FMS Series - HYDAC · FMS Series Safety Information and Instructions Training and Instruction of...

FMS Series FluidMonitoring System

Installation and Maintenance Instructions English (translation of original instructions)

Document No.: 3520000

FMS Series 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 express written consent of HYDAC Filter Systems GmbH. 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 GMBHPostfach 12 5166273 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: [email protected]

HYDAC FILTER SYSTEMS GMBH en(us) / 32

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FMS Series Content


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Content

Trademarks ...............................................................................................................2

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

Content......................................................................................................................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 FMS modification ..................................................................................................10 Training and Instruction of Personnel ...................................................................11 Dangers by pressure in the hydraulic system.......................................................11

Packing, storage.....................................................................................................12

Unpacking the FMS ..............................................................................................12 Storing the FMS....................................................................................................12

Checking the Scope of Delivery............................................................................13

FMS Features..........................................................................................................14

Restrictions pertaining to use ...............................................................................14

FMS-FMM-O… components...................................................................................15

FMS-FMM-P… components ...................................................................................16

Hydraulic diagram – FMS-FMM-O... ......................................................................17

Hydraulic diagram – FMS-FMM-P..........................................................................17

Installing the FMS...................................................................................................18

Dimensions – FMS-FMM-O …................................................................................19

Dimensions – FMS-FMM-P …................................................................................19

Hydraulic connection of the FMS..........................................................................20

Connecting FMS with the hydraulic system ........................................................21

Electrical connection of FMS ................................................................................22

Supplying the SensorMonitoring Unit SMU1200 with power ................................22 Connection cable, color code ...............................................................................22

FMS Series Content


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Error messages / Troubleshooting.......................................................................23

Performing Maintenance........................................................................................24

Changing the Filter Element (Only FMS-FMM-P…) .............................................25

Spare Parts List ......................................................................................................27

FMS-FMM-O… .....................................................................................................27 FMS-FMM-P…......................................................................................................28

Accessories ............................................................................................................29

Decommissioning the FMS....................................................................................29

Disposing of the FMS.............................................................................................29

Technical data ........................................................................................................30

FMS-FMM-O… .....................................................................................................30 FMS-FMM-P…......................................................................................................30

Customer Service...................................................................................................31

Model Code .............................................................................................................31

FMS Series 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 GMBHTechnische DokumentationPostfach 12 5166273 Sulzbach / Saar

Germany

We look forward to receiving your input.

“Putting experience into practice”


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FMS Series Preface


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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:

Fax: +49 (0) 6897 / 509 - 846


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.

http://www.hydac.com/

FMS Series 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.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

Chapter

Page number

Edition date

Document language Documentation no.with index/

file name

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.


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FMS Series Safety Information and Instructions


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Safety Information and Instructions

These installation instructions contain the most important information for operating the FMS in a proper, safe manner.

Obligations and Liability

The basic prerequisite for the safe and proper handling and operation of the FMS is knowledge of the safety precautions and regulations.

These installation instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the FMS.

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 FMS.

The FMS has been designed and constructed with state-of-the-art technology-and in accordance recognized safety regulations. Nevertheless, hazards may be posed to the life and limb of the individual using the product or to third parties. Risk of damage may be posed to the product or other equipment and property.

Use the FMS:

solely for its designated use

only when in a safe, perfect condition

Immediately remedy any malfunctions that might impair safety.

Our General Terms and Conditions apply. They are made available to the owner upon concluding 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 FMS or use deviating from its intended use

improper assembly, installation, commissioning, operation and maintenance of the FMS

operating the FMS when the system equipment or systems are defective

modifications to the FMS made by the user or purchaser

improper monitoring of product components subject to wear and tear

improperly performed repair work


Explanation of Symbols and Warnings, etc.

The following designations and symbols are used in these installation instructions to designate hazards, etc.:

DANGER DANGER denotes situations which can lead to death if safety precautions are not observed.

