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Summary of Contents for Eaton CCS 5
- Page 1 CCS 5 Contamination Control System Particle counting + Water saturation + Temperature Instruction manual Version 0.1 (preliminary) Version valid from: 17.11.2021 software version from:...
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Page 2: Table Of Contents
2.5.4.1. Date/ time ....................24 2.5.4.2. Brightness of the display ................24 2.5.4.3. Update the software of the CCS 5 ............. 25 2.5.5. System information ..................26 SOFTWARE “DATA MANAGER” 3.1. Installation of the Data Manager Software on an external PC ....... 27 Data analysis with “Data Manager”... - Page 3 7.1. Technical data ....................37 7.2. Hydraulic plan ....................39 7.3. Measurement principle ..................39 Laser sensor – Particle Counter for CCS 5 ............ 39 7.3.1. 7.3.2. Water sensor ....................40 7.4. Cleanliness classes according to ISO 4406:99 ..........41 7.5.
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Page 4: Safety Information
Danger for the environment 1.2. Dangers of maloperation The CCS 5 underwent a safety inspection. The integrated electric and hydraulic safety elements ensure safe operation if the device is used as it is intended. In cases of maloperation or abuse, as well as in cases of ignoring the application limits and safety regulations, the following threats can occur regarding the: •... -
Page 5: Hazards By Working At The Hydraulic Or Lubrication System
• risk of slipping • environmental hazards, such as penetration of the fluid into the soil / groundwater Connection of the hoses from the CCS 5 to the hydraulic or lubrication system, see chapter 2.3. Accidental machine movements • Accidental operation of command or control devices. (buttons, levers, proximity switches, and so on) •... -
Page 6: When All Measurements Are Done
The CCS 5 must sit on a flat solid ground. • For outdoor measurements (in the rain) use the CCS 5 only with tilted housing cover. This prevents the entry of water into the CCS 5. Look at the hoses, while closing the housing cover! 1.6. -
Page 7: Limitation Of Use
• Before connecting the CCS 5 to the system, make sure that the oil discharged out of the CCS 5 gets caught in a tank. The oil must not get released to the environment! No unauthorized modifications or changes are allowed to the CCS 5! E.g.: open the unit by removing the front screws and remove the assembly. -
Page 8: Operation And Installation
Operation and installation 2.1. Setup The CCS 5 consists of the equipment case (1), the external power supply (2), the USB – stick (3), high pressure measuring hose (minimess hose) (4), the suction hose and the return hose (5). 2.2. General information External factors have a huge and extensive influence on the lubricant during operation. -
Page 9: Connection To The Hydraulic Or Lubricating System
2.3. Connection to the hydraulic or lubricating system • The CCS 5 can be handled in a suction as well as in a pressure operating mode. Only ONE inlet hose is allowed to be connected at the same time, either... -
Page 10: Connection Into The Suction Operating Mode (Min. -0.2 Bar)
Never connect the OUTLET hose to a pressurized line! • In the suction operating mode the provided suction hose (transparent PVC-hose) is being connected with the [SUCTION PORT] of the CCS 5 using the quick lock coupling (two-sided locking). •... -
Page 11: Battery Operation
• The CCS 5 switches off automatically when the internal battery is completely discharged. Then it is only possible to start the CCS 5 with the external power supply unit. • In standby mode (measurement is not running) the recharge of an empty battery needs around 3 hours;... -
Page 12: Operation With The Ccs 5 Software
(0-45°C is allowed for lithium polymer battery) Car supply With a special adapter it is possible to connect the CCS 5 with a car plug. (the accessory is available on request) 2.5. Operation with the CCS 5 software •... -
Page 13: Measurement
Accomplish of the measurements with various measuring programs (single, continuous, cyclic), and the fluid type in need. The CCS 5 must be connected acc. To the capital 2.3). File system For analysis, transferring and manage of the saved measurement results. - Page 14 For the additional display of the existing theoretical ppm water content during the measurements, the type of oil should be selected. If no test fluid is selected, then the measurements will only display the water saturation in % and not the corresponding ppm. Instruction manual CCS 5, 15/ 10/ 2021...
- Page 15 By touching the filed a new window with all recorded fluids will show up to be selected: Then confirm the selected fluid: then the menu will be automatically switched to the previous menu. The selected fluid is indicated in the display. Instruction manual CCS 5, 15/ 10/ 2021...
