SCHAEFFER MFGSCHAEFFER MFG’’S HYDRAULIC FLUIDSS HYDRAULIC FLUIDSWITH WITH

VARNISHIELDVARNISHIELD™™Lawrence G. Ludwig, Jr., CLS,OMA,CMFSLawrence G. Ludwig, Jr., CLS,OMA,CMFS

TopicsTopics

Functions of a Functions of a hydraulic fluidhydraulic fluidTrendsTrends

EquipmentEquipmentFluid Fluid PerformancePerformanceSpecificationsSpecifications

VarniShieldVarniShield™™technologytechnology

Major ComponentsMajor ComponentsPump Pump –– provides force to causeprovides force to causefluid flowfluid flowValves Valves –– provides fluidprovides fluiddirection control and maintainsdirection control and maintainsfluid pressurefluid pressureReservoir Reservoir –– stores the fluidstores the fluidActuator Actuator –– converts hydraulic energy converts hydraulic energy

into mechanical energyinto mechanical energy-- Linear/cylinderLinear/cylinder-- Rotary/hydraulic motorRotary/hydraulic motor

Hydraulic fluid Hydraulic fluid –– provides mediaprovides mediafor power transmission and for power transmission and

lubricationlubrication

Hydraulic EndHydraulic End--Uses/Markets Uses/Markets ServedServedStationaryStationary

ConveyorsConveyorsFood production Food production FormingFormingInjection moldingInjection moldingManufacturingManufacturingMetal fabricationMetal fabricationPackagingPackagingPaperPaperPower generationPower generation

HydroelectricHydroelectricGas/steam/combined Gas/steam/combined cycle turbinescycle turbinesWind energyWind energyPrintingPrintingTextilesTextiles

MobileMobile

Elevators Elevators Farm machinery Farm machinery Heavy constructionHeavy constructionHoist/CraneHoist/CraneLoggingLoggingMiningMiningWater transportationWater transportation

Functions of a Hydraulic FluidFunctions of a Hydraulic Fluid

Transmit power and Transmit power and maintain pressuremaintain pressure

-- Bulk modulus and Bulk modulus and viscosityviscosity

Lubricate and protect.Lubricate and protect.

-- Proper viscosityProper viscosity

Provide sealing between Provide sealing between moving partsmoving parts

Eliminate heat generated Eliminate heat generated in servicein service

Accept and minimize the Accept and minimize the effects of contaminationeffects of contamination

Hydraulic Equipment TrendsHydraulic Equipment TrendsSystems are becoming smaller

Pumps are getting biggerOperating pressures are increasing

Up to 5000 psi, moving to 6500 psi

Higher fluid temperaturesTransient temperatures of 266°F (130°C)

Drain intervals are increasingIncreased focus on cleanliness/filterabilityNoise Legislation

Encapsulation further reduces fluid cooling

Less Oil + More Work = Increased Fluid Stress

Smaller SystemsSmaller SystemsSmaller systems have a high tank turnover rate

Reduced fluid volumes relative to pump flow rate

Fluid is in constant movement

Time available for air release is reducedLess residence time

At higher pressures air bubbles are more soluble

Cavitation damage can be catastrophicSurface damage due to formation of micropits

Pump vibration

Can also promote lubricant degradationLess time for the fluid to cool

Oxidation and thermal degradation

Effects of Higher Pressures and TemperaturesEffects of Higher Pressures and Temperatures

Lower pump volumetric efficiencyLower pump volumetric efficiencySlower response timeSlower response timeReduced hydraulic powerReduced hydraulic power

Fluid overheatingFluid overheatingFaster depletion of antiFaster depletion of anti--oxidant and antioxidant and anti--wear additiveswear additivesReduced fluid life.Reduced fluid life.Higher oxidation rateHigher oxidation rateRate doubles for every 18Rate doubles for every 18°°F riseF riseFluid darkening, varnish deposits, valve sticking, filter Fluid darkening, varnish deposits, valve sticking, filter plugging, bad odorplugging, bad odorReduced equipment lifeReduced equipment lifeHigher pump wearHigher pump wearShorter hose lifeShorter hose lifeHardening at high temperatureHardening at high temperature

Extended Drain Intervals – Mobile Equipment

Oil Drain Interval, hrs Equipment Manufacturer Previous Interval Today’s Interval Komatsu 2,000 5,000 Hitachi 2,500 4,000 Caterpillar 2,000 4,000 Sumitomo 2,000 5,000 Volvo 2,000 4,000 JCB 1,000 3,000

10,000 hour specifications under developmentRequires all-year, multigrade fluid‘Fill to overhaul is the goal

What do all these equipment and operating trends What do all these equipment and operating trends mean to the hydraulic fluid ?mean to the hydraulic fluid ?

