Schroeder Industries HY-TRAX Manual

An ISO 9001:2015 Certified Company
www.schroederindustries.com
580 West Park Road | Leetsdale, PA 15056
ph. 724.318.1100 | fax [phone]
8
L-4370
Manually Controlled Fluid Sampling System
Operating and Maintenance Instructions

L-4370 | Created 4.2015
Rev. 5.2017

- TABLE OF CONTENTS-
HY-TRAX®
1. Features and Precautions ...............................................................................................................................................6
1.1 Features ......................................................................................................................................................................6
2. Warnings, Cautions, and Notes .....................................................................................................................................6
2.1 Technical Assistance ...................................................................................................................................................8
2.2 Obligations and Liabilty ...............................................................................................................................................9
2.3 Acronym List ................................................................................................................................................................9
2.4 Components ..............................................................................................................................................................10
3. Specications ................................................................................................................................................................11
4. Connecting Your System ..............................................................................................................................................12
5. Operating Instructions ..................................................................................................................................................15
6. Parts List ........................................................................................................................................................................17
7. Maintenance ...................................................................................................................................................................19
8. Trouble Shooting ...........................................................................................................................................................19
9. 24 VDC Connection Instructions ..................................................................................................................................22
TestMate® Contamination Monitor | TCM .........................................................................................................................23
1. Qualications of personnel/target Group ...................................................................................................................24
2. Storing the TCM .............................................................................................................................................................24
2.1. Storage Conditions ...................................................................................................................................................24
3. Decoding the Model Code Label ..................................................................................................................................24
4. Checking the Scope of Delivery ...................................................................................................................................25
5. TCM Features .................................................................................................................................................................26
6. TCM Restrictions on Use ..............................................................................................................................................26
7. TCM Dimensions ...........................................................................................................................................................26
7.1. TCM 1x1x dimensions (without display) ...................................................................................................................26
7.2 TCM1x2x dimensions (with display) ..........................................................................................................................26
8. Hydraulic connection types ..........................................................................................................................................27
8.1 Pipe or hose connection (type TCM) .........................................................................................................................27
8.2 Flange connection type (type TCM) ..........................................................................................................................27
9. Fastening / mounting the TCM .....................................................................................................................................27
10. Display rotatable/Adjustable As Needed ...................................................................................................................28
11. TCM hydraulic installation ..........................................................................................................................................28
11.1. Selecting the measurement point ...........................................................................................................................29
 11.2.Flowrate,di󰀨erentialpressureandviscositycharacteristicTCM...........................................................................29
11.3. Hydraulic connection of the TCM ...........................................................................................................................29
12. Electrical connection of the TCM ...............................................................................................................................31
12.1. Pin assignment .......................................................................................................................................................31
12.2. Connection cable - assignment / color coding .......................................................................................................31
12.3. Connecting cable ends - Examples ........................................................................................................................31
13. Setting the measuring mode ......................................................................................................................................33
13.1. Mode M1: Continuous measurement .....................................................................................................................33
13.2. Mode M2: Continuous measurement and switching ..............................................................................................33
13.3. Mode M3: Filter to cleanliness class and stop .......................................................................................................33
13.4. Mode M4: Filter to continuously monitor cleanliness class ....................................................................................34
13.5. Mode “SINGLE” measurement ...............................................................................................................................34
14. Operating the TCM1x2x using the keypad ................................................................................................................34

