Hydac FluidControl FCU 2000-1 Series Manual

FCU 2000-1 Series
FluidControl Unit
Operating and Maintenance Instructions
Valid from firmware versions 3.22 up
English (translation of original instructions)
Document no.: 3116140d

FCU 2000-1 Series
Trademarks
HYDAC FILTER SYSTEMS GMBH
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
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 made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, no liability is assumed for any
errors or deficiencies inherent in this document, including consequential damage or
loss. The content of the manual is checked regularly. Any corrections required will
be incorporated in subsequent editions. We welcome any suggestions for
improvements.
All details are subject to technical modifications.
Technical specifications of this manual are subject to change without notice.
HYDACFILTERSYSTEMSGMBH
Postfach1251
66273Sulzbach /Saar
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:
[e-mail]

FCU 2000-1 Series
Contents
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Contents
Trademarks.............................................................................................................2
Documentation Representative .............................................................................2
Contents..................................................................................................................3
Changes to the manual ..........................................................................................6
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
How to behave in case of emergency..................................................................12
Maintenance, Servicing and Troubleshooting......................................................12
Modifications to the FCU.....................................................................................12
Training and Instruction of Personnel..................................................................13
Checking the Scope of Delivery ..........................................................................14
Description of the FCU.........................................................................................15
Operating elements / Dimensions .......................................................................16
Restrictions on use –FCU 2010 / 2110 / 2210....................................................17
Restrictions on use –FCU 2011 / 2111 / 2211....................................................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
Programmable limit values FCU 20xx..............................................................27
Programmable limit values FCU 21xx / FCU 22xx...........................................28

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Hydraulic connection of the FCU ........................................................................29
Conducting measurements via the high-pressure port (INLET)........................30
Switching on the FCU...........................................................................................31
Switching on the FCU .........................................................................................31
Selecting the Viscosity Range.............................................................................31
Starting up the FCU..............................................................................................32
Conducting Measurements via the High-Pressure Port (INLET)..........................32
Operating the FCU................................................................................................33
Function of the Keys ...........................................................................................33
Menu and Number Keys (red).............................................................................34
Key Combinations...............................................................................................34
FCU menus............................................................................................................35
MODE - select operating mode...........................................................................35
MODE "M1: Measure" .....................................................................................36
MODE "M2: Measuring and switching" ............................................................36
MODE "M3: Filter to" (performance of automatic filtration)...............................36
MODE "M4: Filtering from to" (performance of automatic filtration)..................37
MEMORY Menu..................................................................................................38
Designating the measurement point ................................................................39
Setting the averaging interval ..........................................................................40
Selective deletion ............................................................................................41
Delete all .........................................................................................................43
Change meas. –point......................................................................................44
Setting the memory mode................................................................................45
PRINT menu.......................................................................................................46
Logs ................................................................................................................47
Contents..........................................................................................................50
All parameters .................................................................................................50
Paper feed.......................................................................................................51
Online Print-out................................................................................................51
Abort print-out..................................................................................................52
LIMITS menu ......................................................................................................52
MODE M2........................................................................................................53
MODE M3........................................................................................................54
MODE M4........................................................................................................54
SETUP menu......................................................................................................56
Autostart..........................................................................................................57
Abort at Q=0....................................................................................................58
Setting the pump start delay............................................................................59
Setting the date and time.................................................................................60

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Set bus address...............................................................................................61
Display operating hours...................................................................................61
Check the battery status..................................................................................62
POWERUP menu................................................................................................62
Selecting the language....................................................................................63
Setting the viscosity range...............................................................................63
Setting the measured volume..........................................................................64
FCU display...........................................................................................................65
Brief Overview of the Menu Structure.................................................................67
Error Messages and Troubleshooting.................................................................69
Performing Maintenance......................................................................................73
Cleaning the FCU................................................................................................73
Changing the FCU Filter Element........................................................................73
Back-flushing the FCU ........................................................................................76
Internal dot-matrix impact printer –replace paper roll / ink ribbon .......................76
Disposing of the FCU ...........................................................................................78
Storing the FCU ....................................................................................................78
Storage conditions ..............................................................................................78
Calibrating the FCU..............................................................................................78
Customer service..................................................................................................79
Germany.............................................................................................................79
USA ....................................................................................................................79
Australia..............................................................................................................79
Brazil...................................................................................................................80
China ..................................................................................................................80
Spare parts............................................................................................................81
FCU 2xx0 (version for mineral oil).......................................................................81
FCU 2xx1 (version for HFD fluids).......................................................................81
FCU 2xxx-x.........................................................................................................82
Accessories ..........................................................................................................82
Explanation of the measuring technology terms used......................................83
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes ..............................84
ISO 4406:1999....................................................................................................84
ISO 4406 table.................................................................................................84
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 .......................................................................................................85
SAE AS 4059......................................................................................................86
SAE AS 4059 table..........................................................................................86
Cleanliness Classes according to SAE............................................................86