Fluid life can be diminished at a greater rate in providing Fluid life can be diminished at a greater rate in providing protection in these harsher systemsprotection in these harsher systems

With less oil in the system, and expectations for longer With less oil in the system, and expectations for longer lifetimes, a greater performance reserve is essentiallifetimes, a greater performance reserve is essential

Hydraulic fluid quality and careful formulating are more Hydraulic fluid quality and careful formulating are more critical than ever before critical than ever before

Fluid PerformanceFluid Performance-- General General RequirementsRequirements

Proper ViscosityProper ViscosityViscosityViscosity is the most important criteria.is the most important criteria.ViscosityViscosity directly influences the efficiency of the power directly influences the efficiency of the power transmissiontransmission

Wear ProtectionWear ProtectionOxidation and Thermal StabilityOxidation and Thermal StabilityCorrosion ProtectionCorrosion ProtectionGood Foam Resistant CharacteristicsGood Foam Resistant CharacteristicsResistant to Air EntrainmentResistant to Air EntrainmentNonNon--CompressibleCompressibleGood Good DemulsibilityDemulsibility

Importance of ViscosityImportance of Viscosity

To high of a viscosity at startTo high of a viscosity at start--up results in inadequate oil up results in inadequate oil flow:flow:

Air entrainmentAir entrainment

CavitationCavitation

Noisy operationsNoisy operations

Sluggish responseSluggish response

Energy lossEnergy loss

Pump breakage in extreme casesPump breakage in extreme cases

Importance of ViscosityImportance of Viscosity

To low of a viscosity once operating temperature is reached To low of a viscosity once operating temperature is reached and the system is operating under load:and the system is operating under load:

High wearHigh wear

Excessive pump leakageExcessive pump leakage

Loss of system efficiencyLoss of system efficiency

Excessive seal leakageExcessive seal leakage

OverheatingOverheating

Further reduction in viscosityFurther reduction in viscosity

Oxidation and thermal breakdownOxidation and thermal breakdown

OEM Viscosity RequirementsOEM Viscosity Requirements

Hydraulic Fluid Performance Trends

FilterabilityAlternative Base

Stocks

Multi-functional

WetFiltrationImproved Fluid

Cleanliness(Servo Systems)

FinerPore Size HWBF PAO, Syn Ester

VHVI FluidsNaturalEsters

Hydraulicand Gear Hydraulic and

MetalworkingHydraulic and

Slideway

Hydraulic Fluid Environmental Trends

Biodegradability

GoverningFactors

Water PollutionClassification

Longer UsefulLife

Less Fluid inLarger

Systems

ExtendedOxidation

Resistance

PerformanceAdditive Packages

Zinc Free Zinc Ashless

Trends in Hydraulics – “Fluids”

“Wear Protection When Wet”

Contamination with Water Often Happens

Water Can Influence the Performance of the Fluid- Corrosion- Hydrolysis- Oxidation

New Pump Tests Have Been Introduced with 1% Water

- Denison T6C- Denison T6H20C

Trends in Hydraulics – “Fluids”“Air Release”

Due to smaller hydraulic systems, base oil air release properties have become important

Systems become less precise when air contaminates the oil

At moderate pressures, e.g. 2000 psi, pumps cavitate

The air release of the base oil impacted by refining process

Some types of antifoam can negatively impact air release

Trends in Hydraulics – “Fluids”

“Shear Stability”

Longer life fluids in mobile hydraulics require a wider operating temperature range

