contamination control system

8/3/2019 Contamination Control System

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CCS 2

CONTAMINATION CONTROL SYSTEM

CE 2001

Instruction manualVersion 1.4

Serial-No.: ..................Version-/Rev.-Date: 12.05.2004

INTERNORMENTechnologyGmbHFriedensstr. 41Germany 68804 Altluheim E-Mail: [email protected]. +49 (0) 6205/2094-0 http://www.internormen.com

To order this part, call Lifco Hydraulics USA Toll Free at 1-800-952-7849
http://www.lifcohydraulics-usa.com/http://www.lifcohydraulics-usa.com/


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List of contentpage

1. Safety 41.1. danger through maloperation 4

1.2. proper use 41.3. sources of danger 51.4. service staff 51.5. safety arrangements on site 51.6. protection device 5

2. Initiation 61.7. electrical connection 61.8. connection of system 81.9. weight and dimensions 91.10. transport 9

3. Maintenance 103.0.1. General information 113.0.2. Control panel and key pad use 12

3.1. Main menu 133.1.1. on-line particle counting 143.1.1.1. mode: on-line single/ ISO 4406 153.1.1.2. mode: on-line single/ NAS 1638 16

3.1.1.3. mode: on-line continuous/ ISO 4406 173.1.1.4. mode: on-line continuous/ NAS 1638 183.1.1.5. setup-menu: on-line cyclic/ ISO 4406 193.1.1.5.1. mode: on-line cyclic/ ISO 4406 203.1.1.6. setup-menu: on-line cyclic/ NAS 1638 213.1.1.6.1. mode: on-line cyclic/ NAS 1638 22

3.1.2. off-line particle counting 23

3.1.3. file system 253.1.3.1. mode: on-line single measurement 25

3.1.3.1.1. report format 263.1.3.1.1.1. mode: single/ ISO 4406 : 99 273.1.3.1.1.1.1. contamination classes trend 273.1.3.1.1.2. mode: single/ NAS 1638 283.1.3.1.1.2.1. contamination classes trend 283.1.3.1.1.3. mode: single/ ISO 4406 : 87 293.1.3.1.1.3.1. contamination classes trend 29

3.1.3.2. mode: on-line continuous measurement 30

3.1.3.2.1. report format 313.1.3.2.1.1. mode: continuous/ ISO 4406 : 99 323.1.3.2.1.1.1. contamination classes trend 323.1.3.2.1.2. mode: continuous/ NAS 1638 333.1.3.2.1.2.1. contamination classes trend 33



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3.1.3.2.1.3. mode: continuous/ ISO 4406 : 87 343.1.3.2.1.3.1. contamination classes trend 343.1.3.3. mode: on-line cyclic measurement 353.1.3.3.1. report format 363.1.3.3.1.1. mode: cyclic/ ISO 4406 : 99 37

3.1.3.3.1.1.1. contamination classes trend 373.1.3.3.1.2. mode: cyclic/ NAS 1638 383.1.3.3.1.2.1. contamination classes trend 383.1.3.3.1.3. mode: cyclic/ ISO 4406 : 87 393.1.3.3.1.3.1. contamination classes trend 39

3.1.3.4. mode: off-line bottle sampling 40

3.1.3.4.1. report format 413.1.3.4.1.1. mode: bottle sampling/ ISO 4406 : 99 423.1.3.4.1.1.1. contamination classes trend 423.1.3.4.1.2. mode: bottle sampling/ NAS 1638 43

3.1.3.4.1.2.1. contamination classes trend 433.1.3.4.1.3. mode: bottle sampling/ ISO 4406 : 87 443.1.3.4.1.3.1. contamination classes trend 44

3.1.4. data transfer 45

3.1.5. data file delete 463.1.5.1. setup menu: date/ time 47

3.2. Instructions in brief for the on-line 48

determination of the contamination classes

3.3. Instructions in brief for the off-line 50determination of the contamination classes

3.4. Printer 513.4.1. Change of printer ribbon 513.4.2. Input of paper 51

3.5. Implementing a new program version from 52

a Laptop or PC3.6. The data manager 533.7. Setting date and time 54

4. Malfunctions/ troubleshooting 555. Service/ maintenance 556. Switch off CCS 2 567. Enclosure 57



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1.0 Safety

1.1. Danger through maloperation

The CCS 2 was subject of a safety acceptance test. In case of proper useaccording to the maintenance instructions the integrated electronic andhydraulic safety elements guarantee a safe operation.

