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CS 2000 series Contamination Sensor Operating and maintenance instructions English (translation of original instructions) Valid from firmware versions V 1.10 up Document No.: 3117721e...
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All rights reserved. This manual may not be reproduced in part or whole without the explicit written agreement from HYDAC Filtertechnik. Contraventions are liable to compensation. Exclusion of liability We made every endeavor to ensure the accuracy of the contents of this document.
ContaminationSensor – CS 2000 series Contents General Safety Precautions ...................9 1.1 Obligations and Liability....................9 1.2 Explanation of Symbols and Warnings, etc..............9 1.2.1 Basic Symbols......................10 1.3 Proper/Designated Use ....................10 1.4 Improper Use....................... 10 1.5 Informal Safety Precautions ..................11 1.6 Training and Instruction of Personnel................12 1.7 Safety measures to be followed in normal operation...........
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ContaminationSensor – CS 2000 series 7.2 Connection assignment AS 2000 series..............29 7.3 HYDACLab Wiring Diagrams ..................30 Serial RS232 Display and Parameter Setting Interface ..........31 8.1 Connecting the Serial RS232 Display Interface ............31 8.2 Measured value output and messages via the RS 232 display interface ....32 8.3 Parameter setting via the serial RS232 display interface ..........
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ContaminationSensor – CS 2000 series 12.1 Setting the IP address ....................62 12.2 Devices with an Ethernet module offer the following 2 applications......62 12.2.1 Transferring commands via the TCP/IP protocol ..........62 12.2.2 CS 2000 as WebServer..................63 12.3 Electrical Installation....................64 13 Analog module (option –1)...................65...
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ContaminationSensor – CS 2000 series Preface For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance. It is intended to help you become acquainted with the ins and outs of the product and use it properly.
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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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ContaminationSensor – CS 2000 series Using the documentation Please note that the method described above of locating specific information does not release you from your responsibility for 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.
ContaminationSensor – CS 2000 series General Safety Precautions These operating instructions contain the key instructions for properly and safely operating the CS. Obligations and Liability The basic prerequisite for the safe and proper handling and operation of the CS is knowledge of the safety instructions and warnings.
ContaminationSensor – CS 2000 series 1.2.1 Basic Symbols DANGER denotes situations DANGER which can lead to death if safety precautions are not observed. WARNING denotes situations WARNING which can lead to death if safety precautions are not observed. CAUTION denotes situations...
CS. Tests conducted with the housing open may only be performed by properly trained, certified electricians. This also applies to all repair work or to any modifications to electrical components approved by HYDAC. The hoses and connection fittings are to be checked daily for leakage (visual check).
ContaminationSensor – CS 2000 series Training and Instruction of Personnel The CS may only be operated by properly trained and instructed personnel. The areas of responsibility of your staff must be established in a clear-cut manner. Staff undergoing training may not use the CS unless supervised by an experienced staff member.
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.
ContaminationSensor – CS 2000 series Packing, Transportation, Storage and Disposal Transportation Packing The CS is delivered packed in foils. When receiving and unpacking the product check it for damage in transit. Report any damage to the forwarding agent immediately .
ContaminationSensor – CS 2000 series Scope of Delivery The ContaminationSensor CS is delivered packed and ready to operate. Before starting up the CS, please check no items are missing from the package. The following items are supplied: Item Qty. Description ContaminationSensor CS2000, ready for connection Connection cable CS <->...
223X are dealt with below for the sake of simplicity. Particulate contamination is recorded using a fiber-optic infrared measurement cell patented by HYDAC and can be output as particle counts or as contamination classes in accordance with NAS 1638 or ISO 4406:1987 / SAE AS 4059 or ISO 4406:1999.
ContaminationSensor – CS 2000 series Installation and Operation Electrical Installation 5.1.1 Terminal Assignment There are two M16x1.5 cable glands through which the electrical power supply and signal lines can be routed into the housing. The housing of the ContaminationSensor contains the identification of the terminal assignment that specifies the particular configuration.
