holthausen elektronik ESW-Compact-Alu User manual

holthausen
elektronik GmbH
User Manual (Translation of the original instructions)
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
date: janvier 15, 2018
technical modification possible
holthausen elektronik GmbH is certified according to DIN EN ISO 9001:2015.
holthausen elektronik GmbH Phone: [phone] - 40 08 [email protected]
Wevelinghoven 38 Fax: [phone] - 89 99 4 www.holthausen-elektronik.de
41334 Nettetal

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
Table of Contents
1. Generally basical safety-indications......................page 4
2. Packing and the transport......................................page 4
3. Application..............................................................page 5
4. Measurement principle...........................................page 5
5. Grounding concept.................................................page
. Mounting of the vibration control unit.....................page 7
7. Opening and closing of the vibration control unit...page 8
8. Maintenance...........................................................page 8
9. Display- and operation- elements..........................page 9
10. Measurement range switching...............................page 10
11. Analog output.........................................................page 10
12. Analog output settings...........................................page 11
13. Adjustment of the limiting values...........................page 11
14. Example for adjustment of the limit value..............page 12
15. Self test & external reset........................................page 13
1 . Housing size...........................................................page 14
17. Cable connection draft...........................................page 14
Technical data........................................................appendix
2

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
Important information
These operation instructions are to be read through completely and carefully heeded
before starting the device. Failure to heed or adhere can result in claims on
manufacturer’s liability becoming null and void for damages ensuing there from.
Manual action of any manner on the device – with the exception of proper procedures
and those described in these operation instructions – lead to forfeit of guarantee and
exclusion from liability.
The device is solely intended for the usage as described below. It is particularly not
intended for the direct or indirect protection of persons.
holthausen elektronik GmbH assumes no liability whatsoever as regards suitability for
some specific purpose.
If any question should remain open, please never hesitate to contact us.
holthausen elektronik GmbH
Wevelinghoven 38, 41334 Nettetal
Phone: [phone] - 40 08, Fax: [phone] - 8 99 94
Mail: [email protected]
3

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
1. Generally basical safety-indications
Don’t use this device as the only invigilator, if a malfunctioning of ESW®-Compact-Alu
could lead to damages on goods or Persons.
To obtain the desired result be sure, that the device with its technical data fits to the
bulk of the object you want to supervise.
The sensor is sensitive to shock. A downfall out lower height to a hard substratum can
destroy the sensor.
The assembling place and the execution of the assembling of the sensor determine
decisively the quality of the sensor signal. The assembling may only happen through
qualified and instructed persons.
The electrical hook up is to be done by instructed persons. A mistake by the connection
can entail to faulty functions, outfall or ruination of the sensor and electronics.
The ESW®-Compact-Alu should not be used on machines with a very energetic high-
frequency solid-borne. Through resonance apparitions in the sensor, the device can
indicate a much too great or too small value.
Powerful noise sources for instance inverters, in direct closeness of the sensor,
electronics or cabling, can result in faulty behaving of the apparatus.
Potential differences and balance currents in the mass guidance can result in faulty
behaving too.
The connection cable is resistant against many but not every type of chemicals.
Through a damaged cable chemicals could get inside the unit and destroy the
electronic. Then the unit would loose their function.
Therefore the conditions from the mounting surrounding must be checked. Then the
cover material from the cable have to be proofed if it resists these requirements. You
can get an overview from the chemical resistance of the cover material from us.
2. acking and the transport
Note:
The sensor is sensitive to shock. A downfall out lower height to an hard
substratum can destroy the sensor.
Avoid to kink or tie a knot in the cable.
Keep the electronic in a dry place.
In case of a downfall or heckling or squeezing, could the casing or the
operation elements or the board get defects.
With adequate warning-labels and through a qualified packaging and storage, you can
protect the sensor and electronics at carriage against influences from outside.
4

