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User Manual
TSG-EMEA@skf.com
for customers in Europe, Middle East and Africa.
Telephone: +46 (0) 31 337 65 00
or
TSG-Americas@skf.com
for customers in North America, South America and Asia.
Telephone: +1 800 523 7514
Telephone in Latin America: +55 11 4448 8620
Installation 6 - 12
..............................................................................................................6
Sensor Mounting - 12
..............................................................................................................6 - 13
Installation
Interpreting Results 7 - 15
Technical Data 8 - 16
..............................................................................................................8 - 16
Environmental
..............................................................................................................8
Power Supply - 17
..............................................................................................................8 - 17
Outputs
..............................................................................................................8 - 17
Sensor
Dimensions 9 - 18
1
Introduction
This manual covers CMSS-ONL-1000 Metallic Particle On-line Sensor for monitoring
the amount of metallic non-ferrous and ferrous wear debris in an oil or fluid medium.
Combining vibration and oil monitoring gives valuable information for the protection of
your assets. Both vibration and oil monitoring have unique capabilities to analyze
machine problems and prevent failures.
· The sensor provides continuous analysis of gearbox, bearing or motor oil.
· It increases reliability with analysis results by providing accurate information on
wear rates.
The Metallic Particle On-line Sensor, together with the SKF Multilog On-line System IMx
gives information on particle type, size and count rate per minute. Combining this
information with vibration data can give a precise location of the damage*.
The sensor is easy to integrate with the SKF Multilog IMx by using Modbus RTU;
· The system gives a trend for each size and type.
· Using derived points in SKF Multilog IMx allows data to be combined in
mathematical formulas; this can, for example, give a better overview by
displaying the total number of particles or estimated weight of debris*.
*Function only enabled in SKF @ptitude Observer; planned to be implemented in SKF @ptitude
Analyst.
The metallic particle sensor needs to be used with low-volume off-loop (kidney loop)
filtration and cooling systems, for example as SKF Oil Conditioning unit (SKF-OCU-XX).
The metallic particle sensor is suitable to place between pump and filter due to bore
size.
SKF-OCU-5 and SKF-OCU-10 have flow rates in oil sensors operating range.
Figure 1-1: SKF Metallic Particle On-line Sensor Figure 1-2: SKF Oil Conditioning unit
(CMSS-ONL-1000) (SKF-OCU-XX)
2
Safety and Requirements
This equipment is designed to comply with EN61010-1.
Warning: This equipment has not been approved for use in an explosive atmosphere.
Please ensure that you thoroughly read and understand this user document before
attempting to install or operate the Metallic Particle Sensor (MPS) covered in this
manual, derivatives or related equipment.
If the equipment is used in a manner, or for a specific purpose other than that described
in this manual, then any safety protection may be impaired.
The MPS is designed to be connected to hydraulic systems many of which will be
pressurized. A responsible body, the end user or system integrator is responsible for
ensuring the safety of associated systems, hoses or pipe-work containing fluids. This
includes isolation for maintenance to the MPS(s).
Important: This equipment must be installed and operated by qualified persons only.
Important: All units are metric unless otherwise stated; millimetres or metres, Bar, °C,
etc.
Before the maintenance, it is important that all common supplies, power and oil must
be turned off. It can be done by disconnecting at source or by closing the valves to the
Metallic Particle Sensor to isolate the MPS from the system. The latter method is
recommended.
· Never use the MPS near combustible gases or liquids.
· Never disassemble, repair, or tamper with the MPS.
· Ensure that the supply voltage is within the specifications and means of
isolation fitted.
· Ensure that the load currents do not exceed the rated values.
· Ensure that all associated equipment and pipe-work specification are the same
or greater than the operating specifications for the MPS.
· Check all associated equipment and pipe-work for correct connection before
powering the unit.
· Check all wiring for correct connection before powering the unit.
· Never weld to a pipe which contains or has contained oil
· The MPS case must be earthed
· Maintenance and cleaning
· The MPS, power supplies & accessories contain no user serviceable parts. Do
not dismantle.
Please retain all original packaging for shipping purposes.
All fluids must be removed from the equipment and the MPS be cleaned appropriately
before the return.
3
LED Status
If the metallic particle sensor is not responding as expected, check the status of LED's.
4
Manintenance
Cleaning
The outer case does not require cleaning during normal use. Wipe clean the MPS with a
soft cloth or tissue.
Conventional methods should be used for cleaning associated pipe-work should it
become blocked.
