SEW-Eurodrive Vibration SmartCheck User manual

*23085355_1116*
Приводная техника \ Приводная автоматизация \ Системная интеграция \ Обслуживание
Дополнение к инструкции по
монтажу и эксплуатации
Система Vibration SmartCheck
Издание 11/2016 23085355/RU

SEW-EURODRIVE—Driving the world

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Важное указание
Дополнение к инструкции по монтажу и эксплуатации – Система Vibration SmartCheck 3
1 Важное указание
ПРИМЕЧАНИЕ
В этом дополнении содержится добавочная информация к инструкции по экс-
плуатации. Эта добавочная информация является обязательной к использова-
нию.
Данный документ не заменяет подробную инструкцию по эксплуатации!
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Оглавление
2FAG SmartCheck - Brief guide............................................................................... 5
2FAG SmartCheck - User manual............................................................................ 7
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FAG Industrial Services GmbH
Kaiserstraße 100
52134 Herzogenrath
Germany
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Webside: www.schaeffler.com/services
All rights reserved.
No part of the documentation or software may be reproduced in any form or processed, duplicated or distributed using
electronic systems without our written consent. We would like to point out that the designations and brand names of the
various companies used in the documentation are generally protected by trademark, brand and patent laws.
Microsoft, Windows and Internet Explorer are brands or registered trademarks of the Microsoft Corporation in the USA and/or
in other countries. Firefox is a trademark of the Mozilla Foundation. Loctite is a trademark of Henkel AG.
The software uses the following third-party provider libraries under their respective licences:
Expat, gcc/g++/libc/libc++, gwt, kiss_fft, Linux, log4cpp, md5, smartgwt, sqlite, zlib
Full licence conditions for the respective libraries can be found in the software's program directory.
Version 1.10.0
Translation of the original user guide.
© 31/05/2016 - FAG Industrial Services GmbH
Imprint
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Contents
Contents
..................................................................................................................................... 4
1General .............................................................................................................................................................................................. 41.1 Safety information
.............................................................................................................................................................................................. 41.2 Hazard symbols and signal words
.............................................................................................................................................................................................. 51.3 About this guide
..................................................................................................................................... 6
2Product description
.............................................................................................................................................................................................. 62.1 Intended use
.............................................................................................................................................................................................. 72.2 Modifications by the user
.............................................................................................................................................................................................. 72.3 Technical data
.............................................................................................................................................................................................. 82.4 Scope of delivery
..................................................................................................................................... 9
3Installation
.............................................................................................................................................................................................. 93.1 Installation site and materials required
.............................................................................................................................................................................................. 103.2 Dimensions
.............................................................................................................................................................................................. 113.3 Installing the device directly on a component
.............................................................................................................................................................................................. 123.4 Installing the device on a sensor mounting plate
..................................................................................................................................... 14
4Set-up .............................................................................................................................................................................................. 154.1 Connection overview
.............................................................................................................................................................................................. 164.2 Connection details
.............................................................................................................................................................................................. 184.3 Connecting inputs and outputs
...................................................................................................................................................................................... 18Connection configuration: Digital speed signal4.3.1 ...................................................................................................................................................................................... 20Connection configuration: Analogue speed signal4.3.2 ...................................................................................................................................................................................... 22Connection configuration: Analogue output signal4.3.3 ...................................................................................................................................................................................... 23Connection configuration: Digital output signal4.3.4 .............................................................................................................................................................................................. 254.4 Connecting PC/Ethernet
.............................................................................................................................................................................................. 254.5 Connecting the power supply
.............................................................................................................................................................................................. 274.6 Connecting multiple devices
..................................................................................................................................... 29
5Operation and controls
.............................................................................................................................................................................................. 315.1 Reset and Teach buttons
..................................................................................................................................... 33
6Further information
..................................................................................................................................... 35
7Maintenance and repair
..................................................................................................................................... 36
8Decommissioning and disposal
..................................................................................................................................... 37
9Manufacturer/support
..................................................................................................................................... 38
10 Appendix
.........................................................................................................................................................0Index
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1 General
1.1 Safety information
The FAG SmartCheck vibration monitoring system is manufactured in accordance with the recognised standards and
guidelines (see the Declaration of Conformity in the Appendix ) and is safe to operate. Nevertheless, the device can
pose unavoidable residual hazards to users and third parties or to property, therefore it is imperative that all of the safety
information given in this guide is observed. The generally applicable safety and accident prevention regulations must also
be taken into account. Failure to do so may result in the health and life of persons being put at risk, or cause damage to
property. The safety information in this guide applies in the Federal Republic of Germany. In other countries, the
relevant national regulations apply.
