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HYDAC FILTER SYSTEMS FCU 2000-4 Series, Operating And Maintenance Instructions Manual

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HYDAC FILTER SYSTEMS FCU 2000-4 Series Operating And Maintenance Instructions Manual Download Page 19

 

Checking the scope of delivery 

 

Checking the scope of delivery 

The FluidControl Unit FCU comes packed and factory-assembled. 
Before commissioning the FCU, 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-4 

2 

2 

Mains device and connection cable 

(configuration depends on the order) 

3 

1 

High pressure hose with mini measurement port DN4, 

L=2000 mm 

4 

1 

Suction hose DN 6 with CPC quick-release coupling, 

L=1000 mm 

5 

1 

Suction hose DN 6 with CPC quick-release coupling, L=250 

mm 

6 

1 

Return hose DN 7, L = 2000 m 

7 

1 

Connection cable FCU <-> PC 

8 

1 

CD with: FluMoS Light software 

- 

1 

Operation and Maintenance Instructions (this document) 

- 

1 

Calibration certificate 

 

 

FCU 2000-4 series 

en(us) 

19 / 120 

BEWA FCU2000-4 3109987h en-us 2017-01-24.docx 

2017-01-24 

 

Summary of Contents for FCU 2000-4 Series

Page 1: ...CU 2000 4 series FluidControl Unit Operating and maintenance instructions Valid from firmware versions 3 22 up English translation of original instructions Keep for future reference Document No 3109987h ...

Page 2: ...iegebiet 66280 Sulzbach Saar Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com 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...

Page 3: ...ersonnel target group 15 FCUtransporting 16 Storing the FCU 17 Decoding the model code label 18 Checking the scope of delivery 19 Description of the FCU 20 Operating elements Dimensions 21 Hydraulic diagram 22 FCUFunction description 23 Adjusting the carry and support handle 26 Working ergonomically 26 FCUElectrical connection 28 Connecting POWER INPUT 28 Connecting POWER INPUT PUMP 29 Connecting ...

Page 4: ... Number Keys red 44 Key Combinations 44 FCU menus 45 MODE Selecting operating mode 45 MODE M1 Measure 46 MODE M2 Measure and switch 46 MODE M3 Filter to performance of automatic filtration 46 MODE M4 Filter from to performance of automatic filtration 47 MODE M5 Measure Autostop 47 MODE M6 Autostop pump 47 MEMORY menu 48 Designating the measurement point 49 Setting the averaging interval 51 Selecti...

Page 5: ...re 82 Error Messages and Troubleshooting 84 Performing maintenance 89 FCUcleaning 89 Changing the FCU filter element 89 Back flushing FCU 91 Replacing the paper roll ink ribbon in the dot matrix printer 92 FCU unit disposal 95 FCU calibration 95 Spare parts 96 FCUFCU 2xx0 x version for mineral oil 96 FCU 2xxx x all versions 97 Accessories 98 Technical data 99 Appendix 102 Model code 102 Explanatio...

Page 6: ...AE AS 4059 110 SAE AS 4059 table 110 Show cleanliness classes to SAE 110 Absolute particle count larger than a defined particle size 110 Specifying a cleanliness code for each particle size 111 Specifying the highest cleanliness code measured 111 NAS 1638 112 Factory default settings 113 EGDeclaration of conformity 114 Index 116 FCU 2000 4 series en us 6 120 BEWA FCU2000 4 3109987h en us 2017 01 2...

Page 7: ...Changes to firmware have been integrated Index f 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 g from firmware version V 3 2x Manual revised CoCos changed to FluMoS Index h from firmware version V 3 2x Manual revised keyword index added FCU 2000 4 series en us 7 120 BEWA FCU2000 4 3109...

Page 8: ...ility 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 49 6897 509 9046 E mail filtersystems hydac com Modifications to the Product We would like to point out that changes to the product e...

Page 9: ... 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 HYDAC Filtertechnik GmbH BeWa 123456a de 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 Ch...

Page 10: ...h may arise between the unit 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 ins...

Page 11: ...ING 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 avoided 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 ...

Page 12: ... 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 directives Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulations FCU 2000 ...

Page 13: ...temporary or continuous monitoring of particulate contamination in hydraulic systems Proper or designated use of the product extends to the following observing all instructions contained in the instruction manual performing inspection and maintenance work Depending on the version see model code you may use the FCU only in connection with the following media WARNING Fire hazard Danger of bodily inj...

Page 14: ... 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 device 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 ...

Page 15: ...e to assess and perform the work assigned to them they are also able to recognize potential hazards Activity Person Knowledge Transport storage Forwarding agent Specialist personnel Proof of knowledge of cargo securing instructions Safe handling operation of hoisting and lifting equipment Hydraulic electrical installation first commissioning Maintenance Troubleshooting repair Decommissioning Disas...

