Contaminationsensor cs1000 series stationary particle sensor (12 pages)
Summary of Contents for Hydac MCS 13 Series
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Metallic Contamination Sensor Operation and Installation Guide English (translation of original instructions) Documentation no.: 3950943b Valid from hardware index B and firmware version V 1.4x up...
Content Content Content ......................2 General ......................6 Imprint......................6 Documentation Representative ..............6 Purpose of this manual ................6 Target group of the manual ................. 7 Target group - Required qualifications/training ..........8 Illustrations in the manual ................9 Illustration of the layout ................
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Content Model Code .................... 31 Storage and transport ................32 Assembly, installation and commissioning ..........33 Mechanical installation/assembly .............. 33 Connecting MCS13xx / 14xx via flange adapter set ....... 34 Fastening sensor to underside ..............35 Fastening MCS 13xx / MCS 14xx ............36 Fastening MCS 15xx ................
General chapters attentively and carefully. Please refer to it every time you require decisive details. This manual informs and warns you of risks, against which the risk reduction through the design and protective measures may not be effective or not fully effective.
General Target group - Required qualifications/training Persons who work on the product must be aware of the hazards associated with its use. Auxiliary and specialist personnel must have read and understood the operating instructions, in particular the General Safety Information and instructions, and applicable regulations before beginning work.
General Illustrations in the manual You will find illustrations in this manual. You can find details regarding these in the following chapters. Illustration of the layout Chapter description Page number Edition date Seite x 200x-xx-xx Document language Documentation no. with index/ file name The documentation number with its index enables you to order another copy of the operating and maintenance instructions.
General Representation of procedural instructions There are these two following representations in the case of procedural instructions: Procedural instructions with a fixed sequence Procedural instructions, whose sequence must be complied with without fail are listed with sequential numbering (1., 2., 3., etc.). An example for procedural instructions with a fixed sequence: 1.
General Signal words and their meaning in the general safety information In these instructions you will find the following signal words: DANGER DANGER – The signal word indicates a hazardous situation with a high level of risk, which, if not avoided, will result lethal or serious injury. WARNING WARNING –...
General Signs used for giving orders These symbols are listed for all general safety information and instructions in these operating instructions that refer to particular dangers to persons, property or the environment. Signs used for the required specialist personnel These symbols show the required training/knowledge for installation work and/or maintenance work.
For the warranty provided by us, please refer to our terms of delivery. They are made available to you at the conclusion of the contract at the latest. In addition, you will find these under www.hydac.com -> General terms and conditions.
General Safety Information General Safety Information The product has been built according to the provisions, directives and standards valid at the time of delivery and satisfies the current safety requirements. Any residual hazards are indicated by the general safety information and are described in this manual. Observe all the safety and warning instructions attached to the product and always keep them up to date and easily legible.
Product overview Product overview Scope of delivery Scope of delivery for MCS 13xx The MetallicContamination Sensor MCS 13xx comes packed and factory- assembled. Before commissioning the sensor, please check no items are missing from the package. The following items are supplied: Qty.
Product overview Scope of delivery for MCS 14xx The MetallicContamination Sensor MCS 14xx comes packed and factory- assembled. Before commissioning the sensor, please check no items are missing from the package. The following items are supplied: Qty. Description MetallicContamination Sensor, MCS 14xx O-ring (25 x 3.53 NBR 70 Shore) Operation and Installation Guide (this document) Page 16 / 80...
Product overview Scope of delivery for MCS 15xx The MetallicContamination Sensor MCS 15xx comes packed and factory- assembled. Before commissioning the sensor, please check no items are missing from the package. The following items are supplied: Qty. Description MetallicContamination Sensor, MCS 15xx o-ring (47.22 x 3.53 NBR 70 Shore) O-ring (110.72 x 3.53 NBR 70 Shore) Operation and Installation Guide (this document)
Product overview Dimensions The dimensions for the available sizes vary. The dimensions for each size can be found below. Dimensions MCS 13xx Flange image SAE 3/4" All dimensions in mm. Page 18 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Product overview Dimensions of the MCS 13xx with the Ethernet module Flange image SAE 3/4" All dimensions in mm. Page 19 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Improper use or use deviating from intended use Any use extending beyond this or deviating therefrom shall not be considered intended use. HYDAC FILTER SYSTEMS GMBH will assume no liability for any damage resulting from such use. This risk is borne solely by the owner.
