Hydac MCS1 Series Operation And Installation Manual Download Page 1

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MCS1xxx /-T005

Metallic
Contamination Sensor

Operation and Installation Guide

English (translation of original instructions)

Documentation no.: 4668567a

Valid from hardware index D and
firmware version C09.30 up

Summary of Contents for MCS1 Series

Page 1: ...S1xxx T005 Metallic Contamination Sensor Operation and Installation Guide English translation of original instructions Documentation no 4668567a Valid from hardware index D and firmware version C09 30 up ...

Page 2: ...tors Mathias Dieter Dipl Kfm Wolfgang Haering Documentation Representative Mr Günter Harge c o HYDAC International GmbH Industriegebiet 66280 Sulzbach Saar Telephone 49 6897 509 1511 Fax 49 6897 509 1394 E mail guenter harge hydac com HYDAC FILTER SYSTEMS GMBH All rights reserved No part of this work may be reproduced in any form print photocopy or by other means or processed duplicated or distrib...

Page 3: ... Use 10 Improper use or use deviating from intended use 11 Qualifications of personnel target group 11 Transporting the sensor 13 Storing the sensor 13 Decoding the model code label 14 Checking the scope of delivery 15 Scope of delivery for MCS 13xx 15 Scope of delivery for MCS 14xx 16 Scope of delivery for MCS 15xx 17 Sensor features 18 Functional principle 18 Sensor dimensions 19 Dimensions 19 D...

Page 4: ...on cable Assignment Color coding 37 Using the switching outputs 38 Function FE NFE factory setting 38 Function ALL RDY 38 Function ALARM 38 Switching logic active low 38 Example Operation 1 particle detected logical active 39 Example Operation no particle detected logical not active 39 Example Operation several particles detected logical active 39 Switching logic active high Default settings 40 Ex...

Page 5: ...ic at the switching output 51 SWT PLS Set pulse length at the switching output 51 SWT TST Set test pulse at the switching output 51 ALARM Setting limit values 52 CANCEL cancel without saving 52 SAVE Save changes 52 Error analysis remedy 52 Performing Maintenance 53 Decommissioning the sensor 54 Disposing of sensor packaging material 54 Spare parts and accessories 55 Channel default settings 57 Cal...

Page 6: ...ractual obligation our liability shall be limited to foreseeable damage Claims due to Product Liability shall remain unaffected Technical Support Contact our technical sales department if you have any questions on our product When contacting us please always include the model type designation serial no and part no of the product Fax 49 6897 509 9046 E mail filtersystems hydac com Modifications to ...

Page 7: ...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 of the operating and maintenance instructions The index is incremented every time the manual is...

Page 8: ...ecure 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 Warning signs used These signs are listed for all general safety information and instructions in these operating instructions which indicate particular dangers to persons prope...

Page 9: ...an result in minor or moderate injury NOTICE NOTICE The signal word indicates a hazardous situation with a high level of risk which if not avoided will result in damage to property Structure of the general 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...

Page 10: ... all instructions in the instruction manual To be used only in conjunction with permissible media To be operated under technically permissible conditions such as operating pressure flow rate media and ambient temperature The sensor is only to be used with the following media NOTICE Impermissible operating media conditions The sensor will be damaged Use the sensor only in conjunction with mineral a...

Page 11: ...articular the safety information and instructions and applicable regulations before beginning work The operating instructions and applicable regulations are to kept so they are accessible for operating and specialist personnel These operating instructions are intended for Auxiliary personnel such persons have been instructed about the sensor and are aware of potential hazards due to improper use S...

Page 12: ...e 12 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Operation Operations control Specialist personnel Product specific knowledge Knowledge about how to handle operating media Disposal Specialist personnel Knowledge about reuse ...

Page 13: ...ction plug will not be subjected to any mechanical strain or impact NOTICE Unsafe transport The connection plug will be damaged Transport the sensor in its original packaging Secure the sensor during transport Storing the sensor Store the sensor in a clean dry place in the original packing if possible Do not remove the packing until you are ready to install the unit For storage conditions refer to...

Page 14: ... of the MetallicContamination Sensor see the type label This is located on the top of the unit and contains the exact product description and the serial number Row Definition Description 1 Model Model according to model code for details see page 61 2 P N Part no 3 S N Serial no 4 Date Year week of production 5 Index Hardware index 6 Max INLET press Maximum operating pressure ...

