L-2693 Testmate In-Line Monitor User Manual
Contents
1. Ne Measuring interval 0 120 9 Yes No Measuring point max 20 characters SI do Yes lintemaluse T T 117 Yes Jntemaus T T 12 No Lower limit M2 relay 1 channel9 10 8o fo 999 48 no Upperlimit M2 relay 1 channel 9710 hao fo 999 14 Limit switch function for relay 1 in M2 0 gt no function 1 gt within range 2 outside range 3 gt exceed 4 gt fall below 15 no Measuring channel for relay 1 in M2 0 gt NAS SAE Ch O 4 6um 1 gt NAS SAE Ch 1 6 14um 2 gt NAS SAE Ch 2 14 21um 3 gt NAS SAE Ch 3 gt 21um ISO Ch 0 gt 4um ISO Ch 1 gt 6um ISO Ch 2 gt 14um NAS SAE class largest value of NAS SAE channels 0 3 8 gt ISO code 9 gt Flow info 10 gt LED current 116 no Lower limit M2 relay 2 channel 9 10 140 Jo 999 17 no Upper limit M2 relay 2 channel 9 10 75 O0 999 Schroeder Industries En Page 59 TestMate In Line Monitor TIM No String Read Designation Default Min Max Only 18 no Limit switch function relay 2 in M2 4 0 4 0 gt no function 1 gt within range 2 gt outside range 3 exceed 4 gt fall below Measuring channel for relay 2 in M2 0 gt NAS SAE Ch 0 4 6um 1 gt NAS SAE Ch 1 6 14um 2 gt NAS SAE Ch 2 14 21um 3 gt NAS SAE Ch 3 gt 21um 4 gt ISO Ch 0 gt 4um O A gt gt AJUIWIW GO POD PO NININININI N O 5 ISO Ch 1 gt 6um 6 gt ISO C2. 11 read particle counts differential on line Command 12 read contamination classes on line Command 13 stop measurement Command 14 start measurement Command 15 test parameters of the TIM Command 16 reset error status Command 17 read LED current Command 18 read flow info Command 19 Reset parameters to factory default setting Command 109 read TIM model and firmware version Schroeder Industries En Page 41 TestMate In Line Monitor TIM 9 5 1 Command 8 Program Parameter s of the TIM The different parameters in the TIM limit values cycle times name of measurement point etc are set by this command The command number is followed by the parameter number and the value of that parameter Example Set parameter 21 to 0 TRANSMIT 8210 parameters 21 set to value 0 NOTE Not all TIM parameters are programmable 9 5 2 Command 9 Read parameter s of the TIM Example Read out parameter 21 The command number is followed by the parameter number TRANSMIT 9 21 reads parameter 21 RECEIVE 9 21 1 parameter value NOTE all TIM parameters are readable Schroeder Industries En Page 42 TestMate In Line Monitor TIM 9 5 3 Command 11 Read Particle Counts Differential On Line This command transmits the values of the last measurement TIM H 4 6um 6 14um 14 21um gt 21um particles flow rate water content and temperature NOTE water content and tempe
3. 3 4 3 Hydraulic diagram for TIM H Schroeder Industries En Page 14 L 2693 Testmate In Line Monitor User Manual 4 Installation and Operation 4 1 Electrical Installation 4 1 1 Terminal Assignment The casing of the in line monitor features two size M16x1 5 heavy gauge threaded cable fittings through which all the electrical supply and signal lines are routed into the casing The lines are connected to the terminals inside the casing The terminals are featured as cage clamp terminals and are suitable for the following conductor cross sections up to 2 5 mm up to 0 5 mm Terminals Power Supply Terminals 1 23 Power Terminal Power supply Signal Terminal Digital Output for PLC Serial RS 232 Display port Modul port Alarm Relay Warning Relay Ready Relay Analog Input Schroeder Industries PE OV OV 24V 24V Case Ground Supply Voltage 0 V Supply Voltage 0 V Supply Voltage 24 V Supply Voltage 24 V Declaration 1 Pair of clamps is for Supply Voltage 2 Pair of clamps is for additional connection i from a load PLC Ground 24 V from PLC PNP Output to PLC RS 232 Ground RS 232 TxD RS 232 RxD Assignment dependent output modul upon Relay 1 NO Relay 1 C Relay 2 NO Relay 2 C Ready Relay NC Ready Relay NO Ready Relay C Analog Supply 12 V Analog S
4. Configuring the parameter settings of the in line monitor can be done via the serial display interface RS 232 or via an optional bus interface This interface is also used to configure the TIM 7 1 Configuration via the Serial RS232 Display Port Disconnect the TIM from the voltage supply and switch your PC off Connect the serial RS 232 display port of the TIM to any non occupied COM port of your PC as shown in the following schematic RS 232 Ground 4 brown RS 232 TxD 5 blanc RS 232 RxD 6 green Serial RS 232 Display Port 23 D SUB 9 pol O O female OOOO Connecting the Serial Display Port to a PC Boot your PC and start a terminal program e g HyperTerminal Configure the COM port as follows 9600 baud 8 data bits 1 stop bit no parity no protocol Port Settings Bits per second sso gt gt gt n Data bits 8 gt Parity None 7 Stop bits fi v Flow contral None gt iY Restore Defaults Configuration Using HyperTerminal Reconnect the TIM to the voltage supply Schroeder Industries En Page 24 TestMate In Line Monitor TIM 7 2 Outputs and Messages via the RS232 Interface After being switched on the TIM is always in Display Mode e Schroeder first appears in the terminal window e After the measurement period elapses the current measurement result is outputted e g ISO_Code 25 22 20 or a malfunction message appears e f the flow r
5. Measure SWItCh at i i i Aa a 19 5 3 Mode M3 FIEF TO 2222222040025042 9020 la c derita a 19 5 4 Mode M4 Filter from tO ccciccciiiiiiicciiiiiiiiiiicciiiiiiiciiiicciiiiiiccceccciiiciinneccneeeces 19 6 77 Analog Mpt 122 281 Ase 0012A DDR eee een er eee Pace er or eer ne 23 6 1 Connector AS 1000 Series 0 0 rr 23 6 2 Connector AS 2000 Sete 32 wAicea san mda da anieaniceunwothteceriaan 23 Connecting an analog 4 20 mA 3 lead sensor of another manufacturer is possible 23 7 Serial RS232 Display and Parameter Interface cciiccccciiciiiiiiiiiiiiiiiiiie iii 24 7 1 Configuration via the Serial RS232 Display POrt cccciiiiiiiiiiiiiiiiiiiii 24 7 2 Outputs and Messages via the RS232 Interface iiicccceeiiiiii eii 25 7 3 Configuration via the Serial RS232 Display POLrt cccciiiiiiiiiiiiiiiiiiiiii 25 7 3 1 Select MOB innra a a AR ebria 25 7 3 2 Parameter Modei opsi ia nia lg manen denah A RGB 26 7 3 3 Measuring TIME Rtas collet aes eet Re ee ee ee a ne we eet as 26 7 3 4 Measuring Mode snei ki A nenn 27 8 Output Signals of the PLC Interface cccccccciiiiiiiiiiiiciiiiiiiiiiiiiiiiiiiiiciiiiiiiine enis 37 9 DIN Measurement Bus MOdUIE ccccccciciicc cici cici ciiiiiciiiiiiiiiiiiiccccccciiiciccccccciiiicccn nn eees 39 9 1 LAGS si ans eia ala a nn ann ni 39 9 2 Settingrt
6. has been changed to the ISO code without any header 7 3 4 9 Setting the Current Output Format for TIM models with the analog module only i Current Output Format enables a selection to be made whether the NAS SAE classification 1 value or the particle information of the 4 channels is outputted via the current output Example for TIM H Current Output Format 1 Schroeder Industries En Page 33 TestMate In Line Monitor TIM SAE max New Current Output Format 1 SAE max 2 Particle Counts press Return only to keep setting 2 Now the Current Output Format is 2 Particle Counts In the example the output format for the current output has been changed from SAE max to Particle counts 7 3 4 10 Setting Check Current Output for TIM models with the analog module only c Check Current Output the 4 20mA output optional can be checked When entering a current value under this menu point that current is outputted on the 4 20mA output until leaving the select mode Example Check current output Enter current between 2 5 and 24 0 mA as xx x mA or enter x to exit 10 0 In the example a current value of 10 0 mA is entered 7 3 4 11 Flow Check f Flow check four values are continuously outputted which inform the SCHROEDER service technician about whether the oil flow through the sensor is suitable for measuring particle counts The respective values represent the flow rate in ml m
7. 10 tiS Storad epee re Seer ete A i a ce an Ga ee aera 10 15 17 Storage conditions sser anre a Acd taal iene 10 1 16 Disposal Recycling and DecommissiOnNINQ c ccc cciccccc cici cc eiicciccccaeccicceiiinaaaas 10 2 SCOPES Ol DEMO Vasa aaa a a ecc a na 11 3 Technical DescrIptiON iciccciciccciiiciiiiiccic AO ae ee as ricer aa 12 3 1 Designated Sa eaii rrene aa nr ala a a 12 3 2 Design Features cirri a E Td rabels T AEE 13 3 3 Restrictions Pertaining to the Use of the TIM cccciiiiiiiiiiiiiiiiiiiiiiiiii 13 3 4 a al Vila a 12 at eter ads a eC ie ot oe etal eae 2 cn 13 3 4 1 Hydraulic diagram for Pressure Viscosity Ranges 1 and 2 e ss 14 3 4 2 Hydraulic diagram for Pressure Viscosity Ranges 3 and 4 csss 14 3 4 3 Hydraulic diagram for TIM 2XXX 0 easily i 14 Installation and Operation ij a Aa teed ive a eaten a 15 Act Electrical iStallatan in E RN Greases 15 4 1 1 Terminal AsSIgnment 0 20 aa A Soares 15 4 2 Electrical Installation siiis sa lE 4020 ag a 17 4 3 Selecta Test DOIN etek aa a a Ea a a Gets a el Get a a eee mi a naga 17 4 4 Hy raulle Mslal a a a Ra aan a a a al ai 17 4 5 Removing the TIM from the Hydraulic System 0000 18 5 Description of the Measurement Modes 200nnneeeeeerrrrrrnnnnnenrerrrrr rann 19 5 1 Mode M1 MEAS a SEN a Sin a Se eee eee 19 5 2 Mode M2
