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HYDAC FILTER SYSTEMS ContaminationSensor CS 1939 Series, Operating And Maintenance Instructions Manual

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HYDAC FILTER SYSTEMS ContaminationSensor CS 1939 Series Operating And Maintenance Instructions Manual Download Page 11

 

General 

 

ContaminationSensor CS 1939 

en 

Page 11 / 

48

 

BeWa CS1939 3978342c V100 en-us 2019-10-08.docx 

2019-10-08 

 

Signs used for the required specialist personnel 

These symbols show the required training/knowledge for installation work 
and/or maintenance work. 

 

Specialist personnel - Electrical 

Such persons have specific 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. 

  

 

Specialist personnel - Mechanical  

Such persons have specific 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. 

 

Supplementary symbols 

You will find the following symbols in the manual as additional details: 

 

 

Tip for handling the product 

 

Required tools  

 

Summary of Contents for ContaminationSensor CS 1939 Series

Page 1: ...nsor Operating and Maintenance Instructions English translation of original instructions Valid from Firmware version V 1 00 Hardware index A Serial number 002S01515K0001305 Documentation no 3978342c Keep for future reference ...

Page 2: ... Exclusion of liability warranty 12 Notes on copyright 12 Validity of this manual 12 General Safety Information 13 Product overview 14 Scope of delivery 15 Dimensions 16 Proper designated use 17 Improper use or use deviating from intended use 18 Technical Data 19 Decoding the model code label 21 Model Code 22 Storage and transport 23 Assembly installation and commissioning 24 Design and placement ...

Page 3: ...inationSensor 34 Resetting 34 Maintenance 35 Cleaning the ContaminationSensor 35 Customer Service Service 35 Customer service USA 35 Customer Service Australia 36 Customer Service Brazil 36 China 36 Troubleshooting fault rectification 37 Removing Disposal 38 Appendix 39 Spare Parts and Accessories 39 Spare Parts 39 Accessories 39 Glossary 40 Explanation of terms and abbreviations 40 Cleanliness cl...

Page 4: ...ILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach Saarland Germany Phone 49 6897 509 01 Fax 49 6897 509 9046 E mail filtersystems hydac com 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 Phone 49 6897 509 1511 F...

Page 5: ...ly and carefully Please refer to it every time you require decisive details This manual informs and warns you of risks against which the risk reduction through the design and protective measures may not be effective or not fully effective Target group of the manual This manual was created for the following target group Target group Tasks Owner This manual and the associated documents must be kept ...

Page 6: ...ormed about potential hazards that can result from 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 Hyd...

Page 7: ...r 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 Note that the method described for locating specific information does not release you from your responsibility of carefully reading all these instructions prior to starting the unit up for the first time and at regular intervals in th...

Page 8: ...ce 2 First fill the product 3 Switch the product on Procedural instructions with a random sequence Procedural instructions that have a random sequence are listed as bullet points An example of a procedural instruction with a random sequence Clean the display Rinse the product Representation of warning general safety information All the warning general safety information in this manual are highligh...

Page 9: ...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 ...

Page 10: ...ar caution in such cases Always keep all symbols pictograms intact and legible 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 Signs used for giving orders These symbols are listed for all general safety information and instruct...

Page 11: ...list 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 Specialist personnel Mechanical Such persons have specific 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 Supplementary s...

Page 12: ... 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 the Product Lia...

Page 13: ...d in this manual Observe all the safety and warning instructions attached to the product and always keep them up to date and easily legible NOTICE Impermissible operating media The ContaminationSensor will be destroyed The ContaminationSensor may only be used in connection with mineral oils or mineral oil based raffinates Note the maximum operating pressure of 350 bar 5075 psi DANGER Unintended us...

Page 14: ...ination in hydraulic and lubrication systems The ContaminationSensor is designed to be used in low or high pressure hydraulic and lubrication circuits and test benches where a small amount of oil 30 500 ml min is diverted for measurement purposes The ContaminationSensor is approved for a maximum operating pressure see specification on type label and viscosity of up to 1000 mm s The particulate con...