WARNING WARNING denotes situations which can lead to death if safety precautions are not observed.

CAUTION CAUTION denotes situations which can lead to severe injuries if safety precautions are not observed.

CAUTION NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

Proper/Designated Use

The FluidMonitoring System FMS was developed for the continuous monitoring of solid particle contamination in hydraulic systems.

Any other use shall be deemed to be improper and not in keeping with the product's designated use.

The manufacturer will not assume any liability for any damage resulting from such use.

Proper or designated use of the product extends to the following:

Observing all instructions in the installation instructions

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 flow hoses and oil leakage pipe.


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Informal Safety Precautions

Always keep the installation / maintenance instructions in the vicinity of the product.

In addition to the manual, the general and local regulations concerning accident prevention and protection of the environment should be available and observed.

Make sure to keep the safety and hazard symbols and warnings on the product in a legible condition.

Check the hoses and connection fittings for leakage daily (visual check). The electrical components of the FMS are to also be regularly checked (visual check once a month). Replace any loose connections or damaged cables immediately.

FMS modification

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

Immediately replace any unit components which are not in perfect condition.

Use only original spare parts. When using non-OEM components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements.


Training and Instruction of Personnel

The FMS 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 FMS unless supervised by an experienced staff member.

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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

Dangers by pressure in 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


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FMS Series Packing, storage


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Packing, storage

Unpacking the FMS

The FMS is inspected for leaks and proper functioning at the factory, then carefully packed for shipment. The connectors/ports are closed off so that no contamination can enter the unit while it is in transit.

When receiving and unpacking the unit check it for damage in transit. Report any damage to the forwarding agent immediately.

The packing material is to be disposed of as specified by law or national regulations. It can be reused .

Storing the FMS

Make sure to store the CSM in a clean, dry place.

Drain and rinse the FMS completely before putting it into extended storage.

FMS Series Checking the Scope of Delivery


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Checking the Scope of Delivery

Upon receiving the FMS check it for any damage in transit. Do not put the FMS into operation unless it is in perfect condition. Report any damages in transit to the transport company or the responsible agent immediately. Do not put the unit into operation.

The following items are included:

Item Qty. Description

- 1 FluidMonitoring System FMS

- 1 Power supply connection cable, length = 5 m

- 1

Technical Documentation, const. of:

- Installation and Maintenance Instructions FMS - Operating and Maintenance Instructions SMU 1200 - Operating and Maintenance Instructions AS 1000 - Calibration certificate of the CS1000

FMS Series FMS Features


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FMS Features

The FluidMonitoring System FMS combines HYDAC's Condition Monitoring Products ContaminationSensor CS1000 and AquaSensor AS1000 and the SensorMonitoring Unit in one system.

The FMS 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 SMU shows the cleanliness class and the fluid temperature as well as the relative humidity. These values are passed on via the signal output for further processing.

The FMS features all of the requisite connectors / adapters, enabling it to be easily connected to existing hydraulic circuits.

Depending on the version, the FMS is suitable for bypass flow and pressure circuits:

FMS-FMM-O… = 6 – 15 bar

FMS-FMM-P… = 15 – 300 bar

Advantages offered by the FMS:

Cost-effective solution

Early warning of critical machine states

Continuous fluid monitoring

Condition-based maintenance planning

Restrictions pertaining to use

CAUTION

Unpermitted operating media

The FMS will be destroyed

► The FMS is only to be used with mineral oils or mineral oil-based raffinates.

