Bosch Rexroth CIMS Mk IV Instruction Manual Download Page 1

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F 037 300 069 (2013.05.21)

Instruction manual

CIMS Mk IV

Bosch Rexroth B.V.

PO Box 32

5280 AA Boxtel

The Netherlands

Summary of Contents for Rexroth CIMS Mk IV

Page 1: ...F 037 300 069 2013 05 21 1 Instruction manual CIMS Mk IV Bosch Rexroth B V PO Box 32 5280 AA Boxtel The Netherlands ...

Page 2: ...F 037 300 069 2013 05 21 2 ...

Page 3: ...4 4 1 2 Phase 2 Check change the cable outlet 16 4 1 3 Phase 3 Mount new cable outlet 17 4 1 4 Phase 4 Installation onto the cylinder 17 4 1 5 Removal from the cylinder 18 4 2 Electrical Installation 18 4 2 1 Wiring 18 4 2 2 Cable termination 19 4 2 3 Shielding and Grounding 19 4 2 4 Internal connector 20 4 2 5 External connector connection 20 4 2 5 1 9 Pin standard connector 21 4 2 5 2 Ex d cable...

Page 4: ...d experienced personal The statements information and data published in this document are to the best of our knowledge accurate reliable and true The publisher of this instruction manual accepts no liability for damage in any form whatsoever arising as a result of incorrectly performed installation putting into use maintenance or repair Since Bosch Rexroth has no control over the use into which ot...

Page 5: ...malfunctioning during the guarantee period please direct all correspondence to Bosch Rexroth B V Customer Service Department PO Box 32 5280 AA Boxtel The Netherlands Tel 31 0 411 651 951 Fax 31 0 411 674 125 To complete your request please include the following data Bosch Rexroth B V order and line number Bosch Rexroth material number R number as engraved in the CIMS Mk IV housing cover The serial...

Page 6: ...r element Permissible stray magnetic field at sensor element with opposing field in all directions without operation 100kA m number and duration of occurrences unlimited If the electronics or cables are installed in an exposed location use screens or other guarding as appropriate to prevent physical damage 2 3 ATEX CERTIFIED CIMS MK IV Besides the non ATEX approved CIMS Mk IV there also is an ATEX...

Page 7: ...The serial no is marked on the housing cover Intermediate piece and the housing base Special conditions for safe use 1 The ATEX approved CIMS Mk IV sensor is suitable for use in an environment with an ambient temperature range from 20 C to 70 C 2 Repairing the sensor is not permitted A defect CIMS Mk IV has to be replaced by trained personal 3 The ATEX approved CIMS Mk IV is only frameproof with a...

Page 8: ...lind hole bottom Safety instructions for installation and commissioning Explosion protection WARNING Explosion hazards when installing The presence of ignition sources such as sparks open flames and hot surfaces can cause explosions in the hazardous area Obtain a written work release prior to starting the installation Only install if the possibility of an explosive atmosphere has been excluded Onl...

Page 9: ...intenance particular attention must be paid to checking that the parts essential for the type of protection and proper functioning are in good condition The threaded gaps must be protected They must not be machined or varnished at any time later Do not use the CIMS Mk IV with defective parts in the flameproof encapsulation please contact supplier these parts have to be replaced with original parts...

Page 10: ...red get in contact with manufacturer Only use the manufacturer s original spare parts or spare parts that are expressly approved by the manufacturer Always contact the manufacturer if there are questions Fault Clearance The CIMS Mk IV is defective if the flameproof encapsulation is damaged and or if one of the components does not function any longer In this case Replace defective parts in the flam...

Page 11: ...t is mechanically and electrically compatible with CIMS Mk II III except for the standard connector that changed from a 6 pin connector to a 9 pin connector 3 2 CHARACTERISTICS CIMS Mk IV features High accuracy combined with unlimited stroke lengths Sensor integrated in sealing flange out of the pressure zone of the cylinder Easy installation or replacement possible without infringement of the hyd...

Page 12: ...ydraulic cylinder see Section 4 1 and a check valve which has to be installed on the cylinder if no leak oil line is connected see Section 4 3 3 2 CIMS MK IV ATEX VERSION The CIMS Mk IV ATEX version is delivered without connector or cable gland see drawing F 037 A00 004 Appendix A It comes together with an adapter ring required for mounting the CIMS on the hydraulic cylinder see Section 4 1 and a ...

Page 13: ...lso prevent that the CIMS is exposed to high accelerations shocks from e g hammer blow screw on with automatic screwdriver etc Especially handle the sensitive surface as indicated in drawing F 037 A00 002 Appendix A with care No deformation or damage of the sensor is allowed The CIMS Mk IV connection must never be disconnected while under power Do not install remove the CIMS from the cylinder with...

