manually controlled fluid sampling system operating and

An ISO 9001:2015 Certified Company www.schroederindustries.com

580 West Park Road | Leetsdale, PA 15056ph. 724.318.1100 | fax 724.318.1200

8

L-4370

Manually Controlled Fluid Sampling SystemOperating and Maintenance Instructions

L-4370 | Created 4.2015Rev. 5.2017

- TABLE OF CONTENTS-

HY-TRAX®

1. Features and Precautions ...............................................................................................................................................6 1.1 Features ......................................................................................................................................................................6 2. Warnings, Cautions, and Notes .....................................................................................................................................6 2.1 Technical Assistance ...................................................................................................................................................8 2.2 Obligations and Liabilty ...............................................................................................................................................9 2.3 Acronym List ................................................................................................................................................................9 2.4 Components ..............................................................................................................................................................103. Specifications ................................................................................................................................................................114. Connecting Your System ..............................................................................................................................................125. Operating Instructions ..................................................................................................................................................156. Parts List ........................................................................................................................................................................177. Maintenance ...................................................................................................................................................................198. Trouble Shooting ...........................................................................................................................................................199. 24 VDC Connection Instructions ..................................................................................................................................22 TestMate® Contamination Monitor | TCM .........................................................................................................................231. Qualifications of personnel/target Group ...................................................................................................................242. Storing the TCM .............................................................................................................................................................24 2.1. Storage Conditions ...................................................................................................................................................243. Decoding the Model Code Label ..................................................................................................................................244. Checking the Scope of Delivery ...................................................................................................................................255. TCM Features .................................................................................................................................................................266. TCM Restrictions on Use ..............................................................................................................................................267. TCM Dimensions ...........................................................................................................................................................26 7.1. TCM 1x1x dimensions (without display) ...................................................................................................................26 7.2 TCM1x2x dimensions (with display) ..........................................................................................................................268. Hydraulic connection types ..........................................................................................................................................27 8.1 Pipe or hose connection (type TCM) .........................................................................................................................27 8.2 Flange connection type (type TCM) ..........................................................................................................................279. Fastening / mounting the TCM .....................................................................................................................................27 10. Display rotatable/Adjustable As Needed ...................................................................................................................2811. TCM hydraulic installation ..........................................................................................................................................28 11.1. Selecting the measurement point ...........................................................................................................................29 11.2.Flowrate,differentialpressureandviscositycharacteristicTCM ...........................................................................29 11.3. Hydraulic connection of the TCM ...........................................................................................................................2912. Electrical connection of the TCM ...............................................................................................................................31 12.1. Pin assignment .......................................................................................................................................................31 12.2. Connection cable - assignment / color coding .......................................................................................................31 12.3. Connecting cable ends - Examples ........................................................................................................................3113. Setting the measuring mode ......................................................................................................................................33 13.1. Mode M1: Continuous measurement .....................................................................................................................33 13.2. Mode M2: Continuous measurement and switching ..............................................................................................33 13.3. Mode M3: Filter to cleanliness class and stop .......................................................................................................33 13.4. Mode M4: Filter to continuously monitor cleanliness class ....................................................................................34 13.5. Mode “SINGLE” measurement ...............................................................................................................................3414. Operating the TCM1x2x using the keypad ................................................................................................................34

14.1. Function of the Keys ..............................................................................................................................................35 14.2. Measured variables on the display .........................................................................................................................36 14.3. ISO (Cleanliness class) ..........................................................................................................................................36 14.4. SAE (Cleanliness class) .........................................................................................................................................36 14.5. NAS (Cleanliness Class - only TCM 13xx) .............................................................................................................3615. Service variables on the display ................................................................................................................................36 15.1.Flow(flowrate) .......................................................................................................................................................36 15.2. Out (Analog output) ................................................................................................................................................37 15.3 Drive (performance of the LED) .............................................................................................................................37 15.4. Temp (Temperature) ...............................................................................................................................................3716. Activate / deactivate keypad lock ..............................................................................................................................3717. Display FREEZE ...........................................................................................................................................................38 17.1. Activate display FREEZE .......................................................................................................................................38 17.2. Deactivate display FREEZE ...................................................................................................................................3918. Menus and modes .......................................................................................................................................................39 18.1. PowerUp Menu ......................................................................................................................................................39 18.2. Measuring Menu (TCM12xx) ..................................................................................................................................41 18.2.1. DSPLAY - Display after sensor is switched on ..............................................................................................42 18.2.2.SWT.OUT–Schaltausgangkonfigurieren ....................................................................................................42 18.2.3. ANA.OUT - Set output signal at analog output ..............................................................................................44 18.3 Measuring menu (TCM13xx) ...................................................................................................................................44 18.3.1. DSPLAY - Display after sensor is switched on ..............................................................................................44 18.3.2.SWT.OUT–Configureswitchingoutput ........................................................................................................44 18.3.3. ANA.OUT - Set output signal at the analog output .......................................................................................4419. Overview of menu structure .......................................................................................................................................45 19.1. Menu TCM 12xx (ISO 4406:1999 and SAE) ..........................................................................................................45 19.2. Menu TCM 13xx (ISO 4406:1987 and NAS / ISO4406:1999 and SAE 4059 D) ....................................................4720. Using switching output ...............................................................................................................................................48 20.1. Mode M1: Continuous measurement .....................................................................................................................48 20.2. Mode M2: Continuous measurement and switching ..............................................................................................48 20.3. Mode M3: Filter to cleanliness class and stop .......................................................................................................48 20.4. Mode M4: Filter to continuously monitor cleanliness class ....................................................................................48 20.5. Mode “SINGLE” measurement ...............................................................................................................................4921. Setting limit values ......................................................................................................................................................4922. Reading the analog output .........................................................................................................................................51 22.1. SAE classes acc. to AS 4059 .................................................................................................................................51 22.1.1. SAE A-D ........................................................................................................................................................52 22.1.2. SAE Class A / B / C / D .................................................................................................................................52 22.1.3. SAE A / SAE B / SAE C / SAE D ...................................................................................................................53 22.1.4. SAE + T .........................................................................................................................................................54 22.1.5. HDA.SAE – Analog signal SAE to the HDA 5500 .........................................................................................56 22.1.6. HDA.SAE Signal 1/2/3/4 ...............................................................................................................................57 22.1.7. HDA.SAE signal 5 (status) ............................................................................................................................57 22.2. ISO code acc. to ISO 4406:1999 ...........................................................................................................................58 22.2.1. ISO 4 / ISO 6 / ISO 14 ..................................................................................................................................59 22.2.2. ISO code, 3-digit ...........................................................................................................................................60 22.2.3. ISO + T ..........................................................................................................................................................61

22.2.4. HDA.ISO – Analog signal ISO to HDA 5500 .................................................................................................61 22.2.5 HDA.ISO Signal 1/2/3/4 .................................................................................................................................62 22.2.6. HDA.ISO signal 5 (status) .............................................................................................................................63 22.3.ISO code signal acc. to ISO 4406:1987 (TCM 13xx only) ...................................................................................64 22.3.1. ISO 2 / ISO 5 / ISO 15 ..................................................................................................................................64 22.3.2. ISO code, 3-digit ...........................................................................................................................................65 22.3.3. ISO + T ..........................................................................................................................................................66 22.3.4. HDA.ISO – Analog signal ISO to HDA 5500 .................................................................................................67 22.3.5. HDA.ISO Signal 1/2/3/4 ................................................................................................................................69 22.3.6. HDA.ISO signal 5 (status) .............................................................................................................................69 22.4 NAS 1638 - National Aerospace Standard (Only TCM 13xx) .............................................................................70 22.4.1 NAS maximum ..............................................................................................................................................71 22.4.2. NAS classes (2 / 5 / 15 / 25) .........................................................................................................................72 22.4.3 NAS 2 / NAS 5 / NAS 15 / NAS 25 ...............................................................................................................73 22.4.4. NAS + T .........................................................................................................................................................74 22.4.5. HDA.NAS – Analog Signal NAS to HDA 5500 ..............................................................................................75 22.4.6. HDA.NAS Signal 1/2/3/4 ...............................................................................................................................75 22.4.7. HDA.NAS signal 5 (status) ............................................................................................................................76 22.5. Fluid temperature TEMP ......................................................................................................................................7723. Status Messages .........................................................................................................................................................77 23.1. Status LED / Display ..............................................................................................................................................77 23.2. Error .......................................................................................................................................................................80 23.3. Exceptions Errors ...................................................................................................................................................81 23.4. Analog Output Error Signals ...................................................................................................................................82 23.5. Analog signal for HDA 5500 ...................................................................................................................................83 23.5.1 HDA Status Signal 5 Table .............................................................................................................................8324. Connecting TCMI-D-5 (Condition Sensor Interface) .................................................................................................85 24.1. TCMI-D-5 Connection overview .............................................................................................................................8525. Connecting the TCM to an RS485 bus .......................................................................................................................8626. Communicating with the TCM via the RS485 bus ....................................................................................................8727. Taking the TCM out of operation ................................................................................................................................8728. Disposing of TCM ........................................................................................................................................................8729. Spare Parts and Accessories .....................................................................................................................................8730. Cleanliness classes - brief overview .........................................................................................................................87 30.1. Cleanliness class - ISO 4406:1999 ........................................................................................................................87 30.2. Table - ISO 4406 ....................................................................................................................................................88 30.3.Overviewofmodifications-ISO4406:1987<->ISO4406:1999 .............................................................................89 30.4. Cleanliness class - SAE AS 4059 ..........................................................................................................................90 30.5. Table - SAE AS 4059 ..............................................................................................................................................90 30.6.Definitionacc.toSAE ............................................................................................................................................90 30.6.1.Particlecount(absolute)largerthanadefinedparticlesize .........................................................................90 30.6.2.Specifyingacleanlinesscodeforeachparticlesize .....................................................................................90 30.6.3. Specifying highest measured cleanliness class ............................................................................................9031. Cleanliness Class - NAS 1638 ....................................................................................................................................9132. Checking/resetting default settings ...........................................................................................................................91 32.1. Measuring menu ..............................................................................................................................................9233. Specifications ..............................................................................................................................................................9234.Recalibration .................................................................................................................................................................9435. Glossary .......................................................................................................................................................................94

L-4370 HY-TRAX® User Manual

6 En Schroeder Industries

1. Features and Precautions

The HY-TRAX® manually controlled sampling system represents the latest in technology and innovation. Features have beendesignedintothesystemtomakeituserfriendlyandsafeforoperation,however,theunitcanconstituteahazardifusedincorrectlybyuntrainedpersonnelorifnotusedasspecifiedinthismanual.Thismayresultin: ■ potential injury ■ damage to the machine and/or other equipment of the client’s

1.1 Features

■Provides Local Visibility to the Fluid Condition of Critical Systems.■IntegratedmicroVSD,(VariableSpeedDrive),pump/motorprovidesoptimalflowforaccuratesensorreadingsin

variable conditions.■The HY-TRAX® Manually Controlled Fluid Sampling System allows a user to retrieve ISO cleanliness levels from a reservoirtankoralow-pressureline(<50psimax).

■The compact design allows for installations with tight space constraints.■The Manual rheostat VSD pump controller is housed in a compact IP 40 enclosure and allows the user to adjust the pumpflowforoptimalsensorreadings.

