HYDAC International CS 1000-A-0-0-0-0/-000 Operating And Maintenance Manual Download Page 11

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ContaminationSensor CS 1000

Safety Information and Instructions

HYDAC FILTER SYSTEMS GMBH

en(us)

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BeWa CS1000 3247149p 240 en-us 2011-02-11.doc

2011-02-11

Explanation of Symbols and Warnings, etc.

The following designations and symbols are used in this manual to designate
hazards, etc.:

DANGER

DANGER denotes situations
which can lead to death if
safety precautions are not
observed.

WARNING

WARNING denotes situations
which can lead to mortal injury
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 ContaminationSensor module CS1000 was developed 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.

Summary of Contents for CS 1000-A-0-0-0-0/-000

Page 1: ...CS1000 series Contamination Sensor Operating and Maintenance Instructions English translation of original instructions Valid from firmware versions V 2 40 up Documentation no 3247149p ...

Page 2: ...curacy of the contents of this document However errors cannot be ruled out Consequently we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject...

Page 3: ... 15 CS1000 Features 16 CS1000 Restrictions on use 16 CS1x1x dimensions without display 17 CS1x2x dimensions with display 17 Hydraulic connection types 18 Pipe or hose connection type CS1xxx x x x x 0 xxx 18 Flange connection type CS1xxx x x x x 1 xxx 18 Fastening mounting the CS1000 19 Display rotatable Adjustable As Needed 20 CS1000 hydraulic installation 21 Selecting the measurement point 22 Flo...

Page 4: ...0 DSPLAY Display after sensor is switched on 40 SWT OUT Set switching output 41 ANA OUT Set output signal 43 Measuring menu CS13xx 44 DSPLAY Display after sensor is switched on 44 SWT OUT Set switching output 45 ANA OUT 47 Overview of menu structure 48 Menu CS 12xx ISO 4406 1999 and SAE 48 Menu CS 13xx ISO 4406 1987 and NAS 50 Using switching output 52 Mode M1 Continuous measurement 52 Mode M2 Con...

Page 5: ...DA 5500 81 HDA Signal 1 2 3 4 82 HDA Status Signal 5 83 Fluid temperature TEMP 84 Status messages 86 Status LED Display 86 Error 86 Exceptions Errors 87 Analog output error signals 89 Analog signal for HDA 5500 90 HDA status signal 5 table 90 Connecting CSI D 5 Condition Sensor Interface 91 CSI D 5 Connection overview 91 CS1000 in RS 485 bus 92 Taking the CS1000 out of operation 93 Disposing of CS...

Page 6: ...tured on the cover sheet of the operating and maintenance manual and in the lower left corner of each page after the part number Index k from firmware version V 1 28 New functions Index l from firmware version V 2 02 Correction of Index k Index n from firmware version V 2 20 ISO code with 1 10 decimal places in the report Changing the switching output normally closed contact Reports about HSI can ...

Page 7: ...ded in an optimal manner Keep it in the vicinity of the product so it is always available 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 additional comments or suggestions con...

Page 8: ...anges 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...

Page 9: ...at do I want to know I determine which topic I am looking for Where can I find the information I m looking for The documentation has a table of contents at the beginning There I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx The documentation number with its index enables you to order another copy ...

Page 10: ...he CS 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 Use the CS solely for its designated use only when in a safe perfect condition Our General T...

Page 11: ...ons which can lead to mortal injury 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 ContaminationSensor module CS1000 was developed for the continuous monitoring of part...

Page 12: ...iating from Intended Use Improper use may result in hazard to life and limb Improper use is Improper connection of the CS voltage and sensor cables Operation with a non approved fluid Operation with impermissibly high pressure WARNING Hydraulic systems are under pressure Danger of bodily injury The hydraulic system must be depressurized before performing any work on the hydraulic system ...

Page 13: ...clear cut manner Staff undergoing training may not use the CS unless supervised by an experienced staff member Individuals Individuals undergoing training Individuals with technical training engineering 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...

Page 14: ...age The cleaning agents and flushing oils used are to be handled and disposed of properly Storage conditions Storage temperature 40 C 80 C 40 F 176 F Relative humidity max 95 non condensing Decoding the model code label For product identification details see the Model code label This is located on the back of the unit and contains the exact product description and the serial number Row Description...

Page 15: ...ng up the CS check that the content of the package is complete The following items are supplied Qty Designation 1 ContaminationSensor CS1000 Series Model in acc with the order see model code 2 O rings optional only with connection type Flange connection model code CS1xxx x x x x 1 xxx 1 CD with Software CoCoS 1000 Operating instructions CoCoS 1000 Operating and maintenance instructions CoCoS 1000 ...

Page 16: ... optical measurement cell The sensor is available with the following options with or without 6 digit display and keypad can be rotated by 270 with a 4 20 mA or 2 10 V analog output results are output as a cleanliness code according to ISO 4406 1999 and SAE AS 4059 D or ISO 4406 1987 and SAE AS 4059 D or NAS pipe hose installation or flange installation All models feature an analog output and an RS...

Page 17: ...BH en us Page 17 108 BeWa CS1000 3247149p 240 en us 2011 02 11 doc 2011 02 11 CS1x1x dimensions without display 12 106 5 100 83 ca 170 25 ISO 228 G1 4 49 2 30 A B All dimensions in mm CS1x2x dimensions with display ca 170 106 5 12 102 83 25 ISO 228 G1 4 54 2 30 A B All dimensions in mm ...

Page 18: ...read G1 4 according to ISO 228 Make sure that the flow runs through the sensor from bottom A to top B A B Flange connection type CS1xxx x x x x 1 xxx Hydraulic connection is done via ports C and D Two O rings are used to form a seal between the CS and a flange connecting plate or manifold mount Four M6 threads are prepared for fixing the CS1000 Ports A and B are sealed off with screw plugs 1 Seali...