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Page 16: Measure-Type: Single
• Both the water saturation and the temperature are shown with each measurement. When a fluid type is selected then the ppm water content is also displayed. • Particle concentration per 1 ml Instruction manual CCS 5, 15/ 10/ 2021... -
Page 17: Measure-Type: Continuous
“Setup”. To assure constant mode of operation of the unit and the accuracy of measurement results, it is recommended to perform a flushing of the CCS 5 with cleaned mineral oil (filtrated H22) for several minutes after finishing the measurements. - Page 18 The last measurement results will not be deleted by continuing the measurement. To assure constant mode of operation of the unit and the accuracy of measurement results it is recommendable to perform a flushing of the CCS 5 with cleaned mineral oil (filtrated H22) for some minutes after finishing the measurements.
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Page 19: Measure-Type: Cyclic
24 hours in half hour steps. Cycle number The total number of measurements can be chosen two-steps wise from 2 to 100. every cyclic measurement will be saved automatically. • Start the cyclic measurement with [ START ]. Instruction manual CCS 5, 15/ 10/ 2021... -
Page 20: File System
To assure constant mode of operation of the unit and the accuracy of measurement results it is recommendable to perform a flushing of the CCS 5 with cleaned mineral oil (filtrated H22) for some minutes after finishing the measurements. -
Page 21: Display The Saved Results In Graphic
Graphic analysis Transfer files to Delete selected files • The saved files will be indicated according date and time. • choose a saved measurement and open the data set. • open the data set. Instruction manual CCS 5, 15/ 10/ 2021... -
Page 22: Delete The Saved Files
The saved measurement files can be also deleted. • in the menu “file system”, select the saved files to be deleted. • Then press the button to delete the selected files • the selected files will be permanently deleted. Instruction manual CCS 5, 15/ 10/ 2021... -
Page 23: Data Transfer
2.5.3.3. Data transfer In this mode the saved measurement results from the CCS 5 can be transferred to an external computer. A transfer of the storage data can be done using a USB-stick. The data transferred in this way are transferred as TXT – Files. -
Page 24: System Settings
2.5.4.2. Brightness of the display • The brightness has 4 levels and can be swiped to 25%, 50%, 75% or 100%. • After all parameters are set, confirm with the button Instruction manual CCS 5, 15/ 10/ 2021... -
Page 25: Update The Software Of The Ccs 5
USB stick, make sure the software is on the root folder: Then insert the USB stick to the CCS 5. • The USB logo will show, if the USB stick is recognized. -
Page 26: System Information
The validity of the calibration certificate is 12 months. • Eaton recommends a calibration interval of one year. For the secondary calibration the CCS 5, the unit is to be sent to Eaton Technologies GmbH in Altlussheim. Instruction manual CCS 5, 15/ 10/ 2021... -
Page 27: Software "Data Manager
PC software for further data analysis is provided on the USB stick. 3.1. Installation of the Data Manager Software on an external PC The CCS 5 DATA MANAGER software was especially developed for the CCS 5 and is provided on the included USB Stick. - Page 28 III. Printed as a report For graphic presentation use the button „GRAPH“. • Depending on the presentation modes, which have been selected in the data manager menu, these are presented graphically. For example: Selection: ISO 4406 Instruction manual CCS 5, 15/ 10/ 2021...
- Page 29 Export in a Excel – data sheet by using the button „EXCEL“ • For further processing the data all standard functions in MS EXCEL are available. Print the report by using the button „PRINT“ • Selection of report type • Selection of the printer. Instruction manual CCS 5, 15/ 10/ 2021...
- Page 30 • Report- printing For exiting the data manager software use Button „EIXIT“. Instruction manual CCS 5, 15/ 10/ 2021...
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Page 31: Evaluation Of Measurement Results
Attention: It is essential to select the correct kind of oil, or the display of the water content will not be equivalent with the effective value for this fluid. Saturation characteristic curves for special oils can be created and implemented by Eaton Technologies GmbH. (Add-on program) - Page 32 Example of a provided saturation characteristic curve: 1200 1000 Temperature in °C Instruction manual CCS 5, 15/ 10/ 2021...
