Hydac FMM-O-M Series User manual

FMM-O-M
FluidMonitoring Module
Installation and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 3874983
(Valid from series no.: 0002S01827N0000401)

Imprin
t
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Telefax: [phone]
E-Mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive director: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-Mail: [email protected]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
All details are subject to technical modifications. The content of this manual is
subject to change without notice.

Documentation Representative
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Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Preface...........................................................................................................5
Customer service.........................................................................................6
Modifications to the Product ........................................................................6
Warranty ......................................................................................................6
Using the documentation .............................................................................7
Safety Information and Instructions............................................................8
Hazard symbols...........................................................................................8
Signal words and their meaning in the safety information and
instructions ..................................................................................................9
Structure of the safety information and instructions.....................................9
Observe regulatory information .................................................................10
Proper/Designated Use .............................................................................10
Improper Use or Use Deviating from Intended Use ...................................11
Qualifications of personnel / target group ..................................................12
Unpacking the FMM ....................................................................................13
Storing the FMM..........................................................................................14
Decoding the model code label .................................................................14
Checking the scope of delivery .................................................................15
FMM Features..............................................................................................16
Components ..............................................................................................17
Dimensions..................................................................................................18
Hydraulic diagram.......................................................................................18
Attaching the FMMP mechanically ............................................................19
FMM hydraulic installation.........................................................................20
Connecting FMM with the hydraulic system ............................................21
Setting flow rate..........................................................................................22
Error messages / Troubleshooting............................................................23

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Decommissioning the FMM........................................................................24
Disposing of the FMM.................................................................................24
Contact/Service...........................................................................................25
Spare Parts and Accessories.....................................................................26
Spare Parts................................................................................................26
Accessories ...............................................................................................27
Technical data.............................................................................................28
Model Code..................................................................................................29
Index ............................................................................................................30

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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.
Note that the information on the unit's engineering contained in the
documentation was that available at the time of publication.Consequently,
there might be deviations in technical details, figures 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.
“Putting experience into practice”

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Customer service
If you have any questions, suggestions, or encounter any problems of a
technical nature, please don't hesitate to contact us. When contacting us,
always include the model/type designation, serial no. and part-no. of the
product:
Telefax: ++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.
After modification or repair work that affects the safety of the product has
been carried out on components, the product may not be returned to
operation until it has been checked and released by a HYDAC technician.
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.
You will find this at www.hydac.com -> Legal information.

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Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
these instructions prior to starting the unit up for the first time and
at regular intervals in the future.
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 documentation has a table of contents at the beginning. There, I
select the chapter I'm looking for and the corresponding page number.
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index number is
incremented upward by one number every time the manual is revised or
changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index
/
file name

Safety Information and Instructions
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Safety Information and Instructions
The module was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the module. They
must always be complete and legible.
Do not operate the module unless all the safety devices are present.
Secure the hazardous areas which may arise between the module and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to operating pressure
Risk of burns due to hot surfaces

Safety Information and Instructions
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Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a danger with a high risk and which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a danger with a medium risk and which can lead to
death or serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor
injury if not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
SIGNAL WORD
Type and source of danger
Consequence of the danger
HAZARD SYMBOL
►Measures to avert danger

Safety Information and Instructions
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Observe regulatory information
Also 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 regulations
Proper/Designated Use
Use the module only for the application described in the following:
The FluidMonitoring Module FMM is for monitoring solid particle
contamination in hydraulic systems.
NOTICE
Impermissible operating fluid
The FluidMonitoring Module will be destroyed
►The FMM may only be used with mineral oils or mineral oil-based
raffinates.
Proper or designated use of the product extends to the following:
• Observing all instructions contained in the instruction manual.
• Performing inspection and maintenance work.

Safety Information and Instructions
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Improper Use or Use Deviating from Intended Use
DANGER
Hazard due to use of the module other than
that intended
Bodily injury and damage to property will result
when operated improperly.
►Never operate the module in potentially
explosive atmospheres.
►The module is only to be used with
permissible media.
Any use extending beyond or deviating therefrom shall not be considered
intended use. HYDAC Filter Systems GmbH will assume no liability for any
damage resulting from such use. The user alone, shall assume any and all
associated risk
Improper use may result in hazards and/or will damage the module.
Examples of improper use:
• Operation in potentially explosive atmospheres.
• Operation with a non-approved medium.
• Operation under non-approved operational conditions.
• Operation when the safety devices are defective.
• modifications to the module made by the user or purchaser
• Inadequate monitoring of parts that are subject to wear and tear
• Improperly performed repair work / maintenance.

Safety Information and Instructions
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Qualifications of personnel / target group
Persons who work on the module must be aware of the associated hazards
when using the module.
Operating and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Operating personnel: such persons have been instructed in module operation
and are aware of potential hazards due to improper use.
Specialist personnel: such persons with corresponding 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.