Page 15: ...e package to make sure everything is present The following items are supplied Qty Description 1 ContaminationSensor CS 1939 Model in acc with the order see model code 2 O rings 4 8 x 1 78 mm 80 Shore FKM only for the connection type flange connection 1 CD with operation and maintenance instructions this document in various languages 1 CD with FluMoS software Fluid Monitoring Software 1 Quick start...

Page 16: ...Product overview ContaminationSensor CS 1939 en Page 16 48 BeWa CS1939 3978342c V100 en us 2019 10 08 docx 2019 10 08 Dimensions All dimensions in mm ...

Page 17: ... use or functionality of the product in this system Use the product only for the application described below The ContaminationSensor CS 1939 serves to continuously monitor solid particulate contamination in hydraulic and lubrication systems Intended use of the product also extends to the following Observing all instructions in the instruction manual Performing inspection and maintenance work Depen...

Page 18: ...r deviating therefrom 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 may result in hazards and or will damage the unit Examples of improper use Operation in potentially explosive atmospheres Operation with a non approved medium Operation under non approved operational...

Page 19: ...indication via status LED and display Measured variables Contamination classes according to ISO 4406 SAE AS 4059 Service variables Flow Status Drive Temp C and F Permitted ambient temperature range 30 80 C 22 176 F Storage temperature range 40 80 C 40 176 F Permitted relative humidity max 95 non condensing Sealing material FKM Protection class III low voltage protection Protection class IP 67 only...

Page 20: ...nection Thread G according to ISO 228 Flange connection DN 4 Permitted measurement flow rate 30 500 ml min Permissible viscosity range 1 to 1000 mm s Fluid temperature range 0 80 C 32 185 F Electrical data Connection plug M12x1 5 pole specified in DIN VDE 0627 Supply voltage 9 36 V DC residual ripple 10 protected against polarity reversal Power consumption 3 W max CAN SAE J1939 HSI HYDAC Sensor In...

Page 21: ...08 Decoding the model code label Details on the product identification are provided on the name plates on the unit and the components Row Description Model For model code see page 22 P N Part number S N Serial number Date Year week of production and hardware index Max INLET press maximum permitted operating pressure ...

Page 22: ...el CS ContaminationSensor Series 1939 Classification ISO 4406 SAE AS 4059 D 4 µm c 6 µm c 14 µm c 21 µm c Interface protocol CAN CAN SAE J1939 No display Electrical connection Plug M12x1 5 pin Fluids 0 based on mineral oil 1 for phosphate esters Hydraulic connection type 0 Pipe or hose connection 1 Flange connection Modification number 000 Standard ...

Page 23: ...e in the original packaging if possible Do not remove the packing until you are ready to install the unit Rinse the ContaminationSensor completely with a suitable cleaning agent or flushing oil before putting it into storage The solvents and flushing oils used must be handled and disposed of correctly Storage temperature 40 80 C 40 176 F Relative humidity maximum 95 non condensing ...

Page 24: ...and placement Install the ContaminationSensor in such a way that the flow runs from bottom to top Use the one lower port as the INLET and the other upper port as the OUTLET When selecting the installation site take ambient factors like the temperature dust water etc into account The ContaminationSensor is designed for protection class IP67 according to DIN 40050 EN 60529 IEC 529 VDE 0470 ...

Page 25: ... to a wall using two cylindrical screws having an M8 hexagonal socket according to ISO 4762 and having a length of at least 40 mm 2 Console mounting Mount on a console using 4 cylindrical screws having an M6 hexagonal socket according to ISO 4762 A B 100 60 12 16 4xM6 15 20 Bottom view All dimensions in mm 3 Installing on a mounting plate Mount on a mounting plate or control block using 4 cylindri...

Page 26: ...the sensor If it is not possible to install it like that take other measures to ensure that air cannot collect in the sensor Use port A C as the INLET and B D as the OUTLET Depending on your order the ContaminationSensor features the following hydraulic connection types Pipe hose connection The ContaminationSensor is connected to the hydraulic system via ports A and B using a pipe or hose Flange c...

