table of contentsc3%c0%b9%fa... · (extended maintenance intervals and mounting cost pressure)....

SCHROEDER INDUSTRIES LLC 1

Table of Contents

Definition of Contamination Management . . . . . . . . . . 3

Contamination Management Basics . . . . . . . . . . . . . . . . 4

Classification of Particulate Contamination in Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Determining the Residual Dirt Quantity of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SMART® Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Analysis of the Cleanliness of Systems on the Flushing/Test Stand . . . . . . . . . . . . . . . . . . . . . . . 16

Contamination Monitoring . . . . . . . . . . . . . . . . . . . . . . . 18

Sources of Contamination in the Manufacturing and Assembly of Hydraulic Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Contamination Management in Practice . . . . . . . . . . . . 29

TestMate® SeriesTCM TestMate® Contamination Monitor . . . . . . . . . . . . . . . 30

TCM-FC TestMate® Flow Conditioning Manifold . . . . . . . . . 31

TMU TestMate® Monitoring Unit . . . . . . . . . . . . . . . . . . . . 34

SMART® Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

TPM TestMate® Particle Counter . . . . . . . . . . . . . . . . . . . . . 38

TIM TestMate® In-Line Counter . . . . . . . . . . . . . . . . . . . . . . 40

CTU TestMate® Contamination Test Unit . . . . . . . . . . . . . . . 42

TWS-C TestMate® Water Sensor . . . . . . . . . . . . . . . . . . . . . 44

ET-100-6 “Original” TestMate® . . . . . . . . . . . . . . . . . . . . . . 46

HMG 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

EasyTestTM SeriesEWC EasyTest™ Water Contamination Sampler . . . . . . . . . . 52

EPK EasyTest™ Patch Test Kit . . . . . . . . . . . . . . . . . . . . . . . 54

HTB Hydraulic Test Bench . . . . . . . . . . . . . . . . . . 56

GS Multi-Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Trouble Check PlusTM Fluid Analysis . . . . . . . . 60

Schroeder Check® Test Point SystemTest Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

JIC Male/Female In-Line Test Points . . . . . . . . . . . . . . . . . . . 63

Direct Gauge Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Gauge to Hose Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Change-Over Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Hose Joiners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Microflex™ Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Adjustable Pressure Limiters . . . . . . . . . . . . . . . . . . . . . . . . . 65

Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Schroeder Pressure Test Kits . . . . . . . . . . . . . . . . . . . . . . . . . 66

Schroeder Custom Test Kits . . . . . . . . . . . . . . . . . . . . . . . . . 66

ProbalizerTM Sampling Test Point . . . . . . . . . . . 67

DiagnosticProductsNEW

PRODUCT

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液压油污染检测专家--美国SCHROEDER

中国总代理：上海巍科机电设备有限公司 TEL: 021-54486710 FAX:021-54486711 Http://www.shweike.com

2 SCHROEDER INDUSTRIES LLC

AFM Auto Flush Filter Cart . . . . . . . . . . . . . . . . . . . . . . . . . 68

MSS, MSD, MFS, MFD Mobile Filtration Systems . . . . . . . . 70

AMS, AMD Air-Operated Mobile Filtration Systems . . . . . . 72

KSS, KSD, KLS, KLD, Kidney Loop Systems . . . . . . . . . . . . . 74

AKS, AKD Air-Operated Kidney Loop Systems . . . . . . . . . . 76

KLC Kidney Loop Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 78

X Series Filter Skids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

X Series Filter Skids – High Viscosity . . . . . . . . . . . . . . . . . . 83

HFS Handy Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 84

MTS Membrane Technology Systems . . . . . . . . . . . . . . . . . 85

SVD Vacuum Dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Comparison Photographs for Fluid Contamination Class . . . 91

Contamination Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Contamination Classification According to

NAS 1638-01/1964 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Contamination Classification According to SAE AS4059: D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Viscosity Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Contamination Classification in Accordance

with ISO 4406:1999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Reference List . . . . . . . . . . . . . . . . . . . . . . . . inside back cover

Table of Contents (cont.)

FluidConditioning

Products

Appendix

NEWPRODUCT

NEWPRODUCT




Definition of Contamination Management

Contamination management pertains to the analysis and optimization of processes with regard to thecleanliness of components, systems and the purity of the fluids used. In today’s hydraulic systems, thehydraulics and mobile hydraulics industry, smaller, lighter and more powerful components are currently beingused compared to 10 years ago. The use of these components also means that the demand of systemcleanliness is now much higher, as has been shown by various studies.

As much as 90% of all hydraulic system outages is due to increased contamination. This failure rate applies to more than classic hydraulics industry. Contamination Management is also a key issue in the automotiveindustry, in which the use of electrohydraulic systems is on the rise. In this context, hydraulic or fluid powersystems are used in a general sense for all industries.

In the past, fluid power systems were equipped with system filtration, which cleaned the system duringcommissioning and then had the task of maintaining system fluid cleanliness at a constant level, e.g. by usingcommissioning filters and initial brief maintenance intervals followed by changing over to system filtration. This approach frequently no longer suffices due to the growing demands made of today’s hydraulic systems(extended maintenance intervals and mounting cost pressure). Precommissioning flushing is performed in largesystems in the hydraulics industry to quickly bring the contamination down to an acceptable level.

However, in small, mass-produced hydraulic systems this is not always possible. That is why contaminationmanagement begins with the manufacturing of individual components and extends throughout the entireprocess up to and including the finished component. Ideally, the design and development departments areintegrated in this process so that component design facilitates the washing of components in a cost-efficientmanner. Suppliers also have to be involved in contamination management when the manufacturing processinvolves a large portion of sourced components. By introducing contamination management to minimizeparticulate concentration in all areas, beginning with manufacturing and extending to the operation of theentire system, system malfunction and failure caused by particulate contamination can be prevented. As aresult, costs savings are achieved. Cutting the costs of machining tools, improving the utilization of teststations, and optimizing the use of washing machines can help do this.

This results in the following contamination management tasks: development of systems which are optimizedso as to facilitate cleaning, optimizing and monitoring washing and flushing processes, training employees and raising their awareness, detecting and eliminating sources of contamination, drafting analysis instructions,and drafting cleanliness specifications for components and systems. An overall cost assessment is done togauge the success of contamination management. Consider the following factors: warranty and non-warrantycourtesy work, energy costs, reworking costs, operating costs of washing machines and test stations,machining tool costs, and labor costs.

Contamination ManagementMonitoring/optimization of cleanliness in material flows and system assembly

Fluid Power SystemHydraulic systems, including automotive systems containing fluid fillings

Basic ContaminationQuantity of contamination present subsequent to assembly

Ingress ContaminationParticulate contamination caused by ingression

Initial DamageDamage to surfaces caused during function testing/commissioning/assembly of systems

Contamination MonitoringAnalysis of processes with regard to the ingress of dirt caused by them

Online Measurement Measurement process which the sample to be analyzed is process fed to a measurement device directly from the system

Offline Measurement Measurement process in which the sample is taken from the process system and analyzed elsewhere, e.g. taking an oil sample and sending it in to a laboratory

Definitions




Contamination Management Basics

Various types of contamination occur in fluid power systems: gaseous (e.g. air), liquid (e.g. water) and solidcontaminants. An overview of the various contamination types is shown in the following diagram.

As you can tell from examining Figure 1, solid contamination is subdivided into three groups: extremely hard,hard and soft particles. Extremely hard particles can cause substantial damage in fluid power systems if they are not removed as quickly as possible. Preventive measures can reduce the ingress of contaminants in systems.

Figure 1. Types of Contamination

Hard particles are frequently listed separately in specifications. Maximum values are specified for thelongest dimension these hard particles may have, e.g. largest abrasive particle: max. 200 µm or 200 x90 µm or no particles > 200 µm.

Not only the hardness of contamination particles play a role but also their number and size distributionas well.

The particle size distribution in new systems is different from that of systems that have been in operationfor a number of hours. In new systems, there is an accumulation of coarse contaminants up to severalmillimeters long, which are then increasingly reduced in size in the course of operation or eliminated byfiltration. After several hours of operation most particles are so small that they are no longer visible tothe naked eye.

When commissioning fluid power systems there is additional particulate contamination by virtue ofabrasive wear in which rough edges are worn away through running-in. Contamination managementcan’t prevent this ingress of contaminants; however, if basic contamination is lower, there is less abrasionduring system startup.

Contamination Types

Effect




Contamination Management Basics

As Figure 2 shows, the level of contamination without contamination management is higher throughoutsystem operation as compared to a system in which contamination management is employed, the resultbeing that more initial damage may be caused to surfaces.

Figure 2. Cleaning of a Fluid Power System With and Without Contamination Management

Microscope images show typical particle samples, containing fine particles, as occur in fluid power systems.(Figure 3)

Figure 3. Typical Particle Samples

An average healthy human eye can see items down to approximately 40 µm in size. Particle analyses areconducted using a microscope or in fluid power systems using particle counters employing the lightextinction principle. (Figure 4)

Figure 4. Sizes of Known Particles in Inches and Microns




Consequences of Particulate Contamination

in Fluid Power Systems

Particulate contaminants circulating in fluid power systems cause surface degradation through generalmechanical wear (abrasion, erosion, and surface fatigue).

This wear causes increasing numbers of particles to be formed, the result being that wear increases if the“chain reaction of wear” is not properly contained (by reducing contamination).

Gaps grow larger, leakage oil flows increase in size, and operating efficiency (e.g. of pumps) decreases.Metering edges are worn away, thus resulting in control inaccuracies. In some cases, blockage of control ducts or nozzle bores occurs.

The chain reaction of wear during the everyday operation of hydraulic systems has to be interrupted byproperly designed and dimensioned filter systems. However, the measure of security afforded the user isdeceptive as highly damaging contaminants seep in during component and system assembly and systeminstallation. This ingress of contaminants not only can cause preliminary damage to system components butalso premature failure as well.

Generally speaking, system filtration concepts are not designed to adequately deal with large quantities of dirt as occur in connection with:

Component machining System assembly System filling

Commissioning System repair work

A study conducted by the University of Hanover describes the factors impacting the fatigue life of rollerbearings as follows: “The quantity of contamination in the lubricant is described by the particle quantity and size. Combining this with particle hardness and geometry results in the type and extent of damage toraceways, with the extent also being affected by the elasto-plastic behavior of the material. The amount ofdamage is determined by the quantity of particles in the lubrication gap and the rollover frequency. Continuedrollover leads to cracking, which in the form of fatigue damage (pitting) leads to roller bearing damage(bearing failure).”

In practice ball bearings with their punctiform contact are shown in most cases to be less sensitive toparticulate contamination than roller bearings with their linear contact. Friction bearings with their largerlubrication gaps are the least sensitive to particulate contamination.

Figure 5. Examples of Wear to Movable Surfaces

Figure 6. Factors Affecting Roller Bearing Life




The table to the right provides an overview of the most common gap sizes illustrated in Figure 7.

Comprehensive studies of particle distributions oncomponents and in hydraulic systems have shownthat at the beginning of a system’s life, i.e. duringassembly and commissioning, the particles are largerthan during subsequent operation.

These large particles – up to several millimeters in size in part – can cause spontaneous outages: valve blockages, substantial preliminary damage to pumps, and destruction of seals and gaskets followed by leakage.

Active contamination management enables this rate can be reduced and costs accordingly cut, i.e.:

Costs caused by production stops

Costs caused by delays in commissioning systems

Costs incurred by longer testing periods since a flushing cycle is required to remove integral contamination

Warranty costs

Reworking costs

Contamination management counters the situation as follows: In new systems the individual components are brought to a uniform cleanliness level, the filling fluid is kept at a defined level, as is the fluid during system operation.

Figure 7

Figure 8

Destroyed raceway of a ball bearing caused byparticulate contamination

Figure 9

Embedded in the surface ofa friction bearing

Component Typical CriticalClearance (µm)

1. Gear Pump (J1, J2) 0.5 - 5

2. Vane-cell Pump (J1) 0.5 - 5

3. Piston Pump (J2) 0.5 - 1

4. Control Valve (J1) 5 - 25

5. Servo Valve (J1) 5 - 8



This international standard describes the gravimetric method for determining the particulate contamination ofhydraulic fluids.

Basic principle

A known volume of fluid is filtered through one or two filter disks using vacuum action and the weightdifferential of the filter disks (upstream and downstream of filtration) measured. The second membrane is usedfor evaluating accuracy.

In order to determine the gravimetric contamination of the fluid, a representative sample has to be taken fromthe system. ISO 4405 describes the cleaning procedure for the equipment being used. It also describes thepreparatory procedures for the analysis membranes.

The membranes are flushed with isopropanol prior to use, dried in a drying oven until they achieve a constantweight, and then cooled in a defined dry environment. It is important that cooling takes place in a defined dryenvironment, otherwise the membrane absorbs moisture from the surroundings, thus skewing the final result.

Afterwards the membrane is weighed and this value recorded as m (T).

The membranes are then fixed in the membrane retainer and the fluid undergoing analysis is filtered. This isfollowed by flushing off the contaminant on the membrane using filtered solvent to completely remove thecontaminant. When analyzing oil-laden fluids it is important that the remaining oil is completely flushed offthe membrane.

This is followed by drying the membrane, cooling, and weighing it (as described above). The measured value isnow recorded as m (E).

Gravimetric contamination is calculated as follows: M(G) = m(E) – m(T)


Classification of Particulate Contamination in Fluids

The objective of the procedures described below is to enable a reproducible classification of particulatecontaminants in fluids.

Currently there are 4 procedures for classifying particulate contaminants in fluids: ISO 4405, ISO 4406:1999, NAS 1638, SAE AS 4059 (see chart below)

Standard ISO 4405 ISO 4406:1999 NAS 1638 SAE AS 4059

Application

Highly contaminatedmedia, e.g. washing Hydraulic fluids Hydraulic fluids Hydraulic fluidsmedia, machining Lubrication oils Lubrication oils Lubrication oilsfluids

Number of particles Number of particles Number of particles > 4 µm(c) 5 - 15 µm > 4 µm(c)> 6 µm(c) 5 - 25 µm > 6 µm(c)

Parameters (mg/liters of fluid) > 14 µm(c) 25 - 50 µm > 14 µm(c)50 - 100 µm > 21 µm(c)

> 100 µm > 38 µm(c)> 70 µm(c)

1. Manual evaluation:The fluid undergoing analysis is filtered through a preparedmembrane and the cleanliness class (contamination rating)estimated or counted by hand using a microscope.

2. Automated particle counting:The fluid undergoing analysis is conducted through a particlecounter, which tallies the particle fractions.

1. Manual evaluation: Very time-consuming, not very exact.

2. Automated particle counting: Result available almost immediately.

AnalysisMethods

In this lab method,1 liter of the fluidundergoing analysisis filtered through aprepared membrane,which is thenweighed

VeryRemarks time-consuming

method

ISO 4405 – “Hydraulic Fluid Power – Fluid

Contamination –Determining Particulate

ContaminationEmploying Gravimetric

Analysis Methods”



Allocation of Particle Counts to Cleanliness Classes

No. of Particles /ml CleanlinessOver Up to Class

1,300,000 2,500,000 > 28640,000 1,300,000 > 27320,000 640,000 > 26160,000 320,000 > 2580,000 160,000 > 2440,000 80,000 > 2320,000 40,000 > 2210,000 20,000 > 215,000 10,000 > 202,500 5,000 > 191,300 2,500 > 18

640 1,300 > 17320 640 > 16160 320 > 1580 160 > 1440 80 > 1320 40 > 1210 20 > 115 10 > 102.5 5 > 91.3 2.5 > 8

In ISO 4406, particle counts are determined cumulatively, i.e. > 4 µm(c), > 6 µm(c) and > 14 µm(c) (manually by filtering the fluid through an analysis membrane or automatically using particle counters) and allocated tomeasurement references.

The goal of allocating particle counts to references is to facilitate the assessment of fluid cleanliness ratings.


ISO 4406: 1999

Figure 10. Microscopic Examination of an OilSample (100 ml) Magnification 100x (ISO 18 /15 /11)

If the number of particles counted in the sample islarger than 20, the result has to be reported with ≥.

Note: increasing the measurement reference by 1causes the particle count to double.

Example: ISO class 18 / 15 / 11 says that thefollowing are found in 1 ml of analyzed sample:

1,300 - 2,500 particles > 4 µm(c)160 - 320 particles > 6 µm(c)10 - 20 particles >14 µm(c)



Like ISO 4406, NAS 1638 describes particle concentrations in liquids. The analysis methods can be applied inthe same manner as ISO 4406:1987.

In contrast to ISO 4406, certain particle ranges are counted in NAS 1638 and attributed to measurementreferences.

The following table shows the cleanliness classes in relation to the particle concentration analyzed.

Particle Size (um)5-15 15-25 25-50 50-100 >100

No. of Particles in 100 ml Sample

00 125 22 4 1 0

0 250 44 8 2 0

1 500 89 16 3 1

2 1,000 178 32 6 1

3 2,000 356 63 11 2

4 4,000 712 126 22 4

5 8,000 1,425 253 45 8

6 16,000 1,850 506 90 16

7 32,000 5,700 1,012 180 32

8 64,000 11,600 2,025 360 64

9 128,000 22,800 4,050 720 128

10 256,000 45,600 8,100 1,440 256

11 512,000 91,200 16,200 2,880 512

12 1,024, 000 182,400 32,400 5,760 1,024

Increasing the class by 1 causes the particle count to double on average.

The particle counts of class 10 are bold-faced in the above table.

Figure 11. Microscopic Examination of an Oil Sample (100 ml) Magnification 100x (NAS 10)


NAS 1638

Cle

an

lin

ess

Cla

ss




Like ISO 4406 and NAS 1638, SAE AS 4059 describes particle concentrations in liquids. The analysis methodscan be applied in the same manner as ISO 4406:1999 and NAS 1638.

The SAE cleanliness classes are based on particle size, number and distribution. The particle size determineddepends on the measurement process and calibration; consequently the particle sizes are labeled with letters (A - F).

The SAE cleanliness classes can be represented as follows:

1. Absolute particle count larger than a defined particle sizeExample: Cleanliness class according to AS 4059:6The maximum permissible particle count in the individual size ranges is shown in the table in boldface.Cleanliness class according to AS 4059:6 BSize B particles may not exceed the maximum number indicated for class 6.6 B = max. 19,500 particles of a size of 5 µm or 6 µm (c)

2. Specifying a cleanliness class for each particle sizeExample: Cleanliness class according to AS 4059: 7 B / 6 C / 5 DSize B (5 µm or 6 µm(c)): 38,900 particles / 100 mlSize C (15 µm or 14 µm(c)): 3,460 particles / 100 mlSize D (25 µm or 21 µm(c)): 306 particles / 100 ml

3. Specifying the highest cleanliness class measuredExample: Cleanliness class according to AS 4059:6 B – FThe 6 B – F specification requires a particle count in size ranges B – F. The respective particle concentrationof cleanliness class 6 may not be exceeded in any of these ranges.

Maximum Particle Concentration* (particles / 100 ml)

Size ISO 4402 Calibration or Visual Counting > 1 µm > 5 µm > 15 µm > 25 µm > 50 µm > 100 µm

Size ISO 11171,Calibration or > 4 µm(c) > 6 µm(c) > 14 µm(c) > 21 µm(c) > 38 µm(c) > 70 µm(c)Electron Microscope**

Size Coding A B C D E F

000 195 76 14 3 1 0

00 390 152 27 5 1 0

0 780 304 54 10 2 0

1 1,560 609 109 20 4 1

2 3,120 1,220 217 39 7 1

3 6,250 2,430 432 76 13 2

4 12,500 4,860 864 152 26 4

5 25,000 9,730 1,730 306 53 8

6 50,000 19,500 3,460 612 106 16

7 100,000 38,900 6,920 1,220 212 32

8 200,000 77,900 13,900 2,450 424 64

9 400,000 156,000 27,700 4,900 848 128

10 800,000 311,000 55,400 9,800 1,700 256

11 1,600,000 623,000 111,000 19,600 3,390 1,020

12 3,200,000 1,250,000 222,000 39,200 6,780

Table shows the cleanliness classes in relation to the particle concentration determined.

*Particle sizes measured according to the longest dimension.

**Particle sizes determined according to the diameter of the projected area-equivalent circle.

SAE AS 4059




A representative sample is taken of the fluid and analyzed as follows:

1. Manual procedure according to ISO 4407 (Hydraulic fluid power – Fluid contamination – Determinationof particulate contamination by the counting method using a microscope).

ISO 4407 contains a description of a microscopic counting method for membranes. 100 ml of the sampleundergoing analysis is filtered through an analysis membrane featuring an average pore size of < 1 µm andsquare markings.

The standard also describes the cleaning procedure and maximum particle count of the negative control.

After the analysis membranes are dried, 10, 20 or 50 squares are counted depending on the size of theparticles, followed by adding the values and extrapolating to the membrane diameter.

The manual count of the particles is done in the “old” levels of > 5 µm and > 15 µm since the longestdimension of a particle is counted in ISO 4407 yet the diameter of the area-equivalent circle is counted in the“new” ISO 4406:1999. As described above, the reference values obtained for this count correspond to thereference values of the “new” evaluation.

This counting method can only be used for very clean samples. Generallyspeaking, the cleanliness classes are estimated on the basis of referencephotographs or the samples automatically counted.

2. Automated particle counting

Below follows a description of how common particle counters employing the lightextinction principle function.

The figure left shows a simplified rendering of the measurement principleemployed in the light extinction principle.

The light source transmits the light (monochromatic light for the most part) ontoan optical sensor, which emits a specific electrical signal.

A shadow is created on the photodiode if a particle (black) comes between thelight source and the photodetector. This shadow causes the electric signal emittedby the sensor to change. This change can be used to determine the size of theshadow cast by this particle and thus the particle size to be determined.

This procedure enables the cleanliness classes according to ISO 4406:1987, ISO4406:1999, NAS 1638 and SAE AS 4059 to be accurately determined.

The “noise” involved in this measurement principle is extraneous liquids and gaseswhich cause the light beam to be interrupted and thus be counted as particles.

The particle counter should be calibrated according to ISO 11943 (for ISO 4406:1999).

Figure 14

Schroeder Industries LLC (from herein referred to as Schroeder) offers six products (see Figure 14) that includeparticle monitoring services: SMART® Kit, TPM TestMate® Particle Counter, TIM TestMate® In-Line Counter,TCM TestMate® Contamination Monitor, TMU TestMate® Monitoring Unit, and AFM Auto Flush Filter Cart.Product information for all of these is included in this catalog.

Procedure in Evaluating Fluid Samples According to

ISO 4406:1999, NAS 1638 and

SAE AS 4059

Figure 13

Figure 12

SMART® Kit TIM TMU AFM

TPM TCM




Determining the residual dirt quantities present on components can be done employing quantitative andqualitative factors.

Quantitative: mg/component Qualitative: length of the largest particle mg/surface unit (oil-wetted surface) (subdivision into hard/soft) mg/kg component weight

no. of particles > x µm/component no. of particles > x µm/surface unit

(oil-wetted surface)

Components with easily accessible surfaces are components in which only the outer surface is of interest for the most part when performing residual dirt analyses. There are exceptions here, e.g. transmission and pumphousings, as the internal surface of interest. These components belong to group 1 and their surfaces are noteasily accessible in most cases.

Components in which the inner surfaces are examined or preassembled assemblies belong to group 2; forthe analysis procedure for this group, refer to page 16.

There are two methods that can be used to determine the residual dirt of group 1 components.

The ultrasound method involves submitting thecomponents to an ultrasonic bath, exposing themfor a defined period of time at a defined ultrasonicsetting and bath temperature. The particulatecontamination is loosened by the exposure and thenflushed off the component using a suitable liquid.

The particle dispersion in the flushing liquidobtained in this manner is analyzed according tospecified evaluation methods.

The ultrasonic energy setting and the duration ofexposure have to be indicated in reporting the result.The ultrasonic procedure is particularly suitable forsmall components in which all surfaces have to beexamined. Cast components and elastomers shouldnot be subjected to ultrasonic washing if possible arisk is posed here of the carbon inclusions in the castpiece being dissolved, thus skewing the results. Theseeffects have to be ascertained prior to performing anultrasonic analysis.

Components with easily accessible surfaces or components in which only surface parts have to be examinedare analyzed using the flushing method. This method involves flushing the surface undergoing analysis in adefined clean environment using an analysis fluid, which also has a defined cleanliness. A “negative control”or basic contamination control is performed prior to analysis in which all the surfaces of the environment,e.g. the collecting basin, are flushed and the value obtained reported as the basic contamination of theanalysis equipment. The flushing fluid is then analyzed using the specified evaluation methods.

The darker areas to the right are the flushing areas; those to the left and lighter are the designated analysisarea. In reality these two circuits are configured using suitable valves in such a manner that switchover canbe done between the two storage tanks. The figure represents a simplified circuit diagram. The analysis fluidis subjected to a pressure of approximately 58 – 87 psi (4 – 6 bar) and conveyed through the system filter andthe spray gun into the analysis chamber. The system filter ensures that the analysis fluid sprayed on thesurface being examined has a defined cleanliness. The particle-loaded fluid collects in the collecting basinand is filtered through the analysis membrane via vacuum action. The membrane is then evaluated accordingto the analysis methods described on the following pages.

