HYDAC FILTER SYSTEMS CMP1 0-2 Series, Installation And Maintenance Instructions Manual

Page 1: ...CMP 1000 series ConditionMonitoring Package Installation and Maintenance Instructions English translation of original instructions Documentation no 3528418d ...

Page 2: ...tive 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 t...

Page 3: ...ure of the safety information and instructions 9 Observe regulatory information 9 Proper Designated Use 10 Improper Use or Use Deviating from Intended Use 11 Qualifications of personnel target group 12 Wear suitable clothing 14 Dangers by pressure in the hydraulic system 14 Unpacking the unit 15 Storing the unit 15 Decoding the model code label 16 Checking the Scope of Delivery 17 CMP Features 18 ...

Page 4: ...MP1xx0 4 27 Electrical connection of the CMP 28 Electrical connection of the ContaminationSensor CS1000 29 Electrical connection of the AquaSensor AS1000 29 Starting up the CMP 30 Required tools and measuring instruments 30 Adjusting the counter balance valve 31 Performing Maintenance 34 Clean the suction strainer 35 Errors and troubleshooting 37 Spare parts list 38 Disposing of the unit 38 Custom...

Page 5: ...imited to foreseeable damage Claims due to Product Liability 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 0 6897 509 9046 E Mail filtersystems hydac com Modifications to the Pr...

Page 6: ...rmine which topic I am looking for WHERE can I find the information I m looking for 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 instr...

Page 7: ...e safety devices are present Secure the hazardous areas which may arise between the unit 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 haza...

Page 8: ...ANGER DANGER indicates a danger with a high risk and which will lead to death or serious injury if not avoided WARNING 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 NOTICE NOTICE indicates a danger which will lead to damage to property if...

Page 9: ...rd indicate the severity of the danger Warning instructions listed before 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 environmenta...

Page 10: ...of the product extends to the following The unit is only to be used with permissible media observing all instructions contained in the operating manual performing inspection and maintenance work NOTICE Impermissible operating media The unit will be destroyed The unit is only to be used with mineral oils or mineral oil based raffinates Do not filter any caustic or explosive media NOTICE Highly cont...

Page 11: ...ded 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 Operation in potentially explosive atmospheres Operation with a non approved medium Operation under non approved operational conditions Operation when the saf...

Page 12: ... training and 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 ...

Page 13: ...General Safety Information CMP1000 en us Page 13 44 MoWa CMP 3528418d en us 2015 01 06 doc 2015 01 06 Knowledge with regard to recycling ...

Page 14: ...ng parts and the danger of getting snagged on projecting parts 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 Dangers by pressure in the hydraulic system WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydrauli...

Page 15: ...packed for shipment 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 Dispose of the packaging material in an environmentally friendly manner Storing the unit Rinse and drain the unit completely before putting it into extended storage Make sure to store the CSM in a clean dry place ...

Page 16: ...he components Item Description 1 Power unit type label 2 Name plate of electric motor 3 Model code for details see page Fehler Textmarke nicht definiert Motor voltage Required electric motor operation voltage Motor grid Number of electric motor phases Frequency Mains frequency Max Flow rate Maximum flow rate Max INLET press Maximum pressure at the inlet Weight Empty weight Sensor voltage Required ...

Page 17: ...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 included in the scope of delivery Qty Designation 1 ConditionMonitoring Package CMP 1000 Series 1 Technical Documentation const of Operating and maintenance Instructions CMP 1000 Operating and maintenance Instructions CS 1000 Series Operating and Maint...

Page 18: ...rement results as they like particulate contamination cause the measurement cell to generate signals The purpose of the CSM is to suppress air bubbles so that the measurement results are not skewed or only minimally impacted Because oil absorbs an increasing quantity of air as the pressure increases rule of thumb 8 air per bar the ContaminationSensor aims to achieve the greatest possible pressure ...

Page 19: ...1 06 doc 2015 01 06 CMP Components Item Designation 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 Counter balance valve 5 ConditionSensor CS1000 series 6 Suction strainer 400 µm 7 Suction port IN 8 Return port connection OUT 9 AquaSensor AS1000 11 Pressure gauge ...

Page 20: ...01 06 doc 2015 01 06 CMP1xx0 2 1 hydraulic schema Item Designation 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 Counter balance valve 5 ConditionSensor CS1000 series 6 Suction strainer 400 µm 7 Suction port IN 8 Return port connection OUT 9 AquaSensor 1000 11 Pressure gauge ...

Page 21: ...01 06 doc 2015 01 06 CMP1xx0 4 1 hydraulic schema Item Designation 1 Electric motor 2 Gear pump 3 Pressure relief valve 4 Counter balance valve 5 ConditionSensor CS1000 series 6 Suction strainer 400 µm 7 Suction port IN 8 Return port connection OUT 9 AquaSensor 1000 11 Pressure gauge ...

Page 22: ...CMP1xx0 2 1 dimensions CMP1000 en us Page 22 44 MoWa CMP 3528418d en us 2015 01 06 doc 2015 01 06 CMP1xx0 2 1 dimensions ...

Page 23: ...CMP1xx0 4 1 dimensions CMP1000 en us Page 23 44 MoWa CMP 3528418d en us 2015 01 06 doc 2015 01 06 CMP1xx0 4 1 dimensions ...

Page 24: ...tion of the CMP CMP1000 en us Page 24 44 MoWa CMP 3528418d en us 2015 01 06 doc 2015 01 06 Hydraulic connection of the CMP Hydraulic connectors CMP1xx0 2 CMP1xx0 4 IN Suction port connection OUT Return port connection ...

