Bosch Rexroth CIMS Mk IV User manual

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Instruction manual
CIMS Mk IV
Bosch Rexroth B.V.
PO Box 32
5280 AA Boxtel
The Netherlands

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1. TABLE OF CONTENTS
1.Table of Contents.....................................................................................................................3
2.General information .................................................................................................................4
2.1.Correspondence ......................................................................................................................5
2.2.Precautions..............................................................................................................................6
2.3.ATEX certified CIMS MK IV .....................................................................................................6
2.3.1.General notes .....................................................................................................................6
2.3.2.ATEX protection type and marking.....................................................................................7
2.3.3.Assembly ............................................................................................................................7
2.3.4.Installation...........................................................................................................................8
2.3.5.Commissioning ...................................................................................................................8
2.3.6.Inspection and maintenance...............................................................................................9
3.CIMS Mk IV: Function, characteristics and scope of delivery ................................................11
3.1.Function.................................................................................................................................11
3.2.Characteristics .......................................................................................................................11
3.3.Scope of delivery ...................................................................................................................12
3.3.1.CIMS Mk IV standard version...........................................................................................12
3.3.2.CIMS Mk IV ATEX version................................................................................................12
4.Installation..............................................................................................................................13
4.1.Mounting CIMS on cylinder....................................................................................................14
4.1.1.Phase 1: Configuration of output connection position.......................................................14
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 entry system................................................................................................22
5.Operation ...............................................................................................................................23
5.1.Startup ...................................................................................................................................23
5.2.Output Signals and Accuracy.................................................................................................23
5.2.1.RS422 Incremental Position Output..................................................................................23
5.2.2.RS485 Diagnostic Output .................................................................................................24
6.Technical Data .......................................................................................................................25
6.1.Power supply .........................................................................................................................25
6.2.RS422 incremental position output........................................................................................25
6.3.RS485 Modbus diagnostic output..........................................................................................25
6.4.Operating and ambient conditions .........................................................................................25
7.Accessories............................................................................................................................27
7.1.Spare part kit..........................................................................................................................27
7.2.CIMS Mk IV Cable .................................................................................................................27
7.3.Connection options ................................................................................................................27
7.4.Signal converters ...................................................................................................................28

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2. GENERAL INFORMATION
This document is intended as an aid to the installation, putting into operation and maintenance of
the CIMS Mk IV sensor supplied by Bosch Rexroth B.V.
Before starting to work with the CIMS Mk IV sensor, the relevant sections of this instruction manual
must be studied properly. The result of installation and maintenance depends primarily on training,
experience and good craftsmanship of the personnel performing the work.
Warning!
The mounting and removal of CIMS Mk IV sensors is specialized work that
can only be carried out properly by qualified and experienced personnel. In
the event of questions or doubts arising, always contact the Bosch Rexroth
service organization or your supplier.
Repairing the sensor is not permitted. A defect CIMS Mk IV has to be replaced by qualified and
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 others may put this product, Bosch
Rexroth does not guarantee that the same results as those described herein will be obtained. Each
user should test under his own conditions to determine the product’s suitability for his own
particular application.
CIMS Mk IV is mechanically and electrically compatible with CIMS Mk II / III, except that the
standard connector changed from a 6-pin connector to a 9-pin connector.
The content of this manual remains the property of Bosch Rexroth B.V., Boxtel, The Netherlands.
Reproduction or disclosure to third parties in any form, whatsoever, is not allowed without the
written consent of Bosch Rexroth B.V.

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2.1. CORRESPONDENCE
Please send requests for spare parts, field service, inspection or repair to the following address:
Bosch Rexroth B.V.
Services
PO Box 32, 5280 AA Boxtel
The Netherlands
Tel : +31 - (0)411 - 651 951
Fax : +31 - (0)411 - 682 860
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
Example: 1234567 / 0010, R905023540
In case of 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 number of the CIMS involved as engraved in the CIMS Mk IV housing cover
Example: 1234567 / 0010, R905023540, 123456 / 123
* The Bosch Rexroth B.V. order and line number can be found on the text plate attached to the
cylinder and are also stamped close to the oil connection at the rod end.