Viscosity modifiers and pour point depressants will be required

Hydraulic fluid shearing

Result: Loss of viscosity, cavitation and pump damage

WhatWhat’’s in a Typical Hydraulic Fluid s in a Typical Hydraulic Fluid and Whyand Why

Base Oil +Additive Package

= Hydraulic Fluid

2 – 20%80 – 98%

Base Fluid Types UsedBase Fluid Types Used

Petroleum BasePetroleum Base

-- Group I Paraffinic Group I Paraffinic –– Solvent RefinedSolvent Refined

-- Group II Paraffinic (Hydrocracked)Group II Paraffinic (Hydrocracked)

Synthetic BaseSynthetic Base

-- PolyalphaolefinPolyalphaolefin

-- DiesterDiester

-- Polyol EsterPolyol Ester

-- Phosphate EstersPhosphate Esters

-- PolyglycolsPolyglycols

Base Fluid Types UsedBase Fluid Types Used

WaterWater-- BasedBased

-- Water GlycolWater Glycol

-- Emulsion TypeEmulsion Type

-- OilOil--inin--WaterWater

-- WaterWater--inin--OilOil

-- Synthetic SolutionsSynthetic Solutions

Vegetable Oil BaseVegetable Oil Base

Components of Hydraulic Fluid Additive Components of Hydraulic Fluid Additive PackagePackage

Additive Package

AntioxidantAntioxidant

Antiwear agentAntiwear agent

DemulsifierDemulsifier

DetergentDetergent

DispersantDispersant

Foam inhibitorPour pointdepressantMetal deactivatorRust inhibitorVI Improver

Denison HFDenison HF--00-- New Approval List IssuedNew Approval List Issued-- Products over 10 years old need reconfirmingProducts over 10 years old need reconfirming-- Products over 15 years old need reapprovalProducts over 15 years old need reapproval

To Obtain HFTo Obtain HF--00-- Hybrid Denison Pump (Jan 2004)Hybrid Denison Pump (Jan 2004)

Hybrid Pump T6H20CHybrid Pump T6H20CPiston and vanePiston and vane600600--hour testhour test

Inlet temperature = 248Inlet temperature = 248°°F/120F/120°°CC for dry testfor dry testInlet temperature = 176Inlet temperature = 176°°F/80F/80°°CC for wet test (1% for wet test (1% water)water)

Industrial Lubricants – Hydraulic TrendsSpecifications - Denison

Trends in Hydraulics – OEMsSpecifications - Denison

T6H20CDenison• Upgrading HF-0

Approval• Vane Pumps

Higher Pressures- up to 4,600 psi

Hydraulics Hydraulics –– Some Key SpecificationsSome Key Specifications

Eaton (Vickers)Eaton (Vickers)

MM--29502950--S S ……. Mobile 35VQ25 vane pump. Mobile 35VQ25 vane pump

II--286286--S S ……. Industrial V. Industrial V--104C vane pump104C vane pump

In lieu of the VIn lieu of the V--104C vane pump no longer being available, 104C vane pump no longer being available, Eaton will accept 35VQ25 test results for the industrial Eaton will accept 35VQ25 test results for the industrial

specificationspecification

Trends in Hydraulics – OEMsMarket Data – Cincinnati Machine

Cincinnati Machine

• Approval Period Reduced from Five to Three Years- P-68: ISO VG 32- P-70: ISO VG 46- P-69: ISO VG 68

Hydraulics Hydraulics –– Some Key SpecificationsSome Key Specifications

DIN 51524 DIN 51524

Part 1 use circulating and R&O fluidsPart 1 use circulating and R&O fluids

Part 2 uses antiPart 2 uses anti--wear; FZG, Vwear; FZG, V--104C + bench tests104C + bench tests

Part 3 is the multigrade versionPart 3 is the multigrade version

SAE HXSAE HX--1 1 -- Asian mobile equipment utilizesAsian mobile equipment utilizes

the Komatsu HPV35+35 piston pump the Komatsu HPV35+35 piston pump

JCMAS JCMAS –– HKHK

JCMAS JCMAS –– HKB (biodegradable)HKB (biodegradable)

Caterpillar HYDO (minimum 900 ppm Zinc)Caterpillar HYDO (minimum 900 ppm Zinc)

