contaminationsensor cs 1939 - hydac danger – the signal word indicates a hazardous situation with...

ContaminationSensor CS 1939

Operating and Maintenance Instructions English (translation of original instructions) Valid from: - Firmware version V 1.00 - Hardware index A - Serial number: 0002S01515K0001305 Keep for future reference.

Document No.: 3978342a

Imprint

Imprint

Manufacturer / publisher and responsible for the content: HYDAC FILTER SYSTEMS GMBH Postfach 1251 66273 Sulzbach / Saar Germany Telephone: +49 6897 509 01 Fax: +49 6897 509 9046 E-mail: [email protected] Homepage: www.hydac.com Court of Registration: Saarbrücken, HRB 17216 Executive director: 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: [email protected]

© 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 distributed using electronic systems without the written consent of the publisher. These documents have been created and inspected with the greatest care. However, errors cannot be ruled out completely. All details are subject to technical modifications. Technical specifications are subject to change without notice.

ContaminationSensor CS 1939 en(us) / 44

BeWa CS1939 3978342a V100 en-us 2017-07-14.docx 2017-07-14

Content

Content

Imprint ............................................................................................................ 2

Documentation Representative ................................................................... 2

Content .......................................................................................................... 3

Preface ........................................................................................................... 5

Technical Support ........................................................................................ 5 Modifications to the Product ........................................................................ 5 Warranty ...................................................................................................... 5 Using the documentation ............................................................................. 6

Safety Information ........................................................................................ 7

Hazard symbols ........................................................................................... 7 Signal words and their meaning in the safety information and instructions .................................................................................................. 8 Structure of the safety information and instructions ..................................... 8 Observe regulatory information ................................................................... 9 Proper/Designated Use ............................................................................... 9 Improper Use or Use Deviating from Intended Use ................................... 10 Qualifications of personnel / target group .................................................. 11

Storing product ........................................................................................... 13

Storage conditions ..................................................................................... 13

Decoding the type label .............................................................................. 13

Checking the scope of delivery ................................................................. 14

ContaminationSensor CS 1939 features ................................................... 15

Dimensions ................................................................................................ 15 Hydraulic connection types ........................................................................ 16

Pipe or hose connection ......................................................................... 16 Flange connection .................................................................................. 17

Installing ContaminationSensor ................................................................ 18

Fastening/mounting the ContaminationSensor .......................................... 18 ContaminationSensor hydraulic installation ............................................... 20

Selecting the measurement location ...................................................... 21

Flow rate, differential pressure p∆ and viscosity ν characteristics ........................................................................................ 22

Hydraulic connection of the ContaminationSensor .................................... 23 Electrical connection of the ContaminationSensor .................................... 24

Pin assignment ....................................................................................... 24 Connection cable - Assignment / Color coding ....................................... 25

Status signals / status LED / troubleshooting .......................................... 26



Content

Applying SAE J1939 protocol .................................................................... 27

Parameter definition .................................................................................. 27 SPN definition......................................................................................... 27

Evaluating/reading measurement reports with FluMoS or FluMoT ........ 28

Performing maintenance ............................................................................ 29

Cleaning the ContaminationSensor ........................................................... 29 Resetting ................................................................................................... 29

Decommissioning the product .................................................................. 29

Disposing of the product ........................................................................... 29

Spare Parts and Accessories .................................................................... 30

Checking/resetting default settings .......................................................... 31

Dialog menu .............................................................................................. 31

Calibrating ContaminationSensor ............................................................. 31

Technical Data............................................................................................. 31

Annex ........................................................................................................... 33

Model code ................................................................................................ 33 Finding Customer Service ......................................................................... 34

Germany ................................................................................................ 34 USA ........................................................................................................ 34 Australia ................................................................................................. 34 Brazil ...................................................................................................... 35 China ...................................................................................................... 35

Cleanliness classes - brief overview .......................................................... 36 Cleanliness class - ISO 4406:1999 ........................................................ 36 Table - ISO 4406 .................................................................................... 36 Overview of modifications - ISO4406:1987 <-> ISO4406:1999 .............. 37

Explanation of terms and abbreviations ..................................................... 38 Index .......................................................................................................... 40



Preface

Preface

These operating instructions were made to the best of our knowledge. Nevertheless and despite the greatest care, it cannot be excluded that errors 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 operating 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 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 code, serial no. and part no. of the product: Fax: +49 6897 / 509 - 9046 E-mail: [email protected]

Modifications to the Product We would like to point out that changes 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 any modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the terms of delivery of HYDAC FILTER SYSTEMS GMBH. You will find these under www.hydac.com -> Legal information.



http://www.hydac.com/

Preface

Using the documentation

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

What 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.

