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Fluid Condition Sensor
HYDACLab
User Manual
Part No.: 669709
Date: 03.03.08
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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
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
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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
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
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.
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.
for activating warning devices or alarms.
under “Downloads”, “Electronic”, or contact the appropriate
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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
I
Start
Rel.
visc.
Rel.
DC
humidity
Rel.
Status
Temp.
Start
2s
2s
30s
t
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.
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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
sensor monitors the particular fluid properties and adapts itself to the
is only
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Instruction Manual HYDACLab 03.03.2008
6.2 Reset via PLC control
To connect the HYDACLab
switch output as per the diagram below.
to the PLC control a voltage divider must be provided on the PLC
PLC
12 VDC 0.5V
HLB1000
Pin 5
U
PLC
R
1
R
2
Over a period of 8s the HYDACLab
detects a cycle of high-low pulses and resets the sensor.
In normal operating conditions, the level at PIN 5 must be 12 VDC 0.5 V.
+12V DC
1 2 3
8
1s 1s
1s
8s
Once the unit has been reset, the status signal indicates the value 5mA.
7. Electrical Connections
HYDACLab
1
2
3
4
RL
+UB
Signal 1
GND
Signal 2
5
HSI* / Reset (PLC)
Signal 1: PNP switch output
Signal 2: Sequential analogue output (4 .. 20 mA)
PIN 5: HSI channel / reset (PLC)
R
= (UB-5V) / 20mA [k] and R ≤ 500
Lmax
Note:
The load resistance R
resistance of the connection lines.
* HSI = HYDAC Sensor Interface (HYDAC internal communication interface)
is the sum of the internal input resistance of the evaluation unit and the
L
1s
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Instruction Manual HYDACLab 03.03.2008
8. Technical Data
Operating Conditions
Relative humidity 0 .. 100 % of saturated concentration
Temperature –25°C .. + 100°C
Viscosity 1 cSt .. 1,000 cSt
Dielectric constant (εR) 1.5 .. 10
Operating pressure < 50 bar
Pressure resistance 600 bar
Fluid flow velocity < 5 m/s
Output data – Humidity measurement
Output signal 4 mA to 20 mA (corresponds to 0 .. 100 %)
Calibration accuracy
Accuracy for measurements in media
Output data – Temperature measurement
Output signal 4 .. 20 mA ( corresponds to – 25 .. + 100°C)
Accuracy
Output data – Relative change in viscosity and dielectric constant (εR)
Output signal 12 mA ± 8 mA (corresponds to ± 30 % of
Accuracy See below **
Switching Output
Signal 1 (NC) PNP-transistor switching output, 0.5 A max.
Preset warning level SP1, relative humidity
Preset warning level SP1, temperature
Preset warning level SP1, viscosity ± 10 % (temperature compensated)
Preset warning level SP1, dielectric constant ± 15 % (temperature compensated)
Ambient Conditions
Nominal temperature range +20 .. +80 °C
Storage temperature -40 .. +90 °C
Fluid compatibility HLP mineral oils (HLP-D on request)
-mark
Protection class to DIN 40050 IP 67
Other Data
Supply voltage (UB) 10 VDC to 36 VDC
Supply voltage ripple
Mechanical fitting G ¾ screw thread to DIN 3852 E
Torque value 30 Nm
Electrical connection
Reverse polarity and short circuit protection Provided
Housing material Stainless steel
Weight Approx. 205 g
“FS” (full scale) refers to the full dynamic range; “IV” refers to “initial value.”
* The best accuracy achievable when measuring relative humidity is strongly dependent upon the type of fluid or fluid
additive(s) involved. More precise information on this is available on request.
** The measurement accuracy of relative changes in viscosity and in dielectric constant vary according to the
application, the types of fluids involved, and the sensor’s own calibration. More detailed information on this is
available on request.
± 2 % of FS max.
± 3 % of FS (typical) *
± 3 % of FS max.
IV)
current draw; switching level: (U
B
85 %
80 °C
Esters: HEES, HETG
Seals: FPM.
