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CCS 2
CONTAMINATION CONTROL SYSTEM
CE 2001

Instruction manual
Version 1.4
Serial-No.: Version-/Rev.-Date: .................. 12.05.2004

INTERNORMEN Technology GmbH Friedensstr. 41 Germany 68804 Altluheim Tel. +49 (0) 6205/2094-0

E-Mail: [email protected] http://www.internormen.com

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CCS 2 List of content

List of content
1.
1.1. 1.2. 1.3. 1.4. 1.5. 1.6.

Safety
danger through maloperation proper use sources of danger service staff safety arrangements on site protection device

page 4
4 4 5 5 5 5

2.
1.7. 1.8. 1.9. 1.10.

Initiation
electrical connection connection of system weight and dimensions transport

6
6 8 9 9

3. Maintenance 3.0.1. General information 3.0.2. Control panel and key pad use 3.1. Main menu 3.1.1. on-line particle counting
3.1.1.1. 3.1.1.2. 3.1.1.3. 3.1.1.4. 3.1.1.5. 3.1.1.5.1. 3.1.1.6. 3.1.1.6.1. mode: on-line single/ ISO 4406 mode: on-line single/ NAS 1638 mode: on-line continuous/ ISO 4406 mode: on-line continuous/ NAS 1638 setup-menu: on-line cyclic/ ISO 4406 mode: on-line cyclic/ ISO 4406 setup-menu: on-line cyclic/ NAS 1638 mode: on-line cyclic/ NAS 1638

10 11 12 13 14
15 16 17 18 19 20 21 22

3.1.2. 3.1.3.
3.1.3.1. 3.1.3.1.1. 3.1.3.1.1.1. 3.1.3.1.1.1.1. 3.1.3.1.1.2. 3.1.3.1.1.2.1. 3.1.3.1.1.3. 3.1.3.1.1.3.1. 3.1.3.2. 3.1.3.2.1. 3.1.3.2.1.1. 3.1.3.2.1.1.1. 3.1.3.2.1.2. 3.1.3.2.1.2.1.

off-line particle counting file system

mode: on-line single measurement report format mode: single/ ISO 4406 : 99 contamination classes trend mode: single/ NAS 1638 contamination classes trend mode: single/ ISO 4406 : 87 contamination classes trend mode: on-line continuous measurement report format mode: continuous / ISO 4406 : 99 contamination classes trend mode: continuous/ NAS 1638 contamination classes trend

23 25
25 26 27 27 28 28 29 29 30 31 32 32 33 33
2

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CCS 2 List of content

3.1.3.2.1.3. 3.1.3.2.1.3.1. 3.1.3.3. 3.1.3.3.1. 3.1.3.3.1.1. 3.1.3.3.1.1.1. 3.1.3.3.1.2. 3.1.3.3.1.2.1. 3.1.3.3.1.3. 3.1.3.3.1.3.1. 3.1.3.4. 3.1.3.4.1. 3.1.3.4.1.1. 3.1.3.4.1.1.1. 3.1.3.4.1.2. 3.1.3.4.1.2.1. 3.1.3.4.1.3. 3.1.3.4.1.3.1.

mode: continuous/ ISO 4406 : 87 contamination classes trend mode: on-line cyclic measurement report format mode: cyclic/ ISO 4406 : 99 contamination classes trend mode: cyclic/ NAS 1638 contamination classes trend mode: cyclic/ ISO 4406 : 87 contamination classes trend mode: off-line bottle sampling report format mode: bottle sampling/ ISO 4406 : 99 contamination classes trend mode: bottle sampling/ NAS 1638 contamination classes trend mode: bottle sampling/ ISO 4406 : 87 contamination classes trend

34 34 35 36 37 37 38 38 39 39 40 41 42 42 43 43 44 44

3.1.4. 3.1.5.
3.1.5.1.

data transfer data file delete

setup menu: date/ time

45 46
47

3.2. Instructions in brief for the on-line determination of the contamination classes 3.3. Instructions in brief for the off-line determination of the contamination classes 3.4. Printer
3.4.1. 3.4.2. Change of printer ribbon Input of paper

48 50 51
51 51

3.5. Implementing a new program version from a Laptop or PC 3.6. The data manager 3.7. Setting date and time

52 53 54

4. 5. 6. 7.

