Schroeder Industries TestMate Series Manual

L-2861
TestMate®Contamination Monitor
Operating and Maintenance Instructions

L-2861 | Updated 5.2016
Rev. 8.2017

Block Installation and Operation Instructions TCM L-2861
Schroeder Industries En
TCM Block Installation and Operation Instructions
General Overview and System Components
The TCM Block is a multifunctional tool used in both high and low
pressure applications, integrating TCM Contamination Sensor
technology, and optional TWS-C / D Aqua Sensor technology. The
design of the TCM Block allows for a high degree of versatility with
multiple inlet and outlet ports to best suit the application and an
adjustableowcontrolvalvetoregulateandmaintainconstantow
through the Contamination Sensor. The combination of all these factors
and robust design of the TCM Block ensure a high degree of reliability,
functionality, and product life.
Installation and Operation
FortheTCMBlock,highpressureisdenedbyanyapplicationwithpressureinexcessof150psi 
andlessthanthemaxallowableworkingpressureof3,500psi.Properinstallationrequiresinletow
throughoneofthetwoHighPressureSAE4threadinletsandreturnowthroughoneofthetwoSAE
4threadoutlets.TheowthroughtheTCMContaminationSensoriscontrolledbyadjustingtheow
controlvalvetoachieveaminimumdifferentialpressureof40psi(e.g.forarangeof500-1,000SUS).
TwogaugescanbeattachedtotheSAE4ports,allowingtheoperatortoseethepressureattheinlet
and outlet.
Whilethemanifoldblockisdesignedforusewithlowpressure/owsituations,anoptionalneedlevalve
canbeplacedimmediatelyfollowingthesensormanifold,especiallywheninuenceofairintheuidis
aproblem(ISOreadingswithequalnumbers).
To achieve ideal operating conditions, the TCM unit should be installed following the factory
recommendedprocedureoutlinedbelowandnotedintheTCMUserManual:
1. InstallTCMinaverticalposition,eitherthein-lineversionortheBlockmountedversion
2. Directionofow:fromIN(bottom)toOUT(top)
3. Selecthydraulichose
- MinimessDN2(2mmID)atIN,max.630mm
- MinimessDN4(4mmID)atIN(whenDN2producesanoverlylargepressureloss)
Specications: Pressure: max.3,500psi
Viscosityrange: upto350cSt(1,750SUS)
Requireddifferentialpressure: 6bar(87psi)>Recommended setting
min.40psiforapplicationsupto500-1,000SUS
Flowrate(TCMreading): OK-(60-100ml/min)
OK(100-200ml/min)>Recommended setting
OK+(200-450ml/min)

L-2861 TCM CS Block Installation and Operation Instructions
En Schroeder Industries
- Thehoseshouldbekeptasshortaspossible(max.630mm);whenmeasuringthree
virtuallyidenticalISOvalues(e.g.16/16/15=airinoil)extendthelengthofthehydraulic
hoseatINupto2mand/orincreasethesystempressuretoreduceairbubbles.
4. ConnecttheTCMviaMinimessHosetothehydraulicsystem
Shutsystemoff–First,connectreturnline(≥4mmID)toOUT–thenconnectINline
Thehoselengthshouldbetheshortestrunpossibleandinastraightlineavoidingbendsintheline:
The functionality and points of interest are shown on the above hydraulic schematic of the TCM Block.
Thesepointsarethefollowingstartingfromtheleftoftheschematic:
■ HighPressureSAE4threadinletportwithTest
PointattachedatasinglelocationonBlock“A”
■ SAE4threadinletport
■ Adjustableowcontrolvalve“B”,toregulate
pressure at the inlet
■ TCMinlet
■ TCMoutlet
■ PresetOrice“C”,locatedwithintheunit
■ TWS-C/Dport(pluggedifnotused)
■ SAE4threadoutletport
■ SAE4threadoutletportwithTestPointattached

FluMoS Software Quick Installation Guide TCM L-2861
Schroeder Industries En
FluMoS Software Quick Installation Guide
1. Install FluMoS application software from the provided CD.
2. Install (A) BB Electronics and (B) Blackbox RS-485 drivers from the provided CD.
A. BB Electronics RS-485 Driver Installation:
B. Blackbox RS-485 Driver Installation:
3. REBOOT YOUR COMPUTER
4. Connect the USB connector from the RS-485 converter to your computer.
5. Connect the RS-485 connector from the RS-485 converter to the particle counter.
6. Connect the power supply connector to the RS-485 converter.
7. Open the FluMoS application.
8. To search for and begin interfacing with your computer, press the Ctr + F keys simultaneously. The
below screen will appear if performed correctly. Once a port is recognized, be sure to select
”Find a device”, ”HIS”, ”+”, and ”9600”.
Note: If no ports are recognized, close the FluMoS application and repeat steps 4 through 8.
9. Click ”Start search”.
10. Once the particle counter is successfully discovered and connected to your computer, the measurement
screen will appear as seen below.