Page 14: ...he connector is not pointing in the desired direction follow the instructions below Do not mount the CIMS with the orientation mark in the wrong direction as this might lead to damage or malfunction of the CIMS At delivery from the factory the connection output is oriented as depicted in Figure 2 and Figure 3 If this is not the desirable configuration the connection output can be changed in steps ...

Page 15: ...otate the housing base with respect to the intermediate piece in the desired position maximum angle of rotation 270 If necessary two hexagon socket screw keys can be used with the holes in CIMS Mk IV see Figure 6 4 Mount the four M6 bolts Bolt B in the intermediate piece 7 5Nm Bolt B 4x Bolt A 4x Figure 6 Holes of hexagon socket screw keys Figure 5 Remove screws Figure 4 CIMS Mk IV housing assembl...

Page 16: ...ner connector from the header carefully avoiding any force from the header to the electronic circuit If it is difficult to reach the connector it is possible to lift the intermediate piece from the housing base after removing the four M6 bolts Bolt B Figure 5 see Figure 8 6 Unscrew the 8 screws Screw F and remove each wire from the detached mating connector see Figure 10 7 Remove the male socket a...

Page 17: ...tall the CIMS onto the cylinder 1 Clean the mounting surface in the cylinder making sure no particles or debris fall inside the cylinder 2 Install the adapter ring on to the cylinder note the adapter ring can be installed in two ways 180 rotated as long as the orientation pin see Figure 14 is aligned with the corresponding holes in the bore pattern in the cylinder 3 Screw the four M6 bolts Bolt G ...

Page 18: ...of DC conductor loss AC loss due to skin effect leakage and losses in the dielectric It is therefore very important to select the appropriate cable like the one selected and delivered specially for CIMS Super Paar Tronic 340 C Pur 4x2x0 25 The cable consists of four twisted pairs 4x2x0 25 The cable has an overall shielding from tinned copper braiding and a full polyurethane outer jacket The cable ...

Page 19: ...om radiated EMI It is recommended to connect the cable shield to ground according the connection diagram as depicted in Figure 15 If a grounding system is available it ensures the CIMS and the customer equipment are on the same potential so the cable shield can be connected at both sides giving the best EMI protection If a grounding system is not available the shield may only be connected to groun...

Page 20: ...to be ordered separately Section 4 2 5 1 describes the assembly instructions for the connector and the maintenance procedure The pin assignment of the standard connector corresponds with Table 1 Other cable connection options are also available like an underwater connector for applications where the CIMS is submerged in water For applications where the cable and or connection should be protected f...

Page 21: ...external sheath by 70 mm 3 Detail A Push back the braided screen such that it stands out at 90 With a rotating motion push the shielded sleeve 4A over the foil or cotton braiding but under the braided screen Cut the braided screen flush with the external diameter of the shielded sleeve 4A 4 Trim the foil wadding and inner insulation 5 Strip the litz wires by 3 5 mm twist and tin plate 6 Pull the c...

Page 22: ...e combination The choice and installation of a suitable cable cable gland should be made according to IEC 60079 14 and or the requirements for the actual installation site Only suitably approved Ex d cable glands should be used which maintain the ingress protection class IP68 Only the G threaded connection according DIN3852 2 of the CIMS MkIV housing can be used to mount the cable gland The cable ...

Page 23: ...utput is a RS422 incremental position output see details in paragraph 5 2 1 This quadrature encoder output provides incremental A and B pulses and also the inverted A and B pulses according to the EIA RS 422 format 2 A RS485 diagnostic output see details in paragraph 5 2 2 with MODBUS protocol 5 2 1 RS422 INCREMENTAL POSITION OUTPUT The position output is a quadrature encoder output with increment...

Page 24: ...mechanical strain and temperature elongation of the piston rod are not measured by the CIMS measuring system 5 2 2 RS485 DIAGNOSTIC OUTPUT The CIMS Mk IV provides a RS485 diagnostic output using the MODBUS protocol Via a USB converter like the one described in Section 7 4 the CIMS can be connected to a PC to read out information about the CIMS Mk IV like the sensor identification number the produc...

Page 25: ...ax Unit Mode of operation differential Quantity of additional drivers allowed on one line Qadd driv 0 Driver Quantity of receivers allowed on one line sum of all receivers max 120 Qrec 10 Receivers Pulse frequency fpulse 410 kHz Driver output voltage Udriv 0 6 V Differential driver output signal level loaded Uload 1 8 2 5 V Differential driver output signal level unloaded Uunload 3 3 4 2 6 V Drive...

