MCMS 2000 Machine Condition Monitoring System: Operating and Maintenance Instructions

MCMS 2000
Machine Condition Monitoring

System
Operating and Maintenance Instructions

English (translation of original instructions)
Documentation no.: 4449960a

Valid from firmware version V 1.1
Content
Content
Content ..........................................................................................................2
General ..........................................................................................................5
Imprint............................................................................................. 5
Documentation Representative ...................................................... 5
Purpose of this manual ................................................................... 5
Target group of the manual ............................................................ 6
Target group - Required qualifications/training ............................... 7
Illustrations in the manual ............................................................... 8
Illustration on the title page ......................................................... 8
Illustration of the layout ............................................................... 9
Representation of requirements .................................................. 9
Representation of procedural instructions ................................. 10
Representation of warning/general safety information .............. 10
Signal words and their meaning in the general safety
information ................................................................................ 11
Representation/explanation of pictograms.................................... 12
Supplementary symbols ............................................................... 13
Exclusion of liability/warranty ........................................................ 13
Notes on copyright ........................................................................ 13
Validity of this manual ................................................................... 13
General safety information ........................................................................ 14
Product overview ........................................................................................ 17
Scope of delivery .......................................................................... 19
Scope of delivery for MCMS 2000 ............................................. 19
System dimensions ...................................................................... 20
Dimensions of data logger unit MCMS 2000 ............................. 20
Proper/designated use.................................................................. 21
Improper Use or Use Deviating from Intended Use ...................... 22
Technical Data .............................................................................. 23
Decoding the model code label .................................................... 27
Model Code ............................................................................... 28
Transport, handling and storage ............................................................... 29
Transporting the system ............................................................... 29
Store the system ........................................................................... 29
Assembly, installation and commissioning ............................................. 30
General process for assembly, installation and commissioning .... 30
Preparing the assembly, installation and commissioning.............. 32
Mechanical installation/assembly ................................................. 33
Install the data logger unit without fixing .................................... 34
Fixing the data logger unit by means of assembly adapter ....... 34
MCMS 2000 en-US Page 2 / 116

BeWa MCMS2000 4449960a V1xx en-us 2019-10-22.docx 2019-10-22
Content
Connecting the system electrically ............................................... 35

Plug pin assignment .................................................................. 35
Power supply – connection cable (DC IN 24V).......................... 38
Network connection (Ethernet) .................................................. 39
Sensor inputs for IEPE accelerometers (VIB) ........................... 39
Speed / Frequency input (RPM) ................................................ 40
Sensor inputs for HYDAC HSI SMART sensors (HSI) .............. 40
Analog inputs (Analog, A) .......................................................... 40
Switching outputs (D 1-2) .......................................................... 41
Examples of connection ............................................................ 43
Hydraulic power unit ............................................................... 44
Industrial transmission systems ............................................. 45
Power train ............................................................................. 46
Electric motors and generators .............................................. 47
Install software FluMoS expert ..................................................... 49
Overview of FluMoS expert Software Suite ............................... 49
Installing the FluMoS expert ...................................................... 51
Installing FluMoS expert Server Manager .............................. 52
Installing the FluMoS expert Client ......................................... 58
Updating the FluMoS expert................................................... 62
Installing the FluMoS expert software add-ons ...................... 70
Installing the FluMoS expert Client additional licenses .......... 72
Commissioning ............................................................................. 73
Parameterizing the MCMS............................................................ 74
Factory settings .......................................................................................... 76
Operation ..................................................................................................... 77
Reading out measured values ...................................................... 77
Reading the measurement reports with FluMoS expert ............ 77
Reading measured values via Modbus®.................................... 78
Modbus® function, "Read Input Register" ............................... 78
Mapping ................................................................................. 78
Evaluating measurement results .................................................. 86
Analyzing the operating parameters .......................................... 86
Analyzing the fluid sensors ........................................................ 87
Analyzing the vibration sensors ................................................. 87
Analyzing external signals ......................................................... 89
Deriving recommended actions .................................................... 90
Assessment of machine condition ............................................. 90
Assessment of machine performance ....................................... 90
Reporting and system optimization ........................................... 91
Maintenance ................................................................................................ 93
Customer Support/Service ............................................................ 93

Content
Troubleshooting/fault rectification ............................................................ 94

Removing / Disposal................................................................................... 95
Decommissioning the system ....................................................... 95
Disposing the system / packaging material................................... 96
Appendix ..................................................................................................... 96
Accessories .................................................................................. 96
Exclusion of Liability for recommended limit values ...................... 99
Limit values for fluid sensors (HSI SMART).................................. 99
Particle counter ......................................................................... 99
Inductive particle counter (e.g. HYDAC MCS 1000) ............... 99
Optical particle counter (e.g. HYDAC CS 1000) ................... 100
Sensors for water content determination (e.g. HYDAC AS
1000) ....................................................................................... 101
Fluid condition sensors (e.g. HYDAC HLB 1400) .................... 103
Limit values for vibrations sensors (e.g. HYDAC VS 3000) ........ 103
Raw (RAW), envelope signal (ENV) and Peak-to-Peak (PtoP)103
Crest factor (CREST factor) .................................................... 104
Vibration speed according to DIN ISO 20816 .......................... 105
Product registration form ............................................................ 107
Index .......................................................................................................... 109
Glossary .................................................................................................... 111
CREST factor (crest factor) ........................................................ 111
Root mean square of a vibration (RMS) ..................................... 111
FluMoS expert – Fluid Monitoring Software ................................ 111
Frequency analysis ..................................................................... 111
Overall Equipment Effectiveness (OEE) ..................................... 111
Total vibration degree of a machine according to DIN ISO
20816.......................................................................................... 112
Envelope signal (Envelope) ........................................................ 112
IEPE accelerometer .................................................................... 112
Key Performance Indicator – KPI ............................................... 112
Overall Equipment Effectiveness – OEE .................................... 112
Predictive maintenance .............................................................. 113
Proactive maintenance ............................................................... 113
Frequency of damage ................................................................. 113
Crest factor ................................................................................. 113
Peak to peak value (Peak-to-Peak) ............................................ 113

General
General
In this chapter, you will find helpful notes on handling these instructions.
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone: +49 6897 509 01
Fax: +49 6897 509 9046
E-mail: filtersystems@hydac.com
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216

Executive directors: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone: +49 6897 509 1511
Fax: +49 6897 509 1394
E-mail: guenter.harge@hydac.com
Purpose of this manual

Before you use this product for the first time or if you have been asked to carry out
other work on the product, please read this manual.
The use and the handling of the product described in the following, as well as its use,
are not self-explanatory and are described in detail in this manual and the associated
technical documentation.
This manual will help you to use this product as intended, appropriately, effectively
and safely. Therefore, you are requested to read the following chapters attentively and
carefully. Please refer to it every time you require decisive details.
The manual informs and warns you about residual risks, against which a risk
minimization through construction and safety measures may not or may not be fully
effective.

General
Target group of the manual

This manual was created for the following target group.
Target group Tasks

Owner This manual and the associated documents must be kept
accessible at the installation location of the product and
also for later use.
Ask the employees to read and follow the manual and the
documents delivered along with it, in particular, the safety
and warning instructions.
Observe the additional product-related instructions and
requirements.
Specialist Read, observe and follow this manual and the associated
personnel documents, in particular, the safety and warning
instructions.

General
Target group - Required qualifications/training

Persons who work on the product must be aware of the hazards associated with its
use.
These operating instructions are intended for:
Auxiliary personnel: Such persons have been instructed about the system and
informed about potential hazards that can result from improper use.
Specialist personnel: such persons with corresponding specialist training and several
years' work experience. They are able to assess and perform the work assigned to
them, they are also able to recognize potential dangers.
Activity Person Knowledge

Transport / storage Forwarding  No specialist knowledge
agent required
Auxiliary
personnel
Electric installation SpecialistFehl  Safe handling/use of tools
First commissioning er! Textmarke  Fitting and connecting
nicht electrical lines
Maintenance,
Troubleshooting definiert.  Knowledge of handling
Maintenance, product-relevant
Troubleshooting measurement systems
and measuring boards
De-commissioning
 Knowledge of network
communication
 Knowledge of handling
Windows PCs and
installing programs or
application software
 Product-specific
knowledge
Operation Specialist  Knowledge of using
Operations control Windows PCs
 Product-specific
knowledge.Fehler!
Textmarke nicht
definiert.
Disassembly Specialist  Proper and
Disposal environmentally friendly
disposal of materials and
substances.
 Knowledge about reuse.

General
Illustrations in the manual
Illustration on the title page

You will find the following information on the title page of this manual:
1 Short name of the product / product name

2 Type of document
3 Language
4 Document no. / Index  Date of printing
5 Additional information about validity of the manual (optional)

General
Illustration of the layout
Chapter description
tel
Produkt / Kapi
Page number
Edition date
HYDAC Filtertechnik GmbH
BeWa 123456a de
de Seite x
200x-xx-xx
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.
Note that the method described for locating specific information

does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
The manual contains a table of contents, an index and a glossary.
Representation of requirements
These are absolutely required for carrying out a work activity on the product and are
marked with a check mark and are in bold in the text.
An example for the representation of requirements:
 The product is assembled and connected
 The product is switched off

General
Representation of procedural instructions

There are these two following representations in the case of procedural instructions:
Procedural instructions with a fixed sequence

Procedural instructions, whose sequence must be complied with without fail are listed
with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence

Procedural instructions that have a random sequence are listed as bullet points (-).
An example of a procedural instruction with a random sequence:
- Clean the display
- Rinse the product
Representation of warning/general safety information

All the warning / general safety information in this manual are highlighted with
pictograms and signal words. The pictogram and the signal word indicate the severity
of the danger.
Warning/general safety information is listed before an activity and is laid out as
follows.
SIGNAL WORD
Type and source of danger
HAZARD SYMBOL Consequence of the danger
► Measures to avert danger

General
Signal words and their meaning in the general safety information

In these instructions you will find the following signal words:
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

General
Representation/explanation of pictograms
The following are the safety symbols / pictograms in this manual. They indicate
specific dangers to persons, property or to the environment. Observe these safety
symbols / pictograms and act with particular caution in such cases. Always keep all
symbols / pictograms intact and legible.
Warning signs used

These signs are listed for all general safety information and instructions in these
operating instructions which indicate particular dangers to persons, property or the
environment.
General hazard
Dangerous electrical voltage warning.
Signs used for giving orders

These symbols are listed for all general safety information and instructions in these
operating instructions which indicate particular dangers to persons, property or the
environment.
Follow the instructions.
Signs used for the required specialist personnel

These symbols show the required training/knowledge for installation work and/or
maintenance work.
Specialist personnel - Electrical

Such persons have specific specialist training and
several years' work experience. They are able to assess
and perform the work assigned to them, they are also
able to recognize potential dangers.

General
Supplementary symbols
You will find the following symbols in the manual as additional details:
Tip for handling the product
Required tools
Exclusion of liability/warranty
For the warranty provided by us, please refer to our terms of delivery. They are made
available to you at the conclusion of the contract at the latest. In addition, you will find
these under www.hydac.com -> General terms and conditions.
This manual was prepared to the best of our knowledge. Nevertheless and despite the
greatest care, it cannot be excluded that mistakes could have crept in. Therefore
please understand that, in the absence of any provisions to the contrary hereinafter,
our warranty and liability – for any legal reasons whatsoever – are excluded in respect
of the information in these instructions. In particular, we shall not be liable for lost profit
or other financial loss.
This exclusion of liability does not apply in cases of intent and gross negligence.
Moreover, it does not apply to defects which have been deceitfully concealed or
whose absence has been guaranteed, nor in cases of culpable harm to life, physical
injury and damage to health. If we negligently breach any material contractual
obligation, our liability shall be limited to foreseeable damage. Claims due to the
Product Liability shall remain unaffected.
Notes on copyright
All rights to this documentation, in particular to the right to reproduction and
distribution, as well as to the translation, are property of HYDAC FILTER SYSTEMS
GMBH.
Distributing and copying this document and utilizing and disclosing its content is not
permitted, except where this has been agreed upon explicitly. Any infringement will
entail liability for damages. All rights reserved in the case of a patent being granted or
a utility model or the design being registered.
Validity of this manual

The diagrams and visualizations in this manual are meant for general illustration
purposes. Therefore, representations and functional options can deviate from those of
the delivered product.
We reserve the right to changes to the contents of this manual without prior notice.

General safety information

The following residual risks can occur through intended use:
NOTICE
Wrong sensor
Erroneous or no communication
► Connect the MCMS with the permitted sensors only.
NOTICE
Exceeding the maximum number of permitted sensors
► Connect only the maximum possible number of sensors to the MCMS.
NOTICE
Exceeding the maximum permissible line length
► Observe the maximum permissible line lengths.
NOTICE
Unsafe transport
The connector plugs, assembly holders or the USB stick will be damaged
► Transport the system in its original packaging.

► Secure the system during transport.

NOTICE
Improper storage
The system will be damaged
► Store the system in its original packaging in a clean and dry place.
► Do NOT store the system at locations with extreme temperatures,
high humidity, close to magnetic fields or in locations with strong
vibrations or impact loading (jolts).
NOTICE
Incorrect installation of lines and cables
Lines, power supply and sensor cables will be damaged or destroyed.
► Protect the cable from external mechanical and thermal effects, e.g. by
using conduits, cable ducts and heat protection plates.
► Keep the sensor cable far from power and signal lines to avoid errors
in the sensor signal (e.g. due to static).
► Prevent the lines and cables from being folded, twisted, bent, knotted
and loaded excessively so as not to damage them.
NOTICE
Incorrect wiring / electrical connection
Danger of property damage or bodily harm
► Ensure that the pins on the data logger unit of MCMS have been
correctly as there is a danger of property damage or bodily injuries due
to a faulty connection of live cables.

NOTICE
Incorrect installation / no earthing
The signal quality is limited
in the sensor signal (e.g. due to static).
NOTICE
Incorrect operation of digital switching outputs
► Ensure that the switching signal from the power supply to be switched
has been decoupled on the digital switching outputs of the data logger
unit of MCMS (e.g. with the interconnection of an optocoupler, relay or
a similar device).

Product overview
Product overview
The Machine Condition Monitoring System MCMS 2000 (MCMS) is a complete
machine condition monitoring and diagnosis system for machines and units that are
critical to process, which consists of the following individual components:
- Data logger for connection of sensors
and for the temporary storage of measured values.
- Fluid Monitoring Software Suite FluMoS expert
for measurement data logging, visualization, analysis and system
parameterization
- Reporting (installation condition, performance and cause analysis)
Based on application, the MCMS focuses on industrial transmission systems, power
trains and stationary hydraulic systems with auxiliary units mounted on anti-friction
bearings such as pumps and electric motors.
Due to the simultaneous measurement of fluid, vibration and process parameters,
imminent damage can be detected early and unplanned system downtimes can be
avoided. The Software Suite FluMoS expert is a central system administration, data
visualization and analysis tool which is specifically tailored to the MCMS. In addition
to the administration of up to 200 MCMS or machines in a software, it enables a
database and cloud-based storage of the measured data as well as effective tools for
visualization of measured data (dashboards) and analysis.
The following sensors can be connected on the sensor side to the data logger of the
MCMS:
- 2 IEPE accelerometers (e.g. HYDAC VS 3000)
- 1 speed sensor
- 3 HYDAC SMART (Fluid)sensors (HSI SMART)
- 10 analog sensors (8 x 4-20 mA; 2 x 0-10 V)
An integration in high-level control and process control systems is carried out via the
integrated Ethernet interface. Furthermore, the MCMS has two switching outputs for
controlling external units (e.g. bypass flow filter units) and/ or annunciators (e.g. signal
lights). Not only is the MCMS used for a clean condition monitoring of machines, but
also acts as a tool for implementing predictive and proactive approaches of
maintenance.

