HYDAC FILTER SYSTEMS CSM 1000 Series Installation And Maintenance Instructions Manual Download Page 1

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CSM 1000 Series

ContaminationSensor Module

Installation and Maintenance Instructions

English (translation of original instructions)

Valid from series no. 0002S02042E0000277

Document no.: 3512624c

Summary of Contents for CSM 1000 Series

Page 1: ...CSM 1000 Series ContaminationSensor Module Installation and Maintenance Instructions English translation of original instructions Valid from series no 0002S02042E0000277 Document no 3512624c ...

Page 2: ...ative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 0 6897 509 1511 Telefax 49 0 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 ...

Page 3: ...ns 8 Structure of the safety information and instructions 10 Observe regulatory information 10 Proper Designated Use 11 Improper use or use deviating from intended use 11 Qualifications of personnel target group 13 Wear suitable clothing 14 Unpacking the CSM 14 Transporting the CSM 15 Storing the CSM 16 Checking the Scope of Delivery 17 CSM Characteristics 18 CSM components 19 Hydraulic Schematic ...

Page 4: ...on of the ContaminationSensor CS1000 28 Electrical connection of the AquaSensor AS1000 28 Starting up the CSM 29 Adjusting the counter balance valve 29 Required tools and measuring instruments 29 Performing Maintenance 34 Clean the suction screen 35 Disposing of the CSM 37 Errors and Troubleshooting 37 Spare parts 38 Accessories 41 Plugs 41 Connection cable shielded 41 Connection cable 41 Connecti...

Page 5: ...roduct for immediate reference Note that the information on the unit s engineering contained in the documentation was that available at the time of publication There may be deviations in technical details figures and dimensions as a result If you discover errors while reading the documentation or have additional comments or suggestions contact us at HYDAC FILTER SYSTEMS GMBH Technische Dokumentati...

Page 6: ...hasing additional options etc may mean that the information in the operating instructions is no longer applicable or adequate After modification or repair work that affects the safety of the product has been carried out on components the product may not be returned to operation until it has been checked and released by a HYDAC technician Please notify us immediately of any modifications made to th...

Page 7: ...n I find the information I m looking for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number CSM 1000 Series en 7 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 Chapter description Page number Edition date Document language Documentation no with index file name The documentation number with its index enab...

Page 8: ...it and other equipment Maintain the unit inspection intervals prescribed by law Document the results in an inspection certificate and keep it until the next inspection Hazard symbols These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or the environment Observe these instructions and act with par...

Page 9: ...G WARNING indicates a danger with a medium risk and which can lead to death or serious injury if not avoided CAUTION CAUTION indicates a danger with a low risk and which can lead to minor injury if not avoided NOTE NOTE indicates a danger which will lead to damage to property if not avoided CSM 1000 Series en 9 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 10: ...e an activity are laid out as follows SIGNAL WORD Type and source of danger Consequence of the danger HAZARD SYMBOL Measures to avert danger Observe regulatory information Observe the following regulatory information and guidelines Legal and local regulations for accident prevention Legal and local regulations for environmental protection Country specific regulations organization specific regulati...

Page 11: ...xplosive atmospheres The unit is only to be used with permissible media Any use extending beyond or deviating therefrom shall not be considered intended use HYDAC Filter Systems GmbH will assume no liability for any damage resulting from such use The user alone shall assume any and all associated risk Improper use may result in hazards and or will damage the unit Examples of improper use o Operati...

Page 12: ... 2012 11 23 NOTE Impermissible operating media The unit will be destroyed The unit is only to be used with mineral oils or mineral oil based raffinates NOTE Highly contaminated fluid The pump will become worn out damaged For long term operation pump only fluid with a maximum contamination of ISO 22 20 18 ...

Page 13: ...nd several years work experience They are able to assess and perform the work assigned to them they 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...

Page 14: ... 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 Unpacking the CSM The CSM is function and leak tested in the factory and properly packed The connectors are closed off so that no contamination can enter the unit while it is in transit When receiving and unpacking the unit check it for damage in transit Dispo...

Page 15: ...t by hand using the handle Transport the unit in a horizontal position on a pallet Support the upper part with a spacer 1 Height 30 mm When lashing the equipment ensure that no protruding components are lashed down CSM 1000 Series en 15 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 16: ...efore putting it into extended storage Make sure to store the CSM in a clean dry place Store the unit standing up or lying flat on a pallet Support the upper part with a spacer 1 Height 30 mm CSM 1000 Series en 16 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 17: ...operation The following items are supplied Item Qty Designation 1 1 Contamination Sensor Modulee CSM 1000 Series 2 1 Pressure gauge with adapter 1 Technical Documentation const of Operating and Maintenance Instructions CSM 1000 Operating and Maintenance Instructions CS 1000 Series Operating and Maintenance Instructions FluMoS light Operating and Maintenance Instructions AS 1000 optional Calibratio...

