FCU 1210 FluidControl Unit · rial contractual obligation, our liability shall be limited to fore-seeable damage. Claims due to the Product Liability shall re-main unaffected. Warranty2.1

FCU 1210FluidControl Unit

Operating and Maintenance InstructionsEnglish • (Translation of original instructions)

Document No. : 3545830b • 12/6/2018

Follow these instructions for proper and safe use.Keep for future reference.

1 | Imprint HYDAC FILTER SYSTEMS GMBH

2 / 92 BeWa FCU1210 3545830b en-us lq

1 ImprintManufacturer / publisher and responsible for the content:

Address of the manufacturer Contact address

HYDAC FILTER SYSTEMSGMBH Industriegebiet 66280 Sulzbach / Saar

HYDAC FILTER SYSTEMSGMBH Justus-von-Liebig-Str., Werk20 66280 Sulzbach / Saar

Germany Germany

E-mail: [email protected]

Homepage: www.hydac.com

Court of Registration: Saarbrücken , HRB 17216

Executive Director: Mathias Dieter ,Dipl.Kfm. Wolfgang Haering

Tab. 1: Impressum

1.1 Documentation RepresentativeThe contact data of the person authorized with the documenta-tion is:

Mr. Günter Harge

c/o HYDAC International GmbH, Industriegebiet, 66280Sulzbach / Saar

Germany

Phone: +49 6897 509 1511

Fax: +49 6897 509 1394


Tab. 2: Documentation Representative

HYDAC FILTER SYSTEMS GMBH Table of Contents

BeWa FCU1210 3545830b en-us lq iii

Table of Contents

1 Imprint ....................................................................................................................... 2

1.1 Documentation Representative........................................................................ 2

2 General ..................................................................................................................... 6

2.1 Warranty........................................................................................................... 6

2.2 © HYDAC FILTER SYSTEMS GMBH, 2018.................................................... 6

2.3 Using this manual............................................................................................. 7

3 General Safety Information ....................................................................................... 9

3.1 Signal words and their meaning in the general safety information................. 10

3.2 Design of Warning - / General Safety Information ......................................... 11

3.3 Safety symbols / pictograms .......................................................................... 11

3.4 Observe regulatory information...................................................................... 14

3.5 Stoppage in an emergency (EMERGENCY STOP)....................................... 14

3.6 Fire-fighting / extinguishing a fire ................................................................... 14

4 Overview ................................................................................................................. 15

4.1 Counting contaminant particles optically (light blockade procedure) ............. 16

4.2 Proper/designated use ................................................................................... 184.2.1 Periodic intermittent duty – operating mode S3................................. 19

4.3 Improper Use or Use Deviating from Intended Use ....................................... 20

4.4 Checking the scope of delivery ...................................................................... 21

4.5 Decoding the model code label...................................................................... 224.5.1 Model code ........................................................................................ 24

4.6 Technical Data ............................................................................................... 25

4.7 Dimensions .................................................................................................... 28

4.8 Hydraulic diagram .......................................................................................... 29

4.9 Opening / closing the case............................................................................. 30

4.10 How it works: ................................................................................................. 31

5 Transporting / storing the FCU................................................................................ 33

5.1 Transporting the FCU..................................................................................... 33

Table of Contents HYDAC FILTER SYSTEMS GMBH

iv BeWa FCU1210 3545830b en-us lq

5.2 Storing the FCU ............................................................................................. 34

6 Putting the FCU into operation................................................................................ 35

6.1 Connecting / disconnecting the power supply................................................ 356.1.1 Disconnecting the power supply ........................................................ 35

6.2 Plug in/Detach return hose............................................................................. 37

6.3 Selecting the measurement location .............................................................. 38

7 Operation ................................................................................................................ 39

7.1 Overview of control panel/operating elements ............................................... 397.1.1 Reading the display and operating the keyboard .............................. 417.1.2 Scrolling through the display ............................................................. 437.1.3 Displaying measured variables.......................................................... 457.1.4 Display service variables ................................................................... 457.1.5 Display FREEZE................................................................................ 47

7.2 Select the operating modes / measurement method according to the pressureinvolved .......................................................................................................... 497.2.1 Measuring from unpressurized containers ........................................ 507.2.2 Measuring oil up to max. 45 bar / 650 psi.......................................... 537.2.3 Oil between 15 ... 345 bar / 217 ... Measuring 5000 psi .................... 56

7.3 Performing Measurements............................................................................. 59

7.4 Restarting/resetting ........................................................................................ 60

7.5 Using the BatteryPack (accessory) ................................................................ 61

8 Performing maintenance ......................................................................................... 62

8.1 Maintenance table.......................................................................................... 62

8.2 Clean the suction strainer. ............................................................................. 63

8.3 Calibrating FCU.............................................................................................. 66

8.4 High-pressure adapter maintenance.............................................................. 678.4.1 Cleaning/changing the strainer .......................................................... 678.4.2 Cleaning / changing the flow control valve ........................................ 69

9 Rinsing / cleaning the FCU ..................................................................................... 72

9.1 FCU flushing .................................................................................................. 72

9.2 Cleaning the FCU........................................................................................... 75

HYDAC FILTER SYSTEMS GMBH Table of Contents

BeWa FCU1210 3545830b en-us lq v

10 Finding / rectifying errors......................................................................................... 76

11 Removing / Disposal ............................................................................................... 80

12 Attachment .............................................................................................................. 81

12.1 Finding spare parts / accessories .................................................................. 81

12.2 Finding a Customer Service team.................................................................. 83

12.3 EC declaration of conformity .......................................................................... 84

Glossary .................................................................................................................. 88

Index ....................................................................................................................... 89

2 | General HYDAC FILTER SYSTEMS GMBH

6 / 92 BeWa FCU1210 3545830b en-us lq

2 GeneralThis manual was prepared to the best of our knowledge. Nev-ertheless and despite the greatest care, it cannot be excludedthat mistakes could have crept in. Therefore, please under-stand that, in the absence of any provisions to the contraryhereinafter, our warranty and liability – for any legal reasonswhatsoever – are excluded in respect of the information in thismanual. In particular, we shall not be liable for lost profit orother financial loss.

This exclusion of liability does not apply in cases of intent andgross negligence. Moreover, it does not apply to defects whichhave been deceitfully concealed or whose absence has beenguaranteed, nor in cases 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 WarrantyFor the warranty provided by us, please refer to the Terms ofDelivery. They are made available to you at the conclusion ofthe contract at the latest. You will also find these underwww.hydac.com -> General Terms and Conditions (T&C).

2.2 © HYDAC FILTER SYSTEMS GMBH, 2018Distributing and copying this document and utilizing and dis-closing its content is not permitted, except where this has beenagreed upon explicitly. Any infringement will entail liability fordamages. All rights reserved in the case of a patent beinggranted or a utility model or the design being registered.