Product overview
Hardware:
Data logger for signal and
measurement data logging, storage,
Data logger unit
preprocessing and transfer to high-
level control systems.
Sensors (vibration, speed, fluid and
analog sensors) and signals (e.g.
Sensors
load) for connection to the MCMS data
logger (signal input).
Units (e.g. for fluid maintenance) and
signaling devices (e.g. machine signal
Units & signal transmitters
lights) for connection to the MCMS
data logger (switching outputs).
Software:
Software for visualization, correlation
and analysis of measured data of
Data analysis Software Suite
condition-monitoring equipments as
FluMoS expert
well as administration of up to 200
MCMS.
Software modules for application-
Application modules for related installation of FluMoS expert
FluMoS expert incl. limit values, measured value
correlations and algorithms.
Expert modules for FluMoS expert
Expert modules for Software Suite for a comprehensive
FluMoS expert analysis of sensor signals (e.g.
vibrations) and measured values.
Reporting:
The MCMS does not include – apart
No from signals generated by the system
reporting – any reporting in the standard
configuration.
Service packages for machine
Machine condition condition monitoring by the HYDAC
reporting Monitoring Center incl. creation of
reports in pdf format.
A connection to the HYDAC CMX
Device performance & portal for performance comparison of
process reporting condition-monitored machines and
their higher-level processes.

Product overview
Scope of delivery
Scope of delivery for MCMS 2000

The Machine Condition Monitoring System MCMS 2000 is packaged and delivered in
ready for operation state. Check if any items are missing from the package before
starting the system.
The following items are included in the scope of delivery:
Qty Designation
Data logger unit of the MCMS 2000 in IP 65 execution
1
with integrated adapters for top hat rail mounting
1 Top hat rail, length 220 mm
USB stick with FluMoS expert Software Suite for data
visualization, analysis and system administration:
1 1x FluMoS expert Start-Up Assistant (public domain)
1x FluMoS expert Server Manager (incl. one software license)
1x FluMoS expert Client Admin (incl. three software licenses)
1 Operating Instruction (this document)

Product overview
System dimensions
The data logger is the central hardware element of the MCMS. The following
dimensions only refer to the data logger. Dimensions of connected cables and sensors
can be found in the respective product documentation.
Dimensions of data logger unit MCMS 2000

The following figure shows the MCMS data logger unit without mounted top hat rail
All dimensions in mm

Product overview
Proper/designated use
Use the system only for the following application described.
HYDAC Machine Condition Monitoring System MCMS 2000 is a monitoring system for
machine condition comprising data logger and software as well as accompanying
services offered for permanent logging, processing, storing and analyzing sensory
measured variables. It is used for analyzing and diagnosing machine conditions on
industrial transmission systems, power trains, stationary hydraulic systems and units
that are mounted on anti-friction bearing such as pumps and electric motors and
compressors.
Following types of sensors can be connected to the data logger:
- IEPE accelerometer
- Speed sensors
- HYDAC SMART sensors (with integrated RS485 interface
- Analog sensors
In addition to the above mentioned signal inputs, the data logger has an Ethernet-
based network interface and several switching outputs for controlling other devices,
systems and units.
The intended use of the product extends to the following:
- Observing all instructions in the instruction manual.
- Only using with the permissible media.
- The operation within the technically permitted conditions, such as
media and ambient temperature.
NOTICE
Wrong sensor
► Connect the MCMS with the permitted sensors only.
NOTICE
Exceeding the maximum number of permitted sensors
► Connect only the maximum possible number of sensors to the MCMS.

Product overview
NOTICE
Exceeding the maximum permissible line length
► Observe the maximum permissible line lengths.
Improper Use or Use Deviating from Intended Use

Any use extending beyond this shall not be considered as intended. HYDAC FILTER
SYSTEMS GMBH will assume no liability for any damage resulting from such use.
This risk is borne solely by the owner.
Improper use may result in dangers and will damage the system. Examples of
improper use:
- Operation with sensors other than the intended design.
- Operation with several sensors
- Operation under impermissible operating conditions.
- Unauthorized structural change to system or data logger.

Product overview
Technical Data
Input data
Fluid condition
HYDAC Sensor Interface for the connection
(HYDAC HSI SMART
of 3 digital HYDAC SMART sensors
via RS485 interface)
Vibration
Voltage input for connection of 2 analog
(Analog interface
IEPE accelerometers
 IEPE and ICP®)
Operation parameters, Sensor interface for connection of 10
Process dimensions, analog sensors:
Fluid parameter - 8 x signal input for power:
(Analog interface 4 … 20 mA (apparent ohmic resistance
for power and voltage signals) 500 Ω)
0 … 20 mA (apparent ohmic resistance
500 Ω)
- 2 x signal input for voltage:
0…10 V, 0…5 V, 2…10 V, 1…5 V
Measuring inaccuracy <0.2 % Full Scale
(FS)
Rotational speed Digital frequency input
Output parameters
- Ethernet Log:
10 Base-T / - DSI TCP/IP (Port 5160)
100 Base-TX - Modbus® TCP (Port 502)
- Digital Out Digital switching output: 0 / 24 V as closer
(normally open contact)
Ambient conditions
Operating temperature range -30 … 70°C
Storage temperature range -30 … 70°C
Relative humidity 0 … 70%, non-condensing
- mark EN 61000-6-2, EN 61000-6-4
Protection class according to IP 65
DIN EN 60529:2014-09 (for closed connecting sockets)

Product overview
Power supply and electrical installation

Supply voltage 24 V DC ± 10 %
Maximum output for power supply unit
24 V DC ± 10 %: 100 W (4.2 A)
Current consumption (module) 200 mA
(including connected sensors)
Sensor feed 12 … 24 V DC (looped through)
Electrical connection
- Accelerometer VIB 1 Connector, M12, 4-pin
(IEPE)
- Accelerometer VIB 2 Connector, M12, 4-pin
(IEPE)
- HYDAC SMART Connector, M12, 8-pin
(Fluid)sensor HSI 1 – 2
- HYDAC SMART Connector, M12, 5-pin
(Fluid)sensor HSI 3
- Analog interface Connector, M12, 5-pin
1 – 2 (current)
3 – 4 (current)
5 – 6 (current)
7 –10
(7 – 8: current;
9 – 10: voltage)
and digital switching
output 1 – 2 Connector, M12, 4-pin
- Rotational speed Connector, M12, 4-pin, d-coded
(frequency)
Connector plug, M12, 5-pin
- Ethernet
- Supply voltage
Internal measurement data memory
Capacity 16 GB Flash (ring memory)
Period of autonomous
approx. 4 weeks
measurement data storage

Product overview
Other specifications
Resolution, sensor input
14 bit
channels
Sampling rate, input channels - HSI-SMART sensors: 1 per minute
(permanently set) - Analog inputs:
o Long-term data: 1 per minute
o Short-term data*: 5 Hz
- Analog acceleration sensors:
o Long-term data: 1 per minute
o Short-term data** RAW: 3.125
kHz
o Short-term data** ENV: 1.5 kHz
Recording interval of high-resolution short-

term data: every 6 hours for 5 minutes (*)
and 6 seconds (**)
Dimensions and weights
Housing dimensions 233 x 172 x 90 mm
Body Aluminum housing, powder-coated
Weight 1870 g
Performance of data analysis software FluMoS expert
Use in conjunction with HYDAC MCMS 2000
PC and parameterization
RJ-45 (Ethernet)
interface
Communication logs
DSI TCP/IP (proprietary)
for Ethernet interfaces
Expansion modules (Apps) - Expert module:
Vibration analysis module VIBpro
- Application modules (upon request)

Product overview
System requirements for PC

Processor
- Number of cores CPU ≥4
- CPU architecture x64
RAM ≥ 8 GB
Graphics card DirectX 11-compatible
Monitor SXGA resolution or greater
Hard drive ≥ 250 MB free memory
Interface 1 network interface (RJ-45)
Operating system - Windows 7 / 8.1 / 10
- Windows Server 2008 R2/
Windows Server 2012 R2
Windows Server 2016
Access rights Role: Administrator and temporary
administrator rights for installation of
application software and making settings to
the system (e.g. network settings)

Product overview
Decoding the model code label

Details for identifying the MCMS are on the type label. Always mention the part no.
and the serial no. when contacting HYDAC.
Row Description
Header Manufacturer information, CE mark
Model For details see model code (page 28)
P/N Part no.
S/N Serial number
Date Year/Week of production – Hardware index
Default Settings See page 76 for factory settings on data communication
Ethernet IP IP address of the MCMS data logger unit
Netmask Subnet mask of MCMS data logger unit
Gateway Gateway of the MCMS data logger unit
Port Port of the MCMS data logger unit
Footer Recommended network settings for a computer that
communicates directly with the MCMS data logger unit via
a network cable (Ethernet). In addition, there are warnings
and information on the protection class.
The name plate is located on the unplugged side of the MCMS data logger unit (see
the illustration below).

Product overview
Model Code
MCMS 2 2 3 3 - 2 - 0 - 0 /- 000
Product
MCMS = Machine Condition
Monitoring
System
Series
2 = 2000 series Model with
integrated
fluid condition monitoring and
structure-borne sound analysis
as well as data visualization and
analysis software FluMoS expert
Signal inputs for structure-borne sound

sensors
2 = 2 x analog input for connection of 2 x
IEPE accelerometers as well as 1x
frequency input for speed signal
Signal inputs for fluid sensors

3 3 x RS485 interface for connection of 3 x
HYDAC SMART Sensors
(HSI SMART)
Signal inputs for operation parameters

3 = 10 x Analog input for connection of:
8 x Sensor with power output 4-20 mA,
2 x Sensor with voltage output 0-10 V
Signal output (Digital)

2 = 2 x Digital switching output (0 / 24 V)
Signal output (network / field bus)

0 = Ethernet (Modbus® TCP, DSI TCP/IP)
Body
0 = Aluminum housing with assembly adapters (top hat rails)
Modification number
000 = Standard

Transport, handling and storage
Transport, handling and storage

Transporting the system
Transport the system upright or on its side, preferably in the packaging in which it was
delivered. Pay attention that any mechanical loads or shocks do not impact the
connection plug, the assembly adapter or the USB stick.
NOTICE
Unsafe transport
The connecting plug, assembly adapter or the USB stick are damaged
► Transport the system in its original packaging.

► Secure the system during transport.
Store the system

Store the system in a clean and dry place, preferably in the packaging in which it was
delivered. Do not remove the packing until you are ready to install the unit.
Storage temperature: -30 … 70°C / -22 … 158 °F
Relative humidity: max. 70%, non-condensing
NOTICE
Improper storage
The system will be damaged
► Store the system in its original packaging in a clean and dry place.
► Do NOT store the system at locations with extreme temperatures,
high humidity, close to magnetic fields or in locations with strong
vibrations or impact loading (jolts).

Assembly, installation and commissioning

This chapter provides instructions on assembly, installation and commissioning.
General process for assembly, installation and commissioning

It is recommended to adhere to the following processes and steps for assembly,
installation and commissioning of MCMS 2000.
1. Make the preparations Make all the necessary preparations before

for assembly, installation the assembly, installation and
and commissioning commissioning of MCMS. Amongst others,
this includes the proper installation of
sensors to be connected, fitting the sensor
and network cables, provision of correct
power supply as well as the IT provision of
the necessary infrastructure (Server, PCs,
IP addresses, ports etc.) and their
connection (e.g. user-based access rights,
firewall settings etc.)
2. Unpack MCMS Unpack the MCMS completely. Remove the
existing outer packing and protective
sheets. Dispose them in an environmentally
friendly manner.
3. Check for damage Check the MCMS for visible damage.
4. Specifying the network Before installing at the destination,
settings and configuring configure the network settings of the MCMS
the data logger unit using the application software FluMoS
expert.
Specify a network ID for the data logger unit
of MCMS and register it with your IT
department or your system administrator.
For the first installation, provide the data
logger unit of MCMS with voltage and
establish a direct network connection
between a PC/ Laptop and the data logger
unit. Use a suitable network cable like the
HYDAC ZBE 45-05 (for this also see page
96).
For the first installation of the network
connection use the application software
"FluMoS expert Start-Up Assistant".
As soon as the network-sided installation of
the data logger unit is completed, first
disconnect the network connection and
subsequently the power supply.

5. Installing the data logger Transport the data logger unit of MCMS to
unit of MCMS on site your site and install it according to the
processes described in this instruction and
maintenance manual.
6. Connecting the sensors Connect all the provided sensors and
sources of signal to the MCMS.
7. Starting the data logger Connect the power supply to the data
unit of MCMS logger unit of MCMS. The operating system
of the data logger then starts up
independently. Once this process is
completed and the status LED on the
housing is illuminated (green), the system is
ready for use. Measurement and data
storage on the data logger unit starts
automatically. It begins as soon as the
operating state of the system is established.
8. Technically integrating Connect the data logger unit of MCMS to
the data logger unit of the target or company network via a
MCMS in the network network cable.
9. Installing the software Install the Fluid Monitoring Software
FluMoS expert server FluMoS expert Server Manager on a server
manager or computer intended for measurement data
logging.
10. Establishing data Integrate the data logger unit using FluMoS
connection between data expert Server Manager in the condition
logger unit monitoring system and configure the data
(machine/equipment) connection, system-related access rights
and data server and system-side operations in case of an
alarm (e.g. automatically sending emails
and information to the mobile network).
Create all the users relevant for the
operation of MCMS and assign appropriate
access rights and authorizations for use of
data.


FluMoS expert Client FluMoS expert Client on the computer of a
(Role: Administrator) system administrator responsible for
MCMS. Edit the access rights assigned to
users created in the step 10 or add more
users and remove the ones already created.
FluMoS expert Client FluMoS expert Client and its optional
(Role: User) available auxiliary modules (e.g. expert
module for vibration-based frequency
analysis) on the desired computers (e.g.
master display, design office, works
management, etc.).
13. Setting up the software Start the Fluid Monitoring Software FluMoS
FluMoS expert Client expert Client and log on with the access
data assigned to you (see steps 10 and 11).
Install the software individually for every
user (creating dashboards, specifying alarm
limits etc.) or install any templates
(optional).
14. Completing the Assembly, installation and commissioning is
assembly, installation completed.
and commissioning
Preparing the assembly, installation and commissioning

The following preliminary works are to be conducted beforehand for a successful and
smooth assembly, installation and commissioning of MCMS.
- Hydraulic and mechanical installation of all the sensors to be
connected to the data logger unit of MCMS on the machine to be
monitored as well as its parameterization (e.g. output voltages and
currents etc.).
- Transferring all the sensor, signal and data lines to the site of MCMS.
- Transfer of a network cable (incl. access) to the site of MCMS as well
as the IT connection of the network connection.
- Provide a server or PC for installing the data analysis software
FluMoS expert.
- Provide a static IP address as well as all the other network-relevant
accesses (e.g. port), so that – if requested – a secure VPN link to the
HYDAC Monitoring Center can be established (e.g. for
commissioning, software maintenance, updates, reporting etc.).

