SEW-Eurodrive DUV40A User manual

*29190266_0320*
Drive Technology \ Drive Automation \ System Integration \ Services
Manual
Diagnostic Unit Vibration
DUV40A
Edition 03/2020 29190266/EN

SEW-EURODRIVE—Driving the world

Table of contents
Manual – DUV40A 3
Table of contents
1 General information.................................................................................................................. 4
1.1 About this documentation ...............................................................................................4
1.2 Structure of the safety notes ...........................................................................................4
1.3 Decimal separator in numerical values ...........................................................................5
1.4 Rights to claim under limited warranty ............................................................................5
1.5 Product names and trademarks......................................................................................5
1.6 Copyright notice ..............................................................................................................5
2 Safety notes .............................................................................................................................. 6
2.1 Preliminary information ...................................................................................................6
2.2 Duties of the user............................................................................................................6
2.3 Target group ...................................................................................................................7
2.4 Transport.........................................................................................................................7
2.5 Maintenance and repair ..................................................................................................8
3 Product description.................................................................................................................. 9
3.1 About DUV40A................................................................................................................9
3.2 Designated use ...............................................................................................................9
3.3 Modification by the user ................................................................................................10
4 DUV40A.................................................................................................................................... 11
4.1 Features........................................................................................................................11
4.2 Mounting the diagnostic unit .........................................................................................26
4.3 Technical data...............................................................................................................29
5 Service..................................................................................................................................... 35
5.1 Waste disposal..............................................................................................................35
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1General information
About this documentation
Manual – DUV40A
4
1 General information
1.1 About this documentation
The documentation at hand is the original.
This documentation is an integral part of the product. The documentation is intended
for all employees who perform work on the product.
Make sure this documentation is accessible and legible. Ensure that persons respon-
sible for the systems and their operation as well as persons who work on the product
independently have read through the documentation carefully and understood it. If you
are unclear about any of the information in this documentation or if you require further
information, contact SEW‑EURODRIVE.
1.2 Structure of the safety notes
1.2.1 Meaning of signal words
The following table shows the grading and meaning of the signal words for safety
notes.
Signal word Meaning Consequences if disregarded
DANGER Imminent hazard Severe or fatal injuries
WARNING Possible dangerous situation Severe or fatal injuries
CAUTION Possible dangerous situation Minor injuries
NOTICE Possible damage to property Damage to the product or its envi-
ronment
INFORMATION Useful information or tip: Simplifies
handling of the product.
1.2.2 Structure of section-related safety notes
Section-related safety notes do not apply to a specific action but to several actions
pertaining to one subject. The hazard symbols used either indicate a general hazard
or a specific hazard.
This is the formal structure of a safety note for a specific section:
SIGNAL WORD
Type and source of hazard.
Possible consequence(s) if disregarded.
• Measure(s) to prevent the hazard.
Meaning of the hazard symbols
The hazard symbols in the safety notes have the following meaning:
Hazard symbol Meaning
General hazard
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1
General information
Decimal separator in numerical values
Manual – DUV40A 5
1.2.3 Structure of embedded safety notes
Embedded safety notes are directly integrated into the instructions just before the de-
scription of the dangerous action.
This is the formal structure of an embedded safety note:
SIGNAL WORD! Type and source of hazard. Possible consequence(s) if disregar-
ded. Measure(s) to prevent the hazard.
1.3 Decimal separator in numerical values
In this document, a period is used to indicate the decimal separator.
Example: 30.5kg
1.4 Rights to claim under limited warranty
Read the information in this documentation. This is essential for fault-free operation
and fulfillment of any rights to claim under limited warranty. Read the documentation
before you start working with the product.
1.5 Product names and trademarks
The brands and product names in this documentation are trademarks or registered
trademarks of their respective titleholders.
1.6 Copyright notice
©2020SEW‑EURODRIVE. All rights reserved. Unauthorized reproduction, modifica-
tion, distribution or any other use of the whole or any part of this documentation is
strictly prohibited.
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2Safety notes
Preliminary information
Manual – DUV40A
6
2 Safety notes
2.1 Preliminary information
The following general safety notes serve the purpose of preventing injury to persons
and damage to property. They primarily apply to the use of products described in this
documentation. If you use additional components, also observe the relevant warning
and safety notes.
