HYDAC FILTER SYSTEMS CSM-E Installation And Maintenance Instructions Manual Download Page 8

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Safety information

Structure of the safety information and instructions

All warning instructions in this manual are highlighted with pictograms and

signal words. The pictogram and the signal word indicate the severity of the

danger.
Warning instructions listed before an activity are laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

►

Measures to avert danger

Warning signs used

These signs are listed for all safety information and instructions in these

operating instructions which indicate particular hazards to persons, property

or the environment.

Hazard, general

Danger due to electrical voltage / current

Risk of burns due to hot surfaces

CSM-E

en(us)

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

2017-12-11

Summary of Contents for CSM-E

Page 1: ...CSM E ContaminationSensor Module Economy Installation and Maintenance Instructions English translation of original instructions Keep for future reference Document No 3911629a ...

Page 2: ...80 Sulzbach Saar Telephone 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 greates...

Page 3: ...ity 10 Observe regulatory information 10 Proper Designated Use 11 Improper Use or Use Deviating from Intended Use 11 Qualifications of personnel target group 13 Wear suitable clothing 15 Procedure in an Emergency 15 Firefighting Extinguishing Fires 15 Unpacking the unit 16 Transporting the unit 16 Storing the unit 16 Decoding the name plate 17 Checking the scope of delivery 18 Characteristics of t...

Page 4: ...2 Starting up the unit 33 Adjusting the counter balance valve 33 Required tools 34 Setting the counter balance valve with a pressure gauge 35 Setting up the counter balance valve without pressure gauge 38 Mounting accessories 40 Performing maintenance 41 Clean the suction strainer 42 Errors and troubleshooting 44 Taking the unit out of operation 44 Shutting down the unit 45 Disposing of the unit 4...

Page 5: ... shall remain unaffected Technical Support If you have any questions suggestions or encounter any problems of a technical nature please don t hesitate to contact us When contacting us please always include the model type designation and article no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Modifications to the Product We would like to point out that changes to the product e...

Page 6: ...or 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 by one digit every time the manual is revised or...

Page 7: ...ificate 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 ...

Page 8: ...re laid out as follows HAZARD SYMBOL SIGNAL WORD Type and source of danger Consequence of the danger Measures to avert danger Warning signs used These signs are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons property or the environment Hazard general Danger due to electrical voltage current Risk of burns due to hot su...

Page 9: ...uctions which indicate particular hazards to persons property or the environment Read and observe the operation and maintenance instructions Others used symbols The following symbols found you in this operation instructions Tip for handling the product Tools required CSM E en us Page 9 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 10: ...personnel Electricity Only specialist personnel with training as electricians and the following knowledge Safe handling use of tools Fitting and connection of electrical lines electrical machinery sockets etc Checking the phase sequence Product specific knowledge Knowledge about how to handle operating media Observe regulatory information Observe the following regulatory information and guidelines...

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

Page 12: ...only to be used with mineral oils or mineral oil based raffinates NOTICE Highly contaminated fluid The pump will become worn out damaged For long term operation pump only fluid with a maximum contamination of ISO 22 20 18 CSM E en us Page 12 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 13: ...en instructed about the product and informed about potential hazards that can result from improper use Operating personnel Such persons have been instructed in power unit operation and are aware of potential hazards due to improper use Specialist personnel Such persons with corresponding specialist training and several years work experience They are able to assess and perform the work assigned to ...

Page 14: ... connection of hydraulic tubes and connections Fitting and connection of electrical lines electrical machinery sockets etc Checking the phase sequence Product specific knowledge Operation Operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating media Knowledge about contamination due to solids and water Disposal Specialist personnel Proper and envi...

Page 15: ...chains or any other jewelry Wear work safety shoes Procedure in an Emergency In case of emergency switch off the power unit or disconnect it Firefighting Extinguishing Fires Use a powder extinguisher that corresponds to fire class B as per EN EN 2 to extinguish any fires Maintain a minimum safe distance from electrical components For a mains voltage of up to 1000 V the minimum safe distance is 1 m...

Page 16: ...ckaging material in an environmentally friendly manner Transporting the unit Only transport the unit as follows Carry the unit by hand holding the pump and fan cover Transport the unit on the rubber buffers in an upright position Storing the unit Rinse and drain the unit completely before putting it into extended storage Store the unit in a clean dry place Store the unit on the rubber buffers in a...

