BeWa - HYDAC€¦ · General ContaminationSensor CS 1939 en Page 4 / 48 BeWa CS1939 3978342c V100 en-us 2019-10-08.docx 2019-10-08 General In this chapter, you will find helpful notes

CS 1939 ContaminationSensor

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.

Content

ContaminationSensor CS 1939 en Page 2 / 48

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

Content

Content .......................................................................................................... 2

General .......................................................................................................... 4

Imprint.......................................................................................................... 4

Documentation Representative ................................................................... 4

Purpose of this manual ................................................................................ 5

Target group of the manual ......................................................................... 5

Target group - Required qualifications/training ............................................ 6

Illustrations in the manual ............................................................................ 7

Illustration of the layout ............................................................................ 7

Representation of procedural instructions ................................................ 8

Representation of warning/general safety information ............................. 8

Signal words and their meaning in the general safety information ........... 9

Representation/explanation of pictograms................................................. 10

Supplementary symbols ............................................................................ 11

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 ............................................................................... 24

Mechanical installation/assembly .............................................................. 25

Hydraulic installation/assembly .................................................................. 26

Types of connection of ContaminationSensor ........................................ 26

Selecting the measurement location ................................................... 26

Flow rate, differential pressure p and viscosity characteristics ..................................................................................... 28

Hydraulic connection of the ContaminationSensor ................................. 29

Electrical installation/assembly .................................................................. 30

Pin assignment ....................................................................................... 30

Connection cable - Assignment / Color coding ....................................... 31

Content



Operation ..................................................................................................... 32

Applying SAE J1939 protocol .................................................................... 32

Parameter definition ............................................................................... 32

SPN definition ..................................................................................... 32

Evaluating measurement reports with FluMoS or FluMoT (only HSI-report) ................................................................................................. 33

Checking/resetting default settings ............................................................ 34

Dialog menu ........................................................................................... 34

Calibrating ContaminationSensor ........................................................... 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 classes - brief overview .......................................................... 41

Cleanliness class - ISO 4406:1999 ........................................................ 41

Table - ISO 4406 .................................................................................... 41

Overview of modifications - ISO4406:1987 <-> ISO4406:1999 .............. 42

Index ............................................................................................................ 43

General



General

In this chapter, you will find helpful notes on handling these instructions.

Imprint

Publisher and responsible for the content:

HYDAC FILTER SYSTEMS GMBH

Postfach 1251

66273 Sulzbach / Saarland

Germany

Phone: +49 6897 509 01

Fax: +49 6897 509 9046

E-mail: [email protected]

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

Fax: +49 6897 509 1394


General



Purpose of this manual

Before you use this product for the first time or if you have been asked to carry out other work on the product, please read this manual

The use and the handling of the product described in the following, as well as its use, are not self-explanatory and are described in detail in this manual and the associated technical documentation.

This manual will help you to use the product as intended, properly, effectively, and safely. Therefore, you are requested to read the following chapters attentively 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 accessible at the installation location of the product and also for later use.

Ask the employees to read and follow the manual and the documents delivered along with it, in particular, the safety and warning instructions.

Observe the additional product-related instructions and requirements.

Specialist personnel

Read, observe and follow this manual and the associated documents, in particular, the safety and warning instructions.

General



Target group - Required qualifications/training

Persons who work on the product must be aware of the hazards associated with its use.

Auxiliary and specialist personnel must have read and understood the operating instructions, in particular the General 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 product and informed 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

Hydraulic / electrical installation,

First commissioning

Maintenance

Troubleshooting

Repair,

Decommissioning

Disassembly


Safe handling/use of tools

Fitting and connection of hydraulic lines and connections

Fitting and connection of electrical lines, electrical machinery, sockets, etc.

Product-specific knowledge

Operation

Operations control


Product-specific knowledge

Knowledge about how to handle operating media.

Disposal Specialist personnel

Knowledge about reuse

General



Illustrations in the manual

You will find illustrations in this manual. You can find details regarding these in the following chapters.

Illustration of the layout

deHYDAC Filtertechnik GmbHBeWa 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 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 the future.

The manual contains a table of contents, an index and a glossary.

Chapter description

Page number

Edition date

Document language

Documentation no. with index/

file name

General



Representation of procedural instructions

There are these two following representations in the case of procedural instructions:

Procedural instructions with a fixed sequence

Procedural instructions, whose sequence must be complied with without fail are listed with sequential numbering (1., 2., 3., etc.).

An example for procedural instructions with a fixed sequence:

1. Remove the transport securing device.

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 highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger.

