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Bühler technologies Fluidcontrol BCM-MS Installation And Operation Instructions Manual

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Fluidcontrol
Bühler Condition Monitor
BCM-MS, BCM-LS
Installation and Operation Instructions
Original instructions
BE150104
Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen
03/2021
Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20
E-Mail: fluidcontrol@buehler-technologies.com
Internet: www.buehler-technologies.com

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  • Page 1 Fluidcontrol Bühler Condition Monitor BCM-MS, BCM-LS Installation and Operation Instructions Original instructions BE150104 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 03/2021 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: fluidcontrol@buehler-technologies.com Internet: www.buehler-technologies.com...
  • Page 2 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 Internet: www.buehler-technologies.com E-Mail: fluidcontrol@buehler-technologies.com Read this instruction carefully prior to installation and/or use. Pay at- tention particularly to all advises and safety instructions to prevent in- juries.

  • Page 3: Table Of Contents

    BCM-MS, BCM-LS Contents Introduction.............................................  3 Intended Use.........................................  3 Functionality.........................................  3 1.2.1 Temperature Measurement................................ 3 1.2.2 Moisture Measurement.................................. 3 1.2.3 Relative Humidity.................................... 3 1.2.4 Conductivity Measurement................................ 4 1.2.5 Measuring Relative Permittivity .............................. 4 1.2.6 Level Measurement.....................................  4 1.2.7 Operating Hours Counter .................................  4 1.2.8 Data Logger ......................................
  • Page 4 BCM-MS, BCM-LS 8 Appendices............................................. 42 BCM-LS Technical Data .................................... 42 BCM-MS Technical Data .................................... 43 Standard pin assignment .................................... 44 Permissible Mechanical Loads.................................. 44 Error Bits Key........................................ 45 Load Factor Of A System .................................... 46 9 Attached documents ........................................ 47 Bühler Technologies GmbH BE150104 ◦ 03/2021...

  • Page 5: Introduction

    BCM-MS, BCM-LS 1 Introduction 1.1 Intended Use The BCM-MS200 and BCM-LS200 are used to measure and document changes in the properties of hydraulic and lubricating me- dia and simultaneously measure the humidity and temperature. The respective measured values used to detect changes in the properties as well as the temperature and humidity are detected continuously, saved and can be read out at any time using a serial port.

  • Page 6: Conductivity Measurement

    BCM-MS, BCM-LS 1.2.4 Conductivity Measurement Fresh oils have a characteristic conductivity. Since the conductivity is oil-specific due to manufacturing variations, it already serves as a criterion for distinguishing oils. To be able to distinguish between oils based on conductivity, the conductivity at a specific temperature or the change in conductivity above the temperature must be significantly distinct.

  • Page 7: Oil Condition

    BCM-MS, BCM-LS 1.2.9 Oil Condition Oil aging generally refers to any change in parameters and properties of the oil over its life. The goal is to use the changes to de- rive significant aging processes in the oil using the parameters measured with the sensor. The automatic oil condition analysis, however, goes beyond this.

  • Page 8: Scope And Basic Parameters For Automatic Condition Analysis And Rul Calculation

    BCM-MS, BCM-LS Since the characteristics measured in phase I do not change, the RUL also cannot be determined based on characteristics. During this phase, however, the RUL can be estimated based on the thermal stress at the measuring point. This is permissible so long as the temperature is the decisive stress factor for the oil and decisive in the aging rate (Arrhenius law).

  • Page 9: Calibration And Sensor Function Test

    BCM-MS, BCM-LS Original parameter Derived characteristic Explanation Abbreviation rel. DK at reference temperature of 40 °C Conductivity at reference temperature of 40 °C RH202 rel. oil humidity compensated to 20 °C oil temperature Tab. 3: Temperature-compensated characteristics Compensation of relative humidity to 20 °C greatly depends on the fluid, temperature profile and other factors The sensor in turn uses original parameters, the temperature gradients and the compensated characteristics to determine time gradients.

