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)!
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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)

2.8.2. Menu structure
The menu structure consists of three levels (plus start screen), the first both levels
serve only navigation for the third level from which the single set options and measuring
options can be started.
The following structure diagram shows the composition of menu navigations.
Transfer Data
Stored Data
(display only)
Data Manager
Delete Data
Viscosity Range
Report Format
Measure
Start
Storage Intervall
CAN Baudrate
Start
CAN
CAN Node ID
Main Menu
Start Screen
Options
Set Limits
Set Time
Calibration
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2.8.3. Main menu
Choose a submenu with the [  ] buttons.
The chosen item is marked with a *on the left side of the menu.
Enter the chosen menu item by hitting the [ ] button.
2.8.3.1. Measure
Selection of the viscosity range, the using classification (ISO 4406 or NAS 1638) and start
of the measuring.
Choose a submenu with the [  ] buttons.
The chosen item is marked with a * on the left side of the menu.
Enter the chosen menu item by hitting the [ ] button.
Use [ ESC ] to go back to the previous menu. (Display shows: )
2.8.3.1.1. Viscosity Range
Selection of the viscosity range from used fluid allowing for the fluid temperature.
Use the [  ] buttons to choose the viscosity range.
The selected menu item will be marked with a *on the left side.
By hitting the [ ] button the selection of a viscosity range is confirmed.
You will automatically jump to the [ MEASURE ] menu.
2.8.3.1.2. Report Format (ISO 4406 or NAS 1638)
Selection of the classification type (ISO 4406 or NAS 1638).
Use the [  ] buttons to select a classification.
The chosen classification is marked with a *on the left side of the menu.
By hitting [ ] the classification type is adopted and you will jump to the [ MEASURE ]
menu automatically.

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2.8.3.1.3. Start
Measurements are performed automatically and the results can be displayed as
contamination classes. (depending upon selected classification type)
During the measuring the particles per counting channel and the volume flow constantly
put out via the RS232 interface. (see chapter 3.2)
Serially, the CCM 01 comes with the data manager software. This software edits and
manages measurements stored by the CCM 01.
For this application a storage interval has to be selected. (see chapter 2.8.3.1.4)
Measurements will be stored continuously on the internal memory of the CCM 01
according to the selected storage interval. They can be transferred to an external
computer using the RS232 interface or the Bluetooth modul EBT 01 in order to be
edited and managed using the data manager software. (see chapter 3.3 )
Fixed limiting values are shown by a rectangle.
Exceeded limiting values are shown by a filled out rectangle in the display.
After disconnecting the power supply during the measurement it will
automatically continue the measurement after reconnecting.
Measurements will be performed until the operator hits [ ESC ] and switches back to the
[ MEASURE ] menu.
2.8.3.1.4. Storage Interval
Use the [  ] button to choose storage interval.
The intervals that can be chosen are between five minutes and seven days. Storing
the set interval will occur in a battery backed RAM. In case of a power outage, the
setting is saved.
100 measurements can be stored. After that, the oldest measurement is overwritten.
Chose the storage interval with the [  ] buttons and confirm by hitting the [ ] button –
automatic return to the [ MEASURE ]–menu.
Use [ ESC ] to go back to the previous menu –changes will not be adopted.

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2.8.3.2. Data Manager
This submenu serves for transferring and deleting of the saved measurements.
Choose submenu with the [  ] buttons.
The chosen item is marked with a *on the left side of the menu.
Enter the chosen menu item by hitting the [ ] button.
Use [ ESC ] to go back to the previous menu. (Display shows: )
2.8.3.2.1. Transfer Data
Data transfer of the stored measurements by using the RS232 interface or the external
printer. (optional available at Eaton Technologies GmbH)
It is necessary to use a special printer with RS232 interface. .
Choose submenu with the [  ] buttons.
The chosen item is marked with a *on the left side of the menu.
Confirm by using the [ ] button.
Start of the data transfer.
2.8.3.2.1.1. Data transfer by using the RS232 - interface
After selecting the menu point „RS232“ a cyclic output of all saved measurements
takes place via the RS232 - interface.
Every measurement is being transferred as a separate ASCII –streak.
Transferring will be performed until the operator ends it by hitting [ ESC ].