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
3. Application
The ESW®-Compact-Alu unit will be installed on machines like ventilators, blasts,
separators or decanters in order to protect these machines in the application against
inadmissible mechanical vibration. The unit monitor continuously the intensity of
vibration and warn reliably during exceeding of, inside the unit, adjusted limit values.
4. Measurement principle
The mechanical vibrations are measured with a piezoelectric acceleration transducer.
The electronic circuit transforms the acceleration signal into a velocity signal (mm/s),
which is evaluated. The measured range is adjusted by DIP-switches inside the unit.
The measured value is compared with two adjustable limiting values G1 and G2, which
could be adjusted in range of 10% - 100% with two potentiometers inside the unit. At
the analog output the limit values of G1 and G2 can be adjusted when setting of the
DIP-switches corresponds to the prove position. If the measured values G2 exceed the
critical limit, alarm relay K2 will be activated after e.g. 5 seconds delay time. If limit
value G1 is exceeded for more than e.g. 10 seconds, alarm relay K1 will be activated. If
measured value falls below the limit value, alarm will be cancelled *).
At the analog output is the measurement value proportional to the fitted measurement
range available, by voting 0 to 20mA or 4 to 20mA.
The unit includes a self-test feature with them all electronic components inside the unit
could be tested. Father more exist also the possibility, for testing purpose to supply one
test signal in to the measurement electronic.
*) The unit consist alarm memory. After the activation of the alarm relay K2 the unit will
remain in the alarm status until an external and manually reset will be activated. This
feature is used in such cases, where the vibration control unit is mounted on
unreviewable and difficult accessible places. Through this advanced memory function
is every alarm registered. Because of variable mounting of one or more parallel
connected reset buttons, it is possible to reset the alarm memory from any place or
location.
The reset occurs by connection of the external rest contact (green wire) to ground.
5

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
5. Grounding concept
If an isolated installation is not specially requested, usually through the attachment with
screws each case is connected to the local machine ground.
Inside the ESW®-Compact-Alu unit, dependent on customer request the cable shield
and / or the signal ground to the case potential could be connected by the factory.
 Connection to the local ground
The Standard delivery condition for ESW®-Compact-Alu is that, shielding of the
connection cable is not connected to the case of the unit.
 Connection is not implemented to the local ground
Inside the optional plug box, the cable shielding, the box ground and the signal ground
could be connected by choice and dependent on local circumstances and
requirements.
In big facilities with considerable energy consumption and distances between the
machines could such big potential difference be build up, that substantial balancing
current on the ground network will occur. Dependent on intensity of such currents is
arising of interference’s or damaging of the unit the result!
Potential differences could also arise on machines, with small distances not clear
crossing of ground potential for example painted color or movable parts like suspension
mounting.
Energetic high frequency interference energy could be added to the measurement
signal-wire by inductivity or trough capacity that could change the real existing
measurement value! In this way, for example parallel going elements could act as
coupling-capacitor and winded up grounding cable could act like a cut off choke.
Memorize: Ground is not equal everywhere!
Check the situation lan the grounding concept Select the facility / realization
local
connection box ground
optional
connection box
vibration control unit ground
local
vibration control unit ground
signal ground
vibration
control unit shield
-Ub
connection box ground
signal ground
main control
box ground
local
main control box ground
shield
main control box
with power supply
+Ub

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
6. Mounting of the vibration control unit
Attention: - Whole mounting-, connecting- and adjustment-work
should be done only from qualified personal!
- It´s strongly prohibited to open the bottom part (black anodized)
of the ESW®-Compact-Alu unit
- rotect the ESW®-Compact-Alu definitely against drop, stroke
and other mechanical shock !
The ESW®-Compact-Alu unit is fastened with means of a screw set AM10 * 25
correspond to DIN 913 to the monitored machine.
Important
1. Measuring axis has to be coinciding with vibration excitation axis (see case drawing
page 14).
2. Take note of the label with instruction notes.
3. The surface has to be plain, clean and free of paint and rust.
4. The tap hole has to be perpendicular to the surface and free of metal-cuttings or
other foreign material. Further more the tap hole and the screw have to be free of
paint, rust, grease or other isolating components.
5. The grub screw has to be locked with liquid thread protection against unintended
loosening.
. The unit has to be fixed, tight on the surface.
7. The user has to fasten the connection cable near the cable insertion in a radius of
app. 20cm. This attachment has to be done so that the cable is not dejected and
damaged.
8. Please follow absolutely the advices for opening and closing the unit.
7

