Schaeffler VarioSense User manual

Schaeffler VarioSense
User manual

Foreword
As a result of the trend towards networked and intelligent machinery
and plant, it is becoming increasingly important to gain information
about the operating mode of machinery. Due to the high precision
of rolling bearings and the accuracy of the adjacent construction,
bearing positions are often the ideal measuring point.
Product Schaeffler VarioSense combines standard rolling bearings with
a modular sensor concept. The product range is being continually
expanded. This makes it possible to offer a large selection of
standard rolling bearings, which can be flexibly combined with
sensors for different measurement values.
Described design The design described in this manual is a combination of deep
groove ball bearings of series 62 with sensor technology for speed
measurement. Optional use of the interface unit, which is also part
of the product range, is possible here.
Further information This manual contains all information required for mounting,
connection and operation.
Further information on Schaeffler VarioSense, such as details on
the characteristics of rolling bearings or guidelines on the design
of the adjacent instruction, can be found in publication TPI 253,
Schaeffler VarioSense.
The current edition of TPI 253 is already available for download at:
■ www.schaeffler.de/std/1D55 .

2 BA 47 Schaeffler Technologies
Page
Contents
About the user manual Described product variants ........................................................ 4
Symbols .................................................................................... 4
Legal guidelines ........................................................................ 4
General safety guidelines Usage for the intended purpose ................................................. 5
Usage not for the intended purpose ........................................... 5
Ambient conditions ................................................................... 6
Electrostatic discharges (ESD) ................................................... 6
Electromagnetic compatibility.................................................... 7
Qualified personnel................................................................... 7
Safety regulations ..................................................................... 8
Scope of delivery Damage during transit ............................................................... 9
Defects...................................................................................... 9
Description Design....................................................................................... 10
Function .................................................................................... 11
Product variants ........................................................................ 11
Interfaces.................................................................................. 12
Transport and storage Transport................................................................................... 13
Storage ..................................................................................... 13
Mounting Demands on the adjacent construction ...................................... 14
Protection against electrostatic discharges ................................ 14
Cleanliness ............................................................................... 14
Sensor/bearing unit .................................................................. 15
Location of the interface unit ..................................................... 19
Laying of cables......................................................................... 20

Schaeffler Technologies BA 47 3
Page
Commissioning System without interface unit.................................................... 21
System with interface unit......................................................... 22
Operation Permissible indirect process materials ...................................... 24
Permissible speeds................................................................... 24
Operating temperatures ............................................................ 24
Troubleshooting and
rectification
................................................................................................ 25
Maintenance Updating the software............................................................... 26
Cleaning ................................................................................... 26
Decommissioning ................................................................................................ 26
Disposal ................................................................................................ 26
Accessories and spare parts Plug connections ...................................................................... 27
Technical data Dimensions of the interface unit................................................ 28
Pin assignment of connection on sensor unit............................. 28
Pin assignment of connection on interface unit.......................... 29
Supply of voltage to sensor unit ................................................ 30
Supply of voltage to interface unit ............................................. 30
Speed signals ........................................................................... 31
Appendix EU Declaration of Conformity..................................................... 33

4 BA 47 Schaeffler Technologies
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About the user manual The user manual is part of the product and contains important
information. It should also be immediately available after mounting
and commissioning.
Described product variants This user manual is valid only for deep groove ball bearings of
series 62 in designs 6205-C to 6210-C in combination with a sensor
fitting of product configuration 001, i.e. with speed measurement as
the sole sensor function.
Symbols The warning and hazard symbols are defined in accordance with
ANSI Z535.6-2011.
WARNING
In case of non-compliance, death or serious injury may occur. 
NOTICE
In case of non-compliance, damage or malfunctions in the product or
the adjacent construction will occur.

Legal guidelines The information in this manual reflects the status as at December
2018. Autonomous modifications and usage of the system not
for the intended purpose are not permissible. Schaeffler accepts no
liability in these cases.