This method is very rarely used, as it is very difficult to reproduce manually. However, results are reproduciblewhen automatic shakers such as those used in chemical laboratories are employed. The analyzed componentsare components subject to wear whose inner surfaces are to be analyzed (e.g. pipes, tanks). The importantthing is that the particles are flushed out of the inside of the components after being shaken.

The table on the following page shows a comparison of the various methods for analyzing components and assemblies.

Ultrasonic Method

Flushing Method

Figure 15

Determining the Residual Dirt Quantity of Components

Shaking Method




Flushing Method Ultrasonic Method

How Components are flushed with the analysis Components are exposed to an ultrasonic bathPreformed fluid in a defined clean environment. and are then flushed with the analysis fluid.

Components in which only surface parts Small components and components in whichhave to be examined and components in all surfaces are to are to be analyzed (the

Applications which ultrasound may damage the surfaces. component size depends on the ultrasonic bath).

Components with a simple design and witheasily accessible surfaces.

Pros Analysis can be performed quickly Reproducibility

Reproducibility Analysis takes a long time

Standards are not yet available The energy acts on the surfaceCons (currently in preparation) undergoing analysis

The surface has to be flushedNo valid standards

ShakingMethod

continued

EvaluationMethods

Evaluating particle-laden flushing fluids can be done according to various criteria. Gravimetric analysis is useful forheavily contaminated components, whereas particle counts in various size ranges are useful for very clean components.

The following table provides an overview of the individual evaluation methods.

Manual Methods Automated Methods

Gravimetric method Counting of particles on Counting of particles on Counting of particles on[mg/m2] the analysis membrane the analysis membrane the analysis membrane

[no. of particles [no. of particles [no. of particles > x µm/m2]* > x µm/m2]* > x µm/m2]*

The particle-laden fluid is filtered through a prepared analysis membrane The particles on theparticle-laden fluid arecounted using an automaticparticle counter

The analysis membrane The number of particles The analysis membrane isHow is weighed before and in the individual size placed under a microscopePreformed after analysis and the ranges are estimated and evaluated using a

gravimetry computed or counted software tool. This soft-on the basis of the < 100 µm estimated ware records the light-difference between > 100 µm counted -dark contrasts on thethe measured values membrane and interrupts

them as particles.

Applications

Samples exhibiting Samples featuring high Samples featuring a Preferred for very cleancontamination a content of coarse low contamination components. When high dirt>10 mg contamination. Often content < 5 mg content is involved, the

combined with sample has to be diluted in gravimetric evaluation. order to perform counting.

Standard ISO 4405 ISO 4407 ISO 11500

Material types can also be analyzed. An overview can be quickly obtained of the Analysis can be performedlargest particles. quickly, can be integrated in

Air and extraneous liquids do not pose a problem (as long as no deposits form process chain as on-line

on the membrane). method, detection of smallAdvantages

Can be used for large particle quantitiesquantities of particlespossible, measurement rangeselectable (2-400µm). Accu-rate measurement method

Takes a long time Takes a long time Depending on the analysis The sample has to be (min. 1 h) No. of particles accuracy this method can prepared (e.g. the sample

Lab Method <100 µm estimated take a very long time. might have to be diluted).

Lab MethodLight particles are not Generally speaking, this interrupted. Light-Dark is a statistical method contrast is manually providing for sufficient selected in most cases. The accuracy.diameter of the area-equiv-alent circle is measured (=> result is not identical to visual appearance)

Application

Lab Method Lab Method On-line process control Used as a control for in manufacturing andindirect measurement assembly.techniques (e.g. off-line process control Can also be used in labsin test stations)

Disadvantages




The following table provides an overview of applications of the analysis and evaluation methods.

Evaluation Gravimetry Particle Counting

Analysis Ultrasonic Ultrasonic FunctionMethod Flushing Method Flushing Method Testing

Simplee.g.

easy-to-access surfaces;U U U U NU

Components gears

Components e.g.internal surfaces pipes, tanks

U NU U NU CU*

Complexcomponents featuring

Componentse.g. various bore holes or CU* NU CU* NU U

ducts; control plates

Simple e.g.

surface is to be analyzedSystems immersed sensors

U U U U NU

Systems e.g.internal surfaces rails ofcommon rail systems

CU* NU CU* NU U

ComplexSystems

e.g. valves, pumps CU* NU CU* NU U

* It has to be ensured that the particles dislodged from the component can be flushed away.

U = Usable CU = Conditionally usableNU = Not usable

SMART®

Technology

PatchTest Kit

SMART® (Schroeder’s Micronic Automated RecirculatingTechnology) utilizes a microprocessor to customize operations based on user input. Products that use SMART®

technology are marked throughout the catalog with theSMART® Kit ready logo.

Schroeder’s EPK Patch Test Kit (shown to the right) providesthe tools needed to pull contaminated fluid through a patchand compare the the resulting patch under a microscope torepresentative photos of various contamination levels todetermine the fluid’s ISO level.




Analysis of the Cleanliness of Systems on a Flushing/ Test Stand

The cleanliness of components and systems that pass through a flushing or test stand can be determined onthe basis of the cleanliness of the test fluid in some cases. This indirect analysis method is preceded by manualanalyses for validation purposes.

For example, hoses are flushed by hand and the results evaluated in accordance with the methods discussedon page 13. At the same time, the cleanliness of the test fluid of the test stand is determined in the returnflow, i.e. downstream of the component.

If a correlation is detected between the manual and the automatic (indirect) value, this means that indirectvalue analysis can be selected as a measure of quality.

The flushing stand used for analyzing the residual dirt content of systems has to feature the following:

1. Flushing has to be done using as turbulent a flow as possible.2. The fluid used has to posses a dispersion effect.3. All channels and surfaces have to be exposed to the flow.4. The effectiveness of flushing can be improved by pulsating the flushing.

The Reynolds number – a dimensionless reference – describes the flow properties of fluids. Below follows abrief description of how the Reynolds number is derived using pipe flow as an example.

Weights are discounted in the calculation of the Reynolds number. Generally speaking, only pressure, frictionand inertial forces affect fluid elements and bodies subjected to flows. They have to be in balance at all pointsof the flow. If the relationship of friction and inertial forces is the same in similar points P1 and P2, then similarflows are said to be present.

The Reynolds equation looks like this when the above properties are taken into account:

Re =mean velocity x internal pipe diameter

kinematic viscosity

Re = 21220 xQ

di x vapplies to pipelines and hoses

Whereby: Q = volumetric flow rate (l/min), v = viscosity (mm2/s), and d = inside pipe diameter (mm).

The critical Reynolds number Recrit depends on kinematic velocity v, flow rate Q of the fluid, and the geometryof the passage through the flow is being conducted. If the Reynolds number of a flow is smaller than Recrit,the flow is said to be laminar. Turbulent flow is said to be present for values above Recrit. The critical Reynoldsnumber for oil is given below.

Recrit oil = 1900 – 3000

(Source: Kahrs, M.: Der Druckverlust in Rohrleitungen Ölhydraulischer Antriebe; VDI Forschungsheft 537, Düsseldorf 1970)

The diagram to the leftshows a parabolic, laminarflow in a pipe. This showsthat the flow velocity of a laminar current in themiddle of the pipe (peak ofthe parabola) is larger thanalong the pipe wall.

In a turbulent flow thisparabola flattens andspreads (when mean valuesare considered), as trans-versal currents are involvedin a turbulent flow. Theycause the flow velocity tobe increased in the vicinityof the pipe walls.

This effect is utilized when flushing systems asincreasing the flow ratecauses particles that havebeen deposited on the wall to be loosened andswept away.

Turbulent Flow

Difference Between Laminar and Turbulent FlowFigure 17. Laminar Flow Figure 18. Turbulent FlowAll particles move without mixing. All particles are continuously mixed.

The path of a particle is described by a The path of a particle cannot be predicted.stream thread.

Parabola-shaped velocity distribution Relatively even time-averaged velocity

(applies to pipes).distribution (flattened parabola).

Reynolds number smaller than Recrit Reynolds number larger than Recrit

Source: University of Würzburg Fluid Mechanics lecture

Figure 16. Similar Flows Around Different Cylinders



The oil used for flushing has to have a dispersion effect so that particles are dislodged and transported off.Special thin-bodied mineral-oil-type flushing oils can contribute instrumentally to improving the flushing effect.They lower the adhesion force between the dirt particles and the pipe wall. By virtue of their excellent surfacewetting properties, they creep into between the dirt particles and the wall, thus causing the particles tobecome dislodged. Experiments have shown that by changing the flushing fluid from an operating fluid to a flushing oil, component/system cleanliness can be increased by a factor of 4. Flushing oils of this type have to then be closely matched to the hydraulic medium used as failure to properly match the two may lead tomarked foaming, filter blockage and clogging of the system.

When setting up the inspection and testing plan, it has to be ensured that all surfaces and ducts are wettedduring flushing.

The cleanliness of components and systems which undergo function testing can be determined on a flushing or function test stand (= flushing stand).

This method is used for pumps, cylinders, transmissions, control units, power steering units, valve blocks, etc.

Once it is ensured that the flushing stand possesses the properties indicated above, an analysis is conducted as described below.

Prior to the analysis the flushing stand is cleaned to a defined high cleanliness level so that the basic contaminationof the test system does not affect the measurement results. Then this basic cleanliness is computed and recorded.

The sampling site for an automatic particle counter is defined as a site upstream or downstream of the testitem, which is subjected to a direct flow. The following is performed if the analysis result is to be additionallysubjected to gravimetric analysis: the entire test fluid is collected and filtered through an analysis membrane or an inline membrane retainer featuring the analysis membrane is integrated in the return-flow line.

Now the test item is tested in accordance with the inspection and testing plan, during which the cleanlinessclasses are recorded.

Example 1: The schematic below shows the analysis performed on a pump test stand.

Figure 19. Analysis Process on a Pump Test StandExample: As-supplied condition:17 / 15 / 12 according to ISO4406:1999

1. Warning point: 18 / 16 / 13for 3 successive measurements

2. Stop signal: When exceeding18 / 16 / 13 limit cleanliness classin 2 successive measurements.

After 5 minutes of testing thepump speed, it is increased to themaximum speed. This causes particulate contamination to be dislodged. The system becomes increasinglycleaner. Particulate contamination is still being released after 1 hour of testing (standard test time: 10-15 min.),consequently the cleanliness of the return-line fluid (blue = downstream of the test item) never achieves thesame cleanliness as upstream of the test item.

This method is suitable for checking the cleanliness of items being delivered quickly and simply in seriestesting, documenting it and then concluding the flushing procedure when the target value is achieved. Byintegrating the measurement circuit in the manufacturing instrumentation and control system it is also possibleto quickly detect any deviations and initiate suitable measures. The goal of continuous cleanliness monitoringis to monitor process reliability with regard to system cleanliness upon delivery.

A specification like this also enables increased system contamination to be responded to quickly. If thesemeasurements are only conducted once a day, a whole day’s output might be affected and have to be remedied.The result is unnecessary costs that can be avoided by integrating a continuous measurement procedure.

When conducting a reference measurement, the system is disassembled after the test run, if possible, and theindividual components analyzed using the flushing method.


Performing a Cleanliness Check on a Flushing Stand

Determining Overall SystemContamination

Dispersion Effect

Flushing of All Ducts and Surfaces




Contamination Monitoring

Planning and Design

How Sampling is Done

Inspection of the Manufacturing and Assembly Line

The reliability of hydraulic systemscan be impacted heavily byparticulate contamination duringthe running-in phase. The risk ofoutages during the first minutes orhours of operation is particularlyhigh as the foreign particlesintroduced or created during theassembly process are still relativelylarge and can thus cause sudden

outages. During continued operation, these large particles are ground into smaller ones, the result being thatdamage can be caused to the surfaces of system components during this crushing process. The consequencesare leakage, degraded output and efficiency, or a shortening of the component’s service life. In many cases,microfiltering is used to quickly clean the system fluid during commissioning.

This is where contamination monitoring is key in the manufacture and assembly of these systems. Byimplementing contamination management a major portion of particulate contamination introduced duringmanufacture and assembly can be removed. The result is cost savings by virtue of smaller performancedeviations on test stands caused by the sudden clogging of particles in sensitive system components plus lowercosts associated with warranty and non-warranty courtesy work. For more information, refer to page 28.

Below follows a description of the goal, design and performance of a process audit.

Contamination monitoring extends to checking the cleanliness status of all manufacturing and assemblyprocesses considered relevant in this connection. Proper preparation and informing all those involved are key in contamination monitoring.

First, the objective of contamination monitoring is specified, e.g.

Determining the current situation

Checking fluctuations between batches

Checking washing processes

Comparing the target with the actual situation

Determining the sampling point

During the planning and design phase, the sampling points for components and taking liquid samples aredetermined using a production plan or operation sheet. The employees to be involved in contaminationmonitoring are informed of the objectives and procedures.

NOTE:

Manufacturing has to continue in the same manner, meaning that no additional cleanliness levels, etc. are tobe integrated. The purpose of contamination monitoring is not to check the quality produced by the employeesbut rather determining the causes and sources of contamination.

The schematic above shows the manufacturing processes and the corresponding sampling points. However, inactuality sampling is more comprehensive, i.e. the description includes the number of the Minimess fittings atwhich sampling is done, for example.

A representative sampling is taken of the fluids and components; the samples are stored so as to prevent anyfurther contamination. Special sampling bottles are used for the fluid samples; the components are stored indefined clean packaging.

The analysis is performed in accordance with the methods specified on pages 13- 17 and the findings recorded.

Properly trained or experienced individuals while inspecting the manufacturing and assembly line can detectsome sources of contamination. That is why such an inspection is conducted during the audit. The findingsmade during inspection are then compared with the results in hand.

Figure 20. Schematic Excerpt of a Manufacturing Line




The contamination monitoring results describe the condition at the time at when sampling is done. Thefindings might look like this:

Figure 21. Housing Processing Figure 22

Figure 23

This chart shows an excerpt of the housing manufacturing process. The component samples are takenupstream and downstream of the washing station. The findings show that the washing station performs welland that it is well positioned here. Subsequent storage is not being done properly as the portion of particulatecontamination is almost double.

By applying a cleanliness specification to components and the system it can be ensured that as-supplied qualityis constant.

The following should be in mind when drafting a cleanliness specification:

State of the art

Benchmarking – what do others do?

Inclusion of previous experience – if available

Defining and implementing contamination management as an “official project”

Inclusion of all hierarchy levels

Accurate documentation of how the specification was developed

Developing clear-cut definitions

Next, it has to be determined which components in the system are the most sensitive. Frequently it is notpossible to achieve the same level of cleanliness throughout the system during assembly.

If suitable filtration takes place upstream of the sensitive components, an area of low-contamination-sensitivecomponents can be defined upstream of this filtration and an area of highly contamination-sensitivecomponents downstream of the filter.

These individual components or system areas should be subdivided into sensitivity areas.

Category Designation Description

A Low particle-sensitivity For the most part low-pressure systems with large gap tolerances

B Particle-sensitive Low-pressure systems with small gap tolerances

C High particle sensitivity High-pressure systems with small gap tolerances and with exactingdemands made of safety and security systems

A maximum particulate contamination value is specified for each of these cleanliness categories.

A car motor illustrates this subdivision below:

Category Motor Area

A Air /Coolant water circuit

B Low-pressure oil circuit

C Diesel direct injection / High-pressure oil circuit

In addition, the fluid cleanliness ratings of the individual system and process fluids are defined.

Drafting aCleanliness Specification

Results

Micro-photographanalysis membrane

Particulatecontamination of a component priorto storage

Micro-photographanalysis membrane

Particulatecontamination of a component afterbeing in storage for 2 weeks



The following parameters aredefined in the cleanlinessspecifications for the components:

1. Goal of the cleanlinessspecification

2. Applicability (system designation)

3. Extent of inspection and testing;inspection and testing cycles

4. Sampling

5. Analysis method

6. Evaluation method

7. Accuracy

8. Analysis fluids to be used

9. Documentation

10. Limit values

This specification has to be made foreach individual system; consequentlya few things are discussed whichhave to be borne in mind.

Work instructions concerningsampling, analysis and evaluationmethods should be described indetail so as to ensure that samplingis always done in a uniform manner.In addition, the analysis resultsdepend on the analysis fluid andmethod, particularly when it comesto component analysis. Documenta-tion should be done using forms sothat all the results are readilyaccessible.

1. Goal of the cleanliness specificationThe goal in implementing this cleanliness specification is to achieve a constant level of cleanliness for system X.

2. Applicability (system designation)This specification applies to system X including its series A, B, and C. It extends to all components whethersourced or manufactured in house. It also specifies the system fluids of system X with regard to their cleanliness.

3. Extent of inspection & testing; inspection & testing cycles5 samples a month of each component are to be taken and analyzed. If the supplier parts achieve a constantcleanliness value after 6 months, the sampling cycle can be extended to every 2 or 3 months. An analysis ofthe entire (assembled) system is to be done at least once a week prior to delivery. Checking of the fluidcleanliness should be done on a continuous basis.

4. SamplingSampling of components is to be done at goods receiving and is to be representative. Samples should bepacked in a dust-tight manner and sent into the laboratory. The fluid samples are to be taken at the samplingpoints indicated in the inspection and testing plan.

Contamination ManagementSystem Power Steering Analysis date Jan. 31, 2001

Component analysis

Component Rack Sampling point After washing 1Part No. Xx1235 Sample taken by Joe SmithBatch size 1 Sampling date Jan. 30, 2001

Analysis method Ultrasonic Lot designation 01-2001Analysis fluid COLD-02 Analysis fluid vol. 1,500 ml

Negative value .02 mg Membrane filter rating 7 µm

Evaluation method

Automated particle Automated particleInline particle counting of the counting of the Manualcounting analysis fluid membrane particle counting

xx

Gravimetry 8 mg/component

Largest abrasive 350 µmparticle

No. of particles / component

> 50 µm > 100 µm > 200 µm

Actual value 100 10 3Limit 0

System Fluid

System Washing 1

Sampline point Flushing bath

Sample taken by Joe Smith

Sampling date Jan. 30, 2001

Measurement method

Automated particle Automated particleInline particle counting of the counting of the Manualcounting analysis fluid membrane particle counting

x

ISO 4406 22/20/18 NAS 1638

Largest abrasive 300 µmparticle

Signature: Date:


Example of a form for entering findings

Establishing Cleanliness

Specifications

Example of a Cleanliness

Specification




Example of a Cleanliness Specificationcontinued

5. Analysis methodThe flushing method should be used for component analysis. The surfaces of the component are flushed in a cleanenvironment using x ml of the test fluid (XY) which has a cleanliness of xx, under a pressure of z bars as specifiedby the inspection and testing plan. The flushed-off particulate contamination is collected on an analysis membraneand subjected to gravimetric analysis. Representative samples are taken of the system fluids at the specifiedsampling points. All testing parameters are specified; the duration of testing, what is tested, the pressures, andspeeds. When conducting static inspection and testing make sure that a flushing effect is present so that thecleanliness of these components can be determined, (the static pressure test has to be followed by a dynamicflushing process in order to analyze the actual quantity of particles which is flushed out of the component.)

6. Evaluation methodIn the component analyses the analysis membrane is dried until it achieves a constant weight, and then cooledin a defined dry environment and weighed. This procedure is repeated subsequent to filtration. The weightdifferential indicates the “gravimetric contamination” of the component. This is followed by visually examiningthe analysis membranes through a microscope and measuring the longest particles. Evaluation of the fluidsamples is done in accordance with ISO 4405, ISO 4407, ISO 4406:1999 or NAS 1638.

7. AccuracyThe analysis equipment has to be brought to a residual dirt content of 0.2 mg prior to conducting the analysisso that the measurements taken of the component samples are sufficiently accurate. This is determined byperforming a negative control, i.e. flushing the equipment without testing. When the result of the analysisdrops below 0.5 mg, the batch size is to be increased and thus a mean value of the results computed.

8. Analysis fluids to be usedThe following analysis fluid should be used for the component analyses: ABC-XX, with a cleanliness class of 14 / 12 / 9 and no particles > 40 µm.

9. DocumentationThe documentation of the results is done using a result sheet.

10. Limit valuesThe components are subdivided into 3 cleanliness classes:

Category Designation Description

A Low particle-sensitivity For the most part low-pressure systems with large gap tolerancesB Particle-sensitive Low-pressure systems with small gap tolerancesC High particle sensitivity High-pressure systems with small gap tolerances and exacting demands

The following cleanliness specifications apply to each of these classes (fictitious example).

Category Gravimetry Particle Sizes

A 20 mg / componentMax. 4 particles > 500 µmMax. size: 400 µmNo fiber bundles

B 10 mg / componentMax. 4 particles > 400 µmMax. size: 800 µmFibers up to 4 mm

C 5 mg / componentMax. 4 particles > 200 µmMax. size: 1,000 µmFibers up to 2 mm

The transmission components are subdivided into the individual categories. Group A: crankcase sump. Group B: intermediate housing, transmission housing, coupling flangeGroup C: valve plate, valve housing, centering plate

Fluid samples:At the end of the test run, the transmission fluid may not fall short a cleanliness rating of 17 / 15 / 13 (c)according to ISO 4406:1999. The system is to be operated using a cleanliness rating of 18 / 16 / 14 (c)according to ISO 4406:1999.

11. Procedure to be followed in the event that the specification is not adhered toThe supplier components are to be returned to the supplier in the event that the specification is not adheredto. If this procedure results in production delays, the components will be cleaned and analyzed by us at thesupplier’s expense.




Sources of Contamination in the Manufacturingand Assembly of Hydraulic Systems

Particulate contamination can enter a fluid power system in various ways. The main sources of ingression areshown in the following diagram.

Figure 24. Sources of Contamination in the Manufacturing of Hydraulic Systems

Some of these sources of contamination can be eliminated in a simple, cost-effective manner.

The ingression of contamination in the manufacturing and assembly of hydraulic systems can be eliminated in a cost-effective manner in various process steps.

Storage and Logistics

When storing and transporting the components and systems care has to be exercised to make sure that theyare properly sealed shut or well packed. Transportation and storage packing has to be in keeping with thecleanliness status of the individual components.

Assembly of Systems and Subassemblies

The assembly of these systems is to be done in accordance with system requirements. This means that theassembly and mechanical fabrication areas have to be separated if necessary in order to prevent the ingress of contamination. The assembly stations have to be kept clean to a defined cleanliness and those working inthese areas have to wear special, lint-free clothing. The assembly equipment has to be properly cleaned so as to prevent the ingress of dirt here, too.

Raising the Awareness of Employees

In order to achieve the objective of “defined cleanliness of components and systems” it is important thatemployees at all levels be involved in this process. Frequently, a considerable savings potential is contained in the employees’ wealth of ideas and experience — particularly those working at assembly lines and infabrication.

Experience has shown that when employees are able to identify with the objective being striven for, they aremore able to help in implementing it quickly and effectively.

Environment — Air Cleanliness

In some cases it will be necessary to set up a clean room for the final assembly of very contamination-sensitivesystems, e.g. fuel systems, brakes shock absorbers, etc. This has to be decided on a case-by-case basis.However, in many cases performing the measures described here suffices.

Generally speaking, particulate contamination is removed from a hydraulic system via filtration. Various typesof filters are used depending on the amount and type of contamination.

Belt filter systems or bag filters are used when large quantities of contaminants are involved. These filters havethe job of removing the major portion of contaminants from the system. These filter types are also used forprefiltration purposes.

In most cases, these coarse filters do their job of “removing a lot of dirt from the system” very well. However,microfiltering also has to be done if a constant defined high level of cleanliness of the system fluid is to beensured.

Whereas microfiltration ensures quality, the job of coarse filtration is to control the quantity of contamination.

Preventing the Ingression of

Contamination in the Manufacturing

and Assembly of Hydraulic Systems

Removal of Particulate

Contamination from Hydraulic

Systems (Practical

Experience) and Components




Individual components are freed of clinging contamination in cleaning systems (particles, remainder ofmachining or corrosion protection fluids, etc.). Cleaning can be done by employing various mechanicalmethods (e.g. spraying, flooding, ultrasonic methods) using various cleaning fluids (aqueous solutions ororganic solvents). The temperature and duration of cleaning also have a decisive effect on the cleaning effect.These factors have to be carefully matched and optimally tuned in order for a favorable cleaning effect to beachieved in an economical amount of time.

Figure 25

Various studies of washing processes have shown that some of these for the most part cost-intensiveprocesses aren’t worthy of the name. Some people refer to washing processes as “particle distributionprocesses”. This “property” was detected in examinations of components sampled upstream and downstreamof a washing process.

Figure 26. Micro-photograph Analysis Membrane Figure 27. Micro-photograph Analysis Membrane

There are two possible responses in a case like this:

1. Discontinue the washing process when component cleanliness becomes worse after washing than before.

Advantage: temporary cost savings

The best alternative:

2. Optimize the process. The following should particularly be borne in mind when optimizing washingprocesses: cleanliness of the washing, flushing and corrosion protection fluid, mechanical aspects, suitability ofthe washing process for the components undergoing washing and filtration of the washing and flushing fluid.

