HYDAC FILTER SYSTEMS CSM 1000 Series User manual

CSM 1000 Series
ContaminationSensor Module
Installation and Maintenance Instructions
English (translation of original instructions)
Valid from series no. 0002S02042E0000277
Document no.: 3512624c

Imprint
CSM 1000 Series en 2 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Telefax: [phone]
E-mail: [email protected]
Homepage: www.hydac.com
Court of Registration: Saarbrücken, HRB 17216
Executive director: Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Telefax: ++49 (0)6897 509 1394
E-mail: [email protected]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
All details are subject to technical modifications. Technical specifications are subject
to change without notice.

Content
CSM 1000 Series en 3 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................6
Modifications to the Product ........................................................................6
Warranty ......................................................................................................6
Using the Documentation ............................................................................7
Safety Information and Instructions............................................................8
Hazard symbols...........................................................................................8
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions...................................10
Observe regulatory information .................................................................10
Proper/Designated Use .............................................................................11
Improper use or use deviating from intended use......................................11
Qualifications of personnel / target group ..................................................13
Wear suitable clothing ...............................................................................14
Unpacking the CSM ....................................................................................14
Transporting the CSM ................................................................................15
Storing the CSM ..........................................................................................16
Checking the Scope of Delivery ................................................................17
CSM Characteristics ...................................................................................18
CSM components........................................................................................19
Hydraulic Schematic...................................................................................20
Dimensions..................................................................................................21
Drilling template for wall mounting.............................................................22
Hydraulic Connection of the CSM .............................................................22
Hydraulic Connectors ................................................................................22
Notes on piping / hosing ............................................................................23
Suction port connection - IN ...................................................................24

Content
CSM 1000 Series en 4 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Return port connection - OUT ................................................................25
Leakage oil connection - LEAKAGE (only with CSM1xxx-2 ...) ..............25
Magnetic coupling (only CSM 1xxx-4…).................................................26
Electrical Connection of the CSM..............................................................27
Electrical connection of the ContaminationSensor CS1000.......................28
Electrical connection of the AquaSensor AS1000 .....................................28
Starting up the CSM....................................................................................29
Adjusting the counter balance valve.........................................................29
Required tools and measuring instruments ...............................................29
Performing Maintenance ............................................................................34
Clean the suction screen ...........................................................................35
Disposing of the CSM.................................................................................37
Errors and Troubleshooting.......................................................................37
Spare parts ..................................................................................................38
Accessories.................................................................................................41
Plugs ......................................................................................................41
Connection cable, shielded ....................................................................41
Connection cable....................................................................................41
Connection cable....................................................................................42
Customer service........................................................................................42
Technical data.............................................................................................43
Model Code..................................................................................................45

Preface
Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep this documentation in the vicinity of the product for immediate reference.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional comments
or suggestions, contact us at:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
CSM 1000 Series en 5 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Preface
CSM 1000 Series en 6 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Technical Support
Contact our technical sales department if you have any questions on our product.
When contacting us, please always include the model/type designation, serial no.
and part-no. of the product:
Fax: [phone] - 846
E-mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects the safety of the product has been
carried out on components, the product may not be returned to operation until it has
been checked and released by a HYDAC technician.
Please notify us immediately of any modifications made to the product whether by
you or a third party.
Warranty
For the warranty provided by us, please refer to the General Terms of Sale and
Delivery of HYDAC Filter Systems GmbH.
You will find these under www.hydac.com -> General terms and conditions.

Preface
Using the Documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior to starting the unit up for the first time and at regular
intervals in the future.
What do I want to know?
I determine which topic I am looking for.
Where can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select the
chapter I'm looking for and the corresponding page number.
CSM 1000 Series en 7 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Chapter description
Page number
Edition date
Document language
Documentation no.
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.