We reserve the right to changes to the contents of this manualwithout prior notice.

http://www.hydac.com

HYDAC FILTER SYSTEMS GMBH General | 2

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2.3 Using this manualYou will find the following information on the title page of thismanual:

Short name of the productProduct name

Operating and Maintenance Instructions

12345678 ● ##.##.####

English (translation of original instructions)

Valid

from

:- f

rom

s/n

o.- .

.. ...

- ...

...

1

5

2

43

Fig. 1: Overview / labeling of the title page

1 Short name of the product / product name2 Type of document3 Language4 Document no./Index ● Date of printing5 Supplementary instructions regarding the validity of the

manual (optional)

Please note that you can directly access informationthrough the directories. However, this does not re-lease you from the obligation to read this manualfully before commissioning.

The document no. with the index (4) is meant for identifyingand reordering the manual. The index is incremented everytime the manual is revised or changed.

2 | General HYDAC FILTER SYSTEMS GMBH

8 / 92 BeWa FCU1210 3545830b en-us lq

The manual contains a table of contents, a list of tables andfigures, an index and a glossary.

You will find the following symbols in the manual as additionaldetails:

Tip for handling the product

Required tools

HYDAC FILTER SYSTEMS GMBH General Safety Information | 3

BeWa FCU1210 3545830b en-us lq 9 / 92

3 General Safety InformationThe product was built according to the 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 inthis manual.

Observe all safety and warning instructions attached to theproduct and keep them always complete and easily legible.

3 | General Safety Information HYDAC FILTER SYSTEMS GMBH

10 / 92 BeWa FCU1210 3545830b en-us lq

3.1 Signal words and their meaning in the generalsafety informationIn these instructions you will find the following signal words:

DANGER

DANGER – The signal word indicates a hazardous situationwith a high level of risk, which, if not avoided, will result lethalor serious injury.

WARNING

WARNING – The signal word indicates a hazardous situationwith a medium level of risk, which, if not avoided, can resultlethal or serious injury.

CAUTION

CAUTION – The signal word indicates a hazardous situationwith a low level of risk, which, if not avoided, can result in mi-nor or moderate injury.

NOTICE

NOTICE – The signal word indicates a hazardous situationwith a high level of risk, which, if not avoided, will result indamage to property.


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3.2 Design of Warning - / General Safety InformationAll the warning / general safety information in this manual arehighlighted with pictograms and signal words. The pictogramand the signal word give you an indication of the severity of thedanger.Warning / general safety information, which are placed aheadof each activity, are represented as follows:

CAUTION

Type and source of danger

Hazard symbolConsequence of the danger

Measures to avert danger►

3.3 Safety symbols / pictogramsThe following are the safety symbols / pictograms in this man-ual. They indicate specific dangers to persons, property or tothe environment. Observe these safety symbols / pictogramsand act with particular caution in such cases. Always keep allsymbols / pictograms intact and legible.

Warning signs used

These signs are listed for all safety information and instructionsin these operating instructions which indicate particular haz-ards to persons, property or the environment.

Danger point warning

Dangerous electrical voltage warning


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Hot surface warning

Signs used for giving orders

These symbols are listed for all General Safety Informationand instructions in these operating instructions which indicateparticular hazards to persons, property or the environment.

Follow the instructions.

Disconnect before working.

Signs used for the required specialist personnel

These symbols show the required training/knowledge for in-stallation work and/or maintenance work.

Specialist personnel / operatorsSuch persons have had the corresponding spe-cialist training and several years' work experi-ence. They are able to assess and perform thework assigned to them, they are also able to rec-ognize potential hazards.

Specialist personnel - MechanicSuch persons have specific specialist trainingand several years' work experience. They areable to assess and perform the work assigned tothem, they are also able to recognize potentialhazards.


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Specialist personnel - ElectricianSuch persons have specific specialist trainingand several years' work experience. They areable to assess and perform the work assigned tothem, they are also able to recognize potentialhazards.

Others symbols used

These signs are listed for the general safety instructions inthese operating instructions, for example, which indicate a par-ticular danger to persons, property or the environment.

Danger due to operating pressure


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3.4 Observe regulatory informationObserve the following regulatory information and directives:

– Legal and local regulations for accident prevention

– Legal and local regulations for environmental protection

– Country-specific regulations, organization-specific 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 fireUse a powder extinguisher that corresponds to fire class B asper EN 2 to extinguish any fires / to fight fires.

Fig. 2: Fire protectionclass B

Maintain a minimum safe distance from electrical components.For a mains voltage of up to 1000 V, the minimum safe dis-tance is 1 m.

Fig. 3: Minimum distance for fire fighting

HYDAC FILTER SYSTEMS GMBH Overview | 4

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4 OverviewThe FluidControl Unit FCU is a portable service unit for takingshort-term measurements of the solid particle contamination,as well as the temperature in the hydraulic systems.

Knowledge on the level and amount of contamination allowsyou to check and document quality standards and introducethe required optimization measures.

The integrated pump and the hoses supplied enable usagewith:

– Control circuits

– Pressure circuits

– Depressurized containers

Additional features include:

– Optical measurement of the degree of solid particle con-tamination

– Measurement of temperature indirectly via housing

– Suitable for hydraulic fluids (up to ISO VG 68)

– 2 … 350 mm²/s / 33 … 1622 Sus

– Automatic measurement and display of cleanliness ratingsin accordance with:

– ISO 4406; SAE AS 4059 (D)

– Measurement accuracy +/- ½ ISO code in the calibratedrange

– Supply voltage of 24 V DC / 4 A for operation on mobilemachine on-board networks

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

4 | Overview HYDAC FILTER SYSTEMS GMBH

16 / 92 BeWa FCU1210 3545830b en-us lq

4.1 Counting contaminant particles optically (lightblockade procedure)The measuring principle of the light blockade procedure isshown in simplified form in the following sketch.

The light source transmits monochromatic light through theflow of oil to a photo detector, which produces a particularelectrical signal. If a particle gets between the light source andthe photo detector, 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 todetermine the size of the shadow cast by the particle and thusto gauge the size of the particle itself.

This procedure makes it possible to determine the cleanlinessclass according to ISO 4406, NAS 1638 and SAE AS 4059.

The disruption factors of this measurement principle are, forexample, foreign fluids and small gas bubbles that lead to re-fractions, thus causing them to be counted as particles as well.

Fig. 4: Light blockade procedure

1 Light source2 Contaminant particle3 Photo detector


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Each of the signal peaks corresponds to the shadow cast byone particle. The signal height or amplitude reflects the particlesize. 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

Thre

shol

d va

lues

Fig. 5: Signal amplitudes


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4.2 Proper/designated useUse the product only for the intended use described below .

The FluidControl Unit FCU is a portable service unit for takingshort-term measurements of the solid particle contamination inhydraulic systems.

