Hydac FMM Manual

FMM
FluidMonitoring Module
Operating and Maintenance Instructions
English (translation of original instructions)
Document No.: 3289566c

FluidMonitoring Modul - FMM 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. Consequently, we accept no liability for such
errors as may exist nor for any damage or loss whatsoever which may arise as a
result of such errors. The content of the manual is checked regularly. Any
corrections required will be incorporated in subsequent editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filter Systems GmbH
Industriegebiet, Werk 6
66280 Sulzbach / Saar
Germany
Telephone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 - 846

FluidMonitoring Modul - FMM Content
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Content
Trademarks ...............................................................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Technical Support...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the documentation ........................................................................................7
General Safety Precautions.....................................................................................7
Obligations and Liability.......................................................................................... 8
Explanation of Symbols and Warnings ................................................................... 9
Proper/Designated Use .......................................................................................... 9
Improper Use .......................................................................................................... 9
Informal Safety Precautions..................................................................................10
Safety Measures to Be Followed during Normal Operation.................................. 10
Modifications to the FMM......................................................................................10
Training and Instruction of Personnel ...................................................................11
Maintenance, Servicing and Troubleshooting.......................................................11
Storing the FMM .....................................................................................................12
Checking the scope of delivery ............................................................................13
FMM Features ......................................................................................................... 14
Instructions for use ............................................................................................... 14
Hydraulic schematic..............................................................................................15
FMM components ................................................................................................. 16
Dimensions ...........................................................................................................17
Display adjustable as needed...............................................................................17
Securing the FMM mechanically...........................................................................18
FMM hydraulic installation .................................................................................... 19
Connecting FMM with the hydraulic system........................................................ 20
Flow regulation....................................................................................................... 21
Error messages / Troubleshooting.......................................................................22
Removing the FMM from the hydraulic system/shutdown................................. 23
Disposing of the FMM ............................................................................................ 23
Spare parts and accessories.................................................................................24
Spare Parts........................................................................................................... 24
Accessories .......................................................................................................... 24

FluidMonitoring Modul - FMM Content
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Technical data ........................................................................................................ 25
Customer Service................................................................................................... 25

FluidMonitoring Modul - FMM 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 will acquaint you with the product and assist you in using it as intended in an
optimal manner.
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. There may be deviations in technical details, figures, and
dimensions as a result.
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”

FluidMonitoring Modul - FMM Preface
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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/type designation and article 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 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
We assume warranty in accordance with the General Terms of Sale and Delivery of
HYDAC Filter Systems GmbH.
They are available at: www.hydac.com Legal information.

FluidMonitoring Modul - FMM General Safety Precautions
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 document has a table of contents at the beginning. 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.
General Safety Precautions
These operating instructions contain the key instructions for properly and safely
operating the FMM.
Documentation no.
with index
/
file name
er

FluidMonitoring Modul - FMM General Safety Precautions
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Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the FMM 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.
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.
The FMM has been designed and constructed in accordance with the current state
of the art and recognized safety regulations. Nevertheless, hazards may be posed to
the life and limb of the individual using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
The FMM is only to be used as follows:
• solely for its designated use
• only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply (Legal information). They are provided to
the owner no later than upon conclusion of purchase of the unit. 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 or use deviating from its designated use
• improper assembly, installation, commissioning, operation and maintenance of
the FMM
• modifications to the FMM made by the user or purchaser
• Improper monitoring of unit components that are subject to wear and tear
• Improperly performed repair work

FluidMonitoring Modul - FMM General Safety Precautions
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 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 was developed for the continuous monitoring of
particulate contamination and water content 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 in the operating manual.
• 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.
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FluidMonitoring Modul - FMM General Safety Precautions
Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance is to be maintained to them.
Make sure to keep the safety and hazard symbols and warnings on the FMM in a
legible condition.
The hoses and connection fittings are to be checked daily for leakage (visual check).
The electrical components of the FMM are to also be regularly checked (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
Safety Measures to Be Followed during Normal Operation
Do not operate the FMM 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.
Modifications to the FMM
Do not make any modifications (design modifications, extensions) to the FMM
without the prior consent of the manufacturer.
Any conversion modifications require written permission from HYDAC Filter Systems
GmbH.
Immediately replace any machine components which are not in perfect condition.
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Use only original spare parts.