Mechanical installation/assembly
The data logger unit is the central hardware element of MCMS.
When selecting the installation site, take the environmental effects such as
temperature, dust, water, strong electrical fields etc. into account.
The data logger unit of MCMS should be installed on a protected site (weatherproof). It
is mandatory to observe a minimum distance of five meters to the electric machines
such as gear motors, transformers etc.
Protect the data logger unit from vibrations and fluids.
The MCMS data logger unit is equipped with protection class IP65 according to
DIN40050 / EN60529 / IEC529 / VDE0470.
The mechanical installation is carried out via the assembly adapters fixed in the
housing on a top hat rail.
Independent of the installation of the data logger, ensure that all the lines, the power
supply cable as well as the sensor cable are laid in conduits so that they are not
damaged or destroyed due to radiating devices.
NOTICE
Incorrect installation of lines and cables
Lines, power supply and sensor cables will be damaged or destroyed.
in sensor signal (e.g. due to static).

Install the data logger unit without fixing

The bearing side of the data logger unit of MCMS is on the far side (side with product
label and status LED) of the assembly adapters in case of a horizontal assembly.
When installing the data logger without fixing, the following additional criteria must be
observed:
- The ground must be even.
- It must be protected from falling (in case of elevated location).
Fixing the data logger unit by means of assembly adapter

The MCMS data logger unit can be assembled in a control cabinet, on a wall or an
even surface by using a top hat rail according to DIN EN 60715 TH35. The clamping
devices/assembly adapters necessary for this have already been fixed in the housing
of the data logger unit. A top hat rail of 220 mm length is available in the scope of
delivery according to the DIN EN 60715 TH35.
Clamping devices/Assembly adapters for assembly on

top hat rail according to DIN EN 60715 TH35

Connecting the system electrically

Plug pin assignment
Pin Description Assignment

1.1 not allocated
1.2 Vibrations sensor 1 (IEPE) Acceleration signal (+IEPE)
1.3 not allocated
1.4 Vibrations sensor 1 (IEPE) GND (-IEPE)
2.1 not allocated
2.2 Vibrations sensor 2 (IEPE) Acceleration signal (+IEPE)
2.3 not allocated
2.4 Vibrations sensor 2 (IEPE) GND (-IEPE)
3.1 Speed sensor + Supply voltage
3.2 not allocated
3.3 Speed sensor Supply voltage GND
3.4 Speed sensor Speed input (frequency)
4.1 Analog sensor 1 – 2 + Supply voltage
4.2 Analog sensor 1 Analog input 1 (current)

4.3 Analog sensor 1 – 2 Supply voltage GND

4.5 Analog sensor 1 – 2 PE
5.3 --- not allocated
5.6 --- (Reserve) GND
5.8 --- (Reserve) PE
6.1 Ethernet port for data transmission
Network (LAN)
+
6.2 Network (LAN) Ethernet port for data transmission -
6.3 Ethernet port for data transmission
Network (LAN)
+
6.4 Network (LAN) Ethernet port for data transmission -
7.1 SMART fluid sensor 1 + Supply voltage
7.3 SMART fluid sensor 1 Supply voltage GND
7.6 SMART fluid sensor 1 HSI Signal input (RS485+)
7.7 SMART fluid sensor 1 HSI Signal input (RS485-)


11.3 Analog sensor 9 Analog input 9 (voltage)
11.4 Analog sensor 10 Analog input 10 (voltage)
11.5 Switching output 1 Digital output 1 (0 / 24 V DC)
11.6 Switching output 2 Digital output 2 (0 / 24 V DC)
11.7 Analog 7-10, SA 1-2 PE
11.8 Analog 7-10, SA 1-2 Supply voltage GND
12.1 Device (MCMS 2000) + Supply voltage
12.3 Device (MCMS 2000) Supply voltage GND

NOTICE
Incorrect installation / no earthing
The signal quality is limited
in sensor signal (e.g. due to static).
Power supply – connection cable (DC IN 24V)

24 V DC must be present as supply voltage on MCMS. The voltage supply source
must provide a nominal flow rate of at least 1.5 A.
The MCMS may only be operated with a DC voltage source (DC source) that complies
with ES1 and PS2 according to IEC62368-1 or SELV and LPS according to IEC60950-
1.
The output power of the power supply (24 V DC ± 10 %) shall be limited to a maximum
of 100W (4.2 A).
NOTICE
Incorrect wiring/electrical connection
► Ensure that the pins on the data logger unit of MCMS have been
correctly as there is a danger of property damage or bodily injuries due
to a faulty connection of live cables.
The accessories list (page 96) includes connection cables of different lengths with a
connection plug (M12x1, 5-pin, according to DIN VDE 0627) and an open end.
The colour coding of the HYDAC accessory cable ZBE47S-xx is shown in the
following table:

Pin Color Connection to

1 brown 9-36 V DC Supply voltage
2 White --- (not allocated)
3 Blue GND power supply
4 black --- (not allocated)
5 grey --- (not allocated)
Body - Shield
Network connection (Ethernet)

The Ethernet connection is established as M12 socket with D-coding. This is used for
data communication and parameterization of data logger unit of MCMS. It is necessary
to establish a link to the memory of data logger and to transfer the data for analysis to
the data analysis software FluMoS expert.
A selection of suitable cables can be found in chapter "Accessories" on page 96.
Sensor inputs for IEPE accelerometers (VIB)

This connection is used for measuring vibrations (structure-borne sound) by means of
acceleration sensors as per the industry standard IEPE (Integrated Electronics Piezo-
Electrics). Sensors – such as the HYDAC VibrationSensor VS 3000 – generate a
voltage signal during dynamic acceleration, which provides increased and filtered
information or signals relevant to the condition of the machine. Static accelerations
such as gravitational accelerations are not recorded by the IEPE sensors.
The signal lines (+IEPE) and the associated 0V connection are connected
(-IEPE). The raw signal is prepared by the data logger unit of MCMS and displayed in
the data visualization and analysis software FluMoS expert as raw (RAW) and
envelope value (ENVELOPE). Furthermore, other vibration parameters such as crest
factor (CREST factor) or the vibration speed vrms is released according to DIN ISO
20816 directly by the data logger. In addition, all mentioned parameters and signals
(RAW, ENVELOPE, CREST factor, vibration speed vrms according to DIN ISO 201816)
are released via the Ethernet interface with the help of Modbus® TCP log and

transferred to high-level control, condition monitoring or process control systems.

Furthermore, the raw signal transmitted as a proprietary format allows frequency
analyses in the time and frequency range. The software plug-in required for this is not
a part of the delivery status. However, it is available as an option. This can be found
as an accessory in the chapter "Spare parts and accessories" on page 96 in addition
to the optionally available sensor connection cables.
Speed / Frequency input (RPM)

The frequency input of MCMS data loggers is specially designed for the connection of
inductive speed sensors. The inductive sensor generates a magnetic field with the
oscillator circuit. If a conductive metallic target (e.g. a feather key, a breaker plate or a
gear) moves through this magnetic field, the oscillating circuit of the oscillator is
changed. The trigger is used to switch the signal in the event of such a change. The
frequency of change between high and low is determined automatically in the data
logger unit of MCMS. With the help of the target number per revolution manually
stored in FluMoS expert, the speed (for example a drive shaft) can be clearly
determined and output.
Suitable sensor connection cables are found as accessories in the chapter "Spare
parts and accessories" on page 96.
Sensor inputs for HYDAC HSI SMART sensors (HSI)

The HSI protocol (HYDAC Sensor Interface) is a network protocol equipped with
special identification, analysis and diagnosis functions – exclusively for HYDAC fluid
sensors. In case the data logger unit of MCMS, only the HYDAC (fluid) sensors with
RS485 interface and implemented HSI SMART protocol are supported for the HSI
signal inputs.
Analog inputs (Analog, A)

In the case of inputs for analog signals (3-wire technology), a differentiation must be
made between the power (Analog 1-8) and the voltage inputs (Analog 9-10) must
differ.
Only signals with the signal range 0 to 20 mA must be applied to a power input. The
voltage inputs are designed for signals in a range of 0 to +10 V. The GND pin of the
respective sensor connectors must be used as zero potential for the voltage inputs so
that the reference potential of sensor is equal to that of MCMS.
In the user software FluMoS expert, the range of the input signal as well as the range
and the unit can be set, in which the signal should be displayed in FluMoS expert.

Input Signal range Connection Pin

Analog 1 0 … 20 mA Analog 1 – 2 2
86
31 5
86
31 5
Analog 7 0 … 20 mA A 7-10 | D 1-2 1
Analog 8 0 … 20 mA A 7-10 | D 1-2 2
Analog 9 0 ... 10 V A 7-10 | D 1-2 3
Analog 10 0 ... 10 V A 7-10 | D 1-2 4
GND 0V Analog 1 – 2 3
GND 0V A 7-10 | D 1-2 44
86
31 5
Switching outputs (D 1-2)

Switching outputs enable the switching of power supplies by the software FluMoS
expert. Every switching output can be switched between high (24 VDC) and low (0
V DC).
It is mandatory that the switching signal is decoupled from the power supply to be
switched for using the switching outputs. The interconnection of an optocoupler, relay
or a similar device is mandatory.

Please note that the Software FluMoS expert Server

Manager application software must be active and a data
connection must be established between the software
(FluMoS expert Server Manager) and the MCMS data
logger unit in order for the switching outputs to operate
correctly. Occurring events such as the maintenance of
computers or servers on which FluMoS expert is installed
can influence the function of the MCMS and its switching
outputs.
NOTICE
Incorrect operation of digital switching outputs
► Ensure that the switching signal is decoupled from the power supply to
be switched at the digital switching outputs of the data logger unit of
MCMS 2000 (e.g. by interconnecting an optocoupler, relay or a similar
device).

Examples of connection
A multitude of different sensors can be connected to the data logger unit of MCMS. An
exemplary pin assignment can be found in the following images. Furthermore, the
following chapters describe the recommended sensor packets for the equipment
condition monitoring of selected applications with the MCMS.

Hydraulic power unit

It is recommended to use the following sensors/measured variables for the condition
monitoring of a hydraulic unit (e.g. on press) with the help of MCMS. Furthermore, it
is recommended to record selected operation signals (e.g. motor current) and
integrate fluid maintenance units (e.g. drainage systems, partial flow filter units)
and/or reporting systems (e.g. signal lights).
Measured
Model Code Part no. Connection E* S* P*
variable
Vibration pump VIB1, VIB2
VS3110-1-0-0/-000 4350671  
(2x) (direct)
FMM-P-M-0-CS1210-A- 4449963
Purity of oil HLB11-0-1-0/-000 incl. incl. HSI 1
  
(particle) CS1220-A-x-x-x-1/-000 3237730 (direct)
& HLB14J8-00S12-000 & 923685
HSI 3
Fluid condition HLB14J8-00S12-000 923685  
(direct)
Differential
A 3-4
pressure VL 2 GW.0 /-V-113 1285170   
(direct)
(Filter)
System A 3-4
due to VL 2 GW ---   
pressure (direct)
Pilot pressure 1x A 7-10
HDA 4846-B-400-000 922203 
p0 (memory) (Adapter)
Volumetric flow
HFT 2136-C-0035- Upon 2x A 1-2
rate, pumps 
0110-7-S-0-000 request (Y-Adapter)
(2x)
A 5-6
Fill level HNT 1226-C-0520-000 923717  
(direct)
Motor current, 1x A 7-10
Signal supplied ---  
pump(n) (Adapter)
FAM-5-M-2-A-05-R-H- 1x D 1-2
Drainage unit 3820052 
S-A-2 (Adapter)
1x D 1-2
Signal light --- --- 
(Adapter)
*Recommendation for extension stage: E = Economy; S = Standard; P =
Premium

For monitoring the hydraulic and

lubrication pump in hydraulic units, it is
recommended to install one IEPE
accelerometer each (max. connectable
number of MCMS 2000: 2 piece)
Industrial transmission systems

monitoring of an industrial transmission systems (e.g. in extrusion equipments) with
the help of MCMS. Furthermore, it is recommended to record selected operation
signals (e.g. motor current on the power unit or load) and integrate fluid conditioning
units (e.g. drainage systems, bypass flow filter units, degassing systems) and/or
reporting systems (e.g. signal lights).
Measured
variable
Vibration, gear VIB1, VIB2
VS3110-1-0-0/-000 4350671  
unit (2x) (direct)
Drive shaft RPM
HSS210-3-050/-000 923193  
speed (direct)
CMP4310-5-0-
4449963
Wear W/N/X60/O60- HSI 2
incl.   
(Particle) HLB11/-000 incl. (direct)
(3665658)
MCS1310-1-0/-000
CSM-E-1100-4-Z- 4026586
Purity of oil HSI 1
W/N/X60/O60/-000 with with 
(particle) (direct)
CS1210-A-x-x-x-1/-000 3314212
HLB14J8-00S12-000 HSI 3
Fluid condition 923685   
(CMP component) (direct)
Differential
A 3-4
pressure VL 2 GW.0 /-V-113 1285170   
(direct)
(Filter)
Volumetric
HFT 2136-C-0035- Upon A 5-6
flow rate, 
0110-7-S-0-000 request (direct)
pump
Process factor 1x A 7-10
Signal supplied --- 
of output end (Adapter)
Motor current
1x A 7-10
of power unit/ Signal supplied ---  
(Adapter)
load

Degassing FAM-1OEM-M-1-A-05- Upon 1x D 1-2


unit Z-Z-Z-2-00 request (Adapter)
1x D 1-2
(Adapter)
Premium
For monitoring industrial transmission systems, it is

recommended to install one IEPE accelerometer each on
the bearing housing of drive shaft and output shaft (max.
connectable number of MCMS 2000: 2 piece).
Power train
It is recommended to use the following sensors/measured variables for condition
monitoring of power trains (e.g. electric motor with coupled industrial transmission
systems) with the help of MCMS. Furthermore, it is recommended to record the
selected operation signals (e.g. motor current on power unit or load) and integrate
fluid conditioning units (e.g. drainage systems, bypass flow filter units, degassing
systems) and/or reporting systems (e.g. signal lights).
Measured
variable
Vibration of E VIB1, VIB2
VS3110-1-0-0/-000 4350671  
Motor (2x) (direct)
Drive shaft RPM
HSS210-3-050/-000 923193  
speed (direct)
CMP4310-5-0-
4449963
Wear W/N/X60/O60- HSI 2
incl.   
(Particle) HLB11/-000 incl. (direct)
(3665658)
MCS1310-1-0/-000
CSM-E-1100-4-Z- 4026586
Purity of oil HSI 1
W/N/X60/O60/-000 with with 
(particle) (direct)
CS1210-A-x-x-x-1/-000 3314212
HLB14J8-00S12-000 HSI 3
(CMP component) (direct)
Differential
A 3-4
pressure VL 2 GW.0 /-V-113 1285170   
(direct)
(Filter)
Volumetric
HFT 2136-C-0035- Upon A 5-6
flow rate, 
0110-7-S-0-000 request (direct)
pump


Motor current
1x A 7-10
(Adapter)
load
Degassing FAM-1OEM-M-1-A-05- Upon 1x D 1-2

unit Z-Z-Z-2-00 request (Adapter)
1x D 1-2
(Adapter)
Premium
For the monitoring of power trains, it is recommended to

install one IEPE accelerometer each on the anti-friction
bearing of the electrical power units (max. connectable
number of MCMS 2000: 2 piece).
Electric motors and generators

monitoring of an electric motor or generator (e.g. on ships) with the help of MCMS.
Furthermore, it is recommended to record selected operation signals (e.g. electrical
load) and integrate fluid conditioning units (e.g. drainage systems, bypass flow filter
units) and/ or reporting systems (e.g. signal lights).
Measured
variable
Vibration of E VIB1, VIB2
VS3110-1-0-0/-000 4350671  
Motor (2x) (direct)
Drive shaft RPM
HSS210-3-050/-000 923193  
speed (direct)
CSM-E-1100-4-Z- 4026586
Purity of oil HSI 1
W/N/X60/O60/-000 with with   
(particle) (direct)
CS1210-A-x-x-x-1/-000 3314212
HLB14J8-00S12-000 HSI 3
(assembly on CSM-E) (direct)
Differential
VL 2 GW.0 /-V-113 A 3-4
pressure (NF 1285170   
(for OLF: D24) (direct)
 OLF)

Motor current
1x A 7-10
(Adapter)
load
Bypass OLF-15/15-G-N- Upon 1x D 1-2

filtration (NF) N15DM002-D24/-PKZ request (Adapter)
1x D 1-2
(Adapter)
Premium
For the monitoring of electrical power units or generators,

it is recommended to install one IEPE accelerometer each
on both the bearings/ ball bearings (max. connectable
number of MCMS 2000:
2 piece).