Page 26: ...erature at max 60 Stor 40 70 C Storage temperature 2 x 2 h Stor 40 85 C Humidity max at 40 C 95 r h Humidity max at 55 C 65 r h EMC tests according to DIN EN 61000 6 2 and DIN EN 61000 6 3 EN 61000 4 2 3 4 5 6 8 Vibration test according to IEC 60068 2 6 2 Hz to 250 Hz at 5 g Shock test according to IEC 60068 2 27 20 g half sine 6 ms Protection IP68 up to 10 bar depending on cable connection ...

Page 27: ...IMS Mk IV 9 pin female angled connector The 9 pin female angled connector is compatible with the 9 pin male connector chassis as delivered with the CIMS Mk IV standard version see drawing F 037 A00 002 Appendix A The brass nickel plated connector is IP67 rated and suitable for outside use if the installation and maintenance instructions as given in Section 4 2 5 1 are strictly followed The connect...

Page 28: ...ut from the CIMS Mk IV to a PC Order number R113089697 RS 422 to analog converter for the CIMS MkIV position output A counter module converter to convert the CIMS Mk IV incremental RS422 output to an analogue 10 V 0 20 mA or 4 20 mA Furthermore the module has a RS 232 and RS 485 interfaces for serial readout of the counter The module is easy to set up by a teach button or by PC and Windows softwar...

Page 29: ...44 C 4 10 Read Application Software Identification Number A0h 45 C 4 11 Read Application Software Version A1h 46 C 4 12 Read MODBUS Interface Version A2h 46 C 5 Sensor Event Management 47 C 5 1 Possible Error Messages 47 C 5 2 Get Last Debug Detail 10h E0FEh 47 C 5 3 Get Sensor Status 03h E000h 48 C 5 4 Read Event Memory 03h E001h E00Ah 48 C 5 5 Clear Event Memory 06h E0FFh 50 C 6 Measurement Data...

Page 30: ...F 037 300 069 2013 05 21 30 Appendix A CIMS MK VI DRAWINGS A 1 F 037 A00 002 CIMS MK IV STANDARD VERSION NON ATEX ...

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Page 34: ...F 037 300 069 2013 05 21 34 A 2 F 037 A00 004 CIMS MK IV ATEX VERSION ...

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Page 38: ...F 037 300 069 2013 05 21 38 Appendix B DRAWING 3 033701 MOUNTING BORE PATTERN ON CYLINDER ...

Page 39: ...000 ms Message format 1 start bit 8 data bits least significant bit sent first 1 bit even Parity 1 stop bit C 2 SENSOR STARTUP TIMING After power up the CIMS sensor starts in the Bootloader Session After some checks the Bootloader switches automatically to the Application Session This checks needs up to 1 second wait time After switching into Application Session the CIMS sensor send out the curren...

Page 40: ...eption Code C 4 1 POSSIBLE ERROR MESSAGES Error CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Error Function Code Function Code 80h ABh 2 Exception Code 0x04 Slave Device Failure If the syntax of the request is wrong XXh 3 CRC XXh 4 XXh C 4 2 READ VENDOR NAME 00H Read out the Vendor Name Request MASTER CIMS Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interface Tran...

Page 41: ...ead Device Identification 0Eh 3 Conformity Level Extended Identification Individual Access 83h 4 More Follows 00h 5 Next Object Id 00h 6 Number of Objects 01h 7 Object ID Customer Number 01h 8 Object Length LLh 9 Payload Coding ASCII string Length Variable the byte 8 contains the used length LL maximum length 16 byte Format R XXX XXX XXX Example R 905 023 540 XXh 8 LL XXh 9 LL CRC XXh 10 LL XXh C ...

Page 42: ...he Manufacturing Date Request MASTER CIMS Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interface Transport 2Bh 2 MEI Type Read Device Identification 0Eh 3 Read Device ID code Specific Identification Object Individual Access 04h 4 Object ID Manufacturing Date 80h 5 CRC XXh 6 XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interfa...

Page 43: ...1h 7 Object ID Serial Number 81h 8 Object Length LLh 9 Payload Coding ASCII string Length Variable the byte 8 contains the used length LL maximum length 16 byte Example 259824 001 XXh 8 LL XXh 9 LL CRC XXh 10 LL XXh C 4 7 READ ORDER NUMBER 90H The Order Number is the Vendor internal part number Request MASTER CIMS Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interface Trans...

Page 44: ... Object ID Bootloader Identification Number B0h 5 CRC XXh 6 XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interface Transport 2Bh 2 MEI Type Read Device Identification 0Eh 3 Conformity Level Extended Identification Individual Access 83h 4 More Follows 00h 5 Next Object Id 00h 6 Number of Objects 01h 7 Object ID Bootloader Identification Number B0h 8 ...

