Schaeffler GreaseCheck User manual

Schaeffler GreaseCheck
User manual

Schaeffler Technologies BA 35 1
Page
Contents
About the user manual Symbols ................................................................................... 2
Availability ............................................................................... 2
Legal guidelines ....................................................................... 2
Original user manual ................................................................ 2
General safety guidelines Usage for the intended purpose ................................................ 3
Usage not for the intended purpose .......................................... 3
Selection and qualification of personnel ................................... 3
Warning notice ......................................................................... 4
Safety regulations..................................................................... 6
Scope of delivery ................................................................................................ 7
Technical description ................................................................................................ 8
Mounting ................................................................................................ 10
Electronic evaluation system..................................................... 11
Sensor head ............................................................................. 14
Commissioning ................................................................................................ 16
Operation ................................................................................................ 16
Troubleshooting and
rectification
................................................................................................ 17
Dismounting ................................................................................................ 18
Decommissioning and
disposal
................................................................................................ 19
Technical data and
accessories
................................................................................................ 20
Appendix EU Declaration of Conformity..................................................... 22
Contact .................................................................................... 23

2 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
About the user manual The purpose of this user manual is to assist the user become
acquainted with GreaseCheck and use it for the intended purpose.
This user manual describes the installation and use of GreaseCheck
and is intended to help in:
■ avoiding hazards
■ increasing the reliability and service life of the device.
This user manual is part of the device and contains important
information.
Symbols The warning and hazard symbols are defined along the lines
of ANSI Z535.6–2006.
DANGER
In case of non-compliance, death or serious injury will occur. 
WARNING
In case of non-compliance, death or serious injury may occur. 
CAUTION
In case of non-compliance, minor or slight injury will occur. 
NOTICE
In case of non-compliance, damage or malfunctions in the product or
the adjacent construction will occur.

Note There follows additional or more detailed information that must be
observed.
Availability This user manual is supplied with each device and can also be
ordered retrospectively.
Note If the user manual is absent, incomplete or illegible, the user may
lack important information relating to safe use of the device and
this may lead to incorrect usage. It must be ensured that this user
manual is always complete and legible and that any persons using
the device have the user manual available.
Legal guidelines The information in this manual corresponded to the most recent
status at the close of editing. The illustrations and descriptions
cannot be used as grounds for any claims relating to devices that
have already been delivered. Schaeffler Technologies AG & Co. KG
accepts no liability for any damage or malfunctions if the device or
accessories have been modified or used in an inappropriate manner.
Original user manual This user manual is the original user manual.

Schaeffler Technologies BA 35 3
General safety guidelines
Usage
for the intended purpose
GreaseCheck may only be used for measurement of the grease
condition and for the monitoring of greases in rolling bearings.
GreaseCheck may only be used in an industrial environment.
Usage not
for the intended purpose
GreaseCheck may not be used in environments with an explosion
risk.
Usage not for the intended purpose can lead to personal injury or
damage to the rolling bearing.
Selection and
qualification of personnel
GreaseCheck may only be fitted and commissioned by qualified
personnel.
A person defined as qualified personnel:
■ is authorised to use GreaseCheck
■ has all the necessary knowledge
■ is familiar with the safety guidelines
■ has read and understood this manual.
Work on electrical devices Work on electrical devices may only be carried out by an electrically
skilled person.
An electrically skilled person is in a position, on the basis of his
technical training, knowledge and experience as well as his knowl-
edge of the appropriate regulations, to assess the work assigned
to him and recognise possible hazards.

4 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
Warning notice Read this document before commissioning the device. Make sure
you are certain that the product is suitable without restrictions for
the relevant applications.
GreaseCheck is not classified as a safety component in accordance
with the Machinery Directive 2006/42/EC.
The device may only be installed by a trained electrician.
Carry out the installation in accordance with the national and inter-
national regulations covering the installation of electro-technical
equipment.
Before mounting the device, check for any external damage.
If damage or some other defect is found, the device must not be
commissioned.
Any interference in or modifications to the device, or the addition
or removal of inappropriate components is impermissible,
can endanger occupational safety and may render null and void any
warranty claim.
Any work on wiring, opening or closing of electrical connections
may only be performed while disconnected from the power supply
and in a voltage-free state.
The use of GreaseCheck is only permissible within the boundaries
of the conditions stated and illustrated in the user manual.
GreaseCheck may only be operated within the limits described
in the data sheet. If GreaseCheck is operated outside these limits,
the device may be damaged or destroyed.
Do not attempt to repair a damaged GreaseCheck.
Any repairs necessary must be carried out by Schaeffler Technologies
AG & Co. KG.
The factory settings of GreaseCheck may only be changed after
consultation with Schaeffler Technologies AG & Co. KG.

