HYDAC HLB 1400 User Manual

Fluid Condition Sensor

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HYDACLab

User Manual

Part No.: 669709

Date: 03.03.08

Instruction Manual HYDACLab 03.03.2008

CONTENTS

1. Introduction ................................................................................................................................... 3

2. Safety instructions......................................................................................................................... 3

3. Installation..................................................................................................................................... 3

4. Functions ...................................................................................................................................... 4

4.1 Switching output (Standard Modification 000) ......................................................................... 4

4.2 Analogue Output...................................................................................................................... 5

5. Sensor Startup .............................................................................................................................. 6

6. Reset Function.............................................................................................................................. 6

6.1 Reset using Reset Adapter...................................................................................................... 6

6.2 Reset via PLC control .............................................................................................................. 7

7. Electrical Connections .................................................................................................................. 7

8. Technical Data .............................................................................................................................. 8

9. Ordering Information ..................................................................................................................... 9

10. Dimensions ................................................................................................................................. 9

11. Accessories............................................................................................................................... 10

11.1 Mechanical........................................................................................................................... 10

11.2 Electrical .............................................................................................................................. 11

12. Display Units ............................................................................................................................. 12

12.1 HDA 5500-0-2-zC-006 ......................................................................................................... 12

12.2 HMG 510 ............................................................................................................................. 12

12.3 HMG 3000 ........................................................................................................................... 13

12.4 CMWIN ................................................................................................................................ 13

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13. Functionality of the HYDACLab

the standard model ......................................................................................................................... 14

13.1 Main Menu........................................................................................................................... 14

HLB 1008-1C-001-F1 (programmable) additional to that of

13.1.1 Reset sensor (Reset function)....................................................................................... 15

13.1.2 Output 1......................................................................................................................... 15

13.1.3 Output 2......................................................................................................................... 16

13.1.4 Restarting the System ................................................................................................... 16

14. Items supplied........................................................................................................................... 16

15. Important tips at a glance.......................................................................................................... 17

Instruction Manual HYDACLab 03.03.2008

1. Introduction

If you have any questions regarding the technical data or suitability of the product for your applications, please contact our Technical Sales Dept. HYDACLab individually calibrated on computerized testing stations and subjected to final testing and operate perfectly when used according to the specifications (see Section 8. “Technical Data”).

If any problems should nevertheless, arise, please contact HYDAC Service. Unauthorized interference with the equipment will invalidate all warranty claims.

2. Safety instructions

The Fluid Condition Sensor HYDACLab presents no safety concerns when 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 note the following safety instructions:

 Before commissioning, check that the unit is in perfect condition.  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 HYDACLab

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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 our customer service department

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. It is recommended that the sensor is mounted vertically with the electrical connector pointing downwards. When fitting, ensure that the sensor is completely submerged in the fluid and that the fluid can circulate freely around the sensor. HYDAC ELECTRONIC provides appropriate installation accessories for installing the HYDACLab (see Section 11.1, Accessories, Mechanical). The electrical connection must be carried out by a qualified electrician according to the relevant regulations of the country concerned (VDE 0100 in Germany). HYDACLab

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Sensors carry the CE mark. A certificate of conformity will be provided on request.

EMC standards: EN 61000-6-1, EN 61000-6-2, EN 61000-6-3 and EN 61000-6-4 have all been met. However, the stipulations of those standards will be met only if the sensor’s housing has been correctly earthed by a qualified electrician. When fitted into a hydraulic block, it is sufficient if the block is earthed via the hydraulic system. Additional installation instructions that, from experience, reduce the effect of electromagnetic interference are:

 Keep line connections as short as possible.  Use screened wires, such as LIYCY 5 x 0.5 mm², only.  The cable screening must be fitted by qualified personnel subject to the ambient conditions and

with the aim of suppressing interference.

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Keep the unit well away from the electrical supply of power equipment, as well as from

any electrical or electronic equipment causing interference.

sensors have been

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Instruction Manual HYDACLab 03.03.2008

4. Functions

HYDACLab sensors are compact, multi-functional sensors for determining the condition of fluids online. Operators are kept informed of changes in fluid condition as they occur and can immediately change the operating conditions accordingly.

Changes in fluid condition that might occur due to ageing or mixing with other fluids, for example, are indicated by measuring temperature, relative humidity and relative changes in viscosity and dielectric constant (also referred to as DC).