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.

Chapter heading

Page number Edition date

Document language Documentation no. with Index /

File name



Safety Information

Safety Information

The product was built according to the statutory provisions valid at the time of delivery and satisfies current safety requirements. Any residual hazards are indicated by safety information and instructions and are described in the operating instructions. Observe all safety and warning instructions attached to the product. They must always be complete and legible. Do not operate the product unless all the safety devices are present. Secure the hazardous areas which may arise between the product and other equipment. Maintain the product inspection intervals prescribed by law. Document the results in an inspection certificate and keep it until the next inspection.

Hazard symbols These symbols are listed for all safety information and instructions in these operating instructions which indicate particular hazards to persons, property or the environment. Observe these instructions and act with particular caution in such cases. Pass all safety information and instructions on to other users.

General hazard

Danger due to electrical voltage / current

Danger due to operating pressure



Safety Information

Signal words and their meaning in the safety information and instructions

The following signal words are to be found in these instructions.

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.

Structure of the safety information and instructions All warning instructions in this manual are highlighted with pictograms and signal words. The pictogram and the signal word indicate the severity of the danger. Warning instructions listed before an activity are laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

► Measures to avert danger



Safety Information

Observe regulatory information Observe the following regulatory information and guidelines:

• Legal and local regulations for accident prevention

• Legal and local regulations for environmental protection

• Country-specific regulations, organization-specific regulations

Proper/Designated Use 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 HYDAC is not responsible. HYDAC is not responsible for the installation, integration, selection of interfaces to / into your system nor for the use or functionality of your 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. Proper/designated use of the product extends to the following:

• observing all instructions contained 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 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.



Safety Information

Improper Use or Use Deviating from Intended Use

DANGER

Hazard due to use of the product other than that intended

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 or deviating therefrom shall not be considered intended use. HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use. The risk is borne solely by the owner. Improper use or use deviating from intended may result in hazards and/or will damage the sensor. 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.



Safety Information

Qualifications of personnel / target group 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 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 hazards.



Safety Information

Activity Person Knowledge

Transport / storage Auxiliary personnel

• No specialist knowledge required

Hydraulic / electrical installation, First commissioning, Maintenance, Troubleshooting, Repair, Decommissioning, Disassembly

Specialist personnel

• Safe handling/use of tools

• Fitting and connection of hydraulic lines and connections

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

• Checking the phase sequence

• Product-specific knowledge

Operation Operations control

Specialist personnel

• Product-specific knowledge

• Knowledge about how to handle operating media.

Disposal Specialist personnel

• Proper and environmentally friendly disposal of materials and substances

• Decontamination of contaminants

• Knowledge about reuse



Storing product

Storing product

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 Cleanoil before putting it into storage. The solvents and flushing oils used must be handled and disposed of correctly.

Storage conditions Storage temperature: -40 … 80 °C / -40 … 176 °F Relative humidity: maximum 95%, non-condensing

Decoding the type label

For identification details of the ContaminationSensor, 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

Model -> Model code; for details, see page 33.

P/N -> Part no.

S/N -> Serial-no.

Date -> Year/week of production and hardware index

Max. INLET press.: -> Maximum operating pressure



Checking the scope of delivery

Checking the scope of delivery

The ContaminationSensor CS 1939 comes packed and factory-assembled. Before commissioning the CS, please check no items are missing from the package. 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 Calibration certificate



ContaminationSensor CS 1939 features


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.

Dimensions

All dimensions in mm.




Hydraulic connection types If possible, install the CS 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.

Pipe or hose connection The hydraulic connection is done via ports A and B. Connection thread G1/4 according to ISO 228. Make sure that the flow runs through the sensor from bottom (A) to top (B).