FCU 2000-1 Series
Changes to the manual
HYDAC FILTER SYSTEMS GMBH
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NAS 1638............................................................................................................87
Technical Data ......................................................................................................88
Factory default settings .......................................................................................90
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 article number.
Index "b" —from firmware version V 3.2x
-Changes to firmware have been integrated
Index "c" - from firmware version V 3.2x
-Changes to firmware have been integrated
-Document standardization acc. 2006/42/EC
-Defined display for excessively dirty fluid
Index "d" —from firmware version V 3.2x
-Revision of Manual

FCU 2000-1 Series
Preface
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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.
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:
HYDACFILTERSYSTEMSGMBH
TechnischeDokumentation
Postfach12 51
66273Sulzbach/Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”

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Preface
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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, please always
include the model/type designation and article no. of the product:
Fax:
+49 (0) 6897 / 509 - 846
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.
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.

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Preface
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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 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 by one number
every time the manual is revised or changed.
Chapter
Page number
Edition date
Document language
Documentation No.
with Index /
File name

FCU 2000-1 Series
Safety Information and Instructions
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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.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The FCU 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.
Use the FCU:
solely for its designated use
only when in a 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 manual, the general and local regulations concerning accident
prevention and protection of the environment should be 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.
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 2000-1 Series
Safety Information and Instructions
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Explanation of Symbols and Warnings
The following designations and symbols are used in this manual to designate
dangers and hazards:
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.
Proper or designated use of the product extends to the following:
Maintaining adherence to all the instructions contained in the operating manual.
Performing requisite inspection and maintenance work.

FCU 2000-1 Series
Safety Information and Instructions
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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 FluidControl Unit pressure and return flow hoses.
Sealing of the FCU return line.
How to behave 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 prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
All operating media are to be protected in case the product is accidentally started
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 any screwed fittings which have been removed to see that they have been
properly secured.
Always check the product to see that it functions properly when performing
maintenance and servicing 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 2000-1 Series
Safety Information and Instructions
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Training and Instruction 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.
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
Individuals undergoing training
Individuals with 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
Decommissioning/storage
X
X
X
X

FCU 2000-1 Series
Checking the Scope of Delivery
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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:
Item
Qty
Description
1
1
FluidControl Unit FCU 2xxx-1
2
2
Mains device and connection cable (configuration depends on
the order)
3
1
hp-hose with mini measurement port DN4, L=2000 mm
4
1
Return hose DN 7, L = 2000 m
5
1
Connection cable FCU <-> PC
6
1
CD-ROM with FluMoS light software
-
1
Operating and Maintenance Instructions
-
1
Certificate of calibration
1
6
5
2
4
3

FCU 2000-1 Series
Description of the FCU
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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 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 1604) 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 2000-1 Series
Description of the FCU
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Operating elements / Dimensions
Item
Description
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
H
Suction port SUCTION INLET (only 2xx0-4)
I
Change-over valve (only 2xx0-4)
J
Dot-matrix printer
K
Display
L
Keyboard
M
Flow rate regulator

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Description of the FCU
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Restrictions on use –FCU 2010 / 2110 / 2210
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 2011 / 2111 / 2211
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 2000-1 Series
Hydraulic diagram
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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 control valve
15
Pressure accumulator

FCU 2000-1 Series
Hydraulic diagram
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FCU Function Description
Item
Description
1
Optical sensor
2
Infrared LED
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 control valve
11
Serial interface
12
Keyboard
13
Relay
14
Printer
15
Pressure accumulator

FCU 2000-1 Series
Hydraulic diagram
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A continuous flow of oil runs through an optical sensor (1) comprised of an infrared
LED (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)