CMC OilQSens OQ 3000 User manual

User Manual
OilQSens®OQ 3000

cmc Instruments GmbH 2 version 3.6-05/18

cmc Instruments GmbH 3 version 3.6-05/18
User manual
OilQSens®OQ 3000
cmc Instruments GmbH E-Mail : [e-mail]
Meß-, Regel- und Analysentechnik
Rudolf Diesel Strasse 12 A Tel.: + 49 6173 320078
D-65760 Eschborn Fax.: + 49 6173 65050

cmc Instruments GmbH 4 version 3.6-05/18
Table of contents
1. ABOUT THIS MANUAL.......................................................................................... 5
2. WARRANTY, SERVICE POLICY, REPAIR SERVICE ........................................... 7
2.1 SERVICE POLICY......................................................................................... 8
2.2 PROPRIETARY RIGHTS.............................................................................. 8
3. SPECIFICATIONS.................................................................................................. 9
4. DESCRIPTION..................................................................................................... 11
4.1 PRINCIPLE OF OPERATION ..................................................................... 11
4.2 SAFETY INSTRUCTIONS........................................................................... 12
4.3 POWER SUPPLY........................................................................................ 12
4.4 ELECTROSTATIC ELECTRICITY............................................................... 12
5. INSTALLATION OF THE SENSOR...................................................................... 13
6. INSTALLATION OF COMMUNICATION UNIT..................................................... 14
7. COMMUNICATION............................................................................................... 15
7.1 POSSIBILITIES OF COMMUNICATION ..................................................... 15
7.2 CAN BUS INTERFACE (optional) ............................................................... 18
7.2 PROFIBUS/PROFINET/MODBUS INTERFACE (optional)......................... 19
7.5 INSTALLATION ON A NETWORK.............................................................. 20
8. WSENS SOFTWARE........................................................................................... 22
8.1 INSTALLATION........................................................................................... 22
8.2 OPERATION & FUNCTION ........................................................................ 23
8.3 CALCULATIONS......................................................................................... 30
9. DRAWINGS.......................................................................................................... 31
9.1 OILQSENS®SENSOR................................................................................ 31
9.2 OILQSENS®COMMUNICATION UNIT....................................................... 31
9.3 OILQSENS®COMMUNICATION MODULE (optional)................................ 32
9.4 OILQSENS® –HIGH TEMPERATURE UNIT (HT, optional)........................ 32
10. MAINTENANCE ................................................................................................. 33
11. CODES............................................................................................................... 33
11.2 PROFIBUS/PROFINET/MODBUS (optional) ............................................ 34
12. DECLARATION OF CONFORMITY................................................................... 35

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1. ABOUT THIS MANUAL
OilQSenswas designed for simple use, according to the „Plug and Play“ principle
and so was this manual. For the benefit of clarity, all electronics, software and physical
details not necessary for the operation of the unit are omitted. It is the way we want it.
We understand that you want to put your OilQSensto use as soon as possible. To
achieve this goal, take the time to read all the manual in its entirety. Every section
is based on the assumption that you have read and understood the preceding one.
Every section has important comments for the user. This analyzer is very simple to
install and to use; also, it is maintenance-free. No special technical knowledge is
required to operate the unit.
We hope that you will enjoy working with OilQSens. In the spirit of progress and
continuous improvement, we would appreciate any comments you may have, negative
or positive, as long they are constructive.
cmc Instruments GmbH believes that the information in this manual is accurate. The
document has been carefully reviewed for technical accuracy. If there should be any
error, cmc Instruments GmbH reserves the right to make changes to subsequent
editions of this document without prior notice to holders of this edition. The reader
should contact cmc Instruments GmbH if errors are suspected. In no event shall cmc
Instruments GmbH be liable for any damages arising out of, or related to, this
document or the information contained in it.
THANK YOU FOR BUYING CMC INSTRUMENTS!

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Unpacking the instrument
To provide appropriate protection during shipping the OilQSenscomes in a sturdy
packaging.
IMPORTANT:
Should the packaging show visible signs of abuse or external damage the analyzer is
to be unpacked immediately with extra care to check for actual damage. If any
indication of a defective instrument is given it should under no circumstance be placed
into service. Immediately contact your sales representative or cmc Instruments GmbH
directly for further advice.
After the instrument is unpacked make sure to check the packaging for additional parts
and manuals.
Should the analyzer be stored again before being placed into service it should be done
in the original shipping container.

