FLTR CCM 01 User manual

CCM 01 - Set
Contamination Control Monitor
Instruction manual
Version 2.7
Serial no. CCM 01: ..................
Serial no. PFS 01: ..................
Version valid from: 22.08.2016
For more information:
WEB: FLTR.com.au PHONE: [phone] EMAIL: [email protected] SKYPE: Purple.Engineering

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Index
Seite
1. SAFETY INFORMATION 4
1.1. Dangers of maloperation...................................................................................4
1.2. Intended applications ........................................................................................4
2. OPERATION AND INSTALLATION 5
2.1. Setup...................................................................................................................5
2.1.1. Block diagram..................................................................................................5
2.2. General information...........................................................................................6
2.3. Measuring principle of the PFS 01 (Particle Flow Sensor)..............................6
2.4. Sensor installation.............................................................................................7
2.5. Optimum operating conditions .........................................................................7
2.6. Installation of the display unit CCM 01.............................................................7
2.7. Electrical connection of the PFS 01 and the CCM 01 ......................................7
2.8. Operating the CCM 01 software ......................................................................10
2.8.1. Control keys...................................................................................................10
2.8.2. Menu structure...............................................................................................11
2.8.3. Main menu.....................................................................................................12
2.8.3.1. Measure....................................................................................................12
2.8.3.1.1. Viscosity Range....................................................................................12
2.8.3.1.2. Report Format (ISO 4406 or NAS 1638)...............................................12
2.8.3.1.3. Start......................................................................................................13
2.8.3.1.4. Storage Interval....................................................................................13
2.8.3.2. Data Manager...........................................................................................14
2.8.3.2.1. Transfer Data .......................................................................................14
2.8.3.2.1.1. Data transfer by using the RS232 - interface....................................14
2.8.3.2.1.2. Data transfer by using the external printer........................................15
2.8.3.2.2. Delete Data ..........................................................................................15
2.8.3.2.3. Stored Data..........................................................................................15
2.8.3.3. Options .....................................................................................................15
2.8.3.3.1. Limits....................................................................................................16
2.8.3.3.2. Set Time...............................................................................................17
2.8.3.3.3. Calibration............................................................................................17
2.8.3.3.4. CAN......................................................................................................18
3. DATA TRANSFER 18
3.1. Connection to an external computer as an evaluation device......................19
3.1.1. Connection via RS232 –interface..................................................................19
3.1.2. Connection of the RS232 –adaptor plug into the interface............................19
3.1.3. Connection of the Bluetooth modul EBT 01...................................................19
3.2. Continuous data transfer of the actual measurements.................................19
3.2.1. HyperTerminal...............................................................................................19
3.2.2. Setup of HyperTerminal.................................................................................20
3.2.3. Procedure......................................................................................................21
3.2.4. Protocol for the contiuous data transfer .........................................................21
3.3. Data transfer of the saved measurements .....................................................22
3.3.1. Export and evaluation of the stored data via “CCM 01 data manager Vers. 2.0”22
3.3.2. One-time program installation........................................................................22
3.3.3. Procedure......................................................................................................23
4. EVALUATING MEASUREMENTS 28
5. CAN INTERFACE 29

