Hydac FluidMonitoring FMM-P-L Series Manual

FMM-P-L ... /060
FluidMonitoring Module
Operating and maintenance instructions
English (translation of original instructions)
Document No.: 3462890

FMM-P-L Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2009 by
HYDAC Filter Systems GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
explicit written agreement from HYDAC Filter Systems. Contraventions are liable to
compensation.
Exclusion of liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. 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
Industriegebiet, Werk 6
66280 Sulzbach / Saar
Germany
Phone: ++49 (0)6897 / 509 – 01
Fax: ++49 (0) 6897 509 846

FMM-P-L Contents
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Contents
Trademarks ...............................................................................................................2
Contents....................................................................................................................3
Preface ...................................................................................................................... 5
Customer Service ...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the documentation ........................................................................................7
Safety Information and Instructions.......................................................................8
Obligations and Liability..........................................................................................8
Explanation of Symbols and Warnings ................................................................... 9
Proper/Designated Use .......................................................................................... 9
Improper use........................................................................................................... 9
Informal Safety Precautions.................................................................................. 10
Training and Instruction of Personnel ...................................................................11
Safety Measures to Be Followed during Normal Operation..................................11
Maintenance, Servicing and Troubleshooting....................................................... 11
Modifications to the FMM-P-L...............................................................................12
Storage ....................................................................................................................12
Checking the scope of delivery ............................................................................13
FMM Features ......................................................................................................... 14
Restrictions on use ...............................................................................................14
Hydraulic schematic .............................................................................................. 15
Dimensions .............................................................................................................15
FMM-P-L components............................................................................................16
Attaching the FMM-P-L mechanically...................................................................17
FMM-P-L hydraulic installation .............................................................................18
Connecting the FMM-P-L with the hydraulic system ..........................................19
Error messages / Troubleshooting.......................................................................20
Performing maintenance ....................................................................................... 20
Maintenance interval............................................................................................. 20
Changing the Filter Element .................................................................................21
Decommissioning the FMM-P-L............................................................................22
Disposing of the FMM-P-L ..................................................................................... 22
Spare parts and accessories.................................................................................23

FMM-P-L Contents
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Technical Data ........................................................................................................24
Customer Service...................................................................................................24

FMM-P-L Preface
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Preface
We have compiled the most important instructions for the operation and
maintenance of our product for you, its user, in this documentation.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
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
Fax: ++49 (0) 6897 509 846
E-Mail: [email protected]
We look forward to receiving your input.
“Putting experience into practice”

FMM-P-L Preface
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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, serial no.
and part-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 additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC Filter Systems GmbH.
Refer to these at www.hydac.com  General terms and conditions.

FMM-P-L Preface
Using the documentation
Please note that the method described above of locating specific
information does not release you from your responsibility for carefully
reading the entire manual prior to starting the unit up for the first time
and carefully rereading the manual at regular intervals later on.
WHAT do you want to know?
I determine which topic I am looking for.
WHERE can I find the information I’m looking for?
The document has a table of contents at the beginning. There, I select the
chapter I'm looking for and the corresponding page number.
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Chapter description
Page numb
Edition date
Document language
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.
Documentation No.
with index
/
file name
er

FMM-P-L Safety Information and Instructions
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Safety Information and Instructions
These operating instructions contain the most important notes for operating the
FMM-P-L safely.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the FMM-P-
L is knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the FMM-P-L.
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 FMM-P-L.
The FMM-P-L 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 FMM-P-L is 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 FMM-P-L or use deviating from its designated use
• improper assembly, installation, commissioning, operation and maintenance of
the FMM-P-L
• modifications to the FMM-P-L made by the user or purchaser
• Improper monitoring of unit components that are subject to wear and tear
• Improperly performed repair work

FMM-P-L Safety Information and Instructions
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 mortal injury
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 safety precautions
are not observed.
Proper/Designated Use
The FluidMonitoring Module FMM-P-L was developed for the continuous monitoring
of particulate contamination and water content 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:
• Observing all the notes contained in these operating instructions.
• 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:
• Improper connection of the pressure and return lines of the FMM-P-L.
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FMM-P-L Safety Information and Instructions
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
In addition to the manual, the general and local regulations concerning accident
prevention and protection of the environment should be available and observed.
Make sure to keep the safety and hazard symbols and warnings on the FMM-P-L in
a legible condition.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FMM-P-L are to also be regularly checked (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.
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WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

FMM-P-L Safety Information and Instructions
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Training and Instruction of Personnel
The FMM-P-L 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 FMM-P-L unless supervised by an
experienced staff member.
Individuals Personnel undergoing training
I
n
di
v
id
ua
l
s w
ith
technical training/ engineering background Electrician 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
Repair work X
Shutdown/
decommissioning X X X X
Safety Measures to Be Followed during Normal Operation
Do not operate the FMM-P-L 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.
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
Any screwed fittings which have been undone/removed are to be checked to see
that they have been properly resecured.

FMM-P-L Storage
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Modifications to the FMM-P-L
Do not make any modifications (design modifications, extensions) to the FMM-P-L
without the prior consent of the manufacturer.
Any modifications require written permission from HYDAC Filter Systems GmbH.
Immediately replace any machine components which are not in perfect condition.
Use only original spare parts. Non-OEM components have no guarantee that they
have been designed and manufactured so as to comply with loading and safety
requirements.
Storage
Store the FMM-P-L in a clean, dry place, in the original packing if possible. Do not
remove the packing until you are ready to install the unit.
Drain the FMM-P-L completely before putting it into storage. If necessary, rinse the
FMM-P-L with n-heptane to prevent it from gumming up.
Use and dispose of used cleaning agents and flushing oils properly.