Schaeffler Technologies BA 47 5
General safety guidelines
Usage for
the intended purpose
Schaeffler VarioSense is intended for fitting in machinery and plant.
Here, the bearing assumes the function of a classic rolling bearing,
which has been expanded to include the recording of measurement
values such as speed or temperature. The available measurement
values are determined by the specific product configuration.
The product configuration described in this manual includes only
the speed measurement.
Schaeffler VarioSense is intended exclusively for applications
in the machine and equipment building sector where no particular
protection requirements apply.
Usage not for
the intended purpose
Any use involving a safety-related application of the measurement
values is excluded. The safety of the machine or equipment itself,
of the adjacent systems and of persons must be taken into account.
Application areas in which the use of Schaeffler VarioSense is not
permitted:
■ explosive environments (ATEX)
■ nuclear power
■ aerospace
■ rail
■ military
■ medical equipment.
Any use that exceeds the operating limits of the integrated bearing is
also excluded.
Further information Detailed information on the integrated bearings:
■ TPI 165, Deep Groove Ball Bearings, Generation C
■ Catalogue HR 1, Rolling Bearings
■ TPI 253, Schaeffler VarioSense.

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Ambient conditions Magnetic or electrically conductive dusts and particles are not
permitted in the area adjacent to the Schaeffler VarioSense, as they
can influence the function of the measuring system.
If there is a fluid circuit in the immediate vicinity of the bearing,
the use of a magnetic separator is recommended.
The permissible ambient pressure for the sensor and interface unit is
in the range of 700 hPa to 1050 hPa.
The sensor unit can be operated under the ambient conditions
permissible for the bearing. The interface unit is designed in accord-
ance with the protection type IP67 to ISO 20653. If dust exposure is
elevated in the area adjacent to Schaeffler VarioSense, please
consult Schaeffler.
Special storage conditions apply, see page 13.
Electrostatic discharges (ESD) The sensor unit and the interface unit contain electrostatically
sensitive components. These can be destroyed by the action of
an electric field or by
e lectro s tatic d ischarge (abbreviated to ESD)
through contact, or influenced in terms of rating life.
The relevant protective measures for working with electrostatically
sensitive components must be observed. These include:
■ Establishing electrostatic potential equalisation between all
persons, who come into direct contact with the components,
and their environment. This requires the use of ESD protection
field equipment (shoes, clothing, anti-static wrist strap).
■ ESD-protected storage of components,
for example in a conductive ESD protective bag.

Schaeffler Technologies BA 47 7
Electromagnetic compatibility The sensor unit, interface unit and all accessories, including
the supplied cables and plug connections, must be designed to
comply with the electromagnetic compatibility requirements of
Directive 2014/30/EU.
The sensor unit cable is shielded. If the customer makes changes to
the coupling or cable for customer-side connection, he is respon-
sible for complying with the requirements for electromagnetic com-
patibility. In particular, it must be ensured that the cable shielding
is contacted at both cable ends. It is not permissible to extend the
cable.
So as not to jeopardise electromagnetic compatibility in the respect-
ive application, the following specifications must be observed:
■ integrated earthing concept between the housings of the sensor
unit and the interface unit on one side and the machine housing
on the other side
■ laying of signal and power cables as far apart as possible
■ additional shielding measures, for example shielded power
cables or earthed cable ducts.
Qualified personnel Schaeffler VarioSense may only be mounted, commissioned,
operated and maintained by qualified personnel. The scope of
competence, area of responsibility and monitoring of personnel
must be precisely regulated by the site operator.
A person defined as qualified personnel:
■ is authorised to perform mounting of the bearing and
electronic components
■ has all the necessary knowledge
■ is familiar with the safety guidelines
■ has read and understood this manual.
Work on electrical devices Work on electrical devices may only be carried out by a trained
electrician.
A trained electrician is in a position, on the basis of his technical
training, knowledge and experience as well as his knowledge of
the appropriate regulations, to assess the work assigned to him and
recognise possible hazards.

