Hydac ContaminationSensor CS1220 VIMS Manual

CS1000 series
ContaminationSensor
for VIMS™ SYSTEM
Operating and maintenance instructions
English
Documentation no.: 3478916
Edition: 15/07/2009

ContaminationSensor CS1000 Trademarks
HYDAC Filter Systems GmbH
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Trademarks
The trademarks of other companies designate the products of those companies
exclusively.
Copyright © 2009 by
HYDAC Filter Systems GmbH
all rights reserved
All rights reserved. This manual may not be reproduced in part or whole, in any
form, without the explicit written agreement of HYDAC Filter Systems. Violations
shall be liable for damages.
Exclusion of liability
We have made every effort to ensure the accuracy of the contents of this document,
however we cannot rule out errors. We do not accept liability for any errors that may
exist nor for any damage or loss whatsoever arising as a result of such errors. The
content of the manual is checked regularly and the necessary corrections are
contained in subsequent editions. We welcome any suggestions for improvement.
All details are subject to technical modification.
The content of these instructions subject to revision without notice.
HYDAC Filter Systems GmbH
Servicetechnik / Filtersysteme
Industriegebiet
66280 Sulzbach / Saar
Germany
Phone: ++49 (0) 6897 / 509 – 01
Fax: ++49 (0) 6897 / 509 – 846

ContaminationSensor CS1000 Content
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Content
Trademarks...........................................................................................................................2
Content .................................................................................................................................3
Preface ..................................................................................................................................5
Technical Support...............................................................................................................6
Product modification ...........................................................................................................6
Warranty.............................................................................................................................6
Using the documentation ....................................................................................................7
General safety guidelines ....................................................................................................8
Obligations and liability .......................................................................................................8
Explanation of symbols and warnings .................................................................................8
Basic symbols .................................................................................................................9
Intended use.......................................................................................................................9
Improper use ......................................................................................................................9
Informal safety precautions...............................................................................................10
Training and instruction of personnel ................................................................................11
Storing ContaminationSensor...........................................................................................12
Storage conditions ............................................................................................................12
Interpreting the type label..................................................................................................13
Checking the scope of delivery.........................................................................................14
CS1220 VIMS Features.......................................................................................................15
CS1000 Restrictions on use..............................................................................................15
CS1x1x dimensions (without display)................................................................................16
Hydraulic connection types ...............................................................................................17
Flange connection type (Type CS1xxx-x-x-x-x-1/-xxx)...................................................17
Fastening / mounting the CS1000.....................................................................................17
CS1000 hydraulic installation............................................................................................18
Selecting the measurement point ..................................................................................19
Flow rate, differential pressure p
∆
and viscosity
ν
characteristics ...............................20
Hydraulic connection of the CS1000 .............................................................................21
Electrical connection of the CS1000 .................................................................................22
Pin assignment..............................................................................................................22
Connection cable - Assignment / Color coding ..............................................................23
CS measurement modes....................................................................................................24
Mode M1: Continuous measurement ................................................................................24
mTIME: measuring period.................................................................................................24
Analog Output ....................................................................................................................25
Status messages................................................................................................................27
Status LED / display..........................................................................................................27
Taking the CS1000 out of operation..................................................................................28
Disposing of CS1000 ........................................................................................................28

ContaminationSensor CS1000 Content
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Spare parts and accessories.............................................................................................28
Cleanliness classes - brief overview.................................................................................29
Cleanliness class - ISO 4406:1999 ...................................................................................29
Table - ISO 4406...........................................................................................................29
Overview of modifications - ISO4406:1987 vs. ISO4406:1999 ......................................30
Application settings / default.............................................................................................31
Power Up menu................................................................................................................31
Measuring menu...............................................................................................................31
Technical data ....................................................................................................................32
Recalibration ......................................................................................................................33
Customer service ...............................................................................................................33
Model code .........................................................................................................................34

ContaminationSensor CS1000 Preface
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Preface
We have compiled the most important instructions for the operation and
maintenance of our product for you, its user, in this documentation.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep it in the vicinity of the product so it is always available.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.
There may be deviations in technical details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have additional
suggestions or notes, contact us at:
HYDAC Filter Systems GmbH
SVFI, Technical Documentation Department
Postfach 12 51
66273 Sulzbach / Saar, Germany
Fax: ++49 (0) 6897 509 846
E-mail: [e-mail]
The editorial board would welcome your contributions.
“Putting experience into practice”

ContaminationSensor CS1000 Preface
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Technical Support
Contact our technical sales department if you have any questions on our product.
When contacting us, always include the model/type designation, serial no. and part-
no. of the product:
Fax: ++49 (0) 6897 509 846
Email: [e-mail]
Product modification
We would like to point out that changes to the product (e.g. purchasing additional
options, etc.) may mean that the information in the operating instructions is no
longer applicable or adequate.
After modification or repair work that affects the safety of the product has been
carried out on components, the product may not be returned to operation until it has
been checked and released by a HYDAC technician.
Report any modifications carried out on the product by you or a third party
immediately.
Warranty
Our warranty applies in accordance with the general terms and conditions of sale
and delivery of HYDAC Filter Systems GmbH.
Refer to these at www.hydac.com General terms and conditions.

