Internormen-Eaton - CCS 2 Contamination Control System - Manual v2.3.pdf

CCS 2

CONTAMINATION CONTROL SYSTEM

CE 2001

Instruction manual Version 2.3

Serial-No.: .................. Version-/Rev.-Date: 12.06.2012

CCS 2 List of content

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List of content Page

1. SAFETY 5

1.1. Danger through maloperation 5

1.2. Proper use 5

1.3. Sources of danger 6

1.4. Service staff 6

1.5. Safety arrangements on site 6

1.6. Protection device 6

2. INITIATION 7

2.1. Electrical connection 7

2.2. Connection of the system 10

2.3. Weight and dimensions 12

2.4. Transport 12

3. MAINTENANCE 13

3.1. General information 14

3.2. Control panel and key pad use 15

3.3. Main menu 17

3.3.1. On-line particle counting 18

3.3.1.1. Mode: on-line single/ ISO 4406 : 99 19

3.3.1.2. Mode: on-line single/ NAS 1638 20

3.3.1.3. Mode: on-line single/ SAE AS 4059 : 01 21

3.3.1.4. Mode: on-line continuous/ ISO 4406 : 99 22

3.3.1.5. Mode: on-line continuous/ NAS 1638 23

3.3.1.6. Mode: on-line continuous/ SAE AS 4059 : 01 24

3.3.1.7. Setup-menu: on-line cyclic/ ISO 4406 : 99 25

3.3.1.7.1. Mode: on-line cyclic/ ISO 4406 26

3.3.1.8. Setup-menu: on-line cyclic/ NAS 1638 27

3.3.1.8.1. Mode: on-line cyclic/ NAS 1638 28

3.3.1.9. Setup-menu: on-line cyclic/ SAE AS 4059 : 99 29

3.3.1.9.1. Mode: on-line cyclic/ SAE AS 4059 30

3.3.2. Off-line particle counting 31

3.3.3. File system 34

3.3.3.1. Mode: on-line single measurement 34

3.3.3.1.1. Report format 34


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3.3.3.1.1.1. Mode: single/ ISO 4406 : 99 36

3.3.3.1.1.1.1. Contamination classes trend 36

3.3.3.1.1.2. Mode: single/ NAS 1638 37


3.3.3.1.1.3. Mode: single/ ISO 4406 : 87 38


3.3.3.1.1.4. Mode: single/ SAE AS 4059 : 01 39


3.3.3.2. Mode: on-line continuous measurement 40


3.3.3.2.1.1. Mode: continuous/ ISO 4406 : 99 42


3.3.3.2.1.2. Mode: continuous/ NAS 1638 42


3.3.3.2.1.3. Mode: continuous/ ISO 4406 : 87 44


3.3.3.2.1.4. Mode: continuous/ SAE AS 4059 : 01 45


3.3.3.3. Mode: on-line cyclic measurement 46


3.3.3.3.1.1. Mode: cyclic/ ISO 4406 : 99 48


3.3.3.3.1.2. Mode: cyclic/ NAS 1638 48


3.3.3.3.1.3. Mode: cyclic/ ISO 4406 : 87 49


3.3.3.3.1.4. Mode: cyclic/ SAE AS 4059 : 01 51


3.3.3.4. Mode: off-line bottle sampling 51


3.3.3.4.1.1. Mode: bottle sampling/ ISO 4406 : 99 54


3.3.3.4.1.2. Mode: bottle sampling/ NAS 1638 54


3.3.3.4.1.3. Mode: bottle sampling/ ISO 4406 : 87 56


3.3.3.4.1.4. Mode: bottle sampling/ SAE AS 4059 : 01 57


3.3.4. Data transfer 58


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3.3.5. Data file delete 59

3.3.5.5. Setup - menu: date/ time 60

3.4. Instructions in brief for the on-line determination of the contamination classes 61

3.5. Instructions in brief for the off-line determination of the contamination classes 63

3.6. Printer 64

3.6.1. Change of the printer ribbon 64

3.6.2. Input of paper 65

3.7. Implementing a new program version from a Laptop or PC 66

3.8. The data manager 67

4. MALFUNCTIONS / TROUBLESHOOTING 68

5. SERVICE / MAINTENANCE 68

6. SWITCH OFF CCS 2 69

7. ENCLOSURE 70

CCS 2 Safety

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1. Safety

1.1. Danger through maloperation

The CCS 2 was subject of a safety acceptance test. In case of proper use according to the maintenance instructions the integrated electronic and hydraulic safety elements guarantee a safe operation. In case of maloperation, misuse or not regarding the operation limits and safety rules danger appears for: body and life of the user; the system and the machines which are connected to the CCS 2; precision of the measurements of the CCS 2; the environment. Therefore it is necessary, that all persons who handle, maintain etc. the CCS 2 pay absolutely attention to the maintenance instructions!

1.2. Proper use

The CCS 2 is a various mobile measuring system for the initiation and automatic surveillance of hydraulic and lubrication systems. The measuring and data managing functions allow a continuous and discontinuous system surveillance in a high accuracy over a big range of use without additional equipment. The CCS 2 enables the rating of solid particles contamination of mineral oils through the determination of number and size distribution of particles and the analysis of the results according to ISO 4406, NAS 1638 or SAE AS 4059. Operation limits The system is only in the following limits usable for on-line operation at hydraulic and lubrication systems:

Input operating pressure: p = 1,5…420 bar (22… 6090 PSI) (depending on viscosity)

Viscosity range: = 10…400 mm²/s (46…1850 SUS)

Oil temperature range: 0… 80 °C (32…176°F)

Ambient temperature range: 0… 50 °C (32…122°F)

Internal temperature range: 0… 45 °C (32…113°F)

The regular function of the CCS 2 and the warranty of safety assumes the usage of by INTERNORMEN Technology GmbH provided and allowed supplies.