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Safety regulations This section contains important safety regulations relating to
working with Schaeffler VarioSense. Further guidelines can be found
in the individual chapters of this user manual.
General handling Schaeffler VarioSense is a sensitive measuring system. Shocks and
compressive loads can damage the components, render the system
unusable or result in erroneous output values. Shocks, such as those
that occur due to falling, and other impermissible mechanical loads
must therefore be avoided.
Adhesive bond The sensor ring and rolling bearing are connected by an adhesive
bond. To protect this connection, the mounting specifications must
be closely observed.
As damage to the adhesive bond cannot be ruled out in dismounting
of the sensor/bearing unit, further use of the sensor/bearing unit is
not permitted after dismounting.
Conversion Unauthorised modifications to the sensor/bearing unit, interface
unit and accessories, including the supplied cables and plug
connections, may affect the safety and function of the device and
are not permitted.
Modifications to the specified components are only permissible
in consultation withSchaeffler. Only components authorised by
Schaeffler may be used.
If unauthorised modifications and conversions are carried out or
unauthorised components are used, Schaeffler cannot accept any
liability for the resulting negative consequences.

Schaeffler Technologies BA 47 9
Scope of delivery Schaeffler VarioSense in product configuration 001 (speed measure-
ment as the only measurement value) can be operated both with and
without an interface unit. As a result, the interface unit is not
included in the scope of delivery, but can be ordered separately,
see
table and Figure 1 .
In product configuration 001, the sensor/bearing unit is only
supplied with open cable ends (without a plug). If required,
the customer can attach a plug for connection to the interface unit,
see page 22.
Scope of delivery
of product configuration 001
● Included in the scope of delivery.
The enclosed safety guidelines are accompanied by a link to this
user manual (BA 47), which is always available online in the latest
version.
Damage during transit Any damage during transit must be reported immediately as
a complaint to the carrier:
 Check the delivery immediately upon arrival for any damage
during transit.
 Report any damage during transit promptly as a complaint to
the carrier.
Defects Any defects must be reported promptly as a complaint:
 Check the product immediately upon delivery for visible defects.
 Report any defects promptly as a complaint to Schaeffler.
Component Product configuration 001
(speed measurement only)
Sensor/bearing unit ●
Interface unit –can be ordered separately
Safety guidelines ●
 Sensor/bearing unit
 Interface unit
(only if ordered separately)
 Safety guidelines
Figure 1
Scope of delivery
1
2
3
000C806F000C806F

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Description Schaeffler VarioSense comprises a standard rolling bearing in
combination with a sensor unit and a separately available evaluation
unit (interface unit) for determining measured values on the bearing.
Design The main components of Schaeffler VarioSense are the
sensor/bearing unit, comprising rolling bearing and sensor unit,
and an optionally available interface unit, which is required
for product configuration 002 and above. The rolling bearing and
sensor unit are rigidly connected by an adhesive bond.
The sensor unit and interface unit are connected by a detachable
plug connection. If speed is the only measurement value to be
measured, the interface unit is not required. Therefore, for product
configuration 002 and above, the interface unit is supplied with
a detachable plug connection and, for product configuration 001,
with open cable ends.
The customer-side interface and an LED for displaying the status are
also located on the end face of the interface unit,
Figure 2 .
 Sensor unit
 Rolling bearing
 Cable
 Detachable plug connection
 Interface unit
 Customer-side connection
 LED for operating mode
Figure 2
Design
4
7
5
1
2
3
6
000B104A000B104A

Schaeffler Technologies BA 47 11
Function The rolling bearing used is a standard rolling bearing. It assumes all
the functions of a conventional rolling bearing of the corresponding
bearing type.
The measurement values are recorded by sensors integrated in
the sensor unit. For the version described in this manual (product
configuration 001), speed is the only measurement value.
The processing of the measurement signals takes place in the inter-
face unit, which also constitutes the interface to the customer
system. A USB communication interface is integrated in the flange
plug for customer-side connection, by way of addition to the signal
and supply connections. This permits the installation of new
software versions, adjustments to the customer-side application
(parameter settings) and the reading out of error and status memory
from service activities.
Product variants The product configurations available as standard are shown below,
see
table .
Product configurations
● Component of product configuration.
Product
configuration
Sensor Interface unit
Speed Temperature Displacement
001 ● – – Optional
002 ● ● – ●
003 ● ● ● ●
004 – – ● ●