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2.2. PRECAUTIONS
The CIMS system can be used under most environmental conditions, see Chapter 6. Please
consult the manufacturer in case of:
Excessive magnetic or electrical fields.
Severe accelerations or shocks.
Excessive temperatures.
Warning!
-Never operate the sensors that do not bear the ATEX mark in explosive
atmospheres.
-The standard CIMS Mk IV is not intended for use in hazardous areas.
-The CIMS Mk IV ATEX version may be used in hazardous areas, but
only in the ATEX area as specified on the rating plate.
The CIMS Mk IV system is not designed for exposure to X-rays, nuclear radiation or high vacuum
environments. Use generally accepted industry standards for installation of precision
instrumentation. Pay attention to electrical shielding and grounding. Suppressors may be required
on inductive loads (such as solenoids and contactors).
Stray magnetic fields have an effect on the measurement behavior of the sensor 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-approved CIMS Mk IV
ATEX Manufacturer:
Exepd GmbH
i_Park Tauberfranken 23
D-97922 Lauda-Königshofen
2.3.1. GENERAL NOTES
When working in hazardous areas, the safety of personnel and equipment depends on compliance
with the relevant safety regulations. The people in charge of installation and maintenance bear a
special responsibility. It is essential that they have an exact knowledge of the applicable rules and
regulations. The instructions provide a summary of the most important safety measures and must
be read by everyone working with the product so that they will be familiar with the correct handling
of the product. The instructions have to be kept for future reference and must be available
throughout the expected life of the product.

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2.3.2. ATEX PROTECTION TYPE AND MARKING
II 2 G Ex d IIB T4 Gb
This means the sensor is designed for use in a non-mining application and a category 2
surrounding (gas, zone 1). Gas group IIB such as ethylene and petrol fumes is applicable and the
maximum temperature of the sensor housing will not exceed 135 ºC (Temperature class T4).
The ATEX approved version is recognizable by the applicable Ex code as stated above that is
engraved in the housing cover of the CIMS Mk IV.
Compliance with the Essential Health and Safety requirements has been assured by compliance
with:
DIN EN 60079-0: 2010-03 DIN EN 60079-1: 2008-04
During installation and maintenance, the CIMS and / or the Ex cable gland needs to be opened or
removed. In that situation the sensor is not Ex approved!
Marking:
Manufacturer Exepd GmbH, D-97922 Lauda
Type CIMSMkIV
Ex-Marking II 2G Ex d IIB T4 Gb
CE and no. notified body CE 0123
EC-Type-Certificate BVS 12 ATEX E 111 X
Nominal voltage 24 V DC (155 mA)
Connecting thread of cable gland G1/2”
Ambient temperature -20°C ≤Ta ≤+70°C
Before starting up read handbook
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 suitable Ex d cable entry system, see
Section 4.2.5.2.
4. The cable gland and the cable have to be suitable for max. operation temperature of 80°C.
5. Inspection and maintenance requirements are given in Section 2.3.6.
Mechanical strength: Impact energy max. 7 Nm
2.3.3. ASSEMBLY
Only authorized and qualified personnel may do any of the assembly, disassembly, installation and
commissioning work. The relevant installation and operating regulations must be observed when
setting up or operating explosion-protected electrical systems.
- Always disconnect the device from voltage before assembly/disassembly.
- Follow the components mounting/operating instructions from this document.
When assembling the device, take care that the distances between the outside edge of the upper
flame-proof gap and the fixed obstacles that are not part of the device are for gas/vapour sub-
group IIB at least 30 mm (1.181 in).