EN 61000-6-1, EN 61000-6-2,
EN 61000-6-3, and EN 61000-6-4
5 %
5-pin, M12x1 male
– 4 V)
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Instruction Manual HYDACLab 03.03.2008
9. Ordering Information
HLB 1 0 0 8 - 1 C - 00X - F 1
Serial number, factory set
Type of connection, mechanical
0 = G 3/4 A DIN 3852
Type of connection, electrical
8 = M12X1, 5 pole (mating connector not supplied)
Type of signal, output 1
1 = NC switching signal
Type of signal, output 2
C = analogue output 4 .. 20 mA, for output to a 3-conductor line
Modification number
000 = standard (pre-set, fixed)
001 = programmable
Seal material (parts in contact with the fluid)
F = FPM seal
Material of connection (parts in contact with the fluid)
1 = stainless steel
10. Dimensions
ppliance plug
5 pole, M12x1
Hex AF 32
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Assume 9.9 mm for flow
diameter of G-1/2 adapter.
Flow rate 8 - 29 liter/min
Instruction Manual HYDACLab 03.03.2008
11. Accessories
11.1 Mechanical
ZBM 21 (Flow)
Adapter to connect the HYDACLab fluid condition sensor in a G 1/2” line,
suitable for flow rates > 8 l/min
Part no.: 3244260
HYDACLab
ZBM 23 (Low Flow)
Adapter to connect the HYDACLab fluid condition sensor in a G 1/4” line,
suitable for flow rates of 1 ... 10 l/min
Part no.: 3299331
ZBM 24 (ISO cover for HLB 1000)
Protective cover to minimise the effects of ambient temperature, recommended when ambient
temperatures fluctuate vigorously.
Part no.: 3363862
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Instruction Manual HYDACLab 03.03.2008
11.2 Electrical
ZBE 08 (5 pole)
Connector M12x1, right-angled
Part no.: 6006786
ZBE 08-02 (5-pole) with 2m cable
Farbkennung:
Part no.:6006792
ZBE 08-05 (5 pole) with 5m cable
Part no.:6006791
ZBE 08S-02 (5 pole)
with 2m screened cable
Part no.:6019455
ZBE 08S-05 (5 pole)
with 5m screened cable
Part no.:6019456
ZBE 08S-10 (5 pole)
with 10m screened cable
Part no.:6023102
ZBE 25
Reset adapter
Part no.:909695
ZBE 26
Y adapter (blue) for HLB
Part no.: 3304374
ZBE 36
Adapter AS / HLB - HMG 3000
Part no.: 909737
ZBE 30-02
Sensor cable M12x1, 2m
Part no.: 6040851
ZBE 30-05
Sensor cable M12x1, 5m
Part no.: 6040852
Colour
coding:
Pin 1: braun
Pin 1: Brown
Pin 2: wei
Pin 2: White
Pin 3: blau
Pin 3: Blue
Pin 4: schwarz
Pin 4: Black
Pin 5: grau
Pin 5: Grey
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12. Display Units
12.1 HDA 5500-0-2-zC-006
The HDA 5500, modification no. 006, is a display unit with 4
programmable switching outputs, which have been specially
designed for use with HYDACLab
It is possible to display the actual measured values using the
HDA 5500.
Part no.: 909926 HDA5500-0-2-DC-006(CM1k)
Connecting to a HDA 5500
X1: Pin 1: + supply HDA 5500
X1: Pin 2: - supply HDA 5500
X1: Pin 1: +12V supply HYDACLab (brown)
X1: Pin 2: GND HYDACLab (blue)
X2: Pin 7: Analogue output HYDACLab (black)
X2: Pin 11: NC (white)
12.2 HMG 510
Portable 2-channel digital recorder, specially designed for use with HSI and SMART sensors.
It is possible to display the actual measured values on the HMG 510 display.
Part no.: 909889 HMG 510-000
Connecting to a HMG 510
Remove the supply cable from the electrical connection of the HYDACLab
blue Y adaptor for HLB "ZBE 26" to the sensor. Reconnect the supply cable to connection A of
the Y adapter and connect connection B using a sensor cable ZBE 30-0z to input A or B of the
HMG 510.
sensors.
and screw the
+Ub
B A
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Instruction Manual HYDACLab 03.03.2008
12.3 HMG 3000
Portable data recorder with a colour display with full graphics capability to display or record
measured values from the HYDACLab
displayed as a curve and archived. In addition, the HMG 3000 can be used to change the
parameters and reset the HYDACLab.
