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motcom® BeCOMS® | BCom

User Manual

Release 

130301 (revision 190211)

Page 6.1

6. Repair

Before any attempts to repair or dismount the BCom devices because of an assumed 

defect or failure you should contact motcom GmbH or its authorized partners.

Based on experience, many failures can be cleared easily by fault diagnostics on 

site. In most cases a repair is not necessary.

Dismounting may only be performed on demand by motcom GmbH or its authorized 

service representatives.

A repair of BCom components is done exclusively by motcom GmbH. Defective 

parts should be sent to motcom GmbH including detailed failure description.

Please get in contact with the headquarter of motcom GmbH for further assistance.

Summary of Contents for BeCOMS BCom

Page 1: ...BeCOMS BCom Bearing Condition Monitoring UserManual Part No 1 900 00 00000 Release 130301 revision 190211...

Page 2: ......

Page 3: ...compliance with following norms EN 55011 2018 05 CISPR 11 2015 mod A1 2017 EN 55032 CISPR 22 EN 61000 4 2 EN 61000 4 3 EN 61000 4 4 EN 61000 4 5 EN 61000 4 6 EN 61000 4 8 66130 Saarbr cken Germany 20...

Page 4: ...nual we offen named figures and pictures with BCom but always follow the instruction and information for BeCOMS too It is recommended to read this manual before commencing the repair assembly or commi...

Page 5: ...Manual Release 130301 revision 190211 Page v Contents 1 System Description 1 1 2 Installation 2 1 3 Commissioning 3 1 4 Performance Maintenance Tests 4 1 5 Troubleshooting 5 1 6 Repair 6 1 7 Spare Par...

Page 6: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page vi...

Page 7: ...g Software opt 1 14 2 Installation 2 1 2 1 General 2 1 2 2 Installation Position 2 2 2 3 SRE Mechanical Adjustments 2 3 2 4 Wiring Diagram 2 4 2 5 Software Installation optional 2 5 2 6 PC Requirement...

Page 8: ...Function Test 4 1 5 Troubleshooting 5 1 5 1 During Software Installation 5 1 5 2 During Software Use 5 2 5 3 Missing Control Signal 5 3 5 4 Very low strong signal on polar diagram 5 4 5 5 Error code...

Page 9: ...s On diesel engines the BCom system measures and evaluates thermal voltage between the crankshaft and bearing shells signalling changes that can be interpreted as dangerous Dry friction R V Fig 1 1 Me...

Page 10: ...r efforts and costs are minimised while early detected problems can be in most cases eliminated together with common maintenance works Thermovoltage peaks can be observed every time the engine starts...

Page 11: ...time The BCom Evaluator monitors all changes that occur during the engine operation and triggers an alarm should these changes indicate danger Fig 1 4 High thermovoltage signal at engine start up The...

Page 12: ...cally at tached to the free end of the crankshaft usually with a vibration damper One BCom Evaluator as the Local Control Panel where the measured values are displayed and the signal evaluation is per...

Page 13: ..._Logger software a CD with Logger installation and a soft copy of this manual i BeCom Evaluator optional PC with Logger software printer Mechanical adapter specific to the engine cable set SRE Slip Ri...

Page 14: ...in the engine control room The Evaluator operates reliably at temperatures between 0 C to 70 C and at relative humidity up to 80 The installation of the Evaluator is performed via 2 assembly rigs If...

Page 15: ...keypad can be wiped with a mild cleaning agent Please never use a solvent After successful installation and testing by service technicians approved by motcom GmbH the settings of the Evaluator should...

Page 16: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 1 8 Fig 1 9 Evaluator dimensions For the exact dimensions please see under 8 3 Drawings...

Page 17: ...4 2nd Alarm Relay NO CAN L SRE 4 5 2nd Alarm Relay COM RS485 SRE 5 6 2nd Alarm Relay NC RS485 SRE 6 7 Ready Relay NO RxD RS485 SRE 7 8 Ready Relay COM RxD RS485 SRE 8 9 Pre Alarm Relay COM GND SRE 9 1...

