HYDAC International CS1000 Series Owner's manual

Programming aid
for
CS 1000 Series and
S7-300 / S7-400
English
Valid from firmware versions V 2.23 up
Doc.: 3333045b/ 2010-07-05

Programming aid CS1000 – S7
HYDAC Filtertechnik GmbH en Page 3
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 2007 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
Tel.: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

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Table of Contents
Table of Contents...................................................................................................................4
Preface ....................................................................................................................................5
Customer Service.................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty...............................................................................................................................6
1 General Safety Precautions ...........................................................................................8
1.1 Obligations and Liability.................................................................................................8
1.2 Explanation of Symbols and Warnings, etc...................................................................8
1.2.1 Basic Symbols........................................................................................................9
2 Introduction.....................................................................................................................9
3 Goal of this Programming Aid.......................................................................................9
4 Electrical Installation....................................................................................................10
4.1 Block diagram..............................................................................................................10
4.2 Connector Cable..........................................................................................................10
4.2.1 Wiring Diagram.....................................................................................................11
5 Operation of CS.............................................................................................................12
5.1 Display and keypad elements (CS1x2x only)..............................................................12
5.1.1 Measuring Menu...................................................................................................13
6 Analog output................................................................................................................15
6.1 SAE classes acc. to AS 4059......................................................................................16
6.1.1 HDA.SAE – Analog signal SAE............................................................................16
6.1.1.1 HDA.SAE signal 1-4 table.............................................................................17
6.1.1.2 HDA status signal 5 table..............................................................................18
6.2 ISO Code acc. to 4406:1999.......................................................................................19
6.2.1 HDA.SAE – Analog signal ISO.............................................................................19
6.2.1.1 HDA.ISO signal 1-4 table..............................................................................20
6.2.1.2 HDA status signal 5 table..............................................................................21
6.3 ISO code acc. to 4406:1987 (CS 13xx only) ...............................................................22
6.3.1 HDA.SAE – Analog signal ISO.............................................................................22
6.3.1.1 HDA.ISO signal 1-4 table..............................................................................23
6.3.1.2 HDA status signal 5 table..............................................................................24
6.4 National Aerospace Standard NAS 1638 (CS 13xx, only)...........................................25
6.4.1 HDA.NAS – Analog Signal NAS...........................................................................25
6.4.1.1 HDA signal 1-4 table.....................................................................................26
6.4.1.2 HDA status signal 5 table..............................................................................27
7 Controller concept Module overview ..........................................................................28
7.1 UDT1 Module - Data storage and E/A signals.............................................................28
7.2 UDT1 Module - Data evaluation..................................................................................29
7.3 FC12 Module - Call up CS1000...................................................................................30
7.4 FC12 Module - Evaluation...........................................................................................31
8 Visualization examples.................................................................................................45
8.1 Presentation of the measured values..........................................................................45
8.2 Defining limit values.....................................................................................................45

Programming aid CS1000 – S7
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Preface
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 (see “What’s New”).
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
Abt.: SVFI, Techn. Dokumentation
Postfach 1251
66273 Sulzbach / Saar
Fax: ++49 (0) 6897 509 846
Email: [email protected]
We look forward to receiving your input.
“Putting experience into practice”.

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Customer Service
If you have any questions, suggestions, or encounter any problems of a technical
nature, please contact us. When contacting us, please always include the model/type
designation and part no. 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 Terms of Sale and
Delivery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com ÖLegal information.

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... 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.
Look for the table of contents.
Skim the boldfaced section headings.
HOW can I find the section and page I’m looking for?
Take the pages of the operating manual and browse through the pages.
Keep an eye on the bottom right margin.
As soon as you see the page number you are looking for, stop paging.
The chapter/section 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 supplemented every time the instructions are revised or changed.
Please note that the method described above of locating specific information
does not release you from your responsibility to carefully read the entire manual
prior to starting the unit up for the first time and carefully reread the manual at
regular intervals later on.
Product description or
Chapter heading
Page no.
Edition date of
ht/ ti
Documentation no. Index
BeWa Product 12345678a en

