SEW-Eurodrive DUV10A User manual

Gearmotors \ Industrial Gear Units \ Drive Electronics \ Drive Automation \ Services
DUV10A Diagnostic Unit
M anual
FE500000
Edition 06/2006
11425016 / EN

SEW-EURODRIVE – Driving the world

Manual – DUV10A Diagnostic Unit
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Contents
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1 Important Notes................................................................................................. 5
1.1 Explanation of symbols............................................................................. 5
1.2 Integral part of the product........................................................................ 5
1.3 Designated use......................................................................................... 6
1.4 Qualified personnel................................................................................... 6
1.5 Liability for defects.................................................................................... 6
1.6 Product names and trademarks................................................................ 6
1.7 Waste disposal.......................................................................................... 6
2 Safety Notes ...................................................................................................... 7
2.1 Preliminary information............................................................................. 7
2.2 General information .................................................................................. 7
2.3 Shipping / putting into storage .................................................................. 8
2.4 Installation / startup................................................................................... 8
2.5 Inspection and maintenance..................................................................... 8
3 Product Description.......................................................................................... 9
3.1 Hardware .................................................................................................. 9
3.2 Continuous monitoring.............................................................................. 9
3.3 Theory of operation................................................................................... 9
4 Delivery Scope and Unit Design.................................................................... 12
4.1 Scope of delivery .................................................................................... 12
4.2 Types and options................................................................................... 12
4.3 Unit designation and nameplate ............................................................. 14
4.4 Design of the DUV10A diagnostic unit.................................................... 15
5 Installation and Startup .................................................................................. 16
5.1 System overview..................................................................................... 16
5.2 Before you begin..................................................................................... 16
5.3 DUV10A-S installation software.............................................................. 17
5.4 Installation and startup procedure........................................................... 18
5.5 Evaluating the switching outputs............................................................. 27
6 Operation and Service.................................................................................... 29
6.1 Settings................................................................................................... 29
6.2 Operation................................................................................................ 30
6.3 Maintenance ........................................................................................... 33
6.4 Customer service.................................................................................... 33
6.5 Faults / repairs........................................................................................ 34
7 Unit Functions................................................................................................. 35
7.1 Sensor functions..................................................................................... 35
7.2 Parameters ............................................................................................. 38
7.3 Application .............................................................................................. 39
7.4 Diagnosis objects.................................................................................... 44
7.5 Rolling element bearing database .......................................................... 56
7.6 Monitoring............................................................................................... 60
7.7 Universal assignment.............................................................................. 62
7.8 History..................................................................................................... 63
7.9 LED code................................................................................................ 64
7.10 Data string............................................................................................... 65

Betriebsanleitung – Explosionsgeschützte Getriebe, Typ R147 LX140 BMG8D
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Manual – DUV10A Diagnostic Unit
Contents
8 Technical Data................................................................................................. 68
8.1 General technical data............................................................................ 68
8.2 Dimension drawing ................................................................................. 69
9 Appendix.......................................................................................................... 70
9.1 Lexicon.................................................................................................... 70
9.2 Dimension sheets for installation locations on the drive......................... 71
10 Index................................................................................................................. 80
Quick Startup................................................................................................... 91

Manual – DUV10A Diagnostic Unit
5
1
Explanation of symbols
Important Notes
Manual
1 Important Notes
1.1 Explanation of symbols
Always follow the safety and warning notes in this documentation.
1.2 Integral part of the product
This manual is an integral part of the DUV10A diagnostic unit and contains important
information on operation and service. The manual is intended for all persons who per-
form assembly, installation, startup and service work on the DUV10A diagnostic unit.
Electrical hazard
Possible consequences: Severe or fatal injuries.
Hazard
Possible consequences: Severe or fatal injuries.
Hazardous situation
Possible consequences: Slight or minor injuries.
Harmful situation
Possible consequences: Damage to the unit and the environment.
Note
Tips and useful information.
Documentation reference
Indicatesareference to adocument,such as operatinginstructions,catalog, data sheet.

