Hydac FCU 8000 Series Operating And Maintenance Instructions Manual Download Page 12

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FCU 8000 series

Safety information and instructions

HYDAC FILTER SYSTEMS GMBH

en(us)

Page 12/112

BEWA FCU8000 3109776d en-us 2011-06-10.doc

2011-06-10

Improper Use

Any use other than described above is prohibited.

Improper use may result in hazard to life and limb.

Example of improper use:



Improper connection of the FCU pressure and return flow hoses.



Sealing of the FCU return line.

What to Do in Case of Emergency

In the event of an emergency, immediately disconnect the FCU from the power
supply and from the hydraulic system.

Properly dispose of any escaping fluid in accordance with environmental guidelines.

Maintenance, Servicing and Troubleshooting

The specified adjustment, maintenance, and inspection work is to be conducted in a
timely fashion.

Secure all operating media against accidental start up.

When performing any maintenance, servicing, inspection or repair work, disconnect
the FCU from the power supply and ensure that it cannot be switched back on
inadvertently.

Check that released threaded joints were refit tightly.

Always check the safety devices to see that they function properly after performing
maintenance work.

Modifications to the FCU

Do not make any structural modifications (design modifications, extensions) to the
FCU without the prior consent of the manufacturer.

Any conversion modifications require written permission from HYDAC FILTER
SYSTEMS GMBH.

Immediately replace any parts which are not in perfect condition.

Use only original spare parts (OEM).

Summary of Contents for FCU 8000 Series

Page 1: ...FCU 8000 series FluidControl Unit Operating and Maintenance Instructions Valid from firmware versions 3 22 up English translation of original instructions Document no 3109776d ...

Page 2: ... the contents of this document However errors cannot be ruled out Consequently we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject to techn...

Page 3: ...Troubleshooting 12 Modifications to the FCU 12 Training of personnel 13 Checking the Scope of Delivery 14 Description of the FCU 15 Operating elements Dimensions 16 Restrictions on use FCU 8110 8210 17 Restrictions on use FCU 8111 8211 17 Hydraulic diagram 18 FCU Function Description 19 Electrical connection of the FCU 22 Connecting the POWER INPUT 22 Connecting the PC interface 23 Serial RS 232 I...

Page 4: ...of the Keys 40 Menu and Number Keys red 41 Key Combinations 41 FCU menus 42 MODE select operating mode 42 MODE M1 Measure 43 MODE M2 Measuring and switching 43 MODE M3 Filter to performance of automatic filtration 43 MODE M4 Filtering from to performance of automatic filtration 44 MODE M5 Flushing BS 44 MODE M6 Bottle Sampler 44 MEMORY Menu 45 Designating the measurement point 46 Setting the avera...

Page 5: ...the battery status 79 POWERUP menu 80 M6 Bottle Sampler 81 Selecting the language 82 Setting the viscosity range 82 Setting the measured volume 83 FCU Display 84 Brief Overview of the Menu Structure 86 Error Messages and Troubleshooting 89 Performing maintenance 94 Cleaning the FCU 94 Changing the FCU Filter Element 94 Back flushing the FCU 97 Internal dot matrix impact printer replace paper roll ...

Page 6: ...4 Overview ISO 4406 SAE AS 4059 and NAS 1638 classes 105 ISO 4406 1999 105 ISO 4406 table 105 Overview of the differences between ISO 4406 1987 and ISO 4406 1999 106 SAE AS 4059 107 SAE AS 4059 table 107 Cleanliness codes according to SAE 107 Absolute particle count larger than a defined particle size 107 Specifying a cleanliness code for each particle size 108 Specifying the highest cleanliness c...

Page 7: ... the vicinity of the device for immediate reference Sometimes the information contained in the documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting edge Consequently there might be deviations in technical details illustrations and dimensions If you discover errors while reading the documentation or have additional...

Page 8: ...he product e g purchasing options etc may result in the information in the operating instructions no longer being completely accurate or sufficient When making modifications or performing repair work to components affecting the safety of the product the product may not be put back into operation until it has been examined and released by a HYDAC representative Please notify us immediately of any m...