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2. WARRANTY, SERVICE POLICY, REPAIR SERVICE
Goods and part(s) (excluding consumable) manufactured by Seller are warranted to
be free from defects in workmanship and material under normal use and service for a
period of twelve (12) months from the date of shipment by Seller. Consumable,
glassholder, O-rings, etc. are warranted to be free from defects in workmanship and
material under normal use and service for a period of twelve (12) months from date of
shipment by Seller. Goods, part(s) and consumable proven by Seller to be defective in
workmanship and /or material shall be replaced or repaired, free of charge, F.O.B.
Seller’s factory provided that the goods, part(s) or consumable are returned to Seller’s
designated factory, transportation charges prepaid, within the twelve (12) months
period of warranty in the case of goods and part(s), and in the case of consumable,
within the twelve (12) months period of warranty. This warranty shall be in effect for
replacement or repaired goods, part(s) and the remaining portion of the twelve (12)
months warrantyin the case of consumable. Adefect in goods,part(s) and consumable
of the commercial unit shall not operate to condemn such commercial unit when such
goods, part(s) and consumable are capable of being renewed, repaired or replaced.
The Seller shall not be liable to the Buyer, or to any other person, for the loss or
damage directly or indirectly, arising from the use of the equipment of goods, from
breach of any warranty, or from any other cause.
All other warranties, expressed or implied are hereby excluded.
In consideration of the herein stated purchase price of the goods, seller grants only the
above stated express warranty. No other warranties are granted including, but not
limited, express and implied warranties of merchantability and fitness for a particular
purpose.
This warranty is the only warranty made by cmc instruments GmbH with respect to the
goods delivered hereunder, and no employee, representative or other person or entity
is authorized to assume for cmc instruments GmbH any obligation or liability beyond
or at variance with this warranty in connection with the sale of cmc instruments
products:

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Limitations of Remedy:
Seller shall not be liable for damages caused by delay in performance. The sole and
exclusive remedy for breach of warranty shall be limited to repair or replacement under
the standard warranty clause. In no case, regardless of the form of the cause of action,
shall seller’s liability exceed the price to buyer of the specific goods manufactured by
seller giving rise to the cause of action. Buyer agrees that in no event shall seller’s
liability extend to include incidental or consequential damages. Consequential
damages shall includebut are not limited to, loss of anticipated profits, loss of use, loss
of revenue, cost of capital and damage or loss of other property or equipment. In no
event shall seller be liable for property damage and/or third party claims covered by
umbrella insurance and/or indemnity coverage provided to buyer, first assignees, and
each successor interest to the goods provided here under.
Force majeure
Seller not be liable for failure to perform due to labor strikes or acts beyond Seller’s
direct control.
2.1 SERVICE POLICY
1. If a product should fail during the warranty period, it will be repaired free of
charge. For out of warranty repairs, the customer will be invoiced for repair charges at
current standard labor and materials rate.
2. Customers who return products for repairs, within the warranty period, and the
product is found to be free of defect, may be liable for the minimum current repair
charge.
3. For parts replacement, the original part must be returned within serial and model
numbers of the analyzer. No part will be shipped if the original is not sent back to cmc
Instruments GmbH.
2.2 PROPRIETARY RIGHTS
Buyer agrees that any cmc Instruments software, firmware and hardware products
ordered or included in the goods ordered are proprietary to cmc Instruments GmbH.
No change, modification, defacement, alteration, reverse engineering, software
decompilations nor reproduction of such software or hardware products or disclosures
of programming content to other parties is authorized without the express written
consent of cmc Instruments GmbH. To maintain cmc Instruments GmbH trade secret
and other proprietary protection of such software and firmware, such items are not sold
hereunder but are licensed to buyer.

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3. SPECIFICATIONS
Ranges:
Conductivity: 0.1 to 20,000 pS/m
Relative permittivity: 1 to 5
Measuring values are independent of viscosity of the oil.
Sensitivity:
Conductivity: 0.01 pS/m
Relative permittivity: 1*10-6
Temperature: 0.1 K
Response time: < 45 sec
Accuracy:
Conductivity: ±1% of value ±0.5 pS/m
Relative permittivity: ±1.5% of value ±0.0001
Maximum oil pressure: 60 barg / 870 psig at 20°C
Oil temperature: -10 °C to +75°C
Sensor-cable: 3 m, shielded cable
(other lengths on request),
water-proof LEMO connectors
Supply: 115-230 V/ 50-60 Hz
Power consumption: 0.2 W
Dimensions (sensor): ø70 mm x 103 mm
Dimensions (communication unit): 210 mm x 250 mm x 165 mm
Dimensions (communication module): 87 mm x 110 mm x 30 mm
Dimensions (HT module, opt.): 150 mm x 120 mm x 60 mm
Weight (sensor) 2.70 kg
Weight (sensor, HT option) 3.35 kg
Weight (communication unit) 4.45 kg
Weight (communication module) 0.25 kg
Max pressure, measurement chamber: 60 barg / 870 psig
Connections: ¼” Swagelok®connector for tube with outer
diameter of 6 mm, other on request