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For the determination of contamination classes with the CCS 2 the oil of the examined system has to be used. Before connecting the CCS 2 to the system make sure, that the discharge oil of the CCS 2 gets caught up in a tank afterwards. No oil may get to the environment or the canalisation! No unauthorized modifications and changes at the CCS 2 are allowed! The conditions for service and maintenance of this maintenance instructions must be strictly followed!

1.3. Sources of danger

An operation of the CCS 2 is only allowed at a shockproof socket. Turn off the CCS 2 (main switch) and pull off the main plug before opening the system.

1.4. Service staff

Only authorized persons are allowed to work with the CCS 2. The operator has to: - hand over the maintenance instruction to the user - make sure that the user reads and understands the instruction

1.5. Safety arrangements on site

The CCS 2 has to sit on a flat solid ground.

1.6. Protection device

Inscriptions at the housing outsides note the possible dangers.

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2. Initiation

2.1. Electrical connection

The CCS 2 works with a voltage from 8 to 15 V DC. External power supply unit You can use this external power supply unit of the accessory with 100 V to 240 V AC, 50/ 60 Hz. It has to be connected to the power supply plug of the CCS 2 (see picture 2.1.-1 on page 9). The power supply unit has its own switch. It is operating when its green control diode shines. Battery operation - The CCS 2 has an integrated rechargeable battery. - It allows without printing about 250 continuous measurements (1 hour

operation). - Printing during battery operation shortens the running time extremly.

Unloading of the rechargeable batteries: Unloading of the rechargeable battery is indicated by the CCS 2 with a

hooter alarm. After the hooter alarm the CCS 2 is to be switched off within 5 min. The operation of the CCS 2 with continuous hooter alarm leads to total battery discharge with rising power consumption which can result in the destruction of the fuse f2 or in the malfunctioning of the control of the CCS 2.

CCS 2 Initiation

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Loading of the rechargeable batteries with the provided battery charger: The battery charger works with 100 ... 240 V AC, 50/ 60 Hz. It has to be plugged into the battery load jack - light up the blue control

diode at the CCS 2.

Loading is indicated at the battery charger by a control diode.

After completion of the loading procedure: Indicate to the control diode of red after green.

The recharge time takes about 6 hours. Car supply With a special cable you can connect a 12 V car plug with the CCS 2.

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Electrical connection values

Voltage: With the external power supply:

12 V DC ( 8...15 V DC) 100…240 V AC 50 / 60 Hz

Fuse protection: f1: 3,15 AT regular use f2: 3,15 AT battery loading

Picture 2.1-1:

Blue control diode

Battery load

fuses

Power supply

(external)

Green control diode

Main switch

Control outlet

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2.2. Connection of the system

The CCS 2 has to sit on a flat solid ground. Any operation in a not steady position is not allowed. The unit may not be exposed to any vibrations. The environmental temperature has to be below 50° C (122°F). 1. Connect the oil discharge hose with the quick acting

closure to the CCS 2 and put its end into an oil tank. The oil tank has to catch up non-stop oil during the

whole operation time, so make sure it is big enough or exchange it punctually!

It is also possible to lead the discharge oil straight back into the tank of the examined system.

The end of the discharge tube has to be let down undisturbed and may in no

case be connected to a pressurized conduit! 2. The high pressure measuring hose with the mini

measuring closure has to be connected to the input of the CCS 2.

3. Connect the high pressure measuring hose with

the measuring connection of the examined system.

4. Connect the external power supply unit of the accessory with the CCS 2 by

plugging it into the power supply jack (see picture 2.1.-1). The power supply unit has its own switch. It is operating when its green control diode shines.

Otherwise the CCS 2 will run with battery! Attention: It has to be assured that the hydraulic connections are totally sealed! Leaking oil has to be absorbed with special material immediately!

CCS 2 Initiation

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CCS 2 Initiation

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2.3. Weight and dimensions

Weight: 10,8 kg Dimensions: see picture 2 (Measurement unit: mm)

Picture 2.3-1

2.4. Transport

The CCS 2 and its accessories are stored in an aluminium suitcase. This case is for the transport of the system to each service place. The case must be kept upright for transport and storage. Make sure that the transport takes place without vibrations.

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3. Maintenance

The CCS 2 has to be connected for the foreseen measuring according to the statements under item 1 and 2. Turn on the CCS 2 by pushing down the main switch. The green control diode has to start glowing now. The processor starts automatically into the English resp. German real version of the measuring and control program. The main menu is on the display.

Note: If the measuring and control program has been ended deliberately

or inadvertent, you can call it from the DOS level. English real version: e12.exe

English demo version: e02.exe German real version: d12.exe

German demo version: d02.exe (Input of new program versions look at chapter 3.7.)

The demo version is operating the same way as the real version. Instead of real measurements the computer simulates the counting and the results. You can use all functions as regular.

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3.1. General information

The oil gets through a mini-measuring connection from the hydraulic system into the CCS 2. A pressure adjustment takes place and then the oil gets into a cylinder. When the cylinder is filled completely, an electronic motor pushes the oil steady-going through a laser sensor, which measures in principle of light blockage impulses according to the size of the particles. The electronic transforms these into number and size. Advantages of this measuring procedure: - the constant measuring volume - the constant flow rate at the sensor - the measuring volume and the flow rate are independent of the condition of

the hydraulic system - the high accuracy of measurements - the good reproducibility Depending on your specifications different measuring programs can be used. There are single, continuous and cyclic measurements. Also off-line measurement are possible in conjunction with the Bottle Sampling (BSS) or Tank Sampling System (TSS). Automatic flushing processes in all programs shall prevent false measurements. Therefore the CCS 2 gets flushed completely with the new oil before the next measurement. Single measurements: - automatic flushing before the first measurement - automatic flushing before following measurements, when more than 10

minutes are gone since the last measurement or when changing the measuring point

Continuous measurements: - automatic flushing when starting the measurement

Cyclic measurement: - automatic flushing before each measurement

Off-line measurement: - individual start of flushing process

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3.2. Control panel and key pad use

Keys for device and menu control: ARROW KEYS for the menu control ESC menu step back ENTER confirm with ENTER F1 F2 Keys for the measuring point control: Numbers Letters F3/ F4/ F5

printer display

function keys

RS 232 interface

DEL

arrow keys ENTER

numbers and letters

space

ESC

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Input of numbers and letters Numbers and letters use the same keys. For numbers you just press the single key. For letters you have to press additionally the function key [ F4 ] (red), [ F5 ] (blue) or [ F6 ] (green), according to the position of the letter resp. its color. Example:

F4 + 2 d DEF

F5 + 2 e DEF

F6 + 2 f DEF

Capital letters The letters are small in regular. To get capital letters you have to press [ F3 ] additionally to the two keys you have to press for the small letter.

