Hydac MCS1 T001 Series Quick start guide

MCS1xxx /-T001
Metallic
Contamination Sensor
Operation and Installation Guide
English (translation of original instructions)
Documentation no.: 4686072
Valid from hardware index D and
firmware version C09.30 up

Imprint
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Imprint
Manufacturer / publisher and responsible for the content:
HYDAC FILTER SYSTEMS GMBH
Industriegebiet
66280 Sulzbach / Saar
Germany
Telephone:
[phone]
Fax:
[phone]
E-mail:
[e-mail]
Homepage:
www.hydac.com
Court of Registration:
Saarbrücken, HRB 17216
Executive directors:
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.

Content
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Content
Imprint............................................................................................................2
Documentation Representative...................................................................2
Content ..........................................................................................................3
Preface...........................................................................................................6
Technical Support...........................................................................6
Modifications to the Product...........................................................6
Warranty.........................................................................................6
Using the documentation................................................................7
Safety information ........................................................................................8
Warning signs used........................................................................8
Others symbols used......................................................................8
Signal words and their meaning in the general safety information..9
Structure of the general safety information and instructions...........9
Observing regulatory information....................................................9
Intended Use................................................................................10
Improper use or use deviating from intended use.........................11
Qualifications of personnel / target group.....................................11
Transporting the sensor.............................................................................13
Storing the sensor......................................................................................13
Decoding the model code label.................................................................14
Checking the scope of delivery.................................................................15
Scope of delivery for MCS 13xx ...................................................15
Scope of delivery for MCS 14xx ...................................................16
Scope of delivery for MCS 15xx ...................................................17
Scope of delivery for MCS 15xx-3 ................................................18
Sensor features...........................................................................................19
Functional principle.......................................................................19
Sensor dimensions.....................................................................................20
Dimensions...................................................................................20
Dimensions for MCS 13xx with Ethernet module..........................21
Dimensions MCS 13xx with flange adapter set (optional
accessories) .................................................................................22
Dimensions...................................................................................23
Dimensions for MCS 14xx with Ethernet ......................................24
Dimensions MCS 14xx with flange adapter set (optional
accessories) .................................................................................25
Dimensions...................................................................................25
Dimensions for MCS 15xx with Ethernet ......................................26

Content
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Dimensions MCS 15xx-3..............................................................27
Dimensions MCS 15xx with flange adapter set (optional
accessories) .................................................................................27
Mechanical installation/assembly .............................................................28
Connecting MCS 13xx / 14xx via flange adapter set....................29
Fastening sensor to underside..................................................................30
Fastening MCS 13xx / MCS 14xx.................................................31
Fastening MCS 15xx ....................................................................31
Fastening MCS 15xx using angle fastening set............................32
Connecting MCS 15xx using pipe adapter set..............................32
Connecting MCS 15xx using flange adapter plate (accessory) ....33
MCS 15xx via SAE 4" per ISO 6162-1 (4xM16)............................34
Hydraulic installation of sensor.................................................................35
Diagram - flow rate, differential pressure
ν
and viscosity
p∆
.....35
Electrical connection of sensor.................................................................37
Plug pin assignment.....................................................................37
Connection cable - Assignment / Color coding.............................38
Using the switching outputs......................................................................39
Function - FE.NFE (factory setting)..............................................39
Function - ALL.RDY......................................................................39
Function - ALARM........................................................................39
Switching logic "active low"...........................................................39
Example: Operation - 1 particle detected = logical "active".......40
Example: Operation - no particle detected = logical "not active"40
Example: Operation - several particles detected = logical
"active"......................................................................................40
Switching logic "active high" (Default settings).............................41
Example: Operation - 1 particle detected = logical "active".......42
Example: Operation - no particle detected = logical "not active"42
Example: Operation - several particles detected = logical
"active" ......................................................................................43
Switching logic „Device Ready“....................................................43
Parameterizing sensor/reading measured values....................................44
Connecting MCS 1000 to SMU 1200............................................44
Connecting MCS to CSI-D-5 (Condition Sensor Interface)...........45
Connecting MCS to HMG 3000....................................................46
Evaluating measurement results...............................................................47
Menu structure............................................................................................48
Overview - PowerUP Menu ..........................................................48
Overview - Measuring Menu.........................................................49

