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FluidControl Unit FCU 1315 EN Operating instructions 4168086c / 2025-03 EN 4168086c / 2025-03 Translation / original language: German © 2025 HYDAC Filter Systems GmbH. All rights reserved. ® All product names used may be trademarks or registered trademarks of HYDAC or the particular owner. This manual was prepared to the best of our knowledge. Nevertheless, and despite the greatest care, it cannot be ruled out that mistakes could have crept in. Please therefore understand that, unless stated otherwise below, our warranty and liability – irrespective of the legal grounds – are excluded in respect of the information in these instructions. In particular, we are not liable for loss of profit or other financial losses. This exclusion of liability does not apply in cases of intent or gross negligence. Moreover, it does not apply to defects that were fraudulently concealed or whose absence was guaranteed, or in cases of culpable injury to life and limb and harm to health. If we negligently breach any material contractual obligation, our liability shall be limited to the foreseeable damage. Claims arising from product liability remain unaffected. Documentation representative: HYDAC Verwaltung GmbH, c/o Zentrales Qualitätswesen, Industriegebiet, D‑66280 Sulzbach/Saar, product_safety@hydac.com UKCA – authorised representative of the manufacturer: HYDAC Technology Limited, De Havilland Way, Windrush Park Witney, Oxfordshire OX29 0YG, United Kingdom mailto:product_safety@hydac.com EN TABLE OF CONTENTS 4168086c / 2025-03 3 / 104 Table of Contents 1. General ........................................................................................................................... 6 1.1 Target group of the manual ................................................................................ 6 1.2 Illustrations in the manual................................................................................... 6 1.2.1 Depiction of warning signs.................................................................... 6 1.2.2 Representation of requirements ........................................................... 8 1.2.3 Representation of procedural instructions............................................ 8 1.2.4 Representation of intermediate results/results ..................................... 9 1.2.5 Supplementary symbols ....................................................................... 9 1.3 Warranty ............................................................................................................. 9 1.4 Notes on copyright.............................................................................................. 9 2. Safety information ........................................................................................................... 10 2.1 Proper use .......................................................................................................... 10 2.2 The operator’s obligations .................................................................................. 11 2.3 Personnel qualifications...................................................................................... 11 2.4 General safety instructions ................................................................................. 12 2.4.1 Dangers during the life cycle ................................................................ 12 2.5 Safety symbols / pictograms............................................................................... 13 2.6 Safety devices .................................................................................................... 15 2.7 Personal protective equipment ........................................................................... 15 2.8 Observing environmental precautions ................................................................ 15 2.9 Observing regulatory information ....................................................................... 16 2.10 Stoppage in an emergency (EMERGENCY STOP) ........................................... 16 2.11 Fire-fighting/Extinguishing a fire ......................................................................... 16 3. Product and technical specifications ............................................................................... 17 3.1 Supplementary product information — scan QR code ....................................... 17 3.2 Counting dirt particles visually (light blockade procedure) ................................. 18 3.3 Checking the scope of supply............................................................................. 19 3.4 Technical Data.................................................................................................... 20 3.4.1 Periodic Intermittent Operation – Operating Mode S3.......................... 22 3.5 Decoding the name plate.................................................................................... 23 3.5.1 Model code........................................................................................... 25 3.6 Dimensions......................................................................................................... 26 3.7 Hydraulic diagram............................................................................................... 27 3.8 Function.............................................................................................................. 28 4. Transport / Storage ......................................................................................................... 29 4.1 Opening / Closing Case...................................................................................... 29 4.2 Prepare FCU for Transport................................................................................. 29 4.3 Transporting the FCU......................................................................................... 31 4.4 Storing the FCU.................................................................................................. 32 EN TABLE OF CONTENTS 4 / 104 4168086c / 2025-03 5. Installing, Connecting, Setting Up and Putting into Operation ........................................ 33 5.1 Connecting / Disconnecting Supply Voltage....................................................... 33 5.2 Attaching / Removing the Return Hose .............................................................. 34 5.3 Connecting the equipotential bond..................................................................... 35 5.4 Selecting the measuring point ............................................................................ 35 6. Factory settings............................................................................................................... 37 7. Operation ........................................................................................................................ 38 7.1 Overview of User Interface / Controls................................................................. 38 7.1.1 Reading the Display and Operating the Keypad .................................. 39 7.1.2 Scrolling through Displays.................................................................... 40 7.1.3 Displaying Measured Variables ............................................................ 42 7.1.4 Displaying Service Variables ................................................................ 42 7.1.5 Freezing the Display – FREEZE........................................................... 43 7.2 Configuring / Setting the FCU – PowerUp Menu................................................ 44 7.2.1 DAT.TIM – Setting Date/Time............................................................... 45 7.2.2 ADDRESS – Setting Bus Address........................................................ 45 7.2.3 DEL.MEM – Deleting Measurement Log Memory ................................ 45 7.2.4 M.TIME – Setting Measuring Time ....................................................... 46 7.2.5 CALIB – Selecting Calibration Type .....................................................by hand. 4. Connect the other end of the INLET pressure hose to the measuring point of the system. 5. Turn on the internal pump at the switch. O The hydraulic installation is complete. The FCU proceeds with the measurement. EN 7. OPERATION 58 / 104 4168086c / 2025-03 7.5 Performing Measurements 9007199345521291 To carry out a measurement, observe the following sequence: ü Set up the FCU, see ▶Sec. 5 "Installing, Connecting, Setting Up and Putting into Operation" ü Set the desired settings for the measurements, see ▶Sec. 7.3 "Operating / Setting Measuring Menu" ü Select an appropriate pressure for the operating mode, see ▶Sec. 7.4 "Select oper- ating modes / measuring methods according to the current pressure" 1. Switch on the pump at the switch. The pump delivers the fluid through the FCU for analysis. 2. After the set measuring time, the result will be shown on the display and the status LED will glow green continuously. 3. Turn off the pump following the measurement. O The measurement is complete. 7.6 Restarting/resetting 9007199341580555 To restart or reset the FCU, remove the power supply for ≈ 10 seconds. Disconnect supply voltage 1. Press the notch on the connector. 2. Pull the connector upwards out of the port. Fig. 43: Disconnecting supply voltage Connect supply voltage 1. Insert the 3-pin female connector, (for example, of the power supply unit) into the socket until you hear the notch click into place. Connect the other end to the voltage source. 2. If the FCU is supplied with voltage, the display shows HYDAC FCU 1### in running text. The firmware version is then displayed for two seconds. The internal sensors are checked after this. The display shows 2. SENS OK as well as the firmware of the sensors. The self-test is followed by a countdown on the display WAIT 99 … WAIT 0. 3. The FCU is now ready to carry out the measurement. 4. If T AMB and > 45C flashes on the display, the FCU is expe- riencing a safety shut down. For details, see .▶Sec. 9 "Finding / eliminating faults". Fig. 44: Connecting supply voltage EN 7. OPERATION 4168086c / 2025-03 59 / 104 7.7 Using the BatteryPack (accessory) 9007199342826507 With the BatteryPack, which is available as an accessory, you can make the FCU inde- pendent of the electrical supply network. The technical details for the BatteryPack can be found in the corresponding instructions. The locking pin (2) securely holds the BatteryPack (1) in the mounting rails (3) during transportation. 1 BatteryPack 2 Indexing plunger 3 Mounting rails Fig. 45: BatteryPack Overview For operation with the BatteryPack, fit the connector into the female connector labelled DC IN of the FCU. Fig. 46: BatteryPack during operation Do not close the case until after disconnecting the supply voltage or removing the plug from the female connector. Disconnect supply voltage 1. Press the notch on the connector. 2. Pull the connector upwards out of the port. Fig. 47: Disconnecting supply voltage EN 7. OPERATION 60 / 104 4168086c / 2025-03 7.7.1 Removing / inserting the BatteryPack 9007199342869003 To insert the BatteryPack into its holder, proceed as follows: ü The case is opened. 1. Remove the plug connector (A) from the female connector on the BatteryPack. 2. Insert the BatteryPack into the mounting rails from above. 3. Pull the locking pin (1). Guide the BatteryPack down to the lower stop in the guide rails (2). Release the locking pin (3). A spring will return the locking pin to its original position, thus securing the BatteryPack. Check the BatteryPack is sufficiently tight/secured. 4. Insert the plug connector into the female connector on the BatteryPack. O The BatteryPack is securely stored and ready for transportation or operation. EN 7. OPERATION 4168086c / 2025-03 61 / 104 Removing BatteryPack To switch off, proceed as follows: ü The operation has ended or an alternative supply voltage has been applied. 1. Remove the connector from the port. 2. Pull out the locking pin to release the BatteryPack (1). Slide the BatteryPack upward (2). 3. Pull the BatteryPack upwards out of the mounting rail. Then, insert the connector back into the BatteryPack port. O The BatteryPack is removed from the FCU. EN 7. OPERATION 62 / 104 4168086c / 2025-03 7.8 Extracting the internal measured value memory 18014398596885131 All measurement data is stored in the internal memory with reference to the meas- urement point until it is explicitly deleted by carrying out the DELMEM function. The size of the memory is > 30000 rows°=°measurement data set. To transfer the data, the target system (e.g. PC or USB flash drive) has to have at least 10 MB of capacity free. The following interfaces are available to read the measurement data set: ● DATA interface, for details, see ▶Sec. 7.8.1 "Extracting measurement reports via DATA interface". ● USB interface, for details, see ▶Sec. 7.8.2 "Extracting / copying measurement reports via USB interface". ● Bluetooth interface, for details, see ▶Sec. 7.8.3 "Transferring measurement logs via Bluetooth interface". 7.8.1 Extracting measurement reports via DATA interface 9007199342152587 The FCU has one DATA interface for conveying the measurement reports. The DATA interface communicates in the HSI protocol. 7.8.1.1 Pins used on the DATA interface 9007199342664715 The HSI interface is designed as a 5 pin connection plug. Pin Assignment 1 Not connected 2 Not connected 3 Not connected 4 GND 5 HSI HYDAC Sensor Interface 6 Shield Tab. 14: Interface assignment DATA 12 3 4 5 6 EN 7. OPERATION 4168086c / 2025-03 63 / 104 7.8.1.2 Connecting the FCU with CSI-B-2 9007199342657291 The FCU can be connected to a PC using the CSI-B-2 kit. Fig. 48: Connecting the FCU CSI-B-2 7.8.1.3 Connecting the FCU with HMG 9007199342659211 The following portable data recorders HMG can be used to give a readout of the FCU via the DATA interface: ● HMG 510 (with firmware version 2, release 15 or higher) ● HMG 3000 (with firmware version 2, release 1 or higher) ● HMG 4000 For further details, see the operating instructions for the HMG. Fig. 49: Connecting the FCUHMG 7.8.2 Extracting / copying measurement reports via USB interface 18014398596908939 Saved measurement logs can be copied onto the USB stick provided. Doing this will not delete the data from the internal memory. Afterwards, explicitly delete the measurement logs from the internal memory. For details, see ▶Sec. 7.2.3 "DEL.MEM – Deleting Measurement Log Memory". Set up USB stick Format the USB memory stick before first use. To do this, insert the USB stick into a free USB port on your PC. Then switch to the file manager (i.e. Explorer) and format the USB stick in FAT32 format. More details can be found in the operating system docu- mentation. EN 7. OPERATION 64 / 104 4168086c / 2025-03 Compatibility with other USB sticks cannot be guaranteed as the FCU communicates directly with the microprocessor. This means that transmission errors are not inter- cepted by software, as they would be with a PC with an operating system. HYDAC does not accept any liability for the functionality and compatibility of the USB stick with your system. This shall not give rise to support or compensation. We recommend using the HYDAC USB stick, which has been success- fully tested by us on numerous PC/operating system combinations. The data carrier must have ≥ 10 MB free memory. No measurement logs are recorded during the copy process. Copy measurement logs onto the USB stick To save the measured values onto the USB stick, proceed as follows: ü The FCU is connected to the supply voltage. 