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Gill 4212-PK-145 User Manual

Weardetect oil debris sensor, sensor with display, sensor without display, inflow fitting
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W
earDetect
Oil Debris Sensor
User Manual
Sensor with display
4212-PK-145
4212-PK-146
4212-PK-147
gillsc.com
4212-PS-361 Issue 5
© Gill Sensors & Controls Limited
Sensor without display
4212-PK-148
4212-PK-149
4212-PK-150
4212-PK-151
Inflow fitting
4212-00-160-100
4212-00-160-150
4212-00-161

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Summary of Contents for Gill 4212-PK-145

  • Page 1 Oil Debris Sensor User Manual Sensor with display Sensor without display Inflow fitting 4212-PK-145 4212-PK-148 4212-00-160-100 4212-PK-146 4212-PK-149 4212-00-160-150 4212-PK-147 4212-PK-150 4212-00-161 4212-PK-151 gillsc.com 4212-PS-361 Issue 5 © Gill Sensors & Controls Limited...

  • Page 2: Table Of Contents

    Contents 1. Welcome 1.1 Thank you for Purchasing 1.2 Overview of Content 1.3 General Notes 2. Product overview 2.1 Description of the Product 2.2 Purpose 2.3 Product Range 2.4 Fitting Adaptors 2.5 Sensor software 2.6 Optional Inflow Fitting 2.7 Accessories 3.

  • Page 4: Welcome

    earDetect Oil Debris Sensor 1. Welcome 1.1 Thank you for Purchasing Thank you for purchasing WearDetect. This manual provides all the necessary information to get the best results from the product. Please visit www.gillsc.com for the latest version of the manual alongside additional information on the product.

  • Page 5: General Notes

    Any attempt to open this part of the product will invalidate the warranty provided by Gill Sensors & Controls. Gill operates a policy of continuous improvement and as such reserves the right to change product details in line with this.

  • Page 6: Product Overview

    earDetect Oil Debris Sensor 2. Product overview 2.1 Description of the Product WearDetect is a condition monitoring sensor that detects particles of ferrous metal in oil. Deposited metal particles in the oil from gears, bearings or other metal contacting surfaces are used to indicate an overload condition, providing an early indication of mechanical failure.

  • Page 7: Purpose

    To cater for the different sizes of sump plug found, Gill offer a range of the most popular thread adaptors, one of which must be chosen alongside selecting the sensor for correct installation.

  • Page 8: Sensor Software

    Also shown below is the Inflow installation kit. These kits contain the adaptor plus isolation valves and supports and can be supplied for either 1” or 1.5” pipe diameters. These options require the sensor to be fitted with an M20 x 1.5 fitting available from Gill - part code 4212-PK- 502, 4212-00-160-100 & 4212-00-160-150...

  • Page 9: Accessories

    earDetect Oil Debris Sensor 2.7 Accessories The following accessories are available for use with the sensor as follows; Debris Strip Used for calibrating the sensor 4212-00-063 Conduit Kit Used to protect the cable on 4212-10-051-X models with the display Thread Kit kit of ten thread adaptors 4212-PK-381 Tool Kit...

  • Page 10: Set Up Weardetect

    3.1 Introduction (with/without display) Weardetect can be installed and operated using the factory installed settings (see Appendix B). However, Gill recommend setting up the product using the sensor software (see www.gillsc.com/support) prior to installation when possible. This section provides details on how to set up the sensor and is split into the following ;...
  • Page 11 earDetect Oil Debris Sensor Connections - Sensors with display Connections - Sensors without display FTDI Drivers Once connected, your computer may automatically recognise the Oil Debris Sensor; if not you may be prompted to search for FTDI driver software, in which case allow your Windows® software to automatically search Windows®...

  • Page 12: Oil Calibration Bench Test

    Weardetect contains a dielectric sensor used to detect significant (>10%) water contamination within the oil or to report a “no-oil” condition. Gill recommend setting up the sensor prior to use by observing the following 3.6 Bench set up Note; Handle the sensor head by the cable only to avoid miscalculations through handling the sensor head body directly Note;...
  • Page 13 earDetect Oil Debris Sensor Navigate to the oil tab within the software - Sensor/Configure/Water Contamination Fully immerse the sensor element into the fresh oil taking care to keep hands away from the sensing element Press the “Set Clean Oil Reference” button to set the level. (Normalised at 1000) Repeat the above steps once the sensor is installed in the equipment Wait 3 seconds and take note of the value Dip in the oil twice more recording the values...