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Resistance to all species of oil.
O-ring: Viton®
Operating temperature: -10°C to +75°C
Storage temperature: -20°C to +85°C
Ports/interface:
Serial (RS232): 9-pin SUB-D- female connector
Network (LAN): LAN (twisted pair-cable Cat.5 or better)
Network wireless (WLAN): IEEE 802.11 b/g with IEEE 802.11i
encryption
Optional communication: RS232/RS485
RS232/USB
RS232/Profibus
RS232/Profinet
RS232/Modbus
RS232/CAN
Analog Output (0..10V, 0/4..20mA)
Web based decentralized condition monitoring system:
Measuring signal transmission to web server,
Data query and presentation of existing Web browser
Software: WSens®/SW
Sensor body:
Sensor bowl: Stainless steel
Sensor carrier: Stainless steel
Sensor head: Stainless steel or Aluminium dep. on model

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4. DESCRIPTION
OilQSensis an instrument for measuring conductivity, relative permittivity and
temperature of oils and other fluids.
The OilQSensconsistsout of two basicmodules, sensor and communication unit with
communication module.
PLEASE READ THE ENTIRE MANUAL BEFORE OPERATING THE ANALYZER!
OilQSensis fully microprocessor controlled and is designed to operate in rough field
service. The amplifier is a high technology, solid state unit.
The measuring signals of the sensor are transferred via special high quality water proof
connectors (IP68) to the communication unit.
4.1 PRINCIPLE OF OPERATION
The OilQSenssensor measures the electrical conductivity, relative permittivity and
the temperature of the fluid.
The sensor consists of three plates which are arranged parallel to each other. These
form a capacitor. The fluid flows between the capacitor plates and forms the dielectric
between the plates.
Thus, it is possible that the capacity of this capacitor can be measured. On the basis
of capacity, the relative permittivity is defined. The dielectric properties of the oils are
especially determined by the water content, which, in the case of products that are not
enriched with additives, becomes accessible via the accurate measurement of the
relative permittivity. Pure water has a relative permittivity of 80, oil has a relative
permittivity of 2 to 5. In the case of oils enriched with additives, statements on the
degradation of additives can also be derived from changes in the relative permittivity.
Furthermore, the resistance between the plates can be measured. For instance, metal
abrasion, broken oil molecules, acids or oil soap all bring about an increase in electric
conductivity, which, on account of the low conductivity value of oil as compared to all
these contamination products, directly correlates to the degree of pollution. Since oil is
an excellent insulator, it has conductivities between 1.0 to 90000pS/m. Opposite is the
conductivity of pure water which is a few μS/m and metals which are some MS/m. This
means with water is more conductive than oil by a factor of 300 to 105or metals than
oil by a factor of 1016.
The temperature is measured to allow comparison of permittivity and conductivity
values at different temperatures. The electrical parameters of relative permittivity and
conductivity are temperature dependent. A self-learning, adaptive temperature
compensation algorithm allows accurate comparison of data taken at different
temperature.