Page 17: ...e unit and the components Item Description 1 Name plate for power unit 2 Name plate of electric motor 3 Model code for details see page 59 Max INLET press Maximum pressure at the inlet section Max Flow rate Maximum flow rate Weight Weight when empty CSM E en us Page 17 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 18: ...ort any damages in transit to the transport company or the responsible agent immediately Do not put the unit into operation The following items are supplied Item Qty Designation 1 ContaminationSensor Module CSM E 4 Fastening screws for the ContaminationSensor 1 Installation and Maintenance Instructions this document CSM E en us Page 18 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 19: ...air release line Its job is to suppress any existing air bubbles within the realm of what is technically possible to such an extent that the measurement result is not skewed or is only negligibly skewed The highest pressure possible in the ContaminationSensor is targeted as oil with increasing pressure can release an increasing quantity of air reference value approx 8 air per bar This is achieved ...

Page 20: ... Suction port IN 7 Tank connection OUT 8 Leakage oil connection LEAK optional 9 Fastening screws for the ContaminationSensor CS1000 21 Rubber buffer for assembly onto connection block 22 Rubber buffer for assembly onto electric motor 23 Screw plug Cavity for the AquaSensor AS1000 AS3000 24 Flange port for the ContaminationSensor CS1000 CSM E en us Page 20 64 MoWa CSM E 3911629a en us 2017 12 11 do...

Page 21: ...eakage oil connection depending on order 3 Pressure relief valve 4 Counter balance valve 5 Suction strainer 400 µm 6 Suction port IN 7 Tank connection OUT 8 Leakage oil connection LEAK optional 23 Cavity for the AquaSensor AS1000 AS3000 24 Flange port for the ContaminationSensor CS1000 CSM E en us Page 21 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 22: ...Hydraulic circuit powerpack Drilling template for fastening All dimensions in mm CSM E en us Page 22 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 23: ...re hooking it up hydraulically NOTICE Operation without ContaminationSensor Fluid leaking Environmental hazard Assemble the ContaminationSensor properly and professionally Before hooking it up hydraulically assemble the ContaminationSensor CS1000 as follows 1 Remove the plastic screw plug 24 at the flange port 2 Use a lint free cloth to clean the sealing surface at the CSM E en us Page 23 64 MoWa ...

Page 24: ...onSensor 30 into the connections at the CS1000 4 Place the ContaminationSensor 30 onto the inline installation and manually screw in the four fastening screws 9 5 Tighten the fastening screws 9 tight using an Allen wrench 5 mm torque 8 0 5 Nm 6 Installation of the ContaminationSensors 30 is complete CSM E en us Page 24 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 25: ...a lint free cloth to clean the sealing surface at the additional sensor 31 and at the connection block 3 Screw the additional sensor 31 by hand in a clockwise direction into the cavity 4 Tighten the additional sensor tight using a fork wrench 27 mm torque 20 2 Nm 5 The installation of the additional sensor 31 is complete CSM E en us Page 25 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 26: ...ydraulic connections The following illustration shows the hydraulic connections on the power unit IN Suction port connection OUT Return port connection LEAK Leakage oil connection optional CSM E en us Page 26 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 27: ...ht pipe runs and hydraulic oils Additional threaded connections and pipe bends increase the pressure differential Keep the height difference between the unit and the oil level in the tank as low as possible Hoses used must be suitable for suction pressures of at least 0 5 bar Avoid constrictions in the connected hoses This reduces the delivery action and increases the risk of cavitation The nomina...

Page 28: ... the power unit in order to prevent excessively high pressure loss Suction port connection to the tank must be made so that it is always below the oil level and not on the bottom of the tank The greatest contamination is found on the bottom of the tank All impurities and other particles are deposited on the bottom of the tank The greatest contamination is found on the bottom of the tank All impuri...

Page 29: ...re that the return port is always open Connecting drain port LEAK with CSM E 1xxx 2 only NOTICE Closed drain port LEAK 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 CSM E en us Page 29 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 30: ...ered when fault finding NOTICE Slipping magnetic coupling Fluid is no longer being pumped the magnetic coupling starts to make noises and is destroyed A Switch off the power unit immediately B Check the pump temperature Switch the unit on only after the pump has cooled down to below 50 C C Check if the tank connection OUT is open D Check the pressure setting on the pressure gauge Correct the press...

Page 31: ...ith 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 delt...

Page 32: ...tion on this can be found in the corresponding installation instructions for the product Electrical connection of the HYDACLab HLB1400 optional More information on this can be found in the corresponding installation instructions for the product Electrical connection of the CSI C 11 optional More information on this can be found in the corresponding installation instructions for the product CSM E e...

Page 33: ...and the electrical connection is available you will need to adjust the counter balance valve 4 The counter balance valve 4 is delivered in a fully opened state Adjusting the counter balance valve Adjust the counter balance valve 4 according to the following steps CSM E en us Page 33 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 34: ...ing tools are needed to set up the counter balance valve Open jaw wrench 13 mm Allen wrench 4 mm The two following procedures described for setting the counter balance valve are possible CSM E en us Page 34 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 35: ... is required Pressure gauge 0 60 bar including gauge port screw connection A matching pressure gauge kit is available as an accessory see Accessories chapter To set the counter balance valve proceed as follows 1 Loosen the screw plug on the right hand side of the CS in a counterclockwise direction and remove it completely 2 Screw the gauge port connector A into the CS CSM E en us Page 35 64 MoWa C...