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Select a quality of connection cable that will meet the requirements in the area of application. In
hazardous areas the connection cable must be laid in a way that ensures it will be protected from
damage.
2.3.4. INSTALLATION
1. Extensions or modifications to the CIMS Mk IV are not permissible.
2. IEC/EN60079-14 must be observed.
3. When connecting directly to the flameproof enclosure, use Ex-certified entries that are suitable
for the enclosure capacity, the gas sub-group and the conductor.
4. When connecting conductors:
Always use suitable crimping tools when crimping the wire-end ferrules to ensure a
consistent quality of pressing each time.
Take care not to damage the individual wires.
Tighten all terminal points securely (including those not in use).
Take care, screws in blind hole have to leave a distance of 1,5mm to blind 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.
- Only use tools authorized for use in the ex-zone.
- Only use machine components with ATEX approval.
Non-observance of these instructions results in the loss of explosion protection.
2.3.5. COMMISSIONING
Before commissioning, check that:
- The device has been installed in compliance with regulations.
- The device is not damaged.
- The connection has been established properly.
- The cables have been laid correctly.
- All screws have been tightened securely with the specified torque.
- The device functions perfectly.
Danger!
During installation and maintenance, the CIMS and / or the Ex cable gland
needs to be opened or removed.
In that situation the sensor is not Ex approved!

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2.3.6. INSPECTION AND MAINTENANCE
It is recommended to perform inspection and maintenance in accordance with IEC 60079-17 /
60079-1 standards.
Ensure that the CIMS housing is not damaged. Especially if the flame paths show evidence of
wear, distortion, corrosion or other damage, the diametric clearance must be checked. Contact
Bosch Rexroth for the valid dimensions and clearances.
The bolts which fix the cover and housing base onto the intermediate piece (see Figure 4) are
made out of stainless steel, quality A4-70, which needs to be maintained and are only to be
replaced by bolts delivered by Bosch Rexroth, see Section 7.1.
Repairing the sensor is not permitted. A defect CIMS Mk IV has to be replaced by trained
personnel.
The operator of the control, regulating and display device must keep it in good condition, operate it
correctly, monitor it and clean it regularly
- Visually inspect the threaded gap.
- Visually inspect the flameproof encapsulation for damage.
- Check sealings for effectiveness.
- Replace old or damaged sealings with new original seals.
- Check that the connecting terminals, cable & conductor entries are secure.
In the course of maintenance 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 immediately.
Only authorized qualified personnel may do any of the work relating to maintenance and fault
clearance.
Never open or remove housing cover and/or the Ex cable gland in an explosive atmosphere.
Only perform tasks if the possibility of an explosive atmosphere has been excluded.
Consider all following special conditions for safe use.
IEC/EN 60079-17 must be observed.
Safety instructions for maintenance
Warning: Explosion hazards when performing maintenance!
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 maintenance tasks.
- Only perform maintenance tasks if the possibility of an explosive atmosphere has been
excluded.
- Only use tools authorized for use in the ex-zone.
- Do not weld on the sensor.
- Do not use the sensor as an earth point when welding.
Non-observance of these instructions results in the loss of explosion protection.

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WARNING!
Dangers of injury if the incorrect spare parts are used! Through the use of the incorrect or defective
spare parts dangers for personnel can occur; and damage, malfunction or total failure, and
explosions in the Ex area can occur.
Repairing according the joint lengths and widths of schedule 1 and 2 of EN 60079-1 are not
permitted. If any of the parts forming the joints shall be repaired 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 flameproof encapsulation with original parts immediately.
Replace or repair the defective components with original parts.
Follow the components mounting instructions/operating instructions to replace or repair the
components.

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3. CIMS MK IV: FUNCTION,CHARACTERISTICS AND SCOPE OF DELIVERY
3.1. FUNCTION
The Cylinder Integrated Measuring System (CIMS) is an integrated displacement measuring
system for use on hydraulic cylinders with an Enduroq 2000 series piston rod coating or the
previous CEC coatings. Grooves underneath the piston rod coating cause a variation in the
magnetic field from the permanent magnet inside the CIMS. The CIMS Hall-effect sensor elements
measure the magnetic field and its variations. Their signals are fed into a micro controller which
calculates the position inside the groove and generates the incremental RS422 output signal. The
sensor and electronics are protected by a robust stainless steel housing, which can be installed
into the head of the cylinder.
Although CIMS Mk IV has a completely new housing, sensor and electronics, which provide
several new features compared to the previous CIMS Mk II / III, it 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 hydraulic integrity of
the cylinder.
Very robust stainless steel housing, protecting the electronics from almost any
environment.
Waterproof, IP68 up to 10bar (depending on output connection type).
Upon request available for potentially explosive atmospheres, ATEX zone 1 certified.
Reliable redundancy possible with multiple CIMS sensors per cylinder.
Contactless operation, no contact between sensor and cylinder rod, no slide pad.
No (manual) calibration necessary, CIMS Mk IV will automatically compensate for mounting
tolerances, magnetic disturbances and temperature effects.
Diagnostic output, gives the possibility to (continuously) retrieve information about sensor
status, sensor identification, current position (since last power on), error codes, etc..