According to its intended use, the Sm artCheck device is not subject to EC Machine Directive
2006/42/EC.
This guide differentiates between
General safety information, which applies to the whole guide and is listed in this chapter
and
Specialised safety information, which you will find in each chapter, either at the start or accompanying individual
actions
General safety information
FAG SmartCheck is integrated in a machine as a system for permanent machine monitoring. The system must be
installed in the machine, connected to machine components and operated in the machine within the specifications set
out in this guide (see Technical data ). The machine owner is responsible for installing the device properly and for
ensuring safe operation in the machine as a whole.
In addition to recording measured values, it is also possible to transfer characteristic values or alarms to superordinate
control systems via the SmartCheck outputs. In doing so, the limitations of use for the connected machine components
must also be observed, in addition to the SmartCheck specification. The machine owner bears sole responsibility for this.
The FAG SmartCheck device m ust not be used for safety-relevant tasks or for critical switching
operations! This applies in particular when these tasks or switching operations have health and
safety im plications.
Operating personnel
SmartCheck may only be installed, operated and maintained by authorised qualified electricians who have received
training in accordance with the applicable, relevant regulations.
1.2 Hazard symbols and signal words
Hazard symbols used in this guide
Safety information and warnings are identified by specific, standardised hazard symbols. If no specific symbol applies, a
general hazard symbol is used.
General hazard symbol
DAN G ER
The nature and source of the hazard are specified here
Measures to prevent the hazard are explained here.
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General
Specific hazard symbols
DAN G ER
DAN G ER FROM ELECTRICAL CURREN T!
This symbol indicates a danger from electric shock that can cause personal injury or even death,
or dam age to property.
Signal words used in this guide
Signal words indicate the severity of the hazard that occurs if the measures to reduce the hazard are not taken.
Caution: Minor damage to property may occur.
Warning: Minor personal injury or severe damage to property may occur.
Danger: Personal injury may occur. There is a risk of fatal injury in particularly severe cases.
1.3 About this guide
This guide describes the installation and use of the FAG SmartCheck device and contains important information about
using the device safely and correctly. Please read through this guide carefully before commissioning the device, and keep
it for future reference.
Make sure that
This guide is available to all users of the device
If the product is passed on to other users, that this guide is also passed on with it
Additions and amendments provided by the manufacturer are always attached to this guide.
Further information
In addition to the device described in this guide, the FAG SmartCheck vibration monitoring system also includes the
integrated FAG SmartWeb software, which is dealt with in a separate manual.
To operate the FAG SmartCheck device, you will also need the supplied FAG SmartUtility Light software. This is also dealt
with in a separate manual. You also have the option of purchasing the FAG SmartUtility software, which features
enhanced functionality.
Definitions
Product: The FAG SmartCheck device described in this manual.
User: person or organisation capable of putting the product into operation and using it.
Qualified person: a person who, by virtue of their relevant training and experience, is qualified to identify risks and
avoid potential hazards that may be caused by the operation or maintenance of a product.
Symbols used
This symbol indicates
Helpful additional information and
Device settings or practical tips that will help you to perform activities m ore efficiently.
Cross-reference symbol : this symbol refers to a page in the manual that provides further information. If you are
reading the manual in PDF format on a screen, clicking the word to the left of the cross-reference symbol will take you
straight to the section in question.
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2 Product description
About the FAG SmartCheck system
FAG SmartCheck is a vibration monitoring system for permanent frequency-selective monitoring. Other measurements
can be captured, recorded and analysed using two integrated signals and up to three connected signals. After the
analysis, the system can switch outputs and display the status using LEDs depending on user-defined alarm limits.
Inputs are available, which record additional signals, to allow the device to be integrated into a superordinate system.
These signals can be used as command variables for a dependent signal analysis, e.g. to initiate time or event-controlled
measurement tasks.
The FAG SmartCheck device can be used to cover a wide range of applications; the SmartCheck device can be configured
to meet your own requirements using the integrated web application and FAG SmartWeb software. Multiple SmartCheck
devices can be combined in a network. Regardless of the number of devices, they can be managed centrally on a PC
using the FAG SmartUtility software.
With FAG SmartCheck, Schaeffler offers status monitoring that is optimised to suit your requirements.