Install software FluMoS expert
Overview of FluMoS expert Software Suite

In addition to the data logger unit, the data visualization, analysis and system
administration software FluMoS expert are included in the scope of delivery of MCMS.
The FluMoS expert is a Software Suite comprising of individual application software
solutions which were optimized for the respective task focus. A corresponding number
of licenses for simultaneous use of the FluMoS expert Client application software on
several decentralized terminals is already included in the scope of delivery (see also
the chapter "Scope of delivery" on page 19). Furthermore, additional user licenses and
expansion modules for FluMoS expert can be acquired.
Functionally, the data analysis, administration and system configuration software for
the MCMS 2000, FluMoS expert are based on a client server architecture. The central
communications hub here is the FluMoS expert Server Manager application software,
which is ideally installed on a dedicated PC or on a central server in the company's
local IT environment. The FluMoS expert Server Manager controls, regulates and
limits communication with the FluMoS expert Clients installed in the MCMS 2000
environment (e.g. in the control room and in the production management office for the
purpose of condition monitoring and data analysis by the end user), as well as the
data connection to the outside world - e.g. for optionally commissioned plant condition
and performance reporting via the HYDAC Monitoring Center and for remote
maintenance purposes via the HYDAC Support Center. The FluMoS expert Client
application software installed on the PC of the end user communicates exclusively
with the FluMoS expert Server Manager. Therefore, there is no direct connection to
the data logger unit of the MCMS 2000.
The distinct assignment and identification of individual network components is done
via freely assignable IP addresses (incl. associated network identification such as
subnet mask and standard gateway) as well as via defined ports for leakage of data
streams (e.g. port 6524 for communication between FluMoS expert Client and Server
Manager for data visualization and analysis on the PC of the end user).

FluMoS expert Purpose of use

FluMoS expert Application software for initial installation of data logger
Start-Up Assistant unit of MCMS.
Focus: First installation of network communication (e.g.
IP address, Modbus® settings etc.).
Furthermore, auxiliary device for commissioning via
the visualization of live data of connected sensors with
the aim of detecting wiring errors and sensor defects.
Target group: Commissioning staff, system
administrator, IT department
FluMoS expert Central administration software of MCMS.
Server Manager Focus: Installation, administration and control of data
streams (databases, cloud connection, REST
interfaces, industrial data communication) and user
authorizations (role management) as well as the
performance of systems in case of error (sending
emails and text messages as well as handling of alarms
in general).
Target group: System administrator, IT department
FluMoS expert Measured data visualization and analysis software at
Client the user level.
Focus: Visualization and analysis of measured data.
Target group: System / Machine user
For a better understanding of the function and mode of operation of FluMoS expert in
connection with the data logger unit of the MCMS 2000, a system-oriented condition
monitoring and optimization concept is presented as an example in the following
illustration. This clarifies that access to an MCMS installed on a machine or the
associated FluMoS expert Server Manager can also take place outside the
respective production plant via the FluMoS expert Client. There is a wide range of
methods available for secure data transmission, which can be adapted to the specific
application if necessary.

Legend:
S = FluMoS expert Server Manager
CA = FluMoS expert Client
CU with administrator rights for user creation
= FluMoS expert Client
Please observe that a data connection is not

established in the delivery status in FluMoS expert and
the MCMS (apart from a standard network
configuration, for this, see the chapter "Factory
settings" on page 76). Therefore, an automatic data
transfer is not conducted externally. A detailed
configuration is carried out during installation and
commissioning. A direct data connection to a HYDAC
company server is not required for operating the
MCMS.
Installing the FluMoS expert

For installation, follow the sequence in chapter "General process for assembly,
installation and commissioning" (see page 30).

Define the required number of software licenses and the number of end devices on
which the FluMoS expert should be installed. Include this in your procurement and
observe the required system prerequisites (see page 23).
Installing FluMoS expert Server Manager

For the first installation of the FluMoS expert Server Manager, run the software
installer provided for your operating system according to the following process. Follow
the instructions on the screen or that on the installation program and keep the required
software license key as well as the server and user data (Credentials  Default user
defined at the plant: „AdminFluMoSexpert“) ready. The software as well as the
appropriate license key and the default user defined at the plant are on the provided
USB stick or can be acquired separately. Please note that the FluMoS expert is
currently only available for Microsoft Windows.
Installation process (first installation) for
FluMoS expert Server Manager application software
1. Opening the file folder and running the software installation file
Store the file folder with the application software "FluMoS expert Server
Manager" on the target system and open the directory in which the application
software "FluMoS expert Server Manager" is stored.
Run the installation assistant by double-clicking on setup.exe.
2. Accepting the software license agreement

Activate the control field for accepting the software license agreement and
click "Next".
Please note that it is a mandatory prerequisite to accept

the software license agreement for continuing the
installation of FluMoS expert.

3. Specifying the scope of software installation

Specify the scope of software installation in which you can select one of the
two options:
- "Install Client + Server" (1)
(Installation of FluMoS expert Client application software
and FluMoS expert Server Manager)
- "Install Client + Server + Database" (2)
(Installation of FluMoS expert Client application software
and FluMoS expert Server Manager as well as an SQL-
Database [MySQL])
If a MySQL-Database has already been installed on the target system
(installation location FluMoS expert Server Manager), please select the option
1 ("Install Client + Server"). Otherwise select the option 2 ("Install Client +
Server + Database")
Once selected, please click on "Next"
4. Entering the software license key
If required, enter the provided software license key for the FluMoS expert
Server Manager in the appropriate field ("Text"). For this, open the .txt file of
the software license key in the same software directory as the installation file
of FluMoS expert Server Manager.

Copy the text in the .txt file of the software license key fully in the clipboard of
your computer (e.g with the command "Ctrl + c") and subsequently paste it in
the field "Text" of the installation assistant of FluMoS expert (e.g. with the
command "Ctrl + v"). Observe the maximum number of users included in the
license ("No. of users"). This corresponds to the maximum number of users
who can access an MCMS concurrently using the FluMoS expert Client
application software (e.g. parallel use of the FluMoS expert Client in the
control room, in the master office and at the machine). Nevertheless, any
number of users can be created in the system by an administrator. The
standard scope of delivery for the MCMS includes 3 user licenses for the
FluMoS expert Client. If a concurrent use of FluMoS expert by more than 3
users is preferred, additional software licenses can be purchased
subsequently (see Accessories on page 96).
Finally click "Next" to continue.
5. Displaying the software version
The software version to be installed is displayed in this step. Ensure that an

installation is fundamentally required. Should this be the case, please click on
"Next" or correct ("Previous") / cancel the installation ("Cancel").
The installation will be started automatically after you have clicked "Next".
6. Executing the installation

Please wait until all the required software components have been completely
installed (all the progress bars must run fully).
Then click on "Next".

7. Completing installation and starting FluMoS expert Server Manager
If the above window is displayed, the installation is completed.

Click "Next" to complete the installation and to end the installation assistant.
If you would like to start the FluMoS expert Server Manager directly after the
installation, you can activate the corresponding control field in this step by
clicking on it or leave it activated. The FluMoS expert Server Manager
automatically starts after the installation is completed.
Installing the FluMoS expert Client

For the first installation of the FluMoS expert Client, run the software installer
provided for your operating system according to the following process. Follow the
instructions on the screen or those of the installation program and have the required
software license keys as well as server and user data (credentials  default user
defined at the factory: "ClientAdminFluMoSexpert" and "ClientUserFluMoSexpert")
ready. The software as well as the appropriate license key and the default user
defined at the plant are on the provided USB stick or can be acquired separately.
Please note that the FluMoS expert is currently only available for Microsoft Windows.

Installation process (first installation) for

FluMoS expert Client application software
Store the file folder with the application software "FluMoS expert Client" on
the target system and open the directory in which the application software
"FluMoS expert Client" is stored.
Run the installation assistant by double-clicking on setup.exe.

click "Install".
Please note that it is a mandatory prerequisite to accept

the software license agreement for continuing the
installation of FluMoS expert.

3. FluMoS expert Client is installed
Please wait until the installation is complete (The progress bar must be
completely scrolled through for this).
4. Completing installation and starting FluMoS expert Client

Click "Finish" to complete the installation and end the installation assistant.
Updating the FluMoS expert
The application software FluMoS expert is subject to regular maintenance and is
continuously improved and updated in its scope of function. In order to always keep
your FluMoS expert Software Suite up to date, HYDAC recommends the conclusion of
a software maintenance agreement which includes at least 1 update per year. For
details, refer to chapter "Accessories" on page 96.
Please note that in order to use additional software
updates or update subscriptions, a product registration of
your MCMS with HYDAC is mandatory. A suitable
product registration form can be found in the appendix of
this document on page 107.
The software can be updated by the system either automatically or manually. It should
be noted that the update process of a PC with FluMoS expert Client installed is usually
controlled and initiated centrally via the update of the FluMoS expert Server Manager.
As a result, there is no need to update individual PCs manually. However, it is still
possible to update the FluMoS expert Client manually on the target PC. Please
execute the appropriate installation file (FluMoS expert.msi) of the current version of
the FluMoS expert Client and follow the procedure described on page 58.
As soon as a new software update is available for your system, you will be notified by
HYDAC Filter Systems after you have registered your product. In the case of an
automatic update, the update process takes place automatically while starting the
FluMoS expert application software and a subsequent manual confirmation is issued.
In the case of a manual update, an appropriate installation file is to be executed (.msi),
which is provided to you at the specified time. In the case of manual provision, the
type of provisioning is carried out in consultation with your contact person at HYDAC
or your HYDAC sales partner. The installation process initiated in the case of a
manual update runs as follows.
Please note that in case of an automatic update, a

permanent or regular (automated) connection between
FluMoS expert and the HYDAC update servers is or must
be established.

Installation process (Update) application software FluMoS expert

1. Discontinuing the DBBServer Database Service
Open the "Services" application program under Microsoft Windows and

search for the "DBBServer" service. Select the "DBBServer" service and quit
the service. Do not close the window (see step 7)

Store the file folder with the application software FluMoS expert on the target
system and open the directory in which the application software FluMoS
expert is stored.
Run the installation assistants by double-clicking the respective .msi file:
- For FluMoS expert Server Manager:
FluMoS expert Server Manager.msi
- For FluMoS expert Client:
FluMoS expert.msi

click "Next".
4. Specifying the scope of software installation

Select one of the following update functions of FluMoS expert:

- "Update Server"
(Installation of application software FluMoS expert Server
Manager)
- "Update Client"
(Installation of application software FluMoS expert Client)
Please note that, as shown in the previous figure, the selection of the options
for a software update may possibly be predefined or restricted by the
installation file (.msi).
Once selected, please click on "Next"
5. Displaying the software version

The software version to be installed is displayed in this step. Ensure that an

installation is fundamentally required. Should this be the case, please click
on "Next" or correct ("Previous") / cancel the installation ("Cancel").
The installation will be started automatically after you have clicked "Next".

6. Executing the installation
Please wait until all the required software components have been completely
installed (all the progress bars must run fully).
Then click on "Next".
7. Restarting the DBBServer database Service

Select the "DBBServer" service and restart it.

8. Complete installation and start FluMoS expert
If the above window is displayed, the installation is completed.

Click "Next" to complete the installation and to end the installation assistant.
If you would like to start the FluMoS expert directly after the installation, you
can activate the appropriate control field in this step by clicking on it or leave it
activated. FluMoS expert then starts automatically after the installation has
been completed.
Installing the FluMoS expert software add-ons

The functional scope of the HYDAC FluMoS expert application software can be
optimally adapted to meet your requirements either by purchasing or activating
software extension modules. You will find an overview in the accessories program on
page 96.
The installation or activation of purchased modules takes place in FluMoS expert
directly. Thereby it is irrelevant whether this is done in FluMoS expert Server
Manager or in FluMoS expert Client.
Please note that installed or activated software expansion

modules for FluMoS expert are linked to the hardware
used. Therefore, the license keys purchased are not
assignable to other MCMS data logger units within the
network.

In order to activate or use the desired software extension modules for FluMoS expert,
please follow the steps below:
1. Opening the FluMoS expert
2. In FluMoS expert, click on the
"MCMS 2000" button
3. Click on the "License" button in
the opened window
4. Enter the license key you have
purchased in the field provided.
After a successful entry, the
modules are displayed in the field
2 "Additional software modules or
templates".