  • Page 14: Install Weardetect

    The sensor head can either be installed as a sump plug replacement or within piped oil circuit, often used as a filter bypass. In this instance, please see separate instruction regarding this installation type from Gill. When installing the sensor head, please obvserve the following guidance for ferrous material monitoring...

  • Page 15: Sensor Head

    earDetect Oil Debris Sensor 4.2 Sensor Head Weardetect contains multiple sensors within one sensor head enclosure as shown below Dielectric Ferrous sensor To allow the product to fit a wide range of equipment types, a seprately supplied thread adaptor is needed for all installations Thread Size M20 x 1.5 to M24 X 1.5...
  • Page 16 Fit the sealing washer to the adaptor or use a suitable thread sealant for NPT adaptors Fit the thread adaptor to the equipment tightening by hand Fully tighten to 50Nm using the correct spanner (see Gill Adaptor instructions) Fit the sensor into the adaptor, pushing passed the o-ring seals fitted to the sensor Once the rear surfaces of the sensor head and adaptor are level with the sensor fully inserted tighten the grub screw using a 2mm hex key to a torque of 1Nm.

  • Page 17: Sensor Electronics

    Oil Debris Sensor 4.3 Sensor Electronics Gill recommend positioning the sensor electronics in a position where vibration is minimised and, with regard to the display model, where the display is visible. Sensor with display Two diameter 6.4mm mounting holes are provided for fixing the sensor electronics to a fixed surface. The mounting holes are accessed by removal of the lid.

  • Page 18: Sensor Cabling

    4.4 Sensor Cabling Gill recommed a maximum of three sensor head cable turns to avoid cable coiling prior to installation. Sensor to electronics cabling may be shotened and re-attached only on models with display using the supplied bootlace ferrules for re-connection. Cable length must not go above 3m to preserve signal reliability.

  • Page 19: Connections (With / Without Display)

    Oil Debris Sensor Cable Protection: Sensors with display models An optional conduit kit (Gill part No. 4212-10-051-X) is offered for additional cable protection for the Sensor with display models. For installation, follow the guidance below: Fit conduit before sensor is fitted to the thread adaptor Remove your Oil Debris Sensor from the Sensor with display electronics enclosure, disconnecting the wiring from the termination block.
  • Page 20 earDetect Oil Debris Sensor Connections - Analogue 4-20mA & 0-10V Wire Colour Designation White Fine Green Coarse Orange Oil/Temp Black Power Gnd (V-) Power (V+) Blue (Not Connected) Clear Screen Connections - Digital CAN J1939 Wire Colour Designation White Can H Blue Can L Orange...

  • Page 21: Sensor Inflow Installation

    Inflow Oil Debris Kit 1” • Inflow Oil Debris Kit 1.5” Use of these kits requires the sensor to be fitted with the Gill M20 x 1.5 sensor head adaptor, part code 4212- PK-502 The following illustrates the sensors and inflow adaptor kit.
  • Page 22 This is a 1.5” diameter BSP fitting and allows connection to smaller pipe sizes with additional pipe size reducers (not supplied). Use of the Inflow Adaptor requires the sensor to be fitted with the Gill M20 x 1.5 sensor head adaptor, part code 4212-PK-502.

  • Page 23: Use Weardetect

    earDetect Oil Debris Sensor 5. Use WearDetect 5.1Configuring the sensor The Sensor can be configured using the WearDetect Software. The configuration functions are outlined below. To access the configuration: Select the Sensor Configure option from the top pull down menu. Note that on the display model of the product, the green LEDs will turn to blue whilst configuring the sensor.
  • Page 24 earDetect Oil Debris Sensor references either 4-20mA, 0-10V, CAN or Modbus output types. Note: The home screen now reflects the options selected. Unused features shall be disabled in this window. Water Contamination /Temperature Channel Select the required third channel output option by clicking the ” Water Contamination “ or “Temperature” button.
  • Page 25 earDetect Oil Debris Sensor The “disable coarse channel” option is switched off by default, meaning the coarse channel is enabled. Disable Water Contamination/Temperature Channel Select the “disable fine channel” option to make the Water Contamination/temperature channel inoperable. The “disable Water Contamination/Temperature channel” option is switched off by default, meaning the channel is enabled in it’s out of the box condition.

