Eaton CCS 5 User manual

CCS 5
Contamination Control System
Particle counting + Water saturation + Temperature
Instruction manual
Version 0.1 (preliminary)
Version valid from: 17.11.2021
software version from: 0.1

Instruction manual CCS 4, 30/ 08/ 2013 2
Index
page
1. SAFETY INFORMATION 4
1.1. Signal glossary...................................................................................................4
1.2. Dangers of maloperation...................................................................................4
1.2.1. Hazards by working at the hydraulic or lubrication system...............................5
1.2.2. When all measurements are done:..................................................................6
1.3. Sources of danger..............................................................................................6
1.4. Service staff........................................................................................................6
1.5. Safety arrangements on site .............................................................................6
1.6. Intended applications ........................................................................................6
1.6.1. Limitation of use ..............................................................................................7
1.6.2. Visual inspection of the used fluid....................................................................7
2. OPERATION AND INSTALLATION 8
2.1. Setup...................................................................................................................8
2.2. General information...........................................................................................8
2.3. Connection to the hydraulic or lubricating system .........................................9
2.3.1. Connection into the pressure operating mode (max. 350 bar)..........................9
2.3.2. Connection into the suction operating mode (min. -0.2 bar)...........................10
2.4. Electrical connection.......................................................................................10
2.4.1. Mains operation.............................................................................................10
2.4.2. Battery operation...........................................................................................11
2.5. Operation with the CCS 5 software.................................................................12
2.5.1. Main menu.....................................................................................................12
2.5.2. measurement.................................................................................................13
2.5.2.1. Measure-type: single.................................................................................16
2.5.2.2. Measure-type: continuous.........................................................................17
2.5.2.3. Measure-type: cyclic .................................................................................19
2.5.3. File system....................................................................................................20
2.5.3.1. Display the saved results in graphic..........................................................21
2.5.3.2. Delete the saved files................................................................................22
2.5.3.3. Data transfer.............................................................................................23
2.5.4. System settings.............................................................................................24
2.5.4.1. Date/ time .................................................................................................24
2.5.4.2. Brightness of the display...........................................................................24
2.5.4.3. Update the software of the CCS 5.............................................................25
2.5.5. System information........................................................................................26
3. SOFTWARE “DATA MANAGER” 27
3.1. Installation of the Data Manager Software on an external PC.......................27
3.2. Data analysis with “Data Manager” ................................................................27
4. EVALUATION OF MEASUREMENT RESULTS 31
4.1. Water sensor ....................................................................................................31
4.1.1. Display in % water saturation.........................................................................31

Instruction manual CCS 5, 15/ 10/ 2021 3
4.1.2. Display of the fluid type and ppm water content.............................................31
5. MAINTENANCE 33
5.1. Pressure INLET ................................................................................................33
5.2. Suction INLET...................................................................................................34
6. CALIBRATION 36
7. APPENDIX 37
7.1. Technical data..................................................................................................37
7.2. Hydraulic plan ..................................................................................................39
7.3. Measurement principle....................................................................................39
7.3.1. Laser sensor –Particle Counter for CCS 5....................................................39
7.3.2. Water sensor.................................................................................................40
7.4. Cleanliness classes according to ISO 4406:99..............................................41
7.5. Cleanliness classes according to NAS 1638..................................................42
7.6. Cleanliness classes according to SAE AS 4059............................................43
7.7. Fields of application –compatibility...............................................................44
7.8. Trouble shooting..............................................................................................44
7.9. Software license and copyright.......................................................................44
7.10. Shipment, parts list..........................................................................................44
7.11. spare parts........................................................................................................45

