Hydac FCU 1310 Operating And Maintenance Instructions Manual Download

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HYDAC FILTER SYSTEMS GMBH

Overview | 4

BeWa FCU1310 3371346g en-us lq

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– Supply voltage of 24 V DC / 4 A for operation on mobile

machine on-board networks with Load Dump fuse protec-
tion

– Network adapter 90 - 240 V AC / 24 V DC 5 A included in

the scope of delivery

– Operating pressure without high-pressure adapter max.

45 bar / max. 650 psi,
Operating pressure with high-pressure adapter max.
345 bar / max. 5000 psi

– Integrated pump for supplying the FCU with the fluid to be

analyzed

Summary of Contents for FCU 1310

Page 1: ... FluidControl Unit Operating and Maintenance Instructions English translation of original instructions Document No 3371346g 1 16 2019 Follow these instructions for proper and safe use Keep for future reference ...

Page 2: ...0 Sulzbach Saar Germany Germany E mail filtersystems hydac com Homepage www hydac com Court of Registration Saarbrücken HRB 17216 Executive director Mathias Dieter Dipl Kfm Wolfgang Haering Tab 1 Impressum 1 1 Documentation Representative The contact data of the person authorized with the documenta tion is Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Germany Pho...

Page 3: ...erve regulatory information 15 3 5 Stoppage in an emergency EMERGENCY STOP 15 3 6 Fire fighting extinguishing a fire 15 4 Overview 16 4 1 Counting contaminant particles optically light blockade procedure 18 4 2 Proper Designated Use 20 4 2 1 Periodic intermittent duty operating mode S3 21 4 3 Improper Use or Use Deviating from Intended Use 23 4 4 Checking the scope of delivery 24 4 5 Decoding the ...

Page 4: ...ory settings 53 6 4 Selecting the measurement location 54 7 Operation 55 7 1 Overview of control panel operating elements 55 7 1 1 Reading the display and operating the keyboard 57 7 1 2 Scrolling through the display 59 7 1 3 Displaying measured variables 62 7 1 4 Display service variables 63 7 2 Operating Setting measuring menu 64 7 2 1 RECORD Record measurements 65 7 2 2 MEMORY Displaying free m...

Page 5: ...nt point 104 7 8 2 Measurement report file names 104 7 8 3 Opening the measurement report 106 7 8 4 The measurements are shown as dates 107 7 9 Evaluating Reading measurement reports with FluMoS 110 8 Performing maintenance 111 8 1 Maintenance table 111 8 2 Clean the suction strainer 112 8 3 Calibrating FCU 115 8 4 High pressure adapter maintenance 116 8 4 1 Cleaning changing the strainer 116 8 4 ...

Page 6: ...Table of Contents HYDAC FILTER SYSTEMS GMBH vi BeWa FCU1310 3371346g en us lq Glossary 145 Index 146 ...

Page 7: ...es of culpable harm to life physical in jury and damage to health If we negligently breach any mate rial contractual obligation our liability shall be limited to fore seeable damage Claims due to the Product Liability shall re main unaffected 2 1 Warranty For the warranty provided by us please refer to the Terms of Delivery They are made available to you at the conclusion of the contract at the la...

Page 8: ...ew labeling of the title page 1 Short name of the product product name 2 Type of document 3 Language 4 Document no Index Date of printing 5 Supplementary instructions regarding the validity of the manual optional Please note that you can directly access information through the directories However this does not re lease you from the obligation to read this manual fully before commissioning The docu...

Page 9: ... FCU1310 3371346g en us lq 9 148 The manual contains a table of contents a list of tables and figures an index and a glossary You will find the following symbols in the manual as additional details Tip for handling the product Required tools ...

Page 10: ...he statutory directives reg ulations and standards valid at the time of delivery and satis fies current safety requirements Any residual hazards are indi cated by the general safety information and are described in this manual Observe all safety and warning instructions attached to the product and keep them always complete and easily legible ...

Page 11: ...of risk which if not avoided will result lethal or serious injury WARNING WARNING The signal word indicates a hazardous situation with a medium level of risk which if not avoided can result lethal or serious injury CAUTION CAUTION The signal word indicates a hazardous situation with a low level of risk which if not avoided can result in mi nor or moderate injury NOTICE NOTICE The signal word indic...

Page 12: ... and source of danger Hazard symbol Consequence of the danger Measures to avert danger 3 3 Safety symbols pictograms The following are the safety symbols pictograms in this man ual They indicate specific dangers to persons property or to the environment Observe these safety symbols pictograms and act with particular caution in such cases Always keep all symbols pictograms intact and legible Warnin...

Page 13: ...red specialist personnel These symbols show the required training knowledge for in stallation work and or maintenance work Specialist personnel operators Such persons have had the corresponding spe cialist training and several years work experi ence They are able to assess and perform the work assigned to them they are also able to rec ognize potential hazards Specialist personnel Mechanic Such pe...

Page 14: ...everal years work experience They are able to assess and perform the work assigned to them they are also able to recognize potential hazards Others symbols used These signs are listed for the general safety instructions in these operating instructions for example which indicate a par ticular danger to persons property or the environment Danger due to operating pressure ...

Page 15: ...regulations organization specific regula tions 3 5 Stoppage in an emergency EMERGENCY STOP Disconnect the product from all sources of energy in an emer gency 3 6 Fire fighting extinguishing a fire Use a powder extinguisher that corresponds to fire class B as per EN 2 to extinguish any fires to fight fires Fig 2 Fire protection class B Maintain a minimum safe distance from electrical components For...

Page 16: ...d containers The internal data memory enables measurements to be recorded together with a time stamp The USB interface can be used to copy all measurements to a USB memory stick or to send them to a mobile device via Bluetooth where they can be analyzed using MS Excel or the FluMoS Fluid Monitoring software Additional features include Optical measurement of the degree of solid particle con taminat...

Page 17: ...e on board networks with Load Dump fuse protec tion Network adapter 90 240 V AC 24 V DC 5 A included in the scope of delivery Operating pressure without high pressure adapter max 45 bar max 650 psi Operating pressure with high pressure adapter max 345 bar max 5000 psi Integrated pump for supplying the FCU with the fluid to be analyzed ...