2 + F6 + F3 F DEF

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3.3. Main menu

Select the desired function by using the arrow keys [ ]. The chosen function is red highlighted. Confirm your selection with [ ENTER ]. On-line particle counting Use this mode to measure while the system is running. The CCS 2 has to be connected according to the statements under item 1 and 2. Off-line particle counting This mode is to analyse bottle samples or oil straight out of a tank. Therefore you need the Bottle Sampling System (BSS 2) or the Tank Sampling System TSS to feed the CCS 2 with the oil of the sample or tank (for connection see also 3.5.). Regard the maintenance instruction of the BSS 2 or TSS1! Certainly you can use this measuring program also for on-line measurements. File system Here you find the saved results of your measurements. You can select to see the results according to different standards. Data transfer This mode is to transfer saved measuring results from the CCS 2 to an external computer. Data file delete This mode is to delete complete files of saved measuring results in the file system and to set time and date.

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3.3.1. On-line particle counting

Setup-menu

Name measure point After entering the setup-menu this function will automatically be chosen. It is red highlighted. Enter the name of your measure point by using the key pad (see key pad use on chapter 3.2.). For erasing a typing error press [ DEL ]. The characters are limited to the number of 20. Use for the same measure point always the same name. Otherwise you won’t be able to compare the results afterwards in the file system. Each result gets automatically a new index in the file system and also date and time of the measurement are saved. If you do not enter any name, the measuring point will be named “noname”.

When you are done use the arrow keys [ ] to choose measure type or report format, the selected option will be red highlighted. Measure type

By using the arrow keys [ ] you can select either single, continuous or cyclic measurement. The selected measure type will be white highlighted.

Go on to report format with the arrow keys [ ]. Report format The measurement can be done either according to ISO 4406, NAS 1638 or to

SAE AS 4059. Select your report format with the arrow keys [ ]. When all functions are adjusted, press [ ENTER ] the get to the next level.

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3.3.1.1. Mode: on-line single/ ISO 4406 : 99

Press [ ENTER ] to start the system. After a couple of flushing circuits the measurement will start. It takes 3 runs. The final result is the average of the three measurements.

Press [ F2 ] to print the result, [ F1 ] to save it. If you want to do another single measurement press [ ENTER ]. To leave this mode press [ ESC ].

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3.3.1.2. Mode: on-line single/ NAS 1638



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3.3.1.3. Mode: on-line single/ SAE AS 4059 : 01



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3.3.1.4. Mode: on-line continuous/ ISO 4406 : 99

Press [ ENTER ] to start the system. After a couple of flushing circuits the continuous measurement will start. The system will show on the display the trend of the results. While measuring you can’t print. The last 100 results of the actual measuring process automatically get saved in the file system. The old results from the last measuring process get deleted when a new continuous measurement starts.

To stop the continuous measurement press [ ESC ]. Now you can print the last result with [ F2 ]. Press [ F1 ] to continue the same measurement process, press [ ENTER ] to start a new continuous measurement or press [ ESC ] to leave this mode. Memory is deleted!

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3.3.1.5. Mode: on-line continuous/ NAS 1638



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3.3.1.6. Mode: on-line continuous/ SAE AS 4059 : 01



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3.3.1.7. Setup-menu: on-line cyclic/ ISO 4406 : 99

Here you can determine the parameters of the cyclic measurement.

With the arrow keys [ ] you can choose the position to change. The possible values are predetermined. You change the value of the red

highlighted position by using the arrow keys [ ]. Cycle period The time between one measurement and the next one can be selected between 0,5 hours to 24 hours in half hour steps. Cycle number The total number of measurements can be chosen two-step-wise from 2 to 100. Automatic storage Optionally every cyclic measurement can be saved automatically by setting the automatic storage to “on”. Automatic print out If you wish a print out of every single result of the cyclic measurement activate the automatic print out. Limits You can supervise the exceeding of certain contamination classes. Set the limit

of a contamination class by using the arrow keys [ ]. Each exceeded limit is signalled with a red field on the display in a notice in between the measurements. A falling below and/or an adherence to the limit value is on the display shown green. And black it indicates that the counter channel was not programmed. Each contamination class limit has its own contact maker and contact breaker on the jack below the main switch ( see enclosure). When exceeding one of the limits, its signal changes. When you have set all parameters press [ ENTER ]. To cancel your settings press [ ESC ].

CCS 2 Maintenance

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3.3.1.7.1. Mode: on-line cyclic/ ISO 4406 : 99

To start the cyclic measurement press [ ENTER ]. Cycle operation: The system flushes and then measures three times. The final result of each cycle is the average of these three. Between two cycles a notice shows the actual time, the time of the next run, the number of done cycles and whether the limits got exceeded. When all cyclic measurements are done, there is a headline on the notice that says “measurement finished”.

To leave this mode press [ ESC ].

