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Metallic Particle On-line Sensor

Part No. 32286500


Revision A

User Manual

Copyright © 2013 by SKF Reliability Systems


All rights reserved.
Aurorum 30, 977 75 Luleå
Sweden
Telephone: +46 (0) 31 337 10 00, Fax: +46 (0) 920 134 40
SKF Reliability Systems

SKF Condition Monitoring Center


Aurorum 30
977 75 Luleå
Sweden
Telephone: +46 (0) 31 337 10 00
FAX: +46 (0) 920 134 40

For technical support, contact:

TSG-EMEA@skf.com
for customers in Europe, Middle East and Africa.
Telephone: +46 (0) 31 337 65 00

or

TSG-Americas@skf.com
for customers in North America, South America and Asia.
Telephone: +1 800 523 7514
Telephone in Latin America: +55 11 4448 8620

Visit us at our web site


www.skf.com/cm

® SKF is a registered trademark of the SKF Group


Table of Contents
Introduction 1-4

Safety and Requirements 2-5


LED Status 3-6
Manintenance 4-7
..............................................................................................................4 - 7
Cleaning
..............................................................................................................4
Calibration and Service -7
..............................................................................................................4
Pressure Testing -7

Particle Detection Information 5-8


..............................................................................................................5
Particle Size - Limit of Detection -8
..............................................................................................................5
Particle Size Classes -8
..............................................................................................................5 - 8
Memory
..............................................................................................................5
Particle Sizing Notes -9
....................................................................................................5
Fluid Flow Rates - 9
....................................................................................................5 - 9
Metallurgy
Volume ....................................................................................................5 - 9
..............................................................................................................5
Particles per Minute - 11
Mass..............................................................................................................5
per Hour - 11

Installation 6 - 12
..............................................................................................................6
Sensor Mounting - 12
..............................................................................................................6 - 13
Installation

Interpreting Results 7 - 15
Technical Data 8 - 16
..............................................................................................................8 - 16
Environmental
..............................................................................................................8
Power Supply - 17
..............................................................................................................8 - 17
Outputs
..............................................................................................................8 - 17
Sensor

Dimensions 9 - 18

Metallic Particle On-line Sensor TOC-3


User Manual, Revision A
Introduction

1
Introduction
This manual covers CMSS-ONL-1000 Metallic Particle On-line Sensor for monitoring
the amount of metallic non-ferrous and ferrous wear debris in an oil or fluid medium.
Combining vibration and oil monitoring gives valuable information for the protection of
your assets. Both vibration and oil monitoring have unique capabilities to analyze
machine problems and prevent failures.
· The sensor provides continuous analysis of gearbox, bearing or motor oil.
· It increases reliability with analysis results by providing accurate information on
wear rates.
The Metallic Particle On-line Sensor, together with the SKF Multilog On-line System IMx
gives information on particle type, size and count rate per minute. Combining this
information with vibration data can give a precise location of the damage*.
The sensor is easy to integrate with the SKF Multilog IMx by using Modbus RTU;
· The system gives a trend for each size and type.
· Using derived points in SKF Multilog IMx allows data to be combined in
mathematical formulas; this can, for example, give a better overview by
displaying the total number of particles or estimated weight of debris*.
*Function only enabled in SKF @ptitude Observer; planned to be implemented in SKF @ptitude
Analyst.
The metallic particle sensor needs to be used with low-volume off-loop (kidney loop)
filtration and cooling systems, for example as SKF Oil Conditioning unit (SKF-OCU-XX).
The metallic particle sensor is suitable to place between pump and filter due to bore
size.

SKF-OCU-5 and SKF-OCU-10 have flow rates in oil sensors operating range.

Figure 1-1: SKF Metallic Particle On-line Sensor Figure 1-2: SKF Oil Conditioning unit
(CMSS-ONL-1000) (SKF-OCU-XX)

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User Manual, Revision A
Safety and Requirements

2
Safety and Requirements
This equipment is designed to comply with EN61010-1.

Warning: This equipment has not been approved for use in an explosive atmosphere.