When purchasing washing systems, make sure to specify the component cleanliness to be achieved and themaximum contamination load of the washing fluid in terms of mg/l or a cleanliness class.

Washing systems used to be subdivided into micro and micronic washing. This was a very imprecise definitionof the cleaning performance to be achieved. Nowadays the permissible residual dirt quantity of the cleanedcomponents is defined.

Specifying these residual dirt quantities is done as follows: mg/component, mg/kg component, mg/surfaceunits or particle concentrations in various size ranges. In addition, the maximum sizes of the particles aredefined which can be on the washed component, e.g. max. 3 particles > 200 µm, no particles > 400 µm.

These values cannot be achieved unless the factors indicated above are matched and fine-tuned. The followingfactors additionally have to be borne in mind: environmental protection and labor safety, local situationrelating to space and power available, and the target throughout rate.

The cleanliness of the washing and flushing fluids also has a decisive impact on the cleaning performance ofthe washing machine.

However, we are concerned here only with the maintenance of the washing and flushing fluids.

Cleaning System

Pipe has been washedand sawed

After sawing andwashing, the pipe isbent and flushed




Liquid,Cleaning Solid Liquid, DissolvedMethod Contamination Non-Dissolved Contamination Contamination

(emulsion) (emulsion)

Filtration

Belt-type Filter X

Bag/Backflush Filter X

Micronic Filter (tube/disk filters) X

Ultrafiltration X X

Distillation X X (for high boiling point differences) X

Separator X X (density difference)

Oil Separator X

Coalescer X

The type and composition of the cleaning medium is to be taken into account in selecting the fluidmaintenance options indicated above. When using ultrafiltration, it has to be known that separating out thecleaning substances cannot be avoided in certain cases. In addition, ultrafiltration can only be used forprecleaned washing media since the performance of the separating membranes is degraded when they areloaded with particulate contamination.

Bag and backflush filters in various microfilter ratings are the standard equipment used in the maintenance ofthe fluid of washing systems. Although these filters are suitable for removing large quantities of contaminationfrom a system, they are not suitable in most cases for maintaining defined cleanliness classes. Owing to theirdesign, they do not offer much resistance, (the counterpressure built up across the filter is very low), below 15psi for the most part. That is why this filter type is frequently used in the full flow when feeding cleaning fluidinto the washing or flushing chamber. The filter housings are equipped with pressure gauges for monitoringthe proper functioning of the filter.

Bag filters pose the risk that overloading can cause the bag to be destroyed and large contaminant quantitiesreleased. That is why it is advisable to additionally define minimum change intervals and to regularly monitorthe cleanliness of the washing fluid in addition to the standard parameters like pH value or microbial count.

Residual dirt values of cleaned components are increasingly being defined and specified as an acceptancecriterion for the cleaning system. It is of paramount importance that constant adherence be maintained tothese values. It is also imperative that the quality of the cleaning fluid be maintained at a high, constant level.

This can be achieved by use of the targeted microfilters, featuring a constant and absolute separation rate. Forthe most part, tube filters or disk filters are used. The advantage of these filter types as compared to standardhydraulic filter elements is their high contaminant retention rate owing to their depth effect.

The high contaminant separation rate offered by these filter types removes a high amount of contaminationfrom the washing fluid. This causes the filters to become quickly exhausted and blocked. A sufficiently longservice life coupled with high washing fluid cleanliness can be achieved by combining filters for removing themain portion of contaminants from the system with absolute microfilters.

Example: At a leading automotive supplier, the camshafts were to be cleaned to a defined cleanliness of 9 mg / component. Point of departure:

Technical Specifications of the Washing Machine Present on Site

Tank Volume: 21 gal. (80 l)

Pump Delivery Rate: 66 gpm (250 l/min) (centrifugal pump)

Washing Agent: Ardox 6478 – chemetall

Concentration: 2.3 – 3%

Bath Temperature: ca. 122°F (50°C)

Filtration: Backflush filter downstream of pump, 50 µm filter rating

Process Data

Bath Change Frequency: 1 time/week

Throughput: 3,000 - 4,000

Wash Cycle: 15 s/component

Challenge: Clogging of the tank, Quality no longer sufficient after 2-3 days, Fluctuation in the contaminationcontent of the components upstream of the line: 30 – 50 mg. Cleaning costs could not be allowed to increase,although quality still had to be improved.

CleaningSystem

continued

Using Filtration as Fluid

Maintenance for Separating out ParticulateContamination




Achieve a residual contaminant value of a maximum of 9 mg/camshaft

Cleanliness of washing fluid of < 30 mg/liter

Extend the service life of washing fluid, i.e. save costs associated with changing the fluid

Prevent clogging of the tank, e.g. save cleaning time

For process reliability reasons, a low-maintenance cleaning system was to result which enabled the camshafts to be cleaned to a residual contaminant content of 9 mg/component, this to be done cost-effectively.

The service life of the cleaning fluid was extended from 1 week to 8 weeks. There was no more clogging ofthe tank. Changing the bath fluid was done on account of the increased chloride content, not on account of contamination.

The residual contaminant values of max. 9 mg/camshaft and max. 30 mg/liter of bath fluid (when using a 5-µm membrane for analysis) were achieved and maintained at this level.

By optimizing the fluid maintenance of this washing line, an improvement in quality was achieved at no addedcost and without comprising process reliability.

This example shows that prior to any such optimization or in new facilities the cleanliness of the componentsupstream of the system, throughput, technical details, targets have to be known and defined, for only in thisway can the success of such an endeavor be ensured.

Investment Recurring Costs Savings / Year($) ($) ($)

Off-line Filtration 5,000.00

Filtration Costs 7,500.00

Extension of the ServiceLife of the Bath

10,000.00

Lower Reworking Costs These costs can’t be quoted.

Down Time of the WashingMachine for Cleaning

These costs can’t be quoted.

Goal ofOptimizing theCleaning Line

Result ofOptimization

EconomicEfficiency Analysis




Figure 28Most systems come into contact with thehydraulic fluid during initial system filling orfunction testing. This process affords themanufacturer a substantial opportunity to impactthe final cleanliness of the entire system. By usingsuitable filtration of the filling and test fluids,system cleanliness can be quickly optimized upondelivery or commissioning.

The cleanliness of the final product can becontrolled via function testing in the same way asby a washing machine. Some companies have thefollowing motto: “The test stand is our lastwashing machine.”

This statement might be true, however it is anexpensive approach in practice. Yet whenperforming process reliability measures forsupplying systems with a defined cleanliness, thisis the first approach.

On a function test stand not only function testingis performed but the components and systems are

run in as well. A frequent side effect of this is the flushing effect of the system undergoing testing. Byemploying targeted fluid maintenance and cleanliness monitoring, this flushing effect can be used to ensurethat systems possess a defined, constant cleanliness status upon delivery.

Cleanliness monitoring provides information on the process stability of the upstream fabrication and cleaningsteps. Frequently, continuous monitoring of test fluid cleanliness results in the cleanliness of the entire systemas supplied being documented. This approach is used in mobile hydraulics, turbines or paper machinery upondelivery or during commissioning in order to demonstrate to the final customer that his system is beingsupplied with the specified cleanliness.

Example: The following study illustrates the cleaning process of a pump during commissioning:

The cleanliness of the test fluid upstream of the test item is maintained at a cleanliness rating of 16 / 14 / 11(c). After 5 minutes of testing the pump speed is briefly increased to the maximum speed. The test run isconcluded after 10 minutes.

In this case, the dirt content of the test item amounted to 1 mg/kg component weight upon the conclusion ofthe test run.

Figure 29. Cleaning Process on a Pump Test Stand As the schematic above shows, theparticle concentration continuously dropsduring the first 4 minutes of the test run.The particle concentration jumps when thepumps are turned up to full speed after 5 minutes. The next 5 minutes are againused for cleaning the system. Now thefollowing can be asked: “How clean arethe valves that leave this test stand?”

The flushing procedure can be monitoredby occasionally disassembling the valves in a defined clean environment andevaluating the dirt content of theindividual components.

Schematic illustrates the basic setup of most test stands

Function Testing




Unfortunately, improper component storage is not uncommon. Seals and gaskets which arrive at the assemblyline clean and packed in bags are unpacked and filled into containers which are dirty for the most part as thisinvolves less work and effort.

In most cases, these factors are not taken into consideration and substantial savings potential that could beeasily utilized through improved packaging and storage is overlooked.

Suitable cleanliness specifications for internally produced and sourced parts enable the ingress of contaminationinto systems to be minimized right from the beginning.

This method is most frequently chosen for large systems in order to minimize wear during commissioning.

The filtration of the flushing stand has to be designed so that during subsequent analysis the contaminantsflushed out of the system undergoing testing are removed and other measurements aren’t skewed. As analternative, cleanliness can be measured and recorded upstream and downstream of the test item during theentire measurement sequence.

In the example above, the specified sampling point waslocated directly downstream of the pump and an onlineparticle counter connected.

The crane jib was extended after 6, 8 and 10 minutes. Thegraph clearly shows that every time a new area was broughton line contaminant sediments were flushed out.

When a system’s characteristic curve/behavior is known,cleanliness testing can be performed at the end of functiontesting and, thus, system cleanliness described subsequentto commissioning. This method enables process control tobe implemented quickly and reliably during series testing/commissioning. The cleaning curve plotted over time is anindication of the ingress of contaminants during assembly.

Figure 30.Valve Test Standwith 5 µmFiltration

Figure 31.Cleanliness ClassAchieved by the Test Fluid: NAS 3

Storage, Logistics andAmbient Conditions

Supplier Parts and ComponentsManufacturedIn-house

CommissioningFlushing

X-SeriesSkid

Flushing

Figure 32. Examination of the HydraulicSystem of a Mobile Crane




The core aspects of contamination management are a cost analysis and efficiency review. The following costsare considered in the cost analysis:

Warranty and non-warranty courtesy work

Energy costs (e.g. cooling and reheating of washing machines during fluid changes)

Test stand costs (test item time)

Costs of the tools and dies of machine tools (increased wear due to high particle concentrations)

Fluid costs (washing machines, test stations, machine tools)

Labor costs (reworking, cleaning of washing machines, machine tools, etc.)

Filter costs

One-off RecurringInvestment Costs /Year

Function Test Stands (5) 6,500 x 5 = 32,500 7,500 x 5 = 35,000

Storage Conditions 2,500Coverings for the PalletsWashing Machine for Cleaning the Pallets 50,000 25,000

Machining Process 2,000 x 7 = 14,000Manpower/Cleaning 750 x 7 = 5,250Filtration 1,250 x 7 = 8,750

Consulting Expenses 10,000 1,750

Total 109,000 75,750

The economic efficiency analysis (above) describes the success of contamination management as illustrated bya manufacturing line in the automotive industry with an output of 3,000 systems/day. Manufacturing is done260 days/year. A contamination review showed that the cleanliness of the function test stand fluid, theintermediate storage conditions and a machining process had to be optimized.

The next step involved forwarding the cleanliness specifications to the suppliers, who received orientationtraining and are periodically monitored.

The results of optimization:

Less tool wear in surface machining

Longer service life of the machining fluid

Enhanced effectiveness of the downstream washing processes as less dirt had to be removed thanks tooptimized storage and machining

Longer intervals between changing the washing and flushing fluids, consequently “Saturday shifts” could bedispensed with

Fewer outages at the test stand, i.e. the system is checked up to 3 times when performance deviationsoccur. These “idle cycles” were reduced by 90%, thus resulting in increased productivity.

Drop in warranty and non-warranty courtesy work by 50% as the main reason for the outages turned out tobe particulate contamination, which resulted in leakage and imprecise control in the system.

Shortening of the test stand time.

Unfortunately we were not permitted to publish the detailed data behind these savings. Following from aneconomic efficiency analysis conducted by the customer in-house, savings of $0.60 per system were achieved.

When expressed in terms of the company’s annual output of 780,000 systems, this translates into savings of: $468,000

This economic efficiency analysis also includes the expenses associated with contamination management(seminars, consulting fees, analysis costs).

Economic Efficiency

Analysis




Contamination Management in Practice

In the previous pages we discussed the impacts of particulate contamination on the service life and reliabilityof hydraulic systems, how the cleanliness of fluids on components can be specified, and how contaminationmonitoring is performed. Deploying contamination management results in the following tasks for allparticipants in the production process:

Suppliers: Ensuring the defined as-supplied condition of products. Selecting the packaging of products to besupplied so that no additional contamination occurs during transportation and storage.

System vendors and manufacturers: Careful transportation, handling, storage and unpacking of products.Keep products clean after they are unpacked or after seals/plugs have been removed. Assemble/install thecomponents in a suitably clean environment.

The following example shows how these individual parts can be combined in contamination management.

Description of the Point of Departure

System X has been successfully manufactured and marketed for years. During the past few years, System Xhas been developed further and a new generation, System Y, created. Y features improved performanceproperties, is more compact than X, and operates at higher system pressures than X. The result is that SystemY is somewhat more sensitive to particulate contamination.

This is reflected in increased performance deviations during function testing. This deviation no longer occurswhen Y is passed through the test stand a second or third time. An investigation of the matter has shown thatthis unwanted behavior is the result of coarse particulate contamination.

The goal of contamination management is now to improve the degree of cleanliness so that this undesirablebehavior no longer occurs on the test stand and the associated costs of warranty and non-warranty courtesywork are reduced.

Step 1: Analysis of the Test Fluid

The cleanliness of the test fluid is determined. The analyses show that the test fluid cleanliness upstream ofthe test item amounts to a cleanliness rating of 22 / 20 / 18 according to ISO 4406, the largest metallicparticles are 400 µm in size, and the largest fibers measure 3,000 µm.

Step 2: Optimizing the Function Test Stand

By additionally integrating bypass microfiltration, which maintains test fluid cleanliness at 15 / 13 / 10, 95% of the performance deviations can be prevented. This also results in a drop in warranty and non-warrantycourtesy work.

Step 3: Lowering the Filter Costs at the Test Stands

By performing a contamination monitoring audit, it might be determined a large amount of particulatecontamination is being transported into the system by the manufacturing processes and sourced components.This particulate contamination has to be removed from the system at the function test stand, which functionshere as the last washing operation. This results in costs that could otherwise be avoided.

A concept is developed in which the washing and machining processes and intermediate storage are optimized.

A cleanliness specification along with a test plan for system fluids is drafted. This specification is forwarded toexternal as well as internal suppliers and the components supplied with a defined, constant cleanliness.

Step 4: Integrating Particle Counting in Quality Assurance

A particle sensor is integrated in the function test stand for the purpose of continuous quality control of theas-supplied quality of System Y. A limit is defined for the maximum contamination of the test fluid in thereturn line. Intervention can be done immediately if this value is exceeded, thus ensuring that no contaminatedsystems leave the factory. Random sampling is done to check the supplier quality and non-conformantcomponents returned to suppliers or washed in-house at the supplier’s expense.

Step 5: Economic Efficiency Analysis

Contamination management started off with analyzing the costs associated with warranty and non-warrantycourtesy work as the result of increased malfunction at the test stands. These costs are reanalyzed afteroptimization and compared. The savings achieved through optimization are briefly described in EconomicEfficiency Analysis. The cost savings in that case amounted to ca. e 468,000/year. This optimization processlasted ca. 2 years.

Step 6: Documentation and New Projects

The contamination management findings are collected in a database and used in the development of newsystems. The defined maximum residual dirt content becomes standard in new systems in the same way thatdimensions, surface grades and tolerances have been. This residual dirt content is primarily in reference to thespecification that applies to System Y.

The specification is adapted in keeping with the experience gained with the prototypes. Cleanliness andcleaning costs are primarily determined by the design of new systems.




Applications

PressureRequirement

Description

TCMTestMate®

Contamination®

Monitor®

TestMate® Series

Features Measures Particles in Four Sizes: >4, >6, >14, >21 microns

In-line or Manifold Mounting

ISO or SAE codes can be output in 4-20 mA analog signal

Compatible with Standard Mineral Fluids & Phosphate Esters

Display and Keypad can be rotated (up to 270°)

Inlet and Outlet Ports are Interchangeable (bi-directional)

Construction Equipment Combination with Filter Unit

Agricultural Machinery Power Units

Test Benches Any hydraulic system that requires on-line monitoring

Industrial Hydraulic Systems Mobile and Stationary Mining Equipment

Schroeder’s TestMate® Contamination Monitor (TCM) is the newest generation of particle monitors that continuously measure solid contamination in fluid. Enclosed in a 4-inch diameter case, the TCM utilizes an optical sensor and measures particles in four sizes: >4, >6, >14 and >21 microns. Measurement results can be output as a contamination code according to ISO 4406:1999 or SAE AS 4059 (D).

The TCM is designed for connection to hydraulic and lubrication lines with pressures up to 4350 psi (300 bar)and viscosities up to 4635 SUS (1000 cSt). The unit requires that a small flow of oil (between 30 mL/min and300 mL/min) is diverted for measurement purposes.

The TCM provides the user with a smaller, tougher, and more versatile stationary sensor. It provides instantaneousreadings and is able to self-diagnose continuously with error indication via the status LED. The attractive cost-to-performance ratio makes it especially applicable for OEM applications. Online, real-time conditionmonitoring allows you to have total predictive maintenance.

As Shown: Standard TCM (TCM-D-H-A) includes:Unit, CoCos Software, Operation Manual andCalibration Certificate

900

750

600

450

300

150

0

60

50

40

30

20

10

0 927 1854 2781 3708 4635

200 400 600 800 1000300 ml/min

100 ml/min

30 ml/min

∆P (b

ar)

∆P p

si

Viscosity (cSt)

Viscosity (SUS)




ModelNumberSelection

Specifications

Model Display Fluid Output Option

TCM D = Display H = Hydraulic Fluids A = 4-20 mA Omit = Std in-lineX = no E = Phosphate Esters (EPR seals) V = 0-10 V M = Flange

TestMate® Series

Measuring Range: Display ISO ranges between 28/27/26 and 9/8/7Calibration within the range ISO 13/11/10 to 23/21/18

Self-Diagnosis: Continuously with error indication via status LED

Inlet/Outlet: 4350 psi (300 bar) max

Connections: Inlet: ISO 228 G1/4 Threaded Outlet: ISO 228 G1/4 Threaded

Sensor Flow Rate: 30 to 300 ml/min

Permissible Viscosity Range: 0 to 4635 SUS (1 to 1,000 cSt)

Fluid Temperature Range: 32°F to 185°F (0°C to +85°C)

Power Supply Voltage: 9 to 36 VDC residual ripple <10%

Power Consumption: 3 Watt max

Electrical Outputs: 4 to 20mA Analog; 0 to 10V Analog (option)RS485 for communication with CoCos 1000 software

Electrical Specifications: 4 to 20 mA Analog output (max burden 300Ω); 0 to 10 V output (min. load resistor 820Ω)Limit switching output (Power MOSFET): max current 1.5A

Ambient Temperature Range: -22°F to 176°F (-30°C to +80°C)

Storage Temperature Range: -40°F to 176°F (-40°C to +80°C)

Relative Humidity: 95%, non-condensing max

Seal Material: Mineral Oil: Viton® Phosphate Ester: EPR

Electrical Safety Class: III (low voltage protection)

IP Class: IP67

Weight: 2.9 lbs (1.3 kg)

All models feature an analog electrical output and an RS485 interface for outputting the measured contaminationlevels and error codes. Additionally, an electronic switching output can be configured to alert the operator aboutrising or falling contamination levels.

Viton® is a registered trademark of DuPont Dow Elastomers.

Flow ConditioningManifoldP/N TCM-FC

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix

Preferred order codes designate shorter lead times and faster delivery.

Features Manifold will have pressure compensated flow control and

orifices for flow conditioning.

Allows installation in only minutes

Compensates for varying pressures, flow rate, and viscosities

Customer to supply power (9-36 VDC) and pressure (200 psi(13.8 bar) or greater)

What’s IncludedTCM-D-H-A-M, manifold, TCM-C-3M, 2 pcs. 4 mm 1620 Microflex hose (p/n SM4-1620-035) and 2 test points(p/n SP1620UN716VM) for installation into hydraulic system.

Please see page 33 for drawing and dimensions.




TestMate® Series

Features Connect any TCM to an 802.11b/g wireless network

Fully compatible with CoCoS 1000

Connect to TCM from anywhere on the customer’s networkincluding VPN connections for off-site monitoring

Monitor ISO and SAE cleanliness codes

Change TCM settings, download history log, and save values inreal-time

What’s IncludedWireless Access Point, Antenna, Power Cable and M12 x 8 cable

Features Allows user to connect TCM to standard wall outlet

What’s Included115 VAC to 24 VDC power adapter

Flow ConditioningManifold with Water Sensor

P/N TCM-FC-W

Features Enables the user to transfer data from TCM to PC

Enables user to change TCM settings

Enables user to have real time monitoring & data storage

What’s IncludedConverter box, 115 VAC to 24 VDC adapter, USB driver, CoCoS 1000 software, communication & powercables, case

Communication KitP/N TCM-RS485/USB

Wireless Communication

KitP/N TCM-WIFI

Power and Communication

CableP/N TCM-C-3M

Power AdapterP/N TCM-PS

Features Manifold has pressure compensated flow control and orifices for

flow conditioning

Customer only needs to supply power (9-36 VDC) and pressure200 psi or greater

Allows installation in only minutes

Compensates for varying pressures, flow rate, and viscosities

Manifold has water sensor TWS-C installed for measurement ofpercentage saturation

What’s IncludedTCM-D-H-A-M, manifold, TCM-C-3M, 2 pcs. 4mm 1620 microflex hose (p/n SM4-1620-035), TWS-C, TWSPower & Communication cable and 2 test points (p/n SP1620UN716VM) for installation into hydraulic system

Features Cable includes leads for power & communication

What’s Included9.8 ft. (3 m) length cable with M12x8 pin electrical connector on one end and flying leads on the other



ISO 228 G 1/4 Thread

1620 Thread


Schroeder Check®

Test Points OptionsFor TCM

Microflex Hose OptionsFor TCM

TCM-FCDimensions

TestMate® Series

G ThreadSealing PartSystem Number

1/4” BSPP WD Seal Viton SP1620G14WDM

Length ∆P (max) Partinches (mm) psi (bar) Number

6 6,500 SM4-1620-006(152) (450)

12 6,500 SM4-1620-012(305) (450)

35 6,500 SM4-1620-035(889) (450)

71 6,500 SM4-1620-071(1803) (450)

Please see SMART® Kit (pages 36 and 37) for another configuration of the Schroeder TCM.

2.40(61)

1.52(39)

3.27(83)

6.31(160)

SP1620UN716VMTest Point x 2

59 x 2 PL31" Deep

35 x 2 PLThru

6.12(155)

.44-20 Female Orb Port x 23.96(101)4.29

(109)

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix

Metric dimensions in ( ).

TCM-FC-WDimensions

TWS-C-M-0-0

2.40(61)

1.46(37)

3.27(83)

7.81(198)

SP1620UN716VMTest Point x 2

59 x 2 PL31" Deep35 x 2 PLThru

4.55(116 )

4.05(103)

6.12(155)





Applications

Description

TMUTestMate®

Monitoring®

Unit®

TestMate® Series

Features

1 = Display and Keyboard

2 = Pump On/Off Switch

3 = Power Supply Connector 24 VDC

4 = Data Interface (DATA)

5 = Outlet Port

6 = Inlet Port

Particulate contamination is detected with an optical measurement cell

Automatic measurement and display of cleanliness ratings as ISO 4406:1999; SAE AS 4059, and NAS 1638

Measurement Accuracy +/- 1/2 ISO code

Supply voltage 24 VDC

Integrated pump for automatic control of oil flow

Viscosity range: 46 to 1622 SUS (10 to 350 cSt)

Pressure stable up to 5000 psi (350 bar) max

Hydraulic systems

Service for mobile hydraulics

Maintenance

The TestMate® Monitoring Unit TMU series combines the advantages of the portable contaminationmeasurement units with the measurement technology of the Testmate® Contamination Monitor (TCM).

The TMU is a portable service unit and is designed for temporary measurement of solid particle contaminationin hydraulic systems.

The integrated pump and the hoses with test point connections, which are included with the TMU, allowoperation on reservoirs, control circuits, and high pressure circuits.




SpecificationsGeneral data Self-Diagnosis: Continuously with error indication via status LED and display

Measured Value: ISO code / SAE Class / NAS Class / Saturation level / Temperature

Measuring Range: Display from ISO code 9/8/7 (MIN) to ISO code 25/24/23 (MAX)Calibrated within the range ISO 13/11/10 to 23/21/18Saturation level 0 to 100 % / Temperature -13°F to 212°F (–25°C to 100°C)

Accuracy: ± 1/2 ISO class in the calibrated range / ± 2 % Full scale max.