Page 16: ...CU in a horizontal or vertical position Always carry the FCU by the carry and support handle or transport the FCU in the appropriate accessory case see accessory FCU 2000 4 series en us 16 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 17: ...g agents and flushing fluids in an environmentally friendly manner Storage temperature 20 85 C 4 185 F Humidity up to 90 relative humidity non condensing Air Clean salt free air not near oxidizing substances rust film Storage duration Indefinite Store the FCU upright or horizontally FCU 2000 4 series en us 17 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 18: ...f the FluidControl Unit see the model code label The type label displays the product ID and important technical data Item Description 1 Type label 2 Model code for details see page 102 3 Hardware index FCU 2000 4 series en us 18 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 19: ...s device and connection cable configuration depends on the order 3 1 High pressure hose with mini measurement port DN4 L 2000 mm 4 1 Suction hose DN 6 with CPC quick release coupling L 1000 mm 5 1 Suction hose DN 6 with CPC quick release coupling L 250 mm 6 1 Return hose DN 7 L 2000 m 7 1 Connection cable FCU PC 8 1 CD with FluMoS Light software 1 Operation and Maintenance Instructions this docume...

Page 20: ...ns 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 measurement port 1604 as an input for connection with the hydraulic unit as well as a DN 7 plug nipple as a return flow outlet A flow rate control valve is available for setting the measurement flow rate This is protected against larger particle c...

Page 21: ... Switch On Off D Electrical connection 24 V DC E Serial interface F Control port G Sealing cover H Suction port connection SUCTION INLET 2xx0 4 only I Change over valve only 2xx0 4 J Dot matrix printer K Display L Keyboard M Flow rate regulator FCU 2000 4 series en us 21 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 22: ... Item Designation 1 Optical sensor 5 Flow rate sensor 7 Flow rate control valve adjustable 8 Filter 9 Flow control valve 10 Pressure relief valve 15 Pressure accumulator 20 Pump 21 Change over valve FCU 2000 4 series en us 22 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 23: ...uation electronics 5 Flow rate sensor 6 Display 7 Flow rate control valve adjustable 8 Filter 9 Flow control valve 10 Pressure relief valve 11 Serial interface 12 Keyboard 13 Relay 14 Dot matrix printer 15 Pressure accumulator FCU 2000 4 series en us 23 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 24: ...ed 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 ...

Page 25: ... interrupted see also in this connection the chapter Error Messages Troubleshooting As soon as the error has been rectified the evaluation electronics recognizes this fact resets the fault message fully automatically and closes the Relay 3 contacts Both the measuring operations and the storing of data are resumed This ensures that measurement operations can restart without requiring the interventi...

Page 26: ...nue as follows Hold down both release buttons a at the same time and select the desired position of the carry and support handle b Once the position has been reached release both release buttons a and ensure that the carry and support handle b audibly and noticeably locks into place Working ergonomically FCU 2000 4 series en us 26 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 27: ...upport handle to position the FCU ergonomically in the working area Ensure that the carry and support handle b audibly and noticeably locks into place FCU 2000 4 series en us 27 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 28: ...arged when the power adapter is plugged in regardless of whether the FCU is switched on or off at the switch or not Connecting POWER INPUT Insert the hollow plug on the supplied power adapter into the rear bushing POWER INPUT Switch on the FCU on or off at the On Off switch on the rear side This connection is used for supplying the FCU electronics and battery charging circuit with power FCU 2000 4...

Page 29: ...he FCU pump Insert the hollow plug on the supplied power adapter into the rear bushing PUMP INPUT In the SETUP menu check whether the item Pump supply is set to external You can find details on page 74 If the parameter is set to internal the pump is only supplied with power via the battery if the power adapter is also connected FCU 2000 4 series en us 29 120 BEWA FCU2000 4 3109987h en us 2017 01 2...

Page 30: ...4 RXD Receiving line 8 GND Ground A corresponding cable for connecting the FCU to a PC is included in the scope of delivery Serial RS485 Interface OPTIONAL Pin Signal function 1 Shield 2 T TA Transmission data 4 R RA Received data 8 GND Ground 9 T TB Transmission data 11 R RB Received data 15 5 V Supply bus termination The pin assignment corresponds to DIN 66348 DIN measurement bus FCU 2000 4 seri...

Page 31: ...he relay contacts Maximum switching voltage 24 V DC 50 V AC maximum switching power 30 W 50 VA Pin 1 24 V operating voltage in battery operation 12 V maximum load capacity 200 mA Pin 4 Ground GND Pin 5 Battery switch off When pin 5 is connected to pin 4 the FCU is not supplied by integrated batteries This enables the FCU to be remote controlled switched on and off via an external power supply The ...

Page 32: ...asured value lower limit Measured value upper limit After switch on or start of a measurement Goes out again when measured value lower limit Fall below lower limit After switch on or start of a measuremen t Goes out again when measured value upper limit lower limit After switch on or start of a measurement Goes out again when measured value upper limit Within range Lower limit measured value upper...

Page 33: ... measured values limit 5 consecutive measured values limit or measuremen t stopped After the first measured value is available Flow error Flow rate within set range M4 Start or result of check measurement after test cycle time upper limit Measuremen t is currently in progress and the measured values limit 5 consecutive measured values limit or measuremen t stopped After the first measured value is...

