FMM-P-L Installation and Maintenance Instructions English (translation of original instructions) Document No.: 3493215
Trademarks Trademarks The trademarks of other companies are exclusively used for the products of those companies. Copyright 2010 by HYDAC FILTER SYSTMES GMBH all rights reserved All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filter Systems. Contraventions are liable to compensation. Exclusion of liability We made every endeavor to ensure the accuracy of the contents of this document. 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 technical modifications. Technical specifications are subject to change without notice. HYDAC FILTER SYSTEMS GMBH Postfach 12 51 66273 Sulzbach / Saar Germany Documentation Representative Mr. Günter Harge c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar Telephone: ++49 (0)6897 509 1511 Telefax: ++49 (0)6897 509 1394 E-mail: guenter.harge@hydac.com HYDAC FILTER SYSTEMS GMBH en Page 2 / 28
Contents Contents Trademarks...2 Documentation Representative...2 Contents...3 Preface...5 Customer Service...6 Modifications to the Product...6 Warranty...6 Using the Documentation...7 Safety Information and Instructions...8 Obligations and Liability...8 Explanation of Symbols and Warnings, etc....9 Proper/Designated Use...9 Improper Use...9 Informal Safety Precautions...10 Training and Instruction of Personnel...11 Safety Measures to Be Followed during Normal Operation...11 Maintenance, Servicing and Troubleshooting...12 Modifications to the FMM...12 Storing the FMM...12 Checking the Scope of Delivery...13 FMM Features...14 Restrictions Pertaining FMM-P-L-0-CS1xx0...15 Restrictions Pertaining FMM-P-x-1-CS1xx1...15 Continuously rotatable display...15 Hydraulic schematic...16 Dimensions...16 FMM components...17 Attaching the FMMP mechanically...18 FMM hydraulic installation...19 Connecting FMM with the hydraulic system...21 Error messages / Troubleshooting...22 Performing Maintenance...22 Maintenance interval...22 Changing the Filter Element...23 Decommissioning the FMM...24 HYDAC FILTER SYSTEMS GMBH en Page 3 / 28
Contents Disposing of the FMM...24 Spare Parts and Accessories...25 Technical data...26 Customer Service...26 Model Code...27 HYDAC FILTER SYSTEMS GMBH en Page 4 / 28
Preface Preface We have compiled the most important instructions for the operation and maintenance of our product for you, its user, in this documentation. It will acquaint you with the product and assist you in using it as intended in an optimal manner. Keep it in the vicinity of the product so it is always available. Note that the information on the unit's engineering contained in the documentation was that available at the time of publication.there may be deviations in technical details, figures, and dimensions as a result. If you discover errors while reading the documentation or have additional comments or suggestions, contact us at: HYDAC FILTER SYSTEMS GMBH Technische Dokumentation Postfach 12 51 66273 Sulzbach / Saar Germany We look forward to receiving your input. Putting experience into practice HYDAC FILTER SYSTEMS GMBH en Page 5 / 28
Preface Customer Service Contact our technical sales department if you have any questions on our product. When contacting us, please always include the model/type designation, serial no. and part-no. of the product: Telefax: ++49 (0)681 509-846 E-mail: filtersystems@hydac.com Modifications to the Product We would like to point out that changes to the product (e.g. purchasing additional options, etc.) may mean that the information in the operating instructions is no longer applicable or adequate. After modification or repair work that affects the safety of the product has been carried out on components, the product may not be returned to operation until it has been checked and released by a HYDAC technician. Please notify us immediately of any modifications made to the product whether by you or a third party. Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH. Refer to these at www.hydac.com General terms and conditions. HYDAC FILTER SYSTEMS GMBH en Page 6 / 28
