HYDAC FILTER SYSTEMS CMP 1321 Manual

CMP 1321
ConditionMonitoring Package
Operating and Maintenance Instructions
English (translation of original instructions)
Document No.: 3765034

CMP Imprint
HYDAC FILTER SYSTEMS GMBH en(us) Page 2 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
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.
The trademarks of other companies are exclusively used for the products of those
companies.

CMP Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 3 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Content
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Customer Service ...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the documentation ........................................................................................7
Safety information .................................................................................................... 8
Obligations and liability ...........................................................................................8
Explanation of Symbols and Warnings, etc. ...........................................................9
Proper/Designated Use .......................................................................................... 9
Improper Use ..........................................................................................................9
Safety Devices......................................................................................................10
Informal Safety Precautions..................................................................................10
Training and Instruction of Personnel ...................................................................11
Safety Measures to Be Followed during Normal Operation.................................. 12
Electrical Hazards.................................................................................................12
Dangers by pressure in the hydraulic system....................................................... 12
CMP modification..................................................................................................12
Packing, storage.....................................................................................................13
Unpacking.............................................................................................................13
Storing the CMP ...................................................................................................13
Checking the scope of delivery.............................................................................14
CMP Features ......................................................................................................... 15
Restrictions pertaining to use ............................................................................... 15
CMP Components................................................................................................... 16
CMP hydraulic diagram..........................................................................................17
CMP dimensions ....................................................................................................18
Hydraulic connection of the CMP ......................................................................... 19
Hydraulic connectors ............................................................................................19
Notes on pipes and hoses ....................................................................................20
Suction port connection - IN..............................................................................21
Return port connection - OUT ...........................................................................22
Electrical connection of the CMP..........................................................................23
Electrical connection of the ContaminationSensor CS1000 .................................24

CMP Content
HYDAC FILTER SYSTEMS GMBH en(us) Page 4 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Starting up the CMP ............................................................................................... 24
Adjusting the counter balance valve.................................................................... 25
Required tools and measuring instruments ..........................................................25
Performing maintenance .......................................................................................29
Clean the suction strainer .....................................................................................30
Disposing of the CMP ............................................................................................ 31
Errors and troubleshooting...................................................................................32
Customer Service................................................................................................... 32
Spare parts list .......................................................................................................33
Technical data ........................................................................................................ 34

CMP 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 obtaining maximum benefit in
the applications for which it is designed.
You should keep it in the vicinity of the product so it is always at your fingertips.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.Consequently, there might be deviations
in technical details, illustrations and dimensions.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”
HYDAC FILTER SYSTEMS GMBH en(us) Page 5 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Preface
HYDAC FILTER SYSTEMS GMBH en(us) Page 6 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Customer Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please don't hesitate to contact us. When contacting us, please always
include the model/type designation and article no. of the product:
Fax: [phone] / 509 - 846
E-Mail: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.)
may result in the information in the operating instructions no longer being completely
accurate or sufficient.
When making modifications or performing repair work to components affecting the
safety of the product, the product may not be put back into operation until it has
been examined and released by a HYDAC representative.
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.

CMP 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 document has a table of contents at the beginning. I select the chapter I'm
looking for and the corresponding page number.
de
HYDACFiltertechnikGmbH
Be
Wa12
3456a
d
e
Se ite x
Produkt/Kapitel
200x-xx-xx
Chapter
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.
HYDAC FILTER SYSTEMS GMBH en(us) Page 7 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Safety information
HYDAC FILTER SYSTEMS GMBH en(us) Page 8 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Safety information
These operating instructions contain the most important information for operating
the CMP in a proper, safe manner.
Obligations and liability
The basic prerequisite for the safe and proper handling and operation of the CMP is
knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered by all those who work with the CMP.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed here are restricted to use of the CMP.
The CMP has been designed and constructed in accordance with the current state
of the art and recognized safety regulations. Nevertheless, hazards may be posed
to the life and limb of the individual using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
Use the CSM:
solely for its designated use
only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply. They are made available to the owner
upon concluding purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
improper use of the CMP or use deviating from its intended use
improper assembly, installation, commissioning, operation and maintenance of
the CMP
operating the CMP when the system equipment or systems are defective
modifications to the CMP made by the user or purchaser
improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

CMP Safety information
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate
hazards, etc.:
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The CMP was developed for the continuous monitoring of solid particle
contamination in hydraulic systems.
Any other uses shall be deemed to be improper and not in keeping with the
product's designated use.
The manufacturer will not assume any liability for any damage resulting from such
use.
Proper or designated use of the product extends to the following:
Maintaining adherence to all the instructions contained herein.
Performing requisite inspection and maintenance work.
Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
Example of improper use:
Improper connection of the pressure and return flow hoses.
HYDAC FILTER SYSTEMS GMBH en(us) Page 9 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Safety information
HYDAC FILTER SYSTEMS GMBH en(us) Page 10 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Safety Devices
Prior to starting up the product, make sure that all the safety devices are properly
fitted to the hydraulic system and are in proper working order.
Informal Safety Precautions
Always keep the operating instructions in the vicinity of the product.
In addition to the operating instructions, the general and local regulations on
accident prevention and environmental protection are to be made available and
observed.
All safety guidelines and hazard warnings on the machine must be maintained in
legible condition and replaced as required.
The hoses and connection fittings are to be checked daily for leakage (visual
check). The electrical equipment of the CMP must also be checked regularly (visual
check once a month). Any loose connections or damaged cables are to be replaced
immediately.

