HYDAC FILTER SYSTEMS CMP 43 0-5 Series Installation And Maintenance Instructions Manual Download

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CMP 43x0-5-…

ConditionMonitoring Package

Installation and Maintenance Instructions

English (translation of original instructions)

Keep for future reference.

Documentation no.: 4191543b

Summary of Contents for CMP 43 0-5 Series

Page 1: ...CMP 43x0 5 ConditionMonitoring Package Installation and Maintenance Instructions English translation of original instructions Keep for future reference Documentation no 4191543b ...

Page 2: ...ulzbach Saar Phone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com 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 H...

Page 3: ...igns 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 12 Qualifications of personnel target group 13 Wear suitable clothing 14 Dangers by pressure in the hydraulic system 14 Unpacking the unit 15 Storing the unit 15 Decoding ...

Page 4: ...000 27 Electrical connection of the AquaSensor AS1000 27 Electrical connection of the HYDACLab HLB1400 27 Connection of the sensor connection box option 27 Starting up the CMP 28 Performing maintenance 29 Clean the suction strainer 30 Errors and troubleshooting 32 Spare parts list 33 Accessories list 33 Disposing of the CMP 33 Technical data 34 Appendix 36 Customer Service Service Address 36 Model...

Page 5: ...iability 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 code serial no and part no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Modifications to the Product We would like to point out that changes to the produc...

Page 6: ...ng for The document has a table of contents at the beginning I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 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 every time the manual is revised or changed ...

Page 7: ...te 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 mediu...

Page 8: ...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 general safety information 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 C...

Page 9: ...uctions which indicate particular hazards to persons property or the environment Disconnect before working Follow the operating manual Others used symbols The following symbols found you in this operation instructions Tip for handling the product Tools required CMP43x0 5 en us Page 9 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 10: ...sonnel 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 Le...

Page 11: ...ssible media Follow all the notes in these operating instructions Comply with inspection and maintenance work NOTICE Impermissible operating media The unit will be destroyed The unit is only to be used with mineral oils or mineral oil based raffinates Do not pump any caustic or explosive media NOTICE Highly contaminated fluid The pump will become worn out damaged For long term operation pump only ...

Page 12: ...e The owner 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 Operation in potentially explosive atmospheres Operation with a non approved medium Operation under non approved operational conditions Operation when the safety devices are defective Modifications to the power unit made b...

Page 13: ...ey are also able to recognize potential hazards 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 too...

Page 14: ...otruding 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 Dangers by pressure in the hydraulic system WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system CMP43x0 5 en us Page 14 40 MoWa CMP43x0...

Page 15: ...n 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 Storing the unit Rinse and drain the unit completely before putting it into extended storage Store the unit in a clean dry place CMP43x0 5 en us Page 15 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 16: ...ate of electric motor 3 Model code for details see page 37 Motor voltage Required electric motor operation voltage Motor grid Number of electric motor phases Frequency Mains frequency Max Flow rate Maximum flow rate Max INLET press Maximum pressure at the inlet Weight Weight when empty Sensor voltage Required sensor operation voltage CMP43x0 5 en us Page 16 40 MoWa CMP43x0 5 4191543b en us 2018 02...

Page 17: ...into operation The following items are supplied Qty Designation 1 ConditionMonitoring Package CMP 4000 Series 1 Technical documentation comprising Operating and Maintenance Instructions CMP 43x0 5 this document Operation and maintenance Instructions MCS 1000 series Operating instructions HYDACLab optional Operating instructions AS1000 optional Installation drawing optional Certificate of calibrati...

Page 18: ...Oil Condition Sensor or the AquaSensor AS is also available as an option for the CMP The two sensors make it possible to determine the relative water content in the oil specified in percentage saturation where the HydacLab detects liquid contaminants with external fluids mixtures using additional measured variables of conductivity and dielectric constant and also permits conclusions to be drawn on...

Page 19: ...ressure relief valve 4 MetallicContamination Sensor MCS1000 series 5 Suction screen 600 µm 6 Suction port IN 7 Return port connection OUT 8 AquaSensor HYDACLab option 9 Sensor connection box option CMP43x0 5 en us Page 19 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 20: ... 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 MetallicContamination Sensor MCS1000 series 5 Suction screen 600 µm 6 Suction port IN 7 Return port connection OUT 8 AquaSensor HYDACLab option CMP43x0 5 en us Page 20 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 21: ...Dimensions Dimensions All dimensions in mm CMP43x0 5 en us Page 21 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 22: ...connection of the CMP Hydraulic connection of the CMP Hydraulic connections IN Suction port connection OUT Return port connection CMP43x0 5 en us Page 22 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 23: ...traight pipe lines and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep the height difference between the pump and the oil level in the tank as low as possible Hoses must be suitable for suction pressures of at least 0 5 bar Constrictions in the connections and lines should be avoided This could compromise suction output and cause cavitation Not...

Page 24: ... 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 The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank Make the suction side connection with a flexible hos...

