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CSM-E ContaminationSensor Module - Economy

Installation and Maintenance Instructions English (translation of original instructions) Keep for future reference.

Document No.: 3911629a

Imprint

Imprint

Manufacturer / publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Industriestraße 66280 Sulzbach / Saar Germany Telephone: +49 6897 509 01 Fax: +49 6897 509 9046 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: +49 6897 509 1511 Fax: +49 6897 509 1394 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.

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MoWa CSM-E 3911629a en-us 2017-12-11.docx 2017-12-11

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 ................................... 11 Qualifications of personnel / target group .................................................. 13 Wear suitable clothing ............................................................................... 15 Procedure in an Emergency ...................................................................... 15

Firefighting/Extinguishing Fires .............................................................. 15

Unpacking the unit ...................................................................................... 16

Transporting the unit .................................................................................. 16

Storing the unit ........................................................................................... 16

Decoding the name plate ........................................................................... 17

Checking the scope of delivery ................................................................. 18

Characteristics of the unit .......................................................................... 19

Unit components ......................................................................................... 20

Hydraulic circuit powerpack ...................................................................... 21

Drilling template for fastening .................................................................... 22

Making the hydraulic connections to the unit .......................................... 23

Installing ContaminationSensor ................................................................. 23 Installing additional sensor(s) AS1000 / AS3000 / HLB1400 ..................... 25

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Content

Overview of the hydraulic connections ...................................................... 26 Notes on pipes/hosing ............................................................................... 27

Connecting the IN suction port ............................................................... 28 Hooking up tank connection OUT ........................................................... 29 Connecting drain port LEAK (with CSM-E 1xxx-2 only…) ...................... 29 For the version with the magnetic coupling (CSM-E 1xxx-4…) please note the following: ....................................................................... 30

Electrical connection of the unit ................................................................ 31

Electrical connection of the ContaminationSensor CS1000 ...................... 32 Electrical connection of the AquaSensor AS1000 / AS3000 (optional) .................................................................................................... 32 Electrical connection of the HYDACLab HLB1400 (optional)..................... 32 Electrical connection of the CSI-C-11 (optional) ........................................ 32

Starting up the unit ..................................................................................... 33

Adjusting the counter balance valve ......................................................... 33

Required tools ........................................................................................... 34 Setting the counter balance valve with a pressure gauge.......................... 35 Setting up the counter balance valve without pressure gauge ................... 38

Mounting accessories ................................................................................ 40

Performing maintenance ............................................................................ 41

Clean the suction strainer .......................................................................... 42

Errors and troubleshooting........................................................................ 44

Taking the unit out of operation ................................................................ 44

Shutting down the unit ............................................................................... 45

Disposing of the unit .................................................................................. 45

Ordering spare parts .................................................................................. 46

Ordering accessories ................................................................................. 49

Technical Data............................................................................................. 53

Appendix ..................................................................................................... 56

Customer service ....................................................................................... 56 Unit dimensions ......................................................................................... 57

Dimensions with CS1000, AS1000 and CSI-C11 ................................... 57 Dimensions with CS1000, HLB1400 and CSI-C11 ................................. 58

Model code ................................................................................................ 59 Explanation of terms and abbreviations ..................................................... 60 Index .......................................................................................................... 61

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Preface

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: +49 6897 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. 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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http://www.hydac.com/

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 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.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite 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 by one digit 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 precautions and are described in the Installation and Maintenance 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 safety information and instructions 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.

Read and observe the operation and maintenance instructions.

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 tubes 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 ContaminationSensor Module CSM-E was developed for the continuous monitoring for solid particle contamination in hydraulic systems. Proper/designated use of the product extends to the following:

• Observing all instructions contained in the instruction manual.

• Performing inspection and maintenance work.

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 user 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: o Operation in potentially explosive atmospheres o Operation with a non-approved medium. o Operation under non-approved conditions o Operation when the system equipment or safety devices are defective o modifications to the unit made by the user or purchaser o Improper monitoring of unit components that are subject to wear and

tear o improperly performed repair work

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Safety information

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

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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 is 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.

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Safety information

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 and substances

• Decontamination of contaminants

• Knowledge about reuse

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Safety information

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.

