Fcu2000 4

FCU 2000-4 Series
FluidControl Unit
Operating and Maintenance Instructions
Valid from firmware versions 3.22 up
English (translation of original instructions)
Document no.: 3109987g

FCU 2000-4 Series Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2010 by
HYDAC FILTER SYSTMES GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC Filter Systems GmbH. Contraventions are liable
to compensation.
Exclusion of Liability
We made every endeavor to ensure the accuracy of the contents of this document.
However, errors cannot be ruled out. Consequently, we accept no liability for such
errors as may exist nor for any damage or loss whatsoever which may arise as a
result of such errors. The content of the manual is checked regularly. Any
corrections required will be incorporated in future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC FILTER SYSTEMS GMBH

Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GMBH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-mail: guenter.harge@hydac.com
HYDAC FILTER SYSTEMS GMBH en(us) Page 2 / 100

BEWA FCU2000-4 3109987g en-us 2011-05-09.doc 2011-05-09
FCU 2000-4 Series Content
Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Changes to the manual ............................................................................................6
Preface ......................................................................................................................7
Customer Service ...................................................................................................8
Modifications to the Product ...................................................................................8
Warranty .................................................................................................................8
Using the Documentation .......................................................................................9
Safety Information and Instructions .....................................................................10
Obligations and Liability........................................................................................10
Explanation of Symbols and Warnings, etc. .........................................................11
Proper/Designated Use ........................................................................................11
Improper Use ........................................................................................................ 12
What to Do in Case of Emergency ....................................................................... 12
Maintenance, Servicing and Troubleshooting....................................................... 12
Modifications to the FCU ......................................................................................12
Training and Instruction of Personnel ................................................................... 13
Checking the scope of delivery ............................................................................14
Description of the FCU ..........................................................................................15
Operating elements / Dimensions......................................................................... 16
Restrictions on use – FCU 2010 / 2110 / 2210 ..................................................... 17
Hydraulic diagram ..................................................................................................18
FCU Function Description.....................................................................................19
Electrical connection of the FCU ..........................................................................22
Connecting the "POWER INPUT".........................................................................22
Connecting the "POWER INPUT PUMP" .............................................................23
Connecting the "PC" interface .............................................................................. 24
Serial RS 232 Interface (Standard) ................................................................... 24
Serial RS 485 Interface (OPTIONAL) ...............................................................24
"Control" – Connecting the control port.................................................................25
Contact assignment (switched position when the FCU is ready for
operation) ..........................................................................................................25
Relay functions..................................................................................................26
Programmable limit values FCU 20xx ............................................................... 28
Programmable limit values FCU 21xx / FCU 22xx ............................................ 29

Hydraulic connection of the FCU..........................................................................30

Conducting measurements via the high-pressure port (INLET) ........................ 31
Conducting measurements via the integrated pump (SUCTION INLET) .......... 32
Switching on the FCU ............................................................................................33
Switching on the FCU ...........................................................................................33
Selecting the Viscosity Range ..............................................................................33
Starting up the FCU................................................................................................34
Conducting Measurements via the High-Pressure Port (INLET) .......................... 34
Conducting measurements via the integrated pump SUCTION INLET ................ 34
Operating the FCU..................................................................................................35
Function of the Keys .............................................................................................35
Menu and Number Keys (red) .............................................................................. 36
Key Combinations................................................................................................. 36
FCU menus .............................................................................................................37
MODE - select operating mode ............................................................................ 37
MODE "M1: Measure" .......................................................................................38
MODE "M2: Measuring and switching" ............................................................. 38
MODE "M3: Filter to" (performance of automatic filtration) ............................... 38
MODE "M4: Filtering from to" (performance of automatic filtration) .................. 39
Mode "M5: Measure Autostop".......................................................................... 39
Mode "M6: Autostop pump"...............................................................................39
MEMORY Menu....................................................................................................40
Designating the measurement point ................................................................. 41
Setting the averaging interval............................................................................42
Selective deletion .............................................................................................. 43
Delete all ...........................................................................................................45
Change measuring point ................................................................................... 46
Setting the memory mode ................................................................................. 47
PRINT menu .........................................................................................................48
Logs ..................................................................................................................49
Contents............................................................................................................52
All Parameters...................................................................................................52
Paper feed.........................................................................................................53
Online print-out..................................................................................................53
Abort print-out ...................................................................................................54
LIMITS menu ........................................................................................................54
MODE M2 .........................................................................................................55
MODE M3 .........................................................................................................56
MODE M4 .........................................................................................................56
MODE M5 .........................................................................................................58

MODE M6 .........................................................................................................59
SETUP menu........................................................................................................60
Autostart............................................................................................................61
Abort at Q=0...................................................................................................... 62
Setting the pump start delay ............................................................................. 63
Setting the date and time ..................................................................................64
Set bus address ................................................................................................65
Display operating hours .................................................................................... 65
Pump supply .....................................................................................................66
Check the battery status ...................................................................................66
POWERUP menu ................................................................................................. 67
Selecting the language......................................................................................68
Setting the viscosity range ................................................................................68
Setting the measured volume ........................................................................... 69
FCU display.............................................................................................................70
Brief Overview of the Menu Structure .................................................................. 72
Error Messages and Troubleshooting.................................................................. 74
Performing Maintenance ....................................................................................... 78
Cleaning the FCU .................................................................................................78
Changing the FCU Filter Element .........................................................................78
Back-flushing the FCU..........................................................................................81
Internal dot-matrix impact printer – replace paper roll / ink ribbon........................ 81
Disposing of the FCU .............................................................................................83
Storing the FCU ......................................................................................................83
Storage conditions ................................................................................................ 83
Calibrating the FCU ................................................................................................83
Customer service ...................................................................................................84
Germany ...............................................................................................................84
USA ......................................................................................................................84
Australia................................................................................................................84
Brazil.....................................................................................................................85
China ....................................................................................................................85
Spare Parts .............................................................................................................86
FCU 2xx0-x (version for mineral oil) ..................................................................... 86
FCU 2xxx-x (all versions)......................................................................................87
Accessories ............................................................................................................87
Explanation of terms used in measurement systems......................................... 89
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes............................... 90

FCU 2000-4 Series Changes to the manual
ISO 4406:1999......................................................................................................90
ISO 4406 table ..................................................................................................90
Overview of the differences between ISO 4406:1987 and ISO
4406:1999 .........................................................................................................91
SAE AS 4059........................................................................................................92
SAE AS 4059 table ...........................................................................................92
Cleanliness codes according to SAE ................................................................ 92
NAS 1638 .............................................................................................................93
Technical data ........................................................................................................94
Factory default settings .........................................................................................97
Changes to the manual

The index is featured on the cover sheet of the operating and maintenance manual
and in the lower left corner of each page after the article number.
Index "d" — from firmware version V 3.2x
- Changes to firmware have been integrated
Index "f" - from firmware version V 3.2x
- Changes to firmware have been integrated
- Document standardization acc. 2006/42/EC
- Defined display for excessively dirty fluid
Index "g" - from firmware version V 3.2x
- Manual revised, CoCos changed to FluMoS.

FCU 2000-4 Series Preface
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication. There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:

Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.

“Putting experience into practice”

Customer Service
Contact our technical sales department if you have any questions on our product.
When contacting us, please always include the model/type designation, serial no.
and part-no. of the product:
Fax: +49 (0) 6897 / 509 - 846
E-mail: filtersystems@hydac.com
Modifications to the Product

We would like to point out that changes to the product (e.g. purchasing additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects the safety of the product has been
carried out on components, the product may not be returned to operation until it has
been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com  General terms and conditions.

Using the Documentation

Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior to starting the unit up for the first time and at regular
intervals in the future.
What do I want to know?

I determine which topic I am looking for.
Where can I find the information I’m looking for?

The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
Chapter
tel
Produkt / Kapi
Page number
HYDAC Filtertechnik GmbH
BeWa 123456a de
de Seite x
200x-xx-xx
Edition date
Documentation no. Document language

with index/
file name
The documentation number with its index enables you to order another copy of the
operating and maintenance instructions. The index is incremented every time the
manual is revised or changed.

FCU 2000-4 Series Safety Information and Instructions
Safety Information and Instructions

These operating instructions contain the key instructions for properly and safely
operating the FCU.
Obligations and Liability

The basic prerequisite for the safe and proper handling and operation of the FCU is
knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the FCU.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The FCU has been designed and constructed in accordance with the current state of
the art and recognized safety regulations. Nevertheless, hazards may be posed to
the life and limb of the individual using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
The FCU is only to be used as follows:
 solely for its designated use
 only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
Always keep the operating and maintenance instructions near the measurement
device.
In addition to the manual, the general and local regulations concerning accident
prevention and protection of the environment should be available and observed.
Ensure that all information relating to safety and potential hazards of the FCU are
kept in a legible condition.Replace them if necessary. Replace them if necessary.
Check the hoses and connectors for leaks on a daily basis.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
► Depressurize the system before performing any

work on it.

Explanation of Symbols and Warnings, etc.

The following designations and symbols are used in this manual to designate
hazards, etc.:
DANGER denotes situations

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

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

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

which can lead to property
NOTICE damage if safety precautions
are not observed.
Proper/Designated Use
The fluid control unit (FCU) was developed for temporary or continuous monitoring
of particulate contamination in hydraulic systems.
Analyzing the size and quantity of contamination enables quality standards to be
verified and documented and the requisite optimization measures to be
implemented.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use; the manufacturer accepts no liability for any damage resulting from
such use.
Proper or designated use of the product extends to the following:
 Maintaining adherence to all the instructions contained herein.
 Performing requisite inspection and maintenance work.

Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
 Improper connection of the FCU pressure and return flow hoses.
 Sealing of the FCU return line.
What to Do in Case of Emergency

In the event of an emergency, immediately disconnect the FCU from the power
supply and from the hydraulic system.
Properly dispose of any escaping fluid in accordance with environmental guidelines.
Maintenance, Servicing and Troubleshooting

The prescribed adjustment, maintenance/servicing and inspection work is to be
conducted in a timely fashion.
All operating media are to be protected/isolated in case the product is accidentally
started up.
When performing any maintenance, servicing, inspection or repair work, disconnect
the FCU from the power supply and ensure that it cannot be switched back on
inadvertently.
Check any screwed fittings which have been removed to see that they have been
properly secured.
Always check the product to see that it functions properly when performing
maintenance and servicing work.
Modifications to the FCU

Do not make any modifications (design modifications, extensions) to the FCU
without the prior consent of the manufacturer.
Any conversion modifications require written permission from HYDAC FILTER
SYSTEMS GMBH.
Immediately replace any parts which are not in perfect condition.
Use only original spare parts.