■OptionalACadapterallowstheunittooperateon115VAC60Hz.24VDCisstandard.■Ruggeddesignforfielduse.■Viton® seals.■Fluid viscosities up to 350 cSt.■Flow control valve providing optimal pressure for accurate sensor readings.

2. Warnings, Cautions And Notes Explanation of Symbols and Warnings

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION—usedwiththesafetyalertsymbol.DANGERidentifies themostserioushazards.GeneralprecautionsareonCAUTIONlabels.

Follow Safety Instructions Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Be sure all operators of this machine understand every safety message. Replace safety labels immediately if missing or damaged.

User Manual HY-TRAX® L-4370

Schroder Industries En 7

Operate Only If Qualified Do not operate this machine unless you have read the operator’s manual carefully and you have been qualifiedbysupervisedtrainingandinstruction.Familiarizeyourselfwiththejobsiteandyoursurroundingsbeforeoperating.

Inspect Machine Inspect the equipment carefully before each use. Keep all parts in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical power cord.

Handle Fluids Safely—Avoid Fires Filteringoffuelorotherflammableliquidsisnotrecommended.Storeflammablefluidsawayfromfirehazards.Donotincinerateorpuncturepressurizedcontainers.Makesuremachineiscleanoftrash,grease,anddebris.Donotstoreoily rags; they can ignite and burn spontaneously.

Prepare for Emergencies Bepreparedifafirestarts.Keepafirstaidkitandfireextinguisherhandy.Keepemergencynumbersfordoctors, ambulanceservice,hospital,andfiredepartmentnearyourtelephone.

Practice Safe Maintenance Understand service procedure before doing work. Work areas should be level, clean, and dry. Before servicing machine: ■ Position the machine on a level surface ■ Allow to cool if hotKeep all parts in good condition and properly installed. Fix damaged components immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris

Handle Chemical Products Safely Directexposuretohazardouschemicalscancauseseriousinjury.Potentiallyhazardouschemicalsusedwithequipmentinclude such items as lubricants, coolants, paints, and adhesives. AMaterialSafetyDataSheet(MSDS)providesspecificdetailsonchemicalproducts:physicalandhealthhazards,safetyprocedures,andemergencyresponsetechniques.ChecktheMSDSbeforeyoustartanyjobusingahazardouschemical.That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.(ContactSchroederpriortousingwithfluidsotherthanhydraulicfluids).

Burn HazardsDo not touchAllow to cool before servicing

Wear Protective Clothing Wearclosefittingclothingandsafetyequipmentappropriatetothejob.Operatingequipmentsafelyrequiresthefullattentionof the operator. Do not wear radio or music headphones while operating the machine.

Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.



Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine.Makesurethebulbisenclosedbyawirecage.Thehotfilamentofanaccidentallybrokenbulbcanignitespilled fuel or oil.

Work In Clean Area Before starting a job: ■ Clean work area and machine ■ Make sure you have all necessary tools to do your job. ■ Have the right parts on hand. ■ Read all instructions thoroughly; do not attempt shortcuts.

Use Proper Tools Usetoolsappropriatetothework.Makeshifttoolsandprocedurescancreatesafetyhazards.Forlooseningandtighteninghardware,usethecorrectsizetools.DONOTuseU.S.measurementtoolsonmetricfasteners. Avoid bodily injury caused by slipping wrenches.

Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste includes such items asoil,fuel,coolant,brakefluid,filters,andbatteries.Useleak-proofcontainerswhendrainingfluids.Donotusefoodorbeverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source.

Electrical Hazards■ All work on the electrical equipment must be carried out by a qualified electrical equipment must be carried out by a qualified electrician.

■ The electrical parts of the cart must be regularly checked. ■ Any loose contacts must be rectified immediately. ■ Thecontrolboxmustalwaysbesecured.Itmaybeaccessedonlybyauthorizedstaff. ■ If work needs to be performed on electrically live parts, a second person must be called in to turn off the main switch, if necessary. ■ Voltage or current hazard sufficient to cause shock, burn, or death. ■ Remove power before servicing.

WARNING DENOTES SITUATIONS WHICH CAN LEAD TO MORTAL INJURY IF SAFETY PRECAUTIONS ARE NOT OBSERVED.

2.1 Technical Assistance

ForTechnicalAssistancepleasecall1-800-722-4810oremailfiltersystems@schroederindustries.com.



TCM: TestMate® Contamination Monitor VAC: Voltage Alternating CurrentTWS: TestMate® Water Sensor VDC: Voltage Direct CurrentORB: O-Ring Boss POT: Potentiometer or RheostatGPM: Gallons Per Minute NPT: National Pipe Thr

2.2 Obligations and Liabilty

Using the Documentation

Notethatthemethoddescribedforlocatingspecificinformationdoesnotreleaseyoufromyourresponsibilityof carefullyreadingtheseinstructionspriortostartingtheunitupforthefirsttimeandatregularintervalsinthefuture.

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, along with the corresponding page number.

The document number with its edition date enables you to order another copy of the operating and maintenance instructions. The index is incremented every time the manual is revised or changed.

While every precaution has been taken to ensure accuracy and completeness in this literature, Schroeder Industries assumes no responsibility, and disclaims all liability for damages resulting from use of this information or for any errors or omissions.

2.3 Acronym List

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

Document Number

Page Number

Edition Date Document Language



2.4 Components

115VAC x 24VDCPower Supply/Converter

ManualController

Variable SpeedPump/Motor

TestMate® ContaminationMonitor (TCM)

Flow ControlValve

0-160PSIPressure Gauge

ManifoldBlock

Component Definitions



Measuring Range: Display ISO ranges between 25/24/23 and 9/8/7 Calibration within the range ISO 13/11/10 to 23/21/18

Contamination Output Code: Standard: ISO 4406:1999 or SAE AS 4059(D)Optional: ISO4406:1987; NAS 1638 and ISO 4406:1999

Self Diagnosis: Continuously with error indication via status LEDFluid Inlet/Outlet: 50 psi (3.4 bar) max

Seal Material: Viton®

Pump Speed: 500-5000 RPM (adjustable)Optimal Sampling

Pump Flow Rating:0.008-0.079 GPM (30-300 mL/min)

Fluid Temperature Range: 32°F to 185°F (0°C to +85°C)Ambient Temperature Range: -22°F to 176°F (-30°C to 80°)

Max Viscosity: 350 cStPump Type: Gear Pump

Power Supply Voltage: 24VDC+/-10%,ResidualRipple<10%Max Power/Current Consumption: 100 Watt/ 4 amp

Electrical Output: 4-20 mA analog output; 0-10 V analog (option for contamination monitor (TCM)RS485 for communication with FluMoS Software

Electrical Specifications 4-20mAanalogoutput(maxburden330Ω)0to10voutput(minloadresistor82Ω)Limitswitching output (Power MOSFET): max current 1.5A

TestMate® Contamination Monitor (TCM) Signal Output Connections

Located on Control Enclosure:

M12 8 pole, Male Port, Analog or Digital, for use with PLC or RS485 Communication, (4 - 20 mA is standard). 0 - 10 V is optional, must specify when ordering TestMate® Contamination Monitor (TCM)

Water Sensor (TWS-D) Signal Output Connection Located on Control

Enclosure:

Water sensor (TWS-D) M12-5 pole Signal Output 5 pole Male Port, located on Control Enclosure

Electrical Safety Class: III (low voltage protection)Enclosure Ratings: IP 40 enclosure

Design Parameters

3. Specifications



4. Connecting your SystemSTEP ONE Unpack manifold assembly and manual controller, along with supplied cables.

STEP TWO Mount unit in accordance with drawing 7612530 (see page 13). ■ Themanifoldneedstobemountedverticallywithflowenteringthebottomandexitingthetop.■ Refertodrawing7612530formountingholesizesandlocations.

STEP THREE Connection suction and discharge hoses to inlet and outlet connections on the manifolds. ■ ThreadsizeonthemanifoldisSAE04inaccordancewithSAEJ1926standards.Suctionlinetobeaminimumof

3/8” I.D. ■ Discharge line to be a minimum of ¼” I.D.

■ If pulling from a reservoir, suction line must be located at least 6” (152 mm) from the bottom of the reservoir.

■ For versatility, front ports have been machined into the manifold and can be used in lieu of the side ports. These ports are supplied with plugs.

WARNINGPower:115VAC/60Hzor24VDC(ifnotusingpowersupply/converter).Refer to section 9 of this manual for instructions to connect the supplied LF-11268 XLR cable connector.

■ Maximum Fluid Viscosity: 350 cSt

■ Maximum length of suction hose: 7 ft (2.1 m).

STEP FOUR For systems with Manual Controller:

■ Connect 8 pin supplied cable to TCM and control box ‘TCM Power connection as shown on drawing 7628266 (see page 14).

■ Connect 5 pin supplied cable to Motor connection and control box ‘Motor/Pump Power’ as shown on drawing 7628266 (see page 14).

WARNING The HY-TRAX® manual controller requires 24 DC power in order to operate. The optional AC/DC converter (SAP# 7600601) can be used. Or, see page 21 for wiring the supplied 24 VDC connector.



1) S

TRAI

GHT

THRE

AD O

-RIN

G PO

RTS

ARE

IN

ACC

ORDA

NCE

WIT

H SA

E J1

926 S

TAND

ARDS

.

NOTE

:

*UNI

T MU

ST B

E MO

UNTE

DVE

RTIC

ALLY

AS

SHOW

N

-+

ANG.

MATE

RIAL

:DE

C. T

OLER

ENCE

CHK.

ALL D

IMEN

SION

S IN

INCH

ES [M

M]AP

P.

DWN.

REV.

CAR

D:RE

V. D

ATE:

REV.

DRAW

ING

NO.

SCAL

E:SH

T.

B.MI

LLER

B.MI

LLER

4/15/2

015

E.SC

HLEM

MER

4/15/2

015

4/15/2

015

4/19/2

017

1365

8

+ - -+3 P

L.2 P

L.INDUSTRIES

HYHM

P

VERT

ICAL

MOU

NTED

HYT

RAX

SYST

EMCO

MPA

NY. T

HEY

ARE

SUBJ

ECT

TO R

ETUR

N UP

ON R

EQUE

ST.

1:11 O

F 1

7612530

SIZE

:

DES

T. W

EIGH

T:

LAYO

UT O

FINDUSTRIES

ww

w.s

chro

ederi

ndustr

ies.c

om

THES

E DR

AWIN

GS, S

PECI

FICA

TION

S, A

ND T

HE ID

EAS

CONT

AINE

D HE

REIN

ARE

THE

EXC

LUSI

VE P

ROPE

RTY

OF S

CHRO

EDER

INDU

STRI

ES A

ND A

RE C

ONFI

DENT

IAL.

