Schaeffler DuraSense User manual

Schaeffler DuraSense
User manual

Foreword
Schaeffler DuraSense is a sensor-based system for analysing
and monitoring the lubrication status of Schaeffler monorail guid-
ance systems. It records the current running behaviour of the
carriage, evaluates and visualises the data, and enables automated
lubrication.
With two operating modes, Schaeffler DuraSense can be used to
provide lubrication in accordance with requirements and to monitor
an existing central lubrication system. The system enables lubricant
savings and the avoidance of unplanned machine downtimes.
The increased productivity creates a decisive competitive advantage
for the user of Schaeffler DuraSense. Schaeffler DuraSense
represents a key step in manufacturing toward Industry 4.0.

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Page
Contents
About the user manual Symbols .................................................................................... 4
Legal guidelines ........................................................................ 4
General safety guidelines Usage for the intended purpose ................................................. 4
Usage not for the intended purpose ........................................... 4
Selection and qualification of operating and
commissioning personnel.......................................................... 5
Electromagnetic compatibility.................................................... 5
Safety regulations ..................................................................... 6
Scope of delivery ................................................................................................. 8
Description Function .................................................................................... 8
Operating modes....................................................................... 10
Output signals........................................................................... 12
Reference run ............................................................................ 12
Measurement runs..................................................................... 13
Storage ................................................................................................. 13
Mounting Plug and cable........................................................................... 14
Fitting the pre-processing unit (PPU) .......................................... 14
Preparing to fit the sensor using a retrofit adapter (optional) ...... 15
Fitting the sensor....................................................................... 16
Setup software
Service Setup Tool (SST)
Download.................................................................................. 17
Start screen............................................................................... 17
General settings ........................................................................ 18
Commissioning Preparation ............................................................................... 19
Connecting setup software SST to the PPU ................................. 19
Configuration ............................................................................ 21
Reference run ............................................................................ 24
Threshold values ....................................................................... 26

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Page
Operation Measurement runs.................................................................... 28
Lubrication parameter............................................................... 29
Operating temperature.............................................................. 29
LEDs on PPU ............................................................................. 30
Lubricants ................................................................................ 30
Permissible indirect process materials ...................................... 30
Troubleshooting and
rectification
................................................................................................ 31
Dismounting ................................................................................................ 33
Decommissioning ................................................................................................ 33
Disposal ................................................................................................ 33
Technical data and
accessories
Voltage supply.......................................................................... 34
Connection to the controller (PLC) ............................................. 35
Connection to sensors .............................................................. 36
Ethernet connection.................................................................. 37
Fieldbus connections (Profinet IRT) ........................................... 38
Technical data Schaeffler DuraSense......................................... 39
Appendix EU Declaration of Conformity

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About the user manual This user manual describes the Schaeffler DuraSense system.
The current version of the associated setup software Service Setup
Tool (SST) is: 03.11.01339.
Symbols The warning and hazard symbols are defined in accordance with
ANSI Z535.6-2011.
NOTICE
In case of non-compliance, damage or malfunctions in the product
or the adjacent construction may occur.

Note There follows additional or more detailed information that must be
observed.
Legal guidelines The information in this manual reflects the status as of
November 2021.
Unauthorised modifications to or improper use of the device are not
permitted. Schaeffler accepts no liability in these cases.
General safety guidelines
Usage
for the intended purpose
Schaeffler DuraSense may only be used to analyse and monitor
Schaeffler monorail guidance systems.
Schaeffler DuraSense may only be used in an industrial
environment.
Usage not
for the intended purpose
Schaeffler DuraSense may not be used in environments with
an explosion risk.
Usage not for the intended purpose can result in personal injury,
damage to the monorail guidance system and damage to adjacent
systems.

