HYDAC FILTER SYSTEMS ContaminationSensor CS 1939 Series Manual

CS 1939
ContaminationSensor
Operating and Maintenance Instructions
English (translation of original instructions)
Valid from:
- Firmware version V 1.00
- Hardware index A
- Serial number: 002S01515K0001305
Documentation no.: 3978342c
Keep for future reference.

Content
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Content
Content ..........................................................................................................2
General ..........................................................................................................4
Imprint..........................................................................................................4
Documentation Representative ...................................................................4
Purpose of this manual................................................................................5
Target group of the manual .........................................................................5
Target group - Required qualifications/training............................................6
Illustrations in the manual............................................................................7
Illustration of the layout ............................................................................7
Representation of procedural instructions................................................8
Representation of warning/general safety information .............................8
Signal words and their meaning in the general safety information ...........9
Representation/explanation of pictograms.................................................10
Supplementary symbols ............................................................................11
Exclusion of liability/warranty.....................................................................12
Notes on copyright.....................................................................................12
Validity of this manual................................................................................12
General Safety Information........................................................................13
Product overview........................................................................................14
Scope of delivery.......................................................................................15
Dimensions................................................................................................16
Proper/designated use...............................................................................17
Improper use or use deviating from intended use......................................18
Technical Data...........................................................................................19
Decoding the model code label .................................................................21
Model Code............................................................................................22
Storage and transport ................................................................................23
Assembly, installation and commissioning .............................................24
Design and placement...............................................................................24
Mechanical installation/assembly ..............................................................25
Hydraulic installation/assembly..................................................................26
Types of connection of ContaminationSensor........................................26
Selecting the measurement location ...................................................26
Flow rate, differential pressure
p
and viscosity

characteristics.....................................................................................28
Hydraulic connection of the ContaminationSensor.................................29
Electrical installation/assembly..................................................................30
Pin assignment.......................................................................................30
Connection cable - Assignment / Color coding.......................................31

Content
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Operation.....................................................................................................32
Applying SAE J1939 protocol....................................................................32
Parameter definition...............................................................................32
SPN definition .....................................................................................32
Evaluating measurement reports with FluMoS or FluMoT (only
HSI-report).................................................................................................33
Checking/resetting default settings............................................................34
Dialog menu...........................................................................................34
Calibrating ContaminationSensor...........................................................34
Resetting................................................................................................34
Maintenance................................................................................................35
Cleaning the ContaminationSensor...........................................................35
Customer Service / Service.......................................................................35
Customer service USA...........................................................................35
Customer Service Australia....................................................................36
Customer Service Brazil.........................................................................36
China......................................................................................................36
Troubleshooting/fault rectification............................................................37
Removing / Disposal...................................................................................38
Appendix .....................................................................................................39
Spare Parts and Accessories ....................................................................39
Spare Parts ............................................................................................39
Accessories............................................................................................39
Glossary ......................................................................................................40
Explanation of terms and abbreviations.....................................................40
Cleanliness classes - brief overview..........................................................41
Cleanliness class - ISO 4406:1999 ........................................................41
Table - ISO 4406....................................................................................41
Overview of modifications - ISO4406:1987 <-> ISO4406:1999..............42
Index ............................................................................................................43

General
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General
In this chapter, you will find helpful notes on handling these instructions.
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Phone:
[phone]
Fax:
[phone]
E-mail:
[email protected]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive directors:
Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Phone:
[phone]
Fax:
[phone]
E-mail:
[email protected]

General
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Purpose of this manual
Before you use this product for the first time or if you have been asked to
carry out other work on the product, please read this manual
The use and the handling of the product described in the following, as well as
its use, are not self-explanatory and are described in detail in this manual
and the associated technical documentation.
This manual will help you to use the product as intended, properly,
effectively, and safely. Therefore, you are requested to read the following
chapters attentively and carefully. Please refer to it every time you require
decisive details.
This manual informs and warns you of risks, against which the risk reduction
through the design and protective measures may not be effective or not fully
effective.
Target group of the manual
This manual was created for the following target group.
Target group
Tasks
Owner
This manual and the associated documents must be kept
accessible at the installation location of the product and
also for later use.
Ask the employees to read and follow the manual and the
documents delivered along with it, in particular, the safety
and warning instructions.
Observe the additional product-related instructions and
requirements.
Specialist
personnel
Read, observe and follow this manual and the associated
documents, in particular, the safety and warning
instructions.

