HYDAC International CSM 1000 Series User manual

CSM 1000 Series
ContaminationSensor Module
Operating and maintenance instructions
English (translation of original instructions)
Document no.: 3265074d / 2008-02-07

CSM 1000 Series
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Trademarks
The trademarks of other companies designate the products of those companies exclusively.
Copyright © 2008 by
HYDAC Filtertechnik GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the explicit
written agreement from HYDAC Filtertechnik. Violations shall be liable for damages.
Exclusion of liability
We made every endeavor to ensure the accuracy of the contents of this document. However,
errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist
nor for any damage or loss whatsoever which may arise as a result of such errors. The
information in this manual is checked regularly and the required corrections shall be
contained in subsequent editions. We welcome any suggestions for improvement.
We reserve the right to make technical changes.
All content is subject to revision without notice.
HYDAC Filtertechnik GmbH
Service Technology Division / Filter Systems
P.O. Box 12 51
66273 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 509 – 846

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Contents
Preface ....................................................................................................................................5
Customer Service ................................................................................................................6
Product modification ............................................................................................................6
Warranty .............................................................................................................................. 6
Using the documentation.....................................................................................................7
1. General safety guidelines .......................................................................................... 8
1.1. Obligations and liability.................................................................................................8
1.2. Explanation of symbols and warnings ..........................................................................9
1.3. Intended use ................................................................................................................. 9
1.4. Improper use................................................................................................................. 9
1.5. Safety devices ............................................................................................................10
1.6. Informal safety precautions......................................................................................... 10
1.7. Training and instruction of personnel.......................................................................... 10
1.8. Safety precautions for normal operation.....................................................................11
1.9. Electrical hazards .......................................................................................................11
1.10. CSM modification .....................................................................................................11
2. Packing, storage ....................................................................................................... 12
2.1. Unpacking CSM..........................................................................................................12
2.2. Storing the CSM .........................................................................................................12
3. Checking the scope of delivery............................................................................... 13
4. Technical description...............................................................................................14
4.1. Application restrictions................................................................................................14
4.2. CSM components .......................................................................................................15
4.3. Hydraulic diagram.......................................................................................................16
4.4. Dimensions CTU 1xxx-1 ... .........................................................................................17
4.5. Dimensions CTU 1xxx-2... ..........................................................................................17
4.6. Drilling template .......................................................................................................... 18
5. Connecting the CSM hydraulically and electrically...............................................18
5.1. Hydraulic connection ..................................................................................................18
5.2. Notes on piping / hosing .............................................................................................19
5.2.1. Suction port - IN .............................................................................................. 20
5.2.2. Return port connection - OUT ......................................................................... 20
5.2.3. Leakage connection - LEAKAGE (only with CSM 1xxx-2....) .......................... 20
5.3. Electrical connection................................................................................................... 21
5.4. Electrical connection of the ContaminationSensor CS1000 ....................................... 22
5.5. Electrical connection of the AquaSensor AS1000 ...................................................... 22

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6. Starting up the CSM .................................................................................................23
6.1. Required tools and measuring instruments ................................................................ 23
6.2. Setting the CSM.......................................................................................................... 24
7. Carrying out maintenance .......................................................................................27
7.1. Cleaning the suction strainer ...................................................................................... 28
7.2. Disposing of the CSM ................................................................................................. 28
8. Errors and troubleshooting .....................................................................................29
9. Spare parts list..........................................................................................................29
9.1. Spare arts diagrams ...................................................................................................30
10. Technical data...........................................................................................................31
11. Model code ................................................................................................................ 33

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Preface
We have compiled the most important instructions for the operation and
maintenance of our product for you, its user, in this documentation.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
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 suggestions or other
useful information, contact us at:
HYDAC Filtertechnik GmbH
SVFI, Technical Documentation Department
Postfach 12 51
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
E-mail: [email protected]
The editorial board would welcome your contributions.
“Putting experience into practice”

CSM 1000 Series
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Customer Service
Contact our technical sales department if you have any questions on our product.
When contacting us, always include the model/type designation, serial no. and part-
no. of the product:
Fax: ++49 (0) 6897 509 846
E-mail: [email protected]
Product modification
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.
Report any modifications carried out on the product by you or a third party
immediately.
Warranty
Our warranty applies in accordance with the general terms and conditions of sale
and delivery of HYDAC Filtertechnik GmbH.
Refer to these at www.hydac.com General terms and conditions.