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1. Safety information
1.1. Signal glossary
•Failure to observe the safety instructions in this manual implies various risks and
endangerment of life and the physical condition of the operator. The notices are marked
with the following signal words:
DANGER implies a dangerous situation which causes death or serious
injuries in case of nonobservance.
WARNING implies a dangerous situation which can cause death or
serious injuries in case of nonobservance.
CAUTION implies, together with the danger symbol, a dangerous
situation which can cause light, medium, or heavy injuries in case of
nonobservance.
•Failure to observe the safety instructions in this manual, which does not cause injuries
but destruction of the system and its operability, are marked with the following signal
word: NOTICE describes the correct way of handling the device.
The above signal words can be combined with the safety symbols or the warning symbols.
General danger
Danger caused by electricity
Danger for the environment
1.2. Dangers of maloperation
The CCS 5 underwent a safety inspection. The integrated electric and hydraulic safety
elements ensure safe operation if the device is used as it is intended.
In cases of maloperation or abuse, as well as in cases of ignoring the application limits and
safety regulations, the following threats can occur regarding the:
•Life or physical condition of the operator;
•
The CCS 5 device, as well as connected machines and systems;
•
The accuracy of measurements made by the CCS 5;
•
The environment.
Therefore, it is necessary that everybody having to do with the operation and the
maintenance of the unit strictly follows this instruction manual!

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1.2.1. Hazards by working at the hydraulic or lubrication system
May occur the following hazards:
•uncontrolled discharge of the pressure fluids
•accidental machine movements
•thrown or bursting of parts
•skin toxicity
•noise emission
Uncontrolled discharge of the pressure fluids
Possible leaking of the hydraulic fluid:
In case of breakage of pipes, upon release of fasteners that are still pressurized, damages of
the hydraulic hose lines or by exposure to excessively high forces.
The consequences can be:
•eye damage
•skin penetration
•fire hazard
•risk of slipping
•environmental hazards, such as penetration of the fluid into the soil / groundwater
Connection of the hoses from the CCS 5 to the hydraulic or lubrication system, see chapter
2.3.
Accidental machine movements
•Accidental operation of command or control devices. (buttons, levers, proximity switches,
and so on)
•Error in control
•Failure of components due to for example: excessive system pressure, material fatigue…
•Contamination of the hydraulic fluid
Thrown or bursting of parts
May be a result of:
•excessive stress of components (e.g: high operating pressures or pressure peaks)
•material fatigue (e.g: demolished hydraulic hose assemblies)
Skin toxicity
•Through contact with hydraulic fluids. Follow the skin protection plan!
•Vapors of pressure fluids can cause respiratory irritation, if inhaled.
Noise emission by
•pump units
•the work process noise generated by machines
Use hearing protection at hazardous noise levels.
One or more hazards can occur simultaneously depending on maintenance work.
Accordingly, several safeguards must be applied.
•Note the five-finger rule of fluid technology during maintenance work!
1. Separate power supply
2. Secure against re-supply
3. Depressurized the system (also the pressure storage), lowering or supporting of the
uphold loads, reduce residual energy
4. Check the release pressure (pressure free)
5. Prevent hazards by neighboring plants.

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1.2.2. When all measurements are done:
1. Switch OFF the CCS 5 and disconnect the external power supply.
2. Disconnect the pressure hose or suction hose (depending on the hydraulic
connection).
3. (at last!) Disconnect the return hose (transparent plastic hose) from the [OUTLET
PORT] of the CCS 5.
1.3. Sources of danger
•An operation of the CCS 5 is only allowed at a shockproof socket.
•Avoid the risk of direct and indirect contact with voltage- or current-carrying
parts. Voltage disappearances, e.g.: avoid due to poor grounding.
1.4. Service staff
•Only authorized persons can work with the CCS 5.
The operator must:
-hand over the maintenance instruction to the user.
-make sure, that the user reads and understands the instruction.
1.5. Safety arrangements on site
•The CCS 5 must sit on a flat solid ground.
•For outdoor measurements (in the rain) use the CCS 5 only with tilted housing cover.
This prevents the entry of water into the CCS 5.
Look at the hoses, while closing the housing cover!
1.6. Intended applications
•The CCS 5 is a mobile diagnostic system meant for continuous monitoring and condition
analyses of hydraulic and lubricating systems, which enables the user to evaluate the up-
to-date condition by measuring the particle contamination, water saturation and
temperature.
•The particle size distribution is being shown in contamination classes according to ISO
4406:99, NAS 1638, and SAE AS 4059.
•Resulting out of measured saturation and temperature values, the theoretical water
content in ppm (mg/kg) is being calculated and displayed for selected fluids.
•By knowing these important parameters, the user is able to evaluate the precise condition
of the system. Having this information will help to initiate actions promptly and cost-
saving measures before major failures can occur.
•The unit is suitable for pressure, as well as for suction operation, i.e., it can be connected
to a pressure line by a minimess connection or absorb fluids which are to be analyzed by
using an integrated suction pump.