Page 34: ...or Flow rate within set range M6 Measuremen t currently in progress Measuremen t stopped After the first measured value is available Flow error Flow rate within set range Relay 3 11 12 11 12 All operating modes FCU is ready for use FCU is not ready for operation FCU 2000 4 series en us 34 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 35: ... 4 15 25 µm channel NAS 6 15 50 µm channel NAS 6 15 5 µm channel ISO 10 23 15 µm channel ISO 9 21 Flow rate 0 150 M3 Filtration limit ISO 10 9 23 21 NAS 2 4 15 15 M4 Filtration limits ISO 10 9 23 21 NAS 2 4 15 15 M4 Test cycle time 0 1440 FCU 2000 4 series en us 35 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 36: ...SO 4 µm c channel ISO 12 25 5 µm channel ISO 6 µm c channel ISO 10 23 15 µm channel ISO 14 µm c channel ISO 9 21 Flow rate Flow rate 0 150 M3 filtration limit FCU21xx x FCU 22xx x ISO ISO 12 10 9 25 23 21 NAS SAE 2 2 4 15 15 15 M4 Filtration limits FCU21xx x FCU 22xx x ISO ISO 12 10 9 25 23 21 NAS SAE 2 2 4 15 15 15 M4 Test cycle time 0 1440 M5 No of measurements 1 100 M6 Start delay 5 120 M6 No o...

Page 37: ...draulic connection WARNING Hydraulic systems are under pressure Danger of bodily injury Depressurize the system before performing any work on it FCU 2000 4 series en us 37 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 38: ...nector and route it into a suitable container e g hydraulic tank 2 Set the change over valve A to the setting INLET 3 Set the flow rate control valve to a value of 5 4 Check the system pressure Ensure that this does not exceed a pressure of 350 bar 5 Connect the high pressure hose to the INLET connection 6 Now connect the other end of the high pressure hose to the system Oil can start to flow thro...

Page 39: ...evere contamination of the fluid on the bottom of the tank The unit will be destroyed Do not prime directly at the bottom of the tank Do not prime in the sump The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank A suction strainer for the su...

Page 40: ...container e g hydraulic tank 2 Set the change over valve to the setting SUCTION 3 Open the flow rate control valve completely 4 Attach the suction hose onto the SUCTION INLET connection 5 Put the other end of the suction hose into the fluid to be measured FCU 2000 4 series en us 40 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 41: ...Battery 13 49 V 80 4 Viscosity range 1 10 mm s 5 Measure OK START Abort STOP The FCU is now ready for operation Selecting the Viscosity Range During startup the viscosity range currently set is shown in the display Before the first measurement check the viscosity of the fluid to be measured and correct the settings if required You can find details on change over of the viscosity range on page 78 T...

Page 42: ... the setting for internal or external in the Pump supply menu For details on change over see page 74 The factory setting of the FCU is internal One battery charge is sufficient for conducting measurements using the pump for approx 2 hours In order to make use of the full viscosity range you must connect both power adapters You can find the permitted viscosity ranges when operating with an internal...

Page 43: ...ighlighted in light gray printed version or yellow PDF file Variable display texts user entries are highlighted in bold printed version or magenta PDF file Comments are shown in italics Function of the Keys Control buttons gray ok start Confirm entries Start measurement stop Cancel entries Stop measurement Scroll through menus when the menu symbol is displayed Scroll through Selection Raise lower ...

Page 44: ...elays 1 and 2 Display particle counts This key responds only when a measurement is being carried out Direct input of multi digit numerals Only in input mode Display Lighting 1x goes out again after 20 s 2x stays switched on press 1x to switch off Key Combinations ok start Insert space in measuring position designation Press the keys simultaneously ok start Deleting space in measuring position desi...

Page 45: ...MODE M1 Measure MODE M2 Measure Switch MODE M3 Filter until MODE M4 Filter from to MODE M5 Measure Autostop MODE M6 Autostop pump ok start Confirm entries and start measurement When autostart is activated confirmation occurs automatically immediately after switching on the FCU stop Accept the setting and exit the MODE menu FCU 2000 4 series en us 45 120 BEWA FCU2000 4 3109987h en us 2017 01 24 doc...

Page 46: ...erence values for triggering these switching sequences The flow volumetric flow rate Cleanliness rating of the hydraulic fluid indicated according to NAS or SAE or ISO Typical applications Signal switching to a control panel at fully automated test benches MODE M3 Filter to performance of automatic filtration MODE M3 Filter to enables the FCU to assume control of an external filtration unit e g OF...

Page 47: ...ntout MODE M5 Measure Autostop MODE M5 Measure autostop enables the number 1 to 100 of single measurements to be programmed via the FCU s high pressure port after which measurement operation is concluded automatically When online printing is activated the result of the last measurement is additionally outputted in the form of particle counts absolute value Typical applications Routine analysis of ...

