Hydac MCS14, MCS15, MCS13 Operation And Installation Manual

Operation and Installation Guide

Documentation no.: 4366964

MCS /-C062
Metallic

Contamination Sensor

English (translation of original instructions)

Valid from hardware index B and
firmware version C09.30 up

Imprint

HYDAC FILTER SYSTEMS GMBH

Industriegebiet

66280 Sulzbach / Saar

Germany

Telephone:

[phone]

Fax:

[phone]

E-mail:

[e-mail]

Homepage:

www.hydac.com

Court of Registration:

Saarbrücken, HRB 17216

Executive director:

Mathias Dieter,
Mr. Günter Harge

c/o HYDAC International GmbH, Industriegebiet, 66280 Sulzbach / Saar

Telephone:

[phone]

Fax:

[phone]

E-mail:

[e-mail]

Imprint

Manufacturer / publisher and responsible for the content:

Dipl.Kfm. Wolfgang Haering

Documentation Representative

© HYDAC FILTER SYSTEMS GMBH

All rights reserved. No part of this work may be reproduced in any form (print,
photocopy or by other means) or processed, duplicated or distributed using
electronic systems without the written consent of the publisher.
These documents have been created and inspected with the greatest care.
However, errors cannot be ruled out completely.

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Content

Content

Imprint ............................................................................................................ 2

Documentation Representative ................................................................... 2

Content .......................................................................................................... 3

Preface ........................................................................................................... 7

Safety Information ........................................................................................ 9

Technical Support ........................................................................................ 7

Modifications to the Product ........................................................................ 7

Warranty ...................................................................................................... 7

Using the documentation ............................................................................. 8

Warning signs used ..................................................................................... 9

Others used symbols ................................................................................... 9

Signal words and their meaning in the general safety information ............. 10

Structure of the safety information and instructions ................................... 10

Observe regulatory information ................................................................. 11

Proper/designated use............................................................................... 11

Improper Use or Use Deviating from Intended Use ................................... 12

Qualifications of personnel / target group .................................................. 13

Transporting the sensor ............................................................................. 14

Storing the sensor ...................................................................................... 14

Decoding the model code label ................................................................. 15

Checking the scope of delivery ................................................................. 16

Scope of delivery for MCS 13xx ................................................................ 16

Scope of delivery for MCS 14xx ................................................................ 17

Scope of delivery for MCS 15xx ................................................................ 18

Sensor features ........................................................................................... 19

Functional principle .................................................................................... 19

Sensor dimensions ..................................................................................... 20

Dimensions MCS 13xx .............................................................................. 20

Dimensions for MCS 13xx with Ethernet module ....................................... 21

Dimensions MCS 13xx with flange adapter set (optional

accessories) .............................................................................................. 22

Dimensions MCS 14xx .............................................................................. 23

Dimensions for MCS 14xx with Ethernet ................................................... 24

Dimensions MCS 14xx with flange adapter set (optional

accessories) .............................................................................................. 25

Dimensions MCS 15xx .............................................................................. 26

Dimensions for MCS 15xx with Ethernet ................................................... 27

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Content

Dimensions MCS 15xx with flange adapter set (optional

accessories) .............................................................................................. 28

Mechanical installation/assembly ............................................................. 29

Connecting MCS13xx / 14xx via flange adapter set .................................. 30

Fastening sensor to underside .................................................................. 31

Fastening MCS 13xx / MCS 14xx .............................................................. 32

Fastening MCS 15xx ................................................................................. 32

Fastening MCS 15xx using angle fastening set ......................................... 33

Connecting MCS 15xx using pipe adapter set ........................................... 33

Connecting MCS 15xx using flange adapter plate (accessory) ................. 34

MCS 15xx via SAE 4" per ISO 6162-1 (4xM16) ......................................... 35

Hydraulic installation of sensor ................................................................. 36

Diagram - flow rate, differential pressure p∆ and viscosity ν .................. 36

Electrical connection of sensor ................................................................. 38

Plug pin assignment .................................................................................. 38

Connection cable - Assignment / Color coding .......................................... 39

Using the switching outputs ...................................................................... 40

Switching output - FE.NFE ........................................................................ 40

Switching output - ALL.RDY (factory setting) ............................................. 40

Switching output - ALARM ......................................................................... 40

Switching logic "active low" ........................................................................ 41

Example: Operation - 1 particle detected ............................................... 41

Example: Operation - no particle detected ............................................. 41

Example: Operation - several particles detected .................................... 42

Switching logic "active high" ...................................................................... 43

Example: Operation - 1 particle detected ............................................... 43

