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Summary of Contents for HYDAC FILTER SYSTEMS CMP 43x0-5 Series
- Page 1 CMP 43x0-5-... ConditionMonitoring Package Installation and Maintenance Instructions English (translation of original instructions) Document No. : 4191543c Follow these instructions for proper and safe use. Keep for future reference.
- Page 2 E-mail: guenter.harge@hydac.com UKCA – Authorized representative of the manufacturer HYDAC Technology Limited De Havilland Way, Windrush Park Witney, Oxfordshire OX29 0YG United Kingdom Phone:+44 1993 - 86 63 66 Print date: 11/25/2022 © HYDAC FILTER SYSTEMS GmbH Subject to technical modifications.
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Page 3: Table Of Contents
HYDAC FILTER SYSTEMS GMBH Table of Contents Table of Contents General ........................ 5 Target group of the manual ................ 5 Illustrations in the manual................ 6 1.2.1 Illustration on the title page .............. 6 1.2.2 Representation of requirements............ 7 1.2.3 Representation of procedural instructions ......... 7 1.2.4 Representation of intermediate results/results........ 8... - Page 4 Table of Contents HYDAC FILTER SYSTEMS GMBH 4.1.3 Connecting outlet OUT .............. 35 Making the electrical connections .............. 36 4.2.1 Connecting the electric motor, 1-phase ........... 37 4.2.2 Connecting the electric motor, 3-phase ........... 37 Commissioning ..................... 39 Operation ........................ 40 Evaluating/reading measurement reports/values with FluMoS .... 40 Rectifying malfunctions................... 41...
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Page 5: General
HYDAC FILTER SYSTEMS GMBH General | 1 1 General Before you use this product for the first time, read this manual at least up to the chapter "Operation". If you would like to carry out maintenance or troubleshooting, you can find the procedure in the respective chapters. -
Page 6: Illustrations In The Manual
1 | General HYDAC FILTER SYSTEMS GMBH 1.2 Illustrations in the manual You will find illustrations in this manual. You can find details regarding these in the following chapters. 1.2.1 Illustration on the title page You will find the following information on the title page of this... -
Page 7: Representation Of Requirements
HYDAC FILTER SYSTEMS GMBH General | 1 The document no. with the index (4) is meant for identifying and reordering the manual. The index is incremented every time the manual is revised or changed. The manual contains a table of contents, a list of tables and figures, an index and a glossary. -
Page 8: Representation Of Intermediate Results/Results
1 | General HYDAC FILTER SYSTEMS GMBH – Rinse the product. 1.2.4 Representation of intermediate results/results In the case of some activities, it is necessary to carry out work steps with intermediate results and end results. Intermediate results are the consequence of activities; they are marked with an indented arrow. -
Page 9: Supplementary Symbols
HYDAC FILTER SYSTEMS GMBH General | 1 1.2.5 Supplementary symbols You will find the following symbols in the manual as additional details: u ## Cross reference to a page / a chapter / a section or another document. Glossary Terms in grey are explained in detail in the glossary, a chapter at the end of the manual. -
Page 10: Signal Words And Their Meaning In The General Safety Information
1 | General HYDAC FILTER SYSTEMS GMBH 1.2.7 Signal words and their meaning in the general safety information 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. -
Page 11: Exclusion Of Liability / Warranty
HYDAC FILTER SYSTEMS GMBH General | 1 1.3 Exclusion of liability / warranty For the warranty provided by us, please refer to our terms of delivery. They are made available to you at the conclusion of the contract at the latest. In addition, you will find these under www.hydac.com ->... -
Page 12: Safety
2 | Safety HYDAC FILTER SYSTEMS GMBH 2 Safety The product is designed as safe. In spite of that, there is danger in some actions that can only be avoided by using the right procedures. These correct procedures and points, which must be followed, are described in this manual. - Page 13 HYDAC FILTER SYSTEMS GMBH Safety | 2 – To provide the necessary protective equipment to the personnel Personnel who work with the product must be aware of the dangers involved in handling it, must be over 14 years of age and must be without any physical impediments in regard to the industrial environment.
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Page 14: Tab. 2 Target Group / Required Personnel Qualification
2 | Safety HYDAC FILTER SYSTEMS GMBH Activity Personnel Knowledge Disposal Specialist Knowledge of environ- personnel - mentally friendly General disposal of materials and matter is required. Knowledge of decon- tamination of contami- nants is required. Knowledge of recycling is required. -
Page 15: Hazard Symbols / Pictograms
HYDAC FILTER SYSTEMS GMBH Safety | 2 2.2 Hazard symbols / pictograms The following are the safety symbols / pictograms in this manual. They indicate specific dangers to persons, property or to the surroundings. Observe these safety symbols / picto- grams and act with particular caution in such cases. - Page 16 2 | Safety HYDAC FILTER SYSTEMS GMBH Used GHS symbols These symbols can be found for all safety and warning instruc- tions in this manual which indicate particular dangers to persons, property or the environment. Hazardous to the environment Others symbols used...