Programming aid CS1000 – S7
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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 to 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 guidelines listed here are restricted to use of the CS.
The CS has been designed and constructed in accordance with the current state of the art
and recognized safety regulations. Nevertheless, hazard may be posed to the life and limb of
the individual using the product or to third parties. The CS is only 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 provided to the owner upon conclusion
of purchase of the unit 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 intended use
• improper assembly/installation, start up, operation and maintenance of the CS
• operating the CS when the system equipment or systems are defective
• modifications to the CS made by the user or purchaser
• improper monitoring of unit components that are subject to wear and tear
• improperly performed repair work
1.2 Explanation of Symbols and Warnings, etc.
The following designations and symbols are used in this manual to designate hazards, etc.:

Programming aid CS1000 – S7
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1.2.1 Basic Symbols
This symbol designates safety guidelines whose non-observance may pose
a hazard to individuals.
This symbol provides important notes for the proper handling of the CS.
Non-observance of these instructions may lead to damage of the CS or its
immediate surroundings.
This symbol identifies tips for usage and other particularly useful information.
This information helps you to optimally utilize all the features offered by your
CS.
2 Introduction
The following description is intended to serve as a programming aid for the data-related
integration of a CS1000 in an S7 controller.
The modules have been extensively tested at our company. Generally speaking, however,
errors cannot be ruled out that were unknown in the period leading up to the day of
manufacture.
Basic programming knowledge in STEP 7 is a prerequisite.
System prerequisites:
SPS: SIMATC S7 300 and S7-400
Programming: FUP / AWL with Siemens STEP 7 programming software
Hardware Siemens: S7 Central assembly, Analog assembly, TouchPanel
Hardware HYDAC: CS1000
3 Goal of this Programming Aid
Extraction of the measurement data of a CS1000 by means of a Siemens S7 SPS with
analog input card.
The analog signal of the measured values is output sequentially via the flow loop (Pin 2 and
4). The output of the measured values starts with a 2 seconds 20 mA or 10 V value.
Synchronization to this signal is a prerequisite.
The SPS program is intended for data output as HDA-xxx.
The settings must be checked and/or the CS must be converted to the edition at
the analog output as HDA-ISO, HDA-SAE or HDA-NAS (siehe Kapitel 5).

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4 Electrical Installation
4.1 Block diagram
Supply voltage 9 – 36 V DC
GND for supply voltage
RS485 +
RS485 -
Not connected
Analog output +
GND for analog and switch outputs
Switch out (normally open)
2
3
45
6
7
1Case
M12x1, 8-pol., male,
specified acc. IEC61984 / VDE0627
8
1
2
3
4
5
6
7
8
Voltage
Regulator
Internal
supply
voltages
galvanically
isolated
supply
galvanic
isolation
Not to be
connected
1 µF
+
-
DC
DC
The analog output is an active source of 4 - 20 mA or 0 - 10 V DC.
The switch output is a passive n-switching Power MOSFET. The switch is normally open.
There is contact between the plug housing and the CS housing.
4.2 Connector Cable
Our accessories list includes connection cables of various lengths with one connection plug
(12-pole, M1x8, according to DIN VDE 0627) and an open end.
HYDAC accessory cable color coding is listed in the table below:
Pin Color Connection to
1 White Supply voltage 9 – 36 V DC
2 Brown Analog output + (active)
3 Green GND supply voltage
4 Yellow GND analog / switch outputs
5 Gray Not connected
6 Pink RS485 +
7 Blue RS485 -
8 Red Switch out (passive, n.o.)
Case - Shield

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4.2.1 Wiring Diagram
Nicht angeschlossen
Not to be connected
Ne connexe pas
RS-485 +
RS-485 -
250
1
2
3
4
5
6
7
8
Shield
24 V DC
5 V DC
SPS Eingang
PLC Input
SPS Entrée
white
green
pink
blue
grey
brown
yellow
red
USB
RS-485
Converter
=
=
1
7
65
4
3
2
Schirm
Shield
Blindage
8
Circuit diagram: with two separate power supplies. (e.g. 24 V DC and 5 V DC)
1
2
3
4
5
6
7
8
Shield
24 V DC
white
green
pink
RS-485 +
RS-485 -
blue
grey
brown
yellow
red
USB
RS-485
Converter
Nicht angeschlossen
Not to be connected
Ne connexe pas
=
250
1
7
65
4
3
2
8
SPS Eingang
PLC Input
SPS Entrée
Schirm
Shield
Blindage
Circuit diagram: with one power supply. (e.g. 24 V DC).
To prevent a ground loop, connect the connection cable screen only if the CS 1000
is not grounded or not adequately connected to the protective earth (PE).