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
7. Opening and closing of the vibration control unit
Before opening the vibration control unit, switch the power supply off.
After adjustment of the unit, please control the position of the DIP-switches.
Before closing the unit the O-Ring must be examine. You have to insert a new O-Ring
( 3 x 1,5mm, NBR 70 – original spare part) if the old one is brittle, deformed, damaged
or already a few month in use.
Please pay attention that thread and the interior room is oil and dirty free. Cleaning
around and inside of the unit should only be done with clean and dry clothe.
8. Maintenance
The ESW®-Compact-Alu unit is maintenance free!
A fixed soldered SMD fuse F1, type OMF 3V/1A, is used. We recommend that only
qualified staff should replace the fuse.
8

holthausen
elektronik GmbH
E S W -C o m p a ct
S
off
on
S2S1 S3 S5S4
S N :
LD2 LD1
R
2
1
S7S8
LD3
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
9. Operating and setting instructions
The display and operating elements will be accessible after unscrewing the cover of the
ESW® Compact unit.
Display elements
LD2 yellow LED Self test “active“
LD1 green LED Operating voltage “on “
LD3 red LED Limit value G1 exceeded for
more than the rise time,
K1 has switched
Operating elements
P1 Potentiometer for setting limiting value G1 10 to 100%
P2 Potentiometer for setting limiting value G2 10 to 100%
S1 Range 0 to 10mm/s ON/OFF
S2 Range 0 to 20mm/s ON/OFF
S3 Range 0 to 50mm/s ON/OFF
S4 Analog output 0 to 20mA ON
4 to 20mA OFF
S5 Analog output corresponds to measured value ON/OFF
S Analog output corresponds to limiting value G1 ON/OFF
S7 Analog output corresponds to limiting value G2 ON/OFF
S8 Self test activated ON/OFF
9

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
Setting instructions
After applying the voltage supply
the green LED LD1 must light up. The
yellow and the red LED should remain
dark. The relays are switching in there
normal position.
10. Measurement range switching
The unit has three measurement ranges, which can be selected by the switches S1, S2
and S3. For a proper operation of the unit, only one switch has to be in position “ON”,
the both other switches should remain in position “OFF“.
Range Switch Position
S1 S2 S3
10mm/s ON OFF OFF
20mm/s OFF ON OFF
50mm/s OFF OFF ON
11. Analog output
As the output value will be submitted constant current, by voting 0 to 20mA or
4 to 20mA. The selection occurs by switching over of switch S4.
An output current of 20mA meets the 100%-value of the selected measurement range.
In the setting of 0 to 20mA is the valid relation 0,2mA per %, in the setting of 4 to 20mA
is the valid relation 4mA + (0,1 mA pro %).
Output range Switch position
S4
0 to 20mA ON
4 to 20mA OFF
10
E S W -C o m p a c t
S
off
on
S2S1 S3 S5S4
S N :
LD2 LD1
R
2
1
S7S8
LD3

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
12. Analog output settings
The 0 to 20mA output can be used for displaying of several values on the analog
output. With the standard setting the output current corresponds to the measured
signal.
For example, an analog current value of 20mA corresponds to a measured vibration
velocity that has reached 100% of the measuring range set.
Important By switching over the Dipswitches, the analog output can be used for
setting or reading of the limit values G1 and G2.
The limit value adjustment means a current of 20mA, so that the switch level close to
100% of the adjusted measurement range.
Output Variable Switch Position
S5 S6 S7
Vibration velocity ON OFF OFF
Limiting value G1 OFF ON OFF
Limiting value G2 OFF OFF ON
13. Adjustment of the limiting values
If the measuring signal exceeds certain limiting values, the ESW®-Compact-Alu shall
react by switching potential-free relay contacts. These limit values can be set inside the
unit by potentiometers. The limit values can be set between 10% and 100% of the
selected measuring range.
The limit value G1 will be adjusted with potentiometer P1. Exceeded the value of G1 for
longer as 10s, then K1 is switched. The limit value G2 will be adjusted with
potentiometer P2. If limit of G2 will be longer than 5s exceeded, then K2 is switched.
Rest the measured value just from time to time over the limit value, so counts the
activation delay time after each overstepping of the limit value once more.
When the analog output of the limiting value setting is switched over, the output current
related to 20mA will correspond to the setting of the limiting value related to 100% of
the measuring range. If, e.g. G1 has to be set to 15mm/s = 30% in the measuring
range of 50mm/s, the output range will be first set to 0 to 20mA via S4 and the output
variable to limit value G1 via S5=OFF, S =ON and S7=OFF. After that, a current
output of mA (= 30% of 20mA) has to be adjusted by potentiometer P1.
A current of 8.8mA (= 4mA + 30% of 1 mA) should be set in the output range 4 to
20mA. The difference between 4 and 20 is 1  30% of 1 mA + 4mA = 8.8mA
After setting the limiting values, please pay attention that S5 will be brought to position
“ON“ and S , S7 to position “OFF“ to activate the function of the analog output as a
measuring output.
11
E S W -C o m p a c t
SS1
off
on
S2S3 S5S4
S N :
R
LD2 LD1
1
S7S8 2
LD3

