HYDAC International CS1000 Series Manual

CS 1000 Series
ContaminationSensor
Operating and maintenance instructions
English
Valid for firmware version V 2.02
Doc.: 3247149L / 2007-02-01

Contents
HYDAC Filtertechnik GmbH en Page 2
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Trademarks
The trademarks of other companies are exclusively used for the products of those companies.
Copyright © 2006 by HYDAC Filtertechnik GmbH all rights
reserved
All rights reserved. This manual may not be reproduced in part or whole without the explicit written
agreement from HYDAC Filtertechnik. Contraventions are liable to compensation.
Exclusion of liability
However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist
nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the
manual is checked regularly. Any corrections required will be incorporated in subsequent editions. We
welcome any suggestions for improvements.
Technical specifications are subject to change without notice.
All details are subject to technical modifications.
HYDAC FILTERTECHNIK GmbH
Industriegebiet
D-66280 Sulzbach/Saar, Germany
Germany
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

Contents
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Contents
Foreword .................................................................................................................................5
Customer Service .................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty ...............................................................................................................................6
1General Safety Precautions ........................................................................................... 8
1.1 Obligations and Liability................................................................................................. 8
1.2 Abbreviations and Basic Symbols .................................................................................8
1.2.1 Basic Symbols........................................................................................................9
1.3 Proper/Designated Use .................................................................................................9
1.4 Improper Use................................................................................................................. 9
1.5 Safety Devices............................................................................................................... 9
1.6 Informal safety precautions ........................................................................................... 9
1.7 Instructions to Be Followed in the Event of an Emergency ......................................... 10
1.8 Training and Instruction of Personnel.......................................................................... 11
2What's New — Document History................................................................................ 12
3Transportation, Packing, Storage................................................................................ 13
3.1 Transportation and Packing......................................................................................... 13
3.2 Storage ........................................................................................................................13
3.2.1 Storage conditions................................................................................................13
4Model code / Product identification ............................................................................ 14
5Scope of Delivery ..........................................................................................................15
6Description ....................................................................................................................16
6.1 Restrictions Pertaining to the CS................................................................................. 16
6.2 CS1x1x Dimensions (without Display).........................................................................17
6.3 CS1x2x Dimensions (with Display)..............................................................................17
6.4 Connection Types........................................................................................................ 18
6.4.1 Pipe or Hose Connection Type (CS1xxx-x-x-x-x0/-xxx) .......................................18
6.4.2 Flange Connection Type (CS1xxx-x-x-x-x-1/-xxx)................................................ 18
7Installation and Wiring.................................................................................................. 19
7.1 Unpacking.................................................................................................................... 19
7.2 Mechanical Mounting................................................................................................... 19
7.2.1 Display Rotatable/Adjustable As Needed.............................................................20
7.3 Hydraulic Installation ...................................................................................................20
7.3.1 Selection Guidelines for a Measurement Point .................................................... 22
7.3.2 Flow Rate Q, Differential Pressure
ν
and Viscosity
ν
Characteristics................ 23
7.3.3 Connect the CS to your system as follows:..........................................................24
7.4 Electrical Installation.................................................................................................... 25
7.4.1 Block Diagram ...................................................................................................... 25
7.4.2 Connection Cable (for accessories see section 16) .............................................25
7.4.3 Typical Wiring Diagram ........................................................................................ 26
8Description of the Measuring Modes .......................................................................... 27
8.1 Mode M1: Measure continuously.................................................................................27
8.2 Mode M2: Measure continuously and switch...............................................................27