Page 9: ...ter on WHAT do I want to know I determine the topic I am looking for WHERE can I find the information I m looking for The documentation has a table of contents at the beginning There 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 anothe...

Page 10: ... state of the art and recognized safety regulations Nevertheless hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property Use the FCU Solely for its designated use Only when in safe perfect condition Immediately remedy any malfunctions that might impair safety Always keep the operati...

Page 11: ...CE NOTICE denotes situations which can lead to property damage if safety precautions are not observed Proper Designated Use The Contamination Sensor FCU was developed for temporary or continuous monitoring of particulate contamination in hydraulic systems Analyzing the type size and quantity of contamination enables quality standards to be verified and documented and the requisite optimization mea...

Page 12: ... Troubleshooting The specified adjustment maintenance and inspection work is to be conducted in a timely fashion Secure all operating media against accidental start up When performing any maintenance servicing inspection or repair work disconnect the FCU from the power supply and ensure that it cannot be switched back on inadvertently Check that released threaded joints were refit tightly Always c...

Page 13: ...ned and instructed personnel may work with the FCU The areas of responsibility of your staff must be established in a clear cut manner Staff who are still being trained may only work on the FCU when supervised by a suitably experienced person Individuals Instructed individuals Personnel with technical training engineerin g background Electricians Supervisor with the appropriate authority Activity ...

Page 14: ... commissioning the SFC check the content of the package to make sure everything is present The following items are supplied Pc Description 1 FluidControl Unit FCU 8xxx 2 Mains device and connection cable configuration depends on the order 1 hp hose with mini measurement port DN2 L 2000 mm 1 Return hose DN 7 L 2000 m 1 Connection cable FCU PC 1 CD ROM with FluMoS light software 1 Operating and Main...

Page 15: ...sent via serial interface to a PC or a central display unit for visualization purposes there Filter units can for example be actuated via relay outputs For input and output functions the FCU possesses a keyboard an LCD Liquid Crystal Display a dot matrix printer control relay outputs and a serial data interface The FCU possesses a mini measurement port System 1620 as an input for connection with t...

Page 16: ... 2011 06 10 doc 2011 06 10 Operating elements Dimensions Item Designation A High pressure port INLET B Return port connection OUTLET C Switch On Off D Electrical connection 24 V DC E Serial interface F Control port G Sealing cover J Dot matrix printer K Display L Keyboard M Flow rate regulator N Filter element ...

Page 17: ...10 8210 NOTICE Impermissible operating conditions The FCU will be destroyed The FCU may only be used with mineral oils or mineral oil based raffinates Restrictions on use FCU 8111 8211 NOTICE Impermissible operating conditions The FCU will be destroyed Only operate the FCU in conjunction with HFD R operating fluids phosphoric acid esters e g Skydrol Fyrquel Hyjet ...

Page 18: ... 112 BEWA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 Hydraulic diagram 9 15 1 8 7 5 10 OUTLET INLET Item Designation 1 Optical sensor 5 Flow rate sensor 7 Flow rate control valve adjustable 8 Filter 9 Flow control valve 10 Pressure relief valve 15 Pressure accumulator ...

Page 19: ...1 06 10 FCU Function Description Item Designation 1 Optical sensor 2 Laser light source 3 Photodetector 4 Evaluation electronics 5 Flow rate sensor 6 Display 7 Flow rate control valve adjustable 8 Filter 9 Flow control valve 10 Pressure relief valve 11 Serial interface 12 Keyboard 13 Relay 14 Printer 15 Pressure accumulator ...

Page 20: ... time clock is available for this purpose A flow control valve 7 is available for adjusting the pressure fluctuation independent flow of oil A hydraulic filter 8 with electrical contamination indicator is positioned upstream from this for the purpose of protecting against failure due to contamination The permanently adjusted valves 9 and 10 and the diaphragm memory 15 enable the connection to extr...

Page 21: ...nterrupted 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 intervention...

Page 22: ...t with online print out for 5 hours The battery is automatically recharged when the power adapter is plugged in regardless of whether the FCU is switched on or off at the switch or not Connecting the POWER INPUT Insert the hollow plug on the supplied power adapter into the rear bush POWER INPUT Switch on the FCU on or off at the On Off switch on the rear side This connection is used for supplying ...