Page 25: ...OUT NOTICE Return port connection OUT closed off The unit will be destroyed Make sure that the return port is always open Note the maximum pressure of 0 5 bar at the return port connection CMP43x0 5 en us Page 25 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 26: ... 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 de...

Page 27: ...ation refer to the HYDACLab Sensor operating instructions included Connection of the sensor connection box option Use a sensor connection box to simplify the electrical installation or implement certain connection codes e g Ethernet The connections of the sensors built into the CMP are combined and connected to terminals or plugs For the assignment of the interfaces and descriptions refer to the t...

Page 28: ...t via the IN OUT port and have also connected the electric motor and the sensor the CMP is ready for operation Start the CMP up by switching the voltage supply on Look for leaks during operation and eliminate them immediately CMP43x0 5 en us Page 28 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 29: ...upply 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 24 hrs or daily 500 hrs or monthly 3000 hrs or twice per yea...

Page 30: ...arly A suction strainer is fitted into a piece of pipe of the suction line to protect the pump from coarse contamination Clean the suction strainer at regular intervals e g by flushing it with solvent or blow flushing it with compressed air Test and clean the suction strainer immediately in the event of insufficient suction or delivery action CMP43x0 5 en us Page 30 40 MoWa CMP43x0 5 4191543b en u...

Page 31: ...trainer insert 3 and the seal ring 2 on the screw plug for damage and replace if necessary 5 Insert the cleaned new strainer insert 3 6 Turn the screw plug 1 with the seal ring 2 clockwise manually and tighten with the fork wrench 22 mm 7 Check the suction strainer fitting for leaks after commissioning 8 Replacing exchanging the suction strainer is now complete CMP43x0 5 en us Page 31 40 MoWa CMP4...

Page 32: ...e of the CMP in the suction or pressure line is closed Open the shut off device Suction strainer of the gear pump is clogged Clean the suction strainer The coupling between the motor and the pump is loose or faulty Check the coupling for proper functioning No function No electrical connection Check the electrical connection the plug cables and socket on the CMP CMP43x0 5 en us Page 32 40 MoWa CMP4...

Page 33: ... MCS1000 1 Motor pump assembly FKM 1 HYDACLab HLB1400 1 AquaSensor AS1000 on request Accessories list Item Part no Qty Description Material 3281243 1 Connecting socket M12x1 8 pin 6006786 1 Connecting socket M12x1 5 pin on request Disposing of the CMP After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly manner CMP43x0 5 en us Page 33 40...

Page 34: ...non condensing Weight CMP4xx0 5 27 kg Hydraulic data Permissible suction pressure at suction port connection IN 0 4 4 bar Pressure at return port connection OUT 0 5 bar max Pump type Gear pump Sealing material FKM Suction port IN G Return port connection OUT G Permissible operating viscosity range 12 to 20 000 mm s Total flow rate 50 Hz 60 Hz CMP4xx0 5 6 l min 7 l min CMP43x0 5 en us Page 34 40 Mo...

Page 35: ... Star Y connection 400 V 50 Hz 3 Ph 460 V 60 Hz 3 Ph Current consumption 1 84 A 1 06 A 1 84 A 1 06 A Nominal power 0 37 kW 0 44 kW Continuous duty rating 100 100 Rotational speed 1380 rpm 1595 rpm IP class IP55 IP55 Insulation class F F CMP43x0 5 en us Page 35 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 36: ... Address HYDAC SYSTEMS SERVICE GMBH Friedrichsthaler Straße 15 Werk 13 66453 Neunkirchen Germany Phone 49 681 509 883 Fax 49 681 509 324 E mail service hydac com CMP43x0 5 en us Page 36 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 37: ...put 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 Other voltages on request Additional sensor z none AS1C AquaSensor AS1000 with 2x analogue output 4 20 mA AS12 AquaSensor AS1000 with 2x switching output AS35 AquaSensor AS1000 with 2x switching output 1x analogue output configurable HLB10 HYDACLab HLB1400 with 2x outputs switching output analogue outp...

Page 38: ...0 22 24 28 34 INLET 16 23 installation 10 13 27 Internal pipe diameter 23 IP 35 IP class 35 ISO 11 M Maintenance 1 13 17 Manufacturer 2 Measures 8 measuring 18 Mineral oil 23 Modbus 27 37 Model code 16 37 Motor pump assembly 33 O operating 5 6 7 8 9 10 11 13 27 30 34 Operation 12 13 17 Operations control 13 OUT 19 20 22 25 28 34 P Pressure differential 23 Pump 34 R Remedy 32 RTU 37 S select 6 Sens...

Page 39: ...Customer Service Service Address TCP IP 37 Transport 13 troubleshooting 32 Troubleshooting 13 W Weight 16 34 CMP43x0 5 en us Page 39 40 MoWa CMP43x0 5 4191543b en us 2018 02 20 doc 2018 02 20 ...

Page 40: ...stfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 6897 509 01 Central Fax 49 6897 509 9046 Technical Department Fax 49 6897 509 577 Sales Department Internet www hydac com E mail filtersystems hydac com ...

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