Page 18: ...e engine are adapted individually for each engine type If necessary SRE can be dismounted for maintenance Info The shaft and the mounting flange are determined designed and manufactured by motcom GmbH...

Page 19: ...witch over contact usually configured as pre alarm Ready 1 relay with 1 ground free switch over contact energized if system is fault free Interface Serial Interface RS485 for standardized industrial b...

Page 20: ...or or via RS485 text based setup using a terminal program x x x Displays Thermosignal in alarm level x x x Displays Thermosignal AC effective in alarm level x x x Displays Thermosignal DC effective in...

Page 21: ...lays thermosignal and mV thermosignal effective and engine speed in one y t graph x x Minimized polar diagram in the main window x Enlarged polar diagram in an own window incl integrated engine geomet...

Page 22: ...d be shown to the operator how to make the best use of the software and to alert of safety issues that may arise The purpose of this manual is to instruct the operator how to make the best use of the...

Page 23: ...y personnel from motcom GmbH or its authorized representatives The installation procedure includes training for the site operation personnel The commissioning data will be stored on the backup CD for...

Page 24: ...Page 2 2 The BCom Slip Ring Encoder is installed at the end of the crankshaft of the combustion engine The evaluator can be installed in the engine room near the engine or alternatively in the engine...

Page 25: ...d without re centering During the BCom installation the SRE has to be synchronized with the engine s crankshaft This has to be done only once This involves positioning the engine at the firing TDC see...

Page 26: ...5 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 2 6 Fig 2 2 Principle connection The cable types for power supply relay output data link and connection of the SRE sensor are shown in F...

Page 27: ...he system specific configuration on site after BCom commissioning Please refer to BCom Data_Logger and Data_Indicator manual for information Upon request a backup CD with 1 a softcopy of this manual 2...

Page 28: ...approx 100MB per day per BCom set supports Windows 7 8 1 and 10 mouse keyboard at least 3 PCI slots Display resolution 1280 x 1024 or higher depending on how many BCom applications running parallel o...

Page 29: ...2 4 2 correct power supply on BCom Evaluator 3 BCom Evaluator display is on 4a correct power supply on RS 485 converter 5a green power light on 6a the RS 485 converter rate setting is correct 4b PCI c...

Page 30: ...sonnel Turn engine to firing TDC of first cylinder number 1 at inline engine A1 at v type engine all valves must be closed Go to chapter 3 6 5 1 10 IS Impuls Offset page 3 12 at the Evaluator menu Sta...

Page 31: ...nverts them into digital signals analyzes evaluates and displays them on its LCD display These data including detected events are continuously made available through the RS485 interface to the install...

Page 32: ...ber is the less sensitive is the system Over speed alarm level is given in RPM Alarm sensitivity levels must be set at the BCom Evaluator If alarm conditions are fulfilled the firmware of the BCom Eva...

Page 33: ...ed by friction With this information of fault on early stage the operator is aware of the progressing problem and has enough time for making decisions on engine maintenance and repair In case of an al...

Page 34: ...if Over speed Alarm triggered Over speed Alarm is not being reset automatically by the system either It must be reset by pressing the RESET button at the Evaluator for 3 seconds Attention Main Alarm c...

Page 35: ...information and settings are organised in a tree like menu The user can view the menu elements on the LC display move between them and change some system settings using Evaluator buttons Evaluator bu...

Page 36: ...eff DCA effective value of thermovoltage in percents of DC alarm level Teff ACA effective value of thermovoltage in percents of AC alarm level Fig 3 3 BCom system measured values default screen 3 6 2...

Page 37: ...d bars are RPM engine rotation speed in RPM Teff ACA effective value of thermovoltage in percents of AC alarm level Teff DCA effective value of thermovoltage in percents of DC alarm level Tsig DCA the...