Hydraulics Hydraulics –– Some key specificationsSome key specifications

ISO ClassificationsISO ClassificationsHH HH -- Non inhibited oilsNon inhibited oilsHL HL -- R & O oilsR & O oilsHM HM -- AntiAnti--wear oilswear oilsHV HV -- AntiAnti--wear multiwear multi--grade oils grade oils HS HS -- Synthetic Fluids non fire resistantSynthetic Fluids non fire resistantHFAE HFAE -- Oil in water emulsions >80% water (fire resistant)Oil in water emulsions >80% water (fire resistant)HFAS HFAS -- Chemical solutions in water >80% water (fire resistant)Chemical solutions in water >80% water (fire resistant)HFB HFB -- Water in oil (invert emulsions) 95/5 (fire resistant)Water in oil (invert emulsions) 95/5 (fire resistant)HFC HFC -- Water Glycol (fire resistant)Water Glycol (fire resistant)HFDR HFDR -- Phosphate ester (fire resistant)Phosphate ester (fire resistant)HFDS HFDS -- Chlorinated Hydrocarbon base (fire resistant)Chlorinated Hydrocarbon base (fire resistant)HDFT HDFT -- Blends of HFDR and HFDS (fire resistant)Blends of HFDR and HFDS (fire resistant)HFDU HFDU -- Synthetic fluid of other types (fire resistant)Synthetic fluid of other types (fire resistant)

SchaefferSchaeffer’’s VarniShields VarniShield™™ TechnologyTechnologyDifferentiation for Hydraulic SystemsDifferentiation for Hydraulic Systems

Fluid Power Trends: Fluid Power Trends: ItIt’’s a tough world for hydraulic fluidss a tough world for hydraulic fluids

Hydraulic systems are getting smallerHydraulic systems are getting smallerReservoir shapes are often not optimumReservoir shapes are often not optimumFlow rates are high relative to oil volumesFlow rates are high relative to oil volumesOil residence times can be very shortOil residence times can be very shortHydraulic systems are designed with higher power Hydraulic systems are designed with higher power densitiesdensitiesOil temperatures are higher Oil temperatures are higher

> 266> 266°°F transients are seenF transients are seen

Oil pressures have increasedOil pressures have increasedOEMs agree these trends are leading to more frequent OEMs agree these trends are leading to more frequent problems in high performance hydraulic systemsproblems in high performance hydraulic systems

Consequences of this tougher worldConsequences of this tougher world

Varnish

Oil Aging

Foaming & Foaming & cavitationcavitationthrough low residence times through low residence times Shorter fluid life due to Shorter fluid life due to increased oxidationincreased oxidationPoor hydraulic valve Poor hydraulic valve response due to sludge and response due to sludge and varnishvarnish build upbuild upIncreased need to replace Increased need to replace blocked filters blocked filters More wear on valves & More wear on valves & pumps

Filter Blockagepumps

Comparing TodayComparing Today’’s Hydraulic s Hydraulic Fluids Fluids

OEMs agree that as operating conditions become more severe varnish formation increases

When sludge & varnish deposits are present sub optimal performance occurs

An increase in varnish & sludge problems has occurred in the field

Standard (duration) pump tests do not show the increased stress placed on many fluids today

What is Varnish?What is Varnish?

The polymerized oil oxidation products and decomposition The polymerized oil oxidation products and decomposition byproducts derived by thermal breakdown.byproducts derived by thermal breakdown.As the oil ages more varnish is formed.As the oil ages more varnish is formed.Can also be formed by Can also be formed by

Static discharge across high flow filtersStatic discharge across high flow filtersCracks the oil generating autoCracks the oil generating auto--oxidationoxidationMicrodieselingMicrodieseling (implosion of entrained air bubbles)(implosion of entrained air bubbles)Localized temperatures of 1,800Localized temperatures of 1,800°°F can be reachedF can be reached

Varnish is polarVarnish is polarEnds up as a tenacious hard lacquerEnds up as a tenacious hard lacquerAttracted to metal surfaces Attracted to metal surfaces Starts as a sticky soft residueStarts as a sticky soft residueAttracts wear debrisAttracts wear debris