Page 19: ...t as the OUTLET When selecting the installation site take ambient factors like the temperature dust water etc into account The CS1000 is designed for IP67 according to DIN 40050 EN 60529 IEC 529 VDE 0470 Fasten the sensor in the following way 1 Wall mounting using 2 cylindrical screws featuring an M8 hexagonal socket minimum length 40 mm according to ISO4762 2 Console mounting using 4 cylindrical ...

Page 20: ...3 Connecting plate or valve manifold mounting using 4 cylindrical screws with an M6 hexagonal socket according to ISO 4762 Display rotatable Adjustable As Needed The CS1000 display can be continuously rotated by a total of 270 180 counterclockwise and 90 clockwise Rotate the display by hand in the corresponding direction No tools are required for rotating the display ...

Page 21: ...ypes Pipe hose connection The CS is connected to the hydraulic system via ports A and B using a pipe or hose Flange connection The CS is screwed to a flange connecting plate manifold mount or control block with flow through the unit via ports C and D on the bottom Ports A and B exist but are sealed with a screw plug Determine the operating pressure of the hydraulic system and see whether it is wit...

Page 22: ...herent in real time select a suitable measuring point according to the following guidelines A B 2 A B 1 3 A 2 1 B WRONG WRONG OK 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 sensor near the measurement point to achieve as timely results as possible 3 During installation avoid creating a sip...

Page 23: ...o achieve the required flow values we carry various Conditioning Modules in our extensive line of accessories 20 Qmin 30 ml min 100 ml min 160 ml min Qmax 300 ml min 0 1 0 2 0 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 18 16 14 12 10 8 6 4 2 0 p bar mm s 2 1 bar 46 mm s 2 50 Qmin 30 ml min 100 ml min Qmax 300 ml min 2 0 0 300 400 500 600 700 800 900 1000 45 40 35 30 25 20 15 ...

Page 24: ...nd of the return line to the system tank for example 3 Check the pressure at the measurement point It has to be within the permissible range 4 Now connect the measurement line to the INLET of the CS Connection thread G1 4 ISO 228 recommended diameter of line 4 mm to prevent particle sedimentation If there are particles larger than 400 microns in the hydraulic system or this is to be expected a str...

Page 25: ...signment Pin Assignment 1 Supply voltage 9 36 V DC 2 Analog output 3 GND for supply voltage 4 GND for analog and switch outputs 5 HSI HYDAC Sensor Interface 6 RS485 7 RS485 8 Switching output n c The analog output is an active source of 4 20 mA or 2 10 V DC The switch output is a passive n switching Power MOSFET The output switch is normally dead open There is contact between the plug housing and ...

Page 26: ...es connection cables of various lengths with one connection plug 8 pole M12x1 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 White Supply voltage 9 36 V DC 2 Brown Analog output active 3 Green GND supply voltage 4 Yellow GND ANALOG SWITCH OUTPUTS 5 Gray HSI HYDAC Sensor Interface 6 Pink RS485 7 Blue RS485 8 Red Sw...

Page 27: ...d USB RS 485 Converter 1 7 6 5 4 3 2 Schirm Shield Blindage 8 Circuit diagram with two separate power supplies e g 24 V DC and 5 V DC 1 2 3 4 5 6 7 8 Shield 24 V DC white green pink RS 485 RS 485 blue grey brown yellow red USB RS 485 Converter HSI 250 1 7 6 5 4 3 2 8 SPS Eingang PLC Input SPS Entrée Schirm Shield Blindage Circuit diagram with one power supply e g 24 V DC To prevent a ground loop c...

Page 28: ...Stand alone sensor with alarm standby display Data output Display RS485 analog output switching output Purpose Continuous measurement and controlling of signal lamps etc Function Continuous measurement of solid contamination continuous monitoring of programmable limit values switching output is activated to switch on the monitor display or an alarm on site Mode M3 Filter to cleanliness class and s...

Page 29: ... undershooting the TARGET the set test cycle time in minutes appears on the display The test cycle time expires After the test cycle time has elapsed the switching output is closed and a measurement is started If the result is still below the TARGET cleanliness the test cycle time begins again Mode SINGLE measurement Application Stand alone sensor Data output Display RS485 analog output Purpose Pe...

Page 30: ... duration of the countdown corresponds to the set measurement time MTIME This means that the countdown runs from 99 0 within the set measurement time factory setting 60 sec B D F E A C Item LED Description For details see page A Status Status display 29 B Display 6 figure display with 17 segments each C Measured variable Display of respective measured variable e g ISO SAE NAS 29 D Service variable...

Page 31: ...the following functions Key Function o k You jump one menu level down You confirm a changed value on the lowest menu level You confirm on the top menu level to save or reject a change in value Esc You jump up one menu level You exit the menu without changing the values You change values settings on the lowest menu level You scroll through the display ISO NAS SAE Flow Out Drive Temp You move throug...

Page 32: ...asured variables give you information on the oil cleanliness in the system You will gain a measured value with an accuracy of 1 2 ISO code within the calibrated range ISO Cleanliness class Display Description 2 1 1 Measured value ISO code SAE Cleanliness class Display Description A 1 SAE class measurement category NAS Cleanliness Class only CS 13xx Display Description 15 1 2 NAS class measurement ...

Page 33: ...vice variables are not calibrated They represent an approximate value for installing the sensor in the hydraulic system Flow flow rate Display Description 120 Flow rate e g 120 ml min Out Analog output Display Description 1 8 Current or voltage output at the analog output example 13 8 mA Drive performance of the LED Display Description 60 Performance 1 100 of the LED in the sensor example 60 Temp ...

