HYDAC International AquaSensor AS 8000 Series User manual

AquaSensor
AS 8000 series
Operating Manual
Doc.: 3215331b

AquaSensor - AS 8000 series
HYDAC Filtertechnik GmbH en Page 2
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Trademarks
The trademarks of other companies are exclusively used for the products of those
companies.
Copyright © 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
We 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. We welcome any suggestions for improvements.
All details are subject to technical modifications.
Technical specifications are subject to change without notice.
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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Contents
Preface ....................................................................................................................................5
Customer Service .................................................................................................................6
Modifications to the Product .................................................................................................6
Warranty 6
1General Safety Precautions ........................................................................................... 8
1. General Safety Guidelines..............................................................................................8
1.1. Obligations and Liability.............................................................................................8
1.2. Explanation of Symbols and Warnings......................................................................8
1.2.1. Basic Symbols ......................................................................................................9
1.3. Proper/Designated Use .............................................................................................9
1.4. Improper Use.............................................................................................................9
1.5. Informal Safety Precautions ......................................................................................9
1.6. Training and Instruction of Personnel......................................................................10
1.7. Safety Measures to Be Followed during Normal Operation.....................................10
1.8. Electrical Hazards.................................................................................................... 11
1.9. Maintenance, Servicing and Troubleshooting .........................................................11
1.10. Modifications to the AS 8000................................................................................... 11
2Storage and Transport.................................................................................................. 11
3Items Delivered.............................................................................................................. 12
4 Product description ......................................................................................................13
4.1 Function Description .............................................................................................13
4.2 Zero correction / Calibration ....................................................................................13
4.3 Restrictions Pertaining to the CS ..........................................................................14
4.4 Dimensions.............................................................................................................. 14
4.4.1 Sensor................................................................................................................. 14
4.4.2 Control Unit .........................................................................................................14
5Mounting and Connections.......................................................................................... 15
5.1 Overview.................................................................................................................. 15
5.2 AS 8000 Control Unit............................................................................................... 16
5.3 AS 8000-Sensor ......................................................................................................16
5.3.1 Sensor - Installation circumstances in a pipe...................................................... 16
5.3.2 Sensor - Installation circumstances in a tank...................................................... 17
5.3.3 Sensor - minimum distance for ambient installation............................................17
5.4 Electrical Installation................................................................................................17
5.4.1 Voltage supply .................................................................................................... 18
5.4.2 RS232 interface ..................................................................................................18
5.4.2.1 Interface parameters for transfers via RS232............................................ 18
5.4.3 RS485 interface ..................................................................................................19

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5.4.4 Analog Outlet ......................................................................................................19
5.4.5 „Ready“ Relay .....................................................................................................19
5.4.6 Alarm Relay......................................................................................................... 20
5.4.7 Digital Input .........................................................................................................20
5.4.8 Sensor 1 / Sensor 2 ............................................................................................ 20
6Commissioning .............................................................................................................21
6.1 Basic settings ..........................................................................................................21
6.2 First Commissioning ................................................................................................21
6.3 Turning on and Commissioning............................................................................... 21
7Operation .......................................................................................................................22
7.1 Setup and Installation .............................................................................................. 22
7.2 Operating................................................................................................................. 23
7.2.1 Parameter Menu .................................................................................................24
7.2.2 System constants menu...................................................................................... 24
7.2.2.1 System constants menu - sensor ..............................................................25
7.2.2.2 System constants menu - Control Unit ......................................................26
7.2.2.2.1 Settings of the analog 4-20 mA interface............................................... 26
8Error codes / Troubleshooting..................................................................................... 27
8.1 Error of the electronic temperature probe in the AS 8000 sensor ........................27
8.2 AS 8000 -Sensor Error ...........................................................................................27
8.3 Simultaneous errors of both systems .....................................................................27
9 Maintenance / Repairs ..................................................................................................28
10 Shutdown .......................................................................................................................28
10.1 Temporary shutdown ...............................................................................................28
10.2 Final Decommissioning / Disposal ...........................................................................28
11 Technical Details........................................................................................................... 28

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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 ins and outs 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. Documentation
Post box 1251
66273 Sulzbach / Saar
Fax: ++49 (0) 6897 509 846
Email: [email protected]
The editor would welcome your involvement.
Our motto: “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 article 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 Conditions of Sale and
Delivery of HYDAC Filtertechnik GmbH.
They are available at: www.hydac.com => E-Business => Legal information.