1. Open the cover of the USB connection by turning anti-clockwise (1) and then lift off the cover (2). 2. Insert the USB stick into the USB port. Note that the USB stick only fits into the USB port in one position. 3. After insertion, the USB stick will be recognised as a storage medium and starts copying the measuring data. 4. The left display shows the numberof measurement data sets to be copied (example: 339) The right display shows the number of logs (example: 4). EN 7. OPERATION 4168086c / 2025-03 65 / 104 5. If the FCU recognises logs on the USB stick, the following message appears on the display. Example: the FCU has recognised log number 4 on the USB stick. This function is particularly useful to compare (synchronise) the copied data with the data on the internal memory of the FCU. The available logs are displayed. 6. After the logs have been successfully copied, the following message appears on the display. 7. Remove the USB stick from the USB port. 8. Close the cover of the USB port (1) by turning anti-clockwise (2). O The measurement logs from the internal measurement memory have been copied onto the USB stick. EN 7. OPERATION 66 / 104 4168086c / 2025-03 7.8.2.1 Error when copying the measurement logs 18014398596916875 If an error occurs during the copying process or if you remove the USB flash drive from the port before saving is complete, the following message ERROR COPY will appear on the display. To rectify the error, proceed as follows: Step Description 1. Insert the USB flash drive into your PC and delete all data. 2. To do this, insert the USB flash drive into the USB port again. The download starts automatically. 3. ->a. The error is repeated -> go to step 4. ->b. The error is not repeated -> go to step 11. 4. Insert the USB flash drive into your PC and format it. 5. To do this, insert the USB flash drive into the USB port again. The download starts automatically. 6. ->a. The error is repeated -> go to step 7. ->b. The error is not repeated -> go to step 11. 7. Use another compatible USB flash drive. 8. To do this, insert the USB flash drive into the USB port again. The download starts automatically. 9. ->a. The error is repeated -> go to step 10. ->b. The error is not repeated -> go to step 11. 10. Contact the HYDAC Service department. 11. The download has been successfully completed. EN 7. OPERATION 4168086c / 2025-03 67 / 104 7.8.3 Transferring measurement logs via Bluetooth interface 9007199342232075 The Bluetooth interface of the FCU is based on Bluetooth Version 1.2, Class 3. Bluetooth Version 1.2 This version is less sensitive to static disturbances (e.g. WLAN), the maximum data transfer rate is 732.2 kBit/s Class 3 The maximum power of 1 mW or 0 dBm is sufficient for a 10 m area outdoors. This distance is strongly dependent on disruptions and obstacles in the vicinity. Fig. 50: Bluetooth interface 7.8.3.1 Connecting/Linking the FCU via Bluetooth 9007199342270219 In the Bluetooth environment, the FCU appears as: FCU1310 or FCU1315. If the connection to the FCU has been established via Bluetooth, the measured values can be read e.g. via FluMoS. The HSI log is used to communicate with the FCU. Data transmission via the Bluetooth connection depends on your PC hardware and the installed software. There are many Bluetooth modules and software drivers available on the market which do not always completely satisfy the IEEEE 802.15 specifications. Bluetooth code / password, see ▶Sec. 6 "Factory settings". EN 7. OPERATION 68 / 104 4168086c / 2025-03 7.9 Evaluating measurement reports 18014398597015051 The measurement logs saved on the FCU and USB stick can be found and evaluated as described below. 7.9.1 Measurement report directories according to measurement point 9007199342277771 If measurement reports are stored under a measurement point MPNT, the meas- urement reports are automatically assigned to the directory for this measurement point. MNPT00 MNPT08 MNPT09 MNPT10 MNPT16 MNPT19 Fig. 51: Explorer presentation of measurement record directories 7.9.2 Measurement report file names 9007199342279691 The file name of the measurement logs consists of the date YY -> year, MM -> month, DD -> day, as well as a consecutive number as the file extension. A new log is created: ● If prompted by STP.STA ● Following a restart of the FCU (see ▶Sec. 7.6 "Restarting/resetting") ● After the measurement logs have been copied (downloaded) onto the USB stick For each new log, the number increases by one. YY _ MM _ DD . Consecutive number 18 _ 08 _ 21 . 026 18 _ 08 _ 22 . 027 18 _ 08 _ 23 . 028 Tab. 15: Example: measurement log file name EN 7. OPERATION 4168086c / 2025-03 69 / 104 7.9.3 Opening the measurement report 9007199342281611 The measurement reports have a file extension e.g. .026. This extension may not be recognised by your PC. Set up your PC so that this file extension is opened with MS Excel in the future. To do this, select the log file with MS Excel by right-clicking onto the file and then clicking open. A dialogue window appears which will prompt you to select a program to open the file => select Excel. This generally applies for all file extensions from .000 … .999. A measured data file is comprised of two parts: Part 1 - General information regarding the recording, sensors and devices. Part 2 - The actual measured data is presented in lines after the word *Data*. The first line contains the column title. Faults are shown as negative values, e.g. –0.1 or –1. Fig. 52: View of measurement report in MS-Excel For details of the column State, see ▶Sec. 9 "Finding / eliminating faults". The values for SAE A-D or NAS 2-25 as well as the temperature units are defined by the corresponding settings. EN 7. OPERATION 70 / 104 4168086c / 2025-03 7.9.4 The measurements are shown as dates 27021597852025355 After the file is opened in Excel, all decimal numbers will be displayed as dates. Proceed as follows to correct the display: ü The MS Excel program is open on your device. 1. Now select the Open command from the menu bar. Open the desired measured data file. Separated Next > Text conversion wizard – step 1 of 32. The text conversion wizard opens. 3. Text conversion wizard – step 1 of 3. Check the settings. Confirm the window by pressing the Next > button. Tab stop Next > Text conversion wizard – step 2 of 3 Text identifier 4. Text conversion wizard – step 2 of 3. Check the settings. Confirm the window by pressing the Next > button. Standard Text conversion wizard - Step 3 of 3 Continue Continue > 5. Text conversion wizard – step 3 of 3. Press the Next button. 1000 separator OK Text conversion wizard – step 3 of 3 Decimal point 6. Change the following settings: Set the decimal point as the decimal separator and the comma as the 1000 separator. EN 7. OPERATION 4168086c / 2025-03 71 / 104 Confirm the changes with the OK button. Standard Finish Text conversion wizard – step 3 of 3 Data format of the columns 7. Click the Finish button to finalise the import of the measured data. O The decimal numbers should now be displayed correctly. 7.10 Reading, evaluating measurement reports / values with FluMoS 72057594125314699 The FluidMonitoring Software FluMoS is used to read and analyse measurement reports / measured values from HYDAC sensors / interfaces or devices. FluMoS light is available for download on the website www.hydac.com. ● Free download ● ≤ 3 sensors can be read / evaluated FluMoS professional can be purchased as an accessory. ● Chargeable ● ≤ 16 sensors can be read / evaluated / parameterised ● Update authorised for major release FluMoS mobile for your mobile ANDROID device is available in the Google Play Store. ● Data is transmitted only by means of a wireless connection between the mobile device and the sensor / interface such as the W-LAN or Bluetooth (depending on the device) ● Free download http://www.hydac.com EN 7. OPERATION 72 / 104 4168086c / 2025-03 The FluidMonitoring Toolkit FluMoS is a package of drivers and programs that helps you to integrate HYDAC sensors into your own user environment / software. To this end, you will have access to all the HYDAC program libraries, a detailed description and help, as well as example programs in various programming languages. FluMoT can be purchased as an accessory withcosts. EN 8. PERFORMING MAINTENANCE 4168086c / 2025-03 73 / 104 8. Performing maintenance 9007199341389963 For a long, trouble-free service life of the product, regular maintenance activities are required. The prescribed installation, maintenance and inspection work must be carried out every six months, but no later than when a fault indication / malfunction makes it necessary. WARNING The hydraulic system is under operating pressure Danger of bodily injury u The hydraulic system must be depressurised before performing any work on it. De-energise the FCU during all maintenance, inspection and repair work, and secure it against unexpected restarting. Check the loosened screw connections for tightness. 8.1 Maintenance table 86933387 D ai ly W ee kl y Ev er y 6 m on th s As re qu ire d Af te r 3 ye ar s 8.4 Flushing the FCU 1 8.2 Cleaning the FCU 1 8.6.1 Cleaning/changing the strainer 2 8.6.2 Cleaning / replacing the flow control valve 2 8.5 Calibrating the FCU 3 1 Operating personnel 2 Specialist personnel – Mechanical 3 Specialist personnel – Service/Administrator 8.2 Cleaning the FCU 9007199341406475 Clean the control panel and the case with a clean, moist cloth. Do not use any chemical or scouring cleaning agents. EN 8. PERFORMING MAINTENANCE 74 / 104 4168086c / 2025-03 8.3 Cleaning the suction strainer 9007199341460107 The strainer is located under the measurement point screw connection on the INLET connector and protects the pump from macro fouling. Regularly clean the strainer. If the FCU is blocked or if there is no flow through the FCU, clean the strainer thoroughly. 1x spanner = 19 mm Compressed air NOTICE Operation without a suction strainer The FCU pump will be damaged / destroyed. u Never use the FCU without a suction strainer. u Clean the suction strainer regularly. Proceed as follows to check / clean the strainer: ü Remove all electrical / hydraulic connections to the FCU. 1. Unscrew the INLET screw connection anti-clockwise with a wrench = 19 mm. 2. Unscrew the INLET screw connection anti-clockwise by hand. 3. Stick your finger into the opening ... 4. ... and remove the strainer by lifting. EN 8. PERFORMING MAINTENANCE 4168086c / 2025-03 75 / 104 5. Clean the strainer by blowing it out with compressed air. 6. Prior to installation, check the gasket ring of the screw connection for damage. Replace if necessary. 7. Wet the gasket ring (C) with fluid before screwing in. 8. Insert the strainer back into the opening. 9. Screw in the INLET screw connection clockwise by hand. 10. Tighten the INLET screw connection with a wrench = 19 mm by turning clockwise. Tighten the screw connection to a torque of 25 Nm. O The changing / cleaning of the strainer is complete. 8.4 Flushing the FCU 9007199341411723 The FCU is a measuring device to determine the fluid cleanliness. To prevent fluids from mixing and causing faulty measurement results, all fluids must have the same defined initial cleanliness. Rinse the FCU after each use, but at least daily, for more details on the permitted flushing fluid, see ▶Sec. 3.4 "Technical Data". EN 8. PERFORMING MAINTENANCE 76 / 104 4168086c / 2025-03 Rinse the FCU immediately after measuring unfiltered oil or oil with a viscosity of > 200 mm²/s or if the measured values appear unusually high / low. Rinse the FCU as described below: 1. Pour≈ 0.5 litres of filtered oil into a clean container. 2. Connect the return hose to the FCU and place the other end in a container for used fluids. 3. Monitor the suction hose on the INLET connector of the FCU. Place the suction hose into the container with filtered fluid. 4. Switch on the FCU pump at the switch. 5. Cleanliness values are displayed during the flushing procedure. These values are not correct, but nonetheless should drop during the flushing procedure. EN 8. PERFORMING MAINTENANCE 4168086c / 2025-03 77 / 104 6. Once the 0.5°litres have been suctioned, turn the pump off at the switch. O Rinsing the FCU is completed. The FCU is ready for operation. 8.5 Calibrating the FCU 9007199341568907 Calibrate the FCU in accordance with ISO 9000 for device measurements. We recommend a re-calibration of the FCU after 3°years at the latest. To calibrate, contact the HYDAC Service. You can find locations near you on our homepage at www.hydac.com. 8.6 High-pressure adapter maintenance 9007199341639051 Check or clean the strainer and the flow control valve in the high-pressure adapter at regular intervals. If the required flow through the FCU is not achieved, check and clean the strainer and the flow control valve in accordance with the following chapters. Fig. 53: High-pressure adapter 8.6.1 Cleaning/changing the strainer 9007199341690635 Clean the strainer (B) in the high-pressure adapter 2 x a year, or more often if necessary due to heavy contamination. 2x spanner = 19 mm 1x screwdriver 9x1 mm or special tool, see ▶Sec. 11.2.1 "Finding accessories") A Test point B Strainer C Flow control valve D Screw connection http://www.hydac.com EN 8. PERFORMING MAINTENANCE 78 / 104 4168086c / 2025-03 NOTICE High-pressure adapter - operation without strainer The flow control valve in the high-pressure adapter will be damaged / destroyed u Never use the high-pressure adapter without a strainer u The suction strainer in the high-pressure adapter must be cleaned regularly 1. Disassemble the measurement coupling (A) by turning a wrench = 19 mm anti- clockwise from the screw connection (D). Then unscrew the strainer anti-clockwise (B) using a screwdriver or the special tool. 2. Clean the strainer (B) and then blow it out with compressed air. 3. To assemble the strainer (B), screw it clockwise into the screw connection (D) using a screwdriver or the special tool. 4. Check gasket ring on the measurement coupling (A) for damage, and replace them if necessary. 5. Screw in the measurement coupling (A) clockwise and tighten with 25°Nm. O Cleaning / replacing the strainer is complete. The high-pressure adapter is ready for operation. 8.6.2 Cleaning / replacing the flow control valve 9007199341877131 The flow control valve regulates the flow to ≈ 0.55 … 0.7 l/min. If the required flow is not reached by the high-pressure adapter, clean or replace the flow control valve. 2x spanner = 19 mm 1 x special tool, see ▶Sec. 11.2.1 "Finding accessories" A Test point B Strainer C Flow control valve D Screw connection Pay attention to the direction of flow when installing the flow control valve. 1. Unscrew the measurement coupling (A) anti-clockwise out of the screw connection (D) using a wrench = 19 mm. 2. Unscrew the strainer (B) anti-clockwise using a screwdriver or the special tool (see ▶Sec. 11.2.1 "Finding accessories" chapter). 3. Clean the strainer (B) and then blow it out with compressed air. 4. Unscrew the flow control valve(C) anti-clockwise using a screwdriver or the special tool (see ▶Sec. 11.2.1 "Finding accessories" chapter). 