Condition Monitoring Unit CMU 1000

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1 Condition Monitoring Unit CMU Description: The CMU1000 is an electronic evaluation unit designed for permanent online condition monitoring of machines and systems. In order to achieve this, the device must be supplied with relevant data which is recorded by the sensors connected to it. This recorded data (processed or unprocessed) can be transferred by the CMU 1000 via different ports or as an analogue value to other devices and/or monitoring levels. The CMU 1000 processes the application program stored in it continuously and cyclically like a PLC. The user creates this program simply and conveniently on a PC using the CM Editor developed for this purpose and then uploads it to the CMU The CM Editor is part of the HYDAC PC software CMWIN Version V03 or higher (supplied) and it provides the various tools and functions in accordance with IEC for designing, integrating and testing the user program using "drag and drop" operations. For status indication and for displaying messages and values on the device itself, there is a back-lit LCD display and three different coloured LEDs. The CMU 1000 is operated and data is input on site using a built-in keypad within the menu structure of the device. The CMU 1000 is designed for use in machines in both the stationary and mobile sectors. It is possible to connect easily to higher-level control, monitoring and bus systems using the built-in interfaces or in combination with an additional coupling module. Special features: 8 input channels for HSI or SMART sensors 8 input channels for analogue sensors 4 input channels for digital signals 2 output channels for analogue signals 4 relay switching outputs with change-over contacts USB slave port for PC connection USB master port for storing measured data on a standard USB memory stick Ethernet interface RS 232 interface 2-line LCD display (2 x 16 characters) to display measured data and status and/or error messages 3 user-programmable LEDs in different colours, for status indication (red, yellow, green) Simple operation using navigation pad Creation of customised application program using the PC software CMWIN supplied E /

2 CM Editor: The CM Editor is part of the HYDAC PC software CMWIN, Version 03 or higher, and provides a wide variety of tools and functions for designing, integrating and testing the application program. An application program consists of many individual functions which can be linked together. During subsequent operation, this user program is processed as for a PLC, cyclically. The program is created according to the IEC (the standard for PLC programming). 15 E /

3 Technical data: Supply Input voltage V DC Current consumption max. 1.5 A (3.5 A when CSI-F-10 connected) Reverse pol. protect.: -30 V Isolation voltage +40 V Connection of sensors Up to 8 sensors with HSI functionality or up to 8 SMART sensors 1) and in addition up to 8 analogue sensors and up to 4 digital sensors 4 x digital / 2 x digital + 2 x frequency / 3 x digital + 1 x frequency Analogue inputs Channel I and J ma ( ± 0.1 % FS max.) (Accuracy) ma ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) Channel K and L ma ( ± 0.1 % FS max.) (Accuracy) ma ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) V ( ± 0.2 % FS max.) L only! Channel M and N ma ( ± 0.1 % FS max.) (Accuracy) ma ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) Channel O and P ma ( ± 0.1 % FS max.) (Accuracy) ma ( ± 0.1 % FS max.) V ( ± 0.1 % FS max.) V ( ± 0.2 % FS max.) P only! Digital inputs Quantity 4, of which 2 are for frequency measurement (Channel Q and R) Trigger threshold approx. 2 V Dynamics 30 khz Measurement channels Quantity 32 - A measurement channel can be a value of a connected sensor (also a subchannel of a SMART sensor) or a value derived (calculated) from sensor data. Analogue outputs Quantity 2 Type individually selectable, current ( ma) or voltage ( V) Digital outputs Quantity 4 Type: Relay output, change-over contact Switching capacity 30V DC / 1 A Calculation unit Analogue value 12 bit A/D converter recording Interfaces Keypad Display (back-lit) USB Mass Storage Device 2) Ethernet, supported protocols Serial Interface 0 (UART 0) HSI Master USB Device CAN Bus Interface Cycle time - 4 arrow keys (up, down, right, left) - OK key - ESC key - Two-line LCD display (2 x 16 characters) - Additional indication of status information via 3 different coloured LEDs is possible - USB 1.1 / USB 2.0 full speed port for connecting a mass storage device (memory stick) - Female connection type "A". - RJ 45 8/8 Ethernet interface - HTTP Server - TCP/IP - Implementing an RS 232 or an HSI master interface - Change-over user-programmable - Connection via plug-in terminals - No handshake lines Cascading the CMU - USB 1.1 / USB 2.0 full speed port for connecting a PC / Notebook to configure the CMU - Female connection type "B". Can be integrated as an option Independently determined at start of program Display of actual cycle time is possible in the CM Editor Operating and environmental conditions Operating temperature C Storage temperature C Relative humidity %, non-condensing Dimensions and weight Dimensions approx. 212 x 106 x 36 mm Weight approx. 600 g Technical standards EMC EN / 2 / 3 / 4 Safety EN Protection class IP 40 1) SMART sensors (Condition Monitoring Sensors) are a generation of sensors from HYDAC, which can provide a variety of different measured values. 2) Recorded data from the CMU can be transferred to a memory stick via this interface. The USB Host supports mass storage devices exclusively. 15 E /