FMS Series FMS-FMM-O… components

FMS-FMM-O… components

Item Designation

1 SensorMonitoring Unit SMU 1200

2 ContaminationSensor CS1000 series

3 AquaSensor AS1000

4 Connection cable CS1000 <-> SMU1200

5 Connection cable AS1000 <-> SMU1200

A Inlet (IN)

B Outlet (OUT)

C Voltage supply

D Signal output CS1000

E Signal output AS1000

F USB A interface

G HSI interface

H Protective grounding


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FMS Series FMS-FMM-P… components

FMS-FMM-P… components

Item Designation

1 SensorMonitoring Unit SMU 1200

2 ContaminationSensor CS1000 series

3 AquaSensor AS1000

4 Connection cable CS1000 <-> SMU1200

5 Connection cable AS1000 <-> SMU1200

6 Filter element

A Inlet (IN)

B Outlet (OUT)

C Voltage supply

D Signal output CS1000

E Signal output AS1000

F USB A interface

G HSI interface

H Protective grounding


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FMS Series Hydraulic diagram – FMS-FMM-O...

Hydraulic diagram – FMS-FMM-O...

Hydraulic diagram – FMS-FMM-P...

CS

IN OUT

AS

TP1 TP2


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FMS Series Installing the FMS

Installing the FMS

NOTICE

Transmission of vibrations from the unit to the FMS

The FMS will be damaged

► Install the FMS with protection against vibrations.Use rubber dampers, for instance, if necessary.

For mounting the FMS on the wall, use 4 bore holes with Ø 10 mm.

Connect the protective grounding to the FMS at connection [H].


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FMS Series Dimensions – FMS-FMM-O …

Dimensions – FMS-FMM-O …

Dimensions – FMS-FMM-P …


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FMS Series Hydraulic connection of the FMS

Hydraulic connection of the FMS

To connect the hydraulics, use the test hoses of the 1604 range or G1/4 threaded connections as per DIN ISO 228.

FMS-FMM-O

FMS-FMM-P

IN = Pressure port connection

OUT = Return port connection


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FMS Series Connecting FMS with the hydraulic system

Connecting FMS with the hydraulic system


Bodily injury

► The hydraulic system must be depressurized before performing any work on the hydraulic system.

Connect the FMS 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 FMS. (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 FMS. (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.

7. The hydraulic installation of the FMS is complete.


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FMS Series Electrical connection of FMS

Electrical connection of FMS

Supplying the SensorMonitoring Unit SMU1200 with power

The scope of delivery includes the power supply cable for the SMU.

NOTICE

Contact of individual wires leads to short circuits

Connected sensors are destroyed

► Insulate and secure any open cable ends not required against inadvertent reciprocal contact

Connect the SMU to a source of power of 12 … 24 V DC as shown on the diagram. Use the cable supplied for this in the scope of delivery.

Connection cable, color code

Connect the connection cable for supply voltage contained in the scope of delivery in accordance with the following table:

Pin Color code Designation

1 Brown Voltage 12 … 24 V DC

2 White

3 Blue GND

4 Black

5 Gray

An appropriate plug-in mains adaptor is included with Article No: 3399939.


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FMS Series Error messages / Troubleshooting

Error messages / Troubleshooting

The following error messages may be displayed.

LED Blink code / Display / Analog output / Switch out

Status To do

- No function Not connected to power supply.

Check the electrical connection, the plug, cables and socket on the FMS.

Red

4.4 mA / 2.2 V*

open

Flow too low

Check flow

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.


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FMS Series Performing Maintenance

Performing Maintenance

WARNING Operating pressure

Bodily injury


The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in accordance with the respective schedules.

The unit is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance, servicing, inspection or repair work.

Once maintenance work is complete, check that the safety devices are still working properly. Any screwed fittings which have been undone/removed are to be checked to see that they have been properly resecured.

