Product manual Oil Streak Sensor INTRODUCTION Oil streak sensors are designed to detect traces of oil travelling through air tubes, down to flows as low as 5mm 3 /min. The product utilizes a master and slave component concept. Master sensors incorporate a 4-segment LED display, 3 soft program and configuration keys plus M12 electrical connectors to facilitate power input and fault signal output. They monitor single air tubes. Slave sensors are normally piggybacked to the master, up to a maximum of 3, or they may be located remotely by using an interconnecting cable. Each slave sensor is capable of monitoring a single 4mm or 6mm tube. The sensor detects and counts pulses generated by oil particles flowing in an air stream as they pass through an optical eye. Count values are periodically checked and compared to a pre-set calibrated value. Whenever the count value falls below the preset level, the unit initiates an alarm. Count value is determined during initial calibration sequencing performed by the operator upon completion of the installation, and as soon as a steady stream of oil can be clearly seen in the tubes. Additional operating parameters are configured utilizing the master sensor program menu. Sensors are sold separately, as part of a kit, or may be integrated within an air-oil spindle lubrication system panel assembly. When supplied for panel use, the sensors are configured for direct interface with the BIJUR DELIMON Surefire controller pump. CONSTRUCTION Master Sensor M12 Connector Membrane Keys (x3) Slave Sensor Connector 4-segment LED Display LED Indicators Green & Red Nylon Housing Zinc-Plated Steel Cover Data Label Tube Clamp Fitting Mounting Feet Page 1 of 12
CONSTRUCTION (continued) Slave Sensor Sensor Interconnector (female) Data Label LED Indicators Green & Red Sensor Interconnector Zinc-Plated Steel Nylon Housing Tube Clamp Fitting Mounting Feet INSTALLATION Orientation Oil streak sensors are installed between an air / oil mixing block and the end bearing point. Exact location and positioning of the device is dependent upon the specific machine installation and the unit s service accessibility situation. The sensors may be installed in either vertical or horizontal orientation with little or no effect on intended function. (Display Inverted) Whenever sensors are piggybacked on master sensors, care should be taken to ensure proper and complete electrical connection and flush assembly. Optional 2-way, 3-way and 4-way brackets are available to assist with proper assembly of the units. Page 2 of 12
INSTALLATION (continued) Individual sensor width corresponds to the pitch of the lube outlets of corresponding air / oil mixing blocks. This enables the sensors to be conveniently mounted directly beneath the blocks when mounted to air / oil panel assemblies or, if otherwise desired. 20 m m 27,5 m m Tail - Tube Insertion Once final location and orientation of the sensors has been established, the tubes should be inserted into the sensors prior to permanently mounting them. To insert the tube, perform the following steps : 1. Make certain that the tube diameter matches the diameter of the sensor s fitting. The sensor is furnished with 4mm or 6mm tube fittings. 2. Only use tubing made of a clear material. BDI recommends use of clear, unmarked polyurethane tubing. However, the sensor will also perform satisfactorily if some markings or writing appear on the tube. 3. Slide the tube through the brass fitting. The o-ring located behind the fitting creates a certain amount of resistance. If the tube is excessively tight going in, simply back the tube fitting off a fraction of a turn. 4. As the tube exits the sensor, it encounters a second o-ring which also offers some resistance. Again, if the tube is excessively tight, simply back off the tube fitting again (by hand) and thread the tube through. 5. Carefully continue to pull the tube through the unit until the tube is long enough to be connected to the system. 6. Hand tighten the tube fittings to seal the tube. Page 3 of 12
INSTALLATION (continued) Perspex Sleeve Brass Tube Fitting Main PCB Brass Tube Fitting 4mm Clear Tube O-ring Seal O-ring Seal Sensors Cut-Away View of Master Sensor 4 mm Tube Slave PCB Brass Tube Fitting Brass Tube Fitting 6mm Clear Tube O-ring Seal Sensors O-ring Seal Cut - Away View of Slave Sensor 6 mm Tube Page 4 of 12