Page 23: ...s RS485 Serial RS 232 Interface Standard Pin Signal function 1 screen 2 TXD Transmission line 4 RXD Receiving line 8 GND Ground 1 2 4 8 A corresponding cable for connecting the FCU to a PC is included in the scope of delivery Serial RS 485 Interface OPTIONAL Pin Signal function 1 screen 2 T TA Transmission data 4 R RA Received data 8 GND Ground 9 T TB Transmission data 11 R RB Received data 15 5V ...

Page 24: ...ntact Relay 3 Device ready 11 12 NO contact 2A is the maximum load for the 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...

Page 25: ... currently in progress Measurement stopped After the first measured value is available Flow error Flow rate within set range M2 Exceed Measured value upper limit After switch on or start of a measurement Goes out again when measured 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 swit...

Page 26: ...ent or Measured value lower limit or Measured value upper limit Outside range Measured value lower limit or Measured value upper limit After switching the unit on or starting a measurement or Lower limit measured value upper limit Measured value lower limit or Measured value upper limit After switching the unit on or starting a measurement or Lower limit measured value upper limit No function Alwa...

Page 27: ...rate within set range When test cycle time elapsed for the duration of a check measurement Test cycle time has elapsed check measurement is running Goes out again when measured value upper limit Test cycle time is restarted M5 Controlling the BSU Controlling the BSU Controlling the BSU Controlling the BSU M6 Controlling the BSU Controlling the BSU Controlling the BSU Controlling the BSU In mode M2...

Page 28: ...c channel SAE 0 15 50 µm channel NAS 38 µm c channel SAE 0 15 100 µm channel NAS 70 µm c channel SAE 0 15 2 µm channel ISO 4 µm c channel ISO 10 25 5 µm channel ISO 6 µm c channel ISO 7 23 15 µm channel ISO 14 µm c channel ISO 5 21 Flow rate Flow rate 0 150 M3 Filtration limit ISO ISO 10 7 5 25 23 21 NAS SAE 0 0 0 15 15 15 M4 Filtration limits ISO ISO 10 7 5 25 23 21 NAS SAE 0 0 0 15 15 15 M4 Test...

Page 29: ...CU in online operation WARNING Hydraulic systems are under pressure Danger of bodily injury Depressurize the system before performing any work on it NOTICE If the OUTLET connection is closed or blocked The FCU will be damaged Never seal the OUTLET connection Put the free end of the OUTLET return hose into an unpressurized container OUT IN ...

Page 30: ...nnector and route it into a suitable container e g hydraulic tank 2 Set the flow rate control valve to a value of 3 3 Check the system pressure Ensure that this does not exceed a pressure of 350 bar 4 Connect the high pressure hose to the INLET connection 5 Now connect the other end of the high pressure hose to the system Oil starts to flow through the FCU as soon as the system has been connected ...

Page 31: ...WA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 FCU in BSU operation only for FCU 8110 8210 The BottleSampling Unit BSU permits the counting of oil sample bottles The procedure of a measurement or a flushing process is controlled completely by the FCU 8xx0 Figure 1 Front view BSU 8000 with FCU 8110 8210 ...

Page 32: ...ottle Sampling Adapter into the FCU 3 Connect the hydraulic ports so they cannot be mixed up to the BSU and seal the port of the FCU marked OUTLET with the quick release plug 4 Plug the control plug of the BSU into the appropriate socket of the FCU 5 Insert the jack plug for the voltage supply socket into the FCU You can find more details on Bottle Sampling operation in the BSU instructions Figure...

Page 33: ...6 10 Diagram of the BottleSampling Unit P Compressed air inlet max 6 bar 90 psi V1 Valve for pressurizing depressurizing the pressure chamber V2 Shut off valve V3 Drain valve A Collection vessel B Sample jar C Test container D Pressure chamber R Control valve on front of BSU M Pressure gauge on front of BSU S Flow rate sensor St Suction tube X Silencer ...