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3.3.1.8. Setup-menu: on-line cyclic/ NAS 1638


With the arrow keys [ ] you can choose which position to change. The possible values are predetermined. You change the value of the red highlighted

position by using the arrow keys [ ]. Cycle period The time between one measurement and the next one can be selected between 0,5 hours to 24 hours in half hour steps. Cycle number The total number of measurements can be chosen two-step-wise from 2 to 100. Automatic storage Optionally every cyclic measurement can be saved automatically by setting the automatic storage to on. Automatic print out If you wish a print out of every single result of the cyclic measurement activate the automatic print out. Limits You can supervise the exceeding of certain contamination classes. Set the limit

for a contamination class by using the arrow keys [ ]. Each exceeded limit is signalled with a red field on the display in a notice in between the measurements. A falling below and/or an adherence to the limit value is green shown the display. And black it indicates that the counter channel was not programmed. Each contamination class limit has its own contact maker and contact breaker on the jack below the main switch - wearing off at the steering wheel socket (see enclosure). When you have set all parameters press [ ENTER ]. To cancel your settings press [ ESC ].

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3.3.1.8.1. Mode: on-line cyclic/ NAS 1638

To start the cyclic measurement press [ ENTER ]. Cycle operation: The system flushes and then measures three times. The final result of each cycle is the average of these three. Between two cycles a notice shows the actual time, the time of the next run, the number of done cycles and whether the limits got exceeded. When all cyclic measurement are done, there is a headline that says “measurement finished”.


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3.3.1.9. Setup-menu: on-line cyclic/ SAE AS 4059 : 01


With the arrow keys [ ] you can choose which position to change. The possible values are predetermined. You change the value of the red highlighted

position by using the arrow keys [ ]. Cycle period The time between one measurement and the next one can be selected between 0,5 hours to 24 hours in half hour steps. Cycle number The total number of measurements can be chosen two-step-wise from 2 to 100. Automatic storage Optionally every cyclic measurement can be saved automatically by setting the automatic storage to on. Automatic print out If you wish a print out of every single result of the cyclic measurement activate the automatic print out. Limits You can supervise the exceeding of certain contamination classes. Set the limit

for a contamination class by using the arrow keys [ ]. Each exceeded limit is signalled with a red field on the display in a notice in between the measurements. A falling below and/or an adherence to the limit value is green shown the display. And black it indicates that the counter channel was not programmed. Each contamination class limit has its own contact maker and contact breaker on the jack below the main switch - wearing off at the steering wheel socket (see enclosure). When you have set all parameters press [ ENTER ]. To cancel your settings press [ ESC ].

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3.3.1.9.1. Mode: on-line cyclic/ SAE AS 4059 : 01

To start the cyclic measurement press [ ENTER ]. Cycle operation: The system flushes and then measures three times. The final result of each cycle is the average of these three. Between two cycles a notice shows the actual time, the time of the next run, the number of done cycles and whether the limits got exceeded. When all cyclic measurement are done, there is a headline that says “measurement finished”.


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3.3.2. Off-line particle counting

Bottle Sampling: 6 channel particle counting

Press [ 1 ] to enter your sample name or the dilution factor. Press [ 2 ] to start the flushing. Press [ 3 ] to start the counting. Name/ dilution

If you do not enter any name, the sample will be named “noname”. Use [ DEL ] to empty the field and enter the name of your sample with the key pad (see key pad use chapter 3.2.). The characters are limited to the number of 15.

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Use for the measurements of one sample always the same name. Otherwise you won’t be able to compare the results afterwards in the file system. Each result gets automatically a new index in the file system and also date and time of the measurement are saved. The dilution factor is automatically put on one. You can change the factor

stepwise with the arrow keys [ ]. To confirm your input press [ ENTER ]. To delete your input press [ ESC ]. Start flushing

The system starts to flush with [2]. On the display you can see the number of flushing cycles. To stop the flushing press [ 5 ].

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Start counting The system makes one measurement.

After the measurement you can save the result [ F1 ] or print it [ F2 ]. If you want to select this measurement to average it with some of your next results, press [ 4 ]. The presentation mode says current average and the number of averaged results. After each measurement that you want to be involved in that average press [ 4 ] again. You will see the current average result of all involved measurements immediately on the display. You can save the current average result [ F1 ] or print it [ F2 ]. The saved average results are in the file system marked with an “M” and an index that shows the number of involved measurements.

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3.3.3. File system

Here you can find your saved results.

Choose with the arrow keys [ ] the measuring mode of which you want to see the saved data. The selected mode is red highlighted. Confirm your choice with [ ENTER ].

3.3.3.1. Mode: on-line single measurement

Use the arrow keys [ ] to select a measurement. Press [ ENTER ] to get to the results. Press [ F1 ] to delete this measurement.

3.3.3.1.1. Report format

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You can choose to see the results according SAE AS 4059 : 01, NAS 1638, the ISO 4406:87 or the up-to-date version of ISO 4406:99.

Select your format with the arrow keys [ ] and confirm with [ ENTER ].

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3.3.3.1.1.1. Mode: single/ ISO 4406 : 99

Press [ F2 ] to print the result. Press [ F1 ] to get a graphic of all single measurements of this measuring run (only possible if there is more than one measurement).

3.3.3.1.1.1.1. Contamination classes trend

Here you get a graphic that shows the trend of all same named single measurements.

Press [ F2 ] to print the graphic. The print out takes a while and has a little break in between for transmitting the graphic data. Press [ ESC ] to leave this mode.

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3.3.3.1.1.2. Mode: single/ NAS 1638





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3.3.3.1.1.3. Mode: single/ ISO 4406 : 87





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3.3.3.1.1.4. Mode: single/ SAE AS 4059 : 01





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3.3.3.2. Mode: on-line continuous measurement


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Select your format with the arrow keys [ ] and confirm with [ ENTER ].

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3.3.3.2.1.1. Mode: continuous/ ISO 4406 : 99

Press [ F2 ] to print the result. Press [ F1 ] to get a graphic of all continuous measurements of this measuring run (only possible if there is more than one measurement).


Here you get a graphic that shows the trend of all same named continuous measurements.


3.3.3.2.1.2. Mode: continuous/ NAS 1638

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3.3.3.2.1.3. Mode: continuous/ ISO 4406 : 87





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3.3.3.2.1.4. Mode: continuous/ SAE AS 4059 : 01





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3.3.3.3. Mode: on-line cyclic measurement


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Select your format with the arrow keys [ ] and confirm with [ENTER ].