Safety Information and Instructions
Safety Information and Instructions
The unit was built according to the statutory provisions valid at the time of delivery
and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and are
described in the operating instructions.
Observe all safety and warning instructions attached to the unit. They must always
be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property or the
environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Danger due to operating pressure
Risk of burns due to hot surfaces
Signal words and their meaning in the safety information and
CSM 1000 Series en 8 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Safety Information and Instructions
instructions
DANGER
DANGER indicates a danger with a high risk and which will lead to death or serious
injury if not avoided.
WARNING
WARNING indicates a danger with a medium risk and which can lead to death or
serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor injury if
not avoided.
NOTE
NOTE indicates a danger which will lead to damage to property if not avoided.
CSM 1000 Series en 9 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Safety Information and Instructions
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and signal
words. The pictogram and the signal word indicate the severity of the danger.
Warning instructions listed before an activity are laid out as follows:
SIGNAL WORD
Type and source of danger
Consequence of the danger
HAZARD SYMBOL
►Measures to avert danger
Observe regulatory information
Observe the following regulatory information and guidelines:
Legal and local regulations for accident prevention
Legal and local regulations for environmental protection
Country-specific regulations, organization-specific regulations
CSM 1000 Series en 10 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Safety Information and Instructions
Proper/Designated Use
Use the unit only for the application described in the following.
The ContaminationSensor module CSM was developed for the continuous
monitoring of particulate contamination in hydraulic systems.
Proper or designated use of the product extends to the following:
observing all instructions contained in the instruction manual.
performing inspection and maintenance work.
Improper use or use deviating from intended use
DANGER
Danger due to unanticipated use of the unit
Bodily injury and damage to property will result when
operated improperly.
►Never operate the unit in potentially explosive
atmospheres.
►The unit is only to be used with permissible
media.
Any use extending beyond or deviating therefrom shall not be considered intended
use. HYDAC Filter Systems GmbH will assume no liability for any damage resulting
from such use. The user alone, shall assume any and all associated risk
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
oOperation in potentially explosive atmospheres.
oOperation with a non-approved medium.
oOperation under non-approved conditions.
oOperation when the system equipment or safety devices are defective.
oModifications to the unit made by the user or purchaser.
oImproper monitoring of unit components that are subject to wear and tear.
oImproperly performed repair work
CSM 1000 Series en 11 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Safety Information and Instructions
CSM 1000 Series en 12 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
NOTE
Impermissible operating media
The unit will be destroyed
►The unit is only to be used with mineral oils or mineral oil-based raffinates.
NOTE
Highly contaminated fluid
The pump will become worn out / damaged.
►For long-term operation, pump only fluid with a maximum contamination of
ISO 22/20/18

Safety Information and Instructions
CSM 1000 Series en 13 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Qualifications of personnel / target group
Persons who work on the machine must be aware of the associated hazards when
using the unit.
Operating and specialist personnel must have read and understood the operating
instructions, in particular the safety information and instructions, and applicable
regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions is intended for:
Operating personnel: such persons have been instructed in machine operation and
are aware of potential hazards due to 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 hazards.
Activity Person Knowledge
Transport / storage Forwarding
agent
Specialist
personnel
Proof of knowledge of cargo
securing instructions
Safe handling/operation of
hoisting and lifting equipment
Hydraulic / electrical
installation,
first commissioning,
maintenance,
troubleshooting,
repair,
decommissioning,
disassembly
Specialist
personnel
Safe handling/use of tools
Fitting and connection of
hydraulic lines and connections
Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
Checking the phase sequence
Product-specific knowledge
Operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to handle
operating media.
Knowledge about contamination
due to solids and water
Disposal Specialist
personnel
Proper and environmentally-
friendly disposal of materials and
substances
Decontamination of
contaminants
Knowledge about reuse

Unpacking the CSM
CSM 1000 Series en 14 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
Wear suitable clothing
Loose-fitting clothing increases the risk of being caught or being drawn in on rotating
parts, and the risk of getting caught on protruding parts. You can be severely injured
or killed.
Wear close-fitting clothing.
Do not wear any rings, chains or any other jewelry.
Wear work safety shoes.
Unpacking the CSM
The CSM is function- and leak-tested in the factory and properly packed. The
connectors are closed off so that no contamination can enter the unit while it is in
transit.
When receiving and unpacking the unit, check it for damage in transit.
Dispose of the packaging material in an environmentally-friendly manner.