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ContaminationSensor – CS 2000 series The terminal assignment of the module port varies according to the various optional output modules. The terminal assignments of the individual modules are shown below: RS 232 Modul (Option –0) You will find the description for this module in Chapter 11.
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ContaminationSensor – CS 2000 series RS 232 / analog module (option –6) This module represents a combination of the variants RS 232 (Option –0) and Analog (Option –1). A description of the funcationalities can be found in Chapter 11 and Chapter 12.
ContaminationSensor – CS 2000 series Electrical connection of the CS Before continuing, check whether the CS is suitable for your display/data capturing system by carefully examining the technical specifications. First connect the signal lines (pins/terminals 1 to 23). Then connect the supply voltage.
ContaminationSensor – CS 2000 series Hydraulic connection of the CS Determine the system pressure of the hydraulic facility and see whether it is within the permissible range for the INLET port. The pressure in the measurement cell is not allowed to exceed 40 bar! The built-in pressure relief valve does not open until there is a pressure differential of 40 bar between the INLET and OUTLET.
ContaminationSensor – CS 2000 series 5. First connect the measurement line (not supplied) to the INLET port of the (Connector thread: G1/4, ISO 228. Recommended internal diameter of conduit (to prevent particle sedimentation): ≤ 4 mm) 6. Now connect the other end of the measurement line to the measurement point.
ContaminationSensor – CS 2000 series Description of the Measuring Modes Mode M1: Measure Continuous measurement without special switching functions. The current measurement result is output via the available interfaces after the measurement interval has elapsed. Mode M2: Measure and switch Continuous measurement, with relays 1 and 2 being switched according to the set measuring channels, switching functions and limit values.
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ContaminationSensor – CS 2000 series Relays 1 and 2 are not switched until after the first measurement interval has expired. Ready relay Ready relay Relay 1 Relay 1 Relay 2 Relay 2 CS ready for CS not ready Measurement Measurement...
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ContaminationSensor – CS 2000 series Ready relay Ready relay Relay 1 Relay 1 Relay 2 Relay 2 upper limit upper limit measurement measureme Off again if all Off again if values ≤ all values ≤ particular particular lower limit lower limit All values ≤...
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ContaminationSensor – CS 2000 series Ready relay Ready relay Relay 1 Relay 1 Relay 2 Relay 2 Start or CS ready for CS not ready Measurement In 5 After first Flow in result of the operation for operation in progress...
ContaminationSensor – CS 2000 series Analog inputs The 4 ... 20 mA outputs of a HYDAC AquaSensor can be connected to the two analog inputs. The connection assignments are shown in the following figure. Connection assignment AS 1000 series Analog Supply +12 V PIN 1 Analog Signal Ch.
ContaminationSensor – CS 2000 series HYDACLab Wiring Diagrams The 24 V voltage supply of the HYDACLab (HLB) is to be tapped at the voltage supply of the CS. The 4 ... 20 mA output of the HYDACLab must be set up in the CS at the analog input module on terminal no.
ContaminationSensor – CS 2000 series Serial RS232 Display and Parameter Setting Interface Measurement results and messages are output as text via the serial RS 232 display interface. Furthermore, the parameters of the ContaminationSensor can be set via this interface. Connecting the Serial RS232 Display Interface Disconnect the CS from the voltage supply and switch your PC off.
ContaminationSensor – CS 2000 series Measured value output and messages via the RS 232 display interface The CS is always in display mode after it is switched on: • Initially, the text Hy0AC appears in the terminal window • After the set measurement interval, the current measurement result (e.g.: ISO Code : 25.22.20) or a fault message is output...
ContaminationSensor – CS 2000 series Press the “p” key and then the Return key to enter Parameter mode, in which you can program the CS settings. 8.3.2 Parameter mode The following display appears after Parameter mode starts: Parameter Mode: x - Go back...
ContaminationSensor – CS 2000 series (Das Messintervall wurde im Beispiel von 20s auf 60s verlängert.) 8.3.4 Measuring mode m = Measuring mode selects the measuring mode (M1, M2, M3 or M4) Current Mode: 3 1=M1, 2=M2, 3=M3, 4=M4 Press key (1, 2, 3, 4) and Return (press Return only to keep setting)2 'Return' Current value for measuring mode: 2 (The measuring mode was changed from M3 to M2 in this example.)
