Hydac MCS1510-5-0 Instruction Manual

MCS 1000 Series
Metallic
Contamination Sensor
Operation and Installation Guide
English (translation of original instructions)
Document no.: 3435427f
Valid from hardware index B and
firmware version V 1.30 up

MCS 1000 Series 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: ++49 (0)6897 509 1511
Fax: ++49 (0)6897 509 1394
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.
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.

MCS 1000 Series Content
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Content
Operation and Installation Guide............................................................................1
Imprint .......................................................................................................................2
Documentation Representative...............................................................................2
Content......................................................................................................................3
Preface ......................................................................................................................6
Technical Support...................................................................................................7
Modifications to the Product ...................................................................................7
Warranty .................................................................................................................7
Using the Documentation .......................................................................................8
Safety information and instructions.......................................................................9
Obligations and Liability..........................................................................................9
Explanation of Symbols and Warnings, etc. .........................................................10
Proper/Designated Use ........................................................................................10
Improper Use ........................................................................................................10
Informal Safety Precautions..................................................................................11
Training and Instruction of Personnel ...................................................................12
Storing the MCS .....................................................................................................13
Decoding the model code label ............................................................................13
Checking the MCS 13xx scope of delivery...........................................................14
Checking the MCS 14xx scope of delivery...........................................................15
Checking the MCS 15xx scope of delivery...........................................................16
MCS Features .........................................................................................................17
Functional principle...............................................................................................17
Usable operating media........................................................................................18
Dimensions .............................................................................................................19
MCS13xx ..............................................................................................................19
MCS13xx with Ethernet module ...........................................................................20
MCS13xx with flange adapter set (optional accessories) ..................................... 21
MCS14xx ..............................................................................................................22
MCS14xx with Ethernet ........................................................................................23
MCS14xx with flange adapter set (optional accessories) ..................................... 24
MCS15xx ..............................................................................................................25
MCS15xx with Ethernet ........................................................................................26
MCS15xx with flange adapter set (optional accessories) ..................................... 27
Mechanical connection types ...............................................................................28
Connecting MCS14xx via flange adapter set........................................................29
Fastening the MCS on the underside ...................................................................30
Fastening the MCS 13xx ......................................................................................31
Fastening the MCS 14xx ......................................................................................31
Fastening the MCS 15xx ......................................................................................32
Fastening MCS15xx via angle fastening set......................................................... 33
Connecting MCS15xx via pipe adapter set...........................................................33

MCS 1000 Series Content
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Connecting MCS15xx via flange adapter plate (accessories) .............................. 34
Connecting MCS15xx via SAE 4" per ISO 6162-1 (4xM16) ................................. 35
MCS hydraulic installation ....................................................................................35
Flow rate, differential pressure p

and viscosity

characteristics .....................36
Electrical connection of the MCS..........................................................................38
Plug pin assignment .............................................................................................38
Connection cable - Assignment / Color coding..................................................... 39
Connecting cable wires.........................................................................................40
Using switching outputs........................................................................................41
Switching output - FE.NFE (factory setting)..........................................................41
Switching output - ALL.RDY .................................................................................41
Switching logic "active low" .................................................................................42
Switching on sensors............................................................................................42
Example: Operation - 1 particle detected..........................................................42
Example: Operation - no particle detected........................................................43
Example: Operation - several particles detected ..............................................43
Switching logic "active high"................................................................................44
Switching on the sensor........................................................................................44
Example: Operation - 1 particle detected..........................................................44
Example: Operation - no particle detected........................................................45
Example: Operation - several particles detected ..............................................45
Switching output "Device Ready" ........................................................................46
Parameterizing MCS / reading off measured values ...........................................47
Connecting MCS 1000 with SMU 1200 ................................................................47
Connecting MCS with CSI-D-5 (Condition Sensor Interface) ............................... 48
Connecting MCS to HMG 3000 ............................................................................49
Evaluating measurement results ..........................................................................50
Menu structure .......................................................................................................51
PowerUp Menu .......................................................................................................52
MODE - select operating mode ............................................................................52
S.TIME - Set storing interval.................................................................................52
SEL.COM - Set protocol .......................................................................................52
ADRESS – Set bus address .................................................................................52
DFAULT - Reset to factory setting........................................................................52
CANCEL - cancel without saving..........................................................................53
SAVE - save changes...........................................................................................53
Measuring menu.....................................................................................................53
DSPLAY - Show measured variable.....................................................................53
SWT.OUT - Set switching output..........................................................................54
SWT.LOG - Set logic at the switching output .......................................................55
SWT.PLS - Set pulse length at the switching output ............................................55
CANCEL - cancel without saving..........................................................................55
SAVE - Save changes ..........................................................................................55
Error analysis / remedy..........................................................................................56