Page 34: ...isplay after 1 second Display FREEZE This function makes it possible for you to call up the last 20 displayed values on the display The active display is then frozen in the set MTIME cycle The display FREEZE function is based on a volatile memory and means that the values can be called up only as long as the CS is supplied with power and the sensor is in display FREEZE The measured values are auto...

Page 35: ... us 2011 02 11 doc 2011 02 11 Activate display FREEZE To activate or deactivate the history memory FREEZE press both keys simultaneously The FREEZE function starts with the display of the most recent measured value Buttons The following appears in the display 1 sec The following appears in the display 3 sec FREEZE 2 1 1 11 19 1 1 12 1 2 1 16 2 2 1 15 ...

Page 36: ...nds 10 minutes Modes and menus The sensor has the following two operating levels menus Menus Mode Description Page PowerUp Menu PowerUp Mode You carry out the basic settings in this menu 29 Measuring Menu Measurement mode This menu starts automatically after powering up 29 PowerUp Menu You can carry out the basic settings for operation of the CS in the PowerUp menu Selection To do Start the PowerU...

Page 37: ...ory memory DFAULT Reset CS to factory default settings CANCEL Discard changes and exit SAVE Save changes and exit CODE For internal use only MODE Select measurement mode Designation M1 Continuous measurement M2 Continuous measurement and switching M3 Filter to cleanliness class and stop M4 Filter with continuous monitoring SINGLE single measurement mTIME Set measuring duration Designation 60 Set m...

Page 38: ...1 doc 2011 02 11 pPRTCT Set pump protection time Designation 0 0 10 number of measurement cycles Make sure that the pump can run dry at an M Time setting of 300 10 3000 seconds 50 minutes ADRESS Set bus address Designation HECOM A a b z IP NO SET MODBUS NO SET CALIB Select calibration Available for model CS 13xx only ISoSAE ISO4406 1999 SAE ISoNAS ISO4406 1987 NAS ...

Page 39: ...ction FREEZE switched off MANUAL Return to display manually via the key combination For details see page 29 TIMOUT Return to display automatically after 10x the measurement duration MTIME For details see page 29 DFAULT Resetting to factory setting Generate factory setting For factory settings see page 29 CANCEL Discard changes and exit SAVE Save changes and exit CODE Activates the service menu For...

Page 40: ...t pressed within 30 seconds the system jumps back automatically Save and exit the measuring menu Scroll through to SAVE and press the o k key Measuring Menu Designation DSPLAY Set display SWtOUT Configure switching output ANaOUT Set analog output output signal CANCEL Discard changes and exit SAVE Save changes and exit DSPLAY Display after sensor is switched on DSPLAY Set display Designation ISO 3 ...

Page 41: ... mode in the PowerUp menu SWtOUT Configure switching output o k Designation M1 Continuous measurement M2 Continuous measurement and switching M3 Filter to cleanliness class and stop M4 Filter to continuously monitor cleanliness class SINGLE Start single measurement stop M1 Continuous measurement o k NO SET M2 Continuous measurement and switching o k SP1 MEAsCH SAEMAX SAE ISO 4 ISO 6 ISO 14 ISO TEM...

Page 42: ...imit values LOWER UPPER M3 Filter to cleanliness class and stop o k Designation MEAsCH ISO ISO code SAE SAE class TARGET Target cleanliness M4 Filter to continuously monitor cleanliness class Designation MEAsCH ISO ISO code SAE SAE class TARGET Target cleanliness RSTART Resume filtration from this class CYCLE 60 Set measurement cycle 1 1440 minutes SINGLE Start single measurement stop o k NO SET ...

Page 43: ...at the analog output see page 55 ANaOUT Set analog output output signal Designation SAeMAX SAE A D SAE SAE class A B C D coded SAE T SAE class temp Code TEMP Fluid temperature HDaISO ISO for HDA 5500 HDaSAE SAE for HDA 5500 ISO 4 ISO 4 code ISO 6 ISO 6 code ISO 14 ISO 14 code ISO ISO 3 digit coded ISO T ISO 3 digit temp coded SAE A SAE class A SAE B SAE class B SAE C SAE class C SAE D SAE class D ...

Page 44: ...ion is selected automatically after 30 s Exit menu and save changes Scroll to SAVE and press o k Measuring Menu Designation DSPLAY Select display SWtOUT Configure switching output ANAOUT Set analog output output signal CANCEL Discard changes and exit SAVE Save changes and exit DSPLAY Display after sensor is switched on DSPLAY Set display Designation ISO 3 digit ISO code NAS 2 NAS class 2 NAS 5 NAS...

Page 45: ...mode in the PowerUp menu SWtOUT Configure switching output o k Designation M1 Continuous measurement M2 Continuous measurement and switching M3 Filter to cleanliness class and stop M4 Filter to continuously monitor cleanliness class SINGLE Start single measurement stop M1 Continuous measurement o k NO SET M2 Continuous measurement and switching o k SP1 MEAsCH NAsMAX NAS ISO 4 ISO 6 ISO 14 ISO TEMP...

Page 46: ...imit values LOWER UPPER M3 Filter to cleanliness class and stop o k Designation MEAsCH ISO ISO code NAS NAS class TARGET Target cleanliness M4 Filter to continuously monitor cleanliness class Designation MEAsCH ISO ISO code NAS NAS class TARGET Target cleanliness RSTART Resume filtration from this class CYCLE 60 Set measurement cycle 1 1440 minutes SINGLE Start single measurement stop o k NO SET ...

