Hydac CS 1000 Series Troubleshooting guide

CS1000 series
ContaminationSensor
Operation and Maintenance Instructions
German (Original Instructions)
Valid from:
- Firmware version V 3.00
- Hardware index F
- Serial number: 0002S01515K0004000
Keep for future reference.
Document no.: 3764916d

Imprint
Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive director:
Mathias Dieter,
Dipl.Kfm. Wolfgang Haering
Documentation representative
Mr. Günter Harge
c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
© HYDAC FILTER SYSTEMS GMBH
All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.
All details are subject to technical modifications. Technical specifications are
subject to change without notice.
The trademarks of other companies are exclusively used for the products of
those companies.
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Content
Content
Imprint............................................................................................................2
Documentation representative ....................................................................2
Content ..........................................................................................................3
Foreword .......................................................................................................8
Technical Support........................................................................................8
Modifications to the Product ........................................................................8
Warranty......................................................................................................8
Using the documentation.............................................................................9
Safety Information ......................................................................................10
Hazard symbols.........................................................................................10
Signal words and their meaning in the safety information and
instructions ................................................................................................11
Structure of the safety information and instructions...................................11
Observe regulatory information .................................................................12
Proper/Designated Use .............................................................................12
Improper Use or Use Deviating from Intended Use...................................13
Qualifications of personnel / target group..................................................14
Storing the sensor......................................................................................16
Decoding the type label..............................................................................16
Checking the scope of delivery.................................................................17
CS1000 Characteristics..............................................................................18
CS1x1x dimensions (without display)........................................................19
CS1x2x dimensions (with display).............................................................19
Fastening/Mounting the sensor.................................................................20
Continuous rotation of sensor display .....................................................21
Hydraulic sensor connection.....................................................................22
Selecting connection type according to sensor type..................................23
Pipe or hose connection (type CS1xxx-x-x-x-x-0/-xxx)...........................23
Flange connection type (Type CS1xxx-x-x-x-x-1/-xxx)...........................24
Selecting measurement location at the hydraulic systems........................25
Flow rate, differential pressure
p
∆
and viscosity
ν
characteristics...........26
Connecting hydraulic sensor .....................................................................27
Electrical connection of sensor.................................................................28
Pin assignment..........................................................................................28
Connection cable - Assignment / Color coding..........................................29
Connecting cable ends - Examples...........................................................30
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Content
Setting the measuring mode......................................................................31
Mode M1: Continuous measurement.........................................................31
Mode M2: Continuous measurement and switching..................................31
Mode M3: Filter to cleanliness class and stop...........................................31
Mode M4: Filter to continuously monitor cleanliness class........................32
Mode "SINGLE": Single measurement......................................................33
Operating the CS1x2x sensor using the keypad......................................34
Function of the Keys..................................................................................35
Measured variables on the display............................................................36
ISO (Cleanliness class)..........................................................................36
SAE (Cleanliness class).........................................................................36
NAS (Cleanliness Class - CS 13xx only)................................................36
Service variables on the display................................................................37
Flow (flow rate).......................................................................................37
Out (Analogue output)............................................................................37
Drive (performance of the LED)..............................................................37
Temp (Temperature)..............................................................................37
Activate / deactivate keypad lock...............................................................38
Display settings.....................................................................38
Activating display ...............................................................39
Deactivating display...........................................................40
Menus and Mode.......................................................................................40
PowerUp Menu.......................................................................................41
Measuring Menu (CS12xx).....................................................................45
- Display after sensor is switched on ...............................46
– Configure switching output...........................................47
M1 – Continuous measurement.......................................................47
M2 – Continuous measurement and switching................................47
M3 – Filter to cleanliness class and stop .........................................48
M4 – Filter to continuously monitor cleanliness class......................48
SINGLE - Start single measurement + stop.....................................49
- Set output signal on analogue output ...........................49
Measuring Menu (CS 13xx).......................................................................51
- Display after sensor is switched on ...............................52
– Configure switching output...........................................53
M1 - Continuous measurement........................................................53
M2 – Continuous measurement and switching................................53
M3 - Filter to cleanliness class and stop..........................................54
M4 - Filter to continuously monitor cleanliness class.......................55
SINGLE - Start single measurement + stop.....................................55
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Content
- Set output signal on analogue output ...........................56
Overview of menu structure ......................................................................57
Menu CS 12xx (ISO 4406:1999 and SAE).................................................57
Menu CS 13xx (ISO 4406:1987 and NAS / ISO4406:1999 und SAE
4059) .........................................................................................................59
Menu CS 13xx (ISO 4406:1987 and NAS / ISO4406:1999 und SAE
