HYDAC FILTER SYSTEMS CMP 43 0-5 Series User manual

CMP 43x0-5-…
ConditionMonitoring Package
Installation and Maintenance Instructions
English (translation of original instructions)
Keep for future reference.
Documentation no.: 4191543b

Imprint
Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriestraße
66273 Sulzbach / Saar
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
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
Phone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© 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.
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Content
Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Modifications to the Product ........................................................................5
Warranty......................................................................................................5
Using the documentation.............................................................................6
Safety information ........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................7
Structure of the safety information and instructions ....................................8
Warning signs used.....................................................................................8
Signs used for giving orders ........................................................................9
Others used symbols...................................................................................9
Signs used for the required specialist personnel.......................................10
Specialist personnel – Mechanical .........................................................10
Specialist personnel – Electricity............................................................10
Observe regulatory information .................................................................10
Proper/designated Use..............................................................................11
Improper use or use deviating from intended use .....................................12
Qualifications of personnel / target group..................................................13
Wear suitable clothing ...............................................................................14
Dangers by pressure in the hydraulic system............................................14
Unpacking the unit......................................................................................15
Storing the unit ...........................................................................................15
Decoding the model code label .................................................................16
Checking the scope of delivery .................................................................17
CMP features...............................................................................................18
CMP components........................................................................................19
Hydraulic diagram.......................................................................................20
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Content
Dimensions .................................................................................................21
Hydraulic connection of the CMP..............................................................22
Hydraulic connections ...............................................................................22
Notes on pipes and hoses.........................................................................23
Connecting the suction port connection - IN ..........................................24
Connecting the return port connection - OUT ........................................25
Electrical connection of the CMP ..............................................................26
Electrical connection of the MetallicContamination Sensor
MCS1000...................................................................................................27
Electrical connection of the AquaSensor AS1000 .....................................27
Electrical connection of the HYDACLab HLB1400 ....................................27
Connection of the sensor connection box (option) ....................................27
Starting up the CMP....................................................................................28
Performing maintenance............................................................................29
Clean the suction strainer..........................................................................30
Errors and troubleshooting .......................................................................32
Spare parts list............................................................................................33
Accessories list...........................................................................................33
Disposing of the CMP.................................................................................33
Technical data.............................................................................................34
Appendix......................................................................................................36
Customer Service / Service Address ........................................................36
Model code................................................................................................37
Index..........................................................................................................38
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Preface
Preface
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. Therefore please understand that, in the
absence of any provisions to the contrary hereinafter, our warranty and
liability – for any legal reasons whatsoever – are excluded in respect of the
information in these operating instructions. In particular, we shall not be
liable for lost profit or other financial loss. This exclusion of liability does not
apply in cases of intent and gross negligence. Moreover, it does not apply to
defects which have been deceitfully concealed or whose absence has been
guaranteed, nor in cases of culpable harm to life, physical injury and damage
to health. If we negligently breach any material contractual obligation, our
liability shall be limited to foreseeable damage. Claims due to Product
Liability shall remain unaffected.
Technical Support
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 code, serial no. and part no. of the product:
Fax:
[phone]
E-mail:
filtersy[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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> Legal information.
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Preface
Using the documentation
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all 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
BeWa123456ade
Se ite x
Produkt/Kapitel
200x-xx- xx
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.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name
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Safety information
Safety information
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.
Signal words and their meaning in the safety information and
instructions
In these instructions you will find the following signal words:
DANGER
DANGER – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING – The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION – The signal word indicates a hazardous situation with a low level
of risk,
which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.
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Safety information
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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
Warning signs used
These signs are listed for all general safety information in these operating
instructions which indicate particular hazards to persons, property or the
environment.
Hazard, general
Danger due to electrical voltage / current
Risk of burns due to hot surfaces
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Safety information
Signs used for giving orders
These symbols are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.
Disconnect before working.
Follow the operating manual.
Others used symbols
The following symbols found you in this operation instructions.
Tip for handling the product
Tools required
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Safety information
Signs used for the required specialist personnel
These symbols show the required training/knowledge for installation work
and/or maintenance work.
Specialist personnel – Mechanical
Only specialist personnel with training as mechanics and
the following knowledge:
•Safe handling/use of tools
•Fitting and connection of hydraulic lines and
connections
•Product-specific knowledge
•Knowledge about how to handle operating media.
Specialist personnel – Electricity
Only specialist personnel with training as electricians and
the following knowledge:
•Safe handling/use of tools
•Fitting and connection of electrical lines, electrical
machinery, sockets, etc.
•Checking the phase sequence
•Product-specific knowledge
•Knowledge about how to handle operating media.