Transporting the CSM
Transporting the CSM
Transport the CSM as described below:
Carry the unit by hand using the
handle.
Transport the unit in a horizontal
position on a pallet.
Support the upper part with a spacer
(1). Height ~ 30 mm.
When lashing the equipment, ensure
that no protruding components are
lashed down.
CSM 1000 Series en 15 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Storing the CSM
Storing the CSM
Rinse and drain the unit completely before putting it into extended storage.
Make sure to store the CSM in a clean, dry place.
Store the unit standing up, or lying
flat on a pallet.
Support the upper part with a spacer
(1). Height ~ 30 mm.
CSM 1000 Series en 16 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Checking the Scope of Delivery
Checking the Scope of Delivery
Upon receiving the CSM check it for any damage in transit. Do not put the CSM into
operation unless it is in perfect condition. Report any damages in transit to the
transport company or the responsible agent immediately. Do not put the unit into
operation.
The following items are supplied:
Item Qty. Designation
11Contamination Sensor Modulee, CSM 1000 Series
21Pressure gauge with adapter
-1
Technical Documentation, const. of:
- Operating and Maintenance Instructions CSM 1000
- Operating and Maintenance Instructions CS 1000 Series
- Operating and Maintenance Instructions FluMoS light
- Operating and Maintenance Instructions AS 1000 (optional)
- Calibration certificate of the CS 1000
CSM 1000 Series en 17 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

CSM Characteristics
CSM 1000 Series en 18 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23
CSM Characteristics
The gear pump sucks the oil to be analyzed and conveys it to the Contamination
Sensor, in which the particulate contamination is captured by an optical sensor and
analyzed according to particle size classifications and counted.
Any air bubbles contained in the oil may skew the measurement results as they, like
particulate contamination, cause the measurement cell to generate signals.
The purpose of the CSM is to suppress air bubbles so that the measurement results
are not skewed or only minimally impacted.
Because oil absorbs an increasing quantity of air as the pressure increases (rule of
thumb: ~ 8% air per bar), the ContaminationSensor aims to achieve the greatest
possible pressure. This is done using a downstream pressure relief valve.
However, pressurized air cannot be immediately dissolved in oil, consequently a
path is provided for between the pump and the sensor.
With highly viscous oil and extremely high amounts of air, an air bubble can get
stuck directly behind the pump so that it does not rise and flow out through the
conduit. The pump is unable to pump against this pressurized air. Through the
slightly opened throttle valve located in the conduit between the pump and the
ContaminationSensor, the pressure can reduce and the pump starts to pump oil
again.
In normal operation, only a small portion of the flow is lost at this throttle valve as
the hydraulic resistance of the oil is extremely high. However, air bubbles can easily
escape at this position.

CSM components
CSM components
Item Designation
1Electric motor
2Gear pump (with or without leakage oil connection depending on order)
3Test point 1
4Pressure relief valve
5Test point 2
6Counter balance valve
7Choker valve (optional)
8ContaminationSensor CS1000 series
9Suction screen, 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor 1000 (optional)
13 Leakage oil connection (LEAKAGE) (only with CSM1xxx-2 ...)
CSM 1000 Series en 19 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23

Hydraulic Schematic
Hydraulic Schematic
8
12
5 6 7
3
4
1
11
10
9
2
LEAKAGE
13
Item Designation
1Electric motor
2Gear pump (with or without leakage oil connection depending on order)
3Test point 1
4Pressure relief valve
5Test point 2
6Counter balance valve
7Choker valve (optional)
8ContaminationSensor CS1000 series
9Suction screen, 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor 1000 (optional)
13 Leakage oil connection (LEAKAGE) (only with CSM1xxx-2 ...)
CSM 1000 Series en 20 / 48
MoWa CSM1000 3512624c en-us 2012-11-26.doc 2012-11-23