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FCU 1000 Series
FluidControl Unit

Operating and Maintenance Instructions

English (Translation of original)

Valid from firmware versions V 1.10 up

Doc.: 3371346a / 2007-12-03

Содержание FCU 1000 Series

Страница 1: ...FCU 1000 Series FluidControl Unit Operating and Maintenance Instructions English Translation of original Valid from firmware versions V 1 10 up Doc 3371346a 2007 12 03 ...

Страница 2: ...e liable to compensation Exclusion of liability We made every endeavor to ensure the accuracy of the contents of this document However errors cannot be ruled out Consequently we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors We welcome any suggestions for improvements All details are subject to technical modificatio...

Страница 3: ...icing and Troubleshooting 12 1 10 Modifications to the FCU 12 1 11 Cleaning the FCU and disposal of the media and agents used 12 2 Transportation Package Storage 13 2 1 Packing transportation 13 2 2 Storage 13 2 2 1 Storage conditions 13 3 Decoding the model code label 13 4 Checking the scope of delivery 14 5 Using the FCU 15 5 1 Mode of Function 16 5 2 Operation panel 18 5 3 Dimensions 19 5 4 Hyd...

Страница 4: ...NAS 35 8 Performing a measurement 35 8 1 Restrictions pertaining to use 35 9 Dismantling the FCU 36 10 FCU interfaces 37 10 1 DATA HYDAC Sensor Interface HSI 37 10 1 1 Connecting the FCU with HMG 510 HMG 3000 38 10 1 2 Connecting the FCU with CSI B 2 39 10 2 Bluetooth interface 40 10 2 1 Installing the Bluetooth USB adaptor 41 10 2 2 Connecting the FCU via Bluetooth 41 10 3 Measurement value reado...

Страница 5: ...1 Absolute particle count larger than a defined particle size 58 15 2 2 2 Specifying a cleanliness class for each particle size 59 15 2 2 3 Specifying the highest cleanliness class measured 59 15 3 NAS 1638 59 16 Service 60 16 1 Shipping Address for Recalibration and Repair Work 60 16 2 Calibrating the FCU 60 17 EC declaration of conformity 61 What s New Document History The index is featured on t...

Страница 6: ...ips 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 suggestions or other useful information please don t hesit...

Страница 7: ...at changes to the product e g purchasing options etc may result in the information in the operating instructions no longer being completely accurate or sufficient When making modifications or performing repair work to components affecting the safety of the product the product may not be put back into operation until it has been examined and released by a HYDAC representative Please notify us immed...

Страница 8: ...on WHAT do I want to know I determine which topic I am looking for WHERE can I find the information I m looking for The document has a table of contents at the beginning I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy of the...

Страница 9: ...ess hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property The FCU is only to be used as follows solely for its designated use only when in a safe perfect condition any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately Our General ...

Страница 10: ... which can lead to property damage if safety precautions are not observed 1 3 Proper Designated Use The FCU was developed for the continuous monitoring of particulate contamination in hydraulic systems Analyzing the size and quantity of contamination enables quality standards to be verified and documented and the requisite optimization measures to be implemented Any other use shall be deemed to be...

Страница 11: ...only be performed by properly trained certified electricians This also applies to all repair work or to any modifications to electrical hydraulic components approved by us The hoses and connection fittings are to be checked daily for leakage visual check The electrical components of the product are to also be regularly checked visual check once a month Any loose connections or damaged cables or ho...

Страница 12: ...pection or repair work Check any screw fittings which have been removed to see that they have been properly secured After performing maintenance and servicing work always check the safety features of the product to see that they function properly 1 10 Modifications to the FCU Do not make any modifications design modifications extensions to the FCU without the prior consent of the manufacturer Any ...

Страница 13: ...CU in a clean dry place If the FCU is to be put into storage for an extended period of time it should be completely drained and flushed to prevent it from gumming up The cleaning agents and flushing oils used are to be handled and disposed of properly 2 2 1 Storage conditions Storage temperature 40 C 80 C 40 F 176 F Relative humidity max 90 non condensing 3 Decoding the model code label For produc...

Страница 14: ...ontrol Unit FCU 1000 Series including attachable bag for cables and hoses 2 1 24 V DC 5 A power supply 3 4 Connection cable Europe USA Canada UK Australia Japan 4 1 INLET suction hose open end clear transparent L 0 3 m 11 81 inch 5 1 INLET high pressure hose with test connector type 1620 color clear transparent length 2 m 6 1 High pressure adaptor 7 1 OUTLET return hose open end transparent length...

