Online Condition Monitoring
● Early indication of oil changes
● Load optimization
● Damage prevention in real time
● WearSens® works from day 1, prior to other technologies limits of detection
● Continuous evaluation of component wear, the degradation of the additives and tribological layers as well as the pollution and aging of the lubricating oil
Huge savings in:
● Money
● Downtime
● Man Hours
Identification of:
● Critical operation conditions
● Oil aging
● Additive consumption
● Deterioration in oil
● Oil contamination
Features:
● Robust communication unit (IP 68 standard)
● Detect change before wear damage
● Patented temperature compensation
● Continuous online monitoring 24/7 to CMS server
● Easy to retrofit into existing wind turbine systems
● Industrial standard interfaces (RS232, LAN, Profibus, ...)
Applications:
● Wind turbine gearboxes
● Contamination detection
● Roller bearing wear detection
● Oil deterioration monitoring
● Oil Condition monitoring solution
WearSens® is a unique, new system for online oil condition monitoring. Early indication of oil changes leads to optimum loading and/or timely preventative maintenance. The result, huge savings in money, downtime and man hours. Change in oil is one of the precursors of particle shearing and pitting in the bearing raceway. Early detection can warn of potential damage states, before damage occurs. WearSens® works from day 1, prior to other technologies limits of detection. Tests have shown that the WearSens® can detect deterioration in oil while standard laboratory analysis still reports oil as good.
Vibration and particle monitoring only detect after damage is done. Conductivity, permittivity and temperature are measured with high precision. Both conductivity and permittivity are temperature dependent, but the temperature compensation for any pollutants is unknown. WearSens® features a self-adapting temperature compensation algorithm similar to a neural network. Conductivity is measured in picosiemens per metre. This sensitive conductivity measurement indicates the formation of compounds from broken oil molecules, the presence of microparticles and the consumption of any additives.
The temperature compensated values allow comparison at any time. Relative permittivity is a measure of the dielectric constant. Permittivity decreases as additives are used up but will then increase once all additives are consumed. Taken in conjunction with the conductivity values, a clear picture emerges of the changes in the oil. The web based, decentralised monitoring system is perfect for remote or inaccessible locations. Measurements are transmitted via LAN, WLAN or the serial interface.
Conceived, developed and manufactured in Germany the WearSens® represents a completely new approach to oil condition monitoring in a variety of applications. For the first time, changes in oil can be detected accurately, online and continuously. The result, optimised loading, reduced wear and cost savings.
Specification
Ranges
Conductivity: 0.1 to 100,000 pS/m (optional, high range: 0.1 to 2.000.000 pS/m)
Relative permittivity: 1 to 5
Sensitivity
Conductivity: 0.1 pS/m
Relative permittivity: 1*10-6
Temperature and pressure
Max oil pressure: 60 barg at 20o C (870 psig at 68o F)
Oil temperature: -10o C to +70o C (optional, high temperature: -10° to + 150°C) (optional, low temperature: -40° to + 65°C)
Operating temperature: -20o C to +70o C
Material:
Sensor material:
Stainless steel (bowl and carrier) and aluminium (head)
Cable: 3 metre, shielded (optional, different cable length)
Connections:
¼” Swagelok® for 6mm o.d. tube (optional connectors available)
Communication Interface:
Serial communication via RS232/RS232-USB (opt.: LAN, GSM, Profibus, Modbus, CAN, 0..10V, 0/4..20mA)
Electrical requirements:
115/230 VAC, 50/60 Hz (optional, +24 VDC)
Weights and Dimensions
Dimensions (mm):
Sensor: 103 (height) x 70 (diameter)
Communication unit: 210 x 250 x 165
Communication module: 87 x 110 x 30
Weights net:
Sensor: 1.7 kg
Communication unit: 4.45 kg
Communication module: 0.25 kg
Part Number |
Description |
WearSens® WS3000 |
Consist of base sensor and communication unit with communication module, standard sensor cable length of 3 meter, serial communication via RS232 / RS232 to USB interface, 115/230 VAC, 50/60 Hz power supply |
Options |
|
-HC |
High Conductivity Range (0.1 to 2.000.000 pS/m) |
-HT |
High Temperature Range (-10°C to + 150°C) |
-LT |
Low Temperature Range (-40°C to +65°C) |
-LAN |
LAN Interface, enables data transfer via TCP/IP |
-GSM |
GSM Interface, enables mobile data transfer via 3G phone network (SIM card has to be provided by the customer, requires LAN interface) |
-PROFIBUS |
PROFIBUS Interface (replaces standard RS232 interface) |
-MODBUS |
MODBUS Interface (replaces standard RS232 interface) |
-CAN |
CANBUS Interface (replaces standard RS232 interface) |
-AO_XY |
Analog Output: 0..10V or 0/4..20mA (X = numbers of channels to be transmitted, Y = V for voltage output or A for current output) |
-1Z |
1 inch connector block (replaces the standard sensor connector block) |
-24VDC |
+24 Volt DC power supply connector (replaces the standard power supply using the more compact communication module for easy installation into existing electrical cabinets) |
Acessories |
|
-PC |
PLA Protection cap for the base sensor during transport |
Service & Spares |
|
WS-OR-NBR |
O-ring for base sensor, optimized for Diesel applications |
WS-OR-FKM |
O-ring for base sensor, standard applications |
WS-FCC |
Factory Calibration Certificate |