Schaeffler Technologies BA 60 5
Selection and qualification
of operating and
commissioning personnel
Schaeffler DuraSense may only be fitted and commissioned by
qualified personnel.
Qualified personnel:
■ are authorised to fit Schaeffler DuraSense by the machine
manufacturer or operator
■ have all the necessary knowledge
■ are familiar with the safety guidelines
■ have read and understood this manual
Work on electrical devices Work on electrical devices and components may only be carried out
by a trained electrician.
On the basis of their technical training, knowledge and experience
as well as their knowledge of the appropriate regulations, trained
electricians are in a position to assess the work assigned to them
and recognise possible hazards.
Electromagnetic compatibility Schaeffler DuraSense is designed to comply with the provisions
on electromagnetic compatibility in accordance with EU Directive
2014/30/EU.
In order not to jeopardise compliance with the provisions on elec-
tromagnetic compatibility (EMC), no unauthorised modifications
may be made to the pre-processing unit (PPU), the cables (including
shielding) and the sensors.
If you have any questions, please contact Schaeffler.

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Safety regulations This section contains important safety regulations relating to work-
ing with Schaeffler DuraSense. Further guidelines can be found in
the individual chapters of this user manual.
Read this document before commissioning the device. Make sure
that the product is suitable without restrictions for the envisaged
use.
The device may only be installed by a trained electrician.
The installation must be carried out in accordance with the national
and international regulations covering the installation of electrical
equipment.
Before fitting the device, check for any external damage.
If damage or some other defect is found, the device must not be
commissioned.
Any interference in or modifications to the device, or the addition
or removal of inappropriate components is impermissible,
can endanger occupational safety and may render any warranty
claim null and void.
Any work on wiring, opening or closing of electrical connections may
only be performed with the device in a voltage-free state.
The use of Schaeffler DuraSense is only admissible within the
boundaries of the conditions stated and illustrated in the user
manual.
Schaeffler DuraSense may only be operated within the limits
described in the technical data. If Schaeffler DuraSense is operated
outside these limits, the device may be destroyed.
Do not carry out repairs on a damaged Schaeffler DuraSense device.
Arrange to have any necessary repairs carried out by Schaeffler.
Only use Schaeffler DuraSense with the lubricants approved for this
product, see page 29.
Only dismount Schaeffler DuraSense when it is in a voltage-free
state.
Never bend the sensor cable and the connection cables of the PPU.
The bending radius of the sensor cable must not fall below the
specified minimum value, see page 36.
The sensor head must not be subjected to external forces.
Any contact with surrounding components is not permitted.
For fixing, use the threaded stud on the sensor only.

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Safe handling
of information interfaces
This product has the following information interfaces:
■ Fieldbus (Profinet IRT)
■ Ethernet
The product can be connected with other devices, components or
internal or external networks (e.g. internet) via each of these
interfaces. Devices (like data carriers) connected via information
interfaces may contain malware or execute malicious functions
undetected. This product, or your company infrastructure (e.g. IT
infrastructure) can be damaged due to the use of these kinds of
information interfaces. In addition, your company’s data security
may be compromised.
Before using our product and its information interfaces, please
familiarise yourself with the following:
■ the security features offered by the product and its information
interfaces
■ the security provisions of your company (e.g. on IT security)
Before commissioning, clarify with your responsible contact person
whether and which safety precautions must be taken when using
the product and its information interfaces.
Maintenance and repair work Maintenance and repair work may only be carried out by qualified
professionals and in compliance with accident prevention regu-
lations. Suitable personal protective equipment must be worn for
all work.
Schaeffler DuraSense must be placed in a voltage-free state before
starting maintenance and repair work.
If any safety devices must be removed during maintenance or repair,
these must be refitted once the work is complete and their function
must be checked.
When carrying out maintenance and repair work, only suitable tools
may be used.
Troubleshooting and rectification Troubleshooting and rectification may only be carried out by quali-
fied professionals and in compliance with accident prevention
regulations. Suitable personal protective equipment must be worn
for all work.
Disposal Schaeffler DuraSense and the corresponding components must
not be disposed of with household waste, as they contain electronic
components that must be disposed of correctly.
Electronic devices must be disposed of in accordance with the
relevant regulations.