Page 47: ...page 29 ANaOUT Set analog output output signal Description NAsMAX NAS maximum NAS NAS class 2 5 15 25 coded NAS T NAS class temp coded TEMP Fluid temperature HDaISO ISO for HDA 5500 HDaNAS NAS or SAE for HDA 5500 ISO 2 ISO class 2 ISO 5 ISO class 5 ISO 15 ISO class 15 ISO ISO 3 digit coded ISO T ISO 3 digit temp coded NAS 2 NAS class 2 NAS 5 NAS class 5 NAS 15 NAS class 15 NAS 25 NAS class 25 CANC...

Page 48: ...s D SAeMAX SAE A D FLOW Flow rate ANaOUT Analog output DRIVE LED current in TEMP C Fluid temperature in C TEMP F Fluid temperature in F SWtOUT Switching Output M1 Mode 1 NO SET M2 Mode 2 SP1 Switching point MEAsCH Test channel SAeMAX SAE A D SAE SAE class A B C D ISO 4 ISO class 4µm ISO 6 ISO class 6µm ISO 14 ISO class 14µm ISO ISO Code TEMP Temperature SAE A SAE class A SAE B SAE class B SAE C SA...

Page 49: ... us Page 49 108 BeWa CS1000 3247149p 240 en us 2011 02 11 doc 2011 02 11 ISO 4 ISO class 4µm ISO 6 ISO class 6µm ISO 14 ISO class 14µm ISO ISO Code ISO T ISO code Temperature SAE A SAE A SAE B SAE B SAE C SAE C SAE D SAE D CANCEL Discard changes and exit SAVE Discard changes and exit ...

Page 50: ...S maximum FLOW Flow rate ANaOUT Analog output DRIVE LED current in TEMP C Temperature in C TEMP F Temperature in F SWtOUT Switching Output M1 Mode 1 NO SET M2 Mode 2 SP1 Switching point MEAsCH Test channel NAsMAX NAS maximum NAS NAS class ISO 4 ISO class 4µm ISO 6 ISO class 6µm ISO 14 ISO class 14µm ISO ISO Code TEMP Temperature NAS 2 NAS 2 µm NAS 5 NAS 5 µm NAS 15 NAS 15 µm NAS 25 NAS 25 µm SwFNC...

Page 51: ...e HYDAC FILTER SYSTEMS GMBH en us Page 51 108 BeWa CS1000 3247149p 240 en us 2011 02 11 doc 2011 02 11 ISO T ISO code Temperature NAS 2 NAS 2 µm NAS 5 NAS 5 µm NAS 15 NAS 15 µm NAS 25 NAS 25 µm CANCEL Discard changes and exit SAVE Discard changes and exit ...

Page 52: ...of programmed limit values the switching output is enabled and switches on the monitoring display or alarm on site Mode M3 Filter to cleanliness class and stop Purpose Clean up hydraulic reservoir Function Control of a filter unit continuous measurement of solid contamination if pre programmed cleanliness level is reached 5 times in sequence the pump is stopped Mode M4 Filter to continuously monit...

Page 53: ...t value After switch on or start of a measurement Becomes conductive again when a value respective upper limit WITHIN Within limit values Lower limit measured value upper limit After switch on or start of a measurement Becomes conductive again when a value respective lower limit or a value respective upper limit OUTSDE Outside limit values Measured value lower limit or measured value upper limit A...

Page 54: ...of an error Mode 3 M3 Switching output OPEN Switching output CONDUCTIVE 5 consecutive tests limit value or measurement stopped Measurement is currently in progress and one or more of the last 5 measured values limit Mode 4 M4 Switching output OPEN Switching output CONDUCTIVE Start or result of check measurement after test cycle time a value upper limit For max 5 consecutive measurements all values...

Page 55: ... type of analog output from the model code of the sensor CS Model code Analog output CS 1 x x x A x x x x xxx 4 20 mA CS 1 x x x B x x x x xxx 2 10 V Observe the design of the analog output in the order It is not possible to internally change the analog output over later In the measuring menu select one of the following signals for the analog output SAE classes acc to AS 4059 ISO code acc to 4406 ...

Page 56: ...4 9 6 V of the output signal is dependent on the ISO contamination class SAE 0 0 14 0 resolution 0 1 class or an error as shown in the table below Current I SAE class error Voltage U I 4 00 mA Cable break U 2 00 V 4 0 mA I 4 1 mA Device error device not ready 2 00 V U 2 05 V 4 1 mA I 4 3 mA Not defined 2 05 V U 2 15 V 4 3 mA I 4 5 mA Flow error flow insufficient 2 15 V U 2 25 V 4 5 mA I 4 8 mA Not...

Page 57: ...an be calculated SAE class I 4 8 mA x 14 14 4 mA SAE class U 2 4 V x 14 7 2 V SAE A D The SAeMAX value is the highest class in any of one of the four SAE A D classes respectively 4 µm c 6 µm c 14 µm c 21 µm c The signal is updated after the measuring period has elapsed the measuring period is set in the PowerUp menu factory setting 60 s The SAeMAX signal is output depending on the maximum SAE clas...

Page 58: ...9 9 Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier SAE A 300 High Low 2 Measured value SAE A 3000 Current Voltage for measured value 3 Identifier SAE B 300 High Low High Low 4 Measured value SAE B 3000 Current Voltage for measured value 5 Identifier SAE C 300 High Low High Low High Low 6 Measured value SAE C 3000 Current Voltage for measured value 7 Identifier SA...