14.1. Function of the Keys ..............................................................................................................................................35
14.2. Measured variables on the display .........................................................................................................................36
14.3. ISO (Cleanliness class) ..........................................................................................................................................36
14.4. SAE (Cleanliness class) .........................................................................................................................................36
14.5. NAS (Cleanliness Class - only TCM 13xx) .............................................................................................................36
15. Service variables on the display ................................................................................................................................36
 15.1.Flow(owrate).......................................................................................................................................................36
15.2. Out (Analog output) ................................................................................................................................................37
15.3 Drive (performance of the LED) .............................................................................................................................37
15.4. Temp (Temperature) ...............................................................................................................................................37
16. Activate / deactivate keypad lock ..............................................................................................................................37
17. Display FREEZE ...........................................................................................................................................................38
17.1. Activate display FREEZE .......................................................................................................................................38
17.2. Deactivate display FREEZE ...................................................................................................................................39
18. Menus and modes .......................................................................................................................................................39
18.1. PowerUp Menu ......................................................................................................................................................39
18.2. Measuring Menu (TCM12xx) ..................................................................................................................................41
18.2.1. DSPLAY - Display after sensor is switched on ..............................................................................................42
  18.2.2.SWT.OUT–Schaltausgangkongurieren ....................................................................................................42
18.2.3. ANA.OUT - Set output signal at analog output ..............................................................................................44
18.3 Measuring menu (TCM13xx) ...................................................................................................................................44
18.3.1. DSPLAY - Display after sensor is switched on ..............................................................................................44
  18.3.2.SWT.OUT–Congureswitchingoutput........................................................................................................44
18.3.3. ANA.OUT - Set output signal at the analog output .......................................................................................44
19. Overview of menu structure .......................................................................................................................................45
19.1. Menu TCM 12xx (ISO 4406:1999 and SAE) ..........................................................................................................45
19.2. Menu TCM 13xx (ISO 4406:1987 and NAS / ISO4406:1999 and SAE 4059 D) ....................................................47
20. Using switching output ...............................................................................................................................................48
20.1. Mode M1: Continuous measurement .....................................................................................................................48
20.2. Mode M2: Continuous measurement and switching ..............................................................................................48
20.3. Mode M3: Filter to cleanliness class and stop .......................................................................................................48
20.4. Mode M4: Filter to continuously monitor cleanliness class ....................................................................................48
20.5. Mode “SINGLE” measurement ...............................................................................................................................49
21. Setting limit values ......................................................................................................................................................49
22. Reading the analog output .........................................................................................................................................51
22.1. SAE classes acc. to AS 4059 .................................................................................................................................51
22.1.1. SAE A-D ........................................................................................................................................................52
22.1.2. SAE Class A / B / C / D .................................................................................................................................52
22.1.3. SAE A / SAE B / SAE C / SAE D ...................................................................................................................53
22.1.4. SAE + T .........................................................................................................................................................54
22.1.5. HDA.SAE – Analog signal SAE to the HDA 5500 .........................................................................................56
22.1.6. HDA.SAE Signal 1/2/3/4 ...............................................................................................................................57
22.1.7. HDA.SAE signal 5 (status) ............................................................................................................................57
22.2. ISO code acc. to ISO 4406:1999 ...........................................................................................................................58
22.2.1. ISO 4 / ISO 6 / ISO 14 ..................................................................................................................................59
22.2.2. ISO code, 3-digit ...........................................................................................................................................60
22.2.3. ISO + T ..........................................................................................................................................................61

22.2.4. HDA.ISO – Analog signal ISO to HDA 5500 .................................................................................................61
22.2.5 HDA.ISO Signal 1/2/3/4 .................................................................................................................................62
22.2.6. HDA.ISO signal 5 (status) .............................................................................................................................63
22.3.ISO code signal acc. to ISO 4406:1987 (TCM 13xx only) ...................................................................................64
22.3.1. ISO 2 / ISO 5 / ISO 15 ..................................................................................................................................64
22.3.2. ISO code, 3-digit ...........................................................................................................................................65
22.3.3. ISO + T ..........................................................................................................................................................66
22.3.4. HDA.ISO – Analog signal ISO to HDA 5500 .................................................................................................67
22.3.5. HDA.ISO Signal 1/2/3/4 ................................................................................................................................69
22.3.6. HDA.ISO signal 5 (status) .............................................................................................................................69
22.4 NAS 1638 - National Aerospace Standard (Only TCM 13xx) .............................................................................70
22.4.1 NAS maximum ..............................................................................................................................................71
22.4.2. NAS classes (2 / 5 / 15 / 25) .........................................................................................................................72
22.4.3 NAS 2 / NAS 5 / NAS 15 / NAS 25 ...............................................................................................................73
22.4.4. NAS + T .........................................................................................................................................................74
22.4.5. HDA.NAS – Analog Signal NAS to HDA 5500 ..............................................................................................75
22.4.6. HDA.NAS Signal 1/2/3/4 ...............................................................................................................................75
22.4.7. HDA.NAS signal 5 (status) ............................................................................................................................76
22.5. Fluid temperature TEMP ......................................................................................................................................77
23. Status Messages .........................................................................................................................................................77
23.1. Status LED / Display ..............................................................................................................................................77
23.2. Error .......................................................................................................................................................................80
23.3. Exceptions Errors ...................................................................................................................................................81
23.4. Analog Output Error Signals ...................................................................................................................................82
23.5. Analog signal for HDA 5500 ...................................................................................................................................83
23.5.1 HDA Status Signal 5 Table .............................................................................................................................83
24. Connecting TCMI-D-5 (Condition Sensor Interface) .................................................................................................85
24.1. TCMI-D-5 Connection overview .............................................................................................................................85
25. Connecting the TCM to an RS485 bus .......................................................................................................................86
26. Communicating with the TCM via the RS485 bus ....................................................................................................87
27. Taking the TCM out of operation ................................................................................................................................87
28. Disposing of TCM ........................................................................................................................................................87
29. Spare Parts and Accessories .....................................................................................................................................87
30. Cleanliness classes - brief overview .........................................................................................................................87
30.1. Cleanliness class - ISO 4406:1999 ........................................................................................................................87
30.2. Table - ISO 4406 ....................................................................................................................................................88
 30.3.Overviewofmodications-ISO4406:1987<->ISO4406:1999 .............................................................................89
30.4. Cleanliness class - SAE AS 4059 ..........................................................................................................................90
30.5. Table - SAE AS 4059 ..............................................................................................................................................90
 30.6.Denitionacc.toSAE ............................................................................................................................................90
  30.6.1.Particlecount(absolute)largerthanadenedparticlesize .........................................................................90
  30.6.2.Specifyingacleanlinesscodeforeachparticlesize.....................................................................................90
30.6.3. Specifying highest measured cleanliness class ............................................................................................90
31. Cleanliness Class - NAS 1638 ....................................................................................................................................91
32. Checking/resetting default settings ...........................................................................................................................91
32.1. Measuring menu ..............................................................................................................................................92
33. Specications ..............................................................................................................................................................92
34.Recalibration .................................................................................................................................................................94
35. Glossary .......................................................................................................................................................................94

