Introduction

Physical fundamentals

Graphic symbols

Pressure liguids

Hydraulic cylinders

Hydraulic pumps

Hydraulic motors

Axial piston units

Directional control valves

Pressure valves

ES
Flow regulating valves

Check valves

Accumulators

Accessories

Circuit logics

Service and maintenance

Proportional hydraulics

References

211
13.1. Task 213

13.2. Effect of contamination 214

13.3. Definition of the contamination degree 214

13.3.1. NAS 1638 215

13.82. ISO DIN 4406 215

13.4. Filter rating 216

13:5; Specification 217

13.6. Grouping of the filters according to the filtering material 218

13.6.1. Surface filter 218

13.6.2. Deep-bed filter 218

13.7. Arrangement in the circuit 218

13.7.1. Return line filter 219

15.7.2. Suction filter 219

13.7.3. Pressure filter 220

13.7.4. Partial flow filtration 220

13.7.5. Tank ventilation filter 221

13.8. installation of Hlters 221

13.9. Maintenance 221

13.10. Filter specification criteria 222

1341. Filter element selection 222

13.12. Filter capacity test (multipacks test) 224

13 LA. Test procedure 224

212
 1 13.1.
In hydraulic systems, very big flow rates pass through small gaps under high pressure. Therefore, these installations
are considerably more sensitive against impurities, in particular solid foreign matters, in the actually used hydraulic
fluid. Experience from practice reveals that appr.80 % of all premature failures are due to a contaminated pressure
liguid. Thus, the task of the filter is to reduce contamination to an admissible rate as regards grain size and
concentration of the suspending dirt particles in order to exclude excessive wear of the components. Filters
prevent failures and at the same time, prolong the lifetime of important as well as expensive components. The
following causes have to be taken into account:

Contamination due to repair work

Contamination by exchange of air

Contamination by new oil

Abrasion by wear owing to movement

213
FI Effectof contamination EE EA "
Dirt particles (sand, dust, metal and rust particles) cause increased abrasive wear of metal parts or seals moving
against each other. Parts especially subject to wear are bearings, vanes, tooth flanks, pistons of hydraulic motors
and pumps as well as the piston, rods and bushings of hydraulic cylinders. Wear on the sliding surface areas
enlarges fits and conseguently, increases loss due to leakage, diminishes the output capacity and the hydraulic
element heats up excessively. The damaging effect depends on hardness, size and concentration of the particles as
well as sensitivity to dirt of the single components. Particularly solid particles, whose size corresponds
approximately to the fit, cause wear.

Normally, relatively big solid particles (250 um) cause failure short-time after start-up, whilst smaller particles (210
um) generally lead to creeping wear characterised by slow damage development. The damaging effect depends on
hardness, size as well as concentration of the particles, senitivity to dirt of the single components. In particular,
solid matters, whose size corresponds approximately to the fit, are responsible for wear.

Damage of a seat-type valve

Damage of a guiding surface

EIE) Definition of the contamination degree Se

In order to define the degree of contamination of the hydraulic fluid, size and concentration of the dirt particles are
specified. Counts led to the result that the freguency grows with decreasing size of the partidles. The
contamination is standardised following the below criteria:

NAS 1638, respectively ISO 4406

The measurement is carried out by means of

particle counters. For secure analysis, the oil sample
is pumped to be air-free with a vacuum pump. The
counter is able indicating the result both in terms of
NAS 1638 or ISO 4406. Counting is possible offline
and online!

Particle counter INTERNORMEN

214
MT Nas 1638
The fluid contamination is divided in 14 purity classes. In each class, a defined number of particles (in 100 ml) is
specified in each of the five size ranges. The table depicts the structure of the contamination classes according to
NAS 1638. The following particle sizes are counted.
5-15um 2 15-25 um 2 25-50 um 2 50-100 um 2 100 um

Contami- Particle size in um

nation dlass
5-15 15-25 25-50
00 125. 22 A
0 250 aa 8
1 500 89 16
2 1000 178 32
3 2000 356 63
4 4000 712 126
5 8000 1425 253
6 16000 2850 506
7 32000 5700 1012 180
8 64000 11400 2025 360
9 128000 22800 4050 720
10 256000 45600 8100 1440
ii 512000 91200 16200 2880
12 1024000 182400 32400 5760

ET (so DIN 4406

Here the particles being bigger than 5 um and 15 um in 100 ml of a pressure liguid are detected and accumulated.
On basis of the two particle numbers, the purity class of the pressure liguid is determined. The classification covers
26 ranges. The designation of the purity classes includes two digits only. The first digit points to the range number
for the particle size * 5 um, whilst the second digit informs on the number for the particle size * 15 um. The below
table delivers recommendations for the reguired purity classes according to ISO DIN 4406 and NAS 1638 for
practical use.

