FMMP. FluidMonitoring Module Pressure. Operating and Maintenance Instructions. English (Translation of original manual) Documentation no.

Transcription

1 FluidMonitoring Module Pressure Operating and Maintenance Instructions English (Translation of original manual) Documentation no.:

2 Safety Guidelines and Instructions Trademarks The trademarks of other companies designate the products of those companies exclusively. Copyright 2009 by HYDAC Filter Systems 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 have made every endeavor to ensure the accuracy of the content of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist in this document nor for any damage or loss whatsoever which may arise as a result of such errors. The information in this manual is checked regularly and the required corrections shall be contained in subsequent editions. We welcome any suggestions for improvement. We reserve the right to make technical changes. All content of this manual is subject to revision without notice. HYDAC Filter Systems GmbH Industriegebiet Sulzbach / Saar Germany Telephone: ++49 (0) 6897 / Fax: ++49 (0) 6897 / HYDAC Filter Systems GmbH en Page 2 / 28 BeWa en doc

3 Safety Guidelines and Instructions Content Preface...4 Customer service...5 Product modification...5 Warranty...5 Using the documentation...6 Safety Guidelines and Instructions...7 Obligations and liability...7 Explanation of symbols and notes...8 Intended use...8 Improper use...8 Informal safety precautions...9 Personnel training and instruction...10 Safety precautions for normal operation...10 Maintenance, servicing and troubleshooting...11 Modifications to the Unit...11 Storing the...11 Checking the scope of delivery...12 Technical specifications...13 components...14 Restrictions pertaining to use...14 Dimensions...15 Hydraulic schematic...15 Attaching the mechanically...16 CS display continuously variable...16 Hydraulic connection of the FMM...17 Connecting the to Your System...18 Error messages / Troubleshooting...19 Performing maintenance...20 Changing the Filter Element...20 Decommissioning...22 Disposing of the...22 Spare parts and accessories...22 Spare parts...22 Accessories...23 Technical details...23 Customer service...24 HYDAC Filter Systems GmbH en Page 3 / 28 BeWa en doc

4 Safety Guidelines and Instructions 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 refers to its status 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 Sulzbach / Saar Germany Fax: ++49 (0) 6897 / filtersystems@hydac.com The editorial board would welcome your contributions. Putting experience into practice HYDAC Filter Systems GmbH en Page 4 / 28 BeWa en doc

5 Safety Guidelines and Instructions 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 / filtersystems@hydac.com Product modification 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. Report any modifications carried out on the product by you or a third party immediately. Warranty We assume warranty in accordance with the General Terms of Sale and Delivery of HYDAC Filter Systems GmbH. Refer to these at General terms and conditions. HYDAC Filter Systems GmbH en Page 5 / 28 BeWa en doc

6 Safety Guidelines and Instructions 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 the 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 no. with index is used for identifying and reordering the instructions. The index is incremented every time the manual is revised or changed. HYDAC Filter Systems GmbH en Page 6 / 28 BeWa en doc

7 Safety Guidelines and Instructions Safety Guidelines and Instructions These operating instructions contain the most important notes for operating the safely. Obligations and liability The basic prerequisite for the safe handling and trouble-free operation of the is knowledge of the basic safety guidelines and regulations. These operating instructions, and the safety guidelines in particular, are to be observed by all those who work with the. In addition, adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used. The safety guidelines listed here are restricted to the use of the. The has been designed and constructed in accordance with the technical state of the art and recognized safety rules and regulations. Nevertheless, hazards may be posed to the life and limb of the individual using the product or to third parties, and risk of damage may be posed to the product or other equipment and property. Use the : Solely for its intended use Only when in safe, perfect condition. Immediately remedy any malfunctions that might impair safety. 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 injury and damage to property shall be excluded in the event they are attributable to one or more of the following causes: Use of the deviating from its intended use Improper assembly/installation, start up, operation and maintenance of the Unauthorized modification of the Improper monitoring of unit components that are subject to wear and tear Improperly performed repair work HYDAC Filter Systems GmbH en Page 7 / 28 BeWa en doc

8 Safety Guidelines and Instructions Explanation of symbols and notes The following designations and symbols are used for hazards and warnings in this manual: 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 instructions are not followed. Intended use The FluidMonitoring Module Pressure was developed to monitor particulate contamination in hydraulic systems. By determining the type, size and quantity of contamination, quality standards can be verified and documented, and the required optimization measures can be implemented. Any other use shall be deemed not in keeping with the product's intended use. The manufacturer is not liable for any damage resulting from this use. Intended use of the product also includes: Maintaining adherence to all the instructions contained herein. Performing requisite inspection and maintenance work. Improper use Any use other than described above is prohibited. Hazards may result from improper use. Examples of improper use: Improper connection of the pressure and return flow lines. HYDAC Filter Systems GmbH en Page 8 / 28 BeWa en doc

