Rexroth Oil Cleanliness Booklet

Oil Cleanliness Booklet | Introduction

Introduction

Oil is the central component of any hydraulic system. If a system fails, contamination is one of the major reasons. This booklet explains the basics of contamination control and serves as a reference and information tool.

Content | Oil Cleanliness Booklet

04 Need for Hydraulic Filtration 05 Sources of Problems with Fluid Systems 06 Classical Oil Analysis 07 MPC 4614 Mobile Particle Counter 08 Contamination Types, Origin, Examples 12 Damage Caused By Contamination 13 The Objective 14 Filtration Grade Particle Sizes 16 Achievable Oil Cleanliness in Accordance with ISO 4406 17 Overview of the Key Filter Properties 18 Fitting Tolerance of Hydraulic Components 19 Recommended Oil cleanliness level 20 Oil Cleanliness Codes in Accordance with ISO 4406 32 Fluid and Product Service 33 Fluidmanagement Products 41 Notes

Oil Cleanliness Booklet | Need

Need for Hydraulic Filtration

Inspecting contamination in hydraulic systems is a major aspect when designing a lter concept.

Sources of Problems | Oil Cleanliness Booklet

Sources of Problems in Fluid Systems

More than of all problems can be traced back to contaminated oil. Monitoring oil cleanliness is therefore the most important factor in preventing system failures. Monitoring hardware only detects around 20 % of all unplanned downtimes.

Components 20 %

80 % Fluid

Oil Cleanliness Booklet | Oil Analysis

Oil Analysis

Types of inspection for oil cleanliness

f Ofine examination of oil samples in the laboratory f Microscopic particle count in accordance with ISO 4407 f Gravimetric test in accordance with ISO 4405 f Microscopic determination of the type of contamination

Vacuum ltration device:

e Oil sample

e Test membrane c Test membrane, 1,2 m

e Vacuum

e Filtrate c Microscopic image, 100 x

Particle Counter | Oil Cleanliness Booklet

Mobile Particle Counter for Conducting Online Measurements of the Oil Cleanliness Class
f Light extinction principle f Laser sensor f Robust and reliable device with all basic functions f Integrated battery pack and memory f Oil cleanliness classes in accordance with ISO 4406 4 m(c), 6 m(c), 14 m(c) f Comprehensive range of accessories, e.g. printer, tank pump, external memory card f Very easy to use

c MPC 4614

c Tank pump

c Printer

Oil Cleanliness Booklet | Types of Contamination

Types of Contamination

1. Solid particles
(abrasion and dirt)

Consequences: f Initial damage through scoring f Impact on control and regulation properties f Component wear f Component failure f Reduction in machine availability Measures: Filtration

Types of Contamination | Oil Cleanliness Booklet

2. Liquid contamination
(usually water, free and in solution) Consequences: f Corrosion, wear f Impairment of viscosity f Chem. reaction with the uid f Impact on lubricating properties f Ageing (oxidation) of oil f Poor lterability f Reduction in lter service intervals f Reduction in machine availability Measures: f Breather lters with AS lter material f Water absorbing lter elements (free) f Vacuum dehydrator (water in solution)

3. Gaseous contamination
(air)

Consequences: f Foam formation in the oil f Inaccurate valve response f Loss of energy f Pump damage f Chem. reaction with the uid f Oxidation f Reduction in machine availability

Measures: f Bleed system f Seal pumps f Use a vacuum dehydrator

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Oil Cleanliness Booklet | Origin

Sources of Contamination
1. Built-in contamination
f Foundry sand, dust f Manufacturing residue: - Welding residue - Metal swarf - Blasting material, lacquer/paint particles - Preservation material f Residue from cleaning agents (textile bers)

2. External contamination
f Dirt from the ambient air, introduced via - Plunger rods - Labyrinth seals - Aeration f Contamination caused by adding oil

3. Self-generated contamination
f Metallic wear caused by abrasion and erosion f Seal abrasion f Chemical corrosion f Oil ageing products f Oxidation residue f Oil-insoluble substances caused by mixing oil

Residual Dirt | Oil Cleanliness Booklet

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Examples of residual dirt

Built-in contamination
Residue from a return line lter (mobile hydraulic systems) f f f f Welding residue Metal swarf Paint residue Resin

Self-generated contamination (wear)

Residue from a high-pressure lter in a hydraulic system within a stainless steel forging press f Coarse brass and steel abrasion particles f Severe sliding wear (grooves and stress marks)

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Oil Cleanliness Booklet | Damage

Damage Caused By Contamination

Material removal (erosion)
caused by a high ow rate along edges combined with a high number of ingressed dirt particles with high speed in the ow.