Training and Instruction of Personnel

The owner is obliged to only let persons work on the FCU, who:
 are familiar with the fundamental occupational safety and accident prevention
regulations and have been properly instructed in the use of the FCU.
 have read and understood these operating instructions.
Only properly trained and instructed personnel may work with the FCU.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff who are still being trained may only work on the FCU when supervised by a
suitably experienced person.
Supervisor with the

training/engineerin
Individuals with
g background
Electricians
undergoing
appropriate
Individuals
Individuals
technical
authority
Activity training
Packing
X X X
Transportation
Commissioning X X X
Operation X X X X
Troubleshooting/
X X X
locating the source of malfunction
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning/storage X X X X

FCU 2000-4 Series Checking the scope of delivery
Checking the scope of delivery

The FluidControl Unit FCU comes packed and ready for operation.
Before commissioning the SFC, check the content of the package to make sure
everything is present.
The following items are supplied:
Item Qty Description
1 1 FluidControl Unit FCU 2xxx-4
2 2 Mains device and connection cable (configuration depends on
the order)
3 1 hp-hose with mini measurement port DN4, L=2000 mm
4 1 Suction hose DN 6 with CPC quick-release coupling, L=1000 mm
5 1 Suction hose DN 6 with CPC quick-release coupling, L=250 mm
6 1 Return hose DN 7, L = 2000 m
7 1 Connection cable FCU <-> PC
8 1 CD-ROM with FluMoS light software
- 1 Operating and Maintenance Instructions
- 1 Certificate of calibration
2 1
6
3
5
7
4

FCU 2000-4 Series Description of the FCU
Description of the FCU

The FCU FluidControl Unit can determine the solid particle contamination of mineral
oils on a continuous basis.
With the FCU, it is possible to record, save and display the Cleanliness Class
completely automatically during continuous operation in accordance with NAS 1638
and/or SAE AS4059 or ISO 4406.
The measured values can be printed out online in the form of either tables or graphs
by means of the built-in printer or sent via serial interface to a PC or a central
display unit for visualization purposes there.
Filter units can for example be actuated via relay outputs.
For input and output functions, the FCU possesses a keyboard, an LCD (Liquid
Crystal Display), a dot-matrix printer, control relay outputs and a serial data interface
The FCU possesses a measurement port 1604 as an input for connection with the
hydraulic unit, as well as a DN 7 plug nipple as a return flow outlet.
A flow rate control valve is available for setting the measurement flow rate.
Media from a depressurized reservoir can be inspected using the integrated pump
with the enclosed suction hoses (DN8).
The FCU has a rechargeable battery for ~ 5 hours of operation independent of the
mains network.
The FCU has a measured value memory for up to 3000 measured values, which are
stored in the form of logs (maximum of 100).

Operating elements / Dimensions
Item Designation
A High pressure port = INLET
B Return port connection - OUTLET
C Switch - On/Off
D Electrical connection - 24 V DC
E Serial interface
F Control port
G Sealing cover
H Suction port SUCTION INLET (only 2xx0-4)
I Change-over valve (only 2xx0-4)
J Dot-matrix printer
K Display
L Keyboard
M Flow rate regulator

Restrictions on use – FCU 2010 / 2110 / 2210
NOTICE
Impermissible operating conditions
The FCU will be destroyed
► The FCU may only be used with mineral oils or mineral oil-based raffinates.

FCU 2000-4 Series Hydraulic diagram
Hydraulic diagram
Item Designation
1 Optical sensor
5 Flow rate sensor
7 Flow rate control valve (adjustable)
8 Filter
9 Flow control valve
10 pressure relief valve
15 Pressure accumulator
20 Pump
21 Change-over valve

FCU Function Description
Item Designation
1 Optical sensor
2 Infrared LED
3 Photodetector
4 Evaluation electronics
5 Flow rate sensor
6 Display
7 Flow rate control valve (adjustable)
8 Filter
9 Flow control valve
10 pressure relief valve
11 Serial interface
12 Keyboard
13 Relay
14 Printer
15 Pressure accumulator

A continuous flow of oil runs through an optical sensor (1) comprised of an infrared
LED (2) and a photo receiver (3). The contamination particles present in the flow of
oil cause pulse-like darkenings of the light beam, which are both classified as
measurement signals in accordance with particle size and counted by an evaluation
electronics system (4).
The measurement of the flow rate, which is necessary for specifying the
contamination class, is carried out by a built-in flow rate sensor (5), the signals from
which are also channeled to the electronic evaluation system (4).
Ultimately, the evaluation electronics (4) calculate on a continuous basis the particle
counts and the SAE / NAS or ISO contamination classes for the reference volume of
100 ml, based on the measurement signals from the optical sensor and the flow rate
sensor.
Here the measured values (up to 3000) are also stored on a continuous basis as
they arise, together with date and time, in a manner that is safe from network
outages. A battery-buffered real-time clock is available for this purpose.
A flow control valve (7) is available for adjusting the pressure fluctuation-
independent flow of oil.
A hydraulic filter (8) with electrical contamination indicator is positioned upstream
from this for the purpose of protecting against failure due to contamination.
The permanently adjusted valves (9) and (10) and the diaphragm memory (15)
enable the connection to extraction points for the pressure range of 1 ... 350 bar at
the "Inlet" access point.
The FCU can be operated via keyboard (12). Characteristic values for the
measurement can be modified and various kinds of presentation can be selected in
the LCD display (6).
If not set otherwise, the following information is continuously displayed during the
measurement (see also in this connection the chapter "The Display of the FCU"):
 selected measurement mode
 Progress of the ongoing measurement
 Current value of the measurement results for 2 of the 4 particle size channels
 Tendency: increasing or decreasing 
 Current flow value
 only in the event of fault -> Error messages
Furthermore, the FCU also possesses 3 built-in relays with the following functions:
Relays 1 and 2 are limit value switches (change-over contacts) and also serve to
control a filtration unit.
Relay 3 outputs the operational readiness signal (DEVICE READY)
(closing device; closed when FCU is ready for operation)

The evaluation electronics in the FCU continuously monitors for this purpose the
following:
 the particle sensor
 the filter clogging indicator
 the flow rate sensor
 the power supply voltage
 the internal evaluation electronics
The contact from Relay 3 is always closed during normal operation.
Relay 3 opens the contact when a malfunction is recognized.
A corresponding fault message appears automatically in the display in the event of a
malfunction, and the storing of data is interrupted. (see also in this connection the
chapter Error Messages / Troubleshooting)
As soon as the error has been rectified, the evaluation electronics recognizes this
fact, resets the fault message fully automatically and closes the Relay 3 contacts.
Both the measuring operations and the storing of data are resumed.
This ensures that measurement operations can restart without requiring the
intervention of operating personnel after malfunctions such as voltage loss, flow
errors caused by drops in pressure, etc. have been eliminated in permanent online
operation.
All of the measured and stored measured values can be read out via the serial
interface (11), e.g. by means of a PC. (Software and cable are included with the unit
as supplied.)
The built-in printer (14) documents the measurements in the form of tables or
graphs.

FCU 2000-4 Series Electrical connection of the FCU
Electrical connection of the FCU

The FCU is equipped with a battery. This allows network-independent measurement
(with online print-out) from ~ 5 hours and measurements with internal pump:
viscosity-dependent from ~ 2 hours.
The battery is automatically recharged when the power adapter is plugged in,
regardless of whether the FCU is switched on or off at the switch or not.
Connecting the "POWER INPUT"

Insert the hollow plug on the supplied power adapter into the rear bush "POWER
INPUT". Switch on the FCU on or off at the On/Off switch on the rear side.
This connection is used for supplying the FCU electronics and battery charging
circuit with power.

Connecting the "POWER INPUT PUMP"
NOTICE
Overloading the internal pumps
► Operate the FCU only using the original power adapter.

The integrated overload protection protects the FCU pump.
Insert the hollow plug on the supplied power adapter into the rear bushing "PUMP
INPUT".
In the SETUP menu, check whether the item Pump supply is set to "external". You
can find details on page 66.
If the parameter is set to "internal", the pump is only supplied with power via the
battery if the power adapter is also connected.

Connecting the "PC" interface

You can communicate with a PC via this interface. This interface is designed in the
standard version as RS232 and optionally as RS485.
Serial RS 232 Interface (Standard)
Pin Signal function
1 - Shield 1 2 4 8
2 TXD Transmission line
4 RXD Receiving line
8 GND GND ground

A corresponding cable for connecting the FCU to a PC is included in the scope of
delivery.
Serial RS 485 Interface (OPTIONAL)
Pin Signal function
1 - Shield 1 2 4 8
2 T- (TA) Transmission data
4 R- (RA) Received data
8 GND GND ground
9 T+ (TB) Transmission data
11 R+ (RB) Received data
9 11 15
15 +5 V Supply, bus termination
The pin assignment corresponds to DIN 66348 (DIN measurement bus)

"Control" – Connecting the control port
4 6 8
1 5 7
9 11 13 15
12 14
Contact assignment (switched position when the FCU is ready for operation)
6 NC contact
Relay 1, programmable by user 7 NO contact
8 Base contact
13 NC contact
Relay 2, programmable by user 14 NO contact
15 Base contact
11 NC contact
Relay 3, Device ready
12 NO contact
2A is the maximum load for the relay contacts. Maximum switching voltage:
24 V DC / 50 V AC, maximum switching power: 30 W / 50 VA.
Pin 1 : 24 V operating voltage (in battery operation 12 V), maximum load
capacity 200 mA
Pin 4 Ground (GND)
Pin 5 : Battery switch-off
When pin 5 is connected to pin 4, the FCU is not supplied by integrated
batteries. This enables the FCU to be remote-controlled-switched on
and off via an external power supply. The battery will however still be
charged, if a power adapter is connected.

