The information in this brochure 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.

HYDAC FILTER SYSTEMS GMBH

Industriegebebiet
D-66280 Sulzbach/Saar
Telephone (06897) 509-01
Fax (06897) 509-9046
EN 7.603.9/04.18

e-mail: [email protected]
Internet: www.hydac.com
Fluid Control
Contamination Handbook

EN 7.603.9/04.18
 Classification of base oils according to API 1509*

API* Group
I II III IV
Raffinate Hydrated Synthetic PAO
Oil type
base oil oil
Amount of saturated <90% >90% >90% 100%
hydrocarbons
Viscosity index 80–120 80–120 >120 -
High Less polar Nearly non- No
Polarity
polarity polar details
Solubility of varnish High Medium Weak Weak
Electrical conduc- Good Bad Very low Low
tivity
* American Petroleum Institute (API)

Composition of
hydraulic and lubrication oils

Hydraulic and
lubrication oils = Base oil + Additives*

* Example additives:
Base oil Additives
––VI-improving agent
––Pour-point lowering
agent
––Oxidation inhibitor
––Corrosion inhibitor
––Antiwear
Hydraulic & ––Anti-foam
EN 7.603.9/04.18

lubrication
oils

2
Classification of hydraulic oils according to DIN

Operating fluid Code Density at 15 °C

(kg/m3)
Mineral oil acc. to H, HL, HLP, HV, HLPD 860
DIN 51524 or
ISO 11158
Fire resistant HFA/HFB 1000
acc. to DIN 5150 or HFC 1090
ISO 12922
HFDR, HFDS 1200
More rapidly HETG 930
biodegradable acc. to HEES 940
ISO 15380
HEPG 1100
HEPR 890
Lubricating oils acc. to CL, CLP, CG 860
DIN 51517

Food-grade oils acc. to NSF International

H1 lubricant “Food-grade (FG) lubricants”

“Food-grade oil”
Occasional, technically unavoidable
contact with foodstuffs not hazardous
H2 lubricant Contact with food not permitted. Use
only outside of the closed production
process.
H3 lubricant Soluble oils for cleaning or rust
protection for machines
EN 7.603.9/04.18

3
 Viscosity – Comparison ISO/SAE

ISO VG Medium point viscosity (40 °C) and Approximate

(DIN 51519) approx. viscosities in mm2/s at classification of the
0 °C 40 °C 50 °C 100 °C Motor Automobile
oils transmission
fluids
SAE SAE
5 8 (1.7 E) 4.6 4 1.5
7 12 (2 E) 6.8 5 2.0
10 21 (3 E) 10 8 2.5
15 34 15 11 3.5 5W
22 55 22 15 4.5 10 W 70 W
75 W
32 88 32 21 5.5
46 137 46 30 6.5 15 W
68 219 68 43 8.5 20 W 80 W
100 345 100 61 11 30
150 550 150 90 15 40 85 W
220 865 220 125 19 50 90
320 1340 320 180 24
460 2060 460 250 30 140
680 3270 680 360 40
1000 5170 1000 510 50
250
1500 8400 1500 740 65

Viscosity index acc. to ISO 2909 – comparison to two

mineral oils
The higher the viscosity index of an oil, the smaller the change in viscosity in relation to the temperature.

Viscosity
High

Oil A

Oil B High viscosity index

EN 7.603.9/04.18

Low viscosity index

Low
Low 40 °C 100 °C High Temperature
4
Contamination types

Solid
contamination
––Corundum, tinder, rust particles
––Wear metals iron, copper, tin, zinc
etc.
––Fibres, rubber particles, paint
particles

Liquid
contamination
––Cooling water
––Steam

Gel-like
contamination
––Oil ageing/varnish
––Oil mixtures
––Additive separation (dropout)

Gaseous
contamination
––Air
––Process gases
EN 7.603.9/04.18

5
 Causes of contamination in oil

Cause

––Installation contamination
––Ambient contamination
––Refilling of operating fluid
––Internal wear processes
Solid
––Oil ageing

––Moisture from the ambient air

––Leakage of cooling systems
––Process water/process steam
––Leakage of seals
––High-pressure cleaner
––Chemical processes
Liquid
(incineration, oxidation, neutralisation)

––Oil ageing
––Oil mixing

Gel-like

––Mixtures
––Outgassing of oil

Gaseous
EN 7.603.9/04.18

6
Consequences of contamination

Consequences

––Abrasive wear
––Increased leakage
––Component failure
––Control inaccuracies
Solid
––Blockage of control pistons
––Short fluid service life

––Corrosion
––Reduction in dynamic viscosity
• Reduction in lubricating film thickness
• Contact with surfaces
• Wear
––Change in the oil properties
Liquid
• Creation of acidic oil degradation products
• Formation of sludge
• Increase in speed of oil ageing
––Cavitation damage

