WSTM 01 - Set Water Saturation Temperature - Monitor CE 2004 - Manual and maintenance instructions Version 1.2 Serial-No.:... Version-/Ref.-Date: 27.05.2005 INTERNORMEN Technology GmbH Friedensstraße 41 Germany 68804 Altlußheim Tel. +49 (0) 6205/2094-0 Email: info@internormen.com http://www.internormen.com
Index Page 1. Safety information 3 1.1 Dangers of maloperation 3 1.2 Intended application 3 2. Installation 4 2.1 Set up 4 2.2 Getting ready for operation 4 3. Measuring the saturation level of oil 6 3.1 Effects of water in hydraulic oils 6 3.2 Measuring principle 6 3.3 Performing a measurement 7 3.4 Operation of the WSTM 01 Software 7 3.4.1 Control keys 7 3.4.2 Menu structure 8 3.4.3 Main menu 9 3.4.3.1 Measure 9 3.4.3.1.1 Storage Interval 9 3.4.3.1.2 Oil Selection 10 3.4.3.1.3 Start 11 3.4.3.2 Data Manager 11 3.4.3.2.1 Transfer Data 12 3.4.3.2.2 Delete Data 12 3.4.3.2.3 Stored Data 12 3.4.3.3 Options 12 3.4.3.3.1 Set Limits 13 3.4.3.3.2 Set Time 13 3.4.3.3.3 Temperature Format 14 3.4.3.3.4 Calibration 14 3.5 Evaluating measurements 15 3.5.1 Result display in %- saturation 15 3.5.2 Result display in ppm water content 16 3.6 Data transfer Data manager 17 4. Maintenance of the WSTM 01 Measuring system 19 4.1 Cleaning the sensor 19 5. Calibration of the WSTM 01- Set 19 5.1 WSPS 03 - Sensor 19 5.2 Built-in temperature sensor 19 6. Appendix 20 6.1 Technical data 20 6.2 Pin assignment 21 6.2.1 WSPS 03 Water sensor 21 6.2.2 WSTM 01 Display unit 22 6.3 Application areas - Compatibility 24 6.4 Contact burdens 24 7. Trouble shooting 25 2
1. Safety information 1.1 Dangers of maloperation The WSTM 01 Set underwent a safety inspection according to IEC 1010-1/ EN 61010 1, part 1. Integrated hydraulic and electronic safety elements ensure safe operation if the device is used as it was intended. In case of maloperation or abuse, as well as in case of insensitivity for application limits and safety regulations threats for the following can occur: Life or physical condition of the operator, the WSTM 01 device, as well as connected machines and systems connected, the accuracy of measurements of the WSTM 01, the environment. This manual does contain information and safety advice, which ensure riskless operations and which help to keep the device in the ideal condition. Therefore it is necessary that all people involved in operating and maintaining the device do note this manual unconditionally. 1.2 Intended applications By purchasing the WSTM 01 Set, you have gained an efficient diagnostic measuring system to determine the saturation level of oil with water and also the water content in ppm. In addition to that, the device is very robust. It works very reliably and does fulfil all requirements of daily measurements. The set is intended and tested to be applied in the following fluids: Standard- Hydraulic oils: HL, HLP Triglyceride: HETG Flight hydraulic oils: Mil H 5606 Synthetic Ester: HEES Lubricating oils: CLP Application in ammonia, bases or the like can cause the destruction of the sensor! Application limits: Maximum acceptable pressure on the sensor element Applicable viscosity range Maximum oil temperature Maximum acceptable flow rate on the sensor element 10 bar 1 1500 mm²/s 70 C 2 m/s Generally, the WSTM 01 Set has to be operated with 12...30 V DC! 3
2. Installation 2.1 Set up The WSTM 01 Set consist of the WSPS 03 Sensor with an integrated temperature sensor, a cable to connect the sensor (Length = 5 m) and the WSTM 01 display unit. 2.2 Getting ready for operation Place the WSTM 01 display unit in your system. Connect the WSPS 03 sensor with the cable. Connecting the sensor cable and the 24 V supply cable to the WSTM 01 display unit. Loosen screws and remove the cover. 4
Connect the included sensor cable (Length = 5 m) according to the pin assignment (see chapter 6.2 or the list on the cover). If necessary, extend the sensor cable using a cable with a diameter of d = 0.5 mm². Screwed cable gland: PG 9 PG 11 PG 13,5 Cable diameter: 4 8 mm 5 10 mm 6 12 mm - Take 24 V DC line cord through the screwed cable glad PG 11 or 13,5 (depending on the cable diameter) and connect according to pin assignment (see chapter 6.2 or list on the cover). - Take cable to transmit the threshold values through screwed cable gland PG 11 or PG 13,5 (depending on cable size) and connect according to the pin assignment (see chapter 6.2 or list on the cover). - If transmission of threshold values is not required, close the free screwed cable gland with the dummy plug included. This is required to get IP-64-protection. After the WSPS 03 Sensors, the line cord and the cable for threshold values are connected to the WSTM 01 display unit, the WSTM 01 Set is ready for operation. 5