9 Safety Guidelines and Instructions Informal safety precautions Always keep the operating instructions in the vicinity of the device. In addition to the operating instructions, the general and local regulations on accident prevention and environmental protection are to be made available and observed. Make sure that the safety and hazard symbols and warnings are always in a legible condition. Check the hoses and connection parts for leaks on a daily basis. 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 9 / 28 BeWa en doc

10 Safety Guidelines and Instructions Personnel training and instruction The 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. Trainees may only use the when supervised by an experienced individual. Individuals Individuals undergoing training Individuals with technical training Electricians Supervisors with required expertise Activity Packing Transport X X X Start up X X X Operation X X X X Troubleshooting X X X Remedying mechanical faults X X Remedying electrical faults X X Maintenance X X X X Repair work X Decommissioning/storage X X X X Safety precautions for normal operation Do not operate the unless all the safety devices function properly. Check the product for visible damage and properly functioning safety equipment at least once a day. HYDAC Filter Systems GmbH en Page 10 / 28 BeWa en doc

11 Storing the Maintenance, servicing and troubleshooting Conduct the specified setting, maintenance and inspection work according to schedule. Protect all operating media from accidental start up. When performing maintenance, inspection or repair work, disconnect the from the power supply and protect the entire system from being inadvertently switched on. Make sure that all screwed fittings which have been undone/ removed are secured. After carrying out maintenance and work, always check that the safety equipment is functioning properly. Modifications to the Unit Do not modify the design of the 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. Only use original spare parts and consumables. Storing the Store the in a clean, dry place, in the original packing if possible. Do not remove the packing until you are ready to install the unit. C ompletely drain the before it is put into storage for an extended period of time (flush with n-heptane if necessary) to prevent it from gumming up. Properly dispose of the cleaning agents and flushing oils used. HYDAC Filter Systems GmbH en Page 11 / 28 BeWa en doc

12 Checking the scope of delivery Checking the scope of delivery The Fluid Monitoring Module Pressure arrives packed and ready for operation. Before commissioning the, please check no items are missing from the package. The following items are included: Item Pc. Description 1 1 FluidMonitoring Module Pressure 2 1 Socket plug, 8-pole, M12x1, screened 3 1 CD with: - CoCoS 1000 PC software package and - Operating instructions CoCoS Operating and maintenance instructions CS Operating and Maintenance Instructions (this document) 5 1 Calibration certificate CS1000 HYDAC Filter Systems GmbH en Page 12 / 28 BeWa en doc

13 Technical specifications Technical specifications The FluidMonitoring Module Pressure is a rugged, stationary system on-line measurement of particulate contamination in hydraulic fluids. for the The features all of the required ports and can thus be easily connected to existing hydraulic circuits. The is typically applied to bar pressure circuits. Advan tages offered by the : Cost-effective solution Early warning of critical machine states Continuous oil condition monitoring Condition-based maintenance planning HYDAC Filter Systems GmbH en Page 13 / 28 BeWa en doc

14 Technical specifications components Item Designation 1 manifold block 2 Test point 1604 (IN/OUT) 3 Filter element insert 4 ContaminationSensor CS1000 series 5 Socket plug, 8-pole, M12x1, with screw clamp Restrictions pertaining to use Impermissible operating fluid The unit will be damaged NOTICE The unit may only be used with mineral oils (or raffinates whose basis is mineral oil). HYDAC Filter Systems GmbH en Page 14 / 28 BeWa en doc

15 Technical specifications Dimensions 52 ca ,5 ø9 ca Hydraulic schematic CS IN OUT HYDAC Filter Systems GmbH en Page 15 / 28 BeWa en doc

16 Technical specifications Attaching the mechanically Note that the direction of flow has to be from bottom to top during installation. When selecting the installation site, check the ambient conditions such as temperature, dust, water, etc. The CS1000 has protection rating IP67 according to DIN / EN60529 / IEC 529 / VDE The can be mounted and secured via the two mounting holes on the CS1000 using 2x cylindrical screw M8 x 55 mm according to ISO CS display continuously variable The CS 1000 display can be continuously rotated by a total of counterclockwise and 90 clockwise. Rotate the display by hand in the direction desired. Do not use any tools to rotate the display. HYDAC Filter Systems GmbH en Page 16 / 28 BeWa en doc

17 Technical specifications Hydraulic connection of the FMM WARNING Impermissible operating pressure Bodily injury The maximum operating pressure of 300 bar may not be exceeded. NOTICE The minimum differential pressure is < 15 bar If the minimum differential pressure is not given, measuring errors will occur. Observe the minimum differential pressure of 15 bar Note that the direction of flow has to be from bottom (IN) to top (OUT) during installation. This prevents measurement errors resulting from trapped air in the system. The is supplied with two test points (type 1604) on the inlet (IN) and outlet (OUT). Remove the test points to connect via the connector thread G1/4 according to ISO 228. Test point 1604 Connector thread: G1/4, ISO 228 HYDAC Filter Systems GmbH en Page 17 / 28 BeWa en doc