Schaeffler Technologies BA 35 5
Use GreaseCheck only for the monitoring of approved greases.
A list of approved greases can be found at
https://www.schaeffler.de/content.schaeffler.de/de/produkte-
und-loesungen/industrie/produktportfolio/instandhaltungs-
produkte/schmierstoffueberwachung/index.jsp
Dismount GreaseCheck only while disconnected from the power
supply and in a voltage-free state.
Do not look into the sensor optics while GreaseCheck is in operation.
Risk of eye damage.
Never bend the sensor cable and the connection cable
of the electronic evaluation system.
Do not subject the sensor head to either torsion or tension.
Only use fasteners of a suitable type that do not change the shape
of the sensor head.

6 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
Safety regulations All important safety specifications are described in the following
sections.
Maintenance and repair work Maintenance and repair work may only be carried out by qualified
professionals and in compliance with accident prevention
regulations. Personal protective equipment must be used for all
work.
GreaseCheck must be placed in a voltage-free state before starting
maintenance and repair work.
If any safety devices must be removed during maintenance or repair,
these must be refitted once the work is complete and their function
must be checked.
When carrying out maintenance and repair work, only suitable tools
may be used and these must be used correctly.
Troubleshooting and rectification Troubleshooting and rectification may only be carried out by
qualified professionals and in compliance with accident prevention
regulations. Personal protective equipment must be used for
all work.
Disposal Do not dispose of either GreaseCheck or associated components
with household waste, since they contain electronic components
that must be disposed of in accordance with the applicable
regulations.
Electronic devices must be disposed of in accordance with
the relevant regulations.
Constructional modifications
(conversion)
For safety reasons, autonomous modifications (conversion) of
GreaseCheck are not permitted.
In order to comply with directives on electromagnetic compatibility
(EMC), no modifications may be made to the sensor head and
controller. Electrical connections to the controller must be carried
out strictly in accordance with the measures described hereinafter.
In case of doubt, please contact Schaeffler Technologies
AG & Co. KG.

Schaeffler Technologies BA 35 7
Scope of delivery The scope of delivery comprises:
■ 1 electronic evaluation system with connection plug
■ 1sensorhead
■ 1 internal clamping screw M8
■ 2covers
■ 1usermanual.
The scope of delivery is shown in
Figure 1 .
A replacement seal for the housing of the electronic evaluation
system is used to maintain the protection class IP67 and is only
required if the housing has been opened more than once.
 Sensor head
 Electronic evaluation system
 Connection plug
 Internal clamping screw M8
 User manual
Figure 1
Scope of delivery
000B5BBA000B5BBA

8 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
Technical description The condition of the grease is determined by means of an optical
reflection method.
For this purpose, the sensor head is immersed in the grease.
Monitoring of the grease is carried out on the basis of characteristic
changes for automatic condition assessment.
A cable provides communication between the sensor head and
the electronic evaluation system.
The measurement depth of the sensor head extends only a few
millimetres into the grease. There must be grease directly in front
of the sensor head for measurement. Air inclusions can lead to
incorrect measurements.
The optimum measurement point will vary from one application to
another. The sensor must not record grease in direct rolling contact.
The grease conditions present in areas adjacent to the raceway will
allow comparable measurement results.
GreaseCheck gives the following output data:
■ water content
– the change in water content of the measured grease relative
to fresh grease or respectively to a defined upper limit
■ grease deterioration
– the change in turbidity and ageing of the measured grease
relative to fresh grease or respectively to a defined upper limit
■ temperature
– output of the current temperature of the grease.

Schaeffler Technologies BA 35 9
Measurement of the grease condition begins approx. 5 seconds after
GreaseCheck is connected to the power supply.
Both the deterioration of the grease and the water content are
determined and outputted via the analogue channel as follows:
■ grease deterioration:
– 11mAto4mA
from fresh grease to 100% grease deterioration
(as a function of the qualification value)
■ water content:
–13mAto20mA
from 0% water content to 100% water content
(as a function of the qualification value).
The analogue output toggles in rhythm between 1 second and
300 seconds between the two measurement ranges (the toggle time
can be defined).
A limit value can be set in order to activate a switching output.
As soon as the grease condition reaches the set switch threshold
in relation to grease deterioration or water content respectively,
the DC-24-V output is set to “high” (power supply). The switch
thresholds can be adjusted accordingly in the EEPROM file.