Warning / general safety information is listed before an activity and is laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

► Measures to avert danger

General



Signal words and their meaning in the general safety information

In these instructions you will find the following signal words:

DANGER DANGER – The signal word indicates a hazardous situation with a high 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 indicates a hazardous situation with a high level of risk, which, if not avoided, will result in damage to property.

General



Representation/explanation of pictograms

The following are the safety symbols / pictograms in this manual. They indicate specific dangers to persons, property or to the environment. Observe these safety symbols / pictograms and act with particular 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 instructions in these operating instructions which indicate particular dangers to persons, property or the environment.

Disconnect before maintenance or repair

General



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

General



Exclusion of liability/warranty

For the warranty provided by us, please refer to our terms of delivery. They are made available to you at the conclusion of the contract at the latest. In addition, you will find these under www.hydac.com -> General terms and conditions.

This manual was prepared to the best of our knowledge. Nevertheless and despite the greatest care, it cannot be excluded that mistakes could have crept in. Therefore please understand that, in the absence of any provisions to the contrary hereinafter, our warranty and liability – for any legal reasons whatsoever – are excluded in respect of the information in these instructions. In particular, we shall not be liable for lost profit or other financial loss.

This exclusion 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 Liability shall remain unaffected.

Notes on copyright

All copyrights for this manual lies with the manufacturer. Any part of this manual may cannot be reproduced, used or copied in any form with the help of electronical systems without the written consent of the manufacturer. Any infringements of the above shall be liable to damage compensation.

Validity of this manual

The diagrams and visualizations in this manual are meant for general illustration purposes. Therefore, representations and functional options can deviate from those of the delivered product.

We reserve the right to changes to the contents of this manual without prior notice.

General Safety Information



General Safety Information

The product has been built according to the provisions, directives and standards valid at the time of delivery and satisfies the current safety requirements. Any residual hazards are indicated by the general safety information and are described 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 use of the product

Bodily injury and damage to property will result when operated improperly.

► Never operate the product in potentially explosive atmospheres.

► Only use the product with permissible media.

Product overview



Product overview

The ContaminationSensor CS 1939 is a stationary measurement unit for the continuous monitoring of particulate contamination 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 mm²/s.

The particulate contamination is recorded by an optical measurement cell.

Product overview



Scope of delivery

The ContaminationSensor CS 1939 comes packed and factory-assembled. Please check the contents of the 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 manual

1 Certificate of calibration

Product overview



Dimensions

All dimensions in mm.

Product overview



Proper/designated use

Claims for defects or liability, regardless of the legal foundation, do not apply with incorrect or improper installation, commissioning, usage, handling, storage, maintenance, repair, use of unsuitable components or other circumstances for which the manufacturer is not responsible.

The manufacturer assumes no responsibility for determining the interfaces for installation in a system or the installation, 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.

Depending on the version (see model code), you may use the CS only in connection with the following media:

NOTICE

Impermissible operating media


► The ContaminationSensor may only be used in connection with mineral oils or mineral oil-based raffinates.


Product overview



Improper use or use deviating from intended use

DANGER

Unintended use of the product

Bodily injury and damage to property will result when operated improperly.

► Never operate the product in potentially explosive atmospheres.

► Only use the product with permissible media.

Any use extending beyond this or 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 conditions.

- Operation when the safety devices are defective.

- Modifications to the product made by the user or purchaser.

- Inadequate monitoring of parts that are subject to wear and tear.

- Improperly performed repair work.

Product overview



Technical Data

General data

Mounting position Any (recommended: vertical position)

Self diagnostics continuously with error 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 with screw-lock connectors)

Weight ≈ 1.3 kg

Product overview



Hydraulic data

Permitted operating pressure maximum 350 bar / 5075 psi

Hydraulic connection

- Pipe or hose connection Thread G ¼ according to ISO 228

- Flange connection DN 4

Permitted measurement flow rate

30 … 500 ml/min

Permissible viscosity range 1 to 1000 mm²/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 Interface) 1 wire, half duplex

Product overview



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

Product overview



Model Code

CS 1939 - 0 - 0 / - 000

Model

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

Storage and transport



Storage and transport

Store the product in a clean, dry place, 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

Assembly, installation and commissioning




Design 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.




Mechanical installation/assembly

Mount the ContaminationSensor as shown in the following examples:

1. Wall mounting:

Mount 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

12/164xM6

15

20

Bottom view All dimensions in mm.

3. Installing on a mounting plate:

Mount on a mounting plate or control block using 4 cylindrical screws having an M6 hexagonal socket according to ISO 4762.