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Interfaces The interface unit forms the interface between the sensor unit
fitted to the bearing and the customer system for processing of
the measurement results. With speed measurement as the only
measurement value, the use of the interface unit is optional.
Interfaces of interface unit The interface unit has the following interfaces, Figure 3 :
■ Flange socket for connection of the sensor unit.
■ Flange plug for the customer-side connection.
This interface is used for the output of measurement signals and
status as well as the supply of voltage.
■ USB communication interface, integrated in the flange plug
for customer-side connection.
This interface is used to access the interface unit via a Windows
PC, for example to install firmware updates or perform settings
in the interface unit (such as weighting of the analog signals).
■ RS485 interface, integrated in the flange plug for customer-side
connection.
Data such as measured values and status messages can be
outputted to the customer-side application or controller,
via this communication interface, on request.
■ LED for display of the operating and error status.
Interfaces
in pure speed measurement
The product configuration 001, in which the only sensor function is
speed measurement, does not have an interface unit as standard.
In this case, the cable on the sensor unit forms the external interface.
For connection information, see page 28.
 Flange socket
for connection of sensor unit
 LED for operating mode
 Flange plug
for customer-side connection,
with integrated
USB communication interface and
integrated RS485 interface
Figure 3
End face of interface unit
123
000B0F5D000B0F5D

Schaeffler Technologies BA 47 13
Transport and storage The specifications for transport and storage apply to
the sensor/bearing unit and to the interface unit.
Transport During transport, the following should be avoided:
■ shocks and compressive loads.
Storage Storage conditions:
During storage, the following should be avoided:
■ action by aggressive media such as gases, mist or aerosols
of acids, alkalis or salts
■ direct sunlight
■ condensation
■ shocks and compressive loads.
For protection against electric fields and electrostatic discharges,
the system should be stored in a conductive ESD protective bag.
■ ambient temperature: +5 °C up to +40 °C
■ relative humidity: ⬍ 65%
■ maximum storage period: 3 years.

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Mounting
Demands
on the adjacent construction
The bearing position and adjacent construction must meet
the requirements resulting from the geometry and function
of the sensor/bearing unit. These requirements are described
in detail in publication TPI 253.
We recommend checking the adjacent construction in respect
of the following criteria before starting mounting work:
■ The bearing position is designed as a locating bearing
arrangement.
■ The bearing is fitted with a stationary outer ring.
■ The mounting dimensions correspond to the requirements.
■ The cable guide permits a minimum bending radius of 35 mm.
Further information ■ TPI 253, Schaeffler VarioSense.
Protection against
electrostatic discharges
The sensor unit and the interface unit are fitted with electrostatically
sensitive components.
NOTICE
Electric fields or electrostatic discharges can damage sensitive
components. Observe the following protective measures.

Protective measures:
 ESD protection field equipment (shoes, clothing, anti-static
wrist band) must be fitted before carrying out any work with
Schaeffler VarioSense.
 Only then can the system be removed from the packaging.
 Always store the system in a conductive ESD protective bag.
 Keep the ESD protective bag for storing the system at a later stage
or for returning the system as necessary.
Cleanliness Contamination can reduce the operating life of rolling bearings and
impair the function of sensors.
To protect against contamination:
 Ensure that all mounting surfaces and components are free
of swarf and other contaminants prior to mounting.
NOTICE
Residues of cleaning agents can contribute to contamination.
Only use volatile solvents and lint-free cloths for cleaning.


Schaeffler Technologies BA 47 15
Sensor/bearing unit The sensor/bearing unit is mounted on the shaft with an interference
fit to the inner ring and in the housing with a sliding seat of the outer
ring.
Recommended mounting methods:
■ mechanical mounting by pressing on
■ thermal mounting.
Due to the sensor unit connected to the bearing, special require-
ments must be observed during mounting, which are described
in detail in this manual.
NOTICE
When dismounting the sensor/bearing unit, damage to the adhesive
bond between the sensor ring and rolling bearing cannot be ruled
out.
A sensor/bearing unit that has already been dismounted once may
not be remounted.

