User handbook

Author: GM

Handbook
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Index
1 Change control .........................................................................................................................................3
2 Introduction ..............................................................................................................................................4
3 INTERFACES ..............................................................................................................................................5
3.1 Hydraulic connection ......................................................................................................................5
3.2 Electrical/comms connection .........................................................................................................5
4 GENERAL SPECIFICATIONS ........................................................................................................................7
5 Modbus communication ..........................................................................................................................8
5.1 Introduction ....................................................................................................................................8
5.2 Modbus address definition .............................................................................................................9
5.3 Operation registers .........................................................................................................................9
5.3.1 Command register ..........................................................................................................................9
5.4 Results data registers................................................................................................................... 10
5.5 Modbus integration ..................................................................................................................... 10
6 Troubleshooting .................................................................................................................................... 12
7 Maintenance.......................................................................................................................................... 13
8 Annex 2: Modbus RTU connection ........................................................................................................ 14
8.1 Required hardware and software ................................................................................................ 14
8.1.1 Hardware ..................................................................................................................................... 14
8.1.2 Software....................................................................................................................................... 14
8.2 Procedure .................................................................................................................................... 14
8.2.1 RS-485 configuration ................................................................................................................... 14
8.2.2 Modbus master configuration ..................................................................................................... 15

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1 Change control
Version FW version Comments
1 - Initial draft
1.2 513 Modification Modbus params
1.3 516 Pinout update, 120Ω, rebrand, added
maintenance

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2 Introduction
This handbook describes the key features of the OilHealthPROBE family, including all variants.
OilHealthProbe is an online monitoring system for fluid degradation status. The sensor, based on optical
principles, allows the state of lubricant degradation to be known at any time, even in systems without
recirculation or with reduced flow rates.
Atten2 OilMoisture (OM) is an online optic sensor that bases its operation on infrared vision to detect the
content of water in the lubricant. It allows reducing the risks associated with mechanical failures and
external contamination processes.
The OilHealth MAX PROBE sensor is an online monitoring system for fluid degradation status and water
content measurement, the latter using NIR technology. The sensor, based on optical principles, allows the
state of lubricant degradation to be known at any time, even in systems without recirculation or with
reduced flow rates.

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3 Interfaces

The system is provided with a bolt based on BSPT ½” male thread. This unit can be installed in pressurized
and non-pressurized systems. Additionally, the unit can be integrated into a dedicated manifold to connect
to a pipe with a 1/8” BSPP hydraulic bypass. So, the system has two distinct interfaces: a hydraulic one plus
an electrical/electronic one.

Figure 1. Hydraulic probe dimensions and manifold.

Regarding hydraulic connection, the following recommendations should be followed:

• Install the sensor head before attempting electrical/wiring connections.
• Do not attempt to screw or tighten the sensor using the body. Always use the “Hex” head with the
correct size spanner.
• Decide on an appropriate location for sensor head installation.
• The system to be fitted with the sensor will have the lubricant drained sufficiently for fitment. Install
the sensor head into the selected location/position, being careful not to overtighten.
• Sensor probe should be installed horizontally or partially vertically (30º max from the horizontal).
Additionally, please make sure that the sensor is installed close to the moving parts to enhance
turbulence and measurement cell flow renovation.

Figure 2. Installation position recommendation.

The power supply and the RS485 interface can be connected via an M8x6 connector, A-coded. The following
pinout should be followed.

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Pin Colour OH-W Item

1 Brown +24VDC
2 White GND
3 Blue R120A
4 Black R120B
5 Grey D+
6 Pink D-
Figure 3. OHPM pinout (connector-female side).

• Please note colour changes when using cables different from the ones provided by Atten2.
• Do not twist the cable relative to the sensor head. Keep away from sharp edges which may cut
into the cable.
• Do not bend the cable.
The sensor has a green LED light indicating that the power supply is established. It will flash continuously
after powering up the system.

The end-of-line resistor in RS485 networks is crucial for preventing signal reflections that can occur due to
impedance mismatches along the communication line. This resistor helps terminate the signal properly,
reducing noise and ensuring reliable data transmission. Atten2 OHPM includes an embedded 120Ω resistor
accessible from the pinout. Pins 3-4 can be shortcircuited to get a end-of-line resistor in parallel.

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4 General specifications
POWER SUPPLY 24 VDC
ENERGY CONSUMPTION < 10 mA
CONNECTIVITY Digital: Modbus RTU (RS485)
OIL PRESSURE 12 bar max.
OPERATING TEMPERATURE From 0°C to 80°C
VISCOSITY RANGE Up to 680 cSt
HYDRAULIC THREAD BSPT Conical 1/2”
Total width: 75mm. Length:
DIMENSIONS
78.4mm
Aluminium (optional: Steel)
CONSTRUCTION MATERIAL Viton sealing
BK7 optics
PROTECTION GRADE IP65
CERTIFICATION CE
Table 1: OHPM specifications.