ContaminationSensor CS1000 Preface
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Using the documentation
Note that the method described for locating specific information does
not release you from your responsibility of carefully reading these
instructions prior to starting the unit up for the first time and at regular
intervals in the future.
WHAT do I want to know?
I assign the information I require to a subject area.
WHERE can I find the information I’m looking for?
The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.
The documentation no. with index is used for identifying and reordering the
instructions. The index is incremented by one after each revision / modification.
Product description /
Chapter heading
Page number
Edition date
Document language
Documentation no.
with index/
file name

ContaminationSensor CS1000 General safety guidelines
HYDAC Filter Systems GmbH
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General safety guidelines
These operating instructions contain the most important notes for operating the CS
safely.
Obligations and liability
The basic prerequisite for the safe handling and trouble-free operation of the CS is
knowledge of the basic safety guidelines and regulations.
These operating instructions in general, and the safety precautions in particular, are
to be observed by all those who work with the CS.
In addition to this, all local accident prevention instructions and regulations must be
observed.
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. Nonetheless, its use may pose risks to life
and limb of the user or to third parties or damage to the unit or other equipment and
property.
The CS is only to be used as follows:
• Solely for its intended use
• Only when in safe, perfect condition
• Faults or malfunctions which may affect safety adversely must be 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
• modifications to the CS made by the user or purchaser
• improper monitoring of unit components subject to wear and tear
• improperly performed repair work
Explanation of symbols and warnings
The following designations and symbols are used for hazards and warnings in this
manual:

ContaminationSensor CS1000 General safety guidelines
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Basic symbols
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Intended use
The ContaminationSensor (CS) was developed for the continuous monitoring of
particulate contamination in hydraulic systems.
By determining the type, size and quantity of contamination, quality standards can
be verified and documented, and the required optimization measures can be
implemented.
Any other use shall be deemed not in keeping with the product's intended use. The
manufacturer is not liable for any damage resulting from this use.
Intended use of the product also includes:
• Permanent monitoring of solid particle contamination in hydraulic and lubrication
systems
• Maintaining adherence to all the instructions contained herein.
Improper use
Improper use may result in hazard to life and limb.
Examples of improper use:
• Improper connection of the CS voltage and sensor cables.
• Operation with non-approved fluids.

ContaminationSensor CS1000 General safety guidelines
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Informal safety precautions
In addition to the operating instructions, the general and local regulations on
accident prevention and environmental protection are to be made available and
observed.
All safety guidelines and hazard warnings on the CS must be maintained in legible
condition and replaced as required.
Check the:
- Connectors for leakage daily
- Electrical supply lines monthly
Any loose connections or damaged cables are to be replaced immediately.
WARNING
Hydraulic systems are under pressure
Bodily injury
►The hydraulic system must be depressurized
before any work is performed on it.

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Training and instruction of personnel
The CS may only be operated by properly trained and instructed personnel.
Clearly determine which personnel are responsible for what.
Trainees may only use the CS when supervised by an experienced individual.
Individuals Instructed individuals Individuals technical training Electrician Supervisor with the appropriate authority
Activity
Packing Transport X X X
Start-up X X X
Operation X X X X
Troubleshooting X X X
Remedying faults
Mechanical X X
Remedying faults Electrical X X
Maintenance X X X X
Repair work X
Decommissioning /
Storage X X X X

ContaminationSensor CS1000 Storing ContaminationSensor
HYDAC Filter Systems GmbH
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Storing ContaminationSensor
Store the CS in a clean, dry place, in the original packing, if possible. Do not remove
the packing until you are ready to install the unit.
If the CS is to be put into storage for an extended period of time, it should be
completely drained and flushed with Cleanoil to prevent it from gumming up.
After a storage period of 6 months, we recommend flushing with Cleanoil.
Properly dispose of the cleaning agents and flushing oils used.
Storage conditions
Storage temperature -40 °C to +80 °C / -40 °F to +176 °F
Relative humidity: max. 95%, non-condensing

ContaminationSensor CS1000 Interpreting the type label
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Interpreting the type label
For ContaminationSensor identification details; see the type label. This is located on
the top of the unit and contains the exact product description and the serial number.
Row Definition Description
1 CS1220-VIMS Model code
2 Serial no. Always list complete serial no.
3 Max. INLET press.: Max. operating pressure in bar / psi

ContaminationSensor CS1000 Checking the scope of delivery
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Checking the scope of delivery
The ContaminationSensor CS1000 comes packed and factory-assembled, ready for
operation. Before starting up the CS, check that the content of the package is
complete.
The following items are included:
Qty Designation
1 ContaminationSensor, CS1000 Series
(Model in acc. with the order - see type designation code).
2 O-rings (already mounted on the flange)
1 Operating and maintenance instructions CS 1000 (this document)
1 Calibration certificate

