FMMP Unit. FluidMonitoring Module Pressure Unit. Operating and Maintenance Instructions. English (translation of original instructions)

Transcription

1 FluidMonitoring Module Pressure Unit Operating and Maintenance Instructions English (translation of original instructions) Document No.: a

2 Trademarks Trademarks The trademarks of other companies are exclusively used for the products of those companies. Copyright 2008 by HYDAC Filtertechnik GmbH all rights reserved All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to compensation. Exclusion of liability We made every endeavour to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. We welcome any suggestions for improvements. All details are subject to technical modifications. Technical specifications are subject to change without notice. HYDAC Filtertechnik GmbH Industriegebiet D Sulzbach / Saar Germany Phone: ++49 (0) 6897 / Fax: ++49 (0) 6897 / HYDAC Filtertechnik GmbH en Page 2 / 28

3 Content Content Trademarks... 2 Content... 3 Technical Support... 5 Modifications to the Product... 5 Warranty... 5 Using the documentation... 6 General Safety Guidelines... 7 Obligations and Liability... 7 Explanation of Symbols and Warnings... 7 Basic Symbols... 8 Proper/Designated Use... 8 Improper Use... 8 Informal Safety Precautions... 9 Safety Measures to Be Followed during Normal Operation... 9 Modifications to the FMMP Unit... 9 Training and Instruction of Personnel Maintenance, Servicing and Troubleshooting Checking the scope of delivery FMMP Unit Properties Storing the FMMP Unit Construction Restrictions Pertaining to the CS Dimensions Hydraulic schematic Hydraulic Installation Regulating the Flow Rate Electrical Installation Connecting the FMMP Unit to Your System Disconnecting the FMMP Unit from Your System Error Messages Performing maintenance Maintenance Intervals Changing the Filter Element Disposing of the FMMP Unit Spare Parts List Accessories list Technical details Customer Service HYDAC Filtertechnik GmbH en Page 3 / 28

4 Content Preface For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance. It is intended to help you become acquainted with the ins and outs of the product and use it properly. You should keep it in the vicinity of the product so it is always at your fingertips. Sometimes the information contained in the documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting-edge. Consequently, there might be deviations in technical details, illustrations and dimensions. If you discover errors while reading the documentation or have suggestions or other useful information, please don t hesitate to contact us: HYDAC Filtertechnik GmbH Division Service technology / Filter systems Technical Documentation Department Postfach Sulzbach/Saar - Germany Fax: ++49 (0) filtersysteme@hydac.com The editor would welcome your involvement. Our motto: Putting experience into practice HYDAC Filtertechnik GmbH en Page 4 / 28

5 Content Technical Support If you have any questions, suggestions, or encounter any problems of a technical nature, please don't hesitate to contact us. When contacting us, please always include the model/type designation and article no. of the product: Fax: ++49 (0) filtersysteme@hydac.com Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient. When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative. Please notify us 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 Conditions of Sale and Delivery of HYDAC Filtertechnik GmbH. They are available at: Legal information. HYDAC Filtertechnik GmbH en Page 5 / 28

6 Content 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 you want to know? I determine which topic I am looking for. WHERE can I find the information I m looking for? The document has a table of contents at the beginning. I select the chapter I'm looking for and the corresponding page number. Product description / Chapter heading 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 is incremented by one number every time the manual is revised or changed. HYDAC Filtertechnik GmbH en Page 6 / 28

7 General Safety Guidelines General Safety Guidelines These operating instructions contain the key instructions for properly and safely operating the FMMP Unit. Obligations and Liability The basic prerequisite for the safe and proper handling and operation of the FMMP Unit is knowledge of the safety instructions and warnings. These operating instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the FMMP Unit. Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the MRF is used. The safety precautions listed herein are limited solely to using the FMMP Unit. The FMMP Unit has been designed and constructed in accordance with the current state of the art and recognized safety regulations Nevertheless, hazard may be posed to the life and limb of the individual using the product or to third parties. The FMMP Unit is only to be used as follows: for the specified correct usage 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 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 FMMP Unit or use deviating from its designated use improper assembly, installation, commissioning, operation and maintenance of the FMMP Unit Modifications to the FMMP Unit made by the user or purchaser Improper monitoring of unit components that are subject to wear and tear improperly performed repair work Explanation of Symbols and Warnings The following designations and symbols are used in this manual to designate hazards, etc.: HYDAC Filtertechnik GmbH en Page 7 / 28