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5.1. Introduction to CAN and CANopen.................................................................29
5.1.1. CAN-Bus .......................................................................................................29
5.1.2. CANopen.......................................................................................................29
5.2. CANopen –functionality..................................................................................30
5.3. Start-up.............................................................................................................30
5.3.1. Baudrate........................................................................................................31
5.3.2. Node ID.........................................................................................................31
5.3.3. Start...............................................................................................................32
5.4. Object dictionary..............................................................................................32
5.4.1. Communication specific part..........................................................................33
5.4.1.1. Error register (Index 1001h) ......................................................................33
5.4.1.2. Manufacturer status register (Index 1002h)...............................................33
5.4.2. Manufacturer specific part..............................................................................34
5.4.2.1. Threshold settings.....................................................................................35
5.4.2.2. Report format............................................................................................35
5.4.2.3. Viscosity range..........................................................................................35
5.4.2.4. Sending measurement results...................................................................35
5.4.2.5. Storage interval.........................................................................................35
5.4.2.6. Stored data ...............................................................................................35
5.4.2.7. Process values..........................................................................................36
5.5. SDO (Service Data Object)...............................................................................36
5.6. Transmit PDO...................................................................................................37
5.7. Emergency Messages......................................................................................37
5.8. Guarding...........................................................................................................37
5.8.1. Nodeguarding................................................................................................37
5.8.2. Heartbeat.......................................................................................................37
5.9. Timestamp........................................................................................................38
5.10. Network Management ......................................................................................38
5.11. EDS-file.............................................................................................................38
5.12. Examples for CAN-communication.................................................................38
6. SENSOR CALIBRATION 38
7. APPENDIX 40
7.1. Technical Data..................................................................................................40
7.1.1. Laser sensor..................................................................................................40
7.1.2. CCM 01 –Display unit...................................................................................40
7.1.3. CCM 01 –housing.........................................................................................41
7.1.3.1. CCM 01 - backside of housing ..................................................................41
7.2. Pin assignment.................................................................................................42
7.2.1. Laser sensor..................................................................................................42
7.2.2. CCM 01 –display unit....................................................................................42
7.2.2.1. RS 232 interface and CAN –option ..........................................................42
7.2.2.2. Sensor connections –X11 ........................................................................43
7.2.2.3. Power supply –24 V DC...........................................................................43
7.3. Pressure difference characateristics..............................................................44
7.4. Cleanliness classes according to ISO 4406:99..............................................45
7.5. Cleanliness classes according to NAS 1638..................................................46
7.6. Application areas - Compatibility....................................................................47
7.7. Trouble shooting..............................................................................................47
7.8. Shipment...........................................................................................................47

1. Safety information
1.1. Dangers of maloperation
The CCM 01 underwent a safety inspection according to IEC 1010-1/ EN 61010 –1, part 1.
Integrated hydraulic and electronic safety elements ensure safe operation if the device is
used as it was intended.
In case of maloperation or abuse, as well as in case of insensitivity for application
limits and safety regulations, the following threats can occur for:
Life or physical condition of the operator,
the CCM 01, as well as connected machines and systems connected,
the accuracy of measurements of the CCM 01,
the environment.
This manual does contain information and safety advice, which ensure risk free operations
and which help to keep the device in an ideal condition.
Therefore, it is necessary that everybody having to do with the operation and maintenance
of the unit strictly follows this instruction manual.
1.2. Intended applications
The CCM 01 –Set is an efficient and robust inline diagnostic measuring system for
determining the contamination classes according to ISO 4406:99 and NAS 1638.
It works very reliably and does fulfil all requirements of daily measurements.
The set is intended and tested to operate with all usual hydraulic and gear fluids as well as
synthetic esters.
Application limits:
Maximum acceptable operating pressure: 50 bar / 725 psi
Maximum oil temperature: 70 °C / 158 °F
Viscosity range: 10...400 mm²/s / 46...1854 SUS
Miniumum volume flow: 500 ml/ min / 0,132 gal/ min
Maximum acceptable volume flow: 50 l/min / 13 gal/min
Generally, the CCM 01 –Set has to be operated with 24 V DC (ripple: < 300 mVpp)!
For more information:
WEB: FLTR.com.au PHONE: [phone] EMAIL: [email protected] SKYPE: Purple.Engineering

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2. Operation and installation
2.1. Setup
The CCM 01 –Set consists of the PFS 01 (Particle Flow rate Sensor), a cable to connect
the sensor (l = 5 m) and the CCM 01 –display unit.
A PFS 01 belongs always to a specific CCM 01. The calibration values of the PFS 01
are stored always in the respective CCM 01!
2.1.1. Block diagram

