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motcom

®

 BeCOMS

®

 

User Manual

Release 

220601

Page 9.1

9 Repair

Before any attempts to repair or dismount the BeCOMS

® 

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. Otherwise, warranty may become void.

A repair of BeCOMS

®

 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.

i

!

!

Summary of Contents for BeCOMS

Page 1: ...BeCOMS BCom Bearing Condition Monitoring UserManual Part No 1 900 00 00000 Release 220601...

Page 2: ...s of Manufacturer motcom GmbH Kurt Schumacher Str 28 30 66130 Saarbr cken Germany Tel 49 0 681 8837904 0 Fax 49 0 681 8837904 19 Email info motcomgmbh com Internet www motcomgmbh com Version Chapter C...

Page 3: ...ction Diagram 2 4 3 System Overview 3 1 3 1 Slip Ring Encoder SRE 3 2 3 2 Evaluator 3 3 3 3 Mechanical Adapter and Cable 3 5 3 4 Optional Data Logger PC with Data_Logger Software 3 8 4 Functional Desc...

Page 4: ...gering 6 4 6 5 Alarm Resetting 6 6 6 6 Error Resetting 6 6 6 7 BeCOMS Data_Logger measurement data storage and management optional 6 7 6 8 Compressing Data Files 6 8 6 9 Capturing the Graphic Screens...

Page 5: ...eCOMS User Manual Release 220601 Page v 10 Spare Parts 10 1 11 Connection Assembly Instructions 11 1 11 1 Connection Cable RS485 PCI Card to Evaluator 11 1 11 2 Assembly of the plug M23 11 4 12 Append...

Page 6: ...motcom BeCOMS User Manual Release 220601 Page vi...

Page 7: ...ll operating personnel has fully understood the contents of these operating instructions The Bearing Condition Monitoring System is sold under the names BeCOMS and BCom For simplification only BeCOMS...

Page 8: ...anic or possess an equivalent level of training These notes contain important information and serve to ensure trouble free functionality These operating instructions may be used only by authorised per...

Page 9: ...s 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 2022 the 23th of February Dipl In...

Page 10: ...isplay of all values It can transmit all data via RS485 interface to a computer running the BeCOMS Data_ Logger software optional for enhanced visualisation and data storage The Data_ Logger and motco...

Page 11: ...to analysis tool for BeCOMS Logfiles User Manual incl CD with Software and instruction manuals Optional Data Logger PC or Notebook completely installed with Operating System Windows 10 64 Bit BeCOMS D...

Page 12: ...n Description BeCOMS Bearing Condition Online Monitoring System Evaluator Control Device IPxx International Protection LED Light Emitting Diode LCD Liquid Cristal Display PC Personal Computer PCIe Per...

Page 13: ...standardized industrial bidirectional communication Communication Protocol Modbus CAN Bus optional User interface LC Display 240 128 dots 1 LED red Shutdown 1 LED red Pre Alarm 1 LED green System Read...

Page 14: ...mosignal in alarm level x x x Displays Thermosignal AC effective in alarm level x x x Displays Thermosignal DC effective in alarm level x x x Displays Thermosignal in mV x x x Triggers Pre Alarm using...

Page 15: ...signal 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 geometry for dama...

Page 16: ...dev_motcom eagle block wiring bcom wiring03 sch Sheet 2 6 Fig 2 1 Basic principle The SRE sensor needs to be connected to the Evaluator connector 6 see Fig 2 1 Ports 1 3 are reserved for 24V power sup...

Page 17: ...The Data_Logger and motcom Analysis software serves as an o ine analysis tool one Set of mechanical parts and cable for mounting the SRE at the engine consists of engine cover adapter disc intermedia...

Page 18: ...nance It s highly rugged design ensures a trouble free operation under typical conditions refer to Chapter 2 General Technical Data and it s redundant thermovoltage read out satisfies even high securi...

Page 19: ...ween 0 70 C and 0 80 relative humidity suitable for installation close to the engine It displays all measurement values and parameters and is used for diagnostics of the BeCOMS system The installation...

Page 20: ...e wiped with a mild cleaning agent Please never use a solvent After installation and commissioning by service technicians approved by motcom GmbH the settings of the Evaluator should not be changed Th...

Page 21: ...or made for each type of engine for an exemple see Fig 3 4 the individual parts must not be removed by untrained non motcom personnel Alignment errors cause high wear and tear and consequential damage...

Page 22: ...e for a particular type of engine the individual parts must not be removed by untrained non motcom personnel Fig 3 5 shows an example of the adaptation with all the individual parts required Alignment...

Page 23: ...adial shaft seal 03 Isolation washer 26 O ring 04 Engine seal 27 O ring 05 Cover 50 53 Cylinder screws 06 Adapter shaft 55 Cylinder screws 07 Cover seal 57 Centering sleeve 08 Isolation bush 59 Washer...

Page 24: ...tware does not replace the interconnection of the Evaluator with the engine safety and alarm system To ensure proper functionality only motcom GmbH approved PC installations are supported to operate w...