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3.3. SCOPE OF DELIVERY
Two variants are available for the CIMS Mk IV, a standard version and an ATEX zone 1 certified
version.
3.3.1. CIMS MK IV STANDARD VERSION
The CIMS Mk IV standard version is delivered with the 9-pin male connector chassis, see drawing
F 037 A00 002, Appendix A. It comes together with an adapter ring, required for mounting the
CIMS on the hydraulic 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 check valve which has to be installed on the cylinder
if no leak oil line is connected (see Section 4).
CIMS Mk IV standard Adapter ring Check valve
CIMS Mk IV ATEX Adapter ring Check valve

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4. INSTALLATION
The CIMS Mk IV is installed into a separate flange in the head of the cylinder outside of the high-
pressure zone. The flange contains a special bore pattern, as shown in Appendix B, drawing 3-
033701, which provides the interface between CIMS and the cylinder.
Installing or replacing of the CIMS can be executed without infringement of the hydraulic integrity of
the hydraulic cylinder.
To prevent pressure build-up of leak oil under the CIMS-sensor, a check
valve has to be installed in the leak oil connection in the sealing flange of the
hydraulic cylinder. This check valve (see Figure 1) is delivered together with
CIMS. The opening pressure of this check valve is 0.25 bar. Through this
check valve the leak oil is bled into the environment. If this is not allowed, the
leak oil connection from the cylinder has to be connected pressureless to a
tank.
Warning!
To prevent pressure build-up of leak oil under the CIMS-sensor, either a
check valve or a pressureless connection to a tank has to be present.
The CIMS Mk IV has to be mounted and demounted with care. Using tools like a hammer or
crowbar may lead to tensions and damage of the sensor. Also 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 the supply voltage being applied.
Do not touch the printed circuit board (PCB) or any other electrical components, as the CIMS
contains electronic components that can potentially be damaged due to electrostatic discharge.
For installing the CIMS Mk IV, it is recommended to use a (electronically controlled) torque wrench
for mounting all screws.
The different parts of the CIMS Mk IV are sealed with O-rings. Those O-rings are vulnerable parts
and have to be handled with care. An O-ring has to be replaced in case of damages. Following
steps should be carried out to change an O-ring:
1. Remove the old O-ring from CIMS Mk IV part,
2. Install the new O-ring (as specified in drawing F 037 A00 002, Appendix A) with some
grease (Shell Rhodina EP (LF)2) to make the mounting of the parts easier and to prevent
damage to the O-rings.
The following sections describe the mounting of CIMS Mk IV onto the hydraulic cylinder and the
mechanical and electrical installation of the cable.
Figure 1: Check valve

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4.1. MOUNTING CIMS ON CYLINDER
The CIMS Mk IV can be mounted and configured in most of the cases without opening the
housing.
The assembly steps are detailed in 4 phases:
- Phase 1: Configuration of the output connection position,
- Phase 2: Check / change the cable outlet,
- Phase 3: Mount new cable outlet,
- Phase 4: Installation onto the cylinder.
The configuration phases (Phases 1, 2 and 3) should be carried out on a clean and stable surface.
4.1.1. PHASE 1: CONFIGURATION OF OUTPUT CONNECTION POSITION
Before starting installation onto the cylinder, make sure the connection output is oriented correctly
with respect to the cylinder. Note that the orientation mark on CIMS Mk IV (see Figure 3) should
always point to the rod side of the cylinder. If the 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 of 90)
according the instructions below. If the connection output is already in the desired orientation,
continue with Phase 2.
Figure 2: Top view CIMS Mk IV on cylinder
The marking on the
CIMS (see zoom in
Figure 3) must be
aligned along the
longitudinal axis of the
cylinder. This results in
an installation situation
like the figure 2, with
the orientation mark
pointing at the rod end
side.
Figure 3: View along longitudinal axis of cylinder, zoom of CIMS Mk IV with its orientation mark.
Orientation mark on CIMS Mk IV
pointing at rod side
Longitudinal
axis cylinder