8 General Safety Guidelines Basic Symbols 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 death 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 FluidMonitoring Modul Pressure FMMP Unit (FMMP Unit) was developed for the continuous monitoring of particulate contamination in hydraulic systems. Analyzing the type, 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 FMMP Unit pressure and return flow lines. HYDAC Filtertechnik GmbH en Page 8 / 28

9 General Safety Guidelines Informal Safety Precautions Make sure to always keep the operating instructions in the vicinity of the product. 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 to be maintained to them. All safety guidelines and hazard warnings on the FMMP Unit must be maintained in legible condition and replaced as required. The hoses and connection fittings are to be checked daily for leakage (visual check). Any loose connections or damaged cables are to be replaced immediately. WARNING Hydraulic systems are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system Safety Measures to Be Followed during Normal Operation Do not operate the FMMP Unit 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. Modifications to the FMMP Unit Do not modify the design of the FMMP Unit without the prior consent of the manufacturer. Any design modifications or extensions may not be made without HYDAC Filtertechnik GmbH s express prior written approval. Immediately replace any machine components which are not in perfect condition. Only use original (OEM) spare parts and consumables. 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. HYDAC Filtertechnik GmbH en Page 9 / 28

10 General Safety Guidelines Training and Instruction of Personnel The FMMP Unit 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 FMMP Unit unless supervised by an experienced staff member. Individuals Individuals undergoing training Individuals with technical training/engineerin g 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 Maintenance, Servicing and Troubleshooting The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a timely fashion. All operating media is to be protected/isolated for the event that the product is accidentally started up. The FMMP is to be disconnected from th epower supply, depressurized and protected against being inadvertentlly swichted back on when perfoming any maintenance, servicing, inspection or repair work. Any screwed fittings which have been undone/removed are to be checked to see that they have been properly resecured. Always check the unit to see that it functions properly when performing maintenance and servicing work. HYDAC Filtertechnik GmbH en Page 10 / 28

11 FMMP Unit Checking the scope of delivery Checking the scope of delivery The FluidMonitoring Module Pressure FMMP Unit comes packed and factoryassembled. Before commissioning the FMMP UNit, check the contents of the consignment to make sure everything is present. The following items are supplied: Item Qty Description 1 1 FluidMonitoring Module Pressure Unit FMMP Unit 2 1 Connector with 2 m cable, coupling receptacle, 8-pin, M12x1 <-> Jack socket, Ø 3.5 mm, 2-pin 3 1 PVC pouch for storing the connector cable 4 1 Operating and Maintenance Instructions FMMP Unit (this document) 5 1 CD-ROM contained: - Operating and maintenance instructions CS Operating Manual CoCoS CoCoS 1000 Software 6 1 Calibration certificate CS 1000 HYDAC Filtertechnik GmbH BeWa FMMP-Unit a en.doc en Page 11 /

12 FMMP Unit Properties FMMP Unit Properties The FluidMonitoring Module Pressure FMMP is a rugged, mobile system for the online measurement of particulate contamination in hydraulic fluids. The FMMP Unit features all of the required connectors / adapters, enabling it to be easily connected to existing hydraulic circuits via the measurement coupling. Typical applications of the FMMP Unit are pressure circuits between bar. Advantages offered by the FMMP unit: o Mobility of the system o Warning in the case of critical machine states o Continuous fluid monitoring o Condition-based maintenance planning o FMMP integrated in a stable case o Comes ready-to-use including measurement lines Storing the FMMP Unit Make sure to store the FMMP Unit in a clean, dry place, in the original packing, if possible.do not remove the packing until you are ready to install the unit. Completely drain the FMMP Unit before it is put into storage for an extended period of time (flush with n-heptane if necessary) to prevent it from gumming up. HYDAC Filtertechnik GmbH en Page 12 / 28

13 Storing the FMMP Unit Construction Item Description 1 Case 2 FMMP (FMMP installation block with CS 1000) 3 Filter element mount 4 High pressure hose (IN) with Test connection type Return line hose (OUT) with test connector type Connector cable, length = 2 m with 8-pin coupling plug, M12x1 and 2-pin coupling plug, Ø 3.5 mm 7 FMMP retaining plate with hose mount HYDAC Filtertechnik GmbH en Page 13 / 28

14 Storing the FMMP Unit Restrictions Pertaining to the CS Non-permissible operating fluid The unit will be damaged. NOTICE The Unit may only be used with mineral oils (or raffinates whose basis is mineral oil). Dimensions Open closed Hydraulic schematic HYDAC Filtertechnik GmbH en Page 14 / 28