THES

E DO

CUM

ENT(

S) S

HALL

NOT

BE

COPI

ED O

RRE

PROD

UCED

IN P

ART

OR IN

FUL

L AS

A B

ASIS

OR

DESI

GN,

MAN

UFAC

TURE

D, O

R SA

LE; A

ND S

HALL

NOT

BE

USED

INAN

Y W

AY D

ETRI

MEN

TAL

TO T

HE IN

TERE

ST O

F TH

IS

B

CONN

ECTI

ON

1/4 N

PT F

EMAL

E

MOTO

R EL

ECTR

ICAL

INLE

T

INLE

T (A

UXILA

RY)

POW

ER/S

IGNA

L CON

NECT

ION

CONT

AMIN

ATIO

N MO

NITO

R

OUTL

ET

7/16-

16 S

TRAI

GHT

THRE

ADO-

RING

BOS

S(S

AE-0

4)

O-RI

NG B

OSS

(SAE

-04)

7/16-

16 S

TRAI

GHT

THRE

AD

OUTL

ET (A

UXILA

RY)

7/16-

16 S

TRAI

GHT

THRE

ADO-

RING

BOS

S(S

AE-0

4)

(2) M

OUNT

ING

HOLE

S: .75(C

-BOR

E IS

ON

OPPO

SITE

SID

E)1/4

-20U

NC-2

B

(2 -

OPTI

ONS)

(2) M

OUNT

ING

HOLE

S:15

mm

8mm

9mm

THRU

MOUN

TING

HOL

ES

692.7

2

1.38 35

2.6968

51

2.00 1275.00

11.44

3.2783



CONN

ECTI

ON T

YPE:

M12

-8F

FOR:

TCM

POW

ERCO

NNEC

TION

TYP

E: M

12-4

FFO

R: M

OTOR

/PUM

P PO

WER

9.33

REF

.

5.23 REF.

CONN

ECTI

ON T

YPE:

NAU

SB-W

POR

TFO

R: LA

PTOP

AND

FLU

MOS

SOFT

WAR

E

CONN

ECTI

ON T

YPE:

NC3

MD-L

X PO

WER

POR

TFO

R: 24

VDC

POW

ER IN

OR

24VD

C/11

5VAC

ADA

PTOR

POW

ER IN

CONN

ECTI

ON T

YPE:

M12

-5F

FOR:

TW

S PO

WER

CONN

ECTI

ON T

YPE:

M12

-5M

FOR:

TW

S OU

TPUT

SCO

NNEC

TION

TYP

E: M

12-8

MFO

R: T

CM O

UTPU

TS

MATE

RIAL

:DE

C. T

OLER

ENCE

CHK.

ALL D

IMEN

SION

S IN

INCH

ES [M

M]AP

P.

DWN.

REV.

CAR

D:RE

V. D

ATE:

REV.

DRAW

ING

NO.

SCAL

E:SH

T.

.01 °B.

MILL

ERB.

MILL

ER4/1

5/201

5

E.SC

HLEM

MER

4/15/2

015

4/15/2

015

2/26/2

016

1365

7

LF-1

1302

MANU

AL C

ONTR

OL B

OX

FOR

HYTR

AX

THES

E DR

AWIN

GS, S

PECI

FICA

TION

S, A

ND T

HE ID

EAS

CONT

AINE

D HE

REIN

ARE

THE

EXC

LUSI

VE P

ROPE

RTY

OF S

CHRO

EDER

INDU

STRI

ES A

ND A

RE C

ONFI

DENT

IAL.

THES

E DO

CUME

NT(S

) SHA

LL N

OT B

E CO

PIED

OR

REPR

ODUC

ED IN

PAR

T OR

IN F

ULL A

S A

BASI

S OR

DES

IGN,

MANU

FACT

URED

, OR

SALE

; AND

SHA

LL N

OT B

E US

ED IN

ANY

WAY

DET

RIME

NTAL

TO

THE

INTE

REST

OF

THIS

COMP

ANY.

THE

Y AR

E SU

BJEC

T TO

RET

URN

UPON

REQ

UEST

.1:1

1 OF

1

7628266

SIZE

:

DES

T. W

EIGH

T:

LAYO

UT O

F INDUSTRIES

www.schroederindustries.com

INDUSTRIES

2 PL.

3 PL.

+ --+-+

ANG.

A



5. Operating Instructions

STEP ONEWith the unit powered on, the TCM display should be illuminated and power will be supplied to the pump/motor. The TCM will show ISO cleanliness readings 90 seconds after powering up.

STEP TWOThe unit is set up correctly when the pressure gauge reads 100 psi, and the TCM’s Flow-Display reads ‘OK-’. Steps 3 and 4 should be used as guidelines to achieve these settings. Refer to drawing C-14685 (see next page) for setting of the rheostat.

STEP THREESetting the Pump Speed:TheRheostatcontrolsthepumpspeed,with0%=poweroff,and100percent=fullspeed.Refer to Dwg. C-14685 for approximate setting of rheostat dial located on the manual control box. As a general rule, lower viscosities require a lower % setting on the rheostat. Higher viscosities require a higher % setting of the rheostat. For viscosities outside of the ones discussed, minimal adjustments of the rheostat are required to achieve correct pump speed.

WARNINGPump speed must be kept to a minimum, therefore rheostat should never be set greater than 50%.

An‘OK-’readingontheTCMflowscreenshouldbedisplayedwhentherheostatissetcorrectly.Turndialtotheappropriatesettingasdefinedbelow.

Forfluidviscositiesof75cSt,therheostatshouldbesetat15%.Viscositieslessthan75cStwillrequirearheostatsetting less than or equal to 15%.

Forfluidviscositiesof140cSt,therheostatshouldbesetat25%.Viscositiesgreaterthan140cStwillrequirearheostatsetting greater than or equal to 25%.

STEP FOUR Setting the Pressure: WithanAllenwrench,turntheflowcontrolvalveoutcounter-clock-wiseuntilitstops.

Forfluidviscositiesof75cSt,turntheflowcontrolvalveclock-wiseapproximately1/2turnuntilthepressuregaugereads100psi.An‘OK-’readingontheTCMflowscreenshouldbedisplayed.Viscositieslessthan75cStwillrequireaflowcontrol valve setting less than or equal to 1/2 turn.

Forfluidviscositiesof140cSt,turntheflowcontrolvalveclock-wiseapproximately3/4turnuntilthepressuregaugereads100psi.An‘OK-’readingontheTCMflowscreenshouldbedisplayed.Viscositiesgreaterthan140cStwillrequireaflowcontrolvalvesettinggreaterthanorequalto3/4turn.

NOTE:Dependingonviscosityandfluidtemperature,smalladjustmentstotherheostatandflowcontrolvalvemayberequiredtoachievean‘OK-’readingontheTCMflowscreen.

STEP FIVEOncethecorrectadjustmentshavebeenmade,allow10-15minutesforthesystemtonormalizeandstartgeneratingaccurate readings. This time allotment allows for air trapped in the hoses to be passed through the system.



www.schroederindustries.com

INDUSTRIES LLC

-C

-146

85LF

-113

02

MATE

RIAL

:DE

C. T

OLER

ANCE

S2 P

L.3 P

L.AN

G

APP.

CHK.

DWN.

ALL D

IMEN

SION

S IN

INCH

[MM]

REV.

CAR

D:RE

V. D

ATE:

B/M

P/N

+- -+

REV.

DRAW

ING

NO.

SETT

INGS

FOR

OIL

VISC

OCIT

IES

.01+

2:1SC

ALE:

SHT.

DETA

IL OF

RHE

OSTA

T

SUBJ

ECT

TO R

ETUR

N UP

ON R

EQUE

ST.

B.MI

LLER

°4/1

5/15

1 OF

1E.

SCH

LEM

MER

4/1

5/15

B.MI

LLER

4/15/1

5

THES

E DR

AWIN

GS, S

PECI

FICA

TION

S, A

ND T

HE ID

EAS

CONT

AINE

D HE

REIN

ARE

THE

EXC

LUSI

VE P

ROPE

RTY

OF S

CHRO

EDER

INDU

STRI

ES L

LC A

ND A

RECO

NFID

ENTI

AL. T

HESE

DOC

UMEN

T(S)

SHA

LL N

OT B

ECO

PIED

OR

REPR

ODUC

ED IN

PAR

T OR

IN F

ULL

AS A

BA

SIS

OF D

ESIG

N, M

ANUF

ACTU

RED,

OR

SALE

; AND

SHAL

L NO

T BE

USE

D IN

ANY

WAY

DET

RIM

ENTA

L TO

THE

INTE

REST

OF

THIS

COM

PANY

. THE

Y AR

E

F(75 cSt) ISO 32 @ 70

RHEO

STAT

(140 cSt) ISO 46 @ 70 F



6. Parts List

ITEM NO. QTY. DESCRIPTION PART NO. OLD PART NO. (REF. ONLY)

1 1 HYTRAX MANIFOLD EXTENSION 7616164 LF-11194

2 1 HYTRAX MANIFOLD 7616163 LF-11195

3 1 MOTOR/PUMP GROUP 7630820 LF-11301

4 2 FITTING, GEAR PUMP/MOTOR UNIT 7609911 LF-11193

5 2 O-RING, ARP-568-109 7618376 9464K44

6 1 CONNECTOR, 04MB-04MP 7608338 6401-04-04

7 1 FILTER, IN-LINE, 8GPM 7630886 LF-11424

8 1 MONITOR, CONTAMINATION W/DISPLAY (EURO) W/FLANGE 3289340

9 2 PLUG, HEX SOCKET, 02MB 7619201 22S-S02V

10 4 PLUG, HEX SOCKET, 04MB, V 7619207 A-600-4V

11 1 PLUG, HEX SOCKET, 06BSPP 7619212 9028-6V

12 1 CONTROL VALVE, SR06-01-C-N-0.3V 2610213 02610213

13 1 GAUGE, PRESSURE, 0-160 PSI 7630848 LF-11369

14 1 CONTROL PANEL 7628106 LF-11302

15 1 POWER SUPPLY, 24V, DC, 120W 7600601

16 2 CAP SCREW, SH, .25-20UNC X 2.50 7628906 04-1082

17 4 CAP SCREW, SH, M6-1.0 X 60 7630814 LF-11295

18 1 CORD, M12-F-90M, 8C, 1M, 300V/4, BLK, PUR, IP67 (NOT SHOWN) 7608415 TCM-117

19 1 CORD, M12-F-M, 5C, 1M, 300V/4, PVC, YLW, IP67 (NOT SHOWN) 7608418 ES-10245

20 1 E-CONN, 4P, M12-M, 250VDC, 4A, IP67 (NOT SHOWN) 7630835 LF-11337

CC

MATERIAL: DEC. TOLERENCE

CHK.

ALL DIMENSIONS IN INCHES [MM]APP.

DWN.

REV. CARD:REV. DATE:

REV.DRAWING NO.

SCALE: SHT.

B.MILLER B.MILLER 01/22/2015

D.COWDER01/21/201501/19/2015

2/14/201713197

HYTRAX MANUALLY CONTROLLED FLUID SAMPLING SYSTEM(HYHMP)

THESE DRAWINGS, SPECIFICATIONS, AND THE IDEASCONTAINED HEREIN ARE THE EXCLUSIVE PROPERTYOF SCHROEDER INDUSTRIES AND ARE CONFIDENTIAL.THESE DOCUMENT(S) SHALL NOT BE COPIED ORREPRODUCED IN PART OR IN FULL AS A BASIS OR DESIGN,MANUFACTURED, OR SALE; AND SHALL NOT BE USED INANY WAY DETRIMENTAL TO THE INTEREST OF THISCOMPANY. THEY ARE SUBJECT TO RETURN UPON REQUEST. N.T.S. 2 OF 2

7633259SIZE:

DEST. WEIGHT:

PARTS LIST DRAWING OF INDUSTRIES

www.schroederindustries.comINDUSTRIES

2 PL.3 PL.

+--+-+

ANG.