Extended Duration Pump TestingExtended Duration Pump Testing

Extended 35VQExtended 35VQ--25 vane pump testing is able to demonstrate 25 vane pump testing is able to demonstrate this effect with various zincthis effect with various zinc--containing fluidscontaining fluidsAfter 500 hours a tenacious varnish deposit starts to form in After 500 hours a tenacious varnish deposit starts to form in the reservoirs and on pump parts when testing traditional the reservoirs and on pump parts when testing traditional hydraulic oils hydraulic oils 1000 hours at full pressure & temperature shows a fluid1000 hours at full pressure & temperature shows a fluid’’s s potential for varnish formation.potential for varnish formation.

Test conditions :Test conditions :Temperature = 203Temperature = 203°°F/F/9595°° CCPressurePressure = 3,000 psi/207 Bar= 3,000 psi/207 BarSpeedSpeed = 2,400 rpm = 2,400 rpm Oil volumeOil volume = 51.6 gals/197 litres= 51.6 gals/197 litres

Why is Varnish so Bad for a Why is Varnish so Bad for a Hydraulic System?Hydraulic System?

Oil that is oxidized does not lubricate.Oil that is oxidized does not lubricate.Higher FrictionHigher Friction

Can cause hydraulic valves to stick Can cause hydraulic valves to stick -- especially especially proportional and servo typesproportional and servo typesShortens the lives of components (valves, filters, pumps, Shortens the lives of components (valves, filters, pumps, bearings, seals etc)bearings, seals etc)Oil flow is hindered and cooling capacity is often lostOil flow is hindered and cooling capacity is often lostPotential system failures lead to equipment downtime and Potential system failures lead to equipment downtime and loss of operational incomeloss of operational incomeBottom line Bottom line –– hydraulic system performance suffers.hydraulic system performance suffers.

Varnish is Bad For Pumps, TooVarnish is Bad For Pumps, Too

Vane pumpsVane pumpsIncreased noiseIncreased noiseDecreased volumetric and mechanical efficiencyDecreased volumetric and mechanical efficiency

Increased energy consumptionIncreased energy consumptionSide plate scuffingSide plate scuffingStuck vanes in rotor slotStuck vanes in rotor slotRotary seal damageRotary seal damagePotential bearing failurePotential bearing failure

Piston pumpsPiston pumpsIncreased piston land friction against the wear plateIncreased piston land friction against the wear plate

Leakage and possible seizureLeakage and possible seizureSticking valvesSticking valves

Unscheduled stoppages during operationUnscheduled stoppages during operationFilter blockageFilter blockage

What are End Users Experiencing?What are End Users Experiencing?

Increased focus on contamination control to Increased focus on contamination control to maximize hydraulic performancemaximize hydraulic performanceStringent filtration is becoming more common < 3 Stringent filtration is becoming more common < 3 micron often seen micron often seen End users are reporting impaired valve function End users are reporting impaired valve function due to varnish due to varnish More frequent filter blockage, higher friction and More frequent filter blockage, higher friction and sticky residues attracting wearsticky residues attracting wear--promoting solid promoting solid particlesparticlesElectrostatic filters used for sludge and varnish Electrostatic filters used for sludge and varnish removal are expensiveremoval are expensive

Traditional fluid technology6 weeks’ continuous use

203°F/95° C 3000 psi/207 BarEaton Vickers 35VQ25

Schaeffer Mfg Has the Solution Schaeffer Mfg Has the Solution ––VarniShieldVarniShield™™

VarniShield™ Technology6 weeks’ continuous use

203°F/95°C;3,000 psi/207 BarEaton Vickers 35VQ25

Varnish Eliminated Varnish Eliminated –– Extended Pump Extended Pump TestingTesting

VarniShieldVarniShield™™Schaeffer MfgSchaeffer Mfg’’s New Technology s New Technology

#112, #112A, #254, #275SW & #275S#112, #112A, #254, #275SW & #275SPerformance Profile:Performance Profile:

Meets and Exceeds Denison Hybrid Pump HFMeets and Exceeds Denison Hybrid Pump HF--0 0 Easily surpasses DIN 51524Easily surpasses DIN 51524--Part 2Part 2Eaton Vickers Vane Pump extended performanceEaton Vickers Vane Pump extended performanceExceeds Cincinnati Machine Thermal Stability Requirements. Exceeds Cincinnati Machine Thermal Stability Requirements. (25 mg sludge maximum)(25 mg sludge maximum)

Advantages over current technologies:Advantages over current technologies:A clean, no varnish, depositA clean, no varnish, deposit--free hydraulic systemfree hydraulic systemLonger oxidation life and reserves of performance (>3500 Longer oxidation life and reserves of performance (>3500 hrs D943)hrs D943)Excellent wear characteristics (FZG 12th Stage)Excellent wear characteristics (FZG 12th Stage)Exceptional thermal stability (1.8 mg sludge in CM test)Exceptional thermal stability (1.8 mg sludge in CM test)

VarniShieldVarniShield™™ –– Pump Wear ProtectionPump Wear ProtectionParker Denison T6H20C Hybrid PumpParker Denison T6H20C Hybrid Pump

PerformancePerformance

Total weight lossTotal weight loss End of dry phase End of wet phaseEnd of dry phase End of wet phaseVanes weight lossVanes weight loss 5.1 mg 5.8 mg5.1 mg 5.8 mgCam ring weight lossCam ring weight loss 18 mg18 mg 161 mg161 mgPistons total of all 9Pistons total of all 9 150 mg150 mg 274 mg274 mg

Increase in wet phase differential pressure wasIncrease in wet phase differential pressure wasexceptionally good (2.9 psi/200 mBar)exceptionally good (2.9 psi/200 mBar)

Hybrid Pump testing meets all criteria for ParkerHybrid Pump testing meets all criteria for ParkerHannifinHannifin’’s (Denison) HFs (Denison) HF--0 specification0 specification

VarniShieldVarniShield™™ –– Pump Wear ProtectionPump Wear Protection

EatonEaton--Vickers 35VQ/25 Vane Pump TestVickers 35VQ/25 Vane Pump Test

3000 psi, 2400 rpm, 2033000 psi, 2400 rpm, 203°°F, 150 hoursF, 150 hours

SchaefferSchaeffer’’ss

Hydraulic Hydraulic FluidsFluids

Eaton Eaton --VickersVickers

MM--29502950--SS

Eaton Eaton ––VickersVickers

II--286286--SS

Total Ring & Total Ring & Vane Wt. Vane Wt. Loss, mgLoss, mg

1616 90 max90 max 90 max90 max

Meets and Exceeds Eaton-Vickers Specifications

Additional Performance BenefitsAdditional Performance Benefits

Excellent Excellent demulsibilitydemulsibility so water separates quickly.so water separates quickly.4040--4040--0 (15 minutes) in ASTM D0 (15 minutes) in ASTM D--1401 1401 DemulsibilityDemulsibility TestTest

Excellent Hydrolytic StabilityExcellent Hydrolytic Stability

Excellent filterability even in the presence of waterExcellent filterability even in the presence of water

Very good antiVery good anti--foam and air release propertiesfoam and air release properties

High level of rust and corrosion protection to High level of rust and corrosion protection to extend component lifeextend component life

Energy savingsEnergy savings

Water ContaminationWater Contamination

Water can enter the fluid through:Water can enter the fluid through:Access plates in the reservoirAccess plates in the reservoir

CondensationCondensation

Wash downWash down

Heat exchanger leaksHeat exchanger leaks

Small amounts of water can be toleratedSmall amounts of water can be tolerated

Too much water in a system can cause:Too much water in a system can cause:Collection of contaminantsCollection of contaminants

Additive depletionAdditive depletion

Sticky valves and servosSticky valves and servos

Formation of acids that can corrode yellow metalsFormation of acids that can corrode yellow metals

Rusting and corrosionRusting and corrosion

Accelerated wearAccelerated wear

Plugged filtersPlugged filters

Excellent Demulsibilty CharacteristicsExcellent Demulsibilty CharacteristicsTodayToday’’s hydraulic systems are s hydraulic systems are smaller and designed to do more smaller and designed to do more workwork

