GS STAUFF OCS User manual

Local Solutions For Individual Customers Worldwide
Manual
Oil Condition Sensor OCS
and Accessories
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The companies of the STAUFF Group assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information,
product or process disclosed in this document.
Reference herein to any specic commercial product, process, service by trade name, trademark, manufacturer, or otherwise, does not constitute or
imply its endorsement, recommendation, or favouring by STAUFF.
Subject to change without prior notication.
Content
1. Overview .......................................................................................................................................................................................................................6
2. Oil Quality Index.............................................................................................................................................................................................................7
2.1. Introduction............................................................................................................................................................................................................7
2.2. Oil Degradation ......................................................................................................................................................................................................7
2.3. OQI Value vs Loss Factor Percentage ......................................................................................................................................................................7
2.4. Traffic Lights ..........................................................................................................................................................................................................7
2.5. Numbering/Levels ..................................................................................................................................................................................................7
2.6. Clean Point (Start Point)..........................................................................................................................................................................................8
2.7. Loss Factor Percentage and OQI Value....................................................................................................................................................................8
2.8. Scaling ..................................................................................................................................................................................................................8
3. Oil Condition Sensor Type OCS - Technical Data .............................................................................................................................................................9
3.1. Safety Notes...........................................................................................................................................................................................................9
3.2. Dimensions ............................................................................................................................................................................................................9
3.3. Mechanical Installation..........................................................................................................................................................................................10
3.4. Precautions ...........................................................................................................................................................................................................10
3.5. Choosing the Sensor Mounting Location................................................................................................................................................................10
3.6. Fitting Method – Summary ....................................................................................................................................................................................10
3.7. Cleaning and Maintenance ....................................................................................................................................................................................10
4. Oil Condition Sensor Type OCS - Electrical Specifications ..............................................................................................................................................11
4.1. Electrical Installation .............................................................................................................................................................................................11
4.1.1. Power Supply.............................................................................................................................................................................................11
4.1.2. Wiring Diagram..........................................................................................................................................................................................11
4.2. 4 ... 20 mA Output.................................................................................................................................................................................................12
4.2.1. Sensor Output............................................................................................................................................................................................12
4.2.2. Oil Condition ..............................................................................................................................................................................................12
4.2.3. Oil Temperature .........................................................................................................................................................................................13
4.2.4. Sensor Calibration .....................................................................................................................................................................................13
4.3. RS485 Communications ........................................................................................................................................................................................13
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4.4. CANbus.................................................................................................................................................................................................................13
4.4.1. Introduction ...............................................................................................................................................................................................13
4.4.2. Wiring........................................................................................................................................................................................................13
4.4.3. Communications Objects ...........................................................................................................................................................................14
4.4.3.1. Bit Rate.......................................................................................................................................................................................14
4.4.3.2. SYNC Event.................................................................................................................................................................................14
4.4.3.3. Transmit PDO1 ............................................................................................................................................................................14
4.4.3.4. NMT Start-up and heartbeat........................................................................................................................................................14
4.4.3.5. Receive SDO...............................................................................................................................................................................14
4.4.3.6. Transmit SDO ..............................................................................................................................................................................14
4.4.4. Object Dictionary Communication Profile ...................................................................................................................................................14
4.4.4.1. Object Dictionary Device Profile – Analogue Input Function Block................................................................................................16
4.5. Modbus.................................................................................................................................................................................................................17
4.5.1. Hardware...................................................................................................................................................................................................17
4.5.2. Configurable Parameters............................................................................................................................................................................18
4.5.3. Communication Mode................................................................................................................................................................................18
4.5.4. Message Framing ......................................................................................................................................................................................18
4.5.4.1. Function Codes ...........................................................................................................................................................................18
4.5.4.2. Query..........................................................................................................................................................................................19
5. Oil Condition Display Type OCD .....................................................................................................................................................................................22
5.1. Overview...............................................................................................................................................................................................................22
5.2. Electrical Installation .............................................................................................................................................................................................22
5.3. Mechanical Installation..........................................................................................................................................................................................22
5.3.1. Dimensions................................................................................................................................................................................................23
5.4. Reading Values......................................................................................................................................................................................................24
5.4.1. Oil Condition ..............................................................................................................................................................................................24
5.4.2. Oil Temperature .........................................................................................................................................................................................24
5.5. Sensor Calibration .................................................................................................................................................................................................24