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5 Modbus communication

Modbus is a communications protocol located at levels 1, 2 and 7 of the OSI Model, based on the
master/slave (RTU) or client/server (TCP/IP) architecture, designed in 1979 by Modicon for its range of
programmable logic controllers (PLCs). Having become a de facto industry standard communications
protocol, it is the most widely available for the connection of industrial electronic devices.
Modbus allows the control of a network of devices and communicates the results to a computer. Modbus is
also used for the connection of a supervisory computer with a remote unit (RTU) in supervisory systems data
acquisition (SCADA). There are versions of the Modbus protocol for serial port and Ethernet (Modbus/TCP).
Information from this section has been obtained from the Modbus organization reference documentation.
Each device in the Modbus network has a unique address. Any device can send Modbus commands,
although usually only one master device is allowed. Each Modbus command contains the address of the
device to which the command is sent. All devices receive the frame, but only the recipient executes it. Each
of the messages includes redundant information that ensures its integrity at reception. The basic Modbus
commands allow an RTU device to be controlled to modify the value of one of its registers or to request the
contents of those registers.
Modbus is based on an approach of coils, registers and functions. The Modbus data model distinguishes
between digital inputs (discrete input), digital outputs (coils), input registers, and holding registers. The
digital inputs and outputs occupy one bit, while the registers, both input and holding, occupy two bytes.
MODBUS uses a ‘big-Endian’ representation for addresses and data items. This means that when a numerical
quantity larger than a single byte is transmitted, the most significant byte is sent first.

Figure 4. Types of data registers in the Modbus protocol.

Each device defines its coils and registers in its physical memory where information is stored, and the master
sends or extracts this information. To extract the information, the master is required to send information
regarding the function and the value.

Figure 5. Modbus communication schema.

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The default RS485 parameters and Modbus slave ID are shown below.
Type Modbus RTU
Interface RS485-2W
Address COM Port
Port -
Baud rate 9600 (115200**)
Slave ID* 10
Data bits: 8
Modbus
Stop bits: 1
configuration
Parity: None
*configurable upon request
**First devices were released at 115200bps
Figure 6. RS485 - Modbus RTU parameters.

The holding registers, responsible for configuring and operating the systems are available in the following
table
Modbus
Type Data Name Description
register
2050 HOLDING uint16_t Command Command for the execution of system processes
2051 HOLDING uint16_t sensor_id Sensor ID (not configurable)
2052 HOLDING uint16_t mb_address Modbus ID (configurable)
Periodic Measurement rate (seconds)
2071 HOLDING uint16_t period_sec
[Limit values: 0s – 65535s]
Figure 7. Holding registers.

The command register accepts the following values:

Command Name Description
Periodic This command starts the periodic measurement process.
measurement Simple measurements are made with the rate indicated in
the period_sec register. The periodic measurement process
stops (disables) when you run the Simple Measure
0
command. If the periodic measurement process is active
when the power is turned off, when the device power is
turned back on, the periodic measurement process continues
to be active.
Simple
1 This command starts the measurement process for one time.
measurement

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Update settings This command writes the "Holding" registers to system

memory.
3
- Periodic measurement rate
- Modbus ID
Figure 8. Command register description.

In the next table the sensor results, based on input registers are shown.

Modbus
Type Data Name Description
register
1058-1059 INPUT float senstemp_value The internal temperature of the system (ºC)
a-channel value of the visible sensor measurement
1060 INPUT uint16_t a_value
[Limit values: 0 – 65535]
b-channel value of the visible sensor measurement
1061 INPUT uint16_t b_value
[Limit values: 0 – 65535]
c-channel value of the visible sensor measurement
1062 INPUT uint16_t c_ch_value
[Limit values: 0 – 65535]
nir-channel value of the NIR sensor measurement
1063 INPUT uint16_t nir_value
[Limit values: 0 – 65535]

1064-1065 INPUT float od_level OD result (%)

1066-1067 INPUT float water_level Water content result (ppm)

Periodic measurement enabled

1068 INPUT uint16_t periodic_msr- 0: No
- 1: Yes

1070-1071 INPUT float temp_value Oil temperature value (ºC)

Figure 9. OHPM Results Modbus map.

A successful Modbus integration in an acquisition system requires that several topics need to be considered:
• Register Addresses and Functions: Modbus data is obtained through a combination of
functions and registers. Some Modbus acquisition systems require the introduction of
both function and register in the same area. For example, reading a Modbus INPUT
register “1001”, requires introducing “41001”, which is the combination of function 4
“READ INPUT REGISTERS” plus the register 1001.

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Figure 10. Table of public functions in Modbus.

