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

CCS 2
CONTAMINATION CONTROL SYSTEM

CE 2001
Instruction manual
Version 2.3
Serial-No.:
Version-/Rev.-Date:
..................
12.06.2012
CCS 2
List of content
List of content
Page
1. SAFETY
1.1.
Danger through maloperation
1.2.
Proper use
1.3.
Sources of danger
1.4.
Service staff
1.5.
Safety arrangements on site
1.6.
Protection device
2. INITIATION
2.1.
Electrical connection
2.2.
Connection of the system
10
2.3.
Weight and dimensions
12
2.4.
Transport
12
3. MAINTENANCE
13
3.1.
General information
14
3.2.
Control panel and key pad use
15
3.3.
Main menu
17
3.3.1.
On-line particle counting
18
3.3.1.1.
Mode: on-line single/ ISO 4406 : 99
19
3.3.1.2.
Mode: on-line single/ NAS 1638
20
3.3.1.3.
Mode: on-line single/ SAE AS 4059 : 01
21
3.3.1.4.
Mode: on-line continuous/ ISO 4406 : 99
22
3.3.1.5.
Mode: on-line continuous/ NAS 1638
23
3.3.1.6.
Mode: on-line continuous/ SAE AS 4059 : 01
24
3.3.1.7.
Setup-menu: on-line cyclic/ ISO 4406 : 99
25
3.3.1.7.1.
3.3.1.8.
3.3.1.8.1.
3.3.1.9.
3.3.1.9.1.
Mode: on-line cyclic/ ISO 4406

Setup-menu: on-line cyclic/ NAS 1638
Mode: on-line cyclic/ NAS 1638
Setup-menu: on-line cyclic/ SAE AS 4059 : 99
Mode: on-line cyclic/ SAE AS 4059
26
27
28
29
30
3.3.2.
Off-line particle counting
31
3.3.3.
File system
34
3.3.3.1.
3.3.3.1.1.
Mode: on-line single measurement

Report format
34
34
CCS 2
List of content
3.3.3.1.1.1.
Mode: single/ ISO 4406 : 99
3.3.3.1.1.1.1.
Contamination classes trend
3.3.3.1.1.2.
Mode: single/ NAS 1638
3.3.3.1.1.2.1.
3.3.3.1.1.3.
3.3.3.1.1.3.1.
3.3.3.1.1.4.
Mode: single/ SAE AS 4059 : 01
3.3.3.1.1.4.1.
3.3.3.2.
Mode: on-line continuous measurement
36
36
37
37
38
38
39
39
40
3.3.3.2.1.
41
Report format
3.3.3.2.1.1.
Mode: continuous/ ISO 4406 : 99
3.3.3.2.1.1.1.
3.3.3.2.1.2.
Mode: continuous/ NAS 1638
3.3.3.2.1.2.1.
3.3.3.2.1.3.
3.3.3.2.1.3.1.
3.3.3.2.1.4.
Mode: continuous/ SAE AS 4059 : 01
3.3.3.2.1.4.1.
3.3.3.3.
Mode: on-line cyclic measurement
42
42
42
43
44
44
45
45
46
3.3.3.3.1.
47
Report format
3.3.3.3.1.1.
Mode: cyclic/ ISO 4406 : 99
3.3.3.3.1.1.1.
3.3.3.3.1.2.
Mode: cyclic/ NAS 1638
3.3.3.3.1.2.1.
3.3.3.3.1.3.
3.3.3.3.1.3.1.
3.3.3.3.1.4.
Mode: cyclic/ SAE AS 4059 : 01
3.3.3.3.1.4.1.
3.3.3.4.
Mode: off-line bottle sampling
48
48
48
49
49
50
51
51
51
3.3.3.4.1.
53
Report format
3.3.3.4.1.1.
Mode: bottle sampling/ ISO 4406 : 99
3.3.3.4.1.1.1.
3.3.3.4.1.2.
Mode: bottle sampling/ NAS 1638
3.3.3.4.1.2.1.
3.3.3.4.1.3.
3.3.3.4.1.3.1.
3.3.3.4.1.4.
Mode: bottle sampling/ SAE AS 4059 : 01
3.3.3.4.1.4.1.
3.3.4.
Data transfer
54
54
54
55
56
56
57
57
58
CCS 2
List of content
3.3.5.
Data file delete
3.3.5.5.
3.4.
3.5.
3.6.
Setup - menu: date/ time
59
60
Instructions in brief for the on-line determination of the

contamination classes
61
Instructions in brief for the off-line determination of the