5.5.1. Resetting the Zero Point.............................................................................................................................................................................24
5.6. Data Logging.........................................................................................................................................................................................................25
5.7. Technical Details ...................................................................................................................................................................................................25
6. USB Interface Type OCS I-USB Interface ........................................................................................................................................................................26
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7. OCS Software ...............................................................................................................................................................................................................27
7.1. Installation ............................................................................................................................................................................................................27
7.1.2. Removal ....................................................................................................................................................................................................28
7.2. Start-up ................................................................................................................................................................................................................29
7.3. Main Screen..........................................................................................................................................................................................................29
7.3.1. Device Explorer..........................................................................................................................................................................................30
7.3.1.1. Automatic Search........................................................................................................................................................................30
7.3.1.2. Refresh All ..................................................................................................................................................................................30
7.3.1.3. Collapse All .................................................................................................................................................................................30
7.3.1.4. Expand All...................................................................................................................................................................................30
7.3.1.5. Device Types...............................................................................................................................................................................30
7.3.2. Main Screen - Oil Condition Sensor Type OCS ............................................................................................................................................31
7.3.2.1. Current Display ...........................................................................................................................................................................31
7.3.2.1.1. Oil Condition / Oil Temperature ...................................................................................................................................31
7.3.2.1.2. Zero Sensor................................................................................................................................................................31
7.3.2.2. Stored Readings..........................................................................................................................................................................32
7.3.2.2.1. Clear Readings ...........................................................................................................................................................32
7.3.2.2.2. Export.........................................................................................................................................................................33
7.3.2.3. Quick Trend.................................................................................................................................................................................33
7.3.2.3.1. Save Image ................................................................................................................................................................34
7.3.2.4. Configuration ..............................................................................................................................................................................34
7.3.2.4.1. Sensor Details ............................................................................................................................................................35
7.3.2.4.2. Communication ..........................................................................................................................................................35
7.3.2.4.3. Current Oil..................................................................................................................................................................35
7.3.3. Main Screen - Oil Condition Display Type OCD ...........................................................................................................................................37
7.3.3.1. Current Display ...........................................................................................................................................................................37
7.3.3.1.1. Oil Condition / Oil Temperature ...................................................................................................................................37
7.3.3.1.2. Zero Sensor................................................................................................................................................................37
7.3.3.2. Configuration ..............................................................................................................................................................................37
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7.3.3.3. Download Data ...........................................................................................................................................................................38
7.3.3.3.1. Data Logging Details ..................................................................................................................................................38
7.3.3.3.2. Set Date and Time ......................................................................................................................................................38
7.3.3.3.3. Set Logging Interval....................................................................................................................................................38
7.3.3.3.4. Downlaod All ..............................................................................................................................................................39
7.3.3.3.5. Download Last ‘n’.......................................................................................................................................................39
7.3.3.3.6. Delete All....................................................................................................................................................................40
7.3.4. File ............................................................................................................................................................................................................41
7.3.4.1. Update Oil Database ...................................................................................................................................................................41
7.3.4.2. Exit .............................................................................................................................................................................................41
7.3.5. Print ..........................................................................................................................................................................................................42
7.3.6. Setup.........................................................................................................................................................................................................42
7.3.6.1. Options .......................................................................................................................................................................................42
7.3.6.1.1. Data Capture ..............................................................................................................................................................42
7.3.6.1.2. Time Interval...............................................................................................................................................................43
7.3.6.1.3. Auto Detect Sensors ...................................................................................................................................................43
7.3.7. Help...........................................................................................................................................................................................................43
7.3.7.1. About ..........................................................................................................................................................................................43
7.3.7.2. View Activity Log.........................................................................................................................................................................44
7.3.7.2.1. Clear Log....................................................................................................................................................................44
7.3.7.2.2. Export.........................................................................................................................................................................45
7.3.7.2.3. Refresh.......................................................................................................................................................................45
7.3.7.2.4. Close..........................................................................................................................................................................45
7.4. Technical Support..................................................................................................................................................................................................46
7.4.1. Installing Updates ......................................................................................................................................................................................46
7.4.2. Updating the Oil Database..........................................................................................................................................................................46
7.4.3. Company Logos.........................................................................................................................................................................................46
7.4.4. Log File and Readings File Location ...........................................................................................................................................................46
This software is designed to work with Windows XP, Windows Vista, Windows 7 and Windows 8 both 32 bit and 64 bit only.