CMP Safety information
HYDAC FILTER SYSTEMS GMBH en(us) Page 11 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Training and Instruction of Personnel
The CMP may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the CMP unless supervised by an
experienced staff member.
Individuals Individuals undergoing training Individuals with technical training/ engineering background Electricians Supervisor with the appropriate authority
Activity
Packing / transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Troubleshooting, mechanical
problem X X
Remedying of electrical faults X X
Maintenance X X X X
Servicing X
Decommissioning / Storage X X X X

CMP Safety information
Safety Measures to Be Followed during Normal Operation
Do not operate the CMP unless all the safety devices function properly.
The unit is to be checked once a day for visible external damage and for the proper
functioning of the safety devices.
Electrical Hazards
DANGER
Electric shock
Danger of fatal injury
►Any work involving the electrical equipment may
only be done by a properly trained, certified
electrician.
Dangers by pressure in the hydraulic system
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
CMP modification
Do not make any modifications (design modifications, extensions) to the CMP
without the prior consent of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Use only original spare parts (OEM). When using non-OEM components it cannot
be ensured that they have been designed and manufactured so as to comply with
loading and safety requirements.
HYDAC FILTER SYSTEMS GMBH en(us) Page 12 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Packing, storage
HYDAC FILTER SYSTEMS GMBH en(us) Page 13 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Packing, storage
Unpacking
The CMP is inspected for leaks and proper functioning at the factory, then carefully
packed for shipment. The connectors/ports 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 packing material as specified by law or national regulations or
recycle it.
Storing the CMP
Make sure to store the CSM in a clean, dry place.
The unit is to be drained completely before being put into extended storage.
The maximum storage duration is 6 months. After that, the CMP must be put into
operation.

CMP Checking the scope of delivery
HYDAC FILTER SYSTEMS GMBH en(us) Page 14 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Checking the scope of delivery
Upon receiving the CMP check it for any damage in transit. Do not put the CMP 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 included in the scope of delivery:
Item Qty. Designation
1 1 CMP
- 1
Technical Documentation, const. of:
- Operating and Maintenance Instructions CMP
- Operating and Maintenance Instructions CS 1000 series
- Calibration certificate of the CS 1000

CMP CMP Features
HYDAC FILTER SYSTEMS GMBH en(us) Page 15 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
CMP Features
The gear pump sucks the fluid to be analyzed and conveys it to the
ContaminationSensor, 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 fluid 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 fluid 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 the fluid, consequently
a path is provided for between the pump and the sensor.
Restrictions pertaining to use
NOTICE
Impermissible operating media
The unit will be destroyed
►The unit may only be used in combination with phosphate esters (HFD-R)
e.g. Skydrol, Hyjet.
NOTICE
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

CMP CMP Components
CMP Components
Item Designation
1 Electric motor
2 Gear pump with integrated pressure relief valve
3 Counter balance valve
4 ContaminationSensor CS1000 series
5 Suction screen, 400 µm
6 Suction port connection (IN)
7 Return port connection (OUT)
HYDAC FILTER SYSTEMS GMBH en(us) Page 16 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP CMP hydraulic diagram
CMP hydraulic diagram
M
IN OUT
400µm
CS
12
3
4
5
67
Item Designation
1 Electric motor
2 Gear pump with integrated pressure relief valve
3 Counter balance valve
4 ContaminationSensor CS1000 series
5 Suction screen, 400 µm
6 Suction port connection (IN)
7 Return port connection (OUT)
HYDAC FILTER SYSTEMS GMBH en(us) Page 17 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP CMP dimensions
CMP dimensions
HYDAC FILTER SYSTEMS GMBH en(us) Page 18 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Hydraulic connection of the CMP
Hydraulic connection of the CMP
Hydraulic connectors
IN = Suction port connection
OUT = Return port connection
HYDAC FILTER SYSTEMS GMBH en(us) Page 19 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25

CMP Hydraulic connection of the CMP
HYDAC FILTER SYSTEMS GMBH en(us) Page 20 / 36
BeWa CMP1321 3765034 en 2012-09-25.doc 2012-09-25
Notes on pipes and hoses
In order to keep the pressure loss as low as possible, use as few threaded
connections as possible.
The pressure loss in a hydraulic line depends upon:
Flow rate
Kinematic viscosity
Pipe dimensions
Fluid density
The pressure loss can be estimated for hydraulic oils as follows:
Δp ~ 6.8 * L / d4* Q * V * D
Δp = Pressure differential in [bar]
L= pipe length [m]
d= internal pipe diameter [mm]
Q= Flow rate [l/min]
V = Kinematic viscosity [mm²/s]
D = Density [kg/dm³] Mineral oil-based hydraulic fluid has a density
of ~ 0.9 kg/cm³.
This applies to straight pipe runs and hydraulic oils. Additional threaded connections
and pipe bends increase the pressure differential.
Keep the height difference between the unit and the oil level in the tank as low as
possible.
Hoses must be suitable for suction pressures of at least -0.5 bar.
Constrictions in the connections and lines should be avoided. This could
compromise suction output and cause cavitation .
Note that the nominal size of the connected hoses/piping must be at least as large
as the cross-section of the INLET connection.
Make sure that no tension or vibrations are carried over to the pump or filter housing
when the pipes are connected. Use hoses or expansion joints if necessary.