Product overview Technical Data Hydraulic data MCS13xx MCS14xx MCS15xx 0.4 … 8 l/min 2 … 40 l/min 10 … 200 l/min Permissible flow rate Maximum operating 20 bar / 20 bar / 20 bar / pressure 290 psi 290 psi 290 psi -40 …...
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Product overview Electrical data 9 … 36 V DC, Operation voltage Residual ripple < 10% Power consumption 5 W max. Electrical outputs 2 configurable switching 1 x Ferromagnetic (Fe) particle outputs 1 x Non-ferromagnetic (nFe) particle (n-switching Power 1 x Particle (Fe + nFe) MOSFET, normally open) 1 x Device Ready signal 1 x Alarm...
Product overview Decoding the type label For identification details of the MetallicContamination Sensor, see the type label. This is located on the top of the unit and contains the exact product description and the serial number. Definition Description Model Model according to model code, for details, see page 31.
Storage and transport Storage and transport Transport the sensor upright or flat, and in the included packaging if possible. Make sure the connection plug will not be subjected to any mechanical strain or impact. NOTICE Unsafe transport The connection plug will be damaged ►...
Assembly, installation and commissioning Assembly, installation and commissioning Mechanical installation/assembly During installation, always observe the direction of flow through the sensor. The direction of flow is indicated by an arrow on the housing. When selecting the installation site, take ambient factors like the temperature, dust, water, etc., into account.
Assembly, installation and commissioning Connecting MCS13xx / 14xx via flange adapter set A flange adapter set is available as an accessory. For the article no., refer to Chapter "Spare Parts and Accessories" on page 73. This flange adapter set makes it possible to connect the MCS directly to pipes or hoses with a G1/2"...
Assembly, installation and commissioning Fastening sensor to underside The sensors have 4 fixing holes on the underside. Use these to secure the MCS. Page 35 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Assembly, installation and commissioning Fastening MCS 13xx / MCS 14xx Below you can see the drilling template for fastening the MCS 13xx/14xx. (All dimensions in mm) Fastening MCS 15xx Below you can see the drilling template for fastening the MCS 13xx/14xx. (All dimensions in mm) Page 36 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx...
3477243. Connecting MCS 15xx using pipe adapter set A pipe adapter set is available as an accessory. HYDAC article no. 3435426. This pipe adapter set makes it possible to connect the MCS directly to two pipes or hoses via the thread 42L per ISO8431-1.
Assembly, installation and commissioning Connecting MCS 15xx using flange adapter plate (accessory) A flange adapter set is available as an accessory. HYDAC article no. 3442518. The SAE4"-SAE1½" (1) flange adapter set can be used to mount the MCS between the filter unit and the pump. The flange adapter plate has three ¼"...
Assembly, installation and commissioning MCS 15xx via SAE 4" per ISO 6162-1 (4xM16) Install the MCS with four screws (M16) to a component/unit. The drilling template corresponds to the SAE 4" per ISO 6162-1. Example: installing the MCS on an NF filter Page 39 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Assembly, installation and commissioning Hydraulic installation / assembly During installation, note the direction of flow through the MCS. The direction of flow is indicated by an arrow on the housing. NOTICE Exceeding the permissible operating pressure The sensor will be destroyed ►...
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Assembly, installation and commissioning Q l/min Q l/min The diagram shows the resulting differential pressure mbar as a function of the flow rate Q l/min at different viscosities. Page 41 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Supply voltage 9-36 V DC Switch output 2 (normally open) GND for supply voltage GND switching output HSI (HYDAC Sensor Interface) RS485 + RS485 - Switch out 1 (normally open) The two switching outputs are in each case a passive, n-switching power MOSFET.