The Sm artCheck device is ready for m easurement as soon as the pow er supply is connected. To
ensure optim um vibration monitoring from the outset, w e recom mend that you do not start the
Sm artCheck device until
All connections have been correctly m ade, and
The machine to be m onitored is in a norm al operating state
2.1 Intended use
The FAG SmartCheck device is intended solely for:
Capturing and analysing vibration measurement signals
Capturing temperature signals
Evaluating signals entering the device at its inputs
The FAG SmartCheck device may only be operated within the limitations of use specified in the Technical data .
Measured-value analyses and changes to settings may only be made using the supplied FAG SmartUtility Light software,
the optional FAG SmartUtility software, the integrated FAG SmartWeb software or, where possible, on the device itself.
Any other or additional use of the device is deemed to be not intended; the user bears sole risk for such use. The user is
responsible for the intended use of the device. This also includes observing this guide.
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Product description
2.2 Modifications by the user
The user must not make any modifications to the FAG SmartCheck device. The user may only make settings on the
device itself or via the FAG SmartWeb or FAG SmartUtility Light/FAG SmartUtility software.
The user bears responsibility for any further modifications! Should you detect a fault with your FAG SmartCheck device,
please contact our Support team.
2.3 Technical data
The SmartCheck device m ust not be used in m easurement voltage categories II, III or IV!
Cover any M12 connections that are not in use with the plugs supplied. This is the only w ay to
ensure that the degree of protection is maintained.
Internal sensors
Vibration
Acceleration sensor (piezoelectric sensor)
Frequency range: 0.8 Hz–10 kHz
Measurement range: ±50 g
Temperature
Measurement range: -20 to +70°C
Measurement
Measurement functions
Acceleration
Speed and path by integration
Temperature
Process parameters (e.g. speed, load, pressure)
Diagnostic methods
Time signal, demodulation, spectrum and trend analysis, speed and frequency tracking
Characteristic values (time range and frequency range)
Defined characteristic values
DIN/ISO 10816
Calculated characteristic
values
RMS, frequency-selective RMS, constant component, peak, peak-to-peak, crest factor, Wellhausen
count, carpet level, condition guard
Other user-defined characteristic values are possible.
Signal processing
Frequency resolution
1600, 3200, 6400 or 12800 lines
Min. line width 0.0039 Hz at 50 Hz (depending on low-pass)
Measurement resolution
24 bit (A/D converter)
Frequency range
0.8 Hz–10 kHz
Low-passes
50 Hz–10 kHz (50 Hz, 100 Hz, 200 Hz, 500 Hz, 1 kHz, 2 kHz, 5 kHz, 10 kHz)
High-passes (demodulation
only)
750 Hz, 1 kHz, 2 kHz (other filters on request)
Memory
Program and data
64 MB RAM, 128 MB flash
Inputs and outputs
Inputs
2 analogue inputs (0-10 V/0-24 V/0-20 mA/4-20 mA), frequency range 0-500 Hz, 12 bit
1 digital input (0-30 V, 0.1 Hz-1 kHz)
Outputs
1 analogue output (0-10 V/0-20 mA/4-20 mA), 12 bit
1 switching output (open collector, max. 1 A, 28 V)
Optional galvanic isolation between inputs and outputs
Interfaces
Control elements
2 capacitive buttons (learning mode, alarm reset, restart, factory settings)
Display elements
1 LED for displaying the status and alarms
1 LED for confirming buttons
2 LEDs for displaying communication
Communication
Ethernet 100 Mb/s
RS485 (not currently supported)
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Electrical connections
3 reverse-polarity protected M12 plug connectors for supply, RS485, inputs/outputs and Ethernet
Miscellaneous
Housing
Glass fibre reinforced plastic
Fixing
M6x45 hex socket head screw
Support area on machine: 25 mm Ø
Power consumption
<200 mA at 24 V
Operating temperature
-20 to +70°C
Internal operating
temperature
-20 to +85°C
Power supply
11 - 32 VDC or
Power over Ethernet (PoE) pursuant to 802.3af Mode A
Dimensions
44 mm x 57 mm x 55 mm
Weight
Approx. 210 g
Protection type
IP 67
Operating system
Embedded Linux
Software
FAG SmartWeb (Mozilla Firefox ESR 38 (recommended). For performance reasons, Internet
Explorer 11 and Internet Explorer 9 are not recommended)
FAG SmartUtility Light or optionally FAG SmartUtility
Languages: German, English, Chinese, Spanish and French
Subject to technical m odifications!