Malfunctions/ troubleshooting Service/ maintenance Switch off CCS 2 Enclosure

55 55 56 57

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CCS 2 Safety

1.0

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 or NAS 1638.

Operation limits
The system is only in the following limits usable for on-line operation at hydraulic and lubrication systems: Input operating pressure: p (depending on viscosity) Viscosity range: Oil temperature range: Ambient temperature range: Internal temperature range: = = 1,5420 bar (22 6090 PSI)

10400 mm/s (461850 SUS) 0 80 C (32176F) 0 50 C (32122F) 0 45 C (32113F)

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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CCS 2 Safety

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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CCS 2 Initiation

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 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 1 on page 7). 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 ).

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 page 7) - 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 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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CCS 2 Initiation

Electrical connection values Voltage: With the external power supply: 12 V DC ( 8...15 V DC)

100240 V AC 50 / 60 Hz f1: 3,15 AT regular use f2: 3,15 AT battery loading

Fuse protection:

Picture 1:

Main switch Green control diode Battery load

Power supply (external power supply unit)

Blue control diode

Control outlet fuses

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CCS 2 Initiation

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 (122F). 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 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!

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CCS 2 Initiation

2.3. Weight and dimensions

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

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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CCS 2 Maintenance

3.0

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: English demo version: e11.exe e01.exe

German real version: German demo version:

d11.exe 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 real measurements the computer simulates the counting and the results. You can use all functions as regular.

10

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CCS 2 Maintenance

3.0.1.

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

11

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CCS 2 Maintenance

3.0.2.

Control panel and key pad use

arrow keys ESC ENTER DEL RS 232 interface

display function keys

space numbers and letters

printer

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.

F4

+ + +

2
DEF

F5

2
DEF

F6

2
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
DEF

F6

F3

F
12

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CCS 2 Maintenance

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 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 3.3.). 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.

13

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CCS 2 Maintenance

3.1.1.

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 3.0.2.). 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 wont 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 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.

14

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CCS 2 Maintenance

3.1.1.1.

Mode: on-line single/ ISO 4406

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 ].

15

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CCS 2 Maintenance

3.1.1.2.

Mode: on-line single/ NAS 1638

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 ].

16

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CCS 2 Maintenance

3.1.1.3.

Mode: on-line continuous/ ISO 4406

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 cant 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!
17

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CCS 2 Maintenance

3.1.1.4.

Mode: on-line continuous/ NAS 1638

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 cant 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!
18

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CCS 2 Maintenance

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 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 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 ( 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 ].
19

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CCS 2 Maintenance

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 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 on the notice that says measurement finished.

To leave this mode press [ ESC ].

20

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CCS 2 Maintenance

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 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 ].
21

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CCS 2 Maintenance

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 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.

To leave this mode press [ ESC ].

22

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CCS 2 Maintenance

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 key pad (see key pad use chapter 3.0.2.). The characters are limited to the number of 15.

23

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CCS 2 Maintenance

Use for the measurements of one sample always the same name. Otherwise you wont 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. On the display you can see the number of flushing cycles. To stop the flushing press [ 5 ].

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.
24

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CCS 2 Maintenance

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.
25

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CCS 2 Maintenance

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 ].

26

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CCS 2 Maintenance

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 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.
27

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CCS 2 Maintenance

3.1.3.1.1.2. Mode: single/ NAS 1638

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).

3.1.3.1.1.2.1.

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.
28

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CCS 2 Maintenance

3.1.3.1.1.3. Mode: single/ ISO 4406 : 87

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).

3.1.3.1.1.3.1.

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.
29

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CCS 2 Maintenance

3.1.3.2.

Mode: on-line continuous measurement

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

30

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CCS 2 Maintenance

3.1.3.2.1. 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 ].

31

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CCS 2 Maintenance

3.1.3.2.1.1. 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).

3.1.3.2.1.1.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named continuous 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.
32

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CCS 2 Maintenance

3.1.3.2.1.2.

Mode: continuous/ NAS 1638

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).

3.1.3.2.1.2.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named continuous 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.
33

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CCS 2 Maintenance

3.1.3.2.1.3. Mode: continuous/ ISO 4406 : 87

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).