Page 18: ...re increases rule of thumb 8 air per bar the ContaminationSensor aims to achieve the greatest possible pressure This is done using a downstream pressure relief valve However pressurized air cannot be immediately dissolved in oil consequently a path is provided for between the pump and the sensor With highly viscous oil and extremely high amounts of air an air bubble can get stuck directly behind t...

Page 19: ...re relief valve 5 Test point 2 6 Counter balance valve 7 Choker valve optional 8 ContaminationSensor CS1000 series 9 Suction screen 400 µm 10 Suction port connection IN 11 Return port connection OUT 12 AquaSensor 1000 optional 13 Leakage oil connection LEAKAGE only with CSM1xxx 2 CSM 1000 Series en 19 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 20: ... 3 Test point 1 4 Pressure relief valve 5 Test point 2 6 Counter balance valve 7 Choker valve optional 8 ContaminationSensor CS1000 series 9 Suction screen 400 µm 10 Suction port connection IN 11 Return port connection OUT 12 AquaSensor 1000 optional 13 Leakage oil connection LEAKAGE only with CSM1xxx 2 CSM 1000 Series en 20 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 21: ...Dimensions Dimensions CSM 1000 Series en 21 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 22: ...ll mounting Hydraulic Connection of the CSM Hydraulic Connectors CSM1xxx 1 CSM1xxx 4 CSM1xxx 2 IN Suction port connection OUT Return port connection LEAKAGE Leakage oil connection CSM 1000 Series en 22 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 23: ... D Density kg dm Mineral oil based hydraulic fluid has a density of 0 9 kg dm This applies to straight pipe runs and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep the height difference between the pump and the oil level in the tank as minimal as possible Hoses must be suitable for suction pressures of at least 0 5 bar Constrictions in the con...

Page 24: ...n a manner so that it is always below the oil level NOTE Severe contamination The unit will be damaged Do not prime directly at the bottom of the tank Do not prime in the sump Never prime without a built in suction screen The greatest contamination is found 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 f...

Page 25: ...urn port connection OUT closed The unit will be destroyed Make sure that the return port is always open Leakage oil connection LEAKAGE only with CSM1xxx 2 NOTE Leakage oil connection LEAKAGE closed The unit will be destroyed Make sure that the leakage oil connection is always open Note the maximum pressure of 0 5 bar at the leakage oil connection ...

Page 26: ...he electric motor and the pump NOTE Slipping magnetic coupling Fluid is no longer being pumped the magnetic coupling starts to make noises and is destroyed A Switch the unit off B Check the pump temperature Switch the unit on only after the pump has cooled down to below 50 C C Check if the return line OUT is open D Check the pressure setting on the pressure gauge Correct the pressure setting if ne...

Page 27: ... 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 An arrow on the ventilator hood shows the sense of rotation To change the direction of rotation commutate two phases Depending on the network voltage connect the motor in a star or delta con...

Page 28: ...2 11 23 Electrical connection of the ContaminationSensor CS1000 For more information refer to the ContaminationSensor operating and maintenance instructions included Electrical connection of the AquaSensor AS1000 For more information refer to the AquaSensor operating and maintenance instructions included ...

Page 29: ...valve B and the throttle valve A are completely open at the time the unit is shipped Adjusting the counter balance valve Required tools and measuring instruments Combination wrench size 22 mm Combination wrench size 13 mm Allen wrench size 4 mm Pressure gauge 0 60 bars included adapter comes standard with the CSM Set the counter balance valve B in accordance with the following steps CSM 1000 Serie...

Page 30: ...ing the counter balance valve 1 If available open the choker valve A by turning it counterclockwise until it is completely opened CSM 1000 Series en 30 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 31: ...on the basis of the sound the pump is making and or at the outlet side OUT then rotate the vacuum gauge A in clockwise direction until it is completely closed 6 The pressure gauge at the test point 1 shows the pressure at the inlet of the ContaminationSensor CS1000 max 60 bar 7 Unscrew the head nut from the counter balance valve B CSM 1000 Series en 31 48 MoWa CSM1000 3512624c en us 2012 11 26 doc...

Page 32: ...ing a size 4 Allen wrench to rotate the set screw on the counter balance valve B Note that a differential in comparison with the pressure measured in Step 6 of a least 10 bar more is to be recommended 10 Tighten the lock nut Make sure that the setting of the counter balance valve B is not changed in the process CSM 1000 Series en 32 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 33: ...e 11 Screw the head nut onto the counter balance valve B and tighten it firmly 12 Unscrew the manometer from the test point 1 13 The CSM is now ready for use CSM 1000 Series en 33 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 34: ... supply and protected against being inadvertently switched back on when performing any maintenance servicing inspection or repair work Once maintenance work is complete check that the safety devices are still working properly Any screwed fittings which have been undone removed are to be checked to see that they have been properly resecured 24 hrs or daily 500 hrs or monthly 3000 hrs or twice per y...