ContaminationSensor CS1000 CS1220 VIMS Features
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CS1220 VIMS Features
The CS1220 VIMS ContaminationSensor is a stationary measurement unit for the
continuous monitoring of solid particle contamination in hydraulic and lubrication
systems.
The CS is designed to be used in low- or high-pressure hydraulic and lubrication
circuits and test benches where a small amount of oil (between 30 ml/min and 300
ml/min) is diverted for measurement purposes.
The ContaminationSensor is approved for a maximum operating pressure up to 300
bar (4350 psi) and viscosity of up to 1000 mm²/s.
The particulate contamination is recorded by an optical measurement cell.
The sensor has the following features:
• 4 analog output voltage outputs 0 – 5 V each, 3 for ISO-code and 1 for status
• results are output as a cleanliness code according to:
ISO 4406:1999
• flange installation
The display and the buttons are without function in this model.
CS1000 Restrictions on use
NOTICE
Prohibited operating fluids
The CS will be destroyed.
►Operate the CS1000 only in conjunction with the permitted operating fluids.
►CS 1xx0 is suitable for operation with petroleum or petroleum-based
refinates.
►Observe the maximum operating pressure on the CS 1000 type label.

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CS1x1x dimensions (without display)
12
1
0
6
,
5
100
83
ca
.
1
7
0
25
ISO 228
G1/4
49,2
3
0
A
B
All dimensions in mm.

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Hydraulic connection types
The direction of flow through the CS has to be from bottom to top. Use one port,
D <-> C as the INLET and the other port as the OUTLET. The direction of the flow
depends on the mounting situation.
Flange connection type (Type CS1xxx-x-x-x-x-1/-xxx)
Hydraulic connection is done via ports Cand D. Two O-rings are used to form a seal
between the CS and a flange, connecting plate or manifold mount. Four M6 threads
are prepared for fixing the CS1000. Ports Aand Bare sealed off with screw plugs
[1]. Sealing with the manifold block or mounting plate is done via two O-rings [2]
(4.48 x 1.78 FPM, see Chapter "Spare Parts + Accessories").
[1]
[2]
[1]
C
A
B
D
C D
2
5
1
5
2
0
100
40
60
12/16
4xM6
[2]
The direction of flow has to be from
bottom (C) to top (D).
View from below.
All dimensions in mm.
Fastening / mounting the CS1000
When attaching the CS make sure that the direction of flow is from bottom to top.
Use the one (lower) port as the INLET and the other (upper) port as the OUTLET.
When selecting the installation site, take ambient factors like the temperature, dust,
water, etc. into account.
The CS is designed for IP67 according to DIN 40050 / EN 60529 / IEC 529 / VDE
0470.
Connecting plate or valve manifold mounting:
using 4 cylindrical screws with an M6
hexagonal socket according to ISO4762.

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CS1000 hydraulic installation
The direction of flow through the CS has to be from bottom to top. Use one
connection port as the INLET and the other as the OUTLET.
Depending on your order, the CS features the following hydraulic connection types:
(also see Chapter "Hydraulic connection types"):
• Flange connection - The CS is screwed to a flange, connecting plate, manifold
mount or control block, with flow through the unit via ports Cand Don the
bottom.
Ports Aand Bexist but are sealed with a screw plug.
Specify the operating pressure of the hydraulic system so the permissible flow for
the CS inlet is achieved.
NOTICE
Working overpressure
The CS will be destroyed.
►Observe the maximum operating pressure on the CS 1000 type label.

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Selecting the measurement point
Proceed carefully when selecting a suitable measuring point in order to obtain
cleanliness values that are continuous and coherent in real time.
A
B
2
A
B
1
3
A
2
1
B
INCORRECT INCORRECT OK
1
The test point has to be selected so that the measured volume is taken
from a turbulent flow area, e.g. a pipe bend.
2
The CS has to be installed in the vicinity of the test point in order to obtain
precision-timed results.
3
While installing the measurement line, avoid creating a "siphon" trap for
sedimentation (particle deposits in the line).

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Flow rate, differential pressure p
∆
and viscosity
ν
characteristics
Differential pressure p
∆
and viscosity
ν
characteristics. All the values indicated in
the figures below apply regardless whether the direction of flow is A->B or B->A.
The permissible measured volumetric flow must be between 30 ml and 300 ml/min.
If you are unable to achieve these flow values, we carry various
ConditioningModules in our extensive line of accessories.
20
Qmin=30ml/min
100ml/min
160ml/min
Qmax=300ml/min
0
10
20
30 40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
20
0
18
16
14
12
10
8
6
4
2
0
p
[
b
a
r
]
∆
[mm /s]
ν
2
1 bar
46 mm /s
2
50
Qmin=30ml/min
100ml/min
Qmax=300ml
/
m
i
n
200 300
400
500
600
700
800
900
100
0
45
40
35
30
25
20
15
10
5
0
160ml/min
p
[
b
a
r
]
∆
[mm /s]
ν
2
For example:
You are using a fluid with a viscosity
ν
of 46 mm²/s at a differential pressure p
∆
of
1 bar, so that you achieve a flow rate of approx. 100 ml/min.
The flow rate depends on the viscosity of the medium and the differential pressure
p
∆
via the sensor.