5. To assemble the new flow control valve (C), screw it clockwise into the screw connection (D) using a screwdriver or the special tool. EN 8. PERFORMING MAINTENANCE 4168086c / 2025-03 79 / 104 6. Tightly screw the strainer (B) clockwise into the screw connection (D) using a screwdriver or the special tool. 7. Then, check the gasket ring of the measurement coupling (A) for damage and replace if necessary. 8. Screw in the measurement coupling (A) clockwise and tighten with 25°Nm. O Cleaning / replacing the flow control valve is complete. The high-pressure adapter is ready for operation. EN 9. FINDING / ELIMINATING FAULTS 80 / 104 4168086c / 2025-03 9. Finding / eliminating faults 9007199341890699 In order to get quick and immediate assistance in the case of errors, you will find the most common faults with their causes, to be rectified by qualified personnel. The following faults / errors can occur during operation. The error codes can be found in the measurement log: Error Codes Description0 Ready for operation Sensor / device is working. 2 Minor error / WARNING Sensor / device is continuing to work. WARNING is automatically reset by the FCU. 3 Medium error Sensor / device in error status. ▶Sec. 7.6 "Restarting/resetting" 4 Severe error Sensor / device is defective. Contact the HYDAC Service department. Tab. 16: Error codes in the measurement log The following faults are shown on the display and via the flashing code of the status LED. Fault / error LED Status LED Display Error code Status / possible causes Solution LED: off Status LED: Display: Error code: - No display No function Check the supply voltage to the FCU. Contact the HYDAC Service department. LED: green Status LED Display: Error code: 0 The FCU is ready for oper- ation. You can carry out measure- ments. EN 9. FINDING / ELIMINATING FAULTS 4168086c / 2025-03 81 / 104 Fault / error LED Status LED Display Error code Status / possible causes Solution LED: red Status LED: Display: Error code: 2 The FCU is below its measuring range ISO 25/24/23. It is currently not possible to determine the oil clean- liness / flow rate. Filter the oil to achieve better cleanliness. EN 9. FINDING / ELIMINATING FAULTS 82 / 104 4168086c / 2025-03 Fault / error LED Status LED Display Error code Status / possible causes Solution LED: red Status LED: Display: Error code: 3 The installed sensors are not found. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. LED: red Status LED: Display: Error code: 3 The contamination sensor causes a medium error. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. LED: red Status LED Display: Error code: 4 The contamination sensor causes a medium error. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. EN 9. FINDING / ELIMINATING FAULTS 4168086c / 2025-03 83 / 104 Fault / error LED Status LED Display Error code Status / possible causes Solution LED: red Status LED: Display: Error code: 2 The AquaSensor is outside the measuring range. Wait for further measurement cycles. LED: red Status LED: Display: Error code: 3 No AquaSensor is connected. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. EN 9. FINDING / ELIMINATING FAULTS 84 / 104 4168086c / 2025-03 Fault / error LED Status LED Display Error code Status / possible causes Solution LED: red Status LED: Display: Error code: 3 The AquaSensor causes a medium error. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. LED: red Status LED Display: Error code: 3 No sensors are connected to the FCU or communi- cation is disrupted. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. LED: red Status LED Display: Error code: 3 The FCU has a medium error. Carry out a restart. See ▶Sec. 7.6 "Restarting/ resetting" If the error recurs, contact the HYDAC Service department. EN 9. FINDING / ELIMINATING FAULTS 4168086c / 2025-03 85 / 104 Fault / error LED Status LED Display Error code Status / possible causes Solution LED: red Status LED Display: Error code: 3 The FCU has a major error. Contact the HYDAC Service department. LED: red Status LED: Display: Error code: - The internal temperature of the FCU is > 45 °C, the safety cut-out is activated. Let the FCU cool down. Tab. 17: Fault / error list EN 10. DECOMMISSIONING/DISPOSAL 86 / 104 4168086c / 2025-03 10. Decommissioning/Disposal 108086391114014091 In the following chapters, you will be provided with information regarding temporary shutdown/final decommissioning and disposal of the product. 10.1 Temporary shutdown 253902219 If the product is being temporarily shut down, the following measures are adequate: 1. Switch the product off and disconnect it from all sources of energy. 2. Follow all the notices in the Transport/storage chapter. 10.2 Permanent shutdown 36028797273021067 If the product is being shut down permanently, proceed as follows: ● Empty the product fully, including all the components, before the shutdown. ● Fully disconnect the product from the surrounding units. ● Slacken or remove the electric, pneumatic or hydraulic connections insofar as they are present. 10.3 Disposal/Recycling 72057594291913739 Dismount and recycle the product that cannot be used any more, not as a whole unit, but in individual parts and according to the kind of the materials. After dismantling the product and separating its various materials into categories, dispose of all parts in an environmentally friendly manner according to the local specifications. Dispose of the drained operating fluids and operating materials according to the local specifications in an environmentally friendly manner. EN 11. APPENDIX 4168086c / 2025-03 87 / 104 11. Appendix 9007199338242699 This Annex contains additional information on the product. 11.1 Contacting Customer Service 72057594095185931 Contact details such as the telephone numbers, e-mail and mailing addresses for the Hotline, product support, Customer Service, branch offices, service partners for mainte- nance, repair and spare parts can be found on our homepage www.hydac.com. HYDAC SYSTEMS & SERVICES GMBH Friedrichsthaler Str. 15, Werk 13 66450 Neunkirchen - Heinitz Germany Phone: +49 6897 509 01 Fax: +49 6897 509 324 E-mail: service@hydac.com Homepage: www.hydac.com 11.2 Finding spare parts/accessories 9007199341235083 Use only original spare parts for a long and defect-free life cycle of the product. When ordering spare parts and accessories make sure to always indicate the exact model code and the serial number. The following spare parts are available for your selection: Item Qty. Designation Auxiliary Part no. - 1 High-pressure hose with screw connection for measuring point, type°1620, colour: black, length°=°2 m 349150 - 1 Return hose, open end, transparent, length°=°2°m 349151 http://www.hydac.com EN 11. APPENDIX 88 / 104 4168086c / 2025-03 Item Qty. Designation Auxiliary Part no. - 1 Suction filter, 400 µm (to INLET connection) 278475 - 1 O-ring for INLET measurement point screw connection (Ø 21 mm, in accordance with DIN3869) 607755 - 1 Strainer, 400 µm (to high-pressure adapter) 3152786 - 1 Flow control valve to high-pressure adapter 710389 - 1 Cover gasket to case 3455429 - 1 Bag for hoses, cables and acces- sories 3335656 - 1 Document pouch, DIN A5 3377173 - 1 Operating instructions (this document) 3371346 - 1 High-pressure adapter, complete 3364502 Tab. 18: Spare parts list EN 11. APPENDIX 4168086c / 2025-03 89 / 104 PS10, Table power supply unit (PS6 replacement) Description Part no. Table power supply unit (PS6 replacement), PS10, Cable length: 1.8 m, XLR Plug, 3 pin, straight, Primary: 100-240 V AC , 47-63 Hz Secondary: 24 V DC , 5000 mA Protection class: IP40 Socket C13 for single-ended cordset C14 4516116 Power supply unit cordset C14, 3 pin (2+PE) Designation Part no. Power supply unit cordset (Europe), 3 pin, length = 1.5 m 6254930 Designation Part no. Power supply unit cordset (United Kingdom), 3 pin, length = 2 m 6254962 Designation Part no. Power pack supply unit cordset (USA/Canada), 3 pin, length = 2 m 6254961 Designation Part no. Power supply unit connectioncable (Australia), 3 pin, length = 2 m 6254963 EN 11. APPENDIX 90 / 104 4168086c / 2025-03 11.2.1 Finding accessories 9007199341237003 The following accessories are provided for the FCU. Item Qty. Designation Auxiliary Part no. - 1 12 / 24 V DC cable with universal plug including 8°A fuse, length = 10°m 3306236 - 1 12 / 24 V DC cable with universal plug including 8°A fuse, length = 1°m 3524138 - 1 8°A fuse for universal plug (Ø 6 x 25 mm, according to DIN 72581) 6052824 - 1 Battery adapter for 12 / 24 V DC with coupling for universal plug, length = 0.3°m 6051653 - 1 Tools to change the flow control valve in the high-pressure adapter 3209986 - 1 USB stick 3442973 - 1 BatteryPack, 24 V DC / 4500 mAh 3504605 - 1 CSI-B-2 Kit ConditionSensor Interface 3409462 - 1 CD with FluMoS Professional 3371637 Tab. 19: Accessories EN 11. APPENDIX 4168086c / 2025-03 91 / 104 Connection cable ZBE08S, Single-ended cordset, shielded Female connector, M12x1 5 pin, angled Open cable end Description Part no. Single-ended cordset, length: 2 m, ZBE08S-02, black, - 6019455 Single-ended cordset, length: 5 m, ZBE08S-05, black, - 6019456 Single-ended cordset, length: 10 m, ZBE08S-10, black, - 6023102 Single-ended cordset, length: 20 m, ZBE08S-20, black, - 6117350 Single-ended cordset, length: 30 m, ZBE08S-30, black, - 6035063 ZBE30, Connecting cable, unshielded, black, Female connector M12x1, 5-pole, A-coded Plug M12x1, 5-pole, A-coded Description Part no. Connecting cable, Length: 0.5 m, ZBE30-005 Cable sheath: -, colour: black, - 4193586 Connecting cable, Length: 2 m, ZBE30-02 Cable sheath: -, colour: black, - 6040851 Connecting cable, Length: 3 m, ZBE30-03 Cable sheath: -, colour: black, - 6053924 Connecting cable, Length: 5 m, ZBE30-05 Cable sheath: -, colour: black, - 6040852 Connecting cable, Length: 20 m, ZBE30-20 Cable sheath: -, colour: black, - 3761071 Connecting cable, Length: 10 m, ZBE30-10 Cable sheath: -, colour: black, - 3534972 Connecting cable, Length: 30 m, ZBE30-30 Cable sheath: -, colour: black, - 3656854 EN 11. APPENDIX 92 / 104 4168086c / 2025-03 11.3 Declaration of conformity 5042528395 The declaration of conformity is provided here for information. We hereby declare that the following designated product, on the basis of its design and construction and in the version which we have brought to market, corresponds to the fundamental safety and health requirements contained in the directives and standards listed below. This declaration becomes invalid if any changes are made to the product without our written consent. VAT ID: Documentation representative: Page 1 of 1 Product details Designation: Type: Part no.: Series no.: HYDAC Verwaltung GmbH Industriegebiet 66280 Sulzbach/Saar product_safety@hydac.com Germany Date by proxy on behalf (Reviewer) (CE officer) Mathias Dieter, Dipl.Kfm. Wolfgang Haering Executive directors: … Registered office: Court of Registration: Tax number: Email: c/o Abt. Zentrales Qualitätswesen66280 Sulzbach / Saar Saarbrücken, HRB 17216 DE 815001609 040/110/50773 66280 Sulzbach / Saar Industriegebiet HYDAC FILTER SYSTEMS GMBH www.hydac.com EU declaration of conformity (Translation from original declaration of conformity) 0002S01831K… ... FCU13XX-... FCU 1000 EN ISO 12100:2010, EN 55011:2009 + A1:2010, EN 60204-1:2018, EN 61000-6-2:2005 Applied directives Applied standards 2006/42/EC Machinery Directive 2011/65/EC RoHS Directive 2011/30/EC EMC Directive 2014/53/EC Radio equipment and repealing Directive Fig. 54: Declaration of conformity EC EN 11. APPENDIX 4168086c / 2025-03 93 / 104 This declaration of conformity is issued under the sole responsibility of the manufacturer. We hereby declare under sole responsibility that the following designated product, on the basis of its design and construction and in the version which we have brought to market complies with the fundamental safety and health requirements contained in the directives and standards listed below. Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity. Registered seat of company: 66280 Sulzbach / Saar Registration Court: Saarbrücken, HRB 17216 Value added tax identification number : DE 815001609 Tax number: 040/110/50773 Authorized representative: Phone: page 1 of 1 Product Details Description: Type: Part-no.: Serial-no.: HYDAC Technology Limited De Havilland Way, Windrush Park Witney Oxfordshire +44 1993 - 86 63 66 HYDAC FILTER SYSTEMS GMBH Industriegebiet 66280 Sulzbach / Saar Germany Internet: www.hydac.com Date by proxy on behalf (inspector) (CE-official) Mathias Dieter Executive directors: Dipl.Kfm. Wolfgang Haering, … OX29 0YG UK Declaration of conformity 0002S01831K… … FCU13XX-... FCU1000 EN ISO 12100:2010, EN 55011:2009 + A1:2010, EN 60204-1:2018, EN 61000-6-2:2005 Applied Standards Applied Regulations 2017 No. 1206 2012 No. 3032 Radio Equipment RoHS 2008 No. 1597 Electromagnetic Compatibility 2016 No. 1091 Electromagnetic Compatibility Fig. 55: Declaration of conformity UKCA EN TABLE OF ILLUSTRATIONS 94 / 104 4168086c / 2025-03 Table of Illustrations Fig. 1 Fire protection classification B/Minimum distance for fire fighting ............................ 16 Fig. 2 Light blockade procedure ......................................................................................... 18 Fig. 3 Signal lamp amplitudes ............................................................................................ 18 Fig. 4 Operating mode S3 – periodic intermittent operation ............................................... 22 Fig. 5 Type label ................................................................................................................. 23 Fig. 6 Model code ............................................................................................................... 25 Fig. 7 DIMENSIONS........................................................................................................... 26 Fig. 8 Hydraulic diagram..................................................................................................... 27 Fig. 9 Hydraulic diagram..................................................................................................... 28 Fig. 10 Open case ................................................................................................................ 29 Fig. 11 Close case................................................................................................................ 29 Fig. 12 Connecting supply voltage ....................................................................................... 33 Fig. 13 Disconnecting supply voltage ................................................................................... 33 Fig. 14 Attaching the return hose ......................................................................................... 34 Fig. 15 Removing the return hose ........................................................................................ 34 Fig. 16 Connecting the equipotential bond........................................................................... 35 Fig. 17 Selecting the measuring point .................................................................................. 36 Fig. 18 User interface / controls............................................................................................ 38 Fig. 19 Display shows........................................................................................................... 