Page 34: ...mber after switching on the compressed air supply via a compressor We recommend 30 seconds using the CompressedAir Unit CAU 8110 Compressed air At this point you must pre set the time required for a constant pressure to be achieved in the pressure chamber after switching on the compressed air supply from the ring main Recommended 5 seconds The following settings must be made in the SETUP menu see ...

Page 35: ...lushing volume is pre set in the LIMITS menu can be set from 50 to 500 ml With the buttons mode and select mode M5 and then press the button ok start Then the pressure in the pressure chamber is first built up Then the shutoff valve is opened and the flushing medium conveyed through the BSU and FCU The flow rate is adjusted using the control knob on the front of the BSU In bottle sampling mode the...

Page 36: ... the sample has to be diluted due to excessive contamination or high viscosity the dilution ratio can be input here The measurement results will automatically be projected to produce values from an undiluted sample The first value to be set specifies the test volume configurable from 1 to 250 The second value is the volume of the thinner e g clean oil configurable from 0 to 250 See also page 70 If...

Page 37: ...has been made or after the button stop has been pressed the pressure chamber is depressurized and the test container drained On the transparent drain hose check that the test container drains empty and no medium gets trapped With high viscosity media this process can take some time If necessary correct the time for the BS draining in the POWERUP menu upward The single measurements which are to be ...

Page 38: ...witched off If all the single measurements are deactivated no average result will be printed out The selection is completed with the OK START button Until the set draining time has elapsed the following message appears in the LC display Display mode M6 Finished draining in progress please wait When the draining time has passed the measuring procedure in mode M6 is complete Display mode Measurement...

Page 39: ...hooting chapter Example 1 HYDAC FILTER SYSTEMS FCU 8110 V3 22 2 Memory 25 4 61 Battery 13 49 V 80 3 Bus address 1 Battery 13 49 V 80 4 Viscosity range 1 10 mm s 5 Measure OK START Abort STOP The FCU is 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 measure...

Page 40: ...sage disappears and measurement operation starts automatically Operating the FCU The various operating menus of the FCU are described below The following conventions are used Fixed display texts are highlighted 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 th...

Page 41: ...s only when a measurement is being carried out limits Set limits for controlling filtration units via relays 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 measurin...

Page 42: ...urement is to be carried out When the FCU is switched on the operating mode last used last is preset mode MODE M1 Measure MODE M2 Measure Switch MODE M3 Filter to MODE M4 Filter from to MODE M5 Flushing BS MODE M6 Bottle Sampler ok start Confirm entries and start measurement When autostart is activated confirmation occurs automatically immediately after switching on the FCU stop Accept the setting...

Page 43: ...ed by two relays An example of this would be an alarm indicator lamp on a control panel Possible reference values for triggering these switching sequences o The flow volumetric flow rate o 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 automa...

Page 44: ...r the test cycle time has elapsed the FCU carries out a testing measurement 100 ml and checks whether the measured values lie within the limit values If yes then the test cycle time begins again if no then the unit is switched on in order to filter the fluid If the test cycle time setting is below LIMITS 0 min then this function is switched off Typical applications Long term monitoring and filtrat...

Page 45: ...e storage of logs The percentage shown in the display indicates how much of the memory has been used 0 0 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 meas point MEMORY 0 0 Memory mode ok start Confirm entries stop Accept the setting and exit the MEMORY menu ...

Page 46: ...This enables frequently occurring designations to be permanently configured and called up as needed memory MEMORY 0 0 Meas point ok start Measuring point 2 Name 1 Select the respective measurement point via the keys ok start Measuring point 2 Name 1 The first letter blinks Measuring point 2 Name 1 Navigate to the position desired using the keys Measuring point 2 Name 2 Select the characters from t...

Page 47: ...al enables the data quantity which accumulates during a measurement to be reduced An averaging interval of 0 min causes only the mean value of all measurements completed within this interval to be saved and printed out The 0 min setting causes 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 i...

Page 48: ...t Log selection Log selection Log selection Date Log selection Meas point Log selection Date Measuring point ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit without saving Log selection Log selection 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 numb...

Page 49: ...rt Are you sure OK YES STOP NO ok start YES The selected logs of dd mm yyyy are deleted stop Abort and exit without saving Log selection Meas point ok start Measuring 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 ex...