Page 59: ...e Signal duration per pulse in ms Current I Voltage U 1 Identifier SAE A 300 High Low 2 Measured value SAE A 3000 Current Voltage for measured value 3 Identifier SAE B 300 High Low High Low 4 Measured value SAE B 3000 Current Voltage for measured value 5 Identifier SAE C 300 High Low High Low High Low 6 Measured value SAE C 3000 Current Voltage for measured value 7 Identifier SAE D 300 High Low Hi...

Page 60: ...ation with the downstream control unit is a prerequisite The signal output is as follows Time Measured variable Signal duration in s Current I Voltage U Start signal 0 2 20 mA 10 V Pause 2 4 mA 2 V Signal 1 SAE A 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 2 SAE B 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 3 SAE C 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 4 SAE D 2 Cu...

Page 61: ... V I 7 43 mA SAE 3 U 3 71 V I 8 57 mA SAE 4 U 4 29 V I 9 71 mA SAE 5 U 4 86 V I 10 86 mA SAE 6 U 5 43 V I 12 00 mA SAE 7 U 6 00 V I 13 14 mA SAE 8 U 6 57 V I 14 29 mA SAE 9 U 7 14 V I 15 43 mA SAE 10 U 7 71 V I 16 57 mA SAE 11 U 8 29 V I 17 71 mA SAE 12 U 8 86 V I 18 86 mA SAE 13 U 9 43 V I 19 77 mA SAE 13 8 U 9 89 V I 19 89 mA SAE 13 9 U 9 94 V I 20 00 mA SAE 14 0 U 10 00 V If the contamination c...

Page 62: ...orrectly U 2 5 V I 6 0 mA Device error CS not ready U 3 0 V I 7 0 mA Flow too low Flow 2 low U 3 5 V I 8 0 mA SAE 0 U 4 0 V I 9 0 mA No measured value flow not defined U 4 5 V If the status signal is 6 0 7 0 9 0 mA or 3 0 3 5 4 5 V signals 1 to 4 are output with 20 mA or 10 V Example I mA U V t s 4 2 6 3 9 4 5 10 0 7 5 3 5 2 5 8 4 20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 30 1 1 0 2 2 3 3 4 4...

Page 63: ...he ISO contamination class 0 0 24 28 resolution 1 class or an error as shown in the table below Current I ISO code error Voltage U I 4 0 mA Cable break U 2 0 V 4 0 mA I 4 1 mA Device error device not ready 2 0 V U 2 05 V 4 1 mA I 4 3 mA Not defined 2 05 V U 2 15 V 4 3 mA I 4 5 mA Flow error flow insufficient 2 15 V U 2 25 V 4 5 mA I 4 8 mA Not defined 2 25 V U 2 4 V I 4 80 mA ISO 0 U 2 40 V I 5 37...

Page 64: ...ISO 24 28 U 9 60 V 19 2 mA I 19 8 mA Not defined 9 60 V U 9 90 V 19 8 mA I 20 mA No measured value 9 90 V U 10 V The current I or voltage U can be calculated for a given ISO contamination class as follows I 4 8 mA ISO code x 19 2 mA 4 8 mA 24 28 U 2 4 V ISO Code x 9 6 V 2 4 V 24 28 The ISO contamination class can be calculated for a given current I or voltage U as follows ISO code I 4 8 mA x 24 28...

Page 65: ...1 3 2 4 6 2 5 1 U V t ms 4 8 19 2 High High Low Low 300 3000 3000 3000 9 75 19 5 2 15 2 05 2 0 9 85 19 7 0 0 19 8 9 9 Time Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 4µm c 300 High Low 2 Measured value 4µm c 3000 Current Voltage for measured value 3 Identifier 6µm c 300 High Low High Low 4 Measured value 6µm c 3000 Current Voltage for measured value 5 Identifier 14µm c 3...

Page 66: ... 5 9 85 4 3 2 15 19 7 9 75 0 0 19 8 9 9 _ Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 4µm c 300 High Low 2 Measured value 4µm c 3000 Current Voltage for measured value 3 Identifier 6µm c 300 High Low High Low 4 Measured value 6µm c 3000 Current Voltage for measured value 5 Identifier 14µm c 300 High Low High Low High Low 6 Measured value 14µm c 3000 Current Vo...

Page 67: ...ization with the downstream control unit is a prerequisite The signal output is as follows Time Measured variable Signal duration in s Current I Voltage U Start signal 0 2 20 mA 10 V Pause 2 4 mA 2 V Signal 1 ISO 4 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 2 ISO 6 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 3 ISO 14 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 4 ISO 21 ...

Page 68: ...9 25 mA ISO 8 U 4 62 V I 9 91 mA ISO 9 U 4 95 V I 10 57 mA ISO 10 U 5 28 V I 11 23 mA ISO 11 U 5 61 V I 11 89 mA ISO 12 U 5 94 V I 12 55 mA ISO 13 U 6 27 V I 13 20 mA ISO 14 U 6 60 V I 13 86 mA ISO 15 U 6 93 V I 14 52 mA ISO 16 U 7 26 V I 15 20 mA ISO 17 U 7 60 V I 15 82 mA ISO 18 U 7 91V I 16 48 mA ISO 19 U 8 24 V I 17 13 mA ISO 20 U 8 56 V I 17 79 mA ISO 21 U 8 90 V I 18 45 mA ISO 22 U 8 23 V I ...

Page 69: ...0 mA Flow too low Flow 2 low U 3 5 V I 8 0 mA ISO 9 8 7 U 4 0 V I 9 0 mA No measured value flow not defined U 4 5 V If the status signal is 6 0 7 0 9 0 mA or 3 0 3 5 4 5 V signals 1 to 4 are output with 20 mA or 10 V Example I mA U V t s 4 2 6 3 9 4 5 10 0 7 5 3 5 2 5 8 4 20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 30 1 1 0 2 2 3 3 4 4 5 5 0 If the status signal is 8 0 mA or 4 0 V signals 1 to ...