AquaSensor - AS 8000 series
... 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?
Page through the operating instructions, keeping your eyes focused on the lower right
corner.
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.
Product Designation
Page no.
Edition date
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:
Documentation no. Index
BeWa Product 12345678a en
-
The documentation no. is a p/no. which is used to order the instructions.
The index is increased every time the instructions are revised or changed.
Please note that the method described above of locating specific information
does not release you from your responsibility for carefully reading the entire
manual prior to starting the unit up for the first time and carefully rereading the
manual at regular intervals later on.
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1 General Safety Precautions
There are no particular dangers inherent in the measurement equipment. Damage to the
measurement cable will cause the sensor to break down, but there are no dangers of
electrical shock.
1. General Safety Guidelines
These operating instructions contain the key instructions for properly and safely operating the
AS 8000.
1.1. Obligations and Liability
• The basic prerequisite for the safe and proper handling and operation of the AS 8000 is
knowledge of the safety instructions and warnings.
• These operating instructions in general, and the safety precautions in particular, are to be
adhered by all those who work with the AS 8000.
• Adherence is to be maintained to pertinent accident prevention regulations applicable at
the site where the product is used.
• The safety precautions listed herein are limited solely to using the AS 8000.
The AS 8000 is designed to comply with latest technological and safety standards.
Nevertheless, hazards may be posed to the life and limb of the individual using the unit or to
third parties. Risk of damage may be posed to the unit or other equipment and property. The
AS 8000 is only to be used as follows:
• for the specified correct usage
• only when in a safe, perfect condition
• Any faults or malfunctions which might impair safety are to be properly repaired or
remedied immediately.
Our General Terms and Conditions apply. They are made available to the owner upon
concluding purchase of the 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 AS 8000
• Improper assembly, installation, commissioning, operation and maintenance of the AS
8000
• Operating the AS 8000 when the system equipment or systems are defective
• Modifications to the AS 8000 made by the user or purchaser
• improper monitoring of unit components subject to wear and tear
• improperly performed repair work
1.2. Explanation of Symbols and Warnings
The following designations and symbols are used in this manual to designate hazards, etc.:

AquaSensor - AS 8000 series
1.2.1. Basic Symbols
This symbol designates safety instructions whose non-observance may pose
a hazard to individuals.
This symbol denotes safety precautions, the non-observance of which can
endanger persons by electrical shock.
This symbol provides important instructions and tips for the proper handling
and operation of the AS 8000.
Non-adherence to these instructions may result in damage to the AS 8000 or
in damage to its immediate surroundings.
This symbol indicates tips for usage and other particularly useful information.
This information helps you to optimally utilize all the features offered by your
AS 8000.
1.3. Proper/Designated Use
The AquaSensor AS 8000 was developed for the continuous monitoring of free water in
hydraulic systems.
By analyzing the amount of free water, quality standards can be verified and documented,
and the requisite optimization measures can be implemented.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
Proper or designated use of the product extends to the following:
• Maintaining adherence to all the instructions contained herein.
1.4. Improper Use
Any use deviating from the proper/designated use described above is prohibited.
Improper use may result in hazard to life and limb.
1.5. Informal Safety Precautions
Make sure to always keep the operating instructions in the vicinity of the product.
Apart from the operating instructions, any and all general and local regulations pertaining to
accident prevention and environmental protection are to be made available and observance
to be maintained to them.
Make sure to keep the safety and hazard symbols and warnings on the AS 8000 in a legible
condition.
Check the AquaSensor and its connection fittings daily for impermeability (visual check).
The electrical components of the AS 8000 are to also be regularly checked (visual check
once a month). Any loose connections or damaged cables are to be replaced immediately.
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AquaSensor - AS 8000 series
Caution: Pressurized fluids can pose a hazard to life and limb.
Consequently, the safety regulations pertaining to working with
pressurized liquids are to be adhered to at all times!
1.6. Training and Instruction of Personnel
The AS 8000 may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the AS 8000 unless supervised by an experienced
staff member.
Individuals
Activity
Individuals
undergoing
training
Individuals
with
technical
training/engi
neering
background
Electrician Supervisor
with the
appropriate
authority
Packing
Transportation X X X X
Commissioning X X X
Operation X X X X
Troubleshooting /
locating the
source of
malfunction
X X X
Troubleshooting,
mechanical
problem
X X
Troubleshooting,
electrical
problem
X X
Maintenance X X X X
Repair work X
Decommissionin
g / Storage X X X X
1.7. Safety Measures to Be Followed during Normal Operation
The product is to be checked once a day for external damage and the proper functioning of
the safety devices.
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1.8. Electrical Hazards
Any work involving the power supply may only be done by a properly trained, certified
electrician.
Make sure to check the electrical equipment of the product on a regular basis. Any loose or
scoured cables are to be remedied/replaced immediately.
If work on live components is required, a second individual should be present to switch off
the unit if necessary.
1.9. Maintenance, Servicing and Troubleshooting
Regular inspections are not necessary. When servicing and installing the units, you should
check for damages to the connections and cables.
When performing any maintenance, servicing, inspection or repair work, disconnect the AS
8000 from the power supply and ensure that it cannot be switched back on inadvertently.
Check any screwed fittings which have been removed to see that they have been properly
resecured.
1.10. Modifications to the AS 8000
Do not make any modifications (design modifications, extensions) to the AS 8000 without the
prior consent of the manufacturer.
Any design modifications or extensions may not be made without HYDAC Filtertechnik
GmbH’s express prior written approval.
Only use original (OEM) spare parts and consumables. When using non-OEM components,
it cannot be ensured that they have been designed and manufactured so as to comply with
loading and safety requirements.
2 Storage and Transport
There are no special precautions for transporting and storing the unit. For longer storage
periods, it should be kept dry and protected from frost.