Page 18: ...then a shadow will be cast on the photo de tector This shadow causes a change in the electrical signal gener ated by the photo detector This change makes it possible to determine the size of the shadow cast by the particle and thus to gauge the size of the particle itself This procedure makes it possible to determine the cleanliness class according to ISO 4406 NAS 1638 and SAE AS 4059 The disrupti...

Page 19: ...f the signal peaks corresponds to the shadow cast by one particle The signal height or amplitude reflects the particle size Thresholds are used to classify the particle sizes 2 5 µm 5 15 µm 15 25 µm 25 µm or 4 µm c 6 µm c 14 µm c 21 µm c time Threshold values Fig 5 Signal amplitudes ...

Page 20: ...th flash points higher than 55 C 131 F u Flush the FCU with low viscosity mineral oils or mineral oil based raffinates with flash points higher than 55 C 131 F u Never flush the FCU with universal thinners or other de greasing fluids u Observe the permissible viscosity range up to ISO VG 68 of 2 350 mm s 33 1622 SUS u Operate the FCU only in periodic intermittent duty S3 with a relative duty cycle...

Page 21: ...proper installation com missioning usage handling storage maintenance repair use of unsuitable components or other circumstances for which the manufacturer is not responsible The manufacturer assumes no responsibility for determining the interfaces for installation in a system or the installation use or functionality of the product in this system 4 2 1 Periodic intermittent duty operating mode S3 ...

Page 22: ...FILTER SYSTEMS GMBH 22 148 BeWa FCU1310 3371346g en us lq Fig 6 Operating mode S3 Periodic intermittent duty PN S3 Nominal power operating mode S3 t time t0 Period t1 Operation t2 Cooling phase downtime C F Temperature ...

Page 23: ...at have a flash point under 55 C 131 F u Operate only with fluids whose temperature is not at least 10 C below their individual flash point u Improper connection of the pressure and return flow hoses u Operation at a measurement point with impermissible pressure u Operation on 24 V DC on board networks without central Load Dump fuse u Operation with damaged connector cable u Operation with faulty ...

Page 24: ...nection cable for power adapter Europe USA Canada UK Australia Japan 1 Suction hose open end clear transparent L 0 3 m 1 High pressure hose with screwed joint type 1620 color black L 2 m 1 High pressure adapter 1 Return hose transparent L 2 m 1 Quick start manual 1 Document bag comprised of Operating and Maintenance Instructions this document Calibration certificate CE Declaration of Conformity CD...

Page 25: ...l The type label displays the product ID and important technical data Item Description 1 Type label for FCU 2 Model code for details see Model Code 27 Model Model code for details see Model Code 27 Date Production year week P N Part no S N Serial no Flow rate Flow rate Weight Weight when empty Viscosity range Permissible viscosity range Pressures Pressure specifications ...

Page 26: ... Description In Permissible pressure at port INLET Out Permissible pressure at port OUTLET Temperatures Temperature specifications Oil Permissible oil temperature range Ambient Permitted ambient tempera ture range Power Power consumption Voltage Voltage Current Current consumption ...

Page 27: ...nnels ISO4406 SAE AS 4059 D 4 µm c 6 µm c 14 µm c 21 µm c Housing 1 Plastic case with bag for mobile utilization Power supply Integrated sensor Power supply adapter 24 V DC AquaSensor AS 1000 only 131x 100 240 V AC 50 60 Hz 1 phase 5000 mA Europe USA Canada UK Australia Japan U AS 1 3 ISO4406 NAS 1638 2 5 µm 5 15 µm 15 25 µm 25 µm can be switched to ISO4406 SAE AS 4059 D 4 µm c 6 µm c 14 µm c 21 µ...

Page 28: ...s NAS class Measured values for fluid temperature 25 to 100 C 13 to 212 F Measured values for water saturation 0 100 Measurement range Display of ISO code between 9 8 7 25 24 23 Calibrated within the range of ISO code 13 11 10 23 21 18 Accuracy Contamination sensor ISO code AquaSensor 3 FullScale Service Display FLOW DRIVE Measuring time config urable 10 300 Seconds Tab 4 Contamination sensor Hydr...

Page 29: ...ssible viscosity range 2 350 mm s 33 1622 Sus for hydraulic oil up to ISO VG 68 Suction height 1 m Suction hose INLET DN4 open end color clear trans parent Length 0 3 m High pressure hose IN LET DN4 with screw connection for mea surement point 1620 color black Length 2 m Return hose OUTLET DN7 open end color clear trans parent Length 1 m Tab 5 Hydraulic data Electrical data Power supply 24 V DC 20...

Page 30: ... low voltage protection Tab 6 Electrical data General data Emission sound pres sure level LPA 70 db A Material of sealings FKM FPM Viton NBR Permitted temperature range of fluid 0 70 C 32 158 F Permitted ambient tem perature range 0 45 C 32 113 F Permitted storage tem perature range 40 80 C 40 176 F Permitted relative hu midity max 90 non condensing Weight when empty 13 kg Tab 7 General data ...

Page 31: ...HYDAC FILTER SYSTEMS GMBH Overview 4 BeWa FCU1310 3371346g en us lq 31 148 4 7 Dimensions The FCU has the following dimensions Fig 8 Dimensions All dimensions in mm ...

Page 32: ...rcuit The FCU has the following hydraulic circuit Fig 9 Hydraulic circuit Item Designation 1 INLET gauge port type 1604 2 Suction strainer 400 µm 3 Gear pump 4 Electric motor 5 Pressure relief valve 6 Contamination sensor 7 Counter balance valve 8 AquaSensor 9 OUTLET DN7 quick coupling nipple ...

Page 33: ...Wa FCU1310 3371346g en us lq 33 148 4 9 Opening closing the case Open the FCU case by releasing the two clips Fig 10 Opening the FCU case Close the FCU using both clips Make sure that these audibly snap into place Fig 11 Closing the FCU case ...

Page 34: ...assified and counted as measurement signals in the contamination sensor The evaluation module shows cleanliness classes continuously with the aid of the measuring signals of the optical sensor with respect to a measurement volume of 100 ml A defined pressure in the flow of oil is gener ated by the counter balance valve 7 This is used to minimize the air bubbles in the system which could skew the m...