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5 Operation of CS
After the CS 1000 is switched on, "HYDAC CS 1000" is displayed in moving letters, then the
firmware version is displayed for 2 seconds.
This is followed by a countdown: WAIT99 to WAIT0.
The duration of the countdown is related to the measurement period set, e.g the countdown
from 99 - 0 runs within the measurement period set (factory setting = 60 sec).
5.1 Display and keypad elements (CS1x2x only)
B
D
F
E
A
C
Item LED Description
A Status Status display, for details, see Operating and Maintenance
Instructions for the ContaminationSensor.
B Display Consists of a 6-digit display and shows the selected measured
values.
C Measured variable Display of the respective measurement category in the display,
i.e.:
ISO / SAE / NAS
D Additional variable Indicates the additional variable of the display value, i.e.:
Flow / Out / Drive / Temp
E Switch point 1 Indicates the status of the switching output. When lit, the
switching output is activated (closed).
F Switch point 2 Reserved for future use

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The keyboard consists of six buttons. These keys are used to operate the CS and to
navigate through the menus (hierarchically structured).
Keyboard Description
o.k.
- one level down
- confirm changed value (lowest level)
- confirm when changes are to be saved or canceled (top level)
Esc
- one level up
- no value change
+
- change value at the lowest level (when display is blinking)
- scroll through display
- scroll through menu
- select digit
5.1.1 Measuring Menu
The measuring menu allows you to change settings during operation.
Selection To do
Start Measuring menu Press button
o.k.
.
Scroll to CANCEL and actuate it Scroll to CANCEL and press
o.k.
,
or the option is selected automatically after 30 s.
Exit menu and save changes Scroll to SAVE and press
o.k.
Measuring Menu: Description
DSPLAY Select displayed measured variable
SWtOUT Set switching output
ANaOUT Select measurement category for
analog output
CANCEL Discard changes and exit
SAVE Save changes and exit

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Analog output ANA.OUT (CS 12xx)
ANaOUT Select measurement
category for analog
output
+
Description
SAeMAX SAE A-D
SAE SAE class A/B/C/D (coded)
SAE+T SAE class + temp. (Code)
TEMP Fluid Temperature
HDaISO ISO for HDA 5500
HDaSAE SAE for HDA 5500
ISO 4 ISO 4 code
ISO 6 ISO 6 code
ISO 14 ISO 14 code
ISO ISO 3-digit (coded)
ISO+T ISO 3-digit + temp. (coded)
SAE A SAE class A
SAE B SAE class B
SAE C SAE class C
SAE D SAE class D
Analog output ANA.OUT (CS 13xx)
ANaOUT Select measurement
category for analog
output
+
Description
NAsMAX NAS maximum
NAS NAS class 2/5/15/25 (coded)
NAS+T NAS class+temp. (coded)
TEMP Fluid Temperature
HDaISO ISO for HDA 5500
HDaNAS NAS or SAE for HDA 5500
ISO 2 ISO 2 code
ISO 5 ISO 5 code
ISO 15 ISO 15 code
ISO ISO 3-digit (coded)
ISO+T ISO 3-digit + temp. (coded)
NAS 2 NAS class 2
NAS 5 NAS class 5
NAS 15 NAS class 15
NAS 25 NAS class 25

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6 Analog output
Depending on CS model, the analog output is available as a 4 – 20 mA or 0 – 10 V signal.
The CS model code allows you to detect the analog output.
CS Model code Analog output
CS 1 x x x - A – x – x – x – x /-xxx 4 - 20 mA
CS 1 x x x - B – x – x – x – x /-xxx 0 – 10 V
The electrical design of the analog output must have already been taken into consideration in
the order. It is no longer possible to internally change the analog output over later.
The following signals can be selected in the measurement menu:
• SAE AS 4059 classes, see section 6.1
• ISO code according to 4406:1999, see section 6.2
• ISO code according to 4406:1987, see section 6.3
• NAS class 1638, see section 6.4