8. 100 34 7 52 0 Explanation NAS SAE class channel 0 cceeeeeesesscceeeeeeeeeeseesneeeneeeeees 6 NAS SAE class Channel 1 cccccceeeeeeeeeeeeeeeeeeeeeeeesenneeeeeeees 7 NAS SAE class channel 2 ccccccceceeeeeeeeeeeeeeeeeeeeeesenneeeeeeees 7 NAS SAE class channel 3 sasssa 6 EOS aa in 100 ml min Measurement value Analog input 1 Water content 34 7 Measurement value Analog input 2 Temperature 52 0 TRANSMIT 12 Parameter 21 1 RECEIVE 12 21181512 100 34 7 52 0 Explanation ISO Glass Ea 21 ISO class channel 1 0 2000neeeererrr renn 18 ISO class channel a insia i i assa 15 ISO class channel a A iiien 12 FIOW rate ost a ne ene eee eee 100 ml min Measurement value Analog input 1 Water content 34 7 Measurement value Analog input 2 Temperature 52 0 9 5 5 Command 13 Stop Measurement This command stops a running measurement TRANSMIT 13 9 5 6 Command 14 Start Measurement This command starts a pre selected measurement mode M1 M4 TRANSMIT 14 Schroeder Industries En Page 44 TestMate In Line Monitor TIM 9 5 7 Command 17 Read LED Current This command transmits the present LED current digital value between 0 and 1023 TRANSMIT 17 RECEIVE 17 156 gt LED current 156 digits 9 5 8 Command 19 Reset parameters to factory default setting This command causes the settings of the T
9. En Page 54 TestMate In Line Monitor TIM 14 5 Electrical Data Supply voltage Power consumption Outputs Standard Optional Conductor cross section Inputs Standard Schroeder Industries 24 V DC 25 max 300 mA 3 relays ready warning alarm max 2A 24 VDC 50 VAC 30 W 50 VA RS 232 for external display PLC signal Analog signal 4 20 mA load lt 5009 or DIN measurement bus or RS 232 or RS 485 or Ethernet Interface supply terminals max 2 5 mm signal terminal max 0 5 mm 2x Analog signal 4 20 mA Ri 240 Q Current source En Page 55 TestMate In Line Monitor TIM 15Model Type code TIM H 1 2 Type Testmate In Line Monitor TIM Fluids For standard mineral oils H For phosphate esters E Pressure Viscosity range Refer to chart below for value Outputs Analog 4 20mA RS 232 DIN measurement bus UE O ND Pressure Viscosity Range 580 AA T TTT ALLL T 435 Q 362 2 290 3 D 3 4 79 H 217 Le Q 145 L 72 l 0 nn 0 232 463 695 927 1158 1390 1622 1854 2085 2317 3244 4171 5098 6025 6952 7879 8806 927C Viscosity SUS Schroeder Industries En Page 56 TestMate In Line Monitor TIM 16150 4406 SAE AS 4059 and NAS 1638 Tables ISO 4406 table Particle count 100 ml up to and including 1 000 000 2 000 000 4 000 000 8 000 000 16000000 32 000 000 64 000 000 Schroeder Industries En
10. Measured value Measured value Measured value channel 1 channel 2 channel 3 channel 4 Schroeder Industries En Page 51 TestMate In Line Monitor TIM 13 Error Messages and Troubleshooting Error message F 225 FO 999999 Schroeder Industries Cause s The flow rate through the TIM is outside of the permissible range set F fault 225 flow rate equals ca 225 ml min The TIM doesn t detect a flow in the particle measurement cell F fault 0 flow rate equals ca 0 ml min Malfunction of the particle measurement cell by virtue of e component defect or e excessively high water or air content in the oil En Remedy Reduce the flow rate leading to the TIM Check to see whether enough pressure is being applied at the sensor input If necessary increase the pressure If this message fault remains this means that the working section measurement section is probably clogged gt Ship the unit in to Schroeder for repair Make sure that no oil witha high water or air content is fed to the TIM If this message fault remains this probably means that the particle measurement cell is defective gt Ship the unit in to Schroeder for repair Page 52 TestMate In Line Monitor TIM 14 Technical Specification 14 1 Fluids Mineral Oil Based Hydraulic Fluids Temperature range OC 70 C 32 F 176 F 14 2 Particle Detection Material solids Particle siz
11. an RS 485 interface however there is a galvanic separation of the interface component and the rest of the circuit as stipulated in DIN 66348 part 2 Data transfer via this interface is only possible via a 4 wire bus in full duplex mode 9 2 Setting the Bus Address Since several TIM s can be connected to the same BUS each sensor has to be assigned an address of its own via which it is accessed According to DIN 66348 the address range extends from 1 to 31 Each address can be assigned only once consequently the maximum number of devices is 31 When the DIP switch is set to 0 the BUS address stored in the TIM is used The BUS address can be set within a range of 1 to 31 in Parameter Mode for more information see Parameter Mode in Serial RS232 Display and Parameter Interface or via one of the optional digital interfaces The BUS address of the TIM is fixed in any other setting and cannot be changed in Parameter Mode or via any of the optional digital interfaces 9 3 Setting the BUS Address Using DIP Switches ON DIP ON DIP ON DIP ON DIP o LL Sti 16 Ub 24 Ubel 123456 123456 123456 123456 ON DIP ON DIP ON DIP 1E oE 17 E 25 E 123 4756 123456 123456 123456 ON DIP ON DIP ON DIP ON DIP 2 Le 10 Lebel 18 a 26 Pa 123456 123456 123456 123456 ON DIP ON DIP ON DIP ON DIP 3 H 1 19 B27 bW 123456 123456 1234 56 ON DIP ON DIP ON DIP ON DIP 4 HR 12 C 20 Ubel 28 Chaban 123456 123456 123456 123456 ON DIP ON
12. fittings are to be checked daily for leakage visual check The electrical components of the product are to also be regularly checked visual check once a month Any loose connections or damaged cables are to be replaced immediately Warning Pressurized fluids pose a hazard to life and limb Consequently the safety regulations pertaining to working with pressurized liquids are to be adhered to at all time 1 7 Instructions to Be Followed in the Event of an Emergency In the event of an emergency immediately disconnect the TIM from the power supply and from the hydraulic system Properly dispose of any exiting fluid in accordance with environmental guidelines Schroeder Industries En Page 7 L 2693 Testmate In Line Monitor User Manual 1 8 Training and Instruction of Personnel e The TIM may only be operated by properly trained and instructed personnel e The areas of responsibility of your staff must be established in a clear cut manner e Staff undergoing training may not use the TIM unless supervised by an experienced staff member Individuals Individuals Individuals with Electrician Supervisor undergoing technical with the training training appropriate Activity engineering authority background e l x x x ransportation Commissioning X Xx X Operation X Troubleshooting locating the source of z x x malfunction Remedying of x x mechanical faults Remedying of electrical faults x x Maintenance and x x x x servicing Repa
13. measured i as follows SAE value 1 i 4 8 mA x 11 14 4 SAE class SAE value rounded up to the next whole number When particles is selected under i in Parameter Mode Duration Current 4 20mA Identifier for particle channel 1 300 ms 19 2 mA 300 ms 4 8mA Log particle count channel 1 3000 ms 4 8mA 19 2mA Identifier for particle channel 2 300 ms 19 2 mA 300 ms 4 8mA 300 ms 19 2 mA 300 ms 4 8mA Log particle count channel 2 3000 ms 4 8mA 19 2mA Error Low 0 4mA Error high 100 20mA After an identifier for the particle channel the particle count of the respective channels is outputted as a current between 4 8 mA and 19 2 mA The current is computed as follows I n Imin log n X Imax Imin log Nmax log Nmin Schroeder Industries En Page 50 TestMate In Line Monitor TIM Whereby n particle count Nmin Minimum particle count 1 Nmax Maximum particle count 20 480 000 Imin Minimum current 4 8mA Imax Maximum current 19 2mA Log logarithm base 10 This results in I n 4 8mA log n x 1 9695mA If the particle count is larger than 20 480 000 19 2 mA is outputted if the particle count 0 4 8mA is outputted The particle count is then computed on the basis of the current as follows n l 4 0 1 4 8mA 1 9695mA Example Identifier channel 1 Identifier channel 2 Identifier channel 3 Identifier channel 4 19 2mA 4 mA Measured value
14. of improper use e improper connection of the TIM pressure and return flow lines 1 5 Safety Devices e Prior to starting up the product each time make sure that all the safety devices are properly fitted to the hydraulic system in which the product is to be used and are in proper working order e Safety devices may not be removed until the product has been shut down and secured against being restarted e g warning sign or padlock on the main switch Schroeder Industries En Page 6 L 2693 Testmate In Line Monitor User Manual e When the product is supplied in partial consignments the safety devices are to be applied by the operator as specified by law pertinent regulations 1 6 Informal Safety Precautions e Make sure to always keep the operating instructions in the vicinity of the product e Apart from the operating instructions any and all general and local regulations pertaining to accident prevention and environmental protection are to be made available and observance to be maintained to them e Make sure to keep the safety and hazard symbols and warnings on the product in a legible condition e The power plug cord of the product is to always be pulled before opening any components of the product Tests conducted with the housing open may only be performed by properly trained certified electricians This also applies to all repair work or to any modifications to electric components approved by us e The hoses and connection