Page 70: ...dent on the ISO contamination class 0 0 24 28 resolution 1 class or an error as shown in the table below Current I ISO code error Voltage U I 4 00 mA Cable break U 2 00 V 4 0 mA I 4 1 mA Device error device not ready 2 0 V U 2 05 V 4 1 mA I 4 3 mA Not defined 2 05 V U 2 15 V 4 3 mA I 4 5 mA Flow error flow insufficient 2 15 V U 2 25 V 4 5 mA I 4 8 mA Not defined 2 25 V U 2 4 V I 4 80 mA ISO 0 U 2 ...

Page 71: ...ISO 24 28 U 9 60 V 19 2 mA I 19 8 mA Not defined 9 60 V U 9 90 V 19 8 mA I 20 mA No measured value 9 90 V U 10 V The current I or voltage U can be calculated for a given ISO contamination class as follows I 4 8 mA ISO code x 19 2 mA 4 8 mA 24 28 U 2 4 V ISO Code x 9 6 V 2 4 V 24 28 The ISO contamination class can be calculated for a given current I or voltage U as follows ISO code I 4 8 mA x 24 28...

Page 72: ...3 2 4 6 2 5 1 U V t ms 4 8 19 2 High High Low Low 300 3000 3000 3000 9 75 19 5 2 15 2 05 2 0 9 85 19 7 0 0 19 8 9 9 Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 2µm 300 High Low 2 Measured value 2µm 3000 Current Voltage for measured value 3 Identifier 5µm 300 High Low High Low 4 Measured value 5µm 3000 Current Voltage for measured value 5 Identifier 15µm 300 Hi...

Page 73: ...5 7 19 5 9 85 4 3 2 15 19 7 9 75 0 0 19 8 9 9 _ Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 2µm 300 High Low 2 Measured value 2µm 3000 Current Voltage for measured value 3 Identifier 5µm 300 High Low High Low 4 Measured value 5µm 3000 Current Voltage for measured value 5 Identifier 15µm 300 High Low High Low High Low 6 Measured value 15µm 3000 Current Voltage ...

Page 74: ...zation with the downstream control unit is a prerequisite The signal output is as follows Time Measured variable Signal duration in s Current I Voltage U Start signal 0 2 20 mA 10 V Pause 2 4 mA 2 V Signal 1 4 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 2 6 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 3 14 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 4 21 µm 2 Cur...

Page 75: ...9 25 mA ISO 8 U 4 62 V I 9 91 mA ISO 9 U 4 95 V I 10 57 mA ISO 10 U 5 28 V I 11 23 mA ISO 11 U 5 61 V I 11 89 mA ISO 12 U 5 94 V I 12 55 mA ISO 13 U 6 27 V I 13 20 mA ISO 14 U 6 60 V I 13 86 mA ISO 15 U 6 93 V I 14 52 mA ISO 16 U 7 26 V I 15 20 mA ISO 17 U 7 60 V I 15 82 mA ISO 18 U 7 91V I 16 48 mA ISO 19 U 8 24 V I 17 13 mA ISO 20 U 8 56 V I 17 79 mA ISO 21 U 8 90 V I 18 45 mA ISO 22 U 8 23 V I ...

Page 76: ...0 V I 7 0 mA Flow too low Flow 2 low U 3 5 V I 8 0 mA ISO 9 8 7 U 4 0 V I 9 0 mA No measured value flow not defined U 4 5 V If the status signal is 6 0 mA or 3 0 V signals 1 to 4 are output with 20 mA or 10 V Example I mA U V t s 4 2 6 3 9 4 5 10 0 7 5 3 5 2 5 8 4 20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 30 1 1 0 2 2 3 3 4 4 5 5 0 If the status signal is 8 0 mA or 4 0 V signals 1 to 4 are ou...

Page 77: ... mA or voltage 2 4 9 6 V of the output signal is dependent on the ISO contamination class 0 0 14 0 resolution 0 1 class or an error as shown in the table below Current I NAS class error Voltage U I 4 00 mA Cable break U 2 00 V 4 0 mA I 4 1 mA Device error device not ready 2 00 V U 2 05 V 4 1 mA I 4 3 mA Not defined 2 05 V U 2 15 V 4 3 mA I 4 5 mA Flow error flow insufficient 2 15 V U 2 25 V 4 5 mA...

Page 78: ...as follows NAS class I 4 8 mA x 14 14 4 mA NAS class U 2 4 V x 14 7 2 V NAS maximum The NAsMAX value designates the largest of the 4 NAS classes NAS class 2 µm 5 µm 15 µm 25 µm Particle size 2 5 µm 5 15 µm 15 µm 25 µm The signal is updated after the measuring period has elapsed the measuring period is set in the PowerUp menu factory setting 60 s The NAsMAX signal is output depending on the maximum...

Page 79: ...0 9 9 Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 2 µm 300 High Low 2 Measured value 2 µm 3000 Current Voltage for measured value 3 Identifier 5 µm 300 High Low High Low 4 Measured value 5 µm 3000 Current Voltage for measured value 5 Identifier 15 µm 300 High Low High Low High Low 6 Measured value 15 µm 3000 Current Voltage for measured value 7 Identifier 25 µ...

Page 80: ... 19 7 0 0 19 8 _ Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier 2 µm 300 High Low 2 Measured value 2 µm 3000 Current for measured value 3 Identifier 5 µm 300 High Low High Low 4 Measured value 5 µm 3000 Current for measured value 5 Identifier 15 µm 300 High Low High Low High Low 6 Measured value 15 µm 3000 Current for measured value 7 Identifier 25 µm 300 High Lo...