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1. Overview
The STAUFF Oil Condition Sensor OCS allows real time reporting of the condition of the oil in virtually any piece of equipment which uses oil.
The OCS sensor utilises sophisticated electronics to indicate the current condition of oil relative to the initial condition of new oil.
Based on the OCS sensor output, the oil drain down intervals may be extended on large industrial equipment where the cost of replacing and monitoring
the oil is expensive. The OCS sensor triggers an investigation into the quality of the oil, preventing the need for expensive routine maintenance.
The STAUFF Oil Condition Sensor OCS can reduce the overall operating cost of machinery through the removal of routine inspections, waste oil disposal
and subsequent renewal.
The OCS sensor sensor is designed to be easy to use in a variety of congurations depending on the monitoring equipment to which you would like to
interface. It uses a simple four wire connection to connect to its power supply and output the oil condition and temperature on individual 4 ... 20 mA
current sink outputs, with an additional two wires if you would like to use an RS485, CANBus or Modbus interface to connect to an external device.
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2. Oil Quality Index
2.1. Introduction
All industries have a various ways to describe oil wear and oil condition, for example some would talk about percentage of life used, other would
look at hours left or perhaps only consider the TAN/TBN crossover point but there are many more.
To make it far easier to monitor and trend the overall oil condition, regardless of your current method, we have introduced the “Oil Quality Index”.
2.2. Oil Degradation
The “Oil Quality Index” has been designed to be easy to understand, to give a very good level of accuracy and to create a common language for
describing overall oil wear and oil condition, which can also be combined with other methods such as ISO cleanliness levels and laboratory test results.
It is important to understand that oil degradation is exponential and the “Oil Quality Index” reects this.
2.3. OQI Value vs Loss Factor Percentage
The underlying value which the sensor is recording for the oil condition is the Loss Factor Percentage which is then converted into an OQI value, this is
explained later.
2.4. Trafc Lights
First and foremost the OQI scale offers a trafc light view of oil condition, so there is a green section, an amber section and a red section to illustrate „OK“,
„Warning“ and „Alarm“ respectively.
OK
Alarm
Warning
2.5. Numbering/Levels
To enable accurate monitoring and trending of the oil condition these three sections of the Oil Quality Index are then divided up, giving you 13 green levels,
4 amber levels and 3 red levels.
OK
Alarm
Warning
The QOI levels are then numbered from 1 to 20, starting at the rst green level.
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2.6. Clean Point (Start Point)
We now have to consider the starting point for an oil, the Clean Point (Start Point) for most oils will generally be between 3 and 5 on the OQI scale.
The actual value will depend on a number of factors but most importantly how pure the base stock is and what additive packages have been included.
Clean Point
From this point as the oil begins to deteriorate the value will increase.
Please note that the reason why we do not start at 1 on the OQI scale for a brand new clean oil, as some oils can be improved by using sophisticated online
or ofine ltration, therefore an oil can also improve on the OQI scale, as well as deteriorate.
2.7. Loss Factor Percentage and OQI Value
The OCS sensor is looking Loss Factor Percentage to determine how degraded or worn as oil is.
When we start with a clean oil we will have a Loss Factor Percentage of approximately 0 % and then as the oil changes and degrades this Loss Factor
Percentage will increase.
For most applications an oil would be considered to be moving towards its “end of life” when we see a Loss Factor Percentage of 25 % and then the oil
would be considered at the “end of life” when we reach a Loss Factor Percentage of 30 % or above.