39 Fig. 20 DAT.TIM – Setting date/time .................................................................................... 45 Fig. 21 ADRESS – Setting bus address ............................................................................... 45 Fig. 22 Deleting measurement log – DEL.MEM ................................................................... 46 Fig. 23 Setting measuring time – M.TIME ............................................................................46 Fig. 24 CALIB – Selecting calibration type ........................................................................... 46 Fig. 25 DFAULT – Resetting to factory settings ................................................................... 47 Fig. 26 Cancel – CANCEL.................................................................................................... 47 Fig. 27 Saving settings / data – SAVE.................................................................................. 47 Fig. 28 RECORD – Recording measuring data .................................................................... 48 Fig. 29 MPNT 00 – MPNT xx – Change measuring point designation ................................. 49 Fig. 30 STP.STA – Restart measurement log ...................................................................... 49 Fig. 31 MEMORY – Display free measurement log memory................................................ 50 Fig. 32 ED.MPNT - Change measurement point designation .............................................. 50 Fig. 33 MPNT 00 – MPNT xx – Change measuring point designation ................................. 50 Fig. 34 TPUNIT – Set unit of temperature ............................................................................ 51 Fig. 35 TPUNIT – Set degrees Celsius................................................................................. 51 EN TABLE OF ILLUSTRATIONS 4168086c / 2025-03 95 / 104 Fig. 36 Cancel – CANCEL.................................................................................................... 51 Fig. 37 Saving settings / data – SAVE.................................................................................. 51 Fig. 38 Operating mode – measuring at 0 bar with suction pipe (A)..................................... 53 Fig. 39 Operating mode – measuring at 0 bar with suction hose (B).................................... 53 Fig. 40 Operating mode – measurement ≤ 45 bar................................................................ 54 Fig. 41 Operating mode - measure≤ 16 bar/ 232 psi............................................................ 55 Fig. 42 Operation mode - measure at 45 … 345 bar............................................................ 56 Fig. 43 Disconnecting supply voltage ................................................................................... 58 Fig. 44 Connecting supply voltage ....................................................................................... 58 Fig. 45 BatteryPack Overview .............................................................................................. 59 Fig. 46 BatteryPack during operation ................................................................................... 59 Fig. 47 Disconnecting supply voltage ................................................................................... 59 Fig. 48 Connecting the FCU CSI-B-2............................................................................. 63 Fig. 49 Connecting the FCUHMG ................................................................................... 63 Fig. 50 Bluetooth interface.................................................................................................... 67 Fig. 51 Explorer presentation of measurement record directories........................................ 68 Fig. 52 View of measurement report in MS-Excel ................................................................ 69 Fig. 53 High-pressure adapter.............................................................................................. 77 Fig. 54 Declaration of conformity EC.................................................................................... 92 Fig. 55 Declaration of conformity UKCA............................................................................... 93 EN INDEX OF TABLES 96 / 104 4168086c / 2025-03 Index of Tables Tab. 1 Target groups ........................................................................................................... 6 Tab. 2 Depiction of the warning levels................................................................................. 8 Tab. 3 Scope of delivery ...................................................................................................... 19 Tab. 4 Contamination sensor............................................................................................... 20 Tab. 5 Electrical data ........................................................................................................... 21 Tab. 6 General data............................................................................................................. 22 Tab. 7 Default settings - DFAULT........................................................................................ 37 Tab. 8 Keyboard overview................................................................................................... 39 Tab. 9 Displays in ISO.SAE................................................................................................. 40 Tab. 10 Displays in ISO.NAS................................................................................................. 41 Tab. 11 Display indicators in the PowerUp menu.................................................................. 44 Tab. 12 Display indicators in the measurement menu........................................................... 48 Tab. 13 Select operating mode / measuring method............................................................. 52 Tab. 14 Interface assignment DATA...................................................................................... 62 Tab. 15 Example: measurement log file name ...................................................................... 68 Tab. 16 Error codes in the measurement log ........................................................................ 80 Tab. 17 Fault / error list.......................................................................................................... 80 Tab. 18 Spare parts list.......................................................................................................... 87 Tab. 19 Accessories .............................................................................................................. 90 EN GLOSSARY 4168086c / 2025-03 97 / 104 Glossary FCU Abbreviation for "FluidControl Unit" FKM The term "Fluororubber" (abbreviation FKM according to DIN SIO 1629 [earlier: FPM] and FKM according to ASTM D 1418) represents an entire group of rubbers, which have, as a common char- acteristic, vinylidene difluoride as one of its monomers. Flash point According to DIN V 14011, the flash point of a substance is the lowest temperature at which an ignitable vapor-air mixture can form above a substance. FluMoS light FluMoS light is available for download on the homepage www.hydac.com. FluMoS light can read a maximum of 3 sensors via LAN / WLAN or Bluetooth, depending on your terminal device. FluMoS mobile FluMoS mobile for your mobile device with Android operating system is available in the Google Play Store. FluMoS mobile can read sensors via W- LAN or Bluetooth, depending on your terminal device. FluMoS professional FluMoS professional can be purchased as an accessory. With FluMoS professional, you can read out and parameterise up to 16 sensors via LAN / WLAN or Bluetooth, depending on your terminal device. EN GLOSSARY 98 / 104 4168086c / 2025-03 FluMoT The FluidMonitoring Toolkit FluMoT is a package of drivers and programs that supports you in integrating HYDAC sensors into your own user environment/ software. All HYDAC program libraries, a detailed description and help as well as sample programs in various software languages are available for this purpose. High-pressure adapter Adapter required for measuring at pres- sures of 15 – 345 bar with the FCU. Load dump Load dump refers to the occurrence of a voltage peak on a vehicle alternator after load shedding. QR code The abbreviation QR stands for "quick response". Thisis a two-dimensional QR code, WLAN Is the abbreviation for Wireless LAN (Local Area Network). Means the same thing as Wi-Fi. EN INDEX 4168086c / 2025-03 99 / 104 Index A Accessories 90 PS10 table power supply unit 89 PS6, see PS10 89 ZBE08S 91 ZBE30 91 ADDRESS Setting 45 Ambient temperature range 22 B BatteryPack Inserting 60 Removing 61 Using the 59 Bluetooth Class 67 Code 37 Connection 67 Interface 67 Password 37 Version 67 C CALIB 46 ISO.NAS 46 ISO.SAE 46 Calibrating FCU 77 CANCEL 47, 51 Case Closing 29 Open 29 Cleaning Strainer 74 Cleaning the FCU 73 Cooling phase 22 Customer service 87 D DAT.TIM Setting 45 Declaration of conformity 92 EU 92 UKCA 93 Decommissioning Permanent 86 Temporary 86 Default settings DFAULT 37 DEL.MEM 45 DFAULT 37, 47 Dirt particles Count 18 Display FREEZE 43 Freezing 43 ISO.NAS 41 ISO.SAE 40 Disposal Disposal 86 Recycling 86 Downtime 22 Drive 42 E ED.MPNT 50 Equipotential bond Connecting 35 Error code 80 Error list 85 EU Declaration of conformity 92 Exclusion of liability 2 F Fault list 85 FCU Calibrating 77 Cleaning the 73 Closing 29 Flushing 75 Open 29 Reset 58 Restart 58 Flash point 20 Flow 42 Flow control valve cleaning 78 FluMoS Download 71 light 71 mobile 71 professional 71 FluMoT 72 Flushing FCU 75 Flushing fluid 20 FREEZE 43 end 43 Starting 43 EN INDEX 100 / 104 4168086c / 2025-03 H High-pressure adapter Clean flow control valve 78 Cleaning the strainer 77 Hotline 87 HYDAC Branch offices 87 Germany 87 Product support 87 Service 87 Service partners 87 Terms of delivery 9 Hydraulic diagram 27 I Interface Data 62 Intermittent duty: 22 L Light blocking process 18 M M.TIME 46 Measured data Incorrect representation 70 Measured value memory read out 62 Measured variable ISO 42 NAS 42 SAE 42 Water Saturation 42 Measurement Performing 58 Measurement logs Analysing - see FluMoS 71 Copy 64 Copying error 66 Evaluating 68 File name 68 Read / copy 63 Reading - see FluMoS 71 Reading - see FluMoT 72 Transferring 67 Measurement menu 48 ED.MPNT 49 MPNT 49 RECORD 48 STP.STA 49 Measurement report Error code 80 Measurement variable Temperature 42 Measuring menu CANCEL 47, 51 ED.MPNT 50 MEMORY 50 SAVE 47, 51 TP.UNIT 51 Measuring point Selecting 35 MEMORY 50 O Operating fluid 20 Operating fluid temperature range 22 Operating mode S3 21 Operating pressure Diesel 21 Hydraulic fluids 20 P Power supply unit Single-ended cordset 89 PowerUp ADDRESS 45 CALIB 46 CANCEL 47, 51 DAT.TIM 45 DEL.MEM 45 DFAULT 47 M.TIME 46 Menu 44 SAVE 47, 51 Product information QR code 17 Q QR code scan 17 R RECORD 48 Reset Performing a 58 S SAVE 47, 51 Scope of delivery 19 Service variable Drive 42 Flow 42 Single-ended cordset C14 89 EN INDEX 4168086c / 2025-03 101 / 104 Spare parts list 87, 88 Storage temperature range 22 Storing 32 STP.STA 49 Strainer cleaning 74, 77 Supply voltage connecting 33, 58 Disconnect 33, 58, 59 T TP.UNIT 51 Transportation 31 U UKCA Declaration of conformity 93 USB stick Prepare 63 Requirement 64 Useful life 22 V voltage supply Power supply unit 21 Wiring system 21 W Warranty 2, 9 Water saturation 17 102 / 104 4168086c / 2025-03 4168086c / 2025-03 103 / 104 HYDAC Filter Systems GmbH Industriestraße 66280 Sulzbach/Saar Germany Tel. +49 6897 509-01 filtersystems@hydac.com www.hydac.com Further addresses: www.hydac.com/en/contacts 41 68 08 6c / 20 25 -0 3 mailto:filtersystems@hydac.com https://www.hydac.com https://www.hydac.com/en/contacts Table of Contents 1 General 1.1 Target group of the manual 1.2 Illustrations in the manual 1.2.1 Depiction of warning signs 1.2.2 Representation of requirements 1.2.3 Representation of procedural instructions 1.2.4 Representation of intermediate results/results 1.2.5 Supplementary symbols 1.3 Warranty 1.4 Notes on copyright 2 Safety information 2.1 Proper use 2.2 The operator’s obligations 2.3 Personnel qualifications 2.4 General safety instructions 2.4.1 Dangers during the life cycle 2.5 Safety symbols / pictograms 2.6 Safety devices 2.7 Personal protective equipment 2.8 Observing environmental precautions 2.9 Observing regulatory information 2.10 Stoppage in an emergency (EMERGENCY STOP) 2.11 Fire-fighting/Extinguishing a fire 3 Product and technical specifications 3.1 Supplementary product information — scan QR code 3.2 Counting dirt particles visually (light blockade procedure) 3.3 Checking the scope of supply 3.4 Technical Data 3.4.1 Periodic Intermittent Operation – Operating Mode S3 3.5 Decoding the name plate 3.5.1 Model code 3.6 Dimensions 3.7 Hydraulic diagram 3.8 Function 4 Transport / Storage 4.1 Opening / Closing Case 4.2 Prepare FCU for Transport 4.3 Transporting the FCU 4.4 Storing the FCU 5 Installing, Connecting, Setting Up and Putting into Operation 5.1 Connecting / Disconnecting Supply Voltage 5.2 Attaching / Removing the Return Hose 5.3 Connecting the equipotential bond 5.4 Selecting the measuring point 6 Factory settings 7 Operation 7.1 Overview of User Interface / Controls 7.1.1 Reading the Display and Operating the Keypad 7.1.2 Scrolling through Displays 7.1.3 Displaying Measured Variables 7.1.4 Displaying Service Variables 7.1.5 Freezing the Display – FREEZE 7.2 Configuring / Setting the FCU – PowerUp Menu 7.2.1 DAT.TIM – Setting Date/Time 7.2.2 ADDRESS – Setting Bus Address 7.2.3 DEL.MEM – Deleting Measurement Log Memory 7.2.4 M.TIME – Setting Measuring Time 7.2.5 CALIB – Selecting Calibration Type 7.2.6 DFAULT – Resetting to Factory Settings 7.2.7 CANCEL 7.2.8 SAVE – Saving Settings / Data 7.3 Operating / Setting Measuring Menu 7.3.1 RECORD – Recording Measuring Data 7.3.2 MEMORY – Display free measurement log memory 7.3.3 ED.MPNT – Change measuring point designation 7.3.4 TP.UNIT – Set unit of temperature 7.3.5 CANCEL 7.3.6 SAVE – Saving Settings / Data 7.4 Select operating modes / measuring methods according to the current pressure 7.4.1 Measuring from unpressurised containers 7.4.2 Measuring up to max. 45 bar / 650 psi with hydraulic fluids 7.4.3 Measuring diesel 7.4.4 Measure hydraulic fluids in the 45 … 345 bar / 650 … 5000 psi range 7.5 Performing Measurements 7.6 Restarting/resetting 7.7 Using the BatteryPack (accessory) 7.7.1 Removing / inserting the BatteryPack 7.8 Extracting the internal measured value memory 7.8.1 Extracting measurement reports via DATA interface 7.8.1.1 Pins used on the DATA interface 7.8.1.2 Connecting the FCU with CSI-B-2 7.8.1.3 Connecting the FCU with HMG 7.8.2 Extracting / copying measurement reports via USB interface 7.8.2.1 Error when copying the measurement logs 7.8.3 Transferring measurement logs via Bluetooth interface 7.8.3.1 Connecting/Linking the FCU via Bluetooth 7.9 Evaluating measurement reports 7.9.1 Measurement report directories according to measurement point 7.9.2 Measurement report file names 7.9.3 Opening the measurement report 7.9.4 The measurements are shown as dates 7.10 Reading, evaluating measurement reports / values with FluMoS 8 Performing maintenance 8.1 Maintenance table 8.2 Cleaning the FCU 8.3 Cleaning the suction strainer 8.4 Flushing the FCU 8.5 Calibrating the FCU 8.6 High-pressure adapter maintenance 8.6.1 Cleaning/changing the strainer 8.6.2 Cleaning / replacing the flow control valve 9 Finding / eliminating faults 10 Decommissioning/Disposal 10.1 Temporary shutdown 10.2 Permanent shutdown 10.3 Disposal/Recycling 11 Appendix 11.1 Contacting Customer Service 11.2 Finding spare parts/accessories 11.2.1 Finding accessories 11.3 Declaration of conformity Table of Illustrations Index of Tables Glossary Index46 7.2.6 DFAULT – Resetting to Factory Settings.............................................. 