CM5115 EN CMSS-ONL-2504 and CMON 2504
Contents
1. Chassis ground bar To CMSS 786M sensor Fig 8 CMON 2504 wiring diagram IMx S IMx W gE AEE i i Relay driver CAN RS485 cht Ch2 Chi Ch2 H L feol E Do a2viDo leav CAN CAN CAN GND 705 NOW Chassis ground bar To CMSS 786M sensor Fig 9 CMON 2504 wiring diagram IMx W SKF CMON 2504 Installation Validation It is recommended that installations of the CMON 2504 be validated before they are commissioned All installations of the CMON 2504 must be validated using a digital voltmeter Furthermore it is recommended that in addition to using a digital voltmeter the entire AEE installation should be validated using the SKF CMAC 2504 acoustic emission pulse generator to Inject a known signal into the installation site and SKF ptitude Observer SKF ptitude Analyst to inspect the system response aKF 1 CMON 2504 Installation Validation Use the digital voltmeter and the provided flow chart gt fig 12 to perform i2. CMON 2504 Acoustic Emission AE Interface Card for the SKF Multilog On line System IMx Fig 1 Top view of CMON 2504 Fig 2 Bottom view of CMON 2504 Introduction This document describes the installation of the CMON 2504 DIN card and the CMSS ONL 2504 cable assembly into an SKF Multilog On line System IMx Requirements The following tools are required to install the CMON 2504 and CMSS ONL 2504 into the IMx e wire cutters e wire strippers e 4mm crosshead screwdriver e 4mm flat blade screwdriver CMON 2504 The base of the CMON 2504 is identified by the sliding metal clip on the lower end of the enclosure at the rear of the module Connectors J2 andJ3 on top of the unit provide power in and signal output J1 on the bottom of the unit provides signal input CMON 2504 terminal block connections e J1 1 AE sensor signal phantom power line Input e J1 2 AE sensor 0V return Input e J1 3 not used e J2 1 12 to 24 V DC power supply input Supply e J2 2 0V DC power supply input and signal ground Supply e J2 3 not used e J3 1 AE DIN interface demodulated output Output e J3 2 not used e J3 3 Signal ground Output It may be convenient to connect the wires before mounting the CMON 2504 on the DIN rail CMSS ONL 2504 The cable will have been pre stripped to 125 mm to aid the installation process CMSS ONL 2504 wires e Blue and green for AE signals e Red and black
3. Power OK Low Power 2 Check CMON 2504 input Check power supply IMx W External supply IMx S v gt 6 9V amp lt 7 1 across J1 1 and J1 Check wiring and IMx DIP settings Check wiring Check wiring lt 6 9V Sensor amp cable OK Check cable polarity Polarity OK gt Cable fault Polarity wrong Correct the polarity j 3 Check CMON 2504 output Measure voltage across J3 1 and J3 gt lt 0 1V 3 gt 0 1V CMON 2504 CMON 2504 OK fault bad power ground Proceed to CMAC 2504 testing Fig 12 CMON 2504 installation validation flow chart Please contact SKF Condition Monitoring Center Lulea Aurorum 30 SE 977 75 Lule Sweden Tel 46 0 31 337 1000 Fax 46 0 920 134 40 Web www skf com cm SKF and MULTILOG are registered trademarks of the SKF Group Loctite is a registered trademark of Henkel Corporation All other trademarks are the property of their respective owners SKF Group 2014 The contents of this publication are the copyright of the publisher and may not be reproduced even extracts unless prior written permis sion is granted Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be ac cepted for any loss or d
4. connected to the body of the sensor and is usu ally grounded by the sensor Where the sensor is glued into position there may not be an electrical connection and the cable screen may need to be connected to the earth strip below the DIN rail Output signal connections e Make a blue green twisted pair cable this may be made from excess wire cut off during the AE sensor signal connection Connect a blue wire of the output twisted pair to CMON 2504 J3 1 Connect the green wire of the output twisted pair to CMON 2504 J3 3 Route the twisted pair to the desired input channel of the IMx Blue signal should be connected to IMx channel terminal A Green ground should be connected to IMx channel terminal B Power connections e Make a black red twisted pair cable e Connect the red 24 V wire from the IMx relay driver CH1 12 V to CMON 2504 J2 1 e Connect the black O V wire from the IMx CAN bus GND to CMON 2504 J2 2 e Connect a wire from J3 3 to IMx W chassis ground e Connect the cable screen to IMx chassis ground bar Fit the CMON 2504 DIN card to the DIN rail with the metal clip at the bottom aKF Multiple cards Each 12 V relay output can be used to power up to two CMON 2504 DIN cards meaning that a maximum of four units can be fitted in the IMx W without the need for a discrete DIN power supply e Connect the power to the four cards as shown in fig 5 Fig 5 Power connection for four CMON 2504 DIN cards fitted in I
