Filtration Station Operating Manual

®

Filtration Station Operating Manual

1. Warnings / Cautions & Notes .......................................................................................................…………..4 1.1 Acronym List………………………................................................................................…………. … 5

2. Specifications..............................................................................................................................................6

3. Controls and Indicators..................................................................................................................………....7

4. General Operations......................................................................................................................………… 11

5. Cleaning Methods & Times...........................................................................................................…………12 5.1 Filtration Technique…………………...............................................................................……….....12 5.2 Manual / Auto Mode Selector Switch..............................................................................………….13 5.3 Start-Up…………………..………….................................................................................………….13

6. Maintenance.................................................................................................................................…………14 6.1 ServicingFilterElements…………...........................................................................................…..14 6.2 ServicingtheStrainer…..…………................................................................................…………..15 6.3 DCMotor……………………………................................................................................…………..15

7. CS1000Operation.........................................................................................................................………...16 8. CS1000 Modes & Menus....................................................................................................................…......19 8.1 Power Up Menu.....…………………...............................................................................……….....20 8.2 Measuring Menu............................................................................................................…………. 20

9. CS1000TechnicalData.....................................................................................................................…..…22

10. Fluid Monitoring Software (FluMoS).....................................................................................………............23 10.1 System Requirements………............................................................................................……......23 10.2 AdapterBox–DriverInstructions....................................................................................…………23 10.3 Installing FluMoS……...………..................................................................................………… ......25 10.4 Uninstall FluMoS…. ……...………............................................................................................. ....28 10.5 Starting FluMoS.....………..............................................................................................………….28 10.6 ScanningforUnits.....……….…...………................................................................................…....28 10.7 Serial Interfaces........……….…...………................................................................................…....29 10.8 ProcessingMeasurementData.....……….…...………...................................................................30 10.9 ExportingMeasurementData...………................................................................................….......31 10.10 Measurement File Format..……….................................................................................................32 10.11 SaveResults..…....................…….................................................................................................33

11. Aqua Sensor (AS1000)....................................................................................................................…...….33 11.1 AS1000TechnicalData...................................................................................................…………35

12. Maintenance Procedure................................................................................................................………...37

Appendix A : Troubleshooting….....……………......................................................................................................39Appendix B : Troubleshooting CS1000 …………………………..…........................................................................41Appendix C1:ISO4406.........………….................................................................................................…………..43Appendix C2:SAEAS4059....……………............................................................................................…………..44Appendix C3:NAS1638..……………….................................................................................................………….45

SalesDrawing……………………….………………........................................................................……….........…....46PartsListDrawing………………….………………..............................................................................……...…….....47HydraulicSchematicDrawing...…….……………….................................................................................…………..48ElectricalSchematic,ControlPanel.........................................................................................................................49Control Panel Schematic......................…………….………………...........................................................................50Control Panel Layout...............................................................................................................................................51ElectricalSchematic,ControlPanel.........................................................................................................................52

TABLE OF CONTENTS

Filtration Station

Hydac L-40214

1. WARNINGS, CAUTIONS AND NOTES Recognize Safety Information This is the safety alert symbol. When you see this symbolonyourmachineorinthismanual,bealertfor the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER,WARNING,orCAUTION — usedwiththesafetyalertsymbol.DANGERidentifiesthemostserioushazards.GeneralprecautionsareonCAUTION labels.

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Reviewthemfrequently.Besurealloperatorsofthismachineunderstandeverysafetymessage.Replacesafetylabels immediately if missing or damaged.

OperateOnlyIfQualifiedDonotoperatethismachineunlessyouhavereadtheoperator’smanualcarefullyandyouhavebeenqualifiedbysupervisedtrainingandinstruction.Familiarizeyourselfwiththejobsiteandyoursurroundingsbeforeoperating.

Inspect Machine Inspect the equipment carefully before each use. Keep all parts in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical power cord.

HandleFluidsSafely—AvoidFiresFilteringoffuelorotherflammableliquidsisnotrecommended.Storeflammablefluidsawayfromfirehazards.Donotincinerateorpuncturepressurizedcontainers.Makesuremachineiscleanoftrash,grease,anddebris.Donot store oily rags; they can ignite and burn spontaneously.

PrepareforEmergenciesBepreparedifafirestarts.Keepafirstaidkitandfireextinguisherhandy.Keepemergencynumbersfordoctors,ambulanceservice,hospital,andfiredepartmentnearyourtelephone.

Practice Safe Maintenance Understandserviceprocedurebeforedoingwork.Workareashouldlevel,clean,anddry.Beforeservicingmachine: -Positionmachineonalevelsurface - Allow to cool if hot

Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Removeanybuildupofgrease,oil,ordebris.

Handle Chemical Products Safely Directexposuretohazardouschemicalscancauseseriousinjury.Potentiallyhazardouschemicalsusedincludesuchitemsaslubricants,coolants,paints,andadhesives.AMaterialSafetyDataSheet(MSDS)providesspecificdetailsonchemicalproducts:physicalandhealthhazards,safetyprocedures,andemergencyresponsetechniques.ChecktheMSDSbeforeyoustartanyjobusingahazardouschemical.Thatwayyouwillknowexactlywhattherisksareandhowtodothejobsafely.Thenfollowprocedures and recommended equipment.

!

Filtration Station

L-4021 Hydac 5

WearProtectiveClothingWearclosefittingclothingandsafetyequipmentappropriatetothejob.Operatingequipmentsafelyrequiresthefullattentionoftheoperator.Donotwearradioormusicheadphoneswhileoperatingthemachine.

ServiceMachinesSafelyTielonghairbehindyourhead.Donotwearanecktie,scarf,looseclothing,ornecklacewhenyouworknearmachinetoolsormovingparts.Iftheseitemsweretogetcaught,severeinjurycouldresult.Removeringsandotherjewelrytopreventelectricalshortsandentanglementinmovingparts.

Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine.Makesurethebulbisenclosedbyawirecage.Thehotfilamentofanaccidentallybrokenbulbcanignite spilled fuel or oil.

Work In Clean Area Beforestartingajob: - Clean work area and machine -Makesureyouhaveallnecessarytoolstodoyourjob. -Havetherightpartsonhand. - Read all instructions thoroughly; do not attempt shortcuts.

Use Proper Tools Usetoolsappropriatetothework.Makeshifttoolsandprocedurescancreatesafetyhazards.Forlooseningandtighteninghardware,usethecorrectsizetools.DONOTuseU.S.measurementtoolsonmetricfasteners.Avoidbodilyinjurycausedbyslippingwrenches.Useonlyservicepartsmeetingspecifications.

DisposeofWasteProperlyImproperlydisposingofwastecanthreatentheenvironmentandecology.Potentiallyharmfulwasteincludesuchitemsasoil,fuel,coolant,brakefluid,filters,andbatteries.Useleak-proofcontainerswhendrainingfluids.Donotusefoodorbeveragecontainersthatmaymisleadsomeoneintodrinkingfromthem.Donotpourwasteontotheground,downadrain,orintoanywatersource.