Страница 15: ...ry can be applied to Control circuits Pressure circuits non pressurized tanks Performance Features Particulate contamination detection by use of an optical measurement cell Applicable for hydraulic fluids 10 350 mm s 16 1622 Sus ISO VG 68 Integrated AquaSensor AS 1000 for the measurement of humidity and temperature Automatic measurement and display of cleanliness ratings as ISO 4406 1987 NAS 1638 ...

Страница 16: ...ht beam to be darkened in a pulse like manner An electronic evaluation module 4 classifies and counts these measurement signals according to particle diameter The evaluation module 4 continuously computes the SAE or ISO cleanliness classes It computes for the reference volume of 100 ml based on the measurement signals of the optical sensor A defined pressure is generated in the oil flow via a coun...

Страница 17: ...nuous monitoring of the following the particle sensor function the oil flow the power supply voltage When a malfunction occurs an error message automatically appears in the display and interrupts the measurement The evaluation module will recognize when the cause of error has been corrected and the unit will reset automatically and resume the measurement operation ...

Страница 18: ...1 Display and Keypad For details see chapter 7 1 2 Pump ON OFF switch Switches the internal pump on off 3 Power supply connector 24 V DC 4 Data interface DATA Connection 5 pole M12x1 5 OUTLET port DN7 with quick action coupling nipple 6 INLET connection Type 1604 with suction strainer 400µm see chapter 11 Bluetooth interface Located inside the FCU ...

Страница 19: ... ca 450 ca 330 410 230 ca 430 410 FCU open FCU closed 5 4 Hydraulic schematic INLET 1 2 3 4 6 7 8 9 5 OUTLET 1 INLET test connector type 1604 6 ContaminationSensor Unit 2 Suction screen 400 µm 7 Counter balance valve 3 Gear pump 8 AquaSensor AS 1000 4 Electric motor 9 OUTLET DN7 Quick coupling nipple 5 Pressure control valve ...

Страница 20: ...measurement point should be selected according to certain criteria For more information see chapter Selecting the measurement point 6 2 3 Establish the operating pressure at the desired measurement point Select the appropriate measurement method according to the pressure at the measurement point Pressure at the measurement site Measurement method Chapter 0 bar 0 psi Connection at the measurement p...

Страница 21: ...t takes approximately 120 ml of oil to completely fill the hydraulic circuit inside the FCU and INLET hose If the FCU is not pre filled an air oil mixture will flow through the FCU at the start of measurement The sensor will interpret the air bubbles as particles thereby falsifying the measurement result For the first sampling without pre filling the FCU and hoses we recommend using at least 300 m...

Страница 22: ...pressure hose color black to the INLET port of the FCU INLET 4 Check the pressure at the measurement point The pressure may not exceed 45 bar If the pressure is 45 bar the high pressure adaptor must be connected upstream see chapter 6 2 2 Conclude by connecting the other end of the INLET pressure hose to the measurement port of the system 45 bar max INLET 5 The hydraulic installation of the FCU is...

Страница 23: ...0 5000 psi 0 5 bar max 7 5 psi max OUTLET We recommend filling the FCU before measurement This ensures immediate and accurate measurements results It takes approximately 120 ml of oil to completely fill the hydraulic circuit inside the FCU and INLET hose If the FCU is not pre filled an air oil mixture will flow through the FCU at the start of measurement The sensor will interpret the air bubbles a...

Страница 24: ...rvoir or to a waste oil canister 2 Now connect the other end of the hose to the OUTLET port of the FCU OUTLET 3 Check the pressure at the measurement point It has to be within the permissible range 4 Screw the high pressure adaptor A onto the INLET port of the FCU 5 Connect the high pressure hose color black to the high pressure adaptor A 6 Connect the other end of the high pressure hose to the me...

Страница 25: ...w area i e a pipe bend This ensures that a typical sample is analyzed The FCU should be installed in the vicinity of the measurement point in order to prevent sedimentation formation of particle deposits in the line and to attain precisely timed results While installing the INLET hose make sure that no siphon trap is created The original INLET high pressure hose may not be extended 3 H L 2 INLET M...