Installing the FluMoS expert Client additional licenses

The standard scope of delivery of the MCMS includes 3 user licenses for concurrent
access to an MCMS from 3 FluMoS expert Clients (distributed on 3 PCs). If a
concurrent access by more than 3 users via the FluMoS expert Client is preferred,
additional software licenses can be purchased subsequently (see Accessories on
page 96).
Please note that additionally installed or activated user

licenses for concurrent access of several FluMoS expert
Clients to the MCMS are linked to the FluMoS expert
Server Manager used. The identification of the respective
FluMoS expert Server Manager is performed by a unique
software ID, which can be found on the login screen and
which is required for product registration prior to the
purchase of other software licenses (see product
registration form on page 107). Therefore, the license
keys purchased are not assignable to other FluMoS
expert Server Managers.
After successful purchase, you will be provided with a current version of the FluMoS
expert Client as well as a one-time generated license key to activate the number of
user licenses purchased in the FluMoS expert Server Manager. In order to enter the
license key generated individually in the FluMoS expert Server Manager, please
proceed as follows.
1. Starting the FluMoS expert Server Manager
Start the FluMoS expert Server

Manager and log on as administrator.
The login data can be obtained - if not
already changed - from the factory
settings on page 76
2. Opening server settings
Click on the "Server" button in the

FluMoS expert Server Manager

3. Checking the number of existing user licenses
In the "License" tile, check the current

number of concurrent users who are
allowed to access the MCMS at the
same time. The standard scope of
delivery of the MCMS already includes
3 licenses. If the number displayed
does not match the number of licenses
you purchased, click the Edit button at
the top right of the tile.
4. Entering license key
In order to activate the user licenses

you have purchased, please enter the
software license key in the field
provided ("Update license key") and
confirm this by clicking the "Ok" button.
Commissioning
To ensure successful commissioning, please run carry out all steps described in the
high-level chapter (Assembly, installation and commissioning) accurately to prepare
for proper commissioning.
Follow the steps described on page 30 for a general process of assembly, installation
and commissioning. Adhere to the specified sequence.

Parameterizing the MCMS

The data logger unit and the overall system is parameterized via the data
analysis software FluMoS expert. This enables:
- Definition of connected sensors, units and annunciators
- Setting of parameters, thresholds and alarms
- Definition of individual measured value correlations and trends
- installation of user and application-based dashboard
- Activation of software updates, additional modules and software plug-
ins Administration of stored machine conditioning report (archive
function)
- Activation of software updates, additional modules and software plug-
ins Administration of stored machine conditioning report (archive
function)
- Creation of users and user groups as well as their authorizations
(roles management)
- Installation of the data communication (databases, cloud connection,
REST interfaces, industrial data communication such as Modbus ®
TCP)
- Administration of the system in case of alarm (sending emails and text
messages as well as the handling of alarms in general)
Please note that the options for parameterization can be limited depending
on the used software variant of FluMoS expert. The following table gives an
overview of the options for parameterization of MCMS by the application
software FluMoS expert as well as its use in the respective commissioning
phase:
Displaying
Establishing Creating & Analyzing
the live data
FluMoS expert the data managing measured
(signal
connections users data
values)
FluMoS expert
Start-Up  1 - -
Assistant
FluMoS expert
Server -   
Manager
FluMoS expert
- - ()2 
Client
1 only selected settings such as network connections (IP
address, subnet mask, standard gateway) and field bus
communication
2 only if administrator rights have been granted to the
respective user or if the "ClientAdminFluMoSexpert"

standard user defined at the factory is registered.

For further details please refer to Online manual for FluMoS expert under
http://manual.flumos.dalog.net/.
Please note that MCMS can only be parameterized using

FluMoS expert (data logger unit and software). It is not
possible to parameterize the connected sensors by
FluMoS expert and via the MCMS respectively. For this
purpose, please use the suitable parameter aids such as
the HYDAC portable measuring instrument of the series
HMG 3000 and HMG 4000

Factory settings
Factory settings
MCMS is delivered with the following factory settings.
Factory setting / Option /
Column Subject
password
IP address 192.168.0.30
Ethernet Subnet screen 255.255.255.0

settings Gateway 192.168.0.1
Port 5161
IP address: 192.168.0.30
Server Mode
Port: 502
Modbus®
IP address: 192.168.0.31
settings Client Mode
Port: 502
Sampling rate 200 ms
Usable HSI sensor addresses a
CS 1000
and e
SMART Usable HSI sensor addresses d
MCS 1000
sensors and h
Usable HSI sensor addresses c
HLB 1400
and g
Analog 1 – 8 Power input [mA]
Analog inputs
Analog 9 - 10 Voltage input [V]
Created AdminFluMoSexpert Q6vv?syz

FluMoS expert ClientAdminFluMoSexpert Main_Us3r!
standard user
software ClientUserFluMoSexpert General_Us3r!

Operation
Operation
For operation, switch on the power supply for data logger unit of MCMS and plug the
power supply unit in a suitable socket. After switching on the power supply, the
system automatically starts up. The LED on the data logger unit lights up in green
during this process. As soon as the process is completed, the LED goes out briefly
for about 1 second and then signals readiness for operation by lighting up again. If it
is not possible to restore readiness for operation, it remains inactive. Therefore,
please check the status LED on the MCMS regularly during operation.
- If the status LED does not illuminate, the data logger unit of MCMS
either does not have voltage or the device is not ready for use. For
details refer to chapter Troubleshooting / fault rectification and repair
(see page 94)
- If the green light of status LED is on, the data logger unit of the MCMS
ready for use and works normally.
Reading out measured values

In order to read / analyze the measured values, you can select one of the following
software packages / protocols.
Reading the measurement reports with FluMoS expert

The application software FluMoS expert is used for reading and analyzing the
measurement reports / measured data.
Furthermore, the analog signals present at the signal input of the data logger (as
current or voltage value) can be read out directly with the help of the application
software FluMoS expert Start-Up Assistant. This is primarily used for checking the
system for properly connected sensors in the installation phase.
Please note that in case of MCMS the measured data

can be read and the data logger can only be
parameterized by means of HYDAC FluMoS expert. It
is not possible to read the measured data by FluMoS
light, professional or mobile.

Operation
Instructions for using and operating the fluid

analysis software FluMoS expert are given in
the online manual ofFluMoS expert. After a
successful installation of FluMoS expert
Software Suite, you can call it up directly from
the software. You are directed to the following
website:
http://manual.flumos.dalog.net/
Online manual
Reading measured values via Modbus®

Via the Ethernet interface, you can integrate the sensors connected to the data
logger unit of MCMS and signals in a network or high-level condition monitoring
(CMS), control (SPS) and process control systems (SCADA).
Here, the measured data are provided via the Ethernet interface as Modbus® protocol
(Modbus® TCP). The input registers to be used are described in the following section.
Modbus® function, "Read Input Register"

One or more registers are read and the data is resent with the Modbus ® function
"Read Input Register" (Function code 0x04). Per register, 2 byte will be sent (high
byte first). For details please refer to the chapter "Factory settings" on page 76.
Mapping
Mapping of Modbus® is given here
Start register Multi-
No. Name signal Description Display area
(2 bytes) plier
High
0x0000
Byte
1 CS_Drive_a Drive 1/1 0 … 100 %
Low
0x0001
Byte
High
0x0002
Byte
2 CS_Flow_a Flow 1/1 11 … 55
Low
0x0003
Byte

Operation
High
0x0004
Byte
3 CS_ISO4_a ISO >04 µm 1/10 8 … 25
Low
0x0005
Byte
High
0x0006
Byte
4 CS_ISO6_a ISO >06 µm 1/10 7 … 24
Low
0x0007
Byte
High
0x0008
Byte
5 CS_ISO14_a ISO >14 µm 1/10 6 … 23
Low
0x0009
Byte
44 High
0x0010
86 Byte
CS_SAEA_a SAE A >4 µm 1/10 0 … 14
31 Low
5 0x0011
Byte
High
0x0012
Byte
7 CS_SAEB_a SAE B >6 µm 1/10 0 … 14
Low
0x0013
Byte
High
0x0014
Byte
8 CS_SAEC_a SAE C >14 µm 1/10 0 … 14
Low
0x0015
Byte
High
0x0016
Byte
9 CS_SAED_a SAE D >21 µm 1/10 0 … 14
Low
0x0017
Byte
High
0x0018
Device Byte
10 CS_Temp_a 1/10 -60 … 150°C
temperature Low
0x0019
Byte
High
0x0020
Byte
11 CS_Drive_e Drive 1/1 0 … 100 %
Low
0x0021
Byte

Operation
High
0x0022
Byte
12 CS_Flow_e Flow 1/1 11 … 55
Low
0x0023
Byte
High
0x0024
Byte
13 CS_ISO4_e ISO >04 µm 1/10 8 … 25
Low
0x0025
Byte
High
0x0026
Byte
14 CS_ISO6_e ISO >06 µm 1/10 7 … 24
Low
0x0027
Byte
High
0x0028
Byte
15 CS_ISO14_e ISO >14 µm 1/10 6 … 23
Low
0x0029
Byte
High
0x0030
Byte
16 CS_SAEA_e SAE A >4 µm 1/10 0 … 14
Low
0x0031
Byte
High
0x0032
Byte
17 CS_SAEB_e SAE B >6 µm 1/10 0 … 14
Low
0x0033
Byte
High
0x0034
Byte
18 CS_SAEC_e SAE C >14 µm 1/10 0 … 14
Low
0x0035
Byte
High
0x0036
Byte
19 CS_SAED_e SAE D >21 µm 1/10 0 … 14
Low
0x0037
Byte
High
0x0038
Device Byte
20 CS_Temp_e 1/10 -60 … 150°C
temperature Low
0x0039
Byte

Operation
High
Electrical 0x0040
Byte 0 … 100
21 HLB14_Cond_c conductivity 1/10
Low nS/m
(absolute) 0x0041
Byte
High
Dielectric 0x0042
Byte
22 HLB14_DC_c constants 1/100 1 … 10
(absolute) Low
0x0043
Byte
High
Relative 0x0044
Byte -100 …
23 HLB14_RCD_c change in the 1/1
Low 200 %
conductivity 0x0045
Byte
Relative High
0x0046
change of Byte
24 HLB14_RCDC_c 1/1 -30 … 30 %
dielectric Low
constants 0x0047
Byte
High
0x0048
Relative water Byte
25 HLB14_Sat_c 1/1 0 … 100 %
saturation Low
0x0049
Byte
High
0x0050
Fluid Byte
26 HLB14_Temp_c 1/10 -25 … 100°C
temperature Low
0x0051
Byte
High
Particle size 0x0052
Byte 0…
27 MCS_FEA_d class A 1/1
Low 2147483647
(Fe) 0x0053
Byte
High
Byte 0…
28 MCS_FEB_d class B 1/1
Low 2147483647
(Fe) 0x0055
Byte
High
Byte 0…
29 MCS_FEC_d class C 1/1
Low 2147483647
(Fe) 0x0057
Byte

Operation
High
0x0058
Particle size Byte 0…
30 MCS_NFED_d 1/1
class D (nFe) Low 2147483647
0x0059
Byte
44 High
0x0060
86 Particle size Byte 0…
MCS_NFEE_d 1/1
31 class E (nFe) Low 2147483647
5 0x0061
Byte
High
0x0062
32 MCS_NFEF_d 1/1
class F (nFe) Low 2147483647
0x0063
Byte
High
0x0064
Device Byte
33 MCS_Temp_d 1/10 -60 … 150°C
temperature Low
0x0065
Byte
High
Byte 0…
34 MCS_FEA_h class A 1/1
Low 2147483647
(Fe) 0x0067
Byte
High
Byte 0…
35 MCS_FEB_h class B 1/1
Low 2147483647
(Fe) 0x0069
Byte
High
Byte 0…
36 MCS_FEC_h class C 1/1
Low 2147483647
(Fe) 0x0071
Byte
High
0x0072
37 MCS_NFED_h 1/1
class D (nFe) Low 2147483647
0x0073
Byte
High
0x0074
38 MCS_NFEE_h 1/1
class E (nFe) Low 2147483647
0x0075
Byte

Operation
High
0x0076
39 MCS_NFEF_h 1/1
class F (nFe) Low 2147483647
0x0077
Byte
High
0x0078
Device Byte
40 MCS_Temp_h 1/10 -60 … 150°C
temperature Low
0x0079
Byte
Acceleration High
0x0080
(Vibration), raw Byte
41 RMS1 1/100 0 ... 10.23 g
signal Low
(as RMS) 0x0081
Byte
Acceleration High
0x0082
(Vibration) Raw Byte
42 PtoP1 1/100 0 ... 20.47 g
signal (peak to Low
peak value) 0x0083
Byte
Acceleration High
0x0084
(Vibration), Byte
43 RMS_ENV1 1/100 0 ... 10.23 g
envelope Low
(as RMS) 0x0085
Byte
Acceleration High
0x0086
(Vibration) Byte
44 PtoP_ENV1 1/100 0 ... 20.47 g
envelope (peak Low
to peak value) 0x0087 Byte
Acceleration High
0x0088
(Vibration) Byte
45 Crest Factor 1 1/100 0 … 40.95
Crest factor Low
(PtoP1/RMS1) 0x0089
Byte
Calculated High
0x0090
speed Byte 0 ... 40.95
46 VV_RMS 1 1/100
(Vibration) Low mm/s
(as RMS) 0x0091
Byte

Operation
Acceleration High
0x0092
(Vibration), raw Byte
47 RMS2 1/100 0 ... 10.23 g
signal Low
(as RMS) 0x0093
Byte
Acceleration High
0x0094
(Vibration) Raw Byte
48 PtoP2 1/100 0 ... 20.47 g
signal (peak to Low
peak value) 0x0095
Byte
Acceleration High
0x0096
(Vibration), Byte
49 RMS_ENV2 1/100 0 ... 10.23 g
envelope Low
(as RMS) 0x0097
Byte
Acceleration High
0x0098
(Vibration) Byte
50 PtoP_ENV2 1/100 0 ... 20.47 g
envelope (peak Low
to peak value) 0x0099 Byte
Acceleration High
0x0100
(Vibration) Byte
51 Crest Factor 2 1/100 0 … 40.95
Crest factor Low
(PtoP2/RMS2) 0x0101
Byte
Calculated High
0x0102
speed Byte 0 ... 40.95
52 VV_RMS 2 1/100
(Vibration) Low mm/s
(as RMS) 0x0103
Byte
High
0x0104
Analog signal Byte
53 Current_meanAI1 1/100 0 … 20 mA
(power) Low
0x0105
Byte
High
0x0106
Analog signal Byte
(power) Low
0x0107
Byte

Operation
High
0x0108
Analog signal Byte
(power) Low
0x0109
Byte
High
0x0110
Analog signal Byte
(power) Low
0x0111
Byte
High
0x0112
Analog signal Byte
(power) Low
0x0113
Byte
High
0x0114
Analog signal Byte
(power) Low
0x0115
Byte
High
0x0116
Analog signal Byte
(power) Low
0x0117
Byte
High
0x0118
Analog signal Byte
(power) Low
0x0119
Byte
High
0x0120
Analog signal Byte
61 Voltage_meanAI9 1/100 -10 ... 10 V
(voltage) Low
0x0121
Byte
High
0x0122
Analog signal Byte
62 Voltage_meanAI10 1/100 -10 ... 10 V
(voltage) Low
0x0123
Byte
High
Speed 0x0124
Byte 0 ... 2047
63 Speed_mean (frequency 1/1
Low U/min
input) 0x0125
Byte

Operation
Evaluating measurement results

The data of sensors connected to the MCMS data logger unit are either output directly
or processed by the MCMS into characteristic values describing the machine or
component condition. The sensory fitting as well as its assembly is decisive for the
quality of the machine condition diagnosis performed by MCMS or by the respective
experts. Exemplary sensor constellations for selected applications can be found in the
chapter "Example of connections" on page 43.
The common objective of all the data analysis strategies is to identify deviations from
the control, good or machine normal state and deriving appropriate recommendations
for action. However, it is not only important to identify deviations or limit value
violations (limit value observation), but to also simultaneously determine the period for
reaching the specified limit value (trend observation). Taking all the relevant
environmental factors (external influences, operation etc.) into consideration, both the
approaches together enable an initial estimation of the remaining components or
system-based service life (RUL), with the aim to extend it with suitable measures
(proactive maintenance) or to schedule the maintenance for recovering the target
condition (predictive maintenance).
The MCMS provides different options for implementing the aforementioned
maintenance approaches by using suitable tools. Therefore, the MCMS has the option
- to form machine / component condition-related parameters
- to correlate measured data and parameters with each other,
- to detect overshooting or undershooting of limit values
- to analyze trend developments,
- to localize damage to machine elements,
- to identify faulty operation, assembly or maintenance,
- to inform the relevant sites or persons in case of alarm and
- to release operating instructions (reporting)
Analyzing the operating parameters

Operating parameters indicate the correct operation of machines or their normal /
controlled operation. A change of the operating parameters usually allows first
conclusions to be drawn for the following circumstances:
- Abnormal / faulty operation
- Damage / Breakdown of system components
- Changes of environmental and external conditions
- Change of contamination level of a systems (fluid)
- Maintenance measures performed
Furthermore, operating parameters present important parameters for correlation with
other – condition-describing – measured variables (e.g. fluid contamination or
vibration characteristics). For example, to carry out vibration analyzes on variable-
speed drives, it is imperative to carry along the speeds and to normalize them to the
respective vibration measurement (orders). The same is applicable while determining
the contamination in fluids. For example, operating cycles of hydraulics temporarily
influence the counting results for the particular contamination in systems.