  • Page 26: Full Scale Fine

    earDetect Oil Debris Sensor Input the desired temperature values into the dialogue box and press the set button to write the value to the Temperature alarm settings sensor. Continuous temperature min / max settings See below for settings for high / low alarm. For the temperature alarm, set the high and low settings between those shown below For a continuous temperature feed, set the range of temperature measurement as shown below.
  • Page 27 Note: The numbers in the boxes displayed above are internal sensor counts, not percentages. For average chip detec- tion Gill Recommend the Coarse 100% be set to 250. Fine 100% can be set to 750 for maximum fine channel range. for customers trending the output.
  • Page 28 earDetect Oil Debris Sensor Full Scale Coarse The “full scale coarse” operation will gauge the output of the sensor to the desired level with the maximum amount of coarse debris applied to the sensor (100% Full Scale Deflection). Add some coarse debris to the sensor head (This should represent what you would constitute to a 100% failure).

  • Page 29: Manual Adjustment

    Note: The numbers in the boxes displayed above are internal sensor counts, not percentages. For average chip detection Gill Recommend the Coarse 100% be set to 250. Fine 100% can be set to 750 for maximum fine channel range. for customers trending the output.
  • Page 30 earDetect Oil Debris Sensor Note: Oil dielectric measurement is not available where the sensor to be used has an NPT thread fitting. WearDetect measures the dielectric property of the liquid surrounding the sensor element. This is used to provide information about dielectric changes such as a no-oil condition (air) or water in oil condition. When a Water Contamination alarm threshold is reached, the sensor output is triggered to full scale.
  • Page 31 earDetect Oil Debris Sensor Select the oil tab from this new window. Fully immerse the sensor element in the selected reference oil (fresh oil) to set the Water Contamination reference value. The value should be normalised to 1000 once set. gillsc.com...
  • Page 32 earDetect Oil Debris Sensor Press the “Set Water Contamination Reference” button and this will return the value to 1000. Note: This Clean Oil Reference is only valid for the bench-top calibration process, and will need to be re-calibrated once the sensor is installed. Now remove the sensor head from the oil, wait 3 seconds, and take note of this value.
  • Page 33 earDetect Oil Debris Sensor To migrate the risk of false alarms, it is advisable to establish the threshold at the highest level allowable. Thoroughly mix at least 10% by volume of water into the oil sample. Fully immerse the sensor element into the mix and record the displayed Water Contamination value.
  • Page 34 earDetect Oil Debris Sensor For bench-top calibrations, follow correct handling practises outlined in section 5.4 This process should be performed following successful installation of the probe into the equipment, to remove disturbances to the reading from surrounding metalwork. No Oil Threshold The “No oil threshold”...

  • Page 35: Sensor Head

    It is recommended that your Oil Debris Sensor zero/span/oil reference is checked periodically to ensure that your sensor is fully functioning using the Gill Oil Debris Monitoring Sensor configurator. Lid screws are fully fastened to prevent ingress into the electronics housing.
  • Page 36 O-Rings are used to seal the sensor head to the thread fitting adaptor. Under normal use the o-rings should not become damaged however, Gill recommend observing the o-ring seal periodically and replacing if necessary.

