HYDAC International CS 2000 Series Manual

FES
Fluid Sampling Set
Operating and Maintenance Instructions
English
(translation of original instructions)
Document No.: 3160266a

Fluid Sampling Set - FES Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
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. Contraventions are liable to
compensation.
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 content of the manual is checked regularly. Any
corrections required will be incorporated in future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filtertechnik GmbH
Service Technology Division / Filter Systems
P.O. Box 12 51
D-66273 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

Fluid Sampling Set - FES Contents
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Contents
Trademarks ............................................................................................................................. 2
Contents..................................................................................................................................3
Preface ....................................................................................................................................4
Customer Service .................................................................................................................5
Modifications to the Product .................................................................................................5
Warranty ...............................................................................................................................5
Using the documentation ...................................................................................................... 6
Safety Information and Instructions..................................................................................... 7
Explanation of Symbols and Warnings ................................................................................. 7
Please observe the instructions in this manual..................................................................... 7
Responsibility of the owner...................................................................................................7
Hazards Posed by Using the FES ........................................................................................8
Proper/Designated Use ........................................................................................................8
Informal Safety Precautions.................................................................................................. 8
Modifications on the FES......................................................................................................8
Cleaning the FES..................................................................................................................8
Checking the scope of delivery ............................................................................................ 9
Fluid Sampling Set properties ............................................................................................10
Source of oil contamination.............................................................................................10
Oil contaminations influence the ageing of the oil...........................................................11
Sampling ...............................................................................................................................12
Static sampling ...................................................................................................................12
Dynamic sampling ..............................................................................................................12
Labelling samples...............................................................................................................14
Performing maintenance .....................................................................................................14
Disposing of the FES ...........................................................................................................14
Spare Parts List ....................................................................................................................15

Fluid Sampling Set - FES Preface
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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 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 additional comments
or suggestions, contact us at:
HYDAC Filtertechnik GmbH
Division Service technology / Filter systems
Technical Documentation Department
Postfach 12 51
66273 Sulzbach/Saar - Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
“Putting experience into practice”

Fluid Sampling Set - FES Preface
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Customer Service
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: ++49 (0) 6897 509 846
Email: [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 Filtertechnik GmbH.
They are available at: www.hydac.com Legal information.

Fluid Sampling Set - FES 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 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
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Se ite x
Produkt/Kapitel
200x-xx-xx
Product
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.
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Fluid Sampling Set - FES Safety Information and Instructions
Safety Information and Instructions
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
TIP denotes situations which
can lead to property damage if
safety precautions are not
observed.
Please observe the instructions in this manual
These operating instructions contain the key instructions for properly and safely
operating the FES. These operating instructions in general, and the safety
guidelines in particular, are to be observed by all those who work with the
FluidSampling Set. In addition, the accident prevention rules and regulation
applicable at the location of use are to be observed.
Responsibility of the owner
The owner of the product shall ensure that the Fluid Sampling Set is operated by
individuals who are familiar with the basic safety and accident prevention guidelines
and who have been trained to handle the FES.
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Fluid Sampling Set - FES Safety Information and Instructions
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Hazards Posed by Using the FES
The Fluid Sampling Set FES is made up of individual components which are
designed and constructed in accordance with the technical state of the art and
recognized safety rules and regulations. Nevertheless, their usage can still
endanger the operator or third parties. In addition, the Fluid Sampling Set may be
damaged during transport or by improper handling. The Fluid Sampling Set is to be
used only as follows:
for the specified correct usage.
Only when in safe, perfect condition.
Faults which could affect safety must be rectified immediately.
Proper/Designated Use
The Fluid Sampling Set FES is a combination of units developed to analyze the
solid particle contamination of mineral oils. Any use extending beyond or deviating
therefrom shall not be considered intended use. HYDAC Filtertechnik GmbH will not
assume any liability for any damage resulting from such use.
Informal Safety Precautions
Always keep the operating instructions in the vicinity of the Fluid Sampling Set. In
addition to the manual, the general and local regulations concerning accident
prevention and protection of the environment should be available and observed.
Keep the safety and hazard symbols and warnings on the Fluid Sampling Set in a
legible condition.
Modifications on the FES
Do not carry out any alterations, conversions or additions to components of the FES
without the written consent of All component modifications required the written
confirmation of HYDAC Filtertechnik GmbH. Immediately replace components that
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. (Also see
chapter on Maintenance)
Cleaning the FES
Maintain the highest level of cleanliness during all work with the Fluid Sampling Set.
Every particle that enters the sample or solvent due to contamination will be isolated
on the filter membrane and distort the results. (See chapter 0.)