Page 36: ...ise of the pump or the outlet side OUT you can hear identify an even flow rate please proceed 5 The pressure gauge B at the gauge port shows the pressure at the input of the ContaminationSensor max 60 bar 6 Unscrew the cap nut from the counter balance valve 7 Release the lock nut on the counter balance valve CSM E en us Page 36 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 37: ...rsion CSM E 4 a maximum pressure increase of 25 bar is possible 9 Tighten the lock nut Make sure that the setting of the counter balance valve is not changed in the process 10 Screw the head nut onto the counter balance valve and tighten it firmly 11 Unscrew the pressure gauge B from the gauge port The gauge port can remain in the CS 12 The unit is ready for operation CSM E en us Page 37 64 MoWa C...

Page 38: ...w rate please proceed 2 Unscrew the cap nut from the counter balance valve 3 Release the lock nut on the counter balance valve 4 When the operating medium is at maximum viscosity set the pressure range by turning the adjusting screw at the load holding valve with a 4 mm Allen wrench 5 Tighten the lock nut Make sure that the setting of the counter balance valve is not changed in the process 6 Screw...

Page 39: ...Adjusting the counter balance valve 7 The unit is ready for operation CSM E en us Page 39 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 40: ...ing Item Designation 1 Montage Kit CSM E consisting of 1x assembly sheet for setup or suspension 1x fastening material screws discs nuts 2 Montage Kit SMU consisting of 1x holder plate for SMU1200 1x fastening material for assembly sheet including discs nuts CSM E en us Page 40 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 41: ...forming any maintenance servicing inspection or repair work Once maintenance work is complete check that the safety devices are still working properly Any screwed fittings which have been undone removed are to be checked to see that they have been properly resecured Please note that the following maintenance intervals are guide values The maintenance intervals shorten depending on the contaminatio...

Page 42: ...nto a piece of pipe of the suction line to protect the pump from coarse contamination Check the suction strainer immediately in the event of insufficient suction or delivery action To replace the suction strainer proceed as follows 1 Open the screw plug with an Allen wrench 6 mm 2 Take out the suction strainer by rotating it with a large flat screwdriver in counterclockwise direction CSM E en us P...

Page 43: ...then blowing it out with compressed air 4 Rotate the suction strainer in clockwise direction into the housing with a large flat screwdriver 5 Screw in the screw plug by hand and tighten it with 12 Nm CSM E en us Page 43 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 44: ... down Switch the unit on again Contact HYDAC With highly viscous oil and extremely high amounts of air an air bubble can get stuck directly behind the pump so that it does not rise and flow out through the conduit The pump is unable to pump against this pressurized air Fully open the downstream valve so that this pressure can drop and the pump can transfer again No function Not connected to power ...

Page 45: ...ter Taking the unit out of operation Disposing of the unit After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly manner CSM E en us Page 45 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 46: ...ering spare parts Make sure to indicate the entire unit designation and the serial number in accordance with the type label when ordering spare parts CSM E en us Page 46 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 47: ...sure relief valve 1 70 Rubber buffer 4 606841 80 Nut 4 90 Lock washer 4 100 Washer 4 110 Rubber buffer 2 6075352 120 Screw connection 2 130 Screw connection 3 140 Screw connection 1 160 Screw connection 2 170 Plug 3 180 Screw 4 220 Screw plug 1 615003 CSM E en us Page 47 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 48: ...ssy 1 260 Pipe elbow assy 1 270 Pipe elbow assy 1 280 Type label 1 290 Screw plug 1 613141 300 Plastic plug with hand lever 2 6044485 Installation and Maintenance Instructions 1 3911629 available on request not deliverable as spare part CSM E en us Page 48 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 49: ...onSensor CS1310 A x x x 1 3336820 ContaminationSensor CS1320 A x x x 1 3332066 ContaminationSensor CS1320 B x x x 1 3381031 AquaSensor AS1008 C 000 909109 AquaSensor AS3008 5 000 922591 HLB14J8 1C000 000 923684 HLB14J8 00S12 000 923685 SensorMonitoring Unit SMU1260 TU 00 3467005 SensorMonitoring Unit SMU1261 TU 00 3791708 SensorMonitoring Unit SMU1270 TU 00 3704282 SensorMonitoring Unit SMU1271 TU...