Page 27: ...NG CORRECT 1 Select the measurement point so that the sample measured comes from a turbulent location with a good flow For example on a pipe elbow etc 2 Install the ContaminationSensor near the measurement point to achieve as timely results as possible 3 During installation avoid creating a siphon trap for particle deposits in the line sedimentation ...

Page 28: ...ply regardless whether the direction of flow is A B or B A Note that the permissible measured volumetric flow is 30 500 ml min If you are unable to achieve the required flow values we offer an extensive line of accessories with various conditioning modules For example You are using a fluid with a viscosity of 46 mm s at a pressure difference p of 0 9 bar so that you achieve a flow rate of approx 2...

Page 29: ... tank for example 3 Check the pressure at the measurement location Note the maximum operating pressure 4 Connect the measurement line to the INLET port of the CS Connector threads G1 4 ISO 228 We recommend an internal Ø 4mm for the line in order to prevent particle deposits sedimentation If particles 400 µm are anticipated in the hydraulic systems install a protective screen upstream from the Cont...

Page 30: ...a CS1939 3978342c V100 en us 2019 10 08 docx 2019 10 08 Electrical installation assembly Pin assignment Pin Assignment 1 9 36 V DC Supply voltage 2 CAN H SAE J1939 3 GND power supply 4 CAN L SAE J1939 5 HSI HYDAC Sensor Interface There is contact between the plug housing and the housing ...

Page 31: ...es list on page 39 includes the required connection cables of various lengths with one connection plug M12x1 5 pole according to DIN VDE 0627 and an open end HYDAC accessory cable color coding is listed in the table below Pin Color Connection to 1 brown 9 36 V DC Supply voltage 2 White CAN H SAE J1939 3 Blue GND power supply 4 black CAN L SAE J1939 5 grey HSI HYDAC Sensor Interface Body Shield ...

Page 32: ...ter definition PGN 61184 Acronym PC Name CS 1939 Length 14 SPN definition SPN Name Position Length Type Resolution Offset Min Value Max Value Unit 516096 Status 1 8 BitField 516097 ISO 4 9 8 integer 0 1 0 0 8 0 25 0 516098 ISO 6 17 8 integer 0 1 0 0 7 0 24 0 516099 ISO 14 25 8 integer 0 1 0 0 6 0 23 0 516100 ISO 21 33 8 integer 0 1 0 0 5 0 22 0 516101 SAE A 41 8 integer 0 1 0 0 0 0 14 0 516102 SAE...

Page 33: ...data FluMoS light is available as freeware on the CD included in the delivery or as a download You will find the link for the download on our homepage at www hydac com You can order FluMoS professional as a fee based accessory See chapter Spare Parts and Accessories page 39 The FluMoT FluidMonitoring Toolkit is comprised of a package of drivers and programs used for connecting the sensor to the cu...

Page 34: ...ngs value HSI Slave address a Measurement period 60 Calibrating ContaminationSensor We recommend calibrating the sensor every two to three years unless otherwise specified The authorized HYDAC service stations can be found in the Customer Service Service chapter on the page 35 Resetting To restart or reset the ContaminationSensor remove the power supply for 10 seconds ...

Page 35: ...t customer service repair and spare parts can always be found on our website at www hydac com Regular inspection and maintenance work is indispensable for ensuring trouble free operation and long service life of the product You can reach the HYDAC customer service at the following contact data HYDAC SERVICE GMBH Friedrichsthaler Str 15A Werk 13 66540 Neunkirchen Heinitz Germany Phone 49 6897 509 0...

Page 36: ...info hydac com au Customer Service Brazil HYDAC TECNOLOGIA LTDA Estrada Fukutaro Yida 225 CEP 09852 060 Cooperativa BR São Bernardo do Campo SÃO PAULO Phone 55 11 4393 6600 Fax 55 11 4393 6617 E mail hydac hydac com br Homepage www hydac com br China HYDAC TECHNOLOGY SHANGHAI LIMITED 28 Zhongpin Lu Shanghai Minhang Economic Technological Development Zone SHANGHAI 200245 P R CHINA Phone 86 21 64 63...