Relay functions
The following tables show the switched position of the relays in the various
operating modes in keeping with the operating condition or measurement result.
Relay 1 Relay 2
6 6 13 13
7 7 14 14
8 8 15 15
M1
Measurement Measurement After the first Flow rate within
currently in stopped measured set range
progress value is
available: Flow
error
M2
Exceed Measured After switch- Measured After switch-on
value ≥ upper on or start of a value ≥ upper or start of a
limit measurement. limit measurement.
Goes out Goes out again
again when when
measured measured
value ≤ lower value ≤ lower
limit limit
Fall below ≤ lower limit After switch- ≤ lower limit After switch-on
on or start of a or start of a
measurement. measurement.
Goes out Goes out again
again when when
measured measured
value ≥ upper value ≥ upper
limit limit
Within range Lower limit ≤ After Lower limit ≤ After switching
measured switching the measured the unit on or
value ≤ upper unit on or value ≤ upper starting a
limit starting a limit measurement
measurement or Measured
or Measured value < lower
value < lower limit or
limit or Measured
Measured value > upper
value > upper limit
limit
Outside range Measured After Measured After switching
value ≤ lower switching the value ≤ lower the unit on or
limit or unit on or limit or starting a

Relay 1 Relay 2
measured starting a measured measurement
value ≥ upper measurement value ≥ upper or
limit or limit lower limit <
lower limit < measured
measured value < upper
value < upper limit
limit
No function Always off Always off
M3
Measurement 5 consecutive After the first Flow rate within
is currently in measured measured set range
progress and values ≤ limit value is
one or more or available: Flow
of the last 5 measurement error
measured stopped
values > limit
M4
Start or result Measurement 5 consecutive After the first Flow rate within
of check is currently in measured measured set range
measurement progress and values ≤ limit value is
after test cycle the measured or available: Flow
time ≥ upper values > limit measurement error
limit stopped
When test cycle Test cycle Goes out
time elapsed, time has again when
for the duration elapsed - measured
of a check check value < upper
measurement measurement limit.
is running. Test cycle
time is
restarted
M5
progress value is
available: Flow
error
M6
progress value is
available: Flow
error

Relay 3
11 11
12 12
All operating
modes
FCU ready for FCU not ready for
operation operation
Programmable limit values FCU 20xx

Min. Max
M2: Switching limits
5 µm channel NAS 2 15
5 µm channel ISO 10 23
15 µm channel ISO 9 21
Flow rate 0 150
M3: Filtration limit

ISO 10 / 9 23 / 21
NAS 2/4 15 / 15
M4: Filtration limits

ISO 10 / 9 23 / 21
NAS 2/4 15 / 15
M4: Test cycle time

0 1440

Programmable limit values FCU 21xx / FCU 22xx

Min. Max
M2: Switching limits
FCU21xx-x FCU 22xx-x

2 µm channel NAS A channel SAE 4 µm(c) 2 15
5 µm channel NAS B channel SAE 6 µm(c) 2 15
15 µm channel NAS C channel SAE 14 4 15
µm(c)
25 µm channel NAS D channel SAE 21 6 15
µm(c)
2 µm channel ISO 4 µm(c) channel ISO 12 25
Flow rate Flow rate 0 150
M3: Filtration limit

ISO ISO 12 / 10 / 9 25 / 23 / 21
NAS SAE 2/2/4 15 / 15 / 15
M4: Filtration limits

ISO ISO 12 / 10 / 9 25 / 23 / 21
NAS SAE 2/2/4 15 / 15 / 15
M4: Test cycle time 0 1440
M5: Number of measurements 1 100
M6: Start delay 0 255
M6: Number of measurements 1 100

FCU 2000-4 Series Hydraulic connection of the FCU
Hydraulic connection of the FCU
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
► Depressurize the system before performing any

work on it.

Conducting measurements via the high-pressure port (INLET)
NOTICE
If the OUTLET connection is closed or blocked
The FCU will be damaged.
► Never seal the OUTLET connection.
► Put the free end of the OUTLET return hose into an unpressurized
container.
OUTLET INLET
[A]
FCU 2xx0-4
To connect the FCU, proceed as follows::

1. Plug the return-line hose into the OUTLET connector and route it into a suitable
container, e.g. hydraulic tank.
2. Set the change-over valve [A] to the setting INLET.
3. Set the flow rate control valve to a value of 5.
4. Check the system pressure. Ensure that this does not exceed a pressure of
350 bar.
5. Connect the high pressure hose to the INLET connection.
6. Now connect the other end of the high pressure hose to the system.
Oil can start to flow through the FCU as soon as the system has been
connected to the pressure fitting.

Conducting measurements via the integrated pump (SUCTION INLET)
NOTICE
Change-over INLET / SUCTION INLET after a high pressure measurement
The pump will be damaged.
► Wait at least 5 minutes after a high pressure measurement before changing

over the suction port connection.
The pressure in the installed pulsation damper must first be reduced via the
OUTLET connection.
To connect the FCU, proceed as follows::

1. Plug the return-line hose into the OUTLET connector and route it into a suitable
container, e.g. hydraulic tank.
2. Set the change-over valve to the setting SUCTION.
3. Open the flow rate control valve completely.
4. Attach the suction hose to the SUCTION INLET connection.
5. Put the other end of the suction hose into the fluid to be measured.

FCU 2000-4 Series Switching on the FCU
Switching on the FCU
Switching on the FCU

When the FCU is switched on, various things are shown in the display, i.e. model
no., firmware version, available memory, battery charge status, bus address and,
possibly, error messages (cf. Error Messages / Troubleshooting chapter).
Example:
HYDAC FILTER SYSTEMS
1.
FCU 2210 V3.22
Memory: 25.4% 61
2.
Battery: 13.49 V 80%
Bus address: 1
3.
Battery: 13.49 V 80%
Viscosity range:
4.
1 … 10 mm²/s
Measure -> OK/START

5.
Abort -> STOP
The FCU is ready for operation.
Selecting the Viscosity Range

During startup, the viscosity range currently set is shown in the display. Before the
first measurement, check the viscosity of the fluid to be measured and correct the
settings if required. You can find details on change-over of the viscosity range on
page 68.
The FCU provides two viscosity ranges for selection:

1 … 10 mm²/s
5 … 1000 mm²/s

FCU 2000-4 Series Starting up the FCU
Starting up the FCU
Conducting Measurements via the High-Pressure Port (INLET)

Press the "START" key and set the flow rate to approx. 100 ml/min. using the flow
control valve on the front.
If an error message appears in the display, turn the flow control valve in the required
direction until the error message disappears and measurement operation starts
automatically.
Conducting measurements via the integrated pump SUCTION INLET
NOTICE
Overloading the internal pumps
► Operate the FCU only using the original power adapter.

The integrated overload protection protects the FCU pump.
Turn the flow control valve knob on the front side of the FCU all the way clockwise.
The installed FCU pump can be supplied with power "internally" via the integrated
battery or "externally" via the power adapter.
Check the setting for "internal" or "external" in the Pump supply menu. For details on
change-over, see page 66.
The factory setting of the FCU is "internal".
One battery charge is sufficient for conducting measurements using the pump for ~
2 hours.
In order to make use of the full viscosity range, you must connect both
power adapters. You can find the permitted viscosity ranges when
operating with an internal pump on page 94.
The power consumption of the pump is dependent on the viscosity of
the fluid to be conveyed. Starting with a viscosity of > 150 mm2/s and
upwards, the power consumption is so great that the overload
protection feature of the power adapter connected may respond after a
certain amount of time and the power supply will be shut off.
This prevents the pump motor from overheating. The ongoing
measurement will be interrupted with a flow error. The power supply will
then switch the power supply back on automatically after it has cooled
down.
Actuate the "START" key to start the measurement. The flow rate is automatically
set to ~ 100 ml/min insofar as the viscosity of the medium permits this.

FCU 2000-4 Series Operating the FCU
Operating the FCU

The various operating menus of the FCU are described below. The following
conventions are used:
- Fixed display textsare highlighted in light gray (printed version) or yellow (PDF
file).
- Variable display texts(user entries) are highlighted in bold (printed version) or
magenta (PDF file) 
- Comments are shown in italics.
Function of the Keys

Control buttons (gray)
ok
start Confirm entries / Start measurement
stop Cancel entries / Stop measurement
Scroll through menus (when the “” menu symbol is displayed)
+
Scroll through Selection. Raise/lower numbers and letters (in
Input mode)

FCU 2000-4 Series Operating the FCU
Menu and Number Keys (red)

mode setup
Select measurement operation Basic settings
(with/without relay actuation) (Autostart, date, time, etc.)
memory Editing measured value

Display ISO code
memory
(This key responds only when
(name of the measuring point,
a measurement is being
measurement intervals,
carried out)
deleting, etc.)
print Display SAE or NAS Code
Print out
(This key responds only when
(Online, measured value
a measurement is being
memory, etc.)
carried out)
limits Display particle counts
Set limits for controlling
filtration units (via relays 1 and (This key responds only when
2) a measurement is being
carried out)
Display – Lighting
Direct input of multi-digit 1x - goes out again after
numerals ~ 20 s.
(Only in input mode) 2x – stays switched on
(press 1x to switch off)
Key Combinations
ok Insert space in measuring position designation.

start + Press the keys simultaneously.
ok
Deleting space in measuring position designation
start + Press the keys simultaneously.
Switch to the PowerUp menu.

+ Press the keys simultaneously. This is possible only if no
measurement had been started beforehand.
ok Activate / deactivate keypad lock.

+ start
Press the keys simultaneously.

FCU 2000-4 Series FCU menus
FCU menus
MODE - select operating mode

In the Menu mode, select the operating mode in which the measurement is to be
carried out. When the FCU is switched on, the operating mode last used last is
preset.
mode
MODE
M1: Measure
MODE
M2: Measure + Switch
MODE
M3: Filter to
MODE
M4: Filter from to
MODE
M5: Measure + Autostop
MODE
M6: Autostop pump
Confirm entries and start When autostart is
ok
start measurement. activated,
confirmation
occurs
automatically
immediately after
switching on the
FCU.
Accept the setting and exit the
stop
MODE menu.