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3.3.3.3.1.1. Mode: cyclic/ ISO 4406 : 99

Press [ F1 ] to get a graphic of all cyclic measurements of this measuring run (only possible if there is more than one measurement).


Here you get a graphic that shows the trend of all same named cyclic measurements.


3.3.3.3.1.2. Mode: cyclic/ NAS 1638

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Press [ F2 ] to print the result. Press [ F1 ] to get a graphic of all cyclic measurements of this measuring run (only possible if there is more than one measurement).




3.3.3.3.1.3. Mode: cyclic/ ISO 4406 : 87

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3.3.3.3.1.4. Mode: cyclic/ SAE AS 4059 : 01





3.3.3.4. Mode: off-line bottle sampling

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Select your format with the arrow keys [ ] and confirm with [ENTER ].

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3.3.3.4.1.1. Mode: bottle sampling/ ISO 4406 : 99

Press [ F2 ] to print the result. Press [ F1 ] to get a graphic of all bottle sampling measurements of this measuring run (only possible if there is more than one measurement).


Here you get a graphic that shows the trend of all same named bottle sampling measurements.


3.3.3.4.1.2. Mode: bottle sampling/ NAS 1638

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3.3.3.4.1.3. Mode: bottle sampling/ ISO 4406 : 87





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3.3.3.4.1.4. Mode: bottle sampling/ SAE AS 4059 : 01





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3.3.4. Data transfer

This mode is to transfer saved measuring results from the CCS 2 to an external computer using the data manager. Therefore the CCS 2 has to be connected to the external computer (RS 232 on the CCS 2).

Confirm with [ ENTER ] to get the CCS 2 ready for transferring the data. The data manager has to be installed on the external computer according to the instructions in chapter 3.8.

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3.3.5. Data file delete

This mode is to delete complete files of saved measuring results in the file system and to set time and date.

Press [ 1 ] to delete the complete single measurement file. Press [ 2 ] to delete the complete continuous measurement file. Press [ 3 ] to delete the complete cyclic measurement file. Press [ 4 ] to delete the complete bottle sampling file. Press [ F1 ] to set date and time. After deleting a file system you get a short note about the successful deletion on the display. To leave this mode press [ ESC ].

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3.3.5.5. Setup - menu: date/ time

Use the arrow keys [ ] to select the option you want to set. The values of each option are predetermined.

To change the value use the arrow keys [ ]. To adopt your settings confirm with [ ENTER ]. To get back to the main menu press [ ESC ].

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These instructions in brief are only for authorized persons, who have read the instructions manual before ! (see also item 1.1 and 1.4 of these instructions)

3.4. Instructions in brief for the on-line determination of the contamination classes

1. Connect the oil discharge hose with the quick acting closure to the CCS 2

and put the other end into an oil tank.

2. One side of the high pressure measuring hose (mini measuring M 16x2) has to be connected to the input of the CCS 2.

3. The second side of the high pressure measuring hose has to be connected

with the measuring connection of the examined system.

4. Build up the electric mains connection (8 to 15 V DC; 90 to 250 V AC, 50/ 60 Hz).

5. Switch on the CCS 2 (green control diode gives light).

6. Confirm with [ ENTER ] to get to the online measuring setup-menu:

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7. Name measure point Enter the name of your measurement by using the key pad.

Go on with the arrow keys [ ]. 8. Single, continuous or cyclic measurement

Select your measure type with the arrow keys [ ].

Go on with the arrow keys [ ]. 9. ISO 4406, NAS 1638 or SAE AS 4059

Select with the arrow keys [ ] the report format that you want to use for analysing the results.

10. Press [ ENTER ] to get to the next level.

11.1 Single measurement Press [ ENTER ] to start the measurement. Afterwards you can save and print the result.

11.2 Continuous measurement

Press [ ENTER ] to start the continuous measurement. To stop it press [ ESC ]. Now you can print the last result.

11.3 Cyclic measurement

- Use the arrow keys [ ] to select an option of the set up menu and

change it with [ ]. - Press [ ENTER ] to get to the cyclic measurement mode. - Start the cyclic measurement with [ ENTER ]. - Press [ ESC ] to leave this mode.

CCS 2 Maintenance

63

These instructions in brief are only for authorized persons, who have read the instructions manual before ! (see also item 1.1 and 1.4 of these instructions)

3.5. Instructions in brief for the off-line determination of the contamination classes

1. Connect the oil discharge hose with the quick acting closure to the CCS 2

and put the other end into an oil tank. 2. Build up the Bottle Sampling System respectively the Tank Sampling

System according to its manual. 3. One side of the high pressure measuring hose (mini measuring M 16x2)

has to be connected to the input of the CCS 2. 4. The second side of the high pressure measuring hose has to be connected

with the measuring connection of the Bottle Sampling System respectively the Tank Sampling System.

5. Build up the electric mains connection of the CCS 2 (8 to 15 V DC; 90 to

250 V AC, 50/ 60 Hz). 6. Switch on the CCS 2 (green control diode gives light). 7. Select “Offline particle counting” on the main menu. Confirm with [ ENTER ]. 8. Enter the sample name and the dilution factor. 9. Get the BSS resp. the TSS ready for measuring (according to its manual). 10. Press [ 2 ] to flush the system before measuring. To stop the flushing press [ 5 ] again. 11. Press [ 3 ] to start the measurement. After the measurement you can save and print the result.

CCS 2 Maintenance

64

3.6. Printer

3.6.1. Change of the printer ribbon

1. Open the front cover of the printer. 2. Push in the cartridge on the labelled spot so that the opposite side of the

printer ribbon loosens from the motor shaft. 3. Take the cartridge out. 4. Tighten the printer ribbon of the new cartridge by turning the rotary knob like

the arrow shows. 5. Put the cartridge back in the mounting and bring the visible part of the printer

ribbon in the slit where the paper is. The visible part of the printer ribbon has to be above the paper.