15. pressure of the hydraulic facility and see whether it is within the permissible range for the INLET port The pressure in the measurement cell may not exceed 580 psi When pressures exceeding 580 psi are capable of occurring at the inlet and pressure has not be relieved at the outlet the TIM has to be protected by way of an additional pressure relief valve as the integrated pressure relief valve doesn t open until a differential pressure of 580 psi between the inlet and outlet is reached Schroeder Industries En Page 17 L 2693 Testmate In Line Monitor User Manual TIM max 580 psi S T Example of protecting the TIM when the pressure has not been relieved at the outlet Connect the TIM to your system as follows 1 First connect the return flow line not supplied to the OUTLET port of the TIM Thread G1 4 ISO 228Recommended internal diameter of line gt 4mm Now connect the other end of the return flow to the system tank for example a the pressure at the measurement point it has to be within the specified imits 4 Now connect the measurement line not supplied to the INLET port of the TIM Thread G1 4 ISO 228 Recommended internal diameter of line to prevent particle sedimentation lt 4mm 5 Now connect the other end of the measurement line to the measurement point has been connected to the pressure fitting This is why it is vital that connection be done in the sequence specified a
16. 0s Schroeder Industries En Page 26 TestMate In Line Monitor TIM 7 3 4 Measuring Mode m Measuring mode enables the measurement mode to be selected M1 M2 M3 or M4 Current Mode 3 1 M1 2 M2 3 M3 4 M4 Press key 1 2 3 4 and Return press Return only to keep setting 2 Return Current value for measuring mode 2 The measurement mode has been changed in the example from M3 to M2 7 3 4 1 Settings for Measuring Mode M2 2 Limits Mode 2 enables the settings to be entered for measurement mode M2 Measurement channel for relay 1 alarm relay oO Oa N DO oa fF WwW NYDN a ek O 12 gt gt gt gt gt gt gt gt gt gt gt gt gt TIM H NAS SAE Channel 0 A gt 4 um NAS SAE Channel 1 B gt 6 um NAS SAE Channel 2 C gt 14 um NAS SAE Channel 3 D gt 21 um ISO Channel 0 gt 4 um ISO Channel 1 gt 6 um ISO Channel 2 gt 14um NAS SAE Chan 0 3 A D ISO Code ISO Chan 0 1 2 Flow info LED current 4 20 mA Input Channel 1 4 20 mA Input Channel 2 Limit function for relay 1 alarm relay 0 gt No function 1 gt Within range 2 Out of range 3 Upper limit exceeded lower hysteresis limit 4 Lower limit fallen short of upper hysteresis limit Schroeder Industries En Page 27 TestMate In Line Monitor TIM Limits for measurement channel relay 1 alarm relay Depending on the measurement channel selected first the lower limit s is are ent
17. 24 Flow rate error Status 00 No new measurement value Mode 22 Measurement Mode M2 Error status Name Binary Description value COMAND_ERROR 64 Error in bus command string semantic TX_ERROR 512 Error in transmission log DIN MESS bus Q_ERROR 1024 Flow rate error ISENSOR_ERROR 4096 Error supply current particle sensor Status Name Binary Description value COUNT_READY 1 A new measurement has been performed Schroeder Industries En Page 40 TestMate In Line Monitor TIM Mode Mode module 10 shows the number of the measurement program 1X gt M1 2X gt 5M2 etc The units position provides an exact definition of the status The following applies to M1 Measure M2 Measure switch M3 Filter to x0 Measurement off x1 Wait for correct flow rate x2 Measurement currently in progress M4 Filter from to 40 Measurement stopped 41 Waiting for a correct flow rate 42 Measurement running testing lower limit 43 Delay in progress 44 Delay elapsed waiting for a correct flow rate 45 Measurement running testing upper limit 9 5 Commands A command always consists of a command number and accompanying command parameters Some commands force the TIM to respond to the next send request The response is always preceded by the command number If the response is longer than one data block it is transmitted in several blocks Command 8 program parameter s of the TIM Command 9 read parameter s of the TIM Command
18. DIN Bus Address fixed by DIP switch New Measuring Point press Return only to keep setting Testpoint Measuring Point Testpoint Current DIN BUS Address 1 Current Measuring Point TIM 2230 In the example the bus address has been changed from 1 to 2 and the measurement site from SCHROEDER to Testpoint The DIN BUS address couldn t be changed as this is fixed by DIP switches Schroeder Industries En Page 31 TestMate In Line Monitor TIM 7 3 4 5 Setting the IP Address for TIM models with Ethernet Interface only When e Set IP Address the IP address for the Ethernet interface is entered The IP address has the following format xxx xxx xxx xxx where xxx are values between 0 and 255 Example IP address part 1 Current setting 129 New setting press Return only to keep setting 192 Current setting 192 IP address part 2 Current setting 42 New setting press Return only to keep setting 168 Current setting 168 IP address part 3 Current setting 14 New setting press Return only to keep setting 16 Current setting 16 IP address part 4 Current setting 150 New setting press Return only to keep setting 36 Current setting 36 In this example the IP address has been changed from 129 42 14 150 to 192 168 16 36 7 3 4 6 Setting Pump Protection p Pump protection a pump controlled by the in line monitor via relay 1 in operating modes M1 M3 and M4 can be protected agains
19. DIP ON DIP ON DIP 5 be 13 ee 21 pA 29 piaba 12 8 475 6 123456 123456 123456 ON DIP ON DIP ON DIP ON DIP GE 14 C 22 Cah 30 a 123456 123456 123456 123456 ON DIP ON DIP ON DIP ON DIP 7 BR 15 R 23 RR 31 BHE 123456 123456 123456 Schroeder Industries En Page 39 TestMate In Line Monitor TIM 9 4 DIN Measurement Bus Commands General All transmissions are ASCll coded there is no transmission of binary values The transmission of strings is done as follows first the number of characters is transmitted then the string enclosed in quotation marks Characters with a decimal value over 127 are transmitted in an escape sequence because the DIN MESS bus transmits only 7 bit characters The escape sequence is initiated by a and then followed by the hexadecimal value as ASCII of the character e g Pump 12 gt 8 Pump 12 Beh lter 3 gt 12 Beh 84lter 3 gt 132 decimal gt 84 hex This example is included to demonstrate how accented characters are handled The master in a DIN measurement bus system controls all communication e To send a command to the TIM it first transmits a receive request and then the command string e To receive a response it first transmits a send request then the TIM sends the answer string e A send request sent to the TIM with no answer string present at the TIM returns an error status status and mode e g 1024 00 22 Explanation Error status 10
20. IM which can be changed by the user to be reset to the factory default settings see 8 4 Parameter List TRANSMIT 19 9 5 9 Command 109 Read TIM Model and Firmware Version The TIM responds with 3 strings indicating the TIM model the TIM series and the firmware version of the EPROM TRANSMIT 109 RECEIVE 109 6 TIM2130 6 TIM 2000 5 V4 00 Explanation Number of places characters spaces in string 7 Device OR meini esene TIM 2130 Number of places characters spaces in string 7 Device famMilY iciiiiiiiiiiiiiiiiiii nesis TIM 2000 Number of places characters spaces in string 5 Firmware MESTOM lt a nea V4 00 Schroeder Industries En Page 45 TestMate In Line Monitor TIM 10RS 232 Module This module uses the same data transmission protocol as the DIN Measurement BUS module described in section DIN Measurement Bus Module The RS 232 module enables the in line monitor to be connected directly to a standard RS 232 computer interface COM port without having to use an interface converter However the RS 232 module does not enable several devices to be networked In addition the RS232 interface exhibits lower noise immunity as compared to the RS 485 interface e Attention This serial RS 232 interface cannot be used to enter settings via a terminal program The RS 232 display interface is to be used for this purpose For mor
21. Page 57 TestMate In Line Monitor SAE AS 4059 table Size ISO 11171 Size Code NAS 1638 table 156 000 623 000 T 10 11 12 1 250 000 1 250 2 500 5 000 wl es e E ef ow a 20 000 s vw e 80 000 7 160 000 8 820 000 of 640 000 0 280 000 n 2550 000 2 20 000 P18 40240 000 P14 20480 000 1 2 3 4 5 7 10 11 12 13 14 Schroeder Industries 256 000 512 000 1 024 000 2 048 000 4 096 000 TIM Maximum particle count 100 ml gt 14 ume gt 21 um gt 38 UM C E gt 27 54 109 217 432 864 152 c 3 5 10 20 39 76 306 1 730 3 460 6 920 13 900 27 700 55 400 111 000 222 000 _ o lt a v gt 8067 26 53 106 212 424 848 1 700 3 390 6 780 1 020 Maximum particle count 100 ml 15 25 um 25 50 um 50 100 um gt 100 um 178 3 712 1 425 2 850 5 700 11 400 22 800 45 600 91 200 182 400 364 800 729 000 22 44 88 56 128 1 2 3 11 22 45 360 720 os 860 4050 720 4 16 32 64 253 506 En Page 58 TestMate In Line Monitor TIM 17Parameter List All parameters are either strings or integers Multiply by a factor of ten as needed String Read Designation Default Max Only Yes intemal use gt use 22 SSS In Line Monitor model 2 TIMH TIME 5 Yes Yes Serialno Yy eel gt yy E pe ee Calibration date A 01 199 i E