NOTICEImpermissible operating conditions

The FCU can be damaged.

u Use the FCU with mineral oils or mineral oil-based raffi-nates with flash points higher than 55°C / 131°F.

u Flush the FCU with low-viscosity mineral oils or mineraloil-based raffinates with flash points higherthan 55°C / 131°F.

u Never flush the FCU with universal thinners or other de-greasing fluids.

u Observe the permissible viscosity range (up toISO VG 68): of 2 - 350 mm²/s / 33 - 1622 SUS.

u Operate the FCU only in periodic intermittent duty (S3)with a (relative) duty cycle of 40% in relation to a useful lifeof 10 minutes (S3 in accordance with DIN EN 60034 /VDE 0530).

u Never use the FCU without a suction strainer.

u Observe all the instructions contained in these Operatingand Maintenance Instructions.

u Comply with all inspection and maintenance work.

Claims for defects or liability, regardless of the legal founda-tion, do not apply with incorrect or improper installation, com-missioning, usage, handling, storage, maintenance, repair, useof unsuitable components or other circumstances for which themanufacturer is not responsible.


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The manufacturer assumes no responsibility for determiningthe interfaces for installation in a system or the installation, useor functionality of the product in this system.

4.2.1 Periodic intermittent duty – operating mode S3Periodic intermittent duty in accordance with DIN EN 60034-1 /DIN VDE 0530, Part 1, means that, during the period t0, opera-tion t1 repeats itself periodically in alternation with the power(PN)S3, followed by the cooling-down phase (downtime) t2. Therelative duty cycle is 40% in relation to a useful life of 10 min-utes.

Fig. 6: Operating modeS3 – Periodic intermittentduty

(PN)S3 Nominal power, operating mode S3t time

t0 Periodt1 Operationt2 Cooling phase (downtime)

°C (°F) Temperature


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4.3 Improper Use or Use Deviating from Intended UseImproper use of the product may result in hazards and/or willdamage/destroy the product.

DANGER

Impermissible operating conditions

Danger of bodily injury

u Operation with non-approved fluids.

u Operation with fluids that have a flash point under55°C / 131°F.

u Operate only with fluids whose temperature is not at least10°C below their individual flash point.

u Improper connection of the pressure and return flowhoses.

u Operation at a measurement point with impermissiblepressure.

u Operation with damaged connector cable.

u Operation with faulty, damaged hoses.

u Modifications to the product made by the user or pur-chaser.

u Operation in potentially explosive atmospheres.

u Continuous operation.


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4.4 Checking the scope of deliveryThe FluidControl Unit comes packed and ready for operation.Before commissioning the FCU, check the contents of the con-signment to make sure everything is present.

Item Qty. Designation

- 1 FluidControl Unit FCU, including attachable bagfor cables and hoses

- 1 Power supply, primary: 90-240 V AC / secondary:24 V DC / 5 A

- 4 Connection 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 Return hose, transparent, L = 2 m

- 1 Document bag, comprising of:- Operating and Maintenance Instructions (thisdocument)- Calibration certificate- CE Declaration of Conformity

Tab. 3: Scope of delivery


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4.5 Decoding the model code labelFor identification of the FluidControl Unit, see the type label.The type label displays the product ID and important technicaldata.

Item -> Description

(1) -> Type label for FCU(2) -> Model code; for details, see

Model code [} 24]

Model -> Model code; for details, seeModel code [} 24]

Date -> Production year/weekP/N -> Part no.S/N -> Serial no.Flow rate -> FlowWeight -> Weight when emptyViscosity range -> Permissible viscosity rangePressures -> Pressure specifications


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Item -> Description

In -> Permissible pressure at portINLET

Out -> Permissible pressure at portOUTLET

Temperatures -> Temperature specificationsOil -> Permissible oil temperature

rangeAmbient -> Permitted ambient tempera-

ture rangePower -> Power consumptionVoltage -> VoltageCurrent -> Current consumption


24 / 92 BeWa FCU1210 3545830b en-us lq

4.5.1 Model codeThe FCU is defined by the following model code:

Product

Contamination code

Series

FCU 1 3 1 0 - 4 - U - AS - 1

FCU = FluidControl Unit

1

2

Fluids

4Options

= Pump, integrated

Hydraulic - lubrication fluids based on mineral oil0 =

1000 series, 4 particle size channels

ISO4406; SAE AS 4059 (D) / >4 µm(c) >6 µm(c) >14 µm(c) >21 µm(c)=

=

Housing1 = 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 µmcan be switched toISO4406; SAE AS 4059 (D) / >4 µm(c) >6 µm(c) >14 µm(c) >21 µm(c)

=

Hydraulic - lubrication fluids based on mineral oil anddiesel in accordance with DIN EN 590 / ASTM D975 4-D

5 =

without=z

Fig. 7: Model code


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4.6 Technical DataThe FCU has the following technical data.

Contamination sensor

Self diagnostics continuously with error indicationvia status LED and display

Display LED, 6 digits, with 17 segments

Measured values forsolid particle contami-nation

ISO code / SAE class

Measurement range Display of ISO code between:9/8/7 … 25/24/23.

Calibrated within the range of ISOcode:13/11/10 … 23/21/18

Accuracy Contamination sensor: ± 1 ISO code

Service Display FLOW / DRIVE / Temp

Measuring time 30 seconds

Tab. 4: Contamination sensor

Hydraulic data

Suitable Fluids Mineral oil or raffinate based on min-eral oil

Hydraulic connections

INLET Test connector type 1604

OUTLET DN7 nipple socket

Maximum permissibleoperating pressure atINLET connection

-0.5 … 45 bar / 0 … 650 psi

Maximum permissibleoperating pressure atOUTLET connection

0 … 0.5 bar / 0 … 7.5 psi

Measurement flow rate 30 - 500 ml/min (viscosity depen-dent)


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Hydraulic data

Permissible viscosityrange

2 … 350 mm²/s / 33 … 1622 Sus(for hydraulic oil up to ISO VG 68)

Suction height ≤ 1 m / ≤ 39.37 inches

Suction hose INLET DN4, open-end, color: clear-trans-parent,Length = 0.3 m

Return hose OUTLET DN7, open-end, color: clear-trans-parent,Length = 1.5 m

Tab. 5: Hydraulic data

Electrical data

Power supply 24 V DC, ± 20%, residual ripple≤ 10%

Power consumption ≤ 100 W

Current consumption ≤ 4 A

Operating mode S3, periodic intermittent duty as perDIN EN 60034-1 / DIN VDE 0530part 1 relating to a useful life of 10minutes.