3.1.3.2.1.3.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named continuous 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.
34

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CCS 2 Maintenance

3.1.3.3.

Mode: on-line cyclic measurement

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

35

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CCS 2 Maintenance

3.1.3.3.1. 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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CCS 2 Maintenance

3.1.3.3.1.1. Mode: cyclic/ ISO 4406 : 99

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).

3.1.3.3.1.1.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named cyclic 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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CCS 2 Maintenance

3.1.3.3.1.2. Mode: cyclic/ NAS 1638

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).

3.1.3.3.1.2.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named cyclic 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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CCS 2 Maintenance

3.1.3.3.1.3. Mode: cyclic/ ISO 4406 : 87

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).

3.1.3.3.1.3.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named cyclic 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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CCS 2 Maintenance

3.1.3.4.

Mode: off-line bottle sampling

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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CCS 2 Maintenance

3.1.3.4.1. 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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CCS 2 Maintenance

3.1.3.4.1.1. 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).

3.1.3.4.1.1.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named bottle sampling 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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CCS 2 Maintenance

3.1.3.4.1.2. Mode: bottle sampling/ NAS 1638

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).

3.1.3.4.1.2.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named bottle sampling 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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CCS 2 Maintenance

3.1.3.4.1.3. Mode: bottle sampling/ ISO 4406 : 87

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).

3.1.3.4.1.3.1.

Contamination classes trend

Here you get a graphic that shows the trend of all same named bottle sampling 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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CCS 2 Maintenance

3.1.4. 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 3.6.

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CCS 2 Maintenance

3.1.5. 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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CCS 2 Maintenance

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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CCS 2 Maintenance

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)

3.2. 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. One side of the high pressure measuring hose (mini measuring M 16x2) has to be connected to the input of the CCS 2. The second side of the high pressure measuring hose has to be connected with the measuring connection of the examined system. Build up the electric mains connection (8 to 15 V DC; 90 to 250 V AC, 50/ 60 Hz). Switch on the CCS 2 (green control diode gives light). Confirm with [ ENTER ] to get to the online measuring setup-menu:

2.

3.

4.

5. 6.

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CCS 2 Maintenance

7.

Name measure point Enter the name of your measurement by using the key pad. Go on with the arrow keys [ ]. Single, continuous or cyclic measurement Select your measure type with the arrow keys [ ]. Go on with the arrow keys [ ]. ISO 4406 or NAS 1638 Select with the arrow keys [ ] the report format that you want to use for analysing the results.

8.

9.

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.

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CCS 2 Maintenance

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 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. Build up the Bottle Sampling System respectively the Tank Sampling System according to its manual. One side of the high pressure measuring hose (mini measuring M 16x2) has to be connected to the input of the CCS 2. 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. Build up the electric mains connection of the CCS 2 (8 to 15 V DC; 90 to 250 V AC, 50/ 60 Hz). Switch on the CCS 2 (green control diode gives light). Select Offline particle counting on the main menu. Confirm with [ ENTER ]. Enter the sample name and the dilution factor. Get the BSS resp. the TSS ready for measuring (according to its manual).

2.

3.

4.

5.

6. 7.

8. 9.

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

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 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.

3.4.2. 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.
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CCS 2 Maintenance

3.5. 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. 2. 3. 4. 5. 6. 7. Switch on the CCS 2. Leave the main menu with [ ESC ]. Press [ F1 ] to start the filelink program. Confirm the first page with [ ENTER ]. Select the slave mode and confirm. Allow the program to overwrite files. Connect the CCS 2 and your computer or laptop with an interface cable (RS 232 interface on the CCS 2). Start your computer or laptop. Copy the new CCS 2 program into the same path as the filelink.exe.

8. 9.

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.

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CCS 2 Maintenance

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. 2. 3. 4. CCS2_DATMA01_D.XLS CCS2_DATMA01_E.XLS WINCOMM.EXE README

During English land attitude in the Windows you install: 5. CCS2_DATM02_D.XLS 6. CCS2_DATM02_E.XLS 7. 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 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 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 you can use the prepared graphic functions of the data manager to demonstrate the counting results and contamination classes.