Fluid spends very little time in the Fluid spends very little time in the reservoir consequently, hydraulic fluids reservoir consequently, hydraulic fluids must have a high degree of demulsibilitymust have a high degree of demulsibility

Demulsibility is the ability of the Demulsibility is the ability of the fluid to separate from waterfluid to separate from water

Schaeffer MfgSchaeffer Mfg’’s hydraulic fluids with s hydraulic fluids with VarniShieldVarniShield™™ have a higher degree have a higher degree of demulsibility as demonstrated by of demulsibility as demonstrated by the ASTM Dthe ASTM D--1401 Test Method For 1401 Test Method For Water SeparabilityWater Separability

Hydrolytic StabilityHydrolytic Stability

Measure of the reactivity of the fluidMeasure of the reactivity of the fluid’’s antis anti--wear additive wear additive system with watersystem with water

Under heat and pressure the antiUnder heat and pressure the anti--wear additives can react with wear additives can react with water to form acidic components.water to form acidic components.

Corrosion of yellow metalsCorrosion of yellow metals

Formation of sludgeFormation of sludge

Loss of antiLoss of anti--wear protectionwear protection

It is important that the fluid have good hydrolytic stability toIt is important that the fluid have good hydrolytic stability toprotect all yellow metal components even when small amounts protect all yellow metal components even when small amounts of water enter the systemof water enter the system

Excellent Hydrolytic StabilityExcellent Hydrolytic Stability

Schaeffer MfgSchaeffer Mfg’’s hydraulic fluids with s hydraulic fluids with VarniShieldVarniShield™™have a higher degree of hydrolytic stability as have a higher degree of hydrolytic stability as demonstrated by the ASTM Ddemonstrated by the ASTM D--2619 Hydrolytic 2619 Hydrolytic Stability Test MethodStability Test Method

ASTM DASTM D--26192619 SchaefferSchaeffer’’ssHydraulic Hydraulic

FluidsFluids

Denison HFDenison HF--OOMaximum Maximum

LimitsLimitsCopper wt. Loss,Copper wt. Loss,

mg/cm2mg/cm20.0560.056 0.20.2

Acidity of Water Acidity of Water Layer, mg Layer, mg

KOH/gKOH/g

00 44

FilterabilityFilterability

Water contamination can cause plugging of Water contamination can cause plugging of filtersfiltersBlocked filters can be a major maintenance issue Blocked filters can be a major maintenance issue in the fieldin the fieldWith the increased use of finer filtration (<3 With the increased use of finer filtration (<3 microns) in order to keep the fluid clean this has microns) in order to keep the fluid clean this has become more of an issuebecome more of an issueThe Denison HFThe Denison HF--O specification address this O specification address this issueissue

Excellent Filterability in the Presence of WaterExcellent Filterability in the Presence of Water

Denison Filterability Test TPDenison Filterability Test TP--0210002100--AA

PerformancePerformance SchaefferSchaeffer’’ss

Hydraulic FluidsHydraulic Fluids

Denison HFDenison HF--OO

Maximum LimitsMaximum Limits

Filtration time Filtration time without water, without water, secondsseconds

146146 600600

Filtration time with Filtration time with 2% water, seconds2% water, seconds 163163 2X filtration time 2X filtration time

without waterwithout water

Foaming and Air ReleaseFoaming and Air ReleaseAir can enter through the reservoir or through air leaks within Air can enter through the reservoir or through air leaks within the hydraulic systemthe hydraulic system

Air can lead to foaming and additional air entrainment Air can lead to foaming and additional air entrainment

Use of smaller reservoirs aggravate the problem.Use of smaller reservoirs aggravate the problem.Not enough setting timeNot enough setting time

Foaming can be aggravated by:Foaming can be aggravated by:High operating pressuresHigh operating pressuresHigh operating temperaturesHigh operating temperaturesHigh flow rates and pump speedsHigh flow rates and pump speedsLow oil levelsLow oil levelsContaminationContamination

Foaming and Air ReleaseFoaming and Air ReleaseFoaming can cause:Foaming can cause:

Accelerated oxidation of the fluidAccelerated oxidation of the fluid

Higher operating temperaturesHigher operating temperatures

Pump cavitationPump cavitation

Decreased lubricityDecreased lubricity

Shortened component lifeShortened component life

Air can also become entrained in the fluidAir can also become entrained in the fluidBubbles suspended in the fluid (<1mm in diameter)Bubbles suspended in the fluid (<1mm in diameter)

Under low pressure the fluid absorbs 10% air by volume.Under low pressure the fluid absorbs 10% air by volume.