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ContaminationSensor – CS 2000 series 0 -> No function 1 -> Within range 2 -> Outside range 3 -> Upper limit value exceeded (lower limit value for hysteresis) 4 -> Value below lower limit value (upper limit value for hysteresis)
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ContaminationSensor – CS 2000 series new setting (press Return only to keep setting):'Return' current setting : 20 Relay 1, lower limit 2: current setting: 15 new setting (press Return only to keep setting): 14 'Return' current setting : 14 Relay 1, upper limit 2:...
ContaminationSensor – CS 2000 series current setting : 50 Relay 2, upper limit 1: current setting: 150 new setting (press Return only to keep setting):'Return' current setting : 150 (50 and 150 ml/min respectively were entered for the lower and upper limit values.) 8.3.4.2...
ContaminationSensor – CS 2000 series current setting: 5 new setting (press Return only to keep setting): 16 'Return' current setting : 16 lower limit 2: current setting: 5 new setting (press Return only to keep setting): 14 'Return' current setting : 14...
Testpoint Current DIN-BUS Address: 1 Current measurement point: CS 2230 (In this example, the measurement point name was changed from "HYDAC" to "Testpoint", the DIN-BUS address could not be changed because it was set to 1 by DIP switch.) 8.3.4.5...
ContaminationSensor – CS 2000 series IP address part 3: current setting: 14 new setting (press Return only to keep setting): 16 current setting: 16 IP address part 4: current setting: 150 new setting (press Return only to keep setting): 36 current setting: 36 In this example, the IP address was changed from 129.42.14.150 to 192.168.16.36.
ContaminationSensor – CS 2000 series (In the example, the output format was changed from ISO to SAE and the output frequency is halved) 8.3.4.8 Display interface r = RS - -232 Display Output Format enables a header (max. 25 characters) to be entered for display on the screen.
ContaminationSensor – CS 2000 series Example for CS 223X (without analog signals): Header in display output: SAE B Measurement value in display output: SAE ch. B Enter new header ('Return' = no header!): New header in display output: 'no header' Enter new measurement value ('Return' = keep current setting): 1 = SAE max.
"Standard" is selected. (The name is read out by the CoCoS software and used as an axis name.) Example: (configuration for HYDAC AquaSensor AS 2030 / 2330) Analog Input Mode 0 = No Analog input, 1 = Standard (2xAI), 2 = HYDACLab signal Current setting: 2 New setting (press Return only to keep setting): ‘1’...
Function available only if 2 analog inputs have been configured (see 8.3.4.13). When h = Display AD Channels, the current measured values of the two analog 4..20 mA inputs are displayed Example: (configuration for HYDAC AquaSensor AS 203x / 233x) Channel 1 4.0 mA Configuration Value: 0.0...
ContaminationSensor – CS 2000 series Channel 2 20.0 mA Configuration Value: 120.0 Temperature Value: 55.4 Press key (x, 'Return'): x 'Return' Entering 'Return' updates the values, x 'Return' exits the display and returns to parameter mode 8.3.4.15 Master reset d = Set default values resets all values that can be set in the parameter mode menu (except the configuration of the analog inputs) to their default values (see Chapter 10.6 Parameter List for more information)
ContaminationSensor – CS 2000 series PLC interface output signals Depending on the set output format (ISO code or NAS/SAE classes), the PLC interface either outputs a three-value ISO code or the NAS/SAE classes of the four particle size channels coded in the form of pulses.
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ContaminationSensor – CS 2000 series 24 V from PLC (P5) 100 nF PNP Output to PLC (P6) 100 nF 10 k PLC Ground (P4) 10 nF Case Ground Figure 2: PLC output switching of the CS HYDAC Filtertechnik GmbH Page 47 BeWa CS2000 3117721e en.doc...