  • Page 37: Software

    (RMA). Please ensure any return units are cleaned prior to shipment. 6.3 Software Please ensure you are using the latest verrsion of the software, available from the Gill website. This allows all the latest features to be available to your sensor.
  • Page 38 earDetect Oil Debris Sensor Appendix A Sensor outputs Analogue Output Setting Description Channel Error level Output level when the sensor is in a failure state. Output level for 0% debris, Water Contamination Threshold met (Alarm / Zero level Continuous), or High Temperature Threshold met (Alarm / Continuous). All three channels Output level for 100% debris, No Oil Threshold met (Alarm / Continuous), Full scale level...
  • Page 39 earDetect Oil Debris Sensor Modbus output settings The default connection settings for the sensor are 19200 Baud, 8 Data Bits, Even Parity, 1 Stop Bit, and Slave ID 1. Communication requires a minimum of 1000 ms delay between transactions to return the contents of all registers.
  • Page 40 Oil Debris Sensor Status (error) codes To aid troubleshooting, the following status codes are shown in the Gill Configurator start up window: Communications (error) codes Code Status Description Normal Operation Normal Operation Temperature alarm Temperature over/below threshold Water Contamination high...
  • Page 41 earDetect Oil Debris Sensor Maximum Range Coarse Debris The following maximum range numbers are provided as a guideline only and these numbers should be confirmed with actual coarse debris samples. Coarse Debris Size Material Type Maximum No. Off Chrome Steel Ball Bearing >20 Chrome Steel Ball Bearing Chrome Steel Ball Bearing...
  • Page 42 earDetect Oil Debris Sensor Sensitivity Scale Parameter Small Third Channel Water contamination (alarm) Inhibit Output During Configuration Disable Fine Channel Switched off Disable Coarse Channel Disable Oil Status / Temperature Channel Switched Off 100% FSD Course 1 x 3mm Chrome steel ball bearing 100% FSD Fine 0.1g iron powder Reference OIl Type...
  • Page 43 earDetect Oil Debris Sensor Sensors with Display (Industrial) Electrical Enclosure Current (mA) Voltage (V) CAN (J1939) Supply voltage +9 V to +26 V DC +6 V to +26 V DC +5 V to +32 V DC Over-voltage protection > 32 V DC >...
  • Page 44 earDetect Oil Debris Sensor Mechanical Sensor Enclosure Size 57 mm x ø24.5mm 105.5 mm (w) x 105.5 mm (l) x 66 mm (h) Mounting Threaded 2 off M6 socket-cap screws (not supplied) Materials Stainless steel, FEP, PEI Al. alloy, Stainless steel, polyester Weight 0.7 kg in total Sensors (Inline)
  • Page 45 earDetect Oil Debris Sensor CAN Connection Specifications Message Format Byte 0 Coarse measurement 0 to 100%, (1%/bit) J1939 Byte 1 Standard Fine measurement 0 to 100%, (1%/bit) Compatible Byte 2 Approval 8 x Status bits 8 bytes Byte 3 Data Length (Mux) Multiplex of next 5 bytes 130816 Byte 4...
  • Page 46 earDetect Oil Debris Sensor Appendix B Analog Output For analogue output sensors, the following values can be set by the user: Error Level The sensor output level at an error state may be set by the user to identify a sensor failure. Input the desired error level value into the dialogue box and press the set button to write the value to the sensor.
  • Page 47 Oil Debris Sensor Note: For alternative CAN configurations consult Gill with your custom requirements For CAN output sensors, the following values are displayed: Function Instance “Function instance” works in combination with the function field. A J1939 network may accommodate several ECUs (Controller Applications) with the same function.
  • Page 48 earDetect Oil Debris Sensor Manufacturer Code The 11 bit Manufacturer code is assigned by the SAE and it indicates which manufacturer produced this particular equipment. “Manufacturer code” is factory set to 07ff. Identity Number The identity number is assigned by the manufacturer and should be used to guarantee unique names within “Identity number”...
  • Page 49 earDetect Oil Debris Sensor PDU Specific PDU specific means that its content is interpreted according to the information in the PDU format. A value 240 to 255 is a destination address broadcast message. A value between 0 – 239 is a group extension peer- to-peer message.
  • Page 50 earDetect Oil Debris Sensor Miscellaneous settings LED Brightness (Sensors with display Only) To make adjustments to the LED brightness: Select the Sensor>Brightness option from the top pull down menu and select the desired LED brightness. Exporting a Configuration File When your WearDetect Oil Debris Sensor is fully configured it is recommended that the configuration is saved for future reference.
  • Page 51 earDetect Oil Debris Sensor Appendix C Grounding Schemes and Recommendations The Oil Debris Sensor complies with International EMC standards. In order to maintain compliance with these standards it is essential that the electrical installation is engineered correctly. Electrical installation standards and practices vary for different countries and installation companies.
  • Page 52 Should a fault arise during the use of your Oil Debris Sensor which is within the warranty period, or if you require a repair to your sensor please contact Gill Sensors & Controls for a Return Material Authorization number (RMA). Please ensure any return units are cleaned prior to shipment.
  • Page 53 All product variants require a thread adaptor to allow installation with the chosen equipment. Please contact Gill for a list of the available adaptors at the time of writing. Gill recommend getting in contact as these are constantly being updated according to demand.
  • Page 54 Oil Debris Sensor Important Notices: Gill Sensors & Controls Limited can take no responsibility for installation and/or use of its equipment if „ this is not done in accordance with the appropriate issue and/or amendment of the manual. „...

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