Page 15: ...or each size Scope of delivery for MCS 13xx The MetallicContamination Sensor MCS 13xx comes packed and factory assembled Before commissioning the sensor please check no items are missing from the package The following items are supplied Qty Description 1 MetallicContamination Sensor MCS 13xx 1 O ring 18 7 x 3 53 NBR 70 Shore 1 O ring 18 7 x 3 53 FPM 70 Shore 1 Operation and Installation Guide this...

Page 16: ...ination Sensor MCS 14xx comes packed and factory assembled Before commissioning the sensor please check no items are missing from the package The following items are supplied Qty Description 1 MetallicContamination Sensor MCS 14xx 1 O ring 25 x 3 53 NBR 70 Shore 1 O ring 25 x 3 53 FPM 70 Shore 1 Operation and Installation Guide this document EC declaration of conformity ...

Page 17: ...d factory assembled Before commissioning the sensor please check no items are missing from the package The following items are supplied Qty Description 1 MetallicContamination Sensor MCS 15xx 1 o ring 47 22 x 3 53 NBR 70 Shore 1 o ring 47 22 x 3 53 FPM 70 Shore 1 O ring 110 72 x 3 53 NBR 70 Shore 1 O ring 110 72 x 3 53 FPM 70 Shore 1 Operation and Installation Guide this document EC declaration of...

Page 18: ...n the MCS has serial communication interfaces with which connection to superordinate monitoring systems is possible The MCS is intended for incorporation in low pressure circuits and test benches Functional principle Within the sensor a high frequency magnetic field is generated using a coil system Two sensor pulses measure changes in the field strength and output certain signals as described belo...

Page 19: ...us Page 19 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Sensor dimensions The dimensions for the available sizes vary The dimensions for each size can be found below Dimensions Flange image SAE 1 2 All dimensions in mm ...

Page 20: ...Sensor dimensions MCS1xxx T005 en us Page 20 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions for MCS 13xx with Ethernet module Flange image SAE 1 2 All dimensions in mm ...

Page 21: ...Sensor dimensions MCS1xxx T005 en us Page 21 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions MCS 13xx with flange adapter set optional accessories All dimensions in mm ...

Page 22: ...Sensor dimensions MCS1xxx T005 en us Page 22 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions Flange image SAE 3 4 All dimensions in mm ...

Page 23: ...Sensor dimensions MCS1xxx T005 en us Page 23 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions for MCS 14xx with Ethernet Flange image SAE 3 4 All dimensions in mm ...

Page 24: ...1xxx T005 en us Page 24 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions MCS 14xx with flange adapter set optional accessories All dimensions in mm Dimensions Flange image SAE 4 All dimensions in mm ...

Page 25: ...Sensor dimensions MCS1xxx T005 en us Page 25 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions for MCS 15xx with Ethernet Flange image SAE 3 4 All dimensions in mm ...

Page 26: ...Sensor dimensions MCS1xxx T005 en us Page 26 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Dimensions MCS 15xx with flange adapter set optional accessories All dimensions in mm ...

Page 27: ... of flow through the sensor The direction of flow is indicated by an arrow on the housing When selecting the installation site take ambient factors like the temperature dust water etc into account The sensor is designed for IP67 according to DIN 40050 EN 60529 IEC 529 VDE 0470 The sensor offers various options for mechanical installation The possible permissible mechanical installations are given ...

Page 28: ... 06 14 docx 2022 06 14 Connecting MCS 13xx 14xx via flange adapter set A flange adapter set is available as an accessory For the article no refer to Chapter Spare parts and accessories on page 55 This flange adapter set makes it possible to connect the MCS directly to pipes or hoses with a G1 2 thread ...

Page 29: ...or to underside MCS1xxx T005 en us Page 29 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Fastening sensor to underside The sensors have four fixing holes on the underside Use these to secure the MCS ...

Page 30: ...05 4668567a en us 2022 06 14 docx 2022 06 14 Fastening MCS 13xx MCS 14xx Below you can see the drilling template for fastening the MCS 13xx MCS 14xx All dimensions in mm Fastening MCS 15xx Below you can see the drilling template for fastening the MCS 15xx All dimensions in mm ...

Page 31: ...using angle fastening set An angle fastening set is available as an accessory HYDAC article no 3477243 Connecting MCS 15xx using pipe adapter set A pipe adapter set is available as an accessory HYDAC article no 3435426 This pipe adapter set makes it possible to connect the MCS directly to two pipes or hoses via the thread 42L per ISO8431 1 ...