ContaminationSensor – CS 2000 series DIN measurement bus module (option -2) 10.1 Interface The configuration of the interface and the protocol structure required for communication are in accordance with the criteria defined in DIN 66348 Part 2. Basically, the electrical properties correspond to those of an RS 485 interface,...
ContaminationSensor – CS 2000 series 10.4 DIN measurement bus commands All transfers are ASCII-coded, i.e. values are not transmitted in binary format. Strings are transferred with a prefix stating the number of places. The string itself is set inside quotation marks ("). The DIN measurement bus only transmits 7-bit characters, therefore characters with a binary value above 127 are transferred in an escape sequence.
ContaminationSensor – CS 2000 series The units digit defines the exact status: The following applies to M1 (Measure), M2 (Measure and switch), M3 (Filter to): x0 Measurement off x1 Wait for correct flow rate x2 Measurement currently in progress The following applies to M4 (Filter from to):...
ContaminationSensor – CS 2000 series 10.5.1 Command '8': Set parameter The individual parameters in the CS (limit values, monitoring times, measurement point name, etc.) can be set with this command. The command number is followed by a parameter number and the parameter value.
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Measured value Analog input 2 (e.g. Temperature) : 52.0 The information about the water content and temperature is only available if a HYDAC AquaSensor is connected to the analog input channels. (The measured values are determined at the end of the measurement interval of the particle counting.)
3 = Oil status not plausible 4 = Internal error The information is available only if a HYDAC HYDACLab is connected to the analog input channel 1. (The measured values are evaluated from the HDA.ISO signal and the current values are output with the end of the measurement interval of the particle count.)
3 = Oil status not plausible 4 = Internal error The information is available only if a HYDAC HYDACLab is connected to the analog input channel 1. (The measured values are evaluated from the HDA.ISO signal and the current values are output with the end of the measurement interval of the particle count.)
ContaminationSensor – CS 2000 series This command reads out the current value of the send current of the sensor LED (digital value between 0 and 1023). SEND '17' RECEIVE : '17 156' Explanation: LED current: 156 digits 10.5.8 Command '19': Set parameter to factory settings: This command resets the settings of the CS that can be changed by the user to the factory settings (see "Parameter List"...
ContaminationSensor – CS 2000 series 10.6 Parameter list / Parameter List Alle Parameter sind entweder vom Typ String oder Integer. All parameters are either strings or integers. Read Description Ex-works -only setting For internal use For internal use For internal use...
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ContaminationSensor – CS 2000 series Read Description Ex-works -only setting Lower limit value in M3 Channel 1 (NAS/SAE / ISO) Lower limit value in M3 Channel 2 (NAS/SAE / ISO) Lower limit value in M4 Channel 0 (NAS/SAE / ISO)
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ContaminationSensor – CS 2000 series Read Description Ex-works -only setting IP Address part 4 For internal use For internal use Analog input 1, Configured value for 4 mA -9999 9999 Analog input 1, Configured value for 20 mA -9999 9999 54 X Analog input 1, designation (max.
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ContaminationSensor – CS 2000 series Read Description Ex-works -only setting For internal use For internal use Measuring mode M1..M4 --> 0..3 81 X Header for RS232 Display Output No to Header Unit for RS232 Display Output CS 2230: 1 = SAE max. , 2 = ISO Code , 3 = Flow rate, 4 = Toggle ISO/Flow, 5 = SAE ch.
ContaminationSensor – CS 2000 series Read Description Ex-works -only setting Upper limit value 3 M2, Relay 2, Channel 0-8 Upper limit value 4 M2, Relay 2, Channel 0-8 (not used) RS 232 Module (Option –0) This module uses the same data transfer protocol as described in the DIN measurement bus chapter.
ContaminationSensor – CS 2000 series Ethernet Module (Option –5) The Ethernet module is designed for the standardized cabling version "10 Base-T" and corresponds to the criteria defined in IEEE 802.3 (bit rate 10 Mbps, transfer medium: Twisted Pair (UTP/STP) cable).