Procedure in an Emergency In case of emergency, switch off the power unit or disconnect it.

Firefighting/Extinguishing Fires Use a powder extinguisher that corresponds to fire class B as per EN EN 2 to extinguish any fires.

Maintain a minimum safe distance from electrical components. For a mains voltage of up to 1000 V, the minimum safe distance is 1 m.

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Unpacking the unit

Unpacking the unit

The unit is function- and leak-tested in the factory and properly packed. 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.

Transporting the unit

Only transport the unit as follows: - Carry the unit by hand holding the pump and fan cover. - Transport the unit on the rubber buffers in an upright position.

Storing the unit

Rinse and drain the unit completely before putting it into extended storage. Store the unit in a clean, dry place. Store the unit on the rubber buffers in an upright position.

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Decoding the name plate

Decoding the name plate

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 59

Max. INLET press -> Maximum pressure at the inlet section

Max. Flow rate -> Maximum flow rate

Weight -> Weight when empty

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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 ContaminationSensor Module, CSM-E

- 4 Fastening screws for the ContaminationSensor

- 1 Installation and Maintenance Instructions, this document

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Characteristics of the unit

Characteristics of the unit

The gear pump sucks the oil to be analyzed and funnels it to the ContaminationSensor where the solid particles are detected by an optical sensor, divided up into classes by size 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. For this reason, the powerpack is fitted with an air release line. Its job is to suppress any existing air bubbles, within the realm of what is technically possible, to such an extent that the measurement result is not skewed or is only negligibly skewed. The highest pressure possible in the ContaminationSensor is targeted as oil with increasing pressure can release an increasing quantity of air (reference value: approx. 8% air per bar). This is achieved using a valve situated downstream of the CS. However, pressurized air cannot be immediately dissolved in oil, consequently a path is provided for between the pump and the sensor.

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Unit components

Unit components

Item Designation

1 Electric motor

2 Gear pump (with or without leakage oil connection depending on order)

3 Pressure relief valve

4 Counter balance valve

5 Suction strainer, 400 µm

6 Suction port (IN)

7 Tank connection (OUT)

8 Leakage oil connection (LEAK) (optional)

9 Fastening screws for the ContaminationSensor CS1000

21 Rubber buffer for assembly onto connection block

22 Rubber buffer for assembly onto electric motor

23 Screw plug / Cavity for the AquaSensor AS1000 / AS3000

24 Flange port for the ContaminationSensor CS1000

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Hydraulic circuit powerpack


CS

IN OUT

M

LEAK

AS

2423

431

2

5

6 8 7

Item Designation

1 Electric motor

2 Gear pump (with or without leakage oil connection depending on order)

3 Pressure relief valve

4 Counter balance valve

5 Suction strainer, 400 µm

6 Suction port (IN)

7 Tank connection (OUT)

8 Leakage oil connection (LEAK) (optional)

23 Cavity for the AquaSensor AS1000 / AS3000

24 Flange port for the ContaminationSensor CS1000

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Drilling template for fastening

All dimensions in mm.

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Making the hydraulic connections to the unit


To hydraulically connect up the power unit, proceed as described in the following.

Installing ContaminationSensor You must mount the ContaminationSensor before hooking it up hydraulically.

NOTICE

Operation without ContaminationSensor

Fluid leaking / Environmental hazard

► Assemble the ContaminationSensor properly and professionally.

Before hooking it up hydraulically, assemble the ContaminationSensor CS1000 as follows:

1. Remove the plastic screw plug (24) at the flange port.

2. Use a lint-free cloth to clean the sealing surface at the

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ContaminationSensor (30) and at the connection block.

3. Insert the two o-rings that were included in the delivery of the ContaminationSensor (30) into the connections at the CS1000.

4. Place the ContaminationSensor (30) onto the inline installation and manually screw in the four fastening screws (9).

5. Tighten the fastening screws (9) tight using an Allen wrench

= 5 mm (torque: 8 ± 0.5 Nm).