Material of Sealings: FPM Viton seals

Ambient Temperature Range: 32°F to 113°F (0°C to +45°C)

Storage Temperature Range: -40°F to 176°F (-40°C to +80°C)

IP Class: IP50 in operation IP67 closed

Weight: Approx. 29 lbs (13 kg)

Hydraulic Data Operating Pressure: IN: -7.25 to 650 psi (-0.5 to 45 bar)OUT: 0 to 7.5 psi (0 to 0.5 bar)

with Adapter for Pressure Lines: IN: 217 to 5000 psi (15 to 345 bar) OUT: 0 to 7.5 psi (0 to 0.5 bar)

Pressure Max.: 5000 psi (345 bar)

Maximum Suction Height: 39 in (1 m)

Permissible Viscosity Range: 46 to 1622 SUS 10 to 350 cSt

Fluid Temperature Range: 32°F to 158°F (0°C to +70°C)

Electrical Data Power Supply Voltage 24 VDC ± 20%, residual ripple < 10%

Max. Power / Current Consumption 100 Watt / 4 A

Interface Plug connection, 5-pole, male, M12x1 and Bluetooth 1.2, Class 3

TestMate® Series


Contamination Integrated Power Model Code Sensor Supply

Adapter

1 = ISO 4406:1999; SAE AS 4059/> 4 µm(c) > 6 µm(c) > 14 µm(c) > 21 µm(c)

Omit = No SensorTMU

AS = Aqua Sensor

We do not guarantee the accuracy or completeness of this information. The information is based on average working conditions. For exceptional operating conditions, please contact our technical department. All details are subject to technical changes.

K = 120 VAC/60 Hz/1 Phase

M = 230 VAC/50 Hz/1 Phase

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix





Description

SMART®

Kit®

TestMate® Series

Features Real time ISO 4406:1999 codes or SAE AS 4509 (D)

Eliminates need for bottle samples to determine contamination

Plug and play with all Schroeder standard kidney loop skids (KLS, KLD, MFS, MFD)

No modification required to mount & use

Can be used on an existing cart or skid already purchased from Schroeder

Inexpensive & reliable way to ensure roll-off cleanliness

Continually displays cleanliness levels

Download data for trending

Can use as a stand-alone system on reservoirs, barrels, totes, etc.

The Schroeder SMART® Kit is the perfect solution for measuring contamination levels in hydraulic andlubricating oils. This unit comes complete with the Schroeder TestMate® Contamination monitor, making iteasy to continuously monitor and display ISO levels in real time. This kit can be added as a retrofit to any of Schroeder’s Standard Filtration Carts (MFS/MFD), Kidney Loops (KLS/KLD) or Skids without any additionalmodifications. Carts and Kidney Loops can also be ordered with the SMART® Kit included. These configurationsare known as Mobile SMART® Filtration Systems (MSS/MSD) and Kidney Loop SMART® Systems (KSS/KSD),respectively.

Includes:

• TestMate® Contamination Monitor (TCM)

• TCM Calibration Certificate

• Operating and Instruction Manual

• CoCos software

• Connection hoses

• Mounting clips and screws

• RS-232 connection for ability to download to PC (only available with SMK units)

• Integrated pump for proper fluid conditioning on low pressure systems




ModelNumberSelectionSMART® Kit

SpecificationsContamination Readout: ISO 4406:1999 or SAE AS 4059 (D)

Maximum Viscosity: 1,000 SUS

Compatibility: All petroleum-based hydraulic fluids

Weight: 18.1 lbs (8.21 kg)

Power Requirement: 115 VAC

Max. Inlet Pressure: 100 psi (<0.48 bar)

Operating Temperature: -20°F to 150°F (-29°C to 65°C)

PartNumber Description

SMK-16 Stand-Alone System

TestMate® Series

ModelNumberSelectionRetrofit

Retrofit For SMART® Kit Model

SMK-16 MFS/MFD Filter Cart (7 and 14 gpm)

SMKK-16 KLS/KLD Kidney Loop (7 and 14 gpm)

6.07(154)

Pressure Gauge300 PSI

1/4” JIC FemaleInlet (Suction)

(2X) 1/4" JIC Male Elbow

AdaptersIncluded(Optional

InstallationMethod)

1/4" JIC Female Outlet (Discharge)

PowerSupplyCord (7 ft)

2.12(54)

(4X) 1.00 Clamps W/Screws included(Optional Installation Method)

0.64

9.15(232)

11.00(279)

12.50(318)

RS-232PC Connection

ContaminationMonitor

Needle Valve

8.12(206)

2.02 (51)

30°

PowerSupplyPlug

(16)

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix





Applications

Description

TPMTestMate®

Particle®

Counter®

TestMate® Series

Features

A = Suction Inlet (suction port)B = Outlet (return flow to tank)C = Inlet (high pressure port)D = On/Off SwitchE = Power Supply Connection (main)F = PC Connector (serial port)G = Control Connector

H = Power Supply Connection (pump)I = Filter CoverJ = Case GroundK = Ball Valve (for INLET/high

pressure port)L = Ball Valve (for SUCTION

INLET/suction port)

Measures and counts solid contaminants in hydraulic and lubrication oil

Completely portable for in-plant and field use

Provides in-line counts for continuous measurement

Built-in printer provides results of particle count for archive

Unit can be programmed to activate a relay when the contamination level reaches target value

Data can be analyzed using Schroeder software or MS-Excel software for single incidence or for trending

Preventive maintenance

Troubleshooting

Roll off cleanliness of mobile and industrial equipment

Proof of clean fluid delivery

Flushing of existing equipment

The TPM is a portable particle counter with an integrated pump that can be used in-line to measurecontamination levels of hydraulic fluid. Particles are measured at the 4, 6, and 14 micron sizes, with resultsavailable in ISO 4406 (1999) and SAE AS 4059, as well as several other options. Various programming optionsare available, including the ability to activate or de-activate system functions when contamination reaches auser-specified level. It is equipped with a built-in printer to provide instant documentation and an RS-232 serialport for data transfer. A custom software package is also included for trend analysis on a PC. The unit’s robustpackaging includes a folding handle which doubles as a stand to provide optimal viewing.






PressureRequirement

SpecificationsParticle Size Channels: 4 µm(c) / 6 µm(c) / 14 µm(c) / 21 µm(c)

Measurement Range: ISO 13/11/10 to 23/21/18 (SAE 2 to 12)

Indication Range: ISO 12/10/9 to 25/23/21 (SAE 2 to 15)

Accuracy: ±1/2 class (ISO, SAE)

Calibration: ISO 11943

Recalibration: 1 to 2 years, dependent on customer’s quality policy

Log Memory: Internal memory can accommodate up to 3000 measured values /100 Test Headers

Inlet Operating Pressure: 45 to 5000 psi (3.1 to 344.8 bar)

Outlet Flow Rate: 800 mL/min max

Outlet Operating Pressure: 45 psi (3.1 bar) backpressure max

Measurement Flow Rate: 50 to 150 mL/min

Permissible Viscosity Range: 50 to 5000 SUS (inlet port, see graph below)

Fluid Temperature Range: 32°F to 160°F (0°C to 70°C)

Power Supply: 24 VDC, ±25% or 110 VAC with supplied adapter


Battery Powered: 5 hoursOperating Duration:

Serial Port: RS-232 with 15-pin Sub D plug

Ambient Temperature Range: 32°F to 130°F (0°C to 55°C)

Storage Temperature Range: -4°F to 185°F (-20°C to 85°C)

Relative Humidity: 90%, non-condensing max

IP Class (Protection Type): IP40

Weight: 30 lbs (13.6 kg)

Includes TestMate® Particle Counter (TPM), Integrated pump and accessory kit TPM-H(adapter, inlet & outlet hose, software package, PC cable, and carrying case).

Transport Case TPM-100

Printer Paper (5 rolls) 00349155

Printer Ink Ribbon 00349156

Line Adapter 110 V 03090803

High Pressure Hose 6.5 feet (2 m) 00349150

Return Hose 6.5 feet (2 m) 00349151

BOLD part numbers indicate IN STOCK

The minimum inlet pressurerequired to achieve a flow rate of100 mL/min for a given viscositycan be found by referring to thegraph at the right. The requiredinlet pressure increases withincreasing clogging of the filterelement.

Viscosity (cSt)

∆P p

si

∆P (b

ar)

200 400 600 800 100030

20

10

TestMate® SeriesTCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

TIMTestMate®

In-Line®

Counter®

TestMate® Series

Features Compatible with hydraulic fluids, lube oils, and fuels

Data can be transmitted to various output devices to perform specific functions, such as illuminate awarning light, sound an alarm, activate an auxiliary filtration system, or even shut down equipment

The robust sensor utilized in the TIM is not susceptible to dark fluids, pressure spikes, vibrations, or hightemperatures, and is identical to that used in the TPM

Small size makes installation unobtrusive

Paper and steel mills

Power generation plants

Lube oil systems

Gear boxes

The TIM from Schroeder is an in-line contamination counter capable of transmitting information regardingfluid cleanliness in various formats to a wide variety of devices in real time. Software is included to transmitdata to a PC. Alternative user-supplied output devices include PLCs, individual display units, and warning lightsvia trigger points. This unit is intended for critical systems where continuous contamination monitoring is a must.

WarningLamps

ISO CodeDisplays

PLC

User’sSoftware

SuppliedSoftware






SpecificationsParticle Size Channels: 4 µm(c) / 6 µm(c) / 14 µm(c) / 21 µm(c)

Measurement Range: ISO 13/11/10 to 23/21/18 (SAE 2 to 12)

Indication Range: ISO 12/10/9 to 25/23/21 (SAE 2 to 15)

Accuracy: ±1/2 class (ISO, SAE)

Calibration: ISO 11943

Recalibration: 1 to 2 years, dependent on customer’s quality policy

*Max Operating Pressure (outlet): 145 psi (10 bar)

*Max Operating Pressure (inlet): 580 psi (40 bar)

*Max Surge Pressure: 5070 psi (350 bar)

Connections: Inlet: Thread G 1/4, ISO 228Outlet: Thread G 1/4 ISO 228

Sensor Flow Rate: 10 to 200 mL/min

Total Flow Rate: 10 to 800 mL/min (pressure dependent)

Fluid Temperature Range: 32°F to 158°F (0°C to 70°C)

Power Supply: 24 VDC ±25%


Electrical Output: • 3 relay outputs: 1 x state of readiness; 2 x limit;• PLC output; • Additional electrical output (see model code)

Ambient Temperature Range: 32°F to 131°F (0°C to 55°C)

Storage Temperature Range: -4°F to 185°F (-20°C to 85°C)

Relative Humidity: 90%, (non-condensing) max

Electrical Safety Class: III (low voltage protection)

IP Class (Protection Type): IP65

Weight: 8.8 lb (4 kg)

*At pressures beyond maximum operating pressure specified above, the sensor will not measure properly. However, the unit can handle pressure spikes up to 5070 psi without incurring damage to the sensor.

In-Line Monitor Fluid Type Pressure / Viscosity Range Output

1 1 = 4-20mA

TIM H = Hyd. Oil 2 3 = RS-485

E = Phosphate Ester 3 4

Refer to chart above for value.

TestMate® Series

Pressure/ViscosityRange

(enables communicationwith software)

4 = PLC output5 = Ethernet

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

CTUTestMate®

Contamination®

Test Unit®

TestMate® Series

Features Cost reduction through lower production failure rates

Identification and elimination of weak process steps

Optimization of both internal and external handling processes

Establishing of cleanliness standards, both internal and external

Documentation of component cleanliness

Survey of fluid cleanliness and filtration concepts

Automotive suppliers

Gear box builders

Engine builders

Suppliers of hydraulic and lubrication components

The CTU-1000 is ideal for determining component cleanliness of small hydraulic components. For example:hoses, CAM shafts, hydraulic manifolds, etc.

Determining the type, size, and quantity of contaminants is useful for verifing quality standards and systemoptimization.

31

(780) 45

(1125)

39(980)

31(780)

60(1500)

61(1535)






Specifications

Installation Size Analysis Supply Extraction SupplementaryModel Series Dimensions Fluid Voltage Process Details

Analysis Room

0 = Solvent A III Class sZ = Rinsing Z = Series0 = 11.81 x 31.50 x 15.75 in 0 = (Flashpoint >60°C, lower K = 120 VAC/60Hz/ sZ = (middle pressure)

CTU0 = (300 x 800 x 400 mm) 0 = explosions limit >0.6% Vol.) K = 1 Phase1 = Analysis U = Rinsing R = external rinsing

1 = Room 2 = 21.65 x 31.50 x 25.59 in 1 = Water with tenside, lower M = 230 VA C/50Hz/ sZ = (middle pressure) R = connection

0 = (550 x 800 x 650 mm) 0 = admissible ph-range 6-10, no K = 1 Phase sZ = additiionally R = .24 in (6 mm),

0 = deionized/demineralized water sZ = ultrasonic R = between hand contact

Scope of Delivery: CTU1000 15" TFT Monitor; Keyboard with Touch Pad; Foot Switch Accessories: Contact Factory

This information relates to the operating conditions and applications described. For applications or operating conditions not described,please contact the relevant technical department. Subject to technical modifications.

TestMate® Series

Overall Dimensions (H x W x L): CTU10 71 in x 39 in x 35 in (1800 mm x 1000 mm x 900 mm)CTU12 71 in x 39 in x 43 in (1800 mm x 1000 mm x 1100 mm)

Weight: CTU10 = 595 lb (270 kg) 639 lb (290 kg) with ultrasonic CTU12 = 683 lb (310 kg)

Mounting: Mobile (mounted on casters)

Power Consumption: 600 W (800 W with ultrasonic)

Ambient Temperature: 59°F to 82°F (15°C to 28°C)

Cleanroom module

Material of Cleanroom: Polished stainless steel

Filling with Analysis Fluid: Via analysis cabinet

Control: PC-controlled with user-friendly software, rinse options and rinsing volumeprogrammable

Reservoir and filtration module

Membrane Holder: 47 mm to 50 mm filter membranes

Vacuum Strainer: For quicker filtration of the analysis fluid

Diffuser: Distribution of analysis fluid on the membrane

Operating Pressure: 11.6 to 87 psi (- 0.8 to 6 bar)

Analysis Fluid Reservoir: 2x 5.3 gal (20 l) (1x reservoir, 1x suction reservoir)

Reservoir Change-over: Automatic

Filtration of Analysis Fluid: Fine filtration according ISO 4406 min. ISO 12/9

Filter Clogging Indicator: 14.5 psi (1 bar) pressure setting

Filter Size, Filtration Rating: 2x LF BN/HC 60, 3 µm (1xx0 series)

Integrated Drip Tray: 6.6 gal (25 litre) with drainage

Services to be provided by operator*

Compressed Air: Filtered (min. 5 µm) and dry compressed air, max. 87 psi (6 bar)Air flow rate: 2.12 cfm, Supply connection: DN 7.2

Power Supply: According to order*Not supplied

Blank Control Values All data depends on ambient conditions

Ambient: CTU 1000Cleanroom: 0.4 to 0.6 mgLaboratory: 0.6 to 1.0 mg

Separate Sampling Room: 0.6 to 1.2 mgWorkshop: 1.0 to 1.4 mg

Maximum Time and Cleaning Time after a short Cleaning Time after a longParticle Size µm Effort standstill period (≤ 24 hours) standstill period (> 24 hours)

100* high 1.5 to 4 hours 3 to 5 hours

150* medium 1 to 2 hours 2 to 4 hours

250* low 0.5 to 1.5 hours 1 to 3 hours*With maximum membrane load of 0.8 mg.

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

TWS-CTestMate®

Water®

Sensor®

TestMate® Series

Features Compatible with hydraulic, lube oils and esters

Measures and displays saturation and temperature continuously

Displays saturation level in percentage (0% indicates oil is dry; 100% indicates oil is saturated)

Data can be monitored to PC, PLC, etc.

Hydraulic systems that are sensitive to water in oil

Gear boxes

Injection molding machines

Turbines

Transformers

Since the effects of free (also emulsified) water is more harmful than thoseof dissolved water, water levels should remain well below the saturationpoint. However, even water in solution can cause damage and thereforeevery reasonable effort should be made to keep saturation levels as low as possible. There is no such thing as too little water. As a guideline, werecommend maintaining saturation levels below 45% in all equipment.

The TWS-C is individually calibrated on computer-controlled test rigs andsubjected to a final test and will operate perfectly when used according tothe specifications.

If you have any questions regarding technical details or the suitability ofthe TWS-C for your application, please contact our sales/technicaldepartment.

The TWS-C is a saturation and temperature sensor for the monitoring of hydraulic and lubrication fluidsaccurately, continuously and on-line. It measures the water content relative to the saturation concentration(saturation point) and outputs the degree of saturation (saturation level) in the range of 0 to 100% as a 4 to20 mA signal. A reading of 0% would indicate the absence of water, while a reading of 100% would indicatethat a fluid is saturated with water.

The special capacitance sensor used in the TWS absorbs water molecules from the fluid and changes itscapacity value that is directly related to the saturation level in the fluid. An integrated thermoelement on thesensor measures the temperature of the fluid in the range of -13°F to 212°F (-25°C to 100°C) and outputs itas a 4 to 20 mA signal.

6KT-SW27 Plug M12x1. 5 pole

1.18 (30)

1.16 (29.5)

0.86(21.9)

0.47(12)

0.47(12)

0.10 (2.5)

2.18 (55.3)

2.64(67.1)

G3/8A

1.06 (27)

DesiredSaturation

LevelSaturation level

Saturationpoint

Dis

solv

ed w

ater

Fre

e w

ater

100%

75%

50%

25%

0%




1.04(26.5)

1.26

(32

) 0

.78

(20

)

1.10

(28)

1.38 (35)



SpecificationsInput Data: Measuring Range: 0 to 100% Saturation; -13°F to 212°F (25°C to 100°C)

Operating Pressure: 725 psi (50 bar) max

Overload Pressure: 9135 psi (630 bar) max

Parts in Contact with Media: Stainless steel, seal Viton or EPR Ceramic with evaporated metal

Output Data: Humidity Measurement:

Output Signal (saturation level): 4 to 20 mA

Calibrated Accuracy: ≤ ± 2% FS max

Accuracy in Media Measurements: ≤ ± 3% FS typ.

Pressure-dependent: + 0.02% FS/bar

Output Data: Temperature Measurement:

Output Signal (temperature): 4 to 20 mA

Accuracy: ± 2% FS max

Ambient Nominal Temperature Range 32°F to 194°F (0°C to 90°C)Conditions: (saturation level measuring):

Ambient Temperature Range: -40°F to 212°F (-40°C to 100°C)

Fluid Temperature Range: -40°F to 257°F (-40°C to 125°C)

Viscosity Range: 32 to 23,175 SUS (1 to 5000 cSt)

Flow Velocity: < 16 ft/s

Media Tolerance: Mineral oil-based fluids, natural and synthetic esters

Mark: EN 50081-1, EN 50081-2, EN 50082-1, EN 61000-6-2

Type of Protection acc. DIN 40050: IP 67

Other Data: Supply Voltage: 12 to 32 VDC

Residual Ripple Supply Voltage: ≤ 5%

Mechanical Connection: G3/8A DIN 3852

Torque Rating: 18.5 ft-lbs

Electrical Connection: M12x1, 5 pole (DIN VDE 0627)Pin 1: +UbPin 2: Signal saturation levelPin 3: 0V / GNDPin 4: Signal temperaturePin 5: Not connected

FS (Full Scale) relative to the full measuring range

TestMate® Water Sensor Type of Medium Signal Technology Signal Technology

TWS-C M = Mineral Oil

E = Esters0 = Saturation Level 0 = Temperature

TestMate® Series

AccessoriesPart Number Description Color Code

ZBE 08 (5 pole) Connector M12x1, right-angled Pin 1: Brown

ZBE 08-02 (5 pole) with 2m cable Pin 2: White

VDP-177 (5 pole) with 5m cable Pin 3: Blue

ZBE 08S-02 (5 pole) with 2m screened cable Pin 4: Black

ZBE 08S-05 (5 pole) with 5m screened cable Pin 5: Grey

ZBE 08S-10 (5 pole) with 10m screened cable


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

ET-100-6The “Original”®

TestMate®

TestMate® Series

Features Easy to use – for beginner or experienced troubleshooters

Large meters are clearly marked with easy-to-read scales

Scale selector switches and the load valve control knob are also large and specially designed to be easy togrip under any conditions

All loose components are stowed in form-fitting recesses in the impact resistant plastic case that also protectsthe meters and circuitry

The electronic sensor and the EasyTestTM fitting are the only components that see hydraulic fluid, so clean-upis limited to draining the sensor and replacing the cap on the EasyTestTM fitting

The load valve allows the operator to simulate operating pressure, if required

Check systems before and after rebuild

Use as part of a preventive maintenance program

Use to troubleshoot in instances of poor system performance or excessive machine downtime

Use to check performance on a production line

Install EasyTestTM fittings on prototypes to accurately evaluate hydraulic performance at any stage of development

Schroeder’s original TestMate® system with the patented EasyTestTM fitting provides the hydraulic user with aquick, convenient method to test, troubleshoot, and obtain preventive maintenance data on hydraulic systems.Flows up to 100 gpm and pressures up to 6000 psi, as well as operating temperature, are measured through anEasyTestTM fitting, which is permanently installed in the hydraulic system.

The sensor and EasyTestTM fittings are robust units designed to operate safely at any system pressure up to themaximum 6000 psi that the sensor load valve is capable of generating. Pressure bearing parts are thick-sectionaluminum extrusions carefully chosen for their combination of high strength and light weight.

If the system’s prime mover is kept at constant rpm, any drop in indicated flow will represent a loss of systemefficiency at the point of test. During testing, system operation can be used to create the load, or the load canbe simulated with the load valve in the sensor block.

The electronic circuitry produces data that accurately reflects system performance at each test point throughoutthe operating pressure range, making it possible to also determine pump and motor efficiency as well as valveand cylinder leakage.

Hydraulic Circuit Tester

Set-up1. Read Manual2. Attach Sensor to Fitting3. Connect Cable4. Open Load Valve

Test1. Set Switches Vertical2. Power On3. Start up Hydraulics4. Run Test

Take-down1. Power Off2. Hydraulics Off3. Remove Sensor4. Drain all Fluid

FLOWgpm

PRESSUREpsi

Pressure meter has lowand high scale, andbattery check.

Flow meter includeslow and high scale, andtemperature scale.

Auxiliary pressure outputallows attachment tooscilloscope.

Three-position selectorswitches are easy tooperate.

Load valve cangenerate 6000 psi.

9' cable connects sensor to TestMate®.

Captive sensorbolts cannot get lost.




EasyTestTM

Fittings

SpecificationsFlow Meter: Type: Electronic turbine

Low Scale Range: 0 to 20 gpm (0 to 75.7 L/min)

Low Scale Accuracy: ±1 gpm @ 3 to 5 gpm (11-19 L/min)±0.2 gpm @ 6 to 20 gpm (22.7-75.7 L/min)

High Scale Range: 0 to 100 gpm (0 to 378.5 L/min)

High Scale Accuracy: ±2% of full scale

Minimum Reading: 3 gpm (11.35 L/min)

Pressure Meter: Type: Electronic transducer

Low Scale Range: 0 to 1000 psi (0 to 3784 L/min)

Low Scale Accuracy: ±35 psi (2.41 bar)

High Scale Range: 0 to 6000 psi (0 to 413.8 bar)

High Scale Accuracy: ±120 psi (8.44 bar)

Auxiliary Pressure Output: BNC connector - 2.5 mv @ 0.1mA per 1000 psi (68.96 bar),linear in the range 0 to 6000 psi (0 to 413.8 bar),independent of meter scale selection

Temperature Scale: 50°F to 250°F (10°C to 121°C)

Power Source: 8 “C” size batteries To be furnished by customer

Weight: 18 lbs (8 kg)

Case Dimensions: 19.87 x 13.93 x 4.68 in (50.4 x 35.4 x 11.9 cm)

EasyTest Fitting Envelope Dimensions: 4.5 x 4 x 3 in (114 x 102 x 76 mm)

EasyTest Fitting Mounting Holes: Qty 2 - .375 to 16 UNC .75 dp.

Clearance to Install Sensor: 11 in (280 mm) min

TestMate® Series

Model Numbers

Port Type and Size Station with Through Flow Station with Blocked Flow for In-Line Testing for “T” Testing

NPTF0.75 A-ET-211 A-ET-1971.00 A-ET-212 A-ET-1981.25 A-ET-213 A-ET-1991.501 A-ET-256 A-ET-312

SAE O-Ring1.06-12 A-ET-215 A-ET-2011.3125-12 A-ET-216 A-ET-2021.625-12 A-ET-217 A-ET-2031.875-121 A-ET-258 A-ET-313

SAE 4-Bolt Boss2

0.75 A-ET-219 A-ET-2051.00 A-ET-220 A-ET-206

BSP PL0.75 A-ET-222 A-ET-3141.00 A-ET-223 A-ET-3151.25 A-ET-224 A-ET-316

1For 3000 psi only 2Depth of holes not per SAE specifications


Original TestMate® Option

ET-100-6 C = MSHA approved*

*Required for any underground coal mining application. Unit will be furnished with the required MSHA tag.

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Features

HMGSoftware

DisplayOptions

TestMate® Series

HMG 3000Data Recorder

The HMG 3000 data recorder is a portable unit for measurement and data capturing tasks involving hydraulicand pneumatic systems. Applications extend primarily to maintenance andservicing, troubleshooting, test stands, and quality inspecting.