Page 50: ... FluMoS Professional 3355176 CD FluMoT driver package 3355177 ContaminationSensor Interface CSI D 5 3249563 ContaminationSensor Interface CSI C 11 CSI V 11 0 0 0 000 4066011 Power supply unit PS5 3399939 Connection cable screened with 5 pole elbow female connector open 6019455 CSM E en us Page 50 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 51: ...Length 2 m ZBE 30 02 6040851 Connection cable with 5 way female connector 5 way male connector Length 3 m ZBE 30 03 6053924 Connection cable with 5 way female connector 5 way male connector Length 5 m ZBE 30 05 6040852 Connection cable with 8 way female connector 5 way male connector Length 0 5 m ZBE 43 005 4193544 Connection cable shielded with 8 pin mating connector 8 pin open end length 2 m ZBE...

Page 52: ...5 Connection cable shielded with 4 pin mating connector RJ45 length 10 m ZBE45 10 3346101 Socket plug 5 pin with screw clamp ZBE08 6006786 Socket plug 8 pin with screw clamp ZBE44 3281243 CSM E en us Page 52 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 53: ...bar 120 bar CSM E1xxx 4 0 4 bar 80 bar Permitted pressure at drain port LEAK CSM E1xxx 2 0 5 bar max Permitted pressure at tank connection OUT CSM E1xxx 1 CSM E1xxx 2 CSM E1xxx 4 5 bar maximum Pump type Gear pump Maximum suction height 500 mm Sealing material NBR FKM Suction port IN G Tank connection OUT G Drain port LEAK G Permissible operating viscosity range CSM E1xxx 1 CSM E1xxx 2 10 3000 mm s...

Page 54: ...Technical Data CSM E en us Page 54 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 55: ...inuous duty rating 100 100 Rotational speed 1425 rpm 1710 rpm IP class IP55 IP55 Insulation class F F Electrical data CSM1xxx x x N AB N60 AB60 Voltage frequency 50 Hz 60 Hz Voltage delta circuit 400 V 50 Hz 3 Ph 400 V 60 Hz 3 Ph Voltage Star Y connection 690 V 50 Hz 3 Ph 690 V 60 Hz 3 Ph Current consumption 0 71 A 0 41 A 0 57 A 0 33 A Nominal power 0 18 kW 0 18 kW Continuous duty rating 100 100 R...

Page 56: ...rk is indispensable for ensuring trouble free operation and long service life for your powerpack HYDAC SERVICE GMBH Friedrichsthaler Straße 15a Werk 13 66540 Neunkirchen Heinitz Germany Telephone 49 681 509 441 Fax 49 681 509 324 E mail service hydac com CSM E en us Page 56 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 57: ...pack has different dimensions depending on how it is equipped with sensors and interface modules Dimensions with CS1000 AS1000 and CSI C11 All dimensions in mm CSM E en us Page 57 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 58: ...Appendix Dimensions with CS1000 HLB1400 and CSI C11 All dimensions in mm CSM E en us Page 58 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

Page 59: ...on mineral oil Hydraulic version 1 Gear pump standard 2 Gear pump inlet pressure stable up to a maximum of 120 bar with oil leakage pipe 4 Gear pump inlet pressure stable up to a maximum of 80 bar without oil leakage pipe Sensors Z without Power supply W N X60 O60 230 V 50 Hz 3 Ph 265 V 60 Hz 3 Ph 400 V 50 Hz 3 Ph 460 V 60 Hz 3 Ph Supplementary details without CSM E en us Page 59 64 MoWa CSM E 391...

Page 60: ...urrent DIN Deutsche Industrie Norm DIN German Industry Standard DN Nominal Diameter EG European Community EU European Union FKM Fluoroelastomer rubber FluMoS FluidMonitoring Software FluMoT FluidMonitoring driver package HLB HYDACLab Sensor IN Inlet INLET Inlet LEAK Leakage oil connection NBR Nitrile rubber OUT Outlet OUTLET Outlet PS PowerSupply SMU SensorMonitoring Unit Upm Rpm ZBE Electronics a...

Page 61: ...CSI 32 50 57 58 60 D DIN 60 E Error 44 F Filter 11 FluMoS 50 60 FluMoT 50 60 I IN 20 21 26 28 33 53 60 INLET 17 60 Installation 1 7 18 24 48 IP 55 ISO 12 O OUT 20 21 26 29 30 33 36 38 53 60 OUTLET 60 S Sensor 60 T Transport 14 16 CSM E en us Page 61 64 MoWa CSM E 3911629a en us 2017 12 11 docx 2017 12 11 ...

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Page 64: ...striegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Central Fax 49 6897 509 9046 Technology Fax 49 6897 509 577 Sales Department Internet www hydac com E mail filtersystems hydac com ...

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