Page 48: ... Memory empty 100 Memory full memory MEMORY 0 0 Meas point MEMORY 0 0 Averaging interval MEMORY 0 0 Selective deletion MEMORY 0 0 Delete all MEMORY 0 0 Change measurement point MEMORY 0 0 Memory mode ok start Confirm entries stop Accept the setting and exit the Memory menu FCU 2000 4 series en us 48 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 49: ...nations to be permanently configured and called up as needed memory MEMORY 0 0 Meas point ok start Measuring point 2 Designation 1 Select the respective measurement point via the keys ok start Measuring point 2 Designation 1 The first letter blinks Measuring point 2 Designation 1 Navigate to the position desired using the keys Measuring point 2 Designation 2 Select the characters from the table vi...

Page 50: ... Q R S T U V W X Y Z Insert character Press the ok start keys simultaneously and a space will be inserted in front of the character just marked Delete character Press the ok start keys simultaneously and the character just marked will be deleted from the measuring point designation FCU 2000 4 series en us 50 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 51: ...auses the averaging function to be deactivated Each measured value is immediately saved and printed out The values 0 1440 minutes are possible for the averaging interval The current non averaged measured value is always shown in the FCU display memory MEMORY 0 0 Averaging interval ok start Averaging interval x Averaging interval x or Averaging interval x min ok start Confirm entries stop Abort and...

Page 52: ...g point ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit without saving Log selection Number ok start Log number from xxx to yyy xxx yyy The default value is the last log number Log number from xxx to yyy Change values or Log number from xxx to yyy ok start Are you sure OK YES STOP NO ok start YES The selected logs are deleted stop No A...

Page 53: ...deleted stop Abort and exit without saving Log selection Meas point ok start Measurement point Designation X Designation X specified value is the measuring point of the last log Measuring point Designation X ok start Are you sure OK YES STOP NO ok start YES The selected logs of designation X are deleted stop Abort and exit without saving FCU 2000 4 series en us 53 120 BEWA FCU2000 4 3109987h en us...

Page 54: ...asuring point Designation X ok start Are you sure OK YES STOP NO ok start YES The selected logs of the date dd mm yyyy and the measuring point are deleted stop Abort and exit without saving Delete all This menu item enables the entire log memory to be deleted memory MEMORY 0 0 Delete all ok start Are you sure OK YES STOP NO ok start YES All logs are deleted stop Abort and exit FCU 2000 4 series en...

Page 55: ...ement point ok start Xxx dd mm yyyy hh mm Designation X Xxx dd mm yyyy hh mm Designation X ok start Change measurement point Designation X or Change measurement point Designation X ok start ok start Confirm entries stop Abort and exit without saving FCU 2000 4 series en us 55 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 56: ...emory If the memory is 100 full the oldest log in the memory is deleted This can continue to be repeated during an ongoing measurement until only one i e the current log is in memory Then the oldest log line is deleted Stop if full Once 100 logs or 3000 measured values have been stored you can start no further measurements Delete one or more logs in order to carry out further measurements A curren...

Page 57: ...arameter list print PRINT Logs PRINT PRINT Contents PRINT PRINT All parameters PRINT Paper feed PRINT online printout PRINT Print out cancel ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 57 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 58: ...n Date Measuring point ok start Confirm entries stop Abort and exit Log selection Number ok start Log number from xxx to yyy ok start Press this key to confirm the operating mode selected and to initiate measurement Printout format List Printout format Graph ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO FCU 2000 4 series en us 58 120 BEW...

Page 59: ...d to initiate measurement Printout format List Printout format Graph ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of NAS SAE SAE with 22xx x only ok start The selected logs are printed stop Abort and exit Log selection Meas point ok start Measuring point Designation X FCU 2000 4 series en us 59 120 BEWA FCU2000 4 3109987h en us...

Page 60: ... 22xx x only ok start The selected logs are printed stop Abort and exit Log selection Date Measuring point ok start Date of log dd mm yyyy ok start Press this key to confirm the operating mode selected and to initiate measurement Measuring point Designation X ok start Press this key to confirm the operating mode selected and to initiate measurement Printout format List Printout format Graph FCU 20...

Page 61: ...ted out The following is output for each log log number measuring position designation starting and stopping time and number of log lines print PRINT PRINT Contents ok start Confirm entries and initiate printing stop Abort and exit PRINT All parameters All the current settings are outputted print PRINT PRINT All parameters ok start Confirm entries and initiate printing stop Abort and exit FCU 2000...

Page 62: ...rintout ok start Online printout ON Online printout OFF ok start Press this key to confirm the operating mode selected and to initiate measurement Printout format List Printout format Graph ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of NAS SAE SAE with 22xx x only ok start Confirm entries FCU 2000 4 series en us 62 120 BEWA F...

Page 63: ...enables settings limits to be entered for the various operating modes limits LIMITS M2 Relay 1 LIMITS M2 Relay 2 LIMITS M3 Filter until LIMITS M4 Filter from to LIMITS M5 Qty Measurements LIMITS M6 Start delay ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 63 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 20...

Page 64: ...nd to initiate measurement M2 Rx Switch func No function M2 Rx Switch func Within range M2 Rx Switch func Outside range M2 Rx Switch func Exceed M2 Rx Switch func Fall below ok start Press this key to confirm the operating mode selected and to initiate measurement M2 Rx limit values xxx yyy Unit Jump from value to value M2 Rx limit values xxx yyy Unit Select limit values by scrolling through them ...