Example: Operation - no particle detected ............................................. 43

Example: Operation - several particles detected .................................... 44

Switching output "Device Ready" .............................................................. 44

Parameterizing sensor/reading measured values .................................... 45

Connecting MCS 1000 to SMU 1200 ......................................................... 45

Connecting MCS to CSI-D-5 (Condition Sensor Interface) ........................ 46

Connecting MCS to HMG 3000 ................................................................. 47

Evaluating measurement results ............................................................... 48

Menu structure ............................................................................................ 49

Overview - Power Up Menu ....................................................................... 49

Overview - Measuring Menu ...................................................................... 50

PowerUp Menu ............................................................................................ 51

MODE - select operating mode ................................................................. 51

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Content

S.TIME - Set storing interval ...................................................................... 51

SEL.COM - Set protocol ............................................................................ 51

ADRESS – Set bus address ...................................................................... 51

DFAULT - Reset to factory setting ............................................................. 51

CANCEL - cancel without saving ............................................................... 51

SAVE - save changes ................................................................................ 51

Measuring menu ......................................................................................... 52

DSPLAY - Show measured variable .......................................................... 52

SWT.OUT – Set the switching output ........................................................ 53

SWT.LOG - Set logic at the switching output ............................................. 54

SWT.PLS - Set pulse length at the switching output ................................. 54

SWT.TST – Set test pulse at the switching output ..................................... 54

ALARM – Setting limit values .................................................................... 55

CANCEL - cancel without saving ............................................................... 55

SAVE - Save changes ............................................................................... 55

Error analysis / remedy .............................................................................. 56

Error status - "active high" and "active low" ............................................... 58

Error status 1 "active low"....................................................................... 58

Error status 1 "active high" ..................................................................... 59

Error status 2 "active low"....................................................................... 60

Error status 2 "active high" ..................................................................... 61

Error status - "Device Ready" .................................................................... 61

Performing maintenance ............................................................................ 62

Decommissioning the sensor .................................................................... 62

Disposing of sensor/packaging material .................................................. 62

Spare Parts and Accessories .................................................................... 63

Channel default settings ............................................................................ 66

Calibrating the sensor ................................................................................ 66

Customer Service/ Service ......................................................................... 66

Technical Data............................................................................................. 67

Detection limits .......................................................................................... 68

Model Code ................................................................................................. 69

EC declaration of conformity ..................................................................... 69

Glossary ...................................................................................................... 70

Ferromagnetic (Fe) .................................................................................... 70

Non-ferromagnetic (nFe) ........................................................................... 70

Certification ................................................................................................ 70

Basics of GL certification ........................................................................ 71

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Content

Germanischer Lloyd Industrial Services GmbH, renewable

energies ..................................................................................................... 71

Index ............................................................................................................ 72

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Preface

Fax:

[phone]

E-mail:

[e-mail]

Preface

This operating manual was made to the best of our knowledge. Nevertheless
and despite the greatest care, it cannot be excluded that mistakes could have
crept in. Therefore please understand that in the absence of any provisions
to the contrary hereinafter our warranty and liability – for any legal reasons
whatsoever – are excluded in respect of the information in these operating
instructions. In particular, we shall not be liable for lost profit or other financial
loss. This exclusion of liability does not apply in cases of intent and gross
negligence. Moreover, it does not apply to defects which have been
deceitfully concealed or whose absence has been guaranteed, nor in cases
of culpable harm to life, physical injury and damage to health. If we
negligently breach any material contractual obligation, our liability shall be
limited to foreseeable damage. Claims due to Product Liability shall remain
unaffected.

Technical Support

Contact our technical sales department if you have any questions on our
product. When contacting us, please always include the model/type
designation, serial no. and part-no. of the product:

Modifications to the Product

We would like to point out that changes to the product (e.g., purchasing
options, etc.) may result in the information in the operating instructions no
longer being completely accurate or sufficient.

After modification or repair work that affects the safety of the product has
been carried out on components, the product may not be returned to
operation until it has been checked and released by a HYDAC technician.

Please notify us immediately of any modifications made to the product
whether by you or a third party.

Warranty

For the warranty provided by us, please refer to the terms of delivery of
HYDAC FILTER SYSTEMS GMBH.

You will find these under www.hydac.com -> Legal information.

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Preface

Note that the method described for locating specific information

these instructions prior to starting the unit up for the first time and

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200x-xx-xx

Chapter description

Page number
Document language

Documentation no.

Using the documentation

does not release you from your responsibility of carefully reading

at regular intervals in the future.

What do I want to know?

I determine which topic I am looking for.

