RMF Systems CMS 2 User Manual Download Page 1

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User Manual
CMS2

Summary of Contents for CMS 2

Page 2: ...1 As a policy of continual improvement RMF reserves the right to alter the specification without prior notice 201 028 REV 1 Date of Issue 18 June 2018...

Page 3: ...orage 8 2 1 Transportation and Handling Conditions 8 2 2 Storage 8 3 Warranty Limitations and Disclaimers 9 4 Product Presentation 11 4 1 Benefits 11 4 2 Product features 11 4 2 1 Moisture Sensor 11 4...

Page 4: ...sposal 51 7 Troubleshooting FAQ 52 7 1 Misuse of Product 52 7 2 Fault Finding 52 7 2 1 LED Flashing Fault Codes 52 7 2 2 Test Status 53 7 2 3 Other Faults 53 7 3 Test Duration 54 8 How to Order 55 8 1...

Page 5: ...11 5 NAS1638 Cleanliness Code System now defunct replaced by SAE AS4059E Table 1 76 11 6 SAE AS4059 REV E Cleanliness Classification for Hydraulic fluids 76 11 7 Recommendations 77 11 8 Hydraulic Syst...

Page 6: ...nt information concerning the product its use or part of this documentation to which special attention must be paid DANGER It means that failure to comply with the relevant safety regulations may resu...

Page 7: ...ay arise and takes the appropriate precautions in order to eliminate the risks of accidents in the workplace 1 3 Operator Position and Dangerous Areas No operator is required for operating the unit Ho...

Page 8: ...e 2018 1 5 Personal Protective Equipment When operating the unit personnel must be wearing safety shoes gloves and goggles In general the PPEs to be used according to the activities on the machinery a...

Page 9: ...ortation and Handling Conditions The unit is shipped in a cardboard box encased in polyurethane foam The packed weight of the CMS and accessories is 2 5kg 2 2 Storage The unit should be stored in a su...

Page 10: ...y product returned for warranty repair must be accompanied by a full fault report specifying the symptoms and the conditions under which the fault occurs Should RMF Systems incur additional cost as a...

Page 11: ...ompense Failure to present this evidence may limit RMF Systems obligations under this warranty THIS WARRANTY IS GIVEN BY RMF SYSTEMS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NO...

Page 12: ...ht source shines through the fluid and lands on a photodiode When a particle passes through the beam it reduces the amount of light received by the diode and from this change in condition the size of...

Page 13: ...windows based software 4 2 2 1 Data Transfer via USB Stick The U version of the CMS allows direct download via a USB memory stick With the CMS powered up plug the USB stick into the USB connector at t...

Page 14: ...t individually calibrated with ISO Medium Test Dust MTD based on ISO 11171 on equipment certified by I F T S ISO 11943 Moisture Temperature Measurement saturation RH and fluid temperature C Mineral Oi...

Page 15: ...e 201 028 REV 1 Date of Issue 18 June 2018 Mounting 2 holes 7mm 126mm apart Weight 1 6kg Connections G1 M16x2 hydraulic connection G3 BSPP Female Port G4 7 16 UNF Female Port Seal Material M N Version...

Page 16: ...te of Issue 18 June 2018 5 4 Fluid Characteristics Fluid compatibility M version mineral oils synthetic fluids and diesels N version water based subsea fluids M version fluids S version Aerospace phos...

Page 17: ...applications contact RMF Systems Differential Pressure Typically 0 5bar 5 5 Environment Ambient working temperature 25 C to 80 C non K version 25 C to 55 C K version IP Rating IP66 IK Rating IK04 5 6...

Page 18: ...a differential pressure of more than approximately 0 5bar placed across the CMS such that a flow of fluid is generated within the range of the unit If there is no suitable differential pressure availa...

Page 19: ...Connector The remote connector is intended for temporary connection of an external communication device e g CMSUSBi so as to allow data download remote control or diagnostics using the RMF View softw...

Page 20: ...te of Issue 18 June 2018 Figure 6 1 Connector Orientation Figure 6 2 Machine Connector External Wiring Example 6 1 2 2 DC Power DC power is connected to pins 7 and 8 of either circular connector Red a...