C



DAN

G.

MATE

RIAL

:DE

C. T

OLER

ENCE

CHK.AL

L DIM

ENSI

ONS

IN IN

CHES

[MM]

APP.

DWN.

REV.

CAR

D:RE

V. D

ATE:

REV.

DRAW

ING

NO.

7633259

+

SCAL

E:SH

T.

B.MI

LLER

B.

MILL

ER

01/22

/2015

D.CO

WDE

R01

/21/20

1501

/19/20

15

HYTR

AX M

ANUA

LLY

CONT

ROLL

ED F

LUID

SAM

PLIN

G SY

STEM

- + - -+3 P

L.2 P

L.

(HYH

MP)

2/14/2

017

1319

7

1 OF

2CO

MPA

NY. T

HEY

ARE

SUBJ

ECT

TO R

ETUR

N UP

ON R

EQUE

ST.

SIZE

:

N.T.

S.ES

T. W

EIGH

T:

PART

S LIS

T DR

AWIN

G OF

INDUSTRIES

ww

w.s

chro

ederi

ndustr

ies.c

om

INDUSTRIES

THES

E DR

AWIN

GS, S

PECI

FICA

TION

S, A

ND T

HE ID

EAS

CONT

AINE

D HE

REIN

ARE

THE

EXC

LUSI

VE P

ROPE

RTY

OF S

CHRO

EDER

INDU

STRI

ES A

ND A

RE C

ONFI

DENT

IAL.

THES

E DO

CUM

ENT(

S) S

HALL

NOT

BE

COPI

ED O

RRE

PROD

UCED

IN P

ART

OR IN

FUL

L AS

A B

ASIS

OR

DESI

GN,

MAN

UFAC

TURE

D, O

R SA

LE; A

ND S

HALL

NOT

BE

USED

INAN

Y W

AY D

ETRI

MEN

TAL

TO T

HE IN

TERE

ST O

F TH

IS

C

14

8

12

4X

9

1

11

3

215

10

13

4X

9

2X

6

16

17

7C

42X

52X



7. Maintenance

■ Checkfittingsperiodicallytoensuretheyaretight.■ Check suction and discharge hoses for leaks, cracks…etc.■ For TCM maintenance, refer to section 9 of this manual.■ Inspect unit periodically for leaks. Internal leaks will be caused by faulty O-rings. Refer to the parts list shown in

Section 6 for O-ring part numbers and contact your sales representative.■ Cleaninletstrainer.Frequencywillbedeterminedbythedirtlevel/sizeofthefluid.

8. Trouble Shooting

Problem SolutionTCM readings for 4 and 6 micron channels are the same.

Thisindicatesairinthesystem.Ensureallfittings/connectionsaretight.

The pressure gauge is reading 0. Ensure the rheostat is turned to the correct %. Ensure all interconnecting and power cables are connected. Ensure suction line and discharge lines are not blocked.

The motor is running hot and shutsoff.

Thisindicatestheviscosityofthefluidistoohigh,resultinginmotoroverload. The unit is designed for 350 cSt (max).

Ensure suction line and discharge lines are not blocked or clogged.

Clean inlet strainer, (if supplied with unit). TCM readings are erratic. Refer to TCM section of this manual for detailed TCM troubleshooting information.



Slide the boot onto the cable.

Insert the positive wire on terminal #1 and thenegative wire on terminal #2 and solder them.

Put chuck onto the cable.

Slide insert and chuck together into thehousing.

Finish the installation by turning the bushingonto the connector.

Prepare cable as shown.

Attention: Pay attention to the guiding key.

A

B

C

E

F

D

A

B

C

D

18

4

E

F

ORDER OF ASSEMBLY

NC FXX

bushing chuck insert housing

ASSEMBLY INSTRUCTIONNC* FXX & NC * MXX XLR Cable Connector|

An ISO 9001:2015 Certified Company www.schroederindustries.com

580 West Park Road | Leetsdale, PA 15056ph. 724.318.1100 | fax 724.318.1200

8

L-4370

TestMate® Contamination Monitor | TCMOperating and Maintenance Instructions


L-4370 TCM User Manual


1. Qualifications of Personnel/Target Group

Personswhoworkonthesensormustbeawareoftheassociatedhazardswhenusingit.Auxiliary and specialist personnel must have read and understood the operating instructions, in particular the safety infor-mation 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 per-sonnel.These operating instructions is intended for:Auxiliarypersonnel:suchpersonshavebeeninstructedaboutthesensorandareawareofpotentialhazardsduetoim-proper use.Specialist personnel: such persons with corresponding specialist training and several years work experience. They are abletoassessandperformtheworkassignedtothem,theyarealsoabletorecognizepotentialhazards

Activity Person KnowledgeTransport / storage Forwarding agent,

Specialist personnel• Proof of knowledge of cargo securing instructions• Safe handling/operation of hoisting and lifting equipment

Hydraulic / electrical installation,firstcommissioning,maintenance,troubleshooting,repair,decommissioning,disassembly

Specialist personnel •Product-specificknowledge• Knowledge about how to handle operating media.

OperationOperations control

Specialist personnel •Product-specificknowledge• 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

2. Storing the TCMStore the TCM in a clean, dry place, in the original packing, if possible. Do not remove the packing until you are ready to install the unit.

Rinse the TCM completely with Cleanoil before putting it into storage.

Thesolventsandflushingoilsusedmustbehandledanddisposedofcorrectly.

2.1. Storage conditionsStorage temperature: -40 °C … 80 °C / -40 °F … + 176 °FRelative humidity: maximum 95%, non-condensing

3. Decoding the model code labelForproductidentificationdetailsseetheModelcodelabel.Thisislocatedonthebackoftheunitandcontainstheexactproduct description and the serial number.

User Manual TCM L-4370


Row DescriptionModel Model CodeP/N Part no.S/N Serial no.Date Year/week of production and hardware indexMax. INLET press Maximum operating pressure

4. Checking the scope of delivery

The TestMate® Contamination Sensor TCM comes packed and factory-assembled, ready for operation. Before starting up the TCM, check that the content of the package is complete.

The following items are supplied:

Qty Description1 TestMate® Contamination Sensor,TCM series

(Model in acc. with the order - see model code)2 O-rings (4.8 x 1.78 mm, 80 Shore, FKM) (Only with connection type “Flange connection” =

model code: TCM1xxx-x-x-x-x-1/-xxx)1 FMM-P upgrade kit with installation instructions (Only with connection type

“Flange connection” = model code: TCM1xxx-x-x-x-x-1/-xxx)1 CD with TCM operation and maintenance instructions (this document in various languages)1 CDwithFluMoSsoftware(fluidmonitoringsoftware)1 Quick start manual1 Calibrationcertificate



5. TCM FeaturesThe TCM Series Contamination Sensor is a stationary measurement unit for the continuous monitoring of particu-late contamination in hydraulic and lubrication systems.

The TCM is designed to be used in low- or high-pressure hydraulic and lubrication circuits and test benches where a small amount of oil (between 30 ml/min and 500 ml/min) is diverted for measurement purposes.

The TestMate®ContaminationSensorisapprovedforamaximumoperatingpressure(seespecificationontypelabel) and viscosity of up to 1000 mm²/s.

Particulate contamination is detected with an optical measurement cell

The sensor is available with the following options:■ With or without 6-digit display and keypad (can be rotated by 270°)■ With a 4 … 20 mA or 2 … 10 V analog output■ Results are output as a cleanliness code according to:

ISO 4406:1999 and SAE AS 4059(D) or ISO 4406:1987 and NAS or ISO4406:1999 and SAE AS 4059(D)■ Pipe/hoseinstallationorflangeinstallation

All models feature an analog electric output and an RS485 interface for outputting the measured cleanliness class. In addition, all TCM’s have a switching output.

6. TCM Restrictions on use

TCM1x1x dimensions (without display)

All dimensions in mm

TCM1x1x dimensions (without display)



8.1. Pipe or hose connection (type TCM)Hydraulic connection is done via ports A and B. Connection thread G1/4 according to ISO 228.Makesurethattheflowrunsthroughthesensorfrombottom(A)totop(B).

8.2. Flange connection type (Type TCM)Hydraulic connection is done via ports C and D. Two O-rings are used to form a seal between theTCMandaflange,connectingplateormanifoldmount.FourM6threadsarepreparedfor fixingtheTCM.PortsAandBaresealedoffwithscrewplugs[1].SealingwiththemanifoldblockormountingplateisdoneviatwoO-rings[2](4.48x1.78FPM,seeChapter“SpareParts+ Accessories”).

9. Fastening / mounting the TCMInstalltheTCMinsuchawaythattheflowrunsfrombottomtotop.

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 TCM is designed for IP67 according to DIN 40050 / EN 60529 / IEC 529 / VDE 0470.

Mount the sensor 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.



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.

10. Display rotatable/Adjustable As Needed

The display can be continuously rotated by a total of 270°; 180° counterclockwise and 90° clockwise.

Rotate the display by hand in the corresponding direction.

No tools are required for rotating the display

11. TCM hydraulic installationIfpossible,installtheTCMsothatfluidflowsfrombottomtotoptoavoidaircollectinginthesensor.Ifitisnotpossibletoinstall 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 TCM features the following hydraulic connection types:

Pipe/hose connection

The TCM is connected to the hydraulic system via ports A and B using a pipe or hose.

Flange connectionTheTCMisscrewedtoaflange,connectingplate,manifoldmountor controlblock,withflowthroughtheunitviaportsCandDonthebottom.Ports A and B exist but are sealed with a screw plug

DeterminetheoperatingpressureofthehydraulicsystemandseewhetheritiswithinthepermissibleflowrangefortheTCM inlet



NOTE Excessive operating pressure The TestMate® Contamination Sensor will be destroyed: Note the maximum operating pressure of 350 bar / 5075 psi.

11.1. Selecting the measurement pointIn order to obtain cleanliness values that are continuous and coherent in real time, select a suitable measuring point ac-cording to the following guidelines:

WRONG WRONG OK

1.Selectthemeasurementpointsothatthesamplemeasuredcomesfromaturbulentlocation,withagoodflow.For example: on a pipe elbow, etc.2. Install the sensor near the measurement point to achieve as timely results as possible.3. During installation, avoid creating a “siphon” trap for particle deposits in the line (sedimentation).

11.2 Flow rate, differential pressure and viscosity v characteristic TCM

DifferentialpressureandviscosityvcharacteristicTCM.AllthevaluesindicatedinthefiguresbelowapplyregardlesswhetherthedirectionofflowisA->BorB->A.

Notethatthepermissiblemeasuredvolumetricflowis30…500ml/min.

Ifyouareunabletoachievetherequiredflowvalues,weofferanextensivelineofaccessorieswithvariousconditioningmodules.



For example:Youareusingafluidwithaviscosityof46mm²/satapressuredifferenceof~0.9bar,sothatyouachieveaflowrateofapprox. 200 ml/min.

Theflowratedependsontheviscosityofthemediumandthedifferentialpressureviathesensor.