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8.3 Mode M3: Filter down to contamination level and stop ...............................................27
8.4 Mode M4: Filter to establish contamination levels continuously.................................. 28
8.5 Mode M5: "SINGLE" measurement............................................................................. 28
9Operating the CS........................................................................................................... 29
9.1 Display and Keypad Elements (CS122x only).............................................................29
9.1.1 Measured variables ..............................................................................................30
9.1.1.1 Measured variable "ISO"............................................................................... 30
9.1.1.2 Measured variable "SAE".............................................................................. 30
9.1.1.3 Measured variable "NAS" CS 13xx only) ......................................................31
9.1.2 Service variables ..................................................................................................31
9.1.2.1 Service variables "Flow"................................................................................ 31
9.1.2.2 Service variables "Out" .................................................................................31
9.1.2.3 Service variables "Drive"............................................................................... 31
9.1.2.4 Service variables "Temp" .............................................................................. 31
9.1.3 Key Lock...............................................................................................................32
9.2 Modes and Menus ....................................................................................................... 32
9.2.1 Power Up Menu....................................................................................................32
9.2.2 Measuring Menu (CS12xx)................................................................................... 35
9.2.3 Measuring Menu (CS13xx)................................................................................... 37
9.3 Description of the Switching Output in the Measuring Modes ..................................... 40
9.3.1 Mode M1: Measure continuously ......................................................................... 40
9.3.2 Mode M2: Measure continuously and switch ....................................................... 40
9.3.3 Mode M3: Filter down to contamination level and stop ........................................ 40
9.3.4 Mode M4: Filter to establish contamination levels continuously........................... 41
9.3.5 Mode M5: "SINGLE" measurement...................................................................... 41
9.4 Switching Behavior of the Switching Output................................................................ 42
10 Menu Overview.............................................................................................................. 44
10.1Menu CS 12xx (ISO 4406:1999 and SAE) .................................................................. 44
10.2Menu CS 13xx (ISO 4406:1987 and NAS) ..................................................................45
11 Analog Output (ANaOUT) .............................................................................................. 47
11.1SAE Classes acc. to AS 4059 ..................................................................................... 47
11.1.1 SAE Signal Table .................................................................................................48
11.1.2 SAE A-D (SAeMAX)........................................................................................... 49
11.1.3 SAE Class A / B / C / D (SAE).............................................................................. 49
11.1.3.1 Time-coded Signal ........................................................................................50
11.1.4 SAE A / SAE B / SAE C / SAE D (SAE A/SAE B/SAE C/SAE D) ........................51
11.1.5 SAE + T (SAE+T) ................................................................................................. 51
11.1.5.1 Time-coded Signal ........................................................................................51
11.1.6 HDA.SAE – Analog signal SAE to HDA 5500 (Digital Display Unit)..................... 52
11.1.6.1 HDA.SAE Signal 1-4 Table ........................................................................... 53
11.1.6.2 HDA Status Signal 5 Table ........................................................................... 53
11.2ISO Code acc. to 4406:1999 .......................................................................................55
11.2.1 ISO Signal Table ..................................................................................................55
11.2.2 ISO 4 / ISO 6 / ISO 14 (ISO 4 / ISO 6 / ISO 14)................................................... 56
11.2.3 ISO Code (ISO), 3-digit ........................................................................................ 57
11.2.3.1 Time-coded Signal ........................................................................................57