1.1 ACRONYM LIST

CS1000 Contamination SensorAS1000 Aqua Sensor

DHC DirtHoldingCapacityGPM Gallons Per MinuteVFD VariableFrequencyDriveVAC Voltage Alternating CurrentVDC VoltageDirectCurrentPOT PotentiometerNPT National Pipe ThreadORB O-Ring Boss

Filtration Station

Hydac L-40216

Process Fluid Type: Hydraulic and lubricating oils Seal Compatibility: NitrilesealsandVitonseals:compatiblewithmostmineralbasedoils.

Inlet Fluid Temperature: -20°F-160°F(-29°C-66°C)MAXInlet Pressure: 15PSIG(1.0bar)(apositiveinletpressuremaydamagepumpshaftsealsand

causefluidloss)Fluid Circulation Rate: 3-8GPM(11-30LPM)withDCDriveOption/9GPM(34L/min)

Operating Viscosity: 230cSt(1000SUS)MAXElectrical Power Requirements: 120/220VAC,1Phase,60Hz,15Amp

120/220VAC,1Phase,50Hz,15AmpWeight: 195 lbs. (88 kg)

Dimensions: 26.6inchx23.5inchx45inch(675.6mmx596.9mmx1143mm)

Design Parameters

Hose Connections:Inlet:

Outlet:1"clearhosewith33”x1”DOMzincplatedwand3/4”clearhosewith33”x3/4”zincplatedwand

Electrical Control Box: NEMA4consolettecontainingvariablespeeddrive,operationcontrols,indicatorlights,particlecounterdisplay,AquaSensordisplay,USBconnection

Motor: 1HP(0.75kw),90VDCVariableSpeed/1HP115/220VACMotorPump: Externalgearpump

Wheels: 10 inch (25.4 cm) pneumatic wheels

Particle Filter:Filtration Ratio wrt

ISO 16889:Dirt Holding Capacity:

Highefficiency10mm element ß4.8(c)≥200 ß6.3(c)≥1000 238gm(8.4oz)

Water Removal Filter: 22oz.(651mL)freewatercapacityParticle Counter: Laser particle monitor for measuring particle contamination; reports data (in 90 second

intervals)asISO4406:1999cleanlinesscode.DownloadresultstoaPCviaUSBconnection.

Aqua Sensor: Monitorsdissolvedwatercontentinsystemfluidanddisplaysmeasurementaspercentoffluidsaturation.

External Components

HYDACAdded Value

2. SPECIFICATIONS

Filtration Station

L-4021 Hydac 7

3. CONTROLS AND INDICATORSControl/Indicator Description

Operator Interface Eachbutton,switch,andknobontheOperatorInterfaceinclearlylabeledoneveryFiltration Station. The numbers on the picture below correspond to the detailed explanation below.

Stop Push Button (1) A red mushroom-head push-button. When depressed push-button will remain in the

depressed condition until operator twists clockwise to reset. Unit will not operate when buttonisdepressed.Themasterstopwillstopunitoperationofmotor,thuscuttingflow.

Manual, Off, Auto Mode Selector Switch (2)

Athreepositionswitch,wherethepositionoftheswitchdeterminesthemodeofoperation. The Manual position is used for oil transfer operations where particle counterreadingsmaybelow,orfortransferringoil.AlthoughtheCS1000particlecounterdisplaywillstillshowreadings,theFiltrationStationwillruncontinuouslyuntilthe operator turns the unit off; the off position turns off the power to the motor. The Autopositionisusedforcirculatingoilthroughthefilteringsystem.Theunitwillshutdownwhenparticlecountsarebelowthepresetlevel.

Note:Theunitwillnotshutdownuntilthedesiredcleanlinessclassisreachedforthreecontinuous measurements.

Flow Control Knob (3) (Optional)

Aflowrangeof3-8gpm(11-30L/min)ispossiblewiththeDCdriveoptionFiltrationStation.Tocontroltheflowturntheknobtothedesiredflowrate.(optional)

AS1000 Display (4) TheHYDACAS1000AquaSensordisplayswatercontent(asapercentofsaturation)of the oil being processed.Note:Whilewatercontentinnewoilmayvary,typicallyitrangesfrom30-40%ofsaturation.Sinceanoil’ssaturationpointriseswithincreasedtemperature,oilwithwatercontentabove50%ofsaturationatoperatingtemperaturecanpotentiallyexhibitfreewateratlowertemperatures.TheFiltrationStationincludesawaterremovalfilterthatremovesfreewaterthatformsatlowertemperatures.Oilswithhighfreewatercontent(above100%saturation)canhavemilkyappearance.The Filtration Station should not be used on fluids with a milky appearance.

USB Communication Port (5)

ThisUSBcommunicationportallowsconnectivitytoalaptopwheretheusercanchangeCS1000settings,recordlivedata,ordownloadtointernalmemorythroughFluMoS.

CS1000 Particle Counter Display (6)

TheHYDACCS1000particlemonitorreportsfluidcleanlinessperISO4406-1999.TheunitisratedatIP67andhasaninternalmemorycapableofsorting100,000measurements.Operationandfunctionalityoftheunitisdefinedlaterinthismanual.

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Filtration Station

Hydac L-40218

Particulate Filter Indicator

TheHYDACvisualindicatorwillextendwhenbypassdifferentialpressureisreached.Whenextended,theindicatorwillbeRED.Note:Runningtheunitatlowerflowswillallowforlongerfilterlife.Changefilterbyfollowing the procedure outlined in the Maintenance Section.

Air Bleed off Valve/Fluid Sampling Port

Thisairbleedoffvalveisusedtoremoveanyairtrappedinthefilterhousingafteran element drainage or when air was accidentally sucked into the Filtration Station throughthesuctionwand.Thisvalvecanalsobeusedtosamplefluidbeingfiltered.

AS1000 Sensor

ThissenorismountedinthebaseofthefilterhousingandmeasuresthepercentofsaturationofthefluidbeingrunthroughtheFiltrationStation.Thissensortakesmeasurementsbeforethefluidreachestheelement.

Filtration Station

L-4021 Hydac 9

Lift Bar

Theliftbaristhedesignatedpickpointforacraneoranyotherliftingdevice.ThiswillallowtheFiltrationStationtobeliftedverticallyatthecenterofgravity.

Element Storage Containers

There is an element storage area on the back of the cart. These containers should be used to store new and used elements.

Filtration Station

Hydac L-402110

Main Filter Bypass Valve

Fornormaloperation(filtermode)thevalvehandleshouldberotatedtoahorizontalposition.Inthisposition,fluidflowisdirectedthroughthefilterhousing.Fortransferoperation(bypassmode)thevalvehandleshouldberotatedtoaverticalposition.Inthisposition,fluidflowisdirectedtotheoutlethose,bypassingtheparticulatefilter.ThisvalvepositionshouldonlybeusedforfluidtransferandwiththeunitinManualoperatingmode.*Note:Whenthecartisinfilterbypassmode,theCS1000will not display ISO codes.

Drip Pan should be removed from front of unit

Aplasticdrippanthatcanberemovedfromthefrontoftheunitfordisposalofanyoilthat was spilled during operation.

Filtration Station

L-4021 Hydac 11

4. GENERAL OPERATIONS

TheFiltrationStationisdesignedtoremoveparticulateandfreewatercontamination,aswellasmonitortheoilcontaminantlevelsinfluidpoweredsystems.FluidcontaminationisdisplayedasanISO4406CleanlinessCodeusingalightblockingtechnology.Dissolvedwatercontentoftheoilisdisplayedaspercentofsaturation.TheFiltrationStationisanoilfilteringsystemthatcapturescontaminantparticlesusinghighperformancefiltersoracombinationofwaterandparticulateremovalelements.