FluidMonitoring Modul - FMM General Safety Precautions
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Training and Instruction of Personnel
The FMM 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 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 Elektrofachkraft Supervisor with the appropriate authority
Activity
Packing Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Servicing X
Decommissioning / storage X X X X
Maintenance, Servicing and Troubleshooting
The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
Disconnect the FMM from the power supply and protect the entire system from
being inadvertently switched on when performing maintenance, inspection or repair
work.
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.

FluidMonitoring Modul - FMM 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.
Completely drain the FMM before it is put into storage for an extended period of time
(flush with n-heptane if necessary) to prevent it from gumming up.
The cleaning agents and flushing oils used are to be handled and disposed of
properly.

FluidMonitoring Modul - FMM Checking the scope of delivery
Checking the scope of delivery
The Fluid Monitoring Module FMM Unit comes packed and factory-assembled.
Before commissioning the unit, check the contents of the package to make sure
everything is present.
The following items are supplied:
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Item Qty. Description
1 1 FluidMonitoring Modul FMM
2 1 Connector (female) with 8-pole, M12x1, shielded
3 1 Connector (female), 5-pole, M12x1
- 1 Operating and Maintenance Instructions FMM (this document)
- 1 Calibration certificate CS 1000
- 1 CD-ROM with:
- Software CoCoS 1000
- Operation and maintenance instructions CS 1000

FluidMonitoring Modul - FMM 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.
It serves the user as a sturdy and stationary system for online measurement in
hydraulic and lubrication fluids. It measures the following:
• Solid particle contamination and water content (e.g. for detecting leakages)
The FMM features all of the requisite connectors / adapters, enabling it to be easily
connected to existing hydraulic circuits.
The FMM is approved for a maximum operating pressure of 40 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
Instructions for use
NOTICE
Impermissible operating conditions
The FMM will be destroyed
►The FMM is only to be used with mineral oils or mineral oil-based raffinates.
►Do not exceed the maximum operating pressure.

FluidMonitoring Modul - FMM FMM Features
Hydraulic schematic
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FluidMonitoring Modul - FMM FMM Features
FMM components
Item Description
1 FMM 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), with test connector type 1604 or G ¼ according to ISO 228r
7 Choker valve inlet (IN)
8 Outlet (OUT), with test connector type 1604 or G ¼ according to ISO
228.
9 Choker valve outlet (OUT)
10 Test connection (TP1), test connector type 1604
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FluidMonitoring Modul - FMM FMM Features
Dimensions
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Display adjustable as needed
The CS 1000 display can be continuously rotated by
a total of 270°; 180° counterclockwise and 90°
clockwise.
To rotate the display, grasp the cover plate with your
hand and turn in the desired direction.
No tools are required for rotating the display.

FluidMonitoring Modul - FMM Securing the FMM mechanically
Securing the FMM 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:
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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

FluidMonitoring Modul - FMM FMM hydraulic installation
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)
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The screw plugs can be exchanged for the test connectors and vice versa.

FluidMonitoring Modul - FMM Connecting FMM with the hydraulic system
Connecting FMM 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.
If there are particles larger than 400 microns in the hydraulic system, or if this is to
be expected, place a strainer (e.g. CM-S) upstream of the FMM.
Connect the FMM 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.
(connector thread G1/4 ISO 228 or test connection 1604)
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.
(connector thread G1/4 ISO 228 of test connection 1604)
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.
7. The hydraulic installation of the FMM is now complete.