HYDAC International FCU 2110-5 Operating And Maintenance Instructions Manual Download Page 4

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Operating and Maintenance Instructions : FCU 2110-5 / FCU 2210-5

Edition 1.10

HYDAC Filtertechnik GmbH

Page 4 of 52

I.II Contents

Explanation of Symbols and Warnings, etc................................................................................ 6

General Safety Precautions and Remarks................................................................................. 7

3 SCOPE

DELIVERY ............................................................................................................ 10

Restrictions Pertaining the Use of the FCU ............................................................................. 11

5 Technical

Description............................................................................................................... 11

5.1 Performance Features.......................................................................................................... 11

5.2 Design Features ................................................................................................................... 11

5.3 Hydraulic Diagram ................................................................................................................ 12

5.4 Principle of Operation ........................................................................................................... 13

5.5 Description of the Display and Control Elements ................................................................. 16

5.5.1 Front

View ..................................................................................................................... 16

5.5.2 Rear

View...................................................................................................................... 17

5.5.3 Function of Keys............................................................................................................ 18

5.6 Connector Pin Assignments ................................................................................................. 20

5.6.1 PC Connector: (Subminiature D, 15-pin, male) ............................................................. 20

5.6.2 Control Connector (Relays) (Subminiature D, 15-pin, female) ...................................... 20

5.6.3 Relay

Functions............................................................................................................. 21

5.6.4 Programmable Relay- Limits ......................................................................................... 23

5.6.5 Supply

Voltage

Plug: ..................................................................................................... 22

Installation and Operation of the FCU...................................................................................... 24

6.1 Electrical Installation............................................................................................................. 24

6.2 Hydraulic Installation and Commissioning............................................................................ 25

6.2.1 Measurements with Suction INLET ............................................................................... 25

6.2.2 Measurements with High Pressure Inlet, (max. 350 bar) .............................................. 27

6.3 The Display of the FCU ........................................................................................................ 28

7 Using

the

FCU.......................................................................................................................... 29

7.1 Measurement Operation....................................................................................................... 29

7.1.1 M1: “Measure” Function ................................................................................................ 29

7.1.2 M2: "M Switch" Function ................................................................................. 29

7.1.3 M3: "Filter to" Function (performing automatic cleaning/flushing) ................................. 34

7.1.4 M4: "Filter from to" Function (performing automatic cleaning/flushing) ......................... 35

7.1.5 M5:

"autostop"

Function ................................................................................ 36

7.2 Using the MEMORY Functions............................................................................................. 38

7.2.1 Entering the Measurement Point and Initiating Measurement without Averaging ......... 38

Summary of Contents for FCU 2110-5

Page 1: ...FluidControl Unit FCU 2110 5 FCU 2210 5 Operating and Maintenance Instructions Ed 1 1 12 2000 ...

Page 2: ...ment including consequential damage or loss The information provided herein is checked on a regular basis with corrections being entered in subsequent editions Any remarks or suggestions for improvement you might have would be appreciated Liability Every effort has been taken to ensure that the information provided herein is correct however errors cannot be precluded Consequently no liability is a...

Page 3: ...structions FCU 2110 5 FCU 2210 5 Edition 1 10 HYDAC Filtertechnik GmbH Page 3 of 52 Copyright 1999 by HYDAC FILTERTECHNIK GmbH Industriegebiet D 66280 Sulzbach Saar Germany Voice 49 681 509 01 Fax 49 681 509 846 Printed in Germany ...

Page 4: ... 5 6 2 Control Connector Relays Subminiature D 15 pin female 20 5 6 3 Relay Functions 21 5 6 4 Programmable Relay Limits 23 5 6 5 Supply Voltage Plug 22 6 Installation and Operation of the FCU 24 6 1 Electrical Installation 24 6 2 Hydraulic Installation and Commissioning 25 6 2 1 Measurements with Suction INLET 25 6 2 2 Measurements with High Pressure Inlet max 350 bar 27 6 3 The Display of the FC...

Page 5: ... in progress 41 7 3 2 Printing Logs Stored in Memory 42 7 4 SETUP Menu 43 7 5 POWER UP Menu 44 8 Error Messages and Troubleshooting 44 9 Maintenance and Servicing of the FCU 48 9 1 Filter Element Exchange 48 9 2 Changing the ink ribbon cartridge 48 9 3 Inserting a new paper roll 49 10 Recalibration 49 11 Spare Parts 50 12 FCU Accessories 50 13 Decommissioning and Final Disposal 50 14 Explanation o...