63
Printer
64
3.6.1.
Change of the printer ribbon
64
3.6.2.
Input of paper
65
3.7.
Implementing a new program version from a Laptop or PC
66
3.8.
The data manager
67
4. MALFUNCTIONS / TROUBLESHOOTING
68
5. SERVICE / MAINTENANCE
68
6. SWITCH OFF CCS 2
69
7. ENCLOSURE
70
CCS 2
1.
Safety
Safety
1.1. Danger through maloperation

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

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

The CCS 2 works with a voltage from 8 to 15 V DC.
External power supply unit

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

operation).
Printing during battery operation shortens the running time extremly.
Unloading of the rechargeable batteries:

Unloading of the rechargeable battery is indicated by the CCS 2 with a
hooter alarm.
After the hooter alarm the CCS 2 is to be switched off within 5 min.
The operation of the CCS 2 with continuous hooter alarm leads to total
battery discharge with rising power consumption which can result in the
destruction of the fuse f2 or in the malfunctioning of the control of the
CCS 2.
CCS 2
Initiation
Loading of the rechargeable batteries with the provided battery charger:

The battery charger works with 100 ... 240 V AC, 50/ 60 Hz.
It has to be plugged into the battery load jack - light up the blue control
diode at the CCS 2.
Loading is indicated at the battery charger by a control diode.
After completion of the loading procedure:

Indicate to the control diode of red after green.
The recharge time takes about 6 hours.
Car supply
With a special cable you can connect a 12 V car plug with the CCS 2.
CCS 2
Initiation
Electrical connection values

Voltage:
12 V DC
( 8...15 V DC)
With the external power

supply:
100240 V AC
50 / 60 Hz
Fuse protection:
f1: 3,15 AT regular use

f2: 3,15 AT battery loading
Picture 2.1-1:
Main switch
Green control diode
Battery load
Power
supply
(external)
Blue control
diode
Control outlet
fuses
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 2.1.-1). The power supply unit
has its own switch. It is operating when its green control diode shines.
Otherwise the CCS 2 will run with battery!

Attention:
It has to be assured that the hydraulic connections are totally sealed!
Leaking oil has to be absorbed with special material immediately!
10
CCS 2
Initiation
11
CCS 2
Initiation
2.3. Weight and dimensions

Weight:
Dimensions:
10,8 kg
see picture 2 (Measurement unit: mm)
Picture 2.3-1
2.4. Transport
The CCS 2 and its accessories are stored in an aluminium suitcase. This case is for
the transport of the system to each service place. The case must be kept upright for
transport and storage. Make sure that the transport takes place without vibrations.
12
CCS 2
3.
Maintenance
Maintenance
The CCS 2 has to be connected for the foreseen measuring according to the
statements under item 1 and 2.
Turn on the CCS 2 by pushing down the main switch. The green control diode
has to start glowing now. The processor starts automatically into the English
resp. German real version of the measuring and control program. The main
menu is on the display.
Note:
If the measuring and control program has been ended deliberately

or inadvertent, you can call it from the DOS level.
English real version:
e12.exe
English demo version:
e02.exe
German real version:
d12.exe
German demo version:
d02.exe
(Input of new program versions look at chapter 3.7.)

The demo version is operating the same way as the real version. Instead of real
measurements the computer simulates the counting and the results. You can
use all functions as regular.
13
CCS 2
Maintenance
3.1. General information

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

the constant measuring volume
the constant flow rate at the sensor
the measuring volume and the flow rate are independent of the condition of
the hydraulic system
the high accuracy of measurements
the good reproducibility
Depending on your specifications different measuring programs can be used.

There are single, continuous and cyclic measurements. Also off-line
measurement are possible in conjunction with the Bottle Sampling (BSS) or
Tank Sampling System (TSS).
Automatic flushing processes in all programs shall prevent false measurements.
Therefore the CCS 2 gets flushed completely with the new oil before the next
measurement.
Single measurements:
- automatic flushing before the first measurement
- automatic flushing before following measurements, when more than 10
minutes are gone since the last measurement or when changing the
measuring point
Continuous measurements:
- automatic flushing when starting the measurement
Cyclic measurement:
- automatic flushing before each measurement
Off-line measurement:
- individual start of flushing process
14
CCS 2
Maintenance
3.2. Control panel and key pad use
arrow keys
ESC
display
ENTER
RS 232 interface
DEL
printer
space
function keys
numbers and letters
Keys for device and menu control:

ARROW KEYS for the menu control
ESC
menu step back
ENTER
confirm with ENTER
F1
F2
Keys for the measuring point control:

Numbers
Letters
F3/ F4/ F5
15
CCS 2
Maintenance
Input of numbers and letters

Numbers and letters use the same keys. For numbers you just press the single
key. For letters you have to press additionally the function key [ F4 ] (red), [ F5 ]
(blue) or [ F6 ] (green), according to the position of the letter resp. its color.
Example:
F4
2
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.
F6
F3
DEF
16
CCS 2
Maintenance
3.3. Main menu
Select the desired function by using the arrow keys [