Page 35: ...3371346g en us lq 35 148 The status display will indicate an error in the event that one occurs The evaluation module will recognize when the cause of error has been corrected and the unit will reset automati cally and resume the measurement operation ...

Page 36: ...t of the FCU the USB stick is to be removed the power supply unit and the hoses are to be packed away neatly and or stored in the bag and the case is to be correctly sealed CAUTION Hot fluid at the connection OUTLET Danger of burns u Let the FCU and the hoses cool down To prepare the FCU for transport observe the following se quence 1 Undo the measurement hose from the measurement point 2 Use the ...

Page 37: ...ng storing the FCU 5 BeWa FCU1310 3371346g en us lq 37 148 3 Remove the USB stick should it be inserted 4 Close the USB socket with the corresponding cover 5 Remove the hose by turning counterclockwise from the INLET connection of the FCU ...

Page 38: ... check valve on the quick action coupling Doing so enables the fluid in the hose to drain off rapidly Plug the two ends of the hose into one another after emptying is complete In this way you can ensure that no more fluid will leak from the hose during transport 7 Release the catch 1 and then pull the socket out of the connector 2 8 Close the FCU using both clips Make sure that both clips audibly ...

Page 39: ...STEMS GMBH Transporting storing the FCU 5 BeWa FCU1310 3371346g en us lq 39 148 5 2 Transporting the FCU Transport the FCU only when it is in closed position carry it flat or by the handle Fig 13 Transporting the FCU ...

Page 40: ...ting it into stor age See the Rinsing the FCU chapter for details on rinsing the FCU Details regarding permissible storage conditions can be found in the Technical Data 28 chapter Store the FCU closed and in a horizontal position in a dry clean place If stored in a vertical position the FCU must not be exposed to any shaking or vibration Fig 14 Storing the FCU ...

Page 41: ...n Connect the other end with the voltage source 2 Once the FCU is supplied with voltage the display will show HYDAC FCU 1 in ticker format Afterwards the firmware version will be shown for 2 seconds The internal sensors will be checked after that The display shows and the firmware of the sensors The self test is followed in the display by a countdown 3 The FCU is now ready for the measurement As l...

Page 42: ...6 Putting the FCU into operation HYDAC FILTER SYSTEMS GMBH 42 148 BeWa FCU1310 3371346g en us lq Fig 16 Disconnecting the power supply ...

Page 43: ...al the connection OUTLET u Put the free end of the OUTLET return hose into an un pressurized container Fig 17 Plug in return hose Fit the quick action coupling on the return hose to the nipple Make sure that the coupling snaps audibly into place on the nipple Make sure that the quick action coupling is firmly seated Fig 18 Detach return hose Put the other end of the return hose into a depressurize...

Page 44: ...t saving Scroll to and use the button for con firmation or wait 30 seconds without actuating a button PowerUp Exit the menu with Save Scroll to and con firm with the button You are scrolling through the PowerUp menu For details see DAT TIM Setting the date time 45 ADRESS Set bus address 46 DEL MEM Deleting the measure ment report memory 47 M TIME Set measuring time 48 CALIB Selecting the calibrati...

Page 45: ...ystem time at DAT TIM If the date has never been set or if the buffer battery is flat the system date will be and the time will be The date format is year month day The time uses the 24 hour format hour minute Fig 19 DAT TIM Setting the date time Use the following buttons to set the date and time Change the values Change the position Confirm the changes Cancel and back ...

Page 46: ...nsmit the mea sured values via the data interface using the HSI protocol There are 26 bus addresses available from A Z Please note that each address may occur only once on any bus Fig 20 ADRESS Set bus address Use the following buttons to set the address Change the values Change the position Confirm the changes Cancel and back The factory setting of the bus address is ...

Page 47: ...rds located in the internal measurement report memory NOTICE Deletion of the measurement report memory Data loss u Backup copy all of the measurement reports to the USB memory stick before deleting them Before deletion back up all of the measure ment records on the USB memory stick Fig 21 DEL MEM Deleting the measurement report memory Push the following buttons for deletion Confirm the changes Can...

Page 48: ...easuring time under M TIME Select the duration in the range from 10 to 300 seconds Use the following buttons to set the duration of the measurement Fig 22 M TIME Set measuring time Use the following buttons to set the duration of the measure ment Change the values Change the position Confirm the changes Cancel and back The factory setting is ...

Page 49: ... Selecting the calibration type Under CALIB select the desired calibration type either or The calibration type ISO SAE is based on ISO4406 SAE The calibration type ISO NAS is based on ISO4406 NAS Fig 23 CALIB Calibration selection Use the following buttons Change the values Confirm the changes Cancel and back ...

Page 50: ...q 6 3 6 DFAULT Reset to default settings Reset the FCU to the factory settings under DFAULT The fac tory settings can be found in chapter Factory settings 53 Fig 24 DFAULT Reset to default settings Use the following buttons Change the values Change the position Confirm the changes Cancel and back ...

Page 51: ...FCU into operation 6 BeWa FCU1310 3371346g en us lq 51 148 6 3 7 CANCEL Cancel Use CANCEL CANCEL to discard all changes and exit the menu Fig 25 CANCEL Cancel Use the following buttons Change the position Confirm the changes Cancel and back ...

Page 52: ...TEMS GMBH 52 148 BeWa FCU1310 3371346g en us lq 6 3 8 SAVE Saving settings data Use SAVE to store all of your changes and exit the menu Fig 26 SAVE Saving settings data Use the following buttons Change the position Confirm the changes Cancel and back ...

Page 53: ... menu item This will cause the following factory settings to be loaded value For details see ADRESS Set bus address 46 M TIME Set measuring time 48 CALIB Selecting the calibra tion type 49 Bluetooth Code 0000 Connecting Linking the FCU via Bluetooth 103 Tab 9 Factory settings The names of the measurement locations as well as all other settings are not affected by the reset ...

Page 54: ...ion so that the sample measured comes from a turbulent location with a good flow For exam ple on a pipe bend A This ensures that a typical sample is analyzed If the FCU is installed near the measurement point B avoid delayed measurement results and sedimentation particle de posits in the line While installing the inlet hose INLET make sure that no siphon C results ...

