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CS 1000 Series ContaminationSensor Operating and maintenance instructions CS 1000 & Operation manual CoCoS 1000 English Valid for firmware version V 1.28 Doc.: 3247149k / 2006-03-15...
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Filtertechnik. Contraventions are ce soit, sans l’autorisation écrite Genehmigung HYDAC liable to compensation. expresse de HYDAC Filtertechnik. Filtertechnik nicht erlaubt. Le manquement à cette condition Zuwiderhandlungen verpflichten zu donnera lieu à des dommages - Schadenersatz. intérêts.
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HYDAC escrito de HYDAC Filtertechnik. HYDAC Filtertechnik. Filtertechnik. violazioni Toda cF responsabilidad Överträdelse medför straffansvar.
6.3.1 Selection Guidelines for a Measurement Point..........21 ν ∆ 6.3.2 Flow Rate Q, differential pressure and viscosity characteristics ..22 6.3.3 Connect the CS to your system as follows: ............ 23 HYDAC Filtertechnik GmbH Page 1 BeWa CS1000 3247149k en.doc 2006-02-24...
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ISO Classes ......................45 9.2.1 ISO Signal Table..................... 45 ISO 4 / ISO 6 / ISO 14 9.2.2 ISO 4 / ISO 6 / ISO 14 ( ) ....... 46 HYDAC Filtertechnik GmbH Page 2 BeWa CS1000 3247149k en.doc 2006-02-24...
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17 Factory default settings / Basic settings ............... 71 17.1 Power Up menu....................71 17.2 Measuring menu....................71 18 Technical data ......................72 19 Service ........................73 20 Model code ....................... 74 HYDAC Filtertechnik GmbH Page 3 BeWa CS1000 3247149k en.doc 2006-02-24...
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If you discover errors while reading the documentation or have suggestions or other useful information, please don’t hesitate to contact us: HYDAC Filtertechnik GmbH Dept.: SFVI, Techn. Documentation P. O. Box 1251 66273 Sulzbach / Saar, Germany Fax: ++49 (0) 6897 509 846 Email: filtersysteme@hydac.com...
When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative. Please notify us immediately of any modifications made to the product whether by you or a third party.
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Please note that the method described above of locating specific information does not release you from carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals later on. HYDAC Filtertechnik GmbH Page 7 en Vorwort.doc 2006-01-06...
• improperly performed repair work Explanation of Symbols and Warnings, etc. The following designations and symbols are used in this manual to designate hazards, etc.: HYDAC Filtertechnik GmbH Page 8 BeWa CS1000 3247149k en.doc 2004-07-12...
(e.g. warning sign or padlock on the main switch). • When the product is supplied in partial consignments, the safety devices are to be applied by the operator as specified by law/pertinent regulations. HYDAC Filtertechnik GmbH Page 9 BeWa CS1000 3247149k en.doc 2004-07-12...
In the event of an emergency, immediately disconnect the CS from the power supply and from the hydraulic system! Properly dispose of any exiting fluid in accordance with environmental guidelines. HYDAC Filtertechnik GmbH Page 10 BeWa CS1000 3247149k en.doc 2004-07-12...
Any work involving the power supply may only be done by a properly trained, certified electrician. • Make sure to check the electrical equipment of the product on a regular basis. Any loose connections or damaged cables are to be remedied/replaced immediately. HYDAC Filtertechnik GmbH Page 11 BeWa CS1000 3247149k en.doc 2004-07-12...
Do not make any modifications (design modifications, extensions) to the CS without the prior consent of the manufacturer. • Any design modifications or extensions may not be made without HYDAC Filtertechnik GmbH’s express prior written approval. • Immediately replace any machine components which are not in perfect condition.
Line Definition Description Model Code Model Code CS1220-A-0-0-0-0/-000 According to the data sheet, see chapter 20 Serial No. Serial-No. max. INLET press.: Max. INLET pressure: 100 bar / 1450 psi HYDAC Filtertechnik GmbH Page 14 BeWa CS1000 3247149k en.doc 2006-03-14...
The CS comes with the following: Qty. Description 1 pc. ContaminationSensor, CS 1000 Series (Model according to order) - Flange connection model (Model code: CS1xxx-x-x-x-x-1/-xxx)comes with two o-rings. 1 pc. CD with: - PC-Software CoCos 1000 and - Operating and Maintenance Instructions (this document) 1 pc.
Installation and Operation Description The CS 1000 Series Contamination Sensor is a stationary measurement unit for the continuous monitoring of particulate contamination in hydraulic and lubrication systems. The CS is designed for connection to low- or high-pressure hydraulic and lubrication lines and testbenches from which a small flow of oil (between 30 ml/min and 300 ml/min) is diverted for measurement purposes.