]. The chosen function
is red highlighted. Confirm your selection with [ ENTER ].
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.
This mode is to analyse bottle samples or oil straight out of a tank. Therefore
you need the Bottle Sampling System (BSS 2) or the Tank Sampling System
TSS to feed the CCS 2 with the oil of the sample or tank (for connection see
also 3.5.). Regard the maintenance instruction of the BSS 2 or TSS1!
Certainly you can use this measuring program also for on-line measurements.
File system
Here you find the saved results of your measurements. You can select to see
the results according to different standards.
Data transfer
This mode is to transfer saved measuring results from the CCS 2 to an external
computer.
Data file delete
This mode is to delete complete files of saved measuring results in the file
system and to set time and date.
17
CCS 2
3.3.1.
Maintenance
Setup-menu
Name measure point

After entering the setup-menu this function will automatically be chosen. It is red
highlighted. Enter the name of your measure point by using the key pad (see
key pad use on chapter 3.2.). For erasing a typing error press [ DEL ]. The
characters are limited to the number of 20.
Use for the same measure point always the same name. Otherwise you 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, NAS 1638 or to
SAE AS 4059. Select your report format with the arrow keys [
].
When all functions are adjusted, press [ ENTER ] the get to the next level.
18
CCS 2
3.3.1.1.
Maintenance
Mode: on-line single/ ISO 4406 : 99
Press [ ENTER ] to start the system. After a couple of flushing circuits the
measurement will start. It takes 3 runs. The final result is the average of the
three measurements.
Press [ F2 ] to print the result, [ F1 ] to save it.

If you want to do another single measurement press [ ENTER ].
To leave this mode press [ ESC ].
19
CCS 2
3.3.1.2.
Maintenance
Mode: on-line single/ NAS 1638
three measurements.

20
CCS 2
3.3.1.3.
Maintenance
Mode: on-line single/ SAE AS 4059 : 01
three measurements.

21
CCS 2
3.3.1.4.
Maintenance
Mode: on-line continuous/ ISO 4406 : 99
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!
22
CCS 2
3.3.1.5.
Maintenance
Mode: on-line continuous/ NAS 1638
23
CCS 2
3.3.1.6.
Maintenance
Mode: on-line continuous/ SAE AS 4059 : 01
24
CCS 2
3.3.1.7.
Maintenance
Setup-menu: on-line cyclic/ ISO 4406 : 99
Here you can determine the parameters of the cyclic measurement.
With the arrow keys [

] you can choose the position to change.
The possible values are predetermined. You change the value of the red
highlighted position by using the arrow keys [
].
Cycle period
The time between one measurement and the next one can be selected between
0,5 hours to 24 hours in half hour steps.
Cycle number
The total number of measurements can be chosen two-step-wise from 2 to 100.
Automatic storage
Optionally every cyclic measurement can be saved automatically by setting the
automatic storage to on.
Automatic print out
If you wish a print out of every single result of the cyclic measurement activate
the automatic print out.
Limits
You can supervise the exceeding of certain contamination classes. Set the limit
of a contamination class by using the arrow keys [
].
Each exceeded limit is signalled with a red field on the display in a notice in
between the measurements. A falling below and/or an adherence to the limit
value is on the display shown green. And black it indicates that the counter
channel was not programmed.
Each contamination class limit has its own contact maker and contact breaker
on the jack below the main switch ( see enclosure). When exceeding one of the
limits, its signal changes.
When you have set all parameters press [ ENTER ].
To cancel your settings press [ ESC ].
25
CCS 2
Maintenance
3.3.1.7.1. Mode: on-line cyclic/ ISO 4406 : 99
To start the cyclic measurement press [ ENTER ].

Cycle operation:
The system flushes and then measures three times. The final result of
each cycle is the average of these three.
Between two cycles a notice shows the actual time, the time of the next run, the
number of done cycles and whether the limits got exceeded. When all cyclic
measurements are done, there is a headline on the notice that says
measurement finished.
26
CCS 2
3.3.1.8.
Maintenance
Setup-menu: on-line cyclic/ NAS 1638

] 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
Cycle number
Automatic storage
Automatic print out
Limits
for a contamination class by using the arrow keys [
].
value is green shown the display. And black it indicates that the counter channel
was not programmed.
on the jack below the main switch - wearing off at the steering wheel socket
(see enclosure).
27
CCS 2
Maintenance
3.3.1.8.1. Mode: on-line cyclic/ NAS 1638