15 Hydraulic Installation Hydraulic Installation Direction of flow through the FMMP Unit from (IN) to (OUT). Determine the system pressure of the hydraulic system and see whether it is within the permissible range for the IN port. Measurement errors may result when the pressure drops below the minimum differential pressure of 15 bar. WARNING Non-permitted operating pressure Bodily injury The maximum operating pressure of 300 bar may not be exceeded. Regulating the Flow Rate The flow rate through the FMMP Unit is controlled by the integrated flow control valve and regulated to the measurement volume of the CS1000. HYDAC Filtertechnik GmbH en Page 15 / 28

16 Electrical Installation Electrical Installation First connect the power cable to the power supply ( 9 36 V DC) via the 2-pin jack socket Ø 3.5 mm (A), then plug it into the 8-pin jack (B) on the CS and screw it tight. The polarity of the jack plug can be found by referring to the diagram below. HYDAC Filtertechnik GmbH en Page 16 / 28

17 Connecting the FMMP Unit to Your System Connecting the FMMP Unit to Your System CAUTION Oil flows after connection to a power cable Bodily injury Connect the FMMP Unit in accordance with the sequence described no below. Mounting the FMMP Unit to your system as follows: 1. First open the case, Carefully remove the hydraulic connector lines from the retaining mounts inside the case. The hoses may not be buckled. Replace any damaged hoses immediately. The high-pressure connector is indicated by a red marking. HYDAC Filtertechnik GmbH en Page 17 / 28

18 Connecting the FMMP Unit to Your System 3. No pressure whatsoever may be present at the return-flow connection port. The hydraulic system must be completely depressurized. 4. Connect the hydraulic OUT port to a non-pressurized connector of the reservoir (e.g. with the system tank of the hydraulic system) or an external collection receptacle. Check the pressure at the measurement site. It must be within the permissible range of bar. The system fluctuations during measurement operation may not exceed 20 bar (machine in standby). Connect the high-pressure line (IN, with the red marking) with the type 1620 test connector on the hydraulic system. 5. First connect the electric connector cable to the power supply ( 9 36 V DC) via the 2-pin jack socket, then plug it into the 8-pin jack on the CS and screw it tight. The display of the CS begins to light up and the unit is autotest mode. The CS begins measurement operation once this is completed. Stable measured values aren't obtained until after several measurement cycles. HYDAC Filtertechnik GmbH en Page 18 / 28

19 Disconnecting the FMMP Unit from Your System Disconnecting the FMMP Unit from Your System CAUTION Oil flows after connection to a power cable Bodily injury Connect the FMMP Unit in accordance with the sequence described no below. Dismounting the FMMP Unit from your system as follows: 1. First disconnect the electric power cable from the power supply via the 2- pin jack socket, then unscrew it from the 8-pin jack on the CS and remove it Slight quantities of oil may exit, consequently the tank line should not be completely depressurized. Disconnect the high-pressure line (IN, with the red marking) from the test connector on the hydraulic system. Seal off the suction connector with the attached dust cap. No pressure whatsoever may be present at the connection port. The hydraulic system must be completely depressurized. Disconnect the OUT hydraulic connector from the test connector on the hydraulic system. HYDAC Filtertechnik GmbH en Page 19 / 28

20 Disconnecting the FMMP Unit from Your System Seal off the suction connector with the attached dust cap. 4. Roll up the hydraulic connector lines and place them in the case. Make sure that the hose connectors are sealed off using the attached dust cap. This ensures that the connectors are protected against the ingress of dirt and contamination and exiting fluid. 5. Affix the hydraulic connector lines at their designated place inside the case. The electric cable has to be stored in the protective pouch so that no oil gets on it. Before closing the case, make sure that no connection fittings, lines, plugs, cables, etc. damage the CS Close the case and secure it using the two latches. HYDAC Filtertechnik GmbH en Page 20 / 28

21 Error Messages Error Messages The following error messages may result when the CS 1000 is combined with the FMMP installation block. LED Blink code / Display / Analog output / SwitchOut Status To do Ensure that the flow is between ml/min. Red 4.4 ma / 2.2 V* Open Flow too low Increase inlet pressure or check outlet pressure on test point. Δ p must amount to a minimum of 15 bar -> if OK, change filter element. Red 19.9 ma / 9.95 V* Open Flow definition not possible The Sensor status definition not possible Check flow. Is the oil cleanliness below the measurement limit (ISO 9/8/7), it can take a few measuring cycles until contamination values will be displayed Increase inlet pressure or check outlet pressure on test point. p Δ must amount to a minimum of 15 bar -> if OK, change filter element. For other error messages, please refer to your CS 1000 operating and maintenance manual. HYDAC Filtertechnik GmbH en Page 21 / 28