6. Installation of the ContaminationSensors (30) is complete.

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Installing additional sensor(s) AS1000 / AS3000 / HLB1400 Install the additional sensor AS1000, AS3000 or HLB1400 as follows:

1. Remove the screw plug (23).

2. Use a lint-free cloth to clean the sealing surface at the additional sensor (31) and at the connection block.

3. Screw the additional sensor (31) by hand in a clockwise direction into the cavity.

4. Tighten the additional sensor tight using a fork wrench = 27 mm (torque : 20 +2 Nm).

5. The installation of the additional sensor (31) is complete.

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Overview of the hydraulic connections The following illustration shows the hydraulic connections on the power unit:

IN = Suction port connection

OUT = Return port connection

LEAK = Leakage oil connection (optional)

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Notes on pipes/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 upon:

• Flow rate

• Kinematic viscosity

• Pipe dimensions

• Fluid density The pressure loss can be estimated for hydraulic oils as follows:

Δp ≈ 6.8 * L / d4 * Q * V * D Δp = Pressure differential in [bar]

L = Pipe length [m]

d = Internal pipe diameter [mm]

Q = Flow rate [l/min]

V = Kinematic viscosity [mm²/s]

D = Density [kg/dm³] Mineral oil-based hydraulic oil has a density of approx. 0.9 kg/dm³.

This applies to straight pipe runs and hydraulic oils. Additional threaded connections and pipe bends increase the pressure differential. Keep the height difference between the unit and the oil level in the tank as low as possible. Hoses used must be suitable for suction pressures of at least -0.5 bar. Avoid constrictions in the connected hoses. This reduces the delivery action and increases the risk of cavitation. The nominal size of the supply lines must be at least as large as the nominal width of the connecting line of the power unit in order to prevent excessively high pressure loss. Make sure that no vibrations or stress/loading are carried over to the pump by fastening the tubes. Mount hoses or expansion joints if necessary.

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Connecting the IN suction port

NOTICE

Overpressure at the suction port (IN)


► Note the maximum pressure on the suction port connection IN for CSM-E 1xxx-1 = -0.4 bar to 0.5 bar for CSM-E 1xxx-2 = -0.4 bar to 120 bar for CSM-E 1xxx-4 = -0.4 bar to 80 bar

Use a negative pressure-resistant, flexible hose or a pipe for the suction-side connection. The nominal size of the supply lines must be at least as large as the nominal width of the connecting line of the power unit in order to prevent excessively high pressure loss. Suction port connection to the tank must be made so that it is always below the oil level and not on the bottom of the tank.

The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank. The greatest contamination is found on the bottom of the tank. All impurities and other particles are deposited on the bottom of the tank.

NOTICE

Contamination too high

The unit will be damaged

► Do not prime directly at the bottom of the tank ► Do not prime in the sump ► Never prime without a built-in suction screen

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Hooking up tank connection OUT

NOTICE

Closed tank connection (OUT)


► Make sure that the return port is always open

Connecting drain port LEAK (with CSM-E 1xxx-2 only…)

NOTICE

Closed drain port (LEAK)


► Make sure that the leakage oil connection is always open ► Note the maximum pressure of 0.5 bar at the leakage oil connection

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For the version with the magnetic coupling (CSM-E 1xxx-4…) please note the following:

The CSM1xx0-4… is equipped with a magnetic coupling between the electric motor and the pump. This magnetic coupling serves as a fuse element. The following needs to be considered when fault-finding.

NOTICE

Slipping magnetic coupling

Fluid is no longer being pumped, the magnetic coupling starts to make noises and is destroyed.

► A) Switch off the power unit immediately. ► B) Check the pump temperature. Switch the unit on only after the

pump has cooled down to below 50°C. ► C) Check if the tank connection (OUT) is open. ► D) Check the pressure setting on the pressure gauge. Correct the

pressure setting if necessary.

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Electrical connection of the unit


DANGER

Exposed electrical components in the terminal box

Danger of fatal injury due to electric shock

► Any work involving the electrical system may only be done by a properly trained, certified electrician.

Compare the voltage and frequency specifications on the type label with the specifications for the available network. The pump motor must be protected from overloading, in accordance with VDE 0113. Check the direction of rotation of the motor by switching it on briefly (jog mode). The rotational direction is indicated by an arrow on the fan cover. To change the direction of rotation, commutate two phases. Depending on the network voltage, connect the motor in a star or delta connection. Check the type label on the motor to accomplish this.

