ZILA FluidIX LUB-VDT Service manual

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 1
Mounting and operating instructions
FluidIX LUB-VDT
Inline Condition Monitoring Sensor
ZILA GmbH
Hollandsmühle 1
98544 Zella-Mehlis
Deutschland
Web: www.zila.de
E-Mail: [email protected]
Telefon: [phone]

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 2
Inhaltsverzeichnis
1. general information .................................... 2
1.1. Safety instructions ..................................... 2
1.2. Intended use .............................................. 3
1.3. Assembly, commissioning & installation
personnel ................................................................ 3
1.4. Repairs....................................................... 3
1.5. Technical progress..................................... 3
2. product description .................................... 3
2.1. Technical data............................................ 4
2.1.1. General specifications .................... 4
2.1.2. Measurement specifications .......... 4
2.2. Mounting instructions ................................ 5
2.3. Pin assignment .......................................... 5
3. data filter.................................................... 6
4. Modbus Interface....................................... 6
4.1. Default Configuration.................................. 6
4.2. Register Map ............................................. 6
4.3. Overview Status Codes.............................. 8
4.4. Modbus Register........................................ 8
1. general information
•Read the safety instructions and keep the
manual
•Installation, commissioning, electrical
connection and repairs may only be carried out
by qualified personnel
•The specified degree of protection is only
guaranteed if the unit is installed in the correct
position and the cables are inserted and screwed
in properly
•Operate the unit only at the specified voltage
•Modification and conversion of the device is not
permitted and releases ZILA GmbH from any
warranty and liability

Read these assembly instructions
carefully before using the unit. Follow
the instructions. Keep these assembly
instructions in a safe place for future
use.
1.1. Safety instructions
Safe operation is only provided if the instructions and
warnings in these operating instructions are observed.
•Assembly and electrical connection only
permitted by qualified personnel.
•Read these operating instructions carefully
before commissioning.
•Only operate the unit with the voltage and
frequency specified on the label.
•Do not make any changes to the unit.
Seals and Labels:
Opening or removing seals or
labels, e.g. with serial numbers or
similar, will result in the
immediate loss of warranty
claims.
ATTENTION

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 3
1.2. Intended use
The manufacturer is not liable for damage resulting from
improper use or use not in accordance with the intended
purpose.
Before operating the unit, please compare the supply
voltage with the specifications on the label.
If it becomes obvious that safe operation is no longer
possible (e.g. in the case of visible damage), please take
the unit out of operation immediately and secure it
against unintentional operation.
In case of improper use or use not in accordance with
the intended purpose, dangers may arise from the unit,
which is why we refer to consistent observance of the
safety instructions.
1.3. Assembly, commissioning &
installation personnel
Assembly, electrical installation, commissioning and
maintenance of the unit may only be carried out by
trained specialist personnel who have been authorised
to do so by the system operator.
The qualified personnel must have read and understood
these operating instructions and follow their
statements.
The unit may only be operated by persons who have
been authorised and instructed by the system operator.
The instructions in this operating manual must be
followed.
Ensure that the unit is correctly connected according to
the electrical connections.
1.4. Repairs
Repairs can only be carried out by trained customer
service personnel.
In this case, please contact ZILA GmbH.
1.5. Technical progress
The manufacturer reserves the right to adapt technical
data to technical development progress without special
notice. For information on the activities and possible
extensions of these operating instructions, please
contact ZILA GmbH.
2. product description
The FluidIX LUB-VDT is a compact sensor for monitoring
mechanical fluid characteristics such as viscosity and
mass density based on a low-frequency resonance
sensor element. The excellent performance of the LUB-
VDT is achieved by combining a patented resonator
evaluation technology with a robust and reliable quartz
crystal tuning fork resonator. The sensor offers high
sensitivity and long-term stability, making it particularly
suitable for oil condition monitoring in predictive
maintenance programmes. Due to the high measuring
rate, excellent data quality can be achieved even under
unstable environmental conditions (pressure,
temperature, flow). The FluidIX LUB-VDT offers digital
and configurable analogue interfaces for easy and cost-
effective integration into existing environments.