––Reduction in lubrication gaps caused by deposits

• Increased friction and temperature
• Increased bearing wear
––Malfunctions in valves
• Unstable control behaviour
Gel-like ––Damage to dynamic seals
• Leakage
––Blockage of filter elements
• Short filter life caused by sludge formation
––Increased bearing temperature caused by caking

––Cavitation
––Oxidation
––Local overheating of oil
• Increase in speed of oil ageing
Gaseous • Control inaccuracies
EN 7.603.9/04.18

7
 Solid particle contamination

Cleanliness classes acc. to ISO 4406

Determining the ISO code

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

ISO Particle count/100 ml Contamination load (ACFTD)

code
More than Up to and incl. [mg/l]
0 0.5           1 –
1 1 2 –
2 2 4 –
3 4 8 –
4 8 16 –
5 16 32 –
6 32 64 0.001
7 64 130 –
8 130 250 –
9 250 500 –
10 500 1,000 0.01
11 1,000 2,000 –
12 2,000 4,000 –
13 4,000 8,000 0.1
14 8,000 16,000 –
15 16,000 32,000 0.2
16 32,000 64,000 0.5
17 64,000 130,000 1
18 130,000 250,000 3
19 250,000 500,000 5
20 500,000 1,000,000 7/10
21 1,000,000 2,000,000 20
22 2,000,000 4,000,000 40
23 4,000,000 8,000,000 80
24 8,000,000 16,000,000 –
25 16,000,000 32,000,000 –
EN 7.603.9/04.18

26 32,000,000 64,000,000 –
27 64,000,000 130,000,000 –
28 130,000,000 250,000,000 –
>28 250,000,000
8
Example: ISO code 18/16/13

Cleanliness
class
Particle count per ml

Example:
Larger than
Larger than
Larger than
EN 7.603.9/04.18

9
 Solid particle contamination

Cleanliness classes according to SAE AS

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

Size ISO 4402

>1 μm >5 μm
Calibration or optical counting*
Size ISO 11171, calibration or electron
  >4 μm(c)   >6 μm(c)
microscope**
Side code A B
000 195 76
00 390 152
0 780 304
1 1,560 609
2 3,120 1,220
Contamination classes

3 6,250 2,430
4 12,500 4,860
5 25,000 9,730
6 50,000 19,500
7 100,000 38,900
8 200,000 77,900
9 400,000 156,000
10 800,000 311,000
11 1,600,000 623,000
12 3,200,000 1,250,000
EN 7.603.9/04.18

* Particle sizes determined on basis of longest dimension

** Particle sizes determined on basis of diameter of projected circle with same surface area

10
 The SAE cleanliness classes are based on the particle size, the particle number
and the particle size distribution. The particle size determined depends on the
measurement process and calibration; consequently the particle sizes are labelled with
letters (A–F).

Max. particle concentration (particle/100 ml)

>15 μm >25 μm >50 μm >100 μm

  >14 μm(c)   >21 μm(c)   >38 μm(c)    >70 μm(c)

C D E F
14 3 1 0
27 5 1 0
54 10 2 0
109 20 4 1
217 39 7 1
432 76 13 2
864 152 26 4
1,730 306 53 8
3,460 612 106 16
6,920 1,220 212 32
13,900 2,450 424 64
27,700 4,900 848 128
55,400 9,800 1,700 256
111,000 19,600 3,390 512
222,000 39,200 6,780 1,020
EN 7.603.9/04.18

11
 Solid particle contamination

Cleanliness classes acc. to NAS 1638

Like ISO 4406 and SAE AS 4059, NAS 1638 describes particle concentrations in
liquids. Although NAS 1638 is no longer a valid industrial standard, it is often used in
practice because of its simplicity (just one key figure).
The analysis methods can be applied in the same manner as ISO 4406.
In contrast to ISO 4406, certain particle size ranges are counted in NAS 1638 and
attributed to key figures.

No. of particles in 100 ml sample

Particle size (µm)

5–15 15–25 25–50 50–100 >100
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
Cleanliness classes

4 4,000 712 126 22 4

5 8,000 1425 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
EN 7.603.9/04.18

12
 EN 7.603.9/04.18

13
 Solid particle contamination

Comparison photo for cleanliness classes

ISO 4406 Class 14/12/9

SAE AS 4059 Class 4
NAS 1638 Class 3

ISO 4406 Class 15/13/10

SAE AS 4059 Class 5
NAS 1638 Class 4
EN 7.603.9/04.18

Magnification: x100
Oil volume: 100 ml
1 scale mark = 10 μm
14
ISO 4406 Class 16/14/11
SAE AS 4059 Class 6
NAS 1638 Class 5