Flange connection The 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 CS1000 threads are prepared for fixing the M6. Ports A and B are sealed off with screw plugs [1]. Sealing with the manifold block or mounting plate is done via two O-rings [2] (4.48 x 1.78 FPM, see Chapter "Spare Parts + Accessories").

View from below. All dimensions in mm.



Installing ContaminationSensor


In the following chapters you will find information on the assembly and the hydraulic and electrical installation of the ContaminationSensors.

Fastening/mounting the ContaminationSensor 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 IP67 according to DIN 40050 / EN 60529 / IEC 529 / VDE 0470. 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 to a console using 4 cylindrical screws having an M6 hexagonal socket according to ISO 4762.

A B

10060

12/164xM6

1520

Bottom view All dimensions in mm.




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




ContaminationSensor hydraulic installation 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.

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






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 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 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 ν characteristics

Differential pressure p∆ and viscosity ν 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 ν 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

NOTICE

Excessive operating pressure



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 connection of the ContaminationSensor Pin assignment

Pin Assignment

1 Supply voltage 9-36 V DC

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 30 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 White Supply voltage 9-36 V DC

2 brown CAN H (SAE J1939)

3 Green GND power supply

4 Yellow CAN L (SAE J1939)

5 grey HSI (HYDAC Sensor Interface)

Housing - Shield



Status signals / status LED / troubleshooting

Status signals / status LED / troubleshooting

The status LED displays the following status signals. Error code

LED Description Remedy

0 Green No error Nothing required

3 Red Error during automatic adjustment

Perform a reset. 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. Contact HYDAC Service if the error still occurs.

5 Red Flow too low Increase the flow rate through the CS.

6 Red Flow too high Reduce the flow rate through the CS.

7 Red Contamination too low

The sensor cannot detect a measured value. The operating fluid is apparently too clean.

8 Red Contamination too high

Reduce fluid contamination by filtration until the CS can measure the fluid purity.

16 Red Error while loading the user setup


17 Red Error while saving the user setup


18 Red Error while loading the calibration data




Applying SAE J1939 protocol

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 13

SPN definition

SP

N

Nam

e

Item

Leng

th

Type

Res

olut

ion

Offs

et

Min

. Val

ue

Max

. V

alue

Uni

t

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 SAE A 33 8 integer 0.1 0.0 0.0 14.0

516101 SAE B 41 8 integer 0.1 0.0 0.0 14.0

516102 SAE C 49 8 integer 0.1 0.0 0.0 14.0

516103 SAE D 57 8 integer 0.1 0.0 0.0 14.0

516104 Temp 65 16 integer 0.1 -60.0 0.0 185.0 °C

516105 Flow 81 16 integer 0.1 0 30 500 ml/ min

516106 Drive 97 8 integer 0.1 0 0 100 %



Evaluating/reading measurement reports with FluMoS or FluMoT

Evaluating/reading measurement reports with FluMoS or FluMoT

The FluidMonitoring 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 30.

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 30.




Performing maintenance

Performing 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 agent as these may damage the film attached to the surface.

Resetting To restart or reset the ContaminationSensor, remove the power supply for 10 seconds.

Decommissioning the product

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.

Disposing of the product

Dispose of the packaging material in an environmentally friendly manner. After dismantling the product and separating its various materials, dispose of it in an environmentally friendly manner.



Spare Parts and Accessories

Spare Parts and Accessories

Description Qty. Part no.

Operating and Maintenance Instructions 1 3978342

O-ring for the flange connection (4.8x1.78 - 80 Shore FKM) 1 6003048

Socket plug (female) with 5 m line, shielded, 5-pole, M12x1

ZBE 47S-05 1 3527626

Extension cable 5 m, Socket plug (female) 5-pole, M12x1 / Socket plug (male) 5-pole, M12x1

ZBE 30-05

1 6040852

Socket plug with screw terminals, 5-pole, M12x1

1 6049128

FluMoS Professional CD-ROM 1 3371637

FluMoT CD-ROM 1 3355177 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.




Checking/resetting default settings

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. You will find the authorized HYDAC Service stations in the "Finding Customer Service" chapter on page 34.