Operation
Finally, it should be mentioned that an evaluation of operating parameters under the

aspect of machine condition diagnosis is often used as monitoring of a permitted
operating range (e.g. temperature).
Analyzing the fluid sensors

HYDAC SMART fluid sensors are used for detection and quantification of
- solid,
- gel-like,
- liquid and
- (indirect) gaseous contaminations in fluid systems.
Examples are the number of metallic particles in the fluid cycles of systems as
indicators of component-related wear, particular fine contamination in the context of
purity of oil, relative water content in percent saturation, fluid deterioration conditions,
mixing with other fluids and (indirect) the entry of air in the fluid systems.
An evaluation of the measurement data is usually based on trends, although
individual procedures permit a limit value observation due to their international
standardization or on the basis of empirical values (e.g. component-related limit
values for oil purity or maximum permissible water contents in fluid systems). In the
attachment on page 99, there is a selection of limit values which can be considered
as the first orientation. Furthermore, corresponding specifications can be found in the
operating and maintenance instructions for individual products, in the technical
literature as well as in selected HYDAC publications (e.g. "Fluid controlling –
contamination primer").
Analyzing the vibration sensors

While analyzing vibrations signals – even more so than with other methods – a trend-
oriented consideration of the measurement signals must be applied. An initial
specification of limit and threshold values is therefore always done after a sufficiently
long (approx. 1 month) and representative monitoring phase (inclusion of
"Fingerprints" of an attachment). Independent of a trend-based analysis of vibration
measurement signals, the MCMS operates with standardized (e.g. vibration speed
according to ISO 20816) or general parameters (e.g. CREST factor) for evaluating
the vibration condition of machines and their components (e.g. gears, ball bearing) as
well as possible damaging conditions (wear, cracks, material breaks etc.). The
following table gives an overview of the vibration measured variables or parameters
provided by MCMS. Limit value recommendations– if applicable – can be found in
attachment on page 103.
In addition to simple vibration parameters, complex frequency analyses can also be
conducted by means of MCMS. This requires the installation of optionally available
expert module VIBpro for FluMoS expert. With the help of this, damage can not
only be localized (e.g. ball bearing inner ring, rolling element, gears etc.) but their
causes can also be determined (e.g. imbalance, misalignment, loose connections,
resonances, component defects, cavitation etc.).

Operation
Condition
Vibration
monitoring
parameter / User level Statement
focus
Signal
component
Broadband parameters
for general evaluation
Vibration speed of machine condition
according to General e.g. for approval tests
Beginner
DIN ISO 20816 vibrations or for machine
(as RMS) protection
( emergency switch
off)
CREST factor Parameter for
Ball bearing,
acceleration Beginner evaluating the total
gears
(CREST factor) wear of components
Raw signal for trend-
Raw signal of an based analysis of
acceleration performance of
(RAW) *1 Gears, general components such as
Advanced
 Basis: vibrations gear wheels as well as
Effective value their entire condition in
(RMS) case of wear and
damage
Envelope signal
of an Filtered signal for
acceleration trend-based analysis of
(ENVELOPE) *1 performance of special
Ball bearings Advanced
components such as
 Basis: ball bearings in case of
Effective value wear and damage
(RMS)
Peak to peak
Local damage to
value of raw
Gears, general components (e.g.
signal of an Advanced
vibrations breaks) such as gear
acceleration
wheels
(PtoP RAW) *1
Peak to peak
value of envelope Local damage to
signal of an components (e.g.
Ball bearings Advanced
acceleration breaks) such as ball
(PtoP bearings
ENVELOPE) *1
*1 Limit value observation possible only after training
phase
(fingerprint); no generally valid
limit values

Operation
As indicated in the overview above, suitable parameters must be selected depending

on the machine or task to be monitored. The following table gives a few examples for
this.
Application Vibration parameter / Number of
Sensor placement
example Signal sensors
- a: ENVELOPE
Radial:
Industrial - a: PtoP (ENV)
Bearing housing on
transmission - a: CREST-F 2
drive shaft and
systems - v according to
output shaft
DIN ISO 20816
- a: RAW
- a: PtoP (RAW) Radial:
Gear pump - a: CREST-F 1 Centrally on pump
- v according to (via gear)
DIN ISO 20816
- a: ENVELOPE
Radial:
- a: PtoP (ENV)
Electric motor / Bearing housing on
- a: CREST-F 2
Generator fixed and floating
- v according to
bearing side
DIN ISO 20816
Legend: a = Vibration acceleration,
v = Vibration speed
Remark: The above specifications are
standard recommendations, which can
deviate in specific cases.
The table above illustrates that the vibration assessment of a machine and its machine
elements is not based on an individual characteristic value. The mentioned
parameters enable the operator to conduct a rough and quick assessment of the
machine condition. A comprehensive assessment can be done via a frequency-
selective vibration analysis.
Analyzing external signals

External signals are often integrated in the condition monitoring. In case of MCMS,
this is done by means of analog inputs on the data logger unit of MCMS.
Types of signals and their information content for the industrial machine condition
monitoring are varied. Usually this deals with external signals:
- Process parameters,
- the operating cycle (of a machine) describing the parameters,
- Load signals (e.g. power input on motor) or
- Start-stop information of a machine / a process.
External signals are rarely used for machine condition monitoring in a narrow sense,
but rather for validating the actual measured variables describing the machine
condition. These availability and efficiency indicators for machines (e.g. Overall
Equipment Effectiveness - OEE) are often used to derive or calculate data.

Operation
Deriving recommended actions

Using the analysis of recorded signals (on the sensors connected to MCMS and
external sensors), parameters derived from that as well as more information sources
such as results from laboratory analysis, maintenance books, operation and process
databases etc., the conditions and performance of individual machines can be
evaluated comprehensively.
This is done for MCMS by forming parameters coordinated to the task, optional
software templates for the data analysis software FluMoS expert and/ or a reporting
coordinated to the application (optional) in combination with targeted operating
instructions for increasing the equipment availability and performance.
The software templates and reporting packages available as an option for the MCMS
are in chapter "Accessories" on page 96.
Assessment of machine condition

The machine condition is rarely assessed on the basis of individual measured
variables and/or limit values. Machines are complex entities and hence require the
consideration, creation and analysis of an entire series of parameters and measured
variables as well as a consideration and analysis individual to machine. Here, hard
limit and threshold values play only a minor role. The chronological (trend) sequence
of selected parameters as well as their individual influencing factors are much more
decisive ( pattern matching).
It is therefore necessary to transfer the "overall picture" of a machine into an
integrated condition monitoring approach, which considers all the relevant
components, operational procedures and process factors within a machine. In this
context, the sensors installed for monitoring act only as indicators, which show
variations from the normal operation. A deeper cause analysis e.g. with an oil or
component analysis in laboratory does not replace this. In fact, both approaches are
added so that an overall method and interdisciplinary condition monitoring approach
for machines, comprising a permanently installed – coordinated to the application –
condition monitoring solution (online) in combination with a laboratory-aided cause
analysis if necessary (offline), can be used for a substantiated assessment of the
machine condition.
Assessment of machine performance

In addition to the machine condition, the assessment of machine performance
presents the second important pillar for machine monitoring. While the focus of
condition monitoring is to prevent downtimes, the assessment of machine
performance focusses on observing the required efficiency or availability indicators
(Overall Equipment Effectiveness – OEE or Key Performance Indicators - KPI),
power consumption, production outputs or on the performance comparison of
machines (e.g. frequencies of failure of machines similar to application in
comparison).
The main parameters used for assessment usually depend on the individual
industries and the respective application (e.g. output of produced parts per hour on
plastic injection molding machines or the information of specific power while
producing cement as indicator for the equipment efficiency).

Operation
In this regard, in addition to the autonomous definition of parameters, efficiency

parameters and correlations, MCMS allows the use of industry and application-
specific templates – developed by HYDAC application specialists. These optionally
available templates are integrated either directly in FluMoS expert (via license
administration) or as cloud reporting on an access-protected and web-based
reporting portal.
Please note that for a target-oriented presentation of

machine condition and performance data on the HYDAC
reporting portal, the crucial machine condition data and
parameters should be uploaded regularly. Data is
provided by the customers after consulting the HYDAC
application experts. Data can be uploaded manually as
well as automatically by MCMS (recommended).
Reporting and system optimization

As already explained in the previous chapters, focus is on ensuring equipment
availability as well as the increase of machine performance.
In this regard, MCMS acts an integrated monitoring system, which not only monitors
the process-critical machines permanently (online) and automatically, but if required
can also actively access (e.g. emergency shutdown  machine protection),
independently report conditions (e.g. via email) or introduce measures which improve
the machine condition (e.g. by connecting a fluid maintenance device for reaching a
maximum permissible fluid contamination level).
Irrespective of the measures taken, a regulation or action taken by the system
inevitably raises the question of the cause or a corresponding recommended action if
required. In addition, the aspects of system efficiency, machine-related error
frequency and availability are often of interest in this context. In order to allow this
factor, HYDAC offers optional expert modules for the data analysis software FluMoS
expert (also see "Accessories" on page 96) as well as service offers (reporting)
coordinated to the task. The MCMS thus offers the possibility of carrying out or
clarifying analyses of the machine condition, the causality of damage that has
occurred and questions relating to machine performance independently, or of
supporting the HYDAC application experts with such tasks. The results would be
prepared in the form of task-related reporting (refer to the following table) and
provided by FluMoS expert and a cloud-based reporting portal. The aim is to detect
damage to machine components at an early stage, to analyze the associated causes
of damage, to reliably estimate any remaining service life (RUL) of components (
predictive maintenance) and to increase the service life of the monitored machine
through targeted measures ( proactive maintenance) or to completely avoid failure
by eliminating relevant sources of error.
Reporting module Content Design Specification

Description of
machine condition
incl. operating Abo-model;
Maschine status instructions for quarterly
peculiarities or .pdf report
informations creation of
damage. .pdf reports
Target group:
Maintenance
Displaying the
availability if
equipment as well Subscription
as their model; active
Dashboard access to
productivity/
Machine performance (web-based) HYDAC
efficiency
HYDAC CMX reporting
Target group: portal for
Division, plant and 1 year
company
management
Laboratory-aided
analysis of fluids
(e.g. fluid) and
components (e.g. One-time,
filter) – incl. reporting if
Cause analysis operating .pdf report required and
instructions for task
peculiarities or in assignment
case of damage.
Target group:
Maintenance
Note:
All the specified modules are available separately and can be combined with
each other in any manner.

Maintenance
Maintenance
The HYDAC Machine Condition Monitoring System MCMS is maintenance-free.
Nevertheless, perform regular inspections for external damage. The inspection should
comprise the following work items:
- Check whether the housing of the MCMS data logger unit shows
cracks, traces of improper handling (e.g. misuse such as climbing) or
other mechanical damages.
- Check that the data logger unit has been assembled correctly and
securely.
- Check that there is no contact fault and that water penetrates the
system or data logger unit at the plug.
- Verify whether the plug of the connecting cable is connected firmly
with the data logger unit as well as the connected sensors.
- Check that the cable is in a good condition and does not have any
breaks and sharp bends.
Replace defective cables, hoses or tubes.
Customer Support/Service
Use the following shipping address for repairs:
HYDAC SERVICE GMBH

Friedrichsthaler Straße 15a, Plant 13
66540 Neunkirchen-Heinitz
Germany
Phone: +49 6897 509 01
Fax: +49 6897 509 324
E-mail: service@hydac.com

Troubleshooting/fault rectification
Troubleshooting/fault rectification
The following errors can occur while operating the MCMS:
Malfunction Remedy
LED does not light Ensure that a power supply of 24 V DC is connected
up properly. For this, observe the pin assignment of the
connectors.
No network 1. Ensure that the correct IP address is set in
connection the MCMS and change it if necessary via the
(Ethernet) for MCMS application software FluMoS expert.
2. Ensure that the data logger unit is accessible
in network. If necessary, send a "Ping“ via the
input console of your computer.
3. Check whether the status LED is illuminated.
If not please check the power supply.
Sensor signal not 1. Check the cable and the sensor for possible
visible damage and defects.
in FluMoS expert 2. Check whether the assignment of plug
matches the assignment of connections.
3. Check whether the corresponding sensor
channel has been activated in der FluMoS
expert software.
Sensor signal is 1. In case of errors in signal, ensure that the
visible, but with electrical devices or electro-magnetic fields in
errors the environment do not affect the measured
signals.
2. Connect PE and GND, by bridging pins 6 and
7 at the analog 3-4 connection.
If the above mentioned measures do not show any improvement, then restart the
MCMS.
1. Disconnect the MCMS from the power supply and wait for 30 seconds for
the system to shut down completely.
2. Connect the MCMS again with the power supply.
3. Test whether a new error occurs after 3 minutes.
If an error is present in spite of using the above mentioned procedures, please contact
the HYDAC customer service or service.

Removing / Disposal
Removing / Disposal
Decommissioning the system
To decommission the unit, proceed as follows:
1. Ensure that all the data and measured values recorded with MCMS are
secured and archived.
2. Disconnect the power supply for data logger unit. To do this, disconnect
the M12 plug provided for this purpose from the device.
3. Disconnect all the other cable connections (e.g. connection sensors or
network connections) to the data logger unit. Remove the respective M12
plug from the device.
4. Dismantle the data logger unit.
5. Uninstall the application software FluMoS expert from the individual
devices / PCs (FluMoS expert Server Manager as well as FluMoS expert
Client Admin and FluMoS expert Client User). Run the FluMoS expert
uninstall program ("Uninstall FluMoS expert").
Please note that once FluMoS expert has been

successfully uninstalled, the measured values and data
can no longer be visualized - unless they have been
exported beforehand (for example, as .csv).