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Manual – DUV10A Diagnostic Unit
1Designated use
Important Notes
1.3 Designated use
The term designated use refers to the procedure specified in the manual.
The DUV10A diagnostic unit is designed for use in industrial and commercial systems.
If you intend to use the DUV10A diagnostic unit in applications other than those in
industrial and commercial systems, it is essential that you contact SEW-EURODRIVE
first.
In compliance with the EC Machinery Directive 98/37/EC, the DUV10A diagnostic unit
is a component designed for installation in machinery and systems. In line with the EC
Directive, you must not take the unit into operation in the designated fashion until you
have established that the end product complies with the Machinery Directive 98/37/EC.
1.4 Qualified personnel
The DUV10A diagnostic unit represents a potential hazard for persons and property.
Consequently, assembly, installation, startup and service work may only be performed
by trained personnel who are aware of the potential hazards.
Employees must be appropriately qualified for the task in hand and must be familiar with
the assembly, installation, startup and operation of the product. The personnel must
read the manual, in particular the safety notes section, carefully and ensure that they
understand and comply with them.
1.5 Liability for defects
Incorrect handling or any action performed that is not specified in this manual could
impair the properties of the product. In this case, you lose any right to claim under limited
warranty against SEW-EURODRIVE GmbH & Co KG.
1.6 Product names and trademarks
The brands and product names in this manual are trademarks or registered trademarks
of the titleholders.
1.7 Waste disposal
Please follow the current national regulations.
Dispose of the individual materials separately in accordance with the country-specific
regulations in force.

Manual – DUV10A Diagnostic Unit
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2
Preliminary information
Safety Notes
2 Safety Notes
2.1 Preliminary information
The following safety notes apply to the DUV10A diagnostic unit.
2.2 General information
Only qualified personnel may carry out the following work:
• Putting into storage
• Installation/assembly
• Connection
•Startup
• Maintenance
•Servicing
The following information and documents must be observed during these processes:
• Relevant operating instructions and wiring diagrams
• Warning and safety signs on the unit
• System-specific regulations and requirements
• National/regional regulations governing safety and the prevention of accidents
Please also observe the supplementary safety notes in the individual sections of
this manual.
Danger of burns during installation on drives!
Touching the drive when it has not cooled down will result in burns. The drive can have
a surface temperature of up to 95 °C.
Only install the DUV10A diagnostic unit once the drive has cooled down after discon-
nection.
Never install damaged products or take them into operation.
Submit a complaint to the shipping company immediately in the event of damage.
Damage to property may result from:
• Improper use
• Incorrect installation or operation
• Unauthorized removal of necessary protection covers or housing

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Manual – DUV10A Diagnostic Unit
2Shipping / putting into storage
Safety Notes
2.3 Shipping / putting into storage
Inspect the shipment for any damage that may have occurred in transit as soon
as you receive the delivery. Inform the shipping company immediately. Do not
operate the DUV10A diagnostic unit if it is damaged.
2.4 Installation / startup
See the information in section 5, "Installation and Startup."
2.5 Inspection and maintenance
See the information in section 6, "Operation and Service."
Possible damage caused by incorrect storage!
Store the diagnostic unit in a dry, dust-free room if it is not to be installed straight away.

Manual – DUV10A Diagnostic Unit
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3
Hardware
Product Description
3 Product Description
3.1 Hardware
The DUV10A diagnostic unit evaluates vibration signals using frequency analysis
methods. A micromechanical acceleration sensor is used in the unit. Data can be
recorded, processed and evaluated decentrally without any expert knowledge.
3.2 Continuous monitoring
The DUV10A diagnostic unit is suitable for early recognition of rolling element bearing
damage or unbalance. The continuous monitoring function offers a reliable and cost-
effective solution compared to intermittent methods.
The DUV10A unit can be used to monitor up to 5 different objects or 20 frequencies. A
rolling element bearing or a shaft is defined as an object, for example.
The DUV10A diagnostic unit enables immediate, permanent vibration monitoring.
3.3 Theory of operation
3.3.1 Brief description
The structure-borne noise is recorded and the frequency spectrum calculated to evalu-
ate the condition of the rolling element bearings, unbalance in the unit etc. The condition
can be read off directly and is visualized using binary switching outputs.
The switching signal can be transmitted via unshielded cables. The unit can also be con-
nected to a bus system.

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Manual – DUV10A Diagnostic Unit
3Theory of operation
Product Description
3.3.2 Detailed description
• TheDUV10A diagnostic unit continuously records the vibrationacceleration ofa non-
rotating machine surface (32,000 values/second) and calculates the amplitudes of
damage frequencies (rolling element bearing: inner ring, outer ring and rolling ele-
ment) of up to 5 different diagnosis objects comprising a maximum of 20 individual
frequencies. The rolling element bearings or diagnosis objects to be monitored are
defined using PC software. They are then transferred as parameter sets to the sen-
sor via an RS-232 interface. The condition of the rolling element bearing is then eval-
uated and monitored relative to the teach-in value (reference value).
58483AEN
ObjectDiagnosis objects
Individual frequencies
Weighted
average
Peak value
Analysis methods
FFT / H-FFT
Object Object Object Object LEVEL
Frequency 1 Frequency 2 Frequency 3 Frequency 4 Frequency 5 Frequency 6 Frequency 7 Frequency 8 Frequency 9
Frequency 10
Frequency 11
Frequency 12 Frequency 13 Frequency 14 Frequency 15 Frequency 16 Frequency 17 Frequency 18 Frequency 19 Frequency 20
FFT spectrum H-FFT spectrum
0
5
10
15
Weighted
average