10 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
Mounting Before mounting the device, check for any external damage.
If damage or some other defect is found, the device must not be
commissioned. In case of doubt, please contact Schaeffler
Technologies AG & Co. KG.
Note Only suitable tools may be used, such as tools with voltage
insulation. Use the tool correctly.
Mounting procedure In mounting, the following operations must be carried out:
■ identification of the measurement position of the sensor head
and the mounting position of the electronic evaluation system
■ if GreaseCheck is the only user of the CAN bus:
– tighten the four screws in the housing cover of the electronic
evaluation system (tightening torque 1,5 Nm)
■ if GreaseCheck is not the only user of the CAN bus:
– deactivate the 120 ohm resistor by changing the jumper
on the circuit board of the evaluation unit,
Figure 2 . Then close
the electronic evaluation system as described above.
■ mounting of the electronic evaluation system and laying of
the connection cable
■ mounting of the sensor head at the measurement position and
laying of the sensor connection cable
■ connection of the sensor connection cable to the electronic
evaluation system
■ connection of the connection cable for the electronic evaluation
system to the infrastructure according to the plan,
Figure 4 ,
page 13
■ commission the GreaseCheck.
Figure 2
120 ohm resistor on circuit board
000B61C2000B61C2

Schaeffler Technologies BA 35 11
Electronic evaluation system The electronic evaluation system is mounted as follows:
 Mount the housing of the electronic evaluation system on
the four mounting brackets (
⭋ 4 mm) using four screws
(tightening torque 1 Nm to 2 Nm),
Figure 3 . Select the mounting
material in accordance with the surface underneath.
 Lay the connection cable of the electronic evaluation system to
the controller in such a way that it is firmly laid and cannot flap.
Observe the minimum bending radius of the connection cable.
 Connectthe supplied plug M12 in accordance with the connection
plan to a 6 strand shielded twisted-pair cable with a cross-section
of 0,5 mm
2
and connect the plug to the electronic evaluation
system,
Figure 4 , page 13. With a cable length of more than 20 m,
signal disruptions may occur in individual cases.
 The electronic evaluation system is mounted and connected to
the controller.
 Electronic evaluation system
 Mounting screws
(not included in scope of delivery)
Figure 3
Mounting of
electronic evaluation system
000B5BBE000B5BBE

12 BA 35 Schaeffler Technologies
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Guidelines on electrical
connections
Any work on wiring, opening or closing of electrical connections
may only be performed while disconnected from the power supply
and in a voltage-free state.
During mounting, ensure that the cables are not subjected to any
mechanical tensile load. If necessary, take measures to relieve
the tensile load.
Observe the minimum permissible bending radii of the cables.
These are stated in the manufacturer’s data sheets. For cables
included in the standard accessories for Schaeffler Technologies
AG & Co. KG, the minimum recommended bending radius is 59 mm.
Mount the cables such that they are firmly laid and cannot flap.
Do not lay signal cables parallel with lines carrying high currents.
Shielding application
■ The shielding must always be applied over an extensive area to
the EMC shielding plates on the switch cabinet side and fully over
the connection plug of the electronic evaluation system.
■ Do not trim the shielding after the application point but continue
it as far as the connection terminals.
CAN bus
■ If a CAN bus is not used, the CAN bus must be applied to unwired
terminals with zero potential.
Switching output
■ If a switching output is not used, the switching output must be
applied to an unwired terminal with zero potential.

Schaeffler Technologies BA 35 13
Analogue output ■ If an analogue output is not used, the analogue output must be
applied to an unwired terminal with zero potential.
The controller is supplied factory fitted with a 120 ohm resistor
for CAN bus communication. This can be deactivated by means of
a jumper. The controller box must be opened and the jumper
moved to the corresponding position.
Figure 4
Connection and pin assignment
000B70E6000B70E6

14 BA 35 Schaeffler Technologies
Schaeffler GreaseCheck
Sensor head For mounting of the sensor head, select a position that is optimum
for monitoring of the grease condition. Ensure that a grease layer of
sufficient thickness is present for measurement by the sensor head.
The grease layer thickness should be at least 5 mm. If the grease
layer is thinner than the minimum value, the measurement signal
may be affected by influences such as rolling elements passing by or
reflecting surfaces.
Note If acceptable mounting is not possible using only the internal
clamping screw M8, a suitable adapter must be used.
Schaeffler Technologies AG & Co. KG can provide assistance
in design of the mounting adapter.
The sensor head should be mounted as follows,
Figure 5 , page 15:
NOTICE
Damage to the rolling bearing. Damage to the rolling bearing as
a result of metal swarf in ongoing operation. Ensure that metal swarf
or drilling residues do not remain in the bearing, bearing housing or
grease.