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4.2 SAFETY INSTRUCTIONS
Do comply with these safety precautions under all circumstances. Failure to comply
with these regulations may be hazardous to the health of the operating personnel
and/or cause damage to the instrument!
OilQSensis not to be operated in an explosive environment without additional
protective measures!
OilQSens®has to be operated in a dry and frost-free environment. Avoid exposure to
direct sun-light and other sources of extensive heat. The OilQSens®is only to be
operated between -20°C and +85°C ambient temperature. If the instrument is operated
outside it is recommended to install it in a weather-proof enclosure.
4.3 POWER SUPPLY
Before placing the unit into service do always cross-check the required voltage given
on the data-plate with your local mains power voltage!
The power-plug is only to be connected to a grounded receptacle. The protective
measures are not to be by-passed by using an ungrounded extension cord!
Every interruption or disconnection of the protective grounding inside or outside of the
instrument can cause the instrument to become a safety hazard. Deliberate disruptions
are not tolerable!
Before any attempt to open, service or repair the analyzer, the instrument is to be
disconnected from any power source!
If working on an open and fully connected instrument is unavoidable it is only to be
done by authorized and trained personnel who are fully aware of all eventual hazards
that are associated with this kind of work!
4.4 ELECTROSTATIC ELECTRICITY
Handling electronic components is a relatively easy task but the electronic components
used in this instrument might be permanently damaged by electrostatic discharge
(ESD). These discharges can be avoided by following these precautions:
Electricity should be discharged prior to opening the instrument. Make sure that there
is no charge build-up while working on the open instrument. The best possible
protection is achieved if all work on the instrument is done at an ESD-safe work place
and an antistatic wristband is worn.
If such a workplace is not available the following guidelines should be strictly followed.
Any electrostatic electricity is to be discharged by touching the metal case of a
protected instrument, which is connected to an appropriate power receptacle.
Do not plug in the instrument you are working on to provide discharge capability!
This procedure is to be repeated several times during working on the instrument.

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5. INSTALLATION OF THE SENSOR
The sensor can be mounted inline by screwing the sensor into the line.
Generally the connection of the sensor cable to the sensor should be on the side and
the flow across the sensor, vertical. If you choose vertical flow the input should be from
the bottom. You should install the sensor direct at the output of your machine and
before a pump or installed filter. You have also to guarantee that the sensor is fully
filled with oil during the whole measurement process.
Figure 1 shows the installation of the OilQSensbasic sensor in bypass line.
Fig. 1: Installation of the OilQSensbasic sensor in a bypass line.
If the OilQSensis operated in bypass line, then a pump may be required to provide
the necessary flow.
Flow rate is not critical but should be as constant as possible and optimally between
100 ml/min –140 ml/min.
During installation, care should be taken that no air bubbles can form or become
trapped in the chamber. For example, a poor choice of pump could cause this. Any
bubbles will affect the results.
It is important to ensure that the communication unit and sensor must be grounded.

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6. INSTALLATION OF COMMUNICATION UNIT
Install the sensor.
Connect the cable from the communication unit / module to the sensor (or in case of
the High Temperature Option, to the separated high temperature box).
Finally, connect the power adapter, first with the communication unit and then the
power supply.
Please note that the supply voltage match the specifications on the nameplate of the
power supply!
OilQSens®is now ready to measure.
3 green LED's are mounted on the communication unit. The top LED indicates whether
WLAN activity is present (optional feature). The middle LED lights up when operation
of the communication unit is established. It flashes briefly when something is sent over
the serial RS232 interface. When it is permanently on, the communication unit is not
ready for use. The lower LED blinks at different time intervals and indicates the sensor
is measuring. If this LED lights permanently, or is permanently out, there is a problem
with the measurement. Please contact the manufacturer.

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7. COMMUNICATION
7.1 POSSIBILITIES OF COMMUNICATION
The following modes are possible:
- RS232 or Profibus/Profinet/Modbus/CAN,
- RS232/Profibus/Profinet/Modbus/CAN and LAN or
RS232/Profibus/Profinet/Modbus/CAN and WLAN,
- 8-channel Analog Output (0-10 V) with USB-Output module
(requires PC or Laptop, Windows version 7 or higher),
- 2-channel Analog Output (0-10 V, requires LAN interface),
- GSM module.
The simultaneous operation of LAN and WLAN is not possible.
The simultaneous operation of RS232 and Profibus/Modbus/CAN is not possible.
Furthermore, it is possible to use a converter RS232/RS485 or RS232/USB the serial
port to establish connectivity to a PC or notebook.
The next figure show the possibilities of communication of the OilQSens.
OilQSens®
OilQSens®
Communication
unit
WLAN
LAN Router/
Switch/
GSM Internet
PC
RS232
90-264V/
47-63Hz Server
cmc
RS232/USB
Converter
Power
Supply
PC
Router/
Switch
User-Side
User-Side
until 100m in buildings
until 300m free air
Process
control
system
RS232/Profibus/
Modubus/CAN
converter
Analog
Out
(USB)
Analog
Out
(LAN)
Fig. 2: Communication of the OilQSens.