The HMG 3000 can concurrently evaluate signals from up to 10 sensors. The unit features 5 input jacks for connecting the sensors. If necessary, this numbercan be doubled using a Y adapter for measurement operations involving morethan 5 sensors. Schroeder offers HSI sensors (HSI = Hydraulic Sensor Interface) for pressure, temperature and flow rate, which are automatically recognized by the HMG 3000. Standard analog sensors can also be used, but these sensors must be manually configured.

The HMG 3000 communicates with a computer via a USB port. Schroeder offers HMGWIN 3000, thematching software for the HMG 3000, for convenient post-processing, rendering, and evaluation ofmeasurements on a PC. It also enables the HMG 3000 to be operated directly from a computer.

The HMG 3000 is equipped with specially developed software providing for fast data collection andprocessing. A measurement curve can comprise up to 500,000 measured values. The HMG 3000’s measuredvalue memory is capable of storing at least 60 of these measurement curves.

In addition to recording measurement curves, the HMG 3000 can be configuredfor event-triggered measurement and recording.

Apart from measurement curves, the HMG 3000 can store user-specific settings(user profiles). The main advantage of this is enabling identical measurements of various equipment items to be repeated for the purpose of preventivemaintenance. All the user has to do is retrieve the respective user profile from the HMG 3000’s memory.

The HMG 3000 features a 3.5" color full-graphics display enabling the measuredvalues to be rendered in an easy-to-read form as text or a measurement curve.Individual measured values can be displayed in a large format (7-segment format),enabling them to be read at an extended distance.

The HMG 3000 also provides for a variety of user-friendly features for displaying,evaluating and processsing measured values:

• Table • Graph • Scaling

• Ruler • Tracker • Zoom

The HMG 3000 is user-friendly by virtue of its easy-access selection menusleading to all of the unit’s functions and settings. The unit features a combinationkeypad for entering numeric values and text.

The HMG 3000 was designed for capturing typical measurement values (pressure,temperature, volumetric flow rates) in hydraulic and pneumatic systems. A varietyof other measurement tasks can be performed by virtue of additional inputs foranalog signal measurement. Example: Checking the actuation of a switchingvalve or plotting the characteristic curve of a valve setpoint. In addition, it ispossible to determine differential values between the measured values of individual sensors. One example of this is taking a volumetric flow measurement using a differential pressure orifice plate.

In addition to the analog measurement inputs, the HMG 3000 features twodigital outputs, enabling frequencies or speeds to be recorded, thus expandingthe unit’s range of potential applications.

When taking measurements of rapid, dynamic machine processes, all 8 analoginput signals can be concurrently captured at a rate of 0.5 ms per sample.

A special feature of the HMG 3000 is its ability to record the dynamic processesof a machine in the form of a measurement curve and render them as a graph –on-line and in real time.




HMG DisplayPanel

TestMate® SeriesTCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix

Connections

On/Off button

Brightness/contrast setting of the display

ESC key – For canceling an entry or going backstep by step

Shift key – Switches the number pad to a textpad when pressed; the text pad isactive only as long as the Shift keyis pressed.

Keypad – Numbers and letters can be enteredvia the combination keypad in afashion similar to that of mobilephones.Numbers: 0 to 9;

“.” (decimal separator) and “-” (minus)

Text Entry: upper and lower case alphanumeric charactersINS = insert; DEL = delete;Entry of spaces: SHIFT + INS (simultaneously)Deletion of characters: SHIFT + DEL (simultaneously)

Graphic display – Display of the menu and operating functions, measured values and measurement curves

5-way navigation key – For navigating step by step in the display OK key for inputting, concluding, acceptingor storing an entry

A - D & E - H 4 sensor input jacks for up to 8 sensors with an analog signal (channel A – D and E – H*),(e.g. for sensors for measuring pressure, temperature or flow rate.) The 4 input jacks can be doubled by plugging in Y adapters.*Channel H can be used for sensors with an analog signal as well as for voltagemeasurements of -10V to 10V.

I / J 1 or 2 input jacks for:2 digital signals, (e.g., for frequency or speed measurements) (channel I, J)1 voltage input (-10V to 10V, channel H*)

DC IN Female connector for power supply

USB 1 USB connector



Sensor Inputs: 4 input jacks for 8 analog inputs (channel A – H)

1 input jack for 2 digital inputs (channel I – J)

Voltage input of -10 V to 10 V (shown at channel H)

Connecting the sensors is done using a standard M12 x 1 plug connector (5-pin)

Channel A to H: Automatic detection for HSI sensors (pressure, temperature, volumetric flow rate transducers)

Connection of standard sensors with current or voltage signals

Differential channels for channel A – B; channel C – D

A & B C & D E to G H4 to 20 mA 4 to 20 mA 4 to 20 mA 4 to 20 mA0 to 20 mA 0 to 20 mA 0 to 20 mA 0 to 20 mA0 to 10 V 0 to 50 V -10 to +10 V0 to 5 V 0 to 10 V1 to 5 V 0 to 5 V1 to 6 V 1 to 5 V0.5 to 4.5 V 1 to 6 V0.5 to 5.5 V 0.5 to 4.5 V

0.5 to 5.5 V

Channel I and J: Frequency channels (speed (rpm) measurement, counting function)

Frequency range: 1 to 30 000 Hz

Switching threshold: 2 V

Maximum input voltage: 50 V

Sampling Rates: The following applies: 0.1 ms = max. 2 analog input signals(The sampling rate which can be set 0.2 ms = max. 4 analog input signals

is dependent on the active 0.5 ms = all 10 input channelsmeasurement channels.)

Battery service times: Without any sensors = 11 hours

(battery is fully charged) With 2 sensors = 9 hours

With 4 sensors = 7 hours

With 8 sensors = 4 hours

Measured Value Memory: Single recording: up to 500,000 measured values

Archive memory: 64 MB

(for approx. 60 individual recordings consisting of 500,000 measured values each)

PC Link Interfaces: USB port

Standard serial port (RS 232) for communication and evaluation using the HMGWIN 3000 software

Dimensions and Weight: Measurements: 9.68 x 6.85 x 2.28 in (246 x 174 x 58 mm)

Weight: 2.42 lbs. (1.10 kg)

Operating and Ambient Conditions: Operating temperature: 0°F to 122°F (0°C to 50°C)

Storage temperature: -4°F to 140°F (-20°C to 60°C)

Relative humidity: 0 - 70 %

Standards with which the EMC: EN 61000-6-1, EN 610 0-6-2, EN 61000-6-3, EN 61000-6-4

HMG 3000 Complies: Safety: EN 61010

Protection type/rating: IP40


HMG 3000continued

Specifications

TestMate® Series液压油污染检测专家--美国SCHROEDER



TestMate® Series

Description Part Number

Diagnostic Unit HMG 3000 HMG-3000Battery and Charging UnitHMGWIN Software USB CableUser Manual

Pressure Transducers with HSI 0 to 232 psi (0 to 16 bar) HDA 4748-H-0016-15 to 131 psi (-1 to 9 bar) HDA 4748-H-00090 to 1450 psi (0 to 100 bar) HDA 4748-H-01000 to 3625 psi (0 to 250 bar) HDA 4748-H-02500 to 5800 psi (0 to 400 bar) HDA 4748-H-04000 to 8700 psi (0 to 600 bar) HDA 4748-H-0600

Temperature Transducer with HSI -13°F to 212°F (-25°C to 100°C) ETS-4548-H

Additional Sensors RPM Sensor (M12x1 2M Cable) HDS-1000-002RPM Sensor Reflective Strips (25 pcs) HMG-100TestMate® Contamination Monitor (TCM) See page 30TestMate® Water Sensor (TWS-C) See page 44

Flow Sensor with HSI 1.6 to 15.9 gpm (Aluminum) EVS-3100-H-110.6 to 159.0 gpm (Aluminum) EVS-3100-H-24.0 to 79.3 gpm (Aluminum) EVS-3100-H-30.3 to 5.3 gpm (Aluminum) EVS-3100-H-51.6 to 15.9 gpm (Stainless Steel) EVS-3110-H-110.6 to 159.0 gpm (Stainless Steel) EVS-3110-H-24.0 to 79.3 gpm (Stainless Steel) EVS-3110-H-30.3 to 5.3 gpm (Stainless Steel) EVS-3110-H-5

Accessories TWS-C Adapter HMG-1012M Cable for M12x1 ZBE-30-025M Cable for M12x1 ZBE-30-05M12/Binder Adapter ZBE-34M12/Hirschmann Adapter ZBE-35M12 “Y” Adapter ZBE-38Universal Connection Module HMG-102Case HMG-103

Spare Parts DC Charging Unit HMG-104

Deluxe HMG Kit – Part Number HMG-3000-D

Quantity Description Part Number

1 HMG-3000 Diagnostic Unit HMG-3000

2 0 to 5800 psi (0 to 400 bar ) Pressure Transducer (w/HSI) HDA-4748-H-04001 0 to 8700 psi (0 to 600 bar ) Pressure Transducer (w/HSI) HDA-4748-H-0600

1 -13°F to 212°F (-25°C to 100°C) ETS-4548-HTemperature Transducer (w/HSI)

4 2M M12x1 Cable ZBE-30-023 Direct Gauge Adapter S1215DCG14CU1 Case HMG-103


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

EWCEasyTestTM

WaterTM

ContaminationTM

SamplerTM

EasyTestTM Series

Features Compatible with hydraulic and lube oils

Five-year battery life (or 5000 tests, whichever comes first)

Auto power shutdown after 6 minutes of inactivity conserves battery life

LCD screen can display six lines of text

On-screen directions and menus make unit easy to use

Kit includes everything necessary for performing tests, including plastic gloves

User selects from three available outputs for expression for water content:• 0.02% to 1.00%• 0% to 10%• 200 ppm to 10,000 ppm (100 ppm = 0.01%)

Portable kit provides results on site in a matter of minutes

Hydraulic systems that are sensitive to water in oil

Gear boxes


Turbines

Transformers

Schroeder’s EasyTestTM Water Contamination Sampler is a portable kit for quantitatively determining the amountof water present in a fluid sample. The heart of the kit is an aluminum mixing vessel, or cell, with a small LCDdisplay and microprocessor built into the lid. When the two reagents supplied in the kit (one liquid and onepowder) are mixed with the sample fluid in the cell, the resulting chemical reaction causes an increase inpressure within the vessel. This change in pressure is converted into water content and displayed on the screenin terms of parts per million (ppm) or % by volume (saturation level).




Procedure

EasyTestTM Series

The following instructions appear in the display after selecting the output (referred to as “Range” on the screen):

Quantity Description Quantity Description

1 Mixing Chamber 1 Tweezers

2 Reagent A, 500 ml bottle 1 Scissors

1 Reagent B, 50 packets 1 Measuring cup, 100 ml

3 Disposable syringe, 5 ml 1 Case, including strap

1 Disposable rubber gloves, bag containing 50 pairs 1 Operating Instructions


Part Number Description Part Number Description

EPK-112 Replacement Parts Pack, consisting of:• 2 pcs. 500 ml bottles of REAGENT A• 50 packets of REAGENT B• 50 pair of gloves• 3 pcs. Disposable syringe 5 ml• 1 ea. Tweezers• 1 ea. Scissors

Accessories

XX = required quantity of oil, depending on testingrange (defined in Operating Instructions).

After careful measurement, Reagent A is pouredinto the mixing chamber.

Using a disposable syringe, fluid sample size (see chart below) is placed into chamber.

Range Fluid Sample

0% to 10% 1 ml0.02% to 1% 5 ml

200 ppm 0 10,000 ppm 5 ml

A packet of Reagent B is placed into the mixingchamber using the tweezers.

A graph is plotted during the test time (120seconds). Continue shaking the cell until thegraph has finished.

To cancel the test, press CANCEL and keep itpressed for 5 seconds.

Your result is displayed after the graph has beenplotted.

Press NEXT to repeat test.

EPK-110 Mixing chamber (cell)

6009983 1 O-ring(Seal ring for cell lid)

1) Add 20ml ReagA2) Add XXml Oil3) Cut ReagB pack4) Place in cell5) Replace lid

BACK START

Test Complete

1.52%Water in Oil

NEXT

501.47%

CANCEL-hold 5 sec

EasyTestTM Water Contamination Sampler Option

EWC None. Kit contents listed below.


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Applications

Description

EPKEasyTestTM

Patch Test KitTM

EasyTestTM Series

Features Compatible with hydraulic and lube oils

Provides results on site in a matter of minutes

Determines both solid and water contamination levels

Includes all necessary equipment in a single lightweight case

Perform quick on-site determination of contamination levels of solid particulate, water, or both

Supplement on-site laboratories

Use as a tool to demonstrate need for improved filtration

Model Number

Selection

EasyTestTM Patch Test Kit

EPK-K No options

EPK-S Patch Test Kit without water measurement capability

The new Patch Test Kit from Schroeder provides the necessary tools to determine levels of both water andsolid particulate contamination present in a particular fluid sample. The kit is named for the patch methodused to visually assess the amount of solid contaminants. Using the vacuum pump contained in the kit, thefluid sample is drawn through a membrane patch. The residual dirt left on the patch is viewed under amicroscope and compared to photos of known contamination levels in the Schroeder Contamination Handbook(included) for a visual assessment. The handbook also provides photos of various contaminants for use inidentifying the type of particulate and its possible source(s).

The water sensing device included in this kit is an aluminum mixing vessel with a small LCD display andmicroprocessor built into the lid – the same one featured in our EWC (EasyTestTM Water ContaminationSampler) kit. When the two reagents supplied in the kit (one liquid and one powder) are mixed with thesample fluid in the cell, the resulting chemical reaction causes an increase in pressure within the vessel. Thischange in pressure is converted into water content and displayed on the screen in terms of parts per million(ppm) or % by volume.





EasyTestTM Series

Kit as supplied includes:

Quantity Description

1 Mixing chamber

2 Reagent A (solvent), 500 ml bottle

1 Reagent B, 50 packets

3 Syringe, 5 ml

1 Syringe, 10 ml

1 Syringe, 30 ml

1 Disposable rubber gloves, bag containing 50 pairs

1 Scissors

1 Tweezers

50 Membrane patches, 0.8 µm, 25 mm diameter

50 Plastic covered slides

1 Microscope, 100x, with flashlight

1 Vacuum pump with folding stand

1 Receptacle bottle, threads onto vacuum pump

1 Plastic funnel

3 Plastic sample bottle, 4 oz

1 Case with foam insert

1 Contamination handbook

1 Instruction manual

Please note: Kit contents subject to change at the discretion of the manufacturer.

Part Number Description

EPK-115 Plastic sample bottle

EPK-116 Membrane patches, 0.8 µm, 25 mm diameter, qty. 50

EPK-120 Plastic covered slides, slides, qty. 50

EPK-112 Replacement parts pack, includes:

2 Reagent A (solvent), 500 ml bottle1 Reagent B, 50 packets3 Syringe, 5 ml1 Disposable rubber gloves, bag containing 50 pairs1 Scissors1 Tweezers

Consumables

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

HTBHydraulic Test Bench

Hydraulic Test Bench

The Schroeder Model HTB hydraulic test bench is the ultimate diagnostic tool, capable of thoroughlytesting a vast array of new or rebuilt components andsubassemblies prior to their installation in a workingsystem. Test bench instrumentation has beendesigned to make diagnosis fast and accurate, withvirtually no requirement for connecting externalinstruments. The bench panel includes a digital flowgauge, a tachometer to measure the speed of testedpumps or motors, and a reservoir temperature gauge.Individual gauges measure pressure on the test benchmain pump, the pump or motor being tested, thetest bench load pump, the cylinder and valve pressureport, and the test bench super charge pump.

Every HTB includes efficient Schroeder hydraulic filtersto keep the bench oil at optimum cleanliness, provid-ing assurance that newly rebuilt components will notbe subjected to harmful levels of dirt. To keep filtersoperating at peak efficiency, the instrument panelincludes a red pilot light that signals the operatorwhen any bench filter needs a new element.

These benches have been refined for over 30 years bySchroeder engineers, based on the comments andrequests of over 700 test bench owners. The versatilehydraulic circuitry present in each of the three modelscan shorten troubleshooting time and take the guess-work out of diagnoses. Current models are powerful,compact units that pay for themselves quickly insaved maintenance time and expenses.




Features

Applications


An ingenious universal mounting bracket makesmounting pumps and motors on the bench asimple, quick operation

Mounting plates are furnished to accommodate flange-mounted and foot-mounted pumps ormotors

Drive adapter equipment includes inserts for keyedshafts, an insert chuck and a universal drive shaft

Quick disconnect porting on the bench providesconvenient hook-up for test components

Includes a factory-trained technician for a two-day, on-site training session

Two complete operating manuals are supplied witheach bench

Kits and spare parts available for upgrades andmaintenance

Pumps and motors can be tested dynamically.Pump and motor testing is aided by the wide speedand torque ranges built into the bench and by theuniversal mounting bracket and mounting acces-sories that come with the bench. An open loophydrostatic variable volume hydraulic systemprovides the power and speed control for the driveshaft. Motors can be dynamically tested, underload, for operating efficiency. Pumps can be testedfor external leakage and volumetric efficiency ineither direction, at speeds from 100 to 2400 rpm.The test bench can also be used to break-in pumpsand motors to manufacturer’s specifications beforethey are installed in a system.

Cylinder leaks are easy to find. Double-actingcylinders may be cycled, and tested for both internaland external leakage at any point of piston travel.Scored cylinder walls and defective packing are easilydetected. Single-acting cylinders are tested atmaximum stroke.

Valve testing time is minimized. Pressures can be set,external and internal leakage spotted, flow andpressure data can be generated and checked againstoperating requirements and overall valve efficiencydetermined. Optional electrical and pilot pressuresupplies are available on the bench for testingsolenoid-actuated and pilot-operated valves.

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



Model HTB-50-E Model HTB-100-E Model HTB-150-E

Speed Range 100 to 2400 rpm 100 to 2400 rpm 100 to 2400 rpmin either direction

Power AvailableFor testing pumps

Expressed torque 275 ft-lbs to 458 ft-lbs to 670 ft-lbs to1200 rpm 1200 rpm 1200 rpm

(decreasing proportionately to 2400 rpm)

Expressed in horsepower 60 hp at 115 hp at 150 hp at1200 rpm 1200 rpm 1200 rpm

(with constant hp to 2400 rpm)

Test Pressure 0 to 5000 psi 0 to 5000 psi 0 to 5000 psi(345 bar) (345 bar) (345 bar)

Test Motor Load 275 ft-lbs 458 ft-lbs 670 ft-lbsMaximum in either direction

Electrical DriveMotor-230/460V, 1800 rpm;3 phase, 60 hertz. 50 hp 100 hp 100 hpA start-stop push button is andmounted on the bench: 50 hpStarter(s) is/are not included. Customer must advise type of starter(s) and service voltagehe will use.

HydraulicsMain Bench Pump (variable piston) 23 gpm /5000 psi 38 gpm /5000 psi 38 gpm /5000 psi

(87 L/min/345 bar) (144 L/min/345 bar) (144 L/min/345 bar)

Auxiliary Main Pump N/A N/A 23 gpm /5000 psi(variable piston) (87 L/min/345 bar)

Supplemental Pump 20 gpm /2000 psi 20 gpm /2000 psi 20 gpm /2000 psi(76 L/min/138 bar) (76 L/min/138 bar) (76 L/min/138 bar)

Pressure and Return Ports 1” quick disconnects 1” quick disconnects 1” quick disconnects

Suction Porting 1” & 2” quick 1” & 2” quick 1” & 2” quickdisconnects disconnects disconnects

Flow Gauge Scales Three Scales: 2 to 14; 8 to 36; 24 to 100 gpm (all models)

Reservoir Capacity 100 gallons (378 L) 100 gallons (378 L) 200 gallons (757 L)

General Full flow 3 micron filtration maintains excellent system cleanliness level; bench includes a 30” x 30” work pan, oil level gauge, fill cap mesh strainer, digital tachometer.

Bench Dimensions and Weight 62” high x 76” long 62” high x 76” long 62” high x 76” longx 43” wide x 43” wide x 55” wide

4100 lbs (1860 kg) 4500 lbs (2041 kg) 6000 lbs (2722 kg)

Auxiliary Power Unit30” high x 50” long30” wide

900 lbs (408 kg)


HTBcontinued


Accessories

Specificationsand

Model Numbers

Suction and pressure hose and fittings group (contains hoseconnection with female quick disconnects on both ends, plus a seriesof separate national pipe thread, straight thread, and SAE four-boltflange adapters, ranging in size from 3/8” through 2”, equipped withmale quick disconnects) (A-TB-2170)

Oil cooler (A-TB-1661)

Solenoid and pilot-operated valve test group (A-TB-1738)

Spline shaft adapter kit (A-TB-2172)

Jib crane (A-TB-1739)

Fully digital instrumentation package (contact factory)





SpecificationsGS-5 GS-6GS-5U GS-6U

Case Diameter: 6.31 in (160.27 mm) O.D. 8.50 in (216 mm) O.D.

Gauge Diameter: 1.50 in (38.1 mm) O.D. 1.50 in (38 mm) O.D.

Approximate Weight: 3.25 lbs (1.47 kg) 4.5 lbs (2.0 kg)

Range: Vacuum (30” Hg) to 5000 psi (344.8 bar) Vacuum (30” Hg) to 6000 psi (3413 bar)

Case: Steel with rubber bumper strip Steel with rubber bumper strip

Vacuum Gauge: 30 in Hg 30 in Hg

Pressure Gauges: 0 to 150 psi (10.35 bar) 0 to 300 psi (20.7 bar)0 to 600 psi (41.38 bar) 0 to 1000 psi (69.0 bar)0 to 5000 psi (344.82 bar) 0 to 6000 psi (414.0 bar)

Part Number Description Pressure/ Vacuum Range

GS-5 Standard Multi-Gauge Vacuum (30” Hg) to 5000 psi (345.0 bar)

GS-5U Multi-Gauge with Microbore Flexhose and Vacuum (30” Hg) to 5000 psi (345.0 bar)Test Point Adapter

GS-6 Multi-Gauge with 2 1/2“ Liquid Filled Gauges Vacuum (30” Hg) to 6000 psi (414.0 bar)

GS-6U Multi-Gauge with 2 1/2“ Liquid Filled Gauges, Vacuum (30” Hg) to 6000 psi (414.0 bar)Microbore Flexhose and Test Point Adapter

Description

GSMulti-Gauge

Features Protects against overpressurization. The 150 psi gauge can not be damaged when a 2500 psi system isbeing checked. This design feature eliminates the need to know the pressure before testing.

Simple yet rugged construction. The dust and moisture proof steel case is provided with a rubber bumperfor shock protection. A hanger is also provided on the case back for the user’s convenience.

Compact and portable. The GS-5 and GS-6 models are 6 1/2” and 8 1/2” in diameter. The GS-5 fits easilyinto the average tool box for instant availability.

Saves time. The three pressure ranges and one vacuum range provided in one case meet most routinehydraulic maintenance requirements.

The Schroeder Multi-Gauge provides multiple pressure readings for hydraulic, transmission, and convertersystems all in one handy, compact enclosure. While one hook-up connects all three gauges, the built-in gaugeprotector automatically protects the low and medium pressure gauges from high pressures. Each gauge isequipped with a high quality poppet valve. The Multi-Gauge is available with two types of connections: (1) the standard braided copper, flexible high pressure hose with male 1/8” pipe universal swivel fitting and (2) microbore flexhose and test point adapter (specified by U in the part number).

Multi-Gauge

P/N GS-5 P/N GS-6U

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

Trouble Check PlusTM Fluid Analysis

Part Numbersand

TestsPerformed

Total Conditioning Analysis Kit 4-in-1 Analysis Kit Water Glycol Kit (P/N THF) (P/N THF-PC) (P/N TWG)

Particle Count Patch TestISO 4406 Cleanliness Code estimated

Water Content

Viscosity

TAN

Photo

Spectrographic Analysis

Explanation of Results

Particle Count and ISO CodesParticle contamination is responsible for most of the wear in hydraulic systems. The level of contamination is determined automatically by a laser particle counter. The results are shown as the cumulative counts permilliliter of fluid according to ISO 4406:1999. (For water glycol fluids the patch test photo is used to estimatethe ISO code). The current sample ISO code is displayed with the target ISO code. The target is based on the cleanliness level required for the most sensitive component in the system. An increase of 1 ISO digit isconsidered a caution limit and an increase of two ISO digits is critical. The results are also graphed for easydetection of increased particle contamination. The accompanying chart lists components and target ISOcleanliness levels. When the target ISO code is exceeded, improvement of the system filtration, elimination of the source of ingression or installation of auxiliary off-line filtration is required.

Water ContentHigh water content in oil encourages oxidation, corrosion and cavitation. The Karl Fischer Method in accordancewith ASTM D 6304-04a determines the water content, which is displayed in parts per million (PPM) and percent(%). The critical upper limit is displayed for comparison purposes. (Water glycol fluids normally have upper andlower limits that are set to manufacturer’s specifications). The results are also graphed for easy identification ofabnormal results. In general, water contents of up to 500 ppm are typically not critical for the operation ofhydraulic and lubrication systems. When the water content exceeds approx. 500 ppm the system should beprotected against water penetration and measures should be introduced to extract water from the oil.

Schroeder’s Trouble Check PlusTM is an easy to use fluid analysisservice that can be utilized as part of any predictive maintenanceprogram.