Content
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PowerUp Menu............................................................................................50
MODE - select operating mode ....................................................50
S.TIME - Set storing interval.........................................................50
SEL.COM - Set protocol...............................................................50
ADRESS – Set bus address.........................................................50
DFAULT - Reset to factory setting................................................50
CANCEL - cancel without saving..................................................50
SAVE - save changes...................................................................50
Measuring menu .........................................................................................51
DSPLAY - Show measured variable.............................................51
SWT.OUT – Set the switching output...........................................52
SWT.LOG - Set logic at the switching output................................52
SWT.PLS - Set pulse length at the switching output ....................52
SWT.TST – Set test pulse at the switching output........................52
ALARM – Setting limit values .......................................................53
CANCEL - cancel without saving..................................................53
SAVE - Save changes..................................................................53
Error analysis / remedy..............................................................................53
Performing Maintenance............................................................................54
Decommissioning the sensor....................................................................55
Disposing of sensor/packaging material..................................................55
Spare parts and accessories.....................................................................56
Channel default settings ............................................................................58
Calibrating the sensor................................................................................58
Customer Service / Service........................................................................59
Technical Data.............................................................................................60
Detection limits.............................................................................61
Model Code .................................................................................................62
EC declaration of conformity.....................................................................63
Glossary ......................................................................................................63
Ferromagnetic (Fe).......................................................................63
Non-ferromagnetic (nFe) ..............................................................63
Index ............................................................................................................64

Preface
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Preface
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 liablefor 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]
E-mail:
[e-mail]
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 warrantyprovidedby us,please refer to theterms of delivery of HYDAC
FILTER SYSTEMS GMBH.
You will find these under www.hydac.com -> General terms and conditions.

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 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 description
Page number
Edition date
Document language
Documentation no.
with index/
file name

Safety information
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Safety information
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 general 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.
Warning signs used
These signs are listed for all general safety information and instructions in
these operating instructions which indicate particular dangers to persons,
property or the environment.
Danger point warning
Warning about dangerous electrical voltage
Others symbols used
The following symbols found you in this operation instructions.
Tip for handling the product
Required tools

Safety information
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Signal words and their meaning in the general safety information
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 general 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 the danger
Observing regulatory information
Observe the following regulatory information and directives:
•Legal and local regulations for accident prevention
•Legal and local regulations for environmental protection
•Country-specific regulations, organization-specific regulations

Safety information
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Intended Use
Use the sensor only for the application described below.
The MetallicContamination Sensor MCS is used for the constant monitoring
of particulate contamination in hydraulic and lubrication systems.
Proper/designated use of the product extends to the following:
•Observing all instructions in the instruction manual.
•To be used only in conjunction with permissible media.
•To be operated under technically permissible 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
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Improper use or use deviating from intended use
Any other use or extended use shall not be considered intended use. HYDAC
FILTER SYSTEMS GMBH will assume no liability for any damage resulting
from such use. This risk is borne solely by the owner.
Improper use or use deviating from intended use may result in hazards
and/or will damage the sensor. Examples of improper use include:
•Operation with a non-approved medium.
•Operation under non-approved operational conditions.
•Modifications to the sensor made by the user or purchaser.
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 dangers.
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

Safety information
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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 flat, 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.
For storage conditions, refer to the chapter "Technical Data" on page 60.

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 62.
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.
Description
1
MetallicContamination Sensor, MCS 13xx
1
O-ring (18.7 x 3.53 NBR 70 Shore)
1
O-ring (18.7 x 3.53 FPM 70 Shore)
1
Operation and Installation Guide (this document)
EC declaration of conformity

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.
Description
1
MetallicContamination Sensor, MCS 14xx
1
O-ring (25 x 3.53 NBR 70 Shore)
1
O-ring (25 x 3.53 FPM 70 Shore)
1
Operation and Installation Guide (this document)
EC declaration of conformity

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.
Description
1
MetallicContamination Sensor, MCS 15xx
1
o-ring (47.22 x 3.53 NBR 70 Shore)
1
O-ring (47.22 x 3.53 FPM 70 Shore)
1
O-ring (110.72 x 3.53 NBR 70 Shore)
1
O-ring (110.72 x 3.53 FPM 70 Shore)
1
Operation and Installation Guide (this document)
EC declaration of conformity

Checking the scope of delivery
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Scope of delivery for MCS 15xx-3
The MetallicContamination Sensor MCS 15xx-3 comes packed and factory-
assembled. Before commissioning the sensor, please check no items are
missing from the package.
The following items are supplied:
Qty.
Description
1
MetallicContamination Sensor, MCS 15xx-3
1
O-ring (32.92 x 3.53 NBR 70 Shore)
1
O-ring (32.92 x 3.53 FPM 70 Shore)
1
Operation and Installation Guide (this document)
EC declaration of conformity

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. 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 second
switch 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 MCS is able to implement variable adjustments to the defined limit
in order to avoid faulty particle counter results. This makes it possible
to suppress the results for Dimension A and D temporarily (Noise
Suppression) in the event of a very strongly fluctuating field strength
(e.g. following excessive air intake into the system).
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
Flange image SAE 1/2"
All dimensions in mm.