Hydraulic component ISO DIN NAS 1638 Filter rating

4406

Servo or control valves 16/14/11 5 5

Proportional control valves 17/15/12 6 5

Vane-type and 18/16/13 7 10

piston pumps / motors

Directional and pressure regulating valves 18/16/13 7 10

Gear pumps / motors 19/17/14 8 10

Throttle valves/cylinders 20/18/15 9 10

New, not yet used fluid 20/18/15 9 10

215
ME ooN:
Number of particles per 100 ml

EE em iem
Purity -

ISO DIN 4406 more than up to more than up to more than up to

22/ 20 (17 2,000,000 4,000,000 500,000 1,000,000 64,000 130,000

21/ 19 /16 1,000,000 2,000,000 250,000 500,000 32,000 64,000

20/ 18 /15 500,000 1,000,000 130,000 250,000 16,000 32,000

19/ 17 /14 250,000 500,000 64,000 130,000 8,000 16,000

18/ 16 /13 130,000 250,000 32,000 64,000 4,000 8,000

17/ 15 /12 64,000 130,000 16,000 32,000 2,000 4,000

16/ 14 /11 32,000 64,000 8,000 16,000 1,000 2,000

15/ 13 /10 16,000 32,000 4,000 8,000 500 1,000

14/12 /9 8,000 16,000 2,000 4,000 250 500

13/ 11 /8 4,000 8,000 1,000 2,000 130 250

12/ 10 /7 2,000 4,000 500 1,000 64 130

11/ 9/6 1,000 2.000 250 500 32 64

10/ 8/5 500 1.000 130 250 16 32

9/ 7/4 250 500 64 130 8 16

8/63 130 250 32 64 4 8

7 5P2 64 130 16 32 2 4

6/ aft 32 64 8 16 $ 2
5/ 3/1 16 32 4 8 1 2

al 2/0 8 16 2 4 0 1

3/1/0 4 8 1 2 0 1

| Filter rating
According to the main filtration group, which the filter is to be allocated to, the proper filter rating has to be
specified. With older technical eguipment and hydraulic components, the reguired filter rating was also separately
indicated. Since the purity degree of fluids is of decisive importance for reliability of hydraulic installations, all the
component producers recommend the appropriate purity classes of fluids in their technical documents.
Referring to this specification, the selection of filters is a difficult matter, since the contamination degree depends
both on particle size and particle number of the contamination. By means of preceding lab and practice tests, the
filter manufacturers are in a position allocating the reguired filter rating to the desired fluid purity.

216
 In addition, the following factors have a decisive impact on the purity class reguired in the existing system:

e Type of installation
* Environmental contamination (kind, guantity)
e Working period of the eguipment
e Filter arrangement
e Operational overpressure

Micro contamination Fine contamination Coarse contamination

Micro particles (3 um to 5 um) cause
failures as well as reduced
performance owing to:
* Erosive effect through micro
particles (control edge
erosion)
* Fine deposits in narrow gaps
(gap filter effect, danger of
clogging)
e Change of the working
medium (oil ageing) due to
chemical reaction on the
particle surface.
Fine particle (5 um to 20 um) cause
friction wear mainly in narrow fits.
Conseguences:
e Enlarged play by wear
(increased internal leakage)
* Temporaryfailure (short-
time jamming of slide-type
piston valves or leaky valve
seats)
e Total breakdown by severe
wear
Coarse particles * 20 um often cause
Sudden total breakdown due to
blocking effect or direct damage.
Typical:
e Nozzleblocking
e Pistonjamming or ,seizure”
e Material cutout due to high
force

Micro filtration Fine filtration Coarse filtration

Efficient separation of micro
dispensed particles.
High pressure-difference resistant
micro filter enhance reliability by
* minimizing the generation
and progress of erosion,
* prevent clogging of narrow
Baps,
s protecting from oil ageing
and
* avoiding eguipment failure.
Partial separation of fine impurities Separation of coarse particles
and complete separation of coarse
matters. Coarse filters protect the system from
coarse impurities and prevent danger
Fine filter monitor reliably the of sudden breakdown or total
acceptable contamination degree of damage.
the system by
* protecting the components
from contamination in
optimum way,
s reducing the friction wear
and
* preventing sudden failure of
parts.

Referring to an already specified purity class of fluid, the most appropriate filter rating may result to be very
difficult to determine. To facilitate replaceability of filters, select such filter size which makes the replacement with
a bigger filter a simple job to do at any time reguired. One of the typical failure reasons in hydraulic installations is
clogging of gaps and nozzles. In this regard, flow regulating valves, throttle valves and servovalves are prone to
clogging. In case of a slow relative movement of the gap areas, there is increased danger of clogging of the gap.
This clearly explains why the absolute filter rating has to be egual or smaller than the gap width demanded by the
component in order to exclude clogging.