Preface Using the Documentation Note that the method described for locating specific information does not release you from your responsibility of carefully reading these instructions prior to starting the unit up for the first time and at regular intervals in the future. 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 documentation has a table of contents at the beginning. There, I select the chapter I'm looking for and the corresponding page number. Chapter description Page number Edition date Documentation no. with index/ file name Document language The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index number is incremented upward by one number every time the manual is revised or changed. HYDAC FILTER SYSTEMS GMBH en Page 7 / 28
Safety Information and Instructions Safety Information and Instructions These operating instructions contain the key instructions for properly and safely operating the FMM. Obligations and Liability The basic prerequisite for the safe and proper handling and operation of the FMM is knowledge of the safety instructions and warnings. These operating instructions in general, and the safety precautions in particular, are to be adhered to by all those who work with the FMM. Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used. The safety precautions listed herein are limited solely to using the FMM. The FMM has been designed and constructed in accordance with the current 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. The FMM 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 Terms and Conditions apply. They are provided to the owner upon conclusion of purchase of the unit at the latest. Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes: improper use of the FMM or use deviating from its designated use improper assembly, installation, commissioning, operation and maintenance of the FMM modifications to the FMM made by the user or purchaser Improper monitoring of unit components that are subject to wear and tear Improperly performed repair work HYDAC FILTER SYSTEMS GMBH en Page 8 / 28
Safety Information and Instructions Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.: DANGER WARNING CAUTION NOTICE DANGER denotes situations which can lead to death if safety precautions are not observed. WARNING denotes situations which can lead to mortal injury if safety precautions are not observed. CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed. NOTICE denotes situations which can lead to property damage if safety precautions are not observed. Proper/Designated Use The FMM was developed for the continuous monitoring of particulate contamination and water content 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 improper and not in keeping with the product's designated use. Proper or designated use of the product extends to the following: Maintaining adherence to all the instructions contained herein. Performing requisite inspection and maintenance work. Improper Use Any use deviating from the proper/designated use described above is prohibited. Improper use may result in hazard to life and limb. Example of improper use: Improper connection of the pressure and return lines of the FMM. HYDAC FILTER SYSTEMS GMBH en Page 9 / 28
Safety Information and Instructions Informal Safety Precautions Always keep the operating instructions in the vicinity of the measurement unit. Apart from the operating instructions, any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance is to be maintained to them. Make sure to keep the safety and hazard symbols and warnings on the FMM in a legible condition. Check the hoses and connection fittings for leakage daily (visual check). The electrical components of the FMM are to also be regularly checked (visual check once a month). Replace any loose connections or damaged cables immediately. WARNING Hydraulic systems are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system. HYDAC FILTER SYSTEMS GMBH en Page 10 / 28
Safety Information and Instructions Training and Instruction of Personnel The FMM may only be operated by properly trained and instructed personnel. The areas of responsibility of your staff must be established in a clear-cut manner. Staff undergoing training may not use the FMM unless supervised by an experienced staff member. Individuals Personnel undergoing training Personnel with technical training/ engineering background Electrician Supervisor with the appropriate authority Activity Packing Transportation X X X Commissioning X X X Operation X X X X Troubleshooting/ locating the source of malfunction X X X Remedying of mechanical faults X X Remedying of electrical faults X X Maintenance X X X X Repair work X Decommissioning/storage X X X X Safety Measures to Be Followed during Normal Operation Do not operate the FMM unless all the safety devices function properly. The product is to be checked once a day for external damage and the proper functioning of the safety devices. HYDAC FILTER SYSTEMS GMBH en Page 11 / 28