In case of maloperation, misuse or not regarding the operation limits and safetyrules 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 2pay absolutely attention to the maintenance instructions!

1.2. Proper use

The CCS 2 is a various mobile measuring system for the initiation and automaticsurveillance of hydraulic and lubrication systems. The measuring and datamanaging functions allow a continuous and discontinuous system surveillancein a high accuracy over a big range of use without additional equipment.

The CCS 2 enables the rating of solid particles contamination of mineral oilsthrough the determination of number and size distribution of particles and theanalysis of the results according to ISO 4406 or NAS 1638.

Operation limits

The system is only in the following limits usable for on-line operation at hydraulicand lubrication systems:

Input operating pressure: p = 1,5420 bar (22 6090 PSI)(depending on viscosity)

Viscosity range: = 10400 mm/s (461850 SUS)

Oil temperature range: 0 80 C (32176F)

Ambient temperature range: 0 50 C (32122F) Internal temperature range: 0 45 C (32113F)

The regular function of the CCS 2 and the warranty of safety assumes theusage of by INTERNORMENTechnologyGmbHprovided and allowed supplies.



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For the determination of contamination classes with the CCS 2 the oil of theexamined system has to be used.

Before connecting the CCS 2 to the system make sure, that the discharge oil ofthe 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 maintenanceinstructions 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 thesystem.

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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2.0 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 unitof the accessory with 100 V to 240 V AC, 50/60 Hz. It has to be connected to the powersupply plug of the CCS 2 (see picture 1 onpage 7). The power supply unit has its own

switch. It is operating when its green controldiode shines.

Battery operation

The CCS 2 has an integrated rechargeable battery. It allows without printing about 250continuous measurements ( 1 hour operation ).

The battery charger works with 12 V, 24 V DC or 230 V AC. It has

to be plugged into the battery load jack (see picture 1 on the page7) - light up the blue control diode at the CCS 2. Loading isindicated at the battery charger by a control diode - aftercompletion of the loading procedure: Indicate to the controldiode of red after green. The recharge time takes about approx.

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)

100240 V AC50 / 60 Hz

Fuse protection: f1: 3,15 AT regular usef2: 3,15 AT battery loading

Picture 1:

Blue controldiode

Battery load

fuses

Power supply(external power

su l unit

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 notallowed.

The unit may not be exposed to any vibrations.

The environmental temperature has to be below 50 C (122F).

1. Connect the oil discharge hose with the quick actingclosure to the CCS 2 and put its end into an oil tank.The oil tank has to catch up non-stop oil during thewhole operation time, so make sure it is big enough orexchange it punctually!It is also possible to lead the discharge oil straight backinto the tank of the examined system.

The end of the discharge tube has to be let down undisturbed and may in nocase be connected to a pressurized conduit!

2. The high pressure measuring hose with the minimeasuring closure has to be connected to theinput of the CCS 2.

3. Connect the high pressure measuring hose withthe measuring connection of the examinedsystem.

4. Connect the external power supply unit of the accessory with the CCS 2 by pluggingit into the power supply jack (see picture 1).The power supply unit has its ownswitch. 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!



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2.3. Weight and dimensions

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

Picture 2:

2.4. Transport

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



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3.0 Maintenance

The CCS 2 has to be connected for the foreseen measuring according to thestatements under item 1 and 2.

Turn on the CCS 2 by pushing down the main switch. The green control diodehas to start glowing now. The processor starts automatically into the Englishresp. German real version of the measuring and control program. The mainmenu is on the display.