Relative duty cycle 40 %

Degree of protection IP 50 (open, in operation)IP 67 (closed)

Protection class III (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 temperaturerange of fluid

0 … 70 °C / 32 … 158 °F

Permitted ambient tem-perature range

0 … 45 °C / 32° … 113 °F


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General data

Permitted storage tem-perature range

-40 … 80 °C / -40 … 176 °F

Permitted relative hu-midity

max. 90%, non-condensing

Weight when empty ≈ 9 kg

Tab. 7: General data


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4.7 DimensionsThe FCU has the following dimensions.

Fig. 8: Dimensions

All dimensions in mm.


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4.8 Hydraulic diagramThe FCU has the following hydraulic circuit.

Fig. 9: Hydraulic circuit

Item Designation

1 INLET, gauge port type 16042 Suction strainer, 400 µm3 Electric motor4 Gear pump5 Contamination sensor6 Counter balance valve7 Pressure relief valve8 OUTLET, DN7 quick coupling nipple


30 / 92 BeWa FCU1210 3545830b en-us lq

4.9 Opening / closing the caseOpen the FCU case by releasing the two clips.

Fig. 10: Opening the FCU case

Close the FCU using both clips. Make sure that these audiblysnap into place.

Fig. 11: Closing the FCU case


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4.10 How it works:From the measurement point (either a pressure port or a reser-voir or a bottle sample) a continuous oil current is establishedthrough the INLET connector by an electrically controlled gearpump (16). The suction screen (17) protects the pump fromcoarse contamination.

The oil current flows through an optical ContaminationSensor(1). The contaminant particles contained in the oil currentcause the light beam to be darkened in a pulse-like manner.An electronic evaluation module (4) classifies and counts thesemeasurement signals according to particle diameter. The eval-uation module (4) continuously computes cleanliness classeswith the aid of the measurement signals of the optical sensorwith respect to a measurement volume of 100°ml.

A defined pressure is generated in the oil flow via a counterbalance valve (10). This serves to minimize air bubbles in thesystem, which could skew the measurement results.

The pressure relief valve (14) protects the pump and the mea-suring cell from excessive pressure.

Use the return hose to channel the oil flow out of the port OUT-LET and into a depressurized tank.

The electronic evaluation module monitors:

– the functioning of the particle sensor

– the oil flow

When a malfunction occurs, an error message automaticallyappears in the display and interrupts the measurement. Theevaluation module will recognize when the cause of error hasbeen corrected, and the unit will reset automatically and re-sume the measurement operation.


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Fig. 12: Function plan

HYDAC FILTER SYSTEMS GMBH Transporting / storing the FCU | 5

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5 Transporting / storing the FCUObserve the following chapter on transport and storage.

5.1 Transporting the FCUTransport the FCU only when it is in closed position; carry itflat or by the handle.

Fig. 13: Transporting the FCU

5 | Transporting / storing the FCU HYDAC FILTER SYSTEMS GMBH

34 / 92 BeWa FCU1210 3545830b en-us lq

5.2 Storing the FCUDrain and rinse the FCU completely before putting it into stor-age. See the"Rinsing the FCU" chapter for details on rinsingthe FCU.

Details regarding permissible storage conditions can be foundin the Technical Data [} 25] chapter.

Store the FCU closed and in a horizontal position in a dry,clean place. If stored in a vertical position, the FCU must notbe exposed to any shaking or vibration.

Fig. 14: Storing the FCU

HYDAC FILTER SYSTEMS GMBH Putting the FCU into operation | 6

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6 Putting the FCU into operationBefore operation, the FCU must first be hydraulically and elec-trically connected, as described below.

6.1 Connecting / disconnecting the power supplyThe FCU has a 3-pole socket for connection with a 24 V DCpower supply.

Fig. 15: Connecting thepower supply

1. Insert the 3-pole socket plug, e.g. of the power pack,into the socket until the ratchet can be heard to click in( ). Connect the other end with the voltagesource.

2. Once the FCU is supplied with voltage, the display willshow "HYDAC FCU 1210" in ticker format, after whichthe Firmware version will be displayed for 2 seconds.The internal sensors are subsequently checked.The self-test is followed in the display by a countdown

.

3. The FCU is now ready for the measurement.

As long as the pump is not running and no fluidis being pumped, the status LED will flash red,and the display will show . Thismeans that there is no oil flow present.

6.1.1 Disconnecting the power supplyTo remove the power supply, press the catch (1) on the con-nector and then pull (2) the connector out.

6 | Putting the FCU into operation HYDAC FILTER SYSTEMS GMBH

36 / 92 BeWa FCU1210 3545830b en-us lq

Fig. 16: Disconnectingthe power supply

HYDAC FILTER SYSTEMS GMBH Putting the FCU into operation | 6

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6.2 Plug in/Detach return hose

NOTICEClosed or blocked outlet at the connection OUTLET

The FCU can be damaged.

u Never seal the connection OUTLET.

u Put the free end of the OUTLET return hose into an un-pressurized container.

Fig. 17: Plug in returnhose

Fit the quick-action coupling on the return hose to the nipple.Make sure that the coupling snaps audibly into place on thenipple. Make sure that the quick-action coupling is firmlyseated.

Fig. 18: Detach returnhose

Put the other end of the return hose into a depressurized con-tainer or tank.

6 | Putting the FCU into operation HYDAC FILTER SYSTEMS GMBH

38 / 92 BeWa FCU1210 3545830b en-us lq

6.3 Selecting the measurement locationSelect the measurement location so that the sample measuredcomes from a turbulent location, with a good flow. For exam-ple: on a pipe bend (A). This ensures that a typical sample isanalyzed.

If the FCU is installed near the measurement point (B), avoiddelayed measurement results and sedimentation (particle de-posits in the line).

While installing the inlet hose INLET, make sure that no siphon(C) results.

HYDAC FILTER SYSTEMS GMBH Operation | 7

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7 OperationObserve the following notices during operation.

7.1 Overview of control panel/operating elementsThe following operating elements can be found on the controlpanel:

Fig. 19: Control panel/operating elements

1 Display of ISO, SAE, FLOW, DRIVE, Temp with key-board

4 ON / OFF switch for the internal pump5 3-pole connection for 24 V DC supply voltage7 Connection OUTLET8 Connection INLET

14 Fastener for the OUTLET connection when the case isclosed

7 | Operation HYDAC FILTER SYSTEMS GMBH

40 / 92 BeWa FCU1210 3545830b en-us lq

15 Holding-down device16 Bag for hoses and accessories


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7.1.1 Reading the display and operating the keyboardThe FCU has a display and additional LEDs for displayingcleanliness classes and temperature.

Fig. 20: Display

1 Status LED Status display Green / RedIn the event of a malfunc-tion, the status LED willshow red and flash ascode.

(Details regarding this canbe found in the "Finding /rectifying errors [} 76]"chapter)

2 Display Consists of a 6-digit dis-play and shows the se-lected measured values.

3 Measured variable Indicates the respectivemeasured variable pre-sented in the display, e.g.: ISO / SAE / Flow / OUT /Drive / Temp


42 / 92 BeWa FCU1210 3545830b en-us lq

The keyboard consists of two keys. These keys are used toscroll through the variables to be displayed.

