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–…
<placeholder> title image
Instruction manual
4622814 / 2023-03
EN
4622814 / 2023-03
Translation of original operating instructions/source language: German
©2023HYDAC 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, HYDACInternationalGmbH, Industriegebiet, D‑66280Sulzbach/Saar, [email protected]
UKCA - Authorized representative of the manufacturer:
HYDACTechnologyLimited, DeHavillandWay, WindrushParkWitney, OxfordshireOX290YG, UnitedKingdom
EN
TABLE OF CONTENTS
4622814 / 2023-03 3/156
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
EN
TABLE OF CONTENTS
4/156 4622814 / 2023-03
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
EN
TABLE OF CONTENTS
4622814 / 2023-03 5/156
7.9 Using / evaluating the analog output - ANA.OUT............................................... 80
7.9.1 SAE classes according to AS4059...................................................... 81
7.9.1.1 SAE .................................................................................... 82
7.9.1.2 SAE.MAX............................................................................ 83
7.9.1.3 SAEA / SAEB / SAEC / SAED........................................ 84
7.9.1.4 SAE+T ................................................................................ 85
7.9.1.5 HDA.SAE............................................................................ 87
7.9.2 ISO code according to ISO4406 >4µm, >6µm, >14µm ................. 91
7.9.2.1 ISO4 / ISO6 / ISO14 ........................................................ 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 ISO4406 >2µm, >5µm, >15µm (only
CS13xx)................................................................................................
99
7.9.3.1 ISO2 / ISO5 / ISO15 ........................................................ 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 NAS1638 NationalAerospaceStandard
(only CS13xx).......................................................................................
106
7.9.4.1 NAS .................................................................................... 107
7.9.4.2 NAS.MAX ........................................................................... 109
7.9.4.3 NAS2 / NAS5 / NAS15 / NAS25 ..................................... 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 HDA5500....................................... 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
EN
TABLE OF CONTENTS
6/156 4622814 / 2023-03
11.5 Overview and definition of the cleanliness classes ............................................ 137
11.5.1 Cleanliness classes according to ISO4406 ......................................... 137
11.5.2 Cleanliness classes according to SAEAS4059 ................................... 140
11.5.3 Cleanliness classes according to NAS1638........................................ 142
Glossary .......................................................................................................................... 149
Index ............................................................................................................................... 151
EN
1. GENERAL
4622814 / 2023-03 7/156
1. General
715128459
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
36028797159348747
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
81064793435152267
You will find illustrations in this manual. You can find details regarding these in the
following chapters.
1.2.1 Representation of requirements
9007199396286475
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
8/156
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
142019083
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
4622814 / 2023-03 9/156
1.2.4 Supplementary symbols
45035996415770251
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
769631883
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
EN
1. GENERAL
10/156
1.2.6 Signal words and their meaning in the general safety information
768384523
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.
EN
1. GENERAL
4622814 / 2023-03 11/156
1.3 Exclusion of liability / warranty
99079191859259787
For the warranty provided by us, please refer to our terms of delivery. They are made
available to you at the conclusion of the contract at the latest. In addition, you will find
these under www.hydac.com -> General terms and conditions .
This manual was prepared to the best of our knowledge. Nevertheless and despite the
greatest care, it 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.
1.4 Notes on copyright
54043195578747019
The copyright for this manual remains with the manufacturer. No part of this manual
may be reproduced in any form without the written consent of the manufacturer or
processed or distributed using electronic systems. Any infringements to the above will
result in compensation for damage.
EN
2. SAFETY
12/156
2. Safety
490566155
The product is designed as safe. In spite of that, there is danger in some actions that
can only be avoided by using the right procedures.
These correct procedures and points, which must be followed, are described in this
manual.
2.1 Target group / Required personnel qualification
63050394831353355
These instructions are intended for owners, project engineers, startup engineers,
machine operators, service and maintenance personnel.
The instructions explain the proper handling of the product to the abovementioned
target group. These instructions provide the target group with an overview of the instal-
lation, commissioning, operation, maintenance work and also troubleshooting on the
product.
An owner is the person who operates the product himself/herself for commercial or
economic purposes or provides it to a third party for use / application and bears the
legal product responsibility to protect the user, the personnel or the third party.
