Aqua Sensor AS 1000
Contents
1. M12x1 5 pole connection IN User Manual AS 1000 09 04 2008 9 Accessories 9 1 Electrical ZBE 08 5 pole Connector M12x1 right angle Order no 6006786 ZBE 08 02 5 pole with 2m cable Order no 6006792 ZBE 08 05 5 pole with 5m cable Colour code Order no 6006791 Pin 1 brown ZBE 08S 02 5 pole Pin 2 white with 2m screened cable Pin 3 blue Order no 6019455 eee Pin 5 grey ZBE 08S 05 5 pole with 5m screened cable Order no 6019456 ZBE 08S 10 5 pole with 10m screened cable Order no 6023102 ZBE 36 Adaptor AS HLB HMG 3000 Order no 909737 ZBE 30 02 Sensor cable M12x1 2m Order no 6040851 ZBE 30 05 Sensor cable M12x1 5m Order no 6040852 9 2 Mechanical _ L ZBM 22 Adapter for connecting to a G1 2 line Order no 3248511 G1 2 User Manual AS 1000 09 04 2008 10 Displays 10 1 HDA 5500 r i The HDA 5500 version HDA 5500 1 1 AC 000 or HDA 5500 1 1 f DC 000 is a display unit with 4 programmable switch outputs e specially designed for use with the AS 1000 In conjunction with the HDA 5500 it is possible to display the actual measured values Order no 908869 HDA 5500 1 1 AC 000 Order no 908870 HDA 5500 1 1 DC 000 Connection to a HDA 5500 X1 Pin 1 supply HDA 5500 X1 Pin 2 supply HDA 5500 X2 Pin 5 GND AS 1000 blue X2 Pin 6 12V supply AS 1000 b2. 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 tank mounting 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
3. Pin 2 analogue output 1 switch output 1 Pin 3 OV GND Pin 4 analogue output 2 switch output 2 Pin 5 HSI Reverse polarity protection of the supply voltage excess voltage override and short circuit protection Weight Note 09 04 2008 0 100 25 100 C max 50 bar max 630 bar Stainless steel Viton or EPDM seal ceramic with vapour deposited metal 4 20mA lt 2 FS max lt 3 FS typ 0 025 FS bar 4 20mA lt 2 FS max PNP switch output 1 A max lt Up 0 90 40 100 C 40 125 C 1 5000 cSt lt 5m s Mineral oil based fluids synthetic and natural esters EN 61000 6 1 EN 61000 6 2 EN 61000 6 3 EN 61000 6 4 IP 67 12 32 V DC lt 5 G3 8A DIN 3852 approx 25 Nm M12x1 5 pole Provided approx 145g FS Full Scale relative to the full measuring range User Manual AS 1000 09 04 2008 7 Order details AS 1X08 X 000 Series 1 Series 1000 Medium 0 Mineral oils 1 Phosphate ester Type of connection mechanical O G 3 8A DIN 3852 Type of connection electrical 8 M12x1 5 pole without connector Signal technology C output 1 Pin 2 saturation level 4 20 mA output 2 Pin 4 temperature 4 20 mA P output 1 programmable output 2 programmable Modification number 000 standard 8 Dimensions orgezg Ee A j pra 30 67 1 i o hex AF27
4. into a menu in which outputs 1 and 2 can be configured independently of the other as either analogue or switching output e Analogue output Here you can set the display parameters The outputs are always configured as current outputs 4 20 mA Possible display parameters e Saturation level Display range 0 100 e Temperature Display range 25 100 C Ok is used to write back the changed data into the sensor Cancel is used to discard the data and to return to the previous menu e Switching output This is used to set the parameters which are to be monitored as well as the values of the switch on and switch off points and the switch direction N C N O In the display area you can select which of the following parameters are to be monitored within their limits using the switch output e Saturation level Display range 0 100 e Temperature Display range 25 100 C In the Switch on point box the value is displayed at which the output switches when the pre set parameter is exceeded In the Switch off point box the value is displayed at which the output switches back once the value falls below the pre set parameter Switch direction is used to determine whether the output switches from GND to the value of the supply voltage Vs N O function or switches from the value of the supply voltage Vs to GND N C function Ok is used to write back the changed data to the sensor Cancel is used to discard
5. 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 mm 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 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