Page 32: ... accessory A flange adapter set is available as an accessory HYDAC article no 3442518 The SAE4 SAE1 1 flange adapter set can be used to mount the MCS between the filter unit and the pump The flange adapter plate offers three connections for the integration of more sensors Example installation in the filter cooling circuit between the pump and the bypass flow filter ...

Page 33: ...BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 MCS 15xx via SAE 4 per ISO 6162 1 4xM16 Install the MCS with four screws M16 to a component unit The drilling template corresponds to the SAE 4 per ISO 6162 1 Example installing the MCS on an NF filter ...

Page 34: ...d by an arrow on the housing NOTICE Exceeding the permissible operating pressure The sensor will be destroyed Note the maximum operating pressure of 20 bar 290 psi Diagram flow rate differential pressure p and viscosity ν Note the measured volumetric flow rate For the MCS 14xx this is between 2 and 40 l min and for the MCS 15xx between 10 and 200 l min For flow rates outside these limits a detecti...

Page 35: ...xx T005 en us Page 35 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 P mbar Q l min P mbar Q l min The diagram shows the resulting differential pressure mbar as a function of the flow rate Q l min at different viscosities p ...

Page 36: ... assignment Pin Description Meaning 1 Vs Power supply 18 30 V DC 2 2 Switching output 2 binary voltage GND Vs 3 GND Reference point for power supply 4 GND Reference point for power supply 5 HSI HYDAC Sensor Interface 6 RS485 Bus Interface 7 RS485 Bus Interface 8 1 Switching output 1 binary voltage GND Vs There is contact between the plug housing and the housing ...

Page 37: ... of various lengths with one connection plug 8 pole M12x1 according to DIN VDE 0627 and an open end The color coding of the HYDAC accessory cable ZBE42 xx is listed in the table below All dimensions in mm Pin Color Connection to 1 White Power supply 18 30 V DC 2 brown Switching output 2 3 Green GND 4 Yellow GND 5 grey HSI HYDAC Sensor Interface 6 Pink RS485 7 Blue RS485 8 Red Switching output 1 Sh...

Page 38: ... ferromagnetic nFe particles at switching output 2 Function Switching output ferromagnetic Fe 1 non ferromagnetic nFe 2 Function ALL RDY A signal for all ferromagnetic Fe particles and all non ferromagnetic nFe particles is output at switching output 1 The switching output 2 outputs the Device Ready signal indicating readiness for use Function Switching output ferromagnetic Fe and non ferromagneti...

Page 39: ...no indication of the shape and size of the particles The duration of alarm signal is set to 30 seconds Note that after the sensor has been switched on or after voltage has returned a start up phase of 70 seconds is necessary before the first measurement can be made Example Operation 1 particle detected logical active Example Operation no particle detected logical not active Example Operation sever...

Page 40: ...both switching outputs emit an impulse with an increasing edge You can set the duration of the signal Δt between 5 and 200 ms This value is factory set to 7 ms The signal gives no indication of the shape and size of the particles Note that after the sensor has been switched on or after voltage has returned a start up phase of 70 seconds is necessary before the first measurement can be made ...

Page 41: ...tching outputs MCS1xxx T005 en us Page 41 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Example Operation 1 particle detected logical active Example Operation no particle detected logical not active ...

Page 42: ...evice Ready The signal indicating that the MCS is ready for use can be emitted on the switching output S2 Note that after the sensor has been switched on and after voltage has returned after an interruption a start up phase of 70 seconds is necessary before the signal can be evaluated After that the switching output Device Ready goes to permanent Vs potential The MCS is now ready for operation ...

Page 43: ...1000 to SMU 1200 The MCS 1000 can be connected to the HYDAC SensorMonitoring Unit SMU 1200 The SMU 1200 makes it possible to set parameters save the MCS measurement data with a time stamp read off stored data via USB memory stick forward the online measurement data to a PC forward the switching outputs to a superordinate controller You can find more details in the SMU 1200 operating instructions ...

Page 44: ...06 14 Connecting MCS to CSI D 5 Condition Sensor Interface The CSI D 5 kit can be used to parameterize the MCS using a PC and to read off online and stored measurement data Connect the CSI D 5 kit HYDAC article no 3249563 in accordance with the following connection diagram USB A USB B PS2 PC CSI D 5 MCS 1000 ZBE 43 05 CSI D 5 Kit ...

Page 45: ...1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Connecting MCS to HMG 3000 You can use the HMG 3000 to set the parameters of the MCS Connect the HMG 3000 to the MCS in accordance with the following connection diagram You can find more details in the HMG 3000 operating instructions ...