5. for ICP signals The drain wires from the two shields are twisted together and may be connected to the IMx ground rail if required IMx S Single module AE sensor signal connections e Route the signal cable through a port on the enclosure base e Connect the blue wire from the sensor cable to CMON 2504 J1 1 e Connect the green wire from the sensor cable to CMON 2504 J1 2 ICP signal connections e The black and red wires coming from the sensor cable are stand ard ICP signals and can be connected to the standard IMx channel e Red signal should be connected to IMx channel terminal A e Black ground should be connected to IMx channel terminal B Terminal A or B refers to IMx S Terminal or refers to Mx W The cable screen is connected to the body of the sensor and Is usu ally grounded by the sensor Note that where the sensor is glued into position there may not be an electrical connection and the cable screen should be connected to the earth strip below the DIN rail Fig 3 Input signal connections from CMSS ONL 2504 cable to CMON 2504 J1 card not yet fitted to DIN rail Output signal connections e Make a blue green twisted pair cable this may be made from excess wire cut off during the AE sensor signal connection Connect a blue wire of the output twisted pair to CMON 2504 J3 1 Connect the green wire of the output twisted pair to CMON 2504 J3 3 Route the twisted pair to the desired input channel of the
6. IMx Blue signal should be connected to IMx channel terminal A Green ground should be connected to IMx channel terminal B Power connections Make a black red twisted pair cable Connect the red wire from the IMx channel terminal PWR 24 V toJ2 1 Connect the black wire from the IMx channel terminal B 0 V output to J2 2 This is the same terminal that the green wire has already been connected to Connect a wire from J3 3 to IMx S chassis ground Connect the cable screen to IMx chassis ground bar Fit the CMON 2504 DIN card to the DIN rail with the metal clip at the bottom Fig 4 ICP signal connections from CMSS ONL 2504 cable to IMx S Ch1 aKF Multiple modules As each IMx S channel has 24 V available multiple CMON 2504 DIN cards are connected in the same way as a single card each connected to two channels one each for the AE signals and the vibration signals IMx W Single cards AE sensor signal connections e Route the signal cable through a port on the enclosure base e Connect the blue wire from the sensor cable to CMON 2504 J1 1 e Connect the green wire from the sensor cable to CMON 2504 J1 2 ICP signal connections e The black and red wires coming from the sensor cable are stand ard ICP signals and can be connected to standard IMx channel e Red signal should be connected to IMx channel terminal A e Black ground should be connected to IMx channel terminal B The cable screen is
7. Mx W Configuration In order to configure IMx S IMx T or IMx M and SKF ptitude Analyst SKF ptitude Observer it is necessary to position DIP switches in the used channels as shown in figs 6 and 7 Changes to DIP settings should only be made when the IMx unit is powered off Termin DIP Settings position 123456 Terminal Fig 6 DIP switch positions for IMx S IMx T and IMx M channels 1 8 DIP A Settings DIP B Settings 100100 0010 a Fig 7 DIP switch positions for IMx M channels 9 16 Installation considerations Sensor mounting In most cases the AE sensor is mounted on a bearing housing ora machine casing Hence the material of the casing and the distance between the source and the sensor can have a significant effect on the attenuation of the AE wave It is vital that the surface onto which the sensor Is to be mounted must be free of paint coat ings or rust have a smooth machine finish and have a suitable AE couplant between the sensor and the surface Choice of couplant and adhesives The right choice of couplant and adhesives between the interfaces are vital in order to avoid attenuation of AE It is important to remove all traces of air between the mating surfaces even smooth ones by means of a couplant with an AE impedance matched closely to steel and with the ability to last for the required period of time required for that application Stud method The stud method provides the best results w