MCS 1000 Series Content
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Error status - "active high" and "active low" ..........................................................58
Error status 1 "active low" .................................................................................58
Error status 1 "active high"................................................................................59
Error status 2 "active low" .................................................................................59
Error status 2 "active high"................................................................................60
Error status - "Device Ready" ............................................................................... 60
Servicing the MCS..................................................................................................61
Decommissioning MCS .........................................................................................61
Disposing of MCS...................................................................................................61
Spare parts and accessories.................................................................................62
MCS channel default settings ...............................................................................64
Technical data ........................................................................................................65
Detection limits .....................................................................................................66
Recalibration / Service...........................................................................................66
Customer Service...................................................................................................66
Model Code .............................................................................................................67
Examples of connection ........................................................................................68
Connection: operation voltage = measurement voltage .......................................68
Using switching output 1 ...................................................................................68
Using switching output 2 ...................................................................................68
Using switching output 1 and 2 .........................................................................69
Connection: operation voltage ≠measurement voltage........................................69
Using switching output 1 ...................................................................................69
Using switching output 2 ...................................................................................70
Using switching output 1 and 2 .........................................................................70
EC declaration of conformity ................................................................................71
Glossary ..................................................................................................................72
Ferromagnetic (Fe) ...............................................................................................72
Non-ferromagnetic (nFe) ......................................................................................72
Certification...........................................................................................................72
Basics of GL certification...................................................................................73
Germanischer Lloyd Industrial Services GmbH, renewable energies................... 73

MCS 1000 Series Preface
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Preface
For you, as the owner of a product manufactured by us, we have produced this
manual, comprising the most important instructions for its operation and
maintenance.
It will acquaint you with the product and assist you in using it as intended in an
optimal manner.
Keep this documentation in the vicinity of the product for immediate reference.
Note that the information on the unit's engineering contained in the documentation
was that available at the time of publication.There may be deviations in technical
details, figures, and dimensions as a result.
If you discover errors while reading the documentation or have suggestions or other
useful information, please don’t hesitate to contact us:
HYDAC FILTER SYSTEMS GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
“Putting experience into practice”

MCS 1000 Series Preface
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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: ++49 (0) 6897 / 509 - 846
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'll find this under www.hydac.com -> Legal information

MCS 1000 Series 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.
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

MCS 1000 Series Safety information and instructions
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Safety information and instructions
These operating instructions contain the key instructions for properly and safely
operating the MCS.
Obligations and Liability
The basic prerequisite for the safe and proper handling and operation of the MCS is
knowledge of the safety instructions and warnings.
These operating instructions in general, and the safety precautions in particular, are
to be adhered to by all those who work with the MCS.
Adherence is to be maintained to pertinent accident prevention regulations
applicable at the site where the product is used.
The safety precautions listed here are restricted to use of the MCS.
The MCS has been designed and constructed in accordance with the current state
of the art and recognized safety regulations. Nevertheless, hazards may be posed to
the life and limb of the individual using the product or to third parties. Risk of
damage may be posed to the product or other equipment and property.
The MCS is only to be used as follows:
solely for its designated use
only when in a safe, perfect condition
Immediately remedy any malfunctions that might impair safety.
Our General Terms and Conditions apply. They are provided to the owner upon
conclusion of purchase of the unit at the latest. Any and all warranty and liability
claims for personal injuries and damage to property shall be excluded in the event
they are attributable to one or more of the following causes:
Improper use of the MCS
improper assembly, installation, commissioning, operation and maintenance of
the MCS
modifications to the MCS made by the user or purchaser
Improper monitoring of unit components that are subject to wear and tear
improperly performed repair work

MCS 1000 Series Safety information and instructions
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Explanation of Symbols and Warnings, etc.
DANGER
DANGER denotes situations
which can lead to death if
safety precautions are not
observed.
WARNING
WARNING denotes situations
which can lead to death if
safety precautions are not
observed.
CAUTION
CAUTION denotes situations
which can lead to severe
injuries if safety precautions
are not observed.
NOTICE
NOTICE denotes situations
which can lead to property
damage if safety precautions
are not observed.
Proper/Designated Use
The MetallicContamination Sensor (MCS) is used for the continuous monitoring of
particulate contamination in hydraulic and lubrication systems.
Analyzing the size and quantity of contamination enables quality standards to be
verified and documented and the requisite optimization measures to be
implemented.
Any other use shall be deemed to be improper and not in keeping with the product's
designated use.
Proper or designated use of the product extends to the following:
Permanent monitoring of solid particle contamination in hydraulic and lubrication
systems
Observing all the notes contained in these operating instructions
Improper Use
Improper use may result in hazard to life and limb.
Improper use includes:
Improper connection of the MCS voltage and sensor cables
Operation with non-approved fluids.