Page 81: ...ation with the downstream control unit is a prerequisite The signal output is as follows Time Measured variable Signal duration in s Current I Voltage U Start signal 0 2 20 mA 10 V Pause 2 4 mA 2 V Signal 1 2 5 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 2 5 15 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 3 15 25 µm 2 Current Voltage for signal Pause 2 4 mA 2 V Signal 4 25 µ...

Page 82: ... V I 7 43 mA NAS 3 U 3 71 V I 8 57 mA NAS 4 U 4 29 V I 9 71 mA NAS 5 U 4 86 V I 10 86 mA NAS 6 U 5 43 V I 12 00 mA NAS 7 U 6 00 V I 13 14 mA NAS 8 U 6 57 V I 14 29 mA NAS 9 U 7 14 V I 15 43 mA NAS 10 U 7 71 V I 16 57 mA NAS 11 U 8 29 V I 17 71 mA NAS 12 U 8 86 V I 18 86 mA NAS 13 U 9 43 V I 19 77 mA NAS 13 8 U 9 89 V I 19 89 mA NAS 13 9 U 9 94 V I 20 00 mA NAS 14 0 U 10 00 V The current I or volta...

Page 83: ...7 0 mA Flow too low Flow 2 low U 3 5 V I 8 0 mA NAS 0 U 4 0 V I 9 0 mA No measured value flow not defined U 4 5 V If the status signal is 6 0 7 0 9 0 mA or 3 0 3 5 4 5 V signals 1 to 4 are output with 20 mA or 10 V Example I mA U V t s 4 2 6 3 9 4 5 10 0 7 5 3 5 2 5 8 4 20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 30 1 1 0 2 2 3 3 4 4 5 5 0 If the status signal is 8 0 mA or 4 0 V signals 1 to 4 ...

Page 84: ...defined 2 25 V U 2 40 V I 4 8 mA 25 C 13 F U 2 40 V I 7 68 mA 0 C 32 F U 3 84 V I 8 26 mA 5 C 41 F U 4 13 V I 8 83 mA 10 C 50 F U 4 42 V I 9 41 mA 15 C 59 F U 4 70 V I 9 98 mA 20 C 68 F U 4 99 V I 10 56 mA 25 C 77 F U 5 28 V I 11 14 mA 30 C 86 F U 5 57 V I 11 71 mA 35 C 95 F U 5 86 V I 12 29 mA 40 C 104 F U 6 14 V I 12 86 mA 45 C 113 F U 6 43 V I 13 44 mA 50 C 122 F U 6 72 V I 14 02 mA 55 C 131 F ...

Page 85: ... I 4 8 mA temperature C 25 x 19 2 mA 4 8 mA 125 I 4 8 mA temperature F 13 x 19 2 mA 4 8 mA 225 U 2 4 V temperature C 25 x 9 6 V 2 4 V 125 U 2 4 V temperature F 13 x 9 6 V 2 4 V 225 The temperature in C or F can be calculated for a given current I or voltage U as follows Temperature C I 4 8 mA x 125 14 4 mA 25 Temperature F I 4 8 mA x 225 14 4 mA 13 Temperature C U 2 4 V x 125 7 2 V 25 Temperature ...

Page 86: ...surement range ISO 9 8 7 Error LED Blink code Display Analog output Switch out Status To do Error no Red 2 LOW 4 4 mA 2 2 V open Flow is too low Check that the flow is between 30 300 ml min Increase the inlet pressure or reduce the outlet pressure 1 Red CHECK 19 9 mA 9 95 V open It is not possible to determine the flow rate The sensor status is undefined Check that the flow is between 30 300 ml mi...

Page 87: ...e sensor is above its measurement range ISO 25 24 23 It is not possible to determine the flow rate Filter the fluid 3 Exceptions Errors LED Blink code Display Analog output Switch output CS1000 Status To do Error no off 0 mA 0 V open CS no display no function Check the supply voltage for CS Contact HYDAC Red 2 LOW 4 1 mA 2 05 V or 19 9 mA 9 95 V open 2 low on Drive If the CS is supplied with 24 V ...

Page 88: ...ed 4 1 mA 2 05 V open Communication error Check the wiring 20 39 Red 4 1 mA 2 05 V open System error Perform a reset To do this disconnect the CS from the voltage supply or contact HYDAC 40 69 Red 4 1 mA 2 05 V open Error during automatic adjustment Perform a reset To do this disconnect the CS from the voltage supply check the flow rate or contact HYDAC 70 Red 4 1 mA 2 05 V open Error measuring ce...

Page 89: ...ime coding is preserved Example Error Flow too low or 2 low for the SAE output signal 4 0 I mA U V t ms 4 8 Low 20 0 19 2 High High Low 4 5 4 3 4 1 19 7 19 5 300 3000 1 3 5 7 1 2 4 6 8 2 0 2 05 2 25 2 4 9 85 9 75 2 15 9 6 0 0 19 8 10 0 9 9 Time Signal Size Signal duration per pulse in ms Current I Voltage U 1 Identifier SAE A 300 High Low 2 Measured value SAE A 3000 4 4 mA 2 2 V 3 Identifier SAE B...

Page 90: ...eady U 3 0 V I 7 0 mA Flow too low Flow 2 low U 3 5 V I 8 0 mA ISO 9 8 7 U 4 0 V I 9 0 mA No measured value flow not defined U 4 5 V If the status signal is 6 0 7 0 9 0 mA or 3 0 3 5 4 5 V signals 1 to 4 are output with 20 mA or 10 V Example I mA U V t s 4 2 6 3 9 4 5 10 0 7 5 3 5 2 5 8 4 20 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 30 1 1 0 2 2 3 3 4 4 5 5 0 If the status signal is 8 0 mA or 4 ...