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6.1 SAE classes acc. to AS 4059
The following SAE classes can be output via the analog output:
6.1.1 HDA.SAE – Analog signal SAE
The HDA.SAE signal consists of 6 values (START / SAE A / SAE B / SAE C / SAE D /
Status) which are output sequentially. Synchronization with the downstream control unit is a
prerequisite.
The signal output is as follows:
I (mA) U (V)
t (s)
42
63
94,5
10,0
7
53,5
2,5
84
20
22222222222 22222222222
30
110223344550
Time Measured
variable Signal duration in s Current (I) / Voltage (U)
Start signal 0 -- 2 20 mA / 10 V
Pause 2 4 mA / 2 V
Signal 1 SAE A 2 Current / voltage for signal (see table 6.1.1.1)
Pause 2 4 mA / 2 V
Signal 2 SAE B 2 Current / voltage for signal (see table 6.1.1.1)
Pause 2 4 mA / 2 V
Signal 3 SAE C 2 Current / voltage for signal (see table 6.1.1.1)
Pause 2 4 mA / 2 V
Signal 4 SAE D 2 Current / voltage for signal (see table 6.1.1.1)
Pause 2 4 mA / 2 V
Signal 5 Status 2 Current / voltage for signal (see table 6.1.1.1)
Pause 30 4 mA / 2 V

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6.1.1.1 HDA.SAE signal 1-4 table
The current or voltage range is dependent on the contamination class according to SAE=0.0
– 14.0 (resolution 0.1 class).
Current I SAE class / error Voltage U
I< 4.00 mA Cable break U< 2.00 V
I = 4.00 mA SAE 0 U = 2.00 V
I = 4.11 mA SAE 0.1 U = 2.06 V
I = 4.23 mA SAE 0.2 U = 2.11 V
... ... ...
I = 5.14 mA SAE 1 U = 2.57 V
I = 6.29 mA SAE 2 U = 3.14 V
I = 7.43 mA SAE 3 U = 3.71 V
I = 8.57 mA SAE 4 U = 4.29 V
I = 9.71 mA SAE 5 U = 4.86 V
I = 10.86 mA SAE 6 U = 5.43 V
I = 12.00 mA SAE 7 U = 6.00 V
I = 13.14 mA SAE 8 U = 6.57 V
I = 14.29 mA SAE 9 U = 7.14 V
I = 15.43 mA SAE 10 U = 7.71 V
I = 16.57 mA SAE 11 U = 8.29 V
I = 17.71 mA SAE 12 U = 8.86 V
I = 18.86 mA SAE 13 U = 9.43 V
... ... ...
I = 19.77 mA SAE 13.8 U = 9.89 V
I = 19.89 mA SAE 13.9 U = 9.94 V
I = 20.00 mA SAE 14.0 U = 10.00 V
If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:
I = 4 mA + SAE class * (20 mA - 4 mA) / 14
U = 2 V + SAE class * (10 V - 2 V) / 14
If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:
SAE class = (I - 4 mA)*(14/16 mA)
SAE class = (U - 2 V)*(14/8 V)

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6.1.1.2 HDA status signal 5 table
The current or voltage of the output signal (5) is dependent on the status of the CS 1000 as
shown in the table below:
Current I Status Voltage U
I = 5.0 mA CS is functioning correctly U = 2.5 V
I = 6.0 mA Device error / CS not ready U = 3.0 V
I = 7.0 mA Flow too low (Flow 2 low) U = 3.5 V
I = 8.0 mA Out of range ISO <9. <8. <7 U = 4.0 V
I = 9.0 mA No measured value (Flow undefined) U = 4.5 V
If the status signal is ≥6.0 mA or ≥3.0 V, signals 1 to 4 are output with 20 mA or 10 V.
Example:
I (mA) U (V)
t (s)
42
63
94,5
10,0
7
53,5
2,5
84
20
22222222222 22222222222
30
110223344550