47 7.2.7 CANCEL............................................................................................... 47 7.2.8 SAVE – Saving Settings / Data ............................................................ 47 7.3 Operating / Setting Measuring Menu.................................................................. 48 7.3.1 RECORD – Recording Measuring Data ............................................... 48 7.3.2 MEMORY – Display free measurement log memory............................ 50 7.3.3 ED.MPNT – Change measuring point designation............................... 50 7.3.4 TP.UNIT – Set unit of temperature ....................................................... 51 7.3.5 CANCEL............................................................................................... 51 7.3.6 SAVE – Saving Settings / Data ............................................................ 51 7.4 Select operating modes / measuring methods according to the current pressure.............................................................................................................. 52 7.4.1 Measuring from unpressurised containers ........................................... 52 7.4.2 Measuring up to max. 45 bar / 650 psi with hydraulic fluids................. 53 7.4.3 Measuring diesel .................................................................................. 55 7.4.4 Measure hydraulic fluids in the 45 … 345 bar / 650 … 5000 psi range 56 7.5 Performing Measurements ................................................................................. 58 7.6 Restarting/resetting ............................................................................................ 58 7.7 Using the BatteryPack (accessory) .................................................................... 59 7.7.1 Removing / inserting the BatteryPack .................................................. 60 EN TABLE OF CONTENTS 4168086c / 2025-03 5 / 104 7.8 Extracting the internal measured value memory ................................................ 62 7.8.1 Extracting measurement reports via DATA interface ........................... 62 7.8.1.1 Pins used on the DATA interface ....................................... 62 7.8.1.2 Connecting the FCU with CSI-B-2...................................... 63 7.8.1.3 Connecting the FCU with HMG .......................................... 63 7.8.2 Extracting / copying measurement reports via USB interface .............. 63 7.8.2.1 Error when copying the measurement logs ........................ 66 7.8.3 Transferring measurement logs via Bluetooth interface....................... 67 7.8.3.1 Connecting/Linking the FCU via Bluetooth......................... 67 7.9 Evaluating measurement reports........................................................................ 68 7.9.1 Measurement report directories according to measurement point ....... 68 7.9.2 Measurement report file names............................................................ 68 7.9.3 Opening the measurement report ........................................................ 69 7.9.4 The measurements are shown as dates .............................................. 70 7.10 Reading, evaluating measurement reports / values with FluMoS ...................... 71 8. Performing maintenance ................................................................................................. 73 8.1 Maintenance table .............................................................................................. 73 8.2 Cleaning the FCU............................................................................................... 73 8.3 Cleaning the suction strainer .............................................................................. 74 8.4 Flushing the FCU................................................................................................ 75 8.5 Calibrating the FCU............................................................................................ 77 8.6 High-pressure adapter maintenance .................................................................. 77 8.6.1 Cleaning/changing the strainer............................................................. 77 8.6.2 Cleaning / replacing the flow control valve ........................................... 78 9. Finding / eliminating faults............................................................................................... 80 10. Decommissioning/Disposal ............................................................................................. 86 10.1 Temporary shutdown.......................................................................................... 86 10.2 Permanent shutdown.......................................................................................... 86 10.3 Disposal/Recycling ............................................................................................. 86 11. Appendix ......................................................................................................................... 87 11.1 Contacting Customer Service............................................................................. 87 11.2 Finding spare parts/accessories......................................................................... 87 11.2.1 Finding accessories.............................................................................. 90 11.3 Declaration of conformity.................................................................................... 92 Glossary .......................................................................................................................... 97 Index ............................................................................................................................... 99 EN 1. GENERAL 6 / 104 4168086c / 2025-03 1. General 63050395498315403 Before you use this product for the first time, read this manual at least up to the chapter "Operation". If you would like to carry out maintenance or troubleshooting, you can find the procedure in the respective chapters. The use and the handling of the product as well as its use are not self-explanatory and are described in detail in this manual. This manual will help you to use the product as intended, properly, effectively, and safely. Please refer to it every time you require specific details or actions. Validity of this manual The diagrams and visualizations in this manual are meant for general illustration purposes. Therefore, representations and functional options can deviate from the delivered product. We reserve the right to modifications to the contents of this manual without prior notice. 1.1 Target group of the manual 36028797159348747 This manual was created for the following target group: Target group Tasks Owner Keep this manual and the applicable documents at the installation location of the product and also for later use. Ask the employees to read and follow the manual and the associated documents, in particular, the safety and warning instructions. Additionally, please observe the product-related instruc- tions and requirements. Operator, specialist personnel Read, observe and follow this manual and the associated documents, in particular, the safety and warning instruc- tions. Tab. 1: Target groups 1.2 Illustrations in the manual 108086391199375243 You will find illustrations in this manual. You can find details regarding these in the following chapters. 1.2.1 Depiction of warning signs 18014401014164619 Information that draws your attention to specific or potential hazards is presented as warnings in these instructions. Function of warnings Warnings serve to protect you from accidents and injuries when handling the product and to prevent material and environmental damage. Read and observe the warnings carefully and follow the specified steps precisely. EN 1. GENERAL 4168086c / 2025-03 7 / 104 Warnings visually highlightedin boxes Warnings visually highlighted in boxes provide the following information in connection with a hazard: DANGER High electrical voltages Life-threatening injury or death! Disconnect the system from the power supply and secure it against being switched back on again. u 1 2 4 3 1 Warning level How high is the risk potential? (▶Tab. 2, p. 8) 2 Type and source of the hazard What is the specific danger? What is the source of the danger? 3 Consequences if not observed What are the consequences if you fail to observe the instructions given in the warning (4)? 4 Actions to be taken What do you have to do specifically to safely eliminate the hazard? Warnings integrated into the text Warnings are sometimes integrated into the body of the text to keep the content easy to read. Example: Loosen the vent screw by rotating it two to three turns anti-clockwise.3. 2 1 3 ATTENTION Do not completely unscrew the vent screw. 1 Context An action step in this example 2 Warning level How high is the risk potential? (▶Tab. 2, p. 8) 3 Safety information What do you have to do specifically to safely elim- inate the hazard? Warning levels The warning level in a warning gives you information on the risk potential associated with a hazard and failure to observe the appropriate warning. EN 1. GENERAL 8 / 104 4168086c / 2025-03 Warning level What this means for you DANGER Warns of dangers for people with a high risk potential. Failure to observe this warning is highly likely to result in serious injury or even death. WARNING Warns of dangers for people with a medium risk potential. Failure to observe this warning may result in serious injury or even death. CAUTION Warns of dangers for people with a low risk potential. Failure to observe this warning may result in minor to moderate injury. ATTENTION Warns of property damage with a high risk potential. Failure to observe this warning may result in serious property and environmental damage. Tab. 2: Depiction of the warning levels 1.2.2 Representation of requirements 18014398651027467 These are absolutely required for carrying out a work activity on the product and are marked with a check mark and are in bold in the text. An example for the representation of requirements: ü The product is assembled and connected. ü The product is switched off. 1. Switch the product on. 2. Select an operating mode. 3. Switch the product off. 1.2.3 Representation of procedural instructions 18014398651173771 In the case of procedural instructions, there are the two following representations: Procedural instructions with a fixed sequence Procedural instructions, the order of which must be strictly adhered to, are listed with sequential numbering (1., 2., 3., etc.). An example for procedural instructions with a fixed sequence: 1. Remove the transport securing device. 2. First fill the product. 3. Switch the product on. Procedural instructions with a random sequence Procedural instructions with a random sequence are listed as bullet points. An example of a procedural instruction with a random sequence: ● Clean the display. ● Rinse the product. EN 1. GENERAL 4168086c / 2025-03 9 / 104 1.2.4 Representation of intermediate results/results 9007199396760075 In the case of some activities, it is necessary to carry out work steps with intermediate results and end results. Intermediate results are the consequence of activities; they are marked with an indented arrow. End results represent the end of an activity and are represented with a flag. An example for a procedural instruction with intermediate result and final result: 1. Switch the product on. ð The display lights up. 2. Press the button. O The product is ready for use. 1.2.5 Supplementary symbols 63050394925252235 You will find the following symbols in the manual as additional details: [ ]u ## Cross reference to a page/a chapter/a section or another document. Glossary Terms in grey are explained in detail in the glossary, a chapter at the end of the manual. Required tool. Information for handling the product. 1.3 Warranty 18014400993738123 For the warranty provided by us, please refer to our terms of delivery. They are made available to you at the conclusion of the contract at the latest. They can also be found at www.hydac.com -> General Terms and Conditions. 1.4 Notes on copyright 54043195578747019 All copyrights for this manual lies with the manufacturer. No part of this manual may be reproduced in any form without the written consent of the manufacturer or processed or distributed using electronic systems. Any infringements to the above shall be liable to damage compensation. http://www.hydac.com EN 2. SAFETY INFORMATION 10 / 104 4168086c / 2025-03 2. Safety information 5547601547 This section gives you important information on the safe handling and use of your product. 