Page 45: ...TIFICATION NUMBER A0H Read out the Application Software Identification Number Request MASTER CIMS Byte Contents Value 0 Slave Address A2h 1 Function Code Encapsulated Interface Transport 2Bh 2 MEI Type Read Device Identification 0Eh 3 Read Device ID code Specific Identification Object Individual Access 04h 4 Object ID Application Software Identification Number A0h 5 CRC XXh 6 XXh Response CIMS MAS...

Page 46: ...yload Coding ASCII string Length 7 Byte Format V 2 digits Major Version 3 digits Minor Version Example V01 024 XXh 15 XXh 16 CRC XXh 17 XXh C 4 12 READ MODBUS INTERFACE VERSION A2H The MODBUS Interface Version is used to identify the supported services of CIMS sensor With this information the master system can use the correct interpretation for the data sent and receive over MODBUS The major versi...

Page 47: ...cribed in 2 In contrast to this specification the Starting Address is not used as a physical address but more as a Service ID The CIMS Sensor supports only access to one Service ID Address at one request C 5 1 POSSIBLE ERROR MESSAGES Error CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Error Function Code Function Code 80h FC 80h 2 Exception Code 0x04 Slave Device Failure If the syntax of t...

Page 48: ... Slave Address A2h 1 Function Code Read Holding Registers 03h 2 Starting Address Service ID Sensor Status E0h 3 00h 4 Quantity of Registers 00h 5 01h 6 CRC XXh 7 XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Read Holding Registers 03h 2 Byte Count 02h 3 Sensor Status Coding 0000h No result available 0001h Sensor ok 0002h Warning 0003h Error XXh 4 XXh 5 CRC XXh 6 ...

Page 49: ...r indicates the order It is a rolling counter after an overflow the counter starts again at 00h XXh 12 Occurrence Counter This counter is incremented each time when the event was tested as passed and turns back to failed again If the counter is FFh the counter is locked to this value XXh 13 Operation Voltage Resolution 0 2 Volt per LSB XXh 14 Operation Temperature Resolution 1 C per LSB 0 C Offset...

Page 50: ...out the Measurement Data the MODBUS function Read Holding Registers 03h is used as described in 2 In contrast to this specification the Starting Address is not used as a physical address but more as a Service ID The CIMS Sensor supports only access to one Service ID Address at one request C 6 1 POSSIBLE ERROR MESSAGES Error CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Error Function Code ...

Page 51: ...to 80000000h XXh 6 XXh 7 XXh 8 XXh 9 CRC XXh 10 XXh C 6 3 SET CURRENT POSITION SINCE LAST POWER UP 06H A010H This service set the stored current position since last power up of the sensor This is useful to set the position at a known reference position It is strongly recommended to use this service only at zero move of the hydraulic piston Request MASTER CIMS Byte Contents Value 0 Slave Address A2...

Page 52: ...XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Read Holding Registers 03h 2 Byte Count 04h 3 Operating Minutes Coding 00h 3 bytes HEX coded Example 0x003823E0 min 3679200 min 61320 hours 7 years 00h 4 XXh 5 XXh 6 XXh 7 CRC XXh 8 XXh C 7 CONFIGURATION DATA To read out the stored Configuration Data the MODBUS function Read Holding Registers 03h is used as described ...

Page 53: ...STER CIMS Byte Contents Value 0 Slave Address A2h 1 Function Code Read Holding Registers 03h 2 Starting Address Service ID MODBUS Baud Rate C0h 3 00h 4 Quantity of Registers 00h 5 01h 6 CRC XXh 7 XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Read Holding Registers 03h 2 Byte Count 02h 3 MODBUS Baud Rate This Baud Rate will be used after next system start Coding 0...

Page 54: ...r next system start 00h 4 A2h 5 CRC XXh 6 XXh C 8 ROUTINE CONTROL To start a Routine the MODBUS function Write Multiple Register 10h is used as described in 2 In contrast to this specification the Starting Address is not used as a physical address but more as a Service ID The CIMS Sensor supports only access to one Service ID Address at one request C 8 1 POSSIBLE ERROR MESSAGES Error CIMS MASTER B...

Page 55: ... Address Service ID Sensor Reset F0h 3 00h 4 Quantity of Registers 00h 5 01h 6 Byte Count 02h 7 Sensor Reset 00h 8 00h 9 CRC XXh 10 XXh Response CIMS MASTER Byte Contents Value 0 Slave Address A2h 1 Function Code Write Multiple Registers 10h 2 Starting Address Service ID Sensor Reset F0h 3 00h 4 Quantity of Registers 00h 5 01h 6 CRC XXh 7 XXh ...

Page 56: ...F 037 300 069 2013 05 21 56 Appendix D DECLARATION OF CONFORMITY EMC DIRECTIVE 2004 108 EC ...

Page 57: ...F 037 300 069 2013 05 21 57 Appendix E DECLARATION OF CONFORMITY ATEX DIRECTIVE 94 9 EG ...

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