MODE "M1: Measure"

Mode M1 "Measurement" is used for measuring oil cleanliness without using the
control functions.
Typical application: Short-time measurement of system cleanliness
MODE "M2: Measuring and switching"

Mode M2 "Measure + switch" can be used for measuring the cleanliness of the oil in
the hydraulic system, at the same time offering the possibility of controlling limit
relays for signaling purposes. This means that this menu enables the user to have
external devices switched by two relays. An example of this would be an alarm
indicator lamp on a control panel.
Possible reference values for triggering these switching sequences:
o The flow (volumetric flow rate)
o Cleanliness rating of the hydraulic fluid (indicated according to NAS
or SAE or ISO)
Typical application: Signal switching to a control panel at fully automated
test benches.
MODE "M3: Filter to" (performance of automatic filtration)

Mode M3 “Filter to” enables the FCU to assume control of an external filtration unit
(e.g. OF5C). In so doing, the external filtration unit is controlled in such a way that it
is switched off by the FCU after it has fallen below the specified limit 5 times.
Typical application: Flushing of hydraulic systems and documentation of
the oil cleanliness rating achieved by way of an online
printout.

MODE "M4: Filtering from to" (performance of automatic filtration)

Mode M4 “Filter from ... to” enables the FCU to assume control of an external
filtration unit (e.g. OF5C). The external filtration unit will be controlled thereby in
such a way that the oil cleanliness in the tank to be monitored will always be within
the specified limits.
If the lower limit value is reached or if it is not met, then the FCU will switch off the
unit to be actuated and the test cycle time begins. After the test cycle time has
elapsed, the FCU carries out a testing measurement (100 ml) and checks whether
the measured values lie within the limit values. If "yes", then the test cycle time
begins again; if "no", then the unit is switched on in order to filter the fluid.
If the test cycle time setting is below LIMITS 0 [min], then this function is switched
off.
Typical application: Long-term monitoring and filtration of the oil
cleanliness in hydraulic systems and documentation
thereof via an online printout.

Mode "M5: Measure Autostop"
Mode M5 "Measure+autostop” enables the number (1 to 100) of single
measurements to be programmed via the FCU’s high-pressure port, after which
measurement operation is concluded automatically. When online printing is
activated, the result of the last measurement is additionally outputted in the form of
particle counts (absolute value).
Typical application: Routine analysis of the cleanliness of a hydraulic
system using a defined number of measurements.
Mode "M6: Autostop pump"

Mode M6 "Autostop pump” enables the number (1 to 100) of single measurements
to be programmed via the FCU’s SUCTION INLET, after which measurement
operation is concluded automatically.
The integrated pump starts up when the OK/START button is pressed.
The first measurement begins immediately after the set start delay. (The start delay
is used to air-bleed and rinse the FCU)
When online printing is activated, the result of the last measurement is additionally
outputted in the form of particle counts (absolute value).
Typical application: Gauging the oil cleanliness of a tank or an oil sample.


MEMORY Menu
In the MEMORY menu you can set the storage of logs.
The percentage shown in the display indicates how much of the memory has been
used. 0.0% = Memory empty <-> 100 % Memory full.
memory
MEMORY 0.0 %
Meas point
MEMORY 0.0%
Averaging interval
MEMORY 0.0 %
Selective deletion
MEMORY 0.0 %
Delete all
MEMORY 0.0 %
Change measuring point
MEMORY 0,0 %
Memory mode
Confirm entries
ok
start
Accept the setting and exit the

stop
Memory menu.

Designating the measurement point

The measuring position designation is used for conveniently assigning a log to a
measurement site at which a measurement is being or was performed. It is stored
together with the measured results and appears on the log printouts.
The measurement site designation can be selected from among 20 customizable
designations.
The FCU features a memory for entering 20 measurement point designations. This
enables frequently occurring designations to be permanently configured and called
up as needed.
memory
MEMORY 0.0 % ok
start
Meas point
Select the
Measuring point: 2 respective
measurement
Designation 1
point via the keys.
Measuring point: 2 The first letter

ok
start blinks.
Designation 1
Measuring point: 2 Navigate to the

position desired
Designation 1 using the keys.
Select the
Measuring point: 2 characters from
the table via the
Designation 2
keys.
or Numbers can be
Measuring point: 2 entered directly
Designation 2 via the keypad.
Confirm the designation for the

ok
start measurement point.
Abort and exit without saving.

stop
The following characters can be selected:

1 2 3 4 5 6 7 8 9 0
. : ! " $ % & / ( ) , = ? ‘
a b c d e f g h i j k l m n o p
q r s t u v w x y z
ä é è ê ö ü ß
A b C D E F G H I J K L M N O P
Q R S T U V W X Y Z
Insert character: ok
start+
Press the keys simultaneously and a space
will be inserted in front of the character just marked.
Delete character: ok
+
start
Press the keys simultaneously and the
character just marked will be deleted from the measuring
point designation.
Setting the averaging interval

Entering an averaging interval enables the data quantity which accumulates during a
measurement to be reduced.
An averaging interval of > 0 min causes only the mean value of all measurements
completed within this interval to be saved and printed out.
The 0 min setting causes the averaging function to be deactivated. Each measured
value is immediately saved and printed out.
The values 0 ... 1440 minutes are possible for the averaging interval.
The current, non-averaged measured value is always shown in the FCU display.
memory
ok
MEMORY 0,0 % start
Averaging interval
Averaging interval:
x [min]
Averaging interval:
x [min]
or
Averaging interval:
x [min]
Confirm entries.
ok
start

stop

Selective deletion
This menu item enables individual or several logs to be deleted. Various criteria are
available for selecting the logs to be deleted.
memory
ok
MEMORY 0,0 % start
Selective deletion
Log selection:
Number
Log selection:
Date
Log selection:
Meas point
Log selection:
Date + Measuring point
Press this key to confirm the
ok
start operating mode selected and to
initiate measurement.
stop
Log selection: ok
start
Number
xxx / yyy — The
Log selection: default value is
from: xxx to: yyy the last log
number.
Log selection: Change values

from: xxx to: yyy
or ok
Log selection: start
from: xxx to: yyy
Are you sure ?!

OK = YES STOP = NO
YES – The selected logs are
ok
start deleted.
No – Abort and exit

stop

Log selection: ok
start
Date
dd.mm.yyyy
Log Date: specified value is
the date of the
dd.mm.yyyy
last log.
Log Date: ok
start
dd.mm.yyyy
Are you sure ?!

OK = YES STOP = NO
ok YES - The selected logs of

start dd.mm.yyyy are deleted.

stop
Log selection: ok
start
Meas point
Designation X
specified value is
Measuring point the measuring
Designation X point of the last
log.
Measuring point ok
start
Designation X
Are you sure ?!

OK = YES STOP = NO
YES – The selected logs of
ok
start designation X are deleted.

stop

Log selection: ok
start
dd.mm.yyyy
Log Date: specified value is
dd.mm.yyyy the date of the
last log.
Log Date: ok
start
dd.mm.yyyy
Designation X
specified value is
Measuring point the measuring
Designation X point of the last
log.
Measuring point ok
start
Designation X
Are you sure ?!

OK = YES STOP = NO
YES – The selected logs of the
ok
start date dd.mm.yyyy and the
measuring point are deleted.
stop
Delete all
This menu item enables the entire log memory to be deleted
memory
ok
MEMORY 0,0 % start
Delete all
Are you sure ?!

OK = YES STOP = NO
YES - All logs are deleted.
ok
start
Press this key to accept the setting

stop
and exit the Power Up menu


This menu item enables the designation of a measuring point to be changed.
memory
ok
MEMORY 0,0 % 0 start
Xxx dd.mm.yyyy hh:mm

Designation X
Xxx dd.mm.yyyy hh:mm ok

start
Designation X
Change measurement point:

Designation X
or
Change measurement point: ok
start
Designation X
Confirm entries.
ok
start

stop

Setting the memory mode

This menu item determines how the FCU behaves when its log memory is full.
memory
ok
MEMORY 0,0 % 0 start
Memory mode
Overwrite
Stop if full
Confirm entries.
ok
start

stop
Overwrite
Once 100 logs or 3000 measured values have been stored, the next log overwrites
the oldest one in the memory.
If the memory is 100% full, the oldest log in the memory is deleted. This can
continue to be repeated during an ongoing measurement until only one (i.e. the
current) log is in memory. Then the oldest log line is deleted.
Stop if full
Once 100 logs or 3000 measured values have been stored, you can start no further
measurements. Delete one or more logs in order to carry out further measurements.
A current measurement is stopped when the memory is 100% full.

PRINT menu
The PRINT menu enables printouts to be initiated of stored logs, ongoing
measurements, the table of contents and the parameter list.
print
PRINT
Logs
PRINT
Contents
PRINT
All Parameters
PRINT
Paper feed
PRINT
Online print-out
PRINT
Abort print-out
ok
Abort and exit.
stop

Logs
Stored logs can be outputted via the built-in printer. Various criteria are available for
selecting the logs to be printed.
print
ok
PRINT start
Logs
Log selection:
Number
Log selection:
Date
Log selection:
Meas point
Log selection:
Confirm entries
ok
start

stop
Log selection: ok
start
Number
Log selection:
from: xxx to: yyy
ok
Printout format:
List
Printout format:
Graph
ok
Printout of:
ISO

(SAE: for 22xx-x

Printout of: only)
NAS (SAE)
The selected logs are printed.

ok
start
Abort and exit

stop
Log selection: ok
start
Date
Log Date:
dd.mm.yyyy
ok
Printout format:
List
Printout format:
Graph
ok
Printout of:
ISO
(SAE: for 22xx-x
Printout of: only)
NAS (SAE)

ok
start
Abort and exit

stop
Log selection: ok
start
Meas point
Measuring point
Designation X


ok
Printout format:
List
Printout format:
Graph
ok
Printout of:
ISO
(SAE: for 22xx-x
Printout of: only)
NAS (SAE)

ok
start
Abort and exit

stop
Log selection: ok
start
Log Date:
dd.mm.yyyy
ok
Measuring point
Designation X
ok
Printout format:
List
Printout format:
Graph


ok
Printout of:
ISO
(SAE: for 22xx-x
Printout of: only)
NAS (SAE)

ok
start
Abort and exit

stop
Contents
A summary of the logs stored in memory is printed out. The following is output for
each log: log number, measuring position designation, starting and stopping time,
and number of log lines.
print
PRINT
Contents
Confirm entries and initiate

ok
start printing.
Abort and exit.