Note: If the measuring and control program has been ended deliberatelyor inadvertent, you can call it from the DOS level.

English real version: e11.exe

English demo version: e01.exe

German real version: d11.exe

German demo version: d01.exe

(Input of new program versions look at chapter 3.5.)

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



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3.0.1. General information

The oil gets through a mini-measuring connectionfrom the hydraulic system intothe 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 theoil steady-going through a laser sensor, which measures in principle of lightblockage impulses according to the size of the particles. The electronictransforms 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-linemeasurement are possible in conjunction with the Bottle Sampling (BSS) orTank 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 nextmeasurement.

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 themeasuring 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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3.0.2. Control panel and key pad use

Input of numbers and letters

Numbers and letters use the same keys. For numbers you just press the singlekey. 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.

F4 d

F5 e

f

Capital lettersThe 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.

printerdisplay

function ke s

RS 232 interface

DEL

arrow keys ENTER

numbers and letters

space

ESC

2D E F

F6

2D E F

2D E F

+

+

+

2D E F +

F6 F3+ F



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3.1. 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 countingUse 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 countingThis mode is to analyse bottle samples or oil straight out of a tank. Thereforeyou need the Bottle Sampling System (BSS 2) or the Tank Sampling SystemTSS to feed the CCS 2 with the oil of the sample or tank (for connection seealso 3.3.). Regard the maintenance instruction of the BSS 2 or TSS1!Certainly you can use this measuring program also for on-line measurements.

File systemHere you find the saved results of your measurements. You can select to see

the results according to different standards.

Data transferThis mode is to transfer saved measuring results from the CCS 2 to an externalcomputer.

Data file deleteThis mode is to delete complete files of saved measuring results in the filesystem and to set time and date.



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3.1.1. On-line particle counting

Setup-menu

Name measure pointAfter entering the setup-menu this function will automatically be chosen. It is redhighlighted. Enter the name of your measure point by using the key pad(seekey pad use on chapter 3.0.2.). For erasing a typing error press [ DEL ]. Thecharacters are limited to the number of 20.

Use for the same measure point always the same name. Otherwise you wontbe able to compare the results afterwards in the file system. Each result getsautomatically a new index in the file system and also date and time of themeasurement 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 typeBy 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 formatThe measurement can be done either according to ISO 4406 or to NAS 1638.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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3.1.1.1. Mode: on-line single/ ISO 4406

Press [ ENTER ] to start the system. After a couple of flushing circuits themeasurement will start. It takes 3 runs. The final result is the average of thethree 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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3.1.1.2. Mode: on-line single/ NAS 1638

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

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




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3.1.1.3. Mode: on-line continuous/ ISO 4406

Press [ ENTER ] to start the system. After a couple of flushing circuits thecontinuous measurement will start. The system will show on the display thetrend of the results. While measuring you cant print.

The last 100 results of the actual measuring process automatically get saved inthe 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 lastresult with [ F2 ]. Press [ F1 ] to continue the same measurement process, press

[ ENTER ] to start a new continuous measurement or press [ ESC ] to leave thismode. Memory is deleted!



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3.1.1.4. Mode: on-line continuous/ NAS 1638

Press [ ENTER ] to start the system. After a couple of flushing circuits thecontinuous measurement will start. The system will show on the display thetrend of the results. While measuring you cant print.

The last 100 results of the actual measuring process automatically get saved inthe 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 lastresult with [ F2 ]. Press [ F1 ] to continue the same measurement process, press

[ ENTER ] to start a new continuous measurement or press [ ESC ] to leave thismode. Memory is deleted!



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3.1.1.5. Setup-menu: on-line cyclic/ ISO 4406

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 redhighlighted position by using the arrow keys [ ].

Cycle periodThe time between one measurement and the next one can be selected between

0,5 hours to 24 hours in half hour steps.

Cycle numberThe total number of measurements can be chosen two-step-wise from 2 to 100.

Automatic storageOptionally every cyclic measurement can be saved automatically by setting theautomatic storage to on.