Page 55: ...The following operating elements can be found on the control panel Fig 27 Control panel operating elements 1 Display of ISO SAE NAS FLOW DRIVE with key board 2 Water saturation display 3 Fluid temperature display 4 ON OFF switch for the internal pump 5 3 pole connection for 24 V DC supply voltage 6 Data interface DATA 7 Connection OUTLET 8 Connection INLET 9 USB interface with cover ...

Page 56: ...ation HYDAC FILTER SYSTEMS GMBH 56 148 BeWa FCU1310 3371346g en us lq 14 Fastener for the OUTLET connection when the case is closed 15 Holding down device 16 Bag for hoses and accessories Bluetooth interface ...

Page 57: ...tus LED Status display Green Red In the event of a malfunc tion the status LED will show red and flash as code Details regarding this can be found in the Finding rectifying errors 125 chapter 2 Display Consists of a 6 digit dis play on which the selected measured values are out put 3 Measured variable Indicates the respective measured variable pre sented in the display e g 4 Service variable Indic...

Page 58: ...e through the menus hierar chically structured Keyboard Description Go one level down Confirmation of a changed value lowest level Confirm in order to save changes or discard them top level Go one level up back Cancel no values changed Change values at the lowest levels If you are at the lowest menu level the display will flash Scroll through the display Scroll through the menu Select positions Ta...

Page 59: ...Wa FCU1310 3371346g en us lq 59 148 See also 2 Finding rectifying errors 125 7 1 2 Scrolling through the display Depending on the selected type of calibration in the Power Up menu you can scroll through the following dis plays using the keys ...

Page 60: ...g en us lq See also 2 Finding rectifying errors 125 7 1 2 1 Displays with ISO SAE The following displays are available Display Description 3 digit ISO code SAE Class A SAE Class B SAE Class C SAE Class D SAE Max Flow status LED current in Tab 11 Displays with ISO SAE ...

Page 61: ...en us lq 61 148 7 1 2 2 Displays with ISO NAS The following displays are available Display Description 3 digit ISO code NAS 2 5 µm channel NAS 5 15 µm channel NAS 15 25 µm channel NAS 25 µm channel NAS Max LED current in Flow status Tab 12 Displays with ISO NAS ...

Page 62: ...ed variable SAE The measured variable is updated depending on the set mea suring time The presentation takes the form of a channel of the SAE class Example SAE class A 13 4 7 1 3 3 Measured variable NAS The measured variable is updated depending on the set mea suring time The presentation takes the form of a channel of the NAS class Example NAS class channel 15 25 13 2 7 1 3 4 Measured variable Wa...

Page 63: ...low and the light source power The service variables are not cali brated 7 1 4 1 Service variable Flow Flow contains the display indicating whether the flow is in the permissible range Example Flow rate OK 7 1 4 2 Service variable Drive Display of the light source efficiency 1 100 with which the ContaminationUnit currently works Example Light source effi ciency 42 ...

Page 64: ...and use the button for con firmation or wait 30 seconds without actuating a button Save and exit the measuring menu Scroll to and con firm with the button You are scrolling through the measuring menu For details see RECORD Record measurements 65 MEMORY Displaying free mea surement report memory 68 ED MPNT Change name of mea surement point 69 TP UNIT Set temperature unit 71 CANCEL Cancel 73 SAVE Sa...

Page 65: ...rd measurements Under RECORD you define under which of the 20 available names of the measurement locations the measurement reports will be stored Fig 29 RECORD Record measurements Use the following buttons Change the values Change the position Confirm the changes Cancel and back Fig 30 MPNT xx ...

Page 66: ...asuring point designation at will maximum 6 characters as described under ED MPNT Fig 31 MPNT00 xx Change to the next measurement point Change the position Confirm the changes Cancel and back Select STP STA to create a new measurement report file in the internal measurement report memory under a new measure ment point designation Confirm with the button after which the display will jump to Confirm...

Page 67: ...R SYSTEMS GMBH Operation 7 BeWa FCU1310 3371346g en us lq 67 148 Fig 32 Restarting the STP STA measurement report Use the following buttons Change the values Change the position Confirm the changes Cancel and back ...

Page 68: ...easurement report memory in If there is no more memory available no measurement reports can be saved NOTICE No free measurement report memory Data loss u Check the measurement report data memory regularly depending on frequency of use for free memory space Fig 33 MEMORY Displaying the free measurement report memory Use the following buttons Confirm the changes Cancel and back ...

Page 69: ...ment point designation with ED MPNT You have a maximum of 6 characters available for the measurement point designation Example TEST01 EXCA VATOR CRANE02 etc Fig 34 Changing the ED MPNT measurement point designation Push the following buttons for deletion Change the values Change the position Confirm the changes Cancel and back Change the values ...

Page 70: ...m the changes Cancel and back The following rolling characters appear after confirmation of the buttons The empty space is located between 9 and A and can be ad justed only from the 6th position to the left This means it is possible to enter a measurement point designation with less than six characters ...

Page 71: ...T you set the units to display the fluid tempera ture You have the choice between degrees Celsius C and de grees Fahrenheit F Fig 35 TPUNIT Setting the temperature unit Use the following buttons Change the values Change the position Confirm the changes Cancel and back Fig 36 TPUNIT setting degrees Celsius Change the values ...

Page 72: ...7 Operation HYDAC FILTER SYSTEMS GMBH 72 148 BeWa FCU1310 3371346g en us lq Change the position Confirm the changes Cancel and back ...

Page 73: ...eration 7 BeWa FCU1310 3371346g en us lq 73 148 7 2 5 CANCEL Cancel Use CANCEL CANCEL to discard all changes and exit the menu Fig 37 CANCEL Cancel Use the following buttons Change the position Confirm the changes Cancel and back ...

Page 74: ...74 148 BeWa FCU1310 3371346g en us lq 7 2 6 SAVE Saving settings data Use SAVE to store all of your changes and exit the menu Fig 38 SAVE Saving settings data Use the following buttons Change the position Confirm the changes Cancel and back ...

Page 75: ...e is at that location Select the measurement method suitable for the fluid to be measured and the prevailing operating pressure Pressure at the measurement point Operating mode measurement method for details see 0 bar 0 psi Measuring from unpressurized contain ers 76 1 45 bar 14 650 psi Measuring up to max 45 bar 650 psi with hydraulic fluids 79 15 345 bar 217 5000 psi Measuring in the range 5 to ...