With the HMG 3000, the actual measured values and the stored measurement curves can be
shown on the HMG 3000 display. The recordings can also be stored and processed on the
HMG 3000 (for a detailed description, see the Operating Manual for the HMG 3000).
Part no.: 909437
HMG 3000-000-E (without accessories)
Connecting to a HMG 3000
Remove the supply cable from the electrical connection of the HYDACLab and screw the
blue Y adapter "ZBE 26" to the sensor.
Connect one of the inputs A to D of the HMG 3000 to connection B of the blue Y adapter
"ZBE 26", using a sensor cable "ZBE 30-0z"
Connect the supply cable to connection A of the blue Y adapter "ZBE 26".
12.4 CMWIN
This is specially developed PC software which communicates with the HYDACLab
communications bridge (HMG 510 or
can be transferred to the PC, stored, displayed and processed or the actual measured values
can be displayed. For HYDACLab
sensor (see Section 13).
CMWIN is supplied with the HMG 510 and HMG 3000.
. The stored data of the HYDACLab can be read out,
+ Ub
via a
HMG 3000). Using this software, measurement curves
modification no. 001 it is also possible to configure the
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13. Functionality of the HYDACLab HLB 1008-1C-001-F1 (programmable)
additional to that of the standard model
In addition to the standard functions it is possible to configure the HYDACLab
001 under menu point "Sensor dialogue" with the aid of the HMG 3000 and the PC software
CMWIN.
The following menu guide applies, and is identical in both HMG 3000 and in the PC-Software
CMWIN:
Main menu
Reset sensor
Analogue output
,
modification no.
Output 1
Switching output
Analogue output
Output 2
Switching output
Restart system
13.1 Main Menu
The HYDACLab
supports German, English and French. It is possible to make the following
settings on the sensor via the main menu:
Reset the sensor (Reset via the software):
Reset sensor to start a new referencing phase
Output 1:
Configure output 1 as analogue or switching output
Output 2:
Configure output 2 as analogue or switching output
Restart system:
Re-start the sensor (software reset of the microcontroller)
Trend
Sequence
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13.1.1 Reset sensor (Reset function)
In the sub-menu "Reset sensor", if you confirm with "OK", the sensor will be reset to its
initial state (see Section 6 "Reset function"). Any stored data, including the referencing
phase, will be completely deleted; the settings for the analogue or switching outputs are
retained. An error message will appear which can be ignored. If you press "Cancel" you
return to the main menu without resetting the sensor.
13.1.2 Output 1
This menu point branches out to a menu in which output 1 can be configured as a
switching or analogue output. In addition a link can be set up between the switching output
and the trend.
Analogue output
Here you can set the display variables, and the type of analogue output can be configured
as current output (4 .. 20mA) or voltage output (0 .. 10V).
Possible display variables:
- Temperature Display range: -25°C ... +100°C
- Viscosity Display range: -30% ... +30%
- Dielectric Constant Display range: -30% ... +30%
- Relative humidity Display range: 0% ... 100%
- Status Display range: 0 ... 64
By pressing "Ok" the changed data is saved in the sensor. By pressing "Cancel" the data
is discarded and you return to the previous menu.
Switching output
Here you can set the variables to be monitored and the values and switching direction
(NC, NO).
In the display panel you can select which of the following variables within their limits will be
monitored with the switching output:
- Temperature Monitoring range: -25°C ... +100°C
- Viscosity Monitoring range: -30% ... +30%
- Dielectric Constant Monitoring range: -30% ... +30%
- Relative humidity Monitoring range: 0%. ... 100%
In the "switch on point“ box, indicate the value at which the output will switch on when
the pre-set variable is exceeded.
In the "switch off point" box, indicate the value at which the output will switch off when
the pre-set variable is exceeded.
Use "switching direction“ to determine whether the output GND switches to the value of
the supply voltage U
(NO function) or it switches from the value of the supply voltage Ub
b
to GND (NC function).