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CCS 2 Maintenance

3.7. Setting date and time

Choose on the main menu the mode data file delete and press [ ENTER ] to get 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

4.0

Malfunctions / troubleshooting
Malfunctions System switched on, no function, control lamp out Reason network connection disturbed; external power supply unit switched off; battery empty network supply faulty fuse of system defect display defect Help Check the power supply; when battery is empty use power supply unit; load battery check the main fuse change the defect fuse call INTERNORMEN

control lamp on, display does not work

5.0

Service / maintenance
To guarantee the accuracy of the measuring results 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!

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CCS 2 Switch off CCS 2

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. 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.

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CCS 2 Enclosure

7.0 Enclosure

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CCS 2 Enclosure A Technical Data

Technical Data
General technical Data:
power supply : external power supply unit: battery charger: internal battery: protection 12 V DC, 35 VA 100 ... 240 V AC/ + 12 V DC/ 5 A, 50/ 60 Hz 12 V, 24 V DC or 230 V AC 12 V f1: 3,15 AT regular use f2: 3,15 AT battery loading l 450 17,7 x x x w 180 7 x x x h 255 10

dimensions (mm): (in.): weight: principle of measurement:

10,8 kg 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 ISO 4 - 24 NAS 00 12

representation of the CC: proceeding of calibration: max. particle concentration: sensor flowrate: kind of measuring: value of measurement: measurement methods:

ISO MTD in oil (ISO 11171:2000) 24000 particle / ml 50 ml / min On-line, Off-line options: bottle-, tank sampling mean value of 3 measurements single, continuous, cyclic measurement (automatically) bottle sampling with BSS 2, tank sampling with TSS 1 240 seconds (flushing, 3 measurements and average) 20 seconds for 1 test result (continuous measurement) 1,5 - 420 bar, 22 - 6090 PSI (depending on viscosity) 10 - 400 mm/s (46 1850 SUS)
58

(Sensor)

test time in seconds:

pressure range: viscosity range:

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CCS 2 Enclosure A Technical Data

oil temperature range: ambient temperature range: internal temperature range: fluid compatibility:

80C (176F) 50C (122F) 45C (113F) hydraulic and lubricating fluids based on mineral oil (also see on separate list of sociability) cleanliness classes, number of particles, beam diagram, graphics cleanliness classes, number of particles, graphics limit value of the contamination classes 4x100 measurements (100 per kind of measurement) 150 ml to p = 420 bar 1 x mini-measuring connection with screw coupling M 16x2, 1 x connector coupling for hose DN 6 external power supply unit, battery charger, high pressure hose, discharge hose, Datamanger (software disc) active LCD - colour display RS 232 connection (for external computer coupling)

display - output:

printer - output: alarm - functions: store capacity: Leakage per measuring: connection:

further serial equipment:

display: computer interface:

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CCS 2 Enclosure A Technical Data

connection:

control outlet

panel jack
(external view)

K2 K1
Relay - contact designation:

(contact maker)

K3
Relay contact performance: maximal switching current: maximal switching voltage: maximal switching performance:

(contact breaker)

2A 60 V DC/AC 60 VA

limiting value

> 4 m / limiting value 5 ... 15 m:

K1 : 2 K2 : 3 K3 : 1 K1 : 5 K2 : 6 K3 : 4 K1 : 8 K2 : 9 K3 : 7

limiting value

> 6 m / limiting value 15 ... 25 m:

limiting value

> 14 m / limiting value 25 50 m:

connector plug:

type

Lemosa

FFA 310.CLAD 927

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CCS 2 Enclosure A Technical Data

Area of use - digestibility CCS 2 A: usable B: reduced usable C: not usable

1. hydraulic oils H, HL, HLP, HLPD and HV 2. gear oils C, CL, CLP 3. spindle oils, white oil 4. engine oils, gas oils 5. MIL-H-5606 E 6. oils on vegetable basis (HTG, Triglyzeride) 7. synthetic ester (HEES) 8. ATF-fluids

1. organic ester (HFD-U) 2. 3. 4. 5. water - glycol (HFC) phosphate ester (HFD-R) polyglycole (PEG) (HPG) fresh water, process water, etc. 6. other hydraulic fluids based on MILspecifications

1. gear oil with MoS2-additive 2. 3. 4. 5. oil in water emulsion (HFA) coulant, aqueous surface water corrosion protecting oils with wax and paraffin contents 6. heavy oils ISO-VG-320 7. general oils with H2Ocontents 500 ppm