Page 21: ...s RTU Modbus is a freely available open standard for industrial control Adapters are available to interface to other industrial control busses The standard RMF View software from RMF Systems itself us...

Page 22: ...or a single supply run through the trunk cable Figure 6 5 Remote Display Unit Including PC Controller Example Figure 6 5 shows how to connect the CMS RDU Remote Display Unit The RDU is used when the C...

Page 23: ...on or a PLC output The input accepts AC or DC signals typically derived from the DC supply voltage The exact function of this input is determined by the Test Mode setting section tbc Item Minimum Maxi...

Page 24: ...inputs or other equipment e g pump on off control The exact function of these outputs is determined by the Alarm Mode setting section 6 3 3 9 The outputs are voltage free contacts that can switch AC o...

Page 25: ...right to alter the specification without prior notice 201 028 REV 1 Date of Issue 18 June 2018 Figure 6 7 4 20mA Example 6 1 3 Hydraulic Connection 1 High or Low Pressure Parallel Connection Figure 6...

Page 26: ...he unit see hydraulic specification 3 2 The CMS measures the flow during operation so this can be used to check that the flow is correct A flow that is out of range will be indicated by a fault code s...

Page 27: ...here is a pair of connections in the hydraulic circuit that operates with a differential pressure near to that calculated then the CMS can be connected there Alternatively create the pressure drop by...

Page 28: ...CMS outlet port 6 1 3 3 Active Flow Control This is only needed for operation at high differential pressures where a too high flow would otherwise be generated A pressure compensated flow control valv...

Page 29: ...lue Alternating Indicates both cleanliness and water content upper limits exceeded Violet Indicates that the upper temperature limit was exceeded Red Flashing White Various fault codes can be indicate...

Page 30: ...display of all codes of the standards supported The unit powers up in Display Mode This displays the test result in the selected format The table below shows those available The screenshots in the ri...

Page 31: ...ow rate is within the limits of the unit The other items are mainly of use to assist in support when reporting problems The STATUS line shows the current state of the unit Any errors such as LOW FLOW...

Page 32: ...e test They can then monitor the progress of each test Each test result is displayed and downloaded into the test database as it is completed Disconnected Operation Here the CMS operates as a standalo...

Page 33: ...ication ports of the computer are available for selection Select the one used to connect the CMS and then press OK If you are unsure which port is correct the device name should be next to the COM por...

Page 34: ...mented and the status of the test is displayed If the status is Ready then the operator can press the Start button again to begin a new test It is also possible to configure the CMS to automatically b...

Page 35: ...connected CMS unit is available The Identification shows the CMS serial number and software version The serial number together with the test timestamp uniquely identifies the test record These two pa...

Page 36: ...l allow more stable results in very clean systems and for the larger particle sizes since there will be a larger total number of particles counted during the test This means that any fluctuations have...

Page 37: ...wn so as not to measure stagnant fluid and provide erroneous readings It may be necessary that the low flow indicator is turned off if filtration is below 10um ISO 14 12 10 NAS Class 4 see figure 6 22...

Page 38: ...op Testing When Clean This is a feature intended for cleaning rigs or filter trolley type applications The CMS continues testing until the fluid is clean at which point an alarm is signaled and testin...

Page 39: ...exible allowing the CMS to be used in many different scenarios 6 3 3 9 1 Alarm Levels The various alarm thresholds are set in the Contamination Code Target Alarm Levels area of the dialogue Alarms can...

Page 40: ...ible to specify codes for the other measured sizes too If this is not needed then the entries can be left blank NAS1638 Alarm Levels Figure 6 25 NAS1638 can be used by selecting this as the test Forma...

Page 41: ...similar except for terminology and reporting format The actual numeric sizes and class thresholds are the same 6 3 3 9 2 Alarm Mode Figure 6 28 The Alarm Mode sets the precise function of the two swit...

Page 42: ...ernal alarm relays can be used to drive an external remote 3 colour LED indicator This is a special type of LED containing both red and green emitters which could be mounted in a control panel This ex...

Page 43: ...on Protocols 6 4 1 Modbus The CMS can be controlled via commands on its serial RS485 interface using the Modbus RTU protocol It is possible to control every aspect and setting of the CMS as is done by...