Keyboard Description

Scroll through the display.

Tab. 8: Keyboard overview


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See also

2 Finding / rectifying errors [} 76]

7.1.2 Scrolling through the display

You can use the keys to scroll throughthe following displays.


44 / 92 BeWa FCU1210 3545830b en-us lq

See also

2 Finding / rectifying errors [} 76]

7.1.2.1 Displays with ISO.SAEThe 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. 9: Displays with ISO.SAE


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7.1.3 Displaying measured variablesThe measured variables supply you with information regardingthe degree of cleanliness, the water saturation and the temper-ature of the hydraulic system under investigation. The mea-surement variables ISO, SAE and NAS are calibrated. They in-dicate a measured value with an accuracy of ± ½ ISO code inthe calibrated range.

7.1.3.1 Measured variable - ISOThe measured variable is updated depending on the set mea-suring time. The presentation appears as a 3-digit ISO code.Example: ISO code 20.18.15

7.1.3.2 Measured variable - SAEThe measured variable is updated depending on the set mea-suring time. The presentation takes the form of a channel ofthe SAE class. Example: SAE class A = 13.4

7.1.4 Display service variablesThese values give you information about the determined flowand the light source power. The service variables are not cali-brated.

7.1.4.1 Service variable – FlowFlow contains the display indicating whether the flow is in thepermissible range. Example: Flow rate = OK

7.1.4.2 Service variable - DriveDisplay of the light source efficiency (1-100%) with which theContaminationUnit currently works. Example: Light source effi-ciency = 42%


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7.1.4.3 Service variable - TemperatureThe fluid temperature is measured indirectly via the housing.Example: Temperature = 37.8.


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7.1.5 Display FREEZEThe FREEZE function makes it possible for you to call up thelast 20 displayed values on the display. The active display isthen frozen in the set MTIME cycle.

The function is based on a volatile memory and means that thevalues can be called up only as long as the sensor is suppliedwith power and the sensor is in display FREEZE.

The measured values are automatically numbered, wherebythe highest incremental number represents the last measuredvalue. That means that when the memory is full (= 20 mea-sured values), the value 20 is the most recent and the value 1is the oldest.

If the memory exceeds 20 display values, the oldest entry willbe overwritten.

7.1.5.1 Starting FREEZETo activate or deactivate the history memory FREEZE , press

the two keys simultaneously. TheFREEZE function starts with the display of the most recentmeasured value.

Keys The following ap-pears in the display(1 sec)

The following appearsin the display (3 sec)

<->

<->

… <-> …


48 / 92 BeWa FCU1210 3545830b en-us lq

Keys The following ap-pears in the display(1 sec)

The following appearsin the display (3 sec)

<->

<->

7.1.5.2 Exiting FREEZEPress both buttons simultaneously to return to the current dis-play.

The monitor display jumps back to the presetdisplay.All of the values present in the FREEZE memoryare deleted.

You are returned automatically to the current display after 10times the value for M.TIME, or manually by pressing both ar-row keys simultaneously.


BeWa FCU1210 3545830b en-us lq 49 / 92

See also

2 Restarting/resetting [} 60]

7.2 Select the operating modes / measurement methodaccording to the pressure involvedAfter you have selected the measurement location accordingto the above-mentioned criteria, determine what the operatingpressure is at that location.

Select the measurement method suitable for the fluid to bemeasured and the prevailing operating pressure:

Pressure at themeasurement point

Operating mode / measurement method,for details, see

0 bar / 0 psi Measuring from unpressurized contain-ers [} 50]

1 … 45 bar /14 … 650 psi

Measuring oil up to max. 45 bar / 650 psi[} 53]

15 … 345 bar /217 … 5000 psi

Oil between 15 ... 345 bar / 217 ... Mea-suring 5000 psi [} 56]

Tab. 10: Selecting the operating mode / measurement method


50 / 92 BeWa FCU1210 3545830b en-us lq

See also

2 Measuring oil up to max. 45 bar / 650 psi [} 53]

2 Oil between 15 ... 345 bar / 217 ... Measuring 5000 psi[} 56]

2 Measuring from unpressurized containers [} 50]

7.2.1 Measuring from unpressurized containersFor the measurement of permissible oil from depressurizedcontainers, proceed as follows:

Required hoses: -Return hose

-Suction hose

Fig. 21: Operating mode - Measurement at 0 bar


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To guarantee valid and direct measurements,prime the FCU. To do this, draw in approx. 120 mlfluid via the inlet hose in order to completely fill thehydraulic circuit and the inlet hose.

If the FCU is not primed, an air-oil mixture at thestart of measurement will flow through the 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 andhoses, you need ≥ 300 ml of fluid.

Make sure that the following sequence is observed:

ü You have performed all of the steps listed in chapterPutting the FCU into operation [} 35].

1. Connect the suction hose (color: clear transparent) withthe INLET of theFCU.Place the other end of the suction hose (color: cleartransparent) into a depressurized container.

ð This completes the hydraulic installation.


52 / 92 BeWa FCU1210 3545830b en-us lq

2. Switch on the internal pump.

ð The FCU will start with the measurement.


BeWa FCU1210 3545830b en-us lq 53 / 92

See also

2 Putting the FCU into operation [} 35]

7.2.2 Measuring oil up to max. 45 bar / 650 psiFor the measurement of permissible oil up to a maximum of45 bar / 650 psi, proceed as follows:

WARNING

Hydraulic systems are under pressure


u The system must be depressurized before performing anywork on the product.

u If the pressurized connection is connected to the hydraulicsystem, oil will flow through the FCU.

u Make sure that the specified sequence is followed.

NOTICEIf the operating pressure exceeds 45 bar / 650 psi

The excess pressure will be discharged via port OUTLET



u When operating, always observe the permissible operatingpressure.

Required hoses: -Return hose

-High-pressure hose


54 / 92 BeWa FCU1210 3545830b en-us lq

Fig. 22: Operating Mode - Measurement ≤ 45 bar



1. Check the pressure at the measurement location. Theexisting 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 INLETconnection of the FCU (1).Rotate the measurement coupling clockwise (2) to theconnection and tighten it by hand.


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3. Connect the other end of the INLET pressure hose tothe measurement point of the system.


ð The hydraulic installation of the FCU is complete.The FCU will start with the measurement.


56 / 92 BeWa FCU1210 3545830b en-us lq

7.2.3 Oil between 15 ... 345 bar / 217 ... Measuring 5000psiFor the measurement of permissible oil up to 15 to 345 bar /217 … 5000 psi, proceed as follows:

WARNING

Hydraulic systems are under pressure


u The system must be depressurized before performing anywork on the product.

u If the pressurized connection is connected to the hydraulicsystem, oil will flow through the FCU.

u Make sure that the specified sequence is followed.

