Hydac MCS 13 series Quick start guide

MCS
Metallic
Contamination Sensor
Operation and Installation Guide
English (translation of original instructions)
Documentation no.: 3435427g
Valid from hardware index B and
firmware version V 1.30 up

Imprint
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Imprint
Publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Postfach 1251
66273 Sulzbach / Saarland
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
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: [email protected]
© 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.

Contents
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Contents
Imprint............................................................................................................2
Documentation Representative ...................................................................2
Contents ........................................................................................................3
Preface...........................................................................................................7
Technical Support........................................................................................7
Modifications to the Product ........................................................................7
Warranty ......................................................................................................7
Using the documentation .............................................................................8
Safety information and instructions............................................................9
Hazard symbols...........................................................................................9
Signal words and their meaning in the safety information and
instructions ................................................................................................10
Structure of the safety information and instructions...................................10
Observe regulatory information .................................................................11
Proper/Designated Use .............................................................................11
Improper Use or Use Deviating from Intended Use ...................................12
Qualifications of personnel / target group ..................................................13
Transporting the sensor.............................................................................14
Storing the sensor ......................................................................................14
Decoding the model code label .................................................................15
Checking the scope of delivery .................................................................16
Scope of delivery for MCS 13xx ................................................................16
Scope of delivery for MCS 14xx ................................................................17
Scope of delivery for MCS 15xx ................................................................18
Sensor features...........................................................................................19
Functional principle....................................................................................19
Sensor dimensions.....................................................................................20
Dimensions for MCS 13xx .........................................................................20
Dimensions for MCS 13xx with Ethernet module.......................................21
Dimensions for MCS 13xx with flange adapter set (optional
accessory) .................................................................................................22
Dimensions for MCS 14xx .........................................................................23
Dimensions for MCS 14xx with Ethernet ...................................................24
Dimensions for MCS 14xx with flange adapter set (optional
accessory) .................................................................................................25
Dimensions for MCS 15xx .........................................................................26
Dimensions for MCS 15xx with Ethernet ...................................................27

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Dimensions for MCS 15xx with flange adapter set (optional
accessory) .................................................................................................28
Mechanical installation/assembly .............................................................29
Connecting MCS14xx via flange adapter set.............................................30
Fastening sensor to underside..................................................................31
Fastening MCS 13xx/MCS 14xx................................................................32
Fastening the MCS 15xx ...........................................................................32
Fastening MCS 15xx with angle fastening set ...........................................33
Connecting MCS 15xx with pipe adapter set .............................................33
Connecting MCS 15xx with flange adapter plate (accessory)....................34
Connecting MCS 15xx with 4" SAE as per ISO 6162-1 (4x M16)..............35
Hydraulic installation of sensor.................................................................36
Diagram - flow rate, differential pressure p

and viscosity

....................36
Electrical connection of sensor.................................................................38
Plug pin assignment ..................................................................................38
Connection cable - Assignment / Color coding ..........................................39
Connecting cable wires..............................................................................40
Examples of connection.............................................................................41
Connection: operation voltage = measurement voltage .........................42
Using switching output 1 .....................................................................42
Using switching output 2 .....................................................................42
Using switching output 1 and 2 ...........................................................43
Connection: operation voltage measurement voltage .........................43
Using switching output 1 .....................................................................43
Using switching output 2 .....................................................................44
Using switching output 1 and 2 ...........................................................44
Using switching outputs ............................................................................45
Switching output - FE.NFE (factory setting)...............................................45
Switching output - ALL.RDY ......................................................................45
Switching logic "active low"........................................................................46
Example: Operation - 1 particle detected ...............................................46
Example: Operation - no particle detected .............................................46
Example: Operation - several particles detected ....................................47
Switching logic "active high" ......................................................................48
Example: Operation - 1 particle detected ...............................................48
Example: Operation - no particle detected .............................................48
Example: Operation - several particles detected ....................................49
Switching output "Device Ready" ..............................................................49
Parameterizing sensor/reading measured values....................................50
Connecting MCS 1000 with SMU 1200 .....................................................50
Connecting MCS with CSI-D-5 (Condition Sensor Interface).....................51