Storing the FMM Maintenance, Servicing and Troubleshooting The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a timely fashion. Disconnect the FMM from the power supply and protect the entire system from being inadvertently switched on when performing maintenance, inspection or repair work. Check any screwed fittings which have been removed to see that they have been properly secured. Always check the product to see that it functions properly when performing maintenance and servicing work. Modifications to the FMM Do not make any modifications (design modifications, extensions) to the FMM without the prior consent of the manufacturer. Any modifications require written permission from HYDAC Filter Systems GmbH Immediately replace any machine components which are not in perfect condition. Use only original spare parts. Storing the FMM Store the FMM in a clean, dry place, in the original packing if possible. Do not remove the packing until you are ready to install the unit. Drain the FMM completely before putting it into storage. If necessary, rinse the FMM with n-heptane to prevent it from gumming up during storage. The cleaning agents and flushing oils used are to be handled and disposed of properly. HYDAC FILTER SYSTEMS GMBH en Page 12 / 28
Checking the Scope of Delivery Checking the Scope of Delivery The Fluid Monitoring Module FMM Unit comes packed and factory-assembled. Before starting up the FMM, check that the content of the package is complete. The following items are supplied: Item Qty. Description 1 1 2 1 Connector (female) with 8-pole, M12x1, shielded 3 1 Connector (female), 5-pole, M12x1-1 Operating and Maintenance Instructions FMM (this document) - 1 Operating and maintenance instructions AS1000-1 CD-ROM with: - Software CoCoS 1000 - Operation and maintenance instructions CS 1000-1 CD-ROM with FluMoS Light software - 1 Calibration certificate CS1000 HYDAC FILTER SYSTEMS GMBH en Page 13 / 28
FMM Features FMM Features The FMM-P-L Series combines HYDAC's Condition Monitoring Products ContaminationSensor CS 1000 and AquaSensor AS 1000 in one system. The FMM is used as a robust and stationary system for online measurement of solid particle contamination and water content in hydraulic and lubricant fluids (e.g. for the detection of leakages). The FMM features all of the requisite connectors / adapters, enabling it to be easily connected to existing hydraulic circuits. The FMM is suitable for the following operating pressures: FMM with pressure accumulator 15 250 bar FMM without pressure accumulator 15 300 bar Advantages offered by the FMM: Cost-effective solution Early warning of critical machine states Continuous fluid monitoring Condition-based maintenance planning HYDAC FILTER SYSTEMS GMBH en Page 14 / 28
FMM Features Restrictions Pertaining FMM-P-L-0-CS1xx0 NOTICE Impermissible operating fluid The module will be destroyed The FMM may only be used with mineral oils or mineral oil-based raffinates. Restrictions Pertaining FMM-P-x-1-CS1xx1 CAUTION Impermissible operating fluid The module will be destroyed The FMM may only be used with HDFR fluids (phosphoric acid esters, e.g. Skydrol, Fryquel, Hyjet). Continuously rotatable display The CS 1000 display can be continuously rotated by a total of 270. 180 counterclockwise and 90 clockwise. To rotate the display, grasp the cover plate with your hand and turn in the desired direction. No tools are required for rotating the display. HYDAC FILTER SYSTEMS GMBH en Page 15 / 28
Hydraulic schematic Hydraulic schematic Dimensions HYDAC FILTER SYSTEMS GMBH en Page 16 / 28
FMM components FMM components Item Description 1 FMM Installation block 2 ContaminationSensor CS 1000 series 3 Connector (female), 8-pole, M12x1 4 AquaSensor AS 1000 series 5 Connector (female), 5-pole, M12x1 6 Inlet (IN), with test connector type 1604 or G ¼ according to ISO 228r 7 Outlet (OUT), with test connector type 1604 or G ¼ according to ISO 228. 8 Test connection (TP1), test connector Type 1604 9 Test connection (TP2), test connector Type 1604 10 Pressure accumulator 11 Filter element (installed) HYDAC FILTER SYSTEMS GMBH en Page 17 / 28