Installation and Operation CS1x1x Dimensions (without Display) All dimensions in mm. CS1x2x Dimensions (with Display) All dimensions in mm. HYDAC Filtertechnik GmbH Page 17 BeWa CS1000 3247149k en.doc 2006-04-06...
CS and a flange, mounting plate or manifold mount. Four M6 threads are prepared for mechanical mounting. Ports A and B are sealed off. Bottom view. All dimensions in mm. O-ring as spare part available, see Spare Parts. HYDAC Filtertechnik GmbH Page 18 BeWa CS1000 3247149k en.doc 2006-04-06...
1. Wall mounting: using 2 cylindrical screws featuring an M8 hexagonal socket, minimum length: 40 mm, according to ISO4762. 2. Console mounting: using 4 cylindrical screws featuring an M6 hexagonal socket according to ISO4762. HYDAC Filtertechnik GmbH Page 19 BeWa CS1000 3247149k en.doc 2006-04-06...
To rotate the display, grasp the cover plate with your hand. No tools may be used for rotating the display, in other words do not use excessive force to rotate it. HYDAC Filtertechnik GmbH Page 20 BeWa CS1000 3247149k en.doc...
(formation of particle deposits) in the inlet line and achieve immediate, i.e. not time-delayed, results. to CS Mainflow Mainflow Mainflow Mainflow to CS WRONG While installing the measurement line, make sure that no "siphon trap" is created. WRONG HYDAC Filtertechnik GmbH Page 21 BeWa CS1000 3247149k en.doc 2006-04-06...
46 mm²/s at a differential pressure of 1 bar, so that you achieve a flow rate of approx. 100 ml/min. ∆ The flow rate corresponds to the viscosity of the medium and the differential pressure HYDAC Filtertechnik GmbH Page 22 BeWa CS1000 3247149k en.doc 2006-04-06...
Oil starts to flow through the CS as soon as it has been connected to the pressure fitting. This is why it is necessary that connection be done in the sequence specified above. The hydraulic installation of the CS is now complete. HYDAC Filtertechnik GmbH Page 23 BeWa CS1000 3247149k en.doc 2006-04-06...
Analog out + (active) Green GND supply voltage Yellow GND analog out / Switch out Grey Not to be connected Pink RS485 + Blue RS485 - Switch out (passive, n.o.) case Shield HYDAC Filtertechnik GmbH Page 24 BeWa CS1000 3247149k en.doc 2006-04-06...
To prevent a ground loop, connect the shield of the connector cable if and only if the CS1000 is not grounded or not sufficiently connected to the protective earth (PE) conductor. HYDAC Filtertechnik GmbH Page 25 BeWa CS1000 3247149k en.doc...
Establish reservoir cleanliness between min/max levels Function: Control of a filter unit, continuous measurement of solid contamination, if pre-programmed min/max levels are exceeded, the pump is switched on/off to keep cleanliness within range HYDAC Filtertechnik GmbH Page 26 BeWa CS1000 3247149k en.doc 2006-04-06...
Mode M5: "SINGLE" measurement Application: Stand-alone sensor Active data outputs: Display & RS485 & analog output Purpose: Perform a single measurement only Function: Single measurement of solid contamination, without any switching functions HYDAC Filtertechnik GmbH Page 27 BeWa CS1000 3247149k en.doc 2006-04-06...
Installation and Operation 8 Operation After the CS 1000 is switched on "HYDAC CS 1000" appears in the display in moving letters, followed by the firmware version being displayed for 2 seconds. WAIT99 WAIT0 This is followed by a countdown: ->...
The following appears in the Description keys display (1 sec) LOCK Key Lock is activated UNLOCK Key Lock is deactivated The display switches to the preset display after 1 second. HYDAC Filtertechnik GmbH Page 29 BeWa CS1000 3247149k en.doc 2006-04-06...
For internal use only CODE Select measuring Description MODE mode Measure continuously Measure continuously and switch Filter down to contamination level and stop Filter to establish contamination levels continuously SINGLE single measurement HYDAC Filtertechnik GmbH Page 30 BeWa CS1000 3247149k en.doc 2006-04-06...
CANCEL Scroll to and press Exit menu without saving changes Happens automatically after 30 s when there is no action Exit menu and save changes SAVE Scroll to and press HYDAC Filtertechnik GmbH Page 31 BeWa CS1000 3247149k en.doc 2006-04-06...
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Measure continuously Measure continuously and switch Filter down to contamination level and stop Filter to establish contamination levels continuously SINGLE Perform single measurement + stop Measure continuously NO SET HYDAC Filtertechnik GmbH Page 32 BeWa CS1000 3247149k en.doc 2006-04-06...
