Hydac CSM 2000 series Operating instructions

CSM 2000 Series
ContaminationSensor Module
Operating and Maintenance Instructions
English (translation of original instructions)
Dokument No.: 3211683h
(from series no. 0002S02043K0000015)

CSM 2000 Series Trademarks
Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2011 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC Filter Systems GmbH. Contraventions are liable
to compensation.
Exclusion of Liability
We have made every endeavor to ensure the accuracy of the content 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 FILTER SYSTEMS GMBH
Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-mail: [email protected]
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CSM 2000 Series Content
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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ...................................................................................................................... 5
Customer Service ...................................................................................................6
Modifications to the Product ...................................................................................6
Warranty .................................................................................................................6
Using the Documentation .......................................................................................7
Safety Information and Instructions.......................................................................8
Obligations and Liability..........................................................................................8
Explanation of Symbols and Warnings, etc. ...........................................................9
Proper/Designated Use .......................................................................................... 9
Improper Use ..........................................................................................................9
Training and Instruction of Personnel ...................................................................10
Electrical Hazards................................................................................................. 11
Dangers by pressure in the hydraulic system....................................................... 11
CSM modification.................................................................................................. 11
Packing, storage..................................................................................................... 12
Unpacking the CSM.............................................................................................. 12
Storing the CSM ...................................................................................................12
Checking the scope of delivery.............................................................................13
CSM Characteristics...............................................................................................14
Restrictions pertaining to use ............................................................................... 15
CSM components ...................................................................................................16
Hydraulic diagram .................................................................................................. 17
Dimensions CSM2x30-1.........................................................................................18
Dimensions CSM2x30-2.........................................................................................19
Drilling template for wall mounting........................................................................ 20
Hydraulic Connection of the CSM......................................................................... 20
Hydraulic Connectors ........................................................................................... 20
Notes on piping / hosing .......................................................................................21
Suction port connection - IN..............................................................................22
Return port connection - OUT ...........................................................................23
Leakage oil connection (LEAKAGE) (only with CSM2x30-2....)........................23
Electrical Connection of the CSM.........................................................................24
Electrical connection of the ContaminationSensor CS2000 ................................. 25

CSM 2000 Series Content
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Electrical connection of the AquaSensor AS1000 ................................................ 25
Switching the CTM on and off...............................................................................25
Starting up the CSM ............................................................................................... 26
Adjusting the counter balance valve....................................................................26
Required tools and measuring instruments .......................................................... 26
Performing Maintenance........................................................................................31
Clean the suction screen ......................................................................................32
Disposing of the CSM ...........................................................................................33
Errors and troubleshooting...................................................................................34
Spare Parts List ...................................................................................................... 34
Spare Parts Diagram ............................................................................................ 35
Customer service ...................................................................................................35
Technical data ........................................................................................................ 36
Model Code .............................................................................................................38
EC declaration of conformity ................................................................................39

CSM 2000 Series 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 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 FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”
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CSM 2000 Series 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
E-mail: [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 FILTER SYSTEMS GMBH.
Refer to these at www.hydac.com General terms and conditions.

CSM 2000 Series 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 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
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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.
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CSM 2000 Series Safety Information and Instructions
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Safety Information and Instructions
These operating and maintenance instructions contain the key instructions for
properly and safely operating the CSM.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the CSM is
knowledge of the safety instructions and warnings.
These operating and maintenance instructions in general, and the safety
precautions in particular, are to be adhered by all those who work with the CSM.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed herein are limited solely to using the CSM.
The unit is to be checked once a day for visible external damage.
The CSM 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 CSM or use deviating from its designated 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 2000 Series Safety Information and Instructions
Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this operating and maintenance
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
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated 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 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 in the operation and
maintenance manual.
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 and oil leakage pipe.
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CSM 2000 Series Safety Information and Instructions
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Training and Instruction of Personnel
The CSM 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 CSM unless supervised by an
experienced staff member.
Individuals Individuals undergoing training Individuals with technical training/engineering background Electrician 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
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning / Storage X X X X

CSM 2000 Series Safety Information and Instructions
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
Bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.
CSM modification
Do not make any modifications to the unit without the prior consent of HYDAC.
Immediately replace any faulty unit components. Use only original spare parts.
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CSM 2000 Series Packing, storage
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Packing, storage
Unpacking the CSM
Before it is delivered, the CSM is inspected for leaks and proper functioning, 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. Report any
damage to the forwarding agent immediately.
Dispose of the packaging material as appropriate for your area.
Storing the CSM
Make sure to store the CSM in a clean, dry place.
The unit is to be drained completely before being put into storage.

CSM 2000 Series Checking the scope of delivery
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 damages in transit to the
transport company or the responsible agent immediately. Do not put the unit into
operation.
The following items are supplied:
Item Qty. Designation
1 1 Contamination Sensor Module, CSM 2000 Series
2 1 Pressure gauge with adapter
- 1
Technical Documentation, const. of:
- Operating and Maintenance Instructions CSM 2000
- Operating and Maintenance Instructions CS 2000 Series
- Operating Instructions CoCoS
- Operating and Maintenance Instructions AS 1000 (optional)
- Calibration certificate of the CS2000
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CSM 2000 Series CSM Characteristics
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CSM Characteristics
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.
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.
In normal operation, only a small portion of the flow is lost at this throttle valve as
the hydraulic resistance of the oil is extremely high. However, air bubbles can easily
escape at this position.

CSM 2000 Series CSM Characteristics
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Restrictions pertaining to use
NOTICE
Impermissible operating media
The unit will be destroyed
►The unit is only to be used with mineral oils or mineral oil-based raffinates.
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

CSM 2000 Series CSM components
CSM components
21 22
23
Item Description
1 Electric motor
2 Gear pump (with or without leakage oil connection depending on order)
3 Test point 1
4 Pressure control valve (30 bars)
5 Test point 2
6 Counter balance valve
7 Throttle valve
8 ContaminationSensor CS2000 series
9 Suction screen, 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor AS1000 (optional)
13 Leakage oil connection (LEAKAGE) (only with CSM2x30-2 ...)
21 On/off switch with motor protection (PKZ)
22 Cable
23 Connection plug
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CSM 2000 Series Hydraulic diagram
Hydraulic diagram
8
12
56 7
3
4
1
11
10
9
2
30 bar
LEAKAGE
13
Item Designation
1 Electric motor
2 Gear pump (with or without leakage oil connection depending on order)
3 Test point 1
4 Pressure control valve (30 bars)
5 Test point 2
6 Counter balance valve
7 Throttle valve
8 ContaminationSensor CS2000 series
9 Suction screen, 400 µm
10 Suction port connection (IN)
11 Return port connection (OUT)
12 AquaSensor 1000 (optional)
13 Leakage oil connection (LEAKAGE) (only with CSM2x30-2 ...)
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CSM 2000 Series Dimensions CSM2x30-1
Dimensions CSM2x30-1
312,5 362,5
360
265
90
min.27
max. 47
75
52
36
418
AA
156
9
75
520
220
36
20
30
119,5
A-A
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CSM 2000 Series Dimensions CSM2x30-2
Dimensions CSM2x30-2
312,5 362,5
360
265
90
min.27
max. 47
75
52
36
418
AA
119,5
A-A
156
9
75
520
220
36
20
90
65
30
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CSM 2000 Series Hydraulic Connection of the CSM
Drilling template for wall mounting
Hydraulic Connection of the CSM
Hydraulic Connectors
CSM2x30-1 CSM2x30-2
IN = Suction port connection
OUT = Return port connection
LEAKAGE = Leakage oil connection
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