Do not use aggressive chemicals or mechanical methods, such as wire brushes or
scrapers to clear a blockage in the MPS bore, as this may scratch and damage the
plastic.
Pressure Testing
The MPS is factory pressure tested; as a result there may be a small amount of test
fluid present in the MPS.
5
Particle Detection Information
Memory
The MPS automatically saves particle measurement data in its memory every three
minutes. Due to the high data rates, data recorded between the save interval may be
lost if the power is interrupted – so much like a computer if the power is lost only the
data since the last save is kept.
Metallurgy
99.99% pure Fe gives the largest signal, the bins have been structured about a
composite of Fe and CrSteel particles. A ferrous particle of 100um will be
over-reported, whilst a chrome steel particle 100um will be under-reported.
Volume
The MPS counts particles based on electro-magnetic properties, which is determined by
the amount of metal present - the volume of the particle. A spherical object has the
greatest size/volume relationship, therefore the volume of a 70 micro-metre (micron)
(0.07mm) will contain the same volume as a particle 150 x 60 x 25 microns (L x W x H).
When the particles are viewed under a microscope, they may appear large, but their
volume is small.
The MPS has been developed using research conducted by independent technical
institutes for tribotechnology. Real wear debris has been captured. The MPS is
calibrated and defined using wear particles of a nominal chord length, therefore
spherical particles may be reported as larger than they are.
6
Installation
Sensor Mounting
Where possible, the entire fluid flow should be diverted through the MPS [full flow].
Care must be taken to ensure the flow rate does not exceed the specified limits.
In many cases a gate valve is fitted to divert flow into the MPS, in some cases it is
possible to fit a pressure relief type of valve. The pressure relief valve is designed to
allow flow into the MPS and bypass as necessary. This ensures flow through the MPS.
Installation
Electrical Connections:
Colour Description Terminal
Red Power supply 18-30V dc PS 24VDC, IMx Ch1&2 A
Black Power Ground 0V dc PS 0 VDC
Pink 4-20mA Input (particles/min) IMx Ch1 B
Yellow 4-20mA Output (particles/min) PS 0 VDC
Blue/Red 4-20mA Input (particle mass/hour) IMx Ch2 B
Orange 4-20mA Output (particle mass/hour) PS 0 VDC
Table 6-3: Electrical connections
SCREEN The Cable screen is connected to the MPS case. Case Ensure MPS body is
earthed, use the wire provided if necessary
For information on how to set up point in @ptitude Analyst, check SKF @Analyst and
SKF Multilog on-line system user manual.
7
Interpreting Results
The clearest indication of the onset of failure is a rapid rise in the wear rate. Although
no two pieces of equipment are the same, generally, most metallic components in a
system will have high wear when initially installed – due to bedding in processes, low
wear in normal operation – adequate lubrication and high wear again as the component
eventually fails. This is often called a classic bath tub curve. With this knowledge specific
warning limits for each piece of equipment can set. If a rapid increase in wear is spotted
early enough, proactive and preventative maintenance can be conducted before critical
breakdown.
8
Technical Data
Environmental
1)
Signal output reduces with the speed of the particle; slower flow rates are optimum. Volumes
quoted are for the SKF Metallic Particle Sensor bore and minimal pipe work (10 mm diameter
and 0,5 m long) equating to 54 ml.
Power Supply
· Power input: 24 V DC (18 to 30 V)
· Power consumption: 0,7 A
· Fuse rating: 1A quick blow
Outputs
· Particles per minute: 4 to 20 mA (Scale 0 to 1 000 ppm)
· Particle mass per hour: 4 to 20 mA (Scale 0 to 99 999 999 mg/h)
· RS485: Two wire half duplex (SKF Multilog IMx-S, IMx-C, IMx-W, IMx-T)
Sensor
· Particle speed: 1,3 to 21,0 l/min (0.34 to 5.55 gal/min) constant flow 2),3)
· Detection limits:
- Ferrous: 40 mm (0.00157 in.) 3)
- Non-ferrous metallic: 135 mm (0.00531 in.) 3)
2)
Signal output reduces with the speed of the particle; slower flow rates are optimum. Volumes
quoted are for the SKF Metallic Particle Sensor bore and minimal pipe work (10 mm diameter
and 0,5 m long) equating to 54 ml.
3) Constant flow rate 0,3 m/s, iron metal (electrolytic) 99.99% Fe purity – spherical particle. The
SKF Metallic Particle Sensor will not detect combined Fe in a non-magnetic compound (for
example, rust).
9
Dimensions