over contacts) and also serve to
control a filtration unit.
Relay 3 outputs the operational readiness signal (DEVICE READY)
(closing device; closed when FCU is ready for operation)