  • Page 10: List Of Parameter Outputs For Specific Commands

    BCM-MS, BCM-LS 1.2.14 List Of Parameter Outputs For Specific Commands The sensors support a series of commands to output the measured, deduced and calculated oil parameters. The following tables list the responses to individual commands. Depending on the sensor firmware version, the order or even the contents of the out- put may vary.
  • Page 11 BCM-MS, BCM-LS Parameter name Unit Explanation Configuration for analog output 1 Configuration for analog output 2 ETrig Error-triggered save to history (1 = on, 0 = off) TrAu Periodic dataset transfer as output for RVal command with an interval of the minutes spe- cified (range 1..60 minutes, if set to 0, automatic transfer is off) ORef Automatic teach-in status...

  • Page 12: Bcm-Ms Model Key

    BCM-MS, BCM-LS 1.3 BCM-MS model key BCM - MS200 - 1DC2A Type designation Bühler Condition Monitor Multisensor Sensor Outputs Process connection 1DC2A 1x CANopen/2x analog G3/4" Item no. Model 1550001000 BCM-MS200-1DC2A 1.4 BCM-LS model key BCM - LS200 - 1DC2A / xxx Type designation Length Bühler Condition Monitor...

  • Page 13: Safety Instructions

    BCM-MS, BCM-LS 2 Safety instructions 2.1 Important advice This device may only be used if: – The product is being used under the conditions described in the operating- and system instructions, used according to the nameplate and for applications for which it is intended. Any unauthorized modifications to the device will void the warranty provided by Bühler Technologies GmbH, –...
  • Page 14 BCM-MS, BCM-LS Maintenance, Repair Please note during maintenance and repairs: – Repairs to the unit must be performed by Bühler authorised personnel. – Only perform conversion-, maintenance or installation work described in these operating and installation instructions. – Always use genuine spare parts. –...

  • Page 15: Installation And Connection

    BCM-MS, BCM-LS 3 Installation and connection 3.1 Dimensions Connection dimensions BCM-MS200 Sealing ring 8 pin A Coding (Male) Connection dimensions BCM-LS200 Sealing ring Distance from oil sump Level measuring range 8 pin A Coding (Male) BCM-LS200: L = 200 mm, Level measuring range = 115 mm BE150104 ◦...

  • Page 16: Installation

    BCM-MS, BCM-LS 3.2 Installation The sensor is a screw-in sensor with ¾" thread. The level sensor must be screwed vertically into application tank from above, the BCM-MS200 can either be installed sideways in the tank or in a flow pipe using a line adapter. Condition monitoring requires the bottom 5 cm of the sensor to be bathed in oil for Level 200/375/615.

  • Page 17: Electrical Connections

    BCM-MS, BCM-LS Tank Fig. 4: Installation recommendations 3.3 Electrical Connections Faulty power supply WARNING Danger to life – risk of injury The device must be installed by an electrician. Observe national and international regulations on the installation of electrical equip- ment. Power supply as per EN50178, SELV, PELV, VDE0100-410/A1.

  • Page 18: Analog Current Outputs (4

    BCM-MS, BCM-LS 3.3.1 Analog Current Outputs (4..20 mA) - Measurement Without Load Resistor The current should be measured with a suitable ammeter as shown below. Sensor cover top view Fig. 6: Measuring the analog 4...20 mA outputs without load resistances Please refer to chapter Calibration [>...

  • Page 19: Calibration

    BCM-MS, BCM-LS 3.3.4 Calibration Output quantity X Output range Quantity equation Formula U / V T in °C -20°C...120°C (6-2) (°C - 55°C °C = R / Ω 8750 U / V RH in % 0%...100% (6-3) - 25% 6250 R / Ω...