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6.2 ISO Code acc. to 4406:1999
The following ISO values can be output via the analog output:
6.2.1 HDA.SAE – Analog signal ISO
The HDA.ISO signal consists of 4 measured values (START / ISO 6 / ISO 6 / ISO 14 / ISO
21 / Status) which are output sequentially. Synchronization with the downstream control unit
is a prerequisite.
The signal output is as follows:
I (mA) U (V)
t (s)
42
63
94,5
10,0
7
53,5
2,5
84
20
22222222222 22222222222
30
110223344550
Time Measured variable Signal duration
in s Current (I) / Voltage (U)
Start signal 0 -- 2 20 mA / 10 V
Pause 2 4 mA / 2 V
Signal 1 ISO 4 2 Current / voltage for signal (see table 6.2.1.1)
Pause 2 4 mA / 2 V
Signal 2 ISO 6 2 Current / voltage for signal (see table 6.2.1.1)
Pause 2 4 mA / 2 V
Signal 3 ISO 14 2 Current / voltage for signal (see table 6.2.1.1)
Pause 2 4 mA / 2 V
Signal 4 ISO 21 2 Current / voltage for signal (see table 6.2.1.1)
Pause 2 4 mA / 2 V
Signal 5 Status 2 Current / voltage for signal (see table 6.2.1.2)
Pause 30 4 mA / 2 V

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6.2.1.1 HDA.ISO signal 1-4 table
The current 4 -20 mA or voltage 2 - 10 V of the output signal is dependent on the ISO
contamination class 0.0 - 25.28 (resolution 1 class) as shown in the table below:
Current I ISO code Voltage U
I< 4.0 mA Cable break U< 2.0 V
I = 4.00 mA ISO 0 U = 2.00 V
I = 4.63 mA ISO 1 U = 2.32 V
I = 5.27 mA ISO 2 U = 2.63 V
I = 5.90 mA ISO 3 U = 2.95 V
I = 6.53 mA ISO 4 U = 3.27 V
I = 7.16 mA ISO 5 U = 3.58 V
I = 7.80 mA ISO 6 U = 3.90 V
I = 8.43 mA ISO 7 U = 4.22 V
I = 9.06 mA ISO 8 U = 4.53 V
I = 9.70 mA ISO 9 U = 4.85 V
I = 10.33 mA ISO 10 U = 5.16 V
I = 10.96 mA ISO 11 U = 5.48 V
I = 11.59 mA ISO 12 U = 5.80 V
I = 12.23 mA ISO 13 U = 6.11 V
I = 12.86 mA ISO 14 U = 6.43 V
I = 13.49 mA ISO 15 U = 6.75 V
I = 14.13 mA ISO 16 U = 7.06 V
I = 14.76 mA ISO 17 U = 7.38 V
I = 15.39 mA ISO 18 U = 7.70V
I = 16.03 mA ISO 19 U = 8.01 V
I = 16.66 mA ISO 20 U = 8.33 V
I = 17.29 mA ISO 21 U = 8.65 V
I = 17.92 mA ISO 22 U = 8.96 V
I = 18.56 mA ISO 23 U = 9.28 V
I = 19.19 mA ISO 24 U = 9.59 V
I = 19.82 mA ISO 25 U = 9.91 V
I = 20.00 mA ISO 25.28 U = 10.0 V

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The current (I) or voltage (U) can be calculated for a given ISO contamination class as
follows:
I = 4 mA + ISO code * (20 mA - 4 mA) / 25.28
U = 2 V + ISO code * (10 V - 2 V) / 25.28
The ISO contamination class can be calculated for a given current I or voltage U as follows:
ISO code = (I - 4 mA)*(25.28 / 16 mA)
ISO code = (U - 2 V)*(25.28 / 8 V)
6.2.1.2 HDA status signal 5 table
The current or voltage of the output signal (5) is dependent on the status of the CS 1000 as
shown in the table below:
Current I Status Voltage U
I = 5.0 mA CS is functioning correctly U = 2.5 V
I = 6.0 mA Device error / CS not ready U = 3.0 V
I = 7.0 mA Flow too low (Flow 2 low) U = 3.5 V
I = 8.0 mA Out of range ISO <9. <8. <7. U = 4.0 V
I = 9.0 mA No measured value (Flow undefined) U = 4.5 V
If the status signal is ≥6.0 mA or ≥3.0 V, signals 1 to 4 are output with 20 mA or 10 V.
I (mA) U (V)
t (s)
42
63
94,5
10,0
7
53,5
2,5
84
20
22222222222 22222222222
30
110223344550