8. amage whether direct indirect or consequential arising out of the use of the information contained herein SKF re serves the right to alter any part of this publication without prior notice PUB CM5115 4 EN May 2014
9. ith least attenuation of the AE It also has the benefit of having only one interface and not requiring any adhesive The mating surface on the bearing or machine housing should be prepared in accordance with the specifications provided in the following table Table 1 Stud method specifications Stud model From To Surface preparation toolkit CMSS 30168700 1 4 28 1 4 28 CMAC 9600 01 CMSS 30168701 1 4 28 M8 CMAC 9600 02 CMSS 30168703 1 4 28 M6 CMAC 9600 10 In cases where It is not possible to drill and tap a hole to allow the stud method to be used the sensor glue mount that Is included with the cable assembly should be used It should be fixed to the mounting surface using a thin layer of Loctite 480 adhesive The use of other adhesives or sensor mounts can significantly attenuate the AE signal For asmall number of applications which utilise an insulated bearing design it is preferable to also use an insulated adhesive mounting pad method by adhering a CMSS 91 0MI cementing stud with 1 4 28 male to the surface of the bearing or machine housing and then use a suitable couplant e g Geocel Marine Silicone between it and the AE sensor This isolated mounting stud allows the sensor to be isolated from the bearing thus preventing any potential ground loops IMx S gE AEE 100110 100100 Chi ch2 plalslejale P 470S NOW
10. nitial validation of the CMON 2504 installation If the CMON 2504 installation is found to be OK then you can proceed to testing the AEE system installation 2 AEE System Validation The CMAC 2504 is used to inject a known signal into the bearing The system response to the signal is used to validate the entire installation The CMAC 2504 generates a pulse train output with 20 V amplitude 2 0 us pulse width and a repetition frequency of 70 Hz To inject a signal acoustic emission couplant is applied to the acoustic emission transducer the transducer is connected to the CMAC 2504 and the device is turned on The transducer Is then placed on the test surface AE sensor or adjacent to AE sensor installation site Before testing with the CMAC 2504 ensure that the AE sensor is connected to a CMON 2504 card which should in turn be connected to an IMx SKF ptitude Observer ptitude Analyst should also be preconfigured to acquire acoustic emission signals Testing the system using the CMAC 2504 is recommended In two steps 1 Use the CMAC 2504 to inject a signal directly into the AE sensor before installing the sensor 2 Then assured that the system is working install the AE sensor and then use the CMC 2504 transducer to inject the signal onto the same flat metallic surface the AE sensor is Installed on ensuring it is free of paint or residue Ensure there Is a direct transmittance path between the CMAC 2504 transducer and the AE senso
11. r e g no cracks joints nuts bolts etc interrupting the path pei orice Coon perry iiare Tort AE 1 Ayh ea aTe 1 4 26 TE J L JLi T LI ya ih JIE T T 34 aan b ma H idi Bie 8636 ia a The system response for both steps should be viewed in SKF ptitude Observer live mode is recommended The system response should be an attenuated pulse train with the same repetition frequency 70 Hz If the system response Is not as expected check the following e TheAE sensor is fixed and secured on its installation site There is acoustic emission couplant on both the AE sensor and the CMAC 2504 transducer There are no cracks joints nuts or bolts interrupting the trans mittance path between CMAC 2504 transducer and AE sensor The cable is connected to the AE sensor If none of the above resolve the issue repeat testing using the digital voltmeter Refer to the CMAC 2504 user manual for further details Fig 10 The SKF CMAC 2504 and acoustic emission transducer ase Bin eS ae FF Ob idot 30 LEJ hiba Labo fob OO lk E a BL pe aL 2 15 Ez Li im Le 1 4 i om is E r Da a M fe a7 Os 1a Bidia Fig 11 Response of a correctly functioning AEE system to the CMAC 2504 input Note the clear pulse train in the time domain which corresponds with 70 Hz in the spectrum aKF 1 Check CMON 2504 Power Supply Measure voltage across J2 1 and J2 2
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