CALIBRATION The lube system should be allowed to prime and run for a period of time until a steady state of oil flow streaks within the tube. Once the operator is satisfied that this is the case, power needs to be provided to the sensors and the calibration sequence should be initiated. Steps for calibration follow: 1. Press and hold the key down for 3 seconds. 2. The display should read CON1 and the Red LED on each sensor should flash continuously. 3. Navigate to CON6 using the right or left arrow keys then Press. 4. The display should read CAL. To begin calibration Press, or Press to access CAnc. To stop calibration at this time Press to cancel. 5. Once calibration has been initiated, the calibration period lasts 180 seconds, and a countdown timer illustrates this period of time. At anytime during the calibration, you may abort by Pressing the key once more. 6. Once calibration has been completed, the sensor systematically checks each of the sensors and displays a signal indicating whether they have passed or failed; plus the count value obtained for each channel. It is necessary to Press to sequence through the channels. For example, upon completion of a 4-channel calibration, the following screens might be displayed: C1 P 80 C2 P 67 C3 P 77 C4 P 62 CON6 Explanation : The master sensor was successfully calibrated with 80 pulses. The slave 1 sensor was successfully calibrated with 67 pulses. The slave 2 sensor was successfully calibrated with 77 pulses. The slave 3 sensor was successfully calibrated with 62 pulses. 7. Whenever there are insufficient pulse counts on a channel during the calibration period, the sensor will fail on this channel. F will be displayed instead of P. For example C1 F 4 In this example, the master sensor failed to calibrate as it only registered 4 counts during the calibration period. The minimum count value required for a channel to pass calibration is 5. 8. Navigate to the run screen using left and right arrow keys and Press. This exits the sensor from calibration mode and enters the run mode of the sensor. 9. If the sensor enters run mode following a failed calibration, the sensor will fault and show an alarm after a period of 20 seconds. In the example above, ALC4 would be displayed indicating that Channel 4 has alarmed due to a calibration failure ( C meaning calibration) Page 5 of 12
RUN MODE 1. The display should show a scrolling cursor, indicating that the sensors are all operating and monitoring flow. 2. A green LED should be illuminated on each sensor. 3. In run mode, the sensor is monitoring oil streaks and counting them. Every 20 seconds it refreshes the pulse value for each sensor. 4. To view the actual count value for each sensor, proceed as follows : - 1 56 2 48 3 58 4 60 3 58 2 48 1 56 - Scrolling Cursor Sensor 2 (Slave 1) Count is 48 Sensor 4 (Slave 3) Count is 60 Scrolling Cursor 5. To view the calibration value for each sensor, proceed as follows: - 1 80 2 67 3 77 4 62 3 77 2 67 1 80 - Scrolling Cursor Sensor 1 (Master) Cal Value is 80 Sensor 3 (Slave 2) Cal Value is 77 Scrolling Cursor SETUP MODE To access setup mode Press and hold down the key for 3 seconds. CON1 should appear on the display. The red LED on each sensor should flash continuously. To navigate through different menus Press the or keys.. diag run CON1 CON2 CON3 To enter any individual menu, Press the key. For example, to enter the CON1 screen, Press the key, toggle between selections using the and keys. Once the desired selection has been made, Press the key to return to the screen. To save the new settings, navigate to run and Press. CON1 Page 6 of 12
CONFIGURATION MENU Menu Description Parameters Default CON1 Number of Channels CH 1, CH 2, CH 3, CH 4 CH 1 (master sensor only) CON2 Time to Alarm (seconds) t 0, t 20, t 40 to t 300 t 100 (100 seconds) CON3 Sensitivity Level SL 1, SL 2, SL 3, SL 4, SL 5 SL 1 (least sensitive) CON4 Start-Up Action AU 1 (automatic) AU 1 AU 0 (manual) CON5 Auto Wait Time (mins) S0 to S60 S1 (1 minute) CON6 Calibration Cal (calibrate) Canc (do not calibrate) Cal CON7 Fault Output Contacts NO (normally open) NC (normally closed) CON8 Fault Reset Time (seconds) S000 to S999 S100 (100 seconds) SOF t Firmware Version n/a S.X.X.X D I a g Diagnostic Check n/a n/a NC RUN Exit Setup & Enter RUN mode n/a n/a CON1 Number of Channels This menu facilitates choosing the number of channels to be monitored. If two (2) channels are being monitored then CH2 should be selected in this menu; e.g., one channel monitored by the master sensor and the other channel monitored by a slave. Selecting a setting of a higher number will cause a calibration failure on those channel(s) which have no sensor. Selecting a lower setting only calibrates and monitors the lower number of channels