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2.2. General information
The effects of contamination on hydraulic or lubricating systems are manifold. It causes
significantly increased wear, increased risk of component failure as well as malfunctions.
The CCM 01 - set fulfils all necessary requirements for continuous monitoring and analysis
of hydraulic systems and test stands. It is an inexpensive stationary monitoring solution.
The CCM 01 has the following functions:
-Automatic particle counting and display of the measuring results acc. to contamination
classes ISO 4406 or NAS 1638 every 20 seconds.
-Storage of 100 measured data in selectable storage intervals.
-Transmission of the current measuring results via RS 232 interface.
-4 programmable contamination limit values with 4 potential free relay contacts. When
exceeding the limit value the appropriate relay contacts closes –thus allowing control
functions in the hydraulic and lubrication system, which has to be observed.
-Transmission of the stored measured data on an external cpmputer in a Windows Excel
file.
The CCM 01 –Set should only be switched on when the PFS 01 is flown through with
oil, because there is installed a thermic volume flow sensor. Very long runnning
times without flow rate can cause damages!
2.3. Measuring principle of the PFS 01 (Particle Flow Sensor)
The PFS 01 consists of two sensor elements:
Laser sensor for particle counting and flow sensor for measuring the volume flow in the
measuring channel.
The PFS 01 operates based on the offline flow principle:
Using a counter balance valve, a partial flow of the oil flowing trough the device is lead
through the flow sensor and the laser particle counting sensor in order to analyze.
The counted particles per volume and the particle concentrations for these following
particle sizes are determined: > 4 µm (c) , > 6 µm(c), > 14 µm(c), > 21 µm(c) or > 6,4 µm(c),
> 14 µm(c), > 21 µm(c), > 37 µm(c) (switchable). Results can be displayed according to
ISO 4406 respectively NAS 1638.
The sensor integrated in the PFS operates based on the light blockade principle and it
is calibrated with ISO MDT according to ISO 11171.

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2.4. Sensor installation
Integrate the PFS 01 in the hydraulic system (Connection: Thread according to ISO
228-G1 or ¾”).
The sensor should be installed and flown through vertically if possible. Optimal, from
bottom to top to avoid air inclusions respectively to dissolve them fastly.
The assembly should be vibration-cushioned and the connection should be made with
hoses.
The installation should not be directly on vibrated components or motors.
2.5. Optimum operating conditions
If there are very fine air bubbles in the oil, there is the possibility that these air bubbles
are counted as particles. With a measurement under pressure (40 bar), a suppression
of air bubbles is reached.
There is another variant of the PFS 01 sensor. With this variant only the measuring
channel of the sensor is flown through. For this variant a constant volume flow of 30 –
100 ml/min must be provided.
At very low viscosities (10 –20 mm²/s) there should be installed a more weak spring in
the bypass valve and the total volume flow through the sensor should not be higher
than 20 l/min.
2.6. Installation of the display unit CCM 01
Mount the CCM 01 display unit to the system. (see chapter 7.1.3.1)
2.7. Electrical connection of the PFS 01 and the CCM 01
Connect the display unit with the sensor using the cable. Extend the sensor cable after
consultation with the manufacturer only.
Connect the 24 V power cable and the CCM 01 display unit.
Loose screws and remove cover.

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Cable screws: PG 9 PG 11 PG 13,5
Cable diameter: 4 –8 mm 5 –10 mm 6 –12 mm
- Place the 24 V DC power cable through the screwed cable gland PG 9 or 13.5
(depending on cable size) and connect it (see chapter 7.2 or the list on the cover).
- Put the threshold transmission cable in the screwed cable gland PG 9 or PG 13.5
(depending on cable size) according to the pin assignment (see chapter 7.2 or the
list on the cover).
- If threshold transmission is not necessary, close the unused screwed cable gland
using the dummy plug in order to keep the IP-65 protection class.
- Connection 15: black/GND, optional defpending on filter board in Sensor cable

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The CCM 01 set is ready for operation, if the laser sensor, the power cable and
the threshold transmission cable are connected to the CCM 01 display unit.

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2.8. Operating the CCM 01 software
After the sensor has been entered into the hydraulic system, considering all application
limits, start the CCM 01.
Wait through the welcome screen until the main menu is being displayed. It can be
operated using the control keys.
2.8.1. Control keys
Menu controls Enter Back
(Escape)