Automatic print outIf you wish a print out of every single result of the cyclic measurement activate

the automatic print out.

LimitsYou can supervise the exceeding of certain contamination classes. Set the limitof a contamination class by using the arrow keys [ ].

Each exceeded limit is signalled with a red field on the display in a notice inbetween the measurements. A falling below and/or an adherence to the limitvalue is green shown the display. And black it indicates that the counter channelwas not programmed.Each contamination class limit has its own contact maker and contact breakeron 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 ].



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3.1.1.5.1. Mode: on-line cyclic/ ISO 4406

To start the cyclic measurement press [ ENTER ].

Cycle operation:The system flushes and then measures three times. The final result ofeach 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 cyclicmeasurement are done, there is a headline on the notice that saysmeasurement finished.




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

Here you can determine the parameters of the cyclic measurement.

With the arrow keys [ ] you can choose which position to change. The

possible values are predetermined. You change the value of the red highlightedposition by using the arrow keys [ ].

Cycle periodThe time between one measurement and the next one can be selected between

0,5 hours to 24 hours in half hour steps.

Cycle numberThe total number of measurements can be chosen two-step-wise from 2 to 100.

Automatic storageOptionally every cyclic measurement can be saved automatically by setting theautomatic storage to on.

Automatic print outIf you wish a print out of every single result of the cyclic measurement activate

the automatic print out.

LimitsYou can supervise the exceeding of certain contamination classes. Set the limitfor a contamination class by using the arrow keys [ ].

Each exceeded limit is signalled with a red field on the display in a notice inbetween the measurements. A falling below and/or an adherence to the limitvalue is green shown the display. And black it indicates that the counter channelwas not programmed.Each contamination class limit has its own contact maker and contact breakeron 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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3.1.1.6.1. 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 ofeach 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 cyclicmeasurement are done, there is a headline that says measurement finished.




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3.1.2. 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 keypad (see key pad use chapter 3.0.2.). The characters are limited to the number

of 15.



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Use for the measurements of one sample always the same name. Otherwiseyou wont be able to compare the results afterwards in the file system. Eachresult gets automatically a new index in the file system and also date and timeof the measurement are saved.

The dilution factor is automatically put on one. You can change the factorstepwise with the arrow keys [ ].

To confirm your input press [ ENTER ].To delete your input press [ ESC ].

Start flushingThe system starts to flush. On the display you can see the number of flushingcycles.

To stop the flushing press [ 5 ].

Start countingThe 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 nextresults, press [ 4 ]. The presentation mode says current average and thenumber of averaged results. After each measurement that you want to beinvolved in that average press [ 4 ] again. You will see the current average resultof all involved measurements immediately on the display. You can save thecurrent 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 ofinvolved measurements.



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3.1.3. 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 ].

3.1.3.1. 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.



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3.1.3.1.1. Report format

You can choose to see the results according 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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3.1.3.1.1.1. 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).

3.1.3.1.1.1.1. Contamination classes trend

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

Press [ F2 ] to print the graphic. The print out takes a while and has a little breakin between for transmitting the graphic data.

Press [ ESC ] to leave this mode.



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3.1.3.1.1.2. Mode: single/ NAS 1638





Press [ F2 ] to print the graphic. The print out takes a while and has a little break

in between for transmitting the graphic data.




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3.1.3.1.1.3. Mode: single/ ISO 4406 : 87









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3.1.3.2. Mode: on-line continuous measurement





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You can choose to see the results according NAS 1638, the ISO 4406:87 or theup-to-date version of ISO 4406:99.

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



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3.1.3.2.1.1. Mode: continuous/ ISO 4406 : 99


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


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





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3.1.3.2.1.2. Mode: continuous/ NAS 1638









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3.1.3.2.1.3. Mode: continuous/ ISO 4406 : 87





Press [ F2 ] to print the graphic. The print out takes a while and has a little break

in between for transmitting the graphic data.




