Schaller Automation BEAROMOS 2020 Instruction Manual

2019/10/07 Operating manual/BEAROMOS 2020/Version 1.0
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Schaller Automation
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
66440 Blieskastel
BEAROMOS 2020
Sensor (thermoelectric effect/Seebeck effect)
for measuring electrical voltage
on hydrodynamically lubricated slide bearings
-Operating manual-

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Dear customer,
this operating manual is intended for all those who work/will work on/with the system described here.
They require knowledge of this operating manual to avoid faults in the system and to operate the system
without issues. They must therefore have knowledge of this operating manual.
This operating manual applies to the following devices:
•BEAROMOS 2020
The operating manual is part of the information for users when the system is placed on the market and
must be kept so that it is accessible to the operating company and the operator. If the system is
relocated, the operating manual and/or the operating manuals (including those of suppliers) must be
provided at the new location.
In all phases of life, all the information in the operating manual and/or the operating manuals (including
those of the supplier) must be observed. Please read the applicable sections in the operating manual
carefully before starting work.
We accept no liability for damage or malfunctions that are the result of failure to comply with this
operating manual.
You must specify clearly who is responsible for the machine (the operating company) and who may work
on the machine (the operator).
The responsibilities of personnel involved in transport, installation, setup, adjustment, operation, care,
maintenance and servicing must be clearly defined.

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Table of contents
1Safety information/safety instructions ....................................................................................................6
2Technical data.......................................................................................................................................7
2.1 Intended use .............................................................................................................................................. 8
2.2 Foreseeable misuse ................................................................................................................................... 8
2.3 Risk and safety declarations...................................................................................................................... 9
3Product description.............................................................................................................................10
4Installation and removal.......................................................................................................................11
4.1 Work and preparations to be completed by the customer ..................................................................... 11
4.2 Installing the sensor ................................................................................................................................. 11
4.3 Installing the sensor ................................................................................................................................. 12
4.3.1 Installing the shaft adapter: ...................................................................................................... 13
4.3.2 Installing the BEAROMOS 2020: .............................................................................................. 14
4.4 Electrical adaptation of the sensor .......................................................................................................... 16
4.5 Software installation................................................................................................................................. 16
4.5.1 System requirements................................................................................................................ 16
4.6 Removing the sensor ............................................................................................................................... 17
5Commissioning ...................................................................................................................................17
6Operation and application ...................................................................................................................17
6.1 Operation ................................................................................................................................................. 18
6.1.1 Main view.................................................................................................................................. 18
6.1.2 Chart view................................................................................................................................. 19
6.1.3 Parameter settings ................................................................................................................... 19
6.1.4 Log file and data storage.......................................................................................................... 20
6.1.5 RS485 log ................................................................................................................................. 20
6.2 Errors/malfunctions.................................................................................................................................. 22
7Maintenance and repair.......................................................................................................................22
7.1 Maintenance ............................................................................................................................................ 22
7.2 Repair....................................................................................................................................................... 23
8Packaging...........................................................................................................................................23
9Disposal..............................................................................................................................................24
10 Part numbers ......................................................................................................................................24
11 Spare parts catalogue .........................................................................................................................24
12 List of figures ......................................................................................................................................25
CONTACT .......................................................................................................................................................26

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Index
Index
Change
Date
Changed by
1.0
Release
07/10/2019

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EC Declaration of Conformity
According to the EC Machinery Directive 2006/42/EC
Annex II A
We hereby declare that the design of the machine described below and the version we have
placed on the market fulfils the essential health and safety requirements of EC Directive
2006/42/EC.
Manufacturer: SCHALLER AUTOMATION
Industrielle Automationstechnik GmbH & Co. KG
Industriering 14
66440 Blieskastel
Type of device: Sensor (thermoelectric effect/Seebeck effect)
Type designation: BEAROMOS 2020
Intended use: Measurement of electrical voltage on hydrodynamically lubricated slide bearings
Furthermore, we declare conformity with further Directives applicable to the product, as follows:
•EC Directive 2014/30/EU (EMC Directive)
•EC Directive 2011/65/EU (RoHS Directive)
Applied harmonised standards:
•EN ISO 12100:2010
•IEC 60529:Edition 2.2
•IEC 60068-2-1: Edition 6.0, 2-2: Edition 5.0, 2-6: Edition 7.0, 2-30: Edition 3.0
•IEC/EN 61000-6-2:2015, 6-4:2007+A1:2011
•IEC/EN 61000-4-2:2009, 4-3:2006+A1:2008+A2:2010, 4-4:2012, 4-5:2014, 4-6:2014, 4-11:2005
•EN ISO 12100:2010
Applied national standards and technical specifications:
•DNVGL-CG-0339:Nov2016
The original version of the operating manual for the BEAROMOS 2020 sensor is provided.
Authorised representative for compiling the technical documents:
Jochen Bock, Industriering 14, 66440 Blieskastel
This EC declaration of conformity shall no longer be valid if:
•the machine is rebuilt, modified or used for purposes other than those for which it is intended
without our written consent.
•the instructions in the operating manual are not followed.
Blieskastel, 2019/09/24
Place, date Stephan Schaller
(Managing Director)