The obligations of the owner are:
● To know and apply the applicable health and safety regulations
● To determine the hazards arising at the operating site in the risk assessment
● To create a user manual for the operation
● To regularly check if the user manual is consistent with the current rules
● *To clearly lay down and define the responsibilities for the installation, operation,
troubleshooting, maintenance and cleaning
● To ensure that all the employees have read and understood the instructions
● To train the personnel at regular intervals and to inform them of the hazards
● To provide the necessary protective equipment to the personnel
Personnel who work with the product must be aware of the dangers involved in handling
it, must be over 14 years of age and must be without any physical impediments in
regard to the industrial environment.
These instructions are intended for:
Activity Personnel Knowledge
Transport,
storage
Specialist
personnel -
General
Knowledge of transport safety is
required
Installation Specialist
personnel -
Mechanical
Specialist
personnel - Elec-
trical
Safe handling/use of tools.
Product-specific knowledge is
required.
EN
2. SAFETY
4622814 / 2023-03 13/156
Activity Personnel Knowledge
Commissioning Specialist
personnel -
Mechanical
Specialist
personnel - Elec-
trical
Safe handling/use of tools.
Product-specific knowledge is
required.
Handling,
operation,
operation monitoring
Operating
personnel -
General
Product-specific knowledge is
required.
Knowledge about handling the oper-
ating fluid/operating medium is
required
Troubleshooting Mainte-
nance Decommissioning,
Disassembly
Specialist
personnel -
Mechanical
Specialist
personnel - Elec-
trical
Safe handling/use of tools.
Product-specific knowledge is
required.
Disposal Specialist
personnel -
General
Knowledge of environmentally friendly
disposal of materials, auxiliary and
operating materials is required.
Knowledge of decontamination of
contaminants is required.
Knowledge of recycling is required.
Transport
Installation,
Commissioning,
Operation,
Troubleshooting
Maintenance
Disposal
Specialist
personnel -
Administrator
Trained and
appointed by the
owner.
Maintenance and repair personnel /
Service personnel /
Administrator.
Extensive experience of the product.
transport Commissioning,
Operation, Troubleshooting
Maintenance Disposal
Specialist
personnel -
Service / Admin-
istrator
Service personnel /
Administrator /
HYDAC Service.
Extensive detailed experience of the
product.
Tab.2:
Target group / Required personnel qualification
EN
2. SAFETY
14/156
2.2 Hazard symbols / pictograms
505626251
The following are the safety symbols / pictograms in this manual. They indicate specific
dangers to persons, property or to the surroundings. Observe these safety symbols /
pictograms and act with particular caution in such cases. Always keep all symbols /
pictograms complete and legible.
Warning signs used
These marks can be found for all safety and warning instructions in this manual which
indicate particular dangers to persons, property or the environment.
Danger point warning
Signs used for giving orders
These symbols can be found for all safety and warning instructions in this manual which
indicate particular dangers to persons, property or the environment.
Follow the direction.
Follow the instructions.
Used GHS symbols
These symbols can be found for all safety and warning instructions in this manual which
indicate particular dangers to persons, property or the environment.
Hazardous to the environment
Signs used for the required specialist personnel
These symbols show the required training/knowledge for installation work and/or main-
tenance work.
Specialist personnel – General / Operating personnel
These persons have a specialist training and several years of work expe-
rience. They are able to assess and perform the work assigned to them
and they are also able to detect potential dangers.
Specialist personnel - Electrical
These persons have specific specialist training and several years of work
experience. They are able to assess and perform the work assigned to
them and they are also able to detect potential dangers.
EN
2. SAFETY
4622814 / 2023-03 15/156
Specialist personnel - Mechanical
These persons have specific specialist training and several years of work
experience. They are able to assess and perform the work assigned to
them and they are also able to detect potential dangers.
Specialist personnel - Service / Administrator
These persons have been trained by the manufacturer and are authorized
to perform service.
2.3 Danger notifications
505741067
The following residual risks can occur in the various life phases of the product:
Life phase - Transport / Storage
The following risks could arise during the commissioning / operation life phase:
NOTICE
Unsafe transport
The connection plug will be damaged.
uTransport the sensor in its original packaging.
uSecure the sensor during transport.
Life phase - Commissioning / Operation
The following risks could arise during the commissioning / operation life phase:
DANGER
Danger due to unintended use
Bodily injury / Damage to property
uUse the product only with permitted operating media and only under
permissible operating conditions.
NOTICE
Impermissible operating conditions or operating fluid.
The product will be damaged.
uTake note of the permitted operating fluid.
uNote the permissible operating conditions.
EN
2. SAFETY
16/156
2.4 Observing environmental precautions
45035996541652875
Take all measures to protect the environment. Ensure that no operating medium is
released into the environment (soil or water).