2.1 Proper use 5548025099 The FluidControl Unit FCU is a portable service unit for taking short-term measurements of the solid particle contamination, the temperature and the water saturation in hydraulic systems and diesel fuels according to DIN EN 590 / ASTMD975 4-D with a flash point > 55 °C. NOTICE Impermissible operating conditions The FCU will be damaged u Operate the FCU within the permissible operating conditions. Permitted areas of application Intended use includes: ● Operation within the permitted operating conditions ● Operation with permitted operating media Improper use/foreseeable misuse Any other use, or use that goes beyond that indicated, is not permitted and is therefore considered improper use. Improper use includes in particular: ● Operation outside of the permitted operating conditions ● Operation with a non-permitted operating medium Claims for defects or liability Claims for defects or liability – on whatever legal grounds – do not exist, particularly in the event of incorrect or improper installation, commissioning, use, handling, storage, maintenance, repair, use of unsuitable components or other circumstances for which the manufacturer is not responsible. The manufacturer assumes no responsibility for determining the interfaces for instal- lation in a system or the installation, use or functionality of the product in this system. EN 2. SAFETY INFORMATION 4168086c / 2025-03 11 / 104 2.2 The operator’s obligations 5547632523 As the owner, you have the following obligations in relation to the use of our product: Instruction and training ● Provision of these instructions The owner must ensure that all employees who are assigned work on the product have read and understood these instructions. ● Regular training on correct use of the product and on the residual hazards asso- ciated with the product (▶Sec. 2.4 "General safety instructions") ● Readability of the warning signs on the product Warning signs that have become illegible must be replaced by the owner. Occupational health and safety ● Creation of own risk assessment and implementation of required measures The owner must determine in their own risk assessment the sources of danger arising from the product being used in their machine or system. On this basis, the owner must independently define appropriate measures for safety of the machine or system and must compile the documentation of their product accordingly. ● Application of the occupational health and safety and accident prevention regula- tions applicable in the country of use ● Clear regulation of which people are responsible for the various types of activities (e.g. assembly, operation, troubleshooting, maintenance) and what qualifications they need to have ● Provision of personal protective equipment (▶Sec. 2.7 "Personal protective equipment") ● Operation of the product only with the prescribed safety devices (▶Sec. 2.6 "Safety devices"). Compliance with standards and regulations ● Observance of the statutory inspection intervals for the system The owner must document the results of inspection in an inspection certificate and retain this certificateuntil the next inspection. ● Compliance with the environmental protection regulations applicable in the country of use 2.3 Personnel qualifications 5547814283 The activities described in these instructions may only be carried out by individuals with specific specialist knowledge in the areas listed below: Activity Qualification Transport / storage ● Specialist personnel for transportation and storage Assembly ● Specialist personnel for electric and mechanical systems Initial commissioning Maintenance ● Specialist personnel for hydraulics and mechanical systems EN 2. SAFETY INFORMATION 12 / 104 4168086c / 2025-03 Activity Qualification Troubleshooting Repair Shutdown Disassembly Disposal Handling, operation, oper- ation monitoring ● Operating personnel Requirements for specialist personnel: ● Specialist training, knowledge and experience in the mentioned area ● Knowledge of the relevant provisions. ● Knowledge about how to handle operating media. ● These individuals can assess work assigned to them, identify possible hazards and take suitable safety measures independently. ● For transport and storage: Safe handling / operation of lifting equipment and acces- sories. Requirements for operating personnel: ● These individuals have received product-related instruction from the owner and have been informed of potential hazards arising from improper conduct. ● Knowledge about how to handle operating media. 2.4 General safety instructions 5547671947 We develop our products in accordance with the latest technological developments. Nevertheless, it is impossible to design products in a way that eliminates all residual risks. An overview of the potential sources of danger is provided below. 2.4.1 Dangers during the life cycle 5071699467 The following dangers can occur in the various life cycles of the product: Life cycle – all life cycles The following risks could arise during all life cycles: NOTICE Impermissible operating conditions The FCU will be damaged u Operate the FCU within the permissible operating conditions. EN 2. SAFETY INFORMATION 4168086c / 2025-03 13 / 104 Life cycle – transportation / storage The following hazards can arise during the transport / storage life cycles: CAUTION Hot fluid at the connection OUTLET Danger of burns u Let the FCU and the hoses cool down. Life cycle – start-up / operation The following dangers can arise during the start-up / operation life cycle: WARNING Statically charged fluid Risk of explosion u Connect the FCU with the plant, system, tank or container, etc. via the potential equalization line during measurement / operation. u Use the hoses or suction pipe included in the scope of delivery to measure fluids. u Return the measured fluid to an open, well-ventilated container below the fluid level. WARNING Hydraulic systems are under pressure Danger of bodily injury u The hydraulic system must be depressurised before performing any work on it. NOTICE Operating pressures above 45 bar / 650 PSI Over pressure is guided to the OUTLET connector u Never close the OUTLET connector. u Place the return hose in a non-pressure container. Life cycle – maintenance / troubleshooting The following dangers can arise in the maintenance / troubleshooting life cycles: WARNING Hydraulic systems are under pressure Danger of bodily injury u The hydraulic system must be depressurised before performing any work on it. 2.5 Safety symbols / pictograms 9007199338276875 The following safety signs / pictograms can be found in this manual. They indicate specific dangers to persons, property or to the surroundings. Observe these safety EN 2. SAFETY INFORMATION 14 / 104 4168086c / 2025-03 signs / pictograms and act with particular caution in such cases. Always keep all safety signs / pictograms complete and legible. Warning signs used These marks can be found for all safety and warning instructions in this manual which indicate particular dangers to persons, property or the environment. Danger point warning Warning about dangerous electrical voltage Hot surface warning Signs used for giving orders These symbols can be found for all safety and warning instructions in this manual which indicate particular dangers to persons, property or the environment. Follow the instructions. Disconnect before working. Signs used for the required specialist personnel These symbols show the required training/knowledge for installation work and/or main- tenance work. Specialist personnel – General/Operating personnel These persons have a specialist training and several years of work expe- rience. They are able to assess and perform the work assigned to them and to recognise potential hazards. Specialist personnel – Mechanical These persons have specific specialist training and several years of work experience. They are able to assess and perform the work assigned to them and to recognise potential hazards. Specialist personnel – Electrical These persons have specific specialist training and several years of work experience. They are able to assess and perform the work assigned to them and to recognise potential hazards. EN 2. SAFETY INFORMATION 4168086c / 2025-03 15 / 104 Others symbols used These marks can be found for all safety and warning instructions in this manual which indicate a particular danger to persons, property or the environment. Danger due to operating pressure 2.6 Safety devices 5547715211 Your product is equipped with the following safety devices and safety functions: Product-internal safety devices ● Main switch ● Temperature Sensor 2.7 Personal protective equipment 5547746955 Personnel are required to wear protective equipment for certain activities. The specific protective equipment required in each case is identified in the corre- sponding sections. Required protective equipment – an overview Eye protection Protective gloves Additional protective measures ● In addition, observe the notices regarding personal protective equipment in the safety data sheets of the operating medium. 2.8 Observing environmental precautions 63050395051134859 Take all measures to protect the environment. Ensure that no operating medium is released into the environment (soil or water). Environmental tip Operating fluid/operating medium is released into the soil or water. Environmental hazard u Remove any escaped operating fluid/operating medium immediately and dispose of it in an environmentally sound manner. EN 2. SAFETY INFORMATION 16 / 104 4168086c / 2025-03 2.9 Observing regulatory information 9007199302626571 Observe the following regulatory information and directives: ● Legal and local regulations for accident prevention ● Legal and local regulations for environmental protection and environmental require- ments ● Country-specific regulations, organisation-specific regulations ● Occupational safety rules 2.10 Stoppage in an emergency (EMERGENCY STOP) 27021597827479947 Disconnect the product from all sources of energy in an emergency. Switch off the product at the main switch. 2.11 Fire-fighting/Extinguishing a fire 72057594101600011 Use a powder extinguisher that corresponds to the fire class B EN 2 to extinguish any fires/to fight fires. Maintain a minimum safe distance from electrical components. For a mains voltage of up to 1000 V, the minimum safe distance is 1 m. Fig. 1: Fire protection classification B/Minimum distance for fire fighting EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 4168086c / 2025-03 17 / 104 3. Product and technical specifications 18014398592987531 The FluidControl Unit FCU is a portable service device used to carry out short-term measurements of solid particle contamination, the temperature and water saturation in hydraulic systems. Knowing the size and quantity of the contamination allows you to monitor and document quality standards and to meet the required optimisation measures. The integrated pump and the supplied hoses allow the use on: ● Control circuits ● Delivery circuits● Non-pressure containers The internal data memory enables measured values to be recorded with real-time reference (time stamp). You can copy all measured values onto a USB stick over the USB interface or send these to a mobile device via bluetooth and analyse them using MS-Excel or the Fluid Monitoring Software FluMoS. Other performance features include: ● Optical recording of solid particle contamination ● Capacitive recording of water saturation in % ● Resistive recording of temperature ● Suitable for hydraulic fluids (up to ISO VG 68) ● 2 … 350 mm²/s / 33 … 1622 Sus ● Automatic measurement and display of cleanliness classes in accordance with: ● ISO 4406; NAS 1638 ● ISO 4406; SAE AS 4059 (D) ● Measurement accuracy ± ½ ISO code in calibrated area 3.1 Supplementary product information — scan QR code 27021603255120779 For additional up-to-date product information, such as instructions and certificates, or to find product tips and tricks on our home page, scan the QR code on the product label. EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 18 / 104 4168086c / 2025-03 3.2 Counting dirt particles visually (light blockade procedure) 9007199340745483 The following sketch shows a simplified version of the measurement principle for the light blocking process. The light source sends monochromatic light through the oil flow to the photodetector, which generates a particular electrical signal. If a particle gets between the light source and the photodetector, a shadow appears on the photodetector. These shadows change the electrical signal generated by the photodetector. These changes make it possible to determine the size of the shadow created by the particle, and therefore determine the size of the particle. Using this method, it is possible to determine the cleanliness class according to ISO 4406, NAS 1638 and SAE AS 4059. The disruptive factors of this measurement principle are foreign fluids and gas bubbles, which cause light refraction and thus count as particles. Fig. 2: Light blockade procedure 1 Light source 2 Dirt particle 3 Photo detector Time Th re sh ol d va lu es Fig. 3: Signal lamp amplitudes Each signal peak signifies shadowing from a particle. The signal amplitude reflects the particle size. The particle size ranges are grouped via threshold values 2-5 µm, 5-15 µm, 15-25 µm, >25 µm and. >4 µm(c), >6 µm(c), >14 µm(c), >21 µm(c). EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 4168086c / 2025-03 19 / 104 3.3 Checking the scope of supply 9007199340774027 Here you will find the scope of supply for the product. ● Check the packaging and the product for damage. Report any damage in transit to the forwarding agent or the HYDAC department in charge. ● Check the scope of supply for completeness. The scope of delivery includes: Item Qty. Designation - 1 FluidControl Unit FCU, including lid pocket - 1 Power supply unit, primary: 100-240°V°AC / secondary: 24°V°DC°/ °5°A - 4 Connection cable for power supply unit (Europe, USA/Canada, UK, Australia, Japan) - 1 Suction pipe, open end - 1 Suction hose adapter - 1 High-pressure hose with screw connection, type°1620, colour: black, L°=°2 m - 1 High-pressure adapter - 1 Return hose, transparent, L°=°2°m - 1 Equipotential bonding conductor - 1 Document pouch consisting of: - operating instructions (this document) - calibration certificate - CE and UKCA declaration of conformity - CD ROM with FluMoS software - USB stick containing operating and maintenance instructions (PDF file) in further languages Tab. 3: Scope of delivery A USB adapter for the PC is a free extra and does not belong to the scope of delivery. EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 20 / 104 4168086c / 2025-03 3.4 Technical Data 9007199340785163 The following technical data applies to the FCU. Contamination sensor Self-diagnosis Continuously with error indication via status LED and display Display LED, 6 / 4 / 4 figures, each with 17 segments Measurement variables ● Solid particle contamination ISO code / SAE class / NAS class ● Water saturation % ● Temperature °C / °F Measurement range ● Solid particle contamination Display of ISO code between: 9/8/7 … 25/24/23 ● Water saturation 0 … 100% ● Temperature -25 … 100 °C / -13 … 212 °F Calibration accuracy ● Solid particle contamination ± ½ ISO code in the calibrated area of ISO 13/11/10 … ISO 23/21/18 ● Water saturation ≤ 2% (Full scale) ● Temperature ≤ 2% (Full scale) Service display FLOW / DRIVE Adjustable measuring time 10 – 300 Seconds Permissible operating media Mineral oils or raffinates based on mineral oils whose flash point is higher than 55°C / 131°F. Permitted flushing mediums Low-viscosity mineral oils or raffinates based on mineral oils whose flash point is higher than 55°C / 131°F. Hydraulic connections ● INLET Measurement coupling type 1604 ● OUTLET DN7 quick-release nipple Permitted operating pressure with hydraulic fluids ● Without high-pressure adapter IN: -0.5 … 45 bar / 0 … 650 psi OUT: 0 … 0.5 bar / 0 … 7.5 psi EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 4168086c / 2025-03 21 / 104 Contamination sensor ● With high-pressure adapter IN: 15 … 345 bar / 217 … 5000 psi OUT: 0 … 0.5 bar / 0 … 7.5 psi Permissible operating pressure with diesel according to DIN EN 590 / ASTM D975-4-D IN: 16 bar / 232 psi OUT: 0 … 0.5 bar / 0 … 7.5 psi Permitted pressure at the INLET connection ≥ 345 bar / 5000 psi Measuring flow rate ≈ 180 ml/min (viscosity dependent) Permitted viscosity range 2 … 350 mm²/s / 33 … 1622 Sus Suction height ≤ 0.5 m Suction hose INLET DN6 open end. High-pressure hose INLET DN4 with screw connection for measuring point, type°1620, colour: black, length°=°2 m Return hose OUTLET DN7 open end, colour: transparent, Length = 1 m Tab. 4: Contamination sensor Electrical data Operating mode in accordance with DIN EN 60034-1 / DIN VDE 0530 Part°1 Periodic intermittent operation, S3 relative duty cycle 40%, for details, see ▶Sec. 3.4.1 "Periodic Intermittent Operation – Operating Mode S3". voltage supply ● Power supply unit 24 V DC ± 20%, residual rippleUnit can be found on the type label. The type label displays the product ID and important technical data. Fig. 5: Type label EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 24 / 104 4168086c / 2025-03 (1) Type label for FCU (2) Model code; for details, see ▶Sec. 3.5.1 "Model code" (3) Information on the permitted flash point of the fluids to be tested (4) Permitted fluids Model Model code; for details, see ▶Sec. 3.5.1 "Model code" Date Year / week of production P/N Article no. S/N Serial no. Flow rate Flow rate Weight Empty weight Viscosity range Permitted viscosity range Pressures Pressure data In Permitted pressure at port INLET Out Permitted pressure at port OUTLET Temperatures Temperature data Oil Permitted oil temperature range Ambient Permitted ambient temperature range Power Power consumption Voltage Voltage Current Current consumption EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 4168086c / 2025-03 25 / 104 3.5.1 Model code 86223499 The FCU is defined by the following type code: Product Contamination code Series FCU 1 3 1 0 – 4 – U – AS – 1 FCU = FluidControl Unit 1 2 Media 4 Options = Pump, integrated Mineral oil-based hydraulic lubricating fluids0 = 1000 series, 4 particle size ducts ISO4406; SAE AS 4059 (D) / >4µm(c) >6µm(c) >14µm(c) >21µm(c)= = Housing 1 = Plastic case with bag, for mobile use Supply voltage Integrated sensor Power supply adapter 24 VDC AquaSensor AS 1000 (only 131x) 100 ... 