Schroeder offers three types of sample kits: two for hydraulic fluid(P/N THF and THF-PC) and one for water glycol (P/N TWG). Refer to the next section for tests performed for each of these kits. Upon receipt of order for any of these part numbers, a sample kitcontaining a clean sample bottle, blank form, and mailing containeris shipped to the customer. After the sample has been taken, thecustomer simply completes the form and encloses it along with thesample in the mailing container provided.

For each sample submitted, a lab report will be generated andforwarded directly to the user via e-mail or postal mail (per the user’srequest). Schroeder will maintain an electronic copy of all results for a two year period. It is strongly recommended that a MSDS (MaterialSafety Data Sheet) and a base line (unused) fluid sample besubmitted with the initial sample to be analyzed. In addition toserving as a baseline for comparison to subsequent results, thesample of new oil will be used to determine warning limits forviscosity and TAN (total acid number).

Information gained by using this service can help identify potentialproblems in a hydraulic system at minimal cost to the user. Fluidanalysis can provide answers to important questions such as these:

Do I have the right filtration system in place for efficientcontamination control?

Is the fluid in my system experiencing changes that couldnegatively impact component life or system performance?

File # Date

File # Date

File # Date

0 1/0/00

0 1/0/00

0 1/0/00

0 1/0/00

0 1/0/00

0 1/0/00

File # Date

)tSc()tSc(

File # Date

0 )tSc()tSc(00/0/1

0 )tSc()tSc(00/0/1

0 )tSc()tSc(00/0/1

0 )tSc()tSc(00/0/1

0 )tSc()tSc(00/0/1

0 )tSc()tSc(00/0/1

ppm %

%

PATCH TEST & PHOTOGRAPH

White Wear Metal - Aluminum or Steel Components

MagnificationSample Volume

25 milliliters

Low Critical

39.3

%

500 0.05

ppm

0.0

0.0

Sample Contains:

Current Sample

High Critical

Upper LimitPrevious Samples (if available)

ppm

315.5 0.03155

0.05

Dirt/Dust - Environmental ExposureMineral Abrasives

WATER CONTENT (Coulometric Karl Fischer Titration - ASTM D 6304-04a)

0.0 0.00000 500

ppm %

0.05

0.000000.0

0.0

53.1

VISCOSITY (ASTM D 445-04)

0.0

53.1

Viscosity @ 40o C

Sample

LE-ENG-FM-2005111-00

Previous Samples (if available)

0.0

Low Critical

39.3

39.3

39.3

0.0

0.05

500 0.05

0.0 0.00000 500

0.0 0.00000

0.0

200x

43.8

Please see photo at right.

Upper LimitCurrent Sample

0.00000

0.00000

500 0.05

500

500

0.05

39.3

39.3

39.3

53.1

53.1

High Critical

53.1

53.1

53.1

0.0

30.00

35.00

40.00

45.00

50.00

55.00

60.00

Vis

cosi

ty

cSt.

Sample

Low Critical

Low Caution

High Caution

High Critical

0

100

200

300

400

500

600

Wat

er C

onte

nt,

ppm

Critical

Sample

Caution

THF Sample Report Form

Model Number

Selection

THF Total Conditioning Analysis Kit

THF-PC 4-in-1 Analysis Kit

TWG Water Glycol Kit

Preferred order codesdesignate shorter

lead times and faster delivery.




Explanation of Results

Trouble Check PlusTM Fluid Analysis

ViscosityMaintaining the correct viscosity is important for achieving long component service life. Viscosity is reported in centistokes (cSt) @ 40° Celsius as per ASTM D 445-04. The data is displayed along with warning limits.Typically the limits are based on new oil data. Caution limits are calculated at ±10% new oil viscosity andcritical limits at ±15% new oil viscosity. (Water glycol fluids can have limits set similarly but the water contentshould also be monitored as changes in it also affect the viscosity. The manufacturer should be consulted).Graphs showing the viscosity trends along with limits allow for quick recognition of abnormal situations.When large changes in viscosity are detected a partial drain of the affected oil and adding fresh fluid maycorrect the problem. However in some instances a complete oil change may be required.

Total Acid Number (TAN) *not applicable to P/N THF-PC and TWG

Oxidation is the primary mechanism of oil degradation. The TAN measures the corrosive acidic by-products ofoxidation. TAN results are reported in mg/g KOH (Potassium Hydroxide). Since all hydraulic fluids have someinherent acidic properties any increases in TAN must be compared to the new oil value as a baseline. Typicallycaution limits are set at +0.6 new oil value and critical limits are set at +1.0 new oil value. Certain applicationspecific fluids may require limits set to manufacturer specifications. The results are graphed along with the limitsto clearly show when oil oxidation has increased above acceptable levels. When the TAN has increased abovethe critical level, the oil should be changed immediately to prevent damage from occurring to your equipment.

Spectrographic Analysis *not applicable to P/N THF-PC and TWG

Additive, wear metal and contaminant levels are displayed in parts-per-million (PPM). The oil sample is analyzedfor eighteen different elements. The results are also graphically displayed for easy detection of increasing ordecreasing levels. The manufacturer blends additives into the oil in different forms and quantities. The additivepackage varies with the oil type. Wear metals indicate wear on particular components of an individual unit.These metals will indicate a wear problem on the microscopic level (< 8 microns) before the problem can bedetected by conventional means. The existence of a wear problem is determined by absolute values of metals,and more importantly, by a relative increase or trend in one or more metals. Contaminants can be an indicatorof internal or external contamination. The source and amount can be determined by a comparison with new oildata. Below is a list of additive types, wear metal and contaminant sources.

Patch Test / Contamination PhotoThe particulate contaminants are separated by pulling the fluid through a membrane using a vacuum pumpand are examined microscopically. The photo of the resulting “patch” is displayed. The particles are describedand identified (if possible). The patch test provides valuable visual evidence of the contamination in the oil.The patch can also be used to estimate the ISO code for water glycol samples.

Status and RecommendationsCorrective actions are recommended when applicable. The status of the sample is rated in three categories:

Normal - System is operating within the parameters established by baseline data & prior samples.- System requires no immediate action.

Caution - System is operating outside of caution limits in one or more areas.- System requires scheduled maintenance.

Critical - System is operating outside of critical limits in one or more areas.- System requires immediate attention.

Additives Function

Magnesium (Mg) Dispersent / DetergentCalcium (Ca) Dispersent / DetergentBarium (Ba) Dispersent / DetergentZinc (Zn) Anti-Wear Molybdenum (Mo) Anti-WearPhosphorous (P) Anti-Wear

Wear Metals Typical SourceTitanium (Ti) Turbine Components, Bearings, PlatingsChromium (Cr) Rings, Roller/Taper, Bearings, Rods, PlatingsIron (Fe) Cylinders, Gears, Rings, Crankshafts, Liners, Bearings, Housings, RustNickel (Ni) Valves, Shafts, Gears, Rings, Turbine ComponentsCopper (Cu) Bearings, Bushings, Bronze, Thrust-Washers, Friction Plates, Oil CoolerSilver (Ag) Bearings, Bushings, PlatingsAluminum (Al) Pistons, Bearings, Pumps, Blowers, Rotors, Thrust-Washers, DirtLead (Pb) Bearing Overlays, Grease, Paint, Possible Additive in Gear OilsTin (Sn) Bearings, Bushings, Piston Platings, Solder, Coolers

Contaminants Typical SourceSodium (Na) Coolant, Sea Water, Dirt, Possible AdditiveBoron (B) Coolant, Sea Water, Possible Additive Silicon (Si) Dirt, Possible Additive (Anti-Foam)

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



Maximum Working Pressure: 10,000 psi (680 bar)

Materials: Standard Body: S12L14 AS 1442 (AISI-SAE composition)

Metal Cap: S12L14 AS 1442 (AISI-SAE composition)

Poppet: S12L14 AS 1442 (AISI-SAE composition)

Secondary Seal: Viton

Ball: Hard Chrome

Seat: Stainless Steel 316

Operating Temperature Range: -22°F to +275°F (-30°C to +135°C)

Optional materials include stainless steel body and stainless steel poppet.


Description

Features

Applications

Specifications

Test Points

Schroeder Check® Test Point System

No MessNo-leak design means sealing is complete before connection is made to hydraulic system.

No ToolsSimply hand tighten gauge, transducer or hose adapter onto Schroeder Check test points under full pressureto 10,000 psi (680 bar).

No ContaminationProper use of test points eliminates the introduction of contaminants into a hydraulic system.

Fluid sampling

Air bleeding

Accumulator charging

Connection for diagnostic products

Schroeder Check® test points provide a fast, easy, and safe way to test pressures up to 10,000 psi (680 bar) inhydraulic or pneumatic systems under operation. They are available in both 1215 (M12 x 1.5 reverse buttress)and 1620 (M16 x 2.0) connection threads with a variety of screw-in port threads. The standard poppet styleshown above features a primary seal and a secondary seal, both Viton®, providing for absolute sealing of fluidor gaseous media. This design allows connection by hand at pressures up to 10,000 psi (680 bar) without anyloss of fluid. Plastic caps are standard on 1215 test points, while metal caps with anti-vibration O-rings arestandard on 1620 test points.

In addition to functioning as a secure access point for checking pressure, they can also effectively be used toobtain oil samples for subsequent testing or to bleed air from a hydraulic system. Schroeder Check® test pointscan be used in conjunction with the gauge adapters, pressure gauges, Microflex hoses and pressure gauge testkits on the following pages.





G Thread Sealing System Part Number

SP1215NPT18VP1/8" NPT Thread

SP1620NPT18VM

SP1215NPT14VP1/4" NPT Thread SP1215NPT14VSSM

SP1620NPT14VM

5/16"- 24 UNF Viton O-Ring SP1215UN516VPSP1215UN716VM

SP1215UN716VP7/16"- 20 UNF Viton O-Ring SP1620UN716VM

SP1215UN716VSSM

SP1215UN916VP9/16"-18 UNF Viton O-Ring

SP1620UN916VM

1/8" BSPP WD Seal NBR SP1620G18WDM

1/4" BSPP WD Seal NBRSP1215G14WDPSP1620G14WDM

7/16" JIC Viton Seal SP1215JIC716FP

9/16" JIC Viton Seal SP1215JIC916FP

SP = Test point with poppet valve; SS = Stainless Steel; P = Plastic Cap; M = Metal Cap; FP = Female PoppetAll Test Points have Viton seals

JIC Male/Female In-Line Test Points

Test Point with plastic cap

Test Point with metal cap

G Tube/Pipe ∆P (max) L A/F Thread dia psi (bar) in (mm) in (mm) Part Number

SP1215L04JICP7/16"- 20 UNF 1/4" 4500 (315) 1.38 (35) .51 (13)

SP1620L04JICM

SP1215L06JICP9/16"-18 UNF 3/8" 4500 (315) 1.38 (35) .63 (16)

SP1620L06JICM

SP1215L08JICVP3/4"-16 UNF 1/2" 4500 (315) 1.50 (38) .83 (21)

SP1620L08JICM

SP1215L12JICVP1-1/16"-12 UNF 3/4" 4500 (315) 1.89 (48) 1.06 (27)

SP1620L12JICM

SP1215L16JICP1-5/16"-12 UNF 1" 4500 (315) 1.97 (50) 1.38 (35)

SP1620L16JICM

JIC according to SAE J514. Male / female threads of the same size.



TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



G ∆P (max) L A/F PartThread Type psi (bar) in (mm) in (mm) Number

S1215DCNPT141/4” NPT 1 10,000 (680) 0.83 (21) 0.75 (19) S1215DCNPT14SS

S1620DCNPT14

1/4” BSPP 1 10,000 (680) 0.83 (21) 0.75 (19)S1215DCG14CUS1620DCG14CU

7/16” UNF 1 10,000 (680) 0.83 (21) 0.75 (19)S1215DCUN716S1620DCUN716

1/4” NPT 2 10,000 (680) 0.83 (21) 0.75 (19) S1215DCMNPT14



DirectGauge

Adapters

Change-OverAdapters

Hose Joiners

There is no internal check valve in these parts. They are used to connect gauges and pressure transducersdirectly onto test points without use of Schroeder Microflex hose.

G Gauge L A/F1 A/F2 PartThread Type Seal in (mm) in (mm) in (mm) Number

S1215GANPT141/4” NPT 1 Thread 1.34 (34) 0.75 (19) —

S1620GANPT14

1/4” NPT 2 Thread 1.85 (47) 0.75 (19) 0.75 (19) S1215GBNPT14

Gauge toHose

Adapters

G ∆P (max) L A/F PartThread psi (bar) in (mm) in (mm) Number

System 1215 10,000 (680) 1.54 (39) 0.55 (14) SJ1215

System 1620 10,000 (680) 1.54 (39) 0.55 (14) SJ1620

There is no internal check valve in this arrangement.

There is no internal check valve in this arrangement. Type 1 is for direct connectionof gauge to hose. Type 2 is for bulkhead connection of gauge to hose withbulkhead mounting.

Type 1

Type 2

Type 1

Type 2





G1 G2 PartThread Thread Number

M12 x 1.5 1/8" NPT Male S1215NPT18P

M12 x 1.5 1/4" NPT Male S1215NPT14

M12 x 1.5 1/4" NPT Male S1215NPT14P

P = Plastic Cap



Part Number Adjustable Range

U1200-01-01 75 to 150 psi (5.2 to 10.4 bar)

U1200-01-02 150 to 350 psi (10.4 to 24.1 bar)

U1200-01-03 350 to 1000 psi (24.1 to 69.0 bar)

U1200-01-04 1000 to 1500 psi (69.0 to 103.0 bar)

U1200-01-05 1500 to 3600 psi (103.0 to 248.0 bar)

U1200-01-06 3600 to 6000 psi (248.0 to 414.0 bar)

Note: All units shipped will be preset at the minimum pressure of itsrange, unless otherwise specified at time of purchase.



Microflex™

Hoses™L ∆P (max) Partin (mm) psi (bar) Number

SM2-1215-0066 (200) 10,000 (680)

SM2-1620-006

SM2-1215-01212 (300) 10,000 (680)

SM2-1620-012

SM2-1215-02424 (400) 10,000 (680)

SM2-1620-024

SM2-1215-03636 (500) 10,000 (680)

SM2-1620-036

SM2-1215-04848 (630) 10,000 (680)

SM2-1620-048

SM2-1215-07272 (800) 10,000 (680)

SM2-1620-072

SM2-1215-09696 (1000) 10,000 (680)

SM2-1620-096

Other lengths available on request.

Stainless steel hose ends available. Insert “SS” after middle four digits. Example: SM2-1215SS-006. Other hose ends available include:

Hose End Description

NTP18 1/8 NPT (Male) Hose End

NPT14 1/4 NPT (Male) Hose End

NPFS14 1/4 NPT (Female Swivel) Hose End

J716 7/16 UNF (Male) Hose End

JFS716 7/16 UNF (Female Swivel) Hose End

J916 9/16 UNF (Male) Hose End

Perforated polyamide / kevlar hose, 2 mm ID, 5 mm OD, plastic dust cap.

AdjustablePressureLimiters

The Schroeder Pressure Limiter is engineered to protect your pressure sensitive components and equipmentfrom system shocks and spikes. This high speed valve is ideal for protecting pressure gauges, pressureswitches, transducers, and any pressure sensitive component or system. Preset at the factory, the SchroederPressure Limiter is supplied in any of six standard ranges.

Standard seals are Viton with other sealing materials available on request.

Housing is aluminum, other parts are zinc-plated steel.

Gauge Connector is 1/4” NPT Female.


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



PressureGauges

SchroederCustom

Test Kits

SchroederPressure Test Kits



• Schroeder Pressure Test Kits are available in four configurations as shownbelow. Highest quality components were selected for versatility and longservice life. Contents of each kit are listed below.

• The optional gauge range should be specified using the order codeshown above.For example: UB102-1-2 specifies one (1) 100 psi gauge and one (1)200 psi

Custom Test Kits are designed for many special requirements. Utilizingcomponents from Schroeder gauge and pressure test kits, these boxes are constructed for reliability and precision.

For additional information on custom test kits, please consult factory.

UB101-(*) UB102-(*)-(*) UB103-(*)-(*)-(*) UB106-(*)-(*)-(*)-(*)-(*)-(*)

1 U401 Gauge (*) 2 U401 Gauges (*)-(*) 3 U401 Gauges (*)-(*)-(*) 6 U401 Gauges (*)-(*)-(*)-(*)-(*)-(*)

1 Microflex Hose 2 Microflex Hoses 3 Microflex Hoses 6 Microflex Hoses, 36” 36”/72” 12”/36”/72” 2x12”/2x36”/2x72”

1 Hose Joiner 1 Hose Joiner 1 Hose Joiner 3 Hose Joiners

1 (Hose) Gauge Adapter 1 (Hose) Gauge Adapter 1 (Hose) Gauge Adapter 3 (Hose) Gauge Adapters

1 Direct Gauge Adapter 1 Direct Gauge Adapter 1 Direct Gauge Adapter 3 Direct Gauge Adapters

3 Schroeder Check 6 Schroeder Check 6 Schroeder Check 12 Schroeder CheckTest Points: Test Points: Test Points: Test Points:

1 ea. 1/4” NPT 2 ea. 1/4” NPT 2 ea. 1/4” NPT 4 ea. 1/4” NPT1 ea. 7/16” UNF 2 ea. 7/16” UNF 2 ea. 7/16” UNF 4 ea. 7/16” UNF1 ea. 9/16” UNF 2 ea. 9/16” UNF 2 ea. 9/16” UNF 4 ea. 9/16” UNF

Pressure test kits are also available with U400 all stainless steel gauges. Part numbers are U101–(*), U102–(*) -(*)…etc.

Part Number Pressure Order Code (needed for test kits below)

U401-30/100-01* 30 in Hg VAC to 100 psi (6.9 bar) 0

U401-100-01 0 to 100 psi (6.9 bar) 1

U401-200-01 0 to 200 psi (13.8 bar) 2

U401-600-01 0 to 600 psi (41.2 bar) 6

U401-1000-01 0 to 1000 psi (70.0 bar) 10

U401-1500-01 0 to 1500 psi (103.0 bar) 15

U401-3000-01* 0 to 3000 psi (207.0 bar) 30

U401-5000-01 0 to 5000 psi (345.0 bar) 50

U401-6000-01* 0 to 6000 psi (414.0 bar) 60

U401-10000-01 0 to 10000 psi (689.0 bar) 100

*Also available is U400-XXX-01 gauge, identical to U401 except with stainless steel internals.

1/4” NPTStandard 2-1/2” Case

With the Schroeder Check System, one top quality gauge can do the workpreviously done by many. Compromising on low cost, short life gauges withquestionable accuracy is no longer necessary. A series of precision instruments,Schroeder gauges are fluid filled with full scale accuracy of ±1.5% (or better).Dual scale dial has a non-reflective white background and a high contrast matteblack pointer. Cases and connections are stainless steel, internals are brass. Idealfor most liquids and gases under pressure or vacuum where contact with theliquid filling would not be hazardous. For additional applications, information,and pressure ranges, please consult factory.


Part Number




ProbalizerTM Sampling Test Point

The ProbalizerTM Sampling Test Point provides a point of access for obtaining representative fluid samples froman operational hydraulic system. The downstream channel is specially sized to accept the sampling probe from a customized cap/probe assembly screwed onto a sample bottle. (See photo). Use of this system minimizesleakage and helps to maintain the integrity of the sample.

Part Number: LF-7611

Flow Rate: 400 mL/min @ 35 psi; 1000 mL/min @ 100 psi

Burst Pressure: 4500 psi (310 bar) min

Sampling Pressure Range: 1 to 100 psi (0.07 to 6.89 bar)

Mounting Thread: 1/4" NPT

P/N LF-7611

Bottle and cap sold separatelyunder P/N LF-7374.

PartNumberSelection

Part Number Description

LF-7611 Probalizer Sampling Test Point

LF-7374 Bottle and cap (pictured above)

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix





Description

AFM

Auto Flush Filter Cart

Features

The Auto Flush Filter Cart (AFM) is capable of flushing, filtering, and monitoring ISO cleanliness levels with user-defined, automatic features. The AFM is designed to transfer cleanliness levels with user-defined, automaticfeatures. The AFM is designed to transfer fluid through two (2) K-size filters in series for staged particulate orwater/particulate removal. Both filters are top-loading and include element indicators in the cap. A particlemonitor reads samples from the pump discharge and displays ISO contamination codes on the control panel.The monitor allows the user to input the desired ISO cleanliness codes for the fluid. In auto mode, the systemwill run until the cleanliness codes are reached. Upon reaching the codes, the pump will stop and the cyclecomplete light will come on. When in manual mode, the system will run continuously and display the ISOcodes. An optional water sensor is available for providing the water saturation and the temperature of the fluid,both displ.ayed through the monitor. With a water sensor, the monitor will allow the user to input set points forboth the water saturation and the ISO codes. An optional variable frequency is also available to give the userthe ability to control the fluid flow as necessary.

23.20(589)

RS232Port

Control Panel

D5C IndicatorOne in Each Cap

39.6

3(1

007)

Female JIC-20 Conncetion

for Main Fluid Discharge

43.9

0

(111

5)

10.00(254)

Female JIC-20 Connection for Suction Fluid Supply

Optional VFD

SuctionStrainer

Hose Wraps

18.5

0(4

70)

10’ 14-3 Cordand NEMA 15PPlug Standard

CycleCompleteLight

On/Off SwitchCONTROL PANEL

The TCM particle monitor can run in automated or manual mode

RS-232 port allows the ISO code data to be downloaded for further processing and/or printing

30 mesh suction strainer and 230 micron filter are included to protect the main pump and particle monitor,respectively, from foreign matter

Constant flow filtration system is standard

Optional Variable Frequency Drive (VFD) allows the user to control and adjust the flow to account foraeration and viscosity

Optional Water Sensor allows monitor to display real-time water saturation and temperatuer values of thefluid

Incorporates SMART® technology using a PLC to customize operations based on user input


U.S.Patents65689196979397



Flow Rating: 12 gpm (45 L/min) max

Motor: 1.5 HP - 12.6 amps at 115 volts AC

Maximum Viscosity: 1000 SUS (216 cSt)

Maximum Pressure: 180 psi (12.5 bar)


Bypass Valve Setting: Cracking: 30 psi (2 bar) x 2

Material: Manifold and cap: Cast aluminum Element case: Steel

Compatibility: All petroleum based hydraulic fluid. Contact factory for use with other fluids.

Element Change Clearance: 8.50 (215) 1K

Weight: 260 lbs (118 kg)


Specifications


Auto Flush Filter Cart

Element ElementCatalog Media Media PumpModel No. of Element First Second Size

Number Elements Length Filter Filter Seals Options (gpm)

091 18

AFM27

2 09

3 09

Notes:***E media elements are only available in 03, 10 and 25 microns.***Water removal (W) elements are indicated by an “EWR” in the part number and are not followed by a

01, 03, 05, 10 or 25.***The number of elements, element length, and seals will be identical for both filter housings.

N = None (Std.)

VFD = Variable Frequency Drive

TWS = Testmate® Water Sensor

12B

V

E*, Z, EWR**plus 01, 0305 10, 25

E*, Z, EWR**plus 01, 0305 10, 25

U.S.Patents65689196979397

Applications In-Plant Service Filter to desired cleanliness levels and extend component life

Mobile Dealer Networks Aid in certified re-builds, service maintenance contracts and totalmaintenance & repair programs

OEM Manufacturers Flush to required roll-off cleanliness levels

Lubricant Reclamation/Recycling Clean oil to extend oil life and reduce hazardous waste


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

MSS MFSMSD MFD

Mobile Filtration Systems

Features Modular base eliminates hoses between components and minimizes leakage

Base-ported filter provides easy element service from the top cap

Single, double and triple bowl length option allows the flexibility of additional dirt-holding capacity

D5 Dirt Alarm® indicates when filter element needs changed

Cleans up oil faster – 7 gpm and 14 gpm models available

Hoses and connection tubes included

Drip pan catches oil before it falls to the ground

Integral suction strainer protects pump

Off-line stationary system available – see Kidney Loop System, page 74

Two 7/16 – 20 UNF sampling ports included on all models

The Schroeder Mobile Filtration System is a compact, self-contained filtration system equipped with highefficiency, high capacity elements capable of removing particulate contamination and/or water quickly,conveniently and economically. It is perfect for cleaning up existing systems as well as for prefiltering newfluids, since new fluids often have contamination levels significantly higher than that recommended for mosthydraulic systems.

The most attractive feature of the Mobile Filtration System is the significant reduction in noise, being reducedfrom 91 decibels to 72 decibels at full load. Additional improvements include a modular base that eliminateshoses and fittings between components, a drip pan, and easier element servicing through the new patentpending K9 base-ported filter housing.

The MFS single filtration unit can remove either water or particulate contamination. The MFD dual filtrationunit can be used to remove both water and particulate contamination, or for staged particulate contaminantremoval. The MSS is a MFS cart with an integrated SMART® Kit. The MSD is a MFD cart with an integratedSMART® Kit (see pages 36 and 37).