NOTICEOperating pressure exceeds 345 bar / 5000 psi

The excess pressure will be discharged via port OUTLET



u When operating, always observe the permissible operatingpressure.

Required hoses / adapters: Return hose

High-pressure hose

High-pressure adapter


BeWa FCU1210 3545830b en-us lq 57 / 92

Fig. 23: Operating mode - Measurement at 15 … 345 bar



1. Check the pressure at the measurement location. Theexisting 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.


58 / 92 BeWa FCU1210 3545830b en-us lq

3. Connect the entry hose (color: black) with the INLETconnection of the FCU (1).Rotate the measurement coupling clockwise (2) to theconnection and tighten it by hand.

4. Connect the other end of the INLET pressure hose tothe measurement point of the system.


ð The hydraulic installation of the FCU is complete.The FCU will start with the measurement.


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7.3 Performing MeasurementsTo carry out a measurement, observe the following sequence:

ü Preparing the FCU, see Putting the FCU into operation

[} 35]

ü Make the desired settings for the measurement, see Op-erating/Setting measuring menu

ü Select a corresponding operating mode for the pressure,see Select the operating modes / measurement method

according to the pressure involved [} 49]

1. Switch on the pump at the switch.The pump conveys the fluid for analysis through theFCU.

2. After the set measurement time, the result is shown onthe display, and the status LED lights up green perma-nently.

3. Switch the pump off after 4 minutes.

ð The measurement is complete.


60 / 92 BeWa FCU1210 3545830b en-us lq

7.4 Restarting/resettingTo restart or reset the FCU, remove the power supply to theFCU 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.


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7.5 Using the BatteryPack (accessory)With the BatteryPack, which is available as an accessory, youcan make the FCU independent of the electrical supply net-work. The technical details for the BatteryPack can be found inthe corresponding instructions.

Fig. 24: Using the BatteryPack

For operation with the BatteryPack, fit the connector into thesocket labeled DC IN of the FCU.

8 | Performing maintenance HYDAC FILTER SYSTEMS GMBH

62 / 92 BeWa FCU1210 3545830b en-us lq

8 Performing maintenanceCarry out the specified configuration, maintenance and inspec-tion work every six months or, at the latest, when an error mes-sage or malfunction makes it necessary.

WARNING

The hydraulic system is under pressure during operation


u The hydraulic system must 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 theyhave been properly secured.

8.1 Maintenance table

Dai

ly

Wee

kly

As re

quire

d

Additional information

9.1 FCU flushing 1

9.2 Cleaning the FCU 1

8.4.2 Cleaning / chang-ing the flow con-trol valve

2

1 - Operating personnel; 2 - Specialist personnel – Mechanical

HYDAC FILTER SYSTEMS GMBH Performing maintenance | 8

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8.2 Clean the suction strainer.

1x Wrench = 19 mm

Compressed air

The suction screen is fitted under the measurement pointunion at the INLET connection and protects the pump fromcontamination by coarse particles.

Clean the suction screen regularly. If the FCU is blocked orthere is no flow through the FCU, clean the suction screenwithout delay.

NOTICEOperation 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 follows:

ü Remove all of the hydraulic and electrical connections tothe FCU.

1. Loosen the INLET connector with a wrench ( = 19 mm) by turning it counterclockwise.


64 / 92 BeWa FCU1210 3545830b en-us lq

2. Unscrew the INLET connector manually, turning 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 theconnector is undamaged.Replace it if necessary.

7. Moisten the sealing ring (C) with fluid before screwing itinto place.


BeWa FCU1210 3545830b en-us lq 65 / 92

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 witha torque of 25 Nm.

ð The replacement / cleaning of the suction strainer is com-plete.


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8.3 Calibrating FCUCalibrate the FCU in accordance with ISO 9000 for devicemeasurement. We recommend a recalibration of the FCU atleast every 3 years.

For calibration, contact HYDAC Service; the locations in yourarea can be found on our homepage under www.hydac.com.



BeWa FCU1210 3545830b en-us lq 67 / 92

8.4 High-pressure adapter maintenanceCheck or clean the strainer and the flow control valve in thehigh-pressure adapter at regular intervals.

If the required flow through the FCU is not achieved, checkand clean the strainer and the flow control valve in accordancewith the following chapters.

Fig. 25: High-pressure adapter

8.4.1 Cleaning/changing the strainer

2x Wrench = 22 mm

1x screwdriver 9x1 mmor special tool (see chapter Finding accessories)

Clean this strainer (B) in the high-pressure adapter at least ev-ery six months, or more frequently if heavy soiling makes itnecessary.

Fig. 26: Cleaning / changing the strainer in the high pressure adapter

A Test pointB Strainer


68 / 92 BeWa FCU1210 3545830b en-us lq

D Screw connection

NOTICEOperation without a strainer

The flow control valve in the high-pressure adapter will bedamaged / destroyed

u Never use the high-pressure adapter without a strainer

u The suction strainer in the high-pressure adapter must becleaned regularly

1. Remove the measurement coupling (A) from the

threaded joint (D) with a wrench ( = 22 mm) by turn-ing it counterclockwise.Then unscrew the strainer (B) counterclockwise with ascrewdriver or the special tool (see chapter Finding ac-cessories).

2. Clean strainer (B) and then blow it out with compressedair.

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 dam-age. Replace it/them if necessary.

5. Screw in the coupling (A) in clockwise direction andtighten it to 25 Nm.

ð The cleaning / replacement of the strainer is complete.The high-pressure adapter is ready for operation.


BeWa FCU1210 3545830b en-us lq 69 / 92

8.4.2 Cleaning / changing the flow control valve

2x Wrench = 22 mm

1x special tool (see chapter Finding accessories)

The flow control valve regulates the flow to ap-prox. 0.55 … 0.7 l/min. If the necessary flow rate through thehigh-pressure adapter is not achieved, then the flow controlvalve will have to be cleaned or replaced.

Fig. 27: Cleaning / changing the flow control valve in the high pressureadapter

A Test pointB StrainerC Flow control valveD Screw connection


70 / 92 BeWa FCU1210 3545830b en-us lq

NOTICEWrong installation / wrong flow direction of the flow controlvalve

Flow control valve is not working

u Pay attention to the direction of flow when installing theflow control valve.

1. Remove coupling (A) using a wrench ( = 22 mm) byturning it counterclockwise out of the screw fitting (D).

2. Unscrew the strainer (B) counterclockwise with a screw-driver or the special tool (see Finding accessories chap-ter).

3. Clean strainer (B) and then blow it out with compressedair.

4. Also unscrew the flow control valve (C) counterclock-wise with a screwdriver or the special tool (see Findingaccessories chapter).