The Loss Factor Percentage value is then converted into an OQI value using the table below:
2.8. Scaling
Oil wear is not linear, it tends to follow more of an exponential curve, therefore any initial change in wear and/or contamination will tend to be fairly slow,
however as the wear and/or contamination increases the rate of at which the oil degrades will become faster and faster.
With this in mind the OQI scale is linear within the green level (1-13) but we reduce the amount of change required by half for the amber level (14-17) and
red level (18-20).
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3. Oil Condition Sensor Type OCS
– Technical Data
3.1. Safety Notes
Please pay attention to following safety notes:
►OCS sensor should not be used near combustible gases or liquid.
►Never reassemble, repair or tamper with the OCS sensor.
►Ensure that the supply voltage is within the specied range.
►Ensure the load currents do not exceed the rated value.
►Check all the wiring for correct connection before powering the unit.
►Ensure the sensor case is earthed.
3.2. Dimensions
31,5
1.24
Ø36,7
1.44
Ø21
.83
Ø11,3
.44
Ø11,3±0,1
.44
Ø7±0,1
.28
Ø5±0,1 .20
36±0,1
1.42
29 .91
13,4 .53
10 .39
31,6 1.24
Ø12
.47
Ø31
1.22
39,9±0,1 1.57
29,5±0,1
1.16
0,4±0,1
.2
10±0,1
.39
1,5x45° .06x45°
13±0,1
.51
1±0,1
.04
Undercut 1mm radius
to root diameter
1/2" BSP
All dimensions in mm / inch.
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3.3. Mechanical Installation
The standard thread is (BSP) G1/2 requiring an M32 spanner for installation.
3.4. Precautions
Please read these instructions before installing the oil condition sensor. The OCS sensor has been designed as robust as possible, however it is
liable to damage through mistreatment.
The following must be noted:
►Install the OCS sensor into the equipment before attempting electrical/wiring connections.
►To avoid thread damage do not use with taper ttings.
►Do not attempt to screw or tighten the OCS sensor using the body. Always use the “Hex” head with the correct size spanner.
►Do not twist the cable relative to the sensor head.
►Keep away from sharp edges which may cut into the cable.
►Do not bend the cable, minimum bend radius = 50 mm (1.97 in).
►Where possible, keep the cable away from sources of heat, (such as an engine block), and electrical interfaces.
3.5. Choosing the Sensor Mounting Location
The performance of the sensor will be enhanced through careful consideration of the mounting location. The following guidelines should be followed:
►The OCS sensor should not be mounted in the bottom of a sump since the measuring head may become restricted preventing correct operation.
►Dynamic oil ow is necessary; do not mount in places where the oil is likely to stagnate or be static, since the oil in the OCS sensor needs to be
representative of the whole system.
►When the oil condition sensor is mounted in a pipeline, please ensure that the sensor will not restrict ow.
►When mounting the oil condition sensor in a lubrication system, for maximum performance, please ensure the sensor is located prior to the oil lters,
oil coolers etc. to ensure oil is representative of the whole system.
3.6. Fitting Method – Summary
►Decide on an appropriate location for installation.
►The system to be tted with the OCS sensor will have the lubricant drained sufciently for tment.
►Install the OCS sensor head into the selected location/position, being careful not to over tighten.
►Route the cable, xing (cable ties) at appropriate intervals. Avoid sharp edges and hot surfaces.
►Connect the OCS sensor to the chosen interface: 4 ... 20mA, computer/PLC, CAN or optional display.
3.7. Cleaning and Maintenance
Please follow this procedure to clean the OCS sensor:
►Clean any excess oil from the measuring head by spraying Loctite 7063 cleaner (or any other low residue cleaner which will dissolve oil):
►Into each of the ve holes at the measuring head.
►Blow out any excess cleaner (by compressed air).
►Rinse the measuring head in distilled water.
►Blow dry the measuring head using a hot air gun (set to a low temperature (~+60 °C to +80 °C / +140 °F to +176 °F)) for one minute to ensure no
solvent or moisture remains.
Please note that the OCS sensor does not require cleaning once it has been installed.
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