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Electrical connection of the ContaminationSensor CS1000 More information on this can be found in the corresponding installation instructions for the product.

Electrical connection of the AquaSensor AS1000 / AS3000 (optional) More information on this can be found in the corresponding installation instructions for the product.

Electrical connection of the HYDACLab HLB1400 (optional) More information on this can be found in the corresponding installation instructions for the product.

Electrical connection of the CSI-C-11 (optional) More information on this can be found in the corresponding installation instructions for the product.

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Starting up the unit

Starting up the unit

After connecting the CSM hydraulically via IN / OUT, if necessary via LEAK, with the overall system and the electrical connection is available, you will need to adjust the counter balance valve (4). The counter balance valve (4) is delivered in a fully opened state.

Adjusting the counter balance valve

Adjust the counter balance valve (4) according to the following steps.

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Required tools The following tools are needed to set up the counter balance valve:

Open-jaw wrench = 13 mm

Allen wrench = 4 mm The two following procedures described for setting the counter balance valve are possible.

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Setting the counter balance valve with a pressure gauge To set up the counter balance valve with a pressure gauge, an additional pressure gauge 0-40 bar with a screw connection and a gauge port screw connection is required.

Pressure gauge 0-60 bar, including gauge port screw connection A matching pressure gauge kit is available as an accessory, see

"Accessories" chapter. To set the counter balance valve, proceed as follows:

1. Loosen the screw plug on the right-hand side of the CS in a counterclockwise direction and remove it completely.

2. Screw the gauge port connector

(A) into the CS.

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3. Screw the pressure gauge (B) onto the gauge port.

4. Switch the unit on.

Check the suction intake behavior of the pump and the oil flow. If, from the noise of the pump or the outlet side (OUT), you can hear/identify an even flow rate, please proceed.

5. The pressure gauge (B) at the gauge port shows the pressure at the input of the ContaminationSensor (max. 60 bar)

6. Unscrew the cap nut from the

counter balance valve.

7. Release the lock nut on the


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8. When the operating medium is at maximum viscosity, set the pressure range to between 25 and 40 bar by turning the adjusting screw at the load holding valve with a 4-mm Allen wrench.

NOTICE With the product version CSM-E … -4, a maximum pressure increase of 25 bar is possible.

9. Tighten the lock nut. Make sure that the setting of the counter balance valve is not changed in the process.

10. Screw the head-nut onto the

counter balance valve and tighten it firmly.

11. Unscrew the pressure gauge (B)

from the gauge port. The gauge port can remain in the CS.

12. The unit is ready for operation.

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Setting up the counter balance valve without pressure gauge To set the counter balance valve without pressure gauge, proceed as follows:

1. Switch the unit on. Check the suction intake behavior of the pump and the oil flow. If, from the noise of pump or at the outlet side (OUT), you can hear/identify an even flow rate, please proceed.

2. Unscrew the cap nut from the counter balance valve.

3. Release the lock nut on the


4. When the operating medium is at

maximum viscosity, set the pressure range by turning the adjusting screw at the load holding valve with a 4-mm Allen

wrench .

5. Tighten the lock nut. Make sure that the setting of the counter balance valve is not changed in the process.

6. Screw the head-nut onto the

counter balance valve and tighten it firmly.

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7. The unit is ready for operation.

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Mounting accessories

Mounting accessories

If you have ordered a montage kit for the power unit, mount it as illustrated in the following.

Item Designation

1 Montage Kit CSM-E, consisting of: - 1x assembly sheet for setup or suspension - 1x fastening material (screws, discs, nuts)

2 Montage Kit SMU, consisting of: - 1x holder plate for SMU1200 - 1x fastening material for assembly sheet (including discs, nuts)

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Performing maintenance


WARNING

Operating pressure

Danger of bodily injury

► The hydraulic system must be depressurized before performing any work on the hydraulic system.

