Hydac CSM 2000 series Operating And Maintenance Manual Download Page 1

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CSM 2000 Series

ContaminationSensor Module

Operating and Maintenance Instructions

English (translation of original instructions)

Dokument No.: 3211683h

(from series no. 0002S02043K0000015)

Summary of Contents for CSM 2000 series

Page 1: ...CSM 2000 Series ContaminationSensor Module Operating and Maintenance Instructions English translation of original instructions Dokument No 3211683h from series no 0002S02043K0000015 ...

Page 2: ...bility for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject to technical modifications Technical specifications are subject to change without notice HYDAC FILTER S...

Page 3: ...l 10 Electrical Hazards 11 Dangers by pressure in the hydraulic system 11 CSM modification 11 Packing storage 12 Unpacking the CSM 12 Storing the CSM 12 Checking the scope of delivery 13 CSM Characteristics 14 Restrictions pertaining to use 15 CSM components 16 Hydraulic diagram 17 Dimensions CSM2x30 1 18 Dimensions CSM2x30 2 19 Drilling template for wall mounting 20 Hydraulic Connection of the CS...

Page 4: ...Switching the CTM on and off 25 Starting up the CSM 26 Adjusting the counter balance valve 26 Required tools and measuring instruments 26 Performing Maintenance 31 Clean the suction screen 32 Disposing of the CSM 33 Errors and troubleshooting 34 Spare Parts List 34 Spare Parts Diagram 35 Customer service 35 Technical data 36 Model Code 38 EC declaration of conformity 39 ...

Page 5: ...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 Dokumentation Postfach 12 51 66273 Sulzbach Saar Germany...

Page 6: ... the product e g purchasing additional options etc may mean that the information in the operating instructions is no longer applicable or adequate After modification or repair work that affects the safety of the product has been carried out on components the product may not be returned to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 mod...

Page 7: ...ng 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 de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx Chapter Page number Edition date Document language Documentation no with index file name The documentation number with its index enables you to order another copy of the operatin...

Page 8: ... constructed in accordance with the current state of the art and recognized safety regulations Nevertheless hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property Use the CSM solely for its designated use only when in a safe perfect condition Immediately remedy any malfunctions tha...

Page 9: ...onSensor module CSM was developed for the continuous monitoring of particulate contamination in hydraulic systems Any other use shall be deemed to be improper and not in keeping with the product s designated use The manufacturer will not assume any liability for any damage resulting from such use Proper or designated use of the product extends to the following Maintaining adherence to all the inst...

Page 10: ...r cut manner Staff undergoing training may not use the CSM unless supervised by an experienced staff member Individuals Individuals undergoing training Individuals with technical training engineering background Electrician Supervisor with the appropriate authority Activity Packing transportation X X X Commissioning X X X Operation X X X X Troubleshooting locating the source of malfunction X X X Re...

Page 11: ...n the hydraulic system WARNING Hydraulic systems are under pressure Bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system CSM modification Do not make any modifications to the unit without the prior consent of HYDAC Immediately replace any faulty unit components Use only original spare parts HYDAC FILTER SYSTEMS GMBH en us Page 11 40 BeWa CSM20...

Page 12: ...arefully packed for shipment The connectors ports 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 Report any damage to the forwarding agent immediately Dispose of the packaging material as appropriate for your area Storing the CSM Make sure to store the CSM in a clean dry place The unit is to be ...

Page 13: ... unit into operation The following items are supplied Item Qty Designation 1 1 Contamination Sensor Module CSM 2000 Series 2 1 Pressure gauge with adapter 1 Technical Documentation const of Operating and Maintenance Instructions CSM 2000 Operating and Maintenance Instructions CS 2000 Series Operating Instructions CoCoS Operating and Maintenance Instructions AS 1000 optional Calibration certificate...

Page 14: ...air as the pressure 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 ...

Page 15: ...01 Restrictions pertaining to use NOTICE Impermissible operating media The unit will be destroyed The unit is 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 ...

Page 16: ...int 2 6 Counter balance valve 7 Throttle valve 8 ContaminationSensor CS2000 series 9 Suction screen 400 µm 10 Suction port connection IN 11 Return port connection OUT 12 AquaSensor AS1000 optional 13 Leakage oil connection LEAKAGE only with CSM2x30 2 21 On off switch with motor protection PKZ 22 Cable 23 Connection plug HYDAC FILTER SYSTEMS GMBH en us Page 16 40 BeWa CSM2000 3211683h en us 2011 12...

Page 17: ...3 Test point 1 4 Pressure control valve 30 bars 5 Test point 2 6 Counter balance valve 7 Throttle valve 8 ContaminationSensor CS2000 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 CSM2x30 2 HYDAC FILTER SYSTEMS GMBH en us Page 17 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 ...

Page 18: ...sions CSM2x30 1 Dimensions CSM2x30 1 312 5 362 5 360 265 90 min 27 max 47 75 52 36 418 A A 156 9 75 520 220 36 20 30 119 5 A A HYDAC FILTER SYSTEMS GMBH en us Page 18 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 19: ...ns CSM2x30 2 Dimensions CSM2x30 2 312 5 362 5 360 265 90 min 27 max 47 75 52 36 418 A A 119 5 A A 156 9 75 520 220 36 20 90 65 30 HYDAC FILTER SYSTEMS GMBH en us Page 19 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 20: ...r wall mounting Hydraulic Connection of the CSM Hydraulic Connectors CSM2x30 1 CSM2x30 2 IN Suction port connection OUT Return port connection LEAKAGE Leakage oil connection HYDAC FILTER SYSTEMS GMBH en us Page 20 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 21: ...sity mm s 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 i...

