Hydac FCU 1310 Manual

FCU 1310
FluidControl Unit
Operating and maintenance instructions
English (translation of original instructions)
Valid from firmware version V 3.00 up
Valid from series no. (S/N) 0002S01831K0001000
Keep for future reference.
Document No.: 3371346f

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saar
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
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
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© 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.
Technical specifications are subject to change without notice.
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Content
Content
Imprint............................................................................................................2
Documentation representative ....................................................................2
Content ..........................................................................................................3
What's New — Changes to the manual.......................................................7
Preface...........................................................................................................8
Technical Support........................................................................................8
Modifications to the Product ........................................................................8
Warranty......................................................................................................8
Using the documentation.............................................................................9
Safety information ......................................................................................10
Hazard symbols.........................................................................................10
Signal words and their meaning in the safety information and
instructions ................................................................................................11
Structure of the safety information and instructions...................................12
Observe regulatory information .................................................................12
Proper/Designated Use .............................................................................13
Periodic intermittent duty - operating mode S3, (as per DIN EN
60034-1 / DIN VDE 0530, part 1) ...........................................................14
Improper Use or Use Deviating from Intended Use...................................15
Qualifications of personnel / target group ..................................................16
Wear personal protection equipment.........................................................17
Stoppage in an emergency (EMERGENCY STOP)...................................17
FCUOpening/Closing..................................................................................18
FCUtransporting .........................................................................................19
FCUstoring ..................................................................................................20
Decoding the model code label .................................................................21
Checking the scope of delivery .................................................................23
What can the product do?..........................................................................24
Counting contaminant particles .................................................................25
How the product works ..............................................................................27
Overview of control panel/operating elements...........................................28
Dimensions................................................................................................29
Hydraulic diagram......................................................................................30
Using the BatteryPack (accessory) ...........................................................31
Preparing the FCU for measurement ........................................................36
Connecting/Disconnecting the FCU electrically.........................................36
Plug in/Detach return hose ........................................................................37
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Content
Selecting the measurement location..........................................................38
Select the measurement method according to the pressure
involved .....................................................................................................39
Measuring up to max. 45 bar / 650 psi.......................................................40
Measuring in the range 5 to 345 bar / 217 to 5000 psi ..............................43
Measuring from unpressurized containers.................................................47
FCUoperating ..............................................................................................49
Display and keypad elements....................................................................49
Clicking through the display.......................................................................51
- Display.............................................................................51
- Display.............................................................................52
Displaying measured variables..................................................................53
"" measured variable ........................................................................53
"" measured variable .......................................................................53
"" measured variable.......................................................................53
"" measured variable ..................................................53
"" measured variable.........................................................53
Display service variables ...........................................................................54
"" service variable...........................................................................54
"" service variable..........................................................................54
Select operating level / configuration menu.............................................55
Operate / Set up menu ..............................................................56
– Setting date/time.............................................................57
- Set bus address...............................................................57
- Delete memory ................................................................58
- Set measuring time .............................................................58
– Select calibration type ........................................................59
– Reset to default settings..................................................59
- Cancel..............................................................................60
– Save data ..............................................................................60
Operating/Setting measuring menu ...........................................................61
– Record measurements....................................................62
- Display free memory ........................................................63
– Change name of measurement point..............................64
- Set temperature unit ........................................................65
- Cancel..............................................................................66
– Save data ..............................................................................66
Performing measurements ........................................................................67
Reading internal measurement memory...................................................68
Read out measured values via DATA interface.........................................69
Connecting FCU with a CSI-B-2 kit ........................................................69
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Content
Pins used on the DATA interface (HYDAC Sensor Interface –
HSI) ........................................................................................................69
Connecting FCU with HMG 510 / HMG 3000 / 4000..............................70
Reading out USB interface measured values............................................71
Copying measurements onto a USB data stick ......................................71
- Data transmission failed .....................................74
Reading out measured values via Bluetooth interface...............................75