3. Measuring the saturation level of oil 3.1 Effects of water in hydraulic oil Water in hydraulic oil is a fluid contamination, which has to be limited urgently due to its negative effects on the characteristics of hydraulic fluids. Among other effects, it does accelerate oil aging, it causes the failure of polarizing additives, it increases the acid number and it worsens filterability. Effects for a hydraulic or lubricating system are very manifold and cause significantly increased wear, drastically increased risk of failure of components as well as malfunctions. Important for these effects of water is whether water present in the fluid is free or emulsified, not the total amount of water. Only free water does have the dangerous chemical or biological reactivity. Therefore the detection of the presence of free water in a hydraulic or lubricating system is of great importance. 3.2 Measuring principle of the WSPS 03 The WSPS 03 does utilize a capacitive sensor for measurements. It uses polymeric foil as dielectric for interelectrode capacitance. This foil is capable of absorbing water molecules due to its microporous structure. This absorption causes a change in capacity of this element, which is converted into the output signal between 4 and 20 milli amps. Measurements are the saturation level (water saturation) of the fluid in percent. In addition to that a temperature sensor is integrated to determine the exact temperature of the fluid while measuring. There is a difference to the absolute water content with the Karl-Fischer-method. The Karl- Fischer-method determines the total amount of free and emulsified water in mg water / kg oil. The WSPS 03 Sensor gives the saturation level of the fluid with water in percent. The indication 100 % means that the fluid is saturated totally. Saturation values depend on the temperature! The connection to the ppm- (mg/ kg) values determined by the Karl Fischer method is being calculated using stored saturation characteristics in combination with temperature of the used fluid for the range of less than 99% saturation. The result is displayed. 6
3.3 Performing a measurement The WSPS 03 Sensor is intended for online measurements. Therefore the sensor should be integrated at a circulating, respectively turbulent point of the hydraulic system in order to generate reliable measurements. Please make sure that maximum limits for flow rate and pressure are not exceeded. The time to reach equilibrium on the sensor can vary and depends on a number of factors, such as the oil s viscosity. After connecting the WSTM 01 to the system, wait through the welcome screen until the main menu is being displayed. 3.4 Operating the WSTM 01 software 3.4.1 Control keys Menu prompting Enter Back (ESC) 7
3.4.2 Menu structure The menu is built up in three levels (plus start screen). The first two levels bring you to the third level. Individual settings and measuring options are available here. The following structure diagram shows the composition of menu navigations. Start screem Main menu Measure Data Manager Options Storage Interval Transfer Data Set Limits Oil Selection Delete Data Set Time Start Stored Data (just display) Temperature Format Calibration 8
3.4.3 Main menu Choose submenu with the [ ] buttons. The chosen item is marked with a * on the left side of the menu. Enter the chosen menu item by hitting the [ ] button. 3.4.3.1 Measure Choose submenu with the [ ] buttons. The chosen item is marked with a * on the left side of the menu. Enter the chosen menu item by hitting the [ ] button. Use [ ESC ] to go back to the previous menu. (Display shows: ) 3.4.3.1.1 Storage Interval Use the [ ] buttons to chose whether and if so in which interval measurements should be stored. The intervals that can be chosen are between five minutes and seven days. Storing the set interval will occur in battery backed RAM. In case of a power outage, the setting is saved. 100 measurements can be stored. After that, the oldest measurement is overwritten. Chose the storage interval with the [ ] buttons and confirm by hitting the [ ] button automatic return to the [ MEASURE ] menu. Use [ ESC ] to go back to the previous menu changes will not be adopted. 9