Grooving (abrasion)
caused by hard, abrasive particles that are roughly the same size as the clearance of the components. Consequence: Reduction in performance due to leaking oil.

The Objective | Oil Cleanliness Booklet

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The Approach

Prevent with Rexroth lter technology.

f Optimum oil cleanliness f Reliable component protection f Major contribution towards machine availability f High degree of customer satisfaction

f High degree of oil contamination f ISO 22/20/18

f Achievable oil cleanliness using ne lter elements f ISO 12/10/8

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Oil Cleanliness Booklet | Filtration Grade Particle Sizes

Filtration Grade Particle Sizes

Viruses 0,003 0,05 m

Bacteria 0,3 20 m

0 mm

Field of application
0,05 0,1 0,2 0,5 1 3 5

c Tobacco smoke 0,01 1 m

c Blood cells 0,5 1,5 m

Filtration Grade Particle Sizes | Oil Cleanliness Booklet

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Pollen ~ 20 m

Human hair ~ 70 m

Rexroth Filter
10 20 30 50 100 200 500 1000 m

c Visibility limit = 40 m

Particle sizes are measured in units called micrometers. A micrometer is one millionth of a meter. The visibility limit of the human eye is approx. 40 m. This means that particles that are the most hazardous to a hydraulic system cannot be detected with the naked eye.

1 mm

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Oil Cleanliness Booklet | Achievable Oil Cleanliness

Achievable Oil Cleanliness in Accordance with ISO 4406

HydroClean XL lter material H20XL 19/16/12 - 22/17/14

H10XL

17/14/10 - 21/16/13

H6XL

15/12/10 - 19/14/11

H3XL

13/10/8 - 17/13/10

H1XL

10/6/4 - 14/8/6

Key Filter Properties | Oil Cleanliness Booklet

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Overview of the most important lter characteristics

Filtration grade
f Nominal (from manufacturer) f Absolute in accordance with ISO 16889 f Mesh width for wire fabric

Dirt absorption capacity

f In accordance with ISO 16889 f ISOMTD test dust

Differential pressure
f In accordance with ISO 3968 f In relation to 30 cSt/25 m

All three properties are mutually interdependent. Rexroth lter elements are characterized by an optimum ratio for these properties, ensuring the best possible ltering action with maximum dirt absorption and minimum p.

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Oil Cleanliness Booklet | Fitting Tolerance

Fitting Tolerance of Hydraulic Components

Gear pump Gear pump, Side plate Gear housing Vane pump Vane tip Vane surfaces Piston pump Piston bore Valve plate cylinder Servo valve Control piston Bafe plate Control valve Control piston Cone valve 0,5 - 5 m 0,5 - 5 m
Extract from CETOP RP 92H

0,5 - 5 m 5 - 13 m 5 - 40 m 1,5 - 10 m 18 - 63 m 2,5 - 8 m 2,5 - 23 m 13 - 40 m Examinations show that even particles with sizes that are 1/ x the clearance width can 3 lead to the clearance becoming blocked. The ltration grade of the system lters should therefore be selected in such a way as to ensure the absolute ltration grade is smaller than or equal to 1/3 of the smallest clearance width in the system.