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11.2.4 ISO + T (ISO+T) ................................................................................................... 58
11.2.4.1 Time-coded Signal ........................................................................................58
11.2.5 HDA.ISO – Analog Signal ISO to HDA 5500 (Digital Display Unit) ......................59
11.2.5.1 HDA.ISO Signal 1-4 Table ............................................................................ 60
11.2.5.2 HDA Status Signal 5 Table ........................................................................... 61
11.3ISO Code acc. to 4406:1987 .......................................................................................62
11.3.1 ISO Signal Table ..................................................................................................62
11.3.2 ISO 2 / ISO 5 / ISO 15 (ISO 2 / ISO 5 / ISO 15)................................................... 63
11.3.3 ISO Code (ISO), 3-digit ........................................................................................ 64
11.3.3.1 Time-coded Signal ........................................................................................64
11.3.4 ISO + T (ISO+T) ................................................................................................... 65
11.3.4.1 Time-coded Signal ........................................................................................65
11.3.4.1.1 4 – 20 mA Signal.................................................................................. 65
11.3.5 HDA.ISO – Analog Signal ISO to HDA 5500 (Digital Display Unit) ......................66
11.3.5.1 HDA.ISO Signal 1-4 Table ............................................................................ 67
11.3.5.2 HDA Status Signal 5 Table ........................................................................... 68
11.4National Aerospace Standard NAS 1638 (CS 13xx, only)...........................................69
11.4.1 NAS Signal Table ................................................................................................. 69
11.4.2 NAS Maximum .....................................................................................................70
11.4.3 NAS Class (2 / 5 / 15 / 25 )................................................................................... 71
11.4.3.1 Time-coded Signal ........................................................................................71
11.4.4 NAS 2 / NAS 5 / NAS 15 / NAS 25.......................................................................72
11.4.5 NAS + T................................................................................................................ 72
11.4.5.1 Time-coded Signal ........................................................................................72
11.4.6 HDA.NAS – Analog Signal NAS to HDA 5500 (Digital Display Unit).................... 73
11.4.6.1 HDA Signal 1-4 Table ................................................................................... 74
11.4.6.2 HDA Status Signal 5 Table ........................................................................... 74
11.5Fluid Temperature (TEMP)......................................................................................... 76
11.5.1 Temperature Table...............................................................................................76
12 Error Messages .............................................................................................................78
12.1Status LED / Display.................................................................................................... 78
12.2Exceptions Errors ........................................................................................................ 79
12.3Analog Output Error Signals........................................................................................ 80
12.3.1 Analog signal time-coded .....................................................................................80
12.3.2 Analog signal for HDA 5500 ................................................................................. 81
12.3.2.1 HDA Status Signal 5 Table ........................................................................... 81
13 Condition Sensor Interface (CSI-D-5)..........................................................................82
13.1Scope of delivery: ........................................................................................................ 82
13.2CSI-D-5 Connection schematic ................................................................................... 82
13.3Power adaptor set-up .................................................................................................. 82
14 RS-485 Interface ............................................................................................................84
15 Removing the CS from the Hydraulic System / Decommissioning..........................85
15.1Disposal / Recycling .................................................................................................... 85
16 Spare parts and Accessories....................................................................................... 85
17 ISO 4406 / SAE AS 4059 / NAS1638 Classes ..............................................................86
17.1ISO 4406:1999 ............................................................................................................ 86

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17.1.1 ISO 4406 table ..................................................................................................... 86
17.1.2 Overview of the differences between ISO 4406:1987 and ISO 4406:1999.......... 87
17.2SAE AS 4059............................................................................................................... 88
17.2.1 SAE AS 4059 table............................................................................................... 88
17.2.2 The SAE cleanliness classes can be represented as follows: ............................. 89
17.2.2.1 Absolute particle count larger than a defined particle size............................ 89
17.2.2.2 Specifying a cleanliness class for each particle size.....................................89
17.2.2.3 Specifying the highest cleanliness class measured ...................................... 89
17.3NAS 1638 .................................................................................................................... 90
18 Factory default settings / Basic settings ....................................................................91
18.1Power Up menu...........................................................................................................91
18.2Measuring menu.......................................................................................................... 91
19 Technical Details...........................................................................................................92
20 Recalibration .................................................................................................................93
21 Service ...........................................................................................................................93
22 Type / Product Key........................................................................................................94

Foreword
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Foreword
For you,
as owner of a product manufactured by us, we have produced this manual, comprising the most
important instructions for its operation and maintenance.
It is intended to help you become acquainted with the proper/designated use of the product and
use it properly. You should keep it in the vicinity of the product so it is always at your fingertips.
Sometimes the information contained in this documentation cannot always keep up with
changes made to the product as we attach considerable importance to keeping our products
cutting-edge. Consequently, there might be deviations in technical details, illustrations and
dimensions.
In these cases we go to every effort to keep your documentation current by sending you
updates.
But we need your help. Please make sure that you incorporate the updates in your
documentation and that non-current sections are removed.
If you discover errors while reading the documentation or have suggestions or other useful
information, please don’t hesitate to contact us:
HYDAC Filtertechnik GmbH
Dept.: SFVI, Techn. Documentation
P. O. Box 1251
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
Email: [email protected]
The editor would welcome your involvement.
“Putting experience into practice”

Foreword
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Customer Service
If you have any questions, suggestions, or encounter any problems of a technical nature, please
contact: When contacting us, please always include the model/type designation and article no. /
serial no. / firmware version of the product:
Fax: ++49 (0) 6897 509 846
Email: [email protected]
Modifications to the Product
We would like to point out that changes to the product (e.g. purchasing options, etc.) may result
in the information in the operating instructions no longer being completely accurate or sufficient.
When making modifications or performing repair work to components affecting the safety of the
product, the product may not be put back into operation until it has been examined and released
by a HYDAC representative.
Please notify us immediately of any modifications made to the product whether by you
or a third party.
Warranty
For the warranty provided by us, please refer to the General Conditions of Sale and Delivery of
HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com Legal information.