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Constructional modifications
(conversion)
For safety reasons, autonomous modifications (conversion) of
Schaeffler DuraSense are not permitted.
Any modifications that will impair electromagnetic
compatibility (EMC) are also not permitted, see page 5.
If you have any questions, please contact Schaeffler.
Scope of delivery The scope of delivery of Schaeffler DuraSense includes:
■ pre-processing unit (PPU)
■ sensors (including sensor cable), number according to order:
– up to 7 sensors can be used per PPU
Not included in the scope of delivery:
■ user manual BA 60, Schaeffler DuraSense
Download at: https://www.schaeffler.de/std/1F35
■ ethernet cable for connection between PPU and Windows
PC (required during setup)
■ power cable with plug
■ plug and cable for connection between PPU and programmable
logic controller (PLC)
■ plug for connection between sensor cable and PPU
Observe the guidelines regarding the required plugs and cables,
see page 34.
Description
Function Schaeffler DuraSense is a sensor-based system for analysing and
monitoring the lubrication status of Schaeffler monorail guidance
systems.
The system consists of a sensor for measuring vibrations, a pre-
processing unit (PPU), a carriage prepared for fitting the sensor and
a guideway.
 Sensor
 Sensor cable
 Pre-processing unit (PPU)
Figure 1
Scope of delivery
1
2
3
0018D1970018D197

Schaeffler Technologies BA 60 9
The PPU fulfils the following functions:
■ conversion of analogue to digital sensor signals
■ calculation of a lubrication parameter from the measured sensor
signals
■ comparison of the lubrication parameters obtained from the
measurements with the threshold value defined on the basis
of the reference run
■ output of the quality of the lubrication status (digital output
signal for threshold values which have been exceeded or
not exceeded; analogue output signal for continuous monitoring)
Schaeffler DuraSense enables two different operating modes for
monitoring the lubrication status:
■ lubrication appropriate to requirements, see page 10
■ monitoring of the lubrication status and lubrication circuit,
see page 11
All of the interfaces required to operate Schaeffler DuraSense are
integrated in the PPU. All inputs and outputs are located on the top
of the housing.
The lubrication status of up to 7 carriages (CH1 to CH7) can be
monitored with a PPU.
The PPU is available in two versions:
■ PPU.DSE07-C-A-AA
(fieldbus interfaces are active)
■ PPU.DSE07-A-A-AA
(fieldbus interfaces have no function)
Externally, there is no discernible difference between the two
versions. Differentiation is provided in the form of a label attached
to each PPU, which bears the designation of the respective version.
Inputs and outputs for:
 Sensors
 Fieldbuses
(Profinet IRT)
 Voltage supply
 Ethernet
 PLC
(and other systems
with digital or analogue interfaces)
Figure 2
PPU inputs and outputs
CH 1
CH 2
CH 3
CH 4
CH 5 CH 7 Ethernet I/O
CH 6 FB 1 FB 2 Supply
1 2 3
12 43
12
43
12
43
1 4 5
00171F6E00171F6E

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Operating modes
Lubrication appropriate to
requirements
The lubrication intervals are controlled by the signals from
Schaeffler DuraSense. When the set threshold value is reached,
the PPU sends a signal to the machine controller that can be
used to initiate a relubrication impulse.
Legend  Reference run
 Measurement run
 Relubrication recommended
 Inadequate lubrication
 Adequate lubrication
 Optimum lubrication
 Overlubrication
 Threshold value, defined on the basis of the reference run
(in the example: threshold value = 1500)
 Output signal according to setting:
24 V, 0 V, 8 mA to 20 mA
 Output signal according to setting:
0 V, 24 V, 4 mA to 8 mA
SKW = lubrication parameter
s = distance travelled
Figure 3
Example
of a lubrication parameter profile
(lubrication appropriate to
requirements)
s
3 3 6
1
2
8
9
1600
1500
1700
1400
1300
1200
1100
SKW
1000
500
km
12
10
11
7
0016685600166856