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1. Unscrew and remove the four M6 bolts (Bolt B) from housing base (see Figure 5),
2. Hold the CIMS Mk IV upside down (sensor surface upward), make sure the four M6 bolts
(Bolt A) are lying loose in the intermediate piece (see Figure 5), so they do not block the
rotation.
3. Rotate 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 assembly component
names.
Bolt A (4x)
(countersunk)
Cover
Intermediate
piece
Housing
base
Adapter
ring

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4.1.2. PHASE 2: CHECK /CHANGE THE CABLE OUTLET
As default the CIMS Mk IV standard (non-ATEX) is supplied with the 9-pin male connector chassis
or no connection (only a threaded hole) for the CIMS Mk IV ATEX version. If another connection is
needed (see Section 4.2.5), or for installation of an Ex d cable gland, Phase 2 and 3 will have to be
executed. If the default connection is suitable, Phase 2 and 3 can be skipped.
1. Unscrew the four M2,5 bolts (Bolt C) on the male socket,
2. Unscrew the four M6 bolts (Bolt D) on the housing cover,
3. Open the housing cover (the 2 threaded holes in the cover can be
used to push off the cover with 2 M6 bolts, see Figure 7) and let it
hang on the side of the housing. A cable fixed at the cover and at the
inside of the intermediate piece prevents that the cover can fall down,
4. Unscrew the two screws (Screw E) fixing the inner connector with its
mating connector (see Figure 9),
5. Remove / lift the inner 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 and the connected wires from CIMS Mk IV.
Figure 10: Inner connector side view.
Screw F (8x)
Figure 9: Inner connector top view.
Screw E (2x)
M5 internal grounding
point
Two pulling off screws
(M6) can be used on
the cover and on the
housing base to make
the removal easier.
Do not apply tension
force on the electrical
wires and make sure
the inside connector is
not damaged during
this operation.
O-rings could be
damaged during this
operation. They have
to be manipulated with
caution and replaced in
case of damage.
Bolt C
(4x)
Bolt D (4x) 2x M6
threaded
holes
2x M6
external
grounding
point
Figure 8: Intermediate piece lifted from housing base.
Inner connector
cable side
Connector
header on PCB Screw F (8x)
Figure 7: CIMS Mk IV cover and connector socket bolts.

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4.1.3. PHASE 3: MOUNT NEW CABLE OUTLET
Follow the global instructions below to install an alternative (see Section 4.2.5) cable outlet,
otherwise continue with Phase 4:
1. Install the alternative cable outlet and if required the electrical cable, make sure all sealings
are installed correctly and any bolts or components are installed with the correct torque.
See also Section 4.2 for information and instructions about the cable, pin numbering, and
alternative cable outlets.
2. Mount a strain-relief (rubber tube or cable ties for example) to avoid damage from vibration
and damage of the cables during operation (see Figure 12).
3. Screw each electrical wire on the internal mating connector according to the pin-
configuration, see Section 4.2.4.
4. If required (see Section 4.2.3), install the screen on the internal grounding point (Figure 9)
of the intermediate piece.
5. Assemble the two internal connector parts together and screw the 2 screws (Screw E) to fix
them, see Figure 9 and Figure 10.
6. Place the cables (electrical and also non losable connection for cover) into the CIMS Mk IV
and close the cover.
7. Screw the four M6 bolts (Bolt D) on the cover to close it (7.5 Nm), see Figure 7.
4.1.4. PHASE 4: INSTALLATION ONTO THE CYLINDER
Follow the instructions below to install 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) on the cylinder (7.5 Nm),
make sure the sealing-rings are positioned correctly, see
Figure 13.
4. Install the CIMS Mk IV into the mounted adapter ring in
the 0º position with respect to the front of the cylinder (the
marking pointing at the rod side as shown in Figure 3).
5. Screw the four long M6 bolts (Bolt A, Figure 4) in the
adapter ring (7.5 Nm).
6. Seal the gap between the housing of the CIMS Mk IV and
the cylinder for water tightness with “Scotch seal AF 800”
or equivalent.
Figure 11: Alternative cable outlet; cable gland.
Before mounting the adapter ring,
clean the mounting surface in the
cylinder.
Make sure to take into account the
orientation marks and pins, when
installing the adapter ring and the
CIMS onto the cylinder. Wrong
installation will lead to damage or
malfunction of CIMS.
To tighten the screws use the
prescribed torque.
To prevent water and dirt to get into
the gap between the CIMS housing
and the cylinder, make sure the
“Scotch seal AF 800” is applied
correctly.
Figure 12: Principle sketch internal cabling.
Pay intention that no
cable is damaged
during this operation