AquaSensor - AS 8000 series
3 Items Delivered
The AquaSensor AS 8000 comes packed and ready for use. Before commissioning the AS
8000, check that the package contents are complete.
The following items are supplied:
Item Quantity Designation
1 1 AS 8000 Control Unit
2 1 AS 8000 Sensor
3 1 Connection cable, l= 8 m
- 1 Operation and Maintenance Instructions (this document)
1
3
2
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4 Product description
The AquaSensor AS 8000 was developed for the continuous monitoring of free water in
hydraulic systems in %.
4.1 Function Description
The AS 8000 Sensor measures the deviation of the emulsion dielectric from the measured
values of the pure fluid components. This measured value is transmitted to the AS 8000
Control Unit and made available for further analysis at interfaces. The measured values can
be exported directly to a computer in a terminal program on an 4-20 mA interface, to an RS
485 interface, or to a relay contact for READY/ALARM.
4.2 Zero correction / Calibration
Zero correction calibrates the sensor to a dry mineral oil. To do this, dip the sensor in a
repository with a correspondingly dry reference oil and proceed with the zero correction as
described below.
The digital input (0 -1) can be occupied with a potential-free contact. After the contact has
been closed for 2 seconds, it can be opened, and the zero correction for sensors 1 and 2 can
take place. The zero correction can either be done by hand with a switch or with a PLC.
The zero correction should be done after installation, after an oil change in a lubrication
system, or after changing oil type, for example.