U.S.Patents6568919

MFS07=1.00 Dia. x 36.00 (914)Long Hose WandMFS 14=1.25 Dia. 36.00 (914)Long Hose Wand

Indicator

SuctionStrainer

HoseWraps

Metric dimensions in ( ). Optional SMART® Kit not shownMFD

07 GPM=1.00 Dia. x 36.00 (914)Long Hose Wand14 GPM=1.25 Dia. 36.00 (914)Long Hose Wand

Indicator

SuctionStrainer

HoseWraps

MFS

MFD

MFS



Flow Rating: 7 gpm (26.5 L/min) max or 14 gpm (53.0 L/min) max

Maximum Viscosity: 1000 SUS (216 cSt) Higher viscosity version available. Contact factory for details.

Hose Pressure Rating: 30 psig (2.0 bar) @ 150°F (65.6°C)Full vacuum @ 150°F (65.6°C)

Operating Temperature: 25°F to 150°F (-4°C to 65°C)

Bypass Valve Setting: Cracking: 30 psi (2 bar)



Motor: 115 VAC Single phase 3/4 hp (7 gpm) or 1-1/2 hp (14 gpm)

Element Change Clearance: 8.50 (215) 1K (9, 18 or 27" depending on model configuration)


Specifications

Applications Supplementing continuous filtration by system filters

Cleaning up a hydraulic system following component replacement

Filtering new fluid before it is put into service

Transferring fluid from storage tanks and drums to system reservoirs

Mobile Filtration SystemsU.S.Patents6568919

WeightsMFS-1K MFS-2K MFS-3K MSS-1K MSS-2K MSS-3K MFD-1K MFD-2K MFD-3K MSD-1K MSD-2K MSD-3Klb lb lb lb lb lb lb lb lb lb lb lb

GPM (kg) (kg) (kg) (kg) (kg) (kg) (kg) (kg) (kg) (kg) (kg) (kg)

7170 180 190 188 198 208 185 203 220 203 221 238(77) (82) (86) (85) (90) (94) (84) (92) (100) (92) (100) (108)

14177 187 197 195 195 215 192 210 227 210 228 245(80) (85) (89) (88) (93) (97) (87) (95) (103) (95) (103) (111)


Element ElementCatalog Media Media PumpModel No. of Element First Second Filter Size

Number Elements Length Filter ***(MFD Only)*** Seals (gpm)

MFS 09 ** **

B = Buta N 071 18

MSS 27MFD 2 09MSD 3 09

V = Viton1 14

Notes:***E media elements are only available in 03, 10 and 25 microns.***Water removal (W) elements are indicated by an “EWR” in the part number and are not followed

by a 01, 03, 05,10 or 25.***When MFD is ordered, the number of elements, element length, and seals will be identical for

both filter housings.


**E*, Z, EWR**plus 01, 0305, 10, 25

**E*, Z, EWR**plus 01, 0305, 10, 25

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

AMSAMD

Air-Operated Mobile Filtration Systems

Schroeder’s AMS and AMD carts feature a pneumatic motor in place of the standard electric motor. Thepneumatic motor offers the same flow capability using the same components, but without the need for anelectrical outlet. This provides a major advantage in the application of this unit. With no need for an electricaloutlet, it is more portable than the standard electric-motored skids and carts.

Because most trucks and industrial machinery are already equipped with an air compressor, a simple connectionto the 1/4” NPT port will easily power the 1.5 HP (or 4.0 HP) motor. At 70 psi, and 2000 rpm, this motorconsumes less than 40 cfm (70 cfm for the 4.0 HP motor) of compressed air. Because no electricity is used, thepneumatic motor is ideal for working in hazardous environments such as mines.

SuctionStrainer

HoseWraps

AFS07=1.00 Dia. x 36.00 (914)Long Hose WandAFS 14=1.25 Dia. 36.00 (914)Long Hose Wand

Indicator

AMSMetric dimensions in ( ).

AMD

AFS07=1.00 Dia. x 36.00 (914)Long Hose WandAFS 14=1.25 Dia. 36.00 (914)Long Hose Wand

Indicator

SuctionStrainer

HoseWraps

Air Inlet

Note: Performance data represents a 4-vane model with no exhaust restriction.

U.S.Patents6568919



Flow Rating: 7 gpm (26.5 L/min) max and 14 gpm (53.0 L/min) max


Housing Pressure Rating: 250 psi (17.2 bar) max operating1000 psi (68.9 bar) min yield

Operating Temperature: -25°F to 150°F (-29°C to 65°C)2




Element Change Clearance: 8.50 (215) 1K (9, 18 or 27" depending on model configuration)1For higher hose pressure applications contact factory.2For higher temperature applications contact factory.



Weights

Applications

Specifications

Air-Operated Mobile Filtration Systems

Element Media Element MediaFilter No. of Element First Second Filter Seal Series Elements Length Filter ***(AMD Only)*** Material GPM1

B = Buna N

AMS

AMD

091 18

27

2 09

3 09

072

142

Notes:1. GPM only valid with fluids up to 1000 SUS.2. 07 GPM - 50 CFM at 70 psi.

14 GPM - 70 CFM at 70 psi.

***E media elements are only available in 03, 10 and 25 microns.***Water removal (W) elements are indicated by an “EWR” in the part number and are not followed by

a 01, 03, 05,10 or 25.***When AMD is ordered, the number of elements, element length, and seals will be identical for both

filter housings.

Supplementing continuous filtration by system filters


Filtering new fluid before it is put into service

Transferring fluid from storage tanks and drums to system reservoirs

Field applications on service trucks

**E*, Z, EWR**plus 01, 0305, 10, 25

**E*, Z, EWR**plus 01, 0305, 10, 25

AMS-1K AMS-2K AMS-3K AMD-1K AMD-2K AMD-3KGPM lb (kg) lb (kg) lb (kg) lb (kg) lb (kg) lb (kg)

7 170 (77) 180 (82) 190 (86) 185 (84) 203 (92) 220 (100)

14 177 (80) 187 (85) 197 (89) 192 (87) 210 (95) 227 (103)

U.S.Patents6568919

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Kidney Loop Systems U.S.Patents6568919

Description

Features Modular base eliminates connections between components and minimizes leakage

Base-ported filter provides easy element service from the top cap

Single, double and triple bowl length option allows the flexibility of additional dirt-holding capacity

D5 Dirt Alarm® indicates when filter element needs changed

Two 7/16 – 20 UNF sampling port included on all models

KSS KLSKSD KLD

Metric dimensions in ( ). Optional SMART® Kit not shown

Schroeder’s new off-line Kidney Loop System is a stationary version of the Mobile Filtration System. It is acompact, self-contained filtration system equipped with high efficiency, high capacity elements capable ofremoving particulate contamination and/or water quickly, conveniently and economically. This off-line systemcan be used to supplement in-line filters when adequate turnover cannot be achieved in the system. It is also ideal for water removal. Like the Mobile Filtration System, the new Kidney Loop System operates at asurprisingly low noise level. Its modular base eliminates hoses and fittings between components. The KLSsingle filtration unit can remove either water or particulate contamination. The KLD dual filtration unit can beused to remove both water and particulate contamination, or for staged particulate contaminant removal. TheKSS is a KLS with an integrated SMART® Kit. The KSD is a KLD with an integrated SMART® Kit (see pages 36and 37).

KLS

KLD

.56 (14)Mtg. Hole(4 Places)

Model Only

Model

KLDKLS




Kidney Loop SystemsU.S.Patents6568919

Applications

Model NumberSelection

Supplementing in-line filtration by system filters when adequate turnover cannot be attained

Large volume systems requiring multiple filters in different locations


Ideal location for water removal

Element FirstCatalog Media Media PumpModel No. of Element First Second Filter Size

Number Elements Length Filter ***(KLD Only)*** Seals (gpm)

KLS 09

KSS1 18

B = Buna N 0727KLD 2 09KSD 3 09

V = Viton 14

Notes:***E media elements are only available in 03, 10 and 25 microns.***Water removal (W) elements are indicated by an “EWR” in the part number and are not followed by a 01, 03, 05, 10 or 25.***When KLD/KSD is ordered, the number of elements, element length, and seals will be identical for both filter housings.Contact factory if EPR seals are required.

Flow Rating: 7 gpm (26.5 L/min) max and 14 gpm (53.0 L/min) max

Maximum Viscosity: 1000 SUS (216 cSt)Higher viscosity version available. Contact factory for details.





Motor: 115 VAC single phase 3/4 hp (7 gpm) or 1-1/2 hp (14 gpm)

Weight: KLS-1: 101 lb (45.9 kg) KSS-1: 118.5 lb (53.9 kg) KLS-2: 112 lb (50.9 kg) KSS-2: 129.5 lb (58.9 kg)KLS-3: 123 lb (55.9 kg) KSS-3: 140.5 lb (93.9 kg)KLD-1: 117 lb (53.2 kg) KSD-1: 134.5 lb (61.1 kg)KLD-2: 139 lb (63.2 kg) KSD-2: 156.5 lb (71.1 kg)KLD-3: 161 lb (73.2 kg) KSD-3: 178.5 lb (81.1 kg)

Specifications

**E*, Z, EWR**plus 01, 0305, 10, 25

**E*, Z, EWR**plus 01, 0305, 10, 25


TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

AKSAKD

Air-Operated Kidney Loop Systems


Air Inlet

Indicatorin Cap

Leng

th

Leng

thLe

ngth

AKSMetric dimensions in ( ).

AKDLe

ngth

Leng

thLe

ngth

Air Inlet

Indicatorin Cap


Schroeder now offers a kidney loop filtration system with a pneumatic motor in place of the standard electricmotor. The pneumatic motor offers the same flow capability using the same components, but without theneed for an electrical outlet. This provides a major advantage in the application of this unit. With no need foran electrical outlet, it is more portable than the standard electric-motored skids and carts.

Because most trucks and industrial machinery are already equipped with an air compressor, a simple connectionto the 1/4” NPT port will easily power the 1.5 HP (or 4.0 HP) motor. At 70 psi, and 2000 rpm, this motorconsumes less than 40 cfm (70 cfm for the 4.0HP motor) of compressed air. Because no electricity is used, thepneumatic motor is ideal for working in hazardous environments such as mines.

Note: Performance data represents a 4-vane model with no exhaust restriction.

AKS

U.S.Patents65689196979397




Air-Operated Kidney Loop Systems

SpecificationsFlow Rating: 7 gpm (26.5 L/min) max and 14 gpm (53.0 L/min) max


Operating Temperature: -20°F to 150°F (-29°C to 65°C)For higher temperature applications contact factory.




Element Change Clearance: 8.50 (215) 1K


Element Media Element MediaFilter No. of Element First Second Filter Seal Series Elements Length Filter ***(AKD Only)*** Material GPM1

B = Buna NAKS

AKD

091 18

27

2 093 09

072

142

Notes:1. GPM only valid with fluids up to 1000 SUS.2. 07 GPM - 50 CFM at 70 psi.

14 GPM - 70 CFM at 70 psi.

***E media elements are only available in 03, 10 and 25 microns.***Water removal (W) elements are indicated by an “EWR” in the part number and are not followed

by a 01, 03, 05, 10 or 25.***When AKD is ordered, the number of elements, element length, and seals will be identical for both

filter housings.

Applications Supplementing in-line filtration by system filters when adequate turnover cannot be attained

Large volume systems requiring multiple filters in different locations


Ideal location for water removal

Field applications on service trucks

**E*, Z, EWR**plus 01, 0305, 10, 25

**E, Z, EWR**plus 01, 0305, 10, 25

U.S.Patents65689196979397

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Kidney Loop Systems

Description

Features Lower operating costs

Extended element service life

Extended fluid life

Cleaner and more efficient systems

Easy installation

High dirt-holding capacity

Requires low volume of oil

Pressure Drop KLE02 (2 µm element without water retention) KLE20 (20 µm element without water retention)

∆P p

si

∆P p

si

KLC P

S

M

VA

12.60(320)

24(605)

Ø 5.67(Ø 144) 5.35

(136)4.41(112) Ø 0.28

(Ø 7)

2.80(71)

8.31(211)Max.

3.54(90)

4.40(112)

4.53(115)

0

2.5

10

11.89(302)

9.96(253)

.35(9)

.39(10)22

538

2.91(74)

1.46

(37)

min 2.36 (60)

6.61(168)

3.19(81)

4.29(109)

7.36(187)

6.30(160)

P

S

51 psi(3.5 bar)

M


Schroeder’s new series of Kidney Loop - Compact (KLC) filters are designed to filter highly contaminatedhydraulic oils efficiently and cost effectively off-line. The KLC is designed for use containing up to 100 gallonsand is perfect for retrofit situations when additional filtration is required. This compact filter is easy to install andideal for gear boxes. They are supplied as ready-to-install off-line units complete with pump/motor assembly.




Kidney Loop Systems

Applications

Model NumberSelection


Machine tools

Gear boxes

Mobile equipment

Filtration of fluids for intermittently operated hydraulic systems and test stands

Model Pump Number Type Voltage Element Indicator

KLC04V = Vane Pump

KLC15

V = Vane PumpF = Flow Control Valve

KLC05(pump & motor notincluded)

Example: KLC04-V-3-20-VD

Viscosity: KLC04 to 10,000 SUS KLC05 to 700 SUSKLC15 to 3,000 SUS

Operating Pressure: 45 psi (3 bar) max

Suction Pressure: 11” Hg (-0.4 to 6 bar) max

Fluid Temperature: 32°F to 175°F (0°C to 80°C)

Ambient Temperature: -4°F to 104°F (-20°C to 40°C)

Seals: Buna N

Maximum Flow Rate: KLC04 1.3 gpmKLC05 1.6 gpmKLC15 4.9 gpm

Fluids: Standard mineral oils, water/oil based fluids (min 40% oil in fluid),Consult factory for other fluids

Media: Membrane with or without water removal capability - (2 µm, 20 µm)

Dirt Holding Capacity: 200g ISO MTD / 185g ISO MTD

Water Retention: Approximately 0.5 quarts (0.5 liters)

Beta Ratio: ßx > 1000

Maximum ∆P: 45 psi (3 bar)

Connections with Pump /Motor: KLC04 Inlet & Outlet: SAE 16 (BSPP G1)KLC05 Inlet & Outlet: SAE 8 (BSPP G1/2)KLC15 Inlet & Outlet: SAE 8 (BSPP G1)

Weight: KLC04 24.3 lbs (11.0 kg)KLC05 15.5 lbs (7.0 kg)KLC15 24.3 lbs (11.0 kg)

Note: SAE connections when using supplied adapters; BSPP connections when supplied adapters are not used. Housing drain standard on all models.

Specifications

1 = 12VDC2 = 24VDC3 = 115V single phase4 = 220V single phase5 = 220/440V 3 phase

A02 = 2 micronA10 = 10 micronA20 = 20 micronA02 = 2 micron w/ water removalA20 = 20 micron w/ water removal

1 = 12VDC2 = 24VDC3 = 115V single phase4 = 220V single phase5 = 220/440V 3 phase

A02 = 2 micronA10 = 10 micronA20 = 20 micronA02 = 2 micron w/ water removalA20 = 20 micron w/ water removal

F = Static Electrical SwitchVD = Differential VisualED = Differential Electrical

EVD = Differential Visual/Electrical

G = Standard GaugeF = Static Electrical Switch

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Description

X Series Filter Skids

ModelNumber

Selection

Schroeder's new X Series filtration skids are compact, self-contained filtration systems equipped with high efficiency,high capacity elements capable of removing particulate contamination and/or water quickly and economically. Theysupplement in-line filters whenever the existing filtration is incapable of obtaining the desired ISO cleanliness level.

It is not uncommon for viscosity to be overlooked when specifying an off-line filtration unit. The results of thisoversight can severely affect system efficiency and longevity, and render the filtration system useless when highviscosity fluid causes the filter to be in constant bypass. Schroeder considers maximum fluid viscosity, (at theminimum operating temperature) in conjunction with flow to properly size the pump and motor.

Standard X Series skids include a hydraulic pump, electric motor, and either a single or dual K9 or QF15 housing.Many different component combinations provide the flexibility to match specific system viscosity, flow, andcleanliness requirements. Multiple housing lengths give the option of adding additional dirt holding capacity.

Skid Flow Filter Designation Element Element

Series (gpm) K9 Filter QF15 Filter Media Media Seal1K 2K 3K 16Q 39Q 1-41st Filter1-4 1-42nd Filter1-4 Material

09 1K 2K 3K

X117 1K 2K 3K 1Q37 1K 2K 3K 1Q 3Q82 3K 1Q 3Q09 1K 2K 3K

2

X21 17 2K 3K 1Q37 3K 3Q82 3Q09 1K 2K 3K 1Q 3Q

2X32 17 2K 3K 1Q 3Q37 3K 3Q09 1K 2K 3K

X417 1K 2K 3K 1Q37 1K 2K 3K 1Q 3Q82 3K 1Q 3Q09 1K 2K 3K

2

X51 17 2K 3K 1Q37 3K 3Q82 3Q09 1K 2K 3K 1Q 3Q

2X62 17 2K 3K 1Q 3Q37 3K 3Q

1. Z1 media not offered for use in 500 to 2000 SUS filtration skids. Contact factory for specific applications.2. Z1 and Z3 media not offered for use in 2000 to 5000 SUS filtration skids. Contact factory for specific applications. 3. All elements are singular construction (no stacked elements)4. QPML and QCLZ coreless elements only available in the QF15 housing.

A = Z1 (K or Q)

B = Z3 (K or Q)

C = Z5 (K or Q)

D = Z10 (K or Q)

E = Z25 (K or Q)

F = QCLQFZ1

G = QCLQFZ3

H = QCLQFZ5

J = QCLQFZ10

L = QCLQFZ25

M = QPMLZ1

P = QPMLZ3

R = QPMLZ5

S = QPMLZ10

T = QPMLZ25

W = W

N = NA

A = Z1 (K or Q)

B = Z3 (K or Q)

C = Z5 (K or Q)

D = Z10 (K or Q)

E = Z25 (K or Q)

F = QCLQFZ1

G = QCLQFZ3

H = QCLQFZ5

J = QCLQFZ10

L = QCLQFZ25

M = QPMLZ1

P = QPMLZ3

R = QPMLZ5

S = QPMLZ10

T = QPMLZ25

W = W

B = Buna (Standard)

H= EPR

V = Viton

XX

XX

XX

XXX

XX

XX

XXX

XXX

XXX

XX

XX

X

X

XX X

X

XX

XXXX

X

X

Dual K9 Filter Version (Series X4, X5 and X6)Metric dimensions in ( ).




ModelNumberSelection(continued)

StarterMotor Control Dirt Vacuum Miscellaneous

Power Frame 5, 6Options5, 6 Alarm Gauge Options

A = 115 VAC8

1.5 hp(Availableonly with109, 209,and 309)

N = 230 /460 VAC 3 PH.

E = 575 VAC9

3 PH.

N = TEFC

W = Washdown(NEMADesign B)

N = None

A = 230 VAC

B = 460 VAC

C = 230 VAC(with VFD)

D = 460 VAC(with VFD)

E = 575 VAC

F = 575 VAC(with VFD)

N = Cartridge inCap(Standard)

G = DifferentialPressureGauge

M = MS115, 6

ElectricCartridge

C = DifferentialPressureGauge withElectricSwitch5, 6

N = None

V = Vacuum Gauge

N = None

S = Suction Strainer

C = 4 Wheeled Cart

B = ContinuousBleed7

P = SMART® Kit10

5. Motor starter control option - C-series, non-disconnect shut-off, “motor on” light, electrical indicator “change element” light, and type 4x wash down enclosure.6. VFD control option - same as above but with enclosed variable frequency drive control and larger metal NEMA enclosure.7. Continuous bleed option - to eliminate filter air buildup in continuously aerated systems. Includes cap vent port, valve, and return line.8. 115 VAC power option includes switch, 10' cord, and plug. For 1.5 hp motors only.9. 575 will be built to CSA standards.

10. Only available on X1 and X4.

SkidSelection

Series Viscosity Range Filter Housing(s) Maximum Flow

X1 150 - 500 SUS (1) QF15 or K9 82 gpm (310 L/min)



X4 150 - 500 SUS (2) QF15 or K9 in series 82 gpm (310 L/min)



Dual QF15 Filter Version (Series X4, X5 and X6)

X Series Filter SkidsTCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



Skid Series Flow (gpm) Weight (lb)* Skid Series Flow (gpm) Weight (lb)*

09 238-357 09 372-442

X1 17 300-504 X4 17 353-66237 329-577 37 398-79182 476-705 82 551-90409 238-357 09 301-442

X2 17 311-504 X5 17 396-68437 348-577 37 497-84982 597-705 82 947-105409 238-479 09 267-650

X3 17 340-580 X6 17 370-65937 461-566 37 502-607

*Weight dependent on options chosen.


Specifications

Protects and extends the life of expensive components

Minimizes downtime and maintenance costs

Designed to handle high viscosity oils up to 5,000 SUS (see Skid Selection; previous page)

Many component combinations and variable starter options allow the flexibility to match specific user needs

Four wheel cart option provides product portability

Integral drip pan with drain plug

Sample valves provided at filter base for fluid sampling

Market leading Schroeder Excellement® synthetic filtering media provides for quick, efficient clean up withmaximum element life

Availability of all plastic, environmentally friendly, coreless elements for QF15 housings

X Series Filter Skids

Flow Rating: Up to 82 gpm (310 L/min)

Temp. Range: -20°F to 225°F (-29°C to 107°C)

Bypass Valve Setting: 50 psi (3.5 bar) for skid series X1, X2, X3, X4, and X540 psi (2.8 bar) for skid series X6

Fluid Viscosity: Up to 5000 SUS (see Skid Selection; previous page)

Compatibility: All petroleum based hydraulic fluids. Contact Schroeder for use with other fluids, including ester and skydrol

Pump: Continuous duty gear pump with integral 150 psi relief. Flow dependent onskid series and motor. Refer to table below.

Motor: Horsepower dependent on skid series and flow. Refer to table below.

Porting: Dependent on flow. Refer to table below.

Skid Series Flow (gpm) Motor (hp) Skid Series Flow (gpm) Motor (hp)

09 1.5 09 2

X1 17 3 X4 17 337 5 37 582 10 82 1009 1.5 09 2

X2 17 3 X5 17 537 5 37 1082 10 82 1509 1.5 09 2

X3 17 5 X6 17 537 10 37 10

Flow Outlet Port Sizes Outlet Port Sizes(gpm) Inlet Port Sizes with K9 & MK9 Filters with QF15 Filters

09 1.625-12UN-2B SAE O-Ring Boss 1.312-12UN-2B SAE O-Ring Boss 1.625-12UN-2B SAE O-Ring Boss

17 1.875-12UN-2B SAE O-Ring Boss 1.625-12UN-2B SAE O-Ring Boss 1.625-12UN-2B SAE O-Ring Boss

37 2” JIC 1.875-12UN-2B SAE O-Ring Boss 1.875-12UN-2B SAE O-Ring Boss

82 2” JIC 1.875-12UN-2B SAE O-Ring Boss 2.500-12UN-2B SAE O-Ring Boss

Pump andMotor

Data

Porting Data

WeightData

Features



**The X7 skid allows for one filter or two filters in series.**The X8 skid will have two QF15 filters in parallel, but both will have the same element type.

This information relates to the operating conditions and applications described. For applications or operating conditions not described,please contact the relevant technical department. Subject to technical modifications.

N = Cartridge in Cap (Standard)

G = Differential Pressure Gauge

M = MS11 Electric Cartridge

C = Differential Pressure Gauge with Electric Switch

Element Element StarterSkid Media Media Seal Motor Control Dirt Miscellaneous

Series 1st 2nd 5, 6Material Frame Options Alarm Options

X7 = 6 gpm

X8 = 30 gpm

C = Z5

D = Z10

E = Z25

C = Z5

D = Z10

E = Z25

X = NotAvailable*

X = NotAvailable*

B = Buna

B = Buna

V = Viton

N = TEFC

W =Washdown

N = None

A = 230 VAC

B = 460 VAC

C = 230 VAC with VFD

D = 460 VAC with VFD

E = 575 VAC

F = 575 VAC with VFD

N = None

C = 4 Wheeled Cart

D = ContinuousBleed

V = Vacuum Gauge

Flow Rating: 6 gpm or 30 gpm

Temperature Rating: 0°F to 180°F (-17°C to 82°C)

Bypass Valve Setting: 50 psi (3.4 bar)

Fluid Viscosity: 100 SUS to 25,000 SUS

Compatibility: Hydraulic and lubricating fluids

Pump: Positive displacement rotary screw pump

Motor: 230/460 VAC 3 phase motor. Horsepower dependent on skid series

Porting: Inlet and outlet ports are 1.5” (1.875-12) MJIC ports


Specifications


X Series Filter Skids - High Viscosity

Features

Description TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix

Schroeder’s new high viscosity X Series skids are compact, self-contained filtration systems. They are designed tohandle fluids that have a viscosity as high as 25,000 SUS. The skids have 39” long QF15 filters to efficiently cleanthe viscous fluids. The filters have a high dirt-holding capacity, capable of holding almost 1000 grams of dirtdepending on the element.

Standard high viscosity X Series skids include a pump, motor, QF15 filter, suction strainer, and dirt indicator. Variousoptions can account for specific user needs.