Page 6: ...o individuals This symbol designates safety instructions whose non observance may result in the injury of individuals by high voltages This symbol provides important instructions and tips for the proper handling and operation of the FCU Non observance of these instructions may result in damage to the FCU or to damage to the surrounding systems or equipment and the environment This symbol designate...

Page 7: ...he FCU is not operated unless it is in perfect working order from the point of view of safety Any faults or malfunctions e g loose screwed connections or exposed wires or cables which might impair safety are to be properly attended to immediately Safety Devices Prior to starting up the FCU each time make sure that all the safety devices are properly installed in the hydraulic facility to be monito...

Page 8: ...turer No modifications or extensions may be made without HYDAC Filtertechnik GmbH s express prior written approval Immediately replace any unit components which are not in perfect condition Only use original replacement parts When using non OEM components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements Please also refer to 9 M...

Page 9: ...her related regulations Adherence is to be maintained to statutory accident prevention regulations safety regulations and safety data sheets for fluids When working directly on or in the vicinity of hydraulic systems there is to be no smoking or open flames fire with every effort being taken to prevent the generation of sparks Collecting basins suction extraction equipment and binding agents are t...

Page 10: ...The scope of delivery extends to the following Pos Pieces Designation 1 1 FluidControl Unit FCU 2110 5 or FCU 2210 5 2 2 Line Adapter 3 1 High pressure hose ID 4 with Minimess connector 1604 1620 2000 mm long 4 1 Suction hose ID 5 with CPC quick disconnect 1000 mm long 5 1 Suction hose ID 5 with CPC quick disconnect 200 mm long 6 1 Return hose ID 7 with quick disconnect 2000 mm long 7 1 Operating ...

Page 11: ...ontrol of filter pump units is enabled via relay outputs The FCU can be connected directly to pressure lines or with the integrated pump the FCU is able to measure oil cleanliness of reservoirs The FCU has rechargeable batteries for mains independent operation for measurements on high pressure lines not with the prototype will be with the series products For operation with the integrated pump an e...

Page 12: ...agram FCU 2110 5 FCU 2210 5 Reservoir or system return line Particle sensor Pressure line 1 350 bar 5000 psi Pulsation attenuator Fixed flow control valve Flow counter Adjuatable Flow control valve Protective filter Minimess hose Pressure relief valve Max 3 bar 44 psi Suction hose Suction pump Shut off valve Ball valve Reservoir ...

Page 13: ...rough an optical sensor 1 the sensor consisting of an infrared semiconductor LED 2 and a receiver diode 3 opposite of it The contaminant particles contained in the oil current dampen the light beam in a pulse like manner this being classified and counted as measurement signals according particle diameter by an evaluation module 4 The measurement of the flow rate required to determine the purity ra...

Page 14: ...ressure inlet The permanently set valves 9 800 ml min max and 10 30 bar max and the diaphragm accumulator 15 enable connection to sampling points for a pressure range of 1 350 bar at the pressure inlet The shut off valve 17 only opens when a measurement is ongoing The pump 16 allows to measure from non pressurized reservoirs via the suction inlet The FCU can be operated via the keypad 12 Measureme...

Page 15: ...on as the error is remedied this is recognized by the microprocessor which resets the error message completely automatically thus causing the contacts of relay 3 to close and measurement and data saving to be resumed This ensures that in the event malfunction occurs during continuous online operation e g as the result of a power outage flow errors as the result of pressure loss etc measurement ope...

Page 16: ... FCU 2210 5 Edition 1 10 HYDAC Filtertechnik GmbH Page 16 of 52 5 5 Description of the Display and Control Elements 5 5 1 Front View mode memory limits ISO NAS setup print LC Display Keypad Flow control valve Flow Control Partikel Figure 2 Front View ...

Page 17: ...mbH Page 17 of 52 5 5 2 Rear View Suction Inlet Pump Power Switch Outlet Pressure Inlet On Off Switch Power Input 24 V DC PC Interface Control Connector Filter Element Cover Case Ground Connector Ball Valve High Pressure Position Ball Valve Suction Position Power Input 24 V DC Figure 3 Rear View ...