stop
All Parameters
All the current settings are outputted.
print
PRINT
All Parameters
Confirm entries and initiate

ok
start printing.
Abort and exit.

stop

Paper feed
The printer paper is transported ~ 1 cm.
print
PRINT
Paper feed
Confirm entries and start paper

ok
start feed.
Abort and exit.

stop
Online print-out
The measured values are outputted on line and on the printer.
print
ok
PRINT start
Online print-out
Online printout
on
Online printout
off
ok
Printout format:
List
Printout format:
Graph
ok
Printout of:
ISO
(SAE: for 22xx-x
Printout of: only)
NAS (SAE)
Confirm entries
ok
start


stop and exit the Power Up menu
Abort print-out
A current print operation is aborted.
print
PRINT
Abort print-out
Confirm entries and start paper

ok
start feed.
Abort and exit.

stop
LIMITS menu
The LIMITS menu enables settings (limits) to be entered for the various operating
modes.
limits
LIMITS
M2: Relay 1
LIMITS
M2: Relay 2
LIMITS
M3: Filter to
LIMITS
M4: Filter from to
LIMITS
M5: Qty. Measurements
LIMITS
M6: Startdelay
ok
Abort and exit.
stop

MODE M2
limits
LIMITS
M2: Relay 1
LIMITS
M2: Relay 2

ok
Values in
M2:Rx Meas. channel: accordance with
xx m chan. unit limits table. See
page 58
ok
M2:Rx Switch func.:

No function
M2:Rx Switch func.:

Within range
M2:Rx Switch func.:

Outside range
M2:Rx Switch func.:

Exceed
M2:Rx Switch func.:

Fall below
ok
M2:Rx Limit values: Jump from value

to value.
xxx yyy Unit
Select limit values
M2:Rx Limit values: by scrolling
xxx yyy Unit through them
using the keys.
ok

Abort and exit.

stop
MODE M3
limits
ok
LIMITS start
M3: Filter to
M3: Limits: Jump from value

to value.
( xx / yy / zz ) Standard
M3: Limits: (zz — not for

20xx-x)
ok
Abort and exit.
stop
MODE M4
limits
ok
LIMITS start
M4: Filter from to
M4: Limit values: Jump from value

to value.
M4: Limit values: (zz — not for

20xx-x)
M4: Limit values: (zz — not for

20xx-x)
( xx / yy / zz ) Standard
ok
M4: Test cycle time: Standard value =

120 min
xxx [min]
ok
Abort and exit.
stop


Limit values table

FCU 2010-x FCU 2110-x FCU 2210-x
5 µm NAS 2 µm NAS 4 µm SAE
5 µm ISO 2 µm ISO 4 µm ISO
15 µm ISO 5 µm ISO 6 µm ISO
Flow rate 15 µm ISO 14 µm ISO

Flow rate Flow rate
MODE M5
limits
ok
LIMITS start
M5: Number of measurements
M5 Number of measurements:
n
or n = 1 … 100
n

ok
Abort and exit.
stop

MODE M6
limits
ok
LIMITS start
M6: Start delay
M6 Start delay: t = 5 … 120

t [sec]
or t = 5 … 120
M6 Start delay:
t

ok
M6 Number of measurements: n = 1 … 100

n
or n = 1 … 100
n

ok
Abort and exit.
stop

SETUP menu
The SETUP menu enables settings to be entered which apply to several or all of the
FCU’s operating modes.
setup
SETUP
Autostart
SETUP
Abort at Q=0
SETUP
Pump start delay
SETUP
Date / Time
SETUP
Bus address
SETUP
Operating hours
SETUP
Pump supply
SETUP
Battery status
ok
Abort and exit.
stop

Autostart
This menu item enables a setting to be entered determining whether the FCU has to
be started manually after having been switched on or whether it automatically
performs a measurement in a preselected MODE.
setup
ok
SETUP start
Autostart
Autostart:
No
Autostart: ok
start
yes
Autostart function:
M1: Measure
Autostart function:
M2: Measuring and switching
Autostart function:
M3: Filter to
Autostart function:
M4: Filter from to
ok
stop

Abort at Q=0
This menu item enables a setting to be entered determining how the FCU acts when
the current flowing through the sensor drops to a value of “0” while a measurement
is in progress.
Measurement can either be interrupted or stopped altogether. An interrupted
measurement automatically continues when a sufficient flow rate is present again.
This function works in all operating modes.
setup
ok
SETUP start
Abort at Q=0
Abort when Q=0

No
Abort when Q=0

yes
ok
stop

Setting the pump start delay

When conducting measurements with the aid of an external pump or an external
filtration unit (e.g. OF5C), this function enables the user to operate the pump for a
limited period of time within which a flow has to start at the FCU.
When the pump start delay has elapsed and the FCU does not detect any flow,
measurement is stopped and the unit connected via a relay is switched off so as to
prevent damage caused by dry running of the pump. This function is in effect in all
operating modes except M2.
Measurement resumes as soon as enough flow is available. The stopping time
ranges from 1 to 200 seconds (practical recommendation: 60 seconds).
The 0 sec. setting causes the averaging function to be deactivated. This means that
the FCU waits as long as you wish for flow
setup
ok
SETUP start
Pump start delay
Pump delay start time

xx s
or
Pump delay start time ok
start
xx s

ok
stop and exit the Power Up menu

Setting the date and time

The date and time are displayed and can be changed.
setup
ok
SETUP start
Date / Time
Date: Selection
dd.mm.yyyy
Date:
dd.mm.yyyy
or
Date: ok
start
dd.mm.yyyy

ok
Time:
hh:mm:ss
Correct the time.
ok
start

stop
Time: Selection
hh:mm:ss
Time:
hh:mm:ss
or
Time: ok
start
hh:mm:ss
Confirm entries.
ok
start

stop

Set bus address

The standard setting is 1; this setting should not be changed. If several units
featuring DIN measurement bus interfaces (type code / - BUS) are connected to one
bus, a bus address between 1 and 31 has to be allocated to each unit. An address
may not be allocated twice.
setup
ok
SETUP start
Bus address
Bus address:
1
or
Bus address: ok
start
3

ok
stop
Display operating hours

The operating hours of the unit are displayed.
The operating hours meter only records the measurement time.
setup
ok
SETUP start
Operating hours
Operating hours:
xxxx h
ok
stop

Pump supply
The FCU’s integrated pump can be supplied either externally via one of the two
power supply units supplied with the FCU or by the integrated batteries.
The external power supply unit provides for a higher voltage than the
batteries, which means higher viscosities can be conveyed when it is
used. For more information, see chapter "Technical Data".
setup
ok
SETUP start
Pump supply
Pump supply:
External
Pump supply:
Internal
ok
stop
Check the battery status

The current battery charge is shown.
setup
ok
SETUP start
Battery status
Battery status:
13,63 V 80 %
ok
stop

POWERUP menu
The POWERUP menu is only available when the FCU is powered up and as long as
no measurement has been started.
Settings are made here which are normally rarely changed.
+
The POWERUP menu is accessed by simultaneously pressing the keys.
POWERUP
+
Language
POWERUP
Viscosity range
POWERUP
Test volume
ok
Abort and exit the Powerup Menu
stop

Selecting the language

This menu item enables the language for the texts shown in the display and on
printouts to be selected.
Language Applying the submenu selected.
ok
start
Language:
German
Language:
English
Language:
French
Language:
Programmable
ok
Abort and exit the Powerup menu
stop
Setting the viscosity range

The viscosity range of the fluid to be measured must be set here. Here we
differentiate between low viscosity (1 … 10 mm²/s) and high viscosity
(5 … 1000 mm²/s) mediums.
Check or correct the viscosity range before starting the measurement.
Viscosity Applying the submenu selected.
ok
range start
Viscosity range:
1 … 10 mm²/s
Viscosity range:
5 … 1000 mm²/s
ok
stop

Setting the measured volume

The volume that is analyzed for the determination of a measured value can be set
here. Permitted values range from 10 ... 100.
Test volume Applying the submenu selected.
ok
start
Measurement volume: Depending

on the key,
100 ml
the value is
increased /
decreased
by 1 ml.
or Enter
measureme
Measurement volume: nt volume
XXX ml via the
keyboard.
ok
stop

FCU 2000-4 Series FCU display
FCU display
FCU 2010/2011
FCU 2110/2111 FCU 2210/2211
1 3 4
ISO
M1 68% ISO M1 68% ISO
Q: 100ml 19/15/10 Q: 100ml 19/15/10
SAE/NAS
M1 68% NAS(5) 2 M1 68% SAE(A) 6
Q: 100ml NAS(15) 5 Q: 100ml SAE(B) 5
particles
M1 68%D 5μm: 43421 M1 68%C 4μm: 43421
Q: 100ml 15μm: 8725 Q: 100ml 6μm: 8725
2 5
1 The FCU is working in MODE M1 (measuring the cleanliness class).
2 Display of the measured flow rate (100 ml/min is recommended).
3 Indicates elapsed measuring time in %. Begins at 0%; the cleanliness class is

displayed again at 100%.
4 Specification of the currently determined contamination.
You can switch back and forth between the display in ISO or NAS (FCU 201x,
211x) or SAE (FCU 221x) coding and the display of particle counts with the
ISO SAE/NAS particles
keys .
During the representation of the contamination class in NAS or SAE classes,
the figures / letters in brackets state the selected particle size range:
FCU 201x:
(5): 5…15 µm, (15): 15…25 µm, (25): 25…50 µm, (50): >50 µm
FCU 211x:
(2): 2…5 µm , (5): 5…15 µm, (15): 15…25 µm ,(25): >25 µm
FCU 221x:
(A): >4 µm , (B): >6 µm, (C): >14 µm ,(D): >21 µm

FCU 2000-4 Series FCU display
The particle sizes displayed can be selected with the keys and .
To display even very slight changes, the "Tendency arrow"
(: increasing contamination, : decreasing contamination) is used. It even
indicates changes which would not otherwise be remarked upon by the
specification of Contamination Class alone.
If the determined contamination lies above the specified display range (see
page 94), >25 >23 or >12 / >15 are shown in all particle size ranges..
5 One can select between differential and cumulative displays of numbers of
particles by using the keys . The selected presentation is indicated

in the display by a "D" (differential) or "C" (cumulative) behind the display of
the expired measurement time.
Differential representation means: particle count in the particle size ranges:
FCU 201x:
5…15 µm, 15…25 µm, 25…50 µm, >50 µm
FCU 211x:
2…5 µm, 5…15 µm, 15…25 µm , >25 µm
FCU 221x:
4…6 µm(c), 6…14 µm(c), 14…21 µm(c), >21 µm(c)
Cumulative representation means: particle count in the particle size ranges:

FCU 201x:
>5 µm, >15 µm, >25 µm, >50 µm
FCU 211x:
>2 µm, >5 µm, >15 µm, >25 µm
FCU 221x:
>4 µm(c), >6 µm(c), >14 µm(c), >21 µm(c)
If the determined particle count lies above the specified display range (see
page 94), ">>>>>>>“ is shown in all particle size ranges as the particle count.