  • Page 20: Operation And Control

    BCM-MS, BCM-LS 4 Operation and Control NOTICE The device must not be operated beyond its specifications. 4.1 RS232 Communication Communication with the sensor takes place either via serial RS232 port, CANopen or via two analog 4...20 mA outputs. The sensors come standard with RS232 port enabled. In this mode it’s quite easy to configure the analog interface and to config- ure the CANopen communication parameters.
  • Page 21 BCM-MS, BCM-LS 4.1.2.1 Read Commands Command Meaning Return format format RVal[CR] Read all measurements followed by checksum $ Time:x.xxx[h];T:xx.x[°C]; (CRC) ..;CRC:x[CR][LF] RID[CR] Read identification followed by checksum (CRC) $BuehlerTechnologies;BCM-MS200 SN:xxxxx;...;CRC:x[CR][LF] RCon[CR] Read configuration parameters and CAN config- $AO1:x;AO2:x;…; uration followed by checksum (CRC) CRC:x[CR][LF] RGrad[CR] Read parameter gradients...
  • Page 22 BCM-MS, BCM-LS 4.1.2.2 Write Commands Command format Meaning Return format SONew[CR] Saves current state as fresh oil. All parameters are erased gradients, ok[CR][LF] reference values, taught-in values), oil age is set to 0 h, teach-in is ini- tialised (Duration: approx. 250 operating hours), data in memory is retained WAHSclxxxx[CR] Set limit for absolute humidity.
  • Page 23 BCM-MS, BCM-LS WLimP40%n [CR] Set limit for permitted P40 change from taught-in reference value in LimP40%:n[%] [CR][LF] When near or over the current P40 deviation of this value, warnings and alarms are set Range n: 1.0..100.0% Default n: 5 % WLimC40%n [CR] Set limit for permitted C40 change from taught-in reference value in LimC40%:n[%] [CR][LF]...
  • Page 24 BCM-MS, BCM-LS 4.1.2.3 CRC Calculation Every character sent in the string (incl. linefeed and carriage return) must be added up, based on a range of 8 bit (0→255). If the result is ZERO, there is no error. Example of sent string: RH:31[%];CRC:Ù[CR][LF] Character Value Ù...

  • Page 25: Setting Analog Current Outputs

    BCM-MS, BCM-LS 4.1.3 Setting Analog Current Outputs The two analog current outputs are factory preset. Channel 1 (Pin 6) is the temperature output, channel 2 (Pin 7) the relative hu- midity. However, the sensor allows changing the preset output parameter. The command is: "SAO1x[CR]" and "SAO2x[CR]" with the corresponding numerical code x.

  • Page 26: Output Triggering

    BCM-MS, BCM-LS 4.1.4 Output Triggering On principle there are two different options to output measurements via the RS232 port, time-triggered or command-triggered. The command list for querying characteristics can be found in chapter Command List and in the appendix. There are both com- mands to query the current characteristics as well as to query recent characteristics (time may vary depending on the settings).