Appendix
Disposing the system / packaging material

Dispose of the packaging material in an environmentally friendly manner.
Dispose of the data logger unit of the MCMS in an environmentally friendly manner
after disassembly and separating all parts according to type.
Appendix
Accessories
The following original accessory is available for MCMS for an optimum system
integration and for expanding the scope of analysis and function:
Connection cable
The following connection cables for providing the data logger unit of MCMS with
voltage are available:
Designation Qty. Part no.
Connection cable 5 m,
coupling socket 5-pin, M12x1 ZBE 47S-05 1 3527626
with cable (open end)
coupling socket 5-pin, M12x1 ZBE 47S-10 1 3527627
with cable (open end)
Connection cable – Sensors

The following connection cables for sensors are available:
coupling socket 5-pin, M12x1 / ZBE 30-05 1 6040852
connection plug, 5-pin, M12x1
coupling socket 5-pin, M12x1 / ZBE 30S-10 1 3729098

Appendix
Connection cable - Ethernet

The following connection cables for Ethernet are available:
Connection cable – Ethernet,
Length 5 m, Patch
ZBE 45-05 1 3346100
coupling socket 4-pin, M12x1 /
RJ45 plug
Connection cable – Ethernet,
Length 10 m, Patch
ZBE 45-10 1 3346101
coupling socket 4-pin, M12x1 /
RJ45 plug
Software-updates for FluMoS expert

The following software programs or modules for expanding the scope of function and
analysis of FluMoS expert are available:
FLUMOS EXPERT CLIENT AL1
Additional license (on USB stick) for data visualization 1 4486161
and FluMoS expert Client analysis software
FLUMOS EXPERT MO-VIB
Software update module for vibration analysis for 1 4486162
application software FluMoS expert "VIBpro"
Software maintenance
Following service offers are used for maintaining and optimizing the FluMoS expert
Software-Suite:
FLUMOS EXPERT UPDATE 1Y
Annual contract for performing regular software updates 1 4486163
for the FluMoS expert Software Suite

Appendix
Reporting
Following reporting packages are available for monitoring the equipment condition and
the machine availability:
REPORT M-CONDITION
1 4486164
Individual report on machine status
REPORTING M-CONDITION 1Y
Annual contract for machine condition reporting 1 4486225
as quarterly report in PDF format
Annual contract for machine condition reporting of
Upon
HYDAC CMX as Cloud-based dashboard 1
request
(access for 1 year)
Cause / Damage analysis by means of application- Upon
1
specific fluid analyses request

Appendix
Exclusion of Liability for recommended limit values

We would like to emphasize that the recommended limit values are based on values
which relate to average applications, which do not necessarily apply in specific
cases. Therefore, we do not assume any guarantee or liability for the validity of this
recommendation.
The aforementioned shall not apply in cases of intent or gross negligence, for defects
which were maliciously concealed or the absence of which was guaranteed, as well
as in cases of culpable loss of life, bodily injury and damage to health or a significant
contractual obligation. Claims under the German Product Liability Act shall remain
unaffected. If we violate an important contractual obligation in a negligent manner,
our liability shall be limited for the foreseeable damage.
Limit values for fluid sensors (HSI SMART)

The recommended limit and threshold values can be found in the respective
instruction manuals of the individual sensors or the selected HYDAC publications
such as the HYDAC "Fluid controlling – Contaminations primer".
Particle counter
For particle counters, the optic and inductive sensors and measurement procedures
are differentiated. While the optical systems for determining fluid purity are usually
based on standardized procedures and broadly recognized limit values, the limit
values for inductive particle counters are based on rough reference values, which
may vary from manufacturer to manufacturer due to a lack of standardization of the
particles.
In this connection, the hydraulic integration of particle counters is not to be neglected,
which can have a very strong influence on the particle counter result depending on
the installation site.
Inductive particle counter (e.g. HYDAC MCS 1000)

As opposed to many optical particle measurement procedures, the inductive particle
measurement systems are currently not subject to any international standard (ISO
standard etc.). This is primarily applicable for the particle size and form, its material
composition and quality as well as its technical size range classification. Hence, at
this point only broad recommendations for limit values are decided. It must be
considered that inductive metal particle counter are usually installed for detecting and
quantifying wear in pumps or industrial transmission systems. Since the resolution is
comparatively rough compared to optical systems (approx. factor 10 and more), the
premise "every detected metal particle is one too many" can be applied - even if a
certain level of wear can be assumed to be normal for such systems. This is also
shown in the following limit value table for industry transmission systems. It shows
average values from the industrial practice, which can strongly differ depending on
the transmission manufacturer, the class, the load as well as the hydraulic
integration. It is applicable to specify and evaluate the basic level of wear in the
application from installation to installation.

Appendix
Transmission < 1MW Transmission > 1MW

Alarm status,
< 300 l oil volume > 300 l oil volume
condition
Number of particles per hour Number of particles per hour
Fe nFe Fe nFe
70 - 500 µm 500 - 1000 µm 70 - 500 µm 500 - 1000 µm
Alarm > 1000 > 750 > 1500 > 850
Warning > 200 > 150 > 380 > 250
OK < 50 < 30 < 80 < 50
The particle sizes correspond to the wear particles (metal) typical to
application with an equivalent spherical diameter.
Optical particle counter (e.g. HYDAC CS 1000)

For optical measurement systems for determining the particular contamination in
fluids, which are calibrated according to ISO 11171 (primary) or ISO 11943
(secondary), the limit values for the purity of fluid – classified according to ISO 4406
– can be accepted in accordance with the following table. For the determination of
the limit value, the component which is most sensitive to contamination must be
selected.
ISO 4406 Filtration

Application grade
Target purity class (in µm)
N H S N H S
Pumps / motors
Gear wheel cells, vane 44
cells 86
20/18/15 19/17/14 18/16/13 20 10
31
5
Plunger 19/17/14 18/16/13 17/15/12 10 5 3
Vane cells (adjustable) 18/16/13 17/15/12 N/A 5 3 N/A
Piston (adjustable) 18/16/13 17/15/12 16/14/11 5 3 3
Actuators
Cylinders 20/18/15 19/17/14 18/16/13 20 10 5
Hydrostatic 16/15!12 16/14/11 15/13/10 3 3 3
Test benches 15/13/10 15/13/10 15/13/10 3 3 3
Valves
Non-return valve 20/18/15 20/18/15 19/17/14 20 20 10

Appendix
ISO 4406 Filtration

Application grade
Target purity class (in µm)
N H S N H S
Directional valve 20/18/15 19/17/14 18/16/13 20 10 5
Flow control valve 20/18/15 19/17/14 18/16/13 20 10 5
Poppet valve 19/17/14 18/16/13 17/15/12 10 5 3
Proportional Valve 17/15/12 17/15/12 16/14/11 3 3 3
Servo Valve 16/14/12 16/14/11 15/13/10 3 3 3
Bearings
Journal Bearings 18/15/12 N/A N/A 10 N/A N/A
Gears 17/15/12 N/A N/A 10 N/A N/A
Ball Bearing 15/13/10 N/A N/A 3 N/A N/A
Roller Bearings 16/14/11 N/A N/A 5 N/A N/A
N = Low / medium pressure < 140 bar (moderate conditions)
H = High pressure 140 . 200 bar (low/medium in case of bad conditions)
S = Very high pressure >200 bar (high pressure in case of bad conditions)
N/A = Not applicable
An alternative method for determining the cleanliness

level required for a fluid system may be defined as ISO
12669. With the help of the methods described in it, limit
values related to particulate solid contamination in fluid
systems can be determined by applying a weighted
evaluation procedure.
Sensors for water content determination (e.g. HYDAC AS 1000)

There are several established measurement procedures for determining the water
content in hydraulic and and lubrication fluids. The following standard values are only
applicable for capacitive sensors for determining the relative water content in percent
saturation (water saturation) such as HYDAC AquaSensor of the series AS 1000.
Here 0% would mean water-free oil and 100% would mean that oil is completely
saturated with water. In principle, the premise that oil cannot be very dry is
applicable. Hence, it is applicable to keep the relative water content in the hydraulic
and lubrication fluids as low as possible. The following table provides current
reference values for this.

Appendix
Alarm status, Limit values for the relative water content (in % saturation)
condition mineral oil-based hydraulic and lubrication oils
Alarm 75
Warning 60
OK 45

Appendix
Fluid condition sensors (e.g. HYDAC HLB 1400)

As in case of the sensors for determining water content, there is also a series of
current measurement procedures for determining fluid conditions. One procedure
from that is the determination of electrical conductivity of fluids by means of products
such as the fluid condition sensor HYDACLab® HLB 1400. Such sensors deal with
multi-parameter sensors which consider measured variables for determining
condition. The following table provides current limit values for using fluid condition
sensors such as the HYDACLab® 1400. It should be noted that the limit values given
in the table can vary greatly depending on the fluid and that the percentage
deviations for the relative change in conductivity and dielectric constant require a
temperature compensation as well as a learning phase on the measuring system
side. This is done automatically for measurement systems such as the HYDACLab®
as soon as the sensor-internal learning phase has been completed.
Electrical
Relative Dielectric constants
Alarm status, conductivity
Water content (relative
condition (relative
(in % saturation) change in %)
change in %)
Alarm 75 > ± 15
Warning 60 ± 15
OK 45 < ± 15
Only temperature-compensated measured values are to be applied for
monitoring/sending alarms in case of limit values for the conductivity and
dielectric constants.
Limit values for vibrations sensors (e.g. HYDAC VS 3000)

While analyzing vibrations signals – even more so than with other methods – a trend-
oriented consideration of the measurement signals must be applied. An initial
specification of limit and threshold values is usually done always after an inspection
and training phase. This is primarily applicable for raw and envelope signals as well
as peak to peak values. Generally valid reference and limit values can be specified
only in case of established factors such as the crest factor (CREST factor) or in case
of standardized methods according to DIN ISO 20816.
Raw (RAW), envelope signal (ENV) and Peak-to-Peak (PtoP)

As already mentioned at the beginning, all-inclusive limit values cannot be accepted
for the vibration accelerations of raw, envelope and peak-to-peak signals since these
can strongly vary depending on the application, machine and installation location.
Hence an alarm is triggered on a percent variation from the initial state which
requires a sufficiently long selected learning and observation phase (at least 1
month) in case of constant operating conditions.

Appendix
Raw signal of
Envelope signal Peak to peak value
vibration
Alarm status, vibration vibration
acceleration
condition acceleration (ENV) acceleration (PtoP)
(RAW)
in g in g
in g
Alarm Average over a month * Factor 2
Warning Average over a month * Factor 1.5
OK Average over a month
Prerequisite for a proper alarm in case of fixed limit values its application to
defined operating conditions (e.g. constant/defined speed) or conditions
(constant/defined loads).
Crest factor (CREST factor)

The crest factor (CREST factor) is used for assessing vibration conditions of
machines – respective to the assessment of wear conditions of monitored
components (e.g. ball bearings). The CREST factor is usually measured over a large
frequency range (1 – 10 kHz). It is therefore a broad-band characteristic value.
Based on the definition, the crest factor deals with the performance of crest (peak) to
root mean square (RMS) of a symmetrical quantity – e.g. of a measured vibration
acceleration. For example, the CREST factor increases if there is a high amount of
local damage to the ball bearings (e.g. breaks/pittings on the track). However this fact
ensures that a widespread damage condition is adjusted with the time, which also
increases the root mean square (RMS). If a new balance is set between the wide-
surface and selective damage, the CREST factor also decreases than the ratio
between the crest factor and the root mean square. This gives the impression that a
damaged component has "recovered" or that a new component can have the same
CREST factor as a severely damaged component. The following figure illustrates this
fact.
Independent of the above described performance, the crest factor is an easily
applicable and easy to interpret broadband parameter, for which one can easily use
the following factors as basis for reference values:
Crest factor (CREST factor)
Alarm status,
(ratio of peak value (peak) to root mean square (RMS) of a
condition
measured vibration acceleration)
Alarm 5
Warning 3.5
OK 2

Appendix
Vibration speed according to DIN ISO 20816

The vibration speed is measured according to DIN ISO 20816 as a broadband
parameter (10 Hz – 1,000 Hz). As a benchmark, the highest measured root mean
square (RMS) forms the basis of vibration speed. The measurement according to this
standard is primarily used for acceptance procedures of machines or if there are no
reference values for the respective machine.
In the following table the general work/operation fields are mapped according to DIN
ISO 20816. Furthermore, there are more tables specific to applications (e.g. pumps,
wind turbine components etc.). However, these must not be seen in detail since they
are also based on the following table.

Appendix
Large
Large
machines
Machines Machines machines
Vibration speed with
up to 15 from with flexible
as RMS in mm/s inflexible
kW 15 to 75 kW connection
connection
(basis)
(basis)
> 28
D
28 D
D
18 D
C
11.2
C
7.1
C B
4.5
C B
2.8
B
1.8
B
1.12
A
0.71 A
A
0.45 A
0.28
A = newly operated machine
B = Continuous operation possible without restrictions
C = Limited further operation
D = Risk of a mechanical breakdown
Notice: The vibration speed is measured as RMS (in mm/s) in a frequency
range from 10 Hz – 1,000 Hz.

Appendix
Product registration form

The following product registration form is used to register your MCMS with the
HYDAC Filter Systems GmbH. A registration of the product in the framework of the
standard scope of delivery is not necessary. A registration of the product detailing
recipient and product-related data is only required in the following cases:
- Purchase of firmware updates for the MCMS data logger unit
- Purchase of software updates for the FluMoS expert application
software
- Purchase of templates or auxiliary modules (e.g. software module for
the execution of vibration analyses "VIBpro") for the FluMoS expert
- Conclusion of subscriptions for MCMS-related services, such as the
creation of machine condition reports, automated software updates or
maintenance contracts

Appendix
Product registration form

MachineConditionMonitoring System
MCMS 2000
Contact data
Customer/ Date:
Company:
Contact:
Address:
Phone number: E-mail address:
Product registration for following systems (MCMS 2000)

P/N S/N Software ID
FluMoS expert Server Manager
Information regarding material (P/N) and serial number (S/N) of the MCMS 2000 as
well as the software ID for the FluMoS expert Server Manager application software
can be obtained from the following sources:
Material- (P/N) and Serial number (S/N) Software ID
Reading location: Reading location: Login

Name plate of data logger unit of MCMS 2000 screen software for FluMoS
expert Server Manager
City, date Signature (customer)

I hereby consent to the processing of personal data in accordance with
Art. 6 Para. 1 S. 1 lit. b DSGVO for the implementation of pre-contractual measures.