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1.6.1. Limitation of use
The device is exclusively adequate for on-line applications in hydraulic and lubricating
systems within the following limitations:
•operation pressure (suction port): p = -0,2…0,2 bar (-2,9…2,9 PSI)
•operation pressure (pressure port): p = 1,5…350 bar (21,75…5000 PSI)
•viscosity range:

= 10…400 mm²/s (46,35…1854 SUS)
•temperature range of the oil: 0…70 °C (32…158°F)
•ambient temperature range: 0…50 °C (32…122°F)
•Internal temperature range: 0…45°C (32…113 °F)
1.6.2. Visual inspection of the used fluid
•If extremely contaminated fluid is introduced to the CCS 5, the internal orifices of the
laser sensor can be blocked and display an anomalous result, e.g.: 00/ 00/ 00. (see
chapter 7.3 of the instruction manual)
Classification of highly contaminated fluids:
➔More than 24.000 parts per ml (>NAS 10 or class 22 acc. to ISO 4406:99)
➔Particles larger than 200 µm (which can be detected without laboratory
microscope)
•If the laser sensor is blocked (e.g. showing low classification code), please take the
following steps:
➔Attempt to flush the system with clean (NAS 4 or ISO 16/13/9 or better) low
viscosity fluid (ISO VG 22) in the continuous mode.
➔If this does not help, please contact the Eaton Technologies GmbH representative
or send the CCS 5 to the Eaton Technologies GmbH service center in Altlussheim.
The regular function of the CCS 5 and the warranty of safety are
guaranteed only if it is used with provided and allowed accessories of Eaton
Technologies GmbH.
•Before measuring with the CCS 5, the oil has to be extracted from the system and
visually examined for extremely large particles that may cause undue wear to the system.
•Before connecting the CCS 5 to the system, make sure that the oil
discharged out of the CCS 5 gets caught in a tank. The oil must not get released to the
environment!
No unauthorized modifications or changes are allowed to the
CCS 5! E.g.: open the unit by removing the front screws and remove the assembly.
The terms and conditions stated in this instruction manual have to be
followed strictly!

Instruction manual CCS 5, 15/ 10/ 2021 8
2. Operation and installation
2.1. Setup
The CCS 5 consists of the equipment case (1), the external power supply (2), the USB –
stick (3), high pressure measuring hose (minimess hose) (4), the suction hose and the return
hose (5).
2.2. General information
External factors have a huge and extensive influence on the lubricant during operation.
External factors are for example forces, energies, and interactions with other materials.
Pressure and shear stress also belong to the force effects. Energy influences are the supply
and the removal of heat (high temperature amplitudes). A lubricant gets in contact with gases
(air, nitrous gases or sulphur dioxid), liquids (water, external liquids like detergents, dissolver
etc.) and solid matters (metals, ceramics, synthetic material parts and sealing materials).
The contamination outcomes are very versatile for the hydraulic and lubricating system and
cause a significantly higher abrasion, an increase of the failure risk of components as well as
malfunctions.
The CCS 5 is for the continuous monitoring and condition analyses of hydraulic and
lubricating systems. The CCS 5 can be handled in suction as well as in pressure operating
mode.
The CCS 5 includes the following functions:
•Particle counting by a laser sensor for hydraulic and lubrication oils within the measuring
range < 24000 particle/ 1 ml and the maximum particle size of < 200 µm.
•Exact evaluation of contamination classes according to ISO 4406:99, NAS 1638 and SAE
AS 4059.
•Measuring of.
-Water saturation (0 … 100%)
-Temperature (0 … 70 °C)
(see also the technical data at chapter 7.1 )
•Calculation and output of the theoretical water content in ppm (mg/kg) based on fluid
specific saturation curves.
•Display of all measurement values on a resistive touchscreen.
•Internal storage of measurements.
•Output of saved measurement files by USB-interface on the USB-stick.
For the data management using an external computer and the LabVIEW Data Manager
Software (export in MS EXCEL).
(1)
(2)
(4)
(5)
(5)
(3)
(4)
(5)