  • Page 27: Can Communication

    BCM-MS, BCM-LS 4.2 CAN Communication 4.2.1 CAN Interface The CAN interface corresponds to "CAN 2.0B Active Specification". The data packets have the format shown below. This illustra- tion is for illustration purposes only, it is implemented according to the CAN 2.0B specification. The sensor supports a limited number of transfer speeds on the CAN bus.
  • Page 28 BCM-MS, BCM-LS 4.2.2.1 "CANopen Object Dictionary" In General CANopen Object Dictionary (OD) is an object directory where each object can be addressed with a 16 bit index. Each object can consist of several data elements which can be addressed with an 8 bit subindex. The principle layout of a CANopen object directory is shown below.
  • Page 29 BCM-MS, BCM-LS Different CANopen protocol services are available depending on the sensor state: Com. Object Initializing Pre-Operational Operational Stopped Synch BootUp Tab. 21: Available CANopen services in various sensor states 4.2.2.3 Service Data Object (SDO) Service Data Objects enable write and read access to the sensor’s object directory. Each SDO is acknowledged and transmission only takes place between two consumers, a so-called Client/Server model.
  • Page 30 BCM-MS, BCM-LS CAN message payload CAN-ID CANopen SDO COB-ID 11 bit Index Subindex CANopen SDO message payload Tab. 22: Structure of an SDO message The following is an example of an SDO query of the sensor serial number from the object directory to index 0x1018, subindex 4, with a data length of 32 bit.
  • Page 31 BCM-MS, BCM-LS 4.2.2.4 Process Data Object (PDO) PDOs are one or more datasets reflecting the object directory with up to 8 bytes of a CAN message to quickly transmit data and with the least possible expenditure of time from a "producer" to one or more "consumers". Each PDO has a unique COB-ID (com- munication object identifier), is only sent from a single node but can be received by multiple nodes and does not need to be ac- knowledged/confirmed.
  • Page 32 BCM-MS, BCM-LS Complete OD, incl. with mappable objects Index Object Type TPDO2 mapping parameter in OD, to index 0 x 1 A01 Type Value Oil temperature TPDO2 communication parameter in OD, to index 0x1801 Object Type Byte in CAN-Msg. Fig. 13: Principle of mapping multiple OD objects in a TPDO The sensor supports certain types of TPDO, which can be entered for the respective communication parameters of the TPDOs.
  • Page 33 BCM-MS, BCM-LS 4.2.2.6 "CANopen Object Dictionary" Details The following tables show the full object directory for the sensor. The first table shows the communication portion of the object directory. Apart from a few exceptions, these settings correspond to the CANopen standard as described in DS 301. There are some communication limitations based on the hardware platform used.
  • Page 34 BCM-MS, BCM-LS Event timer copy of TPDO2 event event timer in ms for asynchronous timer TPDO4, copy of TPDO2 event timer 1A00 TPDO1 Mapping Parameter record Number of entries largest sub index 1st app obj. to be mapped 20000410h Alarms 2nd app obj.
  • Page 35 BCM-MS, BCM-LS 2006 Permittivity related parameters of record the oil Number of entries largest sub index Permittivity Permittivity, multiplied by 1000 Permittivity, temperature com- P @ 40 °C, multiplied by 1000 pensated to 40 °C Permittivity, deviation from fresh deviation of P @ 40 °C from teached value in %, oil value in % multiplied by 100 Threshold for permittivity, devi-...
  • Page 36 BCM-MS, BCM-LS Number of entries largest sub index Level Level in % Threshold for max. oil level Level where an alarm bit is set, range: 0..100 Threshold for im. oil level Level where an alarm bit is set, range: 0..100 2020 Commands record...

  • Page 37: Before Initial Use

    BCM-MS, BCM-LS 4.3 Before Initial Use The following describes the steps required on the PC for initial sensor operation. This requires the following components: – PC/laptop with RS232 port or alternatively USB port serving as measuring computer – Sensor – Sensor cable (Item no.: 1590001001) –...

  • Page 38: Initial Operation With Can Interface

    BCM-MS, BCM-LS 4.4.2 Initial Operation With CAN Interface The sensor comes standard with the RS232 enabled and CAN interface disabled. To permanently enable the CAN interface, the sensor must be configured via RS232 port (command "WCOEN"). You can alternatively contact Bühler Technologies GmbH Ser- vice.

  • Page 39: Application Example

    BCM-MS, BCM-LS 4.5 Application Example The oil condition is a factor formed from various parameters. Limits for specific oil parameters vary by the respective applica- tion, e.g. the components and materials used. The type and speed of oil parameter change in turn varies by application, specific system load and the fluid medium or lubricant used.

  • Page 40: Cleaning And Maintenance

    BCM-MS, BCM-LS 5 Cleaning And Maintenance This device is maintenance-free when used properly. The method for cleaning the devices must be adapted to the IP protection class of the devices. Do not use cleaners which could damage the device materials. Bühler Technologies GmbH BE150104 ◦...

  • Page 41: Service And Repair

    BCM-MS, BCM-LS 6 Service and repair This chapter contains information on troubleshooting and correction should an error occur during operation. Repairs to the unit must be performed by Bühler authorised personnel. Please contact our Service Department with any questions: Tel.: +49-(0)2102-498955 or your agent If the equipment is not functioning properly after correcting any malfunctions and switching on the power, it must be inspected by the manufacturer.