Explanations ad 1. hydraulic oils HLPD ad 1. no problems with HFD-Uare used to disperse fluids in pure state. With water contents (Dwater contents or residual oil additive). At contamination measurings determined water are impossible. Special dispersions these oils calibration necessary. are no more ad 2. HFC-fluid is a typical 2measurable. phase-fluid with partly ad 4. engine oils with solid extreme creation of cloudly wear additives (MoS2 stains. etc.) are not ad 3. generally HFD-R-fluid measurable. cannot be measured ad 6. with increasing because of insufficient hydrolysis HTGs compatibility of all (vegetable oils) are no components. more measurable, as ad 4. polyglycole (PEG, HPG) is they then get a 2measurable, however, when phase-fluid (fatty acid changing the type of oil a + glycerine). Danger thorough flushing has to be of clogging! come. Special calibration necessary! 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 paraffins are separated and lead to clogging. In addition the wax-particles are counted as particles. ad 6. because of too high viscositys heavy oils ISO-VG-320 cannot get measured.

ad 5. water. Normal spring water can have different ad 7. water contamination will be compositions. The partly registered and counted as rather high calcic contents particle. In addition: danger leads to a quick failure of the of corrosion. system.
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CCS 2 Enclosure B Contamination classes according to ISO 4406

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 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 Particles > 14 m Particles > 6 m Particles > 4 m Analysis volume: 1 ml

code - number 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6

Quantity particle of .......... 320000 160000 80000 40000 20000 10000 5000 2500 1300 640 320 160 80 40 20 10 5 2,5 1,3 0,6 0,3

up to inclusive 640000 320000 160000 80000 40000 20000 10000 5000 2500 1300 640 320 160 80 40 20 10 5 2,5 1,3 0,6

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CCS 2 Enclosure C Cleanliness classes according to NAS 1638

Cleanliness classes according to NAS 1638

Analysis volume: 100 ml

Particle quantity x 10 class 5 - 15 m 00 0,125 0 0,250 1 0,5 2 1 3 2 4 4 5 8 6 16 7 32 8 64 9 128 10 256 11 512 12 1024

15 - 25 m 0,022 0,044 0,089 0,178 0,356 0,712 1,425 2,85 5,7 11,40 22,8 45,6 91,2 182,4

25 - 50 m 0,004 0,008 0,016 0,032 0,063 0,126 0,253 0,506 1,012 2,025 4,05 8,1 16,2 32,4

50 - 100 m 0,001 0,002 0,003 0,006 0,011 0,022 0,045 0,090 0,18 0,36 0,72 1,44 2,88 5,76

> 100 m 0 0 0,001 0,001 0,002 0,004 0,008 0,016 0,032 0,064 0,128 0,256 0,512 1,024

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CCS 2 Enclosure D

System type / Range of application

according to standards against fine soiling and mudding-up of sensitive systems lab, aviation and aerospatial against fine soiling and mudding-up of sensitive systems lab, aviation and aerospatial heavy-duty servo systems, high pressure systems with long service life aviation, machine tool, controlling proportional valves - industrial hydraulic with high operating safety higher mobile hydraulic mobile hydraulic, common mechanical engineering, medium pressure system mobile hydraulic heavy industry, low pressure system mobile hydraulic, water hydraulic

needed contamination classes

ISO 4406:99 NAS 1638

filter fineness
x (c) 200

16/ 12/ 8

2-3

17/ 13/ 9

34

19/ 15/ 11

46

20/ 16/ 13

7-8

10

22/ 18/ 15

7-9

15

23/ 19/ 15

9 - 11

20

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CCS 2 Enclosure E

Accessories/ spare parts:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Suitcase complete CCS 2 Power supply unit 100...240 V AC / +12V DC/ 5 A Line cord Battery charger (Fa. Mascot) RS 232 interface cable Controlling output plug High pressure hose Oil discharge hose (set with pos. 8) Disk with data manager Instruction manual Two paper rolls Printer ribbon Calibration certificate Article no.: 322647 320595 320444 323884 324751 314462 320600 313742 324060 320599 320598 322489 316379 after annual maintenance/ calibration at INTERNORMEN
Technology GmbH

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