HYDAC AS 1000 User Manual
Aqua Sensor
AS 1000
User Manual
Part no.: 669705
Status: 09.04.2008
User Manual AS 1000 09.04.2008
CONTENTS
1. General......................................................................................................................................... 3
2. Safety instructions......................................................................................................................... 3
3. Installation..................................................................................................................................... 3
4. Function........................................................................................................................................ 4
4.1 Switching output ...................................................................................................................... 4
4.2 Analogue output....................................................................................................................... 4
4.3 Ideal saturation level in hydraulic and lubrication systems...................................................... 5
5. Electrical connection..................................................................................................................... 5
6. Technical specification.................................................................................................................. 6
7. Order details .................................................................................................................................7
8. Dimensions................................................................................................................................... 7
9. Accessories................................................................................................................................... 8
9.1 Electrical..................................................................................................................................8
9.2 Mechanical............................................................................................................................... 8
10. Displays ......................................................................................................................................9
10.1 HDA 5500..............................................................................................................................9
10.2 HMG 510 ............................................................................................................................... 9
10.3 HMG 3000 ........................................................................................................................... 10
10.4 CMWIN................................................................................................................................10
11. Functions of the AS 1x08-P-000 (programmable) over and above the standard version......... 11
11.1 Main menu........................................................................................................................... 11
11.1.1 Output 1 and 2............................................................................................................... 12
11.1.2 System re-start..............................................................................................................12
12. Items supplied........................................................................................................................... 13
13. Important information - quick reference.................................................................................... 13
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User Manual AS 1000 09.04.2008
1. General
If you have any queries regarding technical details or the suitability of the unit for your application,
please contact our technical sales department. The AS 1000 is individually calibrated on
computer-controlled test rigs and subjected to a final test. In this way we can guarantee that the
unit is fault-free on despatch and conforms to the given specifications.
However, if there is a cause for complaint, please return the unit to HYDAC Service outlining the
fault. Interference by anybody other than HYDAC personnel will invalidate all warranty claims.
2. Safety instructions
The Aqua Sensor AS 1000 presents no safety concerns when installed and operated in
accordance with this user manual. However, in order to avoid any risk to the operator or any
damage due to incorrect handling of the unit, please adhere strictly to the following safety
instructions:
• Before commissioning, please read the operating instructions. Ensure that the unit is suitable for
your application.
• During transportation, extra care must be taken to protect the unit from vibration and shock.
• The AS 1000 must not be put into service if any known defects, either electrical or mechanical,
are apparent.
• The unit must be installed exactly according to the instructions.
• Read the information on the type code label.
• Fault investigation and repairs must only be carried out by HYDAC Service.
• All relevant and generally recognised safety requirements must be adhered to.
• If the unit is not handled correctly, or if the operating instructions and specifications are not
adhered to, damage to the product or to personal injury may result.
3. Installation
The sensor can be installed directly in the hydraulic system via the threaded connection. The
recommended mounting position for hydraulic applications is vertical with the mechanical threaded
connection pointing upwards. When fitting, ensure that the sensor is completely submerged in the
fluid and that the fluid can circulate freely around the sensor. It is important, therefore, when tankmounting, to install the sensor in a position where there is guaranteed turbulence.
The electrical connection must be carried out by a qualified electrician according to the relevant
regulations of the country concerned (VDE 0100 in Germany).
The sensors of the AS 1000 series carry the CE mark. A declaration of conformity is available on
request. The sensor conforms to EMC standards: EN 61000-6-1, EN 61000-6-2, EN 61000-6-3
and EN 61000-6-4. The requirements of the standards are fulfilled only if the sensor housing is
earthed correctly by qualified personnel. When installing into a hydraulic block it is sufficient if the
block is earthed via the hydraulic system.
Additional assembly notes which, from experience, reduce the effect of electromagnetic
interference:
Make inline connections as short as possible.
Use screened cables (e.g. LIYCY 5 x 0.5 mm²).
The cable-screening must be fitted by a qualified person subject to the ambient conditions
and with the aim of suppressing interference.
Direct proximity to connecting lines of user units or electrical or electronic units causing
interference must be avoided as far as possible.
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User Manual AS 1000 09.04.2008
4. Function
The Aqua Sensors in the series AS 1000 are water and temperature sensors for the continuous
and accurate online monitoring of hydraulic and lubrication fluids.
They measure the water content relative to the saturation concentration (saturation point) and read
out the degree of saturation in the range 0..100% as a 4..20mA analogue signal. A reading of 0%
would indicate a fluid free of water, whilst 100% would indicate a fluid that is saturated with water.
The capacitance sensor used in the AS 1000 absorbs water molecules from the fluid which results
in a change in capacitance of the sensor element. The measured value obtained represents the
level of saturation of the fluid in percent.
A thermal element on the sensor measures the temperature in the range
-25 ... +100°C. This is read out as a 4...20mA analogue signal, like the saturation level.
Outputs 1 and 2 can be configured independently of each other as switch or analogue outputs.
4.1 Switching output
With switching output 1 or switching output 2 the following variables can be monitored within
their limits:
Saturation level: 0 % ... 100 %
Temperature: -25 °C ... +100 °C
"Switch on point" is used to indicate the value at which the output switches when the pre-set
value is exceeded.
"Switch off point" is used to indicate the value at which the output switches back when the
value falls below its pre-set level.
"Switching direction" is used to determine whether the output, when exceeding the pre-set
value, switches:
a) from GND to U
b) from U
to GND (N/C function)
b
4.2 Analogue output
With analogue output 1 or analogue output 2 the following variables can be displayed within
their limits:
Saturation level: 0 % ... 100 %
Temperature: -25 °C ... +100 °C
The outputs are always configured as current outputs (4 ... 20 mA).
(N/O function)
b
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User Manual AS 1000 09.04.2008
4.3 Ideal saturation level in hydraulic and lubrication systems
Since the effects of free (or emulsified) water are considerably more damaging than
dissolved water, the water content should always be significantly lower than the
saturation point. However, even dissolved water can cause damage,. All reasonable
measures should be taken therefore to keep the level of saturation as low as
possible. Hydraulic and lubrication fluids cannot be "too dry"!
As a guide, we recommend a saturation level of 45% for all systems.
5. Electrical connection
Saturation level
100%
50 %
25 %
75 %
0 %
Free water
Dissolved water
Saturation
point
1
2
3
AS 1000-P
4
5
+U
b
Progr. output 1
GND
Progr. output 2
(do not connect during normal operation!)
HSI
*
R
= (UB-10V) / 20mA [kΩ]
Lmax
1
2
3
AS 1000-C
4
5
+U
b
RL
Signal saturation level
GND
RL
Signal temp.
(do not connect during normal operation!)
HSI
*
* HSI = HYDAC Sensor Interface (HYDAC internal communication interface)
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