Page 50: ...ation 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 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 STO...

Page 51: ...s menu item enables the designation of a measuring point to be changed memory MEMORY 0 0 0 Change meas 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 ...

Page 52: ...e Once 100 logs or 3000 measured values have been stored the next log overwrites the oldest one in the memory 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 s...

Page 53: ... printouts to be initiated of stored logs ongoing measurements the table of contents and the parameter list print PRINT Logs PRINT BS 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 ...

Page 54: ... print PRINT Logs ok start Log selection Log selection Log selection Date Log selection Meas point Log selection Date Measuring point ok start Confirm entries stop Abort and exit Log selection Log selection 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...

Page 55: ... FCU 82xx ISO ISO Particles Particles Channel NAS 1 3 Channel SAE A C Channel NAS 4 6 Channel SAE A C Log selection Date ok start Date of log dd mm yyyy 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 Printo...

Page 56: ...4 6 Channel SAE A C Log selection Meas point ok start 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 ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of Particles only for print out format List Printout of NAS SAE SA...

Page 57: ...tart 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 ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of Particles only for print out f...

Page 58: ...FCU menus HYDAC FILTER SYSTEMS GMBH en us Page 58 112 BEWA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 FCU 81xx FCU 82xx ISO ISO Particles Particles Channel NAS 1 3 Channel SAE A C Channel NAS 4 6 Channel SAE A C ...

Page 59: ...ed print PRINT BS logs ok start Log selection Log selection Log selection Date Log selection Meas point Log selection Date Measuring point ok start Confirm entries stop Abort and exit Log selection Log selection 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 thi...

Page 60: ... FCU 82xx ISO ISO Particles Particles Channel NAS 1 3 Channel SAE A C Channel NAS 4 6 Channel SAE A C Log selection Date ok start Date of log dd mm yyyy 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 Printo...

Page 61: ...4 6 Channel SAE A C Log selection Meas point ok start 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 ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of Particles only for print out format List Printout of NAS SAE SA...

Page 62: ...tart 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 ok start Press this key to confirm the operating mode selected and to initiate measurement Printout of ISO Printout of Particles only for print out f...

Page 63: ...ntents A summary of the logs stored in memory is printed 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 entri...

Page 64: ...ntout The measured values are outputted on line and on the printer print PRINT Online printout 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 Part...

Page 65: ...NT Print out cancel ok start Confirm entries and start paper feed stop Abort and exit LIMITS menu The LIMITS menu enables settings limits to be entered for the various operating modes limits LIMITS M2 Relay 1 LIMITS M2 Relay 2 LIMITS M3 Filter to LIMITS M4 Filter from to LIMITS M5 Flushing volume LIMITS M6 Pre run volume ok start Press this key to confirm the operating mode selected and to initiat...

Page 66: ... key to confirm the operating mode selected and to initiate measurement M2 R1 Switch func No function M2 R1 Switch func Within range M2 R1 Switch func Outside range M2 R1 Switch func Exceed M2 R1 Switch func Fall below ok start Press this key to confirm the operating mode selected and to initiate measurement M2 R1 Limit values xxx yyy Unit Jump from value to value M2 R1 Limit values xxx yyy Unit S...

Page 67: ... to confirm the operating mode selected and to initiate measurement M2 R2 Switch func No function M2 R2 Switch func Within range M2 R2 Switch func Outside range M2 R2 Switch func Exceed M2 R2 Switch func Fall below ok start Press this key to confirm the operating mode selected and to initiate measurement M2 R2 Limit values xxx yyy Unit Jump from value to value M2 R2 Limit values xxx yyy Unit Selec...

Page 68: ... µm Channel NAS D Channel SAE 50 µm Channel NAS E Channel SAE 100 µm Channel NAS F Channel SAE 2 µm Channel ISO 4 µm Channel ISO 5 µm Channel ISO 6 µm Channel ISO 15 µm Channel ISO 14 µm Channel ISO Flow rate Flow rate MODE M3 limits LIMITS M3 Filter to ok start M3 Limit values xx yy zz Standard Jump from value to value M3 Limit values xx yy zz Standard ok start Press this key to confirm the opera...

