ZILA LUB-VDT Inline Condition Monitoring Sensor Instruction Manual

Mounting and operating instructions
FluidIX LUB-VDT
Inline Condition Monitoring Sensor ZILA GmbH
Hollandsmühle 1
98544 Zella-Mehlis
Deutschland
Web: www.zila.de
E-Mail: info@zila.de
Telefon: +49 (0) 3681 867300

General information

• Read the safety instructions and keep the manual
• Installation, commissioning, electrical connection and repairs may only be carried out by qualified personnel
• The specified degree of protection is only guaranteed if the unit is installed in the correct position and the cables are inserted and screwed in properly
• Operate the unit only at the specified voltage
• Modification and conversion of the device is not permitted and releases ZILA GmbH from any warranty and liability
  Read these assembly instructions carefully before using the unit. Follow the instructions. Keep these assembly instructions in a safe place for future use.

1.1. Safety instructions
Safe operation is only provided if the instructions and warnings in these operating instructions are observed.

• Assembly and electrical connection only permitted by qualified personnel.
• Read these operating instructions carefully before commissioning.
• Only operate the unit with the voltage and frequency specified on the label.
• Do not make any changes to the unit.

ATTENTION
Seals and Labels:
Opening or removing seals or labels, e.g. with serial numbers or similar, will result in the immediate loss of warranty claims.

1.2. Intended use
The manufacturer is not liable for damage resulting from improper use or use not in accordance with the intended purpose.
Before operating the unit, please compare the supply voltage with the specifications on the label.
If it becomes obvious that safe operation is no longer possible (e.g. in the case of visible damage), please take the unit out of operation immediately and secure it against unintentional operation.
In case of improper use or use not in accordance with the intended purpose, dangers may arise from the unit, which is why we refer to consistent observance of the safety instructions.

1.3. Assembly, commissioning & installation personnel
Assembly, electrical installation, commissioning and maintenance of the unit may only be carried out by trained specialist personnel who have been authorised to do so by the system operator. The qualified personnel must have read and  understood these operating instructions and follow their statements.
The unit may only be operated by persons who have been authorised and instructed by the system operator.
The instructions in this operating manual must be followed.
Ensure that the unit is correctly connected according to the electrical connections.

1.4. Repairs
Repairs can only be carried out by trained customer service personnel.
In this case, please contact ZILA GmbH.

1.5. Technical progress
The manufacturer reserves the right to adapt technical data to technical development progress without special notice. For information on the activities and possible extensions of these operating instructions, please contact ZILA GmbH.

Product description

The FluidIX LUB-VDT is a compact sensor for monitoring mechanical fluid characteristics such as viscosity and mass density based on a low-frequency resonance sensor element. The excellent performance of the LUBVDT is achieved by  combining a patented resonator evaluation technology with a robust and reliable quartz crystal tuning fork resonator. The sensor offers high sensitivity and long-term stability, making it particularly suitable for oil condition monitoring in  predictive maintenance programmes. Due to the high measuring rate, excellent data quality can be achieved even under unstable environmental conditions (pressure, temperature, flow). The FluidIX LUB-VDT offers digital and  configurable analogue interfaces for easy and costeffective integration into existing environments.

2.1. Technical data
2.1.1. General specifications

outputs)
Supply voltage| 9…35 V (24V)
Screw connection| G 3/8“
Tightening torque| 31…39 Nm
Elec. Connection| M12-8 A-Coding
Partikelgröße| 250 µm
Oil pressure| 50 bar
Ambient temperature| -40…105 °C
Medientemperatur| -40…125 °C
Analogue outputs| 2x 4…20mA
±1 %FS
Digital output| ModbusRTU
CE conformity| EN 61000-6-1/2/3/4

The unit is suitable for use with the following liquids:

• mineral oils
• Synthetic oils
• Other permissible liquids on request

2.1.2. Measurement specifications
Specifications at 24°C ambient temperature in reference fluid. Cannon Instruments N140 viscosity standard at 40°C unless otherwise stated..

Measuring accuracy according to ISO 5725-1 for Newtonian fluids:

Viscosity
ν ≤ 200cSt
ν >200cSt| ±0.1cSt
± 1
± 5%
---|---
Density|
Temperature| ±0.1 °C

2.2. Mounting instructions

The sensing element of the LUB-VDT is a quartz crystal tuning fork resonator. To protect this resonator from mechanical shocks, the LUB-VDT has a permanent protective cap. Liquid can enter this cap through an opening at the tip and exit through openings at the sides. It is recommended to mount the sensor in a Tpiece (inlet opposite the sensor and outlet on the side) or similar arrangement. For sealing, we recommend a bonded sealing washer; the required torque for these washers is usually in the range of 31-39Nm

The sensor element of the LUB-VDT is practically insensitive to installation position, flow direction or pressure. Despite this, we recommend paying attention to a few details for optimum performance:
Note: Air bubbles change the mechanical properties of a liquid and thus influence the measurement. Ensure that no air bubbles can be trapped at the sensor and potential bubbles are carried away from the sensor by flow or uplift. Avoid
feeding oil with air pockets to the sensor and note that dissolved gases in the oil can form bubbles when the pressure is reduced.
Note: If the sensor is placed in a reservoir or sump, the flow rate may be very low. This can lead to an extremely slow response of the sensor as well as measurement affecting residues or even clogging of the sensor.
Note: Although the sensing element itself is virtually insensitive to pressure, the viscosity of the oil is a function of pressure. The effects of pressure variations on measurements are generally more noticeable at higher pressures.
Note: Consider the heat transfer from the liquid to the sensor housing when working at high liquid temperature.