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2.3. Connection to the hydraulic or lubricating system
•The CCS 5 can be handled in a suction as well as in a pressure operating mode.
Only ONE inlet hose is allowed to be connected at the same time, either PRESSURE
INLET OR SUCTION INLET.
Connection for suction mode connection for pressure mode
•Connections from the top to the bottom:
OUTLET port, pressure INLET port and SUCTION INLET port for the return line.
Use only the labeled hoses, that supplied by Eaton with the CCS 5.
Check the hoses before using.
Also check the cleanliness of the ports at the CCS 5, the hydraulic system and the
hoses.
The ports must be cleaned before using.
2.3.1. Connection into the pressure operating mode (max. 350 bar)
•Connect the return hose (transparent plastic hose) with the [OUTLET PORT] of the CCS
5 and transfer it to an oil collecting tank.
➢The oil collecting tank must be dimensioned according to the time needed to
perform the operation. Otherwise you must provide an empty replacement tank
that may be quickly changed when the first one is full.
➢You may also circulate the measured oil back to the tank of the system.
➢Never connect the recirculation to a pressurized line!
•In the pressure operating mode the provided high pressure hose (minimess hose) is
being connected with the CCS 5 - [PRESSURE PORT] and the hydraulic system.

Instruction manual CCS 5, 15/ 10/ 2021 10
2.3.2. Connection into the suction operating mode (min. -0.2 bar)
•Connect the return hose (transparent plastic hose) with the [OUTLET PORT] of the CCS
5 and transfer it to an oil collecting tank.
➢The oil collecting tank must be dimensioned according to the time needed to
perform the operation. Otherwise, you must provide an empty replacement tank
that may be quickly changed when the first one is full.
➢You may also circulate the measured oil back to the tank of the system.
➢Never connect the OUTLET hose to a pressurized line!
•In the suction operating mode the provided suction hose (transparent PVC-hose) is
being connected with the [SUCTION PORT] of the CCS 5 using the quick lock coupling
(two-sided locking).
•The hose has to be inserted into the tank.
Pay attention to create a distance of minimum 15 cm from the tank bottom
and the tank walls, so that no coarse particles, which are sedimented in the tank,
get absorbed and choke the sensor system.
2.4. Electrical connection
2.4.1. Mains operation
•The operating voltage of the CCS 5 amount to 15 V DC.
•To create the necessary operating voltage, connect the CCS 5 with the external power
supply (100 V bis 240 V AC, 50/60 Hz). The power on the power supply is visible with a
blue power indicator.

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•connection with external power supply.
the green LED turns ON when the power supply is connected, and the battery is being
charged correctly.
•Switch on: turn the “power switcher”–to I.
•Switch off: turn the “power switcher”–to O.
2.4.2. Battery operation
•The rechargeable lithium-polymer battery with internal battery charger is integrated in the
CCS 5.
•It allows for an approximate continuous operating time of 2-4 hours, depends on the
viscosity of the testing fluid.
•The CCS 5 switches off automatically when the internal battery is
completely discharged. Then it is only possible to start the CCS 5 with the external
power supply unit.
•In standby mode (measurement is not running) the recharge of an empty battery needs
around 3 hours; During measurement the recharge takes around 6 hours.