Page 18: ...t measuring mode with without relay control edit log memory name of measuring point print out edit limit switches for control of universal control signals edit setup autostart date time etc display results in ISO Code display illumination on averaging period deletion etc Online stored logs etc filter pump units or as this key only acts during a running measurement display results as particle count...

Page 19: ...nu ok start Press keys ok start and scroll left simultaneously Delete character when editing measurement point in memory menu To enter the power up menu Press keys scroll right and scroll left simultaneously To lock keypad ok start Press keys illumination on and ok start simultaneously key lock on off To switch LCD illumination permanently on 2 x During operation Press key illumination on twice il...

Page 20: ... 1 PC Connector Subminiature D 15 pin male Pin Signal function 1 Shield 2 TXD transmit line 4 RXD receive line 8 GND ground 5 6 2 Control Connector Relays Subminiature D 15 pin female Relay 1 6 7 8 common normally closed 11 12 13 14 15 User programmable normally open Relay 2 User programmable Device ready Relay 3 normally closed normally open common normally open common Maximum load 2A max 24 VDC ...

Page 21: ...user has programmed invalid setting values M3 Filter to Contacts 7 and 8 are closed when measurement has been started and the measured values purity ratings are not within the range limits programmed by the user Contacts 6 and 8 are closed when 5 measurements in a row are identical to the limit programmed by the user or are below it Not in operation M4 Filter from to Contacts 6 and 8 are closed wh...

Page 22: ...tertechnik GmbH Page 22 of 52 M5 Measure autostop Contacts 7 and 8 are closed when measurement has started and is ongoing Contacts 6 and 8 are closed when the FCU not in service Not in operation 5 6 4 Supply Voltage Plug Hollow plug 5 5 mm Internal contact 24V DC External contact GND ...

Page 23: ...AS 4 15 25 µm Channel NAS 6 15 2 µm Channel ISO 12 25 5 µm Channel ISO 10 23 15 µm Channel ISO 9 21 Durchfluß 0 150 Mode M3 ISO 12 10 9 25 23 21 NAS 2 2 4 15 15 15 Mode M4 ISO 12 10 9 25 23 21 NAS 2 2 4 15 15 15 Test cycle time 0 1440 FCU 2210 5 Min Max Mode M2 4 µm c Channel ISO 12 25 6 µm c Channel ISO 10 23 14 µm c Channel ISO 9 21 Durchfluß 0 150 Mode M3 ISO 12 10 9 25 23 21 Mode M4 ISO 12 10 ...

Page 24: ...line adapters themselves have to be connected to mains voltage Because the shut off valve for measurements with high pressure inlet and the pump for measurements with suction inlet need 24 V DC supply FCU 2110 5 FCU 2210 5 can not be operated independently of an external power supply FCU electronics and shut off valve are supplied by the socket Power Input so you don t have to use a second line ad...

Page 25: ...ching to position SUCTION to be sure that the internal accumulator has reliefed its pressure to the Outlet A Plug the return hose DN 7 onto the Outlet connector on the back panel and route it into a suitable container e g hydraulic tank or any other container B Switch the pump switch on the rear panel to ON position refer to Figure 3 Rear View and turn the flow control valve on the front panel clo...

Page 26: ...see chapter 7 1 Measurement Operation then press the START key Set the flow rate to approx 70ml min shown in LCD If an error message appears in the LCD turn the flow control valve in the direction indicated until the error message disappears and measurement operation starts automatically Measurements with suction Inlet may run continuously with viscosities up to 150 cSt For higher viscosities you ...

Page 27: ... pressure of the test point to be checked and see whether it is within the permissible range for the pressure connection inlet 1 350 bar E First connect the high pressure measuring hose to the FCU and then to the Minimess connector of the hydraulic test point As soon as the pressure connection has been made to the system and a measurement is started remind autostart function the oil flows through ...

Page 28: ...ing shown again at 100 C cumulative or D differential is displayed behind sign when particle counts notation is used 4 Shows the current purity rating with each particle size being shown separately when NAS not available with FCU 2210 5 or particle counts notation is being used The tendency arrow or shows very slight changes which would not otherwise be reflected by the purity rating reading 5 Sho...

Page 29: ...easurement Stop measurement ok start stop 7 1 2 M2 Measure Switch Function Purpose Mode M2 Measure Switch is used for measuring the purity of the oil in the hydraulic system at the same time offering the possibility of controlling the limit value relay for signaling purposes This means that this menu enables the user to have external devices switched by two relays for warning purposes Alarm e g an...