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
14. Example to adjust the limit value
Example 1: Analog output 0 to 20mA (mean 0.2mA per %)
Adjust the limit value G1 to 22.5%, and the limit value G2 to 35%:
Measured range 20mm/s S1 OFF
S2 ON
S3 OFF
Analog output 0 to 20mA S4 ON
Balancing of the limit value G1 to 22.5% S5 OFF
S ON
S7 OFF
Set the output current to 4,5mA via P1 (22.5% of 20mA is 4.5mA)
Balancing of the limit value G2 to 35% S5 OFF
S OFF
S7 ON
Set the output current to 7mA via P2 (35% of 20mA is 7mA)
Measuring variable “vibration velocity“ S5 ON
S OFF
S7 OFF
Self test off S8 OFF
Example 2: Analog output 4 to 20mA (mean 0.16mA per %)
Adjust the limit value G1 to 45%, and the limit value G2 to 0%:
Measured range 20mm/s S1 OFF
S2 ON
S3 OFF
Analog output 4 to 20mA S4 OFF
Balancing of the limit value G1 to 45% S5 OFF
S ON
S7 OFF
Set the output current to 11.2mA via P1 (45% of 1 mA is 7.2mA + 4mA)
Balancing of the limit value G2 to 0% S5 OFF
S OFF
S7 ON
Set the output current to 13. mA via P2 ( 0% of 1 mA is 9. mA + 4mA)
Measuring variable “vibration velocity“ S5 ON
S OFF
S7 OFF
Self test off S8 OFF
12

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
15. Self test
A self-test circuit in the unit is integrated to check the ESW®-Compact-Alu for correct
operation. The self-test function could be activated by switches inside the unit and is
optically displayed by a yellow LED. After expiration of fixed delay time has K1 and K2
to be switched, and the red LED “Alarm“ must light up. The analog output must give out
a current of over 22mA. During the self-test function is the whole electronic
incorporated, so that it’s possible to obtain a definite information about the function of
the unit.
Function Switch position
S8
Self test on ON
Self test off OFF
Upon execution of the self-test function, it’s absolutely necessary to return the switch S8
to the position OFF in order to ensure the proper function of the ESW®-Compact-Alu.
The yellow LED must darken and current has to return to his normal value.
In case the yellow LED is lighting and a higher output current is flowing, without of
activation of S8, than the electronic recognize one sensor defect and starts alarm,
because the electronic is continuously monitoring the sensor.
External reset
The external reset connection (green cable) of the main alarm (relay K2), could be
connected trough a switcher or permanent with 0V potential of the power supply 24V.
If the green wire is permanently with 0V (ground) connected, an automatically reset of
the main alarm memory occurs as sun as the signal level after an alarm fall below of
the adjusted alarm level.
13
E S W -C o m p a c t
SS1
off
on
S2S3 S5S4
S N :
R
LD2 LD1
1
S7 S8
2
LD3

holthausen
elektronik GmbH
Electronic Vibration Monitoring Unit
ESW®-Compact-Alu (hol 10)
16. Housing size (mm)
17. Cable connection draft
ESW®-Compact-Alu
14
Regulary here ends the cable shield in the housing and is isolated to the case.
The outlined contacts of the alarm-relays are in position: without supply voltage.
Under normal working conditions are the closer- and middle-contacts connected.
opener contact K2
external Reset
ground
middle contact K1
middle contact K2
closer contact K2
opener contact K1
closer contact K1
analog output
+24V supply volt
: external reset (active by
connection to ground)
green
: shield, see page ´Grounding Concept´pink
: middle contact K1
: closer contact K1
: middle contact K2
: closer contact K2
: opener contact K1
: opener contact K2
: analog output
: +24V supply voltage
brown
violet
yellow
grey
blue
: ground
orange
black
white
red