Page 35: ...a piece of pipe of the suction line to protect the pump from coarse contamination Check the suction screen immediately in the event of insufficient suction or delivery action To replace the suction screen proceed as follows 1 Open the screw plug using a size 6 Allen wrench 2 Take out the suction screen by rotating it with a large flat screwdriver in counterclockwise direction CSM 1000 Series en 35...

Page 36: ...hen blowing it out with compressed air 4 Rotate the suction screen in clockwise direction into the housing with a large flat screwdriver 5 Screw in the screw plug by hand and tighten it with 12 Nm CSM 1000 Series en 36 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 37: ...e CSM in the suction or pressure line is closed Open all the locking features in the suction and pressure lines Suction strainer is clogged Clean the suction strainer See page 35 Only CSM1xxx 1 2 The coupling between the motor and the pump is loose or faulty Contact HYDAC Only CSM1xxx 4 The magnetic coupling is disengaged and is slipping Loud noise emissions Switch the pump off Allow the unit to c...

Page 38: ...e parts Make sure to indicate the entire unit designation and the serial number in accordance with the type label when ordering spare parts CSM 1000 Series en 38 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 39: ...Spare parts CSM 1000 Series en 39 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 40: ...Pressure relief valve 1 557654 330 Throttle valve 1 705426 340 AquaSensor AS 1 420 Type label 1 3137999 430 Circuit diagram sign 1 3265699 435 STRAINER sign 1 3490464 440 IN sign 1 3130347 445 LEAKAGE sign 1 3264852 450 OUT sign 1 3130551 455 DO NOT BLOCK sign 1 3259154 470 Connection for pressure gauge 1 6003824 480 Pressure gauge 1 606764 700 Direction of rotation warning sign 1 3529226 CSM 1000...

Page 41: ...lamp ZBE 08 6006786 Connector female with screw clamp shielded ZBE 44 3281243 Connection cable shielded Connector female Cable ending open Length Part no shield 2 m ZBE 42S 02 3281220 shield 5 m ZBE 42S 05 3281239 shield 2 m ZBE 08S 02 6019455 shield 5 m ZBE 08S 05 6019456 shield 10 m ZBE 08S 10 6023102 shield 30 m ZBE 08S 30 6035063 Connection cable Connector female Cable ending open Length Part ...

Page 42: ... 02 6040851 3 m ZBE 30 03 6053924 5 m ZBE 30 05 6040852 Customer service HYDAC SERVICE GMBH Friedrichsthaler Strasse 15a Werk 13 66540 Neunkirchen Heinitz Germany Telephone 49 0 681 509 883 Fax 49 0 681 509 324 E mail service hydac com CSM 1000 Series en 42 48 MoWa CSM1000 3512624c en us 2012 11 26 doc 2012 11 23 ...

Page 43: ...ort connection IN CSM1xxx 4 0 4 bar 80 bar Permissible pressure at leakage oil connection LEAKAGE CSM1xxx 2 0 5 bar maximum Permissible pressure at return port connection OUT CSM1xxx 1 CSM1xxx 2 CSM1xxx 4 5 bar maximum Pump types Gear pump Maximal suction height 500 mm Sealing material NBR FKM Suction port connection IN G Return port connection OUT G Leakage oil connection LEAKAGE G CSM1xxx 1 CSM1...

Page 44: ...inuous duty rating 100 100 Rotation speed 1425 rpm 1710 rpm IP class IP55 IP55 Insulation class F F Electrical data CSM1xxx x x N AB N60 AB60 Voltage frequency 50 Hz 60 Hz Voltage delta connection 400 V 50 Hz 3 Ph 400 V 60 Hz 3 Ph Voltage Star Y connection 690 V 50 Hz 3 Ph 690 V 60 Hz 3 Ph Current consumption 0 71 A 0 41 A 0 57 A 0 33 A Nominal power 0 18 kW 0 18 kW Continuous duty rating 100 100 ...

Page 45: ... Version 1 Gear pump standard 2 Gear pump inlet pressure stable up to a maximum of 120 bar with oil leakage pipe 4 Gear pump inlet pressure stable up to a maximum of 80 bar without oil leakage pipe Electrical Outlet 1 4 20 mA analog outlet 2 0 10 V analog outlet Supply voltage 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 N AB N60 AB60 400 V 50 Hz 3 Ph 400 V 60 Hz...

Page 46: ...Notes ...

Page 47: ...Notes ...

Page 48: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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