Hydrotechnik HySense CV 100 Manual

Oil condition sensor

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HySense® CV 100

Oil condition sensor

Manual

Version 1.0 EN

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Summary of Contents for Hydrotechnik HySense CV 100

Page 1 HySense® CV 100 Oil condition sensor Manual Version 1.0 EN...
Page 2: Table Of Contents
MANUAL Performance and measurement principles ........................5 General ..................................... 5 Temperature measurement ............................... 5 Viscosity measurement ..............................5 Measuring the relative permittivity ............................ 6 Filling level sensor ................................6 Operating hours counter ..............................6 Data logger ..................................6 Automatic condition evaluation ............................6 Determination of the Remaining Useful Life Time (RUL) ....................
Page 3 The information does not release the user from his own assessments and examinations. Our products are subject to a natural wear and aging process. © All rights at Hydrotechnik GmbH, also in case of patent applications. Any power of disposal, such as copy and transfer rights remains with us.
Page 4: Performance And Measurement Principles
1 PERFORMANCE AND MEASUREMENT PRINCIPLES 1.1 General The HySense® CV 100 oil condition sensor, hereinafter referred to as CV 100 serves to measure and document changes in the properties of the hydraulic and lubricating media. The corresponding measured valuesare continuously recorded, saved and can be read at any time via a serial interface or CAN bus.
Page 5: Measuring The Relative Permittivity
The measurement of the viscosity is done electronically with the help of an acoustic surface wave transducer and, therefore, without mechanical wear parts. It is important to consider that the acoustic surface wave sensor supplies different results due to its measuring principle, compared to results determined by Ubbelohde viscometers.
Page 6: Determination Of The Remaining Useful Life Time (Rul)
A standard parameterization of the aging limits is set at the factory. For specific information regarding the setting of aging limits, plea- se contact the HYDROTECHNIK service team. The limit values should be adjusted for specific applications. The determined residual life represents a reference value, which was determined by linear extrapolation.
Page 7: Overview On All Measured And Derived Parameters
1.11 Overview on all measured and derived parameters For characterization of the oil level, the above-described four original characteristics are measured. These parameters and their meaning are again listed in the following table. Parameter Abbreviation Unit Statement Operating hours Time Counts as soon as the power is turned on Temperature °C...
Page 8: Overview On Issued Parameters For Individual Commands
User Sensor Info: Fresh Reference "History" memory memory Rule base Current data set, Gradients & Thresholds oil condition Algorithms Dataset of measured and calculated data Conductivity Rel. humidity Temperature Rel. permittivity Figure 2: Data processing and interaction between the measured parameters and algorithms in the sensor 1.13 Overview on issued parameters for individual commands The sensors support a series of commands to issue the measured, derived and calculated parameters of the oil.
Page 9 Parameter name Unit Statement Setting for the analog output 1 Setting for the analog output 2 ETrig Error triggered storing in history (1 = on, 0 = off) TrAu Periodic transmission of the data set as it is output at the RVal command in intervals of specified minutes (Range 1..60 minutes, at 0 setting the automatic transmission is turned off) ORef...
Page 10: Technical Specifications
2 TECHNICAL SPECIFICATIONS 2.1 General data Sensor data Size Unit Max. operating pressure Operating conditions Temperature -20 ... +85 °C Rel. humidity 0 ...100 % r.H. (not condensing) Compatible liquids mineral oils (H, HL, HLP, HLPD, HVLP) synthetic esters (HETG, HEPG, HEES, HEPR) polyalkyleneglycols (PAG) zinc and ash-free oils (ZAF) polyalphaolefins (PAO)
Page 11: Dimensions
2.2 Dimensions Abbildung 3: Anschlussmaße CV100...
Page 12: Mounting
3 MOUNTING The sensor is designed as a screw-in sensor with a ¾“ thread. Ideally, the sensor is installed in hydraulic circuits in the tank or in the return line. With gear units with forced flushing, the sensor can also be arranged in the purge line. In general, when placing the sensor, the maximum allowable pressures and temperatures are to be considered (see Chapter 3).
Page 13: Electrical Connection