Page 69: ... Limit values xx yy zz Standard Jump from value to value M4 Limit values xx yy zz Standard M4 Limit values xx yy zz Standard ok start Press this key to confirm the operating mode selected and to initiate measurement M4 Test cycle time xxx min Standard value 120 min ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit ...

Page 70: ...rating mode selected and to initiate measurement stop Abort and exit MODE M6 limits LIMITS M6 Bottle Sampler ok start M6 Pre run volume xxx ml n 10 100 or M6 Pre run volume xxx ml n 10 100 ok start Press this key to confirm the operating mode selected and to initiate measurement M6 Measurement volume xxx ml n 1 100 or M6 Measurement volume xxx ml n 1 100 ok start Press this key to confirm the oper...

Page 71: ... 10 doc 2011 06 10 or M6 Measurements sample n n 1 100 ok start Press this key to confirm the operating mode selected and to initiate measurement M6 Dilution x y n 0 250 or M6 Dilution x y n 0 250 ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit ...

Page 72: ...o be entered which apply to several or all of the FCU s operating modes setup SETUP Autostart SETUP Abort at Q 0 SETUP Pump start delay SETUP Date Time SETUP Bus address SETUP Operating hours SETUP BS pressure supply SETUP Additional test SETUP Battery state ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit ...

Page 73: ...ually after having been switched on or whether it automatically performs a measurement in a preselected MODE setup SETUP Autostart ok start Autostart no Autostart yes ok start Autostart function M1 Measure Autostart function M2 Measuring and switching Autostart function M3 Filter to Autostart function M4 Filter from to ok start Press this key to confirm the operating mode selected and to initiate ...

Page 74: ...h the sensor drops to a value of 0 while a measurement is in progress Measurement can either be interrupted 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 a...

Page 75: ...asurement is stopped and the unit connected via a relay is switched off so as to prevent damage caused 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 ...

Page 76: ...d and can be changed setup SETUP Date Time ok start Date dd mm yyyy Selection Date dd mm yyyy or Date 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 ...

Page 77: ...llocated to each unit An address may not be allocated twice setup SETUP Bus address ok start Bus address 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 unit are displayed The operating hours meter only records the measurement time setup SETUP Operating hour...

Page 78: ...ly ok start BS pressure supply Compressor BS pressure supply Compressed air ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit Additional test setup SETUP Additional test ok start Additional test Yes No ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit ...

Page 79: ...8000 3109776d en us 2011 06 10 doc 2011 06 10 Check the battery status The current battery charge is shown setup SETUP Battery state 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 ...

Page 80: ...wered up and as long as no measurement has been started Settings are made here which are normally rarely changed The POWERUP menu is accessed by simultaneously pressing the keys POWERUP M6 Bottle Sampler 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 ...

Page 81: ...011 06 10 M6 Bottle Sampler Bottle Sampler ok start Bottle Sampler BS draining t s ok start Bottle Sampler Compressor t s Bottle Samper Compressor t s ok start ok start Bottle Sampler Compressed air Bottle Samper Compressed air t s ok start ok start Applying the submenu selected stop Abort and exit the PowerUp menu ...

Page 82: ... start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit the Powerup menu Setting the viscosity range The viscosity range of the fluid to be measured must be set here Here we differentiate between low viscosity 1 10 mm s and high viscosity 5 1000 mm s mediums Check or correct the viscosity range before starting the measurement Viscosity range ok ...

Page 83: ...ation of a measured value can be set here Permitted values range from 10 100 Test volume ok start Applying 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 measureme nt volume via the keyboard ok start Press this key to confirm the operating mode selected and to initiate measurement stop Abort and exit ...

Page 84: ...Specification of the currently determined contamination You can switch back and forth between the display in ISO or NAS FCU 81xx or SAE FCU 82xx coding and the display of particle counts with the keys SAE NAS Partikel ISO During the representation of the contamination class in NAS or SAE coding the figures letters in brackets state the selected particle size range FCU 81xx 2 2 5 µm 5 5 15 µm 15 15...