FCU 2000-4 Series Brief Overview of the Menu Structure
Brief Overview of the Menu Structure

MODE
M1: Measure
M3: Filter to
M4: Filter from to
M6: Autostop pump
MEMORY
Meas point
Measuring point xx
Designation xx
Averaging interval
X min.
Selective deletion
Number
Log selection:
from: xxx to: xxx
Date
Log Date:
dd.mm.yyyy
Meas point
Measuring point
Designation x
Log Date:
dd.mm.yyyy
Measuring point
Designation x
Delete all
Change Measuring point

Xxx dd.mm.yyyy hh:mm
Memory mode
Overwrite
Stop if full
PRINT
Logs
Number
List
Graph
Date
List
Graph
Meas point
List
Graph
List
Graph
Contents
All parameters
Paper feed
Online print-out
On
Off
Abort print-out
LIMITS
M2: Relay 1
M2: R1 Meas. Channel:
Limit values ... (acc. Table)
M2: R1 Switch func:
No function
Within range
Outside range
Exceed
Fall below

FCU 2000-4 Series Brief Overview of the Menu Structure
M2: Relay 2
M2: R2 Meas. Channel:
Limit values ... (acc. Table)
M2: R2 Switch func:
No function
Within range
Outside range
Exceed
Fall below
M3: Filter to
M3: Limits:
 ( xx / xx / xx ) Unit
M4: Filter from to
M4: Limits:
 ( xx / xx / xx ) Unit
 ( xx / xx / xx ) Unit
M4: Test cycle time:
X [min]
X
M6: Start delay
M6: Start delay
XX s
X
SETUP
Autostart
Yes
M1: Measure
M3: Filter to
M4: Filter from to
M6: Autostop pump
no
Abort at Q=0
Yes
No
Pump start delay
X [s]
Date / Time
Date
dd.mm.yyyy
Time
Hh:mm:ss
Bus addr.
X
Operating hours
X [h]
Pump supply:
External
internal
Battery status
xx.xx V yy %
POWERUP
Language
English
English
French
Programmable
Viscosity range
1 … 10 mm²/s
5 … 1000 mm²/s
Test volume
x [ml]

FCU 2000-4 Series Error Messages and Troubleshooting
Error Messages and Troubleshooting

Error message Cause(s) Remedy
Invalid parameter You have entered a value Display the permitted value
which is outside the ranges using the keys
permitted value range (e.g. +
NAS 23). and by scrolling
above the maximum
values. Then the minimum
value is automatically
displayed.
Check parameter The self-monitoring function Rest all parameters using
Defective parameter: of the FCU has detected a the keyboard or transfer
check sum error for one or the parameters with the
No. xx
more parameters. FluMoS software.
Cause: Strong
electromagnetic interference
has changed the
parameters.
Measurement ended The setting for the "Memory Delete the reports or set
Memory for mode" parameter is at "Stop the "Memory mode"
measured values full if full". parameter to "Overwrite".
For details see page 47.
The maximum number of
reports or measured values
has been reached. No more
values can be stored.
Value not accepted An error occurred while Repeat the entry or
storing a value in EEPROM. continue the measurement.
If the fault recurs, contact
HYDAC.


Number of defective The self-monitoring function The defective logs are
logs: of the FCU has detected a deleted automatically. After
check sum error for one or the next power up, this
more stored logs. message is not displayed
Possible causes again if it was just a brief
malfunction.
 Strong electromagnetic
interference has changed If this message is displayed
the measured value several times, this means
memory. that the internal back-up
battery is probably dead.
 The internal back-up Send the FCU to HYDAC
battery is dead. for repair.
 A measurement has been
started and terminated —
for example as a result of
the FCU being switched
off — without any
measured values being
stored.
 A measurement
previously conducted
resulted only in a flow
error.
-> The protocol contains
no values.
No logs stored! You have tried to print logs, Carry out measurements.
but the FCU memory is
empty.
Too few points You have tried to print a Print out the protocol in the
graph, but the selected log form of a list.
has insufficient
measurement values (min.
3) to produce a graph.
Battery needs The rechargeable batteries Measurements are still
charging are dead. possible. However, it is
better to connect a power
adapter, in particular for
printing.
Use power supply The rechargeable batteries The batteries require a
are dead. charging time of ~
11 hours.
You can operate the FCU
using a connected power
supply.


Flow rate error! There is no oil flowing Turn the flow control valve
through the particle sensor control knob clockwise.
Correct: 0 ml
(possibly only air).
Check the change-over
The flow rate sensor is valve setting.
faulty.
Check the hydraulic
Measurement volumes are connections.
set to 0 in the PowerUp
Check the pressure.
Menu.
Fluid must flow through the
(Starting with Firmware
return hose on the
Version 3.20, the minimum
OUTLET from a pressure
measurement volume is min.
of >30bar/420psi. The
10 ml)
pressure control valve must
open (see circuit diagram)
Change the measured
volume to between 10 ...
100 ml)
Send the FCU to HYDAC
for repair.
The batteries are exhausted Connect both power
as a result of measurements adapters (see page 23).
being carried out via the
integrated pump without
additional power supply unit.
Flow rate error! The flow through the particle Turn the flow control valve
sensor is lower than the clockwise until
Correct: 15 ml
minimum value of 50 ml/min measurement operation
required to take starts.
measurements.
Flow rate error! The flow through the particle Turn the flow control valve
sensor is higher than the counterclockwise until
Correct: 250 ml
maximum value of 150 measurement operation
ml/min permitted to take starts.
measurements.
Flow rate error! The internal filter is Replace the FCU filter
contaminated. Because of element.
the inlet pressure of <2 bar,
the "Filter contaminated"
fault message is not issued.
Filter contaminated The internal protection filter Replace the FCU filter
for the flow control valve of element.
the FCU is exhausted.
external inlet active The clogging indicator fitted Replace the filter element
in the OF5C has been at OF5C.
(this message can only
activated, the OF5C filter is
appear with the OF5C
exhausted.
filter unit)


Internal printer not Paper roll empty Insert a new roll of paper.
ready
Printer fault Send the FCU to HYDAC
for repair.
Error in selected The last language selected Download the FCU
language and stored in the FCU has languages to the FCU
been changed due to an again using the PC
internal fault. software package FluMoS.
The internal back-up battery If the fault recurs, send the
is dead. FCU to HYDAC for repair.
Reload languages The internal memory for Download the FCU
languages has been partially languages to the FCU
changed due to an internal again using the PC
fault. software package FluMoS.
The internal back-up battery If the fault recurs, send the
is dead. FCU to HYDAC for repair.
Calibration defect The calibration values in the Send the FCU to HYDAC
EEPROM have been altered for repair.
due to electrical interference.
Device ID defect Internal device designations No measures required, as
in the EEPROM have been these values do not affect
altered due to electrical the FCU function.
interference.
Send the FCU to HYDAC
for repair.
Water/air in oil Warning message when a Nothing needs to be done
sample exhibits a high water unless this message pops
or air content. up when the fluid is clear.
If this fault message also
occurs when the fluid is
clear, then send the FCU to
HYDAC for repair if
necessary.

FCU 2000-4 Series Performing Maintenance
Performing Maintenance
Conduct the specified configuration, maintenance and inspection work every six
months at the latest, or whenever an error message or malfunction makes it
necessary.
All operating media are to be protected/isolated in case the product is accidentally
started up.
Disconnect the FCU from the power supply when performing any maintenance,
inspection or repair work.
Once maintenance work is complete, check that the FCU is still working properly.
Any screwed fittings which have been undone/removed are to be checked to see
that they have been properly resecured.
Cleaning the FCU

Clean the control panel with a clean, moist cloth. Do not use any chemical cleaning
agents, as these may damage the film attached to the surface of the FCU. Clean the
outside of the FCU with a moist cloth.
Changing the FCU Filter Element

The FCU has an internal filter element with a differential pressure switch. The
differential pressure switch switches at 2 bar. The message "Filter clogged" will
appear on the display. Ensure that the flow rate control valve is not closed.
If the filter is contaminated, but the differential pressure of 2 bar cannot be achieved
(e.g. with an inlet pressure <2 bar), then there will be no indication on the display.
Only the message "Flow error" will appear in such cases.
To change the filter, proceed as follows:
1. Put a suitable drip tray in place to catch the oil
(~0.5 l).
Turn the FCU so that the rear side faces
upwards. Ensure that the flow rate control
valve is not damaged.

2. Unscrew the screw plug with a size 19 ring

spanner by turning it counterclockwise.
3. Pull the filter element out upwards by the

strap.
4. Take the strap out of the old filter elements

and push this over the new filter element.
Dispose of the old filter element correctly
according to local regulations and guidelines.
5. Moisten the O-ring on the new filter element

slightly with fluid.

6. Place the new filter element with the strap into

the FCU.
Press the filter element down into the filter
mount.
Do not use excessive force or a hammer, etc.
7. Check the screw plug O-ring for damage.

Replace it if necessary.
8. Insert and manually screw in the screw plug

clockwise.
Tighten the screw plug with a size 19 ring
spanner.
9. The filter element change is now complete.