4 ELECTRICAL CONNECTION 4.1 General information and safety note The device must be installed by a qualified electrician. Follow the national and international regulations for the installation of electrical equipment. Voltage supply according to EN 50178, SELV, PELV, VDE 0100-410 / A1. For installation, disconnect the device from the power and connect the device as follows: Top view sensor cover Pin assignment...
Page 14: Analog Current Outputs (4
4.3 Analog current outputs (4...20 mA) - measurement with load resistance In order to measure the currents of the analog current outputs, a load resistance must be connected to each output as shown in Figure 8. The load resistance should be, depending on the supply voltage, between 25 Ohm and 200 Ohm. With the use of a voltmeter, the voltage at each resistor can now be measured.
Page 15: Calibration
4.3.2 Calibration Output Size X Output range Equation Formula U / V T in °C -20°C...120°C X / °C = · 8750 (°C / A) - 55°C (6-2) R / Ω X = U / V P; P40 1...5 (6-3) ·...
Page 16: Communication
RS232 interface (see Chapter 6.1) During startup, the hash key (#) needs to be kept pressed until the sensor reports with its ID (for example, $HYDROTECHNIK;CV100;SN;000015;0.55.15;CRC:b).In case the sensor does not respond within 10 seconds after applying the power supply, the process must be repeated.
Page 17: Read Commands
Return format format RVal[CR] Reading all measurements with subsequent checksum (CRC) $ Time:x.xxx[h];T:xx.x[°C]; ..;CRC:x[CR][LF] RID[CR] Reading the identification and subsequent checksum (CRC) $HYDROTECHNIK;CV100; SN:xxxxx;...;CRC:x[CR][LF] RCon[CR] Reading the configuration parameters and CAN configuration with $AO1:x;AO2:x;…; subsequent checksum (CRC) CRC:x[CR][LF] RGrad[CR] Reading the parameter gradients with subsequent checksum (CRC), $Time:x.xxx[h];...
Page 18: Write Commands
5.2.2 Write commands Instruction format Meaning Return format SONew[CR] Stores the current state as fresh oil. All parameters are deleted ok[CR][LF] (gradient, reference values, learned values), oil age is set to 0 h, learning process is triggered (duration: approx. 250 hours), data remain in memory.
Page 19 Instruction format Meaning Return format WLimP40% n [CR] Sets limit for allowable change P40 compared to learned referen- LimP40%:n[%] [CR][LF] ce value in % When approaching and exceeding the current P40 deviation from this value, warnings and alerts are set Range n: 1.0..100.0% Default value n: 5% WLimV40% n [CR]...
Page 20: Crc Calculation
5.2.3 CRC calculation Each character sent in the string (incl. Line Feed and Carriage Return) must be added up, based on a range of 8 bits (0→255). If the result is zero, there is no error. Character Value Ù [CR] [LF] 0→OK Table 17: Example of a checksum calculation (CRC)
Page 21: Setting The Analog Current Outputs
In the subsequent input window, the corresponding commands for reading or configuration can be entered. The command list is shown in Chapter 5.2. Note, that by default all characters, which are entered into the terminal program via the keyboard will not be displayed on the screen.
Page 22: Output Trigger
Current Start character Start character Time 2 sec. Figure 13: Sequential output of the values via analog interface 5.5 Output trigger The measured values can in principle be output via the RS232 interface in two different ways: time-triggered or command-trig- gered.
Page 23: Can
6 CAN 6.1 CAN communication he CAN interface corresponds to the „CAN 2.0B Active Specification“. The data packets correspond to the format shown in Figure 7.1. The picture is intended for illustration purposes only, the implementation corresponds to the CAN 2.0B specification. The sensor supports a limited number of transmission speeds on the CAN bus (see Table 20).
Page 24: Canopen Object Dictionary" In General
6.2.1 „CANopen Object Dictionary“ in general The CANopen Object Dictionary (OD) is an object dictionary in which each object can be addressed with a 16-bit index. Each object can consist of several data elements that can be addressed by an 8-bit sub-index. The basic layout of a CANopen object directory is shown in Table 22 CANopen Object Dictionary Index (hex)
Page 25: Service Data Object (Sdo)
Depending on the state of the sensor, different services of the CANopen protocol are available (see Table 7.4). Availability of services, depending on the sensor condition Com. Object Initializing Pre-Operational Operational Stopped Synch BootUp Table 23: Available CANopen services in different sensor states 6.2.3 Service Data Object (SDO) Service Data Objects allow read and write access to the object directory of the sensor.