Filtration grade 1/3 x smallest clearance

Recommended Oil cleanliness | Oil Cleanliness Booklet

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Recommended Oil cleanliness level

Application Oil cleanliness required in accordance with ISO 4406 16/12/9 Recommended lter material/ ltration grade H1XL / 1 m

Systems with extremely high dirt sensitivity and very high availability requirements Systems with high dirt sensitivity and high availability requirements, such as servo valve technology Systems with proportional valves and pressures > 160 bar Vane pumps, piston pumps, piston engines Modern industrial hydraulic systems, directional valves, pressure valves Industrial hydraulic systems with large tolerances and low dirt sensitivity

18/13/10

H3XL / 3 m

19/14/11 18/16/13 20/16/13

H6XL / 6 m H10XL / 10 m H10XL / 10 m

21/17/14

H20XL / 20 m

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Oil Cleanliness Booklet | Oil Cleanliness Codes

Oil Cleanliness Codes in Accordance with ISO 4406 and Examples of Contamination
Number of particles (per 100 ml) from 1.000.000 500.000 250.000 130.000 64.000 32.000 16.000 8.000 4.000 2.000 1.000 500 250 130 64 32 16 to 2.000.000 1.000.000 500.000 250.000 130.000 64.000 32.000 16.000 8.000 4.000 2.000 1.000 500 250 130 64 32 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 Example from ISO 18/16/11: 190.000 particles 4 m(c)/100 ml 58.600 particles 6 m(c)/100 ml 1.525 particles 14 m(c)/100 ml
ISO 4406 counts particles accumulatively, i.e. all particles that are larger than or equal to 4 m. In contradiction to this, NAS 1638 counts the particles in differential size classes, i.e. all particles within the range of 5 15 m, 15 25 m, etc. NAS 1638 became INVALID on 05/30/2001! The replacement standard SAE AS 4059 is a national standard intended for the US aviation industry only. It is therefore no longer permitted to specify contamination classes in accordance with NAS. Specifying contamination in accordance with ISO 4406 on the other hand is considered to be state-of-the-art.

ISOCode

Classication of all particles

4 m(c), 6 m(c) and 14 m(c)

Oil Cleanliness Codes | Oil Cleanliness Booklet

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ISO 10/7/5

(NAS 1638: class 1)

Particle size 4 m(c) Particle count 500 to 1.000 64 to 130 16 to 32 6 m(c) 14 m(c)

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Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 12/11/6

(NAS 1638: class 2)

Particle size 4 m(c) Particle count 2.000 to 4.000 1.000 to 2.000 32 to 64 6 m(c) 14 m(c)

Oil Cleanliness Classes | Oil Cleanliness Booklet

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ISO 14/13/9

(NAS 1638: class 3)

Particle size 4 m(c) Particle count 8.000 to 16.000 4.000 to 8.000 250 to 500 6 m(c) 14 m(c)

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Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 16/14/10

(NAS 1638: class 5)

Particle size 4 m(c) Particle count 32.000 to 64.000 8.000 to 16.000 500 to 1.000 6 m(c) 14 m(c)

Oil Cleanliness Classes | Oil Cleanliness Booklet

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ISO 17/15/13

(NAS 1638: class 6)

Particle size 4 m(c) Particle count 64.000 to 130.000 16.000 to 32.000 4.000 to 8.000 6 m(c) 14 m(c)

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Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 18/16/13

(NAS 1638: class 7)

Particle size 4 m(c) Particle count 130.000 to 250.000 32.000 to 64.000 4.000 to 8.000 6 m(c) 14 m(c)

Oil Cleanliness Classes | Oil Cleanliness Booklet

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ISO 19/17/14

(NAS 1638: class 8)

Particle size 4 m(c) Particle count 250.000 to 500.000 64.000 to 130.000 8.000 to 16.000 6 m(c) 14 m(c)

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Oil Cleanliness Booklet | Oil Cleanliness Classes

ISO 22/19/17

(NAS 1638: class 10)

Particle size 4 m(c) Particle count 2.000.000 to 4.000.000 250.000 to 500.000 64.000 to 130.000 6 m(c) 14 m(c)

Examples of Contamination | Oil Cleanliness Booklet

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Fatigue wear, 500 x

Sliding wear, 500 x

Cutting wear, 100 x

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Oil Cleanliness Booklet | Examples of Contamination

Cutting wear, 500 x

Dark, shiny metal, 500 x

Copper particles, 500 x

Examples of Contamination | Oil Cleanliness Booklet

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Red iron oxide, 500 x

Greasy/resinous residue, 500 x

Seal abrasion, 500 x

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Oil Cleanliness Booklet | Fluid and Product Service