5. To install the new flow control valve (C), screw it firmlyclockwise into the union (D) with a screwdriver or thespecial tool.

6. Screw the strainer (B) clockwise into the union (D) usinga screwdriver or the special tool.

7. Then check the sealing ring on the coupling (A) for dam-age. Replace it if necessary.

8. Turn the coupling (A) in a clockwise direction and tightento 25 Nm.


BeWa FCU1210 3545830b en-us lq 71 / 92

ð The cleaning / replacement of the flow control valve iscomplete. The high-pressure adapter is ready for opera-tion.

9 | Rinsing / cleaning the FCU HYDAC FILTER SYSTEMS GMBH

72 / 92 BeWa FCU1210 3545830b en-us lq

9 Rinsing / cleaning the FCUThe FCU is a measurement device for determining fluid purity.In order to exclude the possibility of fluid mixing and the erro-neous measurement results that would ensue from this, de-fined (i.e. clean) starting conditions are required.

You will find details on rinsing the FCU and cleaning it on theoutside in the following.

9.1 FCU flushingFlush the FCU after each use, but at least daily, with cleanedmineral oil.

Rinse the FCU immediately if you have measured unfiltered oilor oil with a viscosity > 200 mm²/s or if the measured valuesseem unusually high or low.

NOTICEImpermissible flushing media

The FCU will be destroyed.

u Flush the FCU with low-viscosity mineral oils or mineraloil-based raffinates with flash points higherthan 55°C / 131°F.

u Never flush the FCU with universal thinners or other de-greasing fluids.

Flush the FCU as described below:

1. Put approx. 0.5 liters of filtered oil into a clean container.

HYDAC FILTER SYSTEMS GMBH Rinsing / cleaning the FCU | 9

BeWa FCU1210 3545830b en-us lq 73 / 92

2. Connect the return hose to the FCU and put the free endinto a container for the used fluid.

3. Mount the suction hose on the INLET connection of theFCU.Place the suction hose into the reservoir with filteredfluid.

4. Use the switch on the FCU to turn its pump on.

9 | Rinsing / cleaning the FCU HYDAC FILTER SYSTEMS GMBH

74 / 92 BeWa FCU1210 3545830b en-us lq

5. Purity values are displayed during the rinsing procedure.These values are not correct, but nonetheless shoulddrop during the flushing procedure.

6. Once the 0.5 liters have been sucked up, switch off thepump.

ð The FCU flushing procedure is complete. The FCU isready for operation.

HYDAC FILTER SYSTEMS GMBH Rinsing / cleaning the FCU | 9

BeWa FCU1210 3545830b en-us lq 75 / 92

9.2 Cleaning the FCUClean the control panel and the case with a clean, moist cloth.

NOTICEChemical or abrasive cleaning agents

The operating interface will be damaged/destroyed

u Use only water.

10 | Finding / rectifying errors HYDAC FILTER SYSTEMS GMBH

76 / 92 BeWa FCU1210 3545830b en-us lq

10 Finding / rectifying errorsThe following malfunctions / errors can occur during operation.

Disruption / error

LEDStatus-LEDDisplay

Status /Possible causes

Solution

LED: Off

Status LED:

Display:

Error code: -

No display

No function

Check the power supply to theFCU.

Contact the HYDAC ServiceDepartment.

LED: Green

Status LED

Display: (Example)

The FCU is ready for oper-ation.

You can take measurements.

LED: Red

Status LED:

Display:

The flow rate is too low. Check that the flow is between30 … 500 ml/min, as permit-ted.

Check whether the pump isrunning and whether the IN-LET connection is attached

Check/lean the suctionstrainer.

HYDAC FILTER SYSTEMS GMBH Finding / rectifying errors | 10

BeWa FCU1210 3545830b en-us lq 77 / 92

Disruption / error



Solution

LED: Red

Status-LED:

Display:

The flow is too high. Check that the flow is between30 … 300 ml/min, as permit-ted.

Check whether the pump isrunning and whether the IN-LET connection is attached

Check/lean the suctionstrainer.

Reduce the inlet pressure.

LED: Red

Status LED

Display:

It is currently not possibleto determine the cleanli-ness of the oil or its flowrate.

Check that the flow is between30 … 300 ml/min, as permit-ted.

Reduce the inlet pressure.

LED: Red

Status LED:

Display:

Error code: 3

The LED in the sensor isobscured.

There may be foam in themeasurement cell -> rinse theFCU, see FCU flushing [} 72].

If the fault recurs, contact HY-DAC service department.

LED: Red

Status LED:

Firmware error Restart the unit. See Restart-ing/resetting [} 60]


LED: Red

Status LED

General system error Restart the unit. See Restart-ing/resetting [} 60]

10 | Finding / rectifying errors HYDAC FILTER SYSTEMS GMBH

78 / 92 BeWa FCU1210 3545830b en-us lq

Disruption / error



Solution


LED: Red

Status LED:

Error during automatic ad-justment.

Wait for a few more measure-ment cycles.

LED: Red

Status LED:

Error in the measurementcell.

Restart the unit. See Restart-ing/resetting [} 60]


Tab. 11: List of disruptions/errors

HYDAC FILTER SYSTEMS GMBH Finding / rectifying errors | 10

BeWa FCU1210 3545830b en-us lq 79 / 92

See also

2 Restarting/resetting [} 60]

11 | Removing / Disposal HYDAC FILTER SYSTEMS GMBH

80 / 92 BeWa FCU1210 3545830b en-us lq

11 Removing / Disposal– Empty the product completely, including all of its compo-

nents, before decommissioning. Disconnect or remove theelectrical / hydraulic connections.

– Dispose of the packaging material in an environmentallyfriendly manner.

– Dispose of the fluid / operating medium that has beendrained in an environmentally friendly manner.

– After dismantling the product and separating its variousmaterials into categories, dispose of all parts in an envi-ronmentally friendly manner.