Back-flushing the FCU

If the sensor is blocked, use the flushing set available as an accessory. The part-no.
can be found in the spare parts list.
A description of how to back-flush is included with the flushing set.
Internal dot-matrix impact printer – replace paper roll / ink ribbon

1. 2.
3. 4.
5. 6.
7 8.

9 10.
11. 12
13. 14.
15. 16.
17. 18.

FCU 2000-4 Series Disposing of the FCU
Disposing of the FCU

When decommissioning and/or disposing of the FCU, observe all local guidelines
and regulations pertaining to occupational safety and environmental protection. This
applies in particular to the oil in the unit, components covered with oil and electronic
components.
After disassembling the unit and separating the various materials, reuse them or
dispose of them properly in accordance with local regulations.
Storing the FCU

Rinse the FCU completely with n-heptane before putting it into storage.
Dispose of used cleaning agents and rinsing oils properly.
Storage conditions
Storage temperature: -20 … 85°C / -4 … 185°F
Relative humidity: max. 90%, non-condensing
Calibrating the FCU

We recommend that the FCU be recalibrated every 2 to 3 years. You will receive a
calibration certificate at the time of each calibration.

FCU 2000-4 Series Customer service
Customer service
Shipping address for calibration and repair:
Germany
HYDAC Service GmbH
Product Support, Werk 10
66128 Saarbrücken, Germany
Telephone: ++49 (0) 6897 509 883
Fax: ++49 (0) 6897 509 324
E-mail: service@hydac.com
USA
HYDAC Technology Corporation, HYCON Division
2260 City Line Road
USA-Bethlehem, PA 18017
P.O. Box 22050
USA-Lehigh Valley, PA 18002-2050
Telephone: +1 (0) 610 266 0100
Fax: +1 - 610 - 2 31-04 45
E-mail: sales@hydacusa.com
Internet: www.hydacusa.com
Australia
HYDAC Pty. Ltd.
109 Dohertys Road
P.O. Box 224
AUS-3025 Altona North
Telephone: +61 - 3 - 92 72 89 00
Fax: +61 - 3 - 93 69 89 12
E-mail: info@hydac.com.au

FCU 2000-4 Series Customer service
Brazil
HYDAC TECNOLOGIA LTDA
Estrada Fukutaro Yida, 225
CEP 09852-060
Cooperativa
BR-São Bernardo do Campo – SÃO PAULO
Telephone: +55 - 11 - 4393.6600
Fax: +55 - 11 - 4393.6617
E-mail: hydac@hydac.com.br
Homepage www.hydac.com.br
China
HYDAC TECHNOLOGY (SHANGHAI) LIMITED
28 Zhongpin Lu
Shanghai Minhang Economic &
Technological Development Zone
SHANGHAI 200245; P.R. CHINA
Telephone: (0086) 21/64 63 35 10
Fax: (0086) 21/64 30 02 57
E-mail: hydacsh@hydac.com.cn

FCU 2000-4 Series Spare Parts
Spare Parts
FCU 2xx0-x (version for mineral oil)

Part no. Article designation
349154 Filter element replacement set, consisting of:

1x filter element, 1x O-ring, 1x support ring
1260891 Filter element
1251557 High-pressure measuring hose, DN 4, 5000 mm long
349150 High-pressure measuring hose, DN 4, 2000 mm long
349151 Return-line hose, DN 7, 2000 mm long
1251558 Return-line hose, DN 7, 5000 mm long
3036098 Suction hose with coupling, DN 6, 1000 mm long

(for FCU 2xx0–4 only)
3068209 Suction hose with coupling, DN 6, 250 mm long

(for FCU 2xx0–4 only)

FCU 2000-4 Series Accessories
FCU 2xxx-x (all versions)

Part no. Article designation
349204 Connecting cable FCU – PC
349155 Package of paper rolls, printer (5 rolls)
Roll diameter: 50 mm
Roll width: 58 mm
349156 Ribbon cartridge for dot-matrix printer
349157 Connecting cable FCU -> external
printer
3090803 Power supply (without connecting
cable)
Primary: 90-264 V AC
Secondary: 24 V DC, 2300 mA
6008448 Connecting cable for power supply

Euro plug, 2 m long

Plug for UK, 2 m long

Plug for USA, 2 m long

Plug for AUS, 2 m long
Accessories
Part no. Designation
3040814 Carrying case, including filter element replacement set for mineral oil,
2 rolls of paper, 1 ribbon cartridge for printer
1204501 FCU back-flushing kit (mineral oil model)
3355176 FluMoS light Software

(download available free of charge at www.hydac.com)
3371637 FluMoS Professional Software
3053829 LabView Driver Package (Software)
3143926 Windows Driver Package (Software)
3028133 Reservoir Extraction Unit REU 1430-1-M (230V AC/50Hz/1Phase)

FCU 2000-4 Series Accessories
Part no. Designation
FCU adapter kit for sample bottles

3086166 with connection thread GL55 in
accordance with DIN 168-1 (scope
of delivery without sample bottle)
Sample bottle 250 ml with

3143465 connection thread GL 55 in
accordance with DIN 168-1
3487290 Suction strainer

FCU 2000-4 Series Explanation of terms used in measurement systems
Explanation of terms used in measurement systems

Single This refers to the analysis of the contamination of a specified
measurement: sample quantity (measurement volume). The result of a
single measurement is the measured value.
Measuring point The name of the location at which the FCU is connected to
the hydraulic system.
This designation (max. 20 characters) can be entered in the
FCU for documentation purposes.
Example: pump press W3
Measurement Sample quantity which is analyzed for determining a
volume: measured value. (The measurement volume can be set by
the user)
Measured value The contamination codes determined by a single
measurement, shown as a three-digit ISO code or NAS class
or SAE class of the individual particle size channels.
Measurement: After the "OK/START" - key is pressed, a single
measurement begins, followed immediately upon completion
by the next single measurement until the "STOP" - key is
pressed (mode M1, M2, M4) or the target cleanliness (mode
M3) is reached.
This series of single measurements is referred to as a
measurement for convenience reasons.
Log: A measurement is described by a log. It is comprised of the
log header and the log lines. The FCU saves up to 100 logs.
Log header: The log header contains:
A log number (a consecutive log number is automatically
generated every time a measurement sequence is initiated).
The designation of the measurement point (can be entered
by the user), date + time of the beginning and end of the
measurement sequence (generated automatically)
Averaging interval
Number of log lines Measurement volume
Example:
Memory log:.........................6
Measuring point: ..................25
from: ....................................15.09.2003, 8:32
to:.........................................15.09.2003, 10:42
Averaging interval:...............10 min
Number of log lines:.............13
Measurement volume: .........100 ml
Log line: A log line consists of the time and results (4 particle
channels and flow rate with NAS) (3 particle channels and
flow rate with ISO and SAE) of a measurement.
The FCU can store up to 3000 log lines.

FCU 2000-4 Series Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes
Overview - ISO 4406 / SAE AS 4059 and NAS 1638 classes
ISO 4406:1999
In ISO 4406:1999, particle counts are determined cumulatively, i.e. > 4 µm(c), >6
µm(c) and >14 µm(c) (manually by filtering the fluid through an analysis membrane or
automatically using particle counters) and allocated to measurement references.
The goal of allocating particle counts to references is to facilitate the assessment of
fluid cleanliness ratings.
In 1999 the "old" ISO 4406:1987 was revised and the size ranges of the particle
sizes undergoing analysis redefined. The counting method and calibration were also
changed.
This is important for the user in his everyday work: even though the measurement
references of the particles undergoing analysis have changed, the cleanliness code
will change only in individual cases. When drafting the "new" ISO 4406:1999 it was
ensured that not all the existing cleanliness provisions for systems had to be
changed.
ISO 4406 table

Allocation of particle counts to cleanliness classes:
Number of particles / 100 ml Number of particles / 100 ml
Class More than Up to (and Class More than Up to (and

including) including)
0 0 1 15 16,000 32,000
1 1 2 16 32,000 64,000
2 2 4 17 64,000 130,000
3 4 8 18 130,000 250,000
4 8 16 19 250,000 500,000
5 16 32 20 500,000 1,000,000
6 32 64 21 1,000,000 2,000,000
7 64 130 22 2,000,000 4,000,000
8 130 250 23 4,000,000 8,000,000
9 250 500 24 8,000,000 16,000,000
10 500 1,000 25 16,000,000 32,000,000
11 1,000 2,000 26 32,000,000 64,000,000
12 2,000 4,000 27 64,000,000 130,000,000
13 4,000 8,000 28 130,000,000 250,000,000
14 8,000 16,000

Note: increasing the measurement reference by 1 causes the particle count to

double.
Example: ISO class 18 / 15 / 11 means:

Cleanliness class Particle count / 100 ml Size ranges
18 130,000 – 250,000 > 4 µm (c)
15 16,000 – 32,000 > 6 µm (c)
11 1,000 – 2,000 > 14 µm (c)
Are in 100 ml of the analyzed sample.
Overview of the differences between ISO 4406:1987 and ISO 4406:1999

“old” ISO 4406:1987 “new” ISO 4406:1999
Size ranges > 5 µm > 4 µm (c)
> 15 µm > 6 µm (c)
> 14 µm (c)
Dimension Longest dimension of a Diameter of the
determined particle area-equivalent
circle
ISO 11171:1999
Test dust ACFTD dust 1-10 µm ISO 12103-1A1
ultra fine
fraction
SAE Fine, ISO 12103-1A2
AC Fine
SAE 5-80 µm ISO 12103-1A3
ISO MTD
Calibration dust
for particle
counters
SAE Coarse ISO 12103-1A4
Coarse fraction
Comparable size Old ACFTD calibration Comparable New NIST
ranges ACFTD calibration
calibration
----- < 1 µm 4 µm (c)
5 µm 4.3 µm 6 µm (c)
15 µm 15.5 µm 14 µm (c)

SAE AS 4059
Like ISO 4406, SAE AS 4059 describes particle concentrations in liquids. The
analysis methods can be applied in the same manner as ISO 4406:1999.
The SAE cleanliness classes are based on particle size, number and distribution.
The particle size determined depends on the measurement process and calibration;
consequently the particle sizes are labeled with letters (A-F).
The following table shows the cleanliness in relation to the particle concentration
determined.
SAE AS 4059 table