BelowaresummarizedinstructionsforoperatingtheFiltrationStation.

•Allsafetyproceduresassociatedwiththeoperationofelectricalpoweredequipmentmustbeobserved.

•Placethesuction(1”)hoseintothefluidtobefilteredortransferred.Placethedischarge(3/4”)hoseintothemachineryreservoirorwastecontainerdependingondesiredoperation.Ensurethatthewandsaresecuredtoavoidpossiblefluidloss.

• ELECTRICAL WARNING •Thesystem’s1½HPelectricmotordraws15ampsat115volts±10%,60Hzatfullload.Starting

current could be approximately 4 to 8 times greater. A proper circuit breaker should be installed to protectthemotorandmeetnationalandlocalelectriccodes.Recommendedsizeforanextension cable is 12AWG - 3 conductor with a maximum length of 25 feet.

•Themotorisdesignedforoperationonthevoltageandfrequencysuppliedonthemotornameplate

•Normalloadswillbehandledsafelyonvoltagesnotmorethan10%aboveorbelowthe specifiedvoltages

•Runningunitonvoltagesnotwithinrangemaycauseoverheatingandmotorburnout

•Heavyloadsrequirethevoltageatmotorterminalsbenotlessthanthevoltagespecified

•Tostarttheunit,placethemodeselectorswitchinthecorrectposition(ManualorAuto)forthedesiredoperation.Settingthespeedcontrolatabout3gpm(11L/min)isrecommendedforstartupiftheDCdriveoption is equipped.

Donotatanytimeallowpumptorundry.Allowingthepumptorunwithoutfluidflowingthroughitwillgreatlyreducepumplife.Duringfluidtransferoperationitiscriticalthatthepumpinletstaysubmergedinfluid.Pumpsthatareallowedtorundrywillnotbecoveredbywarranty.

Filtration Station

Hydac L-402112

5. CLEANING METHODS & TIMES

ThefollowingtableshavebeendevelopedtohelpdealersestimatethecleaningtimeswiththeFiltrationStation.NewtestingwiththeFiltrationStationhasallowedthedevelopmentoftheupdatedcleaningtimetables.Somefigureswereobtainedbyextrapolation.

Cleaningtimecanbeaffectedbysomefactors.KeepinmindthattheFiltrationStationisalwayscleaningthefluidsevenifthereadingsontheparticlecounterdon’tshowit.Thereasonsforthisfalsereadinginclude:

• The Filtration Station is producing air•TheFiltrationStationiscavitating• The particle counter has air bubbles trapped in sensing line•Thereturnwandisnotsubmergedinfluid•Thefiltertowerhasnotbeenpurged•MorethanoneFiltrationStationisbeingusedsimultaneouslyproducingtoomuchfluidturbulenceinreservoir• The oil is too cold•Theoilisheavilycontaminatedwithwaterandparticles• The speed is set too slow

Cleaningtimescanvary,butshouldrarelytakemorethanonehouronmediumsizeconstructionmachinesthatarenotextremelydirty.Reachinghighcleanlinesslevelsonproductionsizemachines,,couldtakelongerthanonehour.

5.1 Filtration TechniqueWandpositioningisanimportantpartofmaximizingthecleaningspeedoftheFiltrationStation.Thebestsituationoccurswhenthereservoirhasalargebutshortopening.Thatwaythewandscanbecrossedtocreateturbulenceinthereservoirandfilterthefluidfaster.Whenthereservoirissmallerandhasalongornarrowopening,thewandshavetobeoffsetatdifferentheights,asshownbelow.Inthisorientation,theflowandcleaningspeedwillbelowerthan with crossed tubes.

Filtration Station

L-4021 Hydac 13

Whenchangingbetweenreservoirscontainingdifferentfluids,thefollowingprocedureshouldbefollowed:

•Prepareanemptywasteoilcontainer(5gallonbucket),aswellasatop-offcontainerforfluidremovedfromthe hydraulic system (5 gallons).

•Insertsuctionwandintoreservoirandplacedischargewandintothewastecontainer.•Replaceexistingparticlefilterandwaterremovalfilterwiththoseofthefluidinthemachine•RuntheFiltrationStationuntilthewastecontainerisfilledwithabout4gallonsoffluid.•Removedischargewandfromwastecontainer,wipeitclean,andinsertintoreservoir.•Positionwandsinthecorrectorientationandbeginreservoirfiltrationuntildesiredcleanlinesslevelhasbeenachieved.

• Cycle machine hydraulic functions.•Resumereservoirfiltration.

5.2 Manual /Auto Mode Selector Switch ManualPositionisusedforfluidtransfer.TheManualpositionavoidsparticlecountershutdownduetocleanfluid.OperationoftheFiltrationStationwiththeswitchintheManualpositionwouldtypicallybeusedtotransferwastefluidsoutofmachinerytoawastecontainerfordisposalortotransfernewfluidtomachinery.Filtrationisnotnormallyrequiredforwastetransfer.Totransferwithoutfiltration,theMainFilterBypassvalve(yellowhandle)shouldbesetinthehorizontalposition.Inthisposition,fluidisdiverteddirectlyfromthepumpoutletthedischargehose.TheManualpositionmayalsobeusedwhentransferringnewfluidintomachinery,inwhichcase,filtrationisrecommended.ThisisaccomplishedbysettingtheMainFilterBypassvalvetotheverticalposition.

AutoPositionisusedforkidneyloopfiltrationofequipmentreservoirs.InAutoModetheparticlecounterwillshutdowntheFiltrationStationwhenfluidcleanlinessmeetsspecifiedlevels.TheMainFilterBypassvalvemustbeintheverticalpositiontodirectflowthroughtheparticulatefilterhousingandparticlecountertransducer.IftransferingwatersaturatedfluidthroughtheFiltrationStation,theelementcanbechangedtothewaterremovalelementwiththevalveinthehorizontalposition.

For procedure on changing Auto Mode cleanliness levels please see section 8.2.

5.3 Start-Up Afterabovesetupiscomplete,theunitisnowreadyforstartup.Placetheselectorswitchtoeithermanualorautomatic,andadjustthebypassvalve.Flowratecanbeadjustedbyrotatingthemotor-speedcontrolknobonoperatorconsole,clockwiserotationtoincreaseflow.Theparticlecounterinputisdeactivatedforthefirstfiveminutesfollowingthestart-upoftheFiltrationStationtoallowtheparticlecountertoflushoutpreviouslyrunfluid.InAutoMode,theFiltrationStationwillshutdownautomaticallyoncethepresetparticlecountisachieved.Theyellow selector switch (system clean) indicator light will remain illuminated after shut down to indicate that system is clean. Formanualshutdownatanytime,depresstheEmergencyMasterStopbutton.ResettheStopbuttonbytwistingclockwise.Donotallowpumptorundry.

Filtration Station

Hydac L-402114

6. MAINTENANCE Nomaintenanceoperationsotherthanadjustmentoftheflowshouldbecarriedoutwhiletheunitisrunning.Be-forestartinganyothermaintenanceoperations,ensurethatthesystemisshutdownandelectricallysafe.Systempressurecanbecontainedintheunitforsometimeafterithasbeendisconnected.Torelieveexcesspressureopenthebypassvalve.Thisiswillreturnsystempressuretoatmosphere.