Cycle operation:
measurement are done, there is a headline that says measurement finished.
28
CCS 2
3.3.1.9.
Maintenance
Setup-menu: on-line cyclic/ SAE AS 4059 : 01

] 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
Cycle number
Automatic storage
Automatic print out
Limits
for a contamination class by using the arrow keys [
].
value is green shown the display. And black it indicates that the counter channel
was not programmed.
on the jack below the main switch - wearing off at the steering wheel socket
(see enclosure).
29
CCS 2
Maintenance
3.3.1.9.1. Mode: on-line cyclic/ SAE AS 4059 : 01

Cycle operation:
measurement are done, there is a headline that says measurement finished.
30
CCS 2
3.3.2.
Maintenance
Bottle Sampling: 6 channel particle counting
Press [ 1 ] to enter your sample name or the dilution factor.

Press [ 2 ] to start the flushing.
Press [ 3 ] to start the counting.
Name/ dilution
If you do not enter any name, the sample will be named noname.
Use [ DEL ] to empty the field and enter the name of your sample with the key
pad (see key pad use chapter 3.2.). The characters are limited to the number of
15.
31
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 with [2]. On the display you can see the number of
flushing cycles.
To stop the flushing press [ 5 ].
32
CCS 2
Maintenance
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.
33
CCS 2
3.3.3.
Maintenance
File system
Here you can find your saved results.
Choose with the arrow keys [

] the measuring mode of which you want to see
the saved data. The selected mode is red highlighted. Confirm your choice with
[ ENTER ].
3.3.3.1.
Mode: on-line single measurement
Use the arrow keys [

] to select a measurement.
Press [ ENTER ] to get to the results.
Press [ F1 ] to delete this measurement.
3.3.3.1.1. Report format
34
CCS 2
Maintenance
You can choose to see the results according SAE AS 4059 : 01, NAS 1638, the
ISO 4406:87 or the up-to-date version of ISO 4406:99.
Select your format with the arrow keys [
] and confirm with [ ENTER ].
35
CCS 2
3.3.3.1.1.1.
Maintenance
Press [ F2 ] to print the result.

Press [ F1 ] to get a graphic of all single measurements of this measuring run
(only possible if there is more than one measurement).
3.3.3.1.1.1.1.
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.
36
CCS 2
3.3.3.1.1.2.
Maintenance
Mode: single/ NAS 1638

3.3.3.1.1.2.1.
measurements.
37
CCS 2
3.3.3.1.1.3.
Maintenance

3.3.3.1.1.3.1.
measurements.
38
CCS 2
3.3.3.1.1.4.
Maintenance
Mode: single/ SAE AS 4059 : 01

3.3.3.1.1.4.1.
measurements.
39
CCS 2
3.3.3.2.
Maintenance
Mode: on-line continuous measurement

40
CCS 2
Maintenance

] and confirm with [ ENTER ].
41
CCS 2
3.3.3.2.1.1.
Maintenance

Press [ F1 ] to get a graphic of all continuous measurements of this measuring
run (only possible if there is more than one measurement).
3.3.3.2.1.1.1.
Here you get a graphic that shows the trend of all same named continuous
measurements.
3.3.3.2.1.2.
Mode: continuous/ NAS 1638
42
CCS 2
Maintenance

3.3.3.2.1.2.1.
measurements.
43
CCS 2
3.3.3.2.1.3.
Maintenance

3.3.3.2.1.3.1.
measurements.
44
CCS 2
3.3.3.2.1.4.
Maintenance
Mode: continuous/ SAE AS 4059 : 01

3.3.3.2.1.4.1.
measurements.
45
CCS 2
3.3.3.3.
Maintenance
Mode: on-line cyclic measurement

46
CCS 2
Maintenance

] and confirm with [ENTER ].
47
CCS 2
3.3.3.3.1.1.
Maintenance
Press [ F1 ] to get a graphic of all cyclic measurements of this measuring run

3.3.3.3.1.1.1.
Here you get a graphic that shows the trend of all same named cyclic
measurements.
3.3.3.3.1.2.
Mode: cyclic/ NAS 1638
48
CCS 2
Maintenance

3.3.3.3.1.2.1.
measurements.
3.3.3.3.1.3.
49
CCS 2
Maintenance

3.3.3.3.1.3.1. Contamination classes trend

measurements.
50
CCS 2
Maintenance
3.3.3.3.1.4.
Mode: cyclic/ SAE AS 4059 : 01

3.3.3.3.1.4.1. Contamination classes trend

measurements.
3.3.3.4.
Mode: off-line bottle sampling
51
CCS 2
Maintenance

52
CCS 2
Maintenance

] and confirm with [ENTER ].
53
CCS 2
3.3.3.4.1.1.
Maintenance

Press [ F1 ] to get a graphic of all bottle sampling measurements of this
measuring run (only possible if there is more than one measurement).
3.3.3.4.1.1.1.
Here you get a graphic that shows the trend of all same named bottle sampling
measurements.
3.3.3.4.1.2.
Mode: bottle sampling/ NAS 1638
54
CCS 2
Maintenance