Maximum particle count / 100 ml
Size ISO 4402 > 1 µm > 5 µm > 15 µm > 25 µm > 50 µm > 100 µm
Size ISO 11171 > 4 µm(c) > 6 µm(c) > 14 µm(c) > 21 µm(c) > 38 µm(c) > 70 µm(c)
Size Code A b C D E F
000 195 76 14 3 1 0
00 390 152 27 5 1 0
0 780 304 54 10 2 0
1 1,560 609 109 20 4 1
2 3,120 1,220 217 39 7 1
3 6,250 2,430 432 76 13 2
4 12,500 4,860 864 152 26 4
Classes
5 25,000 9,730 1,730 306 53 8

6 50,000 19,500 3,460 612 106 16
7 100,000 38,900 6,920 1,220 212 32
8 200,000 77,900 13,900 2,450 424 64
9 400,000 156,000 27,700 4,900 848 128
10 800,000 311,000 55,400 9,800 1,700 256
11 1,600,000 623,000 111,000 19,600 3,390 512
12 3,200,000 1,250,000 222,000 39,200 6,780 1,020
Cleanliness codes according to SAE

Absolute particle count larger than a defined particle size
Example: cleanliness class to AS 4059:6
The maximum permissible particle count in the individual size ranges is bold-faced
in the above table.
Cleanliness class to AS 4059:6B
Size B particles may not exceed the maximum number indicated for class 6
6 B = max. 19,500 particles > 5 µm in size

Specifying a cleanliness class for each particle size

Example: cleanliness class to AS 4059: 7A/7B/6C/5D
Cleanliness class Particle count / 100 ml
Size A ( > 1 µm / > 4 µm(c)) 100,000
Size B ( > 5 µm / > 6 µm(c)) 38,900
Size C ( > 15 µm / > 14 µm(c)) 3460
Size D ( > 25 µm / > 21 µm(c)) 306
Specifying the highest cleanliness class measured

Example: Cleanliness class according to AS 4059 6A–F
The 6 A – F specification requires a particle count in size ranges A – F.
The respective particle concentration of cleanliness code 6 may not be exceeded in
any of these ranges.
NAS 1638
Like ISO 4406, NAS 1638 describes particle concentrations in liquids. The analysis
methods can be applied in the same manner as ISO 4406:1999.
In contrast to ISO 4406, certain particle ranges are counted in NAS 1638 and
attributed to measurement references.
The following table shows the cleanliness in relation to the particle concentration
determined.
Maximum particle count / 100 ml
2…5 5…15 15…25 25…50 50…100 > 100
µm µm µm µm µm µm
00 625 125 22 4 1 0
0 1,250 250 44 8 2 0
1 2,500 500 88 16 3 1
2 5,000 1,000 178 32 6 1
3 10,000 2,000 356 64 11 2
4 20,000 4,000 712 128 22 4
Cleanliness class
5 40,000 8,000 1,425 253 45 8

6 80,000 16,000 2,850 506 90 16
7 160,000 32,000 5,700 1,012 180 32
8 320,000 64,000 11,400 2,025 360 64
9 640,000 128,000 22,800 4,050 720 128
10 1,280,000 256,000 45,600 8,100 1,440 256
11 2,560,000 512,000 91,200 16,200 2,880 512
12 5,120,000 1,024,000 182,400 32,400 5,760 1,024
13 10,240,000 2,048,000 364,800 64,800 11,520 2,048
14 20,480,000 4,096,000 729,000 129,600 23,040 4,096
Increasing the class by 1 causes the particle count to double on average.

FCU 2000-4 Series Technical data
Technical data
Measured value display Continuous view in LCD display
Self-diagnosis: Continuous self-monitoring with error
indication in LCD display
Particle size channels: FCU 20xx-x:
5 µm / 15 µm / 25 µm / 50 µm
FCU 21xx-x:
2 µm / 5 µm / 15 µm / 25 µm
FCU 22xx-x:
4 µm(c) / 6 µm(c) / 14 µm(c) / 21 µm(c)
Measurement range (calibrated): FCU 20xx-x
NAS 2 … 12
ISO 10 / 09 … 21 / 18
FCU 21xx-x:
NAS 2 … 12
ISO 12 / 10 / 09 … 23 / 21 / 18
FCU 22xx-x:
SAE 2 … 12
ISO 12 / 10 / 09 … 23 / 21 / 18
Indication range: FCU 20xx-x
NAS 2 … 15
ISO 10 / 07 … 23 / 21
FCU 21xx-x:
NAS 2 … 15
ISO 12 / 10 / 07 … 25 / 23 / 21
FCU 22xx-x:
SAE 2 … 15
ISO 12 / 10 / 07 … 25 / 23 / 21
Accuracy: ± 1/2 class (ISO,NAS,SAE)
Calibration: FCU 20xx-x : ISO 4402
FCU 21xx-x : ISO 4402
FCU 22xx-x : ISO 11943
Recalibration: Recommended: every 2 to 3 years
Battery-buffered log memory: Can accommodate up to 3000 measured
values.
Inlet operating pressure: FCU 2xxx-x:
Pressure connection (INLET): 1 … 350 bar
FCU 2xx0-4:
Suction connection (SUCTION): 0.5 bar

The minimum inlet pressure required to achieve a flow rate of 100 ml/min at the
high-pressure inlet (INLET) for a given viscosity can be found by referring to the
graph below.
Required pressure at the high pressure inlet of the FCU

to achieve a flow of 100 ml/min.
(flow regulator completely opened, new filter element)
Pressure [bar]
Viscosity in mm²/s
FCU 2xx0-4
Connectors: Rear: INLET: Mini measurement coupling DN4,
SUCTION: CPC quick-release coupling
Series LC DN6
OUTLET: DN 7 plug nipple
Return-line (OUTLET) flow rate: max. 800 ml/min
at INLET > 300 bar
Return-line (OUTLET) operating max. 3 bar counterpressure
pressure:
Measurement flow rate: 50 … 150 ml/min

FCU 2xx0-4
Permitted viscosity range: 1 … 1000 mm²/s
(high pressure inlet - INLET)
Permitted viscosity range: max. 150 mm²/s in continuous operation
(internal pump - SUCTION max. 350 mm²/s short-term (max. 10 minutes)
INLET)
Fluid temperature range: 0 … 70°C
Supply voltage: 24 V DC, ± 25%
Power consumption: 100 W max.
Battery-powered operating Measurement without pump or pump supplied
duration: externally: ~ 5 hours
Measurement with pump: depending on
viscosity ~ 2 hours
Built-in printer: Dot-matrix printer
Serial port: RS 232 (for models / BUS RS 485)
with 15-pin Sub D plug
Ambient temperature range: 0 … 55°C
Storage temperature: -20 … 85°C
Relative humidity; max. 90%, non-condensing
Protection class IP40
Weight: ~ 15.8 kg

FCU 2000-4 Series Factory default settings
Factory default settings

FCU 20xx-x FCU 21xx-x FCU 22xx-x
POWERUP Menu
Language German German German
Test volume 100 ml 100 ml 100 ml
MEMORY Menu
Meas point HYDAC FCU HYDAC FCU HYDAC FCU
2010 2110 2210
Averaging interval: 0 min 0 min 0 min
Print Menu
Online printout on on on
Printout format: Graph Graph Graph
Printout of: NAS NAS ISO
Log duration: 0.5 h / page (30 0.5 h / page (30 0.5 h / page (30
cm) cm) cm)
SETUP menu
Autostart: No No No
Autostart function: Mode M2: Mode M2: Mode M2:
Measure + Measure + Measure +
switch switch switch
Abort when Q=0 No No No
Pump delay start time 0 seconds 0 seconds 0 seconds
Bus address: 1 1 1
LIMITS Menu
M2:R1 Measurement Flow rate Flow rate Flow rate
channel:
M2:R1 Switching function: No function No function Outside range
M2:R1 Limit values: below: 90 ml 90 ml 90 ml
M2:R1 Limit values: above: 110 ml 110 ml 110 ml
M2:R2 Measurement Flow rate Flow rate Flow rate
channel:
M2:R2 Switching function: No function No function Outside range
M2:R2 Limit values: below: 70 ml 70 ml 70 ml
M2:R2 Limit values: above: 80 ml 80 ml 130 ml
M3:Limit values: 5/5 NAS 5/5/5 NAS 17/14/11 ISO
M4:Limit values: below: 5/5 NAS 5/5/5 NAS 17/14/11 ISO
M4:Limit values: above: 10/10 NAS 10/10/10 NAS 23/19/16 ISO
M4: Test cycle time 120 min 120 min 120 min

Industriegebiet Postfach 1251
66280 Sulzbach/Saar 66273 Sulzbach/Saar
Germany Germany
Phone: +49 (0) 6897 509 01 Central

Fax: +49 (0) 6897 509 846 (Technical Department)
Fax: +49 (0) 6897 509 577 (Sales Department)
Internet: www.hydac.com
E-mail: filtersystems@hydac.com

Fcu2000 4

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FCU 2000-4 Series

English (translation of original instructions)

Document no.: 3109987g

HYDAC FILTER SYSTEMS GMBH

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Hydraulic connection of the FCU..........................................................................30

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Changes to the manual

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Keep it in the vicinity of the product so it is always available.

HYDAC FILTER SYSTEMS GMBH

We look forward to receiving your input.

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Modifications to the Product

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Using the Documentation

What do I want to know?

Where can I find the information I’m looking for?

Documentation no. Document language

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Safety Information and Instructions

Obligations and Liability

Danger of bodily injury

► Depressurize the system before performing any

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Explanation of Symbols and Warnings, etc.

DANGER denotes situations

WARNING denotes situations

DANGER denotes situations

NOTICE denotes situations

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What to Do in Case of Emergency

Maintenance, Servicing and Troubleshooting

Modifications to the FCU

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Training and Instruction of Personnel

Supervisor with the

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Checking the scope of delivery

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Description of the FCU

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Operating elements / Dimensions

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Restrictions on use – FCU 2010 / 2110 / 2210

The FCU will be destroyed

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FCU Function Description

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Electrical connection of the FCU

Connecting the "POWER INPUT"

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Connecting the "POWER INPUT PUMP"