Foreword
HYDAC Filtertechnik GmbH en Page 7
en Vorwort.doc 2006-06-14
... And now for a few tips on using this documentation.
The following example shows you how you can access the information you are looking for quick
and easy.
WHAT do I want to know?
WHERE can I find the information I’m looking for?
The documentation is subdivided into chapters and sections.
1. Look for the table of contents.
2. Skim the boldfaced section headings.
HOW can I find the section and page I’m looking for?
Page through the operating instructions, keeping your eyes focussed on the lower right corner.
As soon as you see the page number you are looking for, stop paging.
The chapter heading is featured in the upper right corner of each page.
The documentation number/edition and index are featured in the lower left corner of each page
and on the cover sheet of the instructions.
This information features the following format:
The documentation no. is a part no. which is used to order the instructions.
The index is increased every time the instructions are revised or changed.
Please note that the method described above of locating specific information
does not release you from carefully reading the entire manual prior to starting
the unit up for the first time and carefully rereading the manual at regular
intervals later on.
Productdescription or
Chapter heading
Page no.
Edition date of chapter/section
Documentation no. Index
BeWa Product 12345678a en

General Safety Precautions
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1 General Safety Precautions
These operating instructions contain the key instructions for properly and safely operating the
CS.
1.1 Obligations and Liability
• The basic prerequisite for the safe and proper handling and operation of the CS is
knowledge of the safety instructions and warnings.
• These operating instructions in general, and the safety precautions in particular, are to be
adhered by all those who work with the CS.
• Adherence is to be maintained to pertinent accident prevention regulations applicable at
the site where the product is used.
• The safety precautions listed herein are limited solely to using the CS.
The CS has been designed and constructed in accordance with the current state of the art
and recognized safety regulations. Nevertheless, hazards may be posed to the life and limb
of the individual using the unit or to third parties. Risk of damage may be posed to the unit or
other equipment and property. The CS is to be used as follows:
• solely for its designated use
• only when in a safe, perfect condition
• Any faults or malfunctions which might impair safety are to be properly repaired or
remedied immediately.
Our General Terms and Conditions apply. They are made available to the owner upon
concluding purchase of the product at the latest. Any and all warranty and liability claims for
personal injuries and damage to property shall be excluded in the event they are attributable
to one or more of the following causes:
• improper use of the CS or use deviating from its designated use
• improper assembly, installation, commissioning, operation and maintenance of the CS
• operating the CS when the system equipment or systems are defective
• modifications to the product made by the user or purchaser
• improper monitoring of product components subject to wear and tear
• improperly performed repair work
1.2 Abbreviations and Basic Symbols
The following designations and symbols are used in this manual to designate hazards, etc.:

General Safety Precautions
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1.2.1 Basic Symbols
This symbol designates safety instructions whose non-observance may pose a
hazard to individuals.
This symbol designates safety instructions whose non-observance may result in the
injury of individuals by electric shock.
This symbol provides important instructions and tips for the proper handling and
operation of the CS.
Non-adherence to these instructions may result in damage to the CS or in damage
to its immediate surroundings.
This symbol is followed by user tips and particularly useful information. This
information helps you to optimally utilize all the features offered by your CS.
1.3 Proper/Designated Use
The Contamination Sensor (CS) was developed for the continuous monitoring of particulate
contamination in hydraulic systems.
Analyzing the size and quantity of contamination enables quality standards to be verified and
documented and the requisite optimization measures to be implemented.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
Proper or designated use of the CTU extends to the following:
• The Contamination Sensor CS 1000 Series is a stationary measurement unit for the
continuous monitoring of particulate contamination in hydraulic and lubrication systems.
• Maintaining adherence to all the instructions contained herein.
1.4 Improper Use
• Any use deviating from the proper/designated use described above is prohibited.
• Improper use may result in hazard to life and limb.
• Example of improper use:
improper connection of the ContaminationSensor pressure and return flow lines.
1.5 Safety Devices
• Prior to starting up the product each time, make sure that all the safety devices are
properly fitted to the hydraulic system in which the product is to be used and are in proper
working order.
• Safety devices may not be removed until the product has been shut down and secured
against being restarted (e.g. warning sign or padlock on the main switch).
• When the product is supplied in partial consignments, the safety devices are to be
applied by the operator as specified by law/pertinent regulations.
1.6 Informal safety precautions
• Make sure to always keep the operating instructions in the vicinity of the product.