11.3. Hydraulic connection of the TCM

NOTE Excessive operating pressure: The TestMate® Contamination Sensor will be destroyed. Note the maximum operating pressure of 350 bar / 5075 psi.

Observe the following sequence when connecting the sensor to the hydraulic system: 1.Connect the return line to the outlet of the TCM. G1/4 ISO 228 threaded connection, recommended diameter of line≥4mm.

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 of the TCM.

G1/4ISO228threadedconnection.WerecommendaninternalØ≤4mmforthelineinordertopreventparticledepos its (sedimentation).

Ifparticles≥400µmareanticipatedinthehydraulicsystem,installastrainerupstreamfromtheTestMate® Contamination Sensor. (e.g. CM-S).5. Connect the other end of the measurement line to the measurement point on the hydraulic system.

WARNINGOilbeginstoflowassoonastheTestMate® Contamination Sensor is connected with the pressure line.

6. The hydraulic connection is complete.



12. Electrical Connection of the TCM12.1. Pin Assignment

Pin Assignment1 Supply voltage 9 ... 36 V DC2 Analog output + (active)3 GND supply voltage4 GND ANALOG / SWITCH OUTPUTS5 HSI (SCHROEDER Sensor Interface)6 RS485 +7 RS485 -8 Switching output (passive, n.c.)

The analog output is an active source of 4 ... 20 mA or 2 ... 10 V DC.The switching output is a passive n-switching power MOSFET and is normally open. There is contact between the plug housing and the housing.



12.2. Connection cable - assignment / color coding

Our accessories list on page 80 includes the required connection cables of various lengths with one connection plug (8-pole, M12x1, according to DIN VDE 0627) and an open end.

SCHROEDER accessory cable color coding is listed in the table below.

Pin Colour Connection to:1 White Supply voltage 9 ... 36 V DC2 Brown Analog output + (active)3 Green GND supply voltage4 Yellow GND ANALOG / SWITCH OUTPUTS5 Gray HSI (SCHROEDER Sensor Interface)6 Pink RS485 +7 Blue RS485 -8 Red Switching output (passive, n.c.)Housing - screen

12.3. Connecting cable ends - Examples



Circuit diagram: with one power supply. (e.g. 24 V DC).To prevent a ground loop, connect the shield of the connector cable if and only if the TCM is not grounded or not sufficientlyconnectedtothePEconductor.

13. Setting the measuring modeOnce the sensor is switched on or supplied with power, it automatically runs in the measuring mode that has been set.

13.1. Mode M1: Continuous measurementApplication: Stand-alone sensorData output: Display & RS485 & analog outputPurpose: Measurement onlyFunction: Continuous measurement of cleanliness class Switching function only for “Device ready”.

13.2. Mode M2: Continuous measurement and switchingApplication: Stand-alone sensor with alarm standby displayData output: Display & RS485 & analog output & switching outputPurpose: Continuous measurement and controlling of signal lamps etc.Function: Continuous measurement of solid contamination, continuous monitoring of programmable limit values; switching output is activated to switch on the monitor display or an alarm on site

13.3 Mode M3: Filter to cleanliness class and stopApplication: ControllingafilterunitData output: Display & RS485 & analog output & switching outputPurpose: For cleaning up a hydraulic reservoirFunction: Controlofafilterunit,continuousmeasurementofsolidcontamination.Ifpre-programmed cleanliness level is achieved 5 times in sequence, the pump is stopped. Load the switching output with a maximum of 2 A and 30 V DC.



13.4. Mode M4: Filter to continuously monitor cleanliness classApplication: ControlofstationaryofflinefiltrationunitData output: Display & RS485 & analog output & switching outputPurpose: Establish continuous monitoring of cleanliness class between min./max. limit values.Function: Controlofafilterunit,continuousmeasurementof solid contamination.

Ifmin./max.limitvaluesarepre-programmed,theTCMswitchesthefiltrationuniton/offtomaintainthecleanlinesswithinthe limit value range.

Once the target cleanliness has been reached (5x undershooting of the TARGET), the set test cycle time in minutes appears on the display. The test cycle time expires

After the test cycle time has elapsed, the switching output is closed and a measurement is started. If the result is still be-low the TARGET cleanliness, the test cycle time (CYCLE) begins again.

13.5. Mode “SINGLE” measurementApplication: Stand-alone sensorData output: Display & RS485 & analog outputPurpose: Perform a single measurement and “stop” the result.Function: Single measurement of solid contamination without switching functions

When Single mode is selected in the PowerUp menu, the display jumps directly to the following message after switching to the Measuring menu or after switching the TCM on:

TheTCMbeginswithindividualmeasurementafterthemessagehasbeenconfirmedbypressingok.

14. Operating the TCM1x2x using the keypadIf the sensor is switched on or supplied with power, the display shows SCHROEDER TCM in moving letters, then the firmwareversionisdisplayedfor2seconds.

This is followed by a countdown: WAIT99 … WAIT0.

The duration of the countdown corresponds to the set measurement time MTIME. This means that the countdown runs from 99 ... 0 within the set measurement time (factory setting = 60 sec).



Item LED DescriptionA Status Status DisplayB Display 6-figuredisplaywith17segmentseachC Measured

VariableDisplay of respective measured variable, e.g: ISO / SAE / NAS

D Additional Variable

Display of respective service variable,e.g.: Flow / Out / Drive / Temp

E Switch Point 1 Indicates the status of the switching output. When the LED is lit, the switching output is activated, i.e. the switch is closed.

F Switch Point 2 Reserved

The following keys are available to you for operating and setting the TCM1x2x.Key FunctionOK You jump one menu level down.

Youconfirmachangedvalueatthelowestmenulevel.Youconfirmatthetopmenuleveltosaveorrejectachangeinvalue.

Esc You jump up one menu level.In order to leave the menu without changing the values, press the ESC key until SAVE appears in the display. With the left and right keys switch to CANCELandconfirmwiththeOKkeyorwait30secondswithoutpressingakey. You exit the menu without changing the values.

Plus, Minus You change values / settings on the lowest menu level.Left Arrow, Right Arrow You scroll through the display

ISO / SAE/NAS / Flow / Out / Drive / Temp.You move through the menu.You select numbers.

Oncethelowestmenulevelhasbeenreached,thevaluesinthedisplaywillstarttoflash.

14.1. Function of the Keys



14.2. Measured variables on the displayThe measured variables give you information on the oil cleanliness in the system.You will gain a measured value with an accuracy of ± 1/2 ISO code within the calibrated range.

15. Service variables on the displayThe service variables inform you about the current status in the TestMate® Contamination Sensor .The service variables are not calibrated. They represent an approximate value for installing the sensor in the hydraulic system.

Flow (Flow Rate)



16. Activate / deactivate keypad lock.Activate or deactivate the keypad lock by pressing both keys simultaneously to prevent further input.

The display switches to the preset display after 1 second.When the supply voltage to the TCM is disconnected, the activated keypad lock “LOCK” is unlocked and reset to “UNLOCK”.



17. Display FREEZEThis function makes it possible for you to call up the last 20 displayed values on the display.

TheactivedisplayisthenfrozeninthesetMTIMEcycle.

The display FREEZE function is based on a volatile memory and means that the values can be called up only as long as the TCM is supplied with power and the sensor is in display FREEZE.

The measured values are automatically numbered, whereby the highest incremental number represents the last mea-sured value. That means that when the memory is full (20 measured values), the value 20 is the most recent and the value 1 is the oldest .

If the memory exceeds 20 display values, the oldest entry will be overwritten.

17.1 Activate display FREEZETo activate or deactivate the history memory FREEZE, press both keys simultaneously.

The FREEZE function starts with the display of the most recent measured value.



17.2. Deactivate display FREEZE

If display FREEZE is set to MANUAL in the PowerUp menu:

Press the following two keys simultaneously to return to the current display

If the display FREEZE is set to TIMEOUT in the PowerUp menu:

You are returned automatically to the current display after 10 times the value for MTIME, or manually by pressing both arrow keys simultaneously.

The factory setting of MTIME is 60 seconds x 10 = 600 seconds = 10 minutes.

18. Menus and modesThe sensor has the following two operating levels / menus.

Menus Mode DescriptionPowerUp Menu PowerUp Mode You carry out the basic settings in this menu.Measuring Menu Measurement mode This menu starts automatically after powering up.

18.1 Power Up MenuYou can carry out the basic settings for operation of the TCM in the PowerUp menu.Selection To doStart the PowerUp menu Press any key while the supply voltage to the sensor

is switched on / generated.Exit the PowerUp menu without saving Scroll through to CANCEL and press the OK key.

If a key is not pressed within 30 seconds, the system jumps back automatically.

Exit the PowerUp menu after saving Scroll through to SAVE and press the ok key



18.2 Measuring Menu (TCM12xx)During measurement operation, you can perform the following settings:



DSPLAY - Display after sensor is switched on

SWT.OUT–SchaltausgangkonfigurierenHere you can adjust the behavior of the switching output. The measurement mode “M1 / M2 / M3 / M4 / SINGLE” is cop-ied from the setting in the PowerUp menu and can no longer be selected here.



ANA.OUT - Set output signal at analog outputThe measured variable set here is output at the analog output



19. Overview of menu structure19.1 Menu TCM 12xx (ISO 4406:1999 and SAE)

Power Up Menu



Measuring Menu



19. Overview of menu structure19.1 Menu TCM 12xx (ISO 4406:1999 and SAE)

Power Up Menu



Measuring Menu

20. Using switching outputYou can use the switching output in the modes described below.

20.1. Mode M1: Continuous measurementPurpose: Measurement onlyFunction: Continuous measurement of cleanliness class Switching function only for “Device ready”.

20.2. Mode M2: Continuous measurement and switchingPurpose: Continuous measurement and controlling of signal lamps etc.Function: Continuous measurement of solid contamination, continuous monitoring of programmed limit values; the switch-ing output is enabled and switches on the monitoring display or alarm on site

20.3. Mode M3: Filter to cleanliness class and stopPurpose: Clean up hydraulic reservoirFunction:Controlofafilterunit,continuousmeasurementofsolidcontamination.Ifpre-programmedcleanlinesslevelisreached 5 times in sequence, the pump is stopped.

20.4. Mode M4: Filter to continuously monitor cleanliness classPurpose: Establish continuous monitoring of cleanliness class between min/max limit valuesFunction:Ifmin/maxlimitvaluesarepre-programmed,theTCMswitchesthefilteruniton/offtokeepcleanlinesswithinthelimit value range

Load the switching output with a maximum of 2 A and 30 V DC.



20.5. Mode “SINGLE” measurementPurpose: Perform a single measurement and “stop” the result.Function: Single measurement of solid contamination without switching functions Switching function only for “Device ready”.

21. Setting limit valuesThe voltage supply to the TCM makes the switching output (SP1) conductive. This condition is maintained for the initial measurement duration (WAIT period). Depending on the measurement mode, the switching output can be used as a De-vice ready function.



22. Reading the analog outputDepending on TCM model, the analog output is available as a 4 ... 20 mA or 2 ... 10 V signal.Youcanrecognizethetypeofanalogoutputfromthemodelcodeofthesensor.