Where can I find the information I’m looking for?

The documentation has a table of contents at the beginning. There, I select
the chapter I'm looking for and the corresponding page number.

Edition date

with index/

file name

The documentation number with its index enables you to order another copy
of the operating and maintenance instructions. The index is incremented
every time the manual is revised or changed.

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Safety Information

Safety Information

The device was built according to the statutory provisions valid at the time of
delivery and satisfies current safety requirements.

Any residual hazards are indicated by safety information and instructions and
are described in the operating instructions.

Observe all safety and warning instructions attached to the unit. They must
always be complete and legible.

Do not operate the unit unless all the safety devices are present.

Secure the hazardous areas which may arise between the unit and other
equipment.

Maintain the unit inspection intervals prescribed by law.

Document the results in an inspection certificate and keep it until the next
inspection.

Warning signs used

These signs are listed for all safety information and instructions in these
operating instructions which indicate particular hazards to persons, property
or the environment.

Others used symbols

The following symbols found you in this operation instructions.

Danger point warning

Dangerous electrical voltage warning

Tip for handling the product

Tools required

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Safety Information

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 – The signal word indicates a hazardous situation with a medium
level of risk,

CAUTION

CAUTION – The signal word indicates a hazardous situation with a low level
of risk, which, if not avoided, can result in minor or moderate injury.

NOTICE

NOTICE – The signal word indicates a hazardous situation with a high level
of risk, which, if not avoided, will result in damage to property.

Signal words and their meaning in the general safety information

In these instructions you will find the following signal words:

which, if not avoided, can result lethal or serious injury.

Structure of the safety information and instructions

All warning instructions in this manual are highlighted with pictograms and
signal words. The pictogram and the signal word indicate the severity of the
danger.

Warning instructions listed before an activity are laid out as follows:

HAZARD SYMBOL

SIGNAL WORD

Type and source of danger

Consequence of the danger

► Measures to avert danger

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Safety Information

Observe regulatory information

Observe the following regulatory information and guidelines:

• Legal and local regulations for accident prevention

• Legal and local regulations for environmental protection

• Country-specific regulations, organization-specific regulations

Proper/designated use

Only use the sensor for the application described in the following.

The MetallicContamination Sensor MCS is used for the constant monitoring
of particulate contamination in hydraulic and lubrication systems.

Proper or designated use of the product extends to the following:

• observing all instructions contained in the instruction manual.

• Only using with the permissible media.

• Operation within permissible technical conditions, such as operating

pressure, flow rate, media and ambient temperature.

The sensor is only to be used with the following media:

NOTICE

Impermissible operating media/conditions

The sensor will be damaged

► Use the sensor only in conjunction with mineral and synthetic oils

(for example: poly-alpha-olefins PAO and polyglycol, as used in the
wind energy industry).

► Note that the media used must be permanently compatible with the

MCS sealing material.

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Safety Information

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. The user alone, shall assume any and
all associated risk.

Improper use or use deviating from intended may result in hazards and/or will
damage the sensor. Examples of improper use:

• Operation with a non-approved medium.

• Operation under impermissible operating conditions.

• Modifications to the sensor made by the user or purchaser.

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Safety Information

Activity

Person

Knowledge

Transport / storage

Forwarding

• No specialist knowledge

Hydraulic / electrical

Specialist

• Safe handling/use of tools

Operation

Specialist

• Product-specific knowledge

Disposal

Specialist

• Knowledge about reuse

Qualifications of personnel / target group

Persons who work on the sensor must be aware of the associated hazards
when using it.

Auxiliary and specialist personnel must have read and understood the
operating instructions, in particular the safety information and instructions,
and applicable regulations before beginning work.

The operating instructions and applicable regulations are to kept so they are
accessible for operating and specialist personnel.

These operating instructions are intended for:

Auxiliary personnel: such persons have been instructed about the sensor
and are aware of potential hazards due to improper use.

Specialist personnel: such persons with corresponding specialist training
and several years' work experience. They are able to assess and perform the
work assigned to them, they are also able to recognize potential hazards.

installation,

First commissioning,

Maintenance,

Troubleshooting,

Repair,

decommissioning,

Disassembly

Operations control

agent

Auxiliary
personnel

personnel

personnel

personnel

required

• Fitting and connection of
hydraulic tubes and
connections

• Fitting and connection of
electrical lines, electrical
machinery, sockets, etc.

• Product-specific knowledge

• Knowledge about how to

handle operating media.

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Transporting the sensor

Transporting the sensor

Transport the sensor upright or on its side, and in the included packaging if
possible. Make sure the connection plug will not be subjected to any
mechanical strain or impact.