CSM 1000 Series
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 assign the information I require to a subject area.
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.
de
HYDACFiltertechnikGmbH
Be
Wa12
3456a
d
e
Se ite x
Produkt/Kapitel
200x-xx-xx
Product designation
Page number
Edition date
Document language
Documentation no.
with index/
file name
The documentation no. with index is used for identifying and reordering the
instructions. The index is incremented every time the manual is revised or changed.
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1. General safety guidelines
These operating instructions contain the most important notes for operating the
CSM safely.
1.1. Obligations and liability
The basic prerequisite for the safe handling and trouble-free operation of the CSM is
knowledge of the basic safety guidelines and regulations.
These operating instructions in general, and the safety guidelines in particular, are
to be observed by all those who work with the CSM.
In addition, the accident prevention rules and regulation applicable at the location of
use are to be observed.
The safety guidelines listed here are restricted to use of the CSM.
The CSM has been designed and constructed in accordance with the current state
of the art and recognized safety regulations. Nonetheless, its use may pose risks to
life and limb of the user or to third parties or damage to the unit or other equipment
and property. The CSM is to be used as follows:
Solely for its intended use
Only when in safe, perfect condition.
Any faults or malfunctions which might impair safety are to be properly repaired
or remedied immediately
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 injury 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 CSM or use deviating from its intended use
improper assembly, installation, commissioning, operation and maintenance of
the CSM
operating the CSM when the system equipment or systems are defective
modifications to the product made by the user or purchaser
improper monitoring of product components subject to wear and tear
improperly performed repair work

CSM 1000 Series
1.2. Explanation of symbols and warnings
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.
NOTE
NOTE denotes situations which
can lead to property damage if
safety precautions are not
observed.
1.3. Intended use
The ContaminationSensor module CSM was developed for the continuous
monitoring of particulate contamination in hydraulic systems.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
The manufacturer will not assume liability for any damage resulting from such use.
Intended use of the product also includes:
Observing all the notes in the operating instructions.
Performing requisite inspection and maintenance work.
1.4. Improper use
Any use other than described above is prohibited.
Hazards may result from improper use.
Example of improper use:
Improper connection of the pressure and return lines of the CSM.
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CSM 1000 Series
1.5. 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.
1.6. 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.
Check the hoses and port fittings for leakage daily (visual check). Also visually
check the electrical components of the CSM (once a month). Replace any loose
connections or damaged cables immediately.
1.7. Training and instruction of personnel
The CSM may only be operated by properly trained and instructed personnel.
Clearly determine which personnel are responsible for what.
Trainees may only use the CSM when supervised by an experienced individual.
Individuals
Activity
Instructed
individuals
Individuals with
technical training
Electrician Supervisor with
required
expertise
Packing
Transport X X X
Start up X X X
Operation X X X X
Troubleshooting X X X
Remedying of
mechanical faults X X
Remedying of
electrical faults X X
Maintenance X X X X
Repair work X
Shutdown /
Storage X X X X
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CSM 1000 Series
1.8. Safety precautions for normal operation
Operate the CSM only if all safety devices are functioning properly.
Check the product for visible damage and properly functioning safety equipment at
least once a day.
1.9. Electrical hazards
WARNING
Electric shock
In the event of an emergency,
immediately disconnect the CSM from
the power supply.
Pull the power plug before performing
work on live parts
1.10. CSM modification
Do not modify the design of the CSM without the prior consent of the manufacturer.
Immediately replace any unit components which are not in perfect condition.
Only use original (OEM) spare parts and consumables. If you use third party
components, we cannot guarantee that they have been designed and manufactured
to comply with loading and safety requirements.
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CSM 1000 Series
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2. Packing, storage
2.1. Unpacking CSM
The CSM is function and leak-tested in the factory, then properly packed. The
connections/ports are sealed so that the unit remains clean while 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.
2.2. Storing the CSM
Store the CSM in a clean, dry place.
Drain the unit completely before putting it into extended storage.
The maximum storage duration is 6 months. After that, the CSM must be put into
operation.