22. TESTMATE IN LINE MONITOR Schroeder 580 West Park Road Leetsdale PA 15056 ph 724 318 1100 fax 724 318 1200 An ISO 9001 2008 Certified Company www schroederindustries com c liroeclar JAR G SEV REGULAT ALA EEDEN INDUSTRIES L 2693 Created 10 2013 Table of Contents 1 General Safety Pr GAUllONsS sr RA eret 5 1 1 Obligations and Ar Ga ia 5 1 2 Explanation of Symbols and Warnings etc eeeeeeerrrnnnnnnnrrrrrrrrrnnn ner 5 1 2 1 Basic SYMBOL i sarena a e a alae See en dende Dew gah airmail 6 1 3 Proper Designated Sissi aa a a RNA na nasir 6 1 4 PPS saa a ak ai A aa 6 1 5 SaletV Devices EE E JAI C na nan A AT D 0 ae 6 1 6 Informal Safety PrecaUtiONS iicciiiiiiiiiiciiiiiiiiiiiiccciiiiiicccccciiicciannncceennes 7 1 7 Instructions to Be Followed in the Event of an Emergency iiicccccie rr 7 1 8 Training and Instruction of Personnel ia ia ieni 8 1 9 Safety Measures to Be Followed in Normal Operatioh ccccccie ii eeeii eii 8 110 Electrical FALAR lE GE eebeuienveks 8 1 11 Maintenance Servicing and Troubleshooting a0nneeeeererrrrnn rr 9 1 12 Modifications to the FIM ina diana aaa a kp ie 9 1 13 Cleaning the TIM and Disposal of the Media and Agents Used sss c 9 Transportation Packing Storage Disposal wv sucesso tender 10 1 14 Transportation amp Packing es 8 a a Oe ae dae ecg nn caey
23. age e Make sure to store the TIM in a clean dry place in the original packing if possible Do not remove the packing until you are ready to install the unit e If the TIM is to be put into storage for an extended period of time it should be completely drained if necessary using n heptane so as to prevent it from gumming up e The cleaning agents and flushing oils used are to be handled and disposed of properly 1 15 1 Storage conditions Storage temperature 20 C 85 C 4 F 185 F Relative humidity max 90 non condensing Practical storage life max 6 months 1 16 Disposal Recycling and Decommissioning e When decommissioning and or disposing of the TIM adherence is to be maintained to local guidelines and regulations pertaining to occupational safety and environmental protection This applies in particular to the oil in the unit components covered with oil and electronic components e After disassembling the unit and separating the various materials they can be reused or disposed of properly in accordance with local regulations Schroeder Industries En Page 10 L 2693 Testmate In Line Monitor User Manual 2 Scope of Delivery The TestMate In line Monitor TIM comes packaged and factory assembled ready for operation Before commissioning the TIM check the contents of the package to make sure everything is present The TIM comes with the following Pos Qty Description 1 1 pc TestMate In lin
24. asuring channel 7 and 8 Exceed TIM ready for TIM notready A value gt After A value gt A value gt operation for operation respective switching the respective respective upper limit unit on or upper limit upper limit starting a measurement Goes out again when all values lt respective lower limit Fall below TIM ready for TIM notready All values lt After All values lt After operation for operation respective switching the respective switching the lower limit unit on or lower limit unit on or starting a starting a measurement measurement Goes out Goes out again when a again when a value gt value gt respective respective upper limit upper limit Within range TIM ready for TIM not ready Respective After Respective After operation for operation lower limit lt switching the lower limit lt switching the all values lt unit on or all values lt unit on or respective starting a respective starting a upper limit measurement upper limit measurement Goes out Goes out again when again when the respective the respective lower limit lt lower limit lt all values lt all values lt upper limit upper limit Schroeder Industries En Page 21 L 2693 Testmate In Line Monitor User Manual Ready Relay Ready Relay Relay 1 Relay 1 Relay 2 Relay 2 on off on off on off po NG a qA O NO A o NO sam i c ec C Out of range TIM ready for TIMnotready A value lt After A value lt After operation for operation respective s
25. ate through the sensor cell is too low a malfunction message such as F XXX is displayed xxx is the approximate flow in ml min e f there is a malfunction e g due to a damaged sensor cell or excess water or air content in the oil 999999 is displayed e After the measurement is stopped Mode M3 target cleanliness reached or via bus interface a Stop message is displayed e In mode M4 after the target cleanliness is reached the elapsed test cycle time is displayed in minutes e g t 25 7 3 Configuration via the Serial RS232 Display Port You can now proceed to Select Mode by pressing RETURN The Ready relay switches off as the sensor does not measure when in Select Mode 7 3 1 Select Mode IS Texts appearing in the terminal window are shown in italiTIM The following appears in the display when you are in Select Mode Schroeder Industries In line monitor TIM2230 Hardware Version 3 0 Firmware Version 4 00 06 01 2004 Schroeder TestMate In line monitor offline Measurement cycle stopped Select mode x Restart Measurement p To Parameter Mode Press key x p and Return To return to Display Mode press the x key followed by RETURN The following appears SCHROEDER ContaminationSensor online Measuring cycle restarted x Restart Measurement p Enter Parameter Mode Press key x p and Return To access Parameter Mode press the p key followed by RETURN Parameter Mode enables you to c
26. ates safety instructions whose non observance may pose a hazard to individuals This symbol designates safety instructions whose non observance may result in the injury of individuals by electric shock This symbol provides important instructions and tips for the proper handling and operation of the TIM Non adherence to these instructions may result in damage to the TIM or in damage to its immediate surroundings This symbol designates tips for usage and other particularly useful information This information helps you to optimally utilize all the features offered by your TIM gt gt 1 3 Proper Designated Use The TestMate In line Monitor TIM was developed for the continuous monitoring of particulate contamination in hydraulic systems Analyzing the size and quantity of contamination enables quality standards to be verified and documented and the requisite optimization measures to be implemented Any other use shall be deemed to be improper and not in keeping with the product designated use The manufacturer will not assume any liability for any damage resulting from such use Proper or designated use of the product extends to the following e Maintaining adherence to all the instructions contained herein e Performing requisite inspection and maintenance work 1 4 Improper Use e Any use deviating from the proper designated use described above is prohibited e Improper use may result in hazard to life and limb e Example
27. be connected to both of the analog inputs The terminal assignment is shown below 6 1 Connector TWS C Series Analog Power 12 V 20 PIN 1 Analog Signal Chan 1 21 PIN 2 Analog Input Analog Ground 22 ping WSC Analog Signal Chan 2 23 PIN 4 6 2 Connector TWS K Series TWS K S C Analog Supply 12 V 20 Analog Input Analog Signal Ch 1 21 ope Analoa Ground 22 Analog Signal Ch 2 23 The water saturation 0 to 100 and the temperature 20 C to 120 C can be used as a measurement channel in mode M2 to switch the relays In addition this information is transmitted via the optional serial interfaces For more information see DIN Measurement Bus Module RS232 Module and Ethernet Module IS Consequently particulate contamination and water induced contamination can be monitored via a single bus link Connecting an analog 4 20 mA 3 lead sensor of another manufacturer is possible Example fj SS SS 3 EST CS 3103 3 3 3 3 3 CC 5 3 SS 3 30 3 3 3 333 JJ 3 1 py Signal Ch 1 TIM H Sensor Ri 1 v 5 pee Ground nS For more information see sections Configure 4 20 mA Input Channels and Display AD Channels in chapter Serial RS232 Display and Parameter Interface Schroeder Industries En Page 23 TestMate In Line Monitor TIM 7 Serial RS232 Display and Parameter Interface
28. bleshooting cccccccceeeeeeeeeeeeeeaeeeeeeeeeeeesecaaaaaeeeeeeseeeeesaaaaes 52 14 Technical Specification a a es ku ken Goda eae nn i ates 53 TAT FIUS ces resected ait tere sd ec Sepa co E evga Shean ees owed gees 53 14 2 Particle Detection ari Ea BA ES T Hecke ia dealt A 53 14 2 1 R6G llbr tld d sa ans aka A ANER En R eA 53 14 3 Hydraulic 2 s ta AR FF I E Se erates 54 14 4 Ambient Conditions sinai in nn 54 14 5 Electrical Data nia ar 7280000222140035 a Gosh sR E T 55 15 Model Type 60d6 2234 06 21220022 300600201 2002 a chen M dorp i ca AIAL NG Backes AT 56 16 ISO 4406 SAE AS 4059 and NAS 1638 Tables 00 2000eeeraanrerrra arena 57 17 Parameter 8 D A a N a Ba eee a ne eee 59 L 2693 Testmate In Line Monitor User Manual 1 General Safety Precautions These operating instructions contain the key instructions for properly and safely operating the TIM 1 1 Obligations and Liability e The basic prerequisite for the safe and proper handling and operation of the TIM is knowledge of the safety instructions and warnings e These operating instructions in general and the safety precautions in particular are to be adhered by all those who work with the TIM e Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used e The safety precautions listed herein are limited solely to using the TIM The TIM has been design