6. If necessary, tighten the printer ribbon again.

CCS 2 Maintenance

65

3.6.2. Input of paper

1. Open the front cover of the printer and take out the empty roll within the axis. 2. Put the new paper roll on the axis. Push the axis in its receiver till you hear it

snapping in.

Important regard the label on the back board, that shows which way the axis has to be placed the paper has to roll off in the back, running upwards

3. Cut the front of the paper even and bring the paper into the introduction slit,

as seen in the picture beside. 4. Push the green paper transport button until the paper is all through the

printer drive. Do not pull manually. The visible part of the printer ribbon has to be above the paper.

5. Bring paper through the slit off the front cover and close it.

CCS 2 Maintenance

66

3.7. Implementing a new program version from a Laptop or PC

For implementing a new program to the CCS 2 the DOS program filelink is required. You find it on the data manager diskette. Please install the program on the laptop or computer that you want to use for the transfer. 1. Switch on the CCS 2. 2. Leave the main menu with [ ESC ]. 3. Press [ F1 ] to start the filelink program. 4. Confirm the first page with [ ENTER ]. 5. Select the slave mode and confirm. 6. Allow the program to overwrite files. 7. Connect the CCS 2 and your computer or laptop with an interface cable

(RS 232 interface on the CCS 2). 8. Start your computer or laptop. 9. Copy the new CCS 2 program into the same path as the filelink.exe. 10. Start the filelink.exe on your computer or laptop. 11. Confirm the first page with [ ENTER ]. 12. Select the setup menu and confirm. 13. Check the current setup options. You need the serial port, the baud rate

has to be on 115200. Correct the options if necessary. Go back to the last screen.

14. Enter the master mode. 15. Select the new program for the CCS 2 on the left side and mark it with

[ SPACE ]. 16. Copy the files to the CCS 2 with [ ALT ] + [ c ]. 17. Wait while transferring the program. 18. When the transfer is finished exit the filelink program on your computer or

laptop. Switch off the CCS 2. Now you can start the CCS 2 as regular.

CCS 2 Maintenance

67

3.8. The data manager

The data manager enables the external administration of data from the CCS 2. To be able to use this program at least Office ’97 resp. Excel ’97 is required. Install these files: 1. CCS2_DATMA01_D.XLS 2. CCS2_DATMA01_E.XLS 3. WINCOMM.EXE 4. README During English land attitude in the Windows you install: 5. CCS2_DATMA02_E.XLS 6. WINCOMM.EXE For the evaluation after SAE AS 4059 you need the following files from the sub file folder "SAE_Manager": 7. CCS2_Datsae01_d.XLS 9. CCS2_Datsae01_e.XLS 10. CCS2_Datsae02_e.XLS of the CD-ROM into a new folder in your PC. You have to write the path of that folder in the menu of Excel at Accessory/ Options/ General as path of the standard folder. This adjustment just has to be done once. - Connect the external computer with the CCS 2 (RS 232 interface at CCS 2). - Start the main menu of the CCS 2. - Choose the data transfer option and confirm with [ ENTER ]. The CCS 2 is

now ready for data transfer. - Start on your computer the file version you needed. (see above) - Excel starts automatically. - Activate the macros, so that the data manager gets opened. - Press the button of the file of which you want to transfer the data. - The data get loaded into the “Data import” table. - Now you can copy the data into a self-made Excel or Word document or you

can use the prepared graphic functions of the data manager to demonstrate the counting results and contamination classes.

CCS 2 Malfunctions/ troubleshooting

68

4. Malfunctions / troubleshooting

Malfunctions Reason Help

System switched on, no function, control lamp out

network connection disturbed; external power supply unit switched off; battery empty

Check the power supply; when battery is empty use power supply unit; load battery

network supply faulty

check the main fuse

fuse of system defect

change the defect fuse

control lamp on, display does not work

display defect call INTERNORMEN

5. Service / maintenance

To guarantee the accuracy of the measuring results of the CCS 2 the integrated laser sensor has to be calibrated yearly through INTERNORMEN Technology

GmbH. With the calibration all necessary maintenance and service workings, that exceed the outside cleaning, will be done. Only competent staff of INTERNORMEN Technology GmbH is allowed to open the CCS 2! Outside cleaning The outside cleaning of the CCS 2 takes place through the user when there is a certain contamination. Attention: Do not use any aggressive media!!! For the housing you can use a rag with wash benzine. Make sure that no benzine gets on the control panel! The keypad and the printer housing should be cleaned with a rag that is lightly soaked with water. Switch off the CCS 2 before cleaning! The display cover is made out of plexiglass and is antireflective. Do use no chemicals except for water or glass cleaner! Switch off the CCS 2 before cleaning!

CCS 2 Switch off CCS 2

69

6. Switch off CCS 2

Switch off the CCS 2 according to the following steps: 1. End the program with [ ESC ] (until the display shows c:\ in the top left). 2. Turn off the CCS 2 by pushing up the main switch. 3. Switch off the external power supply. 4. Pull off the main plug. 5. Release the high pressure measuring hose of the examined system. Put

protection caps on both connection. 6. Release the high pressure measuring hose of the CCS 2 and put protection

caps on both connections. 7. Release the oil discharge hose and put a protection cap on the quick acting

closure. 8. Drain off the oil of the discharge hose into the tank. Seal both ends

afterwards. 9. Dispose the oil of the tank or put it back into the tank of the examined

system.

Attention: Leaking oil must be cleaned up immediately with a rag!

Transport the CCS 2 and the accessory in the suitcase. Just for short distances it is acceptable not to use it.