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SAE D SwFNCT Switching function BEYOND BELOW WITHIN OUTSDE LIMITS Limits LOWER UPPER Filter down to Description contamination level and stop MEAsCH ISO Code SAE Class TARGET Target contamina- tion level HYDAC Filtertechnik GmbH Page 33 BeWa CS1000 3247149k en.doc 2006-04-06...
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ISO 14 code ISO 3-digit (Code) ISO+T ISO 3-digit + temp. (Code) SAE A SAE class A SAE B SAE class B SAE C SAE class C SAE D SAE class D HYDAC Filtertechnik GmbH Page 34 BeWa CS1000 3247149k en.doc 2006-04-06...
If pre-programmed min/max levels are exceeded, the pump is switched on/off to keep cleanliness within range. Mode M5: Single measurement Function: Single measurement of solid contamination, without any switching functions HYDAC Filtertechnik GmbH Page 35 BeWa CS1000 3247149k en.doc 2006-04-06...
After switching the unit on or starting a measurement Outside band a value ≥ respective upper limit Opens again when the respective lower limit < all values < upper limit Always open No switching HYDAC Filtertechnik GmbH Page 36 BeWa CS1000 3247149k en.doc 2006-04-06...
SAE A / SAE B / SAE C / SAE D Only one value is output (see section 9.1.4). • SAE + T All values are sequentially output time-coded (see section 9.1.5). HYDAC Filtertechnik GmbH Page 37 BeWa CS1000 3247149k en.doc 2006-04-06...
19.7 mA < I < 19.8 mA 9.85 V < U < 9.90 V No measured value 19.8 mA < I < 20 mA 9.90 V < U < 10 V HYDAC Filtertechnik GmbH Page 38 BeWa CS1000 3247149k en.doc 2006-04-06...
SAE Class A / B / C / D ( The SAE class A/B/C/D measured value consists of 4 measured values coded with the following time slices (also shown in the following diagram): 9.1.3.1 Time-coded signal HYDAC Filtertechnik GmbH Page 39 BeWa CS1000 3247149k en.doc 2006-04-06...
Current for measured value (see Table 9.1.1) Identifier 19.2 / 4.8 / 19.2 / 4.8 / 19.2 / 4.8 / 19.2 / 4.8 Measured value 3000 Current for measured value (see Table 9.1.1) HYDAC Filtertechnik GmbH Page 40 BeWa CS1000 3247149k en.doc 2006-04-06...
Voltage for measured value (see Table 9.1.1) Identifier 9.6 / 2.4 / 9.6 / 2.4 / 9.6 / 2.4 / 9.6 / 2.4 Measured value 3000 Voltage for measured value (see Table 9.1.1) HYDAC Filtertechnik GmbH Page 41 BeWa CS1000 3247149k en.doc 2006-04-06...
The SAE x setting enables the value of a class to be continuously output via the analog output. SAE+T 9.1.5 SAE + T ( The SAE+T signal consists of 5 measured values which are transmitted time-coded with the following time slices: HYDAC Filtertechnik GmbH Page 42 BeWa CS1000 3247149k en.doc 2006-04-06...
I = 13.34 mA ISO 15 U = 6.67 V I = 13.91 mA ISO 16 U = 6.96 V I = 14.48 mA ISO 17 U = 7.24 V HYDAC Filtertechnik GmbH Page 45 BeWa CS1000 3247149k en.doc 2006-04-06...
The ISO code signal consists of 3 measured values (> 4 µm / > 6 µm /> 14 µm ) and is time-coded with the following time slices. 9.2.3.1 Time-coded Signal HYDAC Filtertechnik GmbH Page 46 BeWa CS1000 3247149k en.doc 2006-04-06...
Current for measured value (see Table 9.2.1) Identifier >14µm 19.2 / 4.8 / 19.2 / 4.8 / 19.2 / 4.8 Measured value >14µm 3000 Current for measured value (see Table 9.2.1) HYDAC Filtertechnik GmbH Page 47 BeWa CS1000 3247149k en.doc 2006-04-06...
Voltage for measured value (s. Table 9.2.1) ISO+T 9.2.4 ISO + T ( The ISO+T signal consists of 4 measured values which are transmitted time-coded with the following time slices: 9.2.4.1 Time-coded Signal HYDAC Filtertechnik GmbH Page 48 BeWa CS1000 3247149k en.doc 2006-04-06...
U = 8.45 V I = 17.47 mA +85 °C / 185 °F U = 8.74 V I = 18.05 mA +90 °C / 194 °F U = 9.02 V HYDAC Filtertechnik GmbH Page 51 BeWa CS1000 3247149k en.doc 2006-04-06...