22 Performing maintenance Performing maintenance Maintenance Intervals Monthly Every 6 Months Annually Rinsing out the FMMP Unit X Changing the Filter Element X 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 The existing connections are to be removed in accordance with the following sequence before replacing the filter element: 1. Supply voltage for the CS High pressure line 3. Return-flow line HYDAC Filtertechnik GmbH en Page 22 / 28

23 Performing maintenance Item Description Fig O-ring 10.77x Filter element 25 µm 30 Support ring Ø O-ring 20x 2 50 Srcew plug Proceed as follows to replace the filter element: 1. Undo the screw plug (50) by turning it in a counterclockwise direction using an Allen wrench (size 10), and remove it. 2. Remove the filter element. 3. Remove all old seals and gaskets (underneath the filter element and on the screw plug). 4. Clean the dirt and oil off the screw plug (50) and the element mount bore using an absorbent, lint-free cloth. 5. Insert the small O ring (10) in the groove designated for that purpose, underneath the element in the block. 6. Insert the filter element (20) in the mount bore with the opening facing in the direction of the block.the filter element is centered by virtue of the shape of the bore. 7. Mount the supporting ring (40) and the O-ring (30) to the screw plug (50) in accordance with Fig. 1. Be sure to use the correct sequence and configuration and to mount cleanly and perfectly. 8. Apply medium to the the O-ring (30) of the screw plug (50). 9. Insert the screw plug (50) and turn it by hand in a clockwise direction. Then tighten it using an Allen wrench (size 10) with a maximum torque of 8-10 Nm. HYDAC Filtertechnik GmbH en Page 23 / 28

24 Disposing of the FMMP Unit Disposing of the FMMP Unit The packing material is to be disposed of as specified by law or national regulations. It can be reused. When decommissioning and/or disposing of the FMMP Unit, adherence is to be maintained to 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 electronic components. After disassembling the unit and separating the various materials, they can be reused or disposed of properly in accordance with local regulations. Spare Parts List Description Qty HYDAC Part no. HUSKY Part no. ContaminationSensor (CS1220-A /-010) Connector cable, 2 m, with coupling receptacle, 8-pin, M12x1 <-> 2-pin, jack socket Ø 3.5 mm Screws for securing the Contamination Sensor O-ring between CS and installation block Flow control valve, 0.3 l/min High-pressure hose DN 2, length = 2 m Return hose DN 2, l=2m Screw plug for filter element Filter element kit, consist of: - 2x o-ring, 1x support ring, 1x filter element Operating and maintenance instructions "Getting started" guide Pocket for documents, self-adhesive * available on request HYDAC Filtertechnik GmbH en Page 24 / 28

25 Accessories list Accessories list Description Qty Part no. Connector 8-pole, M12x1, with screw clamp Connector with 2 m cable, shielded, 8-pin, M12x Connector with 5 m cable, shielded, 8-pin, M12x Extension cable 5 m, socket 8-pole, M12x1 / plug 8-pole, M12x For more spare parts and accessories, please refer to the product documentation. Technical details Technical details FMMP Unit Operating pressure Minimal different pressure Pressure fluctuations bar / psi 15 bar 20 bar max. (in measurement mode) Connectors Test connector type 1620 Sealing material Permissible measuring flow rate Permissible viscosity range Fluid temperature range Ambient temperature range Weight FPM ml/min mm²/s C / F C / F 7.8 kg For further technical details, please refer to the operating and maintenance manuals of the respective component. HYDAC Filtertechnik GmbH en Page 25 / 28

26 Customer Service Customer Service Shipping address for calibration and repair: HYDAC Service GmbH Product Support, Werk 10 Hauptstraße 27 D Saarbrücken Gersweiler, Germany Telephone: ++49 (0) 681 / HYDAC Filtertechnik GmbH en Page 26 / 28

27 Notes

28 HYDAC Filtertechnik GmbH Bereich Servicetechnik / Service Technology Division Industriegebiet Postfach Sulzbach/Saar Sulzbach/Saar Germany Germany Tel: +49 (0) Fax: +49 (0) Technical Department Fax: +49 (0) Sales Department Internet: filtersysteme@hydac.com