The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in accordance with the respective schedules. The Unit is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance, servicing, inspection or repair work. Once maintenance work is complete, check that the safety devices are still working properly. Any screwed fittings which have been undone/removed are to be checked to see that they have been properly resecured. Please note that the following maintenance intervals are guide values. The maintenance intervals shorten depending on the contamination level of the fluid.

24 hrs. or

daily

500 hrs. or

monthly

3000 hrs. or

twice per year

Check for leaks X Visual check of electrical equipment X

Clean the suction strainer X

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Clean the suction strainer

NOTICE

Suction strainer missing / operating without a suction strainer


► Never operate the unit without a suction strainer. ► Clean the suction screen regularly.

A suction strainer is fitted into a piece of pipe of the suction line to protect the pump from coarse contamination. Check the suction strainer immediately in the event of insufficient suction or delivery action. To replace the suction strainer, proceed as follows:

1. Open the screw plug with an

Allen wrench = 6 mm.

2. Take out the suction strainer

by rotating it with a large, flat screwdriver in counterclockwise direction.

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3. Clean the suction strainer by washing it out and then blowing it out with compressed air.

4. Rotate the suction strainer in

clockwise direction into the housing with a large, flat screwdriver.

5. Screw in the screw plug by

hand and tighten it with 12 Nm.

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Errors and troubleshooting

Errors and troubleshooting

Error Cause(n) Remedy

No flow The pump is conveying in the wrong direction

Check the rotational direction of the motor and, if necessary, reverse the phases.

Shut-off device outside of the CSM in the suction or pressure line is closed.

Open all the locking features in the suction and pressure lines.

Suction strainer of the gear pump is clogged.

Clean the suction strainer. See page 42.

Only CSM-E 1xxx-1 / -2: The coupling between the motor and the pump is loose or faulty.

Contact HYDAC.

Only CSM-E 1xxx-4: The magnetic coupling is disengaged and is slipping. Loud noise emissions.

Switch the pump off. Allow the unit to cool down. Switch the unit on again. Contact HYDAC.

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.

Fully open the downstream valve so that this pressure can drop and the pump can transfer again.

No function Not connected to power supply

Check the electrical connection: plug, cable and socket

If there are error messages from the sensors, please consult the corresponding chapters in the operation and maintenance instructions of the corresponding sensors.

Taking the unit out of operation

Drain the unit completely, including all of its components, before decommissioning. Disconnect all electrical and hydraulic connections.

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Shutting down the unit

Shutting down the unit

See chapter "Taking the unit out of operation"

Disposing of the unit

After dismantling the unit and separating the various materials, dispose of the unit in an environmentally-friendly manner.

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Ordering spare parts


Make sure to indicate the entire unit designation and the serial number in accordance with the type label when ordering spare parts.

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Item Designation Qty p/no.

10 Motor pump assembly 1 *

20 Manifold block 1 *

50 Pressure relief valve 1 *

60 Pressure relief valve 1 *

70 Rubber buffer 4 606841

80 Nut 4 *

90 Lock washer 4 *

100 Washer 4 *

110 Rubber buffer 2 6075352

120 Screw connection 2 *




170 Plug 3 -

180 Screw 4 *

220 Screw plug 1 615003

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Item Designation Qty p/no.

230 Strainer element 1 3152786

240 Pipe, assy. 1 *

250 Pipe elbow, assy. 1 *



280 Type label 1 *

290 Screw plug 1 613141

300 Plastic plug with hand lever 2 6044485

- Installation and Maintenance Instructions 1 3911629

*) available on request, -) not deliverable as spare part

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Ordering accessories


The following is a comprehensive range of power unit accessories: Designation p/no. Image

ContaminationSensor CS1210-A-x-x-x-1 3314212

ContaminationSensor CS1210-B-x-x-x-1 3308284






AquaSensor AS1008-C-000 909109

AquaSensor AS3008-5-000 922591

HLB14J8-1C000-000 923684

HLB14J8-00S12-000 923685

SensorMonitoring Unit SMU1260-TU-00 3467005




Pressure gauge Kit 0-60 bar 3942792

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Designation p/no. Image

Assembly Kit SMU (not compatible with CSI-C-11)