Fluid Sampling Set - FES Checking the scope of delivery
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Checking the scope of delivery
The Fluid Sampling Set FES is supplied in a ready-for-operation condition. Check
the individual components for possible damage in transit before putting the FES into
operation.
Item Qty Description
- 1 Hand vacuum pump with manometer
- 1 Aluminum adapter
- 1 Set of sample flasks (2 pieces)
- 1 Spray bottle with removable nozzle, 500 ml
- 1 Disposable membrane filter for spray bottle,
Packing unit = 2 pieces
- 1 Plastic hose, length = 2 m
- 1 Telescope pen, length: 0.9 m
- 1 Cable strip, 20 pcs.
- 1 Dynamic sampling device
- 1 Minimess hose (screw - screw)
- 1 Minimess hose (screw - plug)
- 1 Wide mouth bottle, 500 ml
- 1 Case
- 1 Contamination handbook

Fluid Sampling Set - FES Fluid Sampling Set properties
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Fluid Sampling Set properties
Compliance with and regular monitoring of the particle load in fluid and lubrication
technology is essential for efficient, economical system use.
Static and dynamic sampling for later fluid analysis can be carried out using very
simple means with the Fluid Sampling Set FES.
NOTE
The FluidAnalysis Set may only be used with mineral oils.
Contact us prior to using with other operating fluids.
Source of oil contamination
Contamination of hydraulic media is classified according to the particular physical
state:
Solid
Gaseous
and liquid contamination.
Solid particles enter the hydraulic system because the unit is inadequately sealed,
through maintenance work or new oil, for example. Once present, these particles
produce new ones, leading to a "chain reaction of wear".
Gaseous contamination often results from leakage on the suction side of hydraulic
pumps, poor return flow of the medium to the tank or when pipelines must be
opened (e.g. for maintenance work).
Hydraulic media water contamination can either be caused by condensation or
penetration. The condensation of water is caused by temperature differences in the
hydraulic reservoir. Water can enter through faulty cooler hoses, faulty seals or a
leaky reservoir. Water-absorbent filter elements (filter fineness 3 ... 40 µm) can also
be used for the removal of free water.

Fluid Sampling Set - FES Fluid Sampling Set properties
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Oil contaminations influence the ageing of the oil
Solid particles
In addition to the enormous damage to hydraulic components from wear caused by
solid particles, the materials of these particles also have an impact on oil aging that
cannot be ignored. Reactions with hydrocarbons and additives, which change the
properties of the oil (saponification, for example), can occur. On the other hand,
metal can act as a catalyst for the oxidation of the hydrocarbon molecules, which
reduces the oil's service life considerably. This occurs especially quickly when
several contaminants act on the oil at the same time.
Air
Under normal conditions, mineral oils always contain a certain percentage of
dissolved air. Unfavourable conditions, e.g. a vacuum, can change the dissolved
state of the air. This released air is responsible for the increased compressibility of
the medium, a higher tendency to cavitation, and, above all, a drastic acceleration of
oil aging.
Water
The aging process of mineral oil accelerates when there is water in the oil, and
when there are particles acting as catalysts the process speeds up. The oil additives
are used up quickly, and the charge of oil becomes unusable in a fraction of the
service life of "dry" oil.

Fluid Sampling Set - FES Sampling
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Sampling
NOTE
The FluidAnalysis Set may only be used with mineral oils.
Contact us prior to using with other operating fluids.
Static sampling
This procedure treats the sampling from the reservoir of a system which is not
equipped with sampling valves. This procedures should only be applied in situations
where no other possibility of sampling (e.g. through the use of nipples) exists. Cut
the accompanying plastic hose that is 2 m in length into two parts with the ratio of ≈
0.5 m / ≈1.5 m.
1. Wipe off the outer surface of the reservoir or container near the sampling
point and clean the surface with filtered solvent
2. Use the smaller piece of transparent hose (≈0.5 m) to connect the
aluminium adapter with the manual vacuum pump.
3. Also connect the longer piece of transparent hose with the aluminium
adapter.
4. Open the reservoir by removing the reservoir sealing lock or the tank
ventilation filter.
5. Place the laboratory bottle for blank sampling up against the aluminium
adapter.
6. Guide the longer transparent hose of the manual vacuum pump into the fluid
contained in the reservoir up to approximately half the filling height. The
transparent hose can also be fastened in place to the telescope pen, which
will make handling easier. Make sure during the immersion process that the
hose does not come into contact with the side walls or the bottom of the
reservoir.
7. Actuate the manual vacuum pump and fill the laboratory bottle for "blank
sampling". This is important in order to make sure the hoses, aluminium
adapter and manual vacuum pump are flushed.
8. Replace the bottle with the "blank sample" with one of the two clean
laboratory bottles provided.
9. Now actuate the manual vacuum pump and fill the bottle until the 250 ml
level is reached.
10. Now close the sample bottle carefully and label it as described under
Chapter 0.
Dynamic sampling