Please ensure that you thoroughly read and understand this user document before
attempting to install or operate the Metallic Particle Sensor (MPS) covered in this
manual, derivatives or related equipment.
If the equipment is used in a manner, or for a specific purpose other than that described
in this manual, then any safety protection may be impaired.
The MPS is designed to be connected to hydraulic systems many of which will be
pressurized. A responsible body, the end user or system integrator is responsible for
ensuring the safety of associated systems, hoses or pipe-work containing fluids. This
includes isolation for maintenance to the MPS(s).

Important: This equipment must be installed and operated by qualified persons only.

Important: All units are metric unless otherwise stated; millimetres or metres, Bar, °C,
etc.

Before the maintenance, it is important that all common supplies, power and oil must
be turned off. It can be done by disconnecting at source or by closing the valves to the
Metallic Particle Sensor to isolate the MPS from the system. The latter method is
recommended.
· Never use the MPS near combustible gases or liquids.
· Never disassemble, repair, or tamper with the MPS.
· Ensure that the supply voltage is within the specifications and means of
isolation fitted.
· Ensure that the load currents do not exceed the rated values.
· Ensure that all associated equipment and pipe-work specification are the same
or greater than the operating specifications for the MPS.
· Check all associated equipment and pipe-work for correct connection before
powering the unit.
· Check all wiring for correct connection before powering the unit.
· Never weld to a pipe which contains or has contained oil
· The MPS case must be earthed
· Maintenance and cleaning
· The MPS, power supplies & accessories contain no user serviceable parts. Do
not dismantle.
Please retain all original packaging for shipping purposes.
All fluids must be removed from the equipment and the MPS be cleaned appropriately
before the return.

Metallic Particle On-line Sensor 2-5


User Manual, Revision A
LED Status

3
LED Status
If the metallic particle sensor is not responding as expected, check the status of LED's.

LED number Description Comments


1 Power On = Power is present
Off = No power
2 Status Constant during MPS initialization
after power on.
On = Alarm is triggered
Off = Normal operation
4 4-20 mA Indicates continuity of current
loop (particle mass/hour)
5 4-20 mA Indicates continuity of current
loop (particles/minute)
Table 3-1: LED status

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User Manual, Revision A
Manintenance
Cleaning

4
Manintenance
Cleaning

The outer case does not require cleaning during normal use. Wipe clean the MPS with a
soft cloth or tissue.
Conventional methods should be used for cleaning associated pipe-work should it
become blocked.
Do not use aggressive chemicals or mechanical methods, such as wire brushes or
scrapers to clear a blockage in the MPS bore, as this may scratch and damage the
plastic.

Calibration and Service

The MPS uses proven, patented Magnetometry; combined with internal


micro-processing to indicate metallic particle contamination. Due to the lack of moving
parts and sophisticated production methods, the factory calibrated MPS posses’ high
reliability with long term stability.
For continued performance, it is strongly recommends that the MPS system is serviced,
checked and calibrated regularly. The recommended re-calibration period is two years.

Pressure Testing
The MPS is factory pressure tested; as a result there may be a small amount of test
fluid present in the MPS.

Metallic Particle On-line Sensor 4-7


User Manual, Revision A
Particle Detection Information

5
Particle Detection Information

Particle Size - Limit of Detection


0.3m/s, iron metal (Electrolytic) 99.9% Fe purity - spherical particle

Figure 5-3: Particle size - limit of detection

Particle Size Classes


The MPS automatically classes particles into size categories or classes. These are
termed ‘Bins’.
Ferrous Bins
Fe 1 >40, < 60 micron
Fe 2 >61 - 100 micron
Fe 3 >101, <200 micron
Fe 4 >201 , <300 micron
Fe 5 >300 micron
Non-Ferrous Bins (Copper)
NFe 1 >135, <150 micron
NFe 2 >151, <250 micron
NFe 3 >251, <350 micron
NFe 4 >351, <450 micron
NFe 5 >450 micron

Table 5-2: Particle size classes

Memory
The MPS automatically saves particle measurement data in its memory every three
minutes. Due to the high data rates, data recorded between the save interval may be
lost if the power is interrupted – so much like a computer if the power is lost only the
data since the last save is kept.