Page 37: ...the unit Contact HYDAC Service if the error still occurs 5 Red Flow too low Increase the flow rate through the CS 6 Red Flow too high Reduce the flow rate through the CS 7 Red Contamination too low The sensor cannot detect a measured value The operating fluid is apparently too clean 8 Red Contamination too high Reduce fluid contamination by filtration until the CS can measure the fluid purity 16 R...

Page 38: ...onnection to the product 2 Close any shut off devices in the feed and return lines to the product 2 Depressurize the unit 3 Remove the hydraulic connection lines to the product 4 Remove the product Dispose of the packaging material in an environmentally friendly manner After dismantling the product and separating its various materials into categories dispose of all parts in an environmentally frie...

Page 39: ...8x1 78 80 Shore FKM 6003048 1 Socket plug female with 5 m line shielded 5 pole M 12x1 ZBE 47S 05 3527626 1 Extension cable 5 m Socket plug female 5 pole M 12x1 Socket plug male 5 pole M 12x1 ZBE 30 05 6040852 1 Socket plug with screw terminals 5 pole M12x1 6049128 1 FluMoS Professional CD ROM 3371637 1 FluMoT CD ROM 3355177 1 Accessories You will find other electrical and hydraulic accessories for...

Page 40: ...w ON On and switched on OFF Off and switched off AC Alternating current DC Direct current MIN Minimum MAX Maximum INLET Inlet OUTLET Outlet AIR BLEED VENT Ventilation air bleed port DRAIN Draining connection DN Nominal Diameter DIN German standard EN European standard ISO International standard BEWA Operating and Maintenance Instructions MOWA Installation and Maintenance Instructions UA Conversion...

Page 41: ...everyday work even though the measurement references of the particles undergoing analysis have changed the cleanliness code will change only in individual cases When drafting the new ISO 4406 1999 it was ensured that not all the existing cleanliness provisions for systems had to be changed Table ISO 4406 Assignment of particle counts to cleanliness classes Particle count 100 ml Particle count 100 ...

Page 42: ...SO4406 1987 ISO4406 1999 old ISO 4406 1987 new ISO 4406 1999 Size ranges 4 µm c 5 µm 6 µm c 15 µm 14 µm c Dimension determined Longest dimension of a particle Diameter of the coextensive circle ISO 11171 1999 Test dust ACFTD dust 1 10 µm ultra fine fraction ISO 12103 1A1 SAE Fine AC Fine ISO 12103 1A2 SAE 5 80 µm ISO MTD Calibration dust for particle counters ISO 12103 1A3 SAE Coarse Coarse fracti...

Page 43: ...sure 28 Dimensions 16 DIN 20 24 31 40 Disposal 6 38 Documentation Representative 4 DRAIN 40 E Electrical data 20 Error 37 F filtration 37 Firmware 1 Flange connection 20 22 26 Flow rate 28 Fluid temperature 20 Fluid temperature range 20 FluMoS 15 33 39 FluMoT 33 39 Forwarding agent 6 G Glossary 40 GND 30 31 H half duplex 20 Hardware 1 Hazard symbol 8 HSI 20 30 31 33 34 Hydraulic connection 20 22 2...

Page 44: ... 4 R Relative humidity 23 report 33 S SAE 19 20 22 30 31 32 42 Scope of delivery 15 select 26 Sensor 20 30 31 Service 19 34 35 36 37 Service variable 19 Signal word 8 9 signal words 8 9 Size 42 Specialist personnel 5 6 11 Storage temperature 19 23 Storage temperature range 19 Supply voltage 20 30 31 T Target group 5 6 Transport 6 Troubleshooting 6 37 V VENT 40 W Wall mounting 25 Weight 19 ...

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Page 48: ... SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Central Fax 49 6897 509 9046 Technology Fax 49 6897 509 577 Sales Internet www hydac com E mail ...

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