2.2 Duties of the user
As the user, you must ensure that the basic safety notes are observed and complied
with. Make sure that persons responsible for the machinery and its operation as well
as persons who work on the device independently have read through the documenta-
tion carefully and understood it.
As the user, you must ensure that all of the work listed in the following may be carried
out only by qualified specialists:
• Setup and installation
• Installation and connection
• Startup
• Maintenance and repairs
• Shutdown
• Disassembly
Ensure that the persons who work on the product pay attention to the following regula-
tions, conditions, documentation, and information:
• National and regional safety and accident prevention regulations
• Warning and safety signs on the product
• All other relevant project planning documents, installation and startup instructions,
and wiring diagrams
• Do not assemble, install or operate damaged products
• All system-specific specifications and conditions
Ensure that systems in which the product is installed are equipped with additional
monitoring and protection devices. Observe the applicable safety regulations and leg-
islation governing technical work equipment and accident prevention regulations.
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2
Safety notes
Target group
Manual – DUV40A 7
2.3 Target group
Specialist for me-
chanical work
Any mechanical work may be performed only by adequately qualified specialists. Spe-
cialists in the context of this documentation are persons who are familiar with the
design, mechanical installation, troubleshooting, and maintenance of the product who
possess the following qualifications:
• Qualifications in the field of mechanics in accordance with the national regulations
• Familiarity with this documentation
Specialist for elec-
trotechnical work
Any electrotechnical work may be performed only by electrically skilled persons with a
suitable education. Electrically skilled persons in the context of this documentation are
persons who are familiar with electrical installation, startup, troubleshooting, and main-
tenance of the product who possess the following qualifications:
• Qualifications in the field of electrical engineering in accordance with the national
regulations
• Familiarity with this documentation
Additional qualific-
ations
In addition to that, these persons must be familiar with the valid safety regulations and
laws, as well as with the requirements of the standards, directives, and laws specified
in this documentation.
The persons must have the express authorization of the company to operate, pro-
gram, parameterize, label, and ground devices, systems, and circuits in accordance
with the standards of safety technology.
Instructed persons All work in the areas of transportation, storage, operation and waste disposal must be
carried out by persons who are trained appropriately. The purpose of the training is to
give persons the ability to perform the required tasks and work steps in a safe and cor-
rect manner.
2.4 Transport
Inspect the shipment for damage as soon as you receive the delivery. Inform the ship-
ping company immediately about any damage. If the product is damaged, it must not
be assembled, installed or started up.
Observe the following notes when transporting the device:
• Always use all attachment points if available. The attachment points are designed
to carry only the mass of the product. Severe or fatal injuries. Do not apply any ad-
ditional loads.
• Ensure that the product is not subject to mechanical impact.
If necessary, use suitable, sufficiently dimensioned handling equipment.
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2Safety notes
Maintenance and repair
Manual – DUV40A
8
2.5 Maintenance and repair
The DUV40A is an enclosed and encapsulated system and therefore maintenance-
free in principle. If you determine a defect at the DUV40A, contact
SEW‑EURODRIVE..
You can clean the outside of the DUV40A if necessary.
üDo not use chemical solvents, such as acetone, nitro-cellulose combi thinner or
similar products. Such solvents can damage the housing.
1. Disconnect the DUV40A from the power supply.
2. Clean the DUV40A using a soft, lint-free cloth.
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3
Product description
About DUV40A
Manual – DUV40A 9
3 Product description
3.1 About DUV40A
The DUV40A is a vibration monitoring system for continuous frequency-selective mon-
itoring. With 2 integrated signals and up to 3 connected signals, further measured val-
ues can be detected, recorded, and analyzed. After the analysis and depending on
user-defined alarm limits, the system can switch outputs and display the state using
LEDs.
To allow integration into a higher-level system, inputs are available via which addi-
tional signals are recorded. These signals can be used as reference values for signal
analysis e.g. to trigger time or event-based measuring tasks.