Page 85: ...ted 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 81xx 2 5µm 5 15µm 15 25µm 25 50µm 50 100µm and 100µm FCU 82xx 4 6µm c 6 14µm c 14 21µm c 21 38µm c 38 70µm c and 70µm c Cumulative representation means particle count in the particle size ranges FCU 81xx 2µm 5µm 1...

Page 86: ...in Selective deletion Log selection Log number from xxx to xxx Date Date of log dd mm yyyy Meas point Measuring point Designation 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 Log selection List Graph Date List Graph Meas point List Graph Date Measuring point List Grap...

Page 87: ...ion Within range Outside range Exceed Fall below M3 Filter to M3 Limits xx xx xx Unit M4 Filter from to M4 Limit values xx xx xx Unit xx xx xx Unit M4 Test cycle time X min M5 Flushing BS Flushing volume ml M6 Bottle Sampler Pre run volume XX Test volume X Measurements sample X Dilution X SETUP Autostart Yes M1 Measure M2 Measure Switch M3 Filter to M4 Filter from to no Abort at Q 0 Yes No Pump st...

Page 88: ...ew of the Menu Structure HYDAC FILTER SYSTEMS GMBH en us Page 88 112 BEWA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 POWERUP Language English English French Programmable Viscosity range 1 10 mm s 5 1000 mm s Test volume x ml ...

Page 89: ...e self monitoring function of the FCU has detected a check sum error for one or more parameters Cause 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 ...

Page 90: ...he defective logs are 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 trie...

Page 91: ...measured volume to between 10 100 ml Send the FCU to HYDAC for repair Flow rate error Correct 15 ml The flow through the particle sensor is lower than the minimum value of 20 ml min required to take measurements Turn the flow control valve clockwise until measurement operation starts Flow rate error Correct 250 ml The flow through the particle sensor is higher than the maximum value of 80 ml min p...

Page 92: ...defect The calibration values in the EEPROM have been altered due to electrical interference Send the FCU to HYDAC for repair Device ID defect Internal device designations in the EEPROM have been altered due to electrical interference No measures required as these values do not affect the FCU function Send the FCU to HYDAC for repair BSU connected You are trying to start a MODE M1 M4 for online op...

Page 93: ...le and the time interval of the laser sensor Online operation Make sure that fluid flows through the sensor check pressure port connection and position of the flow control valve Once the FCU has been switched off and on again the error should no longer appear If no flow rate can be set via the sensor perform a backflush to eliminate the blockage If fluid flows through the sensor and the error recu...

Page 94: ...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 contaminated but the differential pressure of ...

Page 95: ...e 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 6 Place the new filter element with the strap into the FCU Press the filter element down into the filter mount Do not use excessive force or a hammer etc ...

Page 96: ...e 96 112 BEWA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 7 Check the screw plug O ring for damage Replace it if necessary 8 Insert and manually screw in the screw plug clockwise Tighten the screw plug with a 19 mm ring spanner 9 The filter element change is now complete ...

Page 97: ...1 06 10 doc 2011 06 10 Back flushing the FCU If the sensor is blocked use the flushing set available as an accessory The part no can be found in the spare parts list A description of how to back flush is included with the flushing set Internal dot matrix impact printer replace paper roll ink ribbon 1 2 3 4 5 6 7 8 ...

Page 98: ...FCU 8000 series Performing maintenance HYDAC FILTER SYSTEMS GMBH en us Page 98 112 BEWA FCU8000 3109776d en us 2011 06 10 doc 2011 06 10 9 10 11 12 13 14 15 16 17 18 ...

Page 99: ...covered with oil and electronical components After disassembling the unit and separating the various materials reuse them or dispose of them properly in accordance with local regulations Storing the FCU Flush the FCU completely with n heptane before putting it into storage Dispose of used cleaning agents and flushing oils properly Storage conditions Storage temperature 20 85 C 4 185 F Relative hum...

Page 100: ...n Telephone 49 0 6897 509 883 Fax 49 0 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 Telephone 1 0 610 266 0100 Fax 1 610 2 31 04 45 E Mail sales hydacusa com Internet www hydacusa com Australia HYDAC Pty Ltd 109 Dohertys Road P O Box 224 AUS 3025 Altona North Telephone ...

