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Bühler technologies Fluidcontrol BCM-LS, Installation And Operation Instructions Manual

The Bühler technologies Fluidcontrol BCM-LS is a versatile and reliable product designed to facilitate fluid control in various applications. Ensure seamless integration with our comprehensive Installation And Operation Instructions Manual, available for free download at manualshive.com. The manual provides detailed instructions for easy and efficient setup and operation, maximizing your system's performance and longevity.

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BCM-MS, BCM-LS

Contents

1

Introduction.....................................................................................................................................................................................................................  3
1.1

Intended Use.........................................................................................................................................................................................................  3

1.2

Functionality.........................................................................................................................................................................................................  3
1.2.1

Temperature Measurement.............................................................................................................................................................. 3

1.2.2

Moisture Measurement...................................................................................................................................................................... 3

1.2.3

Relative Humidity................................................................................................................................................................................. 3

1.2.4

Conductivity Measurement..............................................................................................................................................................  4

1.2.5

Measuring Relative Permittivity .....................................................................................................................................................  4

1.2.6

Level Measurement.............................................................................................................................................................................  4

1.2.7

Operating Hours Counter .................................................................................................................................................................  4

1.2.8

Data Logger ...........................................................................................................................................................................................  4

1.2.9

Oil Condition.......................................................................................................................................................................................... 5

1.2.10

Determining The Remaining Useful Lifetime (RUL) ................................................................................................................... 5

1.2.11

Scope And Basic Parameters For Automatic Condition Analysis And RUL Calculation ..................................................  6

1.2.12

List Of All Measured And Derived Parameters............................................................................................................................  6

1.2.13

Calibration And Sensor Function Test ............................................................................................................................................ 7

1.2.14

List Of Parameter Outputs For Specific Commands..................................................................................................................  8

1.3

BCM-MS model key ...........................................................................................................................................................................................  10

1.4

BCM-LS model key .............................................................................................................................................................................................  10

1.5

Scope Of Delivery...............................................................................................................................................................................................  10

2

Safety instructions........................................................................................................................................................................................................  11
2.1

Important advice ................................................................................................................................................................................................  11

2.2

General hazard warnings ................................................................................................................................................................................  11

3

Installation and connection ....................................................................................................................................................................................... 13
3.1

Dimensions .......................................................................................................................................................................................................... 13

3.2

Installation ..........................................................................................................................................................................................................  14

3.3

Electrical Connections....................................................................................................................................................................................... 15
3.3.1

Analog Current Outputs (4..20 mA) - Measurement Without Load Resistor.................................................................... 16

3.3.2

Analog Current Outputs (4..20 mA) - Measurement With Load Resistor .......................................................................... 16

3.3.3

Load Resistor Size................................................................................................................................................................................ 16

3.3.4

Calibration............................................................................................................................................................................................  17

4

Operation and Control................................................................................................................................................................................................  18
4.1

RS232 Communication.....................................................................................................................................................................................  18
4.1.1

Serial Port (RS232)............................................................................................................................................................................... 18

4.1.2

Command List...................................................................................................................................................................................... 18

4.1.3

Setting Analog Current Outputs.................................................................................................................................................... 23

4.1.4

Output Triggering .............................................................................................................................................................................  24

4.1.5

Save Triggering ..................................................................................................................................................................................  24

4.1.6

Configuration For Automatic Condition Analysis ...................................................................................................................  24

4.2

CAN Communication........................................................................................................................................................................................  25
4.2.1

CAN Interface ....................................................................................................................................................................................... 25

4.2.2

CANopen................................................................................................................................................................................................ 25

4.3

Before Initial Use ...............................................................................................................................................................................................  35

4.4

Initial Operation ................................................................................................................................................................................................  35
4.4.1

Initial Operation With RS232 Port.................................................................................................................................................. 35

4.4.2

Initial Operation With CAN Interface ..........................................................................................................................................  36

4.4.3

Function Range Depending On Configuration.........................................................................................................................  36

4.5

Application Example ........................................................................................................................................................................................  37