Page 38: ...DC the value is 1 otherwise 0 3 6 4 2 SRE advanced infos 2 ISa the current value at the A channel of incremental encoder can be 1 or 0 ISb the current value at the B channel of incremental encoder can...

Page 39: ...press Enter the value field becomes highlighted Use and buttons to increase or decrease the number in the field or to select one of provided text values When the desired value appears in the field pr...

Page 40: ...for Level2 Engine rotation speed in RPM which defines the boundary between RPM zone 1 and RPM zone 2 3 6 5 1 7 Start Alminhibit Time interval in seconds immediately after engine start during which th...

Page 41: ...80 to 199 3 6 5 1 15 AC Alarm percent Scale factor for AC alarm level possible values 80 to 199 3 6 5 2 Setup CPU View and change Evaluator settings If the sublevel was entered pressing Esc restarts t...

Page 42: ...n The screen at fig 3 9 page 3 11 appears then and the system parameters can be changed now If wrong PIN was entered text in the PIN field will be changed to P 3 6 5 2 6 Software Info Firmware version...

Page 43: ...and OFF At the same time the values TS1 and TS2 are displayed signals from the first and the second thermovoltage measurement channels 3 6 5 3 5 Testsignal B Switch the test signal on channel B ON an...

Page 44: ...Com Data_Indicator software is used for reading and analysing the BCom data files For further information please refer to BCom Data_Indicator user manual The daily data files created by BCom Logger ha...

Page 45: ...ht button of the mouse A menu should pop up refer to Fig 3 11 2 Click on the option Add to Archive from the option list 3 Click OK refer to Fig 3 12 and the data file log will be automatically compres...

Page 46: ...format RAR 2 Update mode Add and update files 3 Archiving option no tag selected 4 Compression method best 5 Volume size not limited 6 The original of the data files which have been compressed will no...

Page 47: ...minimize all other software applications except BCom monitoring application so that you can get a clear screen without unnecessary windows at the back ground of BCom monitoring application C Select t...

Page 48: ...t button of the keyboard hold it and move the mouse pointer to the last data files rar to be moved and c press the left button of the mouse once again and release the Shift button All the selected dat...

Page 49: ...perience with this cetain engine type the operator can identify the exact parts that cause the high thermosignal To get reliable failure localization results a continuous time interval should be analy...

Page 50: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 3 22...

Page 51: ...lly isolated from bearings with the lubrication oil film Test signals are visible among measurement data 2 on the stopped engine the crankshaft makes electrical contact with the bearing Test signals a...

Page 52: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 4 2...

Page 53: ...mputer needed for the software If a Not connected message appears in the event window after you have started BCom Data_Logger the following steps may fix the problem in case the RS 485 converter is us...

Page 54: ...a communication problem with the BCom Evaluator is depicted in Fig 5 2 below The operators should use the technical acceptable standards to trace the cause of the errors reported and skillfully fix th...

Page 55: ...display of the Evaluator and in BCom Data_Logger at a running engine then please conduct the following steps 1 Remove the interface housing cover 2 Check whether the metal coupling inside is turning w...

Page 56: ...g and interpretation of the signals over a longer period is important Changes of the signal could be evaluated based on the previous recorded data Based on these results suitable measures for engine o...

Page 57: ...ion signal of the incremental encoder not connected BCom Error 32 BCom test signal dead check all connections The error codes may be summed up For example error code 20 means that the error codes 04 a...

Page 58: ...BCom User Manual Release 130301 revision 190211 Page 5 6 Single codes 32 16 8 4 Summed up codes 12 x x 20 x x 24 x x 28 x x x 36 x x 40 x x 44 x x x 48 x x 52 x x x 56 x x x 60 x x x x Table 5 1 Code...

Page 59: ...experience many failures can be cleared easily by fault diagnostics on site In most cases a repair is not necessary Dismounting may only be performed on demand by motcom GmbH or its authorized service...