Those measurements are available as analogue signals and/or switching signals at the electrical output of the HYDACLab For information on further readout possibilities (e.g. modular connection to a PLC control), please see our website http://www.hydac.com HYDAC agent.

4.1 Switching output (Standard Modification 000)

The NC switching output acts as a warning signal triggered by critical changes in the fluid condition. The switching output will switch whenever any of the following changes in measured values occurs (the values stated are the standard factory settings):

Relative change in viscosity  10 % (temperature compensated) Relative change in dielectric constant  15 % (temperature compensated) Relative humidity  85 % Temperature  80 °C

To activate the switching output the relative changes in viscosity and dielectric constant are evaluated mathematically. It is therefore possible that the analogue values at the point of switching will differ from the switching thresholds given above.

If, as a result of part-filling or re-filling the system, the values for the relative change in viscosity return permanently to a window of  8 % or for the relative change in dielectric constant to a window of  10 %, the switching output is deactivated again.

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for activating warning devices or alarms.

under “Downloads”, “Electronic”, or contact the appropriate

Instruction Manual HYDACLab 03.03.2008

4.2 Analogue Output

Analogue output signals representing measured values are output sequentially to Pin 4, when synchronization with the controller interfaced to the sensor is required.

The sequencing of the signals involved is as shown in the diagram below:

20mA

4mA

Start

Rel.

visc.

Rel.

humidity

Rel.

Status

Temp.

Start

30s

All signals output to the analog output are 4 .. 20 mA current-loop signals, sequenced

and spaced as follows Output signal Duration Start signal: 20 mA 2 s

______________________________________________ Pause (4 mA) 2 s Signal 1: Relative change in viscosity -30% ... +30% 2 s Pause (4 mA) 2 s Signal 2: Relative change in dielectric constant -30% ... +30% 2 s Pause (4 mA) 2 s Signal 3: Relative humidity 0% ... +100% 2 s Pause (4 mA) 2 s Signal 4: Temperature -25°C... +100°C 2 s Pause (4 mA) 2 s Signal 5: Status signal See table below for levels 2 s Pause before next output cycle: 4 mA 30 s

Explanation of status signal:

Status Status signal

(mA)

Referencing phase 5

Operating phase 7

Fluid condition out of range

Internal error

9 or 11

 13

Note: Due to possible tolerances, we recommend setting the threshold in the evaluation electronics approx. 0.25 mA below the

ideal value given in the table.

Instruction Manual HYDACLab 03.03.2008

5. Sensor Startup

HYDACLab sensors start storing data as soon as they have been connected to the supply voltage and fluid temperature has exceeded 25°C for the first time. The output signals for temperature and relative humidity are available immediately following sensor startup. The output signals for relative changes in viscosity and in dielectric constant are set to 12 mA during the referencing phase.

During the referencing phase (duration of data collection is around 100 hours in the valid operating range), the HYDACLab conditions in the given application. It is therefore essential that typical operating conditions, particularly all relevant temperature ranges, are run through during the referencing phase. Termination of the referencing phase will be evident from the signal level of the Status Signal 5 (see Point 4.2).

During the referencing phase, the operator must ensure therefore that the HYDACLab supplied with voltage if the operating conditions in the machine/system are normal. (For example the supply voltage of the sensor can be linked to the pump operation.)

The sensor should be reset if, after the machine/system is part-filled or re-filled, the analogue values for the relative change in viscosity do not fall within a window of  3 % or for the relative change in dielectric constant, within a window of  5 %. This can be caused partly by obvious variations in oil characteristics in different oil batches.

6. Reset Function

With Reset, the entire contents of the memory including the referencing phase is deleted. The sensor begins a new referencing phase once the voltage supply is re-connected and once the fluid temperature of 25 °C is exceeded for the first time. All parameter settings remain unchanged in the sensor. A reset can be carried out in different ways:

6.1 Reset using Reset Adapter

For this you will need the HYDAC Reset Adapter ZBE 25, which can be ordered as an

accessory (see Section 11.2, Accessories, Electrical).

Please follow the instructions given below:

 Disconnect the M12x1 connector on the HYDACLab  Fit the reset adaptor to the HYDACLab  Fit the M12x1 connector to the reset adapter  Wait approx. 10 s (the voltage supply must be on during the entire period)  Disconnect the reset adaptor  Reconnect the M12x1 connector

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sensor monitors the particular fluid properties and adapts itself to the

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is only

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