6. out as a 4 20mMA 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 N O function b from U to GND N C function 4 2 Analogue output With analogue output 1 or analogue output 2 the following variables can be displayed within their limits Saturation level O 100 Temperature 25 C 100 C The outputs are always configured as current outputs 4 20 mA 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 pos
7. voltage supply for the sensor is via the measuring unit 10 4 CMWIN Specially developed PC software which communicates via a communication bridge HMG 510 or HMG 3000 with the AS 1000 Using the software measurement curves can be transferred to your PC saved displayed and edited or the actual measured values can be displayed With the AS 1000 P version it is also possible to configure the sensor according to individual requirements CMWIN is supplied with the HMG 510 and HMG 3000 User Manual AS 1000 11 Functions of the AS 1x08 P 000 programmable over and above the standard version In addition to the standard functions it is possible to configure the AS 1000 P version using the HMG 3000 and the PC software CMWIN under the menu point Sensor dialogue The following menu navigation applies in this case and is identical in both the HMG 3000 and in the PC software CMWIN Main menu Analogue output 1 Output 1 Switching output 1 Analogue output 2 Switching output 2 Output 2 System re start 11 1 Main menu The AS 1000 supports German English and French Use the main menu to access the following setup options of the sensor Configuration of output 1 as analogue or switching output Configuration of output 2 as analogue or switching output System re start Re start of the sensor User Manual AS 1000 09 04 2008 11 1 1 Output 1 and 2 Each of the two menu points subdivides
8. G s ELECTRONIC Aqua Sensor AS 1000 User Manual Part no 669705 Status 09 04 2008 User Manual AS 1000 09 04 2008 CONTENTS EAE ie RR RR festa ee RIR DEDE ERRO T COR E DDR RED A EA TE RE E 3 2 FOAICLY INST UCUON S rasa bia sb caniaeoi nate a ataca dias Gli d E ug E 3 SAS CAN ais saia daN SD eal a ar ea 3 A PUNHO aque icadoa sos Dao a RD Ra Sano 4 AONAN OO Nasi neta anes mera a er ty O a E ae aE an rere in 4 A 2 PMAlO GUC OUND Ua sist ctctanasrnnatecats acess ncia terns dit haat atu cia tadwea nance stones Sia 4 4 3 Ideal saturation level in hydraulic and lubrication systems erre 5 O BICCIICAIMCOMMCCIIOIN css eta so a Raia ee ated teat dc ais UT Estab ns 5 6 FEGhiNIGAl SPECICATION pasa asas a ue od Das ini ialiaici ua Sa atas iga Nida pe lia 6 FAR Ojo igio cito of se E REDE ASR RR a DERA ED E EEE RIR RS EEE 7 E DIMENSIONS enea O a 7 O ACCES ONES saarinen accel anges seas ad CE water ac bateeda Da ater Cedo tr 8 SEIS CIC AL Deere eR een oR to ee Sa a o ee ee eres 8 Ie MECHANIC a eee ete eet CES Ione A ee ee ee een eee 8 10 DISpla yS usaram tert ess ra id RE nas abana soc uee asx GD aC SS came iaertcoakeeoite 9 ROSI NO OO ua Sa a ee eee 9 TO CMS Oseias b a dd SG T a ia 9 TO AMG DDD sr ta a E cute amine aanavenne aeverbeeeencs 10 POA NINA IN asno ps E oeie aa gamle ae aden ed 10 11 Functions of the AS 1x08 P 000 programmable over and above the standard version 11 sil ATE Usada a a rd a O da 11
9. ax 49 0 6897 509 1933 Note The information in this manual relates to the operating conditions and applications described For applications and operating conditions not described please contact the relevant technical department If you have any questions suggestions or encounter any problems of a technical nature please contact your Hydac representative All technical details are subject to change without notice
10. iu OUDE And RSRSRS tenon teen ER REA DRDS 12 MJ SISZ OV Ste MUS SAU sai nGaEo dei orafn is eet eth eee eke ee SORA at dee edt nnceeedemtenea Sh denens 12 T2 temo SUD ONC Ceca tea abeyance cabin a E O 13 13 Important information quick reference cccccecccsscecesececeececeueessaseeceseseeeeseueesseseesegeeseeeesses 13 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 e Before commissioning please read the operating instructions Ensure that the unit is suitable for your application e During transportation extra care must be taken to protect the unit from vibration and shock