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User Manual, Revision A
Particle Detection Information
Particle Sizing Notes

Particle Sizing Notes


Bin sizing is affected by the following:

Fluid Flow Rates


Faster speeds reduce the signal amplitude; the faster a particle travels through the
MPS, the smaller it will appear.

Figure 5-4: Example of fluid flow rates


The volumes quoted express the MPS bore and minimal connected pipe work (10mm
diameter and 0.5m long) in litres (54 ml).

Metallurgy
99.99% pure Fe gives the largest signal, the bins have been structured about a
composite of Fe and CrSteel particles. A ferrous particle of 100um will be
over-reported, whilst a chrome steel particle 100um will be under-reported.

For example; a 100um Fe particle gives the same output as 220CrSt.

Volume
The MPS counts particles based on electro-magnetic properties, which is determined by
the amount of metal present - the volume of the particle. A spherical object has the
greatest size/volume relationship, therefore the volume of a 70 micro-metre (micron)
(0.07mm) will contain the same volume as a particle 150 x 60 x 25 microns (L x W x H).
When the particles are viewed under a microscope, they may appear large, but their
volume is small.
The MPS has been developed using research conducted by independent technical
institutes for tribotechnology. Real wear debris has been captured. The MPS is
calibrated and defined using wear particles of a nominal chord length, therefore
spherical particles may be reported as larger than they are.

Metallic Particle On-line Sensor 5-9


User Manual, Revision A
Particle Detection Information
Particle Sizing Notes

Figure 5-5: Example of particles

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User Manual, Revision A
Particle Detection Information
Particles per Minute

Particles per Minute


The MPS expresses the number of particles counted per minute across all particle bins
(ferrous and NonFerrous)

Mass per Hour


The MPS automatically calculates the mass of particles counted in the previous hour
across all particle bins (ferrous and non ferrous). The mass is calculated by evaluating
the number of particles per bin , the minimum size of that bin and the metal type.

Metallic Particle On-line Sensor 5-11


User Manual, Revision A
Installation

6
Installation

Sensor Mounting
Where possible, the entire fluid flow should be diverted through the MPS [full flow].
Care must be taken to ensure the flow rate does not exceed the specified limits.

Figure 6-6: Example of a typical installation


Most applications require a bypass system. Representative sample flow is very
important: ensure that a known proportion of fluid flows through the MPS, use a factor
to calculate the particles present in the total flow. Measure the volumetric flow rate of
the fluid through the MPS and main pipe.

In many cases a gate valve is fitted to divert flow into the MPS, in some cases it is
possible to fit a pressure relief type of valve. The pressure relief valve is designed to
allow flow into the MPS and bypass as necessary. This ensures flow through the MPS.

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User Manual, Revision A
Installation
Installation

Installation
Electrical Connections:
Colour Description Terminal
Red Power supply 18-30V dc PS 24VDC, IMx Ch1&2 A
Black Power Ground 0V dc PS 0 VDC
Pink 4-20mA Input (particles/min) IMx Ch1 B
Yellow 4-20mA Output (particles/min) PS 0 VDC
Blue/Red 4-20mA Input (particle mass/hour) IMx Ch2 B
Orange 4-20mA Output (particle mass/hour) PS 0 VDC
Table 6-3: Electrical connections
SCREEN The Cable screen is connected to the MPS case. Case Ensure MPS body is
earthed, use the wire provided if necessary

Figure 6-7: IMx electrical installation

Metallic Particle On-line Sensor 6-13


User Manual, Revision A
Installation
Installation
IMx DIP switches are configure as shown in the table below.