4059) .........................................................................................................61
Using switching output..............................................................................63
Mode M1: Continuous measurement.........................................................63
Mode M2: Continuous measurement and switching..................................63
Mode M3: Filter to cleanliness class and stop...........................................63
Mode M4: Filter to continuously monitor cleanliness class........................63
Mode " ": Single measurement ................................................63
Setting limit values.....................................................................................64
Reading the analog output.........................................................................66
SAE - classes acc. to AS 4059..................................................................67
SAE A-D.................................................................................................69
SAE classes A / B / C / D .......................................................................70
SAE A / SAE B / SAE C / SAE D............................................................71
SAE + T..................................................................................................72
HDA.SAE – Analog signal SAE for HDA 5500 .......................................73
HDA.SAE Signal 1/2/3/4.........................................................................74
HDA.SAE Signal 5 (Status)....................................................................75
ISO code according to ISO 4406:1999......................................................77
ISO 4 / ISO 6 / ISO 14............................................................................78
ISO Code, 3-digit....................................................................................79
ISO + T...................................................................................................80
HDA.ISO – Analog signal ISO for HDA 5500 .........................................81
HDA.ISO Signal 1/2/3/4..........................................................................82
HDA.ISO Signal 5 (Status).....................................................................83
ISOISO code signal acc. to ISO 4406:1987 (CS 13xx only)......................85
ISO 2 / ISO 5 / ISO 15............................................................................85
ISO Code, 3-digit....................................................................................87
ISO + T...................................................................................................88
HDA.ISO – Analog signal ISO for HDA 5500.........................................89
HDA.ISO Signal 1/2/3/4..........................................................................90
HDA.ISO Signal 5 (Status).....................................................................91
NAS 1638 - National Aerospace Standard (CS 13xx only)........................93
NAS Maximum .......................................................................................94
NAS classes (2 / 5 / 15 / 25)...................................................................95
NAS 2 / NAS 5 / NAS 15 / NAS 25.........................................................96
NAS + T..................................................................................................97
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Content
HDA.NAS – Analog signal NAS for HDA 5500.......................................98
HDA.NAS Signal 1/2/3/4 ........................................................................99
HDA.NAS Signal 5 (Status)..................................................................100
Fluid temperature TEMP..........................................................................102
Status Messages.......................................................................................103
Status LED / Display................................................................................103
Error.........................................................................................................106
Exceptions Errors....................................................................................107
Analog Output Error Signals....................................................................109
Analog signal for HDA 5500 ....................................................................110
HDA Status Signal 5 Table...................................................................110
Connecting CSI-D-5 (Condition Sensor Interface).................................112
CSI-D-5 connection overview..................................................................112
Connecting the sensor to a RS485 Bus..................................................113
Reading out / setting the sensor via the RS485 bus..............................114
Evaluating/Reading measurement reports with FluMoS.......................115
Performing maintenance..........................................................................116
Calibrating the sensor..............................................................................116
Cleaning the display / user interface........................................................116
Decommissioning the sensor..................................................................116
Disposing of the sensor...........................................................................116
Spare Parts and Accessories ..................................................................117
Technical Data...........................................................................................118
Annex.........................................................................................................120
Finding Customer Service .......................................................................120
Germany ..............................................................................................120
USA......................................................................................................120
Australia ...............................................................................................120
Brazil ....................................................................................................121
China....................................................................................................121
Checking/resetting default settings..........................................................122
PowerUp Menu.....................................................................................122
Measuring menu...................................................................................122
Model code..............................................................................................123
Cleanliness classes - brief overview........................................................124
Cleanliness class - ISO 4406:1999 ......................................................124
Table - ISO 4406..................................................................................124
Overview of modifications - ISO4406:1987 <-> ISO4406:1999............125
Cleanliness class - SAE AS 4059.........................................................126
Table - SAE AS 4059...........................................................................126
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Content
Definition acc. to SAE...........................................................................127
Particle count (absolute) larger than a defined particle size..............127
Specifying a cleanliness code for each particle size .........................127
Specifying highest measured cleanliness class ................................127
Cleanliness class - NAS 1638..............................................................128
- EGDeclaration of conformity..................................................................129
Glossary ..................................................................................................129
Explanation of terms and abbreviations...................................................130
Displays................................................................................................131
Index........................................................................................................132
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Foreword
Foreword
These operating instructions were made to the best of our knowledge.