If cleaning of the sensor is necessary, use suitable solvents (e.g. benzine or alcohol).

ATTENTION
Do not use compressed air, as this can permanently damage the resonator due to the high flow velocity.

ATTENTION
Do not puncture the protective cap with any objects (e.g. needles or wires).

2.3. Pin assignment
Power supply and signals share an M12-8 connector with A-coding according to DIN EN 61076-2-101. Install only with shielded cables.
The internal 120Ω resistor for RS485 bus termination is activated by connecting pin 3 to the RS485 A line (pin 4). To deactivate the termination, either connect pin 3 to the RS485 B line (pin 5) or leave it unconnected.
Any connection should be made as close as possible to the sensor.

Data filter

The raw data rate of the sensor is approximately one measurement per second. To provide reliable, low-noise results in applications with lower data rate requirements, the FluidIX LUB-VDT provides a moving average filter for all measured parameters. The length of the filter is configurable via a Modbus register from 1 to 256 seconds, with the default set to 60s. Incorrect measurements (such as out-of-range) are also stored in the filter, but discarded when  averaging. Therefore, the output of the filter provides valid results as long as valid data is present in the filter.

Modbus Interface

Modbus RTU via RS-485 can be used to retrieve measurement results and status information as well as to configure filter settings, analogue outputs and the Modbus interface itself. All data is organised in 16-bit registers with signed or  unsigned integer values. If necessary, two registers are combined (MSB first) to represent a 32-bit integer.
The supported Modbus functions are:

• 3: read holding registers
• 6: write single holding register
• 16: write multiple holding registers

4.1. Default Configuration
The default configuration is 19200 baud and device address 1. A timeout value of at least 2s should be used when communicating with the device. Please note that all changes to the configuration (with the exception of the Modbus interface) are accepted immediately, but are not permanently saved until a 1 (0x0001) is written to the command register. In the event of a misconfiguration, the sensor can be reset to the factory settings using the following procedure:

• Make sure that the sensor is properly supplied with power.
• Connect pin 2 to the supply voltage (nominal +24VDC, pin 7) for at least 10 seconds.
• Disconnect the sensor from the power supply.
• Connect pin 2 to ground and switch the sensor on again.
• After the restart, the configuration (especially the baud rate and the unit address) is reset to the factory settings.

4.2. Register Map

General
Purpose| This is an unused register that can be used freely. The content of this register can be changed when it is reset.
---|---
HW Revision
ID| Hardware version of the sensor
Serial
Number| Serial number of the sensor
Firmware
Date| UNIX timestamp for the sensor firmware
Error Count| Counter for measurement error incl. outof-range: Value is zero at switch-on
Measuremen
t Results| Each measurement is assigned a sequential number that is reset to 0 at power-up and  can be read from the Modbus registers. The measurement results are scaled and  encoded in signed / unsigned 16-bit integers.
Invalid results are indicated by a value of 0xFFFF.
Status Code| This register is used to report measurement and error/warning conditions. Each bit  that is set to 1 indicates a specific condition
LOCK
Register| Registers of the Config Data Block are prevented from accidental write access by the  LOCK register. To enable write mode for the Config Data Block (including the  Command register) write 44252 (0xACDC) to the LOCK register. After the configuration is finished set the LOCK register 0 to prevent accidental damage to the  configuration.
Command
Register| To permanently save changes write 1 (0x0001) to the Command register.
Please note that this operation may take about 1 s. When writing 255 (0x00FF) to the  Command register the device is restarted.
Baud Rate| Baud rate of the Modbus interface.
Accepted values are 9600, 19200, and 115200 baud. Default value:
19200 baud. Changes are activated after a restart.
Address| Device address of the sensor. Default value: 1. Changes are activated after a restart.
Filter Length| Length of the moving average data filter in the range of 1 to 256. Default value: 60.
OUTx_select| Selection of parameter that is mapped to analog output x, where x is 1 or 2.
OUTx_min| Value that is mapped to 4mA output current. This value must be scaled and encoded  in the same way as the selected measurement parameter (see section 5.2). If the  measurement result is lower than this limit, the output remains at 4mA as long as the result is valid (saturation).
OUTx_max| Value that is mapped to 20mA output current. This value must be scaled and encoded in the same way as the selected measurement parameter (see section 5.2). If the measurement result is higher than this limit, the output remains at 20mA as  long as the result is valid (saturation).

Note: By default, analogue output 1 is configured for temperature (-40 .. 125◦C) and analogue output 2 for viscosity (0 .. 400cSt). An invalid measurement result is represented by an output current of 1mA.

4.3. Overview Status Codes

outside measuring range, sensor damaged or dirty
1| Out of range| At least one parameter is out of range
2| Frequency Controller error| Viscosity or density out of range
3| Noise error| Electromagnetic interference; Very high flow velocity.
4| Invalid

configuration

| Missing or incorrect configuration
5| Resonator error| Resonator damaged
6| Temperature sensor error| Temperature sensor damaged
7| Hardware error| Sensor electronics damaged
8-15| reserved

4.4. Modbus Register

Mounting and operating instructions Version: EN_230424_ANHU_LUB3| 8

Documents / Resources

| ZILA LUB-VDT Inline Condition Monitoring Sensor [pdf] Instruction Manual
LUB-VDT, LUB-VDT Inline Condition Monitoring Sensor, Inline Condition Monitoring Sensor, Condition Monitoring Sensor, Monitoring Sensor, Sensor
---|---

References

• Kompetenz in Druck, Klima, Leckage und Lüftung
• Kompetenz in Druck, Klima, Leckage und Lüftung

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