29. bove The return line connector OUTLET must never be obstructed or closed off Warning Oil starts to flow through the TIM as soon as the system 6 Installation of the TIM is now complete and now continuously outputs the measured values via the electrical interfaces 4 5 Removing the TIM from the Hydraulic System 1 Disconnect the TIM from the voltage supply 2 Disconnect the other electrical connectors 3 Remove the measurement line from the hydraulic system first then from the INLET port of the TIM 4 Remove the return flow line from the OUTLET port of the TIM The TIM can now be removed Schroeder Industries En Page 18 L 2693 Testmate In Line Monitor User Manual 5 Description of the Measurement Modes 5 1 Mode M1 Measure Continuous measurement without any special switching functions The current measured result is outputted via the interfaces upon the measurement interval elapsing 5 2 Mode M2 Measure switch Continuous measurement relays 1 and 2 are switched in accordance with the measurement channels switching functions and limits set The current measured result is outputted via the interfaces upon the measurement interval elapsing 5 3 Mode M3 Filter to Measurement mode relay 1 is closed until 5 consecutive measurements reach or fall below the target cleanliness set Measurement in mode 3 is then stopped If relay 1 has opened it stays open until measurement is renewed Restarting measurem
30. e Thanks to the integrated pressure relief valve the in line monitor is protected against pressure loads of up to 5000 psi 350 bars The measured cleanliness classes or particle counts are continuously outputted via various in part optional electric outputs relays PLC interface serial display ports analog electric output 4 20mA field bus interface and can thus be captured read out via a PLC analog voltmeter or aPC Schroeder Industries En Page 12 L 2693 Testmate In Line Monitor User Manual 3 2 Design Features The in line monitor consists of the following components e aluminum casing e hydraulic ports inlet and outlet e fiber optic infrared measurement cell e pressure relief valve 3 3 Restrictions Pertaining to the Use of the TIM D It is recommended that the TIM H only be used in connection with mineral oils or mineral oil based raffinates The TIM H is qualified for phosphate esters Please contact us first before using the unit with other fluids 3 4 Hydraulic diagram Legend Pos Description 1 Inlet Pressure relief valve 40 bars Fiber optic infrared measurement cell Bypass with orifice Outlet orifice OM oa P O N Outlet Schroeder Industries En Page 13 L 2693 Testmate In Line Monitor User Manual 3 4 1 Hydraulic diagram for Pressure Viscosity Ranges 1 and 2 3 4 2 Hydraulic diagram for Pressure Viscosity Ranges 3 and 4 sr 2
31. e Monitor factory assembled and ready for operation 1 pe Connector Cable TIM lt gt PC 1 pc operating and maintenance instructions Schroeder Industries En Page 11 L 2693 Testmate In Line Monitor User Manual 3 Technical Description 3 1 Designated Use The TestMate In line Monitor TIM H are stationary measurement units for the continuous monitoring of particulate contamination in hydraulic systems They were specifically developed for test station applications where the following are needed measured value capturing in the hydraulic system and remote display at the operator desk in addition to data storage and archiving on a PC Particulate contamination is captured using an infrared fiber optic measurement cell patented by Schroeder Readings can be outputted as particle counts or cleanliness classes according to NAS 1638 or ISO 4406 1987 OR SAE AS 4059 or ISO 4406 1999 Capturing of particulate contamination is done in the following particle size ranges TIM H Particle counts NAS Channels 4 6um 6 14UM 14 21ume gt 21uMo ISO Channels gt 4UM c gt 6UMY c 14UM c The TIM is designed for connection to low pressure hydraulic lines from which a small current of oil is diverted for measurement and analysis purposes By adjusting internal orifices the sensors can be configured for various pressure viscosity ranges by the manufacturer Schroeder Industries see chapter Hydraulic Diagram and Mode Cod
32. e channels TIM H ALM BUM 14M 21 UM Measurement range calibrated TIM H SAE 2 12 ISO 13 11 10 23 21 18 Indication range TIM H SAE 2 15 ISO 12 10 9 25 23 21 Accuracy 1 2 class ISO NAS SAE Calibration to ISO 4402 TIM 203X TIM 213X or ISO 11943 TIM H Measurement interval programmable from 20s 120s 14 2 1 Recalibration Every 2 3 years providing your in house QA system does not prescribe otherwise Schroeder Industries En Page 53 TestMate In Line Monitor TIM 14 3 Hydraulic Data Max inlet pressure 350 bars 5000 psi Operating pressure 0 5 40 bars 7 580 psi Viscosity range 1 200 mm s Total flow rate 10 to 200 ml min Threaded connector G1 4 ISO 228 Max outlet pressure dependent on inlet pressure pressure in the measurement cell max 40 bar 580 psi Pressure viscosity range depending on the individual version Druck Viskositatsbereich Pressure viscosity range Pression plage de viscosit Druck Pressure Pression bar o 50 100 150 200 FA EEE Viskosit t Viscosity Viscosit mm s Druck Pressure Pression bar 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 Viskosit t Viscosity Viscosit mm s 14 4 Ambient Conditions Protection type Ambient temperature Schroeder Industries IP65 EN 6052 OG 55 32 F 131 F
33. e information see section Serial RS232 Display and Parameter Interface Schroeder Industries En Page 46 TestMate In Line Monitor TIM 11 Ethernet Module The Ethernet module is designed for 10Base T standardized cable types and complies with the criteria detailed in IEEE 802 3 e g bit rate 10 Mbps transmission medium twisted pair UTP STP cable Data transfer takes place via the TCP IP communication protocol 11 1 Entering the IP Address Before entering an IP address contact your systems administrator first The assignment of IP addresses is subject to in house rules and international regulations The IP address of each unit can be individual set in order to identify the unit in the network Use only IP addresses which have been assigned by your systems administrator Not doing this may cause serious network outages and other problems Entering the IP address is done during configuration via the RS232 display and parameter interface see 7 3 4 5 for more information This module uses the same data transfer protocol as that described in the section on the DIN measurement bus module When accessing the unit via your Ethernet LAN only the IP address is decisive the bus address is ignored 11 2 Units Featuring an Ethernet Module Provide the Following 2 Functions 11 2 1 Transmission of Commands The commands available here are the same as those described in 9 5 for the DIN measurement bus module Ho
34. ed and constructed in accordance with the current state of the art and recognized safety regulations Nevertheless hazards may be posed to the life and limb of the individual using the product or to third parties Risk of damage may be posed to the product or other equipment and property The TIM is to be used as follows e solely for its designated use e only when in a safe perfect condition e Any faults or malfunctions which might impair safety are to be properly repaired or remedied immediately Our General Terms and Conditions apply They are made available to the owner upon concluding purchase of the product at the latest Any and all warranty and liability claims for personal injuries and damage to property shall be excluded in the event they are attributable to one or more of the following causes e improper use of the TIM or use deviating from its designated use e improper assembly installation commissioning operation and maintenance of the TIM e operating the TIM when the system equipment or systems are defective e modifications to the product made by the user or purchaser e improper monitoring of product components subject to wear and tear e improperly performed repair work 1 2 Explanation of Symbols and Warnings etc The following designations and symbols are used in this manual to designate hazards etc Schroeder Industries En Page 5 L 2693 Testmate In Line Monitor User Manual 1 2 1 Basic Symbols This symbol design
35. ent can be done via the bus interface the RS 232 display interface or by switching off the supply voltage and then switching it back on 5 4 Mode M4 Filter from to Measurement mode relay 1 is closed until 5 consecutive measurements reach or fall below the target cleanliness lower limit set The relay is then opened and the test cycle time starts Upon the test cycle time elapsing relay 1 is closed and a measurement conducted When the upper cleanliness value upper limit is attained or exceeded relay 1 stays closed until the mean value again reaches or falls below the set target cleanliness lower limit value during 5 measurements If the upper cleanliness value upper limit is not achieved or exceeded relay 1 is opened again and the test cycle time is restarted Schroeder Industries En Page 19 L 2693 Testmate In Line Monitor User Manual Ready Relay Ready Relay Relay 1 Relay 1 Relay 2 Relay 2 on off on off on off ae NE a o NO 2 NO J m NO A ele c amp c C c e C M1 TIM ready for TIM not ready Measurement Measurement After the first Flow rate operation for operation currently in stopped measured within set progress value is range available Flow error M2 Measuring channel 1 2 3 4 5 6 9 10 Exceed TIM ready for TIM not ready gt upper limit After gt upper limit After operation for operation switching the switching the unit on or unit on or starting a starting a measurement measurement Goes out Goes o