The DUV40A allows you to cover a large number of applications. Configure the
DUV40A according to your application using the integrated web application and
SmartWeb software. Several DUV40A devices can be combined in one network. Re-
gardless of the number of devices, administration takes place centrally on a PC
equipped with the SmartUtility software.
With the DUV40A SEW‑EURODRIVE offers condition monitoring optimized for your
requirements.
The device is ready for measuring as soon as DUV40A is connected to the supply
voltage. To ensure an optimal vibration monitoring start the DUV40A only after the fol-
lowing steps are complete:
• All the components are connected correctly.
• The monitored machine is in a normal operating state.
3.2 Designated use
DUV40A is designated for the following purposes.
• For the collection and analysis of vibration measurement signals.
• For the detection of temperature signals.
• For the evaluation of incoming signals.
DUV40A may be operated only within the application limits specified in the technical
data.
Analysis of measured values as well as changes to the settings may be performed
only using the software SmartUtility light included in the delivery, the optionally pur-
chased software SmartUtility, the integrated software SmartWeb or directly at the
device, if possible.
Any other way of using the product exceeds the designated use and the user bears
the risk caused by such use. The user is responsible for observing the designated
use, this includes observing the manual.
INFORMATION
DUV40A must not be used for safety-relevant tasks or critical switching operations.
This especially applies if these tasks or switching operations are safety relevant to
prevent death or injury.
DUV40A is included in plants as system for permanent machine monitoring.
For installation in the plant, connection to plant components, and plant operation you
must not exceed the specified values stated in this manual. Observe chapter "Tech-
nical data"(→229).
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3Product description
Modification by the user
Manual – DUV40A
10
The plant operator bears the sole responsibility for correct installation and safe opera-
tion of the overall plant.
In addition to collecting measured values, DUV40A can also provide characteristic val-
ues or alarms to the higher-level control system using its outputs. Observe the
DUV40A specifications as well as the application limit values of the connected plant
components. This is the sole responsibility of the system operator.
3.3 Modification by the user
The user may not modify the DUV40A device. Only settings made at the device or us-
ing the software SmartWeb or SmartUtility Light/SmartUtility are permitted.
The user bears all responsibility for modifications that exceed such settings. If you de-
termine a defect at your DUV40A, contact SEW‑EURODRIVE.
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4
DUV40A
Features
Manual – DUV40A 11
4 DUV40A
4.1 Features
DUV40A is an innovative online system that can be used with various units.
Benefits of the DUV40A:
• Condition monitoring and condition diagnostics of rolling bearings and machines
using a single device
• Small size
• Robustness
• Cost-effective solution
• Intuitive operation
• Expansion options
• A preconfigured system
• Comprehensive information regarding the machine state based on process param-
eters such as power rating, speed, and temperature
• Overview of the machine status provided at a glance in your web browser
• Possible prediction of long-term changes in the machine status enabled by the in-
tegrated data storage
• Connecting interface to the control station or controller
• Safe alarm system based on automatized alarm threshold adjustment
• Direct system access via Ethernet and web browser
• Data protected by a multi-stage access concept
31506305291
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4DUV40A
Features
Manual – DUV40A
12
4.1.1 Operation and communication
DUV40A can be used easily and intuitively using 2 capacitive buttons.
The SmartWeb software installed on the device can be accessed via the web interface
using any standard browser.
Via analog and digital interfaces, the device can be connected e.g. to the controller or
the control station.
RESET
TEACH
[1]
[2]
[3]
[4]
[5]
[6]
31516091787
[1] Status LED, red, yellow, green
[2] TEACH button, membrane keypad, activates teach mode
[3] Ethernet interface, PoE voltage supply
[4] Voltage supply interface
[5] Input and output interfaces, analog and digital
[6] RESET button, membrane keypad, reset alarm
Deactivating the keypad lock
üYou must unlock the keypad before you can use the buttons on the DUV40.
1. Push the RESET button [6] and then the TEACH button [2] within 2seconds.
ðThe LED between the 2 buttons flashes to acknowledge the command.
The keypad lock will automatically reactivate after 2minutes and the LED between the
2 buttons is not lit.
RESET button
The function accessed by the RESET button [6] depends on how long you push the
button.