FMM-P-L Checking the scope of delivery
Checking the scope of delivery
The Fluid Monitoring Module FMM-P-L comes packed and factory-assembled.
Before commissioning the FMM-P-L, check the content of the package to make sure
everything is present.
The following items are supplied:
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Item Qty Designation
1 1 FluidMonitoring module FMM-P-L
2 1 Connector with 8-pole, M12x1, screened
3 1 Connector (female), 5-pole, M12x1
- 1 Operating and Maintenance Instructions FMM-P-L (this document)
- 1 Operating and maintenance instructions AS1000
- 1 CD-ROM with:
- Software CoCoS 1000
- Operation and maintenance instructions CS 1000
- 1 CD-ROM with FluMoS Light software
- 1 Calibration certificate CS1000
1
2
3

FMM-P-L FMM Features
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FMM Features
The FluidMonitoring Module FMM-P-L Series combines HYDAC's Condition
Monitoring Products ContaminationSensor CS 1000 and AquaSensor AS 1000 in
one system.
The FMM-P-L is used as a robust and stationary system for online measurement of
solid particle contamination and water content in hydraulic and lubricant fluids (e.g.
for the detection of leakages).
The FMM-P-L features all of the requisite connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits.
The FMM-P-L is suitable for an operating pressure of 15 ... 300 bar.
Advantages offered by the FMM-P-L:
• Cost-effective solution
• Early warning in the case of critical machine states
• Continuous fluid monitoring
• Condition-based maintenance planning
Restrictions on use
NOTICE
Impermissible operating conditions
The FMM-P-L will be destroyed
►The unit is only to be used with mineral oils or mineral oil-based raffinates.
►Do not exceed the maximum operating pressure.

FMM-P-L Hydraulic schematic
Hydraulic schematic
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CS
IN OUT
AS
TP1 TP2
Dimensions
≈ 325
60
115
190 210
ø6,6
≈ 120

FMM-P-L FMM-P-L components
FMM-P-L components
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6
9
8
7
1
54
2
11 3
Item Designation
1 FMM-P-L Installation block
2 ContaminationSensor CS 1000 series
3 Connector (female), 8-pole, M12x1
4 AquaSensor AS 1000 series
5 Connector (female), 5-pole, M12x1
6 Inlet (IN), female thread G ¼ according to ISO 228
7 Outlet (OUT), female thread G ¼ according to ISO 228
8 Test connection (TP1), test connector Type 1620
9 Test connection (TP2), test connector Type 1620
11 Filter element (installed)

FMM-P-L Attaching the FMM-P-L mechanically
Attaching the FMM-P-L mechanically
Install the FMM-P-L so that the direction of flow is vertical.
When selecting the installation site, check the ambient conditions such as
temperature, dust, water, etc. The CS features a protection rating of IP 67 according
to DIN 40050 / EN60529 / IEC 529 / VDE 0470
Fastening can be carried out by means of the four holes in the installation block with
4 M6 screws in accordance with ISO= 4762 (minimum length 80 mm).
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190
115
60

FMM-P-L FMM-P-L hydraulic installation
FMM-P-L hydraulic installation
To minimize measurement errors resulting from trapped air in the system, we
recommend the flow direction through the FMM-P-L from bottom (IN) to top (OUT).
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IN
OUT

FMM-P-L Connecting the FMM-P-L with the hydraulic
t
Connecting the FMM-P-L with the hydraulic system
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WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Connect the FMM-P-L with the hydraulic system as follows:
1. Check the pressure at the measurement site. It must be within the
permissible range.
2. The hydraulic system has to be completely depressurized.
3. First connect the return-flow line to the outlet port (OUT) of the FMM-P-L.
We recommend an internal Ø ≥4 mm for the return line.
4. Now connect the other end of the return line to the system tank, for
example.
5. Now connect the measurement line to the inlet port (IN) of the FMM-P-L.
We recommend an internal Ø ≥4 mm for the jpressure line in order to
prevent particle deposits.
6. Now connect the other end of the measurement line to the measurement
point.
The hydraulic installation of the FMM-P-L is now complete.

FMM-P-L Error messages / Troubleshooting
Error messages / Troubleshooting
The following error messages may result when the CS 1000 is combined with the
FMM-P-L installation block.
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LED Blink code /
Display /
Analog output /
Switch out
Status To do
Red
4.4 mA / 2.2 V*
open
Flow too low
Check flow
Increase inlet pressure
or check outlet pressure
at measurement point.
p
Δ
must amount to a
minimum of 15 bar -> if
OK, change filter
element.
Red
19.9 mA / 9.95 V*
open
Flow definition not
possible
The Sensor status
definition not possible
Check flow.
If the oil quality is below
the measurement limit
(ISO 9/8/7), it may take
several measurement
cycles until measured
values are displayed
Increase inlet pressure
or check outlet pressure
on test point.
p
Δ
must amount to a
minimum of 15 bar -> if
OK, change filter
element.
For other error messages, please refer to your CS 1000 operating and maintenance
manual.
Performing maintenance
Maintenance interval
Replace the filter element at least every six months.