3.3.3.4.1.2.1.
measurements.
55
CCS 2
3.3.3.4.1.3.
Maintenance

3.3.3.4.1.3.1.
measurements.
56
CCS 2
3.3.3.4.1.4.
Maintenance
Mode: bottle sampling/ SAE AS 4059 : 01

3.3.3.4.1.4.1.
measurements.
57
CCS 2
3.3.4.
Maintenance
Data transfer
This mode is to transfer saved measuring results from the CCS 2 to an external
computer using the data manager. Therefore the CCS 2 has to be connected to
the external computer (RS 232 on the CCS 2).
Confirm with [ ENTER ] to get the CCS 2 ready for transferring the data. The
data manager has to be installed on the external computer according to the
instructions in chapter 3.8.
58
CCS 2
3.3.5.
Maintenance
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.
59
CCS 2
3.3.5.5.
Maintenance
Setup - menu: date/ time
] 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 ].
60
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)
3.4. Instructions in brief for the on-line determination of the

1.
Connect the oil discharge hose with the quick acting closure to the CCS 2
and put the other end into an oil tank.
2.
One side of the high pressure measuring hose (mini measuring M 16x2)
has to be connected to the input of the CCS 2.
3.
The second side of the high pressure measuring hose has to be connected
with the measuring connection of the examined system.
4.
Build up the electric mains connection (8 to 15 V DC; 90 to 250 V AC, 50/

60 Hz).
5.
Switch on the CCS 2 (green control diode gives light).
6.
Confirm with [ ENTER ] to get to the online measuring setup-menu:
61
CCS 2
Maintenance
7.
Name measure point

Enter the name of your measurement by using the key pad.
Go on with the arrow keys [
].
8.
Single, continuous or cyclic measurement

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

Select with the arrow keys [
] the report format that you want to use
for analysing the results.
10. Press [ ENTER ] to get to the next level.
11.1
Single measurement
Press [ ENTER ] to start the measurement.
Afterwards you can save and print the result.
11.2
Continuous measurement
Press [ ENTER ] to start the continuous measurement.
To stop it press [ ESC ]. Now you can print the last result.
11.3
-
Cyclic measurement
] 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 ].
62
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)
3.5. Instructions in brief for the off-line determination of the

1.
Connect the oil discharge hose with the quick acting closure to the CCS 2
and put the other end into an oil tank.
2.
Build up the Bottle Sampling System respectively the Tank Sampling

System according to its manual.
3.
One side of the high pressure measuring hose (mini measuring M 16x2)
has to be connected to the input of the CCS 2.
4.
The second side of the high pressure measuring hose has to be connected
with the measuring connection of the Bottle Sampling System respectively
the Tank Sampling System.
5.
Build up the electric mains connection of the CCS 2 (8 to 15 V DC; 90 to

250 V AC, 50/ 60 Hz).
6.
Switch on the CCS 2 (green control diode gives light).
7.
Select Offline particle counting on the main menu.

Confirm with [ ENTER ].
8.
Enter the sample name and the dilution factor.
9.
Get the BSS resp. the TSS ready for measuring (according to its manual).
10. Press [ 2 ] to flush the system before measuring.

To stop the flushing press [ 5 ] again.
11. Press [ 3 ] to start the measurement.
After the measurement you can save and print the result.
63
CCS 2
Maintenance
3.6. Printer
3.6.1.
Change of the printer ribbon
1. Open the front cover of the printer.

2. Push in the cartridge on the labelled spot so that the opposite side of the
printer ribbon loosens from the motor shaft.
3. Take the cartridge out.
4. Tighten the printer ribbon of the new cartridge by turning the rotary knob like
the arrow shows.
5. Put the cartridge back in the mounting and bring the visible part of the printer
ribbon in the slit where the paper is. The visible part of the printer ribbon has
to be above the paper.
6. If necessary, tighten the printer ribbon again.
64
CCS 2
3.6.2.
Maintenance
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.
65
CCS 2
Maintenance
3.7. Implementing a new program version from a Laptop or PC

For implementing a new program to the CCS 2 the DOS program filelink is
required. You find it on the data manager diskette. Please install the program on
the laptop or computer that you want to use for the transfer.
1.
Switch on the CCS 2.
2.
Leave the main menu with [ ESC ].
3.
Press [ F1 ] to start the filelink program.
4.
Confirm the first page with [ ENTER ].
5.
Select the slave mode and confirm.
6.
Allow the program to overwrite files.
7.
Connect the CCS 2 and your computer or laptop with an interface cable
(RS 232 interface on the CCS 2).
8.
Start your computer or laptop.
9.
Copy the new CCS 2 program into the same path as the filelink.exe.
10. Start the filelink.exe on your computer or laptop.