3.4.3.1.2 Oil Selection The last selected type of oil is being displayed. Select oil number digit by hitting the [ ] button a few times. Use the [ ] buttons to choose the oil number according to the attached effective list and confirm by hitting the [ ] button Selected type of oil will be displayed. Only oil numbers from the effective list can be selected. In any other case the failure message [INVALID NUMBER] will be displayed. Example list: Number DIN Identification Producer Produceridentification Synonym WSTM01 0 -------- -------- -------- NO OIL 1 HLP 22 Shell Tellus 22 HLP 22_1 2 HLP 46 Shell Tellus 46 HLP 46_1 3 HLP 68 Shell Tellus 68 HLP 68_1 4 MIL H5606 Shell Aeroshell MILH5606_1 Fluid 4 5 HEES 46 Fuchs Plantohyd 46 HEES 46_1 S 6 CLP 220 Shell Omala 220 CLP 220_1 7 Red army oil?? Redarmy_RC Use [ ESC ] to go back to the previous menu. 10
3.4.3.1.3 Start Measurement is performed automatically. No oil selected: Device continuously displays temperature and saturation level. If a storage interval was chosen, measurements are stored continuously and can be transferred to a PC via the RS 232-interface. Oil selected: Device continuously displays the temperature, the saturation level and the corresponding water content. If a storage interval was chosen, measurements are stored continuously and can be transferred to a PC via the RS 232-interface. Use [ ESC ] to go back to the previous menu [ MEASURE ]. 3.4.3.2 Data Manager Choose submenu with the [ ] buttons. The chosen item is marked with a * on the left side of the menu. Enter the chosen menu item by hitting the [ ] button. Use [ ESC ] to go back to the previous menu. (Display shows: ) 11
3.4.3.2.1 Transfer Data This option will retrieve all stored measurements using the RS232 interface. Every measurement is being transferred as a separate ASCII streak. Transferring will be performed until the operator ends it by hitting [ ESC ]. 3.4.3.2.2 Delete Data This option will delete all data from the measuring memory. It is irreversible. Therefore the deletion has to be confirmed with [ YES ]. Use the [ ] buttons to select [ YES ] or [ NO ] and confirm by hitting [ ]. Use [ ESC ] to go back to the previous menu. 3.4.3.2.3 Stored Data This is not a menu item that selects anything only the number of stored data is being displayed. 3.4.3.3 Options Choose submenu with the [ ] buttons. 12
The chosen item is marked with a * on the left side of the menu. Enter the chosen menu item by hitting the [ ] button. Use [ ESC ] to go back to the previous menu. 3.4.3.3.1 Set Limits This changes the limits within the measuring range of the saturation level in % and the temperature. These settings are also stored in the battery backed up RAM. Use the [ ] buttons to choose the parameter that has to be changed. The chosen parameter will be highlighted with a * on the left side of the menu. By pushing the [ ] button you can select the digit position. Using the [ ] buttons you can set the new threshold digit by digit. Confirm with [ ]. Use [ ESC ] to go back to the previous menu.. 3.4.3.3.2 Set Time This function allows setting the real time clock that is integrated in the device. Due to the back-up battery, the clock will keep running even if the power supply is shut off. Day, month, year, hour and minute can be adjusted individually and they are being transmitted to the real time clock when the menu is being closed. 13
Select the parameter that has to be changed using the [ ] buttons. The selected parameter is marked with a * on the left side of the menu. By hitting the [ ] button, the position that has to be changed can be switched. The [ ] buttons set a new parameter. Use [ ESC ] to go back to the previous menu. 3.4.3.3.4 Temperature Format This changes the temperature format. Select the temperature format using the [ ] buttons and confirm with the [ ] button. Use [ ESC ] to go back to the previous menu. Since temperature thresholds for C and F are being stored individually, it might be necessary to adjust the thresholds after changing the temperature format. 3.4.3.3.4 Calibration As for all the other menus, every calibration value can be selected and changed individually. Since calibration values are of fundamental importance for measurements and should not be lost, they are saved in an EEPROM. Calibration values will even be saved if the back-up battery is dead. They do not have to be re-entered. 14