Page 91: ...us 2011 02 11 doc 2011 02 11 Connecting CSI D 5 Condition Sensor Interface The CSI D 5 enables the operation from CS1000 via PC Setting parameters and limit values Reading out measurement data online CSI D 5 Connection overview Connect the CSI D 5 to the CS according to the following connection diagram USB A USB B PS2 PC CSI D 5 CS 1000 ZBE 43 xx ...

Page 92: ...d the size of the terminating resistance depend on the quality of cable used The graphic below shows several CS1000 linked via the RS 485 interface and then connected to a PC RS 485 RS 485 RS 485 max 5 m 10 00 m Data Data 10 VDC 30 VDC RS 485 HECOM Bus address HECOM Bus address HECOM Bus address HECOM Bus address RS 485 RS 485 B C Z A 1 3 4 2 1 2 2 U SB B USB A PC _ Item Designation Part no 1 Conv...

Page 93: ...ce to components covered with oil and to electronics components After disassembling the unit and separating the various materials reuse them or dispose of them properly in accordance with local regulations Spare parts and accessories Description Qty Part no CD with PC software pack CoCoS 1000 and Operation and maintenance instructions 1 3251484 ContaminationSensor Interface CSI D 5 1 3249563 O rin...

Page 94: ...t for the user in his 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 Allocation of particle counts to cleanliness classes Number of particles...

Page 95: ...the analyzed sample Overview of modifications ISO4406 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 area equivalent 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 parti...

Page 96: ...o be added e g AS 4059 class 6B 9731 19500 particles 6 µm AS 4059 class 8A 7B 6C 3 value ISO code 4µm 6µm 14µm If an SAE class is given acc to AS 4059 without a letter then it is always particle size B 6 µm The following table shows the cleanliness in relation to the particle concentration determined Table SAE AS 4059 Maximum particle count 100 ml Size ISO 4402 1 µm 5 µm 15 µm 25 µm 50 µm 100 µm S...

Page 97: ... to AS 4059 6 B Size B particles may not exceed the maximum number indicated for code 6 6 B max 19 500 particles 5 µm in size Specifying a cleanliness class for each particle size Example Cleanliness class according to AS 4059 7 B 6 C 5 D Cleanliness class Particle count 100 ml Size B 5 µm 6 µm c 38 900 Size C 15 µm 14 µm c 3460 Size D 25 µm 21 µm c 306 Specify highest measured cleanliness class E...

Page 98: ...ined Maximum particle count 100 ml 2 5 µm 5 15 µm 15 25 µm 25 50 µm 50 100 µm 100 µm 00 625 125 22 4 1 0 0 1 250 250 44 8 2 0 1 2 500 500 88 16 3 1 2 5 000 1 000 178 32 6 1 3 10 000 2 000 356 64 11 2 4 20 000 4 000 712 128 22 4 5 40 000 8 000 1 425 253 45 8 6 80 000 16 000 2 850 506 90 16 7 160 000 32 000 5 700 1 012 180 32 8 320 000 64 000 11 400 2 025 360 64 9 640 000 128 000 22 800 4 050 720 12...

Page 99: ...rUp Menu PowerUp Menu Value MODE M1 M TIME 60 pPRTCT 0 ADRESS HECOM A CALIB NAS CS 13xx only Mode Value MODE M2 SP1 MEAS CH SAeMAX MODE M2 SP1 SW FNCT BEYOND MODE M2 SP1 LIMITS LOWER 17 15 12 MODE M2 SP1 LIMITS UPPER 21 19 16 MODE M3 MEAsCH ISO MODE M3 TARGET 17 15 12 MODE M4 MEAsCH ISO MODE M4 TARGET 17 15 12 MODE M4 RESTART 21 19 16 MODE M4 CYCLE 60 Measuring Menu Measuring Menu Value DSPLY ISO ...

Page 100: ... 30 80 C 22 176 F Storage temperature range 40 80 C 40 176 F Relative humidity max 95 non condensing CS 1xx0 FPM Material of sealings CS 1xx1 EPDM Protection class III low voltage protection IP class IP67 Weight 1 3 kg Electrical data Connection plug M12x1 8 pole specified in DIN VDE 0627 Supply voltage 9 36 V DC residual ripple 10 protected against polarity reversal Power consumption 3 Watt max s...

Page 101: ...ervice We recommend recalibrating the sensor every 2 3 years unless regulated differently by quality assurance Customer service For calibration and repair send the sensor to the following address HYDAC Service GmbH Product Support Plant 10 Hauptstrasse 27 66128 Saarbruecken Gersweiler Germany Telephone 49 0 681 509 1938 Fax 49 0 681 509 1933 E mail service hydac com ...

Page 102: ...ISO4406 1987 NAS 1638 ISO4406 1999 SAE AS4059 D Options 1 without display 2 with display continuously variable rotation by 270 Fluids 0 petroleum based 1 for phosphate esters Analog interfaces A 4 20 mA B 2 10 V Switching Output 0 Switch output threshold Digital interface 0 RS485 Electrical connection type 0 plug connection M12x1 8 pin pin according to VDE0627 or IEC61984 Hydraulic connection type...

Page 103: ...ow Any modification of this product that is not coordinated with us in writing will cause this declaration to lose its validity Designation ContaminationSensor Type CS1000 series Part no Serial no EMC Guideline 2004 108 EG EU directive on electromagnetic compatibility DIN EN 55011 1998 A1 1999 A2 2002 Electromagnetic compatibility immunity EN 61000 6 2 2010 02 15 Thorsten Trier Date Name CE author...

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Page 108: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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