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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