2.8.3.2.1.2. Data transfer by using the external printer
After selecting „Printer“ a singular report print out of all saved
measurements takes place.
Follow the instruction manual of the external
printer!
Use [ ESC ] to go back to the previous menu.
2.8.3.2.2. Delete Data
This option will delete all data from the measuring memory. It is irreversible. Therefore
the deletion has to be confirmed with [ YES ].
Use the [  ] buttons to select [ YES ] or [ NO ] and confirm by hitting [ ].
Use [ ESC ] to go back to the previous menu.
2.8.3.2.3. Stored Data
This is not a menu item that selects anything –only the number of stored data is
being displayed.
2.8.3.3. Options
Choose submenu with the [  ] buttons.
The chosen item is marked with a *on the left side of the menu.
Enter the chosen menu item by hitting the [ ] button.
Use [ ESC ] to go back to the previous menu.
Eaton Technologies GmbH
For more information:
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2.8.3.3.1. Limits
When achieving or exceeding the set limit values in the measuring cycle the corresponding
threshold contacts switch or rather close.
With the setting of zero values the functionality of the threshold contacts is switched off
no switching or rather closing of the threshold contacts.
Threshold settings can be changed for each classification type and each counting
channel.
These settings will also be stored in the back-up RAM.
Use the [  ] buttons to select the type of classification.
The selected type will be marked with a * on the left side of the menu.
Go to the selected classification type by hitting [ ].
Classification ISO 4406:99:
Use the [  ] buttons to choose the counting channel that has to be changed and
confirm by hitting [ ]. Use [  ] to set new contamination class threshold digit by digit
and confirm with [ ].
If new contamination class thresholds are set for all necessary counting channels use
[ ESC ] to go back to the previous menu.
Classification NAS 1638:
Use the [  ] buttons to choose the counting channel that has to be changed and
confirm by hitting [ ].
Use [  ] to set new contamination
class threshold digit by digit and
confirm with [ ].
If new contamination class thresholds are set for all necessary counting channels use
[ ESC ] to go back to the previous menu.

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2.8.3.3.2. Set Time
This function allows setting the real time clock that is integrated in the device.
Due to the back-up battery, the clock will keep running even if the power
supply is shut off.
Day, month, year, hour and minute can be adjusted individually and they are being
transmitted to the real time clock when the menu is being closed.
Select the parameter that has to be changed using the [  ] buttons.
The selected parameter is marked with a *on the left side of the menu.
By hitting the [ ] button, the position that has to be changed can be switched and
set a new parameter with the [  ] buttons.
Use [ ESC ] to go back to the previous menu.
2.8.3.3.3. Calibration
As for all the other menus, every calibration value can be selected and changed
individually. Normally modifications are not necessary!
Since calibration values are of fundamental importance for measurements and should
not be lost, they are saved as EEPROM. Calibration values will even be saved if the
back-up battery is dead. They do not have to be re-entered.
Use the [  ] buttons to select the counting channel that is supposed to be changed.
Confirm by hitting the [ ] button.
The selected parameter will be marked with a *on the left side of the menu.

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Select the digit that shall be changed by hitting the [ ] button and use the [  ]
buttons to set the new value.
Confirm by hitting the [ ] button.
Use [ ESC ] to go back to the previous menu.
The calibration values can be taken from the provided calibration certificate.
2.8.3.3.4. CAN
Choose submenu with the [  ] buttons.
The chosen item is marked with a *on the left side of the menu.
Enter the chosen menu item by hitting the [ ] button.
Use [ ESC ] to go back to the previous menu.
Detail informations and instructions see chapter 5 CAN interface
3. Data transfer
The data transfer from the CCM 01 to external computers is principle made by using the
RS232 - interface. The data can be transferred with an interface cable as well as
wirelessly with a Bluetooth modul.
During the measuring the counted particles per channel (≥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)) and the volume flow are
available. They will be displayed on the external computer with a terminal program such
as HyperTerminals from Microsoft. With the help of the CCM 01 data manager the
stored measurements can be read and exported into an Excel table.

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3.1. Connection to an external computer as an evaluation device
3.1.1. Connection via RS232 –interface
Connect the RS232 –connecting cable with the RS232 –interface on the frontplate
Connect the other side of the RS232 –connecting cable with the computer.
3.1.2. Connection of the RS232 –adaptor plug into the interface
Connect the adaptor with the connection SV 1 on
the CCM 01 (the marked side of the ribbon cable
should point to the case).
Connect the other side of the adaptor cable with the
SUB-D cable (9-pin, 1:1).
In order to prevent damages on the
CCM 01 or your computer, please make sure
that you connect the adaptor plug the right way.
3.1.3. Connection of the Bluetooth modul EBT 01
Bluetooth is an industrial standard according
IEEE 802.15.1 for the wireless networking of
devices over a short distance (outdoor up to
50 meter, depends on the adapter).
The principal purpose is to replace the data
cables between the devices.
Put the Bluetooth modul EBT 01 in the port
SV 1 of the CCM 01.
3.2. Continuous data transfer of the actual measurements
In this mode it is possible to transfer the actual measurement results from the CCM 01 to an
external computer via RS232 or the Bluetooth modul EBT 01. (see chapter 3.1) The
measurement results can be displayed on the computer using a communication program
(for example: HyperTerminal form Microsoft windows)
3.2.1. HyperTerminal
HyperTerminal is a communication program, beginning with version 2.0, that is provided
with the windows system software.
Establish a connection between the computer and the CCM 01 by using the
HyperTerminal on the software side and by using the adaptor plug or the Bluetooth
modul on the hardware side.

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The HyperTerminal isn´t include in Windows Vista. It can be downloaded from the sides
of Hilgraeve.
3.2.2. Setup of HyperTerminal
One-time setup of HyperTerminal under:
START / PROGRAMS / ACCESSORIES / COMMUNICATIONS / HYPER TERMINAL
Choose a symbol and enter a name (e.g. CCM 01). Confirm with OK.
Choose the COM - port