Manual – DUV10A Diagnostic Unit
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3
Theory of operation
Product Description
• As an option, the diagnostic unit can also calculate the maximum weighted average
or maximum acceleration value. In this case, evaluation and monitoring is performed
using absolute limit values without a reference value.
• Indication of early warning or main alarm: The diagnosis object or the level with the
highest degree of damage is indicated via the switching outputs.
• The damage progress of the diagnosis object is also indicated by the LED series on
the DUV10A diagnostic unit.
• The DUV10A diagnostic unit can be used with both constant and variable speeds. To
ensure correct diagnosis when using variable speeds, the current speed has to be
supplied via a 0 ... 20 mA current loop or a pulse input.
• If the roller bearing monitoring function is used with variable speeds, you must
ensure that the operating speed related to the set values remains constant for inter-
mittent periods.
• The maximum operating range is from 12 min–1 to 3500 min–1 shaft speed.
• The sensor is screwed onto the unit near the rolling element bearing radial to the
rotational axis (see section 5 "Installation and Startup"). If the sensor is not installed
directly next to the bearing seat, you must perform an impulse test to check whether
the installation location is suitable for the monitoring mode "Rolling element bearing
monitoring."
The DUV10A diagnostic unit uses different object limit values for early warning (yellow)
and main alarm (red) for all defined spectral diagnosis objects. The limit values of the
diagnosis objects are always based on the set teach-in value and describe a signal fan-
out. "Green" always corresponds to 100 %.
To compensate differences caused by the trigger level for different speeds during vari-
able-speed operation, the diagnostic value is weighted according to the "Weighted sig-
nal" curve. Individual weighted curves are defined for each diagnosis object.
The DUV10A diagnostic unit uses broadband limit values to monitor the vibration level
in the time domain. In contrast to the diagnosis objects, these are absolute acceleration
values (unit 'mg'). To compensate differences caused by the trigger level for different
speeds during variable-speed operation, the level is weighted according to the
"Weighted signal" curve.

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Manual – DUV10A Diagnostic Unit
4Scope of delivery
Delivery Scope and Unit Design
4 Delivery Scope and Unit Design
4.1 Scope of delivery
Scope of delivery of the DUV10A diagnostic unit
• 1 manual per order
4.2 Types and options
4.2.1 Options for the DUV10A diagnostic unit
DUV10A diagnostics unit
Product no. Meaning Designation
14066297 Diagnostic unit DUV10A
Product no. Meaning Designation
14066300 Configuration software DUV10A-S
14066319 Cable for software DUV10A-K-RS232-M8
14066327 Power supply unit DUV10A-N24DC
14066335 Impulse tester DUV10A-I
14066343 Cable with 1 connector, length 2 m DUV10A-K-M12-2m
14066351 Cable with 1 connector, length 5 m DUV10A-K-M12-5m

Manual – DUV10A Diagnostic Unit
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4
Types and options
Delivery Scope and Unit Design
4.2.2 Adapter for installation
Base for mounting on standard gear units (R, F, K, S)
Base for mounting on standard motors
Base for mounting on industrial gear units
Product no. Meaning
13434411 Mounting base with sealing ring M10 x 1
13438271 Mounting base with sealing ring M12 x 1.5
13438298 Mounting base with sealing ring M22 x 1.5
13438301 Mounting base with sealing ring M33 x 2
13438328 Mounting base with sealing ring M42 x 2
Product no. Meaning
13438425 Mounting base M12
13438441 Mounting base M16
Product no. Meaning
13438336 Mounting base with sealing ring G 3/4
13438344 Mounting base with sealing ring G 1
13438352 Mounting base with sealing ring G1 1/4
13438360 Mounting base with sealing ring G1 1/2

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Manual – DUV10A Diagnostic Unit
4Unit designation and nameplate
Delivery Scope and Unit Design
4.3 Unit designation and nameplate
4.3.1 Unit designation of the DUV10A diagnostic unit
4.3.2 Nameplate
58212AXX
Figure 1: DUV10A diagnostic unit
DUV 10 A
Revision number
Type
Diagnostic Unit Vibration (diagnostic unit)
58504AXX
Figure 2: Nameplate
SEW-EURODRIVE
IP67
1: L +, 10 ... 32 VDC
2: OUT2, REACT I = 100 mA
4: OUT1, CHECK I = 100 mA
3: L –
5: IN, CURRENT / PULSE
1: VCC (OUT)
2: TxD (OUT)
3: 0 V (GND)
4: RxD (IN)
GmbH & Co KG
D-76646 Bruchsal
14066297