Page 65: ...rm the operating mode selected and to initiate measurement stop Abort and exit MODE M4 limits LIMITS M4 Filter from to ok start M4 LIMITS xx yy zz Standard Jump from value to value M4 LIMITS xx yy zz Standard zz not for 20xx x M4 LIMITS xx yy zz Standard zz not for 20xx x ok start Press this key to confirm the operating mode selected and to initiate measurement M4 Test cycle time xxx min Standard ...

Page 66: ...S 14 µm SAE 50 µm NAS 25 µm NAS 21 µm SAE 5 µm ISO 2 µm ISO 4 µm ISO 15 µm ISO 5 µm ISO 6 µm ISO Flow 15 µm ISO 14 µm ISO Flow rate Flow MODE M5 limits LIMITS M5 No of measurements ok start M5 No of measurements n or M5 No of measurements n n 1 100 ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 66 120 BEWA FCU2...

Page 67: ... to confirm the operating mode selected and to initiate measurement M6 No of measurements n n 1 100 or M6 No of measurements n n 1 100 ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 67 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 68: ...ostart SETUP Abort at Q 0 SETUP Pump start delay SETUP Date Time SETUP Bus address SETUP Operating hours SETUP Pump supply SETUP Battery voltage ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 68 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 69: ...ted MODE setup SETUP Autostart ok start Autostart no Autostart yes ok start Autostart function M1 Measure Autostart function M2 Measure and switch Autostart function M3 Filter until Autostart function M4 Filter from to ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 69 120 BEWA FCU2000 4 3109987h en us 2017 01 2...

Page 70: ...rupted or stopped altogether An interrupted measurement automatically continues when a sufficient flow rate is present again This function works in all operating modes setup SETUP Abort at Q 0 ok start Abort at Q 0 no Abort at Q 0 yes ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 70 120 BEWA FCU2000 4 3109987h...

Page 71: ...d by dry running of the pump This function is in effect in all operating modes except M2 Measurement resumes as soon as enough flow is available The stopping time ranges from 1 to 200 seconds practical recommendation 60 seconds The 0 sec setting causes the averaging function to be deactivated This means that the FCU waits as long as you wish for flow setup SETUP Pump start delay ok start Pump star...

Page 72: ... dd mm yyyy ok start ok start Press this key to confirm the operating mode selected and to initiate measurement Time hh mm ss ok start Correct the time stop Abort and exit Time hh mm ss Selection Time hh mm ss or Time hh mm ss ok start ok start Confirm entries stop Abort and exit FCU 2000 4 series en us 72 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 73: ...s 1 or Bus address 3 ok start ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit Display operating hours The operating hours of the device are displayed The operating hours meter only records the measurement time setup SETUP Operating hours ok start Operating hours xxxx h ok start Press this key to confirm the operating mode selected and ...

Page 74: ...r voltage than the batteries which means higher viscosities can be conveyed when it is used For more information see chapter Technical Data setup SETUP Pump supply ok start Pump supply External Pump supply internal ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 74 120 BEWA FCU2000 4 3109987h en us 2017 01 24 do...

Page 75: ... shown setup SETUP Battery voltage ok start Battery voltage 13 63 V 80 ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 75 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 76: ... are normally rarely changed The POWERUP menu is accessed by simultaneously pressing the keys POWERUP Language POWERUP Viscosity range POWERUP Test volume ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit the PowerUp menu FCU 2000 4 series en us 76 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 77: ...ter Language ok start Applying the submenu selected Language German German Language German English Language German French Language German Programmable ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit the PowerUp menu FCU 2000 4 series en us 77 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 78: ... s mediums Check or correct the viscosity range before starting the measurement Viscosity range ok start Applying the submenu selected Viscosity range 1 10 mm s Viscosity range 5 1000 mm s ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 78 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 79: ...ing the submenu selected Measurement volume 100 ml Depending on the key the value is increased decreased by 1 ml or Measurement volume XXX ml Enter measurem ent volume via the keyboard ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit FCU 2000 4 series en us 79 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 80: ...n Begins at 0 the cleanliness class is displayed again at 100 4 Specification of the currently determined contamination You can switch back and forth between the display in ISO or NAS FCU 201x 211x and or SAE FCU 221x coding and the display of particle counts with the keys During the representation of the contamination class in NAS or SAE classes the figures letters in brackets state the selected ...

Page 81: ...e selected presentation is indicated in the display by a D differential or C cumulative behind the display of the expired measurement time Differential representation means particle count in the particle size ranges FCU 201x 5 15 µm 15 25 µm 25 50 µm 50 µm FCU 211x 2 5 µm 5 15 µm 15 25 µm 25 µm FCU 221x 4 6 µm c 6 14 µm c 14 21 µm c 21 µm c Cumulative representation means particle count in the par...

Page 82: ... x Date Measuring point Date of log dd mm yyyy Measuring point Designation x Delete all Change Measuring point Xxx dd mm yyyy hh mm Memory mode Overwrite Stop if full PRINT Logs Number List Graph Date List Graph Meas point List Graph Date Measuring point List Graph PRINT Contents All parameters Paper feed Online printout On Off Print out cancel LIMITS M2 Relay 1 M2 R1 Measurement channel Limit val...