Technical Data

General data

Mounting position Any (recommended: vertical position)

Self diagnostics continuously with error indication via status LED and display

Measured variables ISO99 (ISO 4406:1999)

Service variables Flow Status

Drive %

Temp °C and °F

Permitted ambient temperature range -30 to 80 °C / -22 to 176 °F

Storage temperature range -40 … 80 °C / -40 … 176 °F

Permitted relative humidity max. 95%, non-condensing

Material of seal FKM

Protection class III (low voltage protection)

Protection class IP 67 (only with screw-lock connectors)

Weight ≈ 1.3 kg



Technical Data

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

Power supply 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



Annex

Annex

Model code CS 1939 - 0 - 0 / - 000 Model CS = ContaminationSensor Series 1939 = Classification:

ISO 4406:1999; 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



Annex

Finding Customer Service For calibration and repair, send the sensor to the following address:

Germany HYDAC Service GmbH Product Support, Werk 13 Friedrichsthaler Straße 15A 66540 Neunkirchen-Heinitz Telephone: +49 6897 509 883 Fax: +49 6897 509 324 E-mail: [email protected]

USA

HYDAC Technology Corporation, HYCON Division 2260 City Line Road USA-Bethlehem, PA 18017 P.O. Box 22050 USA-Lehigh Valley, PA 18002-2050 Telephone: +1 610 266 01 00 Fax: +1 610 231 04 45 E-mail: [email protected] Internet: www.hydacusa.com

Australia

HYDAC Pty. Ltd. 109 Dohertys Road P.O. Box 224 AUS-3025 Altona North Telephone: +61 392 72 89 00 Fax: +61 393 69 89 12 E-mail: [email protected]



Annex

Brazil HYDAC TECNOLOGIA LTDA Estrada Fukutaro Yida, 225 CEP 09852-060 Cooperativa BR-São Bernardo do Campo – SÃO PAULO Telephone: +55 11 4393 6600 Fax: +55 11 4393 6617 E-mail: [email protected] Homepage www.hydac.com.br

China

HYDAC TECHNOLOGY (SHANGHAI) LIMITED 28 Zhongpin Lu Shanghai Minhang Economic & Technological Development Zone SHANGHAI 200245; P.R. CHINA Telephone: +86 21/64 63 35 10 Fax: +86 21/64 30 02 57 E-mail: [email protected]



Annex

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



Annex

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)



Annex

Explanation of terms and abbreviations An explanation of terms and abbreviations follows below:

AC Alternating current

ACFTD Air Cleaner Fine Test Dust

CAN Controller Area Network

CS ContaminationSensor

DC Direct current

DIN Deutsche Industrie Norm [German Industry Standard]

DN Nominal Diameter

EG European Community

Single measurement A single measurement means the analysis of the contamination in a sample, which flows through the sensor during the configured measurement period. The result of a single measurement is the measured value.

EU European Union

FluMoS FluidMonitoring Software, for details, see page 28.

FluMoT FluidMonitoring Toolkit

HMG HYDAC Measuring device

HSI HYDAC Sensor interface

IN Inlet

INLET Inlet

ISO Classification of the solid particle contamination, details see page 36.

ISO MTD ISO Medium Test Dust

LED Light-emitting diode

Measurement duration Once the measurement duration has elapsed, the measured value is updated which is shown on the display and presented at the interface. The measurement duration is configurable using the M.TIME parameter.

Measuring point This is the name for the point in the hydraulic system where a measurement is carried out.

Measurement Once a CS device has been connected to the electrical power and its boot process has completed, a single measurement will start, after which the next single measurement will



Annex

immediately follow, and so on, until the CS device is disconnected from the power (MODE M1, M2, M4) or until the programmed target purity (MODE M3) has been reached. This series of single measurements is referred to as a measurement for convenience reasons.

Test volume Sample quantity which is analyzed for determining a measured value.

Measured value The contamination codes determined by a single measurement, shown as a three-digit ISO code or NAS codes or SAE codes of the individual particle size channels.