Page 26 An example of a SDO query of the serial number of the sensor from the object directory at index 0x1018, sub-index 4, with data length 32 bits is shown below. The client (controller) sends a read request to the sensor with the ID "NodeID"...
Page 27: Process Data Object (Pdo)
6.2.4 Process Data Object (PDO) PDOs are one or more records, that are reflected from the object dictionary in the up to 8 bytes of a CAN message, to transfer data quickly and with the least possible expenditure of time from a „Producer“ to one or more „Consumers“ (see Figure17). Each PDO has a unique COB-ID (Communication Object Identifier), is sent by a single node, but may be received from a plurality of nodes and does not need to be acknowledged / confirmed.
Page 28 Complete OD, a.o. with map-enabled objects Index Type Object TPDO2 mapping parameters in OD, at Index 0 x 1 A01 Type Value 2001 Oil temperature U 32 0x20010110 2007 Compensated conduct U 32 0x20080110 U 32 0x20060210 2006 Compensated perm U 32 0x20070110 2008...
Page 29 0..10000 1018 Identity object record Number of entries largest sub-index Vendor ID 0000001C0 HYDROTECHNIK GMBH Product Code Revision Number 1000 Serial Number Device dependant lower 3 bytes contain the serial number, the top byte is reserved for future use...
Page 30 Communication Profile Area ldx (hex) Name Type Attr. Default Notes 1A00 TPDO1 Mapping Parameter record Number or entries largest sub index 1st app obj. to be mapped 20000410h Alarms 2nd app obj. to be mapped 20000310h Information 3rd app obj. to be mapped 20000210h Status 4th app obj.
Page 31 Manufacturer-specific Profile Area Idx (hex) Name Type Attr. Default Notes Status of oil age counter Oil age counter, running after boot up (value > 0), to stop counter write a 0, no saving, always 1 after reboot 2006 Permittivity related record parameters of the oil Number of entries...
Page 32 Manufacturer-specific Profile Area Idx (hex) Name Type Attr. Default Notes 200C Aging Progress Aging Progress in % multiplied by 10 2020 Commandos record Number of entries largest sub index New Oil new oil commandos 0x01 = new oil, same as RS232 com- mand “SONew”...
Page 33 7. COMMISSIONING In the following, the commissioning of the sensor is described in each case with the RS232 and CAN interface. Check, if the device is properly installed and securely electrically connected. For proper functionality of the sensor, the condi- tions listed in Chapter 2.1 and Chapter 3 must be observed.
Page 34 7.3 Range of functions depending on the configuration Depending on the desired functionality, the sensor can be configured with additional information, to offer the respective functions. Required configurations for receipt of functions Necessary information on the system Features / Scenario / configuration needs ›...
Page 35 Note in particular the capitalization and lowercase With invalid commands, the sensor returns the entered string with a prefixed question mark Cable wrong or defective If possible, use Hydrotechnik data cables RS232 interface is not activated Activate the RS232-interface either temporarily or permanently, using a terminal program, as described in Chapter 6 ›...
Page 36 9 APPLICATION EXAMPLE The oil condition is a factor, formed out of many parameters. Limits for specific oil parameters are dependent on the particular application, such as the components used and the materials. The type and speed of the oil parameter change is in turn depen- dent on the application, the specific system load as well as on the pressure or lubricating medium used.
Page 37 10 APPENDIX 10.1 Coding of error bits Block Type Description Recommended light status Alarm Low oil level summary Alarm Sensor in air Alarm Oil level falling (reacts with delay) Alarm Sensor partially in air Alarm Reserved Alarm Reserved Alarm Current temperature exceeds limit Alarm Average of temperature history exceeds limits Alarm...
Page 38 Block Type Description Recommended light status Info/warning PowerUp (Sensor has been rebooted, remains active for about 15s) Info/warning Oil change to another oil Info/warning Oil change to another oil Info/warning Oil refreshment to another oil Info/warning Oil refreshment to another oil Info/warning Bit 44/45: Oil type recognition** 44: HLP...
Page 39 11 ACCESSORIES 11.1 Viscosity sensor Part Order number Comment CV 100 3402-CV10-G926C0-000 11.2 Accessories and spare parts Order number Description Comment 8812-00-00.36 Power supply M12x1; 8 pol power supply Socket, with Countries plug adapter 8824-T1-02.50 Measuring cable M12x1; 8 pin CAN connection cable Socket / open end 8824-T6-02.50...
Page 40 Hydrotechnik GmbH D–65549 Limburg Tel.: +49 6431 4004 0 Email: info@hydrotechnik.com www.hydrotechnik.com L3402-CV10-G926C0-00EN...