Entrained air can result in:Entrained air can result in:Spongy controlsSpongy controls

CavitationCavitation

NoiseNoise

Pressure spikesPressure spikes

Loss of horsepowerLoss of horsepower

Temperature increasesTemperature increases

Fluid oxidationFluid oxidation

Foaming and Air ReleaseFoaming and Air ReleaseFoaming can be controlled by the use of antifoam additivesFoaming can be controlled by the use of antifoam additives

Some types of antiSome types of anti--foam or use of too much can impair the foam or use of too much can impair the fluids air release properties.fluids air release properties.

Retard the release of dissolved airRetard the release of dissolved air

A fluidA fluid’’s air release properties are dependent upon the type of s air release properties are dependent upon the type of base stocks used.base stocks used.

Foaming and Air ReleaseFoaming and Air ReleaseSchaefferSchaeffer’’ss

Hydraulic FluidsHydraulic FluidsDIN 51 524 Part 2DIN 51 524 Part 2

Max limitsMax limits

Sequence ISequence I

0/00/0 150/0150/0

Sequence IISequence II

0/00/0 75/075/0

Sequence IIISequence III

0/00/0 150/0150/0

SchaefferSchaeffer’’ss

Hydraulic FluidsHydraulic Fluids

DenisonDenison

HFHF--0 Maximum Limits0 Maximum Limits

Air release time, minutesAir release time, minutes

6.26.2 1010

Plastic Injector MoldingPlastic Injector MoldingVarniShieldVarniShield™™ Cost Savings ExampleCost Savings Example

Plastic Injection Molder ExamplePlastic Injection Molder Example

33--4 servo valves per machine4 servo valves per machine10% of valves replaced annually due to 10% of valves replaced annually due to sticking issuessticking issuesTypical cost to replace servo valveTypical cost to replace servo valve

$2000 to remanufacture$2000 to remanufacture$3000 for new$3000 for new

Average time to replace servo valve is one Average time to replace servo valve is one hourhourLabor rate is $50/hourLabor rate is $50/hour

CostsCosts

Large Injection molding shop may replace 60 Large Injection molding shop may replace 60 valves per yearvalves per year

60 valves x $3000/new valve = $180,000/year or60 valves x $3000/new valve = $180,000/year or60 valves x $2,000/remanufactured valve = $120,000/year60 valves x $2,000/remanufactured valve = $120,000/year

Typical time to replace valvesTypical time to replace valves60 valves x 1 hour/valve = 60 hours60 valves x 1 hour/valve = 60 hours60 hours x $50/hour = $3,00060 hours x $50/hour = $3,000

Total cost*Total cost*$123,000 to $183,000$123,000 to $183,000

*Does not include production downtime or labor and cost for *Does not include production downtime or labor and cost for replacement of pumps replacement of pumps

Total CostTotal Cost

Total cost per year due to varnish not including

production loss is $123,000 to $183,000 per year

Total cost per year due to varnish not including

production loss is $123,000 to $183,000 per year

SummarySummary

The use of Schaeffer MfgThe use of Schaeffer Mfg’’s hydraulic fluids with s hydraulic fluids with VarniShieldVarniShield™™ heralds a new era for cleaner hydraulic heralds a new era for cleaner hydraulic systemssystemsVarnish and sludge problems are minimized or eliminatedVarnish and sludge problems are minimized or eliminatedA high resistance to oxidation means longer oil lifeA high resistance to oxidation means longer oil lifeSystem component life can be extended System component life can be extended Equipment downtime and costs due to maintenance issues Equipment downtime and costs due to maintenance issues can be significantly reducedcan be significantly reducedFor heavily varnished systems it is suggested that a purge For heavily varnished systems it is suggested that a purge with Schaefferwith Schaeffer’’s #287 Food Grade Flush be conducteds #287 Food Grade Flush be conducted