EE Specification

From the effective area of the filter and filter rating the following values can be derived:

Rated flow and difference pressure

— These two interacting values are purposefully indicated in the P-O-diagram of the various manufacturers. In
order to avoid complete clogging of the line, the maximum difference pressure, respectively flow resistance is
limited by a bypass valve.

Lifetime

—- This magnitude specifies the working period in practice until the filter element reaches such high
contamination degree that the admissible flow resistance is exceeded.

217
 'E Grouping of the filters according to the fitering material

! SE | Surface filter

This filter is made up from a very thin fabric layer (wire netting, metal
edges, cellulose, synthetic material or braid fabric) only. To enlarge the @..- ee” “ia i ë
)
effective area, the thin filter layer is star-like folded. The surface filters e e - i
belong to the category of mesh filters and gap ones. Gap filters *— e @ " oe .
consists of stacked metal diskplates, which can be easily cleaned with a @: $ ed . s
dirt wiper, even while in operation. Paper filters are one-way units and e e E
cannot be used anymore after clogging. Ti do
i 6 i e . e e - @

ed
e e Es e j e di
EE ae e
ge

EIEN Deep-ped fier EE Ee BE

This type of filter consists of compressed textile, cellulose, synthetic
material, glass or metal fibres in one or more layers. Alternatively they
contain a sintered metal insert offering the advantage that a
favourable flow resistance can be achieved with even smaller pore
Sizes.

Arrangement of filters in the circuit '

Filters can be incorporated in various places in a hydraulic system bringing out certain advantages and
disadvantages, which shall be described in the following:

(ET sl
FlyslKG ELAIG ZL
Pressure filter

Return line filter

OF os
Suction
filter

| L ) |

218
N Return line fiter Ee DE ee ad EEEA
This arrangement of a filter is the most wide-spread in hydraulics.
Positive: Favourable costs, easy to install and cleaning the entire flow rate in the installation.
Negative: The impurities are separated only when the fluid leaves the circuit. Thus it is assumed that with such
arrangement the smaller particles damage the system after several circulations only and leave the system through
the return line, then. Return line filters are applied as main flow filter with a bypass valve connected in parallel.
Such installation can be encountered in tanks, in most cases, but they are used as line filter as well.

Return line filter for tank installation Spin-on filter

Many oil-hydraulic installations are
wire screen on the suction side to
coarse impurities from the tank.
demand for a minimum suction
realised with fine filters.
eguipped besides the return line filter with a
protect the hydraulic pump from damage by
Fine-pore filters will not do, for the pumps
underpressure of 0.7 bar, which cannot be

Cold oil and a contaminated filter further reduce

the suction underpressure. In order to
compensate for intake problems of a suction filter
located upstream to a pump, the suction filter is
recommended to be completed with an effective
contamination indicator as compromise. In
addition, changing the suction filter must be an
easy job to do.

219
13.7.3.

These filters are installed downstream from the pump (pressure side) to protect
especially sensitive sub-assemblies (proportional or servovalves). The filters,
however, demand for a pressure-resistant housing and thus, are very expensive.

Pressure filter (ARGO-HYTOS)

Partial flow filtration me R

TA
With partial flow filtration, the whole flow is not filtered at once and at the same time, but a portion of it only. This
offers the possibility to run the filtration with relatively small filters. Statistical research revealed that the entire
fluid guantity of the system gets filtered after several circulations. Partial flow filtration works on the principle that
by back pressure a residual flow is lead through a bypass port or separate supply pump.

lal
TEEL)

BE)

Bypass filter

220
EE vonk ventationfiter R EE ER
In recent years, these filters have been ignored guite a bit. According to latest experience,
however, they represent one of the most important members within a filtration system of
hydraulic installations

A big portion of the contamination gets into hydraulic

installations through unsuited bleeding devices. Counter
measures such as pressurised oil tanks are often
uneconomical compared to the today available high-efficiency
ventilation (bleeding) filters. Depending on the reguired
purity, bleeding filters are eduipped with differently fine
changeable elements.

The filters are recommended to be edguipped with a port for

contamination indicators.

The depicted filling and bleeding filter consists of an air filter

to clean the air streaming into the tank and a filling screen to
retain the coarse dirt particles while filling the tank. Spin-on
filter elements have proved to be very economical and effective, since the filtering
surface area is very large and filter change is a simple matter.

Ee installation of filters | EE 13.8

Line and tank-installed filters are available. Tank-installed return line filters are very maintenance-friendly. When
changing or cleaning the filter, there is no contamination by emerging leakage oil.