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4.1.5. REMOVAL FROM THE CYLINDER
1. Unscrew the four M6 bolts (bolt A, Figure 4)
2. Remove the CIMS Mk IV for the adapter ring (some force may be required because of the
o-ring).
4.2. ELECTRICAL INSTALLATION
4.2.1. WIRING
A shielded twisted pair cable with 3x2 or 4x2 twisted pairs (minimum 0.25mm2) is required. With a
3x2 cable, the diagnostic functionality cannot be used and is therefore not recommended.
Losses in a transmission line are a complex combination 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 is suitable for both inside and
outside use, as it is resistant to weather, ozone and UV-radiation, furthermore it has a very good oil
resistance.
Orientation pin
Bolt G (4x)
Figure 13: Adapter ring with bolts and sealing-rings.
Sealing ring
Figure 14: Adapter ring bottom.
Orientation pin

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4.2.2. CABLE TERMINATION
The proper termination of the cable is very important. If the cable is not terminated with its
characteristic impedance, distorted waveforms will result. Normally using 120resistors for cable
termination is adequate, as shown in Figure 15. Note that the diagnostic Modbus output already
has a 120resistor integrated, so an additional resistor at the receiver side is not necessary.
4.2.3. SHIELDING AND GROUNDING
It is necessary to connect the cable shields to a proper ground point to discharge the cable shield
from 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 ground at the customer/receiver side. Also the receiver
electronics must be grounded to prevent unwanted common mode voltages.
The CIMS has both internal and external grounding points, to connect the shield to the CIMS and /
or the CIMS to the cylinder, see Figure 7 and Figure 9. Grounding can be made using an eye cable
tag.
Figure 15: Cable termination and grounding concept.

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4.2.4. INTERNAL CONNECTOR
Inside the CIMS housing is a green 8-pin Phoenix connector, which is used to connect the
incoming cable, directly or via an external connector, to the CIMS electronics. The pin assignment
(Figure 16) of the internal connector is given in Table 1. How to remove or install a cable to the
internal connector is described in Sections 4.1.2 and 4.1.3.
4.2.5. EXTERNAL CONNECTOR /CONNECTION
Several connection types are available to connect the cable to the CIMS. To support this, the CIMS
housing is provided with a G½” threaded connection according DIN3852-2, together with four M2.5
tapped holes for a chassis connection (see drawing F 037 A00 002, Appendix A).
The type of connection depends on the application and the (expected) environmental conditions.
Please contact Bosch Rexroth for any additional information or advice.
CIMS Mk IV Standard version
At delivery from the factory, the CIMS Mk IV Standard version is delivered with a 9-pin male
connector chassis. The corresponding female connector has 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 from the environment, stainless steel protective piping can be delivered to protect
against mechanical damage. Section 7.3 gives more information about the different available
connection options which can be delivered by Bosch Rexroth.
CIMS MK IV ATEX version
At delivery from the factory, the CIMS Mk IV ATEX version does not include an Ex d cable
gland, as the suitability of a cable gland is also depending on the type of cable used. In
section 4.2.5.2 the different selection criteria are given to select a proper cable entry
system for use in an ATEX zone 1 environment. Section 7.3 gives information about the Ex d
certified cable gland which can be delivered by Bosch Rexroth as an accessory.
Pin Signal
1 V+
2 GND
3 A
4 /A
5 B
6 /B
7 Modbus +
8 Modbus -
Table 1: Pin assignment internal/external connector. Figure 16: Internal connector top view.