selected. CON2 Time to Alarm This menu is utilized to establish a time delay between the point at which a low flow condition is detected, and the point at which the sensor generates an alarm signal. The timer resets if an acceptable flow level is detected within this period, automatically cancelling the fault display. The higher the setting, the lower the number of fault alarms. A value between 0 to 300 seconds may be entered in multiples of 20. The default setting is 100 seconds. CON3 Sensitivity Level This menu facilitates choosing a level of acceptable flow. The level chosen corresponds to a % of the flow value obtained during calibration. There are five sensitivity levels as follows : Sensitivity Level Minimum Acceptable Flow Level as % of Cal Value 1 (least sensitive) 10 2 20 3 25 4 30 5 35 Page 7 of 12
CONFIGURATION MENU (continued) To illustrate this by way of an example, assume that following calibration, the count value on CH1 (master sensor) is 100. In this example, if the sensitivity level was set to 5, then this sensor will only initiate a fault if the count value drops to less than 35 (35% of 100). If the sensitivity level was set to 1, then the sensor will only initiate a fault if the count value drops to less than 10 (10% of 100). CON4 Start-Up Action Utilize this menu to establish how the sensor will function on start-up. There are 2 choices: Manual and Automatic. If manual is selected ( AU 0 ), then the sensor, on power-up, will go to stand-by mode and display S t r t. The user must then Press the key to initiate monitoring. No fault alarm is generated during stand-by mode. If Auto is selected ( AU 1 ), then the sensor, on power-up, initiates a countdown based on the value set in the CON5 menu. No fault alarm will be generated during this countdown period. The sensor begins monitoring after this time has elapsed. CON5- Auto Wait Time This menu facilitates establishing a delay in time between the point of initiating power to the sensor, and the point at which it begins monitoring; (assuming Auto was chosen in the previous menu.) This is designed to provide a means of preventing fault alarms while the air/oil lines are being primed. A value from 0 to 60 minutes may be chosen. (Note : The countdown timer displays this time in seconds.) For example, assume that CON5 was programmed for S 5. Then upon start-up, having selected AU 1 previously on CON4, the display will start with 300, 299, 298, etc, etc. CON6 Calibration Use this menu to initiate calibration following completion of new or modified installations. See Calibration section above. CON7 Fault Output Contacts This menu is utilized to select the desired fault output configuration, obtained from pins 2 and 4 of the M12 connector. The default setting is NC (normally closed). This means that in normal operation (nonfault condition), the switch between pins 2 and 4 will be closed. The switch will only open when powered off or when in an alarm condition. The NC setting is considered the failsafe mode as a power failure to the device will also generate an alarm signal. However, NO (normally open) mode may also be selected. In this case, the switch between pins 2 and 4 will always be open, and will only close when there is a fault condition. Whenever a sensor is used in conjunction with a BDI Surefire Controller Lubricator, NC must be selected as the fault output. CON8 Fault Reset Time This menu is used to establish a delay time between the point at which a fault is corrected, and the point at which the sensor begins monitoring again. A value ranging from 0 to 300 seconds may be selected. The default setting is 100 seconds. This menu is extremely important whenever a sensor is connected directly to a Surefire pump. In this case, a sensor fault can disable the pump (provided this option is enabled in the pump controller) and thus prevent system recovery. SOFt Software Version This menu simply displays the current version of Firmware utilized in the form S.X.X.X This information is often useful when troubleshooting. Page 8 of 12