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Page 17: Danger Notifications
HYDAC FILTER SYSTEMS GMBH Safety | 2 These persons have specific specialist training and several years of work experience. They are able to assess and perform the work assigned to them and they are also able to detect potential dangers. - Page 18 2 | Safety HYDAC FILTER SYSTEMS GMBH Environmentally tip Open ports Oil leaking out from open ports u Soak up the leaking oil with an absorbent cloth and dispose of it in an environmentally friendly way. Life phase - Transport / Storage...
- Page 19 HYDAC FILTER SYSTEMS GMBH Safety | 2 DANGER Electric voltage warning Danger of fatal injury u In case of any damage to the insulation, switch off the supply voltage immediately and arrange for repairs to be carried out. u Before carrying out any work on the electrical system and before any maintenance, cleaning or repair work, disconnect the supply line or pull out the power plug.
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Page 20: Observing Regulatory Information
2 | Safety HYDAC FILTER SYSTEMS GMBH 2.4 Observing regulatory information Observe the following regulatory information and directives: – Legal and local regulations for accident prevention – Legal and local regulations for environmental protection and environmental requirements – Country-specific regulations, organization-specific regula- tions –... -
Page 21: Product And Technical Specifications
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3 Product and technical specifications The ConditionMonitoring Package CMP is used to continu- ously monitor fluid power systems for solid and/or liquid contaminants. The CMP is equipped with a gear pump which supplies the oil to be analyzed to the MetallicContamination Sensor MCS, in... -
Page 22: Technical Data
3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.1 Technical data If you are aware of the technical data of the product, you will be able to use it optimally. This chapter provides the technical data of the product:... -
Page 23: Tab. 5 Technical Data - Ambient And Storage Conditions
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 Ambient and storage conditions Permissible ambient -20 … 40 °C / temperature range -4 … 104 °F Permissible storage -40 … 80 °C / temperature range -40 … 176 °F Permissable relative ≤ 90 %, non-condensing humidity Air conditions Clean, salt-free air, not near oxidizing... -
Page 24: Checking The Scope Of Delivery
3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.2 Checking the scope of delivery Here you will find the scope of delivery for the product. – Check the packaging and the product for damage. Report any damage in transit to the forwarding agent or the HYDAC department in charge. -
Page 25: Intended Use
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.3 Intended Use Use the product only for the application described below. The ConditionMonitoring Package CMP is used for continuous monitoring of fluid contamination (solids and fluid contami- nants) in hydraulic systems. -
Page 26: Improper Use Or Use Deviating From Intended Use
3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.4 Improper Use or Use Deviating from Intended Use Any other use or extended use shall not be considered intended use. HYDAC FILTER SYSTEMS GmbH will assume no liability for any damage resulting from such use. This risk is borne solely by the owner. -
Page 27: Decoding The Type Label
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.5 Decoding the type label Details for identifying the product are found on the name plates on the product as well as their components. Always mention the part no. and the serial no. when contacting HYDAC. - Page 28 3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH Max. Inlet Operating pressure, maximum pressure Weight Weight when empty Sensor voltage Connected load of sensor 28 / 60 MoWa CMP43x0-5 4191543c en-us print...