Environmentally tip
Operating fluid/operating medium is released into the soil or water
Environmental hazard
uRemove any escaped operating fluid/operating medium immediately
and dispose of it in an environmentally sound manner.
2.5 Observing regulatory information
9007199302626571
Observe the following regulatory information and directives:
● Legal and local regulations for accident prevention
● Legal and local regulations for environmental protection and environmental require-
ments
● Country-specific regulations, organization-specific regulations
● Occupational safety rules
EN
3. PRODUCT AND TECHNICAL SPECIFICATIONS
4622814 / 2023-03 17/156
3. Product and technical specifications
490568075
The CS1000 series of the ContaminationSensor is a stationary measuring instrument
for the continuous monitoring of solid particle contamination in a hydraulic or lubrication
system.
The ContaminationSensor is designed to be used in low and high-pressure circuits and
on test benches where a small amount of oil is used for measurement purposes.
Particulate contamination is detected with an optical measurement cell
The ContaminationSensor is available with the following options:
● With or without 6-digit display with keypad (can be rotated by 270°)
● With a 4…20mA or 2…10volt analog output
● Measured values are output as cleanliness class according to:
– ISO4406 >4µm, >6µm, >14µm and SAEAS4059 or
– ISO4406 >2µm, >5µm, >15µm and NAS or
– ISO4406 >4µm, >6µm, >14µm and SAEAS4059
● Pipe/Hose installation or flange installation
All the models have an analog output and an RS485 interface for displaying the
measured contamination level. In addition, all the CS1000s have a switching output.
EN
3. PRODUCT AND TECHNICAL SPECIFICATIONS
18/156
3.1 Intended Use
490572299
Use the sensor only for the application described below.
The ContaminationSensor serves to continuously monitor solid particle contamination in
hydraulic and lubrication systems.
Use the sensor only in conjunction with permitted operating media and only under
permitted operating conditions, see .▶Sec.3.4 "Technical data"
Proper or designated use of the product extends to the following:
● Observing all instructions in the instruction manual.
● performing inspection and maintenance work.
HYDAC is not responsible for the installation, integration, selection of interfaces for / in
your system, for the use and functionality in your system.
Claims for defects or liability – regardless of the legal foundation – do not apply with
incorrect or improper installation, commissioning, usage, handling, storage, mainte-
nance, repair, use of unsuitable components or other circumstances for which the
manufacturer is not responsible.
The manufacturer assumes no responsibility for determining the interfaces for instal-
lation in a system or the installation, use or functionality of the product in this system.
NOTICE
Impermissible operating conditions or operating fluid.
The product will be damaged.
uTake note of the permitted operating fluid.
uNote the permissible operating conditions.
EN
3. PRODUCT AND TECHNICAL SPECIFICATIONS
4622814 / 2023-03 19/156
3.2 Improper use or use deviating from intended use
490574219
Any other use or extended use shall not be considered intended use.
HYDACFILTERSYSTEMSGMBH will assume no liability for any damage resulting
from such use. This risk is borne solely by the owner.
Improper use or use deviating from intended use may result in hazards and/or will
damage the sensor. Examples of improper use include:
● Operation in potentially explosive atmospheres.
● Operation with a non-approved operating medium.
● Operation under non-approved operational conditions.
● Modifications to the sensor made by the user or purchaser.
● Inadequate monitoring of parts that are subject to wear and tear.
● Improperly performed repair work.
DANGER
Danger due to unintended use
Bodily injury / Damage to property
uUse the product only with permitted operating media and only under
permissible operating conditions.
EN
3. PRODUCT AND TECHNICAL SPECIFICATIONS
20/156
3.3 Checking the scope of delivery
490570379
Here you will find the scope of delivery for the product.
● Check the packaging and the product for damage.
Report any damage in transit to the forwarding agent or the HYDAC department in
charge.
● Check the scope of delivery for completeness.
The following items are included in the scope of delivery:
Qty. Description
1 CS1000 series ContaminationSensor
(model depending on the order - see model code)
2 O-ring (Ø4.8*1.78mm, 80Shore)
(Only with the
flange connection
type of connection=model code:
CS1xxx-x-x-x-x-1/-xxx)
1 CD with operation and maintenance instructions for CS1000
(this document in various languages)
1 CD with software for FluMoS (FluidMonitoringSoftware)
1 Quick start manual
1 Certificate of calibration
Tab.3:
Checking the scope of delivery
CS1x2x
CS1x1x
Fig.1:
Checking the scope of delivery
Other manuals for CS1000 Series
3
Table of contents
Other HYDAC International Accessories manuals