Страница 26: ...il mixture will flow through the FCU at the start of measurement The sensor will interpret the air bubbles as particles thereby falsifying the measurement result For the first sampling without pre filling the FCU and hoses we recommend using at least 300 ml of fluid 1 Connect the open end of the OUTLET return hose color clear transparent to a waste oil canister first 2 Now connect the other end of...

Страница 27: ...d in the FCU delivery Connect the power plug of the adaptor into the power supply After the unit is plugged in HYDAC FCU 1 appears in moving letters followed by the firmware version which appears for 2 seconds The self test with countdown follows WAIT 99 to WAIT 0 The FCU is now ready As long as the pump is not running the status LED blinks red and the display shows CHECK This means that there is ...

Страница 28: ...ntdown runs from 99 0 within the set measurement time 7 1 Display and keypad elements Item LED Description A Status Indicates the status of the Contamination Sensor for details see chapter 12 B Display Consists of a 6 digit display and shows the selected measured values C Measured variable Indicates the measured variable that is shown in the display i e ISO SAE NAS D Additional variable Indicates ...

Страница 29: ...asurement variables provide the user information about the cleanliness or contamination of the oil in his facility The measurement variables are calibrated They indicate a measured value with an accuracy of 1 2 codes class 7 1 1 1 Measured variable ISO Display Description 2 1 1 The measurement value is updated independently of the set measuring time Display of the ISO code 7 1 1 2 Measured variabl...

Страница 30: ...isplay of the temperature in C Celsius or F Fahrenheit according to setting 7 1 2 Service variables The service variables enable the user to retrieve information on the current status in the FCU The service variables are not calibrated 7 1 2 1 Service variables Flow Display Description 120 Display of the averaged flow through the ContminationSensor unit Example 120 ml min 7 1 2 2 Service variables...

Страница 31: ...scription 2 1 1 3 8 1 3 Changing the active display 7 1 4 Activate deactivate keypad lock The keypad can be locked to prevent entries from being made The keypad can be locked to prevent entries from being made To activate or deactivate keypad locking press both keys simultaneously Buttons The following appears in the display 1 sec Description LOCK Key lock is activated UNLOCK Key lock is deactivat...

Страница 32: ... it down while switching on the supply voltage Leaving the Power Up menu without saving Scroll to CANCEL and press o k or the option is selected automatically after 30 seconds Exit Power up menu and save changes Scroll to SAVE and press o k Power Up Menu Description mTIME Set measuring time ADRESS Set bus address DFAULT Reset to factory defaults CAlIb Select the calibration CANCEL Discard changes ...

Страница 33: ...nu Press button o k Scroll to CANCEL and actuate it Scroll to CANCEL and press o k or the option is selected automatically after 30 s Exit menu and save changes Scroll to SAVE and press o k Measuring Menu Description DSPLAY Select displayed measured variable CANCEL Discard changes and exit SAVE Save changes and exit Display Select displayed measured variable when switching on the sensor DSPLAY Sel...

Страница 34: ...VE Cancel CANCEL Save SAVE 7 2 4 Measuring Menu ISO NAS The measuring menu allows you to change settings during operation Selection To do Enter measuring menu Press button o k Scroll to CANCEL and actuate it Scroll to CANCEL and press o k or the option is selected automatically after 30 seconds Exit menu and save changes Scroll to SAVE and press o k Measuring Menu Description DSPLAY Select display...

Страница 35: ...FLOW Measuring cell LED current DRIVE Cancel CANCEL Save SAVE 8 Performing a measurement 1 Check all the hydraulic and electrical connections to the FCU 2 Now press the green Pump ON switch 3 Now the pump feeds oil through the FCU After the set measurement time the result is shown on the display and the status LED lights up green permanently 8 1 Restrictions pertaining to use TIP The FCU 1000 Seri...

Страница 36: ...nection Unscrew the inlet hose at the measurement point of the hydraulic system Remove the FCU INLET hose To remove the quick action coupling place your hand around the hose and pull back the outer ring of the coupling The coupling releases from the nipple without the use of a tool The fluid remaining in the hose must be drained into a suitable receptacle and disposed of properly Fluid may still e...

Страница 37: ...nterfaces for configuration and the transmission of measurement data C S 1 0 0 0RS 232 RS 485 RS 232 18 35 V DC Customer System PC ZBE 08S xx 5 FCU 1000 Bluetooth DATA 10 1 DATA HYDAC Sensor Interface HSI The HSI interface has connection plug M12x1 5 pole in accordance with DIN VDE 0627 Pin Assignment 1 Not connected 2 Not connected 3 Not connected 4 GND 5 HSI ...