Installing the Bluetooth USB adaptor......................................................76
Guarantee and liability for the USB adapter........................................76
Connecting/Linking the FCU via Bluetooth.............................................76
Evaluating measurement records .............................................................77
Measurement record directories according to measurement point............77
Measurement report file names.................................................................77
Opening measurement reports..................................................................78
The measurements are shown as dates ................................................80
Evaluating/Reading measurement reports with FluMoS .........................82
Preparing the FCU for transport ................................................................83
Performing maintenance............................................................................87
FCUcleaning..............................................................................................87
FCU flushing..............................................................................................88
Clean the suction strainer..........................................................................92
Checking the high pressure adapter..........................................................96
Cleaning / changing the strainer in the high pressure adapter ...............97
Cleaning / changing the strainer in the high pressure adapter ...............98
Identifying and interpreting status/error messages ................................99
Restarting/resetting ..................................................................................103
Taking the FCU out of operation .............................................................103
Shutting down the FCU............................................................................103
FCUdisposing ..........................................................................................103
Locating spare parts.................................................................................104
Selecting accessories..............................................................................105
Checking the measuring accuracy..........................................................107
FCUcalibrating.........................................................................................107
Technical Data...........................................................................................108
Appendix ...................................................................................................110
Model Code .............................................................................................110
Finding Customer Service / Service stations ...........................................111
Germany ..............................................................................................111
USA......................................................................................................111
Australia ...............................................................................................111
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Content
Brazil ....................................................................................................112
Factory default settings............................................................................112
Overview / Definition of the cleanliness classes ......................................113
Cleanliness class acc. to ISO 4406:1999.............................................113
ISO 4406 overview table ...................................................................114
Difference between ISO4406:1987 and ISO4406:1999 .......................115
Cleanliness class acc. to SAE AS 4059 ...............................................116
SAE AS 4059 overview table ............................................................116
Display cleanliness classes according to SAE Absolute particle
count larger than a defined particle size...............................................117
Specifying a cleanliness code for each particle size .........................117
Specifying the highest cleanliness code measured...........................117
Cleanliness class acc. to NAS 1638.....................................................118
EC declaration of conformity....................................................................119
Explanation of terms and abbreviations...................................................121
Index........................................................................................................122
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What's New — Changes to the manual
What's New — Changes to the manual
The index is featured on the cover sheet of the operating and maintenance
manual and in the lower left corner of each page after the part number.
Index "a" from firmware version V 1.10
-Change to the items delivered
-Change of Bluetooth device name to "FCU1310"
Index "b" — from firmware version V 2.00
-Change to the items delivered
-"USB connection" chapter added
-Additions made to user interface chapters
-Additions made to "BatteryPack" chapter
Index "c"
-Index adapted
Index "d"
-Restrictions on use of fluid with flash point < 55 °C added
-Spare parts list adapted
-"Transporting FCU" section updated
-Filling the hose lines before measuring is no longer necessary.
Index "e" from firmware version V 3.00
-From firmware V3.00 / from series no. 0002S01831K0001000
-Update / corrections / reworking
-Index added
Index "f" from firmware version V 3.00
-Update / corrections / reworking
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Preface
Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. Therefore please understand that, in the
absence of any provisions to the contrary hereinafter, our warranty and
liability – for any legal reasons whatsoever – are excluded in respect of the
information in these operating instructions. 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 injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to Product Liability shall remain
unaffected.
Technical Support
If you have any questions, suggestions, or encounter any problems of a
technical nature, please don't hesitate to contact us. When contacting us,
please always include the model code, serial no. and part no. of the product:
Fax:
[phone]
E-mail:
[e-mail]
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.
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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> General Terms and Conditions.
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Preface
Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all 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 document has a table of contents at the beginning. I select the chapter
I'm looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx- xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name
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Safety information
Safety information
The product 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 product. They
must always be complete and legible.
Do not operate the product unless all the safety devices are present.
Secure the hazardous areas which may arise between the product and other
equipment.
Maintain the product 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 electrical voltage / current
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure
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Safety information
Risk of burns due to hot surfaces
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 avoid
ed, can result in minor 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.
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Safety information
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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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 regulations
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Safety information
Proper/Designated Use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Use the product only for the application described below.
The FluidControl Unit FCU is a portable service unit for taking short-term
measurements of the solid particle contamination, temperature und %
saturation level in hydraulic systems.
Proper/designated use of the product extends to the following:
•Observing all the instructions contained in these operation and
maintenance instructions.
•Ensuring the execution of all inspection and maintenance work.