11. Confirm the first page with [ ENTER ].
12. Select the setup menu and confirm.
13. Check the current setup options. You need the serial port, the baud rate
has to be on 115200. Correct the options if necessary. Go back to the last
screen.
14. Enter the master mode.
15. Select the new program for the CCS 2 on the left side and mark it with
[ SPACE ].
16. Copy the files to the CCS 2 with [ ALT ] + [ c ].
17. Wait while transferring the program.
18. When the transfer is finished exit the filelink program on your computer or
laptop. Switch off the CCS 2. Now you can start the CCS 2 as regular.
66
CCS 2
Maintenance
3.8. The data manager

The data manager enables the external administration of data from the CCS 2.
To be able to use this program at least Office 97 resp. Excel 97 is required.
Install these files:
1.
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_DATMA02_E.XLS
6. WINCOMM.EXE
For the evaluation after SAE AS 4059 you need the following files from the sub
file folder "SAE_Manager":
7.
CCS2_Datsae01_d.XLS
9.
CCS2_Datsae01_e.XLS
10.
CCS2_Datsae02_e.XLS
of the CD-ROM into a new folder in your PC.
You have to write the path of that folder in the menu of Excel at Accessory/
Options/ General as path of the standard folder. This adjustment just has to
be done once.
Connect the external computer with the CCS 2 (RS 232 interface at CCS 2).
Start the main menu of the CCS 2.
Choose the data transfer option and confirm with [ ENTER ]. The CCS 2 is
now ready for data transfer.
Start on your computer the file version you needed. (see above)
Excel starts automatically.
Activate the macros, so that the data manager gets opened.
Press the button of the file of which you want to transfer the data.
The data get loaded into the Data import table.
Now you can copy the data into a self-made Excel or Word document or you
can use the prepared graphic functions of the data manager to demonstrate
the counting results and contamination classes.
67
CCS 2
4.
Malfunctions/ troubleshooting
Malfunctions / troubleshooting
Malfunctions
System switched
on, no function,
control lamp out
control lamp on,

display does not
work
5.
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
Service / maintenance
To guarantee the accuracy of the measuring results of the CCS 2 the integrated
laser sensor has to be calibrated yearly through INTERNORMEN Technology
GmbH. With the calibration all necessary maintenance and service workings,
that exceed the outside cleaning, will be done. Only competent staff of
INTERNORMEN Technology GmbH is allowed to open the CCS 2!
Outside cleaning
The outside cleaning of the CCS 2 takes place through the user when there is a
certain contamination.
Attention:
Do not use any aggressive media!!!
For the housing you can use a rag with wash benzine. Make sure that no
benzine gets on the control panel!
The keypad and the printer housing should be cleaned with a rag that is lightly
soaked with water. Switch off the CCS 2 before cleaning!
The display cover is made out of plexiglass and is antireflective. Do use no
chemicals except for water or glass cleaner! Switch off the CCS 2 before
cleaning!
68
CCS 2
6.
Switch off CCS 2
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.
69
CCS 2
Enclosure
7.
Enclosure
7.0 Enclosure
7.0
Enclosure
70
Enclosure A Technical Data
CCS 2
Technical Data
General technical Data:
Power supply:
12 V DC, 35 VA
External power supply unit:
100 ... 240 V AC/ + 12 V DC/ 5 A, 50/ 60 Hz
Battery charger:
100 ... 240 V, 50/ 60 Hz
Internal battery:
12 V
Protection:
f1: 3,15 AT regular use

f2: 3,15 AT battery loading
Protection class
IP 40
Dimensions (mm):
(inch):
l x
450
17,7
Weight:
10,8 kg
Principle of measurement:
particle counting according to the light blockade

principle
w
x
x
x
180
7
h
x
x
255
10
Proceeding of measurement: automatic particle counting

Particle sizes:
> 4 m(c), > 4,6 m(c), > 6 m(c), > 6,4 m(c),
> 10 m(c), >14 m(c), > 21 m(c), > 38 m(c).
Representation of the CC:
ISO
Proceeding of calibration:
ISO MTD in oil (ISO 11171:2000)
4 24, NAS 00 12, SAE 000 - 12
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.
71
CCS 2
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)
Oil temperature range:
0.-.80C (176F)
Ambient temperature range: 0 - 50C (122F)