Страница 38: ...10 HMG 3000 The following portable data recorders HMGs can be used to give a readout of the FCU 1000 via the DATA interface HMG 510 with firmware version 2 release 15 or higher ZBE 30 xx FCU 1000 HMG 510 HMG 3000 with firmware version 2 release 1 or higher HMG 3000 ZBE 30 xx FCU 1000 See the operating instructions for the HMG for further details ...

Страница 39: ...echnik GmbH en Page 39 BeWa_FCU1000_3371346a_en doc 2007 12 04 10 1 2 Connecting the FCU with CSI B 2 The FCU 1000 can be connected to a PC with CSI B 2 and RS 232 C S 1 0 0 0 RS 232 RS 485 RS 232 18 35 V DC Customer System PC ZBE 08S xx 5 FCU 1000 ...

Страница 40: ...based on the Bluetooth Version 1 2 Class 3 This means that 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 performance of 1mW bzw 0 dBm reaches a maximum of 10 m outdoors This distance is strongly influenced by disturbances and obstacles in its vicinity FCU 1000 FCU 1000 Bluetooth 10 m 3 m ...

Страница 41: ...s case diagram similar HYDAC article no See chapter 13 1 Accessories 10 2 2 Connecting the FCU via Bluetooth The FCU 1000 is registered in the Bluetooth vicinity as device FCU 1310 If the connection to the FCU is established via Bluetooth the measured values can be read by FluMoS for example The data transfer through the Bluetooth connection depends on your PC hardware and installed software There...

Страница 42: ...wet cloth making sure that no residue is left 11 2 Rinsing the FCU Flush the FCU 1000 after each use or daily with appropriate mineral oil 11 2 1 Performing a rinsing The FCU 1000 should be flushed cleaned after each use Rinsing the FCU is especially critical when non filtered oil or 50 W or heavier viscosity oil has been sampled Rinsing should also be performed when the operator observes any meas...

Страница 43: ...The suction strainer must be cleaned at regular intervals according to the prescribed maintenance intervals The suction strainer is blocked when no flow exits the FCU TIP If the FCU does not pump any fluid the suction strainer should be checked and cleaned if necessary Operating the FCU without a suction strainer can lead to malfunction 1 Detach all connections to the FCU Open the INLET measuremen...

Страница 44: ...it FCU 1000 Series HYDAC Filtertechnik GmbH en Page 44 BeWa_FCU1000_3371346a_en doc 2007 12 04 2 Unscrew the INLET measurement point by hand INLET 3 Insert your finger in the hole to remove the suction strainer INLET ...

Страница 45: ...ing it or rinsing it with compressed air Before inserting the INLET test point union B check the sealing ring visual check for damage and replace it if necessary see replacement parts list for the part number of the sealing ring Wet the sealing ring C with mineral oil or medium INLET A B C 5 Insert the suction screen back in place INLET TIP Operating the FCU without a suction strainer can lead to ...

Страница 46: ...BeWa_FCU1000_3371346a_en doc 2007 12 04 6 Insert the INLET test point union by hand and screw it in by turning it in a clockwise direction INLET 7 Screw the INLET test point union tight using a wrench size 19 mm inch by turning it in a clockwise direction INLET max 25 Nm ...

Страница 47: ...daptor The strainer B in the high pressure adaptor must be cleaned regularly B D A Remove the measurement coupling A from the union D with an open jaw wrench size 22 mm in a counterclockwise direction Then unscrew the strainer B with a Philips head screwdriver or the special tool see accessories list 13 1 in a counterclockwise direction The strainer B can be washed out and blown dry with compresse...

Страница 48: ...gram The valves do not function if mounted in the wrong direction To mount the new flow control valve C screw it in to the union D in a clockwise direction using a Philips head screwdriver or the special tool Then screw the strainer B into the union D with a Philips head screwdriver or special tool in a clockwise direction Then check the sealing ring at the measurement coupling A for damage and re...

Страница 49: ...8 7 12 2 Error Message LED Blink code Display Status To do Error no Red LOW Flow too low Switch on the pump 1 Red CHECK Flow definition not possible The sensor status definition is not possible Switch on the pump If the the oil cleanliness is below the measurement limit ISO 9 8 7 it can take a few measuring cycles until contamination values are displayed 3 Red 2 2 2 DIRTY The FCU is above its meas...