Page 30: ...E key M1 Measure M2 Measure switch M3 Filter to M4 Filter from to start ok M5 Measure autostop To enter the switching limits select the submenu M2 M3 M4 via the MODE key followed by the Limits menu LIMITS key M2 Relais 1 M2 Relais 2 M3 Filtern to M4 Filtern from to M5 Measure autostop start ok limits M2 Relay1 ok start ok start 2µm NAS chan flow rate Switch func within range outside range exceeded...

Page 31: ... M2 R2 limits 14 18 NAS fall below LIMITS R2 meas channel 0 1 2 3 4 5 6 7 8 9 or ok start 5µm NAS chan 15µm NAS chan 25µm NAS chan 2µm ISO chan 5µm ISO chan 15µm ISO chan ISO Example 2 Switching of a lamp bad indicator outside of a certain oil purity range upper and lower limit limits M2 Relay2 ok start ok start 2µm NAS chan flow rate Switch func within range outside range exceeded no function ok ...

Page 32: ...AS fall below LIMITS R2 meas channel 0 1 2 3 4 5 6 7 8 9 or ok start 5µm NAS chan 15µm NAS chan 25µm NAS chan 2µm ISO chan 5µm ISO chan 15µm ISO chan ISO Example 4 Switching of a lamp good indicator when falling short of a certain oil purity rating upper and lower limit Contacts 14 and 15 are closed when ISO Code 2µm is smaller than 14 they are opened again when ISO Code is higher than 18 limits M...

Page 33: ...33 of 52 Example 5 Disabling the switching functions of relay 1 limits M2 Relay2 ok start ok start 2µm NAS chan flow rate Switch func within range outside range exceeded no function ok start fall below LIMITS R2 meas channel 5µm NAS chan 15µm NAS chan 25µm NAS chan 2µm ISO chan 5µm ISO chan 15µm ISO chan ...

Page 34: ...without the switching relays This is illustrated by the following example Typical Application Flushing of hydraulic systems and documentation of the oil purity rating achieved by way of an online printout Operation MODE key M1 Measure M2 Measure switch M3 Filter to M4 Filter from to start ok M5 Measure autostop Example 1 Programming OF 5 C operation single flushing cleaning action limits M2 Relais...

Page 35: ... example Typical Application Long term monitoring of the oil purity rating in hydraulic systems and documentation thereof by way of an online printout Operation MODE key M1 Measure M2 Measure switch M3 Filter to M4 Filter from to start ok M5 Measure autostop Example 1 Programming OF 5 C operation flushing cleaning between a lower and upper limit limits ok start M4 Limit values 5 5 5 0 1 2 3 4 5 6 ...

Page 36: ...ump button on back panel to ON Position and press the Start button After the start delay time necessary to deaerate and flush the FCU is elapsed the first measurement starts automatically After the last measurement is done the measurement stops automatically Switch Pump button on back panel to OFF Position The results are printed out both in ISO NAS codes and particle counts NAS with FCU 2110 5 on...

Page 37: ...C Filtertechnik GmbH Page 37 of 52 Example 1 Programming 5 measurements after a start up delay of 30 seconds limits ok start M5 stop after 0 1 2 3 4 5 6 7 8 9 or ok start M5 Measure autostop LIMITS ok start M5 start delay seconds 0 1 2 3 4 5 6 7 8 9 or ok start 30 measurements 5 ...

Page 38: ...val function has to be set to zero in order for the measured values to be outputted Typical Application Monitoring of the oil purity of hydraulic assemblies with the possibility of performing comparative measurements at the same measurement point over an extended period of time Operation MEMORY key Measuring point averaging interval Selective deletion Delete all Change meas point ok start ok start...

Page 39: ...ep for information purposes however storage and printout of the measured values take place as averaged values only upon the preprogrammed time elapsing Typical Application Continuous long term monitoring and documentation of the oil purity in hydraulic systems Operation MEMORY key Measuring point averaging interval Selective deletion Delete all Change meas point ok start ok start memory MEMORY 12 ...

Page 40: ...ser whose archiving are of no practical use for subsequent documentation purposes or comparative measurements Operation MEMORY key Measuring point averaging interval Selective deletion Delete all Change meas point ok start Example 1 Deleting logs from memory memory MEMORY 12 measuring point memory selective deletion ok start 0 1 2 3 4 5 6 7 8 9 or ok start memory delete all ok start or log number ...