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Target group - Required qualifications/training
Persons who work on the product must be aware of the hazards associated
with its use.
Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the General Safety Information and
instructions, and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel: such persons have been instructed about the product
and informed about potential hazards that can result from improper use.
Specialist personnel: such persons with corresponding specialist training
and several years' work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential dangers.
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Auxiliary
personnel
No specialist knowledge
required
Hydraulic / electrical
installation,
First commissioning
Maintenance
Troubleshooting
Repair,
Decommissioning
Disassembly
Specialist
personnel
Safe handling/use of tools
Fitting and connection of
hydraulic lines and
connections
Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
Product-specific knowledge
Operation
Operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
Knowledge about reuse

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Illustrations in the manual
You will find illustrations in this manual. You can find details regarding these
in the following chapters.
Illustration of the layout
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx-xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Note that the method described for locating specific information
does not release you from your responsibility of carefully reading
all these instructions prior to starting the unit up for the first time
and at regular intervals in the future.
The manual contains a table of contents, an index and a glossary.
Chapter description
Page number
Edition date
Document language
Documentation no.
with index/
file name

General
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Representation of procedural instructions
There are these two following representations in the case of procedural
instructions:
Procedural instructions with a fixed sequence
Procedural instructions, whose sequence must be complied with without fail
are listed with sequential numbering (1., 2., 3., etc.).
An example for procedural instructions with a fixed sequence:
1. Remove the transport securing device.
2. First fill the product.
3. Switch the product on.
Procedural instructions with a random sequence
Procedural instructions that have a random sequence are listed as bullet
points (-).
An example of a procedural instruction with a random sequence:
- Clean the display
- Rinse the product
Representation of warning/general safety information
All the warning / general safety information in this manual are highlighted with
pictograms and signal words. The pictogram and the signal word indicate the
severity of the danger.
Warning / general safety information is listed before an activity and is laid out
as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger

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Signal words and their meaning in the general safety information
In these instructions you will find the following signal words:
DANGER
DANGER –The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result lethal or serious injury.
WARNING
WARNING –The signal word indicates a hazardous situation with a medium
level of risk, which, if not avoided, can result lethal or serious injury.
CAUTION
CAUTION –The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.
NOTICE
NOTICE –The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

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Representation/explanation of pictograms
The following are the safety symbols / pictograms in this manual. They
indicate specific dangers to persons, property or to the environment. Observe
these safety symbols / pictograms and act with particular caution in such
cases. Always keep all symbols / pictograms intact and legible.
Warning signs used
These signs are listed for all general safety information and instructions in
these operating instructions which indicate particular dangers to persons,
property or the environment.
Danger point warning
Signs used for giving orders
These symbols are listed for all general safety information and instructions in
these operating instructions which indicate particular dangers to persons,
property or the environment.
Disconnect before maintenance or repair

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Signs used for the required specialist personnel
These symbols show the required training/knowledge for installation work
and/or maintenance work.
Specialist personnel - Electrical
Such persons have specific specialist training and several
years' work experience. They are able to assess and
perform the work assigned to them, they are also able to
recognize potential dangers.
Specialist personnel - Mechanical
Such persons have specific specialist training and several
years' work experience. They are able to assess and
perform the work assigned to them, they are also able to
recognize potential dangers.
Supplementary symbols
You will find the following symbols in the manual as additional details:
Tip for handling the product
Required tools

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Exclusion of liability/warranty
For the warranty provided by us, please refer to our terms of delivery. They
are made available to you at the conclusion of the contract at the latest. In
addition, you will find these under www.hydac.com -> General terms and
conditions.
This manual was prepared to the best of our knowledge. Nevertheless and
despite the greatest care, it cannot be excluded that mistakes could have
crept in. Therefore please understand that, in the absence of any provisions
to the contrary hereinafter, our warranty and liability –for any legal reasons
whatsoever –are excluded in respect of the information in these instructions.
In particular, we shall not be liable for lost profit or other financial loss.
This exclusion of liability does not apply in cases of intent and gross
negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to the Product Liability shall
remain unaffected.
Notes on copyright
All copyrights for this manual lies with the manufacturer. Any part of this
manual may cannot be reproduced, used or copied in any form with the help
of electronical systems without the written consent of the manufacturer. Any
infringements of the above shall be liable to damage compensation.
Validity of this manual
The diagrams and visualizations in this manual are meant for general
illustration purposes. Therefore, representations and functional options can
deviate from those of the delivered product.
We reserve the right to changes to the contents of this manual without prior
notice.