24 hrs. or

daily

500 hrs. or

monthly

3000 hrs. or

twice per year

Check for leaks X

Visual check of electrical equipment X

Change the filter element (Only FMS-FMM-P…) X


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Changing the Filter Element (Only FMS-FMM-P…)


Bodily injury


Item Designation

10 O-ring 10.77x2.62

20 Filter element 25 µm

30 O-ring 20x2

40 Support ring Ø 20

50 Screw plug


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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)

FMS Series Spare Parts List

Spare Parts List

FMS-FMM-O…

Item Part no. Qty Description

1 3467005 1 SensorMonitoring Unit SMU1260-TU-00

2 * 1 ContaminationSensor CS 1000

3 909109 1 AquaSensor AS 1000

4 3512828 1 Connection cable, CS <-> SMU

5 3475291 1 Connection cable, AS <-> SMU

- 3527626 1 SMU power supply cable * = on request


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FMS Series Spare Parts List

FMS-FMM-P…

Item Part no. Qty Description

1 3467005 1 SensorMonitoring Unit SMU1260-TU-00

2 * 1 ContaminationSensor CS 1000

3 909109 1 AquaSensor AS 1000

4 3475290 1 Connection cable, CS <-> SMU

5 3475291 1 Connection cable, AS <-> SMU

6 3348645 1 Filter element replacement set

- 3527626 1 SMU power supply cable * = on request


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FMS Series Accessories

Accessories

The following connection cables are available:

Connector female

↔ Cable ending open Length Part no.

8 ↔ 8 + Shield

2 m ZBE 42S-02 3281220

8 ↔ 8 + Shield

5 m ZBE 42S-05 3281239

5 ↔ 5 + Shield

5 m ZBE 47S-05 3484562

5 ↔ 5 + Shield

10 m ZBE 47S-10 3484564

Decommissioning the FMS

Proceed as follows to decommission the FMS:

1. Remove the plug to the SMU 1200.

2. Depressurize the system.

3. Remove the connected hoses/piping from the FMS.

4. Remove the FMS.

Disposing of the FMS

When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the oil contained in the unit, to components coated in oil and to electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.


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FMS Series Technical data


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Technical data

FMS-FMM-O…

Operating pressure 6 ... 15 bar / 87 ... 217 psi

Minimal differential pressure 1 bar, recommended ≥ 3 bar

Connectors (IN / OUT) Test point type 1604 or thread G 1/4 according ISO 228

Sealing material FPM

Permissible viscosity range 1 … 350 mm²/s

Fluid temperature range 0° … 85° C / 32° … 185° F

Ambient temperature range -30° … 80° C / -22° … 176° F

Storage temperature range -40° ... 80° C / -40° ... 176° F

Weight ~ 13 kg

FMS-FMM-P…

Operating pressure

= without accumulator 15 ... 300 bar / 217 ... 4350 psi

with accumulator 15 ... 250 bar / 217 ... 3625 psi

Differential pressure > 15 bar

Connectors (IN / OUT) Test point type 1604 / thread G¼ according ISO 228

Sealing material FPM

Permissible viscosity range 1 ... 1000 mm²/s

Fluid temperature range 0° ... 85° C / 32° ... 185° F

Ambient temperature range -30° ... 80° C / -22° ... 176° F

Storage temperature range -40° ... 80° C / -40° ... 176° F

Weight ~ 20 kg

FMS Series Customer Service


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Customer Service

HYDAC SERVICE GMBH Rehgrabenstrasse 3 66125 Saarbrücken -Dudweiler

Germany

Telephone: ++49 (0)681 509 883

Telefax: ++49 (0)681 509 324


Model Code

FMS - FMM-P - CS - AS - SMU12 - 00 /- 000

Product FMS = FluidMonitoring System

Hydraulic application FMM-O = Offline, bypass flow circulation < 15 bar)

FMM-P = Pressure Line, (pressure circuit > 15 bar)

ContaminationSensor CS = CS 1000 *

Z(CS) = Prepared for CS 1000

AquaSensor AS = AS 1000

Z(AS) = Prepared for AS 1000

SensorMonitoring Unit SMU12 = SMU 1200

Sensor combination number 01 = FMM-O-M-0-CS1310-A-AS-0-0-0/-000

SMU1260-TU-00/-000

02 = FMM-P-L-0-CS1310-A-AS-0-1-0/-000 SMU1260-TU-00/-000

Modification number 000 = Modification number

*) Type defined in sensor combination number

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: [email protected]

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