CCS 2 Enclosure

70

7. Enclosure

7.0 Enclosure

7.0 Enclosure

CCS 2 Enclosure A – Technical Data

71

Technical Data

General technical Data: Power supply: 12 V DC, 35 VA External power supply unit: 100 ... 240 V AC/ + 12 V DC/ 5 A, 50/ 60 Hz Battery charger: 100 ... 240 V, 50/ 60 Hz Internal battery: 12 V Protection: f1: 3,15 AT regular use f2: 3,15 AT battery loading Protection class IP 40 Dimensions (mm): l x w x h 450 x 180 x 255 (inch): 17,7 x 7 x 10 Weight: 10,8 kg Principle of measurement: particle counting according to the light blockade

principle Proceeding of measurement: automatic particle counting Particle sizes: > 4 µm(c), > 4,6 µm(c), > 6 µm(c), > 6,4 µm(c),

> 10 µm(c), >14 µm(c), > 21 µm(c), > 38 µm(c). Representation of the CC: ISO 4 – 24, NAS 00 – 12, SAE 000 - 12 Proceeding of calibration: ISO MTD in oil (ISO 11171:2000) Max. particle concentration: 24000 particle / ml (Sensor) Sensor flowrate: 50 ml / min Kind of measuring: On-line, Off-line options: bottle-, tank sampling Value of measurement: mean value of 3 measurements Measurement methods: single, continuous, cyclic measurement

(automatically) bottle sampling with BSS 2, tank sampling with TSS 1.


72

Test time in seconds: 240 seconds (flushing, 3 measurements and average)

20 seconds for 1 test result (continuous measurement)

Pressure range: 1,5 - 420 bar, 22 - 6090 PSI (depending on

viscosity) Viscosity range: 10 - 400 mm²/s (46… 1850 SUS) Oil temperature range: 0.-.80°C (176°F) Ambient temperature range: 0 - 50°C (122°F) Internal temperature range: 0 - 45°C (113°F) Fluid compatibility: hydraulic and lubricating fluids based on

mineral oil (also see on separate list of sociability)

Display - output: cleanliness classes, number of particles, beam

diagram, graphics Printer - output: cleanliness classes, number of particles,

graphics Alarm - functions: limit value of the contamination classes Store capacity: 4x100 measurements (100 per kind of

measurement)

Leakage per measuring: 150 ml to p = 420 bar Connection: 1 x mini-measuring connection with screw

coupling M 16x2, 1 x connector coupling for hose DN 6

Further serial equipment: external power supply unit, battery charger,

high pressure hose, discharge hose, Datamanger (software disc)

Display: active LCD - colour display Computer interface: RS 232 connection (for external computer

coupling)


73

connection: control outlet

panel jack

(external view)

(contact maker) Relay - contact designation: (contact breaker) Relay contact performance: maximal Switching current: 2 A maximal Switching voltage: 60 V DC/AC maximal Switching performance: 60 VA Limiting value: > 4 µm / limiting value 5 ... 15 µm: K1 : 2 K2 : 3 K3 : 1 Limiting value: > 6 µm / limiting value 15 ... 25 µm: K1 : 5 K2 : 6 K3 : 4 Limiting value: > 14 µm / limiting value 25 … 50 µm: K1 : 8 K2 : 9 K3 : 7 Connector plug: type Lemosa FFA 310.CLAD 927

K2

K3

K1


74

Area of use - digestibility CCS 2

Explanations

A: usable B: reduced usable C: not usable

1. hydraulic oils H, HL,

HLP, HLPD and HV 1. organic ester (HFD-U) 1. gear oil with MoS2-additive

2. gear oils C, CL, CLP 2. phosphate ester (HFD-R) 2. oil in water emulsion (HFA)

3. spindle oils, white oil 3. polyglycole (PEG) (HPG) 3. coulant, aqueous

4. engine oils, gas oils 4. fresh water, process

water, etc. 4. surface water

5. MIL-H-5606 E

5. other hydraulic fluids

based on MIL-

specifications

5. corrosion protecting oils with

wax and paraffin contents

6. oils on vegetable basis

(HTG, Triglyzeride) 6. heavy oils ISO-VG-320

7. synthetic ester (HEES) 7. general oils with H2O-

contents 500 ppm

8. ATF-fluids 8. water - glycol (HFC)

ad 1. hydraulic oils HLPD are used to disperse water contents („D“-additive). At determined water dispersions these oils are no more measurable.

ad 4. engine oils with solid

wear additives (MoS2 etc.) are not measurable.

ad 6. with increasing

hydrolysis HTG´s (vegetable oils) are no more measurable, as they then get a 2-phase-fluid (fatty acid + glycerine). Danger of clogging!

ad 1. no problems with HFD-U-fluids in pure state. With water contents or residual oil contamination measurings are impossible. Special calibration necessary.

ad 2. generally HFD-R-fluid

cannot be measured because of insufficient compatibility of all components.

ad 3. polyglycole (PEG,

HPG) is measurable, however, when changing the type of oil a thorough flushing has to be come. Special calibration necessary!

ad 4. water. Normal spring

water can have different compositions. The partly rather high calcic contents leads to a quick failure of the system.

ad 1. typical fluid charged with fine dispersed solid particles which are counted and registered as particles.

ad 2. typical 2-phase-fluid in

which the oil driplets are registered as particles.

ad 3. like no. 2 (above) ad 4. surface water is

contaminated with different parts. Danger of corrosion and clogging.

ad 5. waxes and paraffin’s are

separated and lead to clogging. In addition the wax-particles are counted as particles.

ad 6. because of too high

viscosity’s heavy oils ISO-VG-320 cannot get measured.