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Contents
Contents.................................................................................................................................. 2
Safety information.................................................................................................................. 6
Hazard symbols.................................................................................................................... 6
Signal words and their meaning in the safety information and instructions......................... 6
Structure of the safety information and instructions............................................................. 7
Observe regulatory information............................................................................................ 7
Proper/Designated Use........................................................................................................ 7
Improper Use or Use Deviating from Intended Use............................................................. 8
Qualifications of personnel / target group ............................................................................ 9
Storing the TCM.................................................................................................................... 10
Storage conditions.............................................................................................................. 10
Decoding the model code label .......................................................................................... 10
Checking the scope of delivery.......................................................................................... 10
TCM Features........................................................................................................................ 11
TCM Restrictions on use..................................................................................................... 12
TCM1x1x dimensions (without display)............................................................................. 12
TCM1x2x dimensions (with display) .................................................................................. 13
Hydraulic connection types................................................................................................ 13
Pipe or hose connection (type TCM).................................................................................. 13
Flange connection type (type TCM)................................................................................... 14
Fastening / mounting the TCM............................................................................................ 14
Display rotatable/Adjustable As Needed........................................................................... 16
TCM hydraulic installation .................................................................................................. 16
Selecting the measurement point....................................................................................... 17
Flow rate, differential pressure
p∆
and viscosity
ν
characteristic TCM.......................... 18
Hydraulic connection of the TCM....................................................................................... 19
Electrical connection of the TCM ....................................................................................... 20
Pin assignment................................................................................................................... 20
Connection cable - assignment / color coding ................................................................... 21
Connecting cable ends - Examples.................................................................................... 22
Setting the measuring mode............................................................................................... 22
Mode M1: Continuous measurement................................................................................. 23
Mode M2: Continuous measurement and switching.......................................................... 23
Mode M3: Filter to cleanliness class and stop ................................................................... 23
Mode M4: Filter to continuously monitor cleanliness class................................................ 23
Mode "SINGLE" measurement .......................................................................................... 24
Operating the TCM1x2x using the keypad ........................................................................ 24
Function of the Keys .......................................................................................................... 25
Measured variables on the display..................................................................................... 25
ISO (Cleanliness class).................................................................................................. 26

User Manual TCM L-2861
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SAE (Cleanliness class)................................................................................................. 26
NAS (Cleanliness Class - only TCM 13xx) .................................................................... 26
Service variables on the display......................................................................................... 26
Flow (flow rate)............................................................................................................... 26
Out (Analog output)........................................................................................................ 27
Drive (performance of the LED)..................................................................................... 27
Temp (Temperature)...................................................................................................... 27
Activate / deactivate keypad lock....................................................................................... 27
Display FREEZE ................................................................................................................ 28
Activate display FREEZE............................................................................................... 28
Deactivate display FREEZE........................................................................................... 29
Menus and modes.............................................................................................................. 30
PowerUp Menu............................................................................................................... 30
Measuring Menu (TCM12xx).......................................................................................... 32
DSPLAY - Display after sensor is switched on .......................................................... 33
SWT.OUT – Schaltausgang konfigurieren................................................................. 33
ANA.OUT - Set output signal at analog output .......................................................... 35
Measuring menu (TCM13xx).............................................................................................. 36
DSPLAY - Display after sensor is switched on .......................................................... 36
SWT.OUT – Configure switching output .................................................................... 37
ANA.OUT - Set output signal at the analog output ................................................... 39
Overview of menu structure................................................................................................ 39
Menu TCM 12xx (ISO 4406:1999 and SAE)...................................................................... 39
Menu TCM 13xx (ISO 4406:1987 and NAS / ISO4406:1999 and SAE 4059 D) ............... 40
Using switching output ....................................................................................................... 42
Mode M1: Continuous measurement................................................................................. 42
Mode M2: Continuous measurement and switching.......................................................... 42
Mode M3: Filter to cleanliness class and stop ................................................................... 42
Mode M4: Filter to continuously monitor cleanliness class................................................ 42
Mode "SINGLE" measurement .......................................................................................... 42
Setting limit values............................................................................................................... 43
Reading the analog output.................................................................................................. 44
SAE classes acc. to AS 4059............................................................................................. 45
SAE A-D......................................................................................................................... 46
SAE Class A / B / C / D.................................................................................................. 46
SAE A / SAE B / SAE C / SAE D ................................................................................... 47
SAE + T.......................................................................................................................... 48
HDA.SAE – Analog signal SAE to the HDA 5500.......................................................... 49
HDA.SAE Signal 1/2/3/4 ................................................................................................ 50
HDA.SAE signal 5 (status)............................................................................................. 50
ISO code acc. to ISO 4406:1999 ....................................................................................... 52
ISO 4 / ISO 6 / ISO 14.................................................................................................... 52
ISO code, 3-digit............................................................................................................. 53
ISO + T........................................................................................................................... 54
HDA.ISO – Analog signal ISO to HDA 5500.................................................................. 55
HDA.ISO Signal 1/2/3/4 ................................................................................................. 56
HDA.ISO signal 5 (status).............................................................................................. 56