36. ered and then the upper limit s Measurement channel for relay 2 warning relay Measurement channels selected in the same manner as for relay 1 Limit function for relay 2 warning relay Limit functions selected in the same manner as for relay 1 Limits for measurement channel relay 2 Entered in the same manner as for relay 1 Example for TIM H Relay 1 measuring channel 0 SAE A 1 SAE B 2 SAE C 3 SAE D 4 ISO ch 0 5 ISO ch 1 6 ISO ch 2 7 SAE A D 8 ISO code 9 flow 10 LED 11 4 20 mA input ch 1 12 4 20 mA input ch 2 Current setting 3 New setting press Return only to keep setting 8 Return Current setting 8 Relay 1 switching function O no function 1 within range 2 outside range 3 exceed 4 fall below Current setting 4 New setting press Return only to keep setting Return Now the setting is 4 selected limit exceeded Relay 1 lower limit 1 Current setting 17 New setting press Return only to keep setting 16 Return Now the setting is 16 Relay 1 upper limit 1 Current setting 20 New setting press Return only to keep setting Return Now the setting is 20 Relay 1 lower limit 2 Current setting 15 New setting press Return only to keep setting 14 Return Now the setting is 14 Relay 1 upper limit 2 Current setting 18 New setting press Return only to keep setting 17 Return Now the setting is 17 Relay 1 lower limit 3 Current setting 13 New setti
37. espective of the pulse frequency selected between the output of the two sizes of the ISO codes or between the NAS SAE classes of two channels The result is displayed again after 10 seconds irrespective of the pulse frequency selected Output is not synchronized with the measurement interval This means that if output has started it is ended even if a new measured value is already present In the event of a flow or device error no pulses are outputted via the PLC interface The same applies when measurement is stopped Modes M3 and M4 The measured result is outputted only once NAS classes 5 6 6 5 5 1 Pulses 6 1 Pulses 6 1 Pulses 5 1 Pulses n a a o High Low ISO Code 17 14 11 17 1 Pulses 14 1 Pulses 11 1 Pulses gt High Low Schroeder Industries En Page 37 TestMate In Line Monitor TIM Examples lt O 24V from PLC P5 100nF 220 elk Ld O PNP Output to PLC P6 WANA utput to P6 100nF 10k e o O PLC Ground P4 gt gt 10NF Case Ground PLC Output Circuit of the TIM Schroeder Industries En Page 38 TestMate In Line Monitor TIM 9 DIN Measurement Bus Module 9 1 Interface The interface and the protocol structure required for communication conform to the criteria listed in DIN 66348 part 2 Generally speaking the electrical properties correspond to those of
38. fe Lower limit 3 M2 relay 1 channels 0 8 C 999 87 No Upperlimit1 M2 relay 1 channels 0 8 18 o 999 88 No Upperlimit2 M2 relay1 channels0 8 15 fo 999 89 No Upperlimit3 M2 relay 1 channels 0 8 12 fo 999 90 No Lower limit 1 M2 relay2 channels0 8 16 fo 999 91 No Lower limit 2 M2 relay 2 channels 0 8 13 fo 999 92 No Lower limit 3 M2 relay 2 channels 0 8 10 fo 999 93 No Upper limit 1 M2 relay 2 channels 0 8 18 fo 999 94 No Upperlimit2 M2 relay 2 channels 0 8 15 fo 999 95 No JUpperlimit3 M2 relay 2 channels 0 8 12 fo 999 Schroeder Industries En Page 61
39. h 2 gt 14um 7 gt NAS SAE class largest value of NAS SAE channels 0 3 8 gt ISO code 9 gt Flow info 10 gt LED current Unit for Command 12 0 NAS SAE 1 gt ISO Lower limit in M3 Channel 0 NAS SAE ISO NAS SAE ISO No No No Lower limit in M3 Channel 1 No Lower limit in M3 Channel 2 NAS SAE ISO No Lower limit in M4 Channel 0 NAS SAE ISO No Lower limit in M4 Channel 1 NAS SAE ISO No Lower limit in M4 Channel 2 NAS SAE ISO No Upper limit in M4 Channel 1 NAS SAE ISO Upper limit in M4 Channel 2 NAS SAE ISO Test cycle time in M4 in minutes Jeo Jo 1440 31 Yes Number of bad parameter see command 15 Unit of limit value in M3 0 gt NAS SAE 1 gt HU ISO Unit of limit value in M4 0 gt NAS SAE 1 gt P y ISO Pump pre running time in seconds 200 Relay 1 switched off Pump Protection N CO PO PO 0 CO PO O1 CO O e oO oO o o No 0 N D tt Measuring mode M1 M4 gt 0 3 1 jo B Header for RS232 Display Output a Schroeder Industries En Page 60 TestMate In Line Monitor TIM No String Read Designation Default Min Max Only 82 No Unit for RS232 Display Output 0 gt NAS SAE 1 1 0 1 ISO 183 No _ Unit for PLC Output 1 gt NAS SAE 2 ISO 2 184 No Lower limit 1 M2 relay 1 channels 0 8 116 lo J99 185 No Lower limit 2 M2 relay 1 channels 0 8 113 Jo 1999 py
40. he BUS AddresS annann did ati na Macken SN 39 9 3 Setting the BUS Address Using DIP Switches 200eeeeeeeeeerrannnneer ner 39 9 4 DIN Measurement Bus Commands General ccccccciiiiciiiiii iiic ciii 40 9 5 KONNI a a mi jan Sl Pe a 41 9 5 1 Command 8 Program Parameter s of the TIM cccciiiiiii iiien 42 9 5 2 Command 9 Read parameter s of the TIM eeeeeeerrrnn ner 42 9 5 3 Command 11 Read Particle Counts Differential On Line 43 9 5 4 Command 12 Read Contamination Classes ISO NAS SAE On Line 44 9 5 5 Command 13 Stop Measurement 0e0eeeeee renna 44 9 5 6 Command 14 Start Measurement eeeeeeerrrnnnnn rr 44 9 5 7 Command 17 Read LE GUrr aa ar s eii 45 9 5 8 Command 19 Reset parameters to factory default setting 45 9 5 9 Command 109 Read TIM Model and Firmware Version cecsceeseeeeeeeees 45 10 PIS 232 Mod le ra 0 a E meen a aa etic oe 46 11 EN a Aas ed eC a a aa 47 Vist Entenng the IP AGGress 7222202220622220 a a a rea 47 11 2 Units Featuring an Ethernet Module Provide the Following 2 Functions 47 11 2 1 Transmission of COMMandsSs a ad A saa Raced rat aie 47 11 2 2 Web Server sta a gi a et ne mare hema ie Seen ee ees 48 12 Analog Module Output SINNA Sir nna A a tens 49 13 Error Messages and Trou
41. ignal Channel 1 Analog Ground Analog Signal Channel 2 En Page 15 L 2693 Testmate In Line Monitor User Manual The terminal assignment of the module port varies according to the various optional output modules The terminal pin assignments are shown in the following figure RS 232 Modul Option 0 7 Free 8 Free 9 Ground 10 Free 11 TxD 12 RxD RS 232 Analog Modul Option 1 4 20 mA Free Free 10 Free 11 Free 12 4 20 mA Analog RS 485 Modul Option 2 7 RB 8 BUS 5V 9 BUS Ground 0 1 RS 485 TB TA 12 RA Ethernet Modul Option 3 7 RxD 8 RxD 9 TxD 10 TxD 11 Free 12 Free Ethernet There is a sticker inside the casing of the in line monitor which shows the pin assignment for the respective model configuration Schroeder Industries En Page 16 L 2693 Testmate In Line Monitor User Manual 4 2 Electrical Installation Before continuing check whether the TIM is suitable for your display data capturing system by carefully examining the technical specifications First connect the signal lines pins terminals 1 to 23 Then connect the supply voltage TIM starts measurement operation as soon as the supply voltage is applied 4 3 Select a Test point ee S WRONG RIGHT 4 4 Hydraulic Installation Determine the system
42. in as determined on the basis of the average flow through time of the particles in the four particle size channels Air bubbles trapped in the oil are noticeable by virtue of the fact that the first value is the first two values are substantially lower than the other values Similarly droplets in a second fluid phase like water grease etc are also noticeable A is outputted when no particles are counted in a channel Examples f Check values 121 118 124 112 flow rate OK Check values 125 130 110 flow rate OK no particles in 4 channel Check values 11 48 121 102 flow rate not OK air bubbles might be present 7 3 4 12 Sensor Check s Sensor check enables the particle sensor to be checked e g in the event of a malfunction 999999 is outputted on the RS 232 display interface and the Ready relay is opened Example S Sensor current ok 253 digit Sensor current low 1 digit Possible reason defective light source Sensor current high 820 digit Water or air in the fluid or sensor clogged Schroeder Industries En Page 34 TestMate In Line Monitor TIM 7 3 4 13 Configuring the 4 20 mA Inputs a Configure 4 20 mA Input Channels enables the two analog 4 20 mA inputs to be configured The following has to be entered for each input the measured values for the 4 mA and 20 mA sensor current and a designation The designation is read out by CoCoS and used as an axis label Exam
43. ir work X Shutdown decommissioning X X X X Storage 1 9 Safety Measures to Be Followed in Normal Operation e Do not operate the TIM unless all the safety devices function properly e The product is to be checked once a day for external damage and the proper functioning of the safety devices 1 10 Electrical Hazards Any work involving the power supply may only be done by a properly trained certified electrician Schroeder Industries En Page 8 L 2693 Testmate In Line Monitor User Manual e Make sure to check the electrical equipment of the product on a regular basis Any loose connections or damaged cables are to be remedied replaced immediately e lf work to live components is required a second individual is required who can switch off the product at the main switch as may prove necessary 1 11 Maintenance Servicing and Troubleshooting e The prescribed adjustment maintenance servicing and inspection work is to be conducted in a timely fashion e All operating media is to be protected isolated for the event that the product is accidentally started up e The TIM is to be disconnected from the power supply and protected against being inadvertently switched back on when performing any maintenance servicing inspection or repair work e Any screwed fittings which have been undone removed are to be checked to see that they have been properly resecured e Always check the product to see that it functions properly when perf