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Monitoring
of the lubrication status and
lubrication circuit
The lubrication intervals are stipulated by the customer, for example
by means of time or distance control. Schaeffler DuraSense is used
for monitoring here.
The system determines and outputs the current lubrication
parameter (SKW). If the monorail guidance system is inadequately
lubricated due to a blocked or torn lubrication line, for example,
the lubrication parameter will rise above the usual level.
In addition to monitoring the lubrication status, indirect monitoring
of the carriage condition can also be performed through a long-term
analysis of the calculated lubrication parameters.
Legend
 Reference run
 Measurement run
 Fixed relubrication interval
 Additional relubrication recommended
 Inadequate lubrication
 Adequate lubrication
 Optimum lubrication
 Overlubrication
 Threshold value, defined on the basis of the reference run
(in the example: threshold value = 1500)
 Output signal according to setting:
24 V, 0 V, 8 mA to 20 mA
 Output signal according to setting:
0 V, 24 V, 4 mA to 8 mA
SKW = lubrication parameter
s = distance travelled
Figure 4
Example
of a lubrication parameter profile
(monitoring
of the lubrication circuit)
4 4 4
5
7
6
1
2
8
1600
1500
1700
1400
1300
1200
1100
1000
500
km
12
9
10
11
SKW
s
00171D3100171D31

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Output signals
Digital When the lubrication parameter reaches the preset threshold value,
the output signal changes from 0 V to 24 V or from 24 V to 0 V,
depending on the setting.
Analogue The calculated lubrication parameter is output using an output
signal in each case in the range from 4 mA to 20 mA. The operator
has the option of using this signal to display the lubrication status.
In addition, the lubrication parameter threshold values must be
programmed in the machine controller and relubrication triggered
when they are reached.
Note When using the analogue output signals, the threshold value must
be set and monitored independently in the machine controller.
Saving the lubrication parameters The user can save the calculated lubrication parameters to
a Windows PC, for example. A local network or cloud system is
not required for this purpose.
Reference run Regardless of the selected operating mode, a reference run must be
carried out:
■ on initial operation
■ in the event of changes to the measurement runs, see page 13,
as a result of modified movement cycles, for example
During each reference run, the sensor attached to the carriage
measures vibration behaviour and transmits the measured
analogue data to the PPU, where the data are processed and output
as a lubrication parameter (digital or analogue). The threshold value
at which lubrication is to be initialised is set on the basis of these
data.
The following conditions apply to the reference run:
■ duration between 0,7 s and 5 s
■ constant velocity
(recommended: between 0,5 m/s and 1 m/s)
■ same cycle (load, duration and velocity) for reference run and
measurement runs
■ for a new carriage after approx. 100 km in a relubricated state:
– repeat reference run and apply new threshold values
if necessary (running-in behaviour taken into consideration)
Note For reference runs with acceleration components, please consult
Schaeffler.

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Measurement runs During operation, regular measurement runs must be initiated by the
PLC. The cycle of the measurement runs (load, duration and velocity)
must match the reference run cycle.
The measurement runs can form part of the existing movement
sequence or can be set up as additional measurement runs.
The measurement runs provide the data for determining the
lubrication parameter.
Note For measurement runs with acceleration components, please
consult Schaeffler.
Storage Conditions for storing Schaeffler DuraSense:
■ storage temperature: –25 °C to +70 °C
■ store in original packaging only

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Mounting
Plugs and cables To connect the sensor and pre-processing unit (PPU), plugs and
cables are required, which are not included in the scope of delivery:
 Taking account of the scope of delivery, see page 8, check which
plugs and cables you require in addition to the components
included in the delivery.
 Procure the necessary plugs and cables, taking into account
the information on accessories, see page 34 onwards.
Fitting
the pre-processing unit (PPU)
The PPU is fitted as follows:
 Determine the mounting position of the PPU. Please note,
in this regard, that the PPU must be attached to the moving axis
of the monorail guidance system and that the sensor cable is
not suitable for drag chain use.
 Adjust the length of the sensor cable (delivered condition: 2 m).
It can be shortened, or lengthened up to a maximum of 5 m.
 Fix the PPU to the mounting position. Use the appropriate
screws (M5) and tighten them firmly.
 Earth the PPU housing using the housing fixing screws.
 Connect the PPU (connector: I/O) and the machine controller
(PLC) using the appropriately prepared cable.
 Supply the PPU with a 24-V power source (for example PLC).
For details on voltage supply, see page 34.
 The PPU is fitted.
Figure 5
PPU (mounting dimensions)
33,2 43,6
66
5,5
201
192,4
12
43
001663C1001663C1