TCM Model code Analogue outputTCM 1 x x x - A – x – x – x – x /-xxx 4 … 20 mATCM 1 x x x - B – x – x – x – x /-xxx 2 … 10 V

Observe the design of the analog output in the order. It is not possible to internally change the analog output over later.

In the measuring menu, select one of the following signals for the analog output:■ SAE classes acc. to AS 4059■ ISO Code acc. to ISO 4406:1999■ ISO code acc. to ISO 4406:1987■ NAS class 1638■ Hydraulicfluidtemperature

22.1. SAE classes acc. to AS 4059

The following SAE values can be read out via the analog output:■ SAE A-D (SAEMAX) Only one single value is output.■ SAE A / B / C / D

All values are sequentially time-coded before output.■ SAE A / SAE B / SAE C / SAE D

Only one value is output.■ SAE+T

All values are sequentially time-coded before output.■ HDA.SAE

All values are sequentially time-coded before output.

This signal is planned for the HDA 5500, but it can be used also in other applications.

The current 4.8 … 19.2 mA or voltage 2.4 … 9.6 V of the output signal depends on the ISO contamination class acc. to SAE = 0.0 … 14.0 (resolution 0.1 class) or on an error as described below:

Current I SAE class / Error Voltage UI<4.00mA Cablebreak U<2.00V4.0mA<I<4.1mA Deviceerror/TheTCMisnotready. 2.00V<U<2.05V4.1mA<I<4.3mA Notdefined 2.05V<U<2.15V4.3mA<I<4.5mA Flowerror(Theflowrateistoolow.) 2.15V<U<2.25V4.5mA<I<4.8mA Notdefined 2.25V<U<2.40VI = 4.80 mA SAE 0 U = 2.4V… … …I = 19.20 mA SAE 14.0 U = 9.60V19.2mA<I<19.8mA Notdefined 9.60V<U<9.90V19.8mA<I<20mA Nomeasuredvalue 9.90V<U<10V

If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:I = 4.8 mA + SAE class x (19.2 mA - 4.8 mA) / 14U = 2.4 V + SAE class x (9.6 V - 2.4 V) / 14

If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:SAE class = (I - 4.8 mA) x (14/14.4 mA)SAE class = (U - 2.4 V) x (14/7.2 V)



22.1.1 SAE-A-DTheSAeMAXvalueisthehighestclassinanyofoneofthefourSAEA-Dclasses(respectively>4µm(c),>6µm(c),>14µm(c),>21µm(c)).

The signal is updated after the measuring period has elapsed (the measuring period is set in the PowerUp menu, factory setting = 60 s).

The SAeMAX signal is output depending on the maximum SAE class.

Example

For basic information about cleanliness classes.

TheSAEclassificationcontainsintegervaluesonly.Bettertrendrecognitionisbasedonaresolutionof0.1contaminationclasses as supplied by the TCM 1000.

To convert a decimal value to an integer, the decimal value has to be rounded up.

For example: a readout of SAE 10.7 is, according to SAE 4059 (D), a class SAE 11.

22.1.2 SAE Class A / B / C / DThe SAE class A/B/C/D signal consists of 4 measured values transmitted with the following time-coded time slices:



22.1.3 SAE A / SAE B / SAE C / SAE DThe SAE X signal consists of a measured value (SAE A / SAE B / SAE C / or SAE D) which is permanently transmitted as described in the following.



mTIME = Duration of the measurement as set in the PowerUp menu, see page 30.

22.1.4. SAE + TThe SAE+T signal consists of 5 measured values which are transmitted time-coded with the following time slices:



21.1.5. HDA.SAE – Analog signal SAE to the HDA 5500

The HDA.SAE signal consists of 6 values (START / SAE A / SAE B / SAE C / SAE D / Status) which are output sequen-tially.Synchronizationwiththedownstreamcontrolunitisaprerequisite.

The signal output is as follows:

Time Measured variable Signal duration Current/Voltage in s

Start signal 0 -- 2 20 mA / 10 V

Pause 2 4 mA / 2 V

Signal 1 SAE A 2 Current / Voltage for signal

Pause 2 4 mA / 2 V

Signal 2 SAE B 2 Current / Voltage for signal

Pause 2 4 mA / 2 V

Signal 3 SAE C 2 Current / Voltage for signal

Pause 2 4 mA / 2 V

Signal 4 SAE D 2 Current / Voltage for signal

Pause 2 4 mA / 2 V

Signal 5 Status 2 Current / Voltage for signal

Pause 30 4 mA / 2 V



22.1.6. HDA.SAE Signal 1/2/3/4The current or voltage range is dependent on the contamination class according to SAE=0.0 – 14.0 (resolution 0.1 class).

Current I SAE class / Error Voltage UI<4.00mA Cablebreak U<2.00VI = 4.00 mA SAE 0 U = 2.00V… … …I = 20.00 mA SAE 14.0 U = 10.00V

If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:I = 4 mA + SAE class x (20 mA - 4 mA) / 14U = 2 V + SAE class x (10 V - 2 V) / 14

If the contamination class is given acc. to SAE, the current I or voltage U can be calculated:SAE class = (I - 4 mA) x (14/16 mA)SAE class = (U - 2 V) x (14/8 V)

22.1.7. HDA.SAE signal 5 (status)

The current or voltage of the output signal (5) is dependent on the status of the TCM as shown in the table below:

Current I Status Voltage UI = 5.0 mA The TCM is functioning correctly. U = 2.5VI = 6.0 mA Device error / U = 3.0V The TCM is not ready. I=7.0mA Theflowrateistoolow. U=3.5VI=8.0mA SAE<0 U=4.0VI = 9.0 mA No measured value U = 4.5V (Theflowrateisnotdefined.)

If the status signal is 6.0 / 7.0 / 9.0 mA or 3.0 / 3.5 / 4.5 V, signals 1 to 4 are output with 20 mA or 10 V. Example:



If the status signal is 8.0 mA or 4.0 V, signals 1 to 4 are output as follows.

Signal Current I Voltage U SAE class1 4.0 mA 2.0 V 02 4.0 mA 2.0 V 03 4.0 mA 2.0 V 04 4.0 mA 2.0 V 0

22.2 ISO code acc. to ISO 4406:1999The following ISO values can be read out via the analog output:■ ISO 4 / ISO 6 / ISO 14

Only one value is output.■ ISOcodein3figures(>4µm(c)/>6µm(c)/>14µm(c))

All values are sequentially time-coded before output.■ ISO+T

All values are sequentially time-coded before output.■ HDA.ISO

All values are sequentially time-coded before output.

This signal is planned for the HDA 5500, but it can be used also in other applications.



The current 4.8 … 19.2 mA or voltage 2.4 … 9.6 V of the output signal depends on the ISO contamination class 0.0 … 24.28 (resolution 1 class) or on an error as described below:

Current I ISO code / error Voltage UI<4.0mA Cablebreak U<2.0V4.0mA<I<4.1mA Deviceerror/ 2.0V<U<2.05V The TCM is not ready. 4.1mA<I<4.3mA Notdefined 2.05V<U<2.15V4.3mA<I<4.5mA Flowerror 2.15V<U<2.25V (Theflowrateistoolow.)4.5mA<I<4.8mA Notdefined 2.25V<U<2.4VI = 4.80 mA ISO 0 U = 2.40V… … …I = 19.20 mA ISO 24.28 U = 9.60V19.2mA<I<19.8mA Notdefined 9.60V<U<9.90V19.8mA<I<20mA Nomeasuredvalue 9.90V<U<10V

The current (I) or voltage (U) can be calculated for a given ISO contamination class as follows:I = 4.8 mA + ISO code x (19.2 mA - 4.8 mA) / 24.28U = 2.4 V + ISO Code x (9.6 V - 2.4 V) / 24.28

The ISO contamination class can be calculated for a given current I or voltage U as follows:ISO code = (I - 4.8 mA) x (24.28 / 14.4 mA)ISO code = (U - 2.4 V) x (24.28 / 7.2 V)

22.2.1. ISO 4 / ISO 6 / ISO 14TheISOXsignalconsistsofameasuredvalue(>4µmor>6µmor>14µm)whichispermanentlytransmitted,asdescribed below.

mTIME = Duration of the measurement as set in the PowerUp menu.



22.2.2. ISO code, 3-digitTheISOcodesignalconsistsof3measuredvalues(>4µm(c)/>6µm(c)/>14µm(c))whicharetransmittedtime-coded.



22.2.3. ISO + TThe ISO+T signal consists of 4 measured values which are transmitted time-coded with the following time slices:

Time Signal Size Signalduration Current(I)/Voltage(U) per pulse in ms

1Identifier >4µm(c) 300 High/Low 2Measuredvalue >4µm(c) 3000 Current/Voltageformeasuredvalue 3Identifier >6µm(c) 300 High/Low/High/Low 4Measuredvalue >6µm(c) 3000 Current/Voltageformeasuredvalue 5Identifier >14µm(c) 300 High/Low/High/Low/High/Low 6Measuredvalue >14µm(c) 3000 Current/Voltageformeasuredvalue 7Identifier temperature 300 High/Low/High/Low/High/ Low / High / Low / High / Low 8 Measured value temperature 3000 Current/Voltage for measured value

22.2.4.HDA.ISO – Analog signal ISO to HDA 5500The HDA.ISO signal consists of 6 measured values (START / ISO 4 / ISO 6 / ISO 14 / ISO 21 / Status) which are output sequentially.Synchronizationwiththedownstreamcontrolunitisaprerequisite.




22.2.5. HDA.ISO Signal 1/2/3/4The current 4 … 20 mA or voltage 2 … 10 V of the output signal depends on the ISO contamination class 0.0 … 24.28 (resolution 1 class) as described below:Current I ISO Code Voltage UI<4.00mA Cablebreak U<2.00VI = 4.00 mA ISO 0 U = 2.00V… … …I = 20.00 mA ISO 24.28 U = 10.0V

The current (I) or voltage (U) can be calculated for a given ISO contamination class as follows:I = 4 mA + ISO code x (20 mA - 4 mA) / 24.28U = 2 V + ISO Code x (10 V - 2 V) / 24.28

The ISO contamination class can be calculated for a given current I or voltage U as follows:ISO code = (I - 4 mA) x (24.28 / 16 mA)ISO code = (U - 2 V) x (24.28 / 8 V)



22.2.6. HDA.ISO signal 5 (status)The current or voltage of the output signal (5) is dependent on the status of the TCM as shown in the table below:

Current I Status Voltage UI = 5.0 mA The TCM is functioning correctly. U = 2.5VI = 6.0 mA Device error / The TCM is not ready. U = 3.0VI=7.0mA Theflowrateistoolow. U=3.5VI=8.0mA ISO<9.<8.<7 U=4.0VI = 9.0 mA No measured value U = 4.5V (Theflowrateisnotdefined.)



Signal Current I Voltage U ISO value1 9.93 mA 4.97 V 92 9.27 mA 4.64 V 83 8.61 mA 4.31 V 74 7.95 mA 3.98 V 6



22.3. ISO code signal acc. to ISO 4406:1987 (TCM 13xx only)The following ISO values can be read out via the analog output:■ ISO 2 / ISO 5 / ISO 15

Only one value is output.■ISOcodein3figures(>2µm(c)/>5µm(c)/>15µm(c))

All values are sequentially time-coded before output.■ ISO+T

All values are sequentially time-coded before output.■HDA.ISO

All values are sequentially time-coded before output.This signal is planned for the HDA 5500, but it can be used also in other applications.