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3.1.3.3. Mode: on-line cyclic measurement





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



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3.1.3.3.1.1. 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 cyclicmeasurements.





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3.1.3.3.1.2. Mode: cyclic/ NAS 1638









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3.1.3.3.1.3. Mode: cyclic/ ISO 4406 : 87









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3.1.3.4. Mode: off-line bottle sampling





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



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3.1.3.4.1.1. Mode: bottle sampling/ ISO 4406 : 99


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


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





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3.1.3.4.1.2. Mode: bottle sampling/ NAS 1638









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3.1.3.4.1.3. Mode: bottle sampling/ ISO 4406 : 87









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3.1.4. Data transfer

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

Confirm with [ ENTER ] to get the CCS 2 ready for transferring the data. Thedata manager has to be installed on the external computer according to theinstructions in chapter 3.6.



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3.1.5. Data file delete

This mode is to delete complete files of saved measuring results in the filesystem 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 onthe display.




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3.1.5.1. 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, whohave read the instructions manual before !(see also item 1.1 and 1.4 of these instructions)

3.2. Instructions in brief for the on-line determination of thecontamination classes

1. Connect the oil discharge hose with the quick acting closure to the CCS 2and 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 connectedwith 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 (greencontrol diode gives light).

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



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7. Name measure pointEnter 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 or NAS 1638Select 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 measurementPress [ ENTER ] to start the measurement.Afterwards you can save and print the result.

11.2 Continuous measurementPress [ 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.



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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)

3.3. Instructions in brief for the off-line determination of thecontamination classes

1. Connect the oil discharge hose with the quick acting closure to the CCS 2and put the other end into an oil tank.

2. Build up the Bottle Sampling System respectively the Tank SamplingSystem 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 connectedwith the measuring connection of the Bottle Sampling System respectivelythe Tank Sampling System.

5. Build up the electric mains connection of the CCS 2 (8 to 15 V DC; 90 to250 V AC, 50/ 60 Hz).

6. Switch on the CCS 2 (greencontrol 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.



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CCS 2 Maintenance

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3.4. Printer

3.4.1. 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 theprinter ribbon loosens from the motor shaft.

3. Take the cartridge out.

4. Tighten the printer ribbon of the new cartridge by turning the rotary knoblike the arrow shows.

5. Put the cartridge back in the mounting and bring the visible part of theprinter ribbon in the slit where the paper is. The visible part of the printerribbon has to be above the paper.

6. If necessary, tighten the printer ribbon again.

3.4.2. Input of paper

1. Open the front cover of the printer and take out theempty roll within the axis.

2. Put the new paper roll on the axis. Push the axis inits receiver till you hear it snapping in.

Important-

regard the label on the back board, that showswhich 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 paperinto the introduction slit, as seen in the picturebeside.

4. Push the green paper transport button until the paper is all through theprinter 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.



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

For implementing a new program to the CCS 2 the DOS program filelinkisrequired. You find it on the data manager diskette. Please install the program onthe 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 filelinkprogram.

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.exeon 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 ratehas to be on 115200. Correct the options if necessary. Go back to the lastscreen.

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 filelinkprogram on your computer orlaptop. Switch off the CCS 2. Now you can start the CCS 2 as regular.



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3.6. 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.XLS2. CCS2_DATMA01_E.XLS3. WINCOMM.EXE4. README

During English land attitude in the Windows you install:5. CCS2_DATM02_D.XLS6. CCS2_DATM02_E.XLS7. WINCOMM.EXE

of the disk 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 tobe 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 isnow ready for data transfer.

- Start on your computer CCS2_DATMA01_E.xls for the English version,CCS2_DATMA01_D.xls for the German version.

- 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 youcan use the prepared graphic functions of the data manager to demonstratethe counting results and contamination classes.



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CCS 2 Maintenance

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3.7. Setting date and time

Choose on the main menu the mode data file delete and press [ ENTER ] toget to the next level.

To set date and time press [ F 1 ].