Page 76: ... fluids 79 2 Measuring in the range 5 to 345 bar 217 to 5000 psi with oil 82 2 Measuring from unpressurized containers 76 7 3 1 Measuring from unpressurized containers For the measurement of permissible oil from depressurized containers proceed as follows Required hoses Return hose Suction hose Fig 39 Operating mode Measurement at 0 bar ...

Page 77: ... FCU The sensor will interpret this air oil mixture as par ticulate soiling and will thus falsify the measure ment result For an initial test without priming the FCU and hoses you need 300 ml of fluid Make sure that the following sequence is observed ü You have performed all of the steps listed in chapter Putting the FCU into operation 41 1 Connect the suction hose color clear transparent with the...

Page 78: ...7 Operation HYDAC FILTER SYSTEMS GMBH 78 148 BeWa FCU1310 3371346g en us lq 2 Switch on the internal pump ð The FCU will start with the measurement ...

Page 79: ...stem must be depressurized before performing any work on the product u If the pressurized connection is connected to the hydraulic system hydraulic fluid will flow through the FCU u Make sure that the specified sequence is followed NOTICE If the operating pressure exceeds 45 bar 650 psi The excess pressure will be discharged via port OUTLET u Never seal the connection OUTLET u Put the free end of ...

Page 80: ...d in chapter Putting the FCU into operation 41 1 Check the pressure at the measurement location The existing pressure must be in the range of 1 45 bar 14 650 psi WARNING If the pressure is greater than 45 bar 650 psi then use the high pressure adapter 2 Connect the entry hose color black with the INLET connection of the FCU 1 Rotate the measurement coupling clockwise 2 to the connection and tighte...

Page 81: ...FCU1310 3371346g en us lq 81 148 3 Connect the other end of the INLET pressure hose to the measurement point of the system 4 Switch on the internal pump ð The hydraulic installation of the FCU is complete The FCU will start with the measurement ...

Page 82: ...rforming any work on the product u If the pressurized connection is connected to the hydraulic system oil will flow through the FCU u Make sure that the specified sequence is followed NOTICE Operating pressure exceeds 345 bar 5000 psi The excess pressure will be discharged via port OUTLET u Never seal the connection OUTLET u Put the free end of the OUTLET return hose into an un pressurized contain...

Page 83: ...ved ü You have performed all of the steps listed in chapter Putting the FCU into operation 41 1 Check the pressure at the measurement location The existing pressure must be in the range of 15 345 bar 217 5000 psi WARNING If the pressure is greater than 345 bar 5000 psi abort the measurement attempt 2 Screw the high pressure adapter onto the INLET con nection of the FCU ...

Page 84: ...NLET connection of the FCU 1 Rotate the measurement coupling clockwise 2 to the connection and tighten it by hand 4 Connect the other end of the INLET pressure hose to the measurement point of the system 5 Switch on the internal pump ð The hydraulic installation of the FCU is complete The FCU will start with the measurement ...

Page 85: ...ment see Op erating Setting measuring menu 64 ü Select a corresponding operating mode for the pressure see Select the operating modes measurement method according to the pressure involved 75 1 Switch on the pump at the switch The pump conveys the fluid for analysis through the FCU 2 After the set measurement time the result is shown on the display and the status LED lights up green perma nently 3 ...

Page 86: ...10 3371346g en us lq 7 5 Restarting resetting To restart or reset the FCU remove the power supply to the FCU for 10 seconds Press the catch 1 on the connector and then pull 2 the con nector out Insert the connector into the socket until it audibly snaps in ...

Page 87: ...dent of the electrical supply net work The technical details for the BatteryPack can be found in the corresponding instructions With the locking pin 2 the BatteryPack 1 is held securely in the mounting rails 3 during transport Fig 42 BatteryPack overview 1 BatteryPack 2 Indexing plunger 3 Mounting rails For operation with the BatteryPack fit the connector into the socket labeled DC IN of the FCU ...

Page 88: ...7 Operation HYDAC FILTER SYSTEMS GMBH 88 148 BeWa FCU1310 3371346g en us lq Fig 43 BatteryPack in operation ...

Page 89: ...emove the connector A from the socket on the Bat teryPack 2 Insert the BatteryPack into the mounting rails from above 3 Pull the locking pin 1 Guide the BatteryPack down to the lower stop in the guide rails 2 Release the locking pin 3 A spring will return the lock ing pin to its original position thus securing the Battery Pack Check the BatteryPack is sufficiently tight secured ...

Page 90: ...ation HYDAC FILTER SYSTEMS GMBH 90 148 BeWa FCU1310 3371346g en us lq 4 Insert the connector into the socket on the BatteryPack ð The BatteryPack is securely stored and ready for trans portation or operation ...

Page 91: ...s follows 5 Remove the connector from the socket 6 Pull the locking pin out to unlock the BatteryPack 1 Slide the BatteryPack upwards 2 7 Pull the BatteryPack up and out of the mounting rails Then insert the connector back into the socket on the BatteryPack ð The BatteryPack is removed from the FCU ...

Page 92: ...es mea surement records To transfer the data the target system e g PC or USB stick has to have at least 10 MB of capacity free The FCU provides you with the following interfaces for reading the measurement memory Available interfaces For details see chapter DATA interface Extracting measurement re ports via DATA interface 93 USB interface Extracting copying measure ment reports via USB interface 9...

Page 93: ...the measure ment reports The DATA interface communicates in the HSI protocol 7 7 1 1 Pins used on the DATA interface HYDAC Sensor Interface HSI Fig 44 5 pole connec tion The HSI interface has connection plug M12x1 5 pole in ac cordance with DIN VDE 0627 Pin Assignment 1 Not connected 2 Not connected 3 Not connected 4 GND 5 HSI 6 Shield Tab 16 Pins used on the interface 5 pole ...

Page 94: ...7 Operation HYDAC FILTER SYSTEMS GMBH 94 148 BeWa FCU1310 3371346g en us lq 7 7 1 2 Connecting the FCU with CSI B 2 The FCU can be connected to a PC using the CSI B 2 kit Fig 45 FCU CSI B 2 ...