Our accessories list includes connection cables of various lengths with one connection plug (8-pole, M12x1, according to DIN VDE 0627) and an open end. The color coding of the HYDAC accessory cable ZBE42-xx is listed in the table below: (All dimensions in mm)
Assembly, installation and commissioning Connecting cable wires To prevent a ground loop, connect the shield of the connector cable only if the sensor is not grounded or not sufficiently connected to the PE conductor. Example: circuit diagram with two power supplies: Lead voltages U and U as well as the load resistances and bridges via a...
Assembly, installation and commissioning Attached you will find sample wiring for the use of the switching outputs S1 / S2 in operation with one or several different supply voltages. To prevent a ground loop, connect the shield of the connector cable only if the sensor is not grounded or not sufficiently connected to the PE conductor.
Assembly, installation and commissioning Connection: operation voltage ≠ measurement voltage In the following examples, a measurement voltage of 10 V DC and an operation voltage of 24 V DC are used. Using switching output 1 Using switching output 2 Page 47 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Assembly, installation and commissioning Using switching output 1 and 2 Using the switching outputs The two switching outputs delivery pulses that can be counted or utilized in a superordinate controller. The logic of the signal outputs is parameterizable. You can select between "active low"...
Assembly, installation and commissioning Switching output - FE.NFE (factory setting) A signal for all ferromagnetic (Fe) particles is output at switching output 1, and a signal for all non-ferromagnetic (nFe) particles at switching output 2. Particle Switching output ferromagnetic (Fe) non-ferromagnetic (nFe) Switching output - ALL.RDY A signal for all ferromagnetic (Fe) particles and all non-ferromagnetic (nFe)
Assembly, installation and commissioning Example: Operation - several particles detected Δt Δt Δt M1/2 Switching logic "active high" Both switching outputs emit a signal when a particle is detected. You can set the duration of the signal Δt between 5 and 200 ms. This value is factory set to 7 ms.
Assembly, installation and commissioning Switching output "Device Ready" When "Device Ready" is set, the buzzer signal of the ferromagnetic and non- ferromagnetic particles is emitted on the switching output S1. The signal indicating that the MCS is ready for use is emitted on the switching output S2.
Assembly, installation and commissioning Parameterizing sensor/reading measured values Connecting MCS 1000 to SMU 1200 The MCS 1000 can be connected to the HYDAC SensorMonitoring Unit SMU 1200. The SMU1200 makes it possible to: set parameters save the MCS measurement data with a time stamp ...
Connecting MCS to CSI-D-5 (Condition Sensor Interface) The CSI-D-5 kit can be used to parameterize the MCS using a PC and to read off online and stored measurement data. Connect the CSI-D-5 kit, HYDAC article no. 3249563, according to the following connection diagram: CSI-D-5 Kit...
Assembly, installation and commissioning Connecting MCS to HMG 3000 You can use the HMG 3000 to set the parameters of the MCS. Connect the HMG 3000 to the MCS in accordance with the following connection diagram. You can find more details in the HMG 3000 operating instructions. Page 56 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Operation Operation Evaluating measurement results The counter readings of the MCS are not comparable with particle concentrations as these are known from optical particle counters per ISO 4406. If the counter reading stays the same, this does not mean that a constant particle concentration is present, but rather the no further particles have been detected.
Operation Menu structure This chapter gives you an overview of the menu structure of the Power Up and Measuring menus. Overview - Power Up Menu Power Up Menu MODE S.TIME SEL.COM ADRESS DEFAULT CANCEL SAVE Page 59 / 80 BeWa MCS1000 3950943b V14x en-us 2018-12-04.docx 2018-12-04...
Operation Overview - Measuring Menu Measuring menu DSPLAY FE A FE B FE C NFE D NFE E NFE F CYC A CYC B CYC C CYC D CYC E CYC F STATUS TEMP C TEMP F SWT.OUT FE.NFE ALL.RDY ALARM SWT.LOG ACT.HI...