Hydraulic installation/assembly

Determine the operating pressure of the hydraulic system and see whether it is within the permissible flow range for the ContaminationSensor inlet.

NOTICE

Excessive operating pressure



Types of connection of ContaminationSensor

If possible, install the ContaminationSensor so that fluid flows from bottom to top to avoid air collecting in 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 connection:

The ContaminationSensor 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.

Selecting the measurement location

In order to obtain cleanliness values that are continuous and coherent in real time, select a suitable measuring point according to the following guidelines:




WRONG WRONG 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).




Flow rate, differential pressure p and viscosity characteristics

Differential pressure p and viscosity characteristics. All the values indicated in the figures below apply 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 mm²/s at a pressure difference p of ≈0.9 bar, so that you achieve a flow rate of approx. 200 ml/min.

The flow rate depends on the viscosity of the medium and the differential

pressure p via the sensor.




Hydraulic connection of the ContaminationSensor

Observe the following sequence when connecting the sensor to the hydraulic system:

1. Connect the return line to the OUTLET of the CS. G1/4 ISO 228 threaded connection, recommended diameter of line ≥ 4 mm.

2. Then connect the other end of the return line to the system 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 ContaminationSensor. (e.g. CM-S)

5. Connect the other end of the measurement line to the measurement point on the hydraulic system.

Oil begins to flow as soon as the ContaminationSensor is connected with the pressure line.

6. The hydraulic connection is complete.




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.




Connection cable - Assignment / Color coding

Our accessories 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

Operation



Operation

Applying SAE J1939 protocol

The CS 1939 has a CAN 2.0B port with access to the SAE J1939 log. Whenever the CS is switched on, it sends an "Address Claiming" message to share its name and address with the other participants. The measurement values are not transmitted cyclically but rather called up by the PGN 61184 on request.

Parameter definition

PGN 61184

Acronym PC

Name CS 1939

Length 14

SPN definition

SP

N

Nam

e

Po

sitio

n

Le

ng

th

Typ

e

Reso

lution

Off

se

t

Min

. V

alu

e

Ma

x.

Va

lue

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 B 49 8 integer 0.1 0.0 0.0 14.0

516103 SAE C 57 8 integer 0.1 0.0 0.0 14.0

516104 SAE D 65 8 integer 0.1 0.0 0.0 14.0

516105 Temp 73 16 integer 0.1 -60.0 0.0 185.0 °C

516106 Flow 89 16 integer 0.1 0 30 500 ml/ min

516107 Drive 105 8 integer 0.1 0 0 100 %

Operation



Evaluating measurement reports with FluMoS or FluMoT (only HSI-report)

The Fluid Monitoring Software FluMoS is for reading and analyzing the measurement reports/measurement 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 customer's own software and solutions.

See chapter “Spare Parts and Accessories“, page 39.

http://www.hydac.com/

Operation



Checking/resetting default settings

Dialog menu

User settings 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.

Maintenance



Maintenance

The ContaminationSensor is maintenance-free. Clean the CS regularly, as described in the "Cleaning the ContaminationSensor" chapter.

Cleaning the ContaminationSensor

Clean the surface with a clean, damp cloth. Do not use any chemical cleaning agents as these may damage the film attached to the surface of the unit.

Customer Service / Service

Current contacts for product support/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 01

Fax: +49 6897 509 324


Customer service USA

HYDAC Technology Corporation, HYCON Division 2260 City Line Road USA-Bethlehem, PA 18017 P.O. Box 22050 USA-Lehigh Valley, PA 18002-2050

Phone: +1 610 266 01 00

Fax: +1 610 231 04 45


Internet: www.hydacusa.com


Maintenance



Customer Service Australia

HYDAC Pty. Ltd. 109 Dohertys Road P.O. Box 224 AUS-3025 Altona North

Phone: +61 392 72 89 00

Fax: +61 393 69 89 12


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


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 35 10

Fax: +86 21/64 30 02 57


Troubleshooting/fault rectification



Troubleshooting/fault rectification

The status LED displays the following status signals.

Error-code

LED Description Rectification

0 Green No error No measures are required.

3 Red Error during automatic adjustment

Reset the unit.

If the error remains, rinse the CS against the direction of flow.

Contact HYDAC Service if the error still occurs.

4 Red Error measuring cell LED

Reset the unit.


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 Red Error while loading the user setup

Reset the unit.


17 Red Error while saving the user setup

Reset the unit.


18 Red Error while loading the calibration data

Reset the unit.