Internal temperature range:
0 - 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, beam

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

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

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

coupling M 16x2, 1 x connector coupling for
hose DN 6
Further serial equipment:
external power supply unit, battery charger,

high pressure hose, discharge hose,
Datamanger (software disc)
Display:
active LCD - colour display
Computer interface:
RS 232 connection (for external computer

coupling)
72
CCS 2
connection:
control outlet
panel jack
(external view)
K2
K1
(contact maker)
Relay - contact designation:
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
Limiting value:
> 6 m / limiting value 15 ... 25 m:
K1 : 5
K2 : 6
K3 : 4
Limiting value:
> 14 m / limiting value 25 50 m:
K1 : 8
K2 : 9
K3 : 7
Connector plug:
type
Lemosa
FFA 310.CLAD 927
73
CCS 2
Area of use - digestibility CCS 2

A:
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
B:
reduced usable
C:
not usable
1. organic ester (HFD-U)
1. gear oil with MoS2-additive
2. phosphate ester (HFD-R)

3. polyglycole (PEG) (HPG)
4. fresh water, process
water, etc.
5. other hydraulic fluids
based on MILspecifications
2. oil in water emulsion (HFA)

3. coulant, aqueous
6. oils on vegetable basis

(HTG, Triglyzeride)
4. surface water
5. corrosion protecting oils with
wax and paraffin contents
6. heavy oils
ISO-VG-320
7. general oils with H2Ocontents 500 ppm

8. water - glycol (HFC)
7. synthetic ester (HEES)

8. ATF-fluids
Explanations
ad 1. hydraulic oils HLPD
are used to disperse water
contents (D-additive). At
determined water
dispersions these oils are
no more measurable.
ad 4. engine oils with solid
wear additives (MoS2 etc.)
are not measurable.
ad 6. with increasing
hydrolysis HTGs
(vegetable oils) are no
more measurable, as they
then get a 2-phase-fluid
(fatty acid + glycerine).
Danger of clogging!
ad 1. no problems with HFD- ad 1. typical fluid charged with

U-fluids in pure state.
fine dispersed solid particles
With water contents or
which are counted and
residual oil contamination
registered as particles.
measurings are
impossible. Special
ad 2. typical 2-phase-fluid in
calibration necessary.
which the oil driplets are
registered as particles.
ad 2. generally HFD-R-fluid
cannot be measured
because of insufficient
compatibility of all
components.
ad 3. polyglycole (PEG,
HPG) is measurable,
however, when changing
the type of oil a thorough
flushing has to be come.
Special calibration
necessary!
ad 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.
ad 4. water. Normal spring
water can have different
compositions. The partly
rather high calcic contents
leads to a quick failure of ad 7.
the system.
because of too high

viscositys heavy oils
VG-320 cannot get
measured.
ISO-
water contamination will be

registered and counted as
particle. In addition: danger
of corrosion
ad 8. HFC-fluid is a typical 2phase-fluid with partly

extreme creation of cloudly
stains
74
Enclosure B Contamination classes according to ISO 4406
CCS 2
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
75
Enclosure C Cleanliness classes according to NAS 1638
CCS 2
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 m
00
0,125
0,022
0,004
0,001
0,250
0,044
0,008
0,002
0,5
0,089
0,016
0,003
0,001
0,178
0,032
0,006
0,001
0,356
0,063
0,011
0,002
0,712
0,126
0,022
0,004
1,425
0,253
0,045
0,008
16
2,85
0,506
0,090
0,016
32
5,7
1,012
0,18
0,032
64
11,40
2,025
0,36
0,064
128
22,8
4,05
0,72
0,128
10
256
45,6
8,1
1,44
0,256
11
512
91,2
16,2
2,88
0,512
12
1024
182,4
32,4
5,76
1,024
76
Enclosure D Cleanliness classes according to SAE AS 4059
CCS 2
Cleanliness classes according to SAE AS 4059

Analysis volume:
100 ml
Particle per 100 ml

Size, ISO
11171
Calibration or > 4 m ( c )
Electron
Microscope
Size Code
> 6 m ( c ) > 14 m ( c ) > 21 m ( c ) > 38 m ( c ) > 70 m ( c )
000
195
76
14
00
390
152
27
780
304
54
10
1560
609
109
20
3120
1220
217
39
6250
2430
432
76
13
12500
4860
864
152
26
25000
9730
1730
306
53
50000
19500
3460
612
106
16
100000
38900
6920
1220
212
32
200000
77900
13900
2450
424
64
400000
156000
27700
4900
848
128
10
800000
311000
55400
9800
1700
256
11
1600000
623000
111000
19600
3390
512
12
3200000
1250000
222000
39200
6780
1020
77
CCS 2
Enclosure E
System type /
Range of
application
according to
standards
against fine soiling
and mudding-up of
sensitive systems
needed contamination classes
filter
fineness
ISO 4406:99
NAS 1638
SAE AS 4059
16/ 12/ 8
2-3
3/ 0/ 00/...
17/ 13/ 9
34
4/ 1/ 0/...
lab, aviation and