Page 95: ...HMG The following portable data recorders HMGs can be used to give a readout of the FCU via the DATA interface HMG 510 with firmware version 2 release 15 or higher HMG 3000 with firmware version 2 release 1 or higher HMG 4000 See the operating instructions for the HMG for further details Fig 46 FCU HMG ...

Page 96: ...f measurement reports during copying Data loss u Do not copy the measurement reports from the internal memory during an ongoing measurement NOTICE Insufficient memory space on the USB memory stick Data loss u Use only a USB memory stick with 10 MB free memory space Format the USB memory stick prior to its first use To do that insert it into a free USB port on your PC Then change to the file manage...

Page 97: ...ike for example on a PC with an operating system We recommend using the HYDAC USB mem ory stick which we successfully tested for many PC operating system combinations HYDAC accepts no guarantee or liability for the functionality and compatibility of the USB mem ory stick with your system We do not offer sup port or replacements in this case ...

Page 98: ...USB memory stick into the USB socket Note that the USB memory stick fits into only one position in the socket NOTICE Do not insert the USB memory into the USB socket with force 3 After inserting the USB memory stick the FCU will de tect it and immediately start copying the measurement data 4 You can see the number of the measurement records to be copied in the left display example 339 You can dete...

Page 99: ...k This function is especially suited to the synchro nization of the copied data with the FCU s internal memory The existing records will be displayed After successfully copying the records the following message will appear on the display 5 Remove the USB memory stick from the USB socket 6 Close the cover to the USB socket 1 by turning it clock wise 2 ð The measurement reports from the internal mea...

Page 100: ...USB stick back in the USB socket of the FCU The download will start automatically 3 a If the error recurs go to step 4 b If the error does not recur go to step 11 4 Insert the USB stick in your PC and reformat it 5 Put the USB stick back in the USB socket of the FCU The download will start automatically 6 a If the error recurs go to step 7 b If the error does not recur go to step 11 7 Use a differ...

Page 101: ...HYDAC FILTER SYSTEMS GMBH Operation 7 BeWa FCU1310 3371346g en us lq 101 148 Ste p Description 11 The download has been successfully completed ...

Page 102: ...ace is based on Bluetooth Version 1 2 Class 3 Bluetooth Version 1 2 is less sensitive to static disturbances e g WLAN the maximum data transfer rate is 732 2 kBit s Class 3 a maximum power of 1 mW or 0 dBm is sufficient for a 10 m area outdoors This distance is strongly dependent on disruptions and obstacles in the vicinity Fig 47 Bluetooth interface ...

Page 103: ...measured values can be read out e g via FluMoS The HSI protocol is used to communicate with the FCU The data transfer through the Bluetooth connection is depen dent on your PC hardware and on the software installed on it There are a multitude of Bluetooth modules and software driv ers on the market that do not completely fulfill the specifica tions of IEEEE 802 15 The Bluetooth Code Password for c...

Page 104: ...ned to the directory for this measurement point MNPT00 MNPT08 MNPT09 MNPT10 MNPT16 MNPT19 Fig 48 Explorer presentation of measurement record directories 7 8 2 Measurement report file names The file name of measurement reports is comprised of the date YY year MM month DD day and a continuous counter as file extension A new record is created On request by After a restart of the FCU see Restarting re...

Page 105: ...HYDAC FILTER SYSTEMS GMBH Operation 7 BeWa FCU1310 3371346g en us lq 105 148 YY _ MM _ DD Incremental number 18 _ 08 _ 23 028 Tab 18 Example Measurement report file names ...

Page 106: ...are prompted to select a program for opening the file select Excel here Generally speaking this applies for every file extension from 000 to 999 A measured data file is comprised of two parts Part 1 General information regarding the recording sensors and devices Part 2 The actual measured data is presented in lines after the word Data The first line contains the column titles Faults are shown as n...

Page 107: ...all decimal numbers will be shown as dates To correct the presentation proceed as follows 1 Start Excel 2 Now execute the Open command via the menu bar Open the desired measured data file Separated Continue Text conversion assistant step 1 of 3 3 The Text Conversion Wizard appears 4 Text Conversion Wizard Step 1 of 3 Check the settings Confirm the window by pressing the Next button ...

Page 108: ...Continue Text conversion assistant step 2 of 3 Text recognition character 5 Text Conversion Wizard Step 2 of 3 Check the settings Confirm the window by pressing the Next button Standard Text conversion assistant step 3 of 3 Other 6 Text Conversion Wizard Step 3 of 3 Press the Next button ...

Page 109: ...the following settings Set the period as the decimal point and the comma as the separation character for 1000s Confirm the changes with the OK button Standard Finish Text conversion assistant step 3 of 3 Data format of the columns 8 Click on the Finish button to complete the import of the measurement data ð The decimal points will now be presented correctly ...

Page 110: ...the measurement reports measurement data FluMoS light is available as freeware on the CD included in the delivery or as a download The link for the download can be found on the homepage un der www hydac com You can obtain FluMoS professional as an accessory for an additional charge See chapter Finding accessories 135 You can get FluMoS mobile for your Android mobile device on the Google Play Store...

Page 111: ...be depressurized before per forming any work on the hydraulic system The FCU is to be disconnected from the power supply and pro tected against being inadvertently switched back on when per forming any maintenance servicing inspection or repair work Check all previously loosened screwed fittings to see that they have been properly secured 8 1 Maintenance table Daily Weekly Every 6 Months As requir...

Page 112: ...ts the pump from contamination by coarse particles Clean the suction screen regularly If the FCU is blocked or there is no flow through the FCU clean the suction screen without delay NOTICE Operation without a suction strainer The FCU pump will be damaged destroyed u Never use the FCU without a suction strainer u Clean the suction screen regularly To check clean the suction strainer proceed as fol...

Page 113: ...ning it anti clockwise 3 Put a finger in the opening 4 and pull out the suction screen upwards 5 Clean the suction screen by blowing it out with com pressed air 6 Before reassembly check that the sealing ring for the connector is undamaged Replace it if necessary 7 Moisten the sealing ring C with fluid before screwing it into place ...