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Page 29: Model Code
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.5.1 Model code The ConditionMonitoring Package is defined by the following model code: CMP 100 0 – 4 – 1 - W/N/X60/O60 – AS11 /-000 CMP = ConditionMonitoring Package ContaminationSensor 121 = CS1000 -> ISO / SAE without display 122 = CS1000 ->... -
Page 30: Hydraulic Diagram
3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.6 Hydraulic diagram The CMP has the following hydraulic diagram: Fig. 4: Hydraulic diagram 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 MetallicContamination Sensor 5 Suction strainer, 600 µm 6 Suction port connection IN... -
Page 31: Dimensions
HYDAC FILTER SYSTEMS GMBH Product and technical specifications | 3 3.7 Dimensions The CMP has the following dimensions: Fig. 5: Dimensions (all specifications are in mm) MoWa CMP43x0-5 4191543c en-us print 31 / 60... -
Page 32: Components
3 | Product and technical specifications HYDAC FILTER SYSTEMS GMBH 3.8 Components The CMP has the following components / operating parts: Fig. 6: Components 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 MetallicContamination Sensor 5 Suction strainer, 600 µm 6 Suction port connection IN... -
Page 33: Assembly, Installation And Commissioning
HYDAC FILTER SYSTEMS GMBH Assembly, installation and commissioning | 4 4 Assembly, installation and commissioning An optimally assembled and installed product ensures a safe and continuous operation. Fasten the CMP using the four bore holes Ø 10 mm to a wall. The dimensions to drilling template, see Dimensions [} 31]. -
Page 34: Fig. 8 Pressure Loss Formula
4 | Assembly, installation and commissioning HYDAC FILTER SYSTEMS GMBH – Flow – Kinematic viscosity – Pipe dimensions – Fluid density The pressure loss can be estimated as follows for mineral oil- based hydraulic oils: Fig. 8: Pressure loss formula Δp Pressure differential... -
Page 35: Connecting The Inlet In
HYDAC FILTER SYSTEMS GMBH Assembly, installation and commissioning | 4 4.1.2 Connecting the inlet IN Make the suction-side connection IN with a flexible hose that is resistant to negative pressure or with pipelines. The nominal size of the hose or pipeline should correspond with the cross section of the connection. -
Page 36: Making The Electrical Connections
4 | Assembly, installation and commissioning HYDAC FILTER SYSTEMS GMBH 4.2 Making the electrical connections Check the connection voltage and the frequency of the electric motor and balance it with the available mains supply. You will find the electric data on the name plate of the electric motor. -
Page 37: Connecting The Electric Motor, 1-Phase
HYDAC FILTER SYSTEMS GMBH Assembly, installation and commissioning | 4 Connection of the sensor connection box (option) Use a sensor connection box to simplify the electrical instal- lation or implement certain types of connection (for example, Ethernet). The connections of the sensors installed in CMP are combined and connected to terminals or plugs. -
Page 38: Fig. 9 Star Delta Connection
4 | Assembly, installation and commissioning HYDAC FILTER SYSTEMS GMBH Fig. 9: Star delta connection Star (Y) connection Delta connection Checking the direction of rotation. Check the direction of rotation on the electric motor by switching it on briefly (manual operation). An arrow on the fan... -
Page 39: Commissioning
HYDAC FILTER SYSTEMS GMBH Assembly, installation and commissioning | 4 4.3 Commissioning ü The CMP is connected hydraulically and electrically. 1. Switch on the hydraulic system 2. Open the existing shut-off devices upstream or down- stream the CMP. 3. Check for leaks. Eliminate leakages immediately. -
Page 40: Operation
5 | Operation HYDAC FILTER SYSTEMS GMBH 5 Operation Procedures, notes and tips for optimum, fault-free operation can be found in this chapter. Open the shut-off devices and switch on the system. 5.1 Evaluating/reading measurement reports/values with FluMoS The FluidMonitoring Software FluMoS is used to read and analyze measurement reports / measured values from the HYDAC sensors / interfaces or devices. -
Page 41: Rectifying Malfunctions
HYDAC FILTER SYSTEMS GMBH Rectifying malfunctions | 6 6 Rectifying malfunctions The following errors could occur when handling or operating the ConditionMonitoring Package CMP: Error Cause(s) Rectification No function. No electric Check the feed tension. line, fuse and The motor pump the switch. -
Page 42: Tab. 8 Error/Cause/Rectification
6 | Rectifying malfunctions HYDAC FILTER SYSTEMS GMBH Error Cause(s) Rectification Heat the fluid to achieve the permissible viscosity. The transport Remove the seals have not transport seals. been removed. The transport seals are the yellow plastic parts. Tab. 8: Error/cause/rectification... -
Page 43: Performing Maintenance
HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 7 7 Performing Maintenance For a long, trouble-free service life of the product, regular maintenance activities are required. This chapter contains the description of the required mainte- nance activities and the qualifications of the staff needed to carry out these tasks. -
Page 44: Maintenance Table
7 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH 7.1 Maintenance table Additional information Visual check for leaks Visual check of electric equipment Cleaning/ Changing the protective screen Cleaning/ Changing the protective screen 1 - Operating personnel; 2 - Specialist personnel – Mechanical 7.2 Visual check for leaks... -
Page 45: Fig. 10 Cleaning The Protective Screen
HYDAC FILTER SYSTEMS GMBH Performing Maintenance | 7 Clean the protective screen at regular intervals, for example, 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. - Page 46 7 | Performing Maintenance HYDAC FILTER SYSTEMS GMBH O The cleaning / changing of the suction strainer is complete. 46 / 60 MoWa CMP43x0-5 4191543c en-us print...