Page 101: ... 225 CEP 09852 060 Cooperativa BR São Bernardo do Campo SÃO PAULO Telephone 55 11 4393 6600 Fax 55 11 4393 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 Telephone 0086 21 64 63 35 10 Fax 0086 21 64 30 02 57 E Mail hydacsh hydac com cn ...

Page 102: ...h pressure measuring hose DN 2 5000 mm long 682859 High pressure measuring hose DN 2 2000 mm long 349151 Return line hose DN 7 2000 mm long 1251558 Return line hose DN 7 5000 mm long FCU 8xx1 version for HFD fluids example Skydrol Fyrquel Hyjet Part no Article designation 349432 Filter element replacement set consisting of 1x filter element 1x O ring 1x support ring HFD R fluids 1262608 Filter ele...

Page 103: ...ower supply Plug for USA 2000 mm long 6008449 Connecting cable for power supply Plug for AUS 2000 mm long Accessories Part no Designation 3040342 BottleSampling Unit BSU 8000 1 K 120 V 60 Hz 349785 BottleSampling Unit BSU 8000 1 M 230 V 50 Hz 3051675 BottleSampling Unit BSU 8000 1 O 240 V 50 Hz 3040814 Carrying case including filter element replacement set for mineral oil 2 rolls of paper 1 ribbon...

Page 104: ...T 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 target cleanliness mode M3 is reached This series of single measurements is referred to as a measurement for convenience reasons Log A measurement is described by a log It is comprised of the log header and the log lines The FCU saves u...

Page 105: ...ortant for the user in his everyday work even though the measurement references of the particles undergoing analysis have changed 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 Particle count...

Page 106: ... analyzed sample Overview of the differences between ISO 4406 1987 and ISO 4406 1999 old ISO 4406 1987 new ISO 4406 1999 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 area equivalent 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 d...

Page 107: ...Size ISO 11171 4 µm c 6 µm c 14 µm c 21 µm c 38 µm c 70 µm c Size code A B C D E F 000 195 76 14 3 1 0 00 390 152 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 2...

Page 108: ...e applied in the same manner as ISO 4406 1999 In contrast to ISO 4406 certain particle ranges are counted in NAS 1638 and attributed to measurement references The following table shows the cleanliness classes in relation to the particle concentration determined Maximum particle count 100 ml 2 5 µm 5 15 µm 15 25 µm 25 50 µm 50 100 µm 100 µm 00 625 125 22 4 1 0 0 1 250 250 44 8 2 0 1 2 500 500 88 16...

Page 109: ...µm c 14µm c 21 µm c 38µm c 70µm c FCU 81xx NAS 0 12 ISO 0 0 0 23 21 18 Measurement range calibrated FCU 82xx SAE 0 12 ISO 0 0 0 23 21 18 FCU 81xx NAS 0 15 ISO 0 0 0 25 23 21 Indication range FCU 82xx SAE 0 15 ISO 0 0 0 25 23 21 Recalibration Recommended annually Battery buffered log memory Up to 3000 measured values Connectors rear INLET Test point type 1620 DN2 OUTLET Plug nipple DN7 INLET Operat...

Page 110: ...ion 25 Watt max Battery powered operating duration 6 hours online pressure off Built in printer Dot matrix printer Serial interface RS 232 for models BUS RS 485 with 15 pin Sub D plug Ambient temperature range 0 55 C 32 131 F Storage temperature range 20 80 C 4 185 F Relative humidity max 90 non condensing Protection class II double insulated IP Class IP40 Weight 14 kg ...

Page 111: ... Autostart function M1 Measure M1 Measure Abort at Q 0 No No Pump start delay 0 seconds 0 seconds Bus address 1 1 BS pressure supply Compressor Compressor Additional test No No LIMITS Menu M2 R1 Measurement channel Flow rate Flow rate M2 R1 Switching function No function No function M2 R1 Limit values below 30 ml 30 ml M2 R1 Limit values above 70 ml 70 ml M2 R2 Measurement channel Flow rate Flow r...

Page 112: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com Email filtersystems hydac com ...

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