Unpacking the FMM
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Activity Person Knowledge
Transport / storage Auxiliary
personnel
• No specialist knowledge
required
Hydraulic / electrical
installation,
first commissioning,
maintenance,
troubleshooting,
repair,
decommissioning,
disassembly
Specialist
personnel
• Safe handling/use of tools
• Fitting and connection of
hydraulic lines and pipelines
and connections
• Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
• Product-specific knowledge
Operation
operations control
Specialist
personnel
• Product-specific knowledge
• Knowledge about how to
handle operating media.
• Knowledge about
contamination due to solids
and water
Disposal Specialist
personnel
• Proper and environmentally-
friendly disposal of materials
and substances
• Decontamination of
contaminants
• Knowledge about reuse
Unpacking the FMM
Before delivery, the FMM is inspected for leaks and proper functioning at the
factory, then carefully packed for shipment.
When receiving and unpacking the module, check it for damage in transit.
Dispose of the packaging material in an environmentally friendly manner.

Storing the FMM
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Storing the FMM
Store the FMM in a clean, dry place, in the original packing if possible. Do not
remove the packing until you are ready to install the unit.
Always store the FMM in a horizontal or vertical position on the block, without
its original packaging.
Drain the FMM completely before putting it into storage. If necessary, rinse
the FMM with n-heptane to prevent it from gumming up during storage.
Decoding the model code label
For product identification details of the ConditionSensor see the Model code
label. This is located on the back of the unit and contains the exact product
description and the serial number.
Row -> Description
Model -> Model code; for details, see page 29
P/N -> Part no.
S/N -> Serial no.
Date -> Year/week of production and hardware index
Min. INLET press.: -> Minimum operating pressure
Max. INLET press.: -> Maximum operating pressure

Checking the scope of deliver
y
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Checking the scope of delivery
The FluidMonitoring Module FMM comes packed and factory-assembled.
Before commissioning the FMM, check the contents of the package to make
sure it has not been damaged during transport and that it is complete.
The following items are supplied:
Qty. Designation
1 FluidMonitoring Module FMM-O-M
1 Installation and Maintenance Instructions (this document)
1 CD Operating and Maintenance Instructions CS 1000
(A PC with a PDF display program is required for displaying
this.)
1 CD FluMoS light (FluidMonitoring Software)
1 Calibration certificate CS 1000
1 Additional sensor manual (optional)

FMM Features
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FMM Features
The FluidMonitoring Module FMM Series combines HYDAC's Condition
Monitoring Products ContaminationSensor CS 1000 and AquaSensor AS
1000 in one system.
The FMM is used as a robust and stationary system for the online
measurement of solid particle contamination and, depending on the
equipment, water content in hydraulic and lubricant fluids (e.g. as an
indication of leakage, defective seals, water ingress, etc.)
The FMM features all of the requisite connectors / adapters, enabling it to be
easily connected to existing hydraulic circuits.
The FMM is suitable for operating pressures between 6 … 15 bar.
Typical applications of the FMM are filter-cooler/heater circuits.
Advantages offered by the FMM:
• Cost-effective solution
• Early warning in the case of critical machine states
• Continuous fluid monitoring
• Condition-based maintenance planning

FMM Features
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Components
The FMM has the following components, depending on the version:
Item Designation
1 FMM-O-M-... connection block
2 ContaminationSensor CS 1000 series
3 AquaSensor AS 1000 series or
AquaSensor AS 3000 series or
No additional sensor
4 INLET (IN),
with test connector type 1604 or G ¼ according to ISO 228
5 OUTLET (OUT), with test connector type 1604 or G ¼ according
to ISO 228
6 Throttle valve
7 Test point (TP1),
test point type 1604

Dimensions
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Dimensions
The FMM has the following dimensions, depending on the version and
additional sensor:
Hydraulic diagram
The FMM has the following hydraulic diagram, depending on the version and
additional sensor:
CS
IN OUT
AS
TP1

Attaching the FMMP mechanicall
y
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Attaching the FMMP mechanically
We recommend installing the unit vertically, so that the flow direction is from
bottom to top. 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 40.050 / EN60.529 / IEC 529 /
VDE 0470
The FMM can be mounted as follows:
Ⓐthe two mounting holes in the installation block using 2x cylindrical
screws M6 x 55 mm according to ISO 4762
Ⓑthe two mounting holes in the CS 1000 using 2x cylindrical screws
M8 x 50 mm according to ISO 4762
Ⓒthe four threaded holes in the installation block using 4x M6 screws
90
5
0
35
90
83
A
C
B

FMM hydraulic installation
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FMM hydraulic installation
To minimize measurement errors resulting from trapped air in the system, we
recommend that the flow direction through the FMM is from bottom (IN) to top
(OUT).
Determine the operating pressure of the hydraulic system and see whether it
is within the permissible flow range for the FMM inlet.
The FMM comes delivered with two test connectors (type 1604), one at the
inlet (IN) and one at the outlet (OUT) port. If the hydraulic connection is done
via the connector thread G 1/4 according to ISO 228, the test connectors
must be removed.
The mounting holes on the FMM are through-holes. There are three
connection possibilities:
IN / TP1 / OUT Connections on the "back side"
IN / TP1 / OUT connections on the "side"
IN / TP1 / OUT connections on the "front side" (position at delivery time)
IN
ININ
OUTOUTOUT
TP1
TP1
TP1
AC
B
The screw plugs can be exchanged for the test connectors and vice versa.