44. n the screen In addition a specification can also be made as to whether the following is to be displayed the NAS SAE maximum one part i e in the form of xx the highest value of the contamination classes determined in the 4 measurement channels is shown the ISO code TIM 213X and H three part in the form of xx xx xx TIM 203X two part in the form of xx xx the flow rate in form of FL xxx with xxx Flow rate in ml min or as an alternative the ISO code and the flow rate the contamination class in SAE channel A NAS channel 0 the contamination class in SAE channel B NAS channel 1 the contamination class in SAE channel C NAS channel 2 the contamination class in SAE channel D NAS channel 3 the cumulative particle counts and the flow rate in the form of KO K1 K2 K3 F whereby Ki cumulative particle counts in channel i and F flow rate Example for TIM H Header in display output SAE B Measurement value in display output SAE ch B Enter new header Return no header New header in display output no header Enter new measurement value Return keep current setting 1 SAE max 2 ISO Code 3 Flow rate 4 Toggle ISO Flow 5 SAE ch A 6 SAE ch B 7 SAE ch C 8 SAE ch D 9 cumulative particle counts flow rate New measurement value in display output ISO code In the example the display output format of SAE channel B featuring the header SAE B
45. ng press Return only to keep setting 12 Return Now the setting is 12 Relay 1 upper limit 3 Current setting 15 New setting press Return only to keep setting Return Schroeder Industries En Page 28 TestMate In Line Monitor TIM Now the setting is 15 Since the ISO code has been selected a three part value has to be entered each for the lower and upper value i e a total of 6 values In the example shown above the ISO code is 16 14 12 for the lower limit and 20 17 15 for the upper limit 0 SAE A 1 SAE B 2 SAE C 3 SAE D 4 ISO ch 0 5 ISO ch 1 6 ISO ch 2 7 SAE A D 8 ISO code 9 flow 10 LED 11 4 20 mA input ch 1 12 4 20 mA input ch 2 Current setting 4 New setting press Return only to keep setting 9 Return Current setting is 9 selected flow rate Relay 2 switching function O no function 1 within range 2 outside range 3 exceed 4 fall below Current setting 0 New setting press Return only to keep setting 1 Return Now the setting is 1 selected Within range Relay 2 lower limit 1 Current setting 30 New setting press Return only to keep setting 50 Return Now the setting is 50 Relay 2 upper limit 1 Current setting 150 New setting press Return only to keep setting Return Now the setting is 150 50 and 150 ml min were entered for the lower and upper value respectively Schroeder Industries En Page 29 TestMate In Line Monitor TIM 7 3 4 2 Se
46. ode Schroeder Industries En Page 35 TestMate In Line Monitor TIM 7 3 4 15 Setting Default Values d Set default values causes all the values that can be set in the Parameter Mode menu to be reset to the factory default values for more information refer to Parameter List Factory default settings recovered r After making your settings don t forget to leave Parameter and Re Operating Mode before disconnecting from the program otherwise no measurements can be performed If you do forget you can reset the in line monitor by briefly interrupting the power supply When restoring the power supply the in line monitor automatically starts up in Display Mode Schroeder Industries En Page 36 TestMate In Line Monitor TIM 8 Output Signals of the PLC Interface Depending on the output format set ISO code or NAS SAE classes either a three part ISO code or the NAS SAE classes of the four particle size channels pulse coded is outputted by the PLC interface The number of pulses outputted corresponds to the ISO class 1 or the NAS SAE class 1 in so doing also enabling a class 0 to be outputted The pulse frequency amounts to ca 10Hz 50 ms High 50 ms Low The pulse frequency normally amounts to ca 10 Hz 50 ms High 50 ms Low however in Parameter Mode it can divided by 2 100 ms High 100 ms Low 3 150 ms High 150 ms Low or 4 gt 200 ms High 200 ms Low There is a pause of 1 second irr
47. onfigure TIM settings Schroeder Industries En Page 25 TestMate In Line Monitor TIM 7 3 2 Parameter Mode The following appears in the display when you are in Parameter Mode Parameter Mode x Go back t Measuring cycle time m Select measuring mode 2 Limits Mode M2 3 Limits Mode M3 4 Limits Mode M4 b Set DIN Bus Address and Name for TIM models with DIN Bus module only e Set IP Address for TIM models with Ethernet Interface only p Pump protection o PLC Output Format r RS 232 Display Output Format i Current Output Format for TIM models with analog module only c Check Current Output for TIM models with analog module only f Flow check s Sensor Check a Configure 4 20 mA Input Channels h Display AD Channels d Recover factory default settings Press key x t m 2 3 4 b e p o r i c f s a h d and Return 7 3 3 Measuring Time t Measuring time is used to set the measurement time 20 s to 120 s When a time shorter than 20 s is set for test purposes it isn t stored in the EEPROM which means that after resetting the TIM a measurement time between 20 s and 120 s is set No time lt 2 s gt or 120 s can be set Current measuring cycle time s set to 20 New value for measuring cycle time s press Return only to keep setting 60 Return Current measuring cycle time s set to 60 The measured result has been extended in the example from 20s to 6
48. orming maintenance and servicing work 1 12 Modifications to the TIM e Do not make any modifications design modifications extensions to the TIM without the prior consent of the manufacturer e Any design modifications or extensions may not be made without Schroeder Industries LLC s express prior written approval e Immediately replace any machine components which are not in perfect condition e Only use original OEM spare parts and consumables When using non OEM components it cannot be ensured that they have been designed and manufactured so as to comply with loading and safety requirements 1 13 Cleaning the TIM and Disposal of the Media and Agents Used e The cleaning agents and flushing oils used are to be handled and disposed of properly e To this end the manufacturer s instructions pertaining to possible use wearing of protective clothing and gear and proper disposal are to be adhered to Some cleaning agents may pose a health hazard especially when undiluted Schroeder Industries En Page 9 L 2693 Testmate In Line Monitor User Manual Transportation Packing Storage Disposal 1 14 Transportation amp Packing e The TIM comes wrapped packed in plastic sheeting e When receiving and unpacking the unit check it for damage in transit Report any damage to the forwarding agent immediately e The packing material is to be disposed of as specified by law or national regulations It can be reused 1 15 Stor
49. ple configuration for the SCHROEDER AquaSensor AS 2030 2330 a Channel 1 value for 4 0 mA Current setting 0 0 New setting press Return only to keep settings Return Channel 1 value for 20 0 mA Current setting 100 0 New setting press Return only to keep settings Return Channel 1 designation Current string Fill level New designation max 16 characters Return no designation Saturation Return Channel 2 value for 4 0 mA Current setting 0 0 New setting press Return only to keep settings 20 Return Channel 2 value for 20 0 mA Current setting 16 0 New setting press Return only to keep settings 120 Return Channel 2 designation Current string Pressure New designation max 16 characters Return no designation Temperature Return 7 3 4 14 4 20 mA Inputs Displaying the Current Measurement Values h Display AD Channels causes the current measurement values of the two analog 4 20 mA inputs to be displayed Example configuration for the SCHROEDER AquaSensor AS 203x 233x h Channel 1 4 0 mA Configuration Value 0 0 Channel 1 20 0 mA Configuration Value 100 0 Saturation Value 35 6 Channel 2 4 0 mA Configuration Value 20 0 Channel 2 20 0 mA Configuration Value 120 0 Temperature Value 55 4 Press key x Return x Return Pressing Return causes the values to be refreshed pressing x Return causes you to exit the display and return to Parameter M
50. rature values have to be discarded because the TIM 2030 TIM 2031 and TIM 2130 TIM 2131 don t have any of these sensors two 0 s are transmitted for compatibility with the FCU protocol TRANSMIT 11 RECEIVE 11 50453 4324 234 67 100 34 7 52 0 Particle counts 5 15um 2 5um 4 6UM oo eee 50453 Particle counts 15 25um 5 15um 6 14 Um 4324 Particle counts 25 50um 15 25um 14 21pmM 234 Particle counts gt 550Um gt 25umM gt 21pM i rr 67 Flow rale kosc aeniea a o a renne raine 100 ml min Measurement value Analog input 1 Water content 34 7 Measurement value Analog input 2 Temperature 52 0 gt The water content saturation and temperature information is not available its unless a SCHROEDER TestMate Water Sensor is connected to the analog input channels The measured values are determined at the end of a measurement interval of the particle count Schroeder Industries En Page 43 TestMate In Line Monitor TIM 9 5 4 Command 12 Read Contamination Classes ISO NAS SAE On Line The values of the last measurement are transmitted Whether NAS SAE or ISO classes are transmitted is selectable by parameter 21 If ISO is selected four ISO codes are transmitted even though gt 25um for TIM 2130 TIM 2131 and gt 25um gt 50um for TIM 2030 TIM 2031 are not defined by ISO 4406 TRANSMIT 12 Parameter 21 0 RECEIVE 126776
