HYDAC FILTER SYSTEMS CMP1000 Series User manual

CMP 1000 series
ConditionMonitoring Package
Installation and Maintenance Instructions
English (translation of original instructions)
Documentation no.: 3528418d

Imprint
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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: [phone]
Telefax: [phone]
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
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Content
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................5
Technical Support........................................................................................5
Modifications to the Product ........................................................................5
Warranty ......................................................................................................5
Using the documentation .............................................................................6
General Safety Information ..........................................................................7
Hazard symbols...........................................................................................7
Signal words and their meaning in the safety information and
instructions ..................................................................................................8
Structure of the safety information and instructions.....................................9
Observe regulatory information ...................................................................9
Proper/Designated Use .............................................................................10
Improper Use or Use Deviating from Intended Use ...................................11
Qualifications of personnel / target group ..................................................12
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
CMP1xx0-2-1 … hydraulic schema............................................................20
CMP1xx0-4-1 … hydraulic schema............................................................21
CMP1xx0-2-1 … dimensions ......................................................................22
CMP1xx0-4-1 … dimensions ......................................................................23
Hydraulic connection of the CMP..............................................................24

Content
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Hydraulic connectors .................................................................................24
Notes on pipes and hoses .........................................................................25
Connecting the suction port connection - IN...........................................26
Connecting the return port connection - OUT.........................................27
Overload protection (only with CMP1xx0-4…)........................................27
Electrical connection of the CMP ..............................................................28
Electrical connection of the ContaminationSensor CS1000.......................29
Electrical connection of the AquaSensor AS1000 .....................................29
Starting up the CMP....................................................................................30
Required tools and measuring instruments ...............................................30
Adjusting the counter balance valve.........................................................31
Performing Maintenance ............................................................................34
Clean the suction strainer ..........................................................................35
Errors and troubleshooting........................................................................37
Spare parts list............................................................................................38
Disposing of the unit ..................................................................................38
Customer Service .......................................................................................38
Technical details .........................................................................................39
Model Code..................................................................................................41
Index ............................................................................................................42

Preface
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Preface
This operating manual was 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 this operating
manual. 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/type designation and article no. of the
product:
Fax: [phone] / 509 - 9046
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'll find this under www.hydac.com -> General terms and conditions.

Preface
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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 you 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
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

General Safety Information
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General 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.
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
Exposed electrical components
Danger of electrical shock
Danger due to operating pressure

General Safety Information
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Risk of burns due to hot surfaces
Signal words and their meaning in the safety information and
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.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.

General Safety Information
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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

General Safety Information
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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.
observing all instructions contained in the operating manual.
performing 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 filter 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

General Safety Information
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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:
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.

General Safety Information
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Qualifications of personnel / target group
Persons who work on the power unit must be aware of the associated
hazards when using the power unit.
Auxiliary 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 are intended for:
Auxiliary 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 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

General Safety Information
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Knowledge with regard to
recycling

General Safety Information
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Wear suitable clothing
Loosely worn clothing increases the danger of getting caught or wound up in
rotating parts and the danger of getting snagged on projecting 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.

Unpacking the unit
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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.
Make sure to store the CSM in a clean, dry place.

Decoding the model code label
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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) -> Power unit type label
(2) -> Name plate of electric motor
(3) -> Model code; for details, see page Fehler!
Textmarke nicht definiert.
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 -> Empty weight
Sensor voltage -> Required sensor operation voltage

Checking the Scope of Delivery
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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:
Qty Designation
1 ConditionMonitoring Package, CMP 1000 Series
1
Technical Documentation, const. of:
- Operating and maintenance Instructions CMP 1000
- Operating and maintenance Instructions CS 1000 Series
- Operating and Maintenance Instructions AS 1000
- Calibration certification of the CS1000

CMP Features
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CMP Features
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.

CMP Components
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CMP Components
Item Designation
1 Electric motor
2 Gear pump
3 Pressure relief valve
4 Counter balance valve
5 ConditionSensor CS1000 series
6 Suction strainer, 400 µm
7 Suction port (IN)
8 Return port connection (OUT)
9 AquaSensor AS1000
11 Pressure gauge

CMP1xx0-2-1 … hydraulic schema
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CMP1xx0-2-1 … hydraulic schema
Item Designation
1 Electric motor
2 Gear pump
3 Pressure relief valve
4 Counter balance valve
5 ConditionSensor CS1000 series
6 Suction strainer, 400 µm
7 Suction port (IN)
8 Return port connection (OUT)
9 AquaSensor 1000
11 Pressure gauge