Signal Terminal DIP setting


4–20 mA + A 000001
- B
Table 6-4: DIP switch positions for current signal in IMx-S and IMx-T

For information on how to set up point in @ptitude Analyst, check SKF @Analyst and
SKF Multilog on-line system user manual.

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User Manual, Revision A
Interpreting Results

7
Interpreting Results
The clearest indication of the onset of failure is a rapid rise in the wear rate. Although
no two pieces of equipment are the same, generally, most metallic components in a
system will have high wear when initially installed – due to bedding in processes, low
wear in normal operation – adequate lubrication and high wear again as the component
eventually fails. This is often called a classic bath tub curve. With this knowledge specific
warning limits for each piece of equipment can set. If a rapid increase in wear is spotted
early enough, proactive and preventative maintenance can be conducted before critical
breakdown.

Figure 7-8: Example of wear rate

Metallic Particle On-line Sensor 7-15


User Manual, Revision A
Technical Data

8
Technical Data

Environmental

· Weight: 1,5 kg (3.3 lbs.)


· IP rating: IP 65
· Ambient operating temperature: –20 to +65 °C (–5 to +150 °F)
· Maximum altitude: 2 000 m (6 561.7 ft.)
· Fluid compatibility: Mineral, synthetic oils and water/oil emulsions
· Wetted surface materials: PEEK, Viton (FPM), Aluminium
· Maximum fluid pressure: 10 Bar (1 MPa)
· Permitted fluid temperatures: –20 to +65 °C (–5 to +150 °F)
· Cable length: 2 m (6.6 ft.)
· Cable specification (ensure appropriate approvals relevant to installation):
- Screened
- CSA: 0,22 mm (0.008 in.) 1), 1 A
- AC: 440 V
- Maximum: 70 °C (160 °F)
· For extension purposes:
- RS485: Twisted pair cable, shielded; minimum 0,22 mm (0.008 in.) 1)
- 4 to 20 mA current loops: Four wires (2 x 2); minimum 0,22 mm (0.008 in.) 1)
· Maximum cable lengths:
- RS485: 1 000 m (3 281 ft.) maximum (shielded and twisted pair cable)
- 4 to 20 mA current loops: 10 m (32.8 ft.) recommended

1)
Signal output reduces with the speed of the particle; slower flow rates are optimum. Volumes
quoted are for the SKF Metallic Particle Sensor bore and minimal pipe work (10 mm diameter
and 0,5 m long) equating to 54 ml.

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User Manual, Revision A
Technical Data
Power Supply

Power Supply
· Power input: 24 V DC (18 to 30 V)
· Power consumption: 0,7 A
· Fuse rating: 1A quick blow

Outputs
· Particles per minute: 4 to 20 mA (Scale 0 to 1 000 ppm)
· Particle mass per hour: 4 to 20 mA (Scale 0 to 99 999 999 mg/h)
· RS485: Two wire half duplex (SKF Multilog IMx-S, IMx-C, IMx-W, IMx-T)

Sensor

· Particle speed: 1,3 to 21,0 l/min (0.34 to 5.55 gal/min) constant flow 2),3)
· Detection limits:
- Ferrous: 40 mm (0.00157 in.) 3)
- Non-ferrous metallic: 135 mm (0.00531 in.) 3)
2)
Signal output reduces with the speed of the particle; slower flow rates are optimum. Volumes
quoted are for the SKF Metallic Particle Sensor bore and minimal pipe work (10 mm diameter
and 0,5 m long) equating to 54 ml.
3) Constant flow rate 0,3 m/s, iron metal (electrolytic) 99.99% Fe purity – spherical particle. The
SKF Metallic Particle Sensor will not detect combined Fe in a non-magnetic compound (for
example, rust).

Metallic Particle On-line Sensor 8-17


User Manual, Revision A
Dimensions

9
Dimensions

Figure 9-9: Dimensions

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User Manual, Revision A
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