Fluid and Product Service

f Oil analysis particles, water content, residual additives f Filter element analysis f System ushing and decontamination f Advice on oil cleanliness and oil maintenance

Products | Oil Cleanliness Booklet

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Extract from the product range

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Oil Cleanliness Booklet | Products

Oil Analysis Case

f Contamination control for hydraulic uids and lubricants f With sampling equipment

Sampling Equipment
f Safe and simple oil sampling from pressure lines and oil containers

Products | Oil Cleanliness Booklet

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Laser Particle Counter

f Measurement category: ISO 4406 oil cleanliness code f SAE AS 4059 oil cleanliness code f Measurement range: 4 21 m(c) with optional printer and pump

Datasheet: 51430

Online Particle Monitor

f Measurement category: ISO 4406 oil cleanliness code f 4, 6, 14 and 21 m(c)

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Oil Cleanliness Booklet | Products

Online Water-Content Measuring Device

f Application: Online determination of water activity in hydraulic systems and lubricating oil f Measurement range: 0 100 % of the saturation of water in oil f With optional data memory, network or alarm module

VacuClean Oil Purication

f Operating data: End vacuum up to 50 mbar f Oil ow rate: 20 l/min, 5 50 l/min, 5 80 l/min

Products | Oil Cleanliness Booklet

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Ofine Filter Units (portable, 2- and 4-wheel design)

f Volume ow: 10, 15, 30, 35, 50, 80 l/min. f Filter type: 40 LE 0018, 7 SL 45, 7 SL 130, 40 FLE 0045, 40 FLE 0095, 40 FLE 0120 f Adjustable volume ow: 40 150 l/min. f Filter type: 40 FLE 0270C

Wide Product Range of Filterelements made of paper, metal and berglass

f Filtration grade: 1 1500 m f Filter area: 10 cm2 4,8 m2

Datasheet: 51420

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Oil Cleanliness Booklet | Products

Inline Filter
Datasheet: 51400 Type 51401 Type 51402 Type 51403 Type 51421 Type 51422 Type 51423 Type 40/100 LEN 0040 to 0400 40 FLEN 0160 to 1000 100 FLEN 0160 to 0630 16 FE 2500 to 7500 245 LEN 0040 to 0400 350 LEN 0040 to 0400 445 LEN 0040 to 1000

Tank Mounted Filter

Datasheet: 51424 Type 10 TEN 004 51425 Type 10 TEN 0160, 0250, 0400, 0630, 1000

Products | Oil Cleanliness Booklet

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Duplex Filter/ Change-Over Inline Filter

Datasheet: 51406 Type 51407 Type 51408 Type 51409 Type 51410 Type 50/150 LDN 0040 to 0400 40 FLDKN 0063 to 0630 40 FLDN 0160 to 1001 100 FLDN 0160 to 1000 16 FD 2500 to 7500

Manifold Mounted Filter

Datasheet: 51417 Type 51418 Type 51419 Type 51427 Type 450 245 350 320 PBFN 0040 to 1000 PSFN 0040 to 0400 PSFN 0040 to 1000 PZR 025, 075, 125

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Oil Cleanliness Booklet | Products

Filter for Mobile Hydraulics

Datasheet: 51426 Type 7SL 30 to 260

Filter for Process Engineering

Type Type Type Type 16 40 16 40 FKE 25/400 to 150/2500 FKE 25/400 to 150/2500 FKD 25/400 to 150/2500 FKD 25/400 to 150/2500

Design coated in Steel and Stainless Steel

Notice | Oil Cleanliness Booklet

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Oil Cleanliness Booklet | Notice

Notice | Oil Cleanliness Booklet

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Bosch Rexroth Filtration Systems GmbH Hardtwaldstrae 43 68775 Ketsch Germany Phone +49 6202 603-0 Fax +49 6202 603-199 [email protected] www.boschrexroth.com/lter

The data specied above only serve to describe the product. As our products are constantly being further developed, no statements concerning a certain condition or suitability for a certain application can be derived from ourinformation. The information given does not release the user from the obligation of own judgment and verication. It must be remembered that our products are subject to a natural process of wear and aging.

RE 08016/2011 Bosch Rexroth AG 2011

Subject to revisions! Printed in Germany