HYDAC International CS1000 Series User manual

ContaminationSensor
CS1000 Series EN
Valid from series no. up 0002S01515K0004000
Valid from Hardware index up F
Valid for firmware versions 3.30–…
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Instruction manual
4622814 / 2023-03

EN
4622814 / 2023-03
Translation of original operating instructions/source language: German
©2023HYDAC Filter Systems GmbH. All rights reserved.
® All product names used may be trademarks or registered trademarks of HYDAC or the particular owner.
This manual was prepared to the best of our knowledge. Nevertheless and despite the greatest care, it is possible that it
may contain errors. 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.
Documentation Representative:
Günter Harge, HYDACInternationalGmbH, Industriegebiet, D‑66280Sulzbach/Saar, [email protected]
UKCA - Authorized representative of the manufacturer:
HYDACTechnologyLimited, DeHavillandWay, WindrushParkWitney, OxfordshireOX290YG, UnitedKingdom

EN
TABLE OF CONTENTS
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Table of Contents
1. General ........................................................................................................................... 7
1.1 Target group of the manual ................................................................................ 7
1.2 Illustrations in the manual................................................................................... 7
1.2.1 Representation of requirements ........................................................... 7
1.2.2 Representation of procedural instructions............................................ 8
1.2.3 Representation of intermediate results/results ..................................... 8
1.2.4 Supplementary symbols ....................................................................... 9
1.2.5 Representation of warning / general safety information ....................... 9
1.2.6 Signal words and their meaning in the general safety information....... 10
1.3 Exclusion of liability / warranty............................................................................ 11
1.4 Notes on copyright.............................................................................................. 11
2. Safety .............................................................................................................................. 12
2.1 Target group / Required personnel qualification................................................. 12
2.2 Hazard symbols / pictograms ............................................................................. 14
2.3 Danger notifications............................................................................................ 15
2.4 Observing environmental precautions ................................................................ 16
2.5 Observing regulatory information ....................................................................... 16
3. Product and technical specifications ............................................................................... 17
3.1 Intended Use ...................................................................................................... 18
3.2 Improper use or use deviating from intended use .............................................. 19
3.3 Checking the scope of delivery........................................................................... 20
3.4 Technical data .................................................................................................... 21
3.5 Decoding the model code................................................................................... 23
3.5.1 Model Code .......................................................................................... 24
3.6 Dimensions......................................................................................................... 25
3.7 Components ....................................................................................................... 26
4. Transportation and storage ............................................................................................. 27
5. Assembly, installation and commissioning...................................................................... 28
5.1 Rotating the display (only CS1x2x) .................................................................... 28
5.2 Assembling / Fastening the sensor .................................................................... 28
5.3 Connecting the hydraulics .................................................................................. 30
5.3.1 Threaded port (only CS1xxx-x-x-x-x-0) ................................................ 30
5.3.2 Flange connection (only CS1xxx-x-x-x-x-1).......................................... 30
5.3.3 Finding the measuring point in the hydraulic system ........................... 31
5.3.4 Flow rate, differential pressure and viscosity characteristics ............... 32
5.3.5 Hydraulic connection of the sensor ...................................................... 33
5.4 Electrical connection........................................................................................... 34
5.4.1 Single-ended cordset / Double-ended cordset - Color coding.............. 35
5.4.2 Connection examples........................................................................... 35

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TABLE OF CONTENTS
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5.5 Commissioning ................................................................................................... 37
6. Factory settings............................................................................................................... 38
7. Operation ........................................................................................................................ 39
7.1 Reading the display / operating the keyboard (only CS1x2x)............................. 40
7.1.1 Displaying the measured variables and service variables.................... 42
7.1.2 Activating / deactivating the key lock – LOCK / UNLOCK .................... 44
7.1.3 Freezing the display - FREEZE............................................................ 45
7.2 PowerUp menu – Configuring the basic settings................................................ 47
7.2.1 Overview of the PowerUp menu structure............................................ 52
7.3 Setting the measuring menu - CS12xx............................................................... 53
7.3.1 Overview of the measuring menu structure CS12xx ............................ 61
7.4 Setting the measuring menu - CS13xx............................................................... 62
7.4.1 Overview of the measuring menu structure CS13xx ............................ 70
7.5 Selecting the operating mode - MODE............................................................... 71
7.6 Dry-running protection - P.PRTCT ..................................................................... 72
7.7 Reading out measured values / Setting the sensor............................................ 72
7.7.1 Connecting, setting, reading the sensor via RS485 ............................. 72
7.7.2 Connecting, setting, reading the sensor via CSI-D-5 ........................... 75
7.7.3 Reading and analyzing the measurement reports / values with
FluMoS .................................................................................................
76
7.8 Using the switching output - SWT.OUT.............................................................. 77

