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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]
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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
E-mail: [email protected]
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.
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
FMS Series Safety Information and Instructions
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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FMS Series Safety Information and Instructions
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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.
FMS Series Safety Information and Instructions
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.
Per
sonn
el
Indi
vidu
als
unde
rgoi
ng t
rain
ing
Indi
vidu
als
with
te
chni
cal
trai
ning
/eng
inee
ring
back
grou
nd
Ele
ctric
ian
Sup
ervi
sor
with
the
appr
opria
te a
utho
rity
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
WARNING Hydraulic systems are under pressure
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 hydraulic system must be depressurized before performing any work on the hydraulic system.
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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FMS Series Performing Maintenance
Changing the Filter Element (Only FMS-FMM-P…)
WARNING Hydraulic systems are under pressure
Bodily injury
► The hydraulic system must be depressurized before performing any work on the hydraulic system.
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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FMS Series Performing Maintenance
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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
E-mail: [email protected]
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]