Use the [ ] buttons to select the calibration factor that has to be changed (Saturation or temperature). The selected parameter is being marked with a * on the left side of the menu. By pushing the [ ] button you can choose the position that has to be changed. Use the [ ] buttons to set the new correction factor digit by digit. Confirm with [ ]. Use [ ESC ] to go back to the previous menu. 3.5 Evaluating measurements 3.5.1 Displaying in % - saturation If no oil was selected, only the percentage of saturation (RH) of the oil is being displayed. - (0...70% Saturation) The presence of free water is unlikely. The water solved in the oil is not a threat! - (70...90% Saturation) The presence of free water in small amounts is probable. Measures to reduce the water content are suggested. - (90...100% Saturation) Water is present in its free form. It is a threat and a potential danger of the hydraulic or lubricating system. Measures to reduce the water content in the fluid are urgently necessary! 15
The calculation to mg/kg (ppm) water content is only possible with the specifically generated saturation characteristic. Saturation characteristics for specific oils are available upon request. 3.5.2 Displaying in ppm Water content If an oil is selected, the saturation level (RH: %), the oil temperature ( C or F) and the water content in ppm (Water: ppm) will be displayed automatically for that fluid. The connection to the ppm- (mg/ kg) values determined by the Karl Fischer method is being calculated using stored saturation characteristics in combination with temperature of the used fluid for the range of less than 99% saturation. The result is displayed. Caution: It is essential to choose the right type of oil. Otherwise the displayed water content in ppm will not be an accurate and precise number and it will not reflect the actual fluids condition. (See table under chapter 3.4.2.1.2. Oil selection) Saturation characteristics for specific oils are available upon request. Example of a saturation characteristic: Wassergehalt in ppm (mg/kg) 1200 1000 800 600 400 200 0-30 -10 10 30 50 70 90 Temperatur in C All data was determined in research by INTERNORMEN Technology GmbH! 16
3.6 Data transfer Data manager The modus Data transfer can transfer stored measurements from the WSTM 01 to an external PC via the RS232 interface. For this plug in the short adapter into the connector SV 1 of the WSTM 01 (the colour marking of the ribbon cable has to point to the housing) and connect the SUB-D cable to the other side of the adapter as shown on the photo. Do not plug in the adapter in the wrong direction to avoid harm to the WSTM 01 or your Computer. Also, install the Data manager software by copying it from the data volume to the computer. The data manager enables data transfer and external managing of measurements based on Microsoft Excel, version Excel 97 and up. For different languages and language settings of the computer, the following different versions of the program have to be used. Program version: 1. WSTM01_D.XLS German table displays 2. WSTM01_E.XLS English table displays The file INT_WSTM.DLL has to be stored in the corresponding windows-system folder. Example: c:\windows\system\ Data transfer procedure - Connect WSTM 01 to external PC using the RS232 interface - Select DATA MANAG. In the main menu and confirm. - Confirm TRANFER DATA 17
- Stored data is provided periodically to the RS232-interface of the WSTM01. This cycle can be cancelled using [ESC] after the data transfer is done. - Start data manager program on external PC - Activate Excel Macros - After starting the excel file, select the used COM in the transfer menu - Start data transfer using the load data button - Stored measurements are being received in the table Data-Import. This overwrites existing data. - For archival storage of data it is essential to copy the data from the Data-Import table to another table. - A new table can be created and named easily using the button make a new data table in the menu bar. - In addition to that, the following buttons and functions are available in the menu bar: delete the selected table graph: saturation graph: temperature selected table will be deleted. The table Data-Import can not be deleted. Graphic displaying of the saturation values of the selected table Graphic displaying of the temperature values of the selected table graph water contamination Graphic displaying of the water contamination of the selected table main menu Displaying the transfer menu For further processing of the data, all standard functions of Excel and VBA can be used. 18