Page 83: ...lay M6 Start delay XX s M6 Qty Measurements X SETUP Autostart Yes M1 Measure M2 Measure Switch M3 Filter until M4 Filter from to M5 Measure Autostop M6 Autostop pump no Abort at Q 0 Yes No Pump start delay X s Date Time Date dd mm yyyy Time Hh mm ss Bus address X Operating hours X h Pump supply External Internal Battery voltage xx xx V yy POWERUP Language German English French Programmable Viscosi...

Page 84: ...e Strong electromagnetic interference has changed the parameters Rest all parameters using the keyboard or transfer the parameters with the FluMoS software Measurement ended Memory for measured values full The setting for the Memory mode parameter is at Stop if full The maximum number of reports or measured values has been reached No more values can be stored Delete the reports or set the Memory m...

Page 85: ...deleted automatically After the next power up this message is not displayed again if it was just a brief malfunction If this message is displayed several times this means that the internal back up battery is probably dead Send the FCU to HYDAC for repair No logs stored You have tried to print logs but the FCU memory is empty Carry out measurements Too few points You have tried to print a graph but...

Page 86: ... setting Check the hydraulic connections Check the pressure Fluid must flow through the return hose on the OUTLET from a pressure of 30bar 420psi The pressure relief valve must open see circuit diagram Change the measured volume to between 10 100 ml Send the FCU to HYDAC for repair The batteries are exhausted as a result of measurements being carried out via the integrated pump without additional ...

Page 87: ...tted in the OF5C has been activated the OF5C filter is exhausted Replace the filter element at OF5C Internal dot matrix printer not ready Paper roll empty Insert a new roll of paper Internal dot matrix printer faulty Send the FCU to HYDAC for repair Error in selected language The last language selected and stored in the FCU has been changed due to an internal fault The internal back up battery is ...

Page 88: ...to electrical interference No measures required as these values do not affect the FCU function Send the FCU to HYDAC for repair Water air in oil Warning message when a sample exhibits a high water or air content Nothing needs to be done unless this message pops up when the fluid is clear If this fault message also occurs when the fluid is clear then send the FCU to HYDAC for repair if necessary FC...

Page 89: ...hese may damage the film attached to the surface of the FCU Clean the outside of the FCU with a moist cloth Changing the FCU filter element The FCU has an internal filter element with a differential pressure switch The differential pressure switch switches at 2 bar The message Filter clogged will appear on the display Ensure that the flow rate control valve is not closed If the filter is contamina...

Page 90: ...by the strap 4 Take the strap out of the old filter elements and push this over the new filter element Dispose of the old filter element correctly according to local regulations and guidelines 5 Moisten the O ring on the new filter element slightly with fluid FCU 2000 4 series en us 90 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 91: ... screw in the screw plug clockwise Tighten the screw plug with a size 19 ring spanner 9 The filter element change is now complete Back flushing FCU If the sensor is blocked in the FCU use the flushing set available as an accessory for back flushing The part no can be found in the accessories list Further details on back flushing are provided in the back flushing instructions FCU 2000 4 series en u...

Page 92: ...the FCU at the switch 2 Lift the cover of the dot matrix printer 3 Remove the ink ribbon from the dot matrix printer in an upward direction To do this press on the right side of the ink ribbon 4 Remove the paper roll from the dot matrix printer in an upward direction FCU 2000 4 series en us 92 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 93: ...ll and place it in the new paper roll 10 Feed the start of the new paper roll into the slot 11 Turn the transport roll with your finger to feed the paper through 14 Pull the paper a little further through the dot matrix printer FCU 2000 4 series en us 93 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 94: ...e dot matrix printer using two fingers 18 Feed the start of the paper through the slot in the cover 19 Close the cover of the dot matrix printer 20 Changing the paper roll ink ribbon is complete Switch on the FCU at the switch FCU 2000 4 series en us 94 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 95: ...vice and separating its various materials dispose of it in an environmentally friendly manner FCU calibration We recommend that the FCU be recalibrated every 2 to 3 years You will receive a calibration certificate at the time of each calibration FCU 2000 4 series en us 95 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 96: ...High pressure measuring hose DN 4 5000 mm long 349150 High pressure measuring hose DN 4 2000 mm long 349151 Return line hose DN 7 2000 mm long 1251558 Return line hose DN 7 5000 mm long 3036098 Suction hose with coupling DN 6 1000 mm long for FCU 2xx0 4 only 3068209 Suction hose with coupling DN 6 250 mm long for FCU 2xx0 4 only FCU 2000 4 series en us 96 120 BEWA FCU2000 4 3109987h en us 2017 01 ...

Page 97: ...Power supply without connecting cable Primary 90 264 V AC Secondary 24 V DC 2300 mA 6008448 Connecting cable for power supply Euro plug 2000 mm long 6008447 Connecting cable for power supply Plug for UK 2000 mm long 6008446 Connecting cable for power supply Plug for USA 2000 mm long 6008449 Connecting cable for power supply Plug for AUS 2000 mm long FCU 2000 4 series en us 97 120 BEWA FCU2000 4 31...