Page 44: ...rmat required can be most easily set using RMF View however it is also possible to set it via Modbus To do this write the required value 0 4 from table 6A to the TEST FORMAT register 19 The factory se...

Page 45: ...ere applicable NOTE User written programs should take note to avoid displays like 32768 32768 32768 appearing on their front panels 6 4 1 2 2 ISO4406 ISO 4406 defines a set of code values to represent...

Page 46: ...be configured to test continuously and automatically so that the contamination measurement can be read out at any time as described above However some applications need a defined test start and test e...

Page 47: ...Count Registers 6 4 1 5 Alarms 6 4 1 5 1 Alarm Mode The CMS includes two relay outputs that can optionally be used for signaling the state of the unit These are normally used in stand alone applicatio...

Page 48: ...ired by your CAN bus network for example configure a CAN bus message ID and baud rate Figure 6 29 Connect the CMS to your CAN bus network and provide a 24VDC power supply as per figure 6 29 The CMS au...

Page 49: ...n 6 3 3 Figure 6 30 Communication Settings Dialogue The CMS can use either CAN 2 0A basic format with 11 bit identifiers or CAN2 0B extended frame format with 29 bit identifiers 6 4 2 2 2 CAN2 0B and...

Page 50: ...2 Operation Typically the installer will have configured the CMS to automatically start continuous testing At the end of each set test interval e g 2 minutes the CMS will emit a CAN Result Codes mess...

Page 51: ...e timer sequence for acquiring the results Parameters are output in a sequence one parameter per second until the end of the list We use an out of range current of 20mA 24mA to indicate parameter not...

Page 52: ...cheme 2 This outputs the parameters as currents using values designed for viewing directly on a programmable process meter There is no sync value but the final parameter stays on for 2 seconds instead...

Page 53: ...that test result 7 2 Fault Finding 7 2 1 LED Flashing Fault Codes The CMS front panel led indicates a fault by a number of white flashes with a red background The number of flashes indicates the fault...

Page 54: ...to occur automatically D User has set a non zero test interval E Or fluid is totally clean no particle counts Flow alarm can be turned off by user if this is a problem for example cleaning rigs 7 2 3...

Page 55: ...reduce the product test time in a production line situation A longer test time enables the unit to average out variations in cleanliness and produce a more stable result This is especially true for t...

Page 56: ...tatus LED to indicate fault conditions RS485 CANBUS 4 20mA communications Measurement in multiple international standard formats All units include 3m pre wired control cable and RMF View test analysis...

Page 57: ...wn in figure 6 4 Please note that the RDU cable provided must be plugged into the right hand remote connector of the CMS for it to work Please note that the RDU only records tests whilst powered up If...

Page 58: ...Service and Recalibration Warranty The CMS is guaranteed for 12 months from date of receipt See section 3 for further details Recalibration The CMS is recommended to be recalibrated every 12 months R...

Page 59: ...lection of Modbus Registers Each register is numbered the CMS has 125 registers Each register holds a number representing some quantity For example register number 2 holds a number indicating the CMS...

Page 60: ...ned integers 64 71 Contamination Limit Upper Array of 8 signed integers 72 79 Contamination Limit Lower Array of 8 signed integers 80 Limit Water Upper x100 signed integer 81 Limit Water Lower x100 si...

Page 61: ...etation Each bit in the register has a separate function The most important example is the status flags register 31 Each register bit encodes a separate function for example result valid new result ov...

Page 62: ...Continuous Mode Log Every Test 4 CONTINUOUS_CONFIRM_TARGET Repeat final test to confirm target level achieved 5 RESERVED 6 RESERVED 7 SIMULATE Produces simulated test results 8 LOW_FLOW_CLEAN_DISABLED...

Page 63: ...lay output s But they can also be monitored directly by a PLC MMI program and used to drive indicators for example Bit 11 is used internally to detect that the CMS is being controlled by Modbus from a...

Page 64: ...odbus implementation For a background to this section the implementer can review the Modbus source documents http www modbus org docs Modbus_over_serial_line_V1 pdf http www modbus org docs Modbus_App...