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 4
2.1. Technical data
2.1.1. General specifications
Dimensions
30x93,4mm
Weight
150g
Protection class
IP68
Material
Stainless steel
Power consumption
1 W (without analogue
outputs)
Supply voltage
9…35 V (24V)
Screw connection
G 3/8“
Tightening torque
31…39 Nm
Elec. Connection
M12-8 A-Coding
Partikelgröße
250 µm
Oil pressure
50 bar
Ambient temperature
-40…105 °C
Medientemperatur
-40…125 °C
Analogue outputs
2x 4…20mA
±1 %FS
Digital output
ModbusRTU
CE conformity
EN 61000-6-1/2/3/4
The unit is suitable for use with the following liquids:
•mineral oils
•Synthetic oils
•Other permissible liquids on request
2.1.2. Measurement specifications
Specifications at 24°C ambient temperature in reference
fluid. Cannon Instruments N140 viscosity standard at
40°C unless otherwise stated..
Resonator frequency
20…25 kHz
Kinematic viscosity
1…400 cSt (=mm²/s)
Density
0,5…1,5 g/m³
Temperature
-40…125°C
Sampling rate
1/s
Measuring accuracy according to ISO 5725-1 for
Newtonian fluids:
Viscosity
ν≤200cSt
ν>200cSt
±0.1cSt
± 1
± 5%
Density
Temperature
±0.1 °C
Normalised relative standard deviation (RSD) of viscosity
as a function of viscosity.
Normalised relative standard deviation (RSD) of density
as a function of viscosity

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 5
2.2. Mounting instructions
The sensing element of the LUB-VDT is a quartz crystal
tuning fork resonator. To protect this resonator from
mechanical shocks, the LUB-VDT has a permanent
protective cap. Liquid can enter this cap through an
opening at the tip and exit through openings at the
sides. It is recommended to mount the sensor in a T-
piece (inlet opposite the sensor and outlet on the side)
or similar arrangement. For sealing, we recommend a
bonded sealing washer; the required torque for these
washers is usually in the range of 31-39Nm
The sensor element of the LUB-VDT is practically
insensitive to installation position, flow direction or
pressure. Despite this, we recommend paying attention
to a few details for optimum performance:
Note: Air bubbles change the
mechanical properties of a liquid and
thus influence the measurement.
Ensure that no air bubbles can be
trapped at the sensor and potential
bubbles are carried away from the
sensor by flow or uplift. Avoid
feeding oil with air pockets to the
sensor and note that dissolved
gases in the oil can form bubbles
when the pressure is reduced.
Note: If the sensor is placed in a
reservoir or sump, the flow rate may
be very low. This can lead to an
extremely slow response of the
sensor as well as measurement-
affecting residues or even clogging
of the sensor.
Note: Although the sensing element
itself is virtually insensitive to
pressure, the viscosity of the oil is a
function of pressure. The effects of
pressure variations on
measurements are generally more
noticeable at higher pressures.
Note: Consider the heat transfer
from the liquid to the sensor housing
when working at high liquid
temperature.
If cleaning of the sensor is necessary, use suitable
solvents (e.g. benzine or alcohol).
Do not use compressed air, as
this can permanently damage the
resonator due to the high flow
velocity.
ATTENTION
Do not puncture the protective
cap with any objects (e.g.
needles or wires).
ATTENTION
2.3. Pin assignment
Power supply and signals share an M12-8 connector
with A-coding according to DIN EN 61076-2-101. Install
only with shielded cables.