Page 25: ...Mineral oil based hydraulic fluid has a density of 0 9 kg cm 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 unit and the oil level in the tank as low as possible Hoses must be suitable for suction pressures of at least 0 5 bar Constrictions in the connections and lines sh...

Page 26: ...ssure loss Suction connection to the tank must be made so that it is always below the oil level NOTICE Contamination too high 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 th...

Page 27: ... at the return port connection Overload protection only with CMP1xx0 4 In order to protect it from overloads the CMP1xx0 4 is equipped with a magnetic coupling between the electric motor and the pump NOTICE The magnetic coupling is slipping No more fluid is being pumped the magnetic coupling starts to make noises and starts to become hot A Switch the unit off B Check the pump temperature Switch th...

Page 28: ...trician Compare the voltage and frequency specifications on the type label 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 The rotational direction is indicated by an arrow on the fan cover To change the direction of rotation commutate two...

Page 29: ...01 06 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 30: ...en completed This is described on page 31 The counter balance valve 1 is completely open at the time the unit is shipped Note that in order to adjust the counter balance valve on the CMP 1xx0 4 the fluid must be in a viscosity range of 10 400 mm s This viscosity can for instance be obtained with ISO VG100 at 20 C and above or with ISO VG150 at 25 C and above Required tools and measuring instrument...

Page 31: ...1 Switch the unit on 2 Check the suction intake behavior of the pump and the oil flow 3 If a uniform volume flow can be heard via the noise of the pump or if it can be detected on the outlet side OUT the pressure gauge will display the pressure at the inlet on the ContaminationSensor CS1000 max 60 bar The counter balance valve is open at the time the unit is shipped The pressure gauge displays the...

Page 32: ...e 4 Unscrew the head nut from the counter balance valve 1 5 Release the lock nut on the counter balance valve 1 6 Set the pressure for a maximum operating medium viscosity to 25 35 bar by using a size 4 Allen wrench to rotate the set screw on the counter balance valve 1 Note that it is recommended that at least10 bar is added to the value measured in step 3 ...

Page 33: ... CMP 3528418d en us 2015 01 06 doc 2015 01 06 7 Tighten the lock nut Make sure that the setting of the counter balance valve 1 is not changed in the process 8 Screw the head nut onto the counter balance valve and tighten it firmly 9 The CMP is now ready for operation ...

Page 34: ...e with the respective schedules The Unit is to be disconnected from the power 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 ...

Page 35: ... strainer Clean the suction screen regularly A suction strainer is fitted into 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 using a size 6 Allen wrench 2 Take out the suction strainer by rotating...

Page 36: ...015 01 06 doc 2015 01 06 3 Clean the suction strainer by washing it out and 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 ...

Page 37: ...losed Open the shut off device Suction strainer is clogged Clean the suction strainer No flow rate The coupling between the motor and the pump is loose or faulty Check the coupling for proper functioning The magnetic coupling is disengaged and is slipping Noise emissions Switch the pump off Allow the CMP to cool down Switch the CMP on again No function Not connected to power supply Check the elect...

Page 38: ...cket M12x1 8 pin 6006786 1 Connecting socket M12x1 5 pin 1 AquaSensor AS 1000 1 Motor pump assembly NBR on request Disposing of the unit After dismantling the unit and separating the various materials dispose of the unit in an environmentally friendly manner Customer Service HYDAC SERVICE GMBH Friedrichsthaler Strasse 15a Werk 13 66453 Neunkirchen Germany Telephone 49 0 681 509 883 Telefax 49 0 68...

Page 39: ...missible suction pressure at suction port connection IN 0 4 bar 80 bar Pressure at return port connection OUT CMP1xx0 2 0 5 bar max CMP1xx0 4 5 bar max Pump type Gear pump Max suction height 500 mm Sealing material NBR Suction port IN G Return port connection OUT G Permissible operating viscosity range CMP1xx0 2 10 3000 mm s CMP1xx0 4 10 1000 mm s Permissible viscosity range for the measurement op...

Page 40: ...68 A Nominal power 0 18 kW 0 18 kW Continuous duty rating 100 100 Rotation speed 1425 rpm 1710 rpm Protection class IP55 IP55 Insulation class f f Electrical data CMP1xxx 4 x N AB N60 AB60 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 r...

Page 41: ...ons 1 without display 2 with display Fluids 0 based on mineral oil Hydraulic Version 2 Pump inlet pressure stability up to a maximum of 80 bar oil leakage pipe connected internally with return port connection 4 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 26...

Page 42: ...ydraulic connection 3 24 Hydraulic data 39 I Imprint 2 3 IN 4 19 20 21 24 26 30 39 INLET 16 25 ISO 10 30 ISO4406 41 1987 41 1999 41 M Maintenance 1 4 17 34 measuring 4 30 Mineral oil 25 Model code 16 O operating 5 6 7 10 12 29 32 35 37 39 Operation 11 12 OUT 4 19 20 21 24 27 30 31 39 Outlet 41 P Pressure differential 25 Pressure gauge 19 20 21 Proper Designated Use 3 10 Protection class 40 Publish...

Page 43: ...Index CMP1000 en us Page 43 44 MoWa CMP 3528418d en us 2015 01 06 doc 2015 01 06 W Weight 16 39 ...

Page 44: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 9046 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com Email filtersystems hydac com ...