2.4 Scope of delivery
Scope of delivery
FAG SmartCheck device with integrated FAG SmartWeb software
User documentation for FAG SmartCheck and FAG SmartWeb on CD-ROM
FAG SmartUtility Light software with user documentation on CD-ROM
1 fixing screw: M6x45 hex socket head screw
1 O-ring to secure the fixing screw in position
1 plug with logo to cover the mounting aperture
3 plugs to cover unused M12 connections
The standard scope of delivery for the FAG Sm artCheck device does not include any cables for
connecting the device.
Optional accessories
An extensive range of optional accessories for the FAG SmartCheck is available from FAG Industrial Services GmbH:
SmartUtility software with user documentation on CD-ROM; this software features enhanced functionality compared
with the SmartUtility Light software
M6 sensor mounting plate for installing the SmartCheck device
Power cable for SmartCheck; 8-pin M12 socket on a free cable end
Ethernet cable for SmartCheck; M12 connector on RJ45
Input/output connection cables; 8-pin M12 connector on free cable end
M12 Y-splitter to facilitate wiring the power supply to multiple SmartCheck devices
Further information is available from your customer support representative .
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Installation
3 Installation
The following sections contain important details about setting up the FAG SmartCheck device on a machine that you wish
to monitor.
Ensure that the device is free from damage prior to installation.
In case of doubt, consult a qualified electrician or contact your customer support representative at
FAG Industrial Services GmbH.
3.1 Installation site and materials required
Installation site
To install the SmartCheck device, select a site with optimum vibration transfer. To monitor a bearing for example, this
would be near the roller bearing you wish to monitor and radial to the axis of rotation. It is recommended to consult a
vibration expert for this step to ensure optimum condition monitoring. FAG Industrial Services GmbH offers a service that
is tailored to your specific requirements. Details of this can be obtained from your customer support representative .
Please also note the following points:
The SmartCheck device must be mounted vertically in relation to the installation surface.
The installation surface must not be curved or uneven
The surface should exhibit a mean roughness index of Ra = 3.2 µm and should be free from impurities
The SmartCheck device can be operated at ambient temperatures from -20°C to +70°C
Installation type
To ensure the SmartCheck device is installed safely and permanently, it should be mounted on the machine and/or
component that you wish to monitor.
The device can be screwed directly into a hole on the component. To do this, you will need to drill a tapped hole at least
9 mm deep at the selected position; the surface must exhibit a mean roughness index of Ra = 3.2 µm.
If this is not possible, you can bond an M6 sensor mounting plate to the installation surface and then screw the device to
the mounting plate. The sensor mounting plate is available as an optional accessory from FAG Industrial Services GmbH.
Materials
The following materials are also required to install the SmartCheck device:
Tool for creating the tapped M6 hole or an M6 sensor mounting plate including an adhesive suitable for vibration
measurement (e.g. Loctite 330)
Some lubricant (oil, grease)
Offset screwdriver for M6 hex socket head screw
A torque wrench (tightening torque 10 Nm) with socket for a 6-mm hex socket head screw
Optional items:
Vibration-resistant screw locking compound (e.g. Loctite 243 medium-strength threadlocker)
Cable ties for securing the cable
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3.2 Dimensions
The following illustrations show the SmartCheck device from different perspectives with dimensions accurate to the
millimetre.
Basic dimensions from the front
This front view shows the connections of the SmartCheck device as well as the fixing screw protruding downward and
the sensor area.
Basic dimensions from the side
The side view shows the angled surface of the SmartCheck device; you can also see how far the connections protrude
and how the sensor area is dimensioned.
Basic dimensions in cross-section
The open cross-section affords a view into the mounting aperture of the SmartCheck device and shows the dimensions
of the fixing screw and sensor area.
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Installation
3.3 Installing the device directly on a component
If you require the SmartCheck device to be screwed directly onto a machine or component, the following prerequisites
for the installation must be satisfied:
The component must have a minimum wall thickness of 9 mm
The installation surface must not be curved or uneven
The surface should exhibit a mean roughness index of Ra = 3.2 µm
Proceed as follows:
1. Prepare a circular, smooth and level installation surface with a minimum diameter of 25 mm.
2. Now drill an M6 hole at least 9 mm deep square to and in the centre of the installation surface.
Detail drawing of device installed on a component
3. Clean the installation surface.
4. Apply a thin film of lubricant to the cleaned surface.
Adding lubricant will improve the transfer of vibrations.
5. Insert the M6x45 hex socket head fixing screw supplied into the SmartCheck mounting aperture.
To prevent the screw from falling out during installation, you can secure it w here necessary
using an O-ring that is also included in the scope of delivery. Ensure that the O-ring does not
slip between the installation surface and the sensor area during installation as this would
impede vibration transfer and distort the m easurement result.