Page 60: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 6 2...

Page 61: ...Only the original parts supplied and approved by motcom GmbH should be used otherwise a proper working system could not be assured Part No 1 010 00 20000 Fig 7 1 Slip Ring Encoder SRE Part No 1 020 0...

Page 62: ...Manual Release 130301 revision 190211 Page 7 2 7 2 Accessories Part No 9 100 20 00000 Part No 9 200 04 22000 Fig 7 4 RS 232 Connection cable for PC to external RS 485 converter Fig 7 5 2 x 2 twisted p...

Page 63: ...BCom User Manual Release 130301 revision 190211 Page 7 3 Fig 7 6 2 core power cable Part No 9 200 02 00000 Fig 7 7 12 core communication cable Fig 7 8 Sub D9 connector Part No 9 301 09 10000 Part No 9...

Page 64: ...m User Manual Release 130301 revision 190211 Page 7 4 Part No 9 300 06 10000 Part No 9 300 12 20000 Part No 9 300 12 10000 Fig 7 9 6 pol female connector Fig 7 10 12 pol female connector Fig 7 11 12 p...

Page 65: ...ision 190211 Page 7 5 Fig 7 12 RS 485 converter Fig 7 13 Power supply unit 24V 24W Part No 9 110 40 00000 Part No 9 100 30 00000 i Mounting position for Part No 9 100 30 00000 Part No 9 110 40 00000 o...

Page 66: ...RS 485 converter Advantec PCI Card 1602B for mounting inside PC Fig 7 15 RS 485 converter PCI Card EX42062IS for mounting inside PC Fig 7 16 RS 485 converter PCIe Card Version EX45062IS for mounting...

Page 67: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 7 7 Part No 1 700 10 01000 Fig 7 17 motcom Loganalyser Software...

Page 68: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 7 8...

Page 69: ...WG 22 motcom GmbH Part No 92000422000 this is used as an example to show how the connection is made This cable has 2 twisted pairs of black brown and black red Cut away the outer insulation approx 25m...

Page 70: ...x 40mm from the end of the cable and pull back the braided shield as shown in Fig 8 1 Cut the braided shield 10mm from the end see Fig 8 1 Cut away the insulation approx 5mm from the end of these 3 wi...

Page 71: ...f wires approx 3 5mm from the end and twist them Solder brown wire of brown black pair into pin No 2 on plug Solder red wire of red black pair into pin No 3 on plug Solder black wire of brown black pa...

Page 72: ...le Push back the braided shield Push the sealings over the wires Fig 8 4 Step 1 Sealing and strain relief Coupling nut Connector housing Fig 8 5 Step 2a Fig 8 6 Step 2b Shielding disc Shielding Solder...

Page 73: ...using by using the installation wrench and a flat wrench No 22 Assemble the Sub D9 connector on the other side of the cable Fig 8 7 Below you ve got two pictures of the connector before and after asse...

Page 74: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 6 8 2 Wiring Diagrams 9 9 2015 5 46 41 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 2 6...

Page 75: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 7 9 9 2015 5 47 12 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 3 6...

Page 76: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 8 9 9 2015 5 47 40 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 4 6...

Page 77: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 9 9 9 2015 5 48 02 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 5 6...

Page 78: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 10 9 9 2015 5 48 32 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 6 6...

Page 79: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 11 8 3 Drawings Fig 8 12 Slip Ring Encoder SRE...

Page 80: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 12 Fig 8 13 Slip Ring Encoder SRE with throughout shaft...

Page 81: ...motcom BeCOMS BCom User Manual Release 130301 revision 190211 Page 8 13 Fig 8 14 BCom Evaluator...

Page 82: ...rbr cken Phone 49 0 681 8837904 0 Fax 49 0 681 8837904 19 eMail info motcomgmbh com Internet www motcomgmbh com motcom BeCOMS BCom User Manual motcom BeCOMS User Manual en BeCOMS is a registered Trade...

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