ISO 4406 Class 17/15/12

SAE AS 4059 Class 7
NAS 1638 Class 6

EN 7.603.9/04.18

Magnification: x100
Oil volume: 100 ml
1 scale mark = 10 μm
15
 Solid particle contamination

ISO 4406 Class 18/16/13

SAE AS 4059 Class 8
NAS 1638 Class 7

ISO 4406 Class 19/17/14

SAE AS 4059 Class 9
NAS 1638 Class 8
EN 7.603.9/04.18

Magnification: x100
Oil volume: 100 ml
1 scale mark = 10 μm
16
ISO 4406 Class 20/18/15
SAE AS 4059 Class 10
NAS 1638 Class 9

ISO 4406 Class 21/19/16

SAE AS 4059 Class 11
NAS 1638 Class 10

EN 7.603.9/04.18

Magnification: x100
Oil volume: 100 ml
1 scale mark = 10 μm
17
 Solid particle contamination

ISO 4406 Class 22/20/17

SAE AS 4059 Class 12
NAS 1638 Class 11

ISO 4406 Class 23/21/18

SAE AS 4059 Class 13
NAS 1638 Class 12
EN 7.603.9/04.18

Magnification: x100
Oil volume: 100 ml
1 scale mark = 10 μm
18
Examples of solid particle contamination

Predominantly rust,
additives (white particles)

Effect:
––Strong oil ageing
––Malfunctions in pumps, valves
––Wear, mostly water in oil

Oil degradation products

Effect:
––Filter blockage
––Sludge accumulating in the system

Metal chips (flow chips)

Effect:
–– Malfunctions in pumps, valves
–– Seal wear
–– Leakage
–– Oil ageing
EN 7.603.9/04.18

Magnification: x48
1 scale mark = 45 μm
19
 Solid particle contamination

Particles/chips, bronze, brass or

copper

Effect:
––Malfunctions in pumps, valves
––Oil ageing
––Leakage
––Seal wear

Gel-like residue

Effect:
––Filter blockage
––Sludge accumulating in the system

Silicates resulting from absent or

insufficient breather filter

Effect:
––Strong wear on components
––Malfunctions in pumps, valves
––Seal wear
EN 7.603.9/04.18

Magnification: x48
1 scale mark = 45 μm
20
Paint particles (red/brown)
Plastic particles (blue)

Effect:
––Malfunctions in pumps, valves
––Seal wear

Fibres resulting from initial

contamination, open tank, cleaning
cloths etc.

Effect:
––Clogging of orifices
––Leakage of poppet valves

EN 7.603.9/04.18

Magnification: x48
1 scale mark = 45 μm
21
 Solid particle contamination

Cleanliness requirements of hydraulic and lubricatio

Low/medium pressure
<140 bar
(Moderate conditions)

ISO 4406 Filtration rating μm

Target cleanliness class

Pumps/motors
Gear or vane 20/18/15 20
Piston 19/17/14 10
Variable vane 18/16/13 5
Variable piston 18/16/13 5
Drives
Cylinder 20/18/15 20
Hydrostatic drives 16/15/12 3
Test benches 15/13/10 3 2)
Valves
Non-return valve 20/18/15 20
Directional valve 20/18/15 20
Standard flow control valve 20/18/15 20
Poppet valve 19/17/14 10
Proportional valve 17/15/12 3
Servo valve 16/14/12 3 2)
Bearing
Plain bearing 3) 18/15/12 10
Gears 3) 17/15/12 10
Ball bearing 3) 15/13/10 3 2)
Roller bearing 3) 16/14/11 5

Cleanliness requirements for diesel

ISO 4406 target cleanliness clas
Tank 18/16/13
Injection system 12/10/8

1) Poor conditions can result from flow rate fluctuations, pressure spikes, frequent cold starts,
EN 7.603.9/04.18

extremely high ingress of contamination or the presence of water.

2) Two or more system filters of the recommended rating may be required
to achieve and maintain the desired target cleanliness level.
3) Valid for the average diameter range

22
on oils

High pressure Very high pressure

140 to 200 bar >200 bar
(Low/medium under (High pressure under bad
bad conditions1) conditions1)
ISO 4406 Filtration rating μm ISO 4406 Filtration rating μm
Target cleanliness class Target cleanliness
class

19/17/14 10 18/16/13 5
18/16/13 5 17/15/12 3
17/15/12 3 not required not required
17/15/12 3 16/14/11 3 2)

19/17/14 10 18/16/13 5
16/14/11 3 2) 15/13/10 3 2)
15/13/10 3 2) 15/13/10 3 2)

20/18/15 20 19/17/14 10
19/17/14 10 18/16/13 5
19/17/14 10 18/16/13 5
18/16/13 5 17/15/12 3
17/15/12 3 16/14/11 3 2)
16/14/11 3 2) 15/13/10 3 2)

not required not required not required not required

not required not required not required not required
not required not required not required not required
not required not required not required not required

ss Filtration rating µm
5 µm (single pass elements)
5 µm (single pass elements)

For system cleanliness, we recommend using one class better than the cleanliness required for
EN 7.603.9/04.18

the most easily damaged component. Filling/rinsing filtration at least one filtration rating finer than
the system filter. According to DIN 51524 a cleanliness of ISO 21/19/16 must be provided for fresh
hydraulic fluid.