MCS 1000 Series Safety information and instructions
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Informal Safety Precautions
Apart from the operating instructions, any and all general and local regulations
pertaining to accident prevention and environmental protection are to be made
available and observance is to be maintained to them.
Make sure to keep the safety and hazard symbols and warnings on the MCS in a
legible condition and to renew them as necessary.
The connection fittings are to be checked regularly for leakage via a visual check.
Replace any loose connections or damaged cables immediately.
WARNING
Hydraulic systems are under pressure
Danger of bodily injury
►The hydraulic system must be depressurized
before performing any work on the hydraulic
system.

MCS 1000 Series Safety information and instructions
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Training and Instruction of Personnel
The MCS may only be operated by properly trained and instructed personnel.
The areas of responsibility of your staff must be established in a clear-cut manner.
Staff undergoing training may not use the MCS unless supervised by an
experienced staff member.
Individuals Persons undergoing training
I
n
di
v
id
ua
l
s w
ith
technical training/engineerin g background Electrician Supervisor with the appropriate authority
Activity
Packing
Transportation X X X
Commissioning X X X
Operation X X X X
Troubleshooting/
locating the source of malfunction X X X
Remedying of mechanical faults X X
Remedying of electrical faults X X
Maintenance X X X X
Repair work X
Decommissioning/storage X X X X

MCS 1000 Series Storing the MCS
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Storing the MCS
Store the MCS 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
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 per model code
2 P/N Part no.
3 S/N Always list complete serial no.
4 Date Year/week of production
5 Index Hardware index
6 Max. INLET press. Max. operating pressure in bar/psi

MCS 1000 Series Checking the MCS 13xx scope of delivery
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Checking the MCS 13xx scope of delivery
The MetallicContamination Sensor MCS14xx comes packed and factory-assembled.
Before starting up the MCS, check that the content of the package is complete.
The following items are supplied:
Qty. Designation
1 MetallicContamination Sensor, MCS13xx
1 O-ring (18.7 x 3.53 NBR 70 Shore)
1 O-ring (25 x 3.53 NBR 70 Shore)
1 Operation and Installation Guide (this document)

MCS 1000 Series Checking the MCS 14xx scope of delivery
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Checking the MCS 14xx scope of delivery
The MetallicContamination Sensor MCS14xx comes packed and factory-assembled.
Before starting up the MCS, check that the content of the package is complete.
The following items are supplied:
Item Qty. Designation
1 1 MetallicContamination Sensor, MCS14xx
2 1 O-ring (25 x 3.53 NBR 70 Shore)
- 1 Operation and Installation Guide (this document)

MCS 1000 Series Checking the MCS 15xx scope of delivery
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Checking the MCS 15xx scope of delivery
The MetallicContamination Sensor MCS15xx comes packed and factory-assembled.
Before starting up the MCS, check that the content of the package is complete.
The following items are supplied:
Item Qty. Designation
1 1 MetallicContamination Sensor, MCS15xx
2 1 O-ring (47.22 x 3.53 NBR 70 Shore)
3 1 O-ring (110.72 x 3.53 NBR 70 Shore)
- 1 Operation and Installation Guide (this document)

MCS 1000 Series MCS Features
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MCS 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 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.
The flow rate through the sensor must be within the limits that hold for the respective
type (see “Technical data”).
The MCS is approved for a maximum operating pressure of 20 bar.
Functional principle
Within the MCS, a high-frequency magnetic field is generated using a coil system.
Two sensor coils detect changes in the field strength of this magnetic field.
Upon entry into this magnetic field of a:
ferromagnetic (Fe) particle, the field strength increases depending on the size of
the particle.
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.

MCS 1000 Series MCS Features
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Usable operating media
NOTICE
Unpermitted operating media
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).
►The media used must be permanently compatible with the MCS sealing
material - low-temperature FKM.

MCS 1000 Series Dimensions
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Dimensions
MCS13xx
Flange image SAE 3/4"
All dimensions in mm.

MCS 1000 Series Dimensions
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MCS13xx with Ethernet module
Flange image SAE 3/4"
All dimensions in mm.