Operation PowerUp Menu MODE - select operating mode Function: Adjustment not possible Parameter: None Factory setting: M2 (Measure and switch) S.TIME - Set storing interval Function: After the time interval set, the total number of particles is written to the memory of the MCS. The number of particles within the time intervals can be seen from the parameter DSPLAY - CYC.
Operation Measuring menu DSPLAY - Show measured variable Function: Select the measured variable that is displayed after switching the unit on and after voltage has returned. The measured variables FE A to NFE F show a summation of the particles in the corresponding category.
Operation STATUS: Status byte (00 at status = O.K.) Field strength of the field coil in the MCS TEMP C: Medium temperature in °C (indirect measurement via sensor in the spool) TEMP F: Medium temperature in °F (indirect measurement via sensor in the spool) Factory setting: FE A The value of 1000 µm is shown on the display as 1k.
Operation SWT.PLS - Set pulse length at the switching output Function: Setting the pulse length of the switching outputs Parameter: 5 - 200 milliseconds Factory setting: SWT.TST – Set test pulse at the switching output Function: Function test of the switching outputs Parameter: TYPE FE = switching output 1...
The sensor is maintenance-free. Calibrating the sensor The sensor does not require regular calibrating. Customer Service / Service Use the following shipping address for repairs: HYDAC SERVICE GMBH Friedrichsthaler Straße 15a, Plant 13 66540 Neunkirchen-Heinitz Germany Phone: +49 6897 509 883...
Troubleshooting/fault rectification Troubleshooting/fault rectification Error analysis / remedy Using several supply voltages makes it necessary to define the following terms for error analysis: Description Description Operation voltage Voltage for operating the MCS (electronics, coil system). Measurement Voltage U at switching output 1/2 for superordinate M1/2 voltage controllers.
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Troubleshooting/fault rectification Status Remedy The MCS has not high detected any particles Error at MCS Contact HYDAC The MCS has not detected any particles high Error at MCS Contact HYDAC Reestablish the Error in measurement measurement voltage voltage. The MCS is switched Reestablish the off;...
Perform a reset. Remove the connection cable of the MCS for 10 seconds. Reconnect the connection cable to the MCS. If there is no change in the error status, contact HYDAC. Observe the starting phase of ≈ 70 seconds. Error status 1 "active low"...
Troubleshooting/fault rectification M1/2 Operation voltage ON or OFF Measurement voltage U M1/2 Error status 2 "active low" The signal at the switching output is permanently voltage-carrying. The MCS has not detected any errors. This error occurs also when operation voltage is switched off and measurement voltage is switched on.
Troubleshooting/fault rectification Error status 2 "active high" The signal at the switching output is permanently free of voltage. The MCS has not detected any errors. This error occurs also when external measurement voltage is switched off. Only a superordinate controller can differentiate between this error signal and normal operation without detection of a particle.
Removing / Disposal Removing / Disposal To decommission the unit, proceed as follows: Remove the electric plug. Depressurize the unit. Remove the connected hoses/piping from the sensor. Remove the sensor. Dispose of the packaging material in an environmentally friendly manner. After removing the sensor and separating its various materials, dispose of it in an environmentally friendly manner.
Appendix Appendix In this annex, you will find supplementary information on the product. Spare Parts and Accessories The following spare parts and accessories are available for the sensor. Description p/no. MCS14xx flange adapter set SAE ¾" - G 1/2", comprised of: 1x SAE flange 1x O-ring (NBR) 4x hexagon screw...
Glossary Glossary Ferromagnetic (Fe) A "ferromagnetic" material is one that turns into a magnet through the influence of an external magnetic field. Examples are iron, cobalt, and nickel, which have this property at room temperature. These materials differ in their residual magnetism (remanence) after being removed from the magnetic field.
Glossary Basics of GL certification - The Guideline for the Certification of Condition Monitoring Systems (CMS) for Wind Turbines, Edition 2007. This guideline states that the sensors must be able to distinguish between ferromagnetic and non-ferromagnetic particles and that the installation location in the cooling filter circuit is upstream of the filter.
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