L-4370 HY-TRAX®User Manual
6 En Schroeder Industries
1. Features and Precautions
The HY-TRAX®manually controlled sampling system represents the latest in technology and innovation. Features have
beendesignedintothesystemtomakeituserfriendlyandsafeforoperation,however,theunitcanconstituteahazardif
usedincorrectlybyuntrainedpersonnelorifnotusedasspeciedinthismanual.Thismayresultin:
■potential injury
■damage to the machine and/or other equipment of the client’s
1.1 Features
■Provides Local Visibility to the Fluid Condition of Critical Systems.
■IntegratedmicroVSD,(VariableSpeedDrive),pump/motorprovidesoptimalowforaccuratesensorreadingsin
variable conditions.
■The HY-TRAX®Manually Controlled Fluid Sampling System allows a user to retrieve ISO cleanliness levels from a
reservoirtankoralow-pressureline(<50psimax).
■The compact design allows for installations with tight space constraints.
■The Manual rheostat VSD pump controller is housed in a compact IP 40 enclosure and allows the user to adjust the
pumpowforoptimalsensorreadings.
■OptionalACadapterallowstheunittooperateon115VAC60Hz.24VDCisstandard.
■Ruggeddesignforelduse.
■Viton®seals.
■Fluid viscosities up to 350 cSt.
■Flow control valve providing optimal pressure for accurate sensor readings.
2. Warnings, Cautions And Notes
Explanation of Symbols and Warnings
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the
potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION—usedwiththesafetyalertsymbol.DANGERidenties
themostserioushazards.GeneralprecautionsareonCAUTIONlabels.
Follow Safety Instructions
Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review
them frequently. Be sure all operators of this machine understand every safety message. Replace safety labels
immediately if missing or damaged.