Page 65: ...MS product ID is 0xD3DD hexadecimal or 54237 decimal This fact can be used as a check when attempting the above implementation Finally we come to extracting the test result Referring to the CMS Modbus...

Page 66: ...the CMS can be connected to a PC using a USB CAN adaptor The adaptor used in this example is the PCAN USB available from Peak System Technik GmbH or a distributor We also need to make up a special ca...

Page 67: ...l anything from 50 150 ohms will work 11 2 1 2 Initial Configuration Initially we connect using the CMS USBi interface so that the CMS can be comfortably configured using RMF View Detailed information...

Page 68: ...ttings for this walk through are Test Duration 10 seconds Test Continuously On interval 0 Start Testing Automatically On Stop Testing When Clean Off Simulate Test On NOTE Simulate Test will cause fict...

Page 69: ...ue within a few seconds A test should have been automatically started The tests should repeat every 10 seconds You should see a test result that starts high and decreases with each further test Close...

Page 70: ...ar connector It should power up and start performing a test If everything is working after about 20 seconds you should see CAN messages similar to that shown below This shows the 2nd result received T...

Page 71: ...GNs 0xFFB5 0xFFB9 Default Broadcast Interval 1s Data Page 0 Priority 6 PDU Format PDU specific Derived from PGN Byte Endianness All data is on little endian byte order Table 11F CAN bus Parameters for...

Page 72: ...25 C 25 50 m 6 38 D 50 100 m 7 50 E 100 m 8 70 F NOTE The basic class is the highest of the individual size classes ISO4406 only defines codes for the first 3 sizes 4 6 and 14 m we extend the concept...

Page 73: ...gs Bitmask This is identical to table 11D page 62 Bits 0 2 are so that external equipment for example RMF View or a PLC MMI can display update and log results intelligently Bits 3 and 4 can be used to...

Page 74: ...oil usually has a water content of 50 300 ppm which it can support without adverse consequences Once the water content exceeds about 500ppm the oil starts to appear hazy Above this level there is a da...

Page 75: ...tinual improvement RMF reserves the right to alter the specification without prior notice 201 028 REV 1 Date of Issue 18 June 2018 Examples Hydraulic Oil 30 C 200ppm 100 Saturation Hydraulic Oil 65 C...

Page 76: ...10 20 11 5 10 10 2 5 5 9 1 3 2 5 8 0 64 1 3 7 0 32 0 64 6 0 16 0 32 5 0 08 0 16 4 0 04 0 08 3 0 02 0 04 2 0 01 0 02 1 0 0 0 01 0 Figure 11 2 Figure 11 3 The International Standards Organization standa...

Page 77: ...15 25 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400 25 50 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400 50 100 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760 Over 100 0...

Page 78: ...t Type ISO 4406 1999 Code Pump Piston slow speed in line Piston high speed variable Gear Vane 22 20 16 17 15 13 19 17 15 18 16 14 Motor Axial Piston Radial Piston Gear Vane 18 16 13 19 17 13 20 18 15...

Page 79: ...ystem user has been able to check cleanliness levels over a considerable period the acceptability or otherwise of those levels can be verified Thus if no failures have occurred the average level measu...

Page 80: ...so not traceable to any national standard of measurement a critical requirement for today s quality management systems There was also an absence of formal controls over the distribution of the test du...

Page 81: ...nding very closely to the previous 5 and 15 m measurements This will ensure consistency in data reporting As the counts derived by microscope counting methods are not affected the particle sizes used...

Page 82: ...Obtained Using ACFTD ISO 4402 1991 m ISO NIST MTD ISO 11171 m c 1 4 2 2 4 6 3 5 1 4 5 8 5 6 4 6 7 1 7 7 7 8 8 4 9 9 1 10 9 8 11 10 6 12 11 3 13 12 1 14 12 9 15 13 6 16 14 4 17 15 2 18 15 9 19 16 7 20...

Page 83: ...following table gives a very general comparison but often no direct comparison is possible due to the different classes and sizes involved ISO4409 1999 DEF STD 05 42 Table A Table B NAS 1638 ISO 11218...

Page 84: ...sample was taken from Do use suitable glass bottles ideally certified clean to take samples along with a hand pump to reduce contamination ingress Do filter your system thoroughly before using it in y...

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