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ISO code signal acc. to ISO 4406:1987 (TCM 13xx only) ................................................. 58
ISO 2 / ISO 5 / ISO 15.................................................................................................... 58
ISO code, 3-digit............................................................................................................. 59
ISO + T........................................................................................................................... 60
HDA.ISO – Analog signal ISO to HDA 5500.................................................................. 61
HDA.ISO Signal 1/2/3/4 ................................................................................................. 62
HDA.ISO signal 5 (status).............................................................................................. 63
NAS 1638 - National Aerospace Standard (Only TCM 13xx)............................................ 64
NAS maximum ............................................................................................................... 64
NAS classes (2 / 5 / 15 / 25) .......................................................................................... 65
NAS 2 / NAS 5 / NAS 15 / NAS 25................................................................................. 66
NAS + T.......................................................................................................................... 66
HDA.NAS – Analog Signal NAS to HDA 5500............................................................... 67
HDA.NAS Signal 1/2/3/4 ................................................................................................ 68
HDA.NAS signal 5 (status)............................................................................................. 69
Fluid temperature TEMP.................................................................................................... 70
Status Messages .................................................................................................................. 70
Status LED / Display .......................................................................................................... 70
error......................................................................................Error! Bookmark not defined.
Exceptions Errors............................................................................................................... 73
Analog Output Error Signals .............................................................................................. 75
Analog signal for HDA 5500............................................................................................... 76
HDA Status Signal 5 Table ............................................................................................ 76
Connecting TCMI-D-5 (Condition Sensor Interface)......................................................... 78
TCMI-D-5 Connection overview......................................................................................... 78
Connecting the TCM to an RS485 bus............................................................................... 78
Communicating with the TCM via the RS485 bus............................................................. 79
Taking the TCM out of operation........................................................................................ 80
Disposing of TCM................................................................................................................. 80
Spare Parts and Accessories.............................................................................................. 80
Cleanliness classes - brief overview.................................................................................. 81
Cleanliness class - ISO 4406:1999.................................................................................... 81
Table - ISO 4406................................................................................................................ 81
Overview of modifications - ISO4406:1987 <-> ISO4406:1999......................................... 82
Cleanliness class - SAE AS 4059...................................................................................... 82
Table - SAE AS 4059......................................................................................................... 83
Definition acc. to SAE ........................................................................................................ 83
Particle count (absolute) larger than a defined particle size.......................................... 83
Specifying a cleanliness code for each particle size...................................................... 83
Specifying highest measured cleanliness class............................................................. 84
Cleanliness Class - NAS 1638........................................................................................... 84
Checking/resetting default settings................................................................................... 85
PowerUp menu................................................................................................................... 85
Measuring menu................................................................................................................. 85
Specifications....................................................................................................................... 85

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Recalibration......................................................................................................................... 87
Customer Service................................................................................................................. 87
Glossary................................................................................................................................ 87
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 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 device 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
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

User Manual TCM L-2861
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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 hazard 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:
HAZARD SYMBOL
SIGNAL WORD
Type and source of danger
Consequence of the danger
►Measures to avert danger
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 TestMate®Contamination Sensor module serves to continuously monitor 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.