Index
Index
FluMoS ... 17, 18, 19, 25, 28, 30, 31, 32, 39, 40, 41, 42, 49,
50, 51, 52, 53, 55, 56, 58, 59, 60, 61, 62, 63, 64, 66,
A 70, 71, 72, 74, 75, 76, 77, 78, 87, 90, 91, 94, 95, 97,
107, 108, 111
Accessories ................................. 39, 56, 62, 72, 90, 91, 96 Forwarding agent ............................................................ 7
ambient temperature .................................................... 21
Analog signal ........................................................... 84, 85
Application .......................................... 18, 25, 50, 89, 100 G
AquaSensor ................................................................. 101
Assignment .................................................................... 35 gear .................................. 33, 40, 45, 87, 88, 89, 111, 112
Auxiliary personnel .......................................................... 7 Gear pump .................................................................... 89
Glossary ...................................................................... 111
GND ............................................ 35, 36, 37, 39, 40, 41, 94
B
Base-T ............................................................................ 23 H
Hardware ................................................................ 18, 27
C Hazard symbol .............................................................. 10
HDA ............................................................................... 44
care................................................................................ 13 HSI ..... 17, 23, 24, 25, 28, 36, 37, 40, 44, 45, 46, 47, 76, 99
Cause ....................................................................... 92, 98
connecting ............................................... 7, 23, 29, 91, 93
Connection ........................... 39, 41, 44, 45, 46, 47, 96, 97 I
Connection cable ..................................................... 96, 97
Content ..................................................................... 2, 91 Imprint ............................................................................ 5
IN 38
installation . 6, 7, 12, 15, 16, 17, 18, 24, 26, 30, 32, 33, 38,
D 50, 51, 52, 53, 54, 55, 56, 58, 59, 60, 61, 62, 64, 65,
66, 67, 68, 70, 73, 74, 77, 78, 87, 99, 103
Date ................................................................... 8, 27, 108 installing ......................................................... 7, 30, 32, 34
degassing ................................................................. 45, 46 Interface .............................................................23, 26, 40
Description .................................................. 27, 35, 78, 92 IP 19, 23, 27, 30, 32, 49, 50, 74, 76, 94
Differential pressure ................................... 44, 45, 46, 47 ISO .......39, 79, 80, 87, 88, 89, 99, 100, 101, 103, 105, 112
Digital output ................................................................ 37
Dimensions .............................................................. 20, 25
DIN ........................... 23, 34, 38, 39, 88, 89, 103, 105, 112 L
disassembly ................................................................... 96
Display ........................................................................... 78 Language ......................................................................... 8
Disposal ..................................................................... 7, 95 Limit value .......................................... 87, 88, 99, 102, 103
Documentation Representative ...................................... 5 Login............................................................................ 108
E M
Electrical conductivity ........................................... 81, 103 Maintenance .............................................. 1, 7, 86, 92, 93
Ethernet . 17, 21, 23, 24, 25, 27, 28, 36, 39, 76, 78, 94, 97 Malfunction................................................................... 94
Manufacturer ................................................................ 27
Measured variable .......................................44, 45, 46, 47
F Measurement ............................................................... 31
Measures ...................................................................... 10
Factory setting................................................... 51, 76, 78 measuring .................................................... 7, 39, 75, 103
Filter ...............................................44, 45, 46, 62, 88, 107 Modbus ...................................... 23, 28, 39, 50, 74, 76, 78
filtration ........................................................................ 48 mounting....................................................................... 19
Filtration ...................................................................... 100
Flow control valve ....................................................... 101
Fluid temperature ......................................................... 81

Index
Service .......................................................... 18, 63, 68, 93

O Signal word ............................................................. 10, 11
signal words ............................................................ 10, 11
Online ............................................................................ 75 Spare part ............................................................... 40, 41
operating ... 7, 9, 12, 22, 31, 51, 52, 58, 78, 86, 87, 89, 90, Spare parts .............................................................. 40, 41
92, 94, 103, 104, 113 Specialist personnel ...............................................6, 7, 12
Operation ...................................................... 7, 22, 23, 77 Storage temperature .............................................. 23, 29
Operations control .......................................................... 7 Storage temperature range .......................................... 23
Out ................................................................................ 23 storing ........................................................................... 21
Overview ....................................................................... 49 Supply voltage ........................................ 24, 35, 36, 37, 39
switching on .................................................................. 77
Switching output ..................................................... 37, 41
P
Protection class ............................................................. 23 T
Publisher ......................................................................... 5
Target group .................................................... 6, 7, 50, 92
TCP ................................................... 23, 25, 28, 39, 74, 78
R TCP/IP ................................................................23, 25, 28
to shut down ................................................................. 94
Register ......................................................................... 78 Transport ....................................................... 7, 14, 29, 31
Relative humidity .................................................... 23, 29 Troubleshooting ...................................................7, 77, 94
Remedy ......................................................................... 94
repairs ................................................................... 93, 113
report .......................................................... 74, 91, 92, 98 U
USB ................................................... 14, 19, 29, 52, 58, 97
S
SAE .......................................................................... 79, 80 W
Scope of delivery ..................................................... 19, 49
select ....................................................................... 55, 77 Water content ............................................................. 103
Sensor......................................... 23, 24, 28, 39, 40, 89, 94 Weight .......................................................................... 25
Sensors ................................................ 18, 28, 39, 96, 101

Glossary
Glossary
CREST factor (crest factor)
The CREST factor is a parameter for determining the wear and damage condition of
the monitored components in machines. The calculation is done by comparing the
peak value of a signal (peak) with its RMS value (RMS). As a result, the crest factor
reacts to the impulsiveness of signals and can therefore be used to assess impulsive
signal sequences - such as those emitted by a punctually damaged rolling bearing, for
example.
Root mean square of a vibration (RMS)

The root mean square (RMS = Root Mean Square) calculates the root mean square
value of a time-variant size (e.g. a sinusoidal symmetrical quantity – respective
vibration). In the field of structure-borne sound and vibration-based equipment
condition monitoring, the root mean square characterizes the basic vibration
characteristics of a machine and of a monitored component (e.g. of a ball bearing or a
gear wheel) and is a degree of its wear condition.
FluMoS expert – Fluid Monitoring Software

The data visualization and analysis software FluMoS expert is a part of the equipment
condition monitoring solution HYDAC MCMS 2000 and is used for the user-oriented
(trend) presentation, correlation and analysis of measured data of connected sensors
as well as external signals. Furthermore,
FluMoS expert acts as a central tool for system administration and parameterization of
one or more MCMS (network comprising several MCMS).
Frequency analysis
The frequency analysis is used for identifying damage frequencies (see illustrations for
"Damage frequencies" in this glossary) in an accepted frequency spectrum. Frequency
analysis makes it possible to determine and locate damage to machines and
components in detail (e.g. damage to a ball bearing inner ring). Furthermore, the
cause of damage(n) can be determined depending on the application (e.g.
misalignments, imbalance etc.). The frequency analysis plays a large part in the
proactive alignment of condition monitoring systems. In terms of the signal processing,
the frequency analysis is based on the Fast Fourier Transformation – better knows as
FFT (FFT = Fast Fourier Transformation).
Overall Equipment Effectiveness (OEE)

The term Overall Equipment Effectiveness (OEE) is a measure for the added value of
an equipment or machine. It can be used as an indicator for the productivity of an
equipment in case of a simultaneous presentation of its losses. This also shows three
factors from which the OEE is composed: Availability factor, service factor and quality
factor. The advantage of OEE is its measurability and the the outward simplified
presentation as total value (0 to 1 and 0 to 100%).

Glossary
Total vibration degree of a machine according to DIN ISO 20816

The DIN ISO 20816 (previously, DIN ISO 10816) describes a procedure for evaluating
the vibrations of machines by measurement on the non-rotating parts. It describes the
intensity of vibration from 10 to 200 Hz (corresponds 600 to 12,000 rpm). Sample
machine types for this are small, directly coupled electric motors and pumps,
production motors, mid-engines, generators, steam and gas turbines, turbo
compressors, turbo pumps and fans. The coupling of some of these machines can be
rigid or flexible as well as via gear wheels. The angular position of the rotating shaft
and/or axle can be of any kind (vertical, horizontal or in any angle). The total vibration
level is assessed (specified via the vibration speed) on the basis of a values table in
combination with defined factors.
Envelope signal (Envelope)

The envelope signal is a filtered signal, which detects prior pulsed processes with low
power (weak deterministic signals of low frequency). The envelope analysis is
primarily used in case of early detection of damage to ball bearings.
IEPE accelerometer
IEPE stands for Integrated Electronics Piezo-Electric and indicates an industry
standard for piezo-electric sensors – for example piezo-based accelerometers –,
which has an integrated negative impedance converter electronic. In addition to
"IEPE", there are more – trademarked – designations such as ICP® or CCLD®.
Piezo-based IEPE accelerometer is amongst the type of "seismic absolute sensor".
They record their measured variables (acceleration) compared to a fixed or uniform
moving reference system – for example a machine. The sensor forms a vibratory
"Spring-Mass-System", which comprises a (seismic) mass, spring (the Piezo-element)
and party a damping. The sensor uses the mass inertia prevalent on the ground, in
which it uses the movement of the fastening point to object/machine as compared to
the seismic mass in sensor as a measured variable.
Key Performance Indicator – KPI

The term Key Performance Indicators (KPI) is also described as performance indicator
in the German-speaking world. It describes the progress or degree of performance of
critical success factors. Selection of machine-relevant factors or KPIs can be found in
the VDMA unit sheet 66412-1, for example. The standardized key figures are:
Document level, throughput, document utilization degree, degree of utilization, Overall
Equipment Effectiveness (OEE), Net Overall Equipment effectiveness (NGE),
availability, effectiveness, quality rate, setup degree, technical degree of utilization,
process level, level of rejections, first past yields (FPY), rate of rejections, rate for
reworking, rate of defects, failure rate, machine capability, critical machine capability,
process capability, critical process capability, degree of interference, reject costs,
measures index and reject costs index.
Overall Equipment Effectiveness – OEE

Refer to Overall Equipment Effectiveness (OEE)

Glossary
Predictive maintenance
Aim of the predictive maintenance (also called: prospective, anticipated or foresightful)
is to avoid failures and unplanned standstill of systems, equipments and machines
with an optimum planning of the time of maintenance. Basis for this is the so-called
"degree of wear" of a machine and its components. The optimum time of maintenance
(Remaining Useful Lifetime RUL) or of the maximum permissible rate of wear of a
component or machine is calculated by considering the progress of wear on the basis
of negative influencing factors – the so-called degradation parameters. In contrast to a
proactive maintenance strategy, it is therefore not the aim to increase the remaining
service life of a system by suitable measures, but only to predict its remaining service
life or the remaining service life of critical components. Predictive and proactive
maintenance approaches are not mutually exclusive, but are supplementary. For
example, measures to extend the service life (proactively) can only be directly
measured and evaluated in monetary terms through the continuous calculation of the
wear reserve and the resulting remaining service life of machine components or
elements (predictive).
Proactive maintenance
Proactive maintenance is a maintenance strategy whose main feature is the
avoidance of conditions that lead to machine failures or damage to individual machine
elements. In contrast to preventive or predictive maintenance, proactive maintenance
concentrates on corrective actions aimed at eliminating causes, not on their symptoms
and the associated assessment of the Remaining Useful Lifetime (RUL) of faulty
machines or damaged components. The central subject matter is increasing the
(remaining) service life of machines and their components – not only the time
estimation until their breakdown. A proactive maintenance strategy therefore requires
close, preferably permanent, condition monitoring (online). It is applicable to detect
and constantly eliminate fault causes such as improper lubrication, old lubricant,
contaminated lubricant as well as poorly conducted repairs, misalignments, imbalance
and operating errors.
Frequency of damage
Frequencies of damage are relevant frequencies of components and machine
elements, with the help of which component-related damage is identified, localized
and can be determined regarding its extent. They are the central part of frequency
analyses which are conducted as a part of structure borne sound-based vibration
measurements on the industrial equipments and machines.
Crest factor
Refer to CREST factor
Peak to peak value (Peak-to-Peak)

The "peak to peak value" of a vibration describes the maximum amplitude and the
magnitude between the vibration high and low of a measured vibration. It frequently
occurs as shock pulse and is a measure for the degree of damage of selective
damaged components – for example a ball bearing with damage to outer ring in the
form of a pitting on the track. In this case, if one of the rolling elements rolls over the
Glossary
damaged spot, a shock impulse acts on the component. This punctual force causes a
pulse-like acceleration of the system or an installed sensor and leads to a strong
amplitude increase in the vibration/acceleration signal.

HYDAC FILTER SYSTEMS GMBH
Industriegebiet Postfach 1251
66280 Sulzbach / Saar 66273 Sulzbach / Saar
Germany Germany
Tel: +49 6897 509 01 Central

Fax: +49 6897 509 9046 Technology
Fax: +49 6897 509 577 Sales
Internet: www.hydac.com
E-mail: filtersystems@hydac.com

MCMS 2000 Machine Condition Monitoring System: Operating and Maintenance Instructions

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MCMS 2000 Machine Condition Monitoring System: Operating and Maintenance Instructions

Uploaded by

Copyright:

Available Formats

MCMS 2000

Machine Condition Monitoring

Operating and Maintenance Instructions

Documentation no.: 4449960a

MCMS 2000 en-US Page 2 / 116

Connecting the system electrically ............................................... 35

MCMS 2000 en-US Page 3 / 116

Troubleshooting/fault rectification ............................................................ 94

MCMS 2000 en-US Page 4 / 116

Court of Registration: Saarbrücken, HRB 17216

Purpose of this manual

MCMS 2000 en-US Page 5 / 116

Target group of the manual

Target group Tasks

MCMS 2000 en-US Page 6 / 116

Target group - Required qualifications/training

Activity Person Knowledge

MCMS 2000 en-US Page 7 / 116

Illustrations in the manual

Illustration on the title page

1 Short name of the product / product name

MCMS 2000 en-US Page 8 / 116

Illustration of the layout

Documentation no. Document language

Note that the method described for locating specific information

The manual contains a table of contents, an index and a glossary.

MCMS 2000 en-US Page 9 / 116

Representation of procedural instructions

Procedural instructions with a fixed sequence

Procedural instructions with a random sequence

Representation of warning/general safety information

HAZARD SYMBOL Consequence of the danger

► Measures to avert danger

MCMS 2000 en-US Page 10 / 116

Signal words and their meaning in the general safety information

MCMS 2000 en-US Page 11 / 116

Warning signs used

Dangerous electrical voltage warning.

Signs used for giving orders

Follow the instructions.

Signs used for the required specialist personnel

Specialist personnel - Electrical

MCMS 2000 en-US Page 12 / 116

Tip for handling the product

Validity of this manual

MCMS 2000 en-US Page 13 / 116

General safety information

► Transport the system in its original packaging.

MCMS 2000 en-US Page 14 / 116

The system will be damaged

Lines, power supply and sensor cables will be damaged or destroyed.

Danger of property damage or bodily harm

MCMS 2000 en-US Page 15 / 116

The signal quality is limited

Danger of property damage or bodily harm

MCMS 2000 en-US Page 16 / 116

MCMS 2000 en-US Page 17 / 116

MCMS 2000 en-US Page 18 / 116

Scope of delivery for MCMS 2000

MCMS 2000 en-US Page 19 / 116

Dimensions of data logger unit MCMS 2000

MCMS 2000 en-US Page 20 / 116

MCMS 2000 en-US Page 21 / 116