Page 46: ... were stirred up by shaking or vibration and then got into the fluid stream For detailed evaluation of the measurement results it is necessary to know the following operating parameters of the system Is a constant variable or only temporarily existent fluid stream through the sensor present Example During the analysis of the particles occurring each day the actual operating duration of the system ...

Page 47: ...CS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 Menu structure This chapter gives you an overview of the menu structure of the PowerUP and Measuring menus Overview PowerUP Menu PowerUP menu MODE M2 S TIME SEL COM HSI ADRESS HSI DEFAULT CANCEL SAVE ...

Page 48: ... 14 Overview Measuring Menu Measuring menu DSPLAY FE A FE B FE C NFE D NFE E NFE F CYC A CYC B CYC C CYC D CYC E CYC F STATUS FI TEMP C TEMP F SWT OUT FE NFE ALL RDY ALARM SWT LOG ACT HI ACT LOW SWT PLS SWT TST Type SWT FE SWT NFE NUM START ALARM A PERIOD LIMIT B PERIOD LIMIT C PERIOD LIMIT CANCEL SAVE ...

Page 49: ...he number of particles within the time intervals can be seen from the parameter DSPLAY CYC Parameter 1 120 minutes Factory setting 60 SEL COM Set protocol Purpose Set transfer protocol to the superordinate system Function Adjustment not possible Parameter None Factory setting HSI ADRESS Set bus address Parameter A Z for the HSI bus Factory setting D DFAULT Reset to factory setting Function Reset t...

Page 50: ...the number of particles per variable that were counted within the current measurement time parameter S TIME The measuring time begins when the voltage is switched on or the power up menu is exited The value of the current interval is always displayed Parameter FE A ferromagnetic particles Fe Class A FE B ferromagnetic particles Fe Class B FE C ferromagnetic particles Fe Class C NFE D non ferromagn...

Page 51: ...the switching output Function You can find a detailed description on page 38 Parameter FE NFE S1 ferromagnetic Fe S2 Non ferromagnetic nFe ALL RDY S1 ferromagnetic Fe and non ferromagnetic nFe S2 Device Ready ALARM S1 Alarm S2 Device Ready Factory setting FE NFE SWT LOG Set logic at the switching output Parameter ACT HI active high ACT LOW active low Factory setting ACT HI SWT PLS Set pulse length...

Page 52: ... exceeding a limit value The alarm indicates that the set limit value has been exceeded and is not necessarily due to any damage to the monitored system Parameter A Minute min PERIOD 10 180 LIMIT 5 232 B Hours h PERIOD 2 72 LIMIT 20 232 C Days d PERIOD 3 30 LIMIT 100 232 Factory setting A PERIOD 30 LIMIT 20 B PERIOD 24 LIMIT 100 C PERIOD 7 LIMIT 500 CANCEL cancel without saving Parameter None SAVE...

Page 53: ...nd 3 as well as 8 and 4 4 Check the supply voltage Vs activated in this way at the cable end on the output side 3 Insert the connection cable into MCS again after 10 seconds at the earliest 4 If the error status is not changed then the sensor is faulty replace the sensor Observe the starting phase of 70 seconds Performing Maintenance Regularly inspect for leaks Replace defective cables hoses or tu...

Page 54: ...t proceed as follows 1 Remove the electric plug 2 Depressurize the unit 3 Remove the connected hoses piping from the sensor 4 Remove the sensor Disposing of sensor packaging material Dispose of the packaging material in an environmentally friendly manner After removing the sensor and separating its various materials dispose of it in an environmentally friendly manner ...

Page 55: ...e sensor Description Qty Part no MCS 14xx Flange adapter set SAE G 1 2 consisting of 1x SAE flange 1x O ring NBR 4x cheese head screw 1 3588249 MCS 15xx Pipe adapter set 42L consisting of 2x pipe adapters 42L 2x O rings NBR 8x cheese head screws 8x washers 8x snap rings 1 3435426 MCS 15xx flange adapter set SAE4 SAE1 consisting of 2x O rings NBR 4x cheese head screw 4x washer 4x snap ring 4x screw...