3942870

Assembly Kit CSM-E 3942869

CD FluMoS light 3141522

CD FluMoS Professional 3355176

CD FluMoT driver package 3355177

ContaminationSensor Interface CSI-D-5 3249563

ContaminationSensor Interface CSI-C-11 CSI-V-11-0-0-0/-000

4066011

Power supply unit, PS5 3399939

Connection cable, screened, with 5-pole elbow female connector, open

6019455

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cable end, length 2 m (ZBE 08S-02) Connection cable, screened, with 5-pole elbow female connector, open cable end, length 5 m (ZBE 08S-05)

6019456

Connection cable, screened, with 5-pole elbow female connector, open cable end, length 10 m (ZBE 08S-10)

6023102

Connection cable with 5-way female connector <-> 5-way male connector Length 0.5 m (ZBE 30-005)

4193586

Connection cable with 5-way female connector <-> 5-way male connector Length 2 m (ZBE 30-02)

6040851

Connection cable with 5-way female connector <–> 5-way male connector Length 3 m (ZBE 30-03)

6053924

Connection cable with 5-way female connector <-> 5-way male connector Length 5 m (ZBE 30-05)

6040852

Connection cable with 8-way female connector <-> 5-way male connector Length 0.5 m (ZBE 43-005)

4193544

Connection cable, shielded with 8-pin mating connector <-> 8-pin open end length 2 m (ZBE42S-02)

3281220

Connection cable, shielded with 8-pin mating connector <-> 8-pin open end length 5 m (ZBE42S-05)

3281239

Connection cable, shielded with 4-pin mating connector <-> RJ45

3346101

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length 5 m (ZBE45-05)

Connection cable, shielded with 4-pin mating connector <-> RJ45, length 10 m (ZBE45-10)

3346101

Socket plug, 5-pin with screw clamp (ZBE08) 6006786

Socket plug, 8-pin with screw clamp (ZBE44) 3281243

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Technical Data

Technical Data

General data

Permitted fluid temperature range 0 … 70 °C / 32 … 158 °F

Permitted ambient temperature range 0 … 40 °C / 32 … 104 °F

Permitted storage temperature range -40 … 80 °C / -40 … 176 °F

Permitted relative humidity maximum 90%, non-condensing Emission sound pressure level LPA < 70 dB(A)

Weight when empty ≈ 12 kg

Hydraulic data

Permissible pressure at suction port (IN)

CSM-E1xxx-1 - 0.4 bar … 0.5 bar

CSM-E1xxx-2 - 0.4 bar … 120 bar

CSM-E1xxx-4 - 0.4 bar … 80 bar

Permitted pressure at drain port (LEAK) CSM-E1xxx-2 0.5 bar max.

Permitted pressure at tank connection (OUT)