  • Page 42: Bcm-Ms Accessories

    BCM-MS, BCM-LS Analog outputs wired incorrectly Observe the information on measuring the analog outputs – No sensor communic- Cable not properly connected First check the electrical connection of the sensor and verify ation via CAN the data and power cable are properly connected. Please note the prescribed pint assignment.

  • Page 43: Disposal

    BCM-MS, BCM-LS 7 Disposal Dispose of parts so as not to endanger the health or environment. Follow the laws in the country of use for disposing of elec- tronic components and devices during disposal. BE150104 ◦ 03/2021 Bühler Technologies GmbH...

  • Page 44: Appendices

    BCM-MS, BCM-LS 8 Appendices 8.1 BCM-LS Technical Data BCM-LS200–1DC2A/xxx 1DC2A Dimensions Version: Compact unit Process connection: G3/4 Material in contact with media: aluminium, HNBR, polyurethane resin, epoxy resin, electroless nickel immersion gold (ENIG), solder, aluminium oxide, glass, gold, silver palladium Medium temperature: -20 °C to +85 °C Ambient temperature:...

  • Page 45: Bcm-Ms Technical Data

    BCM-MS, BCM-LS 8.2 BCM-MS Technical Data BCM-MS200–1DC2A 1DC2A Dimensions Version: Compact unit Process connection: G3/4 Material in contact with media: aluminium, HNBR, polyurethane resin, epoxy resin, electroless nickel immersion gold (ENIG), solder, aluminium oxide, glass, gold, silver palladium Medium temperature: -20 °C to +85 °C Ambient temperature: -20 °C to +85 °C...

  • Page 46: Standard Pin Assignment

    BCM-MS, BCM-LS 8.3 Standard pin assignment Plug connection M12 (base) Number of pins 8-pin Voltage max. 33 V DC IP rating IP67 with IP67 cable box attached Version 1DC2A Connection schematic TxD, CAN low [OUT] RxD, CAN high [IN] Analog output, 4…20 mA Analog output, 4…20 mA Signal earth Shield...

  • Page 47: Error Bits Key

    BCM-MS, BCM-LS 8.5 Error Bits Key Block # Bit Type Description Recommen- ded light status Alarm Low oil level summary Alarm Sensor exposed to air Alarm Oil level dropping (delayed response) Alarm Sensor partly exposed to air Alarm Reserved Alarm Reserved Alarm Current temperature exceeds limit...

  • Page 48: Load Factor Of A System

    BCM-MS, BCM-LS Info/warning Refresh oil with same oil 44 12 Info/warning Bit 44/45: Oil type detection** 44: HLP 45: HEPR 44+45: HEES/HETG Info/warning 46 14 Info/warning Gradient teach-in enabled Info/warning Event-based saving enabled 48 0 Error Reserved 49 1 Error Sensor defective (summary of self-diagnosis, partial sensor failure or specified measuring range greatly exceeded) 50 2...

  • Page 49: Attached Documents

    BCM-MS, BCM-LS 9 Attached documents – Declarations of Conformity KX150004, KX150005 – RMA - Decontamination Statement BE150104 ◦ 03/2021 Bühler Technologies GmbH...
  • Page 52 RMA-Formular und Erklärung über Dekontaminierung RMA-Form and explanation for decontamination RMA-Nr./ RMA-No. Die RMA-Nummer bekommen Sie von Ihrem Ansprechpartner im Vertrieb oder Service./ You may obtain the RMA number from your sales or service representative. Zu diesem Rücksendeschein gehört eine Dekontaminierungserklärung. Die gesetzlichen Vorschriften schreiben vor, dass Sie uns diese Dekontaminierungserklärung ausgefüllt und unterschrieben zurücksenden müssen.
  • Page 53 Dekontaminierungserklärung DE000011 Bühler Technologies GmbH, Harkortstr. 29, D-40880 Ratingen 01/2019 Tel. +49 (0) 21 02 / 49 89-0, Fax: +49 (0) 21 02 / 49 89-20 E-Mail: service@buehler-technologies.com Internet: www.buehler-technologies.com...

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