Page 98: ...7 FluMoS Professional Software 3053829 LabView Driver Package Software 3143926 Windows Driver Package Software 3028133 Reservoir Extraction Unit REU 1430 1 M 230 V AC 50Hz 1Phase 3086166 FCU adapter kit for sample bottles with connection thread GL55 in accordance with DIN 168 1 scope of delivery without sample bottle 3143465 Sample bottle 250 ml with connection thread GL 55 in accordance with DIN ...

Page 99: ... FCU 21xx x NAS 2 12 ISO 12 10 09 23 21 18 FCU 22xx x SAE 2 12 ISO 12 10 09 23 21 18 Indication range FCU 20xx x NAS 2 15 ISO 10 07 23 21 FCU 21xx x NAS 2 15 ISO 12 10 07 25 23 21 FCU 22xx x SAE 2 15 ISO 12 10 07 25 23 21 Calibration accuracy 1 2 class ISO NAS SAE Calibration FCU 20xx x ISO 4402 FCU 21xx x ISO 4402 FCU 22xx x ISO 11943 Recalibration Service Recommended every 2 to 3 years Battery b...

Page 100: ...ure at the high pressure inlet of the FCU to achieve a flow of 100 ml min flow regulator completely opened new filter element Viscosity in mm s FCU 2xx0 4 Connectors rear INLET Mini measurement coupling DN4 SUCTION CPC quick release coupling Series LC DN6 OUTLET DN 7 plug nipple Return line OUTLET flow rate max 800 ml min at INLET 300 bar Return line OUTLET operating pressure max 3 bar counterpres...

Page 101: ...y powered operating duration Measurement without pump or pump supplied externally approx 5 hours Measurement with pump up to approx 2 hours depending on viscosity Built in printer Dot matrix printer Serial interface RS232 for Models BUS RS 485 with 15 pin Sub D plug Permitted ambient temperature range 0 55 C Permitted storage temperature range 20 85 C Relative humidity max 90 non condensing IP cla...

Page 102: ...g 1 for portable use Fluids 0 for mineral oils 1 for phosphate esters HFD R Options 1 standard without options 4 with integral pump not for phosphate esters Power supply K 120 V AC 60 Hz 1 phase USA CDN M 230 V AC 50 Hz 1 phase Europe N 240 V AC 50 Hz 1 phase UK O 240 V AC 50 Hz 1 phase Australia P 100 V AC 50 Hz 1 phase Japan Supplementary details BUS RS485 interface instead of RS232 FCU 2000 4 s...

Page 103: ...ment volume can be set by the user Measured value The contamination codes determined by a single measurement shown as a three digit ISO code or NAS codes or SAE codes of the individual particle size channels Measurement After the OK START key is pressed a single measurement begins followed immediately upon completion by the next single measurement until the STOP key is pressed MODE M1 M2 M4 or the...

Page 104: ... Averaging interval Number of log lines Measurement volume Example Memory log 6 Measuring point 25 from 15 Sept 2003 8 32 to 15 Sept 2003 10 42 Averaging interval 10 min Number of log lines 13 Measurement volume 100 mlml Log line A log line consists of the time and results 4 particle channels and flow rate with NAS 3 particle channels and flow rate with ISO and SAE of a measurement The FCU can sto...

Page 105: ...ty EU European Union FCU FluidControl Unit FluMoS FluidMonitoring Software HMG HYDAC Measuring device HSI HYDAC Sensor interface IN Inlet INLET Inlet ISO Classification of the solid particle contamination LED Light emitting diode NAS Classification of the solid particle contamination OUT Outlet OUTLET Outlet SAE Classification of the solid particle contamination FCU 2000 4 series en us 105 120 BEW...

Page 106: ...6897 509 324 E mail service hydac com USA HYDAC Technology Corporation HYCON Division 2260 City Line Road USA Bethlehem PA 18017 P O Box 22050 USA Lehigh Valley PA 18002 2050 Phone 1 610 266 0100 Fax 1 610 231 0445 E mail sales hydacusa com Internet www hydacusa com Australia HYDAC Pty Ltd 109 Dohertys Road P O Box 224 AUS 3025 Altona North Phone 61 392 72 89 00 Fax 61 393 69 89 12 E mail info hyd...

Page 107: ...93 6617 E mail hydac hydac com br Homepage www hydac com br China HYDAC TECHNOLOGY SHANGHAI LIMITED 28 Zhongpin Lu Shanghai Minhang Economic Technological Development Zone SHANGHAI 200245 P R CHINA Phone 86 21 64 63 35 10 Fax 86 21 64 30 02 57 E mail hydacsh hydac com cn FCU 2000 4 series en us 107 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 01 24 ...

Page 108: ...d the cleanliness code will change only in individual cases When drafting the new ISO 4406 1999 it was ensured that not all the existing cleanliness provisions for systems had to be changed ISO 4406 table Allocation of particle counts to cleanliness classes Number of particles 100 ml Number of particles 100 ml Class More than Up to and including Class More than Up to and including 0 0 1 15 16 000 ...