51. t dry running When no permissible flow rate is present upon the time entered elapsing subsequent to starting measurement or a flow rate error occurs condition larger than the lower limit for permissible flow rate parameter 10 measurement is discontinued and the pump switched off via relay 1 Entering O causes this function to be disabled Current Pump protection time 0 s New value for Pump protection time press Return only to keep setting 10 Now the value for Pump protection time is 10 In the example the switched off function has been activated and a time of 10 s entered 7 3 4 7 Setting the PLC Output Format o PLC Output Format enables a selection to be made as to whether the NAS SAE classification 1 value or the ISO code 3 values is outputted via the PLC interface Current PLC Output Format ISO Schroeder Industries En Page 32 TestMate In Line Monitor TIM Enter 1 for SAE or 2 for ISO press Return only to keep setting 1 Selected PLC Output Format SAE Current PLC Output Format SAE PLC Output Frequency Divider 1 New value 1 4 for PLC output frequency divider press Return only to keep setting 2 PLC output frequency divider set to 2 In the example the output format has been changed from ISO to SAE and the output frequency reduced by half 7 3 4 8 Setting the RS 232 Display Output Format r RS 232 Display Output Format enables a header to be entered max 25 characters for outputting o
52. ting 22 Return Now the setting is 22 Upper limit 2 Schroeder Industries En Page 30 TestMate In Line Monitor TIM Current setting 8 New setting press Return only to keep setting Return Now the setting is 19 Upper limit 3 Current setting 8 New setting press Return only to keep setting 16 Return Now the setting is 16 Test cycle time in minutes Current setting 60 New setting press Return only to keep setting 120 Return Now the setting is 120 In the example the target cleanliness for mode M4 has been changed from SAE 5A 5B 5C to ISO 16 14 12 the cleanliness class for a repeated flushing scrubbing from SAE 8A 8B 8C to ISO 22 19 16 and the test cycle time from 60 min to 120 min 7 3 4 4 Setting the DIN BUS Address and Name for TIM models with the DIN BUS module only b Set DIN Bus Address and Name the bus address for the DIN measurement bus and the measurement sampling site designation are entered DIN Bus Address 1 Measurement Point SCHROEDER New value for DIN Bus Address press Return only to keep setting 2 DIN Bus Address set to 2 New Measurement Point press Return only to keep setting Testpoint Measurement Point Testpoint Current DIN Bus Address 2 Current Measurement Point Testpoint In the example the bus address has been changed from 1 to 2 and the measurement site from SCHROEDER to Testpoint DIN Bus Address 1 Measuring Point SCHROEDER
53. ttings for Measuring Mode M3 3 Limits Mode 3 enables the settings to be entered for measurement mode M3 Example for TIM H Contamination Code Selection 0 SAE 1 ISO Current setting 0 New setting press Return only to keep setting 1 Return Now the setting is 1 Lower limit 1 Current setting 5 New setting press Return only to keep setting 16 Return Now the setting is 16 Lower limit 2 Current setting 5 New setting press Return only to keep setting 14 Return Now the setting is 14 Lower limit 3 Current setting 5 New setting press Return only to keep setting 12 Return Now the setting is 12 In the example the target cleanliness for mode M3 has been changed from SAE 5A 5B 5C to ISO 16 14 12 7 3 4 3 Settings for Measuring Mode M4 4 Limits Mode 4 enables the settings to be entered for measurement mode M4 Contamination Code Selection 0 SAE 1 ISO Current setting 0 New setting press Return only to keep setting 1 Return Now the setting is 1 Lower limit 1 Current setting 5 New setting press Return only to keep setting 16 Return Now the setting is 16 Lower limit 2 Current setting 5 New setting press Return only to keep setting 14 Return Now the setting is 14 Lower limit 3 Current setting 5 New setting press Return only to keep setting 12 Return Now the setting is 12 Upper limit 1 Current setting 8 New setting press Return only to keep set
54. ultaneously accessed as described in section 11 2 1 above e g via the Ethernet LAN using CoCoS version X XX or higher Schroeder Industries En Page 48 TestMate In Line Monitor TIM 12 Analog Module Output Signals The measurement results are outputted as a current between 4mA and 20mA as follows load lt 500 Q When NAS max or SAE max is selected under i in Parameter Mode Current 4 20mA Measurement range from NAS SAE 2 4 8mA Measurement range to 19 2 mA NAS 15 SAE 12 Error Low 4mA Error High 20 mA Error Low means The device is not ready for performing measurements e g on account of a defective sensor or because of excessively high air or water content Error High means flow error N Error High NAS 15 NAS 14 NAS 13 NAS 12 NAS 11 NAS 10 NAS 9 NAS 8 NAS 7 NAS 6 NAS 5 NAS 4 NAS 3 NAS 2 Error Low 4 4 8 19 2 20 i mA The NAS class is computed on the basis of the current measured i as follows NAS value 1 i 4 8 mA x 13 14 4 NAS class NAS value rounded up to the next whole number Schroeder Industries En Page 49 TestMate In Line Monitor TIM N Error High SAE 12 SAE 11 SAE 10 SAE 9 SAE 8 SAE 7 SAE 6 SAE 5 SAE 4 SAE 3 SAE 2 Error Low 4 48 19 2 20 i mA The SAE class is computed on the basis of the current
55. ut again when lt again when lt lower limit lower limit Fall below TIM ready for TIM not ready lt lower limit After lt lower limit After operation for operation switching the switching the unit on or unit on or starting a starting a measurement measurement Goes out Goes out again when gt again when gt upper limit upper limit Within range TIM ready for TIM not ready Lower limit lt After Lower limit lt After operation for operation measured switching the measured switching the value lt upper unit on or value lt upper unit on or limit starting a limit starting a measurement measurement Goes out or again when lt Measured lower limit value lt lower or limit or gt upper limit Measured value gt upper limit Out of range TIM ready for TIM notready Measured After Measured After operation for operation value lt lower switching the value lt lower switching the limit or unit on or limit or unit on or Measured starting a Measured starting a value gt upper measurement value measurement Schroeder Industries En Page 20 L 2693 Testmate In Line Monitor User Manual Ready Relay Ready Relay Relay 1 Relay 1 Relay 2 Relay 2 on off on off on off Fa NG P A O NO oy A o NO fe A o No 6 ae c bc ec C limit or gt upper limit or Lower limit lt Lower limit lt measured measured value value lt upper limit lt upper limit No function TIM ready for TIM not ready Always off Always off operation for operation M2 Me
56. wever transfer of the ASCIl coded commands takes place via the TCP IP protocol For information on how the commands are interpreted and their responses see 9 4 Version 3 xx and higher of CoCoS the Schroeder Contamination Control Software also enables communication with the measurement unit via an Ethernet LAN Schroeder Industries En Page 47 TestMate In Line Monitor TIM 11 2 2 Web Server The Ethernet module enables a readout of the current measurement data cumulative particle counts ISO code classes and other unit data device type firmware serial number using a web browser e g Internet Explorer The forms are stored on the web server in HTML format and can be viewed in the browser by entering the proper IP address see section 11 1 in the URL box Example Address http 192 168 0 30 The following HTML page pops up The HTML page is refreshed every 15 seconds thus it always shows the latest measurement results However the values for the temperature Temperature C and saturation Saturation are not outputted unless a Schroeder TestMate Water Sensor is connected to the TIM Being equipped with an Ethernet module the device takes on the tasks of a server When a link is established with the device this function is locked for IS other clients during this time meaning the server only communicates with one client at a time However while the device is being accessed the web server can be sim
57. witching the respective switching the lower limit unit on or lower limit unit on or or starting a or starting a a value gt measurement a value gt measurement respective Goes out respective Goes out upper limit again when upper limit again when the respective the respective lower limit lt lower limit lt all values lt all values lt upper limit upper limit No function TIM ready for TIM not ready Always off Always off operation for operation M3 TIM ready for TIM not ready Measurement 5 consecutive After the first Flow rate operation for operation is currently in measured measured within set progress and values lt limit value is range one or more or available of the last 5 measurement Flow error measured stopped values gt limit M4 Start or result TIM ready for TIM not ready Measurement 5 consecutive After the first Flow rate of check operation for operation is currently in measured measured within set measurement progress and values lt limit value is range after test one or more or available cycle time gt of the last5 measurement Flow error upper limit measured stopped values gt limit Upon the test Test cycle Goes out cycle time time has again when elapsing for elapsed measured the duration value lt upper of a check limit measurement Restart test cycle time Schroeder Industries En Page 22 L 2693 Testmate In Line Monitor User Manual 6 Analog Input The 4 20 mA outputs of a Schroeder TestMate Water Sensors can
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