4 Block circuit diagram: SRAM Flash Processor 16 Bit CAN transceiver optional The information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department. Subject to technical modifications. CF-Card Real-time clock 15 USB master (Memory Stick) RS-232 / HSI-Master (selectable) USB slave (PC connection) LCD display (2 x 16 characters) Ethernet (HTTP server / TCP/IP) 8 x HSI-IN Keypad (4 x arrows / OK / ESC) 3 x LED (user-programmable) 8 x Analogue-IN 2 x Analogue-OUT 4 x Digital-IN 4 x Digital-OUT Model code: Modification number 000 = Standard Operating manual and documentation D = German E = English F = French CMU X On instruments with a different modification number, please read the label or the technical amendment details supplied with the instrument. Accessories: Appropriate accessories, such as sensor lines for the electrical connection can be found in the Accessories brochure. Dimensions: E / HYDAC electronic GmbH Hauptstraße 27, D Saarbrücken Telephone +49 (0) , Fax +49 (0) electronic@hydac.com Internet:

5 GSM Communication Module CSI-F-10 Description: The GSM communication module CSI-F-10 is an all-purpose electronic instrument for transferring data and digital signals via the GSM mobile communication network. As part of the HYDAC Condition Monitoring concept, amongst other functions, the CSI-F-10 links the sensor level with the interpretation level. The device is designed for both standalone operation and for use as a GSM modem on a CMU 1000 (HYDAC Condition Monitoring Unit). Up to two HYDAC SMART sensors such as HYDACLab, AS 1000 or CS 1000, can be connected to its input sockets. In addition, it is also possible to monitor various different system conditions via the four integrated digital inputs and to relay the data in binary form with the aid of the two integrated digital outputs. Via these digital outputs, the device can also directly access the machine/system being monitored. The CSI-F-10 processes and monitors the input signals using the application program stored in it. Which data is to be monitored, and how, and at what point a particular message is to be given, is defined in detail in this program. This application program can be created easily and conveniently (in accordance with IEC 61131) using the CM Editor, which forms part of the HYDAC PC software CMWIN Version V03 or higher. Depending on the application, the user can choose independently between two operating modes of the CSI-F-10 and hence define the type and content of the communication. Special features: 2 input channels for HYDAC SMART sensors 4 input channels for digital signals 2 output channels for digital signals Status indication for: - Network strength (4 LEDs) - Signals (2 LEDs, programmable) - Device status (1 LED) - GSM status (1 LED) Can be connected to CMU 1000 Simplest form of programming using "Drag & Drop" on graphical user interface Up to 5 telephone numbers can be stored (for access via GSM) Parameters can be set online Sensors connected via M12x1 male connector Very compact design E /