5

Cleaning And Maintenance....................................................................................................................................................................................... 38

6

Service and repair......................................................................................................................................................................................................... 39
6.1

Troubleshooting ................................................................................................................................................................................................ 39

6.2

BCM-MS accessories ........................................................................................................................................................................................  40

6.3

Accessories BCM-LS ..........................................................................................................................................................................................  40

7

Disposal ...........................................................................................................................................................................................................................  41

i

Bühler Technologies GmbH

BE150104 ◦ 03/2021

Summary of Contents for Fluidcontrol BCM-LS

Page 1: ...inal instructions Bühler Condition Monitor BCM MS BCM LS BE150104 03 2021 Bühler Technologies GmbH Harkortstr 29 D 40880 Ratingen Tel 49 0 21 02 49 89 0 Fax 49 0 21 02 49 89 20 E Mail fluidcontrol buehler technologies com Internet www buehler technologies com ...

Page 2: ...ead this instruction carefully prior to installation and or use Pay at tention particularly to all advises and safety instructions to prevent in juries Bühler Technologies can not be held responsible for misusing the product or unreliable function due to unauthorised modifications All rights reserved Bühler Technologies GmbH 2021 Document information Document No BE150104 Version 03 2021 ...

Page 3: ...ion and connection 13 3 1 Dimensions 13 3 2 Installation 14 3 3 Electrical Connections 15 3 3 1 Analog Current Outputs 4 20 mA Measurement Without Load Resistor 16 3 3 2 Analog Current Outputs 4 20 mA Measurement With Load Resistor 16 3 3 3 Load Resistor Size 16 3 3 4 Calibration 17 4 Operation and Control 18 4 1 RS232 Communication 18 4 1 1 Serial Port RS232 18 4 1 2 Command List 18 4 1 3 Setting...

Page 4: ... LS Technical Data 42 8 2 BCM MS Technical Data 43 8 3 Standard pin assignment 44 8 4 Permissible Mechanical Loads 44 8 5 Error Bits Key 45 8 6 Load Factor Of A System 46 9 Attached documents 47 ii Bühler Technologies GmbH BE150104 03 2021 ...

Page 5: ...t these parameters to a fixed reference temperature The sensor continuously measures at various temperatures for this conver sion and uses this data to determine the temperature gradients of the parameters Determining the temperature gradient requires several temperature cycles when commissioning the sensor During operation the temperature gradient is also continuously adjusted when oil is changed...

Page 6: ... e g taking into account batch variances can be used to determine oils being confused mixed or refreshed Oils typically change their polarity throughout the aging process If this causes a significant change in polarity the aging process can also be monitored The measuring range for relative permittivity is 1 7 Since the relative permittivity depends on the temperature the sensor internally convert...

Page 7: ... appendix 1 2 10 Determining The Remaining Useful Lifetime RUL In addition to classifying various conditions or condition changes another sensor function is to determine the remaining useful lifetime RUL based on available data Here we distinguish between two different approaches The following illustration is an example trend of a aging parameter over the operating time After an oil change the oil...

Page 8: ...ameter settings further greatly affect the results A purely mathematical estimate of the RUL based on measured burden factors cannot predict spontaneous condition changes Overall a sufficient data volume and purposeful parameter settings will typically yield a satisfactory accuracy and prediction of the aging process 1 2 12 List Of All Measured And Derived Parameters The 5 original characteristics...

Page 9: ...ient C40 5 C40 MGC40 pS m h C40 gradient over mean period 6 C40 SGC40 pS m h Short term gradient of C40 7 T LGT K h Long term gradient of oil temperature 8 T SGT K h Short term gradient of oil temperature 9 H20 SGH20 h Short term gradient of H2O Tab 4 Time gradients Rapid changes indicate e g oil being added but depending on the extent slow gradients can indicate contamination with a for eign flui...

Page 10: ...ature of electronics or sensor 13 RULT h Temperature based remaining useful lifetime RUL of the oil 14 RULLG h Long term gradient and limit based RUL of the oil 15 RUL h Combined and weighted RUL 16 APP40 Aging progress AP based on P40 and set limits 17 APC40 AP based on C40 and set limits 18 AP Combined and weighted AP 19 fB Temperature load factor since starting teach in or indicates oil refilli...