6.1 Servicing Filter Elements

Priortoservicingthefilter,bleedoffanytrappedpressureintheFiltrationStation.Depressthetopoffthebleedpluguntilallpressureisrelieved.Excessfluidwillbedispensedintothedrippan.

Turnthefiltercapcounterclockwiseusinga1½”wrench or socket until the threads are no longer engaged.Removethecapandinspecto-ringincapfor damage. Replace if required. Next,removetheusedelementandreplacewithanewelement. Additional element and storage is located in the back of the Filtration Station .

Withnewelementinstalled,insertcapbushingintotopof element. Tighten the cap clockwise until all of the threads are engaged.

Uponstart-up,thefilterhousingwillneedtobebledofanytrappedairtoensurealloftheelementisutilizedformaximumefficiency.Depressthebleedvalveuntilfluidstartstocomeoutofthebleedhose.

Filtration Station

L-4021 Hydac 15

Do not run the system without a filter element installed. Use only specified replacement filter elements.

6.2 Servicing the Strainers

TheParticleMonitorstrainerisa1”hexfittinglocatedatthebaseofCS1000-K.Loosenhoseconnection,andremoveentirestrainerbodyfromtheline.Sloshthestrainerinamineralbasefluidtodislodgeanyloosedebris.Donotusepressurizedairorafluidstream,asthismaydamageinternalscreen.Reinstallstrainer.

Becarefulnottoovertightenthecap.AcloggedfilterscreencouldresultinaCS1000“lowflow”error,picturedbelow.

6.3 DC Motor

Themotorshouldbeinspectedatregularintervals(every500hoursofoperationorevery3months,whicheveroccursfirst).Keepthemotorcleanandtheventilationopeningsclear.

Duringoperation,listenforunusualnoises,especiallyintheareasaroundthebearings.Rumblingorrubbingnoisescouldbesignsofinternaldamage.Note:MotorissuppliedwithrectifiedDCpowerandmaymakeahummingnoisewhenoperatingnormally.Thismaybeevenmorenoticeableatlowerspeeds.Ifyouhearagrowling or erratic hum the power supply should be checked for proper operation and phase balance. Improperadjustmentorfunctioningofthepowersupplymaycausethemotortooverheatandshortenitslife.

Filtration Station

Hydac L-402116

7. CS1000 OPERATION

DisplayandKeypadElements(CS1000-D)

Thekeypadconsistsofsixkeys.ThesekeysareusedtooperatetheCS1000andtonavigatethroughthemenus(hierarchically structured).

Measured variablesThemeasurementvariablesprovidetheuserinformationaboutthecleanliness(orcontamination)oftheoilinhisfacility.Themeasurementvariablesarecalibrated.Theyindicateameasuredvaluewithanaccuracyof+/--0.5codes/class.

Measuredvariable“ISO”

Measuredvariable“SAE”

Servicevariables

TheservicevariablesenabletheusertoretrieveinformationonthecurrentstatusintheContaminationMonitor.Theservicevariablesarenotcalibrated.Theyindicateanapproximatevalue.

Pos. LED DescriptionA Status Indicates the status of the Contamination SensorB Display Consistsofsixdigitsandshowsthemeasuredvalues.C Measured Variable Indicatesthemeasuredvariableofthedisplayvalue,i.e.

ISO/SAE/NAS

D Additional Variable Indicatesthemeasuredvariableofthedisplayvalue,i.e.Flow/Out/Drive/Temp

E Switch point 1 Indicatesthestatusoftheswitchingout.Whenlit,theswitchingoutputisactivated(closed).

F Switch point 2 Reservedforfutureuse

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L-4021 Hydac 17

Servicevariables“Flow”

Servicevariables“Out”

Servicevariables“Drive”

Servicevariables“Temp”

Key LockThekeypadcanbelockedtoprevententriesfrombeingmade.Toactivateordeactivatekeypadlocking,pressbothkeyssimultaneously:The display switches to the preset display after 1 second.

Keypad Buttons Description

- oneleveldown- confirmchangedvalue(lowestlevel)- confirmwhenchangesaretobesavedorcancelled(toplevel)

- onelevelup- novaluechange

- changevalueatthelowestlevel(whendisplayisblinking)

- scroll through display- scroll through menu- select digit

Display Description

Displayedmeasuredvariable“ISOcode”

Display Description

Displayedmeasuredvariable“SAE”

Display Description

Flow rate (e.g. 120 ml/min)

Filtration Station

Hydac L-402118

Display Description

Showscurrentorvoltagelevelattheanalogoutput.(example:13.8mA)

Display Description

Showstheefficiency(1-100%)withwhichtheLEDcurrentlyworksintheCS1000.(example:60%)

Display Description

Shows the temperature in the sensor. (example:29.5°Cor84.2°F)

NOTE:Thefluidtemperatureisnotdisplayed,onlythetemperature inside of the CS1000 housing is displayed.

Actuate these keys The following appears in the display (1 sec)

Description

KeyLockisactivated

KeyLockisdeactivated

Filtration Station

L-4021 Hydac 19

8. MODES AND MENUSThesensorfeaturestwooperatingmodes,eachmodewithamenuofitsown

8.1 Power Up Menu:The Power Up menu is for the basic settings.

POWER UP - Menu

MODE - Select Measuring Mode

Menu Mode DescriptionPower Up Menu Power Up Mode For basic settings

Measuring menu Measuring mode Starts automatically after powering upShowscontinuouslymeasuredvalues

Selection How

EnterPowerUpMenu Press any button and hold it down while switchingonthesupplyvoltage

Exitmenuwithoutsavingchanges ScrolltoCANCELandpressOKautomaticallyafter 30s without any action

Exitmenuandsavechanges ScrolltoSAVEandpressOK

Description

MODE Select measuring modemTIME Set measuring time

pPRTCT Set time for pump protectionADRESS Set bus addressDFAULT Reset to factory defaultsCANCEL DiscardchangesandExitSAVE SavechangesandExitCODE For internal use only

Description

M3 Filterdowntocontaminationlevelandstop

Filtration Station

Hydac L-402120

mTIME - Set Measuring Time

pPRTCT - Set Time for Pump Protection

ADRESS - Set Bus Address

DFAULT - Reset to factory defaults

CANCEL-Discardchangesandexit

SAVE-Savechangesandexit

CODE-Activateservicemenu-For internal use only

8.2 Measuring Menu:The Measuring Menu allows the changing of setting during operation.

Description

60 Set time in seconds (10 - 300)

Description

0 Settimeforstopwithnoflowin“seconds”(0-10)

Description

HECOM z Setaddress(a,b,...z)IP NOSET

MODBUS NOSET

Selection HowEnterMeasuringMenu Press OK Button

ScrolltoCANCELandactuateit ScrolltoCANCELandpressOKautomaticallyafter 30 seconds without any action

ExitMenuandsavechanges ScrolltoSAVEandpressOK

Filtration Station

L-4021 Hydac 21

M3-Filterdowntocontaminationlevelandstop

Display-Selectdisplayedmeasuredvariablewhenswitchingonthesensor(default)

DSPLAY-Selectdisplayedmeasuredvariable

MODE-ConfiguremeasuringmodeFor setting the switch output selected in the Power Up menu. (Only the mode selected in the Power Up menu can be set here)