 At a suitable position, drill a hole with a diameter of 6,8 mm.
 Tap a thread M8 in the hole.
 Screw the internal clamping screw M8 into the thread.
 Slide the sensor head into the internal clamping screw until it is
sufficiently immersed in the grease.
NOTICE
Damage to the rolling bearing. Damage to or impairment
of the function of the rolling bearing due to excessive insertion
of the sensor. Do not slide the sensor head too far into the fitting
position.


Schaeffler Technologies BA 35 15
 Tighten the internal clamping screw using an open-end wrench
with an across flats distance of 13 mm and a tightening torque
of 4 Nm.
 Pull the sensor head carefully in order to check that it is securely
seated.
 Prevent any escape of grease at the mounting position by means
of appropriate measures.
 The sensor head is fitted in the rolling bearing at the measurement
position.
Connecting the sensor head to
the electronic evaluation system
The sensor head should be attached to the electronic evaluation
system as follows:
 Lay the connection cable of the sensor in such a way that it is
firmly laid and cannot flap. Observe the minimum bending radius
of the cable.
 Connect the connection cable of the sensor to the appropriate
connection on the electronic evaluation system.
CAUTION
Hazardous radiation. Risk of damage to eyes due to radiation in
the infrared range. Do not look into the sensor optics while
the sensor head and electronic evaluation system are connected to
the power supply.

 The sensor head and electronic evaluation system are connected.
 Tapping of thread M8
 Screwing in the internal
clamping screw
 Inserting the sensor head
 Tightening the internal
clamping screw to 4 Nm
Figure 5
Mounting of sensor head
00019C0200019C02

16 BA 35 Schaeffler Technologies
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Commissioning At the time of delivery, GreaseCheck is in its packaging and is preset
to the factory setting for the appropriate lubricant. The electronic
evaluation system and the sensor head are matched to each other.
There is no need to set GreaseCheck itself. It is only necessary to
find a position in which GreaseCheck can detect the current grease
condition.
Settings may only be made on GreaseCheck after consultation with
the manufacturer.
The basic settings are as follows:
■ grease:
–L
OAD 400
■ switch threshold:
– 90% of the relevant parameter.
A different configuration of GreaseCheck can be carried out by
the technical departments of Schaeffler Technologies AG & Co. KG.
A current list of greases that can be measured using GreaseCheck
can be found at
https://www.schaeffler.de/content.schaeffler.de/de/produkte-
und-loesungen/industrie/produktportfolio/instandhaltungs-
produkte/ schmierstoffueberwachung/index.jsp.
Operation When the controller is connected to the power supply, the LED
will show red for approx. 5 seconds. In this bootloader mode,
external access is possible in order to change configurations.
The sensor then changes autonomously to measurement mode
(the status LED will show continuously green). As soon as data
communication is carried out via the bus, the status LED changes to
flashing green. The sensor generates new measurement values
at an interval of approx. 5 seconds, the current value is stored in
the memory and can be called up via the bus interface.
In order to ensure error-free measurement results, the grease grade
must not be changed during operation. During operation, no setting
work or checking is required.

Schaeffler Technologies BA 35 17
Troubleshooting and
rectification
This section covers errors that may occur and the associated
remedial measures.
Error messages
Error message Cause of error Remedy
Grease signal
does not change
The sensor head is not
in contact with the grease
Immerse the sensor head
in the grease to a greater
depth
The sensor is too far
from the changed grease
Deposits on the sapphire
disc
Clean the sapphire disc
using a microfibre cloth
No signal The sensor head
is not inserted
Insert the sensor head
in the rolling bearing
The sensor head
is defective
Replace the sensor head
Cable breakage
(analogue signal
⬍ 4mA)
GreaseCheck is being
operated outside
the intended range
Replace the signal cable
Power supply is
present but CAN
communication
with the sensor is
not possible
Terminal resistance
is set incorrectly
Set the 120 ohm terminal
resistance for the CAN bus,
see Mounting of evaluation
unit
LED on
controller shows
continuously red
The firmware is caught
in bootloader mode
Disconnect the power to
the sensor and restart

18 BA 35 Schaeffler Technologies
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Dismounting GreaseCheck should be dismounted as follows:
 Ensure that the controller to which the electronic evaluation
system is connected is in a voltage-free state.
 Disconnect the connection cable for the power supply from
the electronic evaluation system.
 Disconnect the sensor cable from the electronic evaluation
system.
 Loosen the internal clamping screw using an open-end wrench
SW13.
 Avoid applying torsion forces to the sensor head.
This can lead to destruction of the sensor head.
 Pull the sensor head carefully and without rotation out of
the internal clamping screw and close off the hole.
 The grease sensor is dismounted.