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1Safety information/safety instructions
To operate the device safely and correctly, the device must be properly transported and stored,
correctly installed and put into operation and must be operated as intended.
Only persons who are familiar with installation, commissioning and operation and have the appropriate
qualifications for their task may work on the device. You must observe the contents of the operating
manual, the information on the device and the relevant safety regulations for the installation and
operation of electrical equipment.
The devices are built and tested in accordance with DIN EN 60947 and leave the factory in a technically
safe condition. In order to maintain this condition, you must observe the safety instructions that are
indicated by “Warning”in the operating manual. Failure to observe the safety instructions may result in
death, personal injury or damage to the device itself and to other devices and equipment.
If the information contained in the operating manual is not sufficient in a given case, please contact
us directly or your representative.
You must observe the applicable regulations that apply in the country of use when using the device, if
the industrial standards and regulations stated in this operating manual and valid in Europe do not apply.
Warning!
The components may heat up during operation.

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2Technical data
Mechanical interfaces
Diameter
140 mm
Total length up to flange connection
125 mm
Weight
4.5 kg
Attachment
Application-specific adaptation
Electrical interfaces
Power supply
9 - 32 V DC
Nominal voltage
24 V DC
Current consumption
Maximum 0.4 A
Rated insulation voltage Ui
48 V
ESD resistance
6000 V (contact discharge)/
8000 V (air discharge)
Overvoltage category
I
Degree of contamination
3
Test voltage, input/output
548 V 50 Hz
EMC interference immunity
EN 61000-6-3
EMC interference emission
EN 60945
Communication interface
2-wire RS485, electrically isolated
Recommended communication cable
M12 Socket straight 4-position, A-coded,
shielded cable
z.B.:
Phoenix Contact
SAC-4P-M12FS SH/.../... –1697483
Environmental conditions
Operating temperature
-20 to +70 °C
Storage temperature range
-25 to +55 °C
Relative humidity
up to 95%
Protection rating
IP 56
Vibrations
5 -13.2 Hz: 1.6mm peak
13.2 - 100 Hz: 40m/s² peak

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2.1 Intended use
The BEAROMOS 2020 sensor may only be used to measure thermoelectric voltages
on slide bearings.
When using the sensor, you must make sure that it is aligned with the shaft when it is installed.
The safety instructions must be observed.
2.2 Foreseeable misuse
The sensor must not be installed/removed without the centring pin provided.
Unauthorised persons must not install or maintain the sensor.
It must not be used in potentially explosive atmospheres.
➔Applications not described in this manual are not allowed!

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2.3 Risk and safety declarations
For welding work on the motor, the sensor must be disconnected from the power supply.
Components of the sensor can become hot. Make sure they have cooled sufficiently before carrying
out maintenance and repair work. Wear heat-insulating gloves if necessary.
WARNING! Risk of being drawn into the device during installation
You may only install the device with the motor switched off. The device may only be
commissioned once all components have been completely installed.
There is a risk of crushing when installing the sensor
The sensor may only be installed by qualified persons. Wear protective gloves if necessary.
The sensor must be aligned correctly, otherwise the sensor shaft may be damaged, which may then
damage the motor as a result. The supplied centring pin must be used for this purpose.
The sensor must be installed by a qualified person. It must be aligned centrally.
WARNING! Risk of being drawn in by rotating parts (shaft).
If disassembled while being operated, parts may be ejected outwards.
The cover may only be removed with the motor switched off.
There may be a risk of slipping, tripping and falling in the working environment.
Depending on the working environment, additional measures may have to be taken to minimise or
eliminate the risk of slipping, tripping or falling.
Hazard from external noise - the sensor does not emit any significant noise.
If necessary, wear appropriate PPE if there is noise in the environment (hearing protection).