6 CM-Editor: The CM Editor is part of the HYDAC PC software CMWIN Version 03 or higher and provides a wide variety of tools and functions for designing, integrating and testing the application program. An application program consists of many individual functions which can be linked together. During subsequent operation, this user program is processed as for a PLC, cyclically. The program is created according to the IEC (the standard for PLC programming). E /

7 Technical specifications: Supply Input voltage V DC Residual ripple 5 % Current consumption Typically: without sensors 90 ma in stand-by and outputs 200 ma for wireless connection Pulsed: 2 A (recomm. power supply 3.5 A) Reverse pol. protect.: -35 V Sensor Inputs Quantity for 2 SMART sensors Output voltage +UB 0.5 V Current supply 500 ma max. at 50 C Logic Measurement Channels Quantity 32 A measurement channel can be a sub-channel of a SMART sensor* or a value derived (calculated) from sensor data. Digital Inputs Quantity 4 Input voltage: V DC Trigger threshold Low: < 0.8 V; High: > 5.0 V Current consumption approx. 4 ma Output voltage +UB 0.5 V Current supply 500 ma max. at 50 C (incl. outputs) Digital Outputs Quantity 2 Switching capacity +U B Out x 0.2 A (per output) Interfaces HSI bus Mobile comm. network GSM 850/950 (2 W EGSM) GSM 1800/1900 (1 W EGSM) Antenna 50 Ω FME plug SIM 3V SIM card Environmental Conditions Operating temperature C (GSM 850/900) C (GSM 1800/1900) Storage temperature C Relative humidity %, non-condensing Dimensions and Weight Dimensions approx. 140 x 95 x 55 without antenna Weight approx. 350 g Technical Standards EMC Conforms to R&TTE Directive 1999/5/EC mark EN / 2 / 3 / 4 Safety: EN / EN Protection class IP 65 * SMART sensors (Condition Monitoring Sensors) are a generation of sensors from HYDAC, which can provide a variety of different measured values. E /

8 Block circuit diagram: Processor Antenna 80 Ohm FME plug The information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department. Subject to technical modifications. 2 x Sensor-IN (HYDAC SMART sensors) HSI bus 4 x Digital IN LED status indication 2 x device status 4 x signal strength 2 x Digital-OUT 2 x LED (user-programmable) Model code: Modification number 000 = Standard Operating manual and documentation D = German E = English F = French CSI F X On instruments with a different modification number, please read the label or the technical amendment details supplied with the instrument. Accessories: Appropriate accessories, such as sensor lines for the electrical connection can be found in the Accessories section. Dimensions: E / electronic GmbH Hauptstraße 27, D Saarbrücken Tel. +49 (0) Fax +49 (0) electronic@hydac.com Internet:

9 Condition Monitoring Interface Module CSI-B-2 15 Description: The condition monitoring interface module CSI-B-2 is another element in the HYDAC condition monitoring concept which connects the sensor level with the interpretation level. It is an all-purpose electronic instrument for converting the HSI signal from HYDAC SMART sensors into a standardised PC signal. Using the HYDAC "CMWIN" PC software, it is therefore possible to read the data and measured values of the connected SMART sensor directly. The long-term memory can also be read as well as adjustments made and parameters set on the connected sensor (the setting options depend on the particular sensor). The HSI signal can be converted either into an RS 232 or an RS 485 signal. The CSI-B-2 can be connected to any PC via the RS 232 interface (and possibly an additional standard RS 232/USB adapter 1) ). The RS 485 interface and appropriate additional coupling modules can also be used to connect to higher-level control and/or bus systems. Special features: 1 input channel for HYDAC SMART sensors Direct connection of the sensor via screw-type terminals Indication of the active interface via LED (RS 232 / RS 485) Very compact design Suitable for mounting on standard DIN rails Protection class IP 40 1) RS 232/USB adapter is not supplied with the device. Technical data: Input data HSI interface Output data Signal output HYDAC Sensor Interface for digital linking of SMART sensors 1) - Male X2 switchable: RS 485 half-duplex or RS Male X1 (RS 485) - SUB-D 9 pole female (RS 232) Environmental Conditions Operating temperature range C Storage temperature range C Relative humidity %, non-condensing mark EN / 2 / 3 / 4 Protection class to IEC IP 40 Other data Supply voltage of the module V DC (male X1) Current consumption (module + sensor) 30 ma to 300 ma max. (depending on the supply voltage and the connected sensor) Sensor supply 15 V DC ± 5 % / 300 ma max. at 23 C (male X2) Electrical connection Cross-section of connection Max. 1.5 mm² X1 : Module supply + RS 232 / RS 485 Male terminal block, 8 pole RM 3.5 X2 : Sensor supply + HSI Male terminal block, 5 pole RM 3.5 SUB-D: RS pole female with thumbscrews Conversion mode options Option HSI - RS 232 or HSI - RS 485 via jumper (bridge): X1.3 - X1.4 open: HSI - RS 232 X1.3 - X1.4 closed: HSI - RS 485 Indication of active conversion mode Green LED: HSI - RS 232 Yellow LED: HSI - RS 485 Dimensions and weight Housing Weight approx. 55 x 106 x 34 mm Housing to be mounted on rails (35 mm) to DIN EN TH 35 (formerly DIN EN 50022) ~ 140 g Reverse polarity protection of the supply voltage, excess voltage, override and short circuit protection are provided. 1) SMART sensors (Condition Monitoring Sensors) are a generation of sensors from HYDAC, which can provide a variety of different measured values. E /

10 15 Model code: Modification number 000 = Standard CSI B On instruments with a different modification number, please read the label or the technical amendment details supplied with the instrument. Accessories: Appropriate accessories, such as sensor lines for the electrical connection can be found in the Accessories brochure. Terminal assignment: Terminal strip X1 Pin Signal 1 RS 485 (-) 2 RS 485 (+) open: HSI to RS closed: HSI to RS RxD RS 232 (connected to Pin 3 SUB-D 9 pole) 6 TxD RS 232 (connected to Pin 2 SUB-D 9 pole) 7 0 V (connected to Pin 5 SUB-D 9 pole) 8 +U B ( V DC) Module supply Dimensions: Terminal strip X2 Pin Signal 1 +U B (15 V DC) Sensor supply 2 0 V 3 HSI signal 4 0 V 5 0 V The information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department. Subject to technical modifications E / HYDAC electronic GmbH Hauptstraße 27, D Saarbrücken Telephone +49 (0) Fax +49 (0) electronic@hydac.com Internet:

11 Oil Condition Sensor HYDACLAB HLB Description: The HYDACLab HLB 1300 is a multifunctional sensor for online condition monitoring of standard and bio oils in stationary and mobile applications. The user is thus informed in real time of changes in the fluids and can take immediate action in the case of deteriorating operating conditions. Assertions can be made about the condition of an oil, e.g. ageing or mixing with other fluids, on the basis of the measured values for the relative change in dielectric constant, the saturation level and the temperature. These measurements are available as sequential analogue signals and switching signals at the electrical output of the HYDACLab (e.g. for activating warning devices or alarms). The measured values can be displayed on various HYDAC display and measurement devices. Special features: Online condition monitoring of oils Applications in industrial and mobile sectors Analogue output signal for: - Saturation level - Temperature - Rel. change in dielectric constant Switching output Compact design Simple cartridge mounting Technical data: Input data Rel. humidity % saturation Temperature C Dielectric constant (ε R ) Operating pressure < 50 bar Pressure resistance < 600 bar Flow velocity < 5 m/s Output data - Saturation level Output signal ma ( %) Calibration accuracy ± 2 % FS max. Accuracy 1) ± 3 % FS typ. Output data - Temperature measurement Output signal ma ( C) Accuracy ± 3 % FS max. Output data - Relative change in dielectric constant (ε R ) Output signal 12 ma ± 8 ma (± 30 % of IV) Accuracy 2) see below Switch output Signal 1 (N/C) PNP switching output 0.5 A max. switching level U B - 4 V Default warning level SP1 85 % Humidity Default warning level SP1 80 C Temperature Default warning level SP1 ± 15 % (temperature compensated) Dielectric constant Environmental conditions Nominal temperature range C Storage temperature C Fluid compatibility Mineral oils HLP (HLP-D on request) Esters: HEES, HETG Seal material: FPM mark EN / 2 / 3 / 4 Protection class to IEC IP 67 Other data Supply voltage U B V DC Residual ripple of supply voltage 5 % Mechanical connection G ¾ DIN 3852 E Torque value 30 Nm Electrical connection M12x1, 5 pole Housing Stainless steel Weight ~ 205 g Reverse polarity protection, short circuit protection provided. FS (Full Scale) = relative to complete measuring range IV (Initial Value) 1) The max. accuracy achievable when measuring relative humidity is heavily dependent on the type of fluid or fluid additive. More precise information on this is available on request. 2) The accuracy achievable when measuring the relative change in dielectric constant is dependent on the application, the type of oil and the individual calibration of the sensor. Detailed information on this is available on request. E /