Page 109: ...9 Size ranges 5 µm 15 µm 4 µm c 6 µm c 14 µm c Dimension determined Longest dimension of a particle Diameter of the coextensive circle ISO 11171 1999 Test dust ACFTD dust 1 10 µm ultra fine fraction ISO 12103 1A1 SAE Fine AC Fine ISO 12103 1A2 SAE 5 80 µm ISO MTD Calibration dust for particle counters ISO 12103 1A3 SAE Coarse Coarse fraction ISO 12103 1A4 Comparable size ranges Old ACFTD calibrati...

Page 110: ...27 5 1 0 0 780 304 54 10 2 0 1 1 560 609 109 20 4 1 2 3 120 1 220 217 39 7 1 3 6 250 2 430 432 76 13 2 4 12 500 4 860 864 152 26 4 5 25 000 9 730 1 730 306 53 8 6 50 000 19 500 3 460 612 106 16 7 100 000 38 900 6 920 1 220 212 32 8 200 000 77 900 13 900 2 450 424 64 9 400 000 156 000 27 700 4 900 848 128 10 800 000 311 000 55 400 9 800 1 700 256 11 1 600 000 623 000 111 000 19 600 3 390 512 12 3 2...

Page 111: ... Size C 15 µm 14 µm c 3460 Size D 25 µm 21 µm c 306 Specifying the highest cleanliness code measured Example Cleanliness class to AS 4059 6 A F The 6 A F specification requires a particle count in size ranges A F The respective particle concentration of cleanliness code 6 may not be exceeded in any of these ranges FCU 2000 4 series en us 111 120 BEWA FCU2000 4 3109987h en us 2017 01 24 docx 2017 0...

Page 112: ...0 44 8 2 0 1 2 500 500 88 16 3 1 2 5 000 1 000 178 32 6 1 3 10 000 2 000 356 64 11 2 4 20 000 4 000 712 128 22 4 5 40 000 8 000 1 425 253 45 8 6 80 000 16 000 2 850 506 90 16 7 160 000 32 000 5 700 1 012 180 32 8 320 000 64 000 11 400 2 025 360 64 9 640 000 128 000 22 800 4 050 720 128 10 1 280 000 256 000 45 600 8 100 1 440 256 11 2 560 000 512 000 91 200 16 200 2 880 512 12 5 120 000 1 024 000 1...

Page 113: ...s address 1 1 1 Pump supply internal internal internal LIMITS menu M2 R1 measurement channel Flow rate Flow rate Flow rate M2 R1 switching function No function No function No function M2 R1 lower limit values 90 ml 90 ml 90 ml M2 R1 upper limit values 110 ml 110 ml 110 ml M2 R2 measurement channel Flow rate Flow rate Flow rate M2 R2 switching function No function No function No function M2 R2 lowe...

Page 114: ...ng will cause this declaration to lose its validity Designation FluidControl Unit FCU2000 4 Type Part no Serial no Applied directives Machinery Directive 2006 42 EG article 1 1a EMC directive 2014 30 EU 2016 03 21 M Eng FH Thorsten Trier Date Name CE official Executive director Documentation Representative Mathias Dieter Dipl Kfm Wolfgang Haering Mr Günter Harge Registered seat of company 66280 Su...

Page 115: ...athias Dieter Dipl Kfm Wolfgang Haering Mr Günter Harge Registered seat of company 66280 Sulzbach Saar c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Court of Registration Saarbrücken HRB 17216 Phone 49 6897 509 1511 Value added tax identification number DE 815001609 Fax 49 6897 509 1394 Tax number 040 110 50773 E mail guenter harge hydac com Page 2 2 FCU 2000 4 series en us 115 ...

Page 116: ... 20 21 23 24 44 73 80 84 Disposal 15 Documentation Representative 2 114 115 Dot matrix printer 21 23 101 E Error 24 25 41 84 87 Error message 24 84 F Filter 14 20 22 23 45 46 47 63 65 69 82 83 87 89 96 Filter element 96 Filter from to 45 47 63 69 82 83 Filter to 46 filtration 25 36 44 46 47 71 Filtration 35 36 83 Firmware 86 Flow control valve 22 23 Flow error 32 33 34 89 Flow rate 21 22 23 32 33 ...

Page 117: ...T 105 Outlet 105 OUTLET 21 38 39 40 86 100 105 Overview 82 108 109 P Paper roll 87 Photodetector 23 Power consumption 101 POWERUP 76 83 113 PRINT 57 58 61 62 63 82 113 Printout format 58 59 60 62 113 Proper Designated Use 13 Publisher 2 Pump 22 29 42 68 71 74 83 113 Pump start delay 68 71 83 113 R Relative humidity 101 Relay 23 25 31 32 34 63 64 82 83 Remedy 84 replacement 96 98 S SAE 24 36 44 46 ...

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Page 120: ...striegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Central Fax 49 6897 509 9046 Technology Fax 49 6897 509 577 Sales Department Internet www hydac com E mail filtersystems hydac com ...

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