The current 4.8 … 19.2 mA or voltage 2.4 … 9.6 V of the output signal depends on the ISO contamination class 0.0 … 24.28 (resolution 1 class) or on an error as described below:

Current I ISO code / error Voltage UI<4.00mA Cablebreak U<2.00V4.0mA<I<4.1mA Deviceerror/TheTCMisnotready. 2.0V<U<2.05V4.1mA<I<4.3mA Notdefined 2.05V<U<2.15V4.3mA<I<4.5mA Flowerror(Theflowrateistoolow.) 2.15V<U<2.25V4.5mA<I<4.8mA Notdefined 2.25V<U<2.4VI = 4.80 mA ISO 0 U = 2.40V… … …I = 19.20 mA ISO 24.28 U = 9.60V19.2mA<I<19.8mA Notdefined 9.60V<U<9.90V19.8mA<I<20mA Nomeasuredvalue 9.90V<U<10V

The current (I) or voltage (U) can be calculated for a given ISO contamination class as follows:I = 4.8 mA + ISO code x (19.2 mA - 4.8 mA) / 24.28U = 2.4 V + ISO Code x (9.6 V - 2.4 V) / 24.28

The ISO contamination class can be calculated for a given current I or voltage U as follows:ISO code = (I - 4.8 mA) x (24.28 / 14.4 mA)ISO code = (U - 2.4 V) x (24.28 / 7.2 V)

22.3.1. ISO 2 / ISO 5 / ISO 15TheISOXsignalconsistsofameasuredvalue(>2µmor>5µmor>15µm)whichispermanentlytransmitted,asde-scribed in the following.



22.3.2. ISO code, 3-digitTheISOcodesignalconsistsof3measuredvalues(>2µm/>5µm/>15µm)whicharetransmittedtime-codedasshownbelow.



22.3.3. ISO + TThe ISO+T signal consists of 4 measured values which are transmitted time-coded with the following time slices:



22.3.4. HDA.ISO – Analog signal ISO to HDA 5500The HDA.ISO signal consists of 4 measured values (ISO 4 / ISO 6 / ISO 14 / ISO 21 / Status) which are output sequentially.Synchronizationwiththedownstreamcontrolunitisaprerequisite.




22.3.5 HDA.ISO Signal 1/2/3/4The current 4 … 20 mA or voltage 2 … 10 V of the output signal depends on the ISO contamination class 0.0 … 24.28 (resolution 1 class) as described below:

Current I ISO Code Voltage UI<4.00mA Cablebreak U<2.00VI = 4.00 mA ISO 0 U = 2.00V… … …I = 19.82 mA ISO 24 U = 9.90VI = 20.00 mA ISO 24.28 U = 10.0V

The current (I) or voltage (U) can be calculated for a given ISO contamination class as follows:I = 4 mA + ISO code x (20 mA - 4 mA) / 24.28U = 2 V + ISO Code x (10 V - 2 V) / 24.28

The ISO contamination class can be calculated for a given current I or voltage U as follows:ISO code = (I - 4 mA) x (24.28 / 16 mA)ISO code = (U - 2 V) x (24.28 / 8 V)

22.3.6. HDA.ISO signal 5 (status)The current or voltage of the output signal (5) is dependent on the status of the TCM as shown in the table below:

Current I Status Voltage UI = 5.0 mA The TCM is functioning correctly. U = 2.5VI = 6.0 mA Device error / The TCM is not ready. U = 3.0VI=7.0mA Theflowrateistoolow. U=3.5VI=8.0mA ISO<9.<8.<7 U=4.0VI=9.0mA Nomeasuredvalue(Theflowrateisnotdefined.) U=4.5V

If the status signal is = 6.0 mA or = 3.0 V, signals 1 to 4 are output with 20 mA or 10 V. Example:

If the status signal is 8.0 mA or 4.0 V, signals 1 to 4 are output as follows:

Signal Current I Voltage U ISO value1 9.93 mA 4.97 V 92 9.27 mA 4.64 V 83 8.61 mA 4.31 V 74 7.95 mA 3.98 V 6



22.4. NAS 1638 - National Aerospace Standard (Only TCM)The following NAS values can be read out via the analog output:■ NAS Maximum

Only one value is output.■ NAS (2 / 5 / 15 / 25)

All values are sequentially time-coded before output.■ NAS 2 / NAS 5 / NAS 15 / NAS 25

Only one value is output in each case.■ NAS+T

All values are sequentially time-coded before output.■ HDA.NAS

All values are sequentially time-coded before output. This signal is planned for the HDA 5500, but it can be used also in other applications.

The current 4.8 … 19.2 mA or voltage 2.4 … 9.6 V of the output signal depends on the ISO contamination class 0.0 … 14.0 (resolution 0.1 class) or on an error as described below:

Current I NAS Class / Error Voltage UI<4.00mA Cablebreak U<2.00V4.0mA<I<4.1mA Deviceerror/TheTCMisnotready. 2.00V<U<2.05V4.1mA<I<4.3mA Notdefined 2.05V<U<2.15V4.3mA<I<4.5mA Flowerror(Theflowrateistoolow.) 2.15V<U<2.25V4.5mA<I<4.8mA Notdefined 2.25V<U<2.40VI = 4.80 mA NAS 0 U = 2.4V… … …I = 19.20 mA NAS 14.0 U = 9.60V19.2mA<I<19.8mA Notdefined 9.60V<U<9.90V19.8mA<I<20mA Nomeasuredvalue 9.90V<U<10V

The current (I) or voltage (U) can be calculated for a given NAS contamination class as follows:I = 4.8 mA + NAS class x (19.2 mA - 4.8 mA) / 14U = 2.4 V + NAS class x (9.6 V - 2.4 V) / 14

The current I or voltage U can be calculated for a given NAS contamination class as follows:NAS class = (I - 4.8 mA) x (14/14.4 mA)NAS class = (U – 2.4 V) x (14/7.2 V)



22.4.1 NAS maximumThe NAsMAX value designates the largest of the 4 NAS classes.

NASclass 2µm 5µm 15µm 25µmParticlesize 2-5µm 5-15µm 15µm >25µm

The signal is updated after the measuring period has elapsed (the measuring period is set in the PowerUp menu, factory setting = 60 s).The NAsMAX signal is output depending on the maximum NAS class.Example:

For basic information about cleanliness classes.

TheNASclassificationconsistsofwholenumbers.Bettertrendrecognitionisbasedonaresolutionof0.1contaminationclasses as supplied by the TCM 1000.

To convert a decimal value to an integer, the decimal value has to be rounded up.

For example: a readout of NAS 10.7 is, according to NAS, a class NAS 11.



22.4.2 NAS classes (2 / 5 / 15 / 25)NAS class signals 2 / 5 / 15 / 25 consist of 4 measured values transmitted with the following time-coded time slices:



22.4.3 NAS 2 / NAS 5 / NAS 15 / NAS 25The NAS X signal consists of a measured value (NAS 2 / NAS 5 / NAS 15 / NAS 25) which is permanently transmitted, as described below.




22.4.4. NAS + TThe NAS+T signal consists of 5 measured values which are transmitted time-coded with the following time slices:



22.4.5 HDA.NAS – Analog Signal NAS to HDA 5500The HDA.NAS signal consists of 4 measured values (Start / NAS 2 / NAS 5 / NAS 15 / NAS 25 / Status) which are output sequentially.Synchronizationwiththedownstreamcontrolunitisaprerequisite.The signal output is as follows:

22.4.6. HDA.NAS Signal 1/2/3/4The current or voltage range is dependent on the contamination class according to NAS=0.0 … 14.0 (resolution 0.1 class).

Current I NAS Class / Error Voltage UI<4.00mA Cablebreak U<2.00VI = 4.00 mA NAS 0 U = 2.00V… … …I = 20.00 mA NAS 14.0 U = 10.00V

The current (I) or voltage (U) can be calculated for a given NAS contamination class as follows:I = 4 mA + NAS class x (20 mA - 4 mA) / 14U = 2 V + NAS class x (10 V - 2 V) / 14

The current I or voltage U can be calculated for a given NAS contamination class as follows:NAS class = (I - 4 mA) x (14/16 mA)NAS class = (U – 2 V) x (14/8 V)



22.4.7HDA.NAS signal 5 (status)The current or voltage of the output signal (5) is dependent on the status of the TCM as shown in the table below:

Current I Status Voltage UI = 5.0 mA The TCM is functioning correctly. U = 2.5VI = 6.0 mA Device error / The TCM is not ready. U = 3.0VI=7.0mA Theflowrateistoolow. U=3.5VI=8.0mA NAS<0 U=4.0VI=9.0mA Nomeasuredvalue(Theflowrateisnotdefined.) U=4.5V



Signal Current I Voltage U NAS class1 4.0 mA 2.0 V 02 4.0 mA 2.0 V 03 4.0 mA 2.0 V 04 4.0 mA 2.0 V 0



22.5Fluid temperature TEMPThecurrentrange4.8…19.2mAorvoltagerange2.4…9.6Visdependentonthefluidtemperatureof-25°C…100°C(resolution: 1°C) or -13°F … 212°F (resolution: 1°F) as shown in the table below.

Current I Temperature / Error Voltage UI<4.00mA Cablebreak U<2.00V4.0mA<I<4.1mA Deviceerror/TheTCMisnotready. 2.00V<U<2.05V4.1mA<I<4.3mA Notdefined 2.05V<U<2.15V4.3mA<I<4.5mA Flowerror(Theflowrateistoolow.) 2.15V<U<2.25V4.5mA<I<4.8mA Notdefined 2.25V<U<2.40VI = 4.8 mA -25 °C / -13 °F U = 2.40V… … …I = 19.20 mA +100 °C / 212 °F U = 9.60V19.2mA<I<19.8mA Notdefined 9.60V<U<9.90V19.8mA<I<20mA Nomeasuredvalue 9.90V<U<10V

The current I or voltage U can be calculated for a given temperature as follows:I=4.8mA+(temperature[°C]+25)x(19.2mA-4.8mA)/125I=4.8mA+(temperature[°F]+13)x(19.2mA-4.8mA)/225U=2.4V+(temperature[°C]+25)x(9.6V-2.4V)/125U=2.4V+(temperature[°F]+13)x(9.6V-2.4V)/225

The temperature in °C or °F can be calculated for a given current I or voltage U as follows:Temperature[°C]=((I-4.8mA)x(125/14.4mA))-25Temperature[°F]=((I-4.8mA)x(225/14.4mA))-13Temperature[°F]=((U-2.4V)x(125/7.2V))-25Temperature[°F]=((U-2.4V)x(225/7.2V))-13

23. Status Messages23.1. Status LED / Display



23.2. Error



23.3 Exceptional Error



* Is not valid for HDA 5500 output signal

23.4. Analog Output Error SignalsIftheTCMentersintoanerrorstatusallfollowingmeasuredvaluesignalsareoutputinaspecificcurrentstrength(I)orvoltage (U). Please refer to chapter “Error status” for the respective values for the current strength or voltage of the output signal during an error status). The time coding is preserved.

Example: “CHECK” error for the SAE output signal.