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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CCS 2 Malfunctions/ troubleshooting

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4.0 Malfunctions / troubleshooting

Malfunctions Reason HelpSystem switched on,no function, control

lamp out

network connectiondisturbed; external

power supply unitswitched off; batteryempty

Check the powersupply; when battery

is empty use powersupply unit; loadbattery

network supply faulty check the main fuse

fuse of system defect change the defectfuse

control lamp on,display does not work

display defect call INTERNORMEN

5.0 Service / maintenance

To guarantee the accuracy of the measuring results the CCS 2 the integratedlaser sensor has to be calibrated yearly through INTERNORMENTechnologyGmbH. With the calibration all necessary maintenance and service workings,that exceed the outside cleaning, will be done. Only competent staff ofINTERNORMENTechnologyGmbHis allowed to open the CCS 2!

Outside cleaning

The outside cleaning of the CCS 2 takes place through the user when there is acertain 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 nochemicals except for water or glass cleaner! Switch off the CCS 2 beforecleaning!



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CCS 2 Switch off CCS 2

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6.0 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. Putprotection caps on both connection.

6. Release the high pressure measuring hose of the CCS 2 and put protectioncaps on both connections.

7. Release the oil discharge hose and put a protection cap on the quick actingclosure.

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

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

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

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



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CCS 2 Enclosure

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7.0 Enclosure



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CCS 2 Enclosure A Technical Data

58

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: 12 V, 24 V DC or 230 V AC

internal battery: 12 V

protection f1: 3,15 AT regular use

f2: 3,15 AT battery loading

dimensions (mm): l x w x h450 x 180 x 255

(in.): 17,7 x 7 x 10

weight: 10,8 kg

principle of measurement: particle counting according to the light gate principle

proceeding of measurement: automatic particle counting

particle sizes: > 4 m, > 4,6 m, > 6 m, > 6,4 m, >14 m, > 21 m,> 37 m

representation of the CC: ISO 4 - 24 NAS 00 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

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 mm/s (46 1850 SUS)



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oil temperature range: 80C (176F)

ambient temperature range: 50C (122F)

internal temperature range: 45C (113F)

fluid compatibility: hydraulic and lubricating fluids based on mineral oil(also see on separate list of sociability)

display - output: cleanliness classes, number of particles, beamdiagram, 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 M16x2, 1 x connector coupling for hose DN 6

further serial equipment: external power supply unit, battery charger, highpressure hose, discharge hose, Datamanger (softwaredisc)

display: active LCD - colour display

computer interface: RS 232 connection (for external computer coupling)



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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/ACmaximal switching performance: 60 VA

limiting value > 4 m / limiting value 5 ... 15 m: K1 : 2K2 : 3K3 : 1

limiting value > 6 m / limiting value 15 ... 25 m: K1 : 5K2 : 6K3 : 4

limiting value > 14 m / limiting value 25 50 m: K1 : 8K2 : 9K3 : 7

connector plug: type Lemosa FFA 310.CLAD 927

K2

K3

K1



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Area of use - digestibility CCS 2

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. water - glycol (HFC) 2. oil in water emulsion (HFA)

3. spindle oils, white oil 3. phosphate ester (HFD-R) 3. coulant, aqueous

4. engine oils, gas oils 4. polyglycole (PEG) (HPG) 4. surface water

5. MIL-H-5606 E 5. fresh water, process water,

etc.

5. corrosion protecting oils with

wax and paraffin contents

6. oils on vegetable basis

(HTG, Triglyzeride)

6. other hydraulic fluids based on

MIL- specifications

6. heavy oils ISO-VG-320

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

contents 500 ppm

8. ATF-fluids

Explanations

ad 1.hydraulic oils HLPDare used to dispersewater contents (D-additive). Atdetermined water

dispersions these oilsare no moremeasurable.

ad 4.engine oils with solidwear additives (MoS2etc.) are notmeasurable.

ad 6.with increasinghydrolysis HTGs

(vegetable oils) are nomore measurable, asthey then get a 2-phase-fluid (fatty acid+ glycerine). Dangerof clogging!