EE voere e. EE
Filters in hydraulic installations reduire regular maintenance to keep them reliable. With excessive clogging, the
difference pressure increases over the filter, a possibly installed bypass valve opens and the oil keeps on flowing
unfiltered. Experience reveals that guite freguently maintenance is neglected. In order to provide for good
maintenance, the following points are to be considered:
Install a contamination indicator.
Easy access
Keep spare parts in stock (close to the site of installation)
Clearly highlight the changing, inspecting and cleaning intervals in the operating manual or even better,
exhibit them at the machine. Particularly with the very first start-up, there is guite a lot of dirt in
Circulation.
Match the filter size to the dirt guantity to provide for adeguate lifetime.
If necessary, install a twin filter to keep the eguipment working even during maintenance intervention.

221
 Filter specification criteria

In addition to the already known criteria such
other decisive items to be considered to find
for the installation and running costs as well
on the design of a filter system.
As for specification, take the following criteria
as reliability and lifetime of the hydraulics components, there are yet
out the most suitable hydraulic filter system. This is particularly true
as disposal costs of the pressure liguid, which really have an impact
into account:

e Sensitivity to dirt of the hydraulic components

e Application of the installation
e Flow rate
ee Admissible back pressure or difference pressure of the filter
e Operating temperature
e Viscosity of the medium
e Compatibility of the media with the filter materials
se Operating temperature range
* Attachments

Filter element selection

The pressure loss through a clean element at operating viscosity within the entire filter system (housing and
element) must not exceed the following parameters:

Line filter without bypass:

Apa * 0.2 * Apindicated

Line filter with bypass:

Apa * 0.15 e Apindicated

Attached return line filter:

Apa * 0.2 @ Apindicated

Recommended
Obtainable purity class according to
Hydraulic installation absolute filter rating
NAS 1638 with
(6.2 100) ISO 6.
particles * 5 um

Installation with servo valves # 16/13

Installations with regulating valves 7 up to 8 16/13

Installation with proportional valves R 18/15

General-purpose hydraulic installation X - 10 to20 9 to 10 19/16

The filter size depends on the filter rating, but the reguired purity class of the entire installation has to be
estimated, which is determined by that component in the whole system being most sensitive to dirt. In order to
obtain a desired purity class, filter elements featuring the absolute filter rating (B, 2 100) have to be applied. The
above table is a selection guideline for a suitable filter rating and necessary filter elements. Once the reduired filter
rating has been specified, the filter size can be fixed.

222
The aim of size determination is to establish a balance between the dirt ingress into the system and dirt separation
through the filter(s). Do not forget a sufficiently long lifetime, in no case. While determining the filter size, take
also the contamination degree of the environment, service and maintenance of the hydraulic system and
maximum operating temperature of the hydraulic fluid into account.

Below see the redguired formula for filter size determination:

Total differential pressure of the filter with new filter

element
Filter location in
the hydraulic Filter design When the single diagrams for When the
system filter housing and filter specification
element apply: diagrams apply.

Attached return-line filter,

fl Aphousing * f e Apelement ) Opecified - Os stem s f $
line filter with bypass
valve $ 0.15 up to 0,2 * Apindicated G
Working filter

Bypass filter, line filter;

separate components

Line filter without bypass fa APhousing * f Apelement ) OER Fi @ ef,e

. valve S 0.2 * Apindicated G
Protective filter

Ty Aphousing fy * Apelement ) Eed s5to1Oe

Suction filter
$O.O1 Opump * 2

In order to simplify the procedure of filter specification, most filter manufacturers make the diagrams in their
technical documentation available to enable specification of the constructional size.

223
EP
With the test standardised according to ISO 4572, the separating behaviour and dirt absorption of a filter element
are checked.

This test is based on the principle of multiple circulation of the contaminated fluid through the filter to be checked.
This test bases on the theory that those dirt particles, which have passed through the filter due to their grain size
with the first circulation, will be separated with the subseguent ones

From system 1 a defined contaminated fluid is injected into the circuit of system 2. By permanent circulation, the
filter to be tested is fed with dirt particles until the maximum admissible difference pressure of the element or test
system is reached. During this time, samples are taken from the system 2 and evaluated in the automatic particle
counter. In this way, it can be found out how the separating performance of the element changes with rising
differential pressure. The temperature is permanently recorded, too.

The test result is output in form of the B,-value. Thus the filtration ratio B, can be displayed as separation degree
iN %.

Determination of the B.-value

Moutgoing flow tincoming flow .

1000 particles 100 000 test dust particles

10 um/100 ml 10 um/100 mI
0.08 mal 10.0 mal

224