Protects and extends the life of expensive components

Designed to handle high viscosity oils up to 25,000 SUS

39” long Q15 filters included to clean high viscosity fluids

Suction strainer and built-in relief valve included to protect pump

Integral drip pan with drain plug prevents oil from dripping on the ground, thereby providing a safer environment

Sample valves provided at the filter base for fluid sampling



Recommended Fluid: Petroleum based oils. Contact Schroeder for other applications.

Nominal Flow: 4 gpm (15 L /min)

Maximum Oil Temperature: 180°F (80°C)

Viscosity Range: 40 to 2300 SUS 5-500 mm2/sec

Maximum Operating Pressure: 50 psi (3.5 bar)

Seal Material: Buna N

Weight: 27.5 lb (12.5 kg)

Electrical Motor: 110 VAC (0.25 hp / 0.18 kw) or 24 VDC (0.27 hp / 0.20 kw)


HFS

Handy Filter Systems

Applications

Specifications

Description

Features Spin-on elements make element changeouts quick and easy and limit oil spillage

All units equipped with a clogging indicator

Suction line incorporates a wire mesh strainer to protect the pump

Relief valve provided in housing

Convenient carrying handle provided in framework

Inlet and outlet wands provided

Transfer and filter hydraulic fluids

Remove water from hydraulic fluids

Provide auxiliary filtration on demand

As the name implies, the HFS is a hand-held filtration unit that utilizes convenient Schroeder M-size spin-onelements. It is powered by an electrical motor that drives a low noise vane pump. All components are securelyfixed to an aluminum framework with integral feet for stable placement. The HFS is ideal for maintaining off-highway vehicles and a wide variety of industrial equipment.

Handy Filter Systems Motor* Element

M3A = 110 VAC M10

HFS MZ3B = 24 VDC MZ10

MW

*24VDC and pneumatic options available. Contact factory.

Absolute Rating Per ISO 4572/NFPA T3.10.8.8 Abs. Rating wrt ISO 16889 7" Using automated particle counter (APC) calibrated per ISO 4402 Using APC calibrated per ISO 11171 Dirt Holding

Element ßx ≥ 75 ßx ≥ 100 ßx ≥ 200 ßx(c) ≥ 200 ßx(c) ≥ 1000 Capacity gm

M3 6.8 7.5 10.0 N/A N/A 50

M10 15.5 16.2 18.0 N/A N/A 37

MZ3 <1.0 <1.0 <2.0 4.7 5.8 105

MZ10 7.4 8.2 10.0 10.0 12.7 104

ElementPerformanceInformation

ModelNumber

Selection

Preferred order codes designate shorter leadtimes and faster delivery.




The MTS from Schroeder is an off-line filtration system that features unique membrane elements constructedof stacked disks where dirt holding capacity is measured in pounds instead of grams, drastically reducing theamount of time required to clean up highly contaminated fluids. The abundant media surface area affordedby the stacked disk construction combined with the highly efficient membrane filtration give the MTS its veryimpressive dirt retention characteristics. The MTS can hold up to four filter elements and can be supplied as astand-alone filter or with a pump and motor.


Membrane Technology Systems

27(686)

MTS-1

64(1626)

MTS-4

52(1321)

MTS-3

40(1016)

MTS-2

8(203)

6(152)Outlet

17.5(445)

24(610)

Features

Description

MTS

Applications

Effectively cleans hydraulic and cleaning fluids, lubricating oils, and coolants

Provides excellent dirt removal efficiency, even in single pass filtration

Available with pump and motor or can be utilized as an individual filter

Included framework makes unit ready to install

Easy to retrofit existing system

Test points provided on all models

Housing drain standard on all units

Off-line filtration for hydraulic systems and test stands

Bypass filtration

Flushing and filling applications

In-line auxiliary filtration

SingleMembrane

Element

Element Cross Section

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Model No. of Elements Flow gpm (L/min)

MTS 1, 2, 3, 4 5 (19)

MTS 2, 3, 4 10 (38)

MTS 3, 4 15 (57)

MTS 4 20 (8)

MTS-1 MTS-2 MTS-3 MTS-4

Number of Elements: 1 2 3 4

Contamination Retention Capacity: 1.1 lbs 2.2 lbs 3.3 lbs 4.4 lbs(500 g) (1000 g) (1500 g) (2000 g)

Filter Efficiency: ßx > 1000 ßx > 1000 ßx > 1000 ßx > 1000

Permissible ∆p Across the Element: 72.5 psi (5.0 bar) 72.5 psi (5.0 bar) 72.5 psi (5.0 bar) 72.5 psi (5.0 bar)

Weight Element: 6.6 lbs (2.99 kg) 13.2 lbs( 5.99 kg) 19.8 lbs (8.98 kg) 26.4 lbs (11.97 kg)

Material of Filter Housing: Stainless Steel Stainless Steel Stainless Steel Stainless Steel

Capacity of Pressure Vessel: 5.25 gal (19.87 L) 10.50 gal (39.75 L) 15.75 gal (59.62 L) 20.5 gal (77.60 L)

Max Operating Pressure Filter Housing: 87 psi (6.0 bar) 87 psi (6.0 bar) 87 psi (6.0 bar) 87 psi (6.0 bar)

Material of Seals-Housing (standard): Buna N Buna N Buna N Buna N

Weight Housing: 25 lbs (11.34 kg) 33 lbs (14.97 kg) 53 lbs (24.04 kg) 62 lbs (28.12 kg)

Fluid Temperature: 15° to 175°F 15° to 175°F 15° to 175°F 15° to 175°F(-9.44° to 79.44°C) (-9.44° to 79.44°C) (-9.44° to 79.44°C) (-9.44° to 79.44°C)

Technical Details for Motor-Pumps Units: 5 gpm 10 gpm 15 gpm 20 gpm (18.93 L/min) (37.85 L/min) (56.78 L/min) (75.71 L/min)

Operating Pressure of the Pump: 65 psi (4.48 bar) 65 psi (4.48 bar) 65 psi (4.48 bar) 65 psi (4.48 bar)

Viscosity Range with Vane Pump (SUS): 75 to 2500 75 to 2500 75 to 2500 75 to 2500

Motor Capacity (watts) Vane Pump: 370 W 570 W 1500 W 1500W

Weight Vane Pump: 17 lbs (7.71 kg) 30 lbs (13.61 kg) 43 lbs (19.50 kg) 43 lbs (19.50 kg)

Material of Seals in Pumps (standard): Buna N Buna N Buna N Buna N

Vane Pump Connectors : ModelMTS-1 1 1/16 -12UN (SAE 12)

MTS-2, 3, and 4 1 5/8 -12UN (SAE 20)


Specifications

ElementSelection

andReplacement

Elements

ElementPressure

Drop

ModelNumber

Selection

Membrane Technology Systems

MTScontinued

Membrane Pump Flow Rate* Absolute Rating OptionsTechnology *No. of* (must be ≤ Type of of Element Dirt (may specify

System Elements No. of Elements) Pump Motor Media Alarm more than one)

MTS

*See Element Selection Chart below for correlation between number of elements and flow. Other pumps available upon request.

1234

1 = 5 gpm2 = 10 gpm3 = 15 gpm4 = 20 gpmX = no pump

V = VaneX = No

PumpG = Gear

Pump

1 = 115 VAC3 = 230/460 VAC

3 PH5 = 575 VAC

3 PH**X = No Motor***

02 = 2 micron10 = 10 micron20 = 20 micron30 = 30 micron

I = IntegratedPressure Gauge

E = Electrical Diff.Pressure Gauge

S = SAE Adapters(BSPPconnections are standard)

V = Viton Seals

∆P (b

ar)

∆P p

si

Differential Pressure at 3.96 gpm (15 L/min)

58

51

44

36

29

22

15

7

Viscosity SUS

Viscosity (cSt)

900 2000 3000 4000

MTE 30

MTE 02

MTE 10

MTE 20


***575 will be built to CSA standard.***Motor is not included if pump is not specified.

Replacement Elements

MTE02 = 2 micron

MTE10 = 10 micron

MTE20 = 20 micron

MTE30 = 30 micron




Sizing Off-lineFiltration

Membrane Technology SystemsTCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix

Contamination Ingression(µg/gal)

Surroundings

Type of System Clean Normal Polluted

Closed circuit 1 3 5

Injection molding machine 3 6 9

Standard hydraulic system 6 9 12

Lubrication system 8 11 14

Mobile equipment 10 13 16

Heavy industrial press 14 18 22

Flushing test equipment 42 60 78

Step 2: Make the correction required for off-line filtration.The contamination input selected above must be multiplied by the factor:

Main System Flow Rate / Desired Off-line Flow Rate

Note: Main system flow rate must be corrected for cycle time. For example, if the flow rate is 500 gpm, butonly runs for 20% of the system cycle, the main system flow rate would be 100 gpm. (500 gpm X 20%)

This yields the expression:

Contamination Factor = Contamination Input (µg/gal) x Main System Flow Rate (gpm)Desired Off-line Flow Rate (gpm)

Calculate the contamination factor using this expression.

Step 3: Determine the attainable cleanliness level. Locate the calculated contamination factor on the y-axis ofthe attached graph. Go to the right to find the intersection point on the curve corresponding to thedesired absolute filter micron rating. Read the resulting attainable cleanliness level on the x-axis. (Incase of dynamic flow through the off-line filter, the attainable cleanliness level will be 2 to 3 timesworse than indicated by the graph.)

Off-line Filtration Sizing Example

Type of System: Heavy industrial press

Surroundings: Normal

Main System Flow Rate: 150 gpm

Desired Off-line Flow Rate: 16 gpm (MTS-4)

Step 1: Using this criterion select the approximate contamination ingression rate from the chart above.This yields a contamination input of 18 µg/gal based on a heavy industrial press with normal surroundings.

Step 2: Make the correction required for off-line filtration.Contamination Factor = 18 µg/gal x 150 gpm / 20 gpm = 135

Step 3: Determine the approximate attainable cleanliness level for each micron rating using the attachedgraph. If the attainable cleanliness level is not acceptable, the desired off-line flow rate should beincreased. The approximate attainable levels for this example are as follows.2 µm - ISO 17/15/12

20 µm - Between ISO 20/18/15 and ISO 21/19/16

The following calculations will help to approximatethe attainable system cleanliness level when applyingoff-line filtration.

Step 1: Select the approximate contaminationingression rate from the chart. Quantitativeinvestigations have yielded the followingapproximate figures.




SVD

Vacuum Dehydrator

Description

Applications

Features

Principle of Operation

Mobile equipment/equipment used outdoors Plastic injection and die cast machines

Pulp and paper plants Reclaimed fluids

Power generation plants

Centrifuge and condensation methods typically only remove free water. The SVD, which uses mass transfer,can remove both free and dissolved water from the oil, as well as dissolved gases. In addition, solidcontaminants are also removed by highly efficient membrane elements. The SVD is intended to be used on large hydraulic and lubricating circuits that have a minimal 200 gallon (760 l) reservoir. Unit automatically shuts down when desired % saturation is reached.

Negative effects of water in hydraulic oil:

Depletion of additives Reduction in lubricity

Increased acidity of oil Accelerated aging of components

When connected to the hydraulicreservoir of a system with wet oil, theSVD unit draws the oil in its chamber.Oil slowly cascades down in thereactor chamber. Water is separated inthe form of vapor and is removed bythe vacuum pump. This vapor can bereleased to atmosphere or condensedinto a separate reservoir. The purifiedoil is drained from the reactor chamberthrough a pump back to systemreservoir at a continuous flow rate.This oil is now dry and free of water(within the specifications provided).

TWS-C standard on all units

Removes 100% of free and over 90% of dissolved water and as well as 100% of free and over 90% of dissolved gases

Automatic mode with automatic shutdown based on user settings

Four models are available to accommodate various flow rates

Use of a vacuum pump avoids any dangerous chemically reactive by-products

Maintenance, operating, troubleshooting instructions are in HMI (touch screen)

58.45(1485)

32.00(813)

58.45(1485)

66.34(1685)

8.00

48.34(1228) 22.00

(559)32.00(813)




Hydraulic Oil Saturation Curve

∆P (b

ar)

∆P p

si

Differential Pressure at 3.96 gpm (15 L/min)

58

51

44

36

29

22

15

7

Viscosity SUS

Viscosity (cSt)

900 2000 3000 4000

MTE 30

MTE 02

MTE 10

MTE 20


Vacuum Dehydrator

Sizing

ElementPressureDrop

Factors That Affect Water Removal RateFactor (increasing/decreasing) Dewatering Speed

Water Content

Fluid Temperature

Detergent Additives

Absolute Pressure in Vacuum Chamber

Humidity

Flow Rate

Ester Oils

Sizing Chart(continuous water ingression)

Tank Volume SVD(gallons) Model

1000 to 2000 SVD05

2000 to 4000 SVD10

4000 to 7000 SVD16

7000 and up SVD23

Sizing of the SVD is normally done through periodic measuring of the water content which will determine thehourly ingestion of water. The typical dewatering speed of the SVD is listed in the technical data table above.If there is a continuous ingression of water (i.e. condensation) the recommended flow rate of the SVD can bedetermined by the the system size (total gallons.) It should circulate 3 or 4 times through the SVD every day.

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



SVD05 SVD10 SVD16 SVD23

Capacity of Pressure Vessel: 5.25 gal (20 L) 10.5 gal (40 L) 20.5 gal (78 L) 26.25 gal (100 L)

Solid Contamination to ISO 4572: 1.1 lbs (500 g) 2.2 lbs (1000 g) 3.3 lbs (1500 g) 5.5 lbs (2500 g)

Bypass Cracking Pressure: 29 psi (2 bar) 29 psi (2 bar) 29 psi (2 bar) 29 psi (2 bar)

Pump Type: Gear pump Gear pump Gear pump Gear pump

Flow Rate: 5 gpm (18.93 L/min) 10 gpm (37.85 L/min) 16 gpm (60.57 L/min) 23 gpm (87.06 L/min)

Maximum Operating Pressure: 87 psi (4.5 bar) 87 psi (4.5 bar) 87 psi (4.5 bar) 87 psi (4.5 bar)

Visc. Range without Heater SUS: 75-2500 75-2500 75-2500 75-2500(cSt): (15-500) (15-500) (15-500) (15-500)

Visc. Range with Heater SUS: 5000 5000 5000 5000

Electrical Cable Length: 25 ft (7.6 m) 25 ft (7.6 m) 25 ft (7.6 m) 25 ft (7.6 m)

Seal Material: NBR NBR NBR NBR

Weight with Heater: 1300 lbs (585 kg) 1350 lbs (608 kg) Contact factory Contact factory

Weight without Heater: 1105 lbs (497 kg)* 1170 lbs (527 kg)* Contact factory Contact factory

Fluid Temperature: 50°F to 175°F 50°F to 175°F 50°F to 175°F 50°F to 175°F(10°C to 79°C) (10°C to 79°C) (10°C to 79°C) (10°C to 79°C)

Ambient Temperature: 5°F to 105°F 5°F to 105°F 5°F to 105°F 5°F to 105°F (-15°C to 41°C) (-15°C to 41°C) (-15°C to 41°C) (-15°C to 41°C)

Max Free Water Removal Rate*(gallons/hour): 0.75 1 1.5 2

Attainable Water Content: <100 ppm <100 ppm <100 ppm <100 ppm

*Estimated weight

Model No. of Elements Flow gpm (L/min)

SVD05 1 5 (18.93)

SVD10 2 10 (37.85)

SVD16 3 16 (56.78)

SVD23 4 23 (75.71)


SVDcontinued

Specifications

Model Number

Selection

ElementSelection

Vacuum Dehydrator

Vacuum OptionsDehy- Flow Number of (may specify drator Rate Fluid Mobility Voltage Power Elements* Media more than one)

SVD

**See Element Selection Chart below for correlation between number of elements and flow.**575 will be built to CSA standards.

05 = 5 gpm10 = 10 gpm16 = 16 gpm23 = 23 gpm

H = Hydraulic andSynthetic OilT = Transformer Oil(requires heater)B =Biodegradable OilF = Fire ResistantOils (mustidentify fluidtype with order)

S = StationaryM = Mobile

23 = 230V/60 Hz/3 Phase

46 = 460V/60 Hz/3 Phase

57 = 575V**/60Hz/3 Phase

XX = Other

19X = 1900 watts27X = 2700 watts32X = 3200 watts51X = 5100 watts09H = 8650 watts

with heater19H = 19200 watts



with heater

02 102030

1234

C = AutomaticCooling water fill(availablefor H andB fluidsonly)





Appendix

ISO 4406: 1999 ISO 14/12/9NAS 1638 Class 3SAE AS 4059: D Class 4










ComparisonPhotographsfor Fluid Contamination ClassMagnification x 100 1 scale mark = 10 µm

Photos are representative of:a) 100 ml sample

pulled through 0.8 µm 47 patchor

b) 28 ml sample pulled through 0.8 µm 25 patch

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix




Appendix

Contamination Types

All photosx 48 magnification

1 scale mark = 45 µm

Particle Type:Mainly rust; white particles; additives

Effect:• Rapid oil aging• Breakdowns in pumps, valves• Wear and tear

Particle Type:Oil aging products

Effect:• Blocking of filters• Silting-up system

Particle Type:Metal

Effect:• Breakdowns in pumps, valves• Wearing of seals• Leakage• Oil aging

Particle Type:Particles in bronze, brass and copper

Effect:• Breakdowns in pumps, valves• Oil aging• Leakage• Wearing of seals



Particle Type:Gel-type residue from filter element

Effect:• Blocking of filter• Silting-up

Particle Type:Silicates due to lack of, or inadequate, airbreather filter

Effect:• Heavy wear on components• Breakdowns in pumps, valves• Wearing of seals

Particle Type:Colored particles (red/brown)Synthetic particles (blue)

Effect:• Breakdowns in pumps, valves• Wearing of seals

Particle Type:Fibers due to initial contamination, open tank, cleaning cloths, etc.

Effect:• Blocking of nozzles• Leaking from seat valves


AppendixAppendix

Contamination TypesAll photosx 48 magnification

1 scale mark = 45 µm

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



Extended to particle range 2 - 5 µm Amount of

ContaminationNAS- Number of Particles/100 ml (ACFTD) Class 2 - 5 µm 5 - 15 µm 15 - 25 µm 25 -50 µm 50 - 100 µm > 100 µm [mg/l]

00 625 125 22 4 1 0 —

0 1,250 250 44 8 2 0 0.01

1 2,500 500 88 16 3 1 —

2 5,000 1,000 178 32 6 1 —

3 10,000 2,000 356 63 11 2 —

4 20,000 4,000 712 126 22 4 0.1

5 40,000 8,000 1,425 253 45 8 —

6 80,000 16,000 2,850 506 90 16 0.2

7 160,000 32,000 5,700 1,012 180 32 0.5

8 320,000 64,000 11,400 2,025 360 64 1

9 640,000 128,000 22,800 4,050 720 128 3

10 1,280,000 256,000 45,600 8,100 1,440 256 5

11 2,560,000 512,000 91,200 16,200 2,880 512 7 - 10

12 5,120,000 1,024,000 182,400 32,400 5,760 1,024 20

13 — 2,048,000 364,800 64,800 11,520 2,048 40

14 — 4,096,000 729,000 129,600 23,040 4,096 80

ISO 4402 Calibration >1 µm >5 µm >15 µm >25 µm >50 µm >100 µm

ISO 11171Calibration >4 µm(c) >6 µm(c) >14 µm(c) >21 µm(c) >38 µm(c) >70 µm(c)

SAE Code A B C D E F

000 195 76 14 3 1 0

00 390 152 27 5 1 0

0 780 304 54 10 2 0

1 1,560 609 109 20 4 1

2 3,120 1,220 217 39 7 1

3 6,250 2,430 432 76 13 2

4 12,500 4,860 864 152 26 4

5 25,000 9,730 1,730 306 53 8

6 50,000 19,500 3,460 612 106 16

7 100,000 38,900 6,920 1,220 212 32

8 200,000 77,900 13,900 2,450 424 64

9 400,000 156,000 27,700 4,900 848 128

10 800,000 311,000 55,400 9,800 1,700 256

11 1,600,000 623,000 111,000 19,600 3,390 512

12 3,200,000 1,250,000 222,000 39,200 6,780 1,020

Co

nta

min

atio

n C

lass

es


Appendix

ContaminationClassification According to

SAE AS 4059: D

ContaminationClassificationAccording to

NAS 1638-01/1964



927,000

463,500231,750

92,70046,35023,17513,905

9,270

4,635

2,3181,8541,391

927695

464348

230185

141

97

78

5955524946

42

40

37 3.0

4.0

5.0

6.07.08.09.010

15

20

30

4050

75100150200300400500

1,000

2,0003,0005,00010,00020,000

50,000100,000

200,000

40W50W

30W20W

10W

ISO10

ISO20

ISO37ISO46

ISO68

ISO320

DTE25

DTE26

VIS

CO

SIT

Y (

SU

S)

VIS

CO

SIT

Y (

CS

)

ISO100ISO150ISO220

3022842562482302121941761581401221048668503214-4-22-40

150140130120110100908070605040302010-10-20-30-40 0

0˚F TEMPERATURE ˚C 100˚F 210˚F

210˚F100˚F0˚F TEMPERATURE ˚F

MIL - H - 5606

140 GEAR OIL

ISO15 MIL - H - 83282C

ISO32 DTE24

VISCOSITY - TEMPERATURE CHART FORHYDROCARBON & OTHER PRODUCTS

Viscosity in SUS and CentistokesTemperature in Degrees F, Degrees C

• Practical limit of operation

DTE13

SKYDROL LD - 4

200,000

100,00050,000

20,00010,0005,0003,0002,000

1,000

50040030020015010075

5040

30

20

15

109.08.07.06.0

5.0

4.0

3.03022842562482302121941761581401221048668503214-4-22-40

37

40

42

4649525559

78

97

141185230

348464695927

1,3911,8542,318

4,635

9,27013,90523,175

46,35092,700

231,750463,500

927,000150140130120110100908070605040302010-10-20-30-40 0

0˚F TEMPERATURE ˚C 100˚F 210˚F

VIS

CO

SIT

Y (

CS

)

210˚F100˚F0˚F TEMPERATURE ˚F

VIS

CO

SIT

Y (

SU

S)

SKYDROL500B - 4

KEROSENE

DIESEL FUEL

JP4- AVERAGE DTE11

DTE135W - 20DTE15DTE16

DTE18DTE19

VISCOSITY - TEMPERATURE CHART FORHYDROCARBON & OTHER PRODUCTS

Viscosity in SUS and CentistokesTemperature in Degrees F, Degrees C

• Practical limit of operation

SCHROEDER INDUSTRIES LLC 95SCHROEDER INDUSTRIES LLC 95

AppendixAppendix

ViscosityCharts

TCM

TCM-FC

TMU

SMART® Kit

TPM

TIM

CTU

TWS-C

ET-100-6

HMG 3000

EWC

EPK

HTB

GS

TroubleCheck Plus

Test Points

Adapters

HoseJoiners

MicroflexHose

PressureLimiters

PressureGauges

Test Kits

Probalizer

AFM

MSS, MDSMFS, MFD

AMS, AMD

KSS, KSDKLS, KLD

AKS, AKD

KLC

X Series

HFS

MTS

SVD

Appendix



Number of Particles / Number of Particles /1 ml 1 ml

ISO- more up to and ISO- more up to andClass than up including Class than up including

0 0.00 0.01 15 160 320

1 0.01 0.02 16 320 640

2 0.02 0.04 17 640 1,300

3 0.04 0.08 18 1,300 2,500

4 0.08 0.16 19 2,500 5,000

5 0.16 0.32 20 5,000 10,000

6 0.32 0.64 21 10,000 20,000

7 0.64 1.3 22 20,000 40,000

8 1.30 2.5 23 40,000 80,000

9 2.50 5 24 80,000 160,000

10 5 10 25 160,000 320,000

11 10 20 26 320,000 640,000

12 20 40 27 640,000 1,300,000

13 40 80 28 1,300,000 2,500,000

14 80 160

New ISO codes are made up of 3 numbers representing the number of particles ≥4 µ(c), ≥6 µ(c) and ≥14 µ(c). The particlecount is expressed as the number of particles per ml.

Reproducibility below scale number 8 is affected by the actual number of particles counted in the fluid sample. Rawcounts should be more than 20 particles. If this is not possible, then refer to bullet below.

When the raw data in one of the size ranges results in a particle count of fewer than 20 particles, the scale number forthat size range shall be labeled with the symbol ≥ .

EXAMPLE: A code of 14/12/≥7 signifies that there are more than 80 and up to and including 160 particles equal to or largerthan 4 µ(c) per ml and more than 20 and up to and including 40 particles equal to or larger than 6 µ(c) per ml. The third partof the code, ≥7 indicates that there are more than 0.64 and up to and including 1.3 particles equal to or larger than 14 µ(c)per ml. The ≥ symbol indicates that less than 20 particles were counted, which lowers statistical confidence. Because of thislower confidence, the 14 µ(c) part of the code could actually be higher than 7, thus the presence of the ≥ symbol.


Appendix

ContaminationClassification

in Accordancewith

ISO 4406:1999



table of contentsc3%c0%b9%fa... · (extended maintenance intervals and mounting cost pressure)....

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