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Indicator of the battery status
The green LED on the front panel indicates the status of the battery in CCS 5.
It turns ON, when the battery is loading correctly.
battery will be always loaded when the external power supply is connected
it flashes when there is a failure with the battery, e.g. the temperature in case is too
high or too low (0-45°C is allowed for lithium polymer battery)
Car supply
With a special adapter it is possible to connect the CCS 5 with a car plug. (the accessory is
available on request)
2.5. Operation with the CCS 5 software
•After connecting the necessary hoses, power and switching on the CCS 5, the unit is
ready for operation. (green control diode lights)
•After switching on the CCS 5, and wait some seconds until the operating system is
booted, then the main menu appears on the display
2.5.1. Main menu
•Start of the CCS 5 and wait until the operating system is booted, then the main menu is
shown on display.
•The main menu enables the selection of the functions which the CCS 5 offers.
measurement
File system
System
Settings
System Information
USB Stick /
battery state /
current time

Instruction manual CCS 5, 15/ 10/ 2021 13
measurement
Accomplish of the measurements with various measuring programs (single, continuous,
cyclic), and the fluid type in need. The CCS 5 must be connected acc. To the capital 2.3).
File system
For analysis, transferring and manage of the saved measurement results.
System settings
Settings of date, time, brightness of the display, as well as software update.
System information
Showing the software version, calibration date, system date/time, charging current of the
battery.
2.5.2. measurement
•For the measuring in the appropriate operating mode (depending upon the hydraulic
connection, see chapter 2.3.
•The following parameters are entered in the setup menu “Setup”:
•Name of the measuring point
•Selection of the measure-mode
•Selection of the report standard (ISO 4406:99, NAS 1638, SAE AS 4059)
•Selection of the flush time (15 ~ 300 seconds)
•Selection of the test fluid
Measuring point:
A virtual keyboard will show up by touching the filed:

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Then a proper name for the saving file can be given:
Enter the name of your measuring point by using the virtual keyboard, the maximum capacity
is 20 characters.
Always use the same name for the same measuring point, so that the stored data can be
systematized within the data file system. Every measurement automatically gets a new index
in the data file system, also the current date and time of the current measurement is stored.
Measurements are displayed depending on the data sorting.
If no identification is entered, “test” is automatically used.
Measure-mode:
Select the measure-mode (single, continuous, cyclic) by choosing the check box.
Report standard:
It is possible to display the measurements according to ISO 4406:99 or NAS 1638 or SAE
AS 4059. Select the classification format by choosing the check box.
Flush time:
It is recommended to flush the system before every measurement, at least 15s.
The flush time can be set between 15 to 300 seconds, it needs about 25 to 500 ml.
Test fluid:
For the additional display of the existing theoretical ppm water content during the
measurements, the type of oil should be selected.
If no test fluid is selected, then the measurements will only display the water saturation in %
and not the corresponding ppm.

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By touching the filed a new window with all recorded fluids will show up to be selected:
Then confirm the selected fluid:
then the menu will be automatically switched to the previous menu.
The selected fluid is indicated in the display.