Page 114: ...lq 8 Put the suction screen back into the opening 9 Manually screw the INLET connector in clockwise 10 Using a wrench 19 mm to tighten the INLET con nector by turning it clockwise Tighten the connector with a torque of 25 Nm ð The replacement cleaning of the suction strainer is com plete ...

Page 115: ...s lq 115 148 8 3 Calibrating FCU Calibrate the FCU in accordance with ISO 9000 for device measurement We recommend a recalibration of the FCU at least every 3 years For calibration contact HYDAC Service the locations in your area can be found on our homepage under www hydac com ...

Page 116: ...t achieved check and clean the strainer and the flow control valve in accordance with the following chapters Fig 50 High pressure adapter 8 4 1 Cleaning changing the strainer 2x Wrench 22 mm 1x screwdriver 9x1 mm or special tool see chapter Finding accessories 135 Clean this strainer B in the high pressure adapter at least ev ery six months or more frequently if heavy soiling makes it necessary Fi...

Page 117: ...e threaded joint D with a wrench 22 mm by turn ing it counterclockwise Then unscrew the strainer B counterclockwise with a screwdriver or the special tool see chapter Finding ac cessories 135 2 Clean strainer B and then blow it out with compressed air 3 To fit the strainer B screw it in clockwise to union D using a screwdriver or the special tool 4 Then check the sealing ring on the coupling A for...

Page 118: ...pter Finding accessories 135 The flow control valve regulates the flow to ap prox 0 55 0 7 l min If the necessary flow rate through the high pressure adapter is not achieved then the flow control valve will have to be cleaned or replaced Fig 52 Cleaning changing the flow control valve in the high pressure adapter A Test point B Strainer C Flow control valve D Screw connection ...

Page 119: ...screw driver or the special tool see Finding accessories 135 chapter 3 Clean strainer B and then blow it out with compressed air 4 Also unscrew the flow control valve C counterclock wise with a screwdriver or the special tool see Finding accessories 135 chapter 5 To install the new flow control valve C screw it firmly clockwise into the union D with a screwdriver or the special tool 6 Screw the st...

Page 120: ... Performing maintenance HYDAC FILTER SYSTEMS GMBH 120 148 BeWa FCU1310 3371346g en us lq ð The cleaning replacement of the flow control valve is complete The high pressure adapter is ready for opera tion ...

Page 121: ...outside in the following 9 1 FCU flushing Flush the FCU after each use but at least daily with cleaned mineral oil Rinse the FCU immediately if you have measured unfiltered oil or oil with a viscosity 200 mm s or if the measured values seem unusually high or low NOTICE Impermissible flushing media The FCU will be destroyed u Flush the FCU with low viscosity mineral oils or mineral oil based raffin...

Page 122: ...1346g en us lq 2 Connect the return hose to the FCU and put the free end into a container for the used fluid 3 Mount the suction hose on the INLET connection of the FCU Place the suction hose into the reservoir with filtered fluid 4 Use the switch on the FCU to turn its pump on ...

Page 123: ...23 148 5 Purity values are displayed during the rinsing procedure These values are not correct but nonetheless should drop during the flushing procedure 6 Once the 0 5 liters have been sucked up switch off the pump ð The FCU flushing procedure is complete The FCU is ready for operation ...

Page 124: ...STEMS GMBH 124 148 BeWa FCU1310 3371346g en us lq 9 2 Cleaning the FCU Clean the control panel and the case with a clean moist cloth NOTICE Chemical or abrasive cleaning agents The operating interface will be damaged destroyed u Use only water ...

Page 125: ... WARNING is automatically re set by the FCU 3 Moderate fault Sensor equipment status is fault Restarting resetting 86 4 Serious fault The sensor or equipment is faulty Contact the HYDAC Service Department Tab 19 Error codes in the measurement report The following malfunctions are output in the display and via the flash code of the status LED Disruption error LED Status LED Display Error code Statu...

Page 126: ...ay Error code 2 The FCU is below its mea surement range ISO 9 8 7 It is currently not possible to determine the cleanli ness of the oil or its flow rate You can make further mea surements LED Red Status LED Display Error code 2 It is not possible to deter mine the flow rate The FCU is in an undefined state Switch the pump on Wait for a few measurement cycles until measured values are again shown L...

Page 127: ...rate LED Red Status LED Display Error code 3 The installed sensors are not found Restart the unit See Restart ing resetting 86 If the fault recurs contact HY DAC service department LED Red Status LED Display Error code 3 The contamination sensor is causing a moderate er ror Restart the unit See Restart ing resetting 86 If the fault recurs contact HY DAC service department LED Red Status LED The co...

Page 128: ...on Display Error code 4 If the fault recurs contact HY DAC service department LED Red Status LED Display Error code 2 The AquaSensor is outside of its measurement range Wait for a few more measure ment cycles LED Red Status LED Display Error code 3 No AquaSensor is con nected Restart the unit See Restart ing resetting 86 If the fault recurs contact HY DAC service department ...

Page 129: ...Restart the unit See Restart ing resetting 86 If the fault recurs contact HY DAC service department LED Red Status LED Display Error code 3 No sensors are attached to the FCU or the communi cation is defective Restart the unit See Restart ing resetting 86 If the fault recurs contact HY DAC service department LED Red Status LED The FCU has a moderate fault Restart the unit See Restart ing resetting...

Page 130: ...a FCU1310 3371346g en us lq Disruption error LED Status LED Display Error code Status Possible causes Solution Display Error code 3 LED Red Status LED Display Error code 3 The FCU has a major fault Contact the HYDAC Service Department Tab 20 List of disruptions errors ...

Page 131: ...HYDAC FILTER SYSTEMS GMBH Finding rectifying errors 10 BeWa FCU1310 3371346g en us lq 131 148 See also 2 Restarting resetting 86 ...

Page 132: ...mmissioning Disconnect or remove the electrical hydraulic connections Dispose of the packaging material in an environmentally friendly manner Dispose of the fluid operating medium that has been drained in an environmentally friendly manner After dismantling the product and separating its various materials into categories dispose of all parts in an envi ronmentally friendly manner ...

Page 133: ...p no Image High pressure hose with screwed joint for measure ment point type 1620 color black L 2 m 349150 Suction hose with open end color clear transparent Length 0 3 m 3297276 Return hose open end transparent length 2 m 349151 Suction strainer 400 µm for INLET port 278475 Seal ring for measurement point union INLET Ø 21 mm according to DIN3869 607755 High pressure adapter complete 3364502 ...