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RS232 / RS232-USB:
Fig. 3a: RS232 / RS232-USB Communication of the OilQSens.
Profibus:
Fig. 3b:PROFIBUS communication of the OilQSens.

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Network (LAN):
OilQSens®
OilQSens®
Communication
unit LAN Router/
Switch Internet
90-264V/
47-63Hz
PC
Server
cmc
Power
Supply
PC
Router/
Switch
User-Side
User-Side
Fig. 4: Network (LAN) communication of the OilQSens.
Network wireless (WLAN)
OilQSens®
OilQSens®
Communication
unit
WLAN
Router/
Switch Internet
90-264V/
47-63Hz
PC
Server
cmc
Power
supply
User-Side
until 100m in buildings
until 300m free air
PC
Router/
Switch
User-Side
Fig. 5: Network wireless (WLAN) communication of the OilQSens.

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7.2 CAN BUS INTERFACE (optional)
The standard setting for the CAN Bus speed is 1Mbit.
The standard CAN address registers are ID 200, ID 201 as shown in table 1.
Reg.
Parameter
# Bytes
Scaling
factor
Example
Value
200
Temperature
[°C]
2 Bytes
1/2.55
0040
25.098
200
Rel. permittivity
3 Bytes
0.000001
31e6bd
3.270333
200
Elec. conductivity
[pS/m]
3 Bytes
0.1
000071
11.3
201
Compens. rel.
permittivity
3 Bytes
0.000001
32220b
3.285515
201
Compens. elec.
conductivity [pS/m]
3 Bytes
0.1
0000d8
21.6
Tab. 1: CAN bus data transmission format.
For the correct connection of the CAN module please refer to the information below:
Fig. 6: CAN bus connection scheme, pin 2 CAN-Low and pin 7 CAN-High.

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7.2 PROFIBUS/PROFINET/MODBUS INTERFACE (optional)
The following table shows the contents of a Profibus/Profinet/Modbus telegram in
detail. The positions are fixed for a simple conversion of the string value. The
corresponding GSD file is provided by Download-Link (Profibus/Profinet only). The
length of the datagram is 224 characters; the Profibus/Profinet master can be
configured as follows: INPUT: 128 Byte (64 word), 64 Byte (32 word), 32 Byte (16
word).
Bit Position
Content
Designation
1
0
Counter
2-14
SNX01-OQ-1234
Serial Number
15
/
Separator
16-18
O
Hardware
19
/
Separator
20-46
FW|CMCWARE V4.0 2016-02-12|
Firmware-Version
47
/
Separator
48
[LF]
Line Feed
49-62
t000000.000000
Temperature
63
[LF]
Line Feed
64-77
e000000.000000
r
78
[LF]
Line Feed
79-92
r000000.000000
r40
93
[LF]
Line Feed
94-107
k00000.0000000

108
[LF]
Line Feed
109-122
j00000.0000000
40
123
[LF]
Line Feed
124-137
d000000.000000
tan 
138
[LF]
Line Feed
139-152
g000000.000000
tan 
153
[LF]
Line Feed
154-157
w100
Water Activity
158
[LF]
Line Feed
159-162
b100
Breakdown Voltage
163
[LF]
Line Feed
164-167
c100
Code
168
[LF]
Line Feed
169-224
…
Service Information
Tab. 1: Bit positon of data transmission.
The command for temperature reset can be send to the oil sensor system via the
Profibus/Profinet/Modbus interface: STKRESETF [LF]
The reference temperature can be set to 40°C for example by the following
command: STC40000000F [LF]

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7.4 RS232 INTERFACE
For connection to a PC / laptop, a 9-pin cable (9-pin D-SUB jack) is necessary.
Communication settings:
Baud rate: 9600 Baud
Parity Bits: none
Data Bits: 8
Stop Bits: 1
Flow control: no
7.5 INSTALLATION ON A NETWORK
Installation of OilQSensin customer network
Depending on the selected mode, LAN or WLAN, it is pre-configured by the
manufacturer.
Installation with a fixed IP address
Prior to delivery the manufacturer assigns a free fixed IP address on its network.
OilQSens®then seeks this address.
Installation with DHCP
After connection to the network by the customer, OilQSens®is automatically assigned
a free IP address by the DHCP server on the router.
Registration on the website
Each OilQSens® has a unique serial number in a database.
Username, password and website access are sent separately from the manufacturer.
Press Enter to proceed to the sensor data. Fig. 7 shows the login page of the website.
Fig. 7: Login mask of the cmc Server.