ad 7. water contamination will be

registered and counted as particle. In addition: danger of corrosion

ad 8. HFC-fluid is a typical 2-

phase-fluid with partly extreme creation of cloudly stains

CCS 2 Enclosure B – Contamination classes according to ISO 4406

75

Contamination classes according to ISO 4406 : 99

For the determination of the ISO - codes (contamination classes) the quantity of the particles in the sizes > 4 µm, > 6 µm and > 14 µm according to ISO 4406 are used. The code is independent of the particle size. Example for presentation: 20 / 16 / 12 Analysis volume: 1 ml

code - number Quantity particle of .......... up to inclusive

26 320000 640000

25 160000 320000

24 80000 160000

23 40000 80000

22 20000 40000

21 10000 20000

20 5000 10000

19 2500 5000

18 1300 2500

17 640 1300

16 320 640

15 160 320

14 80 160

13 40 80

12 20 40

11 10 20

10 5 10

9 2,5 5

8 1,3 2,5

7 0,6 1,3

6 0,3 0,6

Particles > 14 µm Particles > 6 µm Particles > 4 µm

CCS 2 Enclosure C – Cleanliness classes according to NAS 1638

76

Cleanliness classes according to NAS 1638

Analysis volume: 100 ml Particle quantity x 10³

class 5 - 15 µm 15 - 25 µm 25 - 50 µm 50 - 100 µm > 100 µm

00 0,125 0,022 0,004 0,001 0

0 0,250 0,044 0,008 0,002 0

1 0,5 0,089 0,016 0,003 0,001

2 1 0,178 0,032 0,006 0,001

3 2 0,356 0,063 0,011 0,002

4 4 0,712 0,126 0,022 0,004

5 8 1,425 0,253 0,045 0,008

6 16 2,85 0,506 0,090 0,016

7 32 5,7 1,012 0,18 0,032

8 64 11,40 2,025 0,36 0,064

9 128 22,8 4,05 0,72 0,128

10 256 45,6 8,1 1,44 0,256

11 512 91,2 16,2 2,88 0,512

12 1024 182,4 32,4 5,76 1,024

CCS 2 Enclosure D – Cleanliness classes according to SAE AS 4059

77

Cleanliness classes according to SAE AS 4059 Analysis volume: 100 ml

Particle per 100 ml

Size, ISO 11171

Calibration or Electron

Microscope

> 4 µm ( c ) > 6 µm ( c ) > 14 µm ( c ) > 21 µm ( c ) > 38 µm ( c ) > 70 µm ( c )

Size Code A B C D E F

000 195 76 14 3 1 0

00 390 152 27 5 1 0

0 780 304 54 10 2 0

1 1560 609 109 20 4 1

2 3120 1220 217 39 7 1

3 6250 2430 432 76 13 2

4 12500 4860 864 152 26 4

5 25000 9730 1730 306 53 8

6 50000 19500 3460 612 106 16

7 100000 38900 6920 1220 212 32

8 200000 77900 13900 2450 424 64

9 400000 156000 27700 4900 848 128

10 800000 311000 55400 9800 1700 256

11 1600000 623000 111000 19600 3390 512

12 3200000 1250000 222000 39200 6780 1020

CCS 2 Enclosure E

78

System type / Range of application

needed contamination classes filter fineness

according to standards

ISO 4406:99 NAS 1638 SAE AS 4059 x (c) 200

against fine soiling and mudding-up of sensitive systems

lab, aviation and aerospatial

16/ 12/ 8 2 - 3 3/ 0/ 00/... 4

against fine soiling and mudding-up of sensitive systems

lab, aviation and aerospatial

17/ 13/ 9 3 – 4 4/ 1/ 0/... 5

heavy-duty servo systems, high pressure systems with long service life

aviation, machine tool, controlling

19/ 15/ 11 4 – 6 6/ 3/ 2/... 7

proportional valves - industrial hydraulic with high operating safety

higher mobile hydraulic

20/ 16/ 13 7 - 8 7/ 4/ 4/... 10

mobile hydraulic, common mechanical engineering, medium pressure system

mobile hydraulic

22/ 18/ 15 7 - 9 9/ 6/ 6/... 15

heavy industry, low pressure system

mobile hydraulic, water hydraulic

23/ 19/ 15 9 - 11 10/ 7/ 6/... 20

CCS 2 Enclosure F

79

Accessories/ spare parts:

Article no.: 1. Suitcase complete 322647 2. CCS 2 320595 3. Power supply unit 100...240 V AC / +12V DC/ 5 A 320444 4. Line cord 323884 5. Battery charger (Fa. Mascot) 324751 6. RS 232 – interface cable 314462 7. Controlling output plug 320600 8. High pressure hose 313742 9. Oil discharge hose (set with pos. 8) 324060 10. Data manager CD-ROM 327284 11. Instruction manual 320598 12. Two paper rolls 322489 13. Printer ribbon 316379 14. Calibration certificate after annual maintenance/ calibration at INTERNORMEN Technology GmbH

North America — HQ 70 Wood Ave., South, 2nd Floor Iselin, NJ 08830 Toll Free: (800) 656-3344 (North America Only) Voice: (732) 767-4200 China No. 3, Lane 280, Linhong Road Changning District, 200335 Shanghai, P.R. China Voice: +86-21-5200-0099 Singapore 4 Loyang Lane #04-01/02 Singapore 508914 Voice: +65-6825-1668

Europe/Africa/Middle East Friedensstraße 41 D-68804 Altlussheim, Germany Voice: +49-6205-2094-0 Auf der Heide 2 53947 Nettersheim, Germany Voice: +49-2486-809-0 An den Nahewiesen 24 55450 Langenlonsheim, Germany Voice: +49 6704 204-0 Brazil Av. Julia Gaioli, 474 – Bonsucesso 07251-500 – Guarulhos, Brazil Voice: +55 (11) 2465-8822

For more information, please e-mail us at [email protected] Visit us online eaton.com/filtration for a complete list of Eaton´s filtration products. ©2012 Eaton Corporation. All Rights Reserved. All trademarks and registered trademarks are the property of their respective owners. Litho USA.

All information and recommendations appearing in this brochure concerning the use of products described herein are based on tests believed to be reliable. However, it is the user’s responsibility to determine the suitability for his own use of such products. Since the actual use by others is beyond our control, no guarantee, expressed or implied, is made by Eaton as to the effects of such use or the results to be obtained. Eaton assumes no liability arising out of the use by others of such products. Nor is the information herein to be construed as absolutely complete, since additional information may be necessary or desirable when particular or exceptional conditions or circumstances exist or because of applicable laws or government regulations.

Internormen-Eaton - CCS 2 Contamination Control System - Manual v2.3.pdf

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