By pressing "Ok" the changed data is saved in the sensor. By pressing "Cancel" the data
is discarded and you return to the previous menu.
Trend
A special feature is the link between the switching output and the trend. Here the switching
output switches when the pre-set variables are exceeded in either direction. The following
values are pre-set, but can be changed in the sub-menu "Trend":
- Temperature: Switch on point: >80°C Switch-off point: <80°C
- Viscosity: Switch on point: 10% Switch-off point: 8%
- Dielectric Constant: Switch on point: 15% Switch-off point: 10%
- Rel. humidity: Switch on point: >85% Switch-off point: <85%
Switching direction: NO or NC contact
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13.1.3 Output 2
At this menu point, output 2 can be configured as a switching or analogue output. In
addition it is possible to read out all measured variables sequentially using the analogue
output.
Analogue output
See description of the analogue output for output 1.
Switching output
See description of the analogue output for output 1.
Sequence output
With analogue output 2 it is possible to output the variables for temperature, relative
change in viscosity, relative change in dielectric constant (DC), relative humidity and the
status of the sensor sequentially. For this, under the "Sequence" menu, output 2 is
configured as current or voltage output. Press the "Activate" button to activate or
deactivate the sequence output. Press the "Ok" button to save the changed data in the
sensor and then return to the main menu. Press the "Cancel" button to discard the entries
and return to the menu of analogue output 2 (for more detailed explanation of the readout
of sequential analogue output, see Section 4.2).
13.1.4 Restarting the System
Under this menu point, the sensor is forced to restart after every change in sensor
parameter. Only then will all the changed settings for analogue and switching outputs be
adopted.
The stored data including the referencing phase are retained during a system restart.
Press "Ok" to carry out a restart. Press "Cancel" to return to the main menu. The error
message which appears can be ignored. After approx. 2 seconds you can return to the
main menu after pressing "Cancel".
14. Items supplied
1 HYDACLab
1 Operating Manual
Sensor
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Instruction Manual HYDACLab 03.03.2008
15. Important tips at a glance
For hydraulic applications, we recommend that the sensor is fitted in a vertical position with the
electrical connector pointing downwards.
When installing the sensor, ensure that it is totally immersed in the fluid and that the fluid can
circulate freely through the sensor.
Ensure there is constant flow and prevent the formation of air bubbles. With standing oil,
variations in measurement may increase.
In principle the HYDACLab
In other words, disconnect the HYDACLab
system is switched off, stops operating or if the flow is interrupted for a significant period.
Ensure that the operating conditions are typical during the referencing phase (learning phase)
i.e. the whole range of conditions relevant to operation are included.
The start of the learning phase begins as soon as the HYDACLab
supply, and as soon as the temperature exceeds 25°C for the first time.
must only be supplied with voltage if full flow is guaranteed.
from the supply voltage as soon as the
is connected to the voltage
During the referencing phase, avoid mixing fluids and ageing fluids.
In the event of oil change or serious alteration in the ambient conditions, the unit should be
reset
When installing without the mounting block ZBM 21 or ZBM 23 make particularly sure
that the flow of fluid is not impaired by the installation. A minimum distance of 10 mm
must be maintained between the front end of the sensor head and the opposite
pipe/housing wall.
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Instruction Manual HYDACLab 03.03.2008
HYDAC ELECTRONIC GMBH
Hauptstr. 27
D-66128 Saarbrücken
Germany
Web: www.hydac.com
E-Mail: electronic@hydac.com
Tel.: +49 (0)6897 509-01
Fax.: +49 (0)6897 509-1726
HYDAC Service
For enquiries about repairs, please contact HYDAC Service.
HYDAC SERVICE GMBH
Hauptstr. 27
D-66128 Saarbrücken
Germany
Tel.: +49 (0)6897 509-1936
Fax.: +49 (0)6897 509-1933
Note:
The information in this manual relates to the operating conditions and applications
described. For applications or operating conditions not described, please contact the
relevant technical department.
If you have any technical queries, comments or if there is a cause for complaint, please
contact your nearest HYDAC representative.
Subject to technical modifications.
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