You can also use an optional screw locking com pound (e.g. Loctite threadlock) to ensure the
installation is perm anent.
6. Align the sensor area of the SmartCheck device on the installation surface and hand-tighten the fixing screw using an
offset screwdriver. Ensure that SmartCheck is sitting flat on the surface to ensure optimum vibration transfer.
7. Use a torque wrench to tighten and secure the connection to a tightening torque from 5 to 10 Nm.
To avoid damage, select the fixing screw and the torque setting in line w ith the material
properties of both the installation point and the screw.
8. Check that FAG SmartCheck is seated securely.
9. Close the mounting aperture on the device by inserting the plug bearing the logo until it snaps in place.
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Mounting aperture with plug
The plug can be removed by inserting the blade of a flat-tip screw driver under the bevels beside
the logo and carefully levering it out.
You can now set up and connect FAG SmartCheck.
3.4 Installing the device on a sensor mounting plate
If the SmartCheck device cannot be screwed directly onto a machine or component, you can bond an M6 sensor
mounting plate onto the installation surface and then screw the device to the mounting plate. The M6 sensor mounting
plate is available as an optional accessory from FAG Industrial Services GmbH. Please contact your customer support
representative .
In order to install the device using a sensor mounting plate, the following prerequisites must be satisfied:
The installation surface must not be curved or uneven
SmartCheck must be secured square to the installation surface
The surface should exhibit a mean roughness index of Ra = 3.2 µm
Proceed as follows:
1. Prepare a circular, smooth and level installation surface with a minimum diameter of 25 mm.
Detail drawing of device installed on a sensor mounting plate
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Installation
2. Clean the installation surface.
3. Apply an adhesive that is suitable for vibration measurement to the surface (e.g. Loctite 330).
Please select an adhesive that is suitable for the installation site and the am bient conditions.
4. Position the sensor mounting plate on the adhesive and press it down firmly.
Wait until the adhesive has fully dried.
5. Clean the surface of the sensor mounting plate.
6. Apply a thin film of lubricant to the cleaned surface.
Adding lubricant will improve the transfer of vibrations.
7. Insert the M6x45 hex socket head fixing screw supplied into the SmartCheck mounting aperture.
To prevent the screw from falling out during installation, you can secure it w here necessary
using an O-ring that is also included in the scope of delivery. Ensure that the O-ring does not
slip between the installation surface and the sensor area during installation as this would
impede vibration transfer and distort the m easurement result.
You can also use an optional screw locking com pound (e.g. Loctite threadlock) to ensure the
installation is perm anent.
8. Align the sensor area of the SmartCheck device on the installation surface and hand-tighten the fixing screw using an
offset screwdriver. Ensure that SmartCheck is sitting flat on the surface to ensure optimum vibration transfer.
6. Use a torque wrench to tighten and secure the connection to a tightening torque from 5 to 10 Nm.
9. Check that FAG SmartCheck is seated securely.
10.Close the mounting aperture on the device by inserting the plug bearing the logo until it snaps in place.
Mounting aperture with plug
The plug can be removed by inserting the blade of a flat-tip screw driver under the bevels beside
the logo and carefully levering it out.
You can now set up and connect FAG SmartCheck.
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4 Set-up
You can use the connections on the FAG SmartCheck device to
Set up inputs and outputs and various connection configurations
Set up a PC/Ethernet connection and
Connect the power supply
To set up and operate the SmartCheck device, you will need the following connection cables - these are not included in
the standard scope of delivery:
Input/output cables
Ethernet connection cable (Ethernet/PoE)
Power supply cable
The FAG Sm artCheck device m ay only be prepared for use by persons who are verifiably qualified
to do so in accordance with the relevant regulations.
Ensure that the SmartCheck device is de-energised while set-up operations are being carried out.
General
Please note the following information when connecting cables:
Ensure that the sockets for the plug connections are clean and free from impurities. Dirt or moisture in plug
connections can impair signal quality.
When securing cables, ensure that they are not subjected to any mechanical strain. If necessary, fit strain relief
accessories.
Observe the minimum permissible bending radii for the cables. These can be found in the data sheets from the cable
manufacturer. A minimum bending radius of 60 mm is recommended for cables from the standard range of
accessories from FAG Industrial Services GmbH.
Attach the cables in such a way that they are laid firmly and cannot be knocked.
Do not lay signal cables parallel to high-power lines.
Example showing power supply cable from the standard range of accessories
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