Attaching the FMMP mechanically Attaching the FMMP mechanically We recommend installing the unit vertically, so that the flow direction is from bottom to top. When selecting the installation site, check the ambient conditions such as temperature, dust, water, etc. The CS features a protection rating of IP 67 according to DIN 40050 / EN60529 / IEC 529 / VDE 0470. Fastening can be carried out by means of the four holes in the connection stock with four M6 screws in accordance with ISO 4762 (minimum length 80 mm). HYDAC FILTER SYSTEMS GMBH en Page 18 / 28
FMM hydraulic installation FMM hydraulic installation WARNING Non-permitted operating pressure Bodily injury Note the maximum operating pressure of 300 bar. NOTICE The minimum differential pressure is < 15 bar If the minimum differential pressure is not given, measuring errors will occur. Always observe the minimum differential pressure of 15 bar To minimize measurement errors resulting from trapped air in the system, we recommend that the flow direction through the FMM is from bottom (IN) to top (OUT). The FMM comes delivered with four test connectors (Type 1604), one at the inlet (IN) and one at the outlet (OUT) port, as well as at the two testing points (TP1 / TP2). If the hydraulic connection is done via the connector thread G 1/4 according to ISO 228, the test connectors must be removed. HYDAC FILTER SYSTEMS GMBH en Page 19 / 28
FMM hydraulic installation HYDAC FILTER SYSTEMS GMBH en Page 20 / 28
Connecting FMM with the hydraulic system Connecting FMM with the hydraulic system WARNING Hydraulic systems are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system. Connect the FMM with the hydraulic system as follows: 1. Check the pressure at the measurement point. It must be within the permissible range. 2. The hydraulic system has to be completely depressurized. 3. First connect the return-flow line to the outlet port (OUT) of the FMM. (connector thread G1/4 ISO 228 or test connection 1604) We recommend an internal Ø 4 mm for the return line. 4. Now connect the other end of the return line to the system tank, for example. 5. Now connect the measurement line to the inlet port (IN) of the FMM. (connector thread G1/4 ISO 228 or test connection 1604) We recommend an internal Ø 4mm for the pressure line in order to prevent particle deposits. 6. Now connect the other end of the measurement line to the measurement point. The hydraulic installation of the FMM is complete. HYDAC FILTER SYSTEMS GMBH en Page 21 / 28
Error messages / Troubleshooting Error messages / Troubleshooting The following error messages may result when the CS 1000 is combined with the FMM manifold block. LED Blink code / Display / Analog output / Switch out Status To do Check flow Red 4.4 ma / 2.2 V* open Flow too low Increase inlet pressure or check outlet pressure at measurement point. p has to be at least 15 bar -> if OK, replace filter element. Red 19.9 ma / 9.95 V* open Flow specification not possible Sensor status is undefined Check flow If the oil quality is below the measurement limit (ISO 9/8/7), it may take several measurement cycles until measured values are displayed Increase inlet pressure or check outlet pressure at measurement point. p has to be at least 15 bar -> if OK, replace filter element. For other error messages, please refer to your CS 1000 operating and maintenance instructions. Performing Maintenance Maintenance interval Replace the filter element at least every six months. HYDAC FILTER SYSTEMS GMBH en Page 22 / 28
Performing Maintenance Changing the Filter Element WARNING Hydraulic systems are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system. Item Description 10 O-ring 10.77x2.62 20 Filter element 25 µm 30 O-ring 20x2 40 Support ring Ø 20 50 Screw plug HYDAC FILTER SYSTEMS GMBH en Page 23 / 28