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After entering
all the
necessary
measurement
parameters,
confirm with
and
this will take
you to the
next menu.
2.5.2.1. Measure-type: single
•This mode is to accomplish a single measurement.
•The procedure as described in detail below is performed in any selected report standard
(ISO 4406:99, NAS 1638, SAE AS 4059).
•Start the
measurements
with [Start].
The flush process runs before the measurement, it takes from 15
seconds to 300 seconds, based on the selection in the setup
menu.
•The operating mode selected, the report standard type and
the measuring mode are shown in the headline
•Contamination
class.
•Both the water
saturation and the
temperature are
shown with each
measurement.
When a fluid type
is selected then
the ppm water
content is also
displayed.
•Particle concentration per 1 ml

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•Now all results
are displayed and
can be
saved by pressing
button “save”.
The
measurement
results will not be
automatically
saved.
•New start with
[START].
•With back
to the previous
menu “Setup”.
To assure constant mode of operation of the unit and the accuracy of measurement
results, it is recommended to perform a flushing of the CCS 5 with cleaned mineral oil
(filtrated H22) for several minutes after finishing the measurements.
2.5.2.2. Measure-type: continuous
•This mode is to accomplish the continuous measurements.
•After the second measurement a trend of the results will be shown on the display.
•The following details describe the operational sequence that takes place in each selected
measurement mode (single / continuous / cyclic ) and the kind of classification (ISO
4406:99, NAS 1638, SAE AS 4059). (Example: “Cont. / ISO 4406 ”)
•start with button
[START].

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•The measurement
mode selected in the
preceding menu, the
classification type is
shown in the headline.
•Both the water
saturation and the
temperature are shown
with each
measurement. When a
fluid type is also
selected, then the ppm
water content is also
displayed.
•The numbers of each
measurement and the
date of start is
displayed.
•The measurements are
continued until they get
stopped with button
[STOP].
•To continue the
measurement just press
the button [START], The
numbers of each
measurement and the
date of start is
displayed.
•The last measurement results will not be deleted by continuing the measurement.
To assure constant mode of operation of the unit and the accuracy of measurement
results it is recommendable to perform a flushing of the CCS 5 with cleaned mineral
oil (filtrated H22) for some minutes after finishing the measurements.

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2.5.2.3. Measure-type: cyclic
•This mode is to accomplish the cyclic measurements.
•The procedure as described in detail below is performed in any classification type (ISO
4406:99, NAS 1638, SAE AS 4059). (Example: “ISO 4406”).
•Selection of the
measurement mode of “cycl.”
For cyclic measurement.
•Select classification type in
“report standard”.
•Select the “flush Time” in
seconds.
•Select a fluid type if needed.
•Select the desired cycle
period in hour with [ +/ - ]
buttons.
•Select the desired cycle
numbers [2 ~ 100] with [ +/ -]
buttons.
•Confirm the parameter
selection with .
Cycle period in [h]
The time between one measurement and the next one can be selected between 0,5 hour to
24 hours in half hour steps.
Cycle number
The total number of measurements can be chosen two-steps wise from 2 to 100.
every cyclic measurement will be saved automatically.
•Start the cyclic
measurement with
[ START ].

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•The operating mode
selected in the preceding
menu, the classification
type and the measuring
mode are shown in the
headline.
•Both the water saturation
and the temperature are
shown with each
measurement. When a fluid
type is also selected, then
the ppm water content is
also displayed.
To assure constant mode of operation of the unit and the accuracy of measurement
results it is recommendable to perform a flushing of the CCS 5 with cleaned mineral
oil (filtrated H22) for some minutes after finishing the measurements.
2.5.3. File system
•Using this menu
to manage the
stored
measurement
data.
•The measurements in the permanent data storage persist until they are deleted manually,
or the maximum quantity of the storage data is exceeded.
oMax. 100 measurements of each measure-type can be saved in the data storage.
Thereafter, at each subsequent measurement, the data that is on the first place in
the data storage is being deleted and overwritten by new data.
Last in - First out.
oYou may delete a single measurement.
oYou may also delete the complete data set.
•The stored measurements can be transferred, as a TXT –file using the USB –interface
to USB –stick (memory capacity:<2 GB, FAT:16) (see chapter 2.5.3.3)
•The procedure as described in detail on the next page is always the same with all
measuring modes (single, continuous, cyclic, bottle sampling).
For illustration purposes the procedure is shown in one measuring mode only.