Page 11: ...L counts down from Tab 7 Response to command RCon Parameter name Unit Explanation 1 LimP40 5 Oil aging limit for P40 in from fresh oil value default 5 2 LimC40 Oil aging limit for C40 in from fresh oil value up default 300 permissible downward deviation is automatically calculated from this specification 3 LimT C Maximum permissible oil temperature if exceeded the corresponding bit is set in ERC d...

Page 12: ...l key BCM LS200 1DC2A xxx Type designation Outputs 1DC2A Multisensor incl liquid level measurement BCM Bühler Condition Monitor L 1x CANopen 2x analog Sensor S Process connection 0 G3 4 Length 200 mm 375 mm 615 mm Item no Model 1550002200 BCM LS200 1DC2A 200 1550002375 BCM LS200 1DC2A 375 1550002615 BCM LS200 1DC2A 615 1 5 Scope Of Delivery Bühler Condition Monitor BCM Product Documentation 10 Büh...

Page 13: ...risk resulting in severe injuries or death if not avoided WARNING Signal word for a hazardous situation with medium risk possibly resulting in severe injuries or death if not avoided CAUTION Signal word for a hazardous situation with low risk resulting in damaged to the device or the property or minor or medium injuries if not avoided NOTICE Signal word for important information to the product War...

Page 14: ...arts Do not install damaged or defective spare part If necessary visually inspect prior to installation to determine any obvious damage to the spare parts Always observe the applicable safety and operating regulations in the respective country of use when performing any type of maintenance The method for cleaning the devices must be adapted to the IP protection class of the devices Do not use clea...

Page 15: ... LS200 L 200 mm Level measuring range 115 mm 8 pin A Coding Male 8 pin A Coding Male Sealing ring Sealing ring Level measuring range Connection dimensions BCM LS200 Connection dimensions BCM MS200 Distance from oil sump 13 Bühler Technologies GmbH BE150104 03 2021 ...

Page 16: ...ptions Tank Tank Fig 3 Installation options To ensure proper function please observe the following guidelines related to sensor mounting position and location To analyse an oil volume characteristic of the oil condition the sensor should not be immediately in the oil sump of the tank For tank top installation it will preferably be mounted near the return or flushing pipe Ensure the sensor is fully...

Page 17: ...r EN50178 SELV PELV VDE0100 410 A1 To install switch off the machine and connect the device as follows Pin assignment Sensor cover top view Standard cable colour white brown green yellow grey pink blue red Housing shield Fig 5 Sensor plug pin assignment The permitted operating voltage is between 9 V and 33 V DC The sensor cable must be shielded To ensure protective class IP67 only use suitable plu...

Page 18: ...be used to measure the voltage which drops over the respective resistance Sensor cover top view Fig 7 Connecting the load resistances to measure the analog 4 20 mA outputs The default configuration is intended for oil temperature on channel 1 and relative humidity on channel 2 The channel assignment can be changed and is described in chapter Setting Analog Current Outputs page 23 3 3 3 Load Resist...

Page 19: ...the analog current outputs By default the current outputs show the temperature between 20 C and 120 C and the relative humidity between 0 and 100 The upper limit for the absolute humidity AHScl is required to scale the analog current outputs This is freely program mable However the limit is oil specific and must be determined at a laboratory along with the other parameters required to measure the ...

Page 20: ... 10 seconds after connecting power repeat the process 4 1 1 Serial Port RS232 The sensor has a serial port which can be used to read and configure it This requires a PC and the corresponding terminal pro gram or a readout software Both are detailed in the following chapters First you will need to select an existing free COM port on your PC to connect the sensor to A suitable communication cable fo...