NOTICE
Impermissible operating conditions
The FCU will be destroyed
►Use the FCU with mineral oils or mineral oil-based raffinates whose
flash point is higher than 55°C / 131°F.
►Flush the FCU with low-viscosity mineral oils or mineral oil-based
raffinates (e.g. diesel) whose flash point is higher than 55°C / 131°F.
►Never flush the FCU with universal thinners or other degreasing fluids.
►Observe the permissible viscosity range (up to ISO VG 68):
10 - 350 mm²/s / 46 - 1622 SUS.
►Only operate the FCU in periodic intermittent duty (S3) with a relative
duty cycle of 40%
(S3 as per DIN EN 60034 / VDE 0530).
►Never use the FCU without a suction strainer.
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Safety information
NOTICE
Connection to 24 V DC on-board networks without load dump
The FCU will be destroyed.
►Use the FCU only on 24 V DC on-board networks
which have a central
"Load Dump" fuse.
►Before connecting, be sure to check that a load dump is installed with
at least 30 V DC and is effective.
Periodic intermittent duty - operating mode S3,
(as per DIN EN 60034-1 / DIN VDE 0530, part 1)
Operation t0in time t1at power (PN)S3 interchange periodically with the
cooling phases (downtimes) t2. The relative duty cycle is 40%.
(P
N
)
S3
=
Nominal power, operating mode S3
t
=
Time
t
0
=
Period (operation t
1
+ cooling phase t
2
)
t
1
=
Operation
t
2
=
Cooling phase (downtime)
°C (°F)
=
Temperature
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Safety information
Improper Use or Use Deviating from Intended Use
DANGER
Hazard due to use of the product other than
that intended
Bodily injury and damage to property will result
when operated improperly.
►Never operate the product in potentially
explosive atmospheres.
►Only use the product with permissible media.
Any use extending beyond this 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 product.
Examples of improper use:
•Operation with fluid that has a flash point under 55°C / 131°F.
•Flush with universal thinners or other degreasing fluids
•Operation in potentially explosive atmospheres.
•Operation under non-approved operational conditions.
•Modifications to the product made by the user or purchaser.
•Continuous monitoring of the fluid cleanliness (continuous operation)
•Improper connection of the pressure and return flow hoses.
•Operation at a measurement point with impermissible pressure.
•Operation on 24 V DC on-board networks without central
"Load Dump" fuse.
•Operation with an impermissible fluid.
•Operation with faulty or damaged hoses.
•Operation with damaged connector cable.
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Safety information
Qualifications of personnel / target group
Auxiliary, operational 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:
Auxiliary personnel:such persons have been instructed about the product
and informed about potential hazards that can result from improper use.
Operating personnel: such persons have been instructed in product
operation and are aware of potential dangers 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.
Activity
Person
Knowledge
Transport / storage
Auxiliary
personnel
•No specialist knowledge
required
Startup operation
Operations control
Auxiliary
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
Troubleshooting,
Maintenance,
Decommissioning,
Specialist
personnel
•Safe handling/use of tools
•Product-specific knowledge
Disassembly
Service staff
(only with
authorized
HYDAC
Service)
•Very detailed product-specific
knowledge
Disposal
Specialist
personnel
•Proper and environmentally-
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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Safety information
Wear personal protection equipment
Observe the information relating to personal protection equipment in the
safety data sheet of the operations fluid.
•Wear eye protection.
•Wear gloves.
Stoppage in an emergency (EMERGENCY STOP)
In the event of an emergency, disconnect the FCU from the power supply
and from the hydraulic system.
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FCUOpening/Closing
FCUOpening/Closing
Open the FCU by releasing both clips.
Close the FCU using both clips. Make sure that these audibly snap into
place.
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FCUtransporting
FCUtransporting
Transport the FCU only when it is in closed position; carry it flat or by the
handle.
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FCUstoring
FCUstoring
Drain and rinse the FCU completely before putting it into storage. See page
88 in the "FCU flushing" chapter for details on rinsing the FCU.
Observe permissible conditions required for storage on page 108 in the
"Technical Data" chapter.
Store the FCU closed and in a horizontal position in a dry, clean place. If
stored in a vertical position, the FCU must not be exposed to any shaking or
vibration.
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