CSM-E1xxx-1 CSM-E1xxx-2 CSM-E1xxx-4

5 bar maximum

Pump type Gear pump

Maximum suction height 500 mm

Sealing material NBR / FKM*

Suction port (IN) G ¼“ Tank connection (OUT) G ¼“

Drain port (LEAK) G ¼“

Permissible operating viscosity range

CSM-E1xxx-1 CSM-E1xxx-2 10 … 3000 mm²/s

CSM-E1xxx-4 2 … 1000 mm²/s

Permissible viscosity range for the measurement operation

CSM-E1xxx-1 CSM-E1xxx-2 10 … 1000 mm²/s

CSM-E1xxx-4 2 … 800 mm²/s

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Technical Data

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Technical Data

Hydraulic data

Total flow 50 Hz 60 Hz

CSM-E1xxx-1 ≈ 90 ml/min ≈ 110 ml/min

CSM-E1xxx-2 ≈ 180 ml/min ≈ 220 ml/min

CSM-E1xxx-4 ≈ 230 ml/min ≈ 260 ml/min *) According to model code

Electrical data CSM1xxx-x-x-W/N/X60/O60

Voltage frequency 50 Hz 60 Hz

Voltage (delta circuit) 230 V, 50 Hz, 3 Ph 265 V, 60 Hz, 3 Ph

Voltage (Star (Y-) connection) 400 V, 50 Hz, 3 Ph 460 V, 60 Hz, 3 Ph

Current consumption 1.23 A / 0.71 A

1.18 A / 0.68 A

Nominal power 0.18 kW 0.21 kW

Continuous duty rating 100% 100%

Rotational speed 1425 rpm 1710 rpm IP class IP55 IP55

Insulation class F F

Electrical data CSM1xxx--x-x-N/AB/N60/AB60

Voltage frequency 50 Hz 60 Hz

Voltage (delta circuit) 400 V, 50 Hz, 3 Ph 400 V, 60 Hz, 3 Ph

Voltage (Star (Y-) connection) 690 V, 50 Hz, 3 Ph 690 V, 60 Hz, 3 Ph

Current consumption 0.71 A / 0.41 A

0.57 A / 0.33 A

Nominal power 0.18 kW 0.18 kW

Continuous duty rating 100% 100%

Rotational speed 1425 rpm 1755 rpm

IP class IP55 IP55

Insulation class F F For other electrical versions, obtain the respective data from the type label on the electric motor.

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Appendix

Appendix

More details on the powerpack are given in this chapter.

Customer service Regular inspection and maintenance work is indispensable for ensuring trouble-free operation and long service life for your powerpack. HYDAC SERVICE GMBH Friedrichsthaler Straße 15a, Werk 13 66540 Neunkirchen-Heinitz Germany Telephone: +49 681 509 441 Fax: +49 681 509 324 E-mail: [email protected]

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Appendix

Unit dimensions The powerpack has different dimensions depending on how it is equipped with sensors and interface modules.

Dimensions with CS1000, AS1000 and CSI-C11


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Appendix

Dimensions with CS1000, HLB1400 and CSI-C11


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Appendix

Model code CSM-E 1 2 2 0 - 1 - 1 W/N/X60/O60 AS Type CSM-E Series 1 = for CS1000 with flange

connection

Manifold block 0 = Prepared for the assembly of

AS1000 / AS3000

1 = Prepared for the assembly of HLB1400

Type 0 = Standard Fluids 0 = Based on mineral oil Hydraulic version 1 = Gear pump, standard

2 = Gear pump, inlet pressure-stable, up to a maximum of 120 bar, with oil leakage pipe

4 = Gear pump, inlet pressure-stable, up to a maximum of 80 bar, without oil leakage pipe

Sensors Z = without Power supply W/N/X60/O60 = 230 V, 50 Hz, 3 Ph / 265 V, 60 Hz, 3 Ph

400 V, 50 Hz, 3 Ph / 460 V 60 Hz, 3 Ph

Supplementary details - = without

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Appendix

Explanation of terms and abbreviations An explanation of terms and abbreviations follows below:

AC Alternating current

AS AquaSensor

CD Compact Disc (CD-ROM)

CS ContaminationSensor

CSI ContaminationSensor Interface

CSM-E ContaminationSensor Module - Economy

dB Decibel

DC Direct current

DIN Deutsche Industrie Norm (DIN) [German Industry Standard]

DN Nominal Diameter

EG European Community

EU European Union

FKM Fluoroelastomer rubber

FluMoS FluidMonitoring Software

FluMoT FluidMonitoring driver package

HLB HYDACLab Sensor

IN Inlet

INLET Inlet

LEAK Leakage oil connection

NBR Nitrile rubber

OUT Outlet

OUTLET Outlet

PS PowerSupply

SMU SensorMonitoring Unit

Upm Rpm

ZBE Electronics accessories

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Appendix

Index

A AquaSensor 20, 21, 32, 49, 60

C ContaminationSensor 1, 11, 18, 19, 20, 21, 23, 24,

32, 36, 49, 50, 60 CSI 32, 50, 57, 58, 60

D DIN 60

E Error 44

F Filter 11 FluMoS 50, 60 FluMoT 50, 60

I IN 20, 21, 26, 28, 33, 53, 60 INLET 17, 60 Installation 1, 7, 18, 24, 48 IP 55 ISO 12

O OUT 20, 21, 26, 29, 30, 33, 36, 38, 53, 60 OUTLET 60

S Sensor 60

T Transport 14, 16

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HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 6897 509 01 Central Fax: +49 6897 509 9046 Technology Fax: +49 6897 509 577 Sales Department Internet: www.hydac.com E-mail: [email protected]

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