Page 134: ...ntrol valve for high pressure adapter 710389 Cover seal for case 3455429 Attachable bag for hoses cables and accessories 3335656 Document bag 3377173 Operating and Maintenance Instructions this document 3371346 Quick start manual 3546511 Power adapter without con nector cable Primary 100 240 V AC Secondary 24 V DC 5A Cable with 3 pole connec tor Length 1 6 m 6059933 ...

Page 135: ... 6008446 Connection cable for power adaptor plug for Australia AUS Length 2 m 6008449 Tab 21 Locating spare parts 12 1 1 Finding accessories You will receive the following accessories for the FCU Designation p no Image Suction hose open end color transparent length 1 5 m 3325744 12V 24 V DC cable with uni versal plug including 8A fuse Length 10 m 3306236 12V 24 V DC cable with uni versal plug incl...

Page 136: ... USB Memory stick 3442973 BatteryPack 24 V DC 4500 mAh 3504605 CSI B 2 Kit ConditionSensor Interface 3409462 CD with FluMoS Profes sional 3371637 Connection cable screened with 5 way elbow female connector open ca ble end length 2 m ZBE 08S 02 6019455 Connection cable screened with 5 way elbow female connector open ca ble end length 5 m ZBE 08S 05 6019456 Connection cable screened with 5 way elbow...

Page 137: ...ion cable with 5 pole female connector 5 pole male connector Length 2 m ZBE 30 02 6040851 Connection cable with 5 pole female connector 5 pole male connector Length 3 m ZBE 30 03 6053924 Connection cable with 5 pole female connector 5 pole male connector Length 5 m ZBE 30 05 6040852 Tab 22 Finding accessories ...

Page 138: ...EMS SERVICES GMBH Friedrichsthaler Str 15a Werk 13 66450 Neunkirchen Heinitz Germany Phone 49 6897 509 883 Fax 49 6897 509 324 E mail service hydac com Homepage www hydac com Tab 23 Customer service in Germany HYDAC TECHNOLOGY CORPORATION HYCON Division 2260 City Line Road Bethlehem PA 18017 Lehig Valley PA 118002 2050 USA Phone 1 610 231 0100 Fax 1 610 231 0445 E mail sales hydacusa com Homepage ...

Page 139: ...Fukutare Yida 225 CEP 09852 060 Cooperativa São Bernardo do Campo SÃO PAULO Brazil Phone 55 114 393 6600 Fax 55 114 393 6617 E mail hydac hydac com br Homepage www hydac com br Tab 26 Customer Service Brazil 12 3 EC declaration of conformity The CE declaration of conformity can be found in the Technical Documentation that is part of the scope of delivery for the product ...

Page 140: ... Dimensions 31 Fig 9 Hydraulic circuit 32 Fig 10 Opening the FCU case 33 Fig 11 Closing the FCU case 33 Fig 12 Hydraulic circuit 34 Fig 13 Transporting the FCU 39 Fig 14 Storing the FCU 40 Fig 15 Connecting the power supply 41 Fig 16 Disconnecting the power supply 42 Fig 17 Plug in return hose 43 Fig 18 Detach return hose 43 Fig 19 DAT TIM Setting the date time 45 Fig 20 ADRESS Set bus address 46 ...

Page 141: ...ng the ED MPNT measurement point designation 69 Fig 35 TPUNIT Setting the temperature unit 71 Fig 36 TPUNIT setting degrees Celsius 71 Fig 37 CANCEL Cancel 73 Fig 38 SAVE Saving settings data 74 Fig 39 Operating mode Measurement at 0 bar 76 Fig 40 Operating Mode Measurement 45 bar 80 Fig 41 Operating mode Measurement at 15 345 bar 83 Fig 42 BatteryPack overview 87 Fig 43 BatteryPack in operation 8...

Page 142: ... SYSTEMS GMBH 142 148 BeWa FCU1310 3371346g en us lq Fig 50 High pressure adapter 116 Fig 51 Cleaning changing the strainer in the high pressure adapter 116 Fig 52 Cleaning changing the flow control valve in the high pressure adapter 118 ...

Page 143: ...view 58 Tab 11 Displays with ISO SAE 60 Tab 12 Displays with ISO NAS 61 Tab 13 Measuring Menu 64 Tab 14 Selecting the operating mode measurement method 75 Tab 15 Extracting the measured value memory 92 Tab 16 Pins used on the interface 5 pole 93 Tab 17 Bluetooth Code Password 103 Tab 18 Example Measurement report file names 104 Tab 19 Error codes in the measurement report 125 Tab 20 List of disrup...

Page 144: ...Index of Tables HYDAC FILTER SYSTEMS GMBH 144 148 BeWa FCU1310 3371346g en us lq Tab 25 Customer Service Australia 138 Tab 26 Customer Service Brazil 139 ...

Page 145: ...ven that this generally represents an un planned event the switch off is trig gered by automatic devices e g network protection when certain preset measured values are reached and carried out in auto matic sequences by the opening of circuit breakers in transformer sta tions This measure will lead to a power failure for the parts of the network affected by the load dump and the consumers connected...

Page 146: ...ng 132 DFAULT 53 disposal 132 Downtime 21 Duty cycle 20 E exclusion of liability 7 F Flash point 20 H Hotline 138 Hydraulic circuit 32 I Imprint 2 Intended use 20 Intermittent duty 20 L Load dump 21 M manufacturer 2 Measuring menu 64 CANCEL 51 73 ED MPNT 66 69 M TIME 71 MEMORY 68 MPNT 66 RECORD 65 SAVE 52 74 STP STA 66 P Periodic intermittent duty 21 Person authorized with the documenta tion 2 Pow...

Page 147: ...6g en us lq 147 148 ADRESS 46 CALIB 49 CANCEL 51 73 DAT TIM 45 DEL MEM 47 DFAULT 50 M TIME 48 Menu 44 SAVE 52 74 S Service 138 Servicepartners 138 Support 138 T Terms and Conditions 7 Terms of Delivery 7 U Useful life 21 W Warranty 7 Water saturation 16 ...

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