CONFIGURATION MENU (continued) DIAG Diagnostics This menu facilitates initiation of a diagnostic routine to determine if the sensors are operating correctly. The routine involves checking for proper function at each individual sensor pair in each unit. There are 4 sensor pairs on each sensor, thus this routine can check a maximum of 16 sensor pairs (4 channels). Upon completion of the diagnostic routine, the following screens are displayed d i ag 1 P 2 P 3 P 4 P d i ag Initiate Wait ~ Master Sensor Slave 1 Sensor Slave 2 Sensor Slave 3 Sensor Diagnostic 5 seconds Passed Passed Passed Passed Diagnostic routines are preferably initiated with clean, dry tubing. The possibility for diagnostic failure exists, though small, whenever oil is present in the tube. ELECTRICAL CONNECTIONS The master sensor is equipped with an M 12 4-pole connector. Pin-outs are as follows : 2 1 3 4 Pin No Wire Colour Description 1 Brown 10 to 30 V DC 2 White Fault Alarm 3 Blue O V DC 4 Black Fault Alarm N/O or N/C See Setup CON7 Power is supplied via Pins 1 and 3, while Pins 2 and 4 are the fault contacts. Power is supplied to the slave sensors via this master sensor and the 14 way electrical interconnectors. An illuminated green LED on a sensor indicates power is being supplied to the sensor. When the sensor is used on air-oil lube panel in conjunction with the Surefire Controller Pump, the sensor is connected to the pump via an M12 extension cord BDI p/n : M124SS01EXT. The cord is connected to a corresponding M12 connector on the Surefire pump. No further wiring is needed. The status of the fault relay should be set to N/C in CON7 of the setup. Page 9 of 12
COUNT VALUES Count values are used to indicate the presence of oil droplets within the tail tube. However, count values are not linearly related to the quantity of oil being injected into the tube. Count values are more closely related to the degree to which oil particles are broken up in the tail tube. Count values may vary and are dependent on many factors : 1. Airflow in the tail tube. (Dictated by Inlet Air Pressure, Turns-Open of the Air Adjustment Needles, Restriction at the bearing). The higher the airflow, the more oil particles are broken up, the higher the count value. When airflow is too high, tail tubes will dry during pump dwell time, leading to fluctuation in count values. Ultimately, the objective is to balance the air pressure and turns open in order to provide for a reasonable and consistent count value at all times. 2. Injector size. The higher the injector size, the more oil is injected into the tail tube. Count values vary with the degree to which the oil particles are broken up. 3. Pump off-time. The longer the pump remains off, the lower the count value will go, until the pump turns on again. The objective is to establish a pump off time which provides for a consistent count value through the off-time cycle duration, resulting in steady oil flow to the bearing point. 4. Viscosity of the oil. The lower the viscosity, the less pronounced the formation of streaks in the tail tube, the lower the count value. Therefore, it is advisable to allow the oil to reach its maximum operating temperature before performing system calibration. 5. Diameter of the tail tube. In order to achieve similar count value results, use of 6mm tubing necessitates higher airflow volume than does 4mm tube. Oil particles only break up after a certain air velocity has been reached. 6. Distance between sensor and air-oil block. The closer the sensor is to the air-oil block, the more the count value will fluctuate within a given lubrication cycle. When the sensors are placed closer to the bearing points, the count values will become more consistent. Testing also indicates that calibration values tend to be higher as the sensor is moved away from the block. Page 10 of 12
GENERAL SPECIFICATION Only on Master Sensor (OSS-M) Weight: Master :... 50 g Slave :... 40 g Materials Main Housing:... Nylon 66, Black Cover :... Zinc Plated Steel Fasteners :... Zinc Plated Steel Tube Fittings :... Brass M 12 Connector :... Nickel-Plated Brass Electrical Data Operatig Voltage :... 10 V to 30 V DC Power Consumption : Master... 1.5 W Slave... 0.5 W Fault Alarm Replay Contact Rating :... 0.13 A, 24 V Certification :... CE Operating Temperature :... 0 C up to 50 C Protection :... IP 54 Page 11 of 12
TO ORDER Master Sensor 6 mm Tubing... OSS-M6 Master Sensor 4 mm Tubing... OSS-M4 Slave Sensor 6 mm Tubing... OSS-S6 Slave Sensor 4 mm Tubing... OSS-S4 Accessories: Mounting Bracket 2-way... OSS-B2 3-way... OSS-B3 4-way... OSS-B4 (Brackets are furnished with fasteners to facilitate mounting the sensors to the brackets) Electrical Cord (connection to sensor, trailing wires on other end) M 12, 2 m long, straight... M124S02U34 M 12, 5 m long, straight... M124S05U34 M 12, 10 m long, straight... M124S10U34 (For 90 deg equivalents, simply replace S by A in the p/n s above) Electrical Cord Extension (M12 connectors on both ends, for connection to sensor and Surefire pump) M 12, 1 m long, straight... M124SS01EXT Page 12 of 12