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Page 47: Decommissioning / Disposal
HYDAC FILTER SYSTEMS GMBH Decommissioning / Disposal | 8 8 Decommissioning / Disposal In the following chapters, you will be provided with information regarding temporary shutdown/final decommissioning and disposal of the product. 8.1 Temporary shutdown If the product is being temporarily shut down, the following... -
Page 48: A Appendix
A | Appendix HYDAC FILTER SYSTEMS GMBH A Appendix In this annex, you will find supplementary information on the product. A.1 Contacting Customer Service Contact data such as the telephone numbers, e-mail and mailing addresses for the Hotline, product support, Customer... -
Page 49: Finding Spare Parts / Accessories
HYDAC FILTER SYSTEMS GMBH Appendix | A A.2 Finding spare parts / accessories Use only original spare parts for a long and defect-free life cycle of the product. When ordering spare parts and acces- sories make sure to always indicate the exact model code and the serial number. -
Page 50: Finding Accessories
A | Appendix HYDAC FILTER SYSTEMS GMBH A.2.1 Finding accessories The following accessories are available for the ConditionMonitoring Package. Connection cable, 5-pin Screwed connection bushing, , -, ZBE00 Socket M12x1, 5-pole, A-coded Description Part no. Screwed connection bushing, ZBE00, Color: -, -... - Page 51 HYDAC FILTER SYSTEMS GMBH Appendix | A Description Part no. Connecting line, L: 5 m, ZBE30-05 6040852 Line sheath: -, color: black, - Connecting line, L: 20 m, ZBE30-20 3761071 Line sheath: -, color: black, - Connecting line, L: 10 m, ZBE30-10 3534972 Line sheath: -, color: black, - Connecting line, L: 30 m, ZBE30-30 3656854 Line sheath: -, color: black, -...
- Page 52 A | Appendix HYDAC FILTER SYSTEMS GMBH Single-ended cordset , shielded, ZBE47S M12x1 Socket, 5 -pole, even A-coded <-> Open cable Description Part no. Single-ended cordset, L = 5 m, 3527626 Line sheath: - , Color: black, - ZBE47S-05 Single-ended cordset, L = 10 m, 3527627 Line sheath: - , Color: black, - ZBE47S-10 Single-ended cordset, L = 15 m,...
- Page 53 HYDAC FILTER SYSTEMS GMBH Appendix | A Single-ended cordset, shielded, ZBE42S M12x1 Socket, 8 -pin, even A-coded <-> Open cable Designation Part no. Single-ended cordset, L = 2 m, ZBE42S-02 3281220 black, -, - Single-ended cordset, L = 5 m, ZBE42S-05 3281239 black, -, - Single-ended cordset, L = 10 m, ZBE42S-10...
- Page 54 Table of Illustrations HYDAC FILTER SYSTEMS GMBH Table of Illustrations Overview / labeling of the title page ............Fig. 1 Decoding the name plate ................. Fig. 2 Model Code ....................Fig. 3 Hydraulic diagram ..................Fig. 4 Dimensions (all specifications are in mm) ..........
- Page 55 HYDAC FILTER SYSTEMS GMBH List of Tables List of Tables Tab. 1 Target groups ................... Tab. 2 Target group / Required personnel qualification ........Tab. 3 Technical data – Hydraulic data ............... Tab. 4 Technical data – Electrical data..............Tab. 5 Technical data –...
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Page 56: Glossary
Glossary HYDAC FILTER SYSTEMS GMBH Glossary AquaSensor AS1000 Series FluMoS light The AquaSensor AS 1000 is used for online detection of water in oils, FluMoS light is available as a particularly as OEM sensor for download from the homepage at condition monitoring (Condition www.hydac.com zur. - Page 57 HYDAC FILTER SYSTEMS GMBH Glossary and parameterize up to 16 sensors analogue signals and/or switching via LAN/W-LAN or Bluetooth, signals at the electrical outlet of the depending on your terminal device. HYDACLAB® (for example, warning, alarms). The measured values can be depicted and...
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Page 58: Index
Index HYDAC FILTER SYSTEMS GMBH Index Check direction of rotation 38 Connecting 1ph 37 Accessories Connecting 3ph 37 ZBE00 50 Delta connection 38 ZBE08 50 Star (Y) connection 38 ZBE0P 52 Star delta connection 38 ZBE30 50 Emission sound pressure level 23... - Page 59 HYDAC FILTER SYSTEMS GMBH Index Checking the power supply voltage 36 Technical data 22 Installing the motor protection switch Ambient conditions 23 36 Electrical data 22 Manufacturer 2 General data 23 Hydraulic data 22 Connecting 36 Storage conditions 23 measurement reports Analyzing - see FluMoS 40...
- Page 60 www.hydac.com...
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