CSM 1000 Series
3. 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 damage in transit to the
forwarding agent or the HYDAC department in charge immediately and do not start
up the unit.
The following items are included:
Item Pc. Description
1 1 ContaminationSensor CS 1000 series
2 1 Manometer including adapter
- 1
Technical documentation, consisting of:
- Operating and Maintenance Instructions CSM 1000
- Operating and Maintenance Instructions CS 1000 Series
- Operating and Maintenance Instructions CoCoS 1000
- Operating and Maintenance Instructions AS 1000 (optional)
- Calibration certificate of the CS 1000
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4. Technical description
The gear pump takes in the oil to be analyzed and conveys it to the
ContaminationSensor, where the particulate contamination is scanned by an optical
sensor, assigned to a to particle size classification and counted.
Any air bubbles contained in the oil may skew the measurement results as they
cause the measurement cell to generate signals just like particulate contamination
does.
The purpose of this unit is to suppress air bubbles so that the measurement results
are not skewed at all or only minimally.
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.
But because pressurized air cannot be immediately dissolved in oil, a path is
provided 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.
During normal operation, only a small proportion of the volumetric flow is lost at this
throttle valve because the hydraulic resistance of oil is very high. However, air
bubbles can easily escape at this point.
4.1. Application restrictions
NOTE
The CSM is designated for mineral oils (or mineral-oil-based
raffinates).
Contact us before using the unit with other operating fluids.

CSM 1000 Series
4.2. CSM components
Item Description
1 Electric motor
2 Gear pump
3 Test point 1
4 Pressure relief valve (60 bar)
5 Test point 2
6 Pressure relief valve
7 Throttle valve
8 CS 1000 series
9 Suction strainer 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor 1000 (optional)
13 Leakage connection LEAKAGE (only with CSM1xxx-2....)
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CSM 1000 Series
4.3. Hydraulic diagram
8
12
5 6 7
3
4
1
11
10
9
2
60 bar
LEAKAGE
13
Item Description
1 Electric motor
2 Gear pump (with or without leakage oil connection depending on order)
3 Test point 1
4 Pressure relief valve (60 bar)
5 Test point 2
6 Pressure relief valve
7 Throttle valve
8 CS 1000 series
9 Suction strainer 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor 1000 (optional)
13 Leakage connection LEAKAGE (only with CSM1xxx-2....)
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CSM 1000 Series
4.4. Dimensions CTU 1xxx-1 ...
4.5. Dimensions CTU 1xxx-2...
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CSM 1000 Series
4.6. Drilling template
5. Connecting the CSM hydraulically and electrically
5.1. Hydraulic connection
CSM1xxx-1… CSM1xxx-2...
IN = Suction port
OUT = Return port connection
LEAKAGE = Leakage connection
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CSM 1000 Series
5.2. Notes on piping / hosing
Use as few threaded connections as possible in order to keep the pressure loss as
low as possible.
The pressure loss in a hydraulic line depends on:
volumetric flow
kinematic viscosity
pipe dimensions
density of fluid
It can be estimated for hydraulic oils as follows:
  Q
d
L
barp 4
8,6][ 
L = line length [m]
d = inside line diameter [mm]
Q = volumetric flow rate [l/min]
v = kinematic viscosity [mm²/s]
ρ = density [kg/dm³]
(mineral oil ≈ 0.9 kg/dm³)
This applies to straight conduits and hydraulic oil. Additional threaded connections
and pipe bends increase the pressure differential
Keep the height difference between the pump and the oil level in the tank as
minimal as possible. Hoses must be suitable for minimum suction pressures of –0.5
bar.
Avoid constrictions in connecting pipelines because they reduce capacity and
increase the risk of cavitation.
The nominal width of the connecting pipelines must be at least as large as the inlet
port cross-sections.
NOTE
The maximum pressure on the IN suction port may be:
- for CSM1xxx-1 … = -0.4 bar ... 0.5 bar
- for CSM1xxx-2 … = -0.4 bar ... 120 bar
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CSM 1000 Series
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5.2.1. Suction port - IN
NOTE
Intake from the tank sump prohibited
Coarse particles on the bottom (sump) of the reservoir can damage
the pump.
The suction-side connection must be made by a flexible hose that is resistant to
negative pressure or by conduits. The nominal size of the connecting lines must be
at least as large as the inlet/outlet port sizes of the unit in order to prevent an
excessively high pressure loss.
Suction connection to the tank must be made so that it is always below the oil level.
5.2.2. Return port connection - OUT
NOTE
The return-line connection OUT must never be obstructed or closed off!
The pressure may not exceed 5 bar!
The CSM will be damaged.
5.2.3. Leakage connection - LEAKAGE (only with CSM 1xxx-2....)
NOTE
Never seal the LEAKAGE port or line.
Do not exceed 0.5 bar pressure.
The pump will be damaged.