Page 56: ... O ring 18 7 x 3 53 FPM low temperature 70 Shore 1 6140581 O ring 25 x 3 53 NBR 70 Shore 1 601905 O ring 25 x 3 53 FPM low temperature 70 Shore 1 6140582 o ring 47 22 x 3 53 NBR 70 Shore 1 604815 O ring 47 22 x 3 53 FPM low temperature 70 Shore 1 6140584 O ring 110 72 x 3 53 NBR 70 Shore 1 603576 O ring 110 72 x 3 53 FPM low temperature 70 Shore 1 6140585 Socket plug female with 2 m line shielded ...

Page 57: ...E 45 05 1 3346100 Connection cable Ethernet Length 10 m Patch coupling socket 4 pin M12x1 RJ45 plug ZBE 45 10 1 3346101 CD with FluMoS light software 1 3251484 ConditionSensor Interface CSI D 5 kit 1 3249563 Channel default settings Channel Particle MCS 13xx MCS 14xx MCS 15xx Class A Fe 70 100 µm 100 150 µm 200 300 µm Class B Fe 100 150 µm 150 200 µm 300 500 µm Class C Fe 150 µm 200 µm 500 µm Clas...

Page 58: ... 4668567a en us 2022 06 14 docx 2022 06 14 Customer Service Service Use the following shipping address for repairs HYDAC SERVICE GMBH Friedrichsthaler Straße 15a Plant 13 66540 Neunkirchen Heinitz Germany Telephone 49 6897 509 01 Fax 49 6897 509 324 E mail service hydac com ...

Page 59: ...ambient temperature range 40 70 C 40 170 F 40 70 C 40 170 F 40 70 C 40 170 F Seal material in contact with the medium FPM low temperature FPM low temperature FPM low temperature Mechanical connection SAE 3 4 SAE 3 4 SAE 4 4x M16 Protection class to DIN40050 IP 67 IP 67 IP 67 Weight 3 0 kg 2 5 kg 3 5 kg Dimensions L x W x H 83 x 120 x 120 mm 83 x 120 x 120 mm 83 x 162 x 140 mm Vibration 10 58 Hz 0 ...

Page 60: ... Switching output load capacity 350 mA as current sink 3 kΩ internal resistance as current source RS485 interface 2 wire half duplex HSI interface 1 wire half duplex Ethernet 10Base T 100Base TX Storage Permitted storage temperature range 40 80 C 40 176 F Permitted relative humidity during storage 95 non condensing Detection limits MCS 13xx MCS 14xx MCS 15xx Particle size Fe 70 µm 100 µm 200 µm Pa...

Page 61: ...ol 7 2x switching outputs RS485 Ethernet HSI TCP IP protocol Fluids 0 Mineral and synthetic oils particularly used in wind power industry Mechanical connection 1 Flange connection SAE 1 2 according to ISO 6162 1 only for MCS 13xx Switching output 2 Flange connection SAE 3 4 according to ISO 6162 1 only for MCS 14xx 5 Flange connection SAE 4 according to ISO 6162 1 only for MCS 15xx Electrical conn...

Page 62: ...perty at room temperature These materials differ in their residual magnetism remanence after being removed from the magnetic field Materials with high remanence are described as magnetically hard and materials with low remanence are called magnetically soft Non ferromagnetic nFe Many metals used in the industry do not have the above mentioned ferromagnetic property Examples include aluminum alloys...

Page 63: ...rding agent 11 G gear 46 Glossary 62 GND 36 37 60 H half duplex 60 Hardware 14 Hazard symbol 9 HSI 18 36 37 47 49 60 61 Hydraulic data 59 I Imprint 2 INLET 14 installation 11 27 32 34 installing 33 Interface 36 37 44 57 IP 59 ISO 33 46 61 M Maintenance 11 53 Manufacturer 2 Measure 49 Measures 9 measuring 50 Measuring menu 47 48 50 Menu structure 47 MODE 47 49 O operating 6 7 8 10 11 12 14 34 43 45...

Page 64: ...Index MCS1xxx T005 en us Page 64 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 T TCP 61 TCP IP 61 TEMP 48 51 Transport 11 13 Troubleshooting 11 U USB 43 W Weight 59 ...

Page 65: ...Index MCS1xxx T005 en us Page 65 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 ...

Page 66: ...Index MCS1xxx T005 en us Page 66 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 ...

Page 67: ...Index MCS1xxx T005 en us Page 67 68 BeWa MCS1xxx T005 4668567a en us 2022 06 14 docx 2022 06 14 ...

Page 68: ...ustriegebiet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Tel 49 6897 509 01 Central Fax 49 6897 509 9046 Technical Department Fax 49 6897 509 577 Sales Internet www hydac com E Mail filtersystems hydac com ...

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