Страница 50: ...set device re supply voltage to sensor or contact HYDAC 1 19 Red Communication error Check supply voltage for FCU Switch the FCU on and then off Contact HYDAC 20 39 Red System error Check supply voltage for FCU Switch the FCU on and then off Contact HYDAC 40 69 Red Error during automatic adjustment Check supply voltage for FCU Switch the FCU on and then off Contact HYDAC 70 Red Error measuring cel...

Страница 51: ...00054 OUTLET return hose with open end transparent Length 1 m 39 37 inch 278475 Suction strainer 400 µm for INLET port 607755 Seal ring for INLET test point union Ø 21 mm according to DIN3869 3364502 High pressure adaptor complete 3152786 Suction strainer 400 µm for high pressure adaptor 710389 Flow control valve for high pressure adaptor 3335656 Attachable bag for hoses cables and accessories 337...

Страница 52: ...C secondary 24 V DC 5A cable with 3 pole plug Length 1 6 m 62 99 inch 6008448 Connection cable for power adaptor European plug Length 2 m 78 74 inch 6008447 Connection cable for power adaptor plug for England UK Length 2 m 78 74 inch 6008446 Connection cable for power adaptor plug for USA Length 2 m 78 74 inch 6008449 Connection cable for power adaptor plug for Australia AUS Length 2 m 78 74 inch ...

Страница 53: ...or changing the flow control valve in the high pressure adaptor 6060113 Bluetooth USB adaptor ANYCOM BT250 920134 CSI B 2 Condition Sensor Interface 6019455 Connection cable screened with 5 pole connector socket plug bent open length 2 m ZBE 08S 02 6019456 Connection cable screened with 5 pole connector socket plug bent open length 5 m ZBE 08S 05 6023102 Connection cable screened with 5 pole conne...

Страница 54: ... Service Display Flow Drive Measuring time programmable 10 300 seconds Hydraulic data Suitable Fluids Mineral oil Hydraulic Connectors INLET Test connector type 1604 OUTLET DN7 nipple socket INLET operating pressure 0 5 45 bar 0 650 psi With high pressure adaptor 15 345 bar 217 5000 psi OUTLET operating pressure 0 0 5 bar max 0 7 5 psi Measurement flow rate 30 300 ml min viscosity dependant Permis...

Страница 55: ...idual ripple 10 Wattage Current 100 W max 4 A max IP class IP 50 in Operation IP 67 closed Protection class III low voltage protection General data Material of sealings FPM Fluid temperature range 0 70 C 32 158 F Ambient temperature range 0 45 C 32 113 F Storage temperature range 40 80 C 40 176 F Relative humidity max 90 non condensing Weight approx 13 kg ...

Страница 56: ...day 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 15 1 1 ISO 4406 table Allocation of particle counts to cleanliness classes Particle count 100 ml Particle count 10...

Страница 57: ...e 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 ultrafine fraction ISO 12103 1A1 SAE Fine AC Fine ISO 12103 1A2 SAE 5 80 µm ISO MTD Calibration dust for particle counters ISO 12...

Страница 58: ... 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 27 700 4 900 848 128 10 800 000 311 000 55 400 9...

Страница 59: ... 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 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 3 1 2 5 000 1 000 178 32 6 1...

Страница 60: ... Repair Work Germany USA HYDAC Service Center Rehgrabenstrasse Werk 7 D 66125 Saarbruecken Germany HYDAC Technology Corporation Service Department 2280 City Line Road Bethlehem PA 18017 Telephone 49 0 6897 509 01 Telephone 001 0 610 266 0100 16 2 Calibrating the FCU We recommend a recalibration of at least 3 years for device measurement in accordance with ISO 9000 ...

Страница 61: ...FluidControl Unit FCU 1000 Series HYDAC Filtertechnik GmbH en Page 61 BeWa_FCU1000_3371346a_en doc 2007 12 04 17 EC declaration of conformity ...

Страница 62: ...FluidControl Unit FCU 1000 Series HYDAC Filtertechnik GmbH en Page 62 BeWa_FCU1000_3371346a_en doc 2007 12 04 Notes ...

Страница 63: ...FluidControl Unit FCU 1000 Series HYDAC Filtertechnik GmbH en Page 63 BeWa_FCU1000_3371346a_en doc 2007 12 04 Notes ...

Страница 64: ...chnology Division Industriegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 0 6897 509 01 Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com email filtersysteme hydac com ...

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