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Page 33: Maintenance
A suction screen is fitted under the INLET (both for pressure and suction) measurement point union and protects the pump from coarse-particle contamination. When the CCS 5 does not pump any fluid into the measurement channel, usually the measurement results stay at 4/4/4/4 or 0/0/0/0, the indicates that the screen is full with dirty, it has to be cleaned or renewed. -
Page 34: Suction Inlet
Take the screen from the INLET out using a tweezer. Then insert the new screen (ordering no. 355103) into the INLET port. Make sure that the screen is sitting correctly in the port. Instruction manual CCS 5, 15/ 10/ 2021... - Page 35 Put a new copper ring (ordering no. 306330 ) on the port. Then Screw the INLET connector tight to 10 NM using a 17mm wrench. Instruction manual CCS 5, 15/ 10/ 2021...
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Page 36: Calibration
The validity of the calibration certificate is 12 months. • Eaton recommends a calibration interval of one year. For the secondary calibration the CCS 5, the unit is to be sent to Eaton Technologies GmbH in Altlussheim. • The calibration and maintenance package for the CCS 5 contains the following benefits:... -
Page 37: Appendix
Appendix 7.1. Technical data Measuring principle laser sensor: particle counting to the light barrier principle Measuring range laser sensor: for particle sizes of: 4, 6, 14 and 21 µm Particle counting according to: ISO 4406:99, NAS 1638, SAE AS 4059 Particle sizes: >... - Page 38 PVC – discharge hose, PVC – suction hose, data manager, USB Stick (with the software Data Manager) Display: 7-inch resistive color touch display Interfaces: USB (data transfer to USB-stick) Dimensions (mm): Weight: 9.8 kg (without accessories) Instruction manual CCS 5, 15/ 10/ 2021...
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Page 39: Hydraulic Plan
7.2. Hydraulic plan 7.3. Measurement principle Laser sensor – Particle Counter for CCS 5 7.3.1. The laser sensor operates based on the light-blockade principle and generates an output signal depending on the particles’ sizes. This is received, processes and classified by corresponding electronics. -
Page 40: Water Sensor
The measuring of HFA, HFB, HFC and aqueous cooling emulsion is not possible. • Automatic flushing processes in all programs shall prevent false measurements. Therefore, the CCS 5 gets flushed completely with the new oil before the next measurement is done. (a) Single measurements: Automatic flushing before the first measurement. -
Page 41: Cleanliness Classes According To Iso 4406:99
Analysis volume: 1 ml Cleanliness class Number of particles ..Up to and including 320000 640000 160000 320000 80000 160000 40000 80000 20000 40000 10000 20000 5000 10000 2500 5000 1300 2500 1300 Instruction manual CCS 5, 15/ 10/ 2021... -
Page 42: Cleanliness Classes According To Nas 1638
0,022 0,004 1,425 0,253 0,045 0,008 2,85 0,506 0,090 0,016 1,012 0,18 0,032 11,40 2,025 0,36 0,064 22,8 4,05 0,72 0,128 45,6 1,44 0,256 91,2 16,2 2,88 0,512 1024 182,4 32,4 5,76 1,024 Instruction manual CCS 5, 15/ 10/ 2021... -
Page 43: Cleanliness Classes According To Sae As 4059
9730 1730 50000 19500 3460 100000 38900 6920 1220 200000 77900 13900 2450 400000 156000 27700 4900 800000 311000 55400 9800 1700 1600000 623000 111000 19600 3390 3200000 1250000 222000 39200 6780 1020 Instruction manual CCS 5, 15/ 10/ 2021... -
Page 44: Fields Of Application - Compatibility
Malfunctions, which could be eliminated by the operator, are limited to checking cables for breaks. Any other cases require sending the CCS 5 to Eaton Technologies GmbH to recover the functions. A brief description of the problem would expedite the trouble shooting and the repair process. -
Page 45: Spare Parts
USB – stick, 2GB, fat16 337627 Calibration certificate annual maintenance/ calibration at Eaton Technologies GmbH 7.11. spare parts for changing the screen of the INLET: • 1 x copper ring 306330 • 2 x screen 355103 Instruction manual CCS 5, 15/ 10/ 2021... - Page 46 Brazil made by Eaton as to the effects of such use or the results to be obtained. Eaton assumes Singapore Av. Julia Gaioli, 474 –...
- Page 47 Instruction manual CCS 5, 15/ 10/ 2021...
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