However, the values for temperature ([°C]) and saturation ([%]) are only output if a HYDAC AquaSensor or a HYDACLab is connected to the CS. The CS 2000 with Ethernet modul performs the task of a WebServer. If you make a connection to the CS 2000, another client is blocked...
ContaminationSensor – CS 2000 series from accessing this function for the duration of the connection, i.e. the WebServer only ever communicates with one client at a time. However, it is possible to call up the WebServer with a web browser (e.g.
ContaminationSensor – CS 2000 series Analog module (option –1) The measurement results are output as follows as current between 4 mA and 20 mA (load ≤ 500 Ω): If NAS max. or. SAE max. was selected in parameter mode under "i":...
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ContaminationSensor – CS 2000 series "Error High" SAE 12 SAE 11 SAE 10 SAE 9 SAE 8 SAE 7 SAE 6 SAE 5 SAE 4 SAE 3 SAE 2 "Error Low" 19,2 20 i / mA The SAE class is calculated from the measured current i as follows: "SAE value"...
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ContaminationSensor – CS 2000 series = minimum current (4.8mA) = maximum current (19.2mA) Log = Logarithm base 10 This results in: I(n) = 4.8 mA+ log(n) x 1.9695 mA If the particle count is greater than 20,480,000, then 19.2 mA is output. If the particle count = 0, then 4.8 mA is output.
ContaminationSensor – CS 2000 series Cleanliness classes - brief overview 14.1 Cleanliness class - ISO 4406:1999 In ISO 4406:1999 particle counts are determined cumulatively, i.e. > 4 µm , >6 µm and >14 µm (manually by filtering the fluid through an analysis membrane or automatically using particle counters) and allocated to measurement references.
ContaminationSensor – CS 2000 series Note: increasing the measurement reference by 1 causes the particle count to double. Example: ISO class 18 / 15 / 11 means: Cleanliness class Particle count / ml Size ranges 1,300 – 2,500 > 4 µm 160 –...
ContaminationSensor – CS 2000 series 14.2 Cleanliness class - SAE AS 4059 Like 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 number of particles (i.e.
ContaminationSensor – CS 2000 series 14.2.2 SAE definition 14.2.2.1 Absolute particle count larger than a defined particle size Example: Cleanliness class according to AS 4059: 6 The maximum permissible particle count in the individual size ranges is shown in the table in boldface.
ContaminationSensor – CS 2000 series 14.3 Cleanliness Class - NAS 1638 Like ISO 4406, NAS 1638 describes particle concentrations in liquids. The analysis methods can be applied in the same manner as ISO 4406:1999. In contrast to ISO 4406, certain particle ranges are counted in NAS 1638 and attributed to measurement references.
0 = Flow is approx. If the message remains, the 0 ml/min measurement section is probably clogged. -> Ship unit in to HYDAC for repair. 999999 "999999" is output in case of Make sure that no oil with high malfunctions in the particle...
If the message remains, the = Error measurement section is probably = Flow approx. 0 ml/min. clogged. -> Ship unit in to HYDAC for repair. The flow through the CS is F 225 outside of the set, permitted range (10 ...200 ml/min).
ContaminationSensor – CS 2000 series Technical Data General data Mounting position Any (recommended: vertical position) Measurement parameters CS 5µm / 15µm / 25µm / 50 µm 203x calibrated: ISO 11/10 ... 21/18 , NAS 2 ...15 Display: ISO 10/9 ... 23/21, NAS 2 ...15 Measurement parameters CS 2µm / 5µm / 15µm / 25 µm...
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ContaminationSensor – CS 2000 series Hydraulic data Pressure viscosity range (Model code = CS 2xxx-1-U-X-x/-) Electrical data Power supply voltage 24 V DC, residual ripple < 25%, (protected against polarity reversal) Current consumption 300 mA max. Outputs - 3 relays (ready, warning, alarm) (max.
ContaminationSensor – CS 2000 series Electrical data 2x analog signal 4..20 mA, Ri = 240 Ω, current source Input Recalibration / Service We recommend recalibrating the sensor every 2 – 3 years. Customer Service Shipping address for calibration and repair:...
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