General Safety Information
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General Safety Information
The product has been built according to the provisions, directives and
standards valid at the time of delivery and satisfies the current safety
requirements. Any residual hazards are indicated by the general safety
information and are described in this manual.
Observe all the safety and warning instructions attached to the product and
always keep them up to date and easily legible.
NOTICE
Impermissible operating media
The ContaminationSensor will be destroyed.
►The ContaminationSensor may only be used in connection with
mineral oils or mineral oil-based raffinates.
►Note the maximum operating pressure of 350 bar / 5075 psi.
DANGER
Unintended use of the product
Bodily injury and damage to property will result
when operated improperly.
►Never operate the product in potentially
explosive atmospheres.
►Only use the product with permissible media.

Product overview
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Product overview
The ContaminationSensor CS 1939 is a stationary measurement unit for the
continuous monitoring of particulate contamination in hydraulic and
lubrication systems.
The ContaminationSensor is designed to be used in low- or high-pressure
hydraulic and lubrication circuits and test benches where a small amount of
oil (30–500 ml/min) is diverted for measurement purposes.
The ContaminationSensor is approved for a maximum operating pressure
(see specification on type label) and viscosity of up to 1000 mm²/s.
The particulate contamination is recorded by an optical measurement cell.

Product overview
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Scope of delivery
The ContaminationSensor CS 1939 comes packed and factory-assembled.
Please check the contents of the package to make sure everything is
present.
The following items are supplied:
Qty.
Description
1
ContaminationSensor, CS 1939
(Model in acc. with the order - see model code)
2
O-rings (4.8 x 1.78 mm, 80 Shore, FKM)
(only for the connection type "flange connection")
1
CD with operation and maintenance instructions
(this document in various languages)
1
CD with FluMoS software (Fluid Monitoring Software)
1
Quick start manual
1
Certificate of calibration

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Dimensions
All dimensions in mm.

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Proper/designated use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which the manufacturer is not responsible.
The manufacturer assumes no responsibility for determining the interfaces
for installation in a system or the installation, use or functionality of the
product in this system.
Use the product only for the application described below.
The ContaminationSensor CS 1939 serves to continuously monitor solid
particulate contamination in hydraulic and lubrication systems.
Intended use of the product also extends to the following:
-Observing all instructions in the instruction manual.
-Performing inspection and maintenance work.
Depending on the version (see model code), you may use the CS only in
connection with the following media:
NOTICE
Impermissible operating media
The ContaminationSensor will be destroyed.
►The ContaminationSensor may only be used in connection with
mineral oils or mineral oil-based raffinates.
►Note the maximum operating pressure of 350 bar / 5075 psi.

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Improper use or use deviating from intended use
DANGER
Unintended use of the product
Bodily injury and damage to property will result
when operated improperly.
►Never operate the product in potentially
explosive atmospheres.
►Only use the product with permissible media.
Any use extending beyond this or deviating therefrom shall not be considered
intended use. HYDAC FILTER SYSTEMS GMBH will assume no liability for
any damage resulting from such use. This risk is borne solely by the owner.
Improper use may result in hazards and/or will damage the unit. Examples of
improper use:
-Operation in potentially explosive atmospheres.
-Operation with a non-approved medium.
-Operation under non-approved operational conditions.
-Operation when the safety devices are defective.
-Modifications to the product made by the user or purchaser.
-Inadequate monitoring of parts that are subject to wear and tear.
-Improperly performed repair work.

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Technical Data
General data
Mounting position
Any (recommended: vertical position)
Self diagnostics
continuously with error indication
via status LED and display
Measured variables
Contamination classes according to
ISO 4406 / SAE AS 4059
Service variables
Flow
Status
Drive
%
Temp
°C and °F
Permitted ambient temperature
range
-30 … 80 °C / -22 … 176 °F
Storage temperature range
-40 … 80 °C / -40 … 176 °F
Permitted relative humidity
max. 95%, non-condensing
Sealing material
FKM
Protection class
III (low voltage protection)
Protection class
IP 67
(only with screw-lock connectors)
Weight
≈1.3 kg

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Hydraulic data
Permitted operating pressure
maximum 350 bar / 5075 psi
Hydraulic connection
- Pipe or hose connection
Thread G ¼ according to ISO 228
- Flange connection
DN 4
Permitted measurement flow
rate
30 … 500 ml/min
Permissible viscosity range
1 to 1000 mm²/s
Fluid temperature range
0 …80 °C / 32 …185 °F
Electrical data
Connection plug
M12x1, 5 pole, specified in DIN VDE 0627
Supply voltage
9 …36 V DC, residual ripple < 10%,
(protected against polarity reversal)
Power consumption
3 W max.
CAN
SAE J1939
HSI (HYDAC Sensor Interface)
1 wire, half duplex