Unsafe transport

The connection plug will be damaged

► Transport the sensor in its original packaging.

► Secure the sensor during transport.

NOTICE

Storing the sensor

Store the sensor in a clean, dry place, in the original packing, if possible. Do
not remove the packing until you are ready to install the unit.

For storage conditions, refer to the chapter "Technical Data" on page 67.

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Decoding the model code label

Row

Definition

Description

1

Model

Model according to model code,

2

P/N

p/no.

3

S/N

Serial-no.

4

Date

Year/week of production

5

Index

Hardware index

6

Max. INLET press

Maximum operating pressure

Decoding the model code 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.

for details, see page 69.

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Checking the scope of delivery

Qty

Designation

1

MetallicContamination Sensor, MCS 13xx

1

O-ring (18.7 x 3.53 NBR 70 Shore)

1

Operation and Installation Guide (this document)

Checking the scope of delivery

The scope of delivery for the available sizes varies. Below is the scope of
delivery for each size.

Scope of delivery for MCS 13xx

The MetallicContamination Sensor MCS 13xx comes packed and factory­assembled. Before commissioning the sensor, please check no items are
missing from the package.

The following items are supplied:

EC declaration of conformity

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Checking the scope of delivery

Qty

Designation

1

MetallicContamination Sensor, MCS 14xx

1

O-ring (25 x 3.53 NBR 70 Shore)

1

Operation and Installation Guide (this document)

Scope of delivery for MCS 14xx

The MetallicContamination Sensor MCS 14xx comes packed and factory­assembled. Before commissioning the sensor, please check no items are
missing from the package.

The following items are supplied:

EC declaration of conformity

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Checking the scope of delivery

Qty

Designation

1

MetallicContamination Sensor, MCS 15xx

1

O-ring (47.22 x 3.53 NBR 70 Shore)

1

O-ring (110.72 x 3.53 NBR 70 Shore)

1

Operation and Installation Guide (this document)

Scope of delivery for MCS 15xx

The MetallicContamination Sensor MCS 15xx comes packed and factory­assembled. Before commissioning the sensor, please check no items are
missing from the package.

The following items are supplied:

EC declaration of conformity

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Sensor features

Sensor features

The MetallicContamination Sensor MCS is a stationary sensor for continuous
monitoring of contamination of fluids – especially lubrication fluids – with
metallic particles.

With appropriate system knowledge of the monitored system, damage
resulting in detectable metallic particles can be discovered early.

The MCS uses digital signal processing to distinguish between ferromagnetic
(Fe) and non-ferromagnetic (nFe) particles.

Particle results are signaled via two switching outputs. In the factory setting
(default values), the ferromagnetic (Fe) particles are output via the first
switching output and the non-ferromagnetic (nFe) particles via the second
switching output. It is possible to make a switch in the menu so that the first
switching output is used for the total particles (Fe and nFe) and second
switch output is used as a "device ready signal". (For this, see also the
chapter Using switching output.)

In addition, the MCS has serial communication interfaces with which
connection to superordinate monitoring systems is possible.

The MCS is intended for incorporation in low-pressure circuits and test
benches.

Functional principle

Within the sensor, a high-frequency magnetic field is generated using a coil
system. Two sensor pulses measure changes in the field strength and output
certain signals as described below.

• A ferromagnetic (Fe) particle, the field strength increases depending
on the size of the particle.

• A non-ferromagnetic (nFe) particle, the field strength decreases
depending on the size of the particle.

• If a prespecified limit is exceeded, a particle event is signaled.

• The MCS is able to implement variable adjustments to the defined limit

in order to avoid faulty particle counter results. This makes it possible
to suppress the results for Dimension A and D temporarily (Noise
Suppression) in the event of a very strongly fluctuating field strength
(e.g. following excessive air intake into the system).

The output signal at the switching output is always the same and provides no
information about the size of the particle.

Using the serial interfaces (RS 485 or HSI) makes it possible to evaluate
appropriate particle size classes.

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Sensor dimensions

All dimensions in mm.

Sensor dimensions

The dimensions for the available sizes vary. The dimensions for each size
can be found below.

Dimensions MCS 13xx

Flange image SAE 1/2"

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Sensor dimensions

All dimensions in mm.

Dimensions for MCS 13xx with Ethernet module

Flange image SAE 1/2"

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Sensor dimensions

All dimensions in mm.

Dimensions MCS 13xx with flange adapter set (optional accessories)

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Sensor dimensions

All dimensions in mm.

Dimensions MCS 14xx

Flange image SAE 3/4"

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