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
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Safety information
Proper/designated Use
Use the unit only for the application described in the following.
The ConditionMonitoring Package CMP is for the continuous monitoring of
solid particle contamination in hydraulic systems.
Proper or designated use of the product extends to the following:
•The unit is only to be used with permissible media.
•Follow all the notes in these operating instructions.
•Comply with inspection and maintenance work.
NOTICE
Impermissible operating media
The unit will be destroyed
►The unit is only to be used with mineral oils or mineral oil-based
raffinates.
►Do not pump any caustic or explosive media.
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
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Safety information
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 this 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 owner alone, shall
assume any and all associated risk.
Improper use or use deviating from intended may result in hazards and/or
will damage the unit. Examples of improper use:
•Operation in potentially explosive atmospheres.
•Operation with a non-approved medium.
•Operation under non-approved operational conditions.
•Operation when the safety devices are defective.
•Modifications to the power unit made by the user or purchaser.
•Inadequate monitoring of parts that are subject to wear and tear.
•Improperly performed repair work.
•Improper connection of the pressure and return flow hoses and oil
leakage pipe.
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Safety information
Qualifications of personnel / target group
Staff who work with the powerpack must be aware of the dangers involved,
must be over the age of 14 and must be without any physical impediments in
regard to the industrial environment.
These operating instructions are intended for:
Auxiliary personnel:
such persons have been instructed about the product and informed about
potential hazards that can result from improper use.
Operating personnel:
such persons have been instructed in power unit 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 tubes 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
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Safety information
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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.
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.
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Unpacking the unit
Unpacking the unit
The CMP is inspected for leaks and proper functioning at the factory, then
carefully packed for shipment. 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.
Storing the unit
Rinse and drain the unit completely before putting it into extended storage.
Store the unit in a clean, dry place.
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Decoding the model code label
Decoding the model code label
Details for identifying the power unit can be found on the type labels on the
unit and the components.
Item
->
Description
(1)
->
Name plate for power unit
(2)
->
Name plate of electric motor
(3)
->
Model code; for details, see page 37
Motor voltage
->
Required electric motor operation voltage
Motor grid
->
Number of electric motor phases
Frequency
->
Mains frequency
Max. Flow rate
->
Maximum flow rate
Max. INLET press
->
Maximum pressure at the inlet
Weight
->
Weight when empty
Sensor voltage
->
Required sensor operation voltage
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Checking the scope of delivery
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 supplied:
Qty
Designation
1 ConditionMonitoring Package, CMP 4000 Series
1
Technical documentation comprising:
- Operating and Maintenance Instructions CMP 43x0-5-…
(this document)
- Operation and maintenance Instructions MCS 1000 series
- Operating instructions HYDACLab (optional)
- Operating instructions AS1000 (optional)
- Installation drawing (optional)
- Certificate of calibration for the MCS 1000
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CMP features
CMP features
The HYDAC ConditionMonitoring Package CMP is used to continuously
monitor fluid power systems for solid and/or liquid contaminants.
The CMP is equipped with a gear pump which supplies the oil to be analyzed
to the MetallicContamination Sensor MCS in which the metallic solid particles
(e.g. resulting from component wear) are measured using an inductive
measuring procedure, classified in terms of size and material properties
(ferromagnetic/non-ferromagnetic) and also counted.
Furthermore, the HYDACLab Oil Condition Sensor or the AquaSensor AS is
also available as an option for the CMP. The two sensors make it possible to
determine the relative water content in the oil (specified in percentage
saturation), where the HydacLab detects liquid contaminants with external
fluids (mixtures) using additional measured variables of conductivity and
dielectric constant and also permits conclusions to be drawn on the aging
condition of lubricating and hydraulic oils.
The CMP is therefore used for continuous status monitoring of the system
and indicates imminent damage. This makes it an essential component for
implementing a modern maintenance approach.
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CMP components
CMP components
Item Designation
1 Electric motor
2 Gear pump
3 Pressure relief valve
4
MetallicContamination Sensor, MCS1000 series
5 Suction screen, 600 µm
6 Suction port (IN)
7 Return port connection (OUT)
8 AquaSensor / HYDACLab (option)
9 Sensor connection box (option)
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Hydraulic diagram
Hydraulic diagram
M
MCS
4
1
2
3
5
67
AS /
HLB
8
Item Designation
1
Electric motor
2 Gear pump
3 Pressure relief valve
4 MetallicContamination Sensor, MCS1000 series
5 Suction screen, 600 µm
6 Suction port (IN)
7 Return port connection (OUT)
8 AquaSensor / HYDACLab (option)
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