AquaSensor - AS 8000 series
4.3 Restrictions Pertaining to the CS
The AS 8000 may only be used with mineral oils (or raffinates whose basis is
mineral oil).
Please contact us first before using the unit with other fluids.
4.4 Dimensions
4.4.1 Sensor
4.4.2 Control Unit
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5 Mounting and Connections
5.1 Overview
Connect the AS 8000 Control Unit according to the following diagram.
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AquaSensor - AS 8000 series
5.2 AS 8000 Control Unit
The Control Unit is designed for mounting on a top hat rail in a switch cabinet. The Sensor
and Control Unit are connected with the measurement data cable
All connections to the AS 8000 Control Unit, aside from the electrical supply, should
be protected ! The corresponding EMV directives must be followed.
The charge on the relay contacts must not exceed 60 V / 250 mA.
The GROUND connections should be in contact with the grounding as frequently, and with
the shortest cable, as possible.
The protection class of the Control Unit is in accordance with EN 60529 = IP 20.
5.3 AS 8000-Sensor
The Sensor has the protection class IP 67 and can be mounted directly on hoses or pipes or
tanks.
The Sensor should be securely and tightly sealed with an appropriate sealing material, e.g.
Loctite 572, in a G3/4" pipe thread bushing or in a tank wall, gauge approx. 12-15 mm.
5.3.1 Sensor - Installation circumstances in a pipe
In order that it can continuously measure current values in the fluid, the Sensor should be
installed in a pipe according to the following installation examples.
When selecting a location for installation, make sure that no gas or air bubbles will be able to
collect on the Sensor
The Sensor is installed into the pipe from the outside.
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AquaSensor - AS 8000 series
5.3.2 Sensor - Installation circumstances in a tank
In order that it can continuously measure current values in the fluid, the Sensor should be
installed in a tank according to the following installation examples.
It is preferable that the AS 8000 Sensor be installed in a flange that is tightly screwed or
welded to the tank wall. The flange should have a gauge of approx. 15 mm. For pressure
tanks, observe the proper regulations regarding the minimum gauge for flanges.
Rücklauf
Return line
AS 8000 Sensor
5.3.3 Sensor - minimum distance for ambient installation
min. 200 mm
5.4 Electrical Installation
The measurement cable should be protected from mechanical strain.
The system must be wired according to the corresponding VDE regulations. To guarantee a
trouble-free operation, protected signal cables should be used. Take care that the cables in
the switch cabinet are extensively protected. It is recommended you use EMV screw
connections for this purpose.
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AquaSensor - AS 8000 series
5.4.1 Voltage supply
Switch on the power supply with the "Power" connection.
Check for the correct polarity !
5.4.2 RS232 interface
The RS232 interface can be joined directly to a serial interface
or converter with a USB interface on a computer (9-pole
connector male - female). A terminal program such as
Hyperterminal, which is part of the standard delivery with MS
Windows operating systems, can read the instantaneous values
on the Sensors and set the parameters and thresholds of the AS
8000 Control Unit.
5.4.2.1 Interface parameters for transfers via RS232
Bits per second.................................................9600 Baud
.........................................................................Databit 8
.........................................................................Parity none
.........................................................................Stop bits 1
.........................................................................Handshake /
Protocol / Flow control......................................none
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AquaSensor - AS 8000 series
5.4.3 RS485 interface
Several AS 8000 Control Units or other analysis devices, as well
as bus-compatible sensors, can be linked and connected to a
computer via the RS485 interface.
If the computer has only one RS232 interface, a RS485/RS232
converter is required to convert the RS485 signals to RS232
signals.
If the computer has only one USB port, a RS 485/USB converter
is required to convert the RS485 signals to a USB signal.
5.4.4 Analog Outlet
Both electric outputs 4-20 mA (with 1 output for each AS 8000
Sensor) can be connected with a remote indication of the
sensitivity 4-20 mA, where 4 mA corresponds to a pure
component A with 0% component B, and 20 mA corresponds to
a selected mixture ratio of the components A and B (see
parameter menu, parameter view, figure 6).
If there is a sensor error, a current of 2 mA will flow. 25 mA will
flow if the mixture ratio of the components A and B is greater
than the ratio entered in the parameters menu.
5.4.5 „Ready“ Relay
The relay READY is activated (with COM and NO switched on)
when no system error exists. The system errors are displayed on
the RS232 interface in the terminal program.
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AquaSensor - AS 8000 series
5.4.6 Alarm Relay
The alarm relays are activated when the water content
programmed into a sensor's parameters menu is exceeded.
Relay Alarm 1 corresponds to AS Sensor 1 and Relay Alarm 2
corresponds to AS 8000 Sensor 2. The alarm limit must be
exceeded for the 10 following measurements, and then the
alarm relay will be turned on for 10 seconds.
5.4.7 Digital Input
A rule alignment is carried out by the "Digital Input".
The measured values do not have to be entered by hand; rather,
the characteristics of the sensors are automatically aligned.
See Chapter 7.2.2 for more details
5.4.8 Sensor 1 / Sensor 2
Use the cable with plug included in delivery to connect the
sensors.
The cable codification is as follows:
0 = black
E = red
T = brown
Make sure that the plug is not exposed to constant humidity.
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