Page 41: ...Paper feed internal external Online print out Abort print out not all modes 7 3 1 Printing Online Logs only when measurement is in progress Purpose Documenting continuous measurement by outputting the measured results via the integrated printer Typical Application Flushing of an hydraulic assembly is to be documented during the entire cleaning procedure until a certain oil purity rating is achieve...

Page 42: ...sly saved as a consecutive number 2 Date automatically saved along with the measurement 3 Measurement point has to be entered by the user 4 According to date and measurement point Typical Application Data collected for previous measurements have to be referred to in order to compare the current oil purity data of a hydraulic system Operation print ok start PRINT Logs log number 35 0 1 2 3 4 5 6 7 ...

Page 43: ... the current flowing through the sensor drops to 0 measurement is discontinued and the FCU switched off no If the current flowing through the sensor drops to 0 measurement is discontinued however the FCU remains switched on and resumes measurement as soon as the flow rate is sufficient again Pump pre run time When conducting measurements with the aid of the KE1310 conditioning unit or when using a...

Page 44: ...ge simultaneously after power up Test Volume The user can select between English German French and a programmable language via FCUDESK software package The test volume for one single measurement can be set between 10 and 100 ml Results are always referred to 100 ml Measuring accuracy as indicated in chapter 15 Technical Data and Specifications is only guaranteed for a test volume of 100 ml Languag...

Page 45: ...CU has detected a checksum error at one or more stored logs Cause a strong electromagnetic disturbance has changed the parameters the internal back up battery is down The defective logs are automatically deleted That means after the next power up this message is not displayed again if this was just a short disturbance If this message is displayed several times the internal back up battery is down ...

Page 46: ...ted The internal protection filter for the flow control valve of the FCU is clogged Replace FCU filter element ext Input activated this message only occurs with the OF5C filtration unit The clogging indicator of the OF5C is activated the OF5C filter is clogged Replace OF5C filter element Internal printer not ready Paper roll empty Printer damaged Replace with new paper roll Ship FCU to HYDAC for r...

Page 47: ...ion 1 10 HYDAC Filtertechnik GmbH Page 47 of 52 Device ID defect Internal designations in EEPROM are lost by a disturbance This is not a critical error because these designations do not influence the proper function of the FCU Ship FCU to HYDAC for repair eventually ...

Page 48: ...d from the system Undo the contamination retainer filter bowl sealing screw at the rear of the unit using a size 12 Allen screw wrench Note Collect any residual oil in the housing using a suitable container Pull the filter element out of the housing by the strap then insert a new filter element model 0060 D 005 BN 3 HC article no 1260 891 Lubricate the O ring on the filter element somewhat and ins...

Page 49: ...oll d Place new paper roll in the printer so that the paper unrolls from the bottom e Feed paper edge until it stops between the two metal guide plates beneath the feed roller f Press and hold down green button LF while switching on the FCU and wait until approximately 3 cm of printer paper feeds through g Carry out instructions 9 2 Changing the ink ribbon cartridge d to f Guide plates for paper L...

Page 50: ... hose ID 5 with CPC quick disconnect 1000 mm long 349 151 Return hose ID 7 2000 mm long 1251 558 Return hose ID 7 5000 mm long Line adapter 230 V European model Line adapter 120 V U S model Line adapter 240 V Australian model 12 FCU Accessories Article number Designation 3040 814 Transport case incl Filter element replacement set 2 rolls of paper 1 ribbon for integrated printer 349 632 Software pa...

Page 51: ...alues are continuously present which are sequentially stored in the memory as log lines When the memory is full the oldest measured values are overwritten by the latest ones rolling map memory This ensures that no current measured values are lost Log To prevent measurements taken at various measurement points from being stored as one long continuous difficult to manage column of numbers the FCU au...

Page 52: ...ctors Inlet Minimess coupling system 1604 Suction Inlet CPC quick disconnect Outlet quick disconnect coupling ID 7 Return outlet flow rate app 800 ml min at 300 bar Measurement flow rate 50 100 ml min Permissible viscosity range 5 1000 mm2 s for Pressure connection 5 350 mm2 s for suction connection measuring time up to 10 min 5 150 mm2 s for suction connection continuous measurement Media tempera...

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