Fluid Sampling Set - FES Sampling
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This method involves the taking of bottle samples of hydraulic fluid from operating
fluid power systems via sampling valves provided for that purpose. The sampling
should be representative of the operating condition of the hydraulic system.
Therefore, the samples should be taken from the same point in the system each
time, to enable comparisons to be made. Furthermore, it is important that significant
operational demands must be made on the system during the period that the
sample is being taken.
1. The dynamic sampler (sampling valve) should always be protected with a
cap when it is not in use.
2. The sampling valve (e.g. nipple) and the surrounding parts must be carefully
cleaned.
3. Take one of the two sample bottles provided. Make sure that there is no
possibility of contamination in the area of the sealing lock. Undo the seal on
the sample bottle, but do not remove it. Set the sample bottle down in easy
reach.
4. Remove the protective cap from the sampling valve (e.g. nipple) and allow
an amount of fluid that is at least twice the volumetric size of the sampling
line to drain out into a container. This is necessary in order to rinse out the
sampling system. A rinsing volume of 0.5 litres of operating fluid has proven
to be sufficient in everyday practice.
5. Take a container and guide it into the stream of fluid without interrupting it.
Replace the container with the sample bottle without interruping the stream
of fluid. Remove a sufficient amount of sample (at least 150 ml) for the
subsequent analysis. Carefully seal the sample bottle at once.
6. Replace the sample bottles once again with the container and close the
sampling valve. Put the sealing cap back on the sampling valve.
7. Label the sample as describe under Chapter 0

Fluid Sampling Set - FES Performing maintenance
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Labelling samples
The bottle sample should be labelled with the following information:
oSample number
oMachine type
oSampling method
oDate and time of the sampling
oFluid type
Performing maintenance
The Fluid Sampling Set FES is a combination of laboratory-quality components.
Therefore, thorough cleaning of the equipment after every usage is essential for
ensuring the quality of the analysis result of the oil samples. For rinsing the
laboratory bottles, we recommend N-heptane, which should be decanted into the
accompanying spray bottle with membrane filter for this purpose.
Disposing of the FES
When decommissioning and/or disposing of the FES, adhere to local guidelines and
regulations pertaining to occupational safety and environmental protection. This
applies in particular to cleaning agents, solutions and oil samples which are stored
together with Fluid Sampling Set FES.
After disassembling the unit and separating the various materials, they can be
reused or disposed of properly in accordance with local regulations.

Fluid Sampling Set - FES Spare Parts List
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Spare Parts List
Item Qty Article designation Part no.
- 1 Hand vacuum pump with manometer 309 345
- 1 Aluminum adapter 309 349
- 1 Set of sample flasks (2 pieces) 309 352
- 1 Spray bottle with removable nozzle, 500 ml 309 358
- 1 Disposable membrane filter for spray bottle,
Packing unit = 2 pieces
309 371
- 1 Plastic hose, length = 2 m 309 374
- 1 Telescope, length: 0.9 m 309 342
- 1 Kable strip, 20 pcs. 627 500
- 1 Dynamic sampling device 309 348
- 1 Minimess hose (screw - screw) 309 350
- 1 Minimess hose (screw - plug) 309 351
- 1 Wide mouth bottle, 500 ml 309 360
- 1 Case 637 561
- 1 Contamination handbook 349 339

HYDAC Filtertechnik GmbH
Bereich Servicetechnik / Service Technology Division
Industriegebiet Postfach 1251
66280 Sulzbach/Saar 66273 Sulzbach/Saar
Germany Germany
Tel: [phone]
Fax: [phone] (Technical Department)
Fax: [phone] (Sales Department)
Internet: www.hydac.com
email: [email protected]