SWT.OUT-Configureswitchingoutput

M3-Filterdowntocontaminationlevelandstop

Description

DSPLAY SelectmeasuredvariablefordisplayMODE Configuremeasuringmode

ANaOUT SelectmeasuredvariableforanalogoutputCANCEL DiscardchangesandExitSAVE SavechangesandExit

Description

ISO 3-number ISO codeSAEA SAEclassASAEB SAEclassBSAEC SAEclassCSAED SAEclassDSAeMAX SAEclassA-D

FLOW Flow rate (in ml/min)ANaOUT Analog output (in mA)DRIVE LEDcurrent(in%)TEMPC Fluid temperature in °C (Celsius)TEMPF Fluid temperature in °F (Fahrenheit)

Description

M3 Filterdowntocontaminationlevelandstop

Description

MEASCHISO ISO CodeSAE SAEClass

TARGET TargetContaminationLevelANA.OUT - Selectmeasuredvariableforanalogoutput

Filtration Station

Hydac L-402122

Switching Behavior of the Switching Output

Mode 3 (M3) Switch output - OPEN Switch output - CLOSEDMeasurement is currently in progress and all of the last 5measuredvalues<limitor

measurement stopped

5consecutivemeasuredvalues>limit

Mode 4 (M4) Switchoutput-CLOSED Switchoutput-OPENStart or result of check

measurement after test cycle time ≥upperlimit

Measurement is currently in progress and one or more of the last5measuredvalues>limit

5consecutivemeasuredvalues≤limit or measurement stopped

Upon the test cycle time elapsing for the duration of a check

measurement

Test cycle time has elapsed Opensagainwhenmeasuredvalue<upperlimit

Restart test cycle time

Mode Single (SINGLE) Switch output - CLOSED Switch output - OPEN- Always Open

9. CS1000 TECHNICAL DATASelf-diagnosis: continuouslywitherrorindicationvia

statusLEDDisplay(onlyCS1000): 6digits,in17segmentformat

Measuredvariable: ISO/SAE/Flow/Out/Drive/TempAmbienttemperaturerange: -22°...176°F(-30°...+80°C)Storagetemperaturerange: -40°...176°F(-40°...+80°C)

relativehumidity: max.95%,non-condensingMaterialofsealing: FPM ->CS1000

Electricalsafetyclass: III(lowvoltageprotection)IPclass: IP67Weight: 3.3 lbs (1.3 kg)

Measuringrange: Displayshowsclassfrom:min:ISO7/6/5 tomax:ISO28/27/26Calibrated within the range ISO 13/11/10 ... 23/21/18

INLET: 4350 psi max./ 300 bar max. OUTLET: 4350 psi max./ 300 bar max.

Connectors: INLET:ThreadG1/4,ISO228OUTLET:ThreadG1/4,ISO228

Permissiblemeasuringflowrate: 30 - 300 ml/minPermissibleviscosityrange: 15–4635SUS(1-1000cSt)

Fluidtemperaturerange: 32°-185°F(0°-+85°C)

Gen

eral

Dat

aH

ydra

ulic

Dat

a

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10. FLUID MONITORING SOFTWARE (FluMoS)TheFluMoSPC-softwarepackageisfreewareandissuppliedonaCDincludedwiththeFiltrationStation.

10.1 System RequirementsThefollowinghardwareandsoftwarecomponentsarerequiredtorunFluMoS:-ProcessorPentium≥200MHz-RAM ≥64MB-GraphVGAgraphiccard,minimumresolution800x600-Harddrive≥15MBfreememory.- Interface 1 free serial or USB interface which is not being used by any other program (e.g.terminal,modemornetworksoftware).-OperatingsystemWINDOWS2000,WINDOWSXP,WINDOWSVista,WINDOWS7(32bit)-InternetExplorer≥4.0- Access rights Administrator or software installation rights

10.2 Adaptor Box — Driver InstallationBeforeinstallingthesoftwarepackage,theRS485/USBconverterdrivemustbeinstalled.

1)ConnecttheUSBportontheFiltrationStationtoyourPCviatheUSBcable.YourPCdetectsthenewhardware.

2)Select“Installfromalistorspecificlocation(Advanced)”andclick“Next”.

3)PlacetheCS1000softwareCDintheCD-ROMdrive.

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4)Click“Browse”andselectthe“USBDriver”folderontheCD.

5)Click“Next.”Thedriverisnowinstalled. Afterasuccessfuldriverinstallation,clickonStart>ControlPanel>System>Hardware>Device

ManagerandnotetheCOMportnumberassignedtotheBelkinSerialonUSBPortdevice.TheCOM port number will be used when launching the FluMoS software.

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10.3 Installing FluMoS

WerecommendthatyouuninstallolderversionsofFluMoSsoastoensurethatthesoftwarefunctions properly.ReadtheREADMEfile.Thisdocumentcontainsup-to-dateadditionalinformationthat supplementsthismanual.WeadviseyoutoreadtheentirefilebeforeusingFluMoS.TheREADMEfile islocatedontheinstallationCDorintheunzippedfiledownloadedfromourwebsite.

TobegintheinstallationofFluMoS,starttheprogramSETUP_FLUMOS_xxx.EXEontheCDorinthe unzippedfiledownload.

Selectthelanguageforthesetupwizard.

Thesetupwizardwillguideyouthroughtheinstallationprocess.Tocontinue,clickon“Continue”.

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Tocontinuetheinstallation,carefullyreadthroughthelicenceagreementinthenextwindowandthen click “Iaccepttheagreement.”

Duringinstallationonlytheprogramfilesarecopiedtotheinstallationdirectory.Inthenextstep,theinstallationdirectoryisdefined.Iftheinstallationdirectoryalreadyexists,youwillbeaskedifyouwishtooverwritethepath

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Then a start menu directory will be created

Confirming(pressingtheInstallbutton)causestheinstallationprocesstobestarted.

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Clickthe“Finish”buttontoclosethesetupwizard.

10.4 Uninstall FluMoS

TouninstallFluMoS,runtheUNINS000.EXEfilelocatedintheinstallationdirectoryorlaunchuninstall fromthe“Start”menu:

TheDATAdirectorycannotbedeletedfordatabackupreasons.

10.5 Starting FluMoS

Oncetheprogramhasbeeninstalledinthesuggestedpath,itcanbefoundinthe“Start”menuunder “Programs->HYDAC->FluMoS xxx”.Tolaunchtheprogram,clickon“Start FluMoS xxx”.

10.6 Scanning for Units

OnceyouhavestartedFluMoSyouwillbetakentoawindowinwhichthefollowingoptionswillbe available:

Startsearch Thescanwillstartanddevices/sensorswillbelocated Main window You will go directly to the main FluMoS window without a scan.

Fordevices/sensorstocommunicatewiththePCyoumustdefinecertainsearchcriteria.

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10.7 Serial Interfaces

Foraserialinterface,youcanchoosebetweenthefollowingparametersforthesearchmode: -Donotbrowse -Findadevice -Findmultipledevices Seetheoperatinginstructionsforthedevice/sensorconcernedfortherequisitecommunications protocols,busaddressesandBaudrate.