Nevertheless and despite the greatest care, it cannot be excluded that
mistakes could have crept in. 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 operating 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 Product Liability shall remain
unaffected.
Technical Support
Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model code, serial
no. and part no. of the product:
Fax:
[phone]
E-mail:
[e-mail]
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.
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.
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 terms of delivery of
HYDAC FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> Legal information.
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Foreword
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 determine which topic I am looking for.
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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Seite x
Produkt/Kapitel
200x-xx-xx
The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.
Chapter heading
Page number
Edition date
Document language
Documentation no.
with Index /
File name
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Safety Information
Safety Information
The product was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.
Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.
Observe all safety and warning instructions attached to the product. They
must always be complete and legible.
Do not operate the product unless all the safety devices are present.
Secure the hazardous areas which may arise between the product and other
equipment.
Maintain the product inspection intervals prescribed by law.
Document the results in an inspection certificate and keep it until the next
inspection.
Hazard symbols
These symbols are listed for all safety information in these operating
instructions which indicate particular hazards to persons, property or the
environment.
Observe these instructions and act with particular caution in such cases.
Pass all safety information and instructions on to other users.
General hazard
Danger due to electrical voltage / current
Danger due to operating pressure
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Safety Information
Signal words and their meaning in the safety information and
instructions
In these instructions you will find the following signal words:
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.
Structure of the safety information and instructions
All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.
Warning instructions listed before an activity are laid out as follows:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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Safety Information
Observe regulatory information
Observe the following regulatory information and guidelines:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations
Proper/Designated Use
Claims for defects or liability, regardless of the legal foundation, do not apply
with incorrect or improper installation, commissioning, usage, handling,
storage, maintenance, repair, use of unsuitable components or other
circumstances for which HYDAC is not responsible.
HYDAC is not responsible for the installation, integration, selection of
interfaces to / into your system nor for the use or functionality of your system.
Only use the sensor for the application described in the following.
The ContaminationSensor CS1000 serves to continuously monitor solid
particulate contamination in hydraulic and lubrication systems.
Proper/designated use of the product extends to the following:
•observing all instructions contained in the instruction manual.
•performing inspection and maintenance work.
Depending on the version (see model code), you may use the CS only in
connection with the following media:
NOTICE
Impermissible operating media
The ContaminationSensor will be destroyed.
►Operate the ContaminationSensor only with the permissible operating
fluids:
- CS 1xx0 is suitable for operation with mineral oils or
mineral-oil-based raffinates.
- CS 1xx1 is suitable for phosphate esters.
►Note the maximum operating pressure of 350 bar / 5075 psi.
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Safety Information
Improper Use or Use Deviating from Intended Use
DANGER
Hazard due to use of the unit other than that
intended
Bodily injury and damage to property will result
when operated improperly.
►Never operate the sensor in potentially
explosive atmospheres.
►The sensor is only to be used with the
permitted media.
Any use extending beyond or deviating therefrom shall not be considered
intended use. HYDAC FILTER SYSTEMS GMBH will assume no liability for
any damage resulting from such use. The risk is borne solely by the owner.
Improper use or use deviating from intended may result in hazards and/or will
damage the sensor. Examples of improper use:
•Operation in potentially explosive atmospheres.
•Operation with a non-approved 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.
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Safety Information
Qualifications of personnel / target group
Persons who work on the sensor must be familiar with the associated
hazards when using it.
Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.
The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.