Decommissioning the FMM When changing the filter element, proceed as follows: 1. Unscrew the screw plug (50) with an Allen wrench (size 10) by turning it counterclockwise, then remove it. 2. Remove the filter element. 3. Remove all old seals and gaskets under the filter element and at the screw plug. 4. Clean the dirt and oil from the screw plug (50) and the element mount bore using a clean absorbent, lint-free cloth. 5. Insert the O-ring (10) into the groove under the filter element in the block designated for that purpose. 6. Put the filter element (20) into the mount bore with the opening facing in the direction of the block. The shape of the bore centers the filter element. 7. Mount the support ring (40) and the O-ring (30) to the screw plug (50). Be sure to use the correct sequence and to mount cleanly and perfectly. 8. Wet the O-ring (30) and the support ring (40) with medium. 9. Turn the screw plug (50) clockwise manually, then tighten it with an Allen wrench (size 10). (Tightening torque: 8-10 Nm) Decommissioning the FMM To decommissioning the FMM, proceed according to the following steps: 1. Remove the electric plug to the CS1000 and AS1000. 2. Depressurize the system. 3. Remove the connected hoses/piping from the FMM. 4. Remove the FMM. Disposing of the FMM Dispose of the packaging material as appropriate for your area. When decommissioning and/or disposing of the FMM, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil in the unit, components 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. HYDAC FILTER SYSTEMS GMBH en Page 24 / 28
Spare Parts and Accessories Spare Parts and Accessories Description Qty Part no. Screws for securing the CS 1000 4 638229 Accumulator SBO 250-0.075 (40 bar gas pressure) 1 3331980 Screw coupling, Type 1604 4 629477 Filter element replacement kit (FPM), consisting of: - 2x O-ring, 1x support ring, 1x filter element Filter element replacement kit (EPDM), consisting of: - 2x O-ring, 1x support ring, 1x filter element 1 3348645 1 3523517 Description Qty Part no. Socket plug (female), 8-pin, M12x1, with screw clamp 1 3281243 Socket plug (female) with 2 m line, shielded, 8-pole, M12x1 Socket plug (female) with 5 m line, shielded, 8-pole, M12x1 Extension cable 5 m, socket plug (female) 8-pole, M12x1 / socket plug (male) 8-pole, M12x1 1 3281220 1 3281239 1 3281240 Socket plug (female), 5-pole, M12x1, with screw clamp 1 6049128 For more spare parts and accessories, please refer to the product documentation. HYDAC FILTER SYSTEMS GMBH en Page 25 / 28
Technical data Technical data Technical Data FMM Mounting position vertical, with the direction of flow from bottom to top. Operating pressure, maximum = without accumulator 15 300 bar / 217 3625 psi with accumulator 15 250 bar / 217 4350 psi Differential pressure > 15 bar Connectors (IN / OUT) Test point type 1604 / thread G¼ according ISO 228 Sealing material Permissible viscosity range Fluid temperature range Ambient temperature range Storage temperature range Weight FPM 1 1000 mm²/s 0 85 C / 32 185 F -30 80 C / -22 176 F -40 80 C / -40 176 F 12.5 kg For further technical details, please refer to the operating and maintenance manuals of the respective component. Customer Service Shipping address for calibration and repair: HYDAC SERVICE GmbH Rehgrabenstrasse, Werk 7 66125 Saarbrücken Dudweiler Telephone: ++49 (0)681 509-883 Telefax: ++49 (0)681 509-324 E-mail: service@hydac.com HYDAC FILTER SYSTEMS GMBH en Page 26 / 28
Customer Service Model Code Product FMM = Hydraulic application P = Pressure Line (pressure circuit > 15 bar) Sensor combination L = CS 1000 + AS 1000 + HydacLab* Seal 0 = FPM 1 = EPDM ContaminationSensor CS 1000 series CS1210 = ISO / SAE, without display (FPM) CS1220 CS1310 CS1320 CS1211 CS1221 CS1311 = ISO / SAE, with display (FPM) FMM - P - L - 0 - CS1220 - A - AS - 0-1 - 0 / 000 = ISO / SAE / NAS, without display (FPM) = ISO / SAE / NAS, with display (FPM) = ISO / SAE, without display (EPDM) = ISO / SAE, with display (EPDM) = ISO / SAE / NAS, without display (EPDM) CS1321 = ISO / SAE / NAS, with display (EPDM) Analogue interface on the CS 1000 A = 4 20 ma B = 0 10 V DC Additional sensor z = Without AS = AS 1000 Z(AS) = Prepared for AS 1000 Hydraulic accumulator 0 = Without 1 = Diaphragm accumulator SBO 250-0.075, 40 bar gas pressure (not available in EPDM) Filter 1 = Protective filter, 25 µm Options 0 = Without Modification number 000 = Modification number *) Set up for HydacLab HYDAC FILTER SYSTEMS GMBH en Page 27 / 28
HYDAC FILTER SYSTEMS GMBH Industriegebiet 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 E-Mail: filtersystems@hydac.com