Further information Basic information on mounting of rolling bearings:
■ MH 1, Mounting Handbook.
Mounting procedure The procedure for mounting the sensor/bearing unit is as follows:
 Before mounting work is started, familiarise yourself with
the design.
 Check the machine-side connection components for dimensional
and geometrical accuracy.
 Mount the sensor/bearing unit on the shaft.
Use either the mechanical process by pressing on, see page 16,
or the thermal method, see page 17.
 If required by the adjacent construction, pull the sensor unit cable
through the cable guides provided.
 Insert the assembly comprising shaft and sensor/bearing unit
into the housing.
 Finish laying the cable, observing the guidelines for laying cables,
see page 20.
 Secure the outer ring against rotation.
There are various methods available for securing against rotation,
depending on the application, see page 18.

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Mechanical mounting
by pressing on
The preferred mounting method for the sensor/bearing unit is
pressing on. The use of hydraulic presses is permissible.
The procedure for mounting the bearing by pressing on is as follows:
 Apply a thin layer of Arcanol mounting paste to the bearing
seating surface of the shaft.
 Select the pressing direction such that the press-on forces are not
introduced via the sensor unit,
Figure 4 .
 Press the bearing onto the shaft, ensuring the press-on forces are
introduced evenly and uniformly.
NOTICE
If the press-on forces are directed through the rolling elements,
the bearing may become damaged. Press-on forces may only be
introduced to the inner ring. 
NOTICE
Shocks and shock-type loads can damage the bearing.
As a result, the use of mounting sleeves is not permissible.

 Preferred pressing direction
 Sensor ring
 Encoder
Figure 4
Pressing
on the sensor/bearing unit
1
2
3
000B3B48000B3B48

Schaeffler Technologies BA 47 17
Thermal mounting The thermal mounting method requires the following:
■ an electric heating plate with temperature control
■ a metal stud matched to the size of the sensor/bearing unit,
Figure 5 . This must be designed such that it is not in contact
with the bearing seal.
The procedure for mounting the bearing using the thermal method
is as follows:
 Apply a thin layer of Arcanol mounting paste to the bearing
seating surface of the shaft.
 Place the sensor/bearing unit on the heating plate using the stud,
ensuring that the sensor unit is pointing in the direction facing
away from the heating plate,
Figure 5 .
WARNING
Risk of burns during heating of the bearing.
Wear heat-resistant safety gloves.

 Set the temperature control for the heating plate to +80 °C and
switch the heating plate on to heat the bearing.
NOTICE
Excessively high temperatures can damage the bearing or sensor
unit. Observe the maximum heating temperature of +80 °C.

 Push the heated sensor/bearing unit promptly onto the bearing
seat of the shaft.
NOTICE
Induction heating methods can damage the sensor unit and are
therefore not permitted.

Figure 5
Heating of the bearing
using heating plate and stud
I
0
000B3B49000B3B49

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Securing the outer ring
against rotation
Due to the cable connection arrangement, it is necessary to secure
the outer ring against rotation.
Design options for securing against rotation:
■ axial locking at the outer ring, Figure 6
■ bonding the outer ring in place
■ positive anti-rotation locking at the cable output of the sensor
unit or at the outer ring.
NOTICE
If bonding or positive anti-rotation locking is not carried out
correctly, the rolling bearing and the sensor unit may become
damaged. If necessary, please consult Schaeffler.

For axial locking of the outer ring, we recommend a minimum locking
force, see
table .
Minimum locking force
at outer ring
Sensor/bearing
unit
Integrated
bearing
Recommended
minimum locking
force at outer ring
Maximum axial stress
on adhesive bond
N N
SB6205C 6205-C 1200 7500
SB6206C 6206-C 1700 11 000
SB6207C 6207-C 2200 15 000
SB6208C 6208-C 2500 17 000
SB6209C 6209-C 2700 19 500
SB6210C 6210-C 3200 23 500
 Outer ring
 Sensor ring
 Encoder
Figure 6
Axial locking at outer ring
21
3
000B5C5C000B5C5C