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7.9 Using / evaluating the analog output - ANA.OUT............................................... 80
7.9.1 SAE classes according to AS4059...................................................... 81
7.9.1.1 SAE .................................................................................... 82
7.9.1.2 SAE.MAX............................................................................ 83
7.9.1.3 SAEA / SAEB / SAEC / SAED........................................ 84
7.9.1.4 SAE+T ................................................................................ 85
7.9.1.5 HDA.SAE............................................................................ 87
7.9.2 ISO code according to ISO4406 >4µm, >6µm, >14µm ................. 91
7.9.2.1 ISO4 / ISO6 / ISO14 ........................................................ 92
7.9.2.2 ISO ..................................................................................... 93
7.9.2.3 ISO+T ................................................................................. 94
7.9.2.4 HDA.ISO............................................................................. 95
7.9.3 ISO code according to ISO4406 >2µm, >5µm, >15µm (only
CS13xx)................................................................................................
99
7.9.3.1 ISO2 / ISO5 / ISO15 ........................................................ 100
7.9.3.2 ISO ..................................................................................... 101
7.9.3.3 ISO+T ................................................................................. 102
7.9.3.4 HDA.ISO............................................................................. 103
7.9.4 NAS grades according to NAS1638 NationalAerospaceStandard
(only CS13xx).......................................................................................
106
7.9.4.1 NAS .................................................................................... 107
7.9.4.2 NAS.MAX ........................................................................... 109
7.9.4.3 NAS2 / NAS5 / NAS15 / NAS25 ..................................... 110
7.9.4.4 NAS+T ................................................................................ 111
7.9.4.5 HDA.NAS............................................................................ 113
7.9.5 Fluid temperature TEMP ...................................................................... 117
8. Rectifying malfunctions ................................................................................................... 118
8.1 Status and errors using the status LED and display........................................... 118
8.2 Reading the status signal by means of the analog output.................................. 124
8.3 Reading the status signal by means of the HDA5500....................................... 126
9. Carrying out the maintenance ......................................................................................... 128
10. Decommissioning / Disposal ........................................................................................... 129
10.1 Temporary shutdown.......................................................................................... 129
10.2 Permanent shutdown.......................................................................................... 129
10.3 Disposal / Recycling ........................................................................................... 129
11. Appendix ......................................................................................................................... 130
11.1 Contacting Customer Service............................................................................. 130
11.2 Spare parts ......................................................................................................... 131
11.3 Accessories ........................................................................................................ 131
11.4 Declaration of conformity.................................................................................... 135

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11.5 Overview and definition of the cleanliness classes ............................................ 137
11.5.1 Cleanliness classes according to ISO4406 ......................................... 137
11.5.2 Cleanliness classes according to SAEAS4059 ................................... 140
11.5.3 Cleanliness classes according to NAS1638........................................ 142
Glossary .......................................................................................................................... 149
Index ............................................................................................................................... 151

EN
1. GENERAL
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1. General
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Before you use this product for the first time, read this manual at least up to the chapter
"Operation". If you would like to carry out maintenance or troubleshooting, you can find
the procedure in the respective chapters.
The use and the handling of the product as well as its use are not self-explanatory and
are described in detail in this manual.
This manual will help you to use the product as intended, properly, effectively, and
safely. Please refer to it every time you require specific details or actions.
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 the
delivered product.
We reserve the right to make changes to the contents of this manual without prior
notice.
1.1 Target group of the manual
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This manual was created for the following target group:
Target group Tasks
Owner Keep this manual and the applicable documents at the
installation location of the product and also for later use.
Ask the employees to read and follow the manual and the
associated documents, in particular, the safety and
warning instructions.
Additionally, please observe the product-related instruc-
tions and requirements.
Operator, specialist
personnel:
Read, observe and follow this manual and the associated
documents, in particular, the safety and warning instruc-
tions.
Tab.1: Target groups
1.2 Illustrations in the manual
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You will find illustrations in this manual. You can find details regarding these in the
following chapters.
1.2.1 Representation of requirements
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These are absolutely required for carrying out a work activity on the product and are
marked with a check mark and are in bold in the text.
An example for the representation of requirements:

EN
1. GENERAL
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üThe product is assembled and connected.
üThe product is switched off.
uSwitch the product on.
1.2.2 Representation of procedural instructions
9007199396432779
In the case of procedural instructions, there are the two following representations:
Procedural instructions with a fixed sequence
Procedural instructions, the order of which must be strictly adhered to, 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.
1.2.3 Representation of intermediate results/results
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In the case of some activities, it is necessary to carry out work steps with intermediate
results and end results.
Intermediate results are the consequence of activities; they are marked with an indented
arrow.
End results represent the end of an activity and are represented with a flag.
An example for a procedural instruction with intermediate result and final result:
1. Switch the product on.
ðThe display lights up.
2. Press the button.
OThe product is now ready for use.

EN
1. GENERAL
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1.2.4 Supplementary symbols
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You will find the following symbols in the manual as additional details:
[ ]
u##
Cross reference to a page / a chapter / a section or another document.
Glossary
Terms in grey are explained in detail in the glossary, a chapter at the
end of the manual.
Tip for handling the product.
Required tool.
1.2.5 Representation of warning / general safety information
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All the warning / general safety information in this manual are highlighted with picto-
grams and signal words. The pictogram and the signal word give you information of the
risk level of the danger.
Warning/General Safety Information, which is placed ahead of each activity, are repre-
sented as follows:
CAUTION
Type and source of danger
Consequences of the danger
uMeasures to avert the danger

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1. GENERAL
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1.2.6 Signal words and their meaning in the general safety information
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Refer to these instructions for the following signal words relating to the corresponding
levels of risk:
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.
ENVIRONMENTALLY TIP
ENVIRONMENTALLY TIP – The signal word indicates a hazardous situation without a
high level of risk, which, if not avoided, will result in environmental contamination.