• To reset the current alarms push the RESET button [6] for at least 2seconds.
• To restart the DUV40A push the RESET button [6] for at least 10seconds.
TEACH button
üUse the TEACH button [2] to restart the teach mode for all measurement tasks
that use teach mode.
1. To do so, push the TEACH button [2] for at least 5seconds.
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DUV40A
Features
Manual – DUV40A 13
Factory settings
üDUV40A can be reset to factory settings using the TEACH button [2] and the
RESET button [6].
1. Startup of DUV40A must be complete and the device must be ready for measuring
(indicated by the status LED after startup).
2. Simultaneously push the TEACH button [2] and the RESET button [6] for at least
10seconds.
ðThe device is reset to delivery state. Saved data, such as measured values and
configurations will be lost.
4.1.2 Function
DUV40A is ready for operation upon delivery.
The set of integrated characteristic values enables general and reliable monitoring.
To achieve a more precise monitoring part templates are available on the device, e.g.
for rolling bearings or gear units. The part data is entered into the part template.
In case of rolling bearings a rolling bearing database containing data for standard gear
units is integrated on the device. You can add other rolling bearings to this database
at any time.
Certain parameters can be adjusted depending on the selected part template, for ex-
ample:
• Bearing type
• Number of fan blades
• Gearings
• Belt length
Software assistant functions support you when adjusting part templates. The gener-
ated set of characteristic values facilitates monitoring the unit precisely.
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4DUV40A
Features
Manual – DUV40A
14
4.1.3 Configuration
Using a DUV40A you can monitor several components of your unit at the same time.
For example, all bearings in a gearmotor can be monitored by a single monitoring
device. To do so, several part templates are combined into an overall configuration for
the monitored unit. This configuration can be copied to infinite other DUV40A devices.
4.1.4 Monitoring
Vibration and process parameters, such as speed and temperature, are determined
and correlated.
4.1.5 Alarm
The alarm threshold adjustment ensures a reliable alarm. An LED at the device imme-
diately indicates an alarm. The alarm can be transmitted to the control station via inter-
faces.
4.1.6 Use
The device detects damages to the various units early.
4.1.7 Standard templates
The standard template of DUV40A detects the following damages:
• Roller bearing damage
• Imbalance
• Incorrect alignment
• Stop positions
4.1.8 Extended monitoring functionalities
You can choose the standard template for monitoring purposes. In addition, you can
select unit-specific templates. DUV40A analyzes the signals, compares them to data
from the template and recognizes specific damage patterns and their causes. A typical
example is a bearing damage.
But not all detected damages can be automatically assigned by DUV40A. Some dam-
age patterns are very complex and must be analyzed by an expert.
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4
DUV40A
Features
Manual – DUV40A 15
4.1.9 Component-specific templates
The following table shows examples of complex damage patterns:
Component An expert can recognize
Electric motors and gearmotors Damage to windings and loose rotor bars
Vacuum pumps and hydraulic pumps Wear and cavitation
Fans Rotational frequencies of blades and
vanes
Compressors Operation outside of the specified range
Gear unit Damage to the gearing
Separators and decanters Cavitation, imbalance between worm and
drum
Vibrating screen Touching of the screen, loose springs,
broken springs
4.1.10 Concept
Monitoring with the DUV40A is available in 3 stages.
1. In the first stage individual components are monitored decentralized.
2. If you select the second stage, the device is intelligently integrated into the ma-
chine control.
3. In the third stage remote access via the Internet connection is possible.
[3]
[2]
[1]
31503521803
[1] Decentralized machine and process monitoring
[2] Intelligent process integration
[3] Service from a single source
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4DUV40A
Features
Manual – DUV40A
16
Decentralized machine and process monitoring
DUV40A can be installed and wired easily. The device is ready for operation immedi-
ately. The data can be accessed directly via the device.
Intelligent process integration
The intelligent process integration is a communication option using interfaces to ex-
change data and information for example with a controller or a database agent.
Service from a single source
The web interface of DUV40A enables the remote access of measurement data via
the Internet connection so that monitoring tasks can be performed by an external ser-
vice provider.