Page 21: ...terrupt x xxx x xxxx x xxxx x xxxx x xxxx CRC x CR LF x xxx x xxxx x xxxx x xxxx x xxxx CRC x CR LF 10 RMem n i CR Read i datasets in memory starting with cur rent dataset n datasets followed by checksum CRC per dataset data semicolon separated datasets CR LF separated starting with the oldest dataset press any key to interrupt x xxx x xxxx x xxxx x xxxx x xxxx CRC x CR LF x xxx x xxxx x xxxx x xx...

Page 22: ... 250 500 applied after restarting COSpd x CR LF 11 WCOIDx CR Set node ID for CANopen mode Range x 0 127 COB ID of TPDOs is automatically set to defaults TPDO1 COB ID 0x180 node ID TPDO2 COB ID 0x280 node ID TPDO3 COB ID 0x380 node ID TPDO4 COB ID 0x480 node ID Applied after restart COID xxx CR LF 12 WCOHBeatn CR Set heart beat time for CANopen mode Range x 0 10000ms resolution 50ms If n 0 heart be...

Page 23: ... C CR LF 20 SETrign CR Disables n 0 or enables n 1 event triggered save of measure ments Range n 0 1 Default n 0 MemETrig n CR LF 21 WRULhn CR Enter reference lifetime of current oil for temperature based RUL cal culation RULh n CR LF 22 WRULfBn CR Enter reference load factors of current oil for temperature based RUL calculation RULfB n CR LF 23 STrAun CR Disables n 0 or enables n 1 60 automatic t...

Page 24: ...st be added up based on a range of 8 bit 0 255 If the result is ZERO there is no error Example of sent string RH 31 CRC Ù CR LF Character Value R 82 H 72 58 3 51 1 49 91 37 93 59 X 67 P 82 X 67 58 Ù 217 CR 13 LF 10 Sum 0 OK Tab 15 Example of checksum calculation CRC 22 Bühler Technologies GmbH BE150104 03 2021 ...

Page 25: ... Alarm 4mA no alarm 20mA oil level low sensor in air or if level sensor oil level set minimum or free water 95 or very high water content 75 or maximum oil temperature setting exceeded 40 Sequential output of T rel H P C P40 C40 AP and L2 100 Output fixed to 4 mA 101 Output fixed to 12 mA 102 Output fixed to 20 mA Tab 16 Numerical code for output parameters of the analog current outputs 1 This set...

Page 26: ...table example for default configuration Step Parameter 1 Set save interval to 20 minutes WSaveInt20 0 ENTER 2 Write aging values WLimP40 5 0 ENTER WLimV40 20 ENTER 3 Write temperature limits WLimT80 0 ENTER WLimTMean50 0 ENTER 4 Set oil reference lifetime if known WRULhxxxx ENTER 5 Set oil reference load factor if known WRULfBxxxx ENTER 6 Erase memory as needed CMem ENTER 7 Mark current oil as fre...

Page 27: ... The electrical parameters of the CAN interface are shown in this table Parameter Size Unit Typ response time to SDO queries 10 ms Max response time to SDO queries 150 ms CAN Transceiver supply voltage 3 3 V Integrated termination no Tab 19 CAN interface electrical parameters Start of message Address service type PDO SDO etc Data length code Cyclic redundancy checksum Receipt sets bit to Low End o...

Page 28: ...t NMT is services and bus initialization error handling and node management Process Data Objects PDOs are used to transmit real time process data Service Data Objects SDOs allow read and write access to the object directory of a node Special Function Object Protocol allows application specific network synchronisation timestamp transmission and emer gency messages The following is an example for in...

Page 29: ...a type the index and the subindex This leaves 4 byte of the 8 byte of a CAN array for the data content For objects with data contents greater than 4 byte there are two other protocols for so called fragmented or segmented SDO transfer Message Message Sensor Control unit Fig 11 SDO Client Server relationship SDOs are intended to configure the sensor by accessing the object directory request rarely ...

Page 30: ...d Index Subidx SDO payload 1 0 0 3 2 1 0 Message from cli ent to sensor 0x580 NodelD 0x08 0x43 0x18 0x10 0x04 0xBB 0x0D 0x30 0x00 Tab 24 SDO download response from the server to the client The following is an example of a data upload heartbeat time via SDO to the object directory of the sensor to index 0x1017 with a data length of 16 bit The client control unit sends a write request to the sensor ...