Ifyouselected“All”asthebusaddress,FluMoSwillcheckallofthepossiblebusaddressesforthe protocolconcerned.Thiscanbeaverytime-consumingprocesssowedorecommendthatyouconfigure a particular bus address.

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10.8 Processing Measurement Data

Open/save measurement data Savedfilescanbeopenedviathe“File->Openlogfile”menuitemorviathetoolbarbutton. Whenthefileisopen,youcanseethemeasurementsinthemainwindow.

YoucanalsoopenthisfileinMSExcelasatextfile.Itconsistsofseveralcolumnsofdataseparatedby tabs.TheformatofthefileisdescribedinmoredetailintheMeasurementfileformatchapter. Thefollowingtypesoffilecanbeopened: -FluMoSandCoCoSfiles (*.dat) -SMU1100files(*.csv) -HSILogfiles (*.herf,CMU1000,HMG3000andCMWINsoftware) Themeasurementdataisstoredasatextfile(*.dat).Viathe“File->Saveas…”menuitemyoucan createacopyofthemeasurementfile.Notethatforsecurityreasons,theoldfilewillnotbedeleted.

FluMoSsupportsworkwithseveralfilesinparallel,whichmeansthatyoucanviewseveralfilesatthe same time.

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10.9 Exporting Measurement Data

Viathe“File->Export FluMoS data…”menuitem,thecurrentfilecanbeexportedintoadifferentfile format.FluMoSallowsdatatobeexportedinthefollowingformats: -MSExcel(*.xls) -RichTextFormat(MSWordPad,MSWord,*.rtf) -CSVformat(*.csv) -XMLformat(*.xml) - HTML format (*.html) -3graphicformats(*.bmp,*.jpeg,*.gif) Thegraphicsarealwaysexportedinthecurrentgraphicview.

Print Graph Youcanprintanimage(thecurrentview)directlyfromFluMoS.Selectthe“File->Printimage…”menu.

Hereyoucanconfigurethemargins.The“Pages”fieldisonlydisplayedifthegraphrunsovertomore thanonepage.Afterpressingthe“Print...”button,theWindowsdialogtoselecttheprinterandwiththe printer settings will appear.

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10.10 Measurement File Format

FluMoSautomaticallygeneratesthefilename.Itusesthepointintimewhentherecordingwasstarted. Forexample,thefilename„070629_1753.dat“meanstherecordingwasstartedon29.06.2007at17:53.

TheLOGfilealwaysconsistsoftwoparts.Inthefirstpart,generalinformationabouttherecordingand units/sensorsissaved. Theseinclude: • FluMoS – Version •Timewhentherecordingwasstarted,numberofmeasurementdataentries,recordinginterval •Numberofdevices,SensorID,measuringpoints • COM ports (interfaces) of the computer and the bus addresses of the units •Communicationsprotocolusedbythedevices(0->HSI,1->DINinstrumentation-bus) • Channel number for each unit • Upper and lower limit of the measurement category and measurement units • Comment on the recording Aftertheword*Data,*theactualmeasurementdataissaved.Eachmeasurementvalueisplacedina column. The channel name is found in the header.

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10.11 Save ResultsMeasureddataofthesensorcanbestoredasafileonthePCbypressingSave Results.

[ThebuttonchangestoStopSaving]

Thefilenameandthedirectorycanbeselected:

Thefileisstoredina“CustomPattern”format(.SAV),whichcanbeopenedwithatexteditor.Werecommend:WindowsEditororNotepad.

ThedatacanbedirectlyimportedintoMicrosoftExcelorstoredwithvaluesseparatedbytabs.

ThesaveresultsprocedurecanbestoppedbypressingStop Saving.

11. Aqua Sensor (AS1000)

DescriptionTheAS1000isawaterandtemperaturesensorforthecontinuousmonitoringofhydraulicandlubricationfluids-accurately,continuouslyandonline.Itmeasuresthewatercontentrelativetothesaturationconcentration(saturationpoint)andoutputsthedegreeofsaturation(saturationlevel)intherangeof0to100%asa4-20mAsignal.Areadingof0%wouldindicatetheabsenceofwater,whileareadingof100%wouldindicatethatafluidissaturated with water.

ThespecialcapacitancesensorusedintheAS1000absorbswatermoleculesfromthefluidandchangesitscapacityvaluethatisdirectlyrelatedtothesaturationlevelinthefluid.Anintegratedthermoelementonthesensormeasuresthetemperatureofthefluidintherangeof-13to212F(-25to100°C)andoutputsitasa4to20mAsignal.

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FunctionalityWhatisthedesiredsaturationlevelinhydraulicandlubricationsystems?

Sincetheeffectsoffree(alsoemulsified)waterismoreharmfulthanthoseofdissolvedwater,waterlevelsshouldremainwellbelowthesaturationpoint.However,evenwaterinsolutioncancausedamageandthereforeeveryreasonableeffortshouldbemadetokeepsaturationlevelsaslowaspossible.Thereisnosuchthingastoolittlewater.Asaguideline,werecommendmaintainingsaturationlevelsbelow45%inallequipment.

Dimensions

Circuit Diagram

Signal saturation level

TWS-C-M

2 1

3

4

+Ub

Signal temperature RL

RL

5

GND

Pin5reserved

RLmax = (UB-10V)/20mA[kΩ]

RLmin=47Ω

AS1000

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INPUT DATA Measuringrange(saturationlevel): 0...100%Measuringrange(temperature): -13...212F/25..+100°C

Operatingpressure: Max.725psi,/max.50barOverloadpressure: Max.9135psi/max.630bar

Partsincontactwithmedia: stainlesssteel,sealvitonorEPDM,ceramicwithevaporatedmetal

OUTPUT DATA Humidity measurement

Outputsignal(saturationlevel): 4 .. 20 mA Calibratedaccuracy: ≤±2%FSmax.

Accuracyinmediameasurements: ≤±3%FStyp.Pressure-dependent: +0.02%FS/bar

Temperaturemeasurement:Outputsignal(temperature): 4 .. 20 mA

Accuracy: *±2%FSmax.AMBIENT CONDITIONS

Nominaltemperaturerange(saturationlevelmeasuring: 32...194F/0..+90°C

Ambienttemperaturerange: -40...212F/-40..+100°CFluidtemperaturerange: -40...257F-40..+125°C

Viscosityrange: 32 .. 23175 SUS Flowvelocity: <16ft/s

Mediatolerance: mineraloilbasedfluids,naturalandsyntheticestersCEmark: EN50081-1,EN50081-2

EN50082-1,EN61000-6-2TypeofProtectionacc.DIN40050: IP67

OTHER DATA Supplyvoltage: 12..32VDC

Residualripplesupplyvoltage: ≤5%Mechanicalconnection: G3/8ADIN3852

Torquerating: 18.5 ft-lbs. Electricalconnection: M12x1,5pole(DINVDE0627)

Pin1: +UbPin2: SignalsaturationlevelPin3: 0V/GNDPin4: Signal temperaturePin5: not connected

Reversepolarityprotectionofthesupplyvoltage,excessvoltage,overrideandshortcircuitprotection:

standard

11.1 AS1000 TECHNICAL DATA

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Flow Rate: 3-8 GPM (1.4-30.3 l/min)/9GPM (34 l/m)

Max Pressure: 35 PSI (2.4 bar)Viscosity Limit: 1,000SUS

Weight (Approx.): 195 lbs.(117.93 kg)Operating Temperature (Hydraulics):

Depending on Viscosity-20°F to 150°F(-29°Cto65°C)

Operating Temperature (Electronics):Up to 95% non-condensing humity

32°F to 113°F(0°C to 45°C)

Environmental Rating:The Filter Caddy should not be exposed to ex-

treme weather conditions including rain and snowNEMA4

Power Requirements: 120/220VAC50/60HZ@15A

CyclethehydraulicsystemthoroughlyinordertoflushthecontaminatedfluidfromthelinesandsystemcomponentssoallthefluidinasystemwillbefilteredthroughtheFiltrationStation.