12 15 Model code: Variables 3 = 3 variables - Relative change in dielectric constant (DK) - Saturation level - Temperature Mechanical connection 0 = G3/4 A DIN 3852 Electrical connection 8 = Male M12x1, 5-pole (connector not supplied) Type of signal, output 1 1 = Switching output / N/C Type of signal, output 2 C = ma, 3 conductor Modification number 000 = Standard (cannot be adjusted) Seal material (parts in contact with the fluid) F = FPM seal Connection material (in contact with fluid) 1 = Stainless steel HLB C 000 F 1 On instruments with a different modification number, please read the label or the technical amendment details supplied with the instrument. Accessories: Appropriate accessories, such as electrical connectors, can be found in the Electrical Accessories brochure. Dimensions: Pin connections: M12x Pin 1 +U B 2 Signal 1 3 ^ 4 Signal 2 5 HSI* Reset (PLC) * HSI = HYDAC Sensor Interface (HYDAC's own communication interface) Signal 1: PNP switching output Signal 2: Sequential analogue output ( ma) Display and read-out options: HDA Zc-006 Digital Display Unit; the HDA 5500 displays the sequential analogue output of the HYDACLAB and provides the user with 4 programmable switching outputs. HDA AC-006(CM1k) Order no.: HDA DC-006(CM1k) Order no.: male electr. conn. M12x1, 5 pole hex-sw27 HMG 510 Portable 2-channel data recorder, specially designed for use with HSI and SMART sensors Order no.: HMG 3010 Portable data recorder with full graphics colour display for indicating, displaying and editing measured values Order no.: Information on other read-out options can be found on our website at or please contact your HYDAC representative. The information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department. Subject to technical modifications. E /11.13 HYDAC electronic GmbH Hauptstraße 27, D Saarbrücken Telephone +49 (0) Fax +49 (0) electronic@hydac.com Internet: 340