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Preparing to fit the sensor
using a retrofit adapter
(optional)
The retrofit adapter is intended for carriages that do not have
a suitable thread for fitting the sensor.
It can be used for all standard carriages that are free from damage
and show no signs of wear.
The retrofit adapter (cylindrical, diameter = 14 mm) has an internal
thread for connecting the sensor.
Ordering designation Ordering designation for retrofit adapter:
■ DI.DSE.16-0011
Mounting position Demands on the mounting position of the retrofit adapter:
■ on a side or end face of the carriage
■ between upper and lower raceway
■ flat surface so that the adapter piece can be attached by adhesive
to the entire surface of the carriage
■ positioned so that the side surface of the sensor does not come
into contact with any other parts or carriage components once it
has been fitted
Fitting The retrofit adapter is fitted as follows:
 Determine a suitable mounting position for the retrofit adapter.
 Ensure that the carriage and sensor surfaces to be bonded are
clean and free of grease.
 Stick the retrofit adapter to the mounting position on the carriage
using an adhesive that is suitable for bonding metals and for
the environmental conditions associated with the application.
 Once the adhesive connection has set, a sensor can be mounted
on the adapter piece.
 Carriage
 Guideway
 Retrofit adapter
Figure 6
Carriage with retrofit adapter
1
2
3
0019828600198286

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Fitting the sensor The sensor is fitted as follows:
 Attach the plug to the sensor cable to connect to the PPU.
Observe the information on cables and plugs, see page 34
onwards.
 Screw the sensor into the thread provided on the carriage or
into the thread of the retrofit adapter using a tightening torque
of 5 Nm. Use an open-ended torque wrench with a 15 mm jaw
width for this purpose.
 Connect the plug attached to the sensor cable to one of
the inputs CH1 to CH7 of the PPU.
 Make a note of which carriage is connected to which channel.
We recommend storing this information in the control cabinet so
that it is available and accessible at all times.
 The sensor is fitted.
Figure 7
Sensor (mounting dimensions)
 15,86
40
5
M50,8
W15
001663D0001663D0
Figure 8
Fitting the sensor
0018D1870018D187

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Setup software
Service Setup Tool (SST)
The setup software Service Setup Tool (SST) facilitates extensive
communication between the PPU and a Windows PC during
commissioning and servicing.
Following setup, Schaeffler DuraSense will run in normal operation
without setup software SST.
Download The setup software SST for Schaeffler DuraSense is available to
download from Schaeffler under the following link:
■ https://www.schaeffler.de/std/1F7D
Start screen After starting setup software SST, the start screen appears.
If no connection to a PPU is established, only five of the large
buttons are displayed,
Figure 10 , page 19. Once a connection
to a PPU has been established, all six of these buttons will appear,
Figure 9 .
Figure 9
Start screen
4
7
23
6
5
1
0019339C0019339C

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Components of the start screen  General settings
 Restarting the PPU
 Connection status between PPU and Windows PC
 Main menus:
–[
Overview ]:
start screen
–[
Data Acquisition ]:
recording and display of measured values,
e.g. for the definition of threshold values
–[
Configure ]:
configuration
–[
Log ]:
display of LPV profile and log file
 Error and connection status
 Channel status
 Buttons, in some cases with status display; these buttons lead
directly to selected functions or setting options that are arranged
below [
Configure ]
General settings The button for general settings is located at the top right of the
program window.
Menu for general settings
Button Function
Opens the menu for general settings:
■ [ Language ]:
selection of language for setup software SST
■ [ License ]:
information about the licence
■ [ About ]:
information about the program version and current system
■ [ Scaling ]:
adjust the font size