These operating instructions are intended for:
Auxiliary personnel: such persons have been instructed about the sensor
and are aware of potential hazards due to improper use.
Specialist personnel: such persons with corresponding specialist training
and several years' work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential hazards.
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Safety Information
Activity
Person
Knowledge
Transport / storage
Forwarding
agent
Specialist
personnel
•Proof of knowledge of cargo
securing instructions
•Safe handling/operation of
hoisting and lifting equipment
Hydraulic / electrical
installation,
First commissioning,
Maintenance,
Troubleshooting,
Repair,
Decommissioning,
Disassembly
Specialist
personnel
•Safe handling/use of tools
•Fitting and connection of
hydraulic lines and
connections
•Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.
•Checking the phase
sequence
•Product-specific knowledge
Operation
Operations control
Specialist
personnel
•Product-specific knowledge
•Knowledge about how to
handle operating media.
Disposal
Specialist
personnel
•Proper and environmentally
friendly disposal of materials
and substances
•Decontamination of
contaminants
•Knowledge about reuse
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Storing the sensor
Storing the sensor
Store the sensor in a clean, dry place, in the original packing, if possible. Do
not remove the packing until you are ready to install the unit.
Rinse the sensor completely with Cleanoil before putting it into storage.
Use and dispose of used cleaning agents and flushing oils properly and in an
environmentally friendly way.
The conditions required for storage are in the "Technical Data" chapter on
page 118.
Decoding the type label
For identification details of the ContaminationSensor, see the model code
label. This is located on the back of the unit and contains the exact product
description and the serial number.
Row
->
Description
Model
->
Model code; for details, see page 123
P/N
->
Part no.
S/N
->
Serial-no.
Date
->
Year/week of production and hardware index
Max. INLET press.:
->
Maximum operating pressure
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Checking the scope of delivery
Checking the scope of delivery
The ContaminationSensor CS1000 comes packed and factory-assembled.
Before commissioning the CS, please check no items are missing from the
package.
The following items are supplied:
Qty
Description
1
ContaminationSensor, CS1000 series
(Model in acc. with the order - see model code)
2
O-rings (4.8 x 1.78 mm, 80 Shore, FKM)
(Only with connection type "Flange connection" =
model code: CS1xxx-x-x-x-x-1/-xxx)
1
CD with CS1000 operation and maintenance instructions
(this document in various languages)
1
CD with FluMoS software (Fluid Monitoring Software)
1
Quick start manual
1
Calibration certificate
CS 1x2x
CS 1x1x
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CS1000 Characteristics
CS1000 Characteristics
The ContaminationSensor Series CS1000 is a stationary measurement unit
for the continuous monitoring of particulate 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 500 ml/min) is diverted for measurement purposes.
The ContaminationSensor is approved for a maximum operating pressure
(see specification on type label) and viscosity of up to 1000 mm²/s.
Particulate contamination is detected with an optical measurement cell
The sensor is available with the following options:
•with or without 6-digit display and keypad (can be rotated by 270°)
•with 4 - 20 mA or 2 - 10 V analogue output
•Results are output as a cleanliness code according to:
4406:1999 and ISOSAE or
AS 4059 4406:1987 and ISO or ISO4406:1999 and NAS SAEAS 4059
•pipe / hose installation or flange installation
All models feature an analog electric output and an RS485 interface for
outputting the measured cleanliness class. In addition, all CS1000's have a
switching output.
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CS1000 Characteristics
CS1x1x dimensions (without display)
All dimensions in mm.
CS1x2x dimensions (with display)
All dimensions in mm.
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Fastening/Mounting the sensor
Fastening/Mounting the sensor
Install the CS in such a way that the flow runs 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 CS1000 is designed for IP67 according to DIN 40050 / EN 60529 /
IEC 529 / VDE 0470.
Mount the sensor as shown in the following examples:
1.
Wall mounting:
Mount to a wall using two cylindrical
screws having an M8 hexagonal
socket according to ISO 4762 and
having a length of at least 40 mm.
2.
Console mounting:
Mount to a console using 4
cylindrical screws having an M6
hexagonal socket according to
ISO 4762.
AB
100
60
12/16
4xM6
15 20
Bottom view
All dimensions in mm.
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