4. Maintenance of the WSTM 01 Measuring system 4.1 Cleaning the sensor Cleaning the WSPS 03 sensor is necessary from time to time, especially if the sensor is being used for different fluids. As cleaning fluid, distilled water or even clean Isopropanol can be used. For cleaning, carefully remove protective cab. Put it back in place after cleaning. 5. Calibration 5.1 WSPS 03 Water sensor Upon delivery of the WSPS 03 Sensors is calibrated based on defined saline solutions. The calibrations validity is 12 months. After this time, the calibration has to be checked. If recalibration is necessary, send the sensor to the manufacturer. Checking the calibration can be performed either by using defined saline solutions (LiCl und NaCl) or by the manufacturer. The simplest form of checking the calibration is by measuring air humidity and comparing it to the measurement of a standard air humidity meter. 5.2 Integrated temperature sensor Upon delivery of the WSPS 03 Sensor the integrated temperature sensor is calibrated. This calibration is valid for 12 months. After this time, the calibration has to be checked. If recalibration is necessary, send the sensor to the manufacturer. Check the calibration of the temperature sensor at room temperature. As a comparison, use a standard thermometer. 19
6. Appendix 6.1 Technical Data WSPS 03 Sensor: Measuring range: Saturation level: 0 100 % Temperature: - 30...+ 70 C / - 22 F...158 F Accuracy: Saturation level: ± 2 % Temperature: ± 0,4 C / ± 31 F Operating pressure: 0...10 bar Flow rate: 2 m/s / 6,6 ft/s Ambient temperature: - 40...+ 110 C / - 40 F...230 F Temperature range of fluid: - 30...+ 70 C / - 22 F...158 F Power supply: 12...30 VDC Analogue outputs: 4...20 ma Max. ohmic resistance: 600 Ω Switch outputs: 2 x saturation level (max 2 / min 2) 2 x temperature (max 2 / min 2) Serial interface: RS 232 WSTM 01 Display unit: Display: 4 rows with 16 digits each Saturation level: 0 100 % Temperature range: -30...+ 70 C / - 22 F...158 F Saturation range: ppm Fluids: Mineral oil based hydraulic- and lubricating fluids (see separate list for compatibility) Controls: 4 Buttons Protection class: IP 65 Material: PFE Storage capacity: 100 measurements WSTM 01 Case: Dimensions: 160 x 185 x 110 mm x mm x mm 20
6.2 Pin assignment 6.2.1 WSPS 03 - Sensor Pin 1 Pin 2 Pin 3 + 12...30 V DC Output 4...20 ma (Saturation) + 12...30 V DC 1 4 2 5 4 1 4 5 2 Pin 4 Pin 5 Output 4...20 ma (Temperature) No 3 3 Cable color (Connection cable): 1: brown (+ 12...30 V DC ) 2: white (4...20 ma ) Saturation 3: blue (+ 12...30 V DC ) 4: black (4...20 ma ) Temperature WSPS 03 1 (3) 2 (4) ma + 12...30 V DC 0 V DC The maximum acceptable ohmic resistance at 24 V DC is 600 Ω Ausgangssignal in ma/ output signal in ma Sensor - Kennline/ sensor - characteristic 20 18 16 14 12 10 8 6 4 2 0 0 10 20 30 40 50 60 70 80 90 100 % Sättigung/ saturation Ausgangssignal in ma/ output signal in ma 20 18 16 14 12 10 8 6 4 2 0 Temperatur - Kennline/ temperature - characteristic -30-20 -10 0 10 20 30 40 50 60 70 C Temperatur/ C temperatrure 21
6.2.2 WSTM 01 Display unit RS-232 Interface and CAN Option: SV 2 (CAN Option) RESET SV 1 RS-232 Sensor connections: 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 1: Output 24 V 2: Input 4...20 ma, water sensor 3: Power output 4...20 ma, water sensor 4: Output 24 V 5: Input 4...20 ma, temperature sensor 6: Power output 4...20 ma, temperature sensor 7: GND 8: GND 9: Max. temperature (T1) K11 10: Min. temperature (T2) K21 11: Max. saturation (S1) K31 12: Min. saturation (S2) K41 13:... 14:... 15: GND 16:... 17: GND 18:... 19:... 20:... 21: Max. temperature (T1) K12 22: Min. temperature (T2) K22 23: Max. saturation (S1) K32 24: Min. saturation (S2) K42 22
Power supply 24 V DC: 24V 23
6.3 Application areas - Compatibility Applicable Hydraulic oils H, HL, HLP, and HV Gear oils C, CL, CLP Motor oils, Gas oils MIL-H-5606 E Vegetable oils (HTG, Triglyceride) Synthetic ester (HEES) 6.4 Maximum contact burdens 30 V AC / DC; 1 A 24
7. Trouble shooting No settings of the WSPS 03 are done by the operator. Malfunctions, which could be eliminated by oneself, are limited to cleaning the sensor and checking cables for brakes. Any other case requires sending in the WSPS 03 sensor or the display unit WSTM 01 to INTERNORMEN Technology GmbH in order to recover the functions. 25