HYDAC FILTER SYSTEMS GMBH Attachment | 12

BeWa FCU1210 3545830b en-us lq 81 / 92

12 Attachment

12.1 Finding spare parts / accessoriesYou receive the following spare parts for the FCU.

Designation p/no. Image

High-pressure hose withscrewed 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 (forINLET port)

278475

Seal ring for measurementpoint union INLET (Ø 21mm, according to DIN3869)

607755

High-pressure adapter,complete

3364502

12 | Attachment HYDAC FILTER SYSTEMS GMBH

82 / 92 BeWa FCU1210 3545830b en-us lq


Suction strainer, 400 µm forhigh pressure adapter

3152786

Flow control valve for highpressure adapter

710389

Cover seal for case 3455429

Attachable bag for hoses,cables and accessories

3335656

Document bag 3377173

Operating and MaintenanceInstructions(this document)

3545830

Power adapter (without con-nector cable)Primary: 100-240 V ACSecondary: 24 V DC, 5A,Cable with 3-pole connec-tor, Length = 1.6 m

6059933

Connection cable for poweradaptorEuropean plug, Length = 2m

6008448

HYDAC FILTER SYSTEMS GMBH Attachment | 12

BeWa FCU1210 3545830b en-us lq 83 / 92


Connection cable for poweradaptorplug for England (UK), Length = 2 m

6008447

Connection cable for poweradaptorplug for USA,Length = 2 m

6008446

Connection cable for poweradaptorplug for Australia (AUS),Length = 2 m

6008449

Tab. 12: Locating spare parts

12.2 Finding a Customer Service teamThe contact data such as the telephone numbers, e-mail andmailing addresses for the hotline, product support, customerservice, branch offices, service partners for servicing, repairand spare parts can be found, always updated, at our home-page www.hydac.com.

HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15a, Werk 13 66450 Neunkirchen - Heinitz

Germany

Phone: +49 6897 509 883

Fax: +49 6897 509 324


Homepage: www.hydac.com

Tab. 13: Customer service in Germany

HYDAC TECHNOLOGY CORPORATION, HYCON Division 2260 City Line Road, Bethlehem, PA 18017 Lehig Valley, PA 118002-2050

USA


12 | Attachment HYDAC FILTER SYSTEMS GMBH

84 / 92 BeWa FCU1210 3545830b en-us lq

Phone: +1 610 231 0100

Fax: +1 610 231 0445


Homepage: www.hydacusa.com

Tab. 14: Customer service USA

HYDAC PTY LTD 109 Dohertys Road, P.O. Box 224 3025 Altona North

Australia

Phone: +61 392 728 900

Fax: +61 393 698 912


Homepage: www.hydac.com.au

Tab. 15: Customer Service Australia

HYDAC TECHNOLOGIA LTDA Estrada Fukutare Yida, 225 CEP 09852-060, Cooperativa, São Bernardo do Campo –SÃO PAULO

Brazil

Phone: +55 114 393 6600

Fax: +55 114 393 6617


Homepage www.hydac.com.br

Tab. 16: Customer Service Brazil

12.3 EC declaration of conformityThe CE declaration of conformity can be found in the TechnicalDocumentation that is part of the scope of delivery for theproduct.

HYDAC FILTER SYSTEMS GMBH Table of Illustrations

BeWa FCU1210 3545830b en-us lq 85 / 92

Table of Illustrations

Fig. 1 Overview / labeling of the title page ......................................................... 7

Fig. 2 Fire protection class B.............................................................................. 14

Fig. 3 Minimum distance for fire fighting............................................................. 14

Fig. 4 Light blockade procedure ......................................................................... 16

Fig. 5 Signal amplitudes ..................................................................................... 17

Fig. 6 Operating mode S3 – Periodic intermittent duty....................................... 19

Fig. 7 Model code............................................................................................... 24

Fig. 8 Dimensions............................................................................................... 28

Fig. 9 Hydraulic circuit ........................................................................................ 29

Fig. 10 Opening the FCU case............................................................................. 30

Fig. 11 Closing the FCU case .............................................................................. 30

Fig. 12 Function plan............................................................................................ 32

Fig. 13 Transporting the FCU............................................................................... 33

Fig. 14 Storing the FCU........................................................................................ 34

Fig. 15 Connecting the power supply ................................................................... 35

Fig. 16 Disconnecting the power supply............................................................... 36

Fig. 17 Plug in return hose ................................................................................... 37

Fig. 18 Detach return hose................................................................................... 37

Fig. 19 Control panel/operating elements ............................................................ 39

Fig. 20 Display...................................................................................................... 41

Fig. 21 Operating mode - Measurement at 0 bar ................................................. 50

Fig. 22 Operating Mode - Measurement ≤ 45 bar ................................................ 54

Fig. 23 Operating mode - Measurement at 15 … 345 bar.................................... 57

Fig. 24 Using the BatteryPack.............................................................................. 61

Table of Illustrations HYDAC FILTER SYSTEMS GMBH

86 / 92 BeWa FCU1210 3545830b en-us lq

Fig. 25 High-pressure adapter.............................................................................. 67

Fig. 26 Cleaning / changing the strainer in the high pressure adapter ................. 67

Fig. 27 Cleaning / changing the flow control valve in the high pressure adapter . 69

HYDAC FILTER SYSTEMS GMBH Index of Tables

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Index of Tables

Tab. 1 Impressum................................................................................................ 2

Tab. 2 Documentation Representative ................................................................ 2

Tab. 3 Scope of delivery ...................................................................................... 21

Tab. 4 Contamination sensor .............................................................................. 25

Tab. 5 Hydraulic data .......................................................................................... 25

Tab. 6 Electrical data........................................................................................... 26

Tab. 7 General data............................................................................................. 26

Tab. 8 Keyboard overview................................................................................... 42

Tab. 9 Displays with ISO.SAE ............................................................................. 44

Tab. 10 Selecting the operating mode / measurement method............................. 49

Tab. 11 List of disruptions/errors ........................................................................... 76

Tab. 12 Locating spare parts ................................................................................. 81

Tab. 13 Customer service in Germany.................................................................. 83

Tab. 14 Customer service USA ............................................................................. 83

Tab. 15 Customer Service Australia ...................................................................... 84

Tab. 16 Customer Service Brazil ........................................................................... 84

Glossary HYDAC FILTER SYSTEMS GMBH

88 / 92 BeWa FCU1210 3545830b en-us lq

Glossary

FCU

Abbreviation for "FluidControl Unit"

General Terms and Conditions

The General Terms and Conditionsare available at our home pagewww.hydac.com -> General Termsand Conditions.

High-pressure adapter

Adapter required for measurementwith the FCU for pressures of 15 -345 bar.

Viscosity range

Is the range in which the viscosity ofa pressurized fluid meets the re-quirements that have been set.

HYDAC FILTER SYSTEMS GMBH Index

BeWa FCU1210 3545830b en-us lq 89 / 92

Index

B

Branches 83

C

Cooling-down phase 19

D

decommissioning 80disposal 80Downtime 19Duty cycle 18

E

exclusion of liability 6

F

Flash point 18FREEZE 47

H

Hotline 83Hydraulic circuit 29

I

Imprint 2Intended use 18Intermittent duty 18

M

manufacturer 2

P

Periodic intermittent duty 19Person authorized with the documenta-

tion 2

S

Service 83Servicepartners 83Support 83

T

Terms and Conditions 6Terms of Delivery 6

U

Useful life 19

W

Warranty 6

Documents

FCU 1210 FluidControl Unit · rial contractual obligation, our liability shall be limited to fore-seeable damage. Claims due to the Product Liability shall re-main unaffected. Warranty2.1