Precautionary Measures - Follow these simple rules to keep the Filtration Station in top working condition to providequalityfilteringforyearstocome.

The PumpNeverstartuporrunadrypump.Thiswillcausegalling,seizingordestructivewearbetweentherotors,end plates and casting.

Fluid TypesTheFiltrationStationisdesignedforthetransferandfilteringofhydraulicandlubricationoilsonly!Itisnottobeusedforhighlyvolatilefluidssuchasgasolineorpaintthinners.Pleasecontactthefactoryforusesotherthanthosespecified.

Ambient TemperatureThe maximum operating temperature for the Filtration Station is 150°F. Higher temperatures could damage the hoses.

Electric MotorIt is recommended that the electric motor be replaced with a new motor only.

Replacement PartsSinceminimumrepairserviceisgenerallyrequiredontheseunits,itisrecommendedthatanyfailedpartsbereplaced with new parts.

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12 MAINTENANCE PROCEDURESAchievingthebestfilteringefficiency-Inordertoensurethepropercleaningofthereservoirfluid,positiontheendsofboththeinletandtheoutlethoseortubeasfarapartaspossibleinsidethereservoir-preferablyondifferentsidesoftheexistingbaffle

REPLACEMENT ELEMENTS

9 inch Elements 18 inch Elements 27 inch ElementsModel Code Part No. Model Code Part No. Model Code Part No.5.03.09D03BN 2060528 5.03.18D03BN 2060430 5.03.27D03BN 2065003

5.03.09D03BN/-V 2056713 5.03.18D03BN/-V 2071680 5.03.27D03BN/-V 20828555.03.09D05BN 2060529 5.03.18D05BN 2060431 5.03.27D05BN 2065004



5.03.09D20BN/-V 2056716 5.03.18D25BN/-V 2072428 5.03.27D20BN/-V 020960525.03.09D40AM 2075265 5.03.18D40AM 02098017 5.03.27D40AM 2088358

HK/HJ (connector element) 2056730 — — — —

VISUAL INDICATORModel Code Part No.

D5-30 02702213D5V-30 02702561

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SpecificationsFluid CompatibilityAnypetroleumbasedfluidwhichiscapableofbeingcountedusingalaserparticlesensor.

Thefluidmustbefullyhomogeneousandtranslucent.Emulsions,microemulsions,orcertainfluidswithadditivesthatcangivefalseparticlereadings,forexampleMobileFluid424,isnotrecommended.

Appropriate seals should be chosen by the user to ensure compatibility.

WARNING!PerformanceoftheFiltrationStationisbasedupontheuseofHYDACilterelements.TheFiltration

StationisdesignedaroundthepressuredropsandspecificationsofHYDACBetaMicronMedia.

Cleaning after switching fluids - Cross contamination flushingSTEP1-Prepareanemptywasteoilcontainer(5gallonbucket),aswellasatop-offcontainerforfluidremoved

from the hydraulic system (5 gallons).STEP2-Insertsuctionwandintoreservoirandplacereturnwandintothewastecontainer.STEP3-Replaceexistingparticlefilterandwaterremovalfilterwiththoseofthefluidinthemachine(ifFiltration

StationhasHy-GardfiltersandmachineusesPlus-50,theninstallfiltersusedwithPlus-50oil).STEP4-RuntheFiltrationStationuntilthewastecontainerisfilledwithabout4gallonsoffluid.STEP5-Removereturnwandfromwastecontainer,wipeitclean,andinsertintoreservoir.STEP6-Positionwandsinthecorrectorientationandbeginreservoirfiltrationuntildesiredcleanlinesslevelhas

beenachieved.STEP7-Cyclemachinehydraulicfunctions.STEP8-Resumereservoirfiltration.

Sensor VerificationForcleanliness/sensorverification,itisrecommendedthattheusercorrelatereadingsfromtheFiltrationStationwithbottlesamplessenttoindependentlaboratories.ThelaboratorymustprovideparticleconcentrationinformationpertheISO4406:1999,11943and11171requirementsforopticalparticlecounters.

Taking Fluid Sample

STEP1-Toinitiatethesamplingprocess,locatethefilterhousingbleedvalveonthefiltercapoftheinletfilter.

STEP2-Passaminimumof200mLoffluidthroughthefilterblledvalveintoawastecontainerbeforecollectingthefluid.

STEP3-Placethesamplingbottleinpositiontocollectthefluid.Useasamplingbottlehavingacontaminantlevelofatleast2decadeslowerthantheexpectedsampleasqualifiedpertheAmericanNationalStandardProcedureforQualifyingandControllingCleaningMethodsforHydraulicFluidPowerSampleContainers,ANSI/B93.20-1972,ISO3722-1976).

STEP4-Afterremovingthecapfromthesamplebottle,placethebottleunderthestreamoffluid.Donotallowthe sample hose to touch the inside of the bottle.

STEP5-Takeasampleofatleast50-90%ofthesamplingbottlevolume.

STEP6-Toterminatethesamplingprocess,removethebottlefromthefluidstream.

STEP7-Recapthesamplebottleimmediatelyafterfilling.

!

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Appendix A: TroubleshootingProblem Cause Solution

High 4µm channel counts Air present in the system Reduceflow-possibleaerationofsubjectbeingflushedorassociatedfittings.Adjustneedlevalve.Properly bleed the air from the filters

Emulsifiedorfreewaterpresent Verify the presence of water by performing a Crackle Test. Use thewaterremovalelements.

Not reaching desired ISO codes Higherefficiencymediacombination needed.

Selectfinermediacombinationanduseonlyapprovedelements

Fluidbeingflushedisnotrecommended for use with the Filtration Station

Seefluidcompatibilitysection.

Poor circulation in subject being flushed

Ensurethatthesuctionanddischargelinesallowsufficientcirculationandvelocitythroughoutthe entire systemOperatethesubjectbeingflushedtoincreasevelocities.Becarefulnot to aerate while taking counts.

Sedimentationlayerinlowflowareas

IncreasefloworoperatetestsubjectDisassembleandmanuallycleantest subject

Excessivesuctionpressure Fluidviscosityhigh Reduceflowandreduceviscosityby heating by circulating through the unit or by external means

Suction line restriction EliminatereducingfittingsandvalvedQD’sReduceflow

Blocked suction strainer RemoveandcleansuctionstrainerExcessivedischargepressure Fluidviscosityhigh Reduceflowandreduceviscosity

by heating by circulating through the unit or by external means

Dischargelinerestriction EliminatereducingfittingsandvalvedQD’sReduceflow

Excessivepumpnoiseordecreasedsystemflow

Pump is worn Replace PumpObstruction in the suction line Checkthesuctionlinefittingsand

eliminate restrictionsOpensuctionshutoffvalve

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Problem Cause SolutionUnchanging or consistently high ISO codes

Particle monitor blocked with contamination

Consult enclosed particle monitor manual or contact the manufacturer for cleaning instructions

Fluidbeingflushedisnotrecommended for use with the Super Caddy

Seefluidcompatibilitysection.