Page 31: ...e event or timer triggered method transmission is triggered by a timer inside the sensor or an event 2 With the SYNCH triggered method transmission is in response to a SYNCH message CAN message from a SYNCH producer without payload The response with PDO is either for every synch received or can be configured as every SYNCH messages received Message Actuator Control unit Sensor Fig 12 PDO Consumer ...

Page 32: ...ect Sub Type Object Byte in CAN Msg Fig 13 Principle of mapping multiple OD objects in a TPDO The sensor supports certain types of TPDO which can be entered for the respective communication parameters of the TPDOs Type supported cyclic non cyclic synchronous asynchronous 0 yes x x 1 240 yes x x 241 253 no 254 yes x 255 yes x Tab 28 Description of TPDO types 30 Bühler Technologies GmbH BE150104 03 ...

Page 33: ...contain the serial number the top byte is reserved for future use 1800 Transmit PDOs Parameter record 0 Number of entries U8 ro 05h largest sub index 1 COB ID U32 rw 180h NodeID COB ID used by PDO range 181h 1FFh can be changed while not operational 2 Transmission type U8 rw FFh cyclic synchronous asynchronous values 1 240 254 255 5 Event timer U16 rw 1388h event timer in ms for asynchronous TPDO1...

Page 34: ...rectory from index 2000h and listed in the following This part of the object directory is sensor specific and represents the oil parameters measured and derived by the sensor Furthermore some configuration options are supported to for example set the maximum temperature values or configure the settings required to calculate the RUL Manufacturer specific profile area ldx hex Sub Name Type Attr Defa...

Page 35: ... fresh oil value U16 ro Conductivity of the oil compensated to 40 C di vided by 100 0 1 000 000pS m 2008 Humidity related parameters of the oil record 0 Number of entries U8 ro 03h largest sub index 1 rel humidity S16 ro rel humidity of the oil multiplied by 10 range 0 0 100 0 2 rel humidity temperature com pensated to 40 C S16 ro rel humidity of the oil in multiplied by 10 com pensated to 40 C ra...

Page 36: ... Number of entries U8 ro 2h largest sub index 1 RUL Reference Load Factor fB 1000 U16 rw reference load factor fB multiplied by 1000 2 RUL Reference Lifetime in Hours U16 rw 100 30000 h reference life time for this oil in this application 2100 Readmem control functions record 0 Number of entries U8 ro 3 h largest sub index 1 Size of history memory data sets U16 ro size of mem in datasets device de...

Page 37: ...cquisition via RS232 Connect the M12 plug of the sensor cable to the sensor Connect the 9pin Connect the D sub plug of the cable to the corresponding serial port on your PC laptop Connect the power supply and the sensor cable Now properly connect your power supply to the mains with the IEC connector Your sensor is now ready for use E Start the software CMSensorDataViewer and CMSensorConfig can be ...

Page 38: ...nding on the desired functional range the sensor can be configured with additional information to use the corresponding functions The table shown here contains a list of the necessary sensor configurations for the respective functional range For in formation about configuring the sensor please see chapter Configuration For Automatic Condition Analysis page 24 Configurations necessary for function ...

Page 39: ... cannot be detected from this parameter However oil refreshing can be detected through other parameters described below 2 Using the correct oil Whether the prescribed lubricants is used can be determined by the conductivity and the relative DK The respective parameters must be stored in the system for fresh oil The theoretical and actual values can then be compared 3 Oil aging Oxidative aging of f...

Page 40: ...s device is maintenance free when used properly The method for cleaning the devices must be adapted to the IP protection class of the devices Do not use cleaners which could damage the device materials 38 Bühler Technologies GmbH BE150104 03 2021 ...

Page 41: ...rrect communication port selected Check and if necessary correct the selected communication port e g COM1 Incorrect sensor command syntax Check the syntax of the sensor commands Particularly note capitalisation If the commands are invalid the sensor will return the string with a question mark in front of it Incorrect or defective cable If possible use original data cables RS 232 interface not enab...