ad 1. no problems with HFD-U-fluids in pure state. Withwater contents or residual oilcontamination measuringsare impossible. Special

calibration necessary.

ad 2.HFC-fluid is a typical 2-phase-fluid with partlyextreme creation of cloudlystains.

ad 3.generally HFD-R-fluidcannot be measuredbecause of insufficientcompatibility of all

components.ad 4. polyglycole (PEG, HPG) is

measurable, however, whenchanging the type of oil athorough flushing has to become. Special calibrationnecessary!

ad 5.water. Normal spring watercan have differentcompositions. The partly

rather high calcic contentsleads to a quick failure of thesystem.

ad 1. typical fluid charged withfine dispersed solidparticles which are countedand registered as particles.

ad 2. typical 2-phase-fluid inwhich the oil driplets areregistered as particles.

ad 3. like no. 2 (above)

ad 4. surface water iscontaminated with differentparts. Danger of corrosionand clogging.

ad 5. waxes and paraffins are

separated and lead toclogging. In addition thewax-particles are countedas particles.

ad 6.because of too highviscositys heavy oils ISO-VG-320 cannot getmeasured.

ad 7.water contamination will be

registered and counted asparticle. In addition: dangerof corrosion.



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CCS 2 Enclosure B Contamination classes according to ISO 4406

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Contamination classes according to ISO 4406 : 99

For the determination of the ISO - codes (contamination classes) the quantity of theparticles in the sizes > 4 m, > 6 m and > 14 m 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 500018 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 m

Particles > 6 m

Particles > 4 m



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CCS 2 Enclosure C Cleanliness classes according to NAS 1638

63

Cleanliness classes according to NAS 1638

Analysis volume: 100 ml

Particle quantity x 10

class 5 - 15 m 15 - 25 m 25 - 50 m 50 - 100 m > 100 m00 0,125 0,022 0,004 0,001 00 0,250 0,044 0,008 0,002 01 0,5 0,089 0,016 0,003 0,001

2 1 0,178 0,032 0,006 0,0013 2 0,356 0,063 0,011 0,002

4 4 0,712 0,126 0,022 0,0045 8 1,425 0,253 0,045 0,0086 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 0,0649 128 22,8 4,05 0,72 0,12810 256 45,6 8,1 1,44 0,25611 512 91,2 16,2 2,88 0,512

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



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CCS 2 Enclosure D

64

System type / Rangeof application needed contaminationclasses

filter fineness

according to standards ISO 4406:99 NAS 1638 x (c) 200

against fine soiling andmudding-up of sensitivesystems

lab, aviation and aerospatial

16/ 12/ 8 2 - 3 4

against fine soiling andmudding-up of sensitivesystems

lab, aviation and aerospatial

17/ 13/ 9 3 4 5

heavy-duty servo systems,high pressure systems withlong service life

aviation, machine tool,controlling

19/ 15/ 11 4 6 7

proportional valves - industrialhydraulic with high operating

safety

higher mobile hydraulic20/ 16/ 13 7 - 8 10

mobile hydraulic, commonmechanical engineering,medium pressure system

mobile hydraulic

22/ 18/ 15 7 - 9 15

heavy industry, low pressuresystem

mobile hydraulic, waterhydraulic

23/ 19/ 15 9 - 11 20



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CCS 2 Enclosure E

Accessories/ spare parts:

Article no.:

1. Suitcase complete 3226472. CCS 2 3205953. Power supply unit 100...240 V AC / +12V DC/ 5 A 3204444. Line cord 3238845. Battery charger (Fa. Mascot) 3247516. RS 232 interface cable 3144627. Controlling output plug 3206008. High pressure hose 3137429. Oil discharge hose (set with pos. 8) 32406010. Disk with data manager 32059911. Instruction manual 320598

12. Two paper rolls 32248913. Printer ribbon 31637914. Calibration certificate after annual

maintenance/ calibrationat INTERNORMENTechnologyGmbH


contamination control system

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