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3Product description
The engines/gears/etc. for which the BEAROMOS is intended have slide bearings in which oil is pressed
between the bearing shell and the bearing point by a pump. As a result, the bearing point of the rotating
shaft is lifted off the bearing shell, so that there is no longer any contact between the bearing journal and
the bearing shell. The bearing then operates outside the mixed friction range. If the lubricating film is
interrupted by an operating state or defect, the temperature increases due to friction between the
bearing shell and the rotating shaft. Given the large mass of the rotating shaft, the bearing shell sees a
greater temperature increase, resulting in an electrical voltage between the bearing shell and the rotating
shaft due to the Seebeck effect. This voltage is detected by our BEAROMOS device.
The BEAROMOS signal is used to display the status of the monitored bearing(s). It is possible to infer
from the signal level and the associated speed whether the friction is hydrodynamic or mixed. If the
bearing is operating in the hydrodynamic friction range, there is no indication of wear, deformation or
damage from the friction itself. (However, wear, deformation or damage may occur or arise without the
lubricating film having first been affected or interrupted). If the bearing is exposed to mixed friction for a
longer period of time, this can cause damage to both the bearing and the rotating shaft, which - in the
case of the rotating shaft - means substantial downtimes/repair times and therefore considerable cost.
As a basic principle, a distinction must be made between three mechanisms of damage:
1. Wear
2. Wear and deformation
3. Thermally-induced damage
The Chart view can be used for further analysis and to identify the relevant mechanism of damage.
However, not every mixed friction state is always an error criterion, just as not every error is reflected in
or indicated by a mixed friction state. During run-up phases, changes of load, etc., mixed friction very
commonly occurs in the bearings, but this is a normal operating condition. The final analysis of the
BEAROMOS signal is the responsibility of the operating company on site. If there are several bearing
points, the BEAROMOS sensor records a cumulative signal across all thermoelectric voltages of the
bearing points. It is not possible to link a signal directly to a single bearing. The sensor and the
BEAROMOS signal are therefore only a tool for detecting wear, deformation and damage.
The sensor is contacted at the free shaft end with a customer-specific adaptation. By contacting the
shaft end on the outside of the machine housing, it is not necessary to interfere with the inside of the
machine.
The sensor indicates irregularities such as friction, wear or deformation in the area of the bearings, which
in many cases makes it possible to take measures to avoid major damage. Monitoring with this sensor
unfortunately does not offer complete certainty that irregularities will be detected in all cases in time
and/or that damage will be avoided.

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4Installation and removal
4.1 Work and preparations to be completed by the customer
Make sure that the sensor housing has a good earth connection, otherwise the sensor will not function
properly. If necessary, you must install an additional earth connection (machine - sensor). The shaft
adaptation must also have good electrical conductivity.
As the principle on which the sensor operates relies on measuring the electrical voltage between the
bearing and shaft, these must be electrically isolated from each other during operation.
Figure 1: Measuring principle of the sensor
4.2 Installing the sensor
No adjustments have to be made to the sensors. The correct COM port of the RS485 adapter that is
used for sensor communication must be set up in the PC software (see 6.1.3 Parameter settings).
•The user must follow safety rules and regulations.
•The sensor is installed with a crankshaft adapter.
•The device is rated to IP56.
•The M12 plug adapter requires “hand-tight”torque of approx. 50 cNm.
Do not exceed the maximum permissible temperature during installation. Make sure there
is sufficient distance from other devices and sources of heat. If cooling is made more difficult, e.g.
because devices with increased surface temperature are next to each other or because the cooling air
flow is obstructed, the allowed ambient temperature is lower.
The sensor circuit cables must be laid as separate control cables. Wires from the engine supply cable
or other main power cables must not be used. Shielded control cables must be used.
When installing and removing, make sure that the sensor is not placed on the shaft journal.
This can cause initial damage to the inner bellows coupling.
Shaft
Bearing

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4.3 Installing the sensor
The BEAROMOS 2020 sensor is installed on the stand of the object to be monitored with a
supporting tube. Make sure that the connection is electrically conductive. You must also make sure
that the flange surface is flat, so that the sensor can be aligned.
If liquid is likely to enter the sensor from the object to be monitored (e.g. oil spraying in the direction
of the sensor shaft), a suitable splash guard must be installed (available from Schaller Automation on
request), as ingress of liquid will cause the sensor to fail.
Figure 2: Stand hole pattern
The shaft of the slide bearing is connected using a specific shaft adapter (available on request from
Schaller Automation), which is connected to the sensor with an expansion cone connection. Once
again, make sure that the connection is electrically conductive.
Figure 3: Expansion cone connection

