Hydac CS 2000 ContaminationSensor for Test Rigs and Lube Systems

Hydac CS 2000 ContaminationSensor for test rigs and critical hydraulic systems

The Hydac CS 2000 is a stationary online particle sensor designed for permanent monitoring of solid contamination in fluids where the trend of cleanliness matters, such as test rigs, lubrication systems and critical hydraulic systems. It uses the field-proven sensor technology of the earlier FCU 2000 and presents four particle size channels as ISO 4406, NAS 1638 or SAE AS 4059 classes. Compared with the compact CS 1000, the CS 2000 has more outputs: relay contacts for ready and limit signals, a PLC output and an RS 232, RS 485, Ethernet or analogue interface, depending on the model. Seven Star LLC supplies Hydac products in Oman and the GCC as an independent supplier in Muscat.

CS 2000 technical specifications

Reading the CS 2000 model code

The datasheet example is CS 2 2 3 0 – 1 – U – 3 – 2. CS means ContaminationSensor and the first number, 2, shows the resolution of four particle size channels. The next digit is the contamination code: 0 for ISO 4406:1987 with NAS 1638 (>5, >15, >25 and >50 µm), 1 for ISO 4406:1991 with NAS 1638 (>2, >5, >15, >25 µm), or 2 for ISO 4406:1999 with SAE AS 4059 (D) (>4, >6, >14, >21 µm(c)). The housing digit 3 is for stationary use, and the fluid digit selects 0 for standard mineral oils or 1 for phosphate esters.

After the options digit (1, standard) the letter U denotes 24 V DC supply. A pressure and viscosity range number from 1 to 4 follows, and it refers to the graphs in the datasheet. Finally the electrical output digit selects 0 RS 232 (DIN 66348 protocol), 1 analogue 4 to 20 mA (only for SAE or NAS and particle counts), 2 RS 485 (DIN 66348) or 5 Ethernet (IEEE 802.3, TCP/IP). Because these choices cannot be changed later, the code should be confirmed with the control system supplier.

Pressure and viscosity limits of the CS 2000

The CS 2000 measures a small flow, and the datasheet shows pressure and viscosity ranges for inlet and outlet. For standard conditions, the inlet pressure is limited to 40 bar at low viscosity, and the allowed pressure falls as viscosity rises: the datasheet graph runs from 0 to 500 mm²/s for the first ranges and 500 to 2000 mm²/s for the higher viscosity ranges. If the system pressure is higher than 40 bar, the datasheet states that higher pressures are possible with an external pressure relief valve. A designer must therefore reduce the sampling pressure with a suitable restrictor or pressure reducer; do not connect the inlet directly to a high pressure main line.

Where CS 2000 fits in a condition monitoring system

The CS 2000 suits test benches and lube oil systems where a trend is recorded, and the CoCoS ContaminationControl software shows and stores measurements graphically and in tables. The FluMoS software reads and processes data from Hydac fluid sensors, and FluMoT allows Hydac sensors to be integrated into customer software. The ContaminationSensor Display CSD-1-U (14 mm display) and CSD-2-U (57 mm display) give a local readout. For smaller, simpler installations, the CS 1000 may be enough, and for cleaning systems, the CS can be combined with the OLF offline filters.

Selection and ordering checklist for CS 2000

• Cleanliness standard: ISO 4406:1987, 1991 or 1999 with NAS 1638 or SAE AS 4059.
• Fluid: mineral oil or phosphate ester.
• Output: RS 232, RS 485, Ethernet or 4 to 20 mA, plus the relay outputs.
• Pressure and viscosity range number 1 to 4, from the graphs.
• Whether a local CSD display and PC software are wanted.
• Sampling arrangement: pressure at the measuring point, with or without a relief valve.

Installation and commissioning of the CS 2000

Connect the inlet to a sample point, and take the outlet to a low-pressure return, since the outlet limit is 10 bar. Provide a stable 24 V DC supply with enough capacity for the 25 W power consumption, and wire the relay outputs to the alarm system. The programming cable supplied helps with configuration, and the calibration certificate documents the factory calibration. Start the flow, bleed trapped air, and allow the readings to settle before using them to judge the oil. Protect the sensor from vibration and water splash; IP 65 protects against jets but not against immersion.

CS 2000 applications in Oman and the GCC

Test rigs at workshops, hydraulic and lube oil systems for turbines, compressors and large pumps, and critical valve control hydraulics at oil and gas and power plants all benefit from continuous oil cleanliness data. Wear and ingress show first as a change in the particle count, so the sensor gives early warning in plants that are far from laboratories. Ambient temperature must stay within 0 to +55°C, so for outdoor use a shaded or ventilated cabinet is recommended in Gulf summers.

Information to send with a CS 2000 RFQ

• Model code or the required cleanliness standard, fluid and output.
• Pressure at the sampling point and fluid viscosity.
• Number of sensors, displays and software.
• Control system interface and supply voltage.

Documents and quotation

The Hydac CS 2000 series datasheet is attached on this page with the technical data, model code and accessories.

Send the model code or application data and Seven Star LLC will confirm the CS 2000 configuration and quote supply to Oman and the GCC.