Erraticparticlemonitoroperation Particle monitor bad Replace Particle MonitorUnit is connected to power source with no lights being illuminated

Tripped Circuit Breaker Reset Main Circuit BreakerBlown Fuse Test and/or Replace control power

circuit fuseDefectivePowerCord Test Power Cord for continuity.

Replace/Repair as necessary.Unit will not start. Start light is not flashingornotilluminated.

Stop button left in the depressed position

Pull stop button to extended position. Start button should beflashingsignalinga“Ready”condition

Unit will not start. Start light is a solid green.

Unit will not start. Start light is a solid green.

Speed control dial is at the ‘O” position

Turn speed control knob clockwise.

Blown Armature Fuse Test and/or Replace Armature fuse on side of electrical cabinet

Blown Line Fuse (F1) Test and/or Replace Line fuse on DCDrivecard..

No Fluid Flow Speedcontroldialisatthe“O”position

Turn speed control knob clockwise. Check for motor fan rotation. If motor is not rotating checkDCdrivefuses.

SuctionWandisnotbelowfluidlevel

Ensurethatsuctionwandisbelowfluidlevel.Donotrunpumpdry.

Air Leak in suction hose Inspect hose for cracks or cuts. Checkforlooseinletfittings.Repair replace as needed.

Inlet“Y”strainerplugged Removesuctionwandfromfluidsource.Disconnectcaddyfrompowersource.Removedrainplugfrominlet“Y”strainer.Drainintosuitablecontainer.Removehexbushingfrom“Y”strainer.Removeandinspectscreen.Clean or replace the screen and reassemble. Place suction want intofluidsource.Startunitandcheck for leaks.

Suction wand is blocked Check suction wand ensure that it is not blocked or in full contact withbottomoffluidreservoir

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Appendix B : Troubleshooting CS1000LED Blink code/ Display/ Analog

Output/ Switch OutCS1000 status How Error number

Green No errors---

-

Off

4.4 mA / 2.2 V* open

No digits displayedCheck power supply -

No function

Red

4.4 mA / 2.2 V open

Flow too low

Ensurethattheflowisbetween30 -300 ml/min. Increase inlet pressure or reduce outlet pressure

-

Red

19.6mA/9.8Vopen

Flow too high

Ensurethattheflowisbetween30 -300 ml/min. Increase inlet pressure or reduce outlet pressure

-

Red

19.9 mA / 9.95 V open

Definingflownotpossible

Checkflowandfluidcleanliness -

Red Definingflownotpossible

Checkflow.Increase or reduce inlet pressure

4

Red4.1 mA / 2.05 V open

Communication error Check wiring -20 - -39

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Appendix B: Troubleshooting CS1000LED Blink code/ Display/ Analog

Output/ Switch OutCS1000 status How Error number

Red4.1 mA/ 2.05 V* open

FirmwareError

Resetdevice(re-supplyvoltagetosensor) or contact HYDAC

-1 - -19


General system error


-40--69


Errorduringautomatic

adjustment


-70


Error,measuringcellLED


-100

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Particle Count / 100 ml Particle Count / 100 ml

Class More Than Up to (and including) Class More Than Up to

(and including)0 0.00 0.01 15 160 3201 0.01 0.02 16 320 6402 0.02 0.04 17 640 1,3003 0.04 0.08 18 1,300 2,5004 0.08 0.16 19 2,500 5,0005 0.16 0.32 20 5,000 10,0006 0.32 0.64 21 10,000 20,0007 0.64 1.3 22 20,000 40,0008 1.30 2.5 23 40,000 80,0009 2.50 5 24 80,000 160,000

10 5 10 25 160,000 320,00011 10 20 26 320,000 640,00012 20 40 27 640,000 1,300,00013 40 80 28 1,300,000 2,500,00014 80 160

APPENDIX C

C.1 ISO 4406 AND SAE AS 4059 CLASSES

ISO 4406:1999InISO4406particlecountsaredeterminedcumulatively,i.e.>4µm(c),>6µm(c)and>14µm(c)(manuallybyfilteringthefluidtroughanautomaticallyusingparticlecounters)andallocatedtomeasurementreferences.Thegoalofallocatingparticlecountstoreferencesistofacilitatetheassessmentoffluidcleanlinessratings.In1999the“old”ISO4406wasrevisedandthesizerangesoftheparticlesizesundergoinganalysisredefined.The counting method and calibration were also changed.Thisisimportantfortheuserinhiseverydaywork:Eventhoughtthemeasurementreferencesoftheparticlesundergoinganalysishavechanged,thecleanlinesscodewillchangeonlyinindividualcases.Whendraftingthe“new”ISO4406itwasensuredthatnotalltheexistingcleanlinessprovisionsforsystemshadtobechanged.

ISO 4406:1999 TableAllocationofparticlecountstocleanlinessclasses:

Note: increasing the measurement reference by 1 causes the particle count to double.

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C.2 SAE AS 4059TheanalysisMethodscanbeappliedinthesamemannerasISO4406:1999.TheSAEcleanlinessclassesarebasedonparticlesize,numberanddistribution.Theparticlesizedetermineddependsonthemeasurementprocessandcalibration;consequentlytheparticlesizeislabeledwithletters(A-F).The following table shows the cleanliness in relation to the particle concentration determined.

SAE AS 4059 Table:

Maximum Particle Count / 100 mlSize ISO

11171 > 4 µm(c) > 6 µm(c) > 14 µm(c) > 21 µm(c) > 38 µm(c) > 70 µm(c)

SizeCode A B C D E F000 195 76 14 3 1 0

00 390 152 27 5 1 00 780 304 54 10 2 01 1,560 609 109 20 4 12 3,120 1,220 217 39 7 13 6,250 2,430 432 76 13 24 12,500 4,860 864 152 26 45 25,000 9,730 1,730 306 53 86 50,000 19,500 3,460 612 106 167 100,000 38,900 6,920 1,220 212 328 200,000 77,900 13,900 2,450 424 649 400,000 156,000 27,700 4,900 848 128

10 800,000 311,000 55,400 9,800 1,700 25611 1,600,000 623,000 111,000 19,600 3,390 51212 3,200,000 1,250,000 222,000 39,200 6,780 1,020

Cla

ssse

s

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C.3 NAS 1638LikeISO4406,NAS1638describesparticleconcentrationsinliquids.TheanalysismethodscanbeappliedinthesamemannerasISO4406:1987.

IncontrasttoISO4406,certainparticlerangesarecountedinNAS1638andattributedtomeasurementreferences.

Thefollowingtableshowsthecleanlinessclassesinrelationtotheparticleconcentrationanalyzed.

Increasingtheclassby1causestheparticlecounttodoubleonaverage.

Theparticlecountsofclass10arebold-facedintheabovetable.

Figure 2. Microscopic Examination of an Oil Sample (100 ml) Magnification 100x (NAS 10)

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Internet:www.hydac.comE-Mail:[email protected]

Filtration Station Operating Manual

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