OUT Outlet

OUTLET Outlet

SAE Society of Automotive Engineers



Annex

Index

A

Accessories ............................................. 17, 30 accident prevention ......................................... 9 ambient temperature ..................................... 31 Assignment ........................................24, 25, 36 Auxiliary personnel .................................. 11, 12

C

calibrating ...................................................... 31 Calibration................................................ 14, 37 care .............................................................. 2, 5 cleaning ......................................................... 29 Cleanliness .............................................. 36, 37 connecting .................................. 17, 20, 23, 28 Connection ........................................16, 25, 32 Connection cable ........................................... 25 Connection plug ............................................. 32 Console mounting .......................................... 18 Contamination class ................................ 36, 37 Contamination classes .................................. 36 ContaminationSensor .. 1, 9, 13, 14, 15, 18, 20,

21, 23, 24, 29, 31, 33, 38 Content ............................................................ 3

D

Date ............................................................... 13 default setting ................................................ 31 Description .................................. 13, 14, 26, 30 diagnostics ..................................................... 31 Differential pressure ...................................... 22 Dimensions .................................................... 15 DIN .............................................. 18, 25, 32, 38 Disposal ......................................................... 12 Documentation Representative ....................... 2

E

Electrical data ................................................ 32 Error ............................................................... 26

F

filtration .......................................................... 26 Firmware .......................................................... 1 Flange connection ...................... 17, 20, 32, 33 Flow rate ........................................................ 22 Fluid temperature .......................................... 32 Fluid temperature range ................................ 32 FluMoS ....................................... 14, 28, 30, 38

FluMoT .............................................. 28, 30, 38

G

GND ........................................................ 24, 25

H

half duplex ..................................................... 32 Hardware ........................................................ 1 Hazard symbol ............................................ 7, 8 HSI ........................................ 24, 25, 31, 32, 38 Hydraulic connection................... 16, 23, 32, 33 Hydraulic data ............................................... 32

I

Imprint ............................................................. 2 IN 38 Inlet ............................................................... 38 INLET .............................. 13, 16, 18, 20, 23, 38 installation ............................... 9, 12, 18, 20, 21 Interface ...................................... 24, 25, 32, 33 IP 31 ISO ... 16, 18, 19, 23, 27, 31, 32, 33, 36, 37, 38,

39 ISO4406 ........................................................ 37

1987 ......................................................................... 37 1999 ......................................................................... 37

M

Maintenance ....................................... 1, 12, 30 Manufacturer ................................................... 2 Measured value ............................................ 39 Measured variable ........................................ 31 Measurement .......................................... 31, 38 Measures ........................................................ 8 measuring ............................................... 21, 26 Measuring point ............................................ 38 MODE ........................................................... 38 Model code ............................................. 13, 33 mounting ........................................... 17, 18, 19 Mounting position .......................................... 31

N

NAS ............................................................... 39



Annex

O

operating .. 5, 6, 7, 9, 11, 12, 13, 15, 20, 23, 26, 32

Operation ................................................. 10, 12 Operations control ......................................... 12 OUT ............................................................... 39 Outlet ............................................................. 39 OUTLET................................ 16, 18, 20, 23, 39 Overview ........................................................ 37

P

Power consumption ....................................... 32 Proper/Designated Use ................................... 9 Protection class ............................................. 31

R

Relative humidity ........................................... 13 Remedy ......................................................... 26

S

SAE ........................... 24, 25, 27, 32, 33, 37, 39

select ......................................................... 6, 21 Sensor ......................................... 24, 25, 32, 38 Serial-no ........................................................ 13 Service .............................................. 26, 31, 34 Service variable ............................................ 31 Signal word ..................................................... 8 signal words .................................................... 8 Single measurement ..................................... 38 Size ............................................................... 37 Specialist personnel ................................ 11, 12 Storage conditions ........................................ 13 Storage temperature ............................... 13, 31 Storage temperature range ........................... 31 Supply voltage ........................................ 24, 25

T

Test volume .................................................. 39 Transport ....................................................... 12 troubleshooting ............................................. 26 Troubleshooting ............................................ 12

W

Wall mounting ............................................... 18 Weight ........................................................... 31



HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Tel: +49 6897 509 01 Central Fax: +49 6897 509 9046 Technology Fax: +49 6897 509 577 Sales Department Internet: www.hydac.com E-mail: [email protected]

contaminationsensor cs 1939 - hydac danger – the signal word indicates a hazardous situation with...

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