11. rown X2 Pin 4 temperature black X2 Pin 2 saturation point white 10 2 HMG 510 Portable 2 channel data recorder specially designed to display measured values from HSI and SMART sensors In conjunction with the HMG 510 it is possible to display the actual measured values on the display of the HMG 510 Order no 909889 HMG 510 000 Connection to a HMG 510 Remove the supply cable from the electrical connection of the AS 1000 and screw the connection adaptor AS HLB ZBE 36 into the sensor Connect one of the inputs A or B of the HMG 510 to the output of the ZBE 36 using a sensor cable ZBE 30 0x User Manual AS 1000 09 04 2008 10 3 HMG 3000 Portable data recorder with a full graphical colour display for displaying or recording measured values of the AS 1000 In addition changes can be made to the parameters of the AS 1000 using the HMG 3000 In conjunction with the HMG 3000 the actual measured values can be shown on the HMG 3000 display The recordings can also be saved on the HMG 3000 and edited for a more detailed description see HMG 3000 Operating Manual Order no 909437 HMG 3000 000 E without accessories Connection to a HMG 3000 Remove the supply cable from the electrical connection of the AS 1000 and screw the connection adaptor AS HLB ZBE 36 into the sensor Connect one of the inputs A to D of the HMG 3000 to the output ZBE 36 using a sensor cable ZBE 30 0x When connecting to an HMG 3000 the
12. sible Hydraulic and lubrication fluids cannot be too dry As a guide we recommend a saturation level of 45 for all systems D 4 z D Saturation level ra o aturation 100 point re Same 75 2 50 2 O D 25 a 0 5 Electrical connection 1 y y 2 Progr output 1 3 AS 1000 P anD Progr output 2 HSI do not connect during normal operation Rimas Up 10V 20MA KO AS 1000 C HSI HYDAC Sensor Interface HYDAC internal communication interface yet RL HF Signal saturation level GND RL H Signal temp HSI do not connect during normal operation GI RB O N User Manual AS 1000 6 Technical specification Input data Measuring range saturation level Measuring range temperature Operating pressure Overload pressure Parts in contact with the fluid Output data Saturation level Output signal Calibration accuracy Accuracy when measuring in fluids Pressure dependence Output data Temperature Output signal Accuracy Switch output 1 and 2 Output signal Switch level Ambient conditions Nominal temperature range measurement of saturation level Ambient temperature range Temperature range of fluid Viscosity range Flow velocity Fluid compatibility CE mark Protection class to DIN 40050 Other data Supply voltage Residual ripple supply voltage Mechanical connection Torque value Electrical connection Pin 1 U
13. the data and to display the previous menu 11 1 2 System re start Use this menu point to force the sensor to re start Afterwards all the settings previously made become active Use the Ok button to re start Use Cancel to return to the main menu This should avoid making changes to the output configuration during operation which can cause damage to the sensor The error message which appears can be ignored Use Cancel to return to the main menu after the re start User Manual AS 1000 09 04 2008 12 Items supplied 1 AS 1000 sensor 1 Operating Manual 13 Important information quick reference e We recommend that for hydraulic applications the sensor is fitted vertically with the electrical plug pointing downwards e When installing please ensure that the sensor is completely submerged in the fluid and that the fluid can circulate freely through the sensor e Please ensure a constant flow and prevent the formation of air bubbles as much as possible If the oil is not flowing the possibility of deviations in measurement is increased User Manual AS 1000 09 04 2008 HYDAC ELECTRONIC GMBH Hauptstr 27 D 66128 Saarbrucken 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 or alterations please contact HYDAC Service HYDAC SERVICE GMBH Hauptstr 27 D 66128 Saarbrucken Germany Tel 49 0 6897 509 1936 F
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