General Safety Precautions
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• Apart from the operating instructions, any and all general and local regulations pertaining
to accident prevention and environmental protection are to be made available and
observance to be maintained to them.
• Make sure to keep the safety and hazard symbols and warnings on the product in a
legible condition.
• The hoses and connection fittings are to be checked daily for leakage (visual check). The
electrical components of the product are to also be regularly checked (visual check once
a month). Any loose connections or damaged cables are to be replaced immediately.
Warning: Pressurized fluids pose a hazard to life and limb.
Consequently, the safety regulations pertaining to working
with pressurized liquids are to be adhered to at all time!
1.7 Instructions to Be Followed in the Event of an Emergency
In the event of an emergency, immediately disconnect the CS from the
power supply and from the hydraulic system!

General Safety Precautions
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1.8 Training and Instruction of Personnel
• The CS may only be operated by properly trained and instructed personnel.
• The areas of responsibility of your staff must be established in a clear-cut manner.
• Staff undergoing training may not use the CS unless supervised by an experienced staff
member.
Individuals
Activity
Individuals
undergoing
training
Individuals
with
technical
training/
engineering
background
Electrician Supervisor
with the
appropriate
authority
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the
source of
malfunction
X X X
Remedying of
mechanical fault X X
Remedying of
electrical fault X X
Maintenance
Instructions X X X X
Repair work X
Decommissionin
g
Storage
X X X X

What's New — Document History
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2 What's New — Document History
The index is featured on the cover sheet of the operating and maintenance manual and in the lower
left corner of each page after the p/no (=> Doc.).
Index j — from firmware version V 1.25
Index k — from firmware version V 1.28
- Menu has been enhanced
- Key Lock feature added
- Analog output and switching output enhanced.
- 0 – 10 V added to Analog Output section
- Error Codes section expanded
- CS 1000 Operating and Maintenance Manual divided into a German and an English
section
Index l — from firmware version V 2.02
- What's New section added
- When indicating the operating pressure ® Reference to rating plate of the CS 1000
- Installation section corrected and better graphics added with regard to the mounting
position and hydraulic installation (CS rotated)
- Description, Analog Output, Factory Settings, and Technical Specification sections
supplemented with regard to specification of the operating pressure and the
ISO4406:1987 / NAS Classes option
- Analog Output section:
Supplemented with description of HDA+ISO / HDA+SAE / HDA+NAS interface
Graphics of (mA) + (V) version combined.
- Menu Structure section supplemented
- CoCoS 1000 sections removed
- CoCoS 1000 user's guide created as separate document.
- CoCoS 1000 added to Included with the Unit As Supplied section
- Data Sheet / Model/Type Code sections updated
- CoCoS version 2.01 or higher needed for operating and reading out the CS 1000
with firmware 2.01.
Consequently, transfer of the measured values via RS485 interface effected from
version 2.01 in 16-bit format.