23.5. Analog signal for HDA 5500HDA Status Signal 5 TableThe current or voltage of the analog signal (5) is dependent on the status of the TCM as shown in the table below:

Current I Status Voltage UI = 5.0 mA The TCM is functioning correctly. U = 2.5VI = 6.0 mA Device error / The TCM is not ready. U = 3.0VI=7.0mA Theflowrateistoolow. U=3.5VI=8.0mA ISO<9.<8.<7 U=4.0VI=9.0mA Nomeasuredvalue(Theflowrateisnotdefined.) U=4.5V





Signal mA V1 10 5.02 9.2 4.63 8.6 4.34 8.0 4.0



Signal mA V1 10 5.02 9.2 4.63 8.6 4.34 8.0 4.0



24. Connecting TCMI-D-5 (Condition Sensor Interface)The TCMI-D-5 makes it possible to operate the TCM using a PC:■Setting parameters and limit values.■Reading out measurement data online.

24.1. TCMI-D-5 Connection overviewConnect the TCMI-D-5 to the TCM according to the following connection diagram



25. Connecting the TCM to an RS485 busThe RS485 interface on the TCM is a two-wire interface and operates in half-duplex mode.The number of TCMs per RS485 bus is limited to 26. Use letters A to Z to address the HECOM bus address.Thelengthofthebuslineandthesizeoftheterminatingresistordependonthequalityofcableused.Connect several TCM’s using the RS485 interfaces according to the following illustration:

Item Description Part no.:1 Converter RS232<->RS485 60132811 Converter USB<->RS485 60423372.1 Connection cable RS232, 9-pole -2.2 Connectioncable USB[A]<->USB[B] -3 Recommended cable twisted pair -4 Terminator ~120Ω -



26. Communicating with the TCM via the RS485 busTo communicate with the TCM, start a terminal program (e,g, Hyperterminal) on the PC.Use the following settings to communicate via the COM interface:

Bits per second = 9600 BaudData bits = 8Parity = NoneStop bits = 1Report = None

The TCM can send and receive only HSI commands.An overview of the HSI commands is provided in our “Getting started” guide for HSI commands, p/no.: 3737763. This “Gettingstarted”guideisavailableasaPDFonrequestbysendinganemailtofltersystems@Schroeder.com.

27. Taking the TCM out of operationTo decommission, proceed as follows:1. Disconnect and remove the electric connection to the TCM.2.Closeanyshut-offdevicesinthefeedandreturnlinesoftheTCM.2.Depressurizetheunit.3. Remove the hydraulic connection lines to the TCM.4. Remove the TCM.

28. Disposing of TCMDispose of the packaging material in an environmentally-friendly manner.After dismantling the device and separating its various materials, dispose of it in an environmentally friendly manner.

29. Spare Parts and AccessoriesDescription Qty Part no.CD-ROM with operating and maintenance instructionsindifferentlanguages 1 3764919TestMate® Contamination Sensor Interface TCMI-D-5 1 3249563O-ringfortheflangeconnection (4.8x1.78-80ShoreFKM) 1 6003048Socket plug (female) with 5 m line, shielded, 8-pole, M12x1 ZBE 42-05 1 3281239Extension cable 5 m, Socket plug (female) 8-pole, M12x1 / ZBE 43-05 1 3281240Socket plug (male) 8-pole, M12x1 Schroeder Digital display unit HDA5500-0-2-AC-006 1 909925Schroeder Digital display unit HDA5500-0-2-DC-006 1 909926

30. Cleanliness classes - brief overview30.1. Cleanliness class - ISO 4406:1999InISO4406:1999,particlecountsaredeterminedcumulatively,i.e.>4µm(c),>6µm(c)and>14µm(c)(manuallybyfilteringthefluidthroughananalysismembraneorautomaticallyusingparticlecounters)andallocatedtomeasurementreferences.

Thegoalofallocatingparticlecountstoreferencesistofacilitatetheassessmentoffluidcleanlinessratings.

In1999the“old”ISO4406:1987wasrevisedandthesizerangesoftheparticlesizesundergoinganalysisredefined.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 under-going 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.



30.2. Table - ISO 4406 Assignment of particle counts to cleanliness classes:

Particle Count/100 ml Particle Count/100 mlClass More than Up to

(and including)Class More than Up to (and

including)0 0 1 15 16,000 32,0001 1 2 16 32,000 64,0002 2 4 17 64,000 130,0003 4 8 18 130,000 250,0004 8 16 19 250,000 500,0005 16 32 20 500,000 1,000,0006 32 64 21 1,000,000 2,000,0007 64 130 22 2,000,000 4,000,0008 130 250 23 4,000,000 8,000,0009 250 500 24 8,000,000 16,000,00010 500 1,000 25 16,000,000 32,000,00011 1,000 2,000 26 32,000,000 64,000,00012 2,000 4,000 27 64,000,000 130,000,00013 4,000 8,000 28 130,000,000 250,000,00014 8,000 16,000

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

Example: ISO class 18 / 15 / 11 means:

Cleanlinessclass Particlecount/ml Sizeranges18 1,300–2,500 >4µm(c)15 160–320 >6µm(c)11 10–20 >14µm(c)



30.3 Overview of modifications - ISO4406:1987 <-> ISO4406:1999“old” ISO 4406:1987 “new” ISO 4406:1999

SizeRanges >5µm>15µm

>4µm(c)>6µm(c)>14µm(c)

Dimension determined

Longest dimension of a particle

Diameter of the area-equivalent circleISO 11171:1999

Test dust ACFTD dust 1-10µmultrafine fraction SAE Fine, AC Fine

SAE5-80µmISO MTD Calibration dust for particle counters

SAE Coarse Coarse fraction

ISO 12103-1A1

ISO 12103-1A2

ISO 12103-1A3

ISO 12103-1A4

Comparablesizeranges

Old ACFTD calibration-----5µm15µm

Comparable ACFTD dusts<1µm4.3µm15.5µm

New NIST calibration4µm(c)6µm(c)14µm(c)

30.4. Cleanliness class - SAE AS 4059Like ISO 4406, NAS 4059 describes particle concentrations in liquids. The analysis methods can be applied in the same manner as ISO 4406:1999.

An additional feature in common with ISO 4406:1999 is that cleanliness classes are grouped on the basis of cumulative numberofparticles(i.e.allparticlesthatarelargerthanacertainlimitvalueare>4µm,forexample).

AsopposedtoISO,SAEAS4059usesdifferentlimitvaluesamongthevariousparticlesizesforcontaminationclasses.

Forthisreason,thecorrespondingdesignationoftheparticlesizebeingexaminedalwayshastobeadded,e.g.:

AS4059class6B -> 9731–19500particles>6µm

AS4059class8A/7B/6C -> 3-valueISOcode>4µm/>6µm/>14µm

IfanSAEclassisgivenacc.toAS4059withoutaletter,thenitisalwaysparticlesizeB(>6µm).



30.5. Table - SAE AS 4059

Maximum particle count / 100 mlSizeISO4402 >1µm >5µm >15µm >25µm >50µm >100µmSizeISO11171 >4µm(c) >6µm(c) >14µm(c) >21µm(c) >38µm(c) >70µm(c)Sizecoding A B C D E F

000 195 76 14 3 1 000 390 152 27 5 1 00 780 304 54 10 2 01 1,560 609 109 20 4 12 3,120 1,220 217 39 7 13 6,250 2,430 432 76 13 24 12,500 4,860 864 152 26 45 25,000 9,730 1,730 306 53 86 50,000 19,500 3,460 612 106 167 100,000 38,900 6,920 1,220 212 328 200,000 77,900 13,900 2,450 424 649 400,000 156,000 27,700 4,900 848 12810 800,000 311,000 55,400 9,800 1,700 25611 1,600,000 623,000 111,000 19,600 3,390 51212 3,200,000 1,250,000 222,000 39,200 6,780 1,020

30.6. Definition acc. to SAE30.6.1 Particle count (absolute) larger than a defined particle size

Example: Cleanliness class according to AS 4059: 6

Themaximumpermissibleparticlecountintheindividualsizerangesisbold-facedinthetable.

Cleanliness class acc. to AS 4059= 6 B

SizeBparticlesmaynotexceedthemaximumnumberindicatedforcode6:6B=max.19,500particles>5µminsize

30.6.2. Specifying a cleanliness code for each particle size

Example: Cleanliness class according to AS 4059=7 B / 6 C / 5 DCleanliness class Max. particles / 100 mlSizeB(>5µm/>6µm(c)) 38,900SizeC(>15µm/>14µm(c)) 3460SizeD(>25µm/>21µm(c)) 306

30.6.3. Specifying highest measured cleanliness class

Example: Cleanliness class according to AS 4059= 6 B – F

The6B–FspecificationrequiresaparticlecountinsizerangesB–F.Therespectiveparticleconcentrationof cleanliness class 6 may not be exceeded in any of these ranges.

Cla

sses



Cla

sses

31. Cleanliness Class - NAS 1638Like ISO 4406, NAS 1638 describes particle concentrations in liquids. The analysis methods can be applied in the same manner as ISO 4406:1987.

In contrast to ISO 4406, certain particle ranges are counted in NAS 1638 and attributed to measurement references.

The following table shows the cleanliness classes in relation to the particle concentration determined:

Maximum particle count / 100 ml2..5µm 5..15µm 15..25µm 25..50µm 50..100µm >100µm

00 625 125 22 4 1 00 1,250 250 44 8 2 01 2,500 500 88 16 3 12 5,000 1,000 178 32 6 13 10,000 2,000 356 64 11 24 20,000 4,000 712 128 22 45 40,000 8,000 1,425 253 45 86 80,000 16,000 2,850 506 90 167 160,000 32,000 5,700 1,012 180 328 320,000 64,000 11,400 2,025 360 649 640,000 128,000 22,800 4,050 720 12810 1,280,000 256,000 45,600 8,100 1,440 25611 2,560,000 512,000 91,200 16,200 2,880 51212 5,120,000 1,024,000 182,400 32,400 5,760 1,02413 10,240,000 2,048,000 364,800 64,800 11,520 2,04814 20,480,000 4,096,000 729,000 129,600 23,040 4,096

Increasing the class by 1 causes the particle count to double on average.

32. Checking/resetting default settings

32.1 PowerUp menu



32.1 Measuring Menu

33. Specifications



14. RecalibrationWerecommendrecalibratingthesensorevery2…3yearsunlessotherwisespecified.

Customer ServiceFor calibration and repair, send the sensor to the following address:580 West Park Road Leetsdale, PA 15056

15. GlossarySingle measurement Asinglemeasurementmeanstheanalysisofthecontaminationinasample,whichflowsthrough thesensorduringtheconfiguredmeasurementperiod.Theresultofasinglemeasurementisthe measured value.

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

Test volume Samplequantitywhichisanalyzedfordeterminingameasuredvalue.

Measured value The contamination codes determined by a single measurement, shown as a three-digit ISO code orNAScodesorSAEcodesoftheindividualparticlesizechannels.

Measurement duration Once the measurement duration has elapsed, the measured value is updated which is shown on the display and presented at the interface.

ThemeasurementdurationisconfigurableusingtheM.TIMEparameter.

Measurement Once a TCM 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 immediately follow, and so on, until the TCM 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.

manually controlled fluid sampling system operating and

Documents