18 Technical specifications Determine the system pressure of the hydraulic system and see whether it is within the permissible flow range for the CS1000 for the inlet. Ensure the flow rate is control led by the integrated flow control valve and is regulated to the measurement volume of the CS1000. The flow rate displayed by the CS1000 does not correspond to the total flow through the. Connecting the to Your 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 with the hydraulic system as follows: 1. Check the pressure at the measurement site. It must be within the permissible range. 2. Depressurize the system. 3. Connect the return flow line with the outlet port (OUT) of the (connector thread G1/4 ISO 228 or test connection 1604). Use an internal Ø 4mm for the return flow line. 4. Now connect the other end of the return line to the system tank, for example. 5. Connect the measurement line to the inlet port (IN) of the. (connector thread G1/4 ISO 228 of test connection 1604) Use an internal Ø 4mm to prevent particle deposit. 6. Connect the other end of the measurement line to the measurement point. 7. The hydraulic installation of the is now complete. HYDAC Filter Systems GmbH en Page 18 / 28 BeWa en doc

19 Error messages / Troubleshooting Error messages / Troubleshooting The following error messages may result when the CS 1000 is combined with the manifold block. LED Blink code / Display / Analog output / Switch out Status Action Red 4.4 ma / 2.2 V* Open Flow too low Check flow Increase inlet pressure or check outlet pressure at the measurement point. The Δp has to be at least 15 bar -> if OK, change the 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. The Δp has to be at least 15 bar -> if OK, change filter element. For other error messages, please refer to your CS1000 operating and maintenance instructions. HYDAC Filter Systems GmbH en Page 19 / 28 BeWa en doc

20 Performing maintenance Performing maintenance Replace the filter element at least every six months. 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 Designation 10 O-ring 10.77x Filter element 25 µm 30 O-ring 20x 2 40 Support ring Ø Endplate HYDAC Filter Systems GmbH en Page 20 / 28 BeWa en doc

21 Performing maintenance To change the filter, 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 mount 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) HYDAC Filter Systems GmbH en Page 21 / 28 BeWa en doc

22 Decommissioning Decommissioning For decommissioning, proceed according to the following steps: 1. Remove the electric plug to the CS Depressurize the system. 3. Remove the connected hoses/piping from the. 4. Remove the. Dispos ing of the Dispose of the packaging material as appropriate for your area. Whe n decommissioning and/or disposing of the MCS, observe all local guidelines and r egulations pertaining to occupational safety and environmental protection. This applies in particular to the oil 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. Spare parts and accessories Spare parts Description Pc. Part no. Manifold block 1 * Flow control valve ContaminationSensor CS 1000 (depending on the design) 1 * Screws for securing the CS O-ring between CS1000 and manifold block Test point type Endplate for filter element Filter element replacement kit, consisting of: - 2x O-ring, 1x support ring, 1x filter element * Available on request HYDAC Filter Systems GmbH en Page 22 / 28 BeWa en doc

23 Technical details Accessories Designation Pc. Part-no. Socket plug, 8-pole, M12x1, with screw clamp Socket plug (female) with 2 m line, shielded, 8-pole, M12x Socket plug with 5 m line, screened, 8-pole, M12x Extension cable 5 m, socket plug 8-pole, M12x1/ plug (male) 8-pole, M12x For more spare parts and accessories, please refer to the product documentation. Technical details Technical data Mounting position Operating pressure Minimal differential pressure Pressure fluctuations Ports vertical, direction of flow from bottom to top bar / psi 15 bar 20 bar max. (recommended in measurement mode) Test point type 1604 or thread G 1/4 according ISO 228 Sealing material Permissible viscosity range Fluid temperature range Ambient temperature range Weight FPM mm²/s C / F C / F 4.3 kg For further technical data, refer to the operating and maintenance instructions of the respective component. HYDAC Filter Systems GmbH en Page 23 / 28 BeWa en doc

24 Customer service Customer service Shipping address for calibration and repair: HYDAC Service GmbH Rehgrabenstrasse Saarbrücken - Dudweiler Germany Telephone: ++49 (0) Fax: ++49 (0) service@hydac.com HYDAC Filter Systems GmbH en Page 24 / 28 BeWa en doc

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28 HY DAC Filter System s Gm bh Industriegebiet P.O. Box Sulzba ch/saa r Sulzbach/Saar Germany Germany Phone : +49 (0) Central Fax: +49 (0) Technical Department Fax: +49 (0) Sales Department Internet: filtersystems@hydac.com