Page 25: ...ay per BeCOMS system supports Windows 7 8 1 and 10 Mouse Keyboard at least 3 free PCI PCIe slots Display resolution 1280 x 1024 or higher RS485 Interface RS2323 via optional converter depending on num...

Page 26: ...motcom BeCOMS User Manual Release 220601 Page 3 10...

Page 27: ...anges therein can hint to a potentially dangerous engine failure Dry friction R V Crankshaft Bearing Fig 4 1 Measurement principle in an engine This thermovoltage is typically low 1 mV during normal e...

Page 28: ...with the firing sequence help to determine the location where the oil film ruptures see Fig 4 3 Fig 4 3 Thermovoltage signal course shown as screenshot of Data_Indicator Software The BeCOMS system is...

Page 29: ...ble integration into alarm control systems motor management enhances security even further During start up shut down procedure BeCOMS will detect relatively large thermovoltage peaks compared to stead...

Page 30: ...ncel the change of system value If Esc is pressed after entering the sublevel of menu items Setup Parameter or Setup CPU the Evaluator will restart Enter enter a sublevel or confirm a selected system...

Page 31: ...C 1 1 AC Alarm percent 1 15 Setup CPU 2 LCD large font 2 2 Modbus enable 2 4 Modbus address 2 5 PIN for Setup 2 6 LCD brightness 2 1 Software Info 2 7 Test Features 3 Alarm Relay 3 2 Alm2 Pre Relay 3...

Page 32: ...5 Graphic overview 4 5 1 BeCOMS graphical data indicator Menu level 1 Menu level 2 Menu level 3 Descriptions Measured values 2 Screenshot Shows further current BeCOMS measured values for the connecte...

Page 33: ...he 0 channel of incremental encoder 0 or 1 4 7 Parameter setup Displays advanced system values 1 TS1 the value at the analog digital converter of the first thermovoltage measurement channel TS2 the va...

Page 34: ...le 1 on page 4 9 To get write access to this parameter a PIN must be entered see Table 2 on page 4 11 Setup CPU View and change BeCOMS parameters If the sublevel was entered pressing Esc restarts the...

Page 35: ...eed alarm in RPM Possible values 0 to 3000 step 50 The 0 value disables the alarm TS Alm Level1 AC The value of AC main alarm level in the RPM zone 1 Possible values 0 to 5 The 0 value disables the al...

Page 36: ...buttons It is used during the impulse offset setup procedure as an indicator To start the procedure a PIN must be entered refer to Table 2 on page 4 11 PIN Impuls Offs PIN for impulse offset setup th...

Page 37: ...ode Allows communication in both directions simultaneously Modbus enable Enable or disable values ON and OFF accordingly the Modbus interface Modbus address Modbus address in the range of 0 to 99 PIN...

Page 38: ...d OFF Testsignal A Switch the test signal on channel A ON and OFF At the same time the values TS1 and TS2 are displayed signals from the first and the second thermovoltage measurement channels Testsig...

Page 39: ...to the customer as part of the training for later reference During the initial installation the current BeCOMS wiring will be adapted to the existing alarm and monitoring system on site For further de...

Page 40: ...installation and after each re installation The SRE must be synchronized with the engine crankshaft This procedure must be carried out during the initial installation as well as after each dismantlem...

Page 41: ...unning a BeCOMS Advanced or BeCOMS Professional system The Data_Logger and Data _Indicator software comes pre installed with the supplied Data Logger PC The programmes must be configured correctly acc...

Page 42: ...motcom BeCOMS User Manual Release 220601 Page 5 4...

Page 43: ...ing as given in Chapter 12 Appendix see Fig 12 1 12 4 2 correct power supply on Evaluator 3 Evaluator display is on 4a correct power supply on RS 485 converter 5a green power light on see Fig 6 1 6a t...

Page 44: ...onnel 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 Table 1 page 4 10 IS Impuls Offset at the Evaluator menu Start Impuls Of...

Page 45: ...al signals analyzes evaluates and displays them on its LC display These data including detected events are continuously made available through the RS485 interface to the installed PC with Data_Logger...

Page 46: ...holds as alarm condition Thermosignal alarm levels are encoded as numbers from 1 to 5 the higher the number is the less sensitive is the system Over speed alarm level is given in RPM Alarm sensitivity...

Page 47: ...electing the appropriate sensitivity level the operator defines up to which extend he would allow moving parts to be affected by friction With this information of fault on early stage the operator is...

Page 48: ...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 can...

Page 49: ...are is used for reading and analysing the BeCOMS data files For further information please refer to the BeCOMS Data_Indicator user manual The daily data files created by BeCOMS Data_Logger have an app...

Page 50: ...data file which is to be compressed with the right button of the mouse A menu should pop up refer to Fig 6 2 2 Click on the option Add to Archive from the option list 3 Click OK refertoFig 6 3 andthe...

Page 51: ...the data files may not be modified 1 Archive 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...