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 6
The internal 120Ωresistor for
RS485 bus termination is
activated by connecting pin 3 to
the RS485 A line (pin 4). To
deactivate the termination, either
connect pin 3 to the RS485 B line
(pin 5) or leave it unconnected.
Any connection should be made
as close as possible to the
sensor.
ATTENTION
PIN
Signal
Anmerkung
1
OUT 1
4-20mA output
2
CFG reset
Connect to Ground
3
RS485 A
Modbus RTU
4
Terminator
Connect to pin 4 for termination
5
RS485 B
Modbus RTU
6
OUT 2
4-20mA output
7
+24V
Supply
8
0V
Ground
3. data filter
The raw data rate of the sensor is approximately one
measurement per second. To provide reliable, low-noise
results in applications with lower data rate
requirements, the FluidIX LUB-VDT provides a moving
average filter for all measured parameters. The length of
the filter is configurable via a Modbus register from 1 to
256 seconds, with the default set to 60s. Incorrect
measurements (such as out-of-range) are also stored in
the filter, but discarded when averaging. Therefore, the
output of the filter provides valid results as long as valid
data is present in the filter.
4. Modbus Interface
Modbus RTU via RS-485 can be used to retrieve
measurement results and status information as well as
to configure filter settings, analogue outputs and the
Modbus interface itself. All data is organised in 16-bit
registers with signed or unsigned integer values. If
necessary, two registers are combined (MSB first) to
represent a 32-bit integer.
The supported Modbus functions are:
•3: read holding registers
•6: write single holding register
•16: write multiple holding registers
4.1. Default Configuration
The default configuration is 19200 baud and device
address 1. A timeout value of at least 2s should be used
when communicating with the device. Please note that
all changes to the configuration (with the exception of
the Modbus interface) are accepted immediately, but
are not permanently saved until a 1 (0x0001) is written
to the command register. In the event of a
misconfiguration, the sensor can be reset to the factory
settings using the following procedure:
•Make sure that the sensor is properly supplied
with power.
•Connect pin 2 to the supply voltage (nominal
+24VDC, pin 7) for at least 10 seconds.
•Disconnect the sensor from the power supply.
•Connect pin 2 to ground and switch the sensor
on again.
•After the restart, the configuration (especially
the baud rate and the unit address) is reset to the
factory settings.
4.2. Register Map
General
Purpose
This is an unused register that can be
used freely. The content of this register
can be changed when it is reset.
HW Revision
ID
Hardware version of the sensor
Serial
Number
Serial number of the sensor
Firmware
Date
UNIX timestamp for the sensor
firmware

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 7
Error Count
Counter for measurement error incl. out-
of-range: Value is zero at switch-on
Measuremen
t Results
Each measurement is assigned a
sequential number that is reset to 0 at
power-up and can be read from the
Modbus registers. The measurement
results are scaled and encoded in
signed / unsigned 16-bit integers.
Invalid results are indicated by a value
of 0xFFFF.
Status Code
This register is used to report
measurement and error/warning
conditions. Each bit that is set to 1
indicates a specific condition
LOCK
Register
Registers of the Config Data Block are
prevented from accidental write access
by the LOCK register. To
enable write mode for the Config Data
Block (including the Command register)
write 44252 (0xACDC)
to the LOCK register. After the
configuration is finished set the LOCK
register 0 to prevent accidental
damage to the configuration.
Command
Register
To permanently save changes write 1
(0x0001) to the Command register.
Please note that this operation
may take about 1 s. When writing 255
(0x00FF) to the Command register the
device is restarted.
Baud Rate
Baud rate of the Modbus interface.
Accepted values are 9600, 19200, and
115200 baud. Default value:
19200 baud. Changes are activated
after a restart.
Address
Device address of the sensor. Default
value: 1. Changes are activated after a
restart.
Filter Length
Length of the moving average data filter
in the range of 1 to 256. Default value:
60.
OUTx_select
Selection of parameter that is mapped
to analog output x, where x is 1 or 2.
OUTx_min
Value that is mapped to 4mA output
current. This value must be scaled and
encoded in the same way as
the selected measurement parameter
(see section 5.2). If the measurement
result is lower than this limit,
the output remains at 4mA as long as
the result is valid (saturation).
OUTx_max
Value that is mapped to 20mA output
current. This value must be scaled and
encoded in the same way as
the selected measurement parameter
(see section 5.2). If the measurement
result is higher than this limit,
the output remains at 20mA as long as
the result is valid (saturation).
Note:By default, analogue output 1
is configured for temperature (-40 ..
125◦C) and analogue output 2 for
viscosity (0 .. 400cSt). An invalid
measurement result is represented
by an output current of 1mA.

BA FluidIX LUB-VDT EN
Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 8
4.3. Overview Status Codes
Bit
Description
Causes
0
No resonance
detected
Resonance search is
still in progress, liquid
outside measuring
range, sensor damaged
or dirty
1
Out of range
At least one parameter
is out of range
2
Frequency
Controller error
Viscosity or density out
of range
3
Noise error
Electromagnetic
interference; Very high
flow velocity.
4
Invalid
configuration
Missing or incorrect
configuration
5
Resonator error
Resonator damaged
6
Temperature sensor
error
Temperature sensor
damaged
7
Hardware error
Sensor electronics
damaged
8-15
reserved
4.4. Modbus Register