User Manual HY-TRAX®L-4370
Schroder Industries En 7
Operate Only If Qualied
Do not operate this machine unless you have read the operator’s manual carefully and you have been
qualiedbysupervisedtrainingandinstruction.Familiarizeyourselfwiththejobsiteandyoursurroundingsbeforeoperating.
Inspect Machine
Inspect the equipment carefully before each use. Keep all parts in good condition and properly installed. Fix damage and
replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical power cord.
Handle Fluids Safely—Avoid Fires
Filteringoffuelorotherammableliquidsisnotrecommended.Storeammableuidsawayfromrehazards.Donot
incinerateorpuncturepressurizedcontainers.Makesuremachineiscleanoftrash,grease,anddebris.Donotstoreoily
rags; they can ignite and burn spontaneously.
Prepare for Emergencies
Bepreparedifarestarts.Keeparstaidkitandreextinguisherhandy.Keepemergencynumbersfordoctors,
ambulanceservice,hospital,andredepartmentnearyourtelephone.
Practice Safe Maintenance
Understand service procedure before doing work. Work areas should be level, clean, and dry.
Before servicing machine:
■Position the machine on a level surface
■Allow to cool if hot
Keep all parts in good condition and properly installed. Fix damaged components immediately. Replace worn or broken
parts. Remove any buildup of grease, oil, or debris
Handle Chemical Products Safely
Directexposuretohazardouschemicalscancauseseriousinjury.Potentiallyhazardouschemicalsusedwithequipment
include such items as lubricants, coolants, paints, and adhesives.
AMaterialSafetyDataSheet(MSDS)providesspecicdetailsonchemicalproducts:physicalandhealthhazards,safety
procedures,andemergencyresponsetechniques.ChecktheMSDSbeforeyoustartanyjobusingahazardouschemical.
That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended
equipment.(ContactSchroederpriortousingwithuidsotherthanhydraulicuids).
Burn Hazards
Do not touch
Allow to cool before servicing
Wear Protective Clothing
Wearclosettingclothingandsafetyequipmentappropriatetothejob.Operatingequipmentsafelyrequiresthefullattention
of the operator. Do not wear radio or music headphones while operating the machine.
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools
or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent
electrical shorts and entanglement in moving parts.

L-4370 HY-TRAX®User Manual
8 En Schroeder Industries
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the
machine.Makesurethebulbisenclosedbyawirecage.Thehotlamentofanaccidentallybrokenbulbcanignitespilled
fuel or oil.
Work In Clean Area
Before starting a job:
■Clean work area and machine
■Make sure you have all necessary tools to do your job.
■Have the right parts on hand.
■Read all instructions thoroughly; do not attempt shortcuts.
Use Proper Tools
Usetoolsappropriatetothework.Makeshifttoolsandprocedurescancreatesafetyhazards.
Forlooseningandtighteninghardware,usethecorrectsizetools.DONOTuseU.S.measurementtoolsonmetric
fasteners. Avoid bodily injury caused by slipping wrenches.
Dispose of Waste Properly
Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste includes such items
asoil,fuel,coolant,brakeuid,lters,andbatteries.Useleak-proofcontainerswhendraininguids.Donotusefoodor
beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a
drain, or into any water source.
Electrical Hazards
■All work on the electrical equipment must be carried out by a qualified electrical equipment must be
carried out by a qualified electrician.
■The electrical parts of the cart must be regularly checked.
■Any loose contacts must be rectified immediately.
■ Thecontrolboxmustalwaysbesecured.Itmaybeaccessedonlybyauthorizedstaff.
■If work needs to be performed on electrically live parts, a second person must be called in to turn off the
main switch, if necessary.
■ Voltage or current hazard sufficient to cause shock, burn, or death.
■ Remove power before servicing.
WARNING DENOTES SITUATIONS WHICH CAN LEAD TO MORTAL INJURY IF SAFETY
PRECAUTIONS ARE NOT OBSERVED.
2.1 Technical Assistance
 ForTechnicalAssistancepleasecall1-800-722-4810oremail[email protected].

User Manual HY-TRAX®L-4370
Schroder Industries En 9
TCM: TestMate®Contamination Monitor VAC: Voltage Alternating Current
TWS: TestMate®Water Sensor VDC: Voltage Direct Current
ORB: O-Ring Boss POT: Potentiometer or Rheostat
GPM: Gallons Per Minute NPT: National Pipe Thr
2.2 Obligations and Liabilty
Using the Documentation
 Notethatthemethoddescribedforlocatingspecicinformationdoesnotreleaseyoufromyourresponsibilityof 
 carefullyreadingtheseinstructionspriortostartingtheunitupfortherst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 nd 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, along with the
corresponding page number.
The document number with its edition date enables you to order another copy of the operating and maintenance
instructions. The index is incremented every time the manual is revised or changed.
While every precaution has been taken to ensure accuracy and completeness in this literature, Schroeder Industries
assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors
or omissions.
2.3 Acronym List
de
HYDACFiltertechnikGmbH
BeWa123456ade
Se ite x
Produkt/Kapitel
200x-xx- xx
Document Number
Page Number
Edition Date Document Language

L-4370 HY-TRAX®User Manual
10 En Schroeder Industries
2.4 Components
115VAC x 24VDC
Power Supply/Converter
Manual
Controller
Variable Speed
Pump/Motor
TestMate®Contamination
Monitor (TCM)
Flow Control
Valve
0-160PSI
Pressure Gauge
Manifold
Block
Component Definitions