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Connecting MCS to HMG 3000 .................................................................52
Evaluating measurement results...............................................................53
Menu structure............................................................................................54
PowerUp Menu ............................................................................................55
MODE - select operating mode .................................................................55
S.TIME - Set storing interval......................................................................55
SEL.COM - Set protocol ............................................................................55
ADRESS – Set bus address ......................................................................55
DFAULT - Reset to factory setting.............................................................55
CANCEL - cancel without saving...............................................................55
SAVE - save changes................................................................................55
Measuring menu .........................................................................................56
DSPLAY - Show measured variable..........................................................56
SWT.OUT - Set switching output...............................................................57
SWT.LOG - Set logic at the switching output.............................................58
SWT.PLS - Set pulse length at the switching output .................................58
CANCEL - cancel without saving...............................................................58
SAVE - Save changes ...............................................................................58
Error analysis / remedy ..............................................................................59
Error status - "active high" and "active low" ...............................................62
Error status 1 "active low".......................................................................62
Error status 1 "active high" .....................................................................63
Error status 2 "active low".......................................................................63
Error status 2 "active high" .....................................................................64
Error status - "Device Ready" ....................................................................64
Performing maintenance............................................................................65
Decommissioning the sensor ....................................................................65
Disposing of sensor/packaging material ..................................................65
Spare parts and accessories .....................................................................66
Channel default settings ............................................................................69
Calibrating the sensor ................................................................................69
Customer Service .......................................................................................69
Technical specifications ............................................................................70
Detection limits ..........................................................................................71
Model Code..................................................................................................72
EC declaration of conformity.....................................................................73
Glossary ......................................................................................................74
Ferromagnetic (Fe)....................................................................................74

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Non-ferromagnetic (nFe) ...........................................................................74
Certification................................................................................................74
Basics of GL certification........................................................................75
Germanischer Lloyd Industrial Services GmbH, renewable
energies.....................................................................................................75
Index ............................................................................................................76

Preface
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Preface
This operating manual was 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 this instruction
manual. 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/type
designation, serial no. and part-no. of the product:
Fax: [phone] - 9046
E-mail: [email protected]
Modifications to the Product
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.
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 Terms of Sale
and Delivery of HYDAC Filter Systems GmbH.
You will find these under www.hydac.com -> Legal information.

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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 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
BeWa12
34
56a
d
e
Seit e 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 description
Page number
Edition date
Document language
Documentation no.
with index/
file name

Safety information and instructions
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Safety information and instructions
The device 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 unit. They must
always be complete and legible.
Do not operate the unit unless all the safety devices are present.
Secure the hazardous areas which may arise between the unit and other
equipment.
Maintain the unit 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 and instructions 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

Safety information and instructions
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Signal words and their meaning in the safety information and
instructions
DANGER
DANGER indicates a hazard with a high risk and which will lead to death or
serious injury if not avoided.
WARNING
WARNING indicates a hazard with a medium risk and which can lead to
death or serious injury if not avoided.
CAUTION
CAUTION indicates a danger with a low risk and which can lead to minor
injury if not avoided.
NOTICE
NOTICE indicates a danger which will lead to damage to property if not
avoided.
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:
SIGNAL WORD
Type and source of danger
Consequence of the danger
HAZARD SYMBOL
Measures to avert danger

Safety information and instructions
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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
Only use the sensor for the application described in the following.
The MetallicContamination Sensor (MCS) is used for the constant monitoring
of particulate contamination in hydraulic and lubrication systems.
Proper or designated use of the product extends to the following:
observing all instructions contained in the instruction manual.
only using with permissible media.
operating within permissible technical conditions, such as operating
pressure, flow rate, media and ambient temperature.
The sensor is only to be used with the following media:
NOTICE
Impermissible operating media/conditions
The sensor will be damaged
Use the sensor only in conjunction with mineral and synthetic oils
(for example: poly-alpha-olefins PAO and polyglycol, as used in the
wind energy industry).
Note that the media used must be permanently compatible with the
MCS sealing material.

Safety information and instructions
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Improper Use or Use Deviating from Intended Use
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 user alone, shall assume any and all
associated risk
Improper use may result in hazards and/or will damage the sensor. Examples
of improper use:
Operation with a non-approved medium.
Operation under impermissible operating conditions.
Modifications to the sensor made by the user or purchaser.