Transportation, Packing, Storage
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3 Transportation, Packing, Storage
3.1 Transportation and Packing
• The CS comes packed in a cardboard box.
• Unpack the unit and check it for damage in transit. Report any damage to the forwarding
agent immediately.
3.2 Storage
• Make sure to store the CS in a clean, dry place, in the original packing, if possible. Do not
remove the packing until you are ready to install the unit.
• If the CS is to be put into storage for an extended period of time, it should be completely
drained (if necessary, it should be flushed, using n-heptane) so as to prevent it from
gumming up.
• The cleaning agents and flushing oils used are to be handled and disposed of properly.
3.2.1 Storage conditions
Storage temperature: -40°C ... +80°C / -40°F ... + 176°F
Relative humidity: max. 95%, non-condensing

Model code / Product identification
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4 Model code / Product identification
For product identification details see the Model code label. This is bonded on top side and
contains the exactly product description as well as serial-no.
600083230 C
1
2
3 xxx xxxx
Line Definition Description
1 Model Code
CS1220-A0-0-0-0/000
Typ product key
According to the data sheet, see chapter 22
2 Serial No. Specify Serial-no. allways complete !
3 max. INLET press.: Operation pressure max. in bar / psi

Scope of Delivery
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5 Scope of Delivery
The Contamination Sensor CS 1000 comes packed and factory-assembled ready for
operation. Before commissioning the CS, check the content of the package to make sure
everything is present.
The microscope comes with the following:
Qty. Designation
1 pc. ContaminationSensor, CS 1000 Series (Model according to order).
Flange connection model (Model code: CS1xxx-x-x-x-x-1/-xxx)comes with two
o-rings.
1 pc. CD with:
- PC-Software CoCos 1000 and
- Manual CoCoS 1000
- Operating and Maintenance Instructions CS 1000 (this document)
1 pc. Quick start manual
1 pc. Calibration certificate

Installation and Operation
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6 Description
The CS 1000 Series Contamination Sensor is a stationary measurement unit for the continuous
monitoring of particulate contamination in hydraulic and lubrication systems.
The CS is designed for connection to low- or high-pressure hydraulic and lubrication lines and test
benches from which a small flow of oil (between 30 ml/min and 300 ml/min) is diverted for
measurement purposes.
The Contamination Sensor is approved for a maximum operating pressure of (see specification on
rating plate) and viscosity of up to 1000 mm²/s.
Particulate contamination is detected by an optical measurement cell.
The sensor is available with the following options:
• with or without 6-digit display and keypad (the display can be rotated by 270°)
• with a 4 – 20 mA or 0 – 10 V analog output
• Measurement results are outputted as a cleanliness rating code according to the following
standards: ISO 4406:1999 and SAE AS 4059(D) or ISO 4406:1987 or NAS
• pipe / hose mounting or flange mounting
All models feature an analog electric output and an RS485 interface for outputting the measured
contamination levels. Additionally, an electronic switching output can be configured to alert the
operator about rising or falling contamination levels.
6.1 Restrictions Pertaining to the CS
The CS 1xx0 is qualified for mineral oils (or mineral-oil-based raffinates).
The CS 1xx1 is qualified for phosphate esters.
Please contact us first before using the unit with other fluids.

Installation and Operation
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6.2 CS1x1x Dimensions (without Display)
12
106,5
100
83
ca. 170
25
ISO 228
G1/4
49,2
30
AB
All dimensions in mm.
6.3 CS1x2x Dimensions (with Display)
ca. 170
106,5
12
102
83
25
ISO 228
G1/4
54,2
30
AB
All dimensions in mm.

Installation and Operation
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6.4 Connection Types
The direction of flow through the CS has to be from bottom to top. Use the one port, A <-> B or D<->C,
as the INLET and the other port as the OUTLET.
6.4.1 Pipe or Hose Connection Type (CS1xxx-x-x-x-x0/-xxx)
Hydraulic connection is done via ports A and B.
Connector thread: G1/4 pursuant to ISO 228
The direction of flow through the CS has to be
from bottom (A) to top (B).
A
B
6.4.2 Flange Connection Type (CS1xxx-x-x-x-x-1/-xxx)
Hydraulic connection is done via ports C and D. Two O-rings are used to form a seal between the CS
and a flange, mounting plate or manifold mount. Four M6 threads are prepared for securing the CS.
Ports A and B are sealed off with screw plugs [1]. Sealing with the manifold block or mounting plate is
done via two O rings [2] (4,48x1,78 FPM, see Spare Parts).
[1] [2]
[1]
C
A
B
D
CD
25
15 20
100
40
60
12/16
4xM6 [2]
Bottom view.
All dimensions in mm.