240 VAC / 50/60 Hz / 1-phase / 5000 mA (Europe, USA/Canada, UK, Australia, Japan) = = = U AS 1 3 ISO4406; NAS 1638 / 2-5µm, 5-15µm, 15-25µm, >25µm can be changed over to ISO4406; SAE AS 4059 (D) / >4µm(c) >6µm(c) >14µm(c) >21µm(c) = Mineral oil-based hydraulic lubricating fluids as well as diesel according to DIN EN 590 / ASTM D975 4-D 5 = without=Z Fig. 6: Model code EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 26 / 104 4168086c / 2025-03 3.6 Dimensions 9007199340787083 The FCU has the following dimensions. Fig. 7: DIMENSIONS All dimensions in mm. EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 4168086c / 2025-03 27 / 104 3.7 Hydraulic diagram 9007199340909451 The FCU has the following hydraulic diagram. Fig. 8: Hydraulic diagram 1 INLET 2 Strainer, 400 µm 3 gear pump 4 Electric motor 5 Pressure relief valve 6 Contamination sensor 7 Counterbalance valve 8 AquaSensor 9 OUTLET EN 3. PRODUCT AND TECHNICAL SPECIFICATIONS 28 / 104 4168086c / 2025-03 3.8 Function 9007199340781323 A continuous oil flow is established from the measuring point (either a pressure port or a tank or sampling bottle) by the INLET connection of an electrically controlled gear pump (16). The suction strainer (17) protects the pump from coarse dirt. The oil flows through an optical contamination sensor (6). The dirt particles in the oil flow cause pulsed shading of the light beam, which is classified and counted as meas- urement signals in the contamination sensor. The evaluation module continuously displays cleanliness classes using the measurement signals from the optical sensor in relation to a measurement volume of 100 ml. The counter-balance valve (7) generates a defined pressure in the oil flow. This serves to minimise the air bubbles in the system, which would falsify the measurement result. The pressure relief valve (5) protects the pump and measuring cell from excessive pressure. The oil flows out of the connection (9) OUTLET and is fed through the return hose into an unpressurised reservoir. Fig. 9: Hydraulic diagram The electronic evaluation module monitors: ● The function of the contamination sensor ● The oil flow rate ● The function of the AquaSensor In the event of a fault, the status display indicates an error. As soon as the fault has been corrected, the evaluation module automatically resets itself and continues the measurement. EN 4. TRANSPORT / STORAGE 4168086c / 2025-03 29 / 104 4. Transport / Storage 9007199340670475 Observe the following chapters on transport and storage. CAUTION Hot fluid at the connection OUTLET Danger of burns u Let the FCU and the hoses cool down. 4.1 Opening / Closing Case 9007199340849931 Open the case by releasing the two latches. Fig. 10: Open case Close the case with the two latches. Make sure that you hear them click into place. Fig. 11: Close case 4.2 Prepare FCU for Transport 9007199342052875 Before the FCU is transported, the USB flash drive must be removed, the power supply unit and hoses must be neatly packed away or stowed in the bag, and the case must be properly closed. To prepare the FCU for transport, observe the following sequence: ü The measurement and operation are complete. 1. Detach the measuring hose from the measuring point. 2. Switch off the internal pump at the switch. EN 4. TRANSPORT / STORAGE 30 / 104 4168086c / 2025-03 3. Remove the USB flash drive if one is inserted. 4. Close the USB port with the corresponding cover. 5. Remove the hose from the INLET connection by turning it counterclockwise. 6. Loosen the quick-release coupling of the return hose by lifting the outer ring. 7. Empty the hose into an unpressurised container. To ventilate the hose, open the non-return valve of the quick-release coupling by pressing a thin object into the quick-release coupling. This allows the fluid in the hose to drain quickly. EN 4. TRANSPORT / STORAGE 4168086c / 2025-03 31 / 104 After emptying, plug the two ends of the hose together. This ensures that no further fluid escapes from the hose during transport. 8. Unlock the catch (1) and then pull the female connector out of the plug connector (2). 9. Close the FCU with the two latches. Make sure that you hear both latches click into place. 10. Stow the hoses and the power supply unit in the bag. O The FCU is ready for transport. 4.3 Transporting the FCU 9007199342086667 Only transport the FCU when closed, either lying down or carrying it by the handle. EN 4. TRANSPORT / STORAGE 32 / 104 4168086c / 2025-03 4.4 Storing the FCU 9007199340674571 Empty and flush the FCU completely before storage, for details see ▶Sec. 8.4 "Flushing the FCU". Details on the permissible storage condi- tions can be found in chapter ▶Sec. 3.4 "Technical Data". Store the FCU closed in a clean and dry place. When stored upright, the FCU must not be exposed to shocks or vibrations. EN 5. INSTALLING, CONNECTING, SETTING UP AND PUTTING INTO OPERATION 4168086c / 2025-03 33 / 104 5. Installing, Connecting, Setting Up and Putting into Operation 9007199341387659 Before commissioning, connect the unit and the FCU hydraulically and electrically as described below. 5.1 Connecting / Disconnecting Supply Voltage 9007199343194251 The FCU has a 3-pin female connector for connection to the supply voltage. Connect supply voltage 1. Insert the 3-pin female connector, (for example, of the power supply unit) into the socket until you hear the notch click into place. Connect the other end to the voltage source. 2. If the FCU is supplied with voltage, the display shows HYDAC FCU 1### in running text. The firmware version is then displayed for two seconds. The internal sensors are checked after this. The display shows 2. SENS OK as well as the firmware of the sensors. The self-test is followed by a countdown on the display WAIT 99 … WAIT 0. 3. The FCU is now ready to carry out the measurement. 4. If T AMB and > 45C flashes on the display, the FCU is expe- riencing a safety shut down. For details, see .▶Sec. 9 "Finding / eliminating faults". Fig. 12: Connecting supply voltage As long as the pump is not running and no fluid is being delivered, the status LED flashes red and the display shows CHECK. This means that there is no oil flow. Disconnect supply voltage 1. Press the notch on the connector. 2. Pull the connector upwards out of the port. Fig. 13: Disconnecting supply voltage EN 5. INSTALLING, CONNECTING, SETTING UP AND PUTTING INTO OPERATION 34 / 104 4168086c / 2025-03 5.2 Attaching / Removingthe Return Hose 9007199343230475 Attach the quick-release coupling of the return hose to the nipple. Make sure that you can feel the coupling engage on the nipple. Check that the quick-release coupling is firmly seated. Fig. 14: Attaching the return hose Ensure that the OUTLET connection is open. Place the other end of the return hose in an unpres- surised container or reservoir. Fig. 15: Removing the return hose EN 5. INSTALLING, CONNECTING, SETTING UP AND PUTTING INTO OPERATION 4168086c / 2025-03 35 / 104 5.3 Connecting the equipotential bond 9007199347137291 Connect the equipotential bond conductor when operating with diesel. The permitted types of diesel have a low conduc- tivity. This can lead to a static charge when flowing through pipes or hoses, which can become a source of ignition for explosive mixtures if the elec- trostatic discharge is uncontrolled. The flow rate through the FCU is so low that the fluid cannot normally become statically charged. However, it is not possible to rule out that statically charged fluid will be sucked out of the system, which then discharges electrostatically in an uncon- trolled manner when it exits the FCU. This can lead to the formation of sparks, which become a source of ignition for any potentially explosive mixtures present. Fig. 16: Connecting the equipotential bond The FCU has a safety shut-down which shuts down the pump if the ambient temper- ature exceeds > 45°C. This temperature is measured inside the case wall. If the safety shut-down is active, T AMB and > 45C flashes on the display. For details, see ▶Sec. 9 "Finding / eliminating faults". WARNING Statically charged fluid Risk of explosion u Connect the FCU with the plant, system, tank or container, etc. via the potential equalization line during measurement / operation. u Use the hoses or suction pipe included in the scope of delivery to measure fluids. u Return the measured fluid to an open, well-ventilated container below the fluid level. 5.4 Selecting the measuring point 9007199343234827 Select the measuring point so that the measuring volume comes from a turbulent, well- flowing environment. For example: at a pipe bend (A). This ensures that a represent- ative sample is analysed. By installing the FCU close to the measuring point (B), you avoid delayed measurement results and sedimentation (deposits of particles in the line). When installing the inlet hose INLET, make sure that no siphon effect (C) is created. EN 5. INSTALLING, CONNECTING, SETTING UP AND PUTTING INTO OPERATION 36 / 104 4168086c / 2025-03 Fig. 17: Selecting the measuring point EN 6. FACTORY SETTINGS 4168086c / 2025-03 37 / 104 6. Factory settings 9007199345329675 Under menu item DFAULT, reset the FCU to its factory settings. This will load the following factory settings: Value For details, see . ▶Sec. 7.2.2 "ADDRESS – Setting Bus Address" ▶Sec. 7.2.4 "M.TIME – Setting Meas- uring Time" ▶Sec. 7.2.5 "CALIB – Selecting Cali- bration Type" Bluetooth Code 0000 ▶Sec. 7.8.3.1 "Connecting/Linking the FCU via Bluetooth" Tab. 7: Default settings - DFAULT The measurement point designations, as well as any other settings, are not affected by the reset. EN 7. OPERATION 38 / 104 4168086c / 2025-03 7. Operation 27021597850852619 Procedures, notes and tips for optimum, fault-free operation can be found in this chapter. 7.1 Overview of User Interface / Controls 9007199341368715 You will find the following controls on the user interface: Fig. 18: User interface / controls 1 Display of ISO, SAE/NAS, FLOW, DRIVE with keyboard 2 Display of water saturation 3 Display of fluid temperature 4 Switch ON/OFF for the internal pump 5 Supply voltage connection, 3-pin 6 Data interface DATA 7 Connection OUTLET 8 Connection INLET 9 USB interface with cover 10 Socket for connecting the equipotential bond conductor 11 Equipotential bond conductor 14 Catch for connection OUTLET when the case is closed 15 Hold-down device 16 Bag for hoses and accessories - Bluetooth interface EN 7. OPERATION 4168086c / 2025-03 39 / 104 7.1.1 Reading the Display and Operating the Keypad 9007199343721227 The FCU has three displays and additional LEDS to display the cleanliness classes, water saturation and temperature. Fig. 19: Display shows 1 Status LED Status display green / red In the event of a fault, the LED turns red and flashes as code. For details, see ▶Sec. 9 "Finding / eliminating faults" 2 Display Consists of a 6 digit display which displays the selected values. 3 Measurement variable Display of the respective measured variables shown on the display e.g.:ISO / SAE/NAS 4 Service variable Display of the respective service variables shown on the display e.g.:Flow / Drive 5 Unit of measurement Units available for the fluid temperate display: °C / °F The keyboard consists of six keys. These keys are used to operate the FCU and to navigate the hierarchically structured menu. Keyboard Description Go one level lower Confirming a changed value (lowest level) Confirm to save or delete a value (highest level) Go one lever higher (back) Abort (no values changed) Change values on the lowest level (the display will flash if you are on the lowest menu level). Scroll through the display Scroll through the menu Select points Tab. 8: Keyboard overview EN 7. OPERATION 40 / 104 4168086c / 2025-03 7.1.2 Scrolling through Displays 9007199344323467 Depending on the selected calibration type (settings under CALIB, for details, see ▶Sec. 7.2.5 "CALIB – Selecting Calibration Type"), you can scroll through the following display indicators in the Power Up using the arrow keys. Displays in ISO.SAE Display Description 3-digit ISO code SAE class A SAE class B SAE class C SAE class D SAE Max. Flow rate status LED flow in % Tab. 9: Displays in ISO.SAE EN 7. OPERATION 4168086c / 2025-03 41 / 104 Displays in ISO.NAS Display Description 3-digit ISO code NAS 2-5 µm channel NAS 5-15 µm channel NAS 15-25 µm channel NAS > 25 µm channel NAS Max. LED flow in % Flow rate status Tab. 10: Displays in ISO.NAS EN 7. OPERATION 42 / 104 4168086c / 2025-03 7.1.3 Displaying Measured Variables 9007199344723979 The measured variables provide information about the degree of cleanliness, water saturation and temperature of the hydraulic system under investigation. The measured variables ISO, SAE and NAS are calibrated and provide a measured value with an accuracy of ± ½ ISO code within the calibrated range. Measured variable – ISO The measured variable is updated depending on the set meas- uring time. It is displayed as a 3-digit ISO code. Example: ISO code 20.18.15 Measured variable – SAE The measured variable is updated depending on the set meas- uring time. It is displayed as a channel of the SAE class. Example: SAE class A = 13.4 Measured variable – NAS The measured variable is updated depending on the set meas- uring time. It is displayed as a channel of the NAS class. Example: NAS class, channel 15-25 = 13.2 Measured variable – Water Saturation The integrated AquaSensor continuously measures the satu- ration. The measured value is shown on the display as water saturation of the fluid in % saturation. Example: 19.3% water saturation Measurement variable – Temperature The integrated AquaSensor continuously measures the fluid temperature. The value as Celsius °C or Fahrenheit °F can be set under TP.UNIT. Example: Temperature = 37.8 °C 7.1.4 Displaying Service Variables 9007199344789387 The service variables provide you with information about the average flow rate and the light source output. The service variables are not calibrated. Service variable – Flow Flow indicates whether the flow rate is within the permissible range. Example: Flow = OK Service variable - Drive Display of LED power (1-100%), with which the contamination sensor is currently working. Example: LED power = 42% EN 7. OPERATION 4168086c / 2025-03 43 / 104 7.1.5 Freezing the Display – FREEZE 9007199346932363The FREEZE function allows you to call up the last 20 display values shown on the