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Figure 4: Sensor setup
4.3.1 Installing the shaft adapter:
1. Insert the shaft adapter and screw it to the shaft with a 36x41 spark plug spanner.
Figure 5: Installing the shaft adapter
Central bolt

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2. Screw the hexagon nut onto the adjusting adapter
3. The adjusting adapter is screwed into the adapter for the crankshaft until the adjusting
adapter is flush with the stand plate. To help you during installation, we recommend using
an angle to check the alignment as well.
4. Tighten the hexagon nut.
Figure 6: Shaft adapter alignment
4.3.2 Installing the BEAROMOS 2020:
1. Before installing, remove the orange cover using the four Allen screws and remove the
transport lock (black plastic pin) from the sensor shaft.
2. Insert the centring pin and fasten it with the enclosed bolts
Figure 7: Alignment and installation - Part 1

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3. Insert the sensor into the shaft adapter, align the sensor with the hole circle of the supporting
tube, and tighten the screw connections (6x) crosswise.
4. Tighten the central bolt to 25Nm, while counterholding the centring pin with a spanner (size
46).
5. Loosen the bolts of the centring pin, press the centring pin down evenly using its set screws
and remove it.
6. Put the brush in place on the shaft by pulling the black lever of the brush forward and turning
it in the direction of the shaft.
Figure 8: Alignment and installation - Part 2
7. Connect sensor cable M12 (“hand-tight”, to approx. 50 cNm)
8. Install the cover, making sure that the O-ring seal is seated correctly.
Figure 9: Final installation

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4.4 Electrical adaptation of the sensor
1 brown +Ub
2 white GND
3 blue RS485 A
4 black RS485 B
Shield on housing
Connection plug on the rear
(M12 plug connector must be tightened “hand-tight”to torque of approx. 50 cNm)
4.5 Software installation
Insert the DVD into the DVD-ROM drive of your computer and run the “Setup.exe”file, which is
located in the root directory of the DVD. Follow the instructions of the installation routine. When
choosing the installation path, make sure that the subsequent user also has write permissions for the
folder you choose. A shortcut to the BEAROMOS Recorder is created automatically on the Windows
desktop. The program is started by double-clicking the BEAROMOS icon.
For the Recorder to work properly, the driver of your bus adapter has to be installed first! Please
follow the instructions of the adapter manufacturer (not included).
To make sure that data is saved properly, the “Documents”folders of the user account that is used
must not be located on a network drive. If it is, you will get the "<No path>" error message under
“Data path”.
4.5.1 System requirements
•Intel Atom 1.6 GHz
•min. 1GB RAM
•Microsoft Windows 7 SP1/Windows 10
•approx. 3GB free HDD space
•RS485 interface (virtual COM port)
•Language for software/installation routine: English

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4.6 Removing the sensor
The sensor is removed as follows:
1. Remove the M12 sensor cable
2. Remove the cover by removing the four Allen screws.
3. Lift off the brush by pulling the black lever of the brush forward and switching it in the
direction of the sensor housing.
4. Loosen the central bolt.
5. Insert the centring pin and fasten it with the enclosed bolts
6. Screw in the middle setscrew of the centring pin and use the central bolt to push the
expansion cone out of the shaft adapter, while counterholding the centring pin with a spanner
(size 46).
7. Loosen the screws of the supporting tube (x6) crosswise.
8. Pull the sensor off the stand and shaft adapter.
After removing, the sensor should be stored with the centring pin inserted; alternatively, the transport
lock can also be used.
5Commissioning
Warning!
Before you switch on the device, make sure that the supply voltage
of the device and the mains voltage match
If the sensor is correctly connected, the “BUS connection”indicator on the software window should
come on green after the supply voltage is switched on and the correctly configured software is
started.
During commissioning and after modification of the system, the RS485 BUS resistance must
be measured with a suitable measuring instrument. If the resistance is < 50 Ω, the BUS circuit must
be checked for any shortcircuit.
Warning! Check the sensor only with measuring voltages < 2.5 V
6Operation and application
The sensor itself is a built-in device with LED status indicator. The LED is used to check that the
sensor is working:
-Flashing green: Sensor is rotating
-Flashing yellow: Slip rings are worn –service necessary
-Warning! If the shaft is stationary and therefore resting on the bearing, the LED may
be continuous yellow. It may also be the case that the LED does not come on during
operation, because the rotating magnet for speed detection is not in the region of the Hall
sensors. These are not error states.
PC software is used to monitor and evaluate the sensor signal.