Page 22: ...rime 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 For the suction port connection IN use a flexible hose that is resistant to negative pressure Ensure that the nominal size of the supply lines is at least as large as the cross section of the unit in order to prevent excessi...

Page 23: ... OUT NOTICE Return port connection OUT closed off The unit will be destroyed Make sure that the return port is always open Leakage oil connection LEAKAGE only with CSM2x30 2 NOTICE 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 24: ...pe label with the specifications for the available network Plug the power plug into a suitable power outlet Check the direction of rotation of the motor by switching it on briefly jog mode An arrow on the fan cover shows the direction of rotation If the direction of rotation needs to be changed this can be done by turning the phase inverter in the connection plug as per the following drawing HYDAC...

Page 25: ...perating and maintenance instructions included Electrical connection of the AquaSensor AS1000 For more information refer to the AquaSensor operating and maintenance instructions included Switching the CTM on and off Switch the CSM on or off at the on off switch HYDAC FILTER SYSTEMS GMBH en us Page 25 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 26: ...s been completed The counter balance valve A and the throttle valve B are completely open at the time the unit is shipped Adjusting the counter balance valve Required tools and measuring instruments Open jaw wrench size 22 mm Open jaw wrench size 13 mm Allen wrench size 4 mm Pressure gauge 0 40 bars including adapter comes standard with the CSM HYDAC FILTER SYSTEMS GMBH en us Page 26 40 BeWa CSM20...

Page 27: ...et the counter balance valve A in accordance with the following steps 1 Open the throttle valve B by turning it counterclockwise until it is completely opened HYDAC FILTER SYSTEMS GMBH en us Page 27 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 28: ...the basis of the sound the pump is making and or at the outlet side OUT then rotate throttle valve gauge B 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 CS2000 max 30 bar 7 Unscrew the head nut from the counter balance valve A HYDAC FILTER SYSTEMS GMBH en us Page 28 40 BeWa CSM2000 3211683h e...

Page 29: ...len wrench to rotate the set screw on the counter balance valve A Note that an increase in pressure in comparison with the value 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 A is not changed in the process HYDAC FILTER SYSTEMS GMBH en us Page 29 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01...

Page 30: ... 11 Screw the head nut onto the counter balance valve A and tighten it firmly 13 Unscrew the manometer from the test point 1 14 The CSM is now ready for use HYDAC FILTER SYSTEMS GMBH en us Page 30 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 31: ...y 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 year Ch...

Page 32: ...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 HYDAC FILTER SYSTEMS ...

Page 33: ...SM When decommissioning and or disposing of the unit observe all local guidelines and regulations pertaining to occupational safety and environmental protection This applies in particular to the oil in the unit components covered with oil and electronical components After disassembling the unit and separating the various materials reuse them or dispose of them properly in accordance with local reg...

Page 34: ...t and if necessary replace it No function Not connected to power supply Check the connection to the power supply plug cable and power outlet For CS2000 error messages refer to the corresponding chapter in your CS2000 operating and maintenance manual Spare Parts List Item Part no Qty Description Material 3135672 3 Part of joint 3152786 1 Suction screen 400 µm 140 10 1 Gear pump 140 30 6032344 1 Pum...

Page 35: ... 40 140 10 Customer service HYDAC SERVICE GMBH Rehgrabenstrasse 3 66125 Saarbrücken Dudweiler Germany Telephone 49 0 681 509 883 Fax 49 0 681 509 324 E mail service hydac com HYDAC FILTER SYSTEMS GMBH en us Page 35 40 BeWa CSM2000 3211683h en us 2011 12 01 doc 2011 12 01 ...

Page 36: ...ort IN CSM2x30 2 0 4 bar 120 bar Permissible pressure at leakage oil connection LEAKAGE CSM2x30 2 maximum 0 5 bar Pressure at return port connection OUT CSM2x30 1 maximum 0 5 bar Pressure at return port connection OUT CSM2x30 2 maximum 0 5 bar Pump types Gear pump Max suction height 500 mm Sealing material NBR FPM Suction port connection IN G Return port connection OUT G Leakage oil connection LEA...

Page 37: ...Insulation class F Electrical data CSM1xxx x x N PKZ Voltage delta connection 400 V 50 Hz 3 Ph Current consumption 0 71 A 0 41 A Nominal power 0 18 kW Continuous duty rating 100 Rotation speed 1425 rpm IP class IP55 Insulation class F For other electrical versions obtain the respective data from the type label on the electric motor HYDAC FILTER SYSTEMS GMBH en us Page 37 40 BeWa CSM2000 3211683h e...

Page 38: ...ure stable up to a maximum of 120 bar with oil leakage pipe Electrical Outlet 0 RS232 DIN 66348 protocol 1 4 20 mA analog outlet 2 RS485 DIN 66348 protocol 5 Ethernet IEEE 802 3 TCP IP protocol 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 3 Ph 690 V 50 Hz 3 Ph 690 V 60 Hz 3 Ph Other voltages on request Sup...

Page 39: ...dinated with us in writing will cause this declaration to lose its validity Description ContaminationSensor Module CSM2000 Type CSM2x3x x x x PKZ Part no Serial no EU Machinery Directive 2006 42 EG EU Electrical Equipment Regulations 2006 95 EG EMC Guidline 2004 108 EG 2009 01 15 Thorsten Trier Date Name CE authorized person Executive director Documentation Representative Mathias Dieter Dipl Kfm W...

Page 40: ...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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