23
 Liquid contamination

Saturation point
Dissolved water
Below the saturation point
––Water is present in the oil in dissolved form – like the water
that is present in humid air.
––All water molecules are deposited on polar oil components
(e.g. additives, particles, oil degradation products)

Free water
Above the saturation point
––Water is present as an emulsion (similar to fog), with ultra-
fine water droplets distributed throughout the oil in a stable
suspension. This causes clouding of the oil.
––Water is present in free form, normally settling on the base.

Saturation limit of water in oil

1200

1000

800
Water content [ppm]

Free and
600 emulsified water

400

200 Dissolved water

EN 7.603.9/04.18

0
-20 -10 0 10 20 30 40 50
Temperature [°C]

24
 Water saturation curves

Group V
Water saturation [ppm]

Diesel
Group IV

Group I, II, III

Temperature [°C]

Life expectancy of bearings in relation to

water content
Relative life expectancy
of roller bearings

EN 7.603.9/04.18

Water content [%]

Source: FAG/Schaeffler
25
 Gel-like contamination (oil degradation product/varnish)

Varnish – analysis procedure

Laboratory analyses – varnish:

––MPC (membrane patch colorimetry)
based on ASTM D7843-12

Laboratory analysis – specific:

––Particle measurement at 20°C and 80°C
based on ISO 11500

Particle count in an oil sample

At 22 °C At 80 °C
Particle difference
Cleanliness class acc. to ISO 4406
Particle count per 1 ml
EN 7.603.9/04.18

26
Example images

Valve piston with Oil samples at room temperature with Filter membrane before and
deposits slight clouding after varnish separation

Typical images of deposits

in a steam turbine

Coupling sleeve Gear, planetary stage

Turbine radial & axial bearing Emergency oil pump

EN 7.603.9/04.18

Gear teeth Oil cooler fins (on oil side)

27
 Gaseous contamination

Solubility of air in oil

Relationship between pressure and temperature

At 20 °C and 1 bar
(atmospheric pressure)
Approx. 10 % dissolved air
Dissolved air quantity [vol.%]

80 °C  in 100 litres oil,

20
approx. 10 litres air

20 °C With pressure reduction to

0.8 bar
10
8
Only 8 % of air soluble
 in 100 litres oil,
2 litres of air released!

0 0,5 1,0 1,5 2,0 2,5

0,8
Pressure [bar]

Fluid ageing
caused by cavitation
Gas bubble

Range Pressure Temperature

A 1 bar 38 °C
EN 7.603.9/04.18

F 69 bar 766 °C
H 138 bar 994 °C
I 207 bar 1140 °C
Oil carbon/varnish
28
Air release capacity for fresh oils

Limit values of typical standard for fresh oil

ISO VG/type 32 46 68 100 (150) (>320)
Turbine oil
5 5 6 x x x
DIN 51515, ISO 8068
Hydraulic fluid HLP/HM
5 10 13 21 32 x
DIN 51524/2, ISO 11158

Example images

EN 7.603.9/04.18

29
 Product portfolio

Contamination type Measurement devices (online/offline)

ContaminationSensor Metallic ContaminationSensor

CS 1000 MCS 1000
Solid

ContaminationSensor Module FluidControl Unit

Economy CSM-E FCU 1315

AquaSensor
AS 1000 & AS 3000
Liquid

ContaminationSensor Module FluidControl Unit

Economy CSM-E FCU 1315

Gel-like
EN 7.603.9/04.18

Gaseous

30
 Typical separation method/oil conditioning devices
Filter element

MobileFiltration Unit OffLine Filter OffLine Filter BiDirectional

MFU OLF 5 OLFBD
Vacuum evaporation Coalescence Superabsorber

FluidAqua Mobil OffLine Separator MobileFiltration Unit

FAM OLS MFU

LowViscosity Housing Aquamicron

Coalescer Diesel LVH-CD AM
Cold filtration Ion exchanger

VarnishElimination Unit Ion eXchange Unit

VEU-F IXU
Vacuum drying
EN 7.603.9/04.18

FluidAqua Mobil OXiStop

FAM OXS
31