Safety information and instructions
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Qualifications of personnel / target group
Persons who work on the sensor must be aware of 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.
Activity Person Knowledge
Transport / storage Forwarding
agent
Auxiliary
personnel
No specialist knowledge
required
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.
Product-specific knowledge
Operation
operations control
Specialist
personnel
Product-specific knowledge
Knowledge about how to
handle operating media.
Disposal Specialist
personnel
Knowledge about reuse

Transporting the sensor
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Transporting the sensor
Transport the sensor upright or on its side, and in the included packaging if
possible. Make sure the connection plug will not be subjected to any
mechanical strain or impact.
NOTICE
Unsafe transport
The connection plug will be damaged
Transport the sensor in its original packaging.
Secure the sensor during transport.
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.
Storage temperature: -40 … 80 °C / -40 … 176 °F
Relative humidity: max. 95%, non-condensing

Decoding the model code label
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Decoding the model code label
For identification details of the MetallicContamination Sensor, 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 Model Model according to model code,
for details, see page 72.
2 P/N Part no.
3 S/N Serial-no.
4 Date Year/week of production
5 Index Hardware index
6 Max. INLET press. Maximum operating pressure

Checking the scope of delivery
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Checking the scope of delivery
The scope of delivery for the available sizes varies. Below is the scope of
delivery for each size.
Scope of delivery for MCS 13xx
The MetallicContamination Sensor MCS 13xx comes packed and factory-
assembled. Before commissioning the sensor, please check no items are
missing from the package.
The following items are supplied:
Qty. Designation
1 MetallicContamination Sensor, MCS 13xx
1 O-ring (18.7 x 3.53 NBR 70 Shore)
1 Operation and Installation Guide (this document)

Checking the scope of delivery
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Scope of delivery for MCS 14xx
The MetallicContamination Sensor MCS 14xx comes packed and factory-
assembled. Before commissioning the sensor, please check no items are
missing from the package.
The following items are supplied:
Qty. Designation
1 MetallicContamination Sensor, MCS 14xx
1 O-ring (25 x 3.53 NBR 70 Shore)
1 Operation and Installation Guide (this document)

Checking the scope of delivery
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Scope of delivery for MCS 15xx
The MetallicContamination Sensor MCS 15xx comes packed and factory-
assembled. Before commissioning the sensor, please check no items are
missing from the package.
The following items are supplied:
Qty. Designation
1 MetallicContamination Sensor, MCS 15xx
1 O-ring (47.22 x 3.53 NBR 70 Shore)
1 O-ring (110.72 x 3.53 NBR 70 Shore)
1 Operation and Installation Guide (this document)

Sensor features
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Sensor features
The MetallicContamination Sensor MCS is a stationary sensor for continuous
monitoring of contamination of fluids – especially lubrication fluids – with
metallic particles.
With appropriate system knowledge of the monitored system, damage
resulting in detectable metallic particles can be discovered early.
The MCS uses digital signal processing to distinguish between ferromagnetic
(Fe) and non-ferromagnetic (nFe) particles.
Particle results are signaled via two switching outputs. In the factory setting
(default values), the ferromagnetic (Fe) particles are output via the first
switching output and the non-ferromagnetic (nFe) particles via the second
switching output. It is possible to make a switch in the menu so that the first
switching output is used for the total particles (Fe and nFe) and the second
switching output is used as a "device ready signal". (For this, see also the
chapter Using switching output.)
In addition, the MCS has serial communication interfaces with which
connection to superordinate monitoring systems is possible.
The MCS is intended for incorporation in low-pressure circuits and test
benches.
Functional principle
Within the sensor, a high-frequency magnetic field is generated using a coil
system. Two sensor pulses measure changes in the field strength and output
certain signals as described below.
A ferromagnetic (Fe) particle, the field strength increases depending
on the size of the particle.
A non-ferromagnetic (nFe) particle, the field strength decreases
depending on the size of the particle.
If a prespecified limit is exceeded, a particle event is signaled.
The output signal at the switching output is always the same and provides no
information about the size of the particle.
Using the serial interfaces (RS 485 or HSI) makes it possible to evaluate
appropriate particle size classes.

Sensor dimensions
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Sensor dimensions
The dimensions for the available sizes vary. The dimensions for each size
can be found below.
Dimensions for MCS 13xx
Flange image SAE 3/4"
All dimensions in mm.