The length of the bus line and the size of the terminating resistance are depending on the quality of cable used. The graphic below shows several CS 1000 connected via the RS-485 interface and then connected in turn to a PC. HYDAC Filtertechnik GmbH Page 53 BeWa CS1000 3247149k en.doc 2006-04-06...
CD with PC-Software package CoCoS 1000 and Operation and Maintenance Instructions CS 1000 & CoCoS 1000 11.2 CSI-D-5 Connection schematic The CSI-D-5 has to be connected according to the following schematic. HYDAC Filtertechnik GmbH Page 54 BeWa CS1000 3247149k en.doc 2006-02-14...
Check output voltage at 12 Volt. If not, set to 12. Check the arrows of the plug and socket as shown. The "+" symbol must be connected to the inner contact of the plug. If not, reverse the plug. HYDAC Filtertechnik GmbH Page 55 BeWa CS1000 3247149k en.doc 2006-02-14...
If you do not have a driver installed, your PC will ask you to insert a driver CD. The CoCoS 1000 setup makes a note of the USB port during installation. Installation may have to be repeated if you use different USB port later on. HYDAC Filtertechnik GmbH Page 56 BeWa CS1000 3247149k en.doc...
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If installation is successful, you will find the driver with the corresponding COM port no. in your device manager. Locate the COM port no. You now have to run CoCoS 1000. HYDAC Filtertechnik GmbH Page 57 BeWa CS1000 3247149k en.doc...
CS, which should be installed automatically with ONTS the software. 3) To install the software, run SETUP The following screens will appear during installation. HYDAC Filtertechnik GmbH Page 58 BeWa CS1000 3247149k en.doc 2006-03-14...
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CoCoS 1000 Press Select your installation path and then press HYDAC Filtertechnik GmbH Page 59 BeWa CS1000 3247149k en.doc 2006-03-14...
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CoCoS 1000 Press Wait until installation is completed. Now press HYDAC Filtertechnik GmbH Page 60 BeWa CS1000 3247149k en.doc 2006-03-14...
D-5 and insert the power adaptor in the AC line (see section 11.2) 1) To launch CoCoS1000, run CoCoS1000.exe in the installation folder. 2) After launching the software, the serial port has to be set first. HYDAC Filtertechnik GmbH Page 61 BeWa CS1000 3247149k en.doc...
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5 to your PC and the power adaptor is inserted in the AC line. Press This screenshot shows a virtual CS 1000 front panel. Its appearance and handling is similar to a real CS 1000 with the display option (see section 8.1). HYDAC Filtertechnik GmbH Page 62 BeWa CS1000 3247149k en.doc 2006-03-14...
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Exits the program In the event of an error (see also section 16) the status LED is continuously red (no blinking code) and the error code is shown below the keypad. HYDAC Filtertechnik GmbH Page 63 BeWa CS1000 3247149k en.doc...
The following data is stored. Values are separated by tabs. Year Month Hours Temp Flow Drive 4µm 6µm 14µm 2005 26.7 2005 26.7 2005 26.7 2005 26.7 2005 26.7 The save procedure can be stopped by pressing Stop Saving. HYDAC Filtertechnik GmbH Page 64 BeWa CS1000 3247149k en.doc 2006-03-14...
If the display shows different characters, the CS font has to be installed manually. • The typeface CS 1000-Liteon Standard (CS 1000-Liteon.ttf) is installed under Control Panel → Fonts. When asked, press to overwrite the TFF file already installed. HYDAC Filtertechnik GmbH Page 65 BeWa CS1000 3247149k en.doc 2006-03-14...
Flow definition not Increase or reduce inlet possible pressure. 19,9 mA / 9,95 V open CHECK Flow definition not Check flow and fluid possible cleanness. 19,9 mA / 9,95 V open HYDAC Filtertechnik GmbH Page 69 BeWa CS1000 3247149k en.doc 2006-03-14...
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-40...-69 contact HYDAC Reset device (re-supply Error during automatic voltage to sensor, check adjustment flow or contact HYDAC Reset device (re-supply Error measuring cell LED voltage to sensor, check -100 flow or contact HYDAC HYDAC Filtertechnik GmbH Page 70 BeWa CS1000 3247149k en.doc...
Switching Output passive, n-switching Power MOSFET: max. current 1,5 A, normally open RS-485 Interface 2 wire, half duplex HYDAC Single Wire interface For HMG 3000 use only Service Shipping Address for Recalibration and Repair Work HYDAC Servicenter GmbH Rehgrabenstrasse, Werk 7 66121 Saarbrücken, Germany...
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