HYDAC International CS1000 Series Operating instructions

CS1000 series
Contamination Sensor
Operating and Maintenance Instructions
English (translation of original instructions)
Valid from firmware versions V 2.40 up
Documentation no.: 3247149p

ContaminationSensor CS 1000 Trademarks
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2011 by
HYDAC FILTER SYSTEMS GMBH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole without the
express written consent of HYDAC Filter Systems GmbH. Contraventions are liable
to compensation.
Exclusion of Liability
We have made every endeavor to ensure the accuracy of the contents of this
document. 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 future editions. We welcome any
suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
HYDAC Filter Systems GmbH
Postfach 12 51
66273 Sulzbach / Saar
Germany
Documentation Representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
E-mail: [email protected]

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Content
Trademarks ...............................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
What's New — Document History...........................................................................6
Preface ......................................................................................................................7
Technical Support...................................................................................................8
Modifications to the Product ...................................................................................8
Warranty .................................................................................................................8
Using the Documentation .......................................................................................9
Safety Information and Instructions.....................................................................10
Obligations and Liability........................................................................................10
Explanation of Symbols and Warnings, etc. .........................................................11
Proper/Designated Use ........................................................................................11
Improper Use or Use Deviating from Intended Use..............................................12
Training and Instruction of Personnel ...................................................................13
Storing the CS ........................................................................................................14
Storage conditions ................................................................................................14
Decoding the model code label ............................................................................14
Checking the scope of delivery ............................................................................15
CS1000 Features ....................................................................................................16
CS1000 Restrictions on use ..................................................................................16
CS1x1x dimensions (without display).................................................................. 17
CS1x2x dimensions (with display)........................................................................17
Hydraulic connection types ..................................................................................18
Pipe or hose connection (type CS1xxx-x-x-x-x-0/-xxx) .........................................18
Flange connection (type CS1xxx-x-x-x-x-1/-xxx) ..................................................18
Fastening / mounting the CS1000.........................................................................19
Display rotatable/Adjustable As Needed..............................................................20
CS1000 hydraulic installation ...............................................................................21
Selecting the measurement point .........................................................................22
Flow rate, differential pressure p

and viscosity

characteristics .....................23
Hydraulic connection of the CS1000 ....................................................................24
Electrical connection of the CS1000.....................................................................25
Plug pin assignment .............................................................................................25
Connection cable - Assignment / Color coding..................................................... 26
Connecting cable ends - Examples ......................................................................27
CS1000 Measurement mode..................................................................................28
Mode M1: Continuous measurement....................................................................28
Mode M2: Continuous measurement and switching.............................................28
Mode M3: Filter to cleanliness class and stop ......................................................28
Mode M4: Filter to continuously monitor cleanliness class................................... 29

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Mode "SINGLE" measurement ............................................................................. 29
Operating the CS1000 using the keyboard (only CS1x2x) ................................. 30
Function of the Keys .............................................................................................31
Measured variables .............................................................................................. 32
ISO (Cleanliness class).....................................................................................32
SAE (Cleanliness class)....................................................................................32
NAS (Cleanliness Class - only CS 13xx) ..........................................................32
Service variables ..................................................................................................33
Flow (flow rate)..................................................................................................33
Out (Analog output)...........................................................................................33
Drive (performance of the LED) ........................................................................33
Temp (Temperature) .........................................................................................33
Activating/deactivating key lock ............................................................................34
Display FREEZE...................................................................................................34
Activate display FREEZE ..................................................................................35
Deactivate display FREEZE..............................................................................36
Modes and menus ................................................................................................36
PowerUp Menu .................................................................................................36
Measuring menu (CS12xx) ...............................................................................40
DSPLAY - Display after sensor is switched on.............................................. 40
SWT.OUT – Set switching output ..................................................................41
ANA.OUT - Set output signal.........................................................................43
Measuring menu (CS13xx) ................................................................................... 44
DSPLAY - Display after sensor is switched on.............................................. 44
SWT.OUT – Set switching output ..................................................................45
ANA.OUT.......................................................................................................47
Overview of menu structure..................................................................................48
Menu CS 12xx (ISO 4406:1999 and SAE) ...........................................................48
Menu CS 13xx (ISO 4406:1987 and NAS) ...........................................................50
Using switching output..........................................................................................52
Mode M1: Continuous measurement....................................................................52
Mode M2: Continuous measurement and switching.............................................52
Mode M3: Filter to cleanliness class and stop ......................................................52
Mode M4: Filter to continuously monitor cleanliness class................................... 52
Mode "SINGLE" measurement ............................................................................. 52
Setting limit values.................................................................................................53
Analog output .........................................................................................................55
SAE classes acc. to AS 4059 ...............................................................................56
SAE A-D............................................................................................................57
SAE Class A / B / C / D .....................................................................................58
SAE A / SAE B / SAE C / SAE D ......................................................................58
SAE + T.............................................................................................................59
HDA.SAE – Analog signal SAE to the HDA 5500 ............................................. 60
HDA.SAE Signal 1/2/3/4 ...................................................................................61
HDA Status Signal 5 .........................................................................................62
ISO Code acc. to 4406:1999 ................................................................................63

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ISO 4 / ISO 6 / ISO 14.......................................................................................64
ISO code, 3-digit ...............................................................................................65
ISO + T..............................................................................................................66
HDA.ISO – Analog signal ISO to HDA 5500 ..................................................... 67
HDA.ISO Signal 1/2/3/4 ....................................................................................68
HDA Status Signal 5 .........................................................................................69
ISO code signal acc. to 4406:1987 (CS 13xx only) .............................................. 70
ISO 2 / ISO 5 / ISO 15.......................................................................................71
ISO code, 3-digit ...............................................................................................72
ISO + T..............................................................................................................73
HDA.ISO – Analog signal ISO to HDA 5500 ..................................................... 74
HDA.ISO Signal 1/2/3/4 ....................................................................................75
HDA Status Signal 5 .........................................................................................76
NAS 1638 - National Aerospace Standard (Only CS 13xx) .................................. 77
NAS maximum ..................................................................................................78
NAS classes (2 / 5 / 15 / 25) .............................................................................79
NAS 2 / NAS 5 / NAS 15 / NAS 25....................................................................79
NAS + T.............................................................................................................80
HDA.NAS – Analog Signal NAS to HDA 5500 .................................................. 81
HDA Signal 1/2/3/4............................................................................................82
HDA Status Signal 5 .........................................................................................83
Fluid temperature TEMP.......................................................................................84
Status messages ....................................................................................................86
Status LED / Display.............................................................................................86
Error......................................................................................................................86
Exceptions Errors .................................................................................................87
Analog output error signals...................................................................................89
Analog signal for HDA 5500 .................................................................................90
HDA status signal 5 table..................................................................................90
Connecting CSI-D-5 (Condition Sensor Interface) ..............................................91
CSI-D-5 Connection overview ..............................................................................91
CS1000 in RS-485 bus............................................................................................92
Taking the CS1000 out of operation .....................................................................93
Disposing of CS1000..............................................................................................93
Spare parts and accessories.................................................................................93
Cleanliness classes - brief overview ....................................................................94
Cleanliness class - ISO 4406:1999.......................................................................94
Table - ISO 4406 ..................................................................................................94
Overview of modifications - ISO4406:1987 <-> ISO4406:1999............................95
Cleanliness class - SAE AS 4059.........................................................................96
Table - SAE AS 4059............................................................................................ 96
Definition acc. to SAE ...........................................................................................97
Particle count (absolute) larger than a defined particle size..............................97
Specifying a cleanliness class for each particle size.........................................97
Specify highest measured cleanliness class.....................................................97