• Modbus offset: In the Modbus/RTU and Modbus/TCP protocols, the addresses are
encoded using 16 bits with a number between 0 and 65,535. These are 0-based
addresses. Therefore, the Modbus protocol address is equal to the Holding Register
Offset minus one. Some acquisition devices have the offset predefined, but others do not.
So, it is essential to check that the address is pointing to the correct register.
• Confusion about Little-Endian vs Big-Endian Word Order: Although Modbus.org standard
documents provide some guidance for implementing the Modbus protocol, they do not
address the question of word order beyond the register level. Modbus implementers
have to make an arbitrary choice as to which address of the register pair contains the
most significant word of 32-bit values such as IEEE-754 single-precision floats and signed
or unsigned 32-bit integers. Most programs for communicating with Modbus slaves can
be configured for either register word order, but the most common default word order
today is Little-Endian.
• Register sectioning: Some of the data contained in the sensor Modbus map encapsulates
two different data values in the same register, one in each byte. The acquisition system
should be able to section this data and interpret this data separately.
• Data type interpretation: Different programming languages offer different names for the
variable types available. Once collected, registers have to be interpreted correctly. The
following table defines the variables as proposed by the sensor interface, with expected
ranges.
Variable type Bytes Range Definition
INT 4 0-42949697295 Unsigned 32-bits integer

FLOAT 4 ±1,5 x 10-45 -±3,4 x 1038 Floating number

SHORT 2 0-65535 Unsigned 16-bits integer

SSHORT 2 -32767 - +32767 Signed 16-bits integer

CHAR 1 0-255 Unsigned 8-bits integer

Figure 11. Variables definition and range.

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6 Troubleshooting
Issue Solution

The sensor is not Please check the on-off switch. Please check the power supply, please check cable
powering up. integrity. Please ensure the voltage and current are correct.
Communication Please check cable pinout and integrity, please check RS485 hardware and
cannot be established. firmware, and please check RS485 parameters and Modbus address. Please check
that there is only one master acquiring. Please check the correct Modbus registers
are used.
Sensor output values Please check that the periodic measurement is enabled, and register INPUT 1068.
are not changing Please make sure the sensor is connected and powered up.
Please make sure there is flow renovation through the sensor.
Data is not consistent Please check the bubble content to ensure air entrainment. Bubble content should
be limited to a minimum to reduce influence.

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7 Maintenance
OilWear sensor has been designed and manufactured to operate autonomously during the equipment
lifetime of the machine. Nevertheless, it is strongly recommended to perform a cleaning procedure once a
year to enhance sensor response and durability. Please follow this procedure carefully.
1. Please ensure that the lubrication feeding system to the sensor is blocked or stopped. If
necessary, the circuit must be depressurized.
2. Remove the sensor power supply.
3. After that, proceed to disconnect the hydraulic hoses connected to the sensor. It should
be noted that this action may spill some of the hoses remaining oil. It is strongly
recommended to have a drain pan or any other means for containment and cleaning
procedures:
4. Plastic plugs hose ends.
5. Use absorbent cloths for containment and area cleaning.
6. Container for oil drain if necessary.
7. Then, a flushing system with petroleum ether is required. If no pump is available, this
procedure could be done with the help of a syringe, discharging in the sensor oil inlet,
and making sure the ether comes out from the outlet port. This operation should be
performed until the outgoing ether appearance is similar to the fresh ether. Please note
that the ether is a volatile product, and check the material safety data sheet before use.
8. After ether cleaning, a similar procedure with flowing air is required through the sensor
circuit. Please ensure that the compressed air supply line is filtered and moisture-free.
9. Finally, please connect the hoses back to the system and power the sensor again. Turn on
the lubrication system, and please make sure there are no leakages in the circuit. At this
point, please check that the sensor is delivering correct readings, according to the
installation procedure.

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8 Annex 2: Modbus RTU connection

The laptop is directly connected to the sensor via an RS-485 cable, following the image structure. An RS-485
to USB adaptor may be required. Please follow the cable pinout to successfully connect the device.

Figure 12. Modbus RTU Comms scheme.

Please note that the sensor must be turned on during this operation.

The laptop should be equipped with a standard Modbus master, such as Modbus Poll.

The first step is to configure the RS-485 port in the computer according to the sensor configuration. In the
case of Modbus Poll, these parameters can be configured in the main software.

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Figure 13. Example of RS-485 configuration in Modbus Poll.

If your device uses a baud rate of 9600, the response timeout should be above 5000 ms.

In Modbus Poll, acquisition windows can be set up with defined Modbus parameters.

Figure 14. Modbus Poll window configuration.

After configuring, relevant data and no errors should appear on the screen, according to the Modbus map
provided. Whether it's not, please contact Atten2.

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