4.1.11 Software
DUV40A can be configured via SmartWeb, SmartUtility light or SmartUtility.
Range of functions
Function SmartWeb SmartUtility light SmartUtility
Display status of
characteristic
values
×××
Display system
information
×××
Display measure-
ment data
×××
Display trend × × ×
Select component
template
×××
Configure inputs
and outputs
×××
Configure and
activate validation
×××
Configure and
activate trigger
×××
Configure user
management
×××
Display input
signals in real time
×××
TCP/IP settings × × ×
Update firmware × × ×
Download and save
data
×××
Manage all
DUV40A of the
supply system
– × ×
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4
DUV40A
Features
Manual – DUV40A 17
Function SmartWeb SmartUtility light SmartUtility
Analyze data – – ×
Load and check
configurations
– – ×
Create measure-
ment report
– – ×
SmartWeb
The software SmartWeb software is integrated into each DUV40A. Using a web
browser, you can enter the IP address of a device and directly access this device.
It is typically used when using a single DUV40A.
SmartUtility light
The free PC software SmartUtility light is included in the delivery. This software has
the same features as SmartWeb, in addition a list with the IP addresses of all connect-
ed DUV40A devices is displayed and devices can be selected quick and easy. Manu-
ally entering the IP address is not required.
It is typically used when using multiple DUV40A devices. Using this software requires
an Windows PC, see chapter "Technical data"(→229).
SmartUtility
The paid SmartUtility software allows unlimited access to all functions of DUV40A.
Multiple devices can be configured simultaneously. Saved configurations can be
loaded and for example sent to other locations. In addition, data can be analyzed and
all DUV40A devices in the network can be managed.
It is typically used when managing the production machines at all your locations cent-
rally or when analyzing data, where a large amount of expert knowledge is required.
Using this software requires an Windows PC, see chapter "Technical data"(→229).
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4DUV40A
Features
Manual – DUV40A
18
4.1.12 Accessing the sensor (SmartWeb)
Initial view of the signals in a browser
When the DUV40A unit has been started and is in measurement mode, you can view
the measurement data on your computer using the SmartWeb software. Doing so, you
can check if a valid vibration or temperature signal is detected, if the inputs are cor-
rectly connected and configured, and if DUV40A is functioning correctly.
The following points are required for connecting the device to a computer.
• DUV40A must be connected to the network or directly connected to the computer
via Ethernet cable.
• If DUV40A not been assigned an address via DHCP, it has the IP address
192.168.1.100 by default. In this case the IP address of the computer must be
192.168.1.x.
Proceed as follows:
• Open your Internet browser and enter the IP address of the DUV40A device into
the address field.
• The SmartWeb web application opens.
9007231880747403
To change the language, perform the following steps:
• Click "Edit program settings" in the "Edit" menu.
• Click "Language".
• Select the required language from the list and confirm your selection with "OK".
• Refresh the browser page for the changes to take effect.
• Click the "Real-time display" button in the left part of the window.
Here, you can view the individual signals from each input and from each scaling factor
created.
• For example, select "Vibration sensor input" from the menu on the left.
• If DUV40A is connected correctly the "Real-time display" area will display the data
from the vibration sensor or the selected signal input.
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DUV40A
Features
Manual – DUV40A 19
9007231880749835
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4DUV40A
Features
Manual – DUV40A
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4.1.13 Data analysis
DUV40A offers multiple possibilities to analyze measurement data and evaluate the
status of the monitored unit.
The following general characteristic values are determined base on acceleration and
acceleration envelope signal.
• ISO10816
• RMS broadband
• Peak-to-peak value
But DUV40A not only calculates general characteristic values. The part templates on
the device also offer frequency-selective monitoring possibilities tailored to several
components.
Characteristic patterns of components such as shafts, belt pulleys, or fan wheels indic-
ate incipient damage at an early stage. The device provides time signals that are dis-
played in the viewer. This analysis tool is part of the SmartUtility software and enables
experts to analyze the time signals. In combination with process parameters such as
temperature, load, or speed, damage progressions can be precisely traced back and
the cause of a failure can be determined.
31655938187
[1] Trend
[2] Time signals
[3] Frequency spectrum
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