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Using the BEAROMOS sensor signal, the BEAROMOS Recorder software visualises the status of the
monitored bearing(s) for the Seebeck effect (described in section 3) and the evaluation algorithm by
the software. This visualisation and the speed recorded by the BEAROMOS sensor are used to make
astatement about the state of bearing operation: hydrodynamic friction or mixed friction. This state
is visualised by a barchart (Figure 10: Main view) and by the average value over time (Figure 11:
Chart view). The event horizon of the Chart view (x-axis) can be scaled step by step, and is max.
60 min. The transition from mixed friction to hydrodynamic friction is determined by a sliding
threshold value and a sensitivity that can be configured. The last transition from hydrodynamic
friction to mixed friction is recorded with date, time, duration and revolution speed.
An LED indicates that the PC software is communicating correctly with the BEAROMOS sensor.
The Sensor Fault LED indicates any failure of the BEAROMOS sensor sliding contacts. If the
indicator is flashing, at least one of the sliding contacts is worn out and is no longer in contact with
the slip ring.
There is a button to print the current screen for both the Main screen and the Chart screen. The
content of the Chart screen can also be exported to a CSV file using separate buttons.
A freely editable (editable under the Parameter view) field is provided so that the software can
be associated with the test object. All data in this field is kept when the software is restarted.
At runtime, the Parameter view allows you to edit the freely editable field, to select the COM port of
the RS485 adapter that is used, to set the save path for the log file and data and to configure the
sensitivity. The current software version is also displayed on this tile.
The window is 800 x 600 pixels. The software provides support for using the BEAROMOS sensor.
6.1 Operation
6.1.1 Main view
Figure 10: Main view
Freely editable field (the same
data is displayed on all tiles; the
content is retained across restart)
Schaller logo as a link button to
the Schaller homepage
Indicator for correct BUS
communication
Detects state of carbon brush
wear
Send printout of current view
to printer
Display the current status as
barchart
Record the last time that the
threshold values were exceeded
with date, time, duration and
revolution speed when exceeded

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6.1.2 Chart view
Figure 11: Chart view
6.1.3 Parameter settings
Figure 12: Parameter settings
Schaller logo as a link button
to the Schaller homepage
Indicator for correct BUS
communication
Detects state of carbon brush
wear
Freely editable field (the same
data is displayed on all tiles; the
content is retained across restart)
COM port used for RS485
adapter
Save location for ring buffer/log
file
Version number
Freely editable field (the same
data is displayed on all tiles; the
content is retained across restart)
Schaller logo as a link button
to the Schaller homepage
Indicator for correct BUS
communication
Detects state of carbon brush
wear
Indicator for thresholds having
been exceeded
Send printout of current view
to printer
Export the current data content
from the chart to a CSV file
Display the average value over
time and the sliding limits
Record the last time that the
threshold values were exceeded
with date, time, duration and
revolution speed when exceeded

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6.1.4 Log file and data storage
6.1.4.1 Log file
To record and track changes in the state of the slide bearing, the threshold value with date, time and
duration that the threshold is exceeded is recorded in a log file when the thresholds are exceeded.
This log file is created in CSV format and has the following structure:
YYYY.MM.DD; HH:MM; [Maximum_value_while_exceeded]; [Duration_exceeded_in_sec];
[Rotation_speed_while_exceeded]
6.1.4.2 Data storage
The average signal over time is stored in a ring buffer (FiFo principle) for a period of 60 days. This file
also stores the rotation speed for the current average value, in addition to the average value. This
data is saved in separate files, each file containing the data for one day. The file name of the
individual files has the following structure with a time stamp:
BEAROMOS_AV_ YYYY-MM-DD_HH-MM .csv
If recording is interrupted, e.g. by closing the Recorder program, a new file is created when recording
continues.
6.1.5 RS485 log
•Baud rate: 230,400 kBit/s
•Parity: None
•Data bits: 8
•Stop bits: 1
•Flow control: None
•Interval of the individual messages: 1.024ms
The BEAROMOS sensor transmits data in binary format as follows:
Log Message format1 (MF1) ADC value
1. Start character 0xA0 1Byte
2. Consecutive number LL 2Byte
3. Measured value MMM 3Byte
4. Check byte C 1Byte
5. End character 0x55 1Byte
The data represent an ADC measured value in 24Bit signed representation. As this format does not
exist in this form, it must be converted into I32.
ADC = ADC << 8; // 32Bit is created from the 24Bit (eight zeros added to the right)
// In particular, the I24 sign bit is moved
// to the I32 sign bit position!
ADC = ADC >> 8; // Restore original value, expand sign
Log Message format2 (MF2) Time offset of round trip pulse, amplification