13 AquaSensor AS Description: The AquaSensor AS 1000 is the culmination of continued development of the successful AS 2000 series for online detection of water in oils, in particular as an OEM sensor for fluid conditioning monitoring. It measures the degree of saturation and the temperature of the fluid. In the analogue output version, the AS 1000 transmits the values for the degree of saturation and the temperature as a ma signal. In the version with 2 switch outputs, the AS 1000 can be configured individually using the HYDAC service instrument HMG 3010, the Condition Monitoring Unit CMU 1000 and the interface module CSI-B-2. The following parameters can be adjusted: - Saturation level / temperature - Switch points - Switch mode of the switch outputs - Switching direction - Switch delay times The AS 1000 therefore enables hydraulic and lubrication oils to be monitored accurately, continuously and online. Special features: Reliable due to its compact and robust design Cost-effective sensor, also for use in OEM applications Not necessary to calibrate to different types of oil Pressure-resistant also during pulsations Wide fluid temperature range Individual configuration Early detection of water problems thereby preventing breakdowns and unnecessary interruption to operations. Technical data: Input data Saturation level % Temperature C Operating pressure bar Burst pressure 630 bar Mechanical connection G3/8 A DIN 3852 Torque value 25 Nm Parts in contact with medium Mech. connection: Stainless steel / Vacuum-metallized ceramic Seal: FPM or EPDM Output data Pin 2: Saturation level Output signal ma (corresponds to %) R Lmax. = (U B - 10 V) / 20 ma [kw] or switch output (configurable) Calibration accuracy ± 2 % FS max. Accuracy in media measurements ± 3 % FS typ. Pressure dependency ± 0.2 % FS / bar Pin 4: Temperature Output signal ma (corresponds to %) RLmax. = (U B - 10 V) / 20 ma [kw] or switch output (configurable) Accuracy ± 2 % FS max. Pin 5: HSI (HYDAC Sensor Interface) Automatic sensor recognition Switch outputs Type PNP transistor outputs (configurable as N/O or N/C) Switching current max. 1 A per switch output Environmental conditions Compensated temperature range C Operating temperature range 1) C / C Storage temperature range C Fluid temperature range 1) C / C Viscosity range cst Flow velocity < 5 m/s Fluid compatibility mineral oil based fluids, synthetic and natural esters mark EN / 2 / 3 / 4 Protection class to IEC IP 67 Other data Supply voltage V DC Residual ripple of supply voltage 5 % Weight ~ 145 g Reverse polarity protection, short circuit protection are provided. FS (Full Scale) = relative to complete measuring range 1) -25 C with FPM or EPDM seal, -40 C on request E /

14 15 Model code: Medium 0 = Mineral oils 1 = Phosphate ester, e.g. Skydrol Mechanical connection 0 = G3/8 A DIN 3852 Electrical connection 8 = Male M12x1, 5 pole (connector not supplied) Signal technology C = Output 1 Pin 2 saturation level ( ma) Output 2 Pin 4 temperature ( ma) 2 = 2 switching outputs Dimensions: AS 1 X 0 8 X 000 Modification number 000 = Standard Notice: On instruments with a different modification number, please read the label or the technical amendment details supplied with the instruments. Accessories: Appropriate accessories, such as electrical connectors, can be found in the Accessories brochure. hex.-sw27 elastomer profile seal ring DIN3869 male electr. conn. M12x1 5 pole Pin connections: M12x Pin AS 1X08-C AS 1X U B +U B 2 Saturation level SP ma 3 0 V 0 V 4 Temperature ma SP 2 5 HSI* HSI* * HSI = HYDAC Sensor Interface (HYDAC's own communication interface) Display, read-out and configuration options: HDA xC-000 Digital Display Unit with 2 programmable switch outputs, which have been specifically designed for use with the AS 1000 HDA AC-000 Order no.: HDA DC-000 Order no.: HMG 510 Portable 2-channel data recorder, specially designed for displaying measured values with HSI and SMART sensors Order no.: HMG 3010 Portable data recorder with full graphics colour display for indicating, displaying and editing measured values as well as for configuration of HSI and SMART sensors Order no.: CMU 1000 Electronic evaluation unit for online measured value monitoring as well as for the configuration of HSI and SMART sensors Order no CSI-B-2 Interface module, enables configuration of HSI and SMART sensors using HYDAC PC software CMWIN Order no Information on other read-out options can be found on our website at or please contact your HYDAC representative. E / The information in this brochure relates to the operating conditions and applications described. For applications or operating conditions not described, please contact the relevant technical department. Subject to technical modifications. HYDAC electronic GmbH Hauptstraße 27, D Saarbrücken Telephone +49 (0) Fax +49 (0) electronic@hydac.com Internet:

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