Page 52: ...itoring application 3 Select the part of the diagram you want to save 4 Press the alt and Print Scrn button of the keyboard once 5 Then change back to MS Word so the YYYYMMDD_EngineXXX doc will be sho...

Page 53: ...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 data files rar...

Page 54: ...with this certain 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 analysed in...

Page 55: ...earings 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 are not visible The...

Page 56: ...motcom BeCOMS User Manual Release 220601 Page 7 2...

Page 57: ...al computer needed for the software If a Not connected message appears in the event window after you have started Data_Logger the following steps may fix the problem in case the RS 485 converter is us...

Page 58: ...nication problem with the Evaluator is depicted in Fig 8 2 below The operators should use the technical acceptable standards to trace the cause of the errors reported and skillfully fix the problem If...

Page 59: ...the interface housing cover 2 Check whether the metal coupling inside is turning with the engine Warning Do not touch moving parts with tools or hands 3 If the coupling is broken it must be exchanged...

Page 60: ...ring circuit e g grounding of the engine block generator is bad Wiring problems from the system itself the metal coupling can slip which leads to incorrect speed values Interference voltages or ground...

Page 61: ...ncremental encoder not connected BeCOMS Error 32 BeCOMS test signal dead check all connections The error codes may be summed up For example error code 20 means that the error codes 04 and 16 appeared...

Page 62: ...com BeCOMS User Manual Release 220601 Page 8 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 8 1 Code combinatio...

Page 63: ...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 Otherwise wa...

Page 64: ...motcom BeCOMS User Manual Release 220601 Page 9 2...

Page 65: ...used otherwise a proper working system could not be assured Picture Description Part No BeCOMS Slip Ring Encoder SRE 1 010 00 20000 BeCOMS Slip Ring Encoder SRE with throughout shaft 1 010 00 20011 Be...

Page 66: ...e 220601 Page 10 2 Picture Description Part No 12 core communication cable 9 200 12 00000 Sub D9 connector 9 301 09 10000 6pol female connector 9 300 06 10000 12pol female connector 9 300 12 10000 12p...

Page 67: ...Picture Description Part No RS485 converter PCI card for mounting inside PC 9 100 40 00000 RS485 converter PCI card for mounting inside PC 9 100 40 00010 RS485 converter PCIe card for mounting inside...

Page 68: ...motcom BeCOMS User Manual Release 220601 Page 10 4...

Page 69: ...outer insulation approx 23mm from the end of the cable Push back the braided shield Push the sealings over the wires Fig 11 1 Step 1 Sealing Coupling nut Connector housing Fig 11 2 Step 2a Sealing an...

Page 70: ...over the wires Pull the enclosure cylinder over the soldered wires Finally seize the connector housing by using the installation wrench and a flat wrench No 22 For the correct assembling of the plug...

Page 71: ...nector on the other side of the cable Fig 11 8 Below you ve got two pictures of the connector before and after assembly Fig 11 6 Step 5 Installation wrench Connector housing Flat wrench No 22 Fig 11 7...

Page 72: ...n of wires approx 3 5mm from the end and twist them Solder green wire into pin No 5 on plug Solder blue wire into pin No 6 on plug Solder violet wire into pin No 7 on plug Solder grey wire into pin No...

Page 73: ...motcom BeCOMS User Manual Release 220601 Page 12 1 12 Appendix 9 9 2015 5 47 12 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 3 6 Fig 12 1 Cable connection...

Page 74: ...motcom BeCOMS User Manual Release 220601 Page 12 2 9 9 2015 5 47 40 PM f 0 65 Z Daten dev_motcom eagle block wiring bco m wiring03 sch Sheet 4 6 Fig 12 2 Pin configuration 1 2...

Page 75: ...motcom BeCOMS User Manual Release 220601 Page 12 3 9 9 2015 5 48 02 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 5 6 Fig 12 3 Pin configuration 2 2...

Page 76: ...COMS User Manual Release 220601 Page 12 4 9 9 2015 5 48 32 PM f 0 65 Z Daten dev_motcom eagle block wiring bcom wiring03 sch Sheet 6 6 Fig 12 4 Connectors and pin out of the BeCOMS Evaluator see also...

Page 77: ...rm 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 10 Pre Alarm Relay NC GND SRE 10 11 Pre Ala...

Page 78: ...motcom BeCOMS User Manual Release 220601 Page 12 6 Fig 12 6 Dimension Slip Ring Encoder SRE...

Page 79: ...motcom BeCOMS User Manual Release 220601 Page 12 7 Fig 12 7 Dimension Slip Ring Encoder SRE with throughout shaft...

Page 80: ...motcom BeCOMS User Manual Release 220601 Page 12 8 Fig 12 8 Dimensions Evaluator...

Page 81: ...motcom BeCOMS User Manual Release 220601 Page 12 9...

Page 82: ...mbH Kurt Schumacher Str 28 30 D 66130 Saarbr cken Phone 49 0 681 8837904 0 Fax 49 0 681 8837904 19 eMail info motcomgmbh com Internet www motcomgmbh com motcom BeCOMS User Manual en BeCOMS is a regist...

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