Removing / Disposal



Removing / Disposal

To decommission, proceed as follows:

1. Disconnect and remove the electric connection 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 friendly manner.

Appendix



Appendix

In this annex, you will find supplementary information on the product.

Spare Parts and Accessories

Spare Parts

Description Part no. Qty.

Operating and Maintenance Instructions 3978342 1

O-ring for the flange connection (4.8x1.78 - 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 fluid sensors in our general accessories brochure no. 7.623. This brochure can be downloaded free of charge from our website www.hydac.com.


Glossary



Glossary

Explanation of terms and abbreviations

An explanation of terms and abbreviations follows below:

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 instructions

Glossary



Cleanliness classes - brief overview

Cleanliness class - ISO 4406:1999

In ISO 4406:1999, particle counts are determined cumulatively, i.e. > 4 µm(c), >6 µm(c) and >14 µm(c) (manually by filtering the fluid through an analysis membrane or automatically using particle counters) and allocated to measurement references.

The goal of allocating particle counts to references is to facilitate the assessment of fluid cleanliness ratings.

In 1999 the "old" ISO 4406:1987 was revised and the size ranges of the particle sizes undergoing analysis redefined. The counting method and calibration were also changed.

This is important 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

Assignment of particle counts to cleanliness classes:

Particle count / 100 ml Particle count / 100 ml

Class More than Up to (and including)

Class More than Up to (and including)

0 0 1 15 16,000 32,000

1 1 2 16 32,000 64,000

2 2 4 17 64,000 130,000

3 4 8 18 130,000 250,000

4 8 16 19 250,000 500,000

5 16 32 20 500,000 1,000,000

6 32 64 21 1,000,000 2,000,000

7 64 130 22 2,000,000 4,000,000

8 130 250 23 4,000,000 8,000,000

9 250 500 24 8,000,000 16,000,000

10 500 1,000 25 16,000,000 32,000,000

11 1,000 2,000 26 32,000,000 64,000,000

12 2,000 4,000 27 64,000,000 130,000,000

13 4,000 8,000 28 130,000,000 250,000,000

14 8,000 16,000

Glossary



Note: increasing the measurement reference by 1 causes the particle count to double.

Example: ISO Code 18 / 15 / 11 says:

Cleanliness class Particle count / ml Size ranges

18 1,300 – 2,500 > 4 µm(c)

15 160 – 320 > 6 µm(c)

11 10 – 20 > 14 µm(c)

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 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 fraction

ISO 12103-1A4

Comparable size ranges

Old ACFTD calibration Comparable ACFTD dusts

New Nist calibration

----- < 1 µm 4 µm(c)

5 µm 4.3 µm 6 µm(c)

15 µm 15.5 µm 14 µm(c)

Index



Index

A

Accessories 39 ambient temperature 19 Assignment 30, 31, 41 Auxiliary personnel 6

B

BLEED 40

C

calibrating 34 Calibration 42 care 12 cleaning 23, 35 Cleanliness 41, 42 connecting 26, 29, 33 Connection 20, 31 Connection cable 31 Connection plug 20 Console mounting 25 Contamination class 19, 41, 42 Contamination classes 41 ContaminationSensor 1, 13, 14, 15, 17, 22, 23, 24, 25, 26,

27, 29, 34, 35 Content 2 Customer service 35

D

Date 21 default setting 34 Description 15, 21, 37, 39 diagnostics 19 Differential pressure 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, 29 Hydraulic data 20

I

Imprint 4 Inlet 40 INLET 21, 24, 26, 29, 40 installation 5, 6, 11, 17, 24, 25, 26, 27, 30 Interface 20, 22, 30, 31 IP 19 ISO 19, 20, 22, 25, 29, 32, 40, 41, 42 ISO4406 42

1987 42 1999 42

M

Maintenance 1, 6, 35, 39, 40 Measured variable 19 Measurement 34 Measures 8 measuring 26, 37 mounting 25 Mounting position 19

O

OFF 40 operating 6, 7, 10, 13, 14, 17, 20, 21, 26, 29, 37 Operation 6, 18, 32 Operations control 6 Outlet 40

Index



OUTLET 24, 26, 29, 40 Overview 42

P

Power consumption 20 Protection class 19 Publisher 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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Germany Germany

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Documents

BeWa - HYDAC€¦ · General ContaminationSensor CS 1939 en Page 4 / 48 BeWa CS1939 3978342c V100 en-us 2019-10-08.docx 2019-10-08 General In this chapter, you will find helpful notes