Page 42: ...rface with the RS232 port CMSensorConfig or a terminal program as described in chapter Operation and Control page 18 Absolute humidity measurement incor rect Calibrating parameter settings incor rect The calibrating parameters are specific to the oil and must be programmed Please contact Bühler Technologies GmbH Service Measuring range setting incorrect The measuring range is specific to the oil a...

Page 43: ...posal Dispose of parts so as not to endanger the health or environment Follow the laws in the country of use for disposing of elec tronic components and devices during disposal 41 Bühler Technologies GmbH BE150104 03 2021 ...

Page 44: ...olyalkylene glycol PAG zinc and ash free oils ZAF poly alpha olefins PAO Weight 170 g for 200 mm version 210 g for 375 mm version 250 g for 615 mm version Operating voltage UB 9 33 V DC Power input max 0 2 A Measuring range Temperature 20 C 85 C Rel humidity 0 100 Rel permittivity 1 7 Conductivity 100 800 000 pS m Liquid Level 115 mm for 200 mm version 288 mm for 375 mm version 515 mm for 615 mm v...

Page 45: ...oils H HL HLP HLPD HVLP syn thetic esters HETG HEPG HEES HEPR polyalkylene glycol PAG zinc and ash free oils ZAF poly alpha olefins PAO Weight 140 g Operating voltage UB 9 33 V DC Power input max 0 2 A Measuring range Temperature 20 C 85 C Rel humidity 0 100 Rel permittivity 1 7 Conductivity 100 800 000 pS m Measuring accuracy Temperature 2 K Rel humidity 3 Rel permittivity 0 015 Conductivity 100 ...

Page 46: ...nsors When exceeding the vibration resistance of the level sensors additional mechanical stabilisation is required at the bottom end of the sensor Load Size Unit max longitudinal vibration BCM MS und BCM LS Test based on DIN EN 60068 2 6 f 5 9 A 15 f 9 200 a 10 HZ mm HZ g max transverse vibration BCM MS Testing based on DIN EN 60068 2 6 f 5 9 A 15 f 9 200 a 10 HZ mm HZ g max transverse vibration B...

Page 47: ...Viscosity Measuring range exceeded 2 25 9 Info warning Temperature Measuring range exceeded 2 26 10 Info warning Reserved 2 27 11 Info warning Reserved 2 28 12 Info warning rel DZ Measuring range exceeded 2 29 13 Info warning Oil does not correspond to specified reference oil characteristics of the oil deviate significantly from the values of the taught in fresh oil 2 30 14 Info warning Reserved 2...

Page 48: ...d assigned bit code After an oil change these parameters will only be available after completing the teach in phase depending on the system after 10 to 250 operating hours and several load conditions as the required grants can only be detected with adequate precision after some teach in time This condition analysis is currently in the test phase 8 6 Load Factor Of A System Calculating a system s l...

Page 49: ...BCM MS BCM LS 9 Attached documents Declarations of Conformity KX150004 KX150005 RMA Decontamination Statement 47 Bühler Technologies GmbH BE150104 03 2021 ...

Page 50: ......

Page 51: ......

Page 52: ...aminated Ja kontaminiert mit Yes contaminated with explosiv explosive entzündlich flammable brandfördernd oxidizing komprimierte Gase compressed gases ätzend caustic giftig Lebensgefahr poisonous risk of death gesundheitsge fährdend harmful to health gesund heitsschädlich health hazard umweltge fährdend environmental hazard Bitte Sicherheitsdatenblatt beilegen Please enclose safety data sheet Das ...

Page 53: ...ersetzen Sie vor der Inbetrieb nahme die Verkabelung wieder in den ursprünglichen Zustand Fragen Sie im Zweifel beim Hersteller nach weiteren Informationen Analysing defective assemblies is an essential part of quality assurance at Bühler Technologies To ensure conclusive analysis the goods must be inspected unaltered if possible Modifications or other damages which may hide the cause or render it...

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