display. The active display is frozen in the set MTIME cycle. The function is based on a volatile memory and means that the values can only be called up as long as the sensor is supplied with voltage and the sensor is in the display FREEZE. The measured values are numbered automatically, with the highest counter repre- senting the most recently measured value. This means that when the memory is full (= 20 measured values), the value 20 is the most recent and the value 1 is the oldest. If the memory exceeds the number of 20 display values, the oldest entry is overwritten. Starting FREEZE To activate or deactivate the history memory FREEZE, press the two arrow buttons simultaneously. The FREEZE function starts with the display of the last measured value. Buttons Display (1 sec.) Display (3 sec.) … … End FREEZE Press both buttons at the same time to return to the current display: The display jumps back to the pre-set display. All available values in the FREEZE memory are deleted. EN 7. OPERATION 44 / 104 4168086c / 2025-03 The system automatically returns to the current display after 10 values have been entered for M.TIME, or before this manually be pressing both keys. 7.2 Configuring / Setting the FCU – PowerUp Menu 9007199345010315 In the PowerUp menu, you can set the basic settings to operate the FCU. Selection What to do Start the PowerUp menu Press and hold a key whilst the supply voltage is inserted. Leave the PowerUp menu without saving Scroll to CANCEL and confirm using the key or wait for 30°seconds without confirming via a key. Leave the PowerUp menu after saving Scroll to SAVE and confirm using the key. Display indicators in the PowerUp menu: Sub-menu For details, see . ▶Sec. 7.2.1 "DAT.TIM – Setting Date/Time" ▶Sec. 7.2.2 "ADDRESS – Setting Bus Address" ▶Sec. 7.2.3 "DEL.MEM – Deleting Measurement Log Memory" ▶Sec. 7.2.4 "M.TIME – Setting Measuring Time" ▶Sec. 7.2.5 "CALIB – Selecting Calibration Type" ▶Sec. 7.2.6 "DFAULT – Resetting to Factory Settings" ▶Sec. 7.2.7 "CANCEL" ▶Sec. 7.2.8 "SAVE – Saving Settings / Data" Tab. 11: Display indicators in the PowerUp menu Press the key to switch to the desired sub-menu. EN 7. OPERATION 4168086c / 2025-03 45 / 104 7.2.1 DAT.TIM – Setting Date/Time 9007199345048971 Under DAT.TIM, set/change the system date/system time. If the date has not yet been updated or the backup battery is discharged, the system date is set to 00.01.01 and the time is set to 0000. The date format is: YY.MM.DD => year / month / day. The time has the 24-hour format: HH.MM => hour / minute. Fig. 20: DAT.TIM – Setting date/time - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back 7.2.2 ADDRESS – Setting Bus Address 9007199345056139 Use ADRESS to set the bus address for transmitting the measured values via the data interface in the HSI protocol. 26 bus addresses of A - Z are available here. Please note that an address is only allowed to appear once within a bus. Factory setting, see ▶Sec. 6 "Factory settings". Fig. 21: ADRESS – Setting bus address - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back 7.2.3 DEL.MEM – Deleting Measurement Log Memory 9007199345145099 Use DEL.MEM to permanently delete all measurement data records in the internal measurement log memory. Deleting the measurement log memory will result in data loss. Back up the measurement logs to the USB flash drive before deleting them, for details see ▶Sec. 7.8.2 "Extracting / copying measurement reports via USB interface". EN 7. OPERATION 46 / 104 4168086c / 2025-03 Fig. 22: Deleting measurement log – DEL.MEM o.k. Confirm changes Esc Cancel and back 7.2.4 M.TIME – Setting Measuring Time 9007199345170955 Set the measuring time under M.TIME. Select the measuring time in the range of 10 … 300 seconds. Set the measuring time using the following buttons: Factory setting, see ▶Sec. 6 "Factory settings". Fig. 23: Setting measuring time – M.TIME - / + Change calibration ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back 7.2.5 CALIB – Selecting Calibration Type 9007199345247883 Under CALIB, select the desired calibration type between ISO.SAE or ISO.NAS. ● The calibration type ISO.SAE is based on ISO 4406 / SAE. ● The calibration type ISO.NAS is based on ISO 4406 / NAS. Fig. 24: CALIB – Selecting calibration type - / + Change calibration o.k. Confirm changes Esc Cancel and back EN 7. OPERATION 4168086c / 2025-03 47 / 104 7.2.6 DFAULT – Resetting to Factory Settings 9007199345274891 The FCU can be reset to the factory settings under DFAULT. Factory settings, see ▶Sec. 6 "Factory settings". Fig. 25: DFAULT – Resetting to factory settings - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back 7.2.7 CANCEL 9007199345299211-1 Use CANCEL to discard all changes and exit the menu. Fig. 26: Cancel – CANCEL o.k. Confirm changes Esc Cancel and back 7.2.8 SAVE – Saving Settings / Data 9007199345311115-1 Use SAVE to save all changes and exit the menu. Fig. 27: Saving settings / data – SAVE o.k. Confirm changes Esc Cancel and back EN 7. OPERATION 48 / 104 4168086c / 2025-03 7.3 Operating / Setting Measuring Menu 9007199345354507 During operation, the following settings are available in the measuring menu. Selection What to do Starting the measurement menu Press the o.k. key. Leaving the measurement menu without saving Scroll to CANCEL and confirm using the o.k. key or wait for 30°seconds without confirming via a key. Leaving the measurement menu after saving Scroll to SAVE and confirm using the o.k. key. Display indicators in the measurement menu: Sub-menu For details, see . ▶Sec. 7.3.1 "RECORD – Recording Measuring Data" ▶Sec. 7.3.2 "MEMORY – Display free meas- urement log memory" ▶Sec. 7.3.3 "ED.MPNT – Change measuring point designation" ▶Sec. 7.3.4 "TP.UNIT – Set unit of temperature" ▶Sec. 7.3.5 "CANCEL" ▶Sec. 7.3.6 "SAVE – Saving Settings / Data" Tab. 12: Display indicators in the measurement menu Press the o.k. Key to switch to the desired sub-menu. 7.3.1 RECORD – Recording Measuring Data 9007199345360267 Under RECORD, specify one of the 20 available measurement point designations in which the measurement log will be saved. Fig. 28: RECORD – Recording measuring data - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back EN 7. OPERATION 4168086c / 2025-03 49 / 104 MPNT – Measurement point Under MPNT, there are 20 freely-definable measurement points available. Upon delivery, the measurement points are defined as MPNT 00…MPNT 19. This meas- urement point designation can be adapted freely (≤ 6 characters), as described under point ED.MPNT. Fig. 29: MPNT 00 – MPNT xx – Change meas- uring point designation - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back STP.STA – Restart the measurement log Select STP.STA, to create a new measurement log file under a new measurement point designation in the internal measurement log memory. Confirm with the o.k. button, the display will then jump to SAVE. Confirm it again by pressing the o.k. button. Fig. 30: STP.STA – Restart measurement log - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back EN 7. OPERATION 50 / 104 4168086c / 2025-03 7.3.2 MEMORY – Display free measurement log memory 9007199345366283 Under MEMORY, check the current free internal measurement log memory in %. No measurement logs will be saved if no more free memory is available. No free measurement log memory leads to data loss. Check the measurement log data memory regularly (depending on the frequency of use) for free memory space. Fig. 31: MEMORY – Display free measurement log memory o.k. Confirm changes Esc Cancel and back 7.3.3ED.MPNT – Change measuring point designation 9007199345372683 Change the measuring point designation with ED.MPNT. A maximum of 6 characters are available for the measuring point designation. Example: TEST01, BAGGER, KRAN02, etc. Fig. 32: ED.MPNT - Change measurement point designation - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back Fig. 33: MPNT 00 – MPNT xx – Change meas- uring point designation - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back The following characters appear scrolling after the arrow keys are pressed. The space is located between 9 … A and can only be set from the 6th position to the left. This makes it possible to enter a measuring point designation with fewer than six characters. EN 7. OPERATION 4168086c / 2025-03 51 / 104 7.3.4 TP.UNIT – Set unit of temperature 9007199345380235 Use TP.UNIT to set the unit of the fluid temperature display. You can choose between degrees Celsius °C or degrees Fahrenheit °F. Fig. 34: TPUNIT – Set unit of temperature - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back Fig. 35: TPUNIT – Set degrees Celsius - / + Change setting ◄ / ► Change cursor position o.k. Confirm changes Esc Cancel and back 7.3.5 CANCEL 9007199345299211-2 Use CANCEL to discard all changes and exit the menu. Fig. 36: Cancel – CANCEL o.k. Confirm changes Esc Cancel and back 7.3.6 SAVE – Saving Settings / Data 9007199345311115-2 Use SAVE to save all changes and exit the menu. Fig. 37: Saving settings / data – SAVE o.k. Confirm changes Esc Cancel and back EN 7. OPERATION 52 / 104 4168086c / 2025-03 7.4 Select operating modes / measuring methods according to the current pressure 18014398596113547 After you have selected the measurement point according to the criteria, for details, see ▶Sec. 5.4 "Selecting the measuring point", determine the current operating pressure at the measurement point. Select the appropriate measuring method based on the operating fluid to be measured and the prevailing operating pressure: Fluid Pressure at the measurement point Operating mode / measuring method, for details, see Diesel / oil ±0 bar / ±0 psi ▶Sec. 7.4.1 "Measuring from unpressurised containers" Diesel 1 … 16 bar / 14 … 232 psi ▶Sec. 7.4.3 "Measuring diesel" Oil 1 … 45 bar / 14 … 650 psi ▶Sec. 7.4.2 "Measuring up to max. 45 bar / 650 psi with hydraulic fluids" Oil 15 … 345 bar / 217 … 5000 psi ▶Sec. 7.4.4 "Measure hydraulic fluids in the 45 … 345 bar / 650 … 5000 psi range" Tab. 13: Select operating mode / measuring method 7.4.1 Measuring from unpressurised containers 9007199343561227 Pre-fill the FCU to receive immediate and valid results. To do this, aspirate ≈ 120°ml of fluid through the entrance hose to completely fill the hydraulic circuit and entrance hose. If the FCU is not pre-filled, an air and oil mixture flows through the FCU prior to the measurement. The sensor interprets this air and oil mixture as a contamination, leading to falsified measurement results. For initial sampling without pre-filling the FCU and hoses, you will need ≥ 300 ml of fluid. To measure permitted oil or diesel from non-pressure containers, proceed as follows: Required hoses: ● Return hose ● Suction pipe (A) or suction hose(B) and hose adapter EN 7. OPERATION 4168086c / 2025-03 53 / 104 Fig. 38: Operating mode – measuring at 0 bar with suction pipe (A) Fig. 39: Operating mode – measuring at 0 bar with suction hose (B) Take note of the following points: ü According to all steps, the FCU is set up, see ▶Sec. 5 "Installing, Connecting, Setting Up and Putting into Operation". 1. Connect the suction hose (colour: transparent) to the INLET of the FCU. Place the other end of the suction hose (colour: transparent) into a non-pressure container. ð The hydraulic installation is complete. 2. Turn on the internal pump at the switch. O The FCU starts measuring. 7.4.2 Measuring up to max. 45 bar / 650 psi with hydraulic fluids 18014398597997835 To measure permissible hydraulic fluids up to maximum 45 bar / 650 psi, proceed as follows: WARNING Hydraulic systems are under pressure Danger of bodily injury u The hydraulic system must be depressurised before performing any work on it. NOTICE Operating pressures above 45 bar / 650 PSI Over pressure is guided to the OUTLET connector u Never close the OUTLET connector. u Place the return hose in a non-pressure container. Required hoses: ● Return hose ● High-pressure hose EN 7. OPERATION 54 / 104 4168086c / 2025-03 Fig. 40: Operating mode – measurement ≤ 45 bar Make sure that the following sequence is followed: ü You have performed all of the steps listed in chapter ▶Sec. 5 "Installing, Connecting, Setting Up and Putting into Operation". 1. Check the pressure at the measuring point. The existing pressure must be in the range of 1 … 45 bar / 14 … 650 psi. WARNING If the pressure is greater than 45 bar / 650 psi, then use the high-pressure adapter. 2. Connect the inlet hose (colour: black) to the INLET port of the FCU (1). Turn the measuring coupling clockwise (2) onto the port and tighten it by hand. 3. Connect the other end of the INLET pressure hose to the measuring point of the system. 4. Switch on the internal pump at the switch. O The hydraulic installation is complete. The FCU starts with the measurement. EN 7. OPERATION 4168086c / 2025-03 55 / 104 7.4.3 Measuring diesel 9007199347210891 Proceed as follows to measure diesel: To limit the flow velocity in the hydraulic system and eliminate the risk of statically charging the operating fluid, the pressure must be ≤ 16 bar / 232 psi. Required hoses: ● Return hose ● High-pressure hose Fig. 41: Operating mode - measure≤ 16 bar/ 232 psi ü You have completed all the steps set out in the ▶Sec. 5 "Installing, Connecting, Setting Up and Putting into Operation" chapter and established equipotential bonding. 1. Check the pressure at the measurement point. The pending pressure must be in the range between 0 … 16 bar / 0 … 232 psi. WARNING Do not carry out any measurements if the pressure exceeds 16 bar / 232 psi. The higher flow of velocity causes a static charge of the operating medium. 2. Connect the entrance hose (colour: black) to the INLET connector (1). Screw the measuring coupling clockwise (2) onto the connector and tighten by hand. 3. Connect the other end of the INLET pressure hose to the measuring point of the system. EN 7. OPERATION 56 / 104 4168086c / 2025-03 4. Turn on the internal pump at the switch. O The hydraulic installation is complete. The FCU proceeds with the measurement. 7.4.4 Measure hydraulic fluids in the 45 … 345 bar / 650 … 5000 psi range 18014398598292363 To measure permissible hydraulic fluids in the 45 … 345 bar / 650 … 5000 psi range, proceed as follows: WARNING Hydraulic systems are under pressure Danger of bodily injury u The hydraulic system must be depressurised before performing any work on it. NOTICE Operating pressures above 45 bar / 650 PSI Over pressure is guided to the OUTLET connector u Never close the OUTLET connector. u Place the return hose in a non-pressure container. Required hoses / adapters: ● Return hose ● High-pressure hose ● High-pressure adapter Fig. 42: Operation mode - measure at 45 … 345 bar EN 7. OPERATION 4168086c / 2025-03 57 / 104 Take note of the following points: ü You have completed all the steps set out in the ▶Sec. 5 "Installing, Connecting, Setting Up and Putting into Operation" chapter. 1. Check the pressure at the measurement point. The pending pressure must be in the range between 45 … 345 bar / 650 … 5000 psi. WARNING If the pressure exceeds 345 bar / 5000 psi, abort the measurement. 2. Screw the high-pressure adapter onto the INLET connector of the FCU. 3. Connect the entrance hose (colour: black) to the INLET connector of the FCU (1). Screw the measurement coupling clockwise (2) onto the connector and tighten
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