aerospatial
heavy-duty servo
systems, high
pressure systems
with long service life
19/ 15/ 11
46
6/ 3/ 2/...
aviation, machine
tool, controlling
proportional valves industrial hydraulic
with high operating
safety
20/ 16/ 13
7-8
7/ 4/ 4/...
10
22/ 18/ 15
7-9
9/ 6/ 6/...
15
23/ 19/ 15
9 - 11
10/ 7/ 6/...
20
lab, aviation and

aerospatial
against fine soiling
and mudding-up of
sensitive systems
higher mobile
hydraulic
mobile hydraulic,
common
mechanical
engineering,
medium pressure
system
mobile hydraulic
heavy industry, low
pressure system
mobile hydraulic,
water hydraulic
200
x (c)
78
CCS 2
Enclosure F
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)
Data manager CD-ROM
Instruction manual
Two paper rolls
Printer ribbon
Calibration certificate
Article no.:
322647
320595
320444
323884
324751
314462
320600
313742
324060
327284
320598
322489
316379
after annual
maintenance/
calibration at
INTERNORMEN
Technology GmbH
79
North America HQ
70 Wood Ave., South, 2nd Floor
Iselin, NJ 08830
Toll Free: (800) 656-3344
(North America Only)
Voice: (732) 767-4200
China
No. 3, Lane 280, Linhong Road
Changning District, 200335
Shanghai, P.R. China
Voice: +86-21-5200-0099
Singapore
4 Loyang Lane #04-01/02
Singapore 508914
Voice: +65-6825-1668
Europe/Africa/Middle East
Friedensstrae 41
D-68804 Altlussheim, Germany
Voice: +49-6205-2094-0
Auf der Heide 2
53947 Nettersheim, Germany
Voice: +49-2486-809-0
An den Nahewiesen 24
55450 Langenlonsheim, Germany
Voice: +49 6704 204-0
Brazil
Av. Julia Gaioli, 474
Bonsucesso
07251-500 Guarulhos, Brazil
Voice: +55 (11) 2465-8822
For more information, please e-mail us at

filtrationinfo@eaton.com
Visit us online eaton.com/filtration for a complete
list of Eatons filtration products.
2012 Eaton Corporation. All Rights Reserved.
All trademarks and registered trademarks are the property of their respective
owners. Litho USA.
All information and recommendations appearing in this brochure concerning the

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

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CCS 2

CONTAMINATION CONTROL SYSTEM

Danger through maloperation

Safety arrangements on site

Connection of the system

Weight and dimensions

Control panel and key pad use

On-line particle counting

Mode: on-line single/ ISO 4406 : 99

Mode: on-line single/ NAS 1638

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

Mode: on-line continuous/ ISO 4406 : 99

Mode: on-line continuous/ NAS 1638

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

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

Mode: on-line cyclic/ ISO 4406

Off-line particle counting

Mode: on-line single measurement

Data file delete

Setup - menu: date/ time

Instructions in brief for the on-line determination of the

Instructions in brief for the off-line determination of the

Change of the printer ribbon

Implementing a new program version from a Laptop or PC

The data manager

6. SWITCH OFF CCS 2

1.1. Danger through maloperation

1.2. Proper use

(22 6090 PSI)

1.3. Sources of danger

1.4. Service staff

hand over the maintenance instruction to the user

1.5. Safety arrangements on site

1.6. Protection device

2.1. Electrical connection

External power supply unit

The CCS 2 has an integrated rechargeable battery.

It allows without printing about 250 continuous measurements (1 hour

Printing during battery operation shortens the running time extremly.

Unloading of the rechargeable batteries:

Loading of the rechargeable batteries with the provided battery charger:

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

After completion of the loading procedure:

Electrical connection values

With the external power

f1: 3,15 AT regular use

2.2. Connection of the system

Otherwise the CCS 2 will run with battery!

2.3. Weight and dimensions

If the measuring and control program has been ended deliberately

English demo version:

German real version:

German demo version:

(Input of new program versions look at chapter 3.7.)

3.1. General information

Advantages of this measuring procedure:

Depending on your specifications different measuring programs can be used.

3.2. Control panel and key pad use

numbers and letters

Keys for device and menu control:

Keys for the measuring point control:

Input of numbers and letters

3.3. Main menu