Manual – DUV10A Diagnostic Unit
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4
Design of the DUV10A diagnostic unit
Delivery Scope and Unit Design
4.4 Design of the DUV10A diagnostic unit
58210AXX
Figure 3: Design of the DUV10A diagnostic unit
[1] M5 screw
[2] Washer
[3] Spacer bushing
[4] Sensor base
[5] Machine surface
[A] Measuring axis
[A]
[1]
[2]
[4]
[3]
[5]

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Manual – DUV10A Diagnostic Unit
5System overview
Installation and Startup
5 Installation and Startup
5.1 System overview
5.2 Before you begin
5.2.1 Prerequisites for installation and startup
5.2.2 Required tools / resources
• Set of wrenches/Allen keys
• PC or notebook with RS-232 interface for parameter setting
59361AXX
Figure 4: DUV10A system overview
[1] Object to be monitored
[2] DUV10A diagnostic unit
+ DC 24 V
[2][1]
The diagnostic unit may only be installed if:
• the data on the nameplate of the diagnostic unit matches the voltage supply system
data
• the diagnostic unit is undamaged (no damage caused by shipping or storage)
Ensure that the following requirements have been met:
• Ambient temperature must be between –30 °C and +60 °C. Please contact
SEW-EURODRIVE if the ambient temperatures are higher or lower.

Manual – DUV10A Diagnostic Unit
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5
DUV10A-S installation software
Installation and Startup
5.3 DUV10A-S installation software
5.3.1 DUV10A-S configuration and monitoring software
The optional DUV10A-S configuration and programming software can be used to
monitor up to 5 different objects or 20 individual frequencies.
A configuration file is generated in the DUV10A-S software. The file is then transferred
to the DUV10A diagnostic unit.
An online help is available for all functions. To call up the help text for each function,
press the <F1> key.
5.3.2 System prerequisites
The DUV10A-S software requires a PC with:
• Pentium II 266 MHz processor or higher (Pentium III recommended)
• At least 128 MB main memory (RAM)
• VGA 800 x 600m or higher
• Microsoft Windows 95 / 98 / NT / 2000 / XP operating system.
5.3.3 Installing the DUV10A-S software
The configuration and programming software is supplied on a CD. When you place the
CD in your CD ROM drive the installation will start automatically. If not, select [Run...]
from the Start menu and enter the command D:/DUV10A-S.exe (D: stands for the CD
ROM drive). Install the programming software by clicking on the name and following the
instructions.

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Manual – DUV10A Diagnostic Unit
5Installation and startup procedure
Installation and Startup
5.4 Installation and startup procedure
Perform the following steps to start up the DUV10A diagnostic unit. Each step is
described in detail.
5.4.1 Loading or creating a parameter file
Use the software provided to create a suitable parameter set.
58213AEN
Open or load
parameter file
Mount
Electrical connection
Conduct impulse test
Transfer parameters
to sensor
Teach-in and
data recording
11290AEN

Manual – DUV10A Diagnostic Unit
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5
Installation and startup procedure
Installation and Startup
• Click the button [Load or create parameter file].
• The software now asks you to enter the parameter data using the wizard or load an
existing file.
• If you have not created a parameter file yet, call up the wizard. Enter the required
data and choose [Finished].
5.4.2 Installation
11291AEN
11294AEN

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Manual – DUV10A Diagnostic Unit
5Installation and startup procedure
Installation and Startup
The DUV10A diagnostic unit is installed using a sensor base (see section 4.2.2 on page
13), which is screwed into either a screw plug bore of the gear unit or a crane hook eye
of the motor. Observe the following installation rules:
• Install the unit close to the rolling element bearing and, preferably, radial to the rota-
tional axis (see section 9.2 on page 71).
• Use the washer and bushing provided with the diagnostic unit.
All 'rolling element bearing' diagnosis objects defined must have a sufficiently good
signal strength. A transfer constant of >5 mg/N is required.
• Tighten the M5 screw using a torque of 7 Nm.
• Once you have installed the DUV10A diagnostic unit, click on the button [Mount
sensor] in the DUV10A software.
Ensure that the following prerequisites are met during installation:
• The DUV10A diagnostic unit must always be freely accessible.
• The LEDs must always be visible.
• Do not connect the unit at the oil drain plug or breather valves.
• Pay attention to the oil level during installation.
Bear in mind that if the unit is installed below the oil level, oil may leak out of the
gear unit.
• If